2002 Subaru Impreza WRX Service

I 3
2002 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX
GENERAL INFOMATION
SECTION
This service manual has been prepared

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

cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUJI HEAVY INDUSTRIES LTD. G1830BE1

I
FOREWORD
~~~~
FWa
Page
1. Foreword.....................................................................................................2
FOREWORD
FOREWORD
~
1. Foreword
A: FOREWORD
These manuals are used when performing mainte-
nance, repair or diagnosis of the Subaru IMPREZA.
Applied model: GG***** and GD***** from 2001MY.
The additional manuals below are also available:

AUTOMATIC TRANSMISSION SERVICE MANU-
AL (Pub. No. G0853ZE)
The manuals contain the latest information at the

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

A: HOW TO USE THIS MANUALS
1. STRUCTURE
Each section consists of SCT that are broken down
into SC that are divided into sections for each com-
ponent. The specification, maintenance and other
information for the components are included, and
the diagnosis information has also been added
where necessary.
2. INDEX
The first page has an index with tabs. And at the
end of each section is an alphabetical index.
3. COMPONENTS
For each component, a composition drawing is in-
cluded.
4. SPECIFICATIONS
f f necessary, specifications are also included
5. INSPECTION
Inspections are included to be carried out before
and after maintenance.
6. MAINTENANCE
Maintenance instructions are provided for each
component. When multiple components comprise
one process, refer to the instructions for that pro-
cess for each component.
7. DIAGNOSIS
Tables showing a step-by-step process make it
easy to conduct diagnosis.
8. SI UNITS
Measurements in these manuals are according to
the SI units. Metric and yard/pound measurements
are also included.
HU-2
SPECIFICATIONS
SPC
1. lmpreza ...................,................,.......,................,.......,.................................2
Page a
IMPREZA
SPECIFICATIONS
1. lmpreza
A: DIMENSIONS
Model Sedan Waaon OUTBACK
Overall lennth mm (in) I 4,405 (173.4)
Overall width mm (in) 1,730 (68.1) 1,695 (66.7) 1,710 (67.3)
Overall height (at CW) mm (in) 1,465 (57.7), 1,475 (58.1),
1,440 (56.7)
1,485 (58.5)*2 1,495 (58.9)*2
Compartment Length mm (in) 1,890 (74.4) 1,845 (72.6)
Width mm (in) 1,380 (54.3)
I Height
mm (in)
I 1, I 80 (46.5)
I 1,200 (47.2),
1,150 (45.3)*3 I 1,200 (47.2),
1,150 (45.3)*3
Tread I Front mm (in) I

\ I
1.485 (58.5)
, \ ,
1.465 (57.7)
. \ ,
1.460 (57.5)
I \ ,
Rear mm (in) 1,475 (58.1),

1,455 (57.3) 1,455 (57.3)
1,480 (58.3)*1
Minimum road clearance mm (in) 150 (5.9), 150 (5.9),
160 (6.3)
155 (6.1)*1 155 (6.1)*1
B: ENGINE
Model Turbo 2.0 L 2.5 L
I valve arranqement I Overhead camshaft tvDe 1

Bore x Stroke mm (in) 92 x 75 99.5 x 79.0
(3.62 x 2.95) (3.917 x 3.1 IO)
Displacement cm3 (cu in) 1,994 (121.67) 2,457 (149.9)
ComDression ratio 8.0 10.0
I Firinq order I 1-3-2-4 -1
I Idle speed at Park/Neutral
position (NC OFF)
Maximum output kW (HP)/rpm
rpm I 750
169 (227)/6,000
650 (MT)
700 (AT)
123 (165)/5,600
Maximum torque N.m (kgf-m, ft-lb)/rpm 294 (30.0, 217)/4,000 226 (23.0, 166)/4,000
SPC-2
IMPREZA I
SPECIFICATIONS
C: ELECTRICAL
Model I
Turbo 2.0 L I
2.5 L
Ignition timing at idling speed BTDC/rpm MT: 1O"k10°/650
12"+10"/750
AT: 1O"k10"/700
Spark plug CHAMPION: RCI OYC4(Standard)
NGK: PFR6G NGK: BKR5E-11
NGK: BKR6E-11
Generator 12V - 75A 12V - 90A
Battery Type MT: 12V - 48AH (55D23L) MT: 12V - 48AH (55D23L)
AT: 12V - 52AH (65D23L) AT: 12V - 52AH (75D23L)
Reserve capacity min MT: 99 MT: 99
AT: 111 AT: 118
Cold cranking amp MT: 356 MT: 356
amperes AT: 420 AT: 520
r M m ~ I Turbo 2.0 L I
Transmission type 5MTSrl 4ATlr2
Clutch type DSPD TCC
-'
Gear ratio I 1st 3.454 2.785
I L I I 4
II 1L 3rd I
I
1.366 I 1.ooo I
I
14th I 0.972 I 0.694 I
5th 0.738 -
,
' Reductiongear
(Front drive)
1st reduction
Final reduction
Reverse
Type of gear
Gear ratio
Type of gear
3.333
-
-
Hypoid
2.272
Helical
1.000
Hypoid
I I I Gear ratio I 3.900 I 4.1 11 I
Reductiongear Transfer reduction Type of gear Helical -
(Rear drive) Gear ratio 1.100 -
Final reduction Type of gear Hypoid Hypoid
Gear ratio 3.545 4.111
SPC-3
IMPREZA I
SPECIFICATIONS
Model 2.5 L
RS Others
Transmission type 5MT*1 4ATlr2 5MTlrl 4AT*2
Clutch type DSPD TCC DSPD TCC
I 1st I 3.454 I 3.027 I 3.454 I 2.785 I
2nd 2.062 1.619 2.062 1.545
3rd 1.448 1.ooo 1.448 1.ooo
~~~
4th 1.088 0.694 1.088 1.694

5th 0.780 - 0.780 -
I Reverse I 3.333 I 2.272 I 3.333 I 2.272 1
r
Dual range - - - -
Reductiongear 1st reduction Type of gear - Helical - Helical
(Front drive) Gear ratio - 1.ooo - 1.ooo
...
Final reduction Type of gear Hypoid Hypoid Hypoid Hypoid
r
Gear ratio 4.1 11 4.444 3.900 4.1 11
Reductiongear Transfer reduction Type of gear HeIical - HeIical -
(Rear drive) Gear ratio 1.ooo - 1.000 -
Final reduction Type of gear Hypoid Hypoid Hypoid Hypoid
Gear ratio 4.1 11 4.444 3.900 4.1 11
I
5 M T M : 5 forward speeds with synchromesh and I -reverse
4AT+2: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse
DSPD: Dry Single Plate Diaphragm
TCC: Torque Converter Clutch
E: STEERING
I
Type Rack and Pinion

Turns, lock to lock 3.2 3
Minimum turning circle m (ft) Curb to curb 10.2 (33.5) 10.8 (35.4)
Wall to wall 11.I (36.3) 11.7 (38.3)
Front Macpherson strut type, Independent, Coil spring

Rear Dual-link strut type, Independent, Coil spring
Model SEDAN WAGON

Service brake system Dual circuit hydraulic with vacuum suspended power unit
Front Ventilated disc brake
Rear Disc brake Drum brake, Disc brakelrl
Parking brake Mechanical on rear brakes
H: TIRE
Rim size 15 x 6JJ 16 x 6’/2JJ

Tire size P I 95/60R15 87H P205/55R16 89V
Type Steel belted radial, Tubeless
SPC-4
IMPREZA
SPECIFICATIONS
I: CAPACITY
I 5MT I
I
4AT I 5MT I 4AT I
Fuel tank Q (US gal, Imp gal) 60 (15.9, 13.2) 60 (15.9, 13.2)
Engine oil Upper level Q (US qt, Imp qt) 4.5 (4.8, 4.0) 4.0 (4.2, 3.5)
Lower level Q (US qt, Imp qt) 3.5 (3.7, 3.1) 3.0 (3.2, 2.6)
Transmission gear oil Q (US qt, Imp qt) 3.5 - 3.5 -
(3.7, 3.1) (3.7, 3.1)
Automatic transmission fluid Q (US qt, Imp qt) - 9.3 (9.8, 8.2) - 9.5 (10.0, 8.4)
AT differential gear oil Q (US qt, Imp qt) - 1.2 (1.3, 1. I ) - 1.2 (1.3, 1.1)
AWD rear differential gear oil Q (US qt, Imp qt) 0.8 (0.8, 0.6)
Power steering fluid Q (US qt, Imp qt) 0.7 (0.7, 0.6)
Engine coolant Q (US qt, Imp qt) 7.7 (8.1, 6.8) I 7.6 (8.0, 6.7) I 7.0 (7.4, 6.2) 1 6.9 (7.3, 6.1)
t-
Model I AWD I
Turbo 2.0 L 2.5 L
WRX RS
5MTlrl 4ATJrl 5MT 4AT
Curb weight (C.W.) Front kg (Ib) 826 (1,820) 851 (1,875) 778 (1,715) 803 (1,770)
Rear ka (IblI 1
w . 569 (1.255)
. . 569 (1.255) 567 (1.250). 567 (1,250)
I I I
I
I I . I
I I .
I
Total ka (Ib) I 1,395 (3,075) I 1,420 (3,130) 1 1,345 (2,965) I 1,370 (3,020)
Gross vehicle weight Front kg (Ib) 998 (2,200) 998 (2,200) 939 (2,070) 939 (2,070)
(G.V.W.) Rear kg (Ib) 857 (1,890) 857 (1,890) 857 (1,890) 857 (1,890)
Total kg (Ib) 1,837 (4,050) 1,795 (4,050) 1,778 (3,920) 1,837 (4,050)
SPC-5
IMPREZA I
SPECIFICATIONS
Model AWD
Xirbo 2.0 L
WRX
5MTt2 4ATt2
Curb weight (C.W.) Front kg (Ib) 825 (1,820) 851 (1,875)
Rear ka (Ib) 606 (1.335) 605 (1,335)
ka ob) 1 I
~~
htai 1,431 (3,155) 1,458 (3,210)

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

(G.V. W.) Rear kg (Ib) 925 (2,040) 925 (2,040)
Total kg (Ib) 1,901 (4,190) 1,901 (4,190)
2.5 L
-
TS OUTBACK
5MTtl 4ATt 1 5MT 4AT
Rear kg (Ib) 603 (1,330) 606 (1,335) 601 (1,325) 603 (1,330)
Total kg (Ib) 1,376 (3,035) 1,402 (3,090) 1,384 (3,050) 1,408 (3,l 05)
-(G.v.w.) Rear kg
- (Ib) 925 (2,040) 925 (2,040) 925 (2,040) 925 (2,040)
Total kg (Ib) [ 1,833 (4,040) I 1,833 (4,040) I 1,833 (4,040) I 1,833 (4,040)
tl:Excludes weight of ABS, cruise control.
t 2 : Excludes weight of side air bag.
SPC-6
IMPREZA
SPECIFICATIONS
I
2. CANADA SPEC. VEHICLE
Sedan
Model
Turbo 2.0 L 2.5 L
WRX RS
5MT 4AT 5MT 4AT
Rear kg (Ib) 573 (1,265) 573 (1,265) 567 (1,250) 567 (1,250)
Total kg (Ib) 1,399 (3,085) 1,424 (3,140) 1,345 (2,965) 1,370 (3,020)
(G.V.W.) Rear kg (Ib) 857 (1,890) 857 (1,890) 857 (1,890) 857 (1,890)
Total kg Ob) 1,837 (4,050) 1,837 (4,050) 1,778 (3,920) 1,778 (3,920)
Wagon
.-
*1: Excludes weight of air conditioner
SPC-7
IMPREZA
SPECIFICATIONS
c- .
SPC-8
I
PRECAUTION
PC
Page
1. Precaution................................................................................................... 2
PRECAUTION
PRECAUTION
1. Precaution 7. AIRBAG MODULE

Adhere to the following when handing and storing
A: PRECAUTION the airbag module to prevent bodily injury from un-
Please clearly understand and adhere to the follow- expected deployment:
ing general precautions. They must be strictly fol- Do not hold the harnesses or connectors to carry
lowed to avoid minor or serious injury to the person the module.
doing the work or people in the area. Do not face the bag in the direction that it opens
1. ABS towards yourself or other people.
Do not face the bag in the direction that it opens
Handle the ABS as a total system. Do not disas- towards the floor or walls.
semble or attempt to repair individual parts. Doing
so could prevent the ABS system from operating 8. AIRBAG SPECIAL TOOLS
when needed or cause it to operate incorrectly and To prevent unexpected deployment, only use spe-
result in injury. cial tools.
2. BRAKE FLUID 9. WINDOW
If brake fluid gets in your eyes or on your skin, do Always wear safety glasses when working around
the following: any glass to prevent glass fragments from damag-
Wash out your eyes and seek immediate medical ing your eyes.
attention.
Wash your skin with soap and then rinse thor- 1O.WINDOW ADHESIVE
oughly with water. Atways use the specified urethane adhesive when
3. ELECTRIC FAN attaching glass to prevent it from coming loose and
falling, resulting in accidents and injury.
The electric fan may rotate without warning, even
when the engine is not on. Do not place your hand,
cloth, tools or other items near the fan at any time.
4. ROADTESTS
Always conduct road tests in accordance with traf-
fic rules and regulations to avoid bodily injury and
interrupting traffic.
5. AIRBAG
To prevent bodily injury from unexpected deploy-
ment of airbags and unnecessary maintenance, fol-
low the instructions in this manual when performing
maintenance on the airbag components or nearby,
and the airbag wiring harnesses or nearby.
To prevent unexpected deployment, perform one of
the steps below and then wait at least 20 seconds
to discharge electricity before beginning work.
Step 1: Turn the ignition switch OFF.
Step 2: Remove the negative battery terminal.
6. AIRBAG DISPOSAL
To prevent bodily injury from unexpected airbag
deployment, do not dispose the airbag modules in
the same way as other refuse. Follow instructions
of SOA (distributor) service for disposal of airbag
module. Follow all government regulations con-
cerning the disposal of refuse.
PC-2
I
NOTE
NT
Page
1. Note ............................................................................................................. 2
NOTE
NOTE
1. Note
A: NOTE
This is the information that can improve the effi-
ciency of maintenance and assure the sound work.
1. FASTENER NOTICE
Fasteners are used to prevent the parts from dam-
age and dislocation due to looseness. Fasteners
must be tightened to the specified torque.
Do not apply paint, lubricant, rust retardant or other
substances to the surface around bolts, fasteners,
etc. Doing so will make it difficult to obtain the cor-
rect torque and result in looseness and other prob-
lems.
2. STATIC ELECTRICITY DAMAGE
Do not touch the ECM, connectors, logic boards
and other such parts when there is a risk of static
electricity. Always use a static electricity prevention
cord or touch grounded metal before conducting
work.
3. IGNITION OFF BATTERY
When removing the battery cables, always be sure
to turn the ignition off to prevent electrical damage
to the ECM from rush current.
4. SERVICE PARTS
Use authentic service parts for maximum perfor-
mance and maintenance, when conducting repairs.
Subaru/FHI will not be responsible for poor perfor-
mance resulting from the use of parts not specified
by a genuine dealer.
NT-2
NOTE I
NOTE
5. LIFTS AND JACKS

When using a lift or jack-ridged rack to raise a vehicle, always follow the instructions concerning jack-up
points and weight limits to prevent the vehicle from falling, which could result in injury. Be especially careful
to make sure the vehicle is balanced before raising it.
Support locations
Pantograph jack
I Without side sill cover
With-ver
fi.w
Lift
Safety stand
GI0166
NT-3
NOTE I
NOTE
Front
nt cross member
Rear Rear differential
GI0121
NT-4
NOTE 3
NOTE
6. TIE DOWNS
Tie downs are used when transporting vehicles and when using the chassis dynamo. Attach tie downs only
to the specified points on the vehicle.
Hook for tie-down
Hook for towing
-1
Hook for tie-down Hook for towing

and tie-down
GI0122
NT-5
I NOTE I
NOTE
20 20’
20 20”
20 20”
20 20”
7. TOWING
Avoid towing vehicles except when the vehicle can-
not be driven. For vehicles with AWD, AT or VTD,
use a loader instead of towing. When towing other
vehicles, to prevent excessive weight from damag-
ing the hook or vehicle:
Do not tow other vehicles with a front towing
hook.
Make sure the vehicle towing is heavier than the
vehicle being towed.
8. TRAINING
For an information about training, contact a dealer
or agent.
9. GENERAL SCAN TOOL
Using general scan tools will greatly improve the ef-
ficiency of repairing engine electronic controls. The
Subaru Select Monitor can be used to diagnose the
engine and also the ABS, the air conditioner and
other parts.
NT-6
IDENTIFICATION
ID
Page
1. Identification................................................................................................2
IDENTIFICATION I
IDENTIFICAT10 N
1. Identification
A: IDENTIFICATION
1. IDENTIFICATION NUMBER AND LABEL LOCATIONS
The VIN (Vehicle Identification Numbers) is used to classify the vehicle.
Positioning of the plate label for identification
Vacuum hose piping label

/
number plate
pressure label
..
Vehicle
' Model number plate
GI0161
Transmission serial number
Engine sdrial number G l0007A I o. G10008A I
ID-2
IDENTIFlCATlON I
IDENTIFICATION
Model number plate /
b 'I L3 F r'z"'!it
trim code engine type E J 2 0 ENMABA~
9+#L2-F 230 s v 5 3 > w
GlOOllA
ID-3
IDENTIFICATION
IDENTIFICATION
2. MEANING OF V.I.N.
The meaning of the VIN is as follows:
North America
]JF1GD255X2G500001[
The starting and ending brackets ( I[ ) are stop marks.
Digits Code Meaning Details

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

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

Series G: IMPREZA
2
ID Body style D: 4 Door Sedan
G: Wagon
Engine displacement A: 2.0 L AWD Turbo
Drive system E: 2.5 L AWD
Sumension svstem
Minor chanae A: Initial
5 IY Destination Y: Left-hand drive for United States and Canada
Grade 4: TS
6: RS
7: OUTBACK
8: WRX
7 IR Transmission, fuel feed R: SOHC MPI 4-speed AT
system P: DOHC B MPI 4-speed AT
J: SOHC MPI 5-speed MT AWD
D: DOHC B MPI 5 - s ~ e e dMT AWD
3 and 4 25 Displacement 20: 2.0 L

25: 2.5 L
5 1 Fuel feed system 1: D-MPI SOHC-A
5: MPI Turbo
6 A Exhaust reuulations US Federal & California
7
8
Iw
3
Transmission
Minor change
I 3: 3 is applied for this vehicle.
9to10 AB Detailed specifications Used when ordering parts. See the parts catalog for details.
ID-5
I IDENTIFlCATlON
IDENTIFICATION
Transmission
TV1 A421AA
Transmission T: Transmission
I3 and 4
5
14
Transmission type
Classification
Series
Y: Full-time AWD MT center differential
V: Full-time AWD AT center differential
Z: Full-time AWD AT MPT
75: MT
1A: AT
I M T 14:5MT
AT 14: New AT
I
6 Z Transmission specifica- V: Full-time AWD 5-speed MT with viscous coupling center dif-
tions ferential single range
Z: Full-time AWD 4-speed AT with MPT
Y: Full-time AWD 4-speed AT with VTD
7 I1 Minor change I I : Initial I
8 to 10 I AA Detailed specifications I Used when ordering parts. See the parts catalog for details. I
Rear differential
EH
Code Reduction LSD
aear ratio
I EG 13.900 I No I
4.1 11
4.1 11 Viscous
ID-6
I
RECOMMENDED MATERIALS
RIM
Page
1. Recommended Materials ,..........................,................................................2
I RECOMMENDED MATERIALS
~
1. Recommended Materials
A: RECOMMENDED MATERIALS
1. GENERAL
To insure the best performance, always use the
specified oil, gasoline, adhesive, sealant, etc. or
that of equivalent quality.
2. FUEL
Always use a gasoline of the same or higher octane
value than specified in the owner's manual. Ignor-
ing the specifications below will result in damage or
poor operation of the engine and fuel injection sys-
tem. Use the specified gasoline to correct perfor-
mance.
Unleaded gasoline
Use unleaded gasoline and not leaded gasoline on
vehicles with a catalytic converter installed to re-
duce air pollution. Using leaded gasoline will dam-
age ihe catalytic converter.
RM-2
3. LUBRICANTS
Use either the lubricants in the table below or equivalent lubricants. See the table below to choose the correct
SAE viscosity.
Lubricant Recommended Alternative
API Spec. ACEA Spec.
Engine oil SJ Grade “Energy conserving” A1 , A2 or A3 API: SH or SG
GlOOOl
GI0002
Manual transmission oil GL-5 -
Front differential GL-5 -
Rear differential GL-5 -
SAE viscosity SAE viscosity No. and applicable temperature SAE J300
Engine oil
< 5W-30 Recommend I
G10003A
RM-3
RECOMMENDED MATER IALS
SAE viscosity SAE viscosity No. and applicable temperature SAE J300
Manual transmission oil
("C) -30 -20 -1 0 0 10 20 30 40
(OF) -22 -4 14
I
32 50 68 86 104
I I I I
>
I I I I
l l
I I I
90
/
85W
3ear differential
I
80W
I I I I I I
7 75W-90 2
G10004A
'ront differential
('C) -30 -20 -1 0 0 10 20 30 40
(OF) -22 -4 14 32 50 68 86 104
G10005A
4. FLUID
Use the fluids specified in the table below. Do not mix two different kinds or makes of fluid.
Fluid Recommended Alternative Remarks

Automatic transmission fluid DEXRON I l l -
Power steerina fluid DEXRON Ill -
Brake fluid FMVSS No. 116 DOT3 FMVSS No. 116 DOT4
Clutch fluid FMVSS No. 1 16 DOT3 FMVSS No. 116 DOT4
5. COOLANT
Use the genuine coolant to protect the engine. The table below shows the ratio of coolant to distilled water.
Coolant Recommended Item number Alternative

Coolant SUBARU coolant 000016218 None
Water for dilution Distilled water - Tap water
Air conditioner Recommended Item number Alternative

Refrigerant HFC134a - None
Compressor oil DH-PR - None
RECOMMENDED MATERIALS I
7. GREASE
Use the grease and supplementary lubricants shown in the table below.
Grease Application point Recommended Item number Alternative

Supplementary lubricants 0 2 sensor SUBARU CRC 004301003 -
Bolts. etc.
Grease MT main shaft I FX clutch clrease I 000040901 I -
Clutch master cylinder Slicolube G-40M 004404003 -
push rod
Steering shaft bush SUNLIGHT2 003602010 -
(Toe board)
Gear shift bush
Steering gear box Valiant grease M-2 003608001 -
Disc brake Niglube RX-2 003606000 or -
725191040
I I -
~~
I
Drum brake
Brake pad
Brake shoe
1 Molvkote No. 7439
Molykote AS-880N
72519460
26298AC000
I
Front axle SFJ SSG-6003 28093TAOOO -
Front axle EBJ NTG 2218 28093AA000 -
Rear axle EBJ NTG 2218 28093AA000 -
._ (Turbo model)
Rear axle BJ Molylex No. 2 723223010 -
(Non-turbo model)
Rear axle DOJ VU-3A702 23223GA050 -
Control cable Slicolube G-30M 004404002 -
Throttle linkage
Water pump
Door latch
Door striker
8. ADHESIVES
Use the adhesives shown in the table below, or equivalent.
Adhesive Windshield and body Essex Chemical Crop’s Ure- - Sunstar 580
thane E
Soft vinyl Cemedine 540 - 3M’s EC-776 EC-847 or EC-1022
(Spray type)
Momentarv sealant Cemedine 3000 - Armstrona’s Eastman 910
9. SEAL MATERIAL
I Enaine case I Three Bond 1215 I004403007 I Dow Corning’s No. 7038 I
Transmission oil pan Three Bond 12178 K0877YA020 -
Torque converter clutch Three Bond 12158 004403007 Dow Corning’s No. 7038
case
Rear differential Three Bond 1324 004403042 -
Rear differential Three Bond 1105 004403010 -
I Weatherstrip I Starcalking B-33A I000018901 I Butyl Rubber sealant I
Steering adjusting screw Three Bond 1102 004403006 -
SOHC cam cap Three Bond 12808 K0877YA018 -
RM-5
I RECOMMENDED MATERIALS 1
RECOMMENDEDMATERIALS
c-
RM-6
I
PRElDELlVERY INSPECTION
PI
Page
1. Pre-delivery Inspection...................... ........................ .................................. 2
I PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION
1. Pre-delivery Inspection
A: GENERAL
The purposes of the pre-delivery inspection (PDI)
are as follows.
Remove the additional parts used for ensuring
the vehicle quality during transportation and restore
the vehicle to its normal state.
Check if the vehicle before delivery is in a normal
state.
Check for any damage or missing parts that may
have taken place during transportation or storage.
Make sure to provide a complete vehicle to the
customer.
Because of the above reasons, all dealerships
must always carry out the PDls before delivering a
vehicle.
In addition, all franchised shops and PDI centers
must check the status of every vehicle received to
identify who is responsible for any possible defects.
PI-2
B: PDI PROCEDURE
Follow the procedures shown in the table below.
Static Checks Just After Vehicle Receipt
Step Check point

I . Appearance check (1) If the vehicle is covered with protective coating, visually check the vehicle
body for damage and dents. If the protective coating has been removed,
visually check the body paints for small areas of damage or stains.
(2) Visually check the glass and light lenses for any damage and cracks or
excessive gaps to the body sheet metal.
(3) Visually check the plated parts for any damage.
2. Tire check (4) Check the tires for damage, abnormal conditions, and dents on the
wheels.
f5) Check the tire air Dressure.
~
3. Fuse installation (6) If the vehicle is about to be delivered to the customer, attach a room lamp
fllRF!
E h e c k the doors for locklunlock and openlclose (7) Using the key, check if the door can be locked and unlocked normally.
iperations. (8) Open and close all doors to see that there are no abnormal conditions.
(9) Operate the power door locking switch to check that all doors is locked
and unlocked normally.
5 . Power window oDeration check (10) Check the power window for correct operations.
ii+Check the trunk lid openlclose operations. (11) Operate the trunk lock release lever to check that the trunk opens nor-
mally.
(12) Using the key, check if the trunk lid can be unlocked normally.
(13) Open and close the trunk lid to see that there are no abnormal condi-
tions.
7. Check the rear gate for locklunlock and open1 (14) Using the key, check if the rear gate can be lock and unlocked normally.
:lose operations. (15) Open and close the rear gate to see that there are no abnormal condi-
tions.
(16) Operate the power door locking switch to check that the rear gate is
locked and unlocked normally.
3. Operation check of trunk lid release handle (17) Operate the trunk lid release lever to check the trunk is unlocked nor-
mally.
3. Operation check of fuel lid opener lock release (18) Operate the fuel lid opener to check that the fuel lid is unlocked normally.
ever
10. Accessory check Check the following accessories are provided:
Owner's manual
Warranty booklet
Service booklet
Spare key
Jack
Tool set
Spare tire
11. Operation check of hood lock release system (1) Operate the hood lock release lever to check that the hood opens nor-
mallv.
~
12. Connection of air conditioner harness (2) If the vehicle is about to be delivered to the customer, connect the air con-
ditioner harness.
13. Battery (3) Check the battery for any abnormal conditions such as rust and trace of
battery fluid leaks.
14. Brake fluid (4) Check the fluid amount.
15. Engine oil (5) Check the oil amount.
16. Transmission fluid (6) Check the fluid amount.
(7) For AT, check the front differential oil.
17. AT front differential oil (8) Check the AT front differential oil amount.
18. Coolant f9) Check the coolant amount.
19. Clutch fluid (10) Check the clutch fluid amount.
20. Window washer fluid (11) Check the window washer fluid amount.
21. Hood latch check (12) Check that the hood is closed and latched securely.
PI-3
PRE-DELIVERY INSPECTION I
Step Check point

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

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

43. ATF level I (1) Check that the ATF level is normal.
44. Power steerina fluid level I 12) Check that the Dower steerina fluid level is normal.
I
, \ I
1
8. I
45. Fluid leak check I 13) Check for fluid/oil leaks.

\ ,
146. Water leak check I (4) Sprav the vehicle with water and check for water leaks.
47. Appearance check 2 (5) Remove the protective coating (if any).
(6) Check the body paints for damage and smears.
(7) Check the plated parts for damage and rust.
PI-4
PRE-DELIVERY INSPECTION 1
1. APPEARANCE CHECK 4. CHECK THE DOOR OPERATIONS,

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

Manipulate the power window switches one by one
to check that each of the power windows goes up
and down with no abnormal noises.
(A) G10084A
PI-5
6. CHECK THE TRUNK LID OPERATIONS, 8. OPERATION CHECK OF TRUNK LID RE-
OPEN/CLOSE, AS FOLLOWS. LEASE HANDLE
Operate the trunk lock release lever and verify 1) Use a screwdriver with a thin blade. Slide the
that the trunk lid opens. screwdriver blade from the slit aperture of the lock
Using the key, open the trunk lid several times to assembly fully to the end until you hear a click. This
check for normal operation. places the latch in the locked position.
Open and close the trunk lid several times for
smooth movement.
GI0157
7. CHECK THE REAR GATE OPERATIONS,

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

cle, in the direction of the arrow to check if the latch
is released.
171
Operate the power door locking switch to check

that the rear gate is locked and unlocked normally.
I GI0160 I
PI-6
9. OPERATION CHECK OF FUEL LID 11.OPERATION CHECK OF HOOD LOCK

OPENER LOCK RELEASE LEVER RELEASE SYSTEM
Operate the fuel lid opener and verify that the fuel Unlatch and open the hood while checking that no
lid opens normally. Check that the filler cap is se- abnormal conditions are found. Then, support the
curely closed. hood with the hood stay.
1O.ACCESSORY CHECK
Check that the following accessories are provided
in the luggage compartment or cargo area.
Owner's manual
Warranty booklet
Service booklet
Spare key
Jack
Tool set
Spare tire
GI0151
P1-7
I PRE-DELIVERY INSPECTION I
12.CONNECTION OF AIR CONDITIONER 16.TRANSMISSION FLUID

HARNESS Check the transmission fluid amount. If the amount
A vehicle just delivered has its air conditioner har- is insufficient, check that no leaks are found. Then,
ness disconnected to protect the air conditioner add the necessary amount of the specified fluid.
compressor. Connect the harness as shown in the
figure.
Oil level gauge
Upper level
Lower level
I
_- G10088A I
17.AT FRONT DIFFERENTIAL OIL

Check the AT front differential oil amount. If the
13.BATTERY amount is insufficient, check that no leaks are
Check the battery terminals to make sure that no found. Then, add the necessary amount of the
rust or corrosions due to fluid leaks are found. specified AT front differential oil.
check that the battery caps are securely tightened.
1
18.COOLANT
_I
- Upper level
-Lower level
GlOO89Al
14.BRAKE FLUID Check the coolant amount on the reservoir. If the

Check the brake fluid amount. If the amount is in- amount is insufficient, check that no leaks are
sufficient, carry out a brake line test to identify found. Then, add the necessary amount of coolant
brake fluid leaks and check the brake operation. Af- with the specified concentration.
ter that, refill the brake fluid tank with the specified
type of fluid. 19.CLUTCH FLUID
Check the clutch fluid amount. If the amount is in-
15.ENGINE OIL sufficient, check that no leaks are found. Then, add
Check the engine oil amount. If the amount is insuf- the necessary amount of the specified fluid.
ficient, check that no leaks are found. Then, add I
the necessary amount of the specified engine oil.
P Upper level
About 1.Oe
(1.1 us qt,
0.9 Imp qt)
Lower level
I G10087A I
PI-8
20.WlNDOW WASHER FLUID Press the “LOCWARM” button on the transmitter

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

Using the horn, the system will give you an audi-
ble signal when the doors lock and unlock.
If desired, you may turn the audible signal off.
To turn the audible signal off, carry out the unlock-
GI0091 ing procedure of keyless entry system, then simul-
taneously depress LOCWARM and UNLOCW
Press the “UNLOCWDISARM” button on the
DISARM buttons for more than two seconds.
transmitter momentarily once and check if the driv-
The horn will sound two times to inform you that the
er’s door is unlocked, the horn chirps twice and the
audible signal has been turned off.
dome light illuminates.
To turn the audible signal on, carry out the unlock-
I I
ing procedure of keyless entry system, then simul-
taneously depress LOCWARM and UNLOCW
DISARM buttons for more than two seconds.
The forn will sound one time to inform you that the
audible signal has been turned on.
GI0092

transmitter momentarily once again within five sec-
onds and check if all the doors including the rear
gate on wagon are unlocked.
a little bit of time (approx. 1.5 sec.) and check if a
panicking condition occurs; the horn sounds contin-
uously. Also, check if that condition lasts for 30 sec-
onds or until any button of the transmitter is
pressed.
23.SECURITY SYSTEM Then, bring all the doors including the rear gate
(wagon) in closed condition and check if the arming
Check the security system operations as follows:
Fully open all the door windows. condition is brought about; all the doors are locked,
Remove the key from the ignition switch and the horn chirps once and the parking lights flash
once.
close all the doors including rear gate (wagon). Press the “LOCK’ side of the power door locking
switch with any one of the doors including the rear
momentarily once and check if all the doors are
gate (wagon) open. Then, bring all the doors in-
locked, the horn chirps once, the parking lights
cluding the rear gate (wagon) in the closed condi-
flash once and the security indicator light flashes
tion and check if all the doors are locked, the horn
slowly to ensure that the security system has been chirps once and the parking lights flash once to en-
brought into the arming state.
sure that the security system has been brought into
the arming state.
LOCK
c-
GI0091

transmitter momentarily once and check if the driv- Unlock a door using the inner lock knob or the
er’s door is unlocked, the horn chirps twice, the key and open the door while the security system is
parking light flash twice, the dome light illuminates in the arming state. Check to ensure that the alarm-
and the security indicator light goes off to ensure ing condition occurs, i.e. the horn sounds continu-
that the system has been brougt into the disarming ously, the parking lights flash and security indicator
state. light flashes rapidly, and that it lasts for 30 seconds
I I
or until the “UNLOCWDISARM” button on the
transmitter is pressed. Also, check to ensure that
turning the ignition key to the “START position in
the arming state does not cause the starter motor
to turn, thus the engine being prevented from start-
ing.
Apply a shock to the vehicle body with the secu-
rity system in arming state, and check to ensure
that the alarming condition occurs.
Troubleshoot the security system if any one of
GI0092
the above-mentioned checks does not meet the re-
Press the “UNLOCWDISARM” button on the quirements.
transmitter momentarily once again within five sec-
24.SEAT
onds and check if all the doors including the rear
gate on wagon are unlocked. Check that each seat provides full functionality in
Press the “LOCWARM” button on the transmitter sliding and reclining. Check all available functions
a little bit of time (approx. 1.5 sec.) and check if a of the rear seat such as a trunk-through center arm
panicking condition occurs; the horn sounds contin- rest.
uously, the parking lights flash and the security in-
dicator light flashes rapidly. Also, check if that
25.SEAT BELT
condition lasts for 30 seconds or until any button of Pull out the seat belt and then release it. Check
the transmitter is pressed. that the belt webbing retracts smoothly.
Press the “LOCWARM” button on the transmitter Check the seatbelt warning light and chime oper-
momentarily once with one of the doors including ations.
the rear gate (wagon) open and check if the horn
chirps three times to warn of a door ajar.
PI-I 0
PRE-DELIVERY INSPECTION 1
26.WHEEL ALIGNMENT 35. LIGHTING SYSTEM

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

Check that the chime sounds when the driver’s
door opens and the key is in the “LOCK’ or “ACC” Rear Injection position:
position. A: 39 mm (2.36 in)
29. STA RTING CONDIT10N B: 72”
Start the engine and check that the engine starts Nozzle
smoothly. If any battery voltage problems are (/
I \
found, recharge or replace the battery. If any ab- I
I \
\
normal noises are observed, immediately stop the 1?K
engine and check and repair the necessary compo-
nents.
30.EXHAUST SYSTEM
Listen to the exhaust noise to see if no abnormal
noises are observed.
31.INDICATOR LIGHT
Check that all the indicator lights are off.
32.CLOCK
Check the clock for normal operations and enough
accuracy.
33.RADIO
Check the radio for full functionality and normal
noise level. Also check the CD unit operations.
34.CIGARETTE LIGHTER
Check the cigarette lighter operations.
PI-I 1
40.AT SHIFT CONTROL 45.POWER STEERING FLUID LEVEL

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

Position 46.FLUID LEAK CHECK
Yes Yes Yes Check the entire areas of the vehicle for any trace
Yes Yes Yes of coolant/oil/fluid leaks.
I I I
I 2
1 I
Yes
Yes I
Yes 47.WATER LEAK TEST
Spray the vehicle with water and check that no wa-
Check the shift lock system operations. ter enters the passenger compartment.
Check the key interlock system operations. Before performing the water leakage test, re-
move anything that may obstruct the operation or
41 .HEATER & VENTILATION which must be kept dry.
Operate the heater and ventilation system to check Close all of the windows completely, and then
for normal airflow and heating capacity. close all of the doors tightly. Close the hood and
trunk lid before starting the test.
42.AIR CONDITIONER Connect a hose to a tap, and spray water on the
Operate the air conditioner. Check that the A/C vehicle. The rate of water discharge must be ap-
compressor operates normally and enough cooling prox. 20 to 25 liters (5.3 to 6.6 US gal, 4.4 to 5.5
is provided. Imp gal) per minute.
When spraying water on areas adjacent to the floor
43.CRUISE CONTROL and wheel house, increase the pressure. When di-
Operate the cruise control system. Check that the recting water on areas other than the floor portion
system is activated and deactivated correctly. and wheel house, decrease the pressure. But the
force of water must be made strong occasionally by
44.ATF LEVEL pressing the end of the hose.
Check that the ATF level is normal. If insufficient, NOTE:
check that no leaks are found. Then add the neces- Be sure to keep the hose at least 10 cm (3.9 in)
sary amount of the specified ATF. from the vehicle.
Check the following areas:
Front window and body framework mating
portion
Door mating portions
Glass mating portions
Rear quarter window mating portions
1-
Rear window and body framework mating
Lower level <-upper level portion
Lower level Around roof drips
G10098A
PI-I 2
I PRE-DELIVERY INSPECTION I
If any dampness in the compartments is discov-

ered after the water has been applied, carefully
check all areas that may have possibly contributed
to the leak.
48.APPEARANCE CHECK 2
Check the vehicle body paints, plated faces, glass,
and lenses for any dirt or damage.
PI-I 3
PI-I 4
PERIODIC MAINTENANCE SERVICES
PM
Page
1. General Description .................................................................................... 2
2. Schedule ..................................................................................................... 3
3. Engine Oil .................................................................................................... 5
4. Engine Oil Filter........................................................................................... 7
5. Spark Plugs ................................................................................................. 8
6. Drive Belt(s) ................................................................................................ 9
7. Camshaft Drive Belt .................................................................................. 11
8. Fuel Line ................................................................................................... 14
9. Fuel Filter .................................................................................................. 15
10. Air Cleaner Element .................................................................................. 16
.
11. Cooling System ......................................................................................... 17
12. Coolant ...................................................................................................... 18
13. Idle Mixture................................................................................................ 20
14. Clutch System ........................................................................................... 21
15. Transmission Oil ....................................................................................... 22
16. ATF ........................................................................................................... 23
17. Front & Rear Differential Oil ...................................................................... 24
18. Brake Line ................................................................................................. 25
19. Brake Fluid ................................................................................................ 27
20 . Disc Brake Pads and Discs ....................................................................... 28
21 . Brake Linings and Drums .......................................................................... 29
22 . Suspension ............................................................................................... 31
23 . Wheel Bearing........................................................................................... 33
24 . Axle Boots & Joints ................................................................................... 34
25 . Steering System (Power Steering) ............................................................ 35
26 . Supplemental Restraint System ................................................................ 38
GENERAL DESCRIPTION I
1. General Description
A: GENERAL
Be sure to perform periodic maintenance in order to
maintain vehicle performance and find problems
before they become serious.
PM-2
SCHEDULE I
--I1--Clutchsystem I I I I I I I I
12 Transmission oil I I I I
13 ATF I I I I Note (3)
14 Front 8, rear I I I I
differential oil
15 Brake line I I I I I I I I
16 Brake fluid R R R R
17 Disc brake pads & I I I I
discs
18 Brake linings and I I I I
drums
19 Parking brake I I I I I I I I
20 Suspension I I I I I I I I
21 Wheel bearing I I (1)
22 Axle boots &joints I I I I I I I I
23 Tire rotation I I I I I I I I I I I I I I I INote(4)
24 Steering system I I I I I I I I
(Power steering)
25 Supplement
Inspect every 10 years
restraint system
Symbols used:
R: Replace
I: Inspection
(R) or (I): Recommended service for safe vehicle operation.
NOTE:
(1)This inspection is not required to maintain emission warranty eligibility and it dose not affect the manufacturer’sobligations under
EPA’s in-use compliance program.
(2)When the vehicle is used in extremely dusty conditions, the air cleaner element should be replaced more often.
(3)ATF filter is maintenance free part. ATF filter needs replacement, when it has physically damaged or ATF leaked.
(4) A tire should be replaced when the tread wear indicator appears as a solid band across the tread. The indicators appear when
the remaining tread has been worn to 1.6 mm (0.063in) or less.
PM-3
I SCHEDULE
B: MAINTENANCE SCHEDULE 2
Item High humid- Repeat tow-
ity or moun- ing trailer
road drive used or tain area
coastal area
Engine oil R
Engine oil filter 3.75 months R

6,000 km
3,750 miles
Fuel filter 15 months
24,000 km
15,000 miles
Fuel line 15 months
24,000 km
15,000 miles
Transmission oil 15 months
-. 15,000 miles
AT F
Front & rear

differential oil
Brake line
15 months
24,000 km
15,000 miles
15 months
24,000 km
I I
R
15,000 miles
Brake fluid 15 months
15,000 miles
Disc brake pads
& discs
I
1 I
Brake linings 15 months I I I I

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

joints
Steering system
(Power steering)
7,500 miles
-izzzGl
7,500 miles
7.5 months
12,000 km
7,500 miles
I
I
I
II
I
I
I
I
I
I
II
I
I
I
T
-
PM-4
ENGINE OIL I
3. Engine Oil 5) Fill the engine oil through filler pipe up to the up-
per point on level gauge. Make sure that the vehicle
A: REPLACEMENT is placed level when checking oil level. Use engine
1) Drain the engine oil by loosening engine oil drain oil of proper quality and viscosity, selected in accor-
Plug. dance with the table in figure.
Engine oil capacity (Non-TURBO model):
Upper level
4.0 0 (4.2 US qt, 3.5 Imp qt)
Lower level
3.0 0 (3.2 US qt, 2.6 Imp qt)
Engine oil capacity (TURBO model):
Upper level
4.5 0 (4.8 US qt, 4.0 Imp qt)
Lower level
3.5 0 (3.7 US qt, 3.1 Imp qt)
2) Open the engine oil filler cap for quick draining of
the engine oil.
SAE Viscosity No. and Applicable Temperature
("C) -30 -20-15 0 15 30 40
( O F ) -22 4 5 32 59 86 104
I I I I I I I
Upper level
About 1.0 L
(1.1 us qt,
0.9 Imp qt)
Lower level
G10015A
U
Thc proper viscosity helps vehicle get good cold
G10013A and hot starting by reducing viscous friction and
thus increasing cranking speed.
3) Replace the drain plug gasket.
4) Tighten the engine oil drain plug after draining NOTE:
engine oil. When replenishing oil, it does not matter if the oil
to be added is a different brand from that in the en-
Tightening torque: gine; however, use oil having the API classification
44 N-m (4.5 kgf-m, 33 fi-lb) and SAE viscosity No. designated by SUBARU.
If vehicle is used in desert areas with very high
temperatures or for other heavy duty applications,
the following viscosity oils may be used:
API classification: SJ or SH
SAE Viscosity No.: 30, 40, 1OW-50, 2OW-40, 20W-
50
6) Close the engine oil filler cap.
7) Start the engine and warm it up for a time.
PM-5
I ENGINE OIL
8) After the engine stops, recheck the oil level. B: INSPECTION

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

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

oil to the seal rubber.
3) Install the oil filter by turning it by hand, being
careful not to damage seal rubber.
4)-Tighten more (approximately 2/3 to 3/4 turn) af-
ter the seal rubber contacts the oil pump case. Do
not tighten excessively, or oil may leak.
5 ) After installing oil filter, run the engine and make
sure that no oil is leaking around seal rubber.
NOTE:
The filter element and filter case are permanently
joined; therefore, interior cleaning is not necessary.
6) Check the engine oil level. <Ref. to PI-3, PDI
PROCEDURE, Pre-delivery Inspection.>
PM-7
I SPARK PLUGS
5. Spark Plugs
A: REPLACEMENT
1) Remove the intake duct and intake chamber.
2) Remove the washer tank and put it aside.
3) Disconnect the spark plug cord.
4) Remove the spark plug with a plug-wrench.
5) Set the new spark plug.

Recommended
c-- spark plug :
Non-Turbo model
CHAMPION RClOYC4 (Standard)
NGK BKRSE-11
NGK BKRGE-11
Spark plug gap
1.0 - 1.1 mm (0.039 - 0.043 in)
Turbo model
NGK PFRGG
Spark plug gap
0.7- 0.8 mm (0.028 - 0.031 in)
6) Tighten the spark plug lightly with hand, and then
secure with a plug-wrench to the specified torque.
Tightening torque:
20.6 N.m (2.10 kgf-m, 15.19 ft-lb)
NOTE:
Be sure to place the gasket between the cylinder
head and spark plug.
If the torque wrench is not available, tighten
spark plug until gasket contacts cylinder head; then
tighten further 1/4 to 1/2 turns.
PM-8
DRIVE BELT(S) 1
6. Drive Belt(s) B: REPLACEMENT

A: INSPECTION 1. V-BELT COVER
1) Replace the belts, if cracks, fraying or wear is 1) Remove the V-belt cover.
found.
2) Check the drive belt tension and adjust it if nec-
essary by changing generator installing position
and/or idler pulley installing position.
Belt tension
(4
replaced: 7 - 9 mm (0.276 - 0.354 in)
reused: 9.0 - 10.0 mm (0.354 - 0.394 in)
( 9 )*
replaced: 7.5 - 8.5 mm (0.295 - 0.335 in)
reused: 9.0 - 10.0 mm (0.354 - 0.394 in)
*: There is no belt (B) on models without an air con- 2. FRONT SIDE BELT (DRIVING POWER
ditioner. STEERING OIL PUMP AND GENERATOR)
98 N (10 ka. 22 Ib) NOTE:
Wipe off any oil or water on the belt and pulley.
1) Loosen the lock bolt (A).
2) Loosen the slider bolt (B).
3) Remove the front side belt (C).
4) Install a new belt, and tighten the slider bolt so as
to obtain the specified belt tension.
5) Tighten the slider bolt (B).
6) Tighten the lock bolt (A).
Tightening torque:
C/P Crankshaft pulley
Lock bolt, through bolt:
25 N-m (2.5 kgf-m, 18 ft-lb)
GEN Generator
Slider bolt:
P/S Power steering oil pump pulley
8 N.m (0.8 kgf-m, 5.8 ft-lb)
A/C Air conditioning compressor pulley
I/P Idler pulley
G10021A
PM-9
I DRIVE BELT(S)
3. REAR SIDE BELT (DRIVING AIR CONDI-

TIONER)
NOTE:
Before removing the rear side belt, remove the
front side belt.
1) Loosen the lock nut (A).
2) Loosen the slider bolt (9).
3) Remove the rear side belt.
4) Install a new belt, and tighten the slider bolt so as
to obtain the specified belt tension.
5) Tighten the slider bolt (9).
6) Tighten the lock nut (A).
Tightening torque:
22.6 N*m (2.3 kgf-m, 16.6 ff-lb)
PM-10
CAMSHAFT DRIVE BELT
1
7. Camshaft Drive Belt 10) Turn the crankshaft and align alignment marks
on crankshaft, and left and right camshaft sprock-
A: REPLACEMENT ets with notches of belt cover and cylinder block:
ST 499987500 CRANKSHAFT SOCKET
1. SOHC MODEL
Notch
1) Remove the radiator fan <Ref. to CO-9, Radia-
tor Main Fan System.> and air conditioner fan.
<Ref. to CO-17, Radiator Sub Fan System.>
2) Remove the V-belt cover.
ent mark
Notch
3)Remove the V-belts. <Ref. to ME(S0HC)-43, V-

belt.>
4) Remove the air conditioning compressor drive
belt tensioner.
5 ) Remove the pulley bolt. To lock crankshaft use
ST. G10025A
ST 499977t00 CRANKSHAFT PULLEY 11) Remove the belt idler.
WRENCH 12) Remove the belt idler (No. 2).
GI0026
6) Remove the crankshaft pulley. 13) Remove the timing belt.
7) Remove the left side belt cover. 14) Remove the automatic belt tension adjuster as-
8) Remove the front belt cover. sembly.
9) Remove the timing belt guide. (MT vehicle only)
PM-11
I CAMSHAFT DRIVE BELT 3
2. DOHCMODEL 10) Turn the crankshaft and align alignment marks

on crankshaft, and left and right camshaft sprock-
1) Remove the radiator fan and air conditioner fan. ets with notches of belt cover and cylinder block. To
turn crankshaft, use ST:
ST 499987500CRANKSHAFT SOCKET
Notch Notch
Alignment
mark
Alignment
mark
Notch -
2) Remove the V-belts. <Ref. to ME(D0HC TUR- Alignment
BO)-44, V-belt.> mark
belt tensioner.
4) Remove the pulley bolt. To lock crankshaft use ,Alignment
ST.
ST. 499977300
c-
CRANKSHAFT PULLEY
WRENCH
BOO139
11) Remove the belt idler.
5) Remove the crankshaft pulley.

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

installed, interference between pistons and
valves may occur.
--
4) Install the left and right timing belt covers.
2. DOHCMODEL
1) Remove the left and right timing belt covers.
2) While cranking engine at least four rotations,
check the timing belt back surface for cracks or
damage. Replace the faulty timing belt as needed.
3) Measure the timing belt width W. If it is less than
30 mm (1.18 in), check the idlers, tensioner, water
pump pulley and cam sprocket to determine idler
alignment (squareness). Replace the worn timing
belt.
4) Install the left and right timing belt covers.
GI0143
PM-13
I FUEL LINE
8. Fuel Line
A: INSPECTION
The fuel line is located mostly internally, so check
the pipes, areas near pipes, and engine compart-
ment piping for rust, hose damage, loose bands,
etc. If the faulty parts are found, repair or replace
them. <Ref. to FU(S0HC)-68, Fuel Delivery, Re-
turn and Evaporation Lines.> or <Ref. to FU(D0HC
TURBO)-68, Fuel Delivery, Return and Evapora-
tion Lines.>
c- .
PM-14
FUEL FILTER
9. Fuel Filter
A: REPLACEMENT
For fuel filter replacement procedures, refer to “FU”
section.
<Ref. to FU(S0HC)-65, Fuel Filter.> or <Ref. to
FU(D0HC TURBO)-65, Fuel Filter.>
PM-15
I AIR CLEANER ELEMENT
1O.Air Cleaner Element 2. TURBO MODEL
A: REPLACEMENT
NOTE:
Do not attempt to clean the air cleaner element.
The filter paper of the element is wetted with a spe-
cial non-inflammable slow-evaporating viscous liq-
uid. It is resistant to cold weather and has a long
service life. Dirt adhering to this filter paper forms
porous laminations with the viscous liquid, which
function as a filtration layer to reduce dust penetra-
tion into the filter paper. If this filter paper is 012E
cleaned, the filtration layer thus formed will be lost 1) Remove the clip (B) above the air cleaner case.
along with the viscous liquid.
1. NON-TURBO MODEL
2) Remove the air cleaner.

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

CAUTION:
Fasten with a clip after inserting the lower tab
of the case.
PM-16
COOLING SYSTEM
3
11.Cooling System Radiator cap valve open pressure

Standard value:
A: INSPECTION 93 - 123 kPa (0.95 - 1.25 k g / c d , 14 - 18
1) Check the radiator for leakage, filling it with cool- Psi)
ant and attach radiator cap tester to the filler neck. Service limit:
Then apply a pressure of 157 kPa (1.6 kg/cm2 , 23 83 kPa (0.85 k g / c d , 12 psi)
psi) and check the following points:
Each portion of radiator for leakage
Hose joints and other connections for leakage
NOTE:
When attaching or detaching tester and when
operating tester, use special care not to deform ra-
diator filler neck.
TURBO model tion,
/
Crack, deformation
damage, rust
G10035P
3) If the coolant temperature exceeds 76.0 to

80.0"C (169 to 176°F) while radiator is not so hot,
check thermostat. If thermostat does not open at
76.0 to 80.0"C (169 to 176"F), replace it with a new
one.
4) If electric fan does not operate when coolant
temperature exceeds 90 to 94°C (194 to 201"F),
check thermoswitch or fan motor.
When performing this check, be sure to keep the
engine stationary and fill radiator with coolant.
Wipe off check points before applying pressure.
Use care not to spill coolant when detaching
tester from radiator.
2) Check the radiator cap valve open pressure us-
ing radiator cap tester.
NOTE:
Rust or dirt on cap may prevent valve from func-
tioning normally: be sure to clean cap before test-
ing.
Raise the pressure until the needle of gauge stops
and see if the pressure can be retained for five to
six seconds. The radiator cap is normal if a pres-
sure above the service limit value has been main-
tained for this period.
PM-17
I COOLANT
12.Coolant 11) Stop the engine and wait until coolant temper-
ature lowers. Then open the radiator cap to check
A: REPLACEMENT coolant level and add coolant up to radiator filler
neck. Next, add coolant into reservoir tank up to
1. REPLACEMENT OF COOLANT “FULL” level.
WARNING: 12) After adding coolant, securely the install radia-
The radiator is of the pressurized type. Do not tor and reservoir tank caps.
attempt to open the radiator cap immediately
after the engine has been stopped.
1) Lift up the vehicle.
2) Remove the under cover.
3) Place a container under drain pipe.
4) Loosen and remove the drain plug to drain en-
gine coolant into the container.
5) For quick draining, open the radiator cap.

CAUTION:
Be careful not to spill coolant on the floor.
6) Drain the coolant from reservoir tank.
7) Tighten the radiator drain screw securely after
draining coolant.
8) Slowly pour the prepared coolant from radiator
filler port to neck of filler, then pour into the reser-
voir tank up to “FULL” level.
Coolant capacity (fill up to “FULL” level)
Non-turbo AT model:
Approx. 6.9 Q (7.3 US qt, 6.1 Imp qt)
Non-turbo MT model:
Approx. 7.0 Q (7.4 US qf, 6.2 Imp qt)
Turbo AT model:
Turbo MT model:
NOTE:
The SUBARU Genuine Coolant containing anti-
freeze and anti-rust agents is especially made for
SUBARU engine, which has an aluminum crank-
case. Always use SUBARU Genuine Coolant,
since other coolant may cause corrosion.
9) Securely install the radiator cap.
10) Run engine for more than five minutes at 2,000
to 3,000 rpm. (Run engine until radiator becomes
hot in order to purge air trapped in cooling system.)
PM-18
COOLANT I
2. RELATIONSHIP OF SUBARU COOLANT 3. PROCEDURE TO ADJUST THE CON-

CONCENTRATION AND FREEZING TEM- CENTRATION OF THE COOLANT
PERATURE To adjust the concentration of the coolant accord-
The concentration and safe operating temperature ing to temperature, find the proper fluid concentra-
of the SUBARU coolant is shown in the diagram. tion in the above diagram and replace the
Measuring the temperature and specific gravity of necessary amount of coolant with an undiluted so-
the coolant will provide this information. lution of SUBARU genuine coolant (concentration
[Example] 50).
If the coolant temperature is 25°C (77°F) and its The amount of coolant that should be replaced can
specific gravity is 1.054, the concentration is 35% be determined using the diagram.
(point A), the safe operating temperature is -1 4°C [Example]
(7°F) (point B), and the freezing temperature is - Assume that the coolant concentration must be in-
20°C (-4°F) (point C). creased from 25% to 40%. Find point A, where the
25% line of coolant concentration intersects with
the 40% curve of the necessary coolant concentra-
Safe operating temperature
tion, and read the scale on the vertical axis of the
/ ,Concentration
of coolant
graph at height A. The quantity of coolant to be
drained is 2.1 liters (2.2 US qt, 1.8 Imp qt). Drain
2.1 liters (2.2 US qt, 1.8 Imp qt) of coolant from the
cooling system and add 2.1 liters (2.2 US qt, 1.8
Imp qt) of the undiluted solution of SUBARU cool-
ant.
If a coolant concentration of 50% is needed, drain
all the coolant and refill with the undiluted solution
only.
-
I
-2
I
U Necessary concentration
r of coolant
Coolant temperature "C ("F)
G10037A
I
c 10 20 30 40 5C
0
-
c
%
c
(t(
Concentration of coolant in the vehicle
cooling system
3 Concentration of coolant in vehicle

and quantity to be drained
G10038A
PM-19
IDLE MIXTURE
13.Idle Mixture
A: INSPECTION AND ADJUSTMENT
1. IDLE MIXTURE
Before measuring the idle mixture, make sure that
the ignition timing and the engine idle speed are
within specifications.
1) Set the gear position at “Neutral” for MT, or “N” or
“P” for AT.
2) Warm up the engine sufficiently until cooling fan
starts to operate.
3) Measure the idle mixture with the CO meter.
Engine idle speed co
700+100 rpm 1.0+0.5% I
I GI01 14A 1
NOTE:
If driving the vehicle on out of specified data, the
“trouble code 49” is indicated in many case.
PM-20
CLUTCH SYSTEM
1
14.Clutch System 5) Check the fluid level using the scale on the out-
side of the clutch master cylinder tank (A). If the lev-
A: INSPECTION AND ADJUSTMENT el is below “MIN” (B), add clutch fluid to bring it up
1) Push the release lever to retract the push rod of to “MAX (C).
the operating cylinder and check if the fluid level in Recommended clutch fluid:
the clutch reservoir tank rises or not. FMVSS No. 116, fresh DOT3 or DOT4 brake
fluid
NOTE:
Avoid mixing different brakes of brake fluid to
prevent degradation of the fluid.
Be careful not to allow dirt or dust to get into the
reservoir tank.
TURBO model, \
2) If the fluid level rises, pedal free play is correct.

3) If the fluid level does not rise, or the push rod
cannot be retracted, adjust the clutch pedal. <Ref.
to CL-26, Clutch Pedal.>
4) Inspect the underside of master cylinder, clutch
damper and operating cylinder for clutch system,
hoses, piping and their couplings for fluid leaks.
If the fluid leaks are found, correct them by retight-
ening their fitting bolt and/or replacing their parts.
PM-21
I TRANSMISSION OIL
PERIODIC MAINTENANCE SERVJCES
~ ~~
15.Transmission Oil
A: REPLACEMENT
1. MANUAL TRANSMISSION
1) Drain the gear oil by removing drain plug after al-
lowing the engine to cool for 3 to 4 hours.
NOTE:
Before starting work, cool off the engine well.
2) Reinstall the drain plug after draining gear oil

and tighten it to the specified torque.
Tightening torque:
44 N.m (4.5 kgf-m, 32.5 ft-lb)
NOTE:
Be sure to place a gasket between the transmis-
sion case and drain plug.
Replace the gasket with a new one.
Each oil manufacturer has its base oil and addi-
tives. Thus, do not mix two or more brands.
3) Fill the transmission gear oil through the oil level
gauge hole up to the upper point of level gauge.
Gear oil capacity:
3.5 8 (3.7 US qt, 3.1 Imp qt)
\-upper
--Lower level
I
G10042P
PM-22
ATF 1
16.ATF 2. ATF FILTER
A: REPLACEMENT NOTE:
ATF filter is maintenance free part. ATF filter needs
1. AUTOMATIC TRANSMISSION FLUID replacement, when it has physically damaged or
ATF leaked.
1) Drain ATF (Automatic Transmission Fluid) by re-
moving drain plug after allowing the engine to cool For the replacement procedures Of the ATF filter:
for 3 to 4 hours. <Ref. to AT-44, ATF Filter.>
NOTE:
2) Reinstall the drain plug after draining ATF, and

tighten it to the specified torque.
Tighfening torque:
24.5 N.m (2.5 kgf-m, 78.7 ff-16)
3 ) Fill ATF up to the middle of the “COLD” side on
level gauge by using the gauge hole.
Recommended fluid:
Dexron 111 type automatic transmission fluid
Fluid capacity:
Fill the same amount drained from ATF drain
plug hole.
4) Run the vehicle until the ATF temperature rises
to 60 to 80°C (140 to 176°F) and check the ATF
level.
I “Hot”
Lower
level
G10044P
PM-23
I FRONT & REAR DIFFERENTIAL OIL I
17.Front & Rear Differential Oil 3. REAR DIFFERENTIAL

1) Drain the oil by removing drain plug.
A: REPLACEMENT 2) Remove the filler plug for quick draining oil.
1. FRONT DIFFERENTIAL (MANUAL 3) Reinstall the drain plug after draining oil.
TRANSMISSION) NOTE:
For M/T vehicle, manual transmission oil works as Apply the fluid packing to drain plug threads be-
differential oil to lubricate differential. Refer to fore installation in Except Non-TURBO AT model.
“Transmission Oil”. <Ref. to PM-22, Transmission Fluid packing:
Oil.> Three Bond 1105
2. FRONT DIFFERENTIAL (AUTOMATIC Tightening torque:
TRANSMISSION) 49.0 N-m (5.0 kgf-m, 36.2 ff-lb)
1) Drain the differential gear oil by removing drain 4) After installing drain plug onto rear differential
plug after allowing the engine to cool for 3 to 4 gear case firmly, fill oil up fully to the mouth of filler
hours. Plug.
NOTE:
L Drain plug
GI0165
Oil capacity:
0.8 8 (0.8 US 9t, 0.7 Imp 9t)
2) Reinstall drain plug after draining differential NOTE:
gear oil and tighten it to the specified torque. Each oil manufacturer has its base oil and addi-
tives. Thus, do not mix two or more brands.
Tightening torque:
5) Install the filler plug onto rear differential gear
44 N-m (4.5 kgf-m, 32.5 ff-lb)
case firmly.
NOTE:
NOTE:
Be sure to place a gasket between the transmis-
Apply the fluid packing to filler plug before installa-
sion case and drain plug.
Replace the gasket with a new one. tion.
Each oil manufacturer has its base oil and addi- Fluid packing:
tives. Thus, do not mix two or more brands. Three Bond 1105
3) Fill differential gear oil through the oil level gauge Tightening torque:
hole up to the upper point of level gauge. 49.0 Nom(5.0 kgf-m, 36.2 ff-lb)
Differential gear oil capacity:
1.1-1.3 8 (1.2-11.4US9t, l.0-11.11mp9t)
-Upper level
-Lower level
G10046A
PM-24
BRAKE LINE I
18.Brake Line B: CHECKING

A: INSPECTION 1. SERVICE BRAKE
1) Check the free play of brake pedal with a force of
1. BRAKE LINE less than 10 N (1 kgf, 2 Ib).
1) Check the scratches, swelling, corrosion and/or
Brake pedal free play:
traces of fluid leakage on brake hoses or pipe
joints. 1 - 3 mm (0.04 - 0.12 in)
2) Check the possibility of adjacent parts interfering
with brake pipedhoses during driving, and loose
connections/clamps.
3) Check any trace of fluid leakage, scratches, etc.
Brake booster
on master cylinder, wheel cylinder and pressure operating rod
control valve. Pedal play
1-3"
NOTE: (0.04 - 0.12 in)
When the brake fluid level in the reservoir tank is
lower than the specified limit, the brake fluid warn-
ing light on the combination meter will come on. G10050A
Visually check brake hose (using a mirror where
it is difficult to see) for any damage. he free play is out of specifications above, ad-
- just the brake pedal as follows:
C. - (1) Be sure the engine is off. (No vacuum is ap-
plied to brake booster.)
(2) There should be play between brake boost-
er clevis and pin at brake pedal installing por-
tion.
[Depress brake pedal pad with a force of less
than 10 N (1 kgf, 2 Ib) to a stroke of 1 to 3 mm
(0.04 to 0.12 in).]
(3) Depress the surface of brake pad by hand.
48A (4) If there is no free play between clevis pin
and clevis, turn brake switch adjusting nut until
the clearance between stopper and screw of
brake switch becomes 0.3 mm (0.012 in).
Brake switch
/
Lock nut
56 \ 0.3 mm (0.012 in)
Brake booster
operating rod
Play at pin
(0.04.- 0.12 in)
G10051A
PM-25
I BRAKE LINE I
3) Check the pedal stroke. 4) Check the valve is built into vacuum hose. Dis-
While the engine is idling, depress the brake pedal connect the vacuum hose to inspect function of
with a 490 N (50 kgf, 110 Ib) load and measure the check valve.
distance between the brake pedal and steering Blow air into vacuum hose from its brake booster
wheel. With the brake pedal released, measure the side end: Air must flow out of engine side end of
distance between the pedal and steering wheel hose. Next blow air into hose from engine side: Air
again. The difference between the two measure- should not flow out of hose.
ments must be less than 95 mm (3.74 in). If the dis- Replace the both check valve and vacuum hose if
tance is more than specified, there is a possibility the check valve is faulty. Engine side of vacuum
air is in the inside of the hydraulic unit. hose is indicated by marking “ENGINE as shown.
Brake pedal reserve distance: A
more than 95 mm (3.74 in)/490 N (50 kgf, 1 10
lb)
Engine side Brake booster side
ti - 1 2 = A
I steer i ng 4\
G10053A
.
c-
5) Check the vacuum hose for cracks or other dam-
age.
NOTE:
4) Check to see if air is in the hydraulic brake line by When installing the vacuum hose on the engine
the feel of pedal operation. If air appears to exist in and brake booster, do not use soapy water or lubri-
the line, bleed it from the system. cating oil on their connections.
5) Check for even operation of all brakes, using a 6) Check the vacuum hose to make sure it is tight
brake tester or by driving the vehicle for a short dis- and secure.
tance on a straight road.
2. BRAKE SERVO SYSTEM
1) With the engine off, depress the brake pedal
several times applying the same pedal force: Make
sure the travel distance should not change.
2) With the brake pedal depressed, start the en-
gine: Make sure the pedal should move slightly to-
ward the floor.
3) With the brake pedal depressed, stop the engine
and keep the pedal depressed for 30 seconds:
Make sure the pedal height should not change.
PM-26
BRAKE FLUID I
19.Brake Fluid NOTE:

Cover the bleeder with waste cloth, when loosen-
A: REPLACEMENT ing it, to prevent brake fluid from being splashed
1) Either jack up the vehicle and place a safety over surrounding parts.
stand under it, or lift up the vehicle. During bleeding operation, keep the brake re-
2) Remove the both front and rear wheels. serve tank filled with brake fluid to eliminate entry of
3) Draw out the brake fluid from master cylinder air.
with syringe. Brake pedal operation must be very slow.
4) Refill the reservoir tank with recommended For convenience and safety, it is advisable to
brake fluid. have two men working.
The amount of brake fluid required is approxi-
Recommended brake fluid: mately 500 m 0 (16.9 US fl oz, 17.6 Imp fl 02) for to-
FMVSS No. 116, fresh DOT3 or 4 brake fluid tal brake system.
NOTE: 6) Instruct your co-worker to depress the brake
Avoid mixing different brands of brake fluid to pedal slowly two or three times and then hold it de-
prevent degrading the quality of the fluid. pressed.
Be careful not to allow dirt or dust to get into the 7) Loosen the bleeder screw approximately 1/4 turn
reservoir tank. until a small amount of brake fluid drains into con-
Bleeding sequence (1) -+ (2) -+ (3) -+ (4) tainer, and then quickly tighten screw.
8) Repeat steps 6) and 7) above until there are no
I I air bubbles in drained brake fluid and new fluid
flows through vinyl tube.
NOTE:
Add the brake fluid as necessary while performing
the air bleed operation, in order to prevent the tank
from running short of brake fluid.
9) After completing the bleeding operation, hold
brake pedal depressed and tighten the screw and
install the bleeder cap.
Tightening torque:
(1) Front right 8 Nom(0.8 kgf-m, 5.8 ft-lb)
(2) Rear left 10) Bleed the air from each wheel cylinder by fol-
(3) Front left lowing the previous 5 steps.
(4) Rear right 11) Depress the brake pedal with a force of approx-
(5) Secondary imately 294 N (30 kgf, 66 Ib) and hold it there for ap-
(6) Primary proximately 20 seconds. At this time check pedal to
see if it makes any unusual movement. Visually in-
5) Install one end of a vinyl tube onto the air bleeder spect bleeder screws and brake pipe joints to make
and insert the other end of the tube into a container sure that there is no fluid leakage.
to collect the brake fluid. 12) Install the wheels, and drive the vehicle for a
short distance between 2 to 3 km (1 to 2 miles) to
make sure that brakes are operating properly.
I GI0055
PM-27
DISC BRAKE PADS AND DISCS
20.Disc Brake Pads and Discs 4) Measure the disc rotor runout at a point less than
5 mm (0.20 in) from the outer periphery of the rotor.
A: INSPECTION Disc rotor runout limit:
1. DISC BRAKE PAD AND DISC Front: 0.075 mm (0.0030 in)
Rear: 0.070 mm (0.0028 in)
1) Jack up the vehicle and support with rigid racks.
Then remove wheels. NOTE:
2) Visually check pad thickness through inspection When replacing a pad, always replace the pads for
hole of disc brake assembly. Replace the pad if both the left and right wheels at the same time. Also
necessary. replace pad clips if they are twisted or worn.
G10056A
GI0147
Pad thickness including back metal mm (in)

Front Rear
Standard 17 (0.67) 14 (0.55)
. .
I I
I
~I
1
Service limit I 7.5 (0.295) I 6.5 (0.256)
Thickness
of pad
3) Check the disc rotor, and correct or replace if it is

damaged or worn.
Brake disc thickness mm (in) 1
Front Rear
Standard 24 (0.94) 10 (0.39)
Wear limit 22 (0.87) 8.5 (0.335)
PM-28
BRAKE LININGS AND DRUMS 1
21.Brake Linings and Drums 3) Check the brake drum for wear, dents or other
damage.
A: INSPECTION If the inside surface of brake drum is streaked, cor-
rect the surface with emery cloth (#200 or more). If
1. REAR DRUM BRAKE it is unevenly worn, tapered, or the outside surface
1) Remove the brake drum, and check that there is of brake drum is damaged, correct or replace it.
no fluid leakage from wheel cylinder. Brake drum inner diameter
If there is fluid leakage from wheel cylinder, replace Standard value: 228.6 mm (9.000 in)
it. Service limit: 230.6 mm (9.079 in)
2) Inspect the brake shoes for damage or deformi-
If deformation or wear of back plate, shoe, etc. is
ties and check the brake linings for wear.
noticeable, replace the affected parts.
NOTE:
Always replace both leading and trailing brake
shoes for the left and right wheels at the same time.
When either the left or the right brake assembly
is replaced, always replace the leading shoe and
trailing shoe of the other.
The cotter pin, once removed, cannot be reused.
Thickness of lining (except back metal)
Standard value: 4.1 mm (0.161 in)
--
- Service limit: 1.5 mm (0.059 in)
I Y
I Measuring inside diameter
G10060A
2. PARKING BRAKE (REAR DISC BRAKE)

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

Clevis pin should also be replaced if worn.
Brake -shoe’ Brake shoe
(Primary) (Secondary)
G10061A
PM-29
I BRAKE LININGS AND DRUMS 1
2) Check the brake drum for wear, dents or other B: ADJUSTMENT

damage. If the inside surface of brake drum is
streaked, correct the surface with emery cloth 1. REAR DRUM BRAKE
(#200or more). If it is unevenly worn, tapered, or The main brake is adjusted automatically, and so
the outside surface of brake drum is damaged, cor- there is no need to adjust it.
rect or replace it.
Brake drum inside diameter
Standard value: 170 mm (6.69 in) For rear disc brake, adjust parking brake after
Wear limit: 171 mm (6.73 in) bleeding the air.
1) Remove rear cover (rubber) installed at back
plate.
2) Turn adjuster toward arrow mark (upward) until it
is locked slightly, by using slot-type screwdriver as
shown in illustration.
Adjuster
\
-Uinside diameter
Measuring
G10062A
3).If the deformation or wear of back plate, shoe,

etc. is noticeable, replace them.
4) When the shoe return spring tension is exces-
sively weakened, replace it, taking care to identify G10063A
upper and lower springs.
3)Turn back (downward) the adjuster 3 to 4 notch-
es.
4) Install the cover (rubber) at original position cor-
rectly.
PM-30
SUSPENSION I
22.Suspension 5 ) Damage of dust seal

Visually inspect ball joint dust seal. If it is damaged,
A: INSPECTION remove the transverse link. <Ref. to FS-17, Front
Transverse Link.> And measure free play of ball
1. SUSPENSION BALL JOINT joint. <Ref. to FS-19, Front Ball Joint.>
1) Jack up the vehicle until front wheels are off (1) When looseness exceeds standard value,
ground. replace ball joint.
2) Next, grasp the bottom of tire and move it in and (2) If the dust seal is damaged, replace with the
out. If relative movement is observed between new ball joint.
brake disc cover and end of transverse link, ball NOTE:
joint may be excessively worn. When transverse link ball joint has been removed
3) Next, grasp the end of transverse link and move or replaced, check toe-in of front wheel. If front
it up and down. Relative movement between hous- wheel toe-in is not at specified value, adjust toe-in.
ing and transverse link boss indicates ball joint may <Ref. to FS-8, Wheel Alignment.>
be excessively worn.
4) If the relative movement is observed in the im-
mediately preceding two steps, remove and inspect
the ball joint. If the free play exceeds standard, re-
place the ball joint. <Ref. to FS-19, Front Ball
Joint.>
G10066b
2. TRANSVERSE LINK'S REAR BUSHING

-Disc cover Check oil leaks at around liquid-filled bushing. If oil
Transv leaks, replace bushing.
Ball join{ w i v e movement
G10064A
Relative movement
Transverse link
Ball join;
G10065A
PM-31
I SUSPENSION I
3. WHEEL ARCH HEIGHT 3) When the toe-in and thrust angle are out of stan-
dard value, adjust them so that they conform to re-
1) Unload the cargoes and set the vehicle in curb
spective service standard.
weight (empty) condition.
2) Then, check the wheel arch height of front and 6. OIL LEAKAGE OF STRUT AND SHOCK
rear suspensions to ensure that they are within ABSORBER
specified values.
Visually inspect front strut and rear strut for oil leak-
3) When the wheel arch height is out of standard,
age as instructed. Replace front strut and rear strut
visually inspect following components and replace
if oil leaks excessively.
deformed parts.
Suspension components [Front strut assembly 7. TIGHTNESS OF BOLTS AND NUTS
and rear strut assembly]
Check the bolts and nuts shown in the figure for
Body parts to which suspensions are installed.
looseness. Retighten the bolts and nuts to speci-
4) When no components are deformed, adjust fied torque. If self-lock nuts and bolts are removed,
wheel arch height by replacing coil spring in the replace them with new ones.
suspension whose wheel arch height is out of stan-
Front suspension: <Ref. to FS-2, General Descrip-
dard. <Ref. to FS-8, Wheel Alignment.> <Ref. to
tion.>
RS-9, Wheel Alignment.>
Rear suspension: <Ref. to RS-2, General Descrip-
4. WHEEL ALIGNMENT OF FRONT SUS- tion.>
PENSI0N 8. DAMAGE TO SUSPENSION PARTS
1) Check the alignment of front suspension to en- 1) Check the following parts and the fastening por-
Sure that following items conform to standard val- tion of the vehicle body for deformation or exces-
ues. sive rusting which impairs the suspension. If
Toe-in necessary, replace damaged parts with new ones.
Camber angle If minor rust formation, pitting, etc. are noted, re-
Caster angle move rust and apply remedial anti-corrosion mea-
Steering angle sures.
<Ref. to FS-8, Wheel Alignment.> Front suspension
2) When the caster angle does not conform to stan- Transverse link
dard value, visually inspect following components Crossmember
and replace deformed parts. Strut
Suspension components [Strut assembly, cross- Rear suspension
member, transverse link, etc.] Crossmember
Body parts to which suspensions are installed. Lateral links
3) When the toe-in and camber are out of standard
Trailing link
value, adjust them so that they conform to respec-
Strut
tive service standard.
In the district where salt is sprayed to melt snow
4) When the right-and-left turning angles of tire are
out of standard, adjust to standard value. on a road in winter, check suspension parts for
damage caused by rust every 12 months after
5. WHEEL ALIGNMENT OF REAR SUS- lapse of 60 months. Take rust prevention measure
PENSI0N as required.
1) Check the alignment of rear suspension to en-
sure that following items are within standard val-
ues.
Toe-in
Camber angle
Thrust angle
<Ref. to RS-9, Wheel Alignment.>
2) When the camber angle does not conform to
standard value, visually inspect parts listed below.
If the deformation is observed, replace damaged
parts.
Suspension components [Strut assembly, cross-
member, trailing link, lateral links, etc.]
Body parts to which suspensions are installed.
PM-32
WHEEL BEARING 1
23.Wheel Bearing 6) While supporting rear drive shaft horizontally

with one hand, turn the hub COMPL with the other
A: INSPECTION to check for noise or binding.
If the hub COMPL is noisy or binds, disassemble
1. FRONT WHEEL BEARING the rear axle and check condition of oil seals, bear-
NOTE: ings, etc.
Inspect the condition of front wheel bearing grease.
1) Jack up the front of vehicle.
2) While holding front wheel by hand, swing it in
and out to check bearing free play.
3) Loosen the wheel nuts and remove the front
wheel.
4) If the bearing free play exists in step 2) above, at-
tach a dial gauge to hub and measure axial dis-
placement in axial direction.
Service limit:
Straight-ahead position within 0.05 mm
(0.0020 in)
5) Remove the bolts and self-locking nuts, and ex-
tract transverse link from the front crossmember.
--
6) While lightly hammering spring pin which se-
cures S.F.J. to transmission spindle, remove it.
7) Extract S.F.J. from the transmission spindle.
<Ref. to DS-17, Front Axle.>
8) While supporting front drive shaft horizontally
with one hand, turn the hub with the other to check
for noise or binding.
If the hub is noisy or binds, disassemble the front
axle and check condition of oil seals, bearing, etc.
Outer oil seal
I Hub’
GI0133
2. REAR WHEEL BEARING

1) Jack up the rear of vehicle.
2) While holding rear wheel by hand, swing it in and
out to check bearing free play.
3) Loosen the wheel nuts and remove the rear
wheel.
4) If the bearing free play exists in step 2) above, at-
tach a dial gauge to hub COMPL and measure ax-
ial displacement in axial direction.
Service limit:
Straight-ahead position within 0.05 mm
(0.0020 in)
5) Remove the DOJ of rear drive shaft from rear dif-
ferential. <Ref. to DS-39, Rear Drive Shaft.>
PM-33
I AXLE BOOTS & JOINTS I
24.Axle Boots & Joints

A: INSPECTION
1. FRONT AND REAR AXLE BOOTS
Inspect the front axle boots (A) and rear axle boots
(B) for deformation, damage or failure. If faulty, re-
place them with new ones. <Ref. to DS-32, Front
Drive Shaft.> <Ref. to DS-39, Rear Drive Shaft.>
c- .
2. PROPELLER SHAFT
Inspect the propeller shaft for damage or failure. If
faulty, replace with new one. <Ref. to DS-14, Pro-
peller Shaft.>
PM-34
STEERING SYSTEM (POWER STEERING) I
25.Steering System (Power 2. STEERING SHAFT JOINT

Steering) 1) When the steering wheel free play is excessive,
disconnect the universal joint of steering shaft and
A: INSPECTION check it for any play and yawing torque (at the point
of the crossing direction). Also inspect for any dam-
1. STEERING WHEEL age to sealing or worn serrations. If the joint is
1) Set the steering wheel in a straight-ahead posi- loose, retighten the mounting bolts to the specified
tion, and check the wheel spokes to make sure torque.
they are correctly set in their specified positions. Tightening torque:
2) Lightly turn the steering wheel to the left and right 24 N.m (2.4 kgf-m, 17.4 ff-lb)
to determine the point where front wheels start to
move.
Measure the distance of the movement of steering
wheel at the outer periphery of wheel.
Steering wheel free play:
0 - 17 mm (0 - 0.67 in)
I -Free play
3. GEARBOX
1) With wheels placed on a level surface, turn the
steering wheel 90" in both the left and right direc-
tions.
G10074A While the wheel is being rotated, reach under vehi-
cle and check for looseness in gearbox.
Move the steering wheel vertically toward the shaft
to ascertain if there is play in the direction. Tightening torque:
59 N-m (6.0 kgf-m, 43.4 ff-lb)
Maximum permissible play:
0.5 mm (0.020 in)
3 ) Drive the vehicle and check the following items
during operation.
(1) Steering force:
The effort required for steering should be
smooth and even at all points, and should not
vary.
(2) Pull to one side:
Steering wheel should not be pulled to either
side while driving on a level surface.
(3) Wheel runout:
Steering wheel should not show any sign of 2) Check the boot for damage, cracks or deteriora-
runout. tion.
(4) Return factor: 3) With vehicle on a level surface, quickly turn
steering wheel to the left and right.
Steering wheel should return to its original posi-
tion after it has been turned and then released. While steering wheel is being rotated, check the
gear backlash. If any unusual noise is noticed, ad-
Maximum permissible play: just the gear backlash in the following manner.
0.5 mm (0.020 in) (1) Tighten adjusting screw to 7.4 N.m (0.75
kgf-m, 5.4 ft-lb) and then loosen. Repeat this op-
eration twice.
(2) Retighten adjusting screw to 7.4 N.m (0.75
kgf-m, 5.4 ft-lb) and back off 25".
PM-35
I STEERING SYSTEM (POWER STEERING)
(3) Apply the liquid packing to at least 113 of en- 5. POWER STEERING FLUID LEVEL
tire perimeter of adjusting screw thread.
NOTE:
The fluid level must be checked when the temper-
ature of the reservoir tank surface is approximately
20°C (68°F).
1) Place the vehicle with engine “off” on the flat and
Apply liquid packing
to at least 1/3 of entire
level surface.
perimeter 2) Check the fluid level using the scale on the out-
side of the reservoir tank (A). If the level is below
“MIN” (B), add fluid to bring it up to “MAX’ (C).
w G10077A
(4) Install the lock nut. While holding adjusting

screw with a wrench, tighten lock nut using ST.
ST 926230000 SPANNER
Tightening torque (Lock nut):
39 N.m (4.0 kgf-m, 29 ft-lb)
Hold the adjusting screw with a wrench to pre-
vent it from turning while tightening the lock nut.
c-
4. TIE-ROD
NOTE:
1) Check the tie-rod and tie-rod ends for bends, If fluid level is at MAX level or above, drain fluid to
scratches or other damage. keep the level in the specified range of indicator by
using a syringe or the like.
Recommended fluid:
\ Dexron IIE or Ill
Fluid capacity:
0.7 Q (0.7 US qt, 0.6 Imp qt)
6. POWER STEERING FLUID FOR LEAKS
Inspect the underside of oil pump and gearbox for
power steering system, hoses, piping and their
G10105A couplings for fluid leaks.
2) Check the connections of knuckle ball joints for If the fluid leaks are found, correct them by retight-
play, inspect for damage on dust seals, and check ening their fitting bolts (or nuts) and/or replacing
free play of ball studs. If castle nut is loose, retight- their parts.
en it to the specified torque, then tighten further up NOTE:
to 60” until cotter pin hole is aligned. Wipe the leakage fluid off after correcting fluid
Tightening torque: leaks, or a wrong diagnosis is taken later.
27 N.m (2.75 kgf-m, 79.9 ft-lb) Also pay attention to clearances between hoses
(or pipings) and other parts when inspecting fluid
3) Check the lock nut on the tie-rod end for tight-
leaks.
ness. If it is loose, retighten it to the specified
torque.
Tightening torque:
83 N-m (8.5 kgf-m, 67.5 ft-lb)
PM-36
STEERING SYSTEM (POWER STEERING)
~
7. HOSES OF OIL PUMP FOR DAMAGES

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

A-GE
Check the power steering pipes for corrosion and
damage.
Replace the pipes with new one if necessary.
9. GEARBOX BOOTS
Inspect both sides of gearbox boots as follows, and
correct the defects if necessary.
1) (A) and (B) positions of gearbox boot are fitted
correspondingly in (A) and (B) grooves of gearbox
and the rod.
2) Clips are fitted outside of (A) and (B) positions of
boot.
3) Boot does not have crack and hole.
NOTE:
Rotate (B) position of gearbox boot against twist of
it produced by adjustment of toe-in, etc.
Apply clrease
G10023A
10.FITTING BOLTS AND NUTS

Inspect the fitting bolts and nuts of oil pump and
bracket for looseness, and retighten them if neces-
sary.
Inspect and/or retighten them when engine is cold.
PM-37
I SUPPLEMENTAL RESTRAINT SYSTEM
26.Supplemental Restraint System

A: INSPECTION
Check the airbag system in accordance with the result of the self-diagnosis. <Ref. to AB-2, Basic Diagnostic
Procedure.>
1) Ensure that airbag connectors are connected. If not, properly connect. When the ignition switch is turned
ON with the connector(s) disconnected, the airbag warning light blinks to identify the fault.
2) Turn the ignition switch ON, and connect the airbag diagnosis terminal of the service connector (located
below lower cover) to the ground terminal.
3) The warning light blinks to indicate a trouble code (a fault is identified). When the airbag system is in good
order (no trouble codes are stored in the memory), the warning light blinks on and off at 0.6 second intervals
(as long as the diagnosis terminal is connected to the ground terminal).
4) When the warning light indicates a trouble code, check the airbag system in accordance with the trouble-
shooting procedure. <Ref. to AB-2, Basic Diagnostic Procedure.>
PM-38
2002 IMPREZA SERVICE MANUAL
QUICK REFERENCE INDEX
NEW CAR INFORMATION SECTION
FOREWORD
This manual has been prepared to provide information

for the construction, operation and other technical de-
tails of SUBARU vehicles.
Read this manual thoroughly and make the most of it
to give better service to your customers and improve
your knowledge of vehicle maintenance.
All information, illustration and specifications con-

tained in this manual are based on the latest product
information available at the time of publication ap-
proval.
FUJI HEAVY INDUSTRIES LTD.

W1830BE
FOREWORD
I) * - D
* e
FOREWORD
FOREWORD
All right reserved. This book may not be reproduced or

copied, in whole or in part, without the written permis-
sion of FUJI HEAVY INDUSTRIES LTD., TOKYO JA-
PAN
SUBARU, @and @ are trademarks of FUJI

HEAVY INDUSTRIES LTD.
0 Copyright 2001 FUJI HEAVY INDUSTRIES LTD.

SPECIFICATIONS SPCa
Page
1. lmpreza . . . . . ...................... . . . . . ................. . . . . . . . . ......... . . . . . . . . .. . .. . 2
IMPREZA
Specifications
1. lmpreza
A: DIMENSIONS
Model Sedan Wagon OUTBACK
Overall length mm (in) 4,405 (173.4)
Overall width mm (in) 1,730 (68.1) 1,695 (66.7) 1,710 (67.3)
Overall height (at CW) mm (in) 1,440 (56.7) 1,465 (57.7), 1,475 (58.1),
I
1,485 (58.5)*2 I
1,495 (58.9)*2
Compartment Length mm (in) 1,890 (74.4) 1,845 (72.6)
Width mm (in) 1,380 (54.3)
Height mm (in) 1,180 (46.5) 1,200 (47.2), 1,200 (47.2),
1,I 50 (45.3)*3 1,I 50 (45.3)*3
Wheelbase mm (in) 2,525 (99.4)
Tread Front mm (in) 1,485 (58.5) 1,465 (57.7) 1,460 (57.5)
Rear mm (in) 1,475 (58.1), 1,455 (57.3) 1,455 (57.3)
1,480 (58.3)*1
Minimum road clearance mm (in) 150 (5.9), 150 (5.9), 160 (6.3)
155 (6.1)*1 155 (6.1)*1
B: ENGINE
Engine type Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine
I Valve arrangement I Overhead camshaft type
~~
Bore x Stroke mm (in) 92 x 75 99.5 x 79.0

(3.62 x 2.95) (3.917 x 3.1 10)
Displacement cm3 (cu in) 1,994 (121.67) 2,457 (149.9)
Compression ratio 8.0 10.0
Firing order 1-3-2-4
Idle speed at ParWNeutral rPm 650 (MT)
position (NC OFF) 750 700 (AT)
Maximum output kW (HP)/rpm 160 (215)/6,000 123 (165)/5,600
Maximum torque N.m (kgf-m,ft-lb)/rpm 294 (30.0, 217)/4,000 226 (23.0, 166)/4,000
SPC-2
IMPREZA
Specifications

Ignitiontiming at idling speed BTDC/rpm MT: 10" f 10°/650
12" k 10"/750
AT: 10" f 1O"I700
Spark plug NGK: PFRGG CHAMPION: RC1OYC4 (standard)
NGK: BKR5E-11
NGK: BKR6E-11
Generator 12V - 75A 12V - 90A
Battery Type MT: 12V - 48AH (55D23L) M I 12V - 48AH (55D23L)
AT: 12V - 52AH (65D23L) AT: 12V - 52AH (75D23L)
Reserve capacity min MT: 99 MT: 99
AT: 111 AT: 118
Cold cranking amp MT: 356 MT: 356
amperes AT: 420 AT: 520
I Model Turbo 2.0 L

Transmission type 5MTk1 4ATk2
Clutch type DSPD TCC
Gear ratio I 1st 3.454 2.785
I
I I
2nd 1.947 1.545 I

4th 0.972 0.694
5th 0.738 -
J
Reverse 3.333 2.272

Reduction 1st reduction Type of gear - Helical
gear (Front - 1.000
drive) Gear ratio
Final Tvpe of gear Hypoid Hypoid
Reduction Transfer Type of gear Helical -

gear (Rear -
reduction Gear ratio 1.100
drive)
Final Tvpe of gear Hypoid Hypoid
I I I I I I
5MT*l:5 forward speeds with synchromesh and 1-reverse

4AT*2:Electronically controlled fully-automatic, 4-forward speeds and 1-reverse
DSPD:Dry Single Plate Diaphragm
TCC:Torque Converter Clutch
SPC-3
IMPREZA
Specifications
Model 2.5 L
RS OTHERS
Transmission type 5MTA1 4ATA2 5MTA1 4ATA2
Clutch type DSPD TCC DSPD TCC
1st I 3.454 I 3.027 I 3.454 I 2.785 I
2nd I 2.062 I 1.619 I 2.062 I 1.545 I
3rd I 1.448 I 1.000 I 1.448 I 1.ooo I
4th I 1.088 I 0.694 1 1.088 1 1.694 I
5th I 0.780 I - I 0.780 I - I
Reverse I 3.333 I 2.272 I 3.333 I 2.272 I
Dual range I -
I - I -
I - I
Reduction 1st reduction Typeofgear I - I Helical I - I Helical 1
gear (Front
drive) Gear ratio I - I 1.000 I - I ~~
1.000
~
1
Final Type of gear Hypoid Hypoid Hypoid Hypoid
reduction
Gear ratio 4.111 4.444 3.900 4.111
Reduction Transfer Type of gear Helical - Helical -
gear (Rear reduction
drive) Gear ratio 1.ooo - 1.000 -
Final Type of gear Hypoid Hypoid Hypoid Hypoid
reduction
Gear ratio 4.111 4.444 3.900 4.111
SPC-4
IMPREZA
a
Specifications
E: STEERING
Turns, lock to lock 3.2 3

Minimum turning m (ft) Curb to curb 10.2 (33.5) 10.8 (35.4)
circle Wall to wall 11.1 (36.3) 11.7(38.3)
F: SUSPENSION
Front Macpherson strut type, Independent, Coil spring
Rear Dual link type, Independent, Coil spring
G: BRAKE
I
Service brake system Dual circuit hydraulic with vacuum suspended power unit
Front Ventilated disc brake
Rear Disc brake Drum brake, Disc brakekl I
I ParkinQ brake I Mechanical on rear brakes I
H: TIRE
Model TS OTHERS
Rim size 15 x 6JJ 16 x 6 '/2 JJ
Tire size P195/60R15 87H P205/55R16 89V
Type Steel belted radial, Tubeless
I: CAPACITY
II Model I
Turbo 2.0 L
I
2.5 L
5MT 4AT 5MT 4AT
Fuel tank e (US gal, Imp gal) 60 (15.9, 13.2) 60 (15.9, 13.2)
Engine oil 1 Upper level e (US qt, Imp qt) 4.5 (4.8,4.0) 4.0 (4.2, 3.5)
Lower level (US qt, Imp qt) 3.5 (3.7,3.1) 3.0 (3.2, 2.6)
Transmission gear oil e (US qt, Imp qt) 3.5 (3.7, 3.1) - 3.5 (3.7,3.1) -
Automatic transmission fluid (US qt, Imp qt) - 9.3 (9.8,8.2) - 9.5 (10.0,8.4)
AT differentialgear oil e (US qt, Imp qt) - 1.2 (1.3, 1.l) - 1.2(1.3, 1.1)
AWD rear differentialgear oil e (US qt, Imp qt) 0.8 (0.8,0.6)
Power steering fluid e (US qt, Imp qt) 0.7 (0.7, 0.6)
Engine coolant e (US qt, Imp qt) 7.7 (8.1, 6.8) I 7.6(8.0,6.7) I 7.0(7.4,6.2) I 6.9 (7.3,6.1)
SPC-5
IMPREZA
Specifications
J: WEIGHT
1. U.S. SPEC. VEHICLE
Sedan
Model I AWD I
I Turbo 2.0 L I 2.5 L I
I WRX I RS I
5MTA1 4ATA 1 5MT 4AT
Curb weight (C.W.) I Front kgf (Ib) 826 (1,820) 851 (1,875) 778 (1,715) 803 (1,770)
I Rear kgf (Ib) I 569 (1,255) I 569 (1,255) I 567 (1,250) I 567 (1,250) I
I Total kgf (Ib) I 1,395 (3,075) 1 1,420 (3,130) I 1,345 (2,965) I 1,370 (3,020) I
Gross vehicle weight Front kgf (Ib) 1 998 (2,200) I 998 (2,200) I 939 (2,070) I 939 (2,070) I
(G.V. W.)
Rear kgf (Ib) I 857 (1,890) I 857 (1,890) I 857 (1,890) I 857 (1,890) I
Total kgf (Ib) I 1,837 (4,050) I 1,837 (4,050) I 1,778 (3,920) I 1,778 (3,920) I
A1 :Excl,udesweight of side air bag.
Wagon
Model I AWD
I Turbo 2.0 L I 2.5 L
I WRX I TS I OUTBACK
1 5MTA1 4ATkl 5MTk2 4ATA2 5MT 4AT
Curb weight (C.W.) Front 851 773 796 783 805
(1,875) (1,705) (1,755) (1,725) (1,775)
Rear
kgf (Ib) I (1,335)
606
605
(1,335) 1 603
(1,330) 1 606
(1,335) I 601
(1,325) 1 603
(1,330)
Total
kgf (Ib) I (3,155)
1,458
(3,210) I 1,376
(3,035) 1 1,402
(3,090) I 1,384
(3,050) 1 1,408
(3,105)
Gross vehicle weight
(G.V.W.)
Front
(2,200)
998
(2,200) 1 939
(2,070) 1 939
(2,070) 1 939
(2,070) 1 939
(2,070)
Rear 925
(2,040) 1 925
(2,040) I 925
(2,040) [ 925
(2,040) I 925
(2,040)
Total
A1 :Excludes weight of side air bag.

1,901
(4,109) 1 1,833
(4,040) 1 1,833
(4,040) I 1,833
(4,040) I 1,033
(4,040)
A2:Excludes weight of ABS, cruise control.
SPC-6
IMPREZA
Specifications
2. CANADA SPEC. VEHICLE
Model AWD
Turbo 2.0 L 2.5 L
I WRX
I
RS I
5MT 4AT 5MT 4AT
Curb weight (C.W.) I Front kgf (Ib) 826 (1,820) 851 (1,875) 778 (1,715) 803 (1,770)
Rear kgf (Ib) 573 (1,265) 573 (1,265) 567 (1,250) 567 (1,250)
Total kgf (Ib) 1,399 (3,085) 1,424 (3,140) 1,345 (2,965) 1,370 (3,020)
I I I I I
Gross vehicle weight 1 Front kgf (Ib) I 998 (2,200) I 998 (2,200) I 939 (2,070) I 939 (2,070)
(G.V.W.)
Rear kgf (Ib) 857 (1,890) 857 (1,890) 857 (1,890) 857 (1,890)
Total kgf (Ib) 1,837 (4,050) 1,837 (4,050) 1,778 (3,920) 1,778 (3,920)
Rear kgf (Ib) 925 925 925 925 925 925

(2,040) (2,040) (2,040) (2,040) (2,040) (2,040)
Total kgf (Ib) 1,901 1,901 1,833 1,833 1,833 1,833
(4,190) (4,190) (4,040) (4,040) (4,040) (4,040)
SPC-7
IMPREZA
SDecifications
MEMO
SPC-8
FUEL INJECTION
(FUEL SYSTEM) FU WHC)
1.
2.
3.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .
Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
Fuel Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
2
3 I
4. Sensors and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5. Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6. On-board Diagnosis System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
GENERAL
Fuel Injection (Fuel System)
1. General
0 The Multipoint Fuel Injection (MFI) system supplies optimum air-fuel mixture under every engine
operating condition through the use of the latest electronic control technology.
This system pressurizes the fuel to a constant pressure and injects it into each intake air port in
the cylinder head. The injection quantity of fuel is controlled by an intermittent injection system
where an electro-magnetic injection valve or injector opens for a short period that is precisely con-
trolled depending on the quantity of air appropriate for each condition of operation. In actual con-
trol, an optimum fuel injection quantity is achieved by varying the duration of an electric pulse ap-
plied to the injector. This way of control enables simple, yet highly precise metering of the fuel.
0 The engine control module (ECM) that controls the fuel injection system corrects the fuel injec-
tion amount depending on the vehicle speed, throttle opening, coolant temperature and other ve-
hicle-operation-related information. The ECM receives the information in the form of electric sig-
nals from the corresponding sensors and switches.
The MFI system also has the following features:
0 Reduced exhaust emissions
0 Reduced fuel consumption
0 Increased engine output
0 Quick response to accelerator and brake pedal operation
Superior startability and warm-up performance in cold weather due to corrective controls made
according to coolant and intake air temperatures
FU-2
AIR LINE
2. Air Line
A: GENERAL
The air filtered by the air cleaner enters the throttle body where it is regulated in the volume by the
throttle valve and then enters the intake manifold. It is then distributed to each cylinder where the
air is mixed with fuel injected by the injector. During idling operation, air flows into the cylinder
through the idle air control solenoid valve, bypassing the throttle valve. This enables controlling
the engine idling speed properly.
B: INTAKE MANIFOLD PRESSURE AND AIR TEMPERATURE SENSORS

The intake manifold pressure sensor and the intake air temperature sensor are integrated into a
single unit. The unit is mounted on the intake manifold and measures the absolute air pressure in
the intake manifold as well as the temperature of the intake air.
The measured pressure and temperature are converted into electrical signals and sent to the
ECM. The ECM uses these signals to control injection and ignition timing as well as the fuel injec-
tion amount.
H2H2825B
(1) Pressure sensor

(2) Intake air temperature sensor
FU-3
I
AIR LINE
C: ATMOSPHERIC PRESSURE SENSOR

The atmospheric pressure sensor converts pressure values into electric signals, and sends the
signals to the ECM.
NF0007
(1) Sensor unit (6) Terminal

(2) O-ring (7) Inner lead
(3) Case (8) Resin
(4) Pipe (9) Metal lid
(5) Through capacity
D: THROTTLE BODY
In response to operation of the accelerator pedal, the throttle valve in the throttle body opens/
closes to regulate the volume of the air drawn into the combustion chamber.
0 During idling, the throttle valve is almost fully closed and the volume of air passing through the
throttle body is less than that passing through the idle air control solenoid valve.
0 More than half of the air necessary for idling is supplied to the intake manifold via the idle air
control solenoid valve which controls properly the engine idling speed, so the idling speed needs
not be adjusted.
FU-4
a
AIR LINE
E: THROTTLE POSITION SENSOR

0 The throttle position sensor is mounted in the throttle body and linked to the throttle valve.
0 The throttle position sensor sends the ECM voltage signal corresponding to the opening of the
throttle valve. When the sensor’s output voltage exceeds a predetermined level, the ECM inter-
prets it as complete closure of the throttle valve. When the output voltage is at another predeter-
mined level, the ECM recognizes that the throttle valve is at a wide open position. Since the output
characteristics of the sensor change over years, the ECM is provided with a learning function to
be able to interpret signals into throttle valve angles always correctly.
B2H2004B
(1) Lever
(2) Terminal
FU-5
AIR LINE
F: IDLE AIR CONTROL SOLENOID VALVE

0 The idle air control solenoid valve is located in the throttle body and regulates the amount of in-
take air that flows bypassing the throttle valve into the intake manifold during engine idling. It is
activated by a signal from the ECM in order to maintain the engine idling speed at a target speed.
0 The idle air control solenoid valve is a stepping motor type solenoid-actuated valve which con-
sists of coils, a shaft, a permanent magnet, a spring and a housing. The housing is an integral part
of the throttle body.
The stepping motor consists of two paired coils, the coils of each pair being arranged face to
face with a shaft in between.
0 The shaft has a screw at the end around which the permanent magnets are arranged.
0 As current flows in the form of pulses through the paired coils sequentially while alternating the
polarity, the N and S poles of the permanent magnets around the shaft are repelled by the same
poles of the magnetism generated by the coils. This causes a nut externally fixed to the magnets
and internally engaging with the screw of the shaft to turn.
The shaft then goes upward or downward.
This upward and downward motions of the shaft open or close the valve port, adjusting the
amount of bypass air.
B2H2005B
(1) Connector
(2) Permanent magnet
(3) Shaft
(4) Coil
(5) Spring
FU-6
I m
AIR LINE
G: AIR ASSIST INJECTOR SOLENOID VALVE

The air assist injector solenoid valve is located in the piping between the throttle body and the in-
jector and secured to the intake manifold.
This solenoid valve is opened or closed by the signals from the ECM, adjusting the flow rate of air
supplied to the injector.
82H34478
(1) Valve sheet A: From idle air control solenoid valve

(2) Solenoid B: To injector
(3) Plunger and valve
(4) Spring
(5) Connector
FU-7
FUEL LINE
3. Fuel Line
A: GENERAL
0 The fuel pressurized by the fuel tank inside pump is delivered to each fuel injector by way of the
fuel pipe and fuel filter. Fuel injection pressure is regulated to an optimum level by the pressure
regulator.
0 Each injector injects fuel into the intake port of the corresponding cylinder where the fuel is
mixed with air. The mixture then enters the cylinder.
Fuel injection amount and timing are regulated by the ECM.
NF0477
(1) Fuel gauge Canister (19) Fuel tank

(2) Combination meter ECM (20) Vent valve
(3) Fuel injector Pressure control solenoid valve (21) Shut-off valve
(4) Pressure regulator Fuel tank pressure sensor (22) Drain filter
(5) Throttle body Fuel temperature sensor (23) Fuel sub level sensor
(6) Intake manifold Fuel level sensor
(7) Fuel filter Fuel pump
(8) Purge control solenoid valve Jet pump (a) Fuel line
(9) Drain valve Fuel cut valve (b) Evaporation line
FU-8
FUEL LINE
Fuel lniection (Fuel System\
B: PRESSURE REGULATOR
The pressure regulator is installed at the injector end of the fuel supply line. It has a fuel chamber
and spring chamber separated by a diaphragm. Fuel chamber is connected to the fuel supply
line and the spring chamber is connected to the intake manifold. Fuel chamber also has a relief
valve connected to the fuel return line through which fuel returns to the fuel tank. When the intake
manifold vacuum increases, the diaphragm is pulled and the relief valve opens to decrease the
fuel supply line pressure (or fuel injection pressure). When the intake manifold vacuum decreases,
the diaphragm is pushed by the spring to increase the fuel supply line pressure. Thus, the differ-
ence between the fuel injection pressure and the intake manifold vacuum is kept at a constant level
of 299.1 kPa (3.05 kgf/cm2, 43.4 psi) to precisely control the amount of injected fuel.
A
S2H0623C
(1) Relief valve A: To intake manifold

(2) Diaphragm B: Fuel IN
C: FuelOUT
FU-9
I
FUEL LINE
C: FUEL INJECTORS
0 The MFI system employs top feed type fuel injectors with an air assist feature.
0 Each injector is installed in the fuel pipe in such a way that the injector is cooled by fuel.
0 The features of this type of fuel injector are as follows:
1) High heat resistance
2) Low driving noise
3) Easy to service
4) Small size
0 The injector injects fuel according to the valve open signal from the ECM. The needle valve is
lifted by the solenoid which is energized on arrival of the valve open signal.
0 Since the injector’s nozzle hole area, the lift of valve and the fuel pressure are kept constant, the
amount of fuel injected is controlled only by varying the duration of the valve open signal from the
ECM.
0 Fuel atomization is enhanced using assist air supplied from the idle air control solenoid valve
passing through the passage formed in the intake manifold at the area in which each injector is
installed. This contributes not only to higher combustion efficiency and higher output but also to
cleaner exhaust emissions.
S2H1943A
(1) Filter (4) Seal

(2) O-ring (5) O-ring
(3) Plunger (6) Connector
FU-10
FUEL LINE
D: FUEL TANK
The fuel tank utilizes a two-compartment design to ensure sufficient capacity without interfering
with the rear differential. It is provided with a suction jet pump (included in the fuel pump and fuel
level sensor assembly) which transfers fuel from one compartment to the other. Each compartment
has an individual fuel level sensor.
The fuel tank is located under the rear seat and secured with hold-down bands.
NF0473
(1 ) Fuel pump and fuel level sensor assembly (4) Cushion

(2) Fuel sub level sensor (5) Steel
(3) Band
FU-11
FUEL LINE
E: FUEL PUMP AND FUEL LEVEL SENSOR ASSEMBLY

1. FUELPUMP
The fuel pump consists of a motor, impeller, pump casing, pump cover, check valve and filter. It
is located in the fuel tank and combined with the fuel level sensor into a single unit. The operation
of this impeller type pump is very quiet.
NF0474
(1) Fuel pump (9) Motor armature

(2) Fuel level sensor (IO) Suction
(3) Jet pump (11) Discharge
(4) Mesh filter (12) Vane groove
(5) Fuel temperature sensor
(6) Impeller A: From engine (return line)
(7) Check valve B: From sub tank
(8) Pump casing C: To engine (delivery line)
0 When the ignition switch is turned ON, fuel pump relay is activated. Then the motor operates
to rotate the impeller.
0 As the impeller rotates, fuel in a vane groove of the impeller flows along the fuel passage into
the next vane groove by centrifugal force. When fuel flows from one groove to the next, a pressure
difference occurs due to friction. This creates a pumping effect.
0 The fuel pushed up by rotation of the impeller then passes through the clearance between the
armature and the magnet of the motor and is discharged through the check valve.
0 When the fuel discharge pressure reaches the specified level, the relief valve opens and excess
fuel is released into the fuel tank. In this manner, the relief valve prevents an abnormal increase
in fuel pressure.
0 When the engine and the fuel pump stop, spring force acts on the check valve to close the dis-
charge port, so that the fuel pressure in the fuel delivery line is retained.
FU-12
FUEL LINE
2. FUEL LEVEL SENSOR

The fuel level sensor forms part of the fuel pump and located in the fuel tank. The sensor outputs
an electric resistance signal that varies with movement of its float to indicate the level of the fuel
remaining in the tank.
NF0327
(1) Fuel level sensor

(2) Float
FU-13
FUEL LINE
3. JETPUMP
0 The jet pump utilizes the velocity of fuel returning from the engine to produce negative pressure
in it.
0 Using the pumping effect produced by the negative pressure, the jet pump transfers fuel from
the sub-compartment to the main compartment of the fuel tank.
0 When the return line nozzle is clogged, the fuel sent back through the return line flows back into
the fuel tank via the relief valve.
A A
+ t
(1) Relief valve A: Return line

(2) Nozzle
FU-14
m
FUEL LINE
Fuel lniection (Fuel System)
F: SUB-COMPARTMENT FUEL LEVEL SENSOR

This sensor detects the level of the fuel in the sub-compartment (the compartment in which the
fuel pump is not located) and acts as part of the fuel transfer line when the jet pump is in operation
to maintain the fuel in both compartments at the same level.
NF0396
(1) Fuel level sensor A: Tojet pump

(2) Float
G: FUEL FILTER
The fuel filter located in the engine compartment is a pressure-withstanding, cartridge type. It has
a filter element in a metal case. The fuel entering the filter flows from the perimeter of the element
to the center of the filter and goes out from there.
NF0018
FU-15
SENSORS AND SWITCHES
Fuel lniection (Fuel Svstem)
4. Sensors and Switches

A: FRONT OXYGEN (NF)SENSOR
0 The front oxygen sensor uses zirconium oxide (Zr02) which is a solid electrolyte, at portions ex-
posed to exhaust gas.
0 The zirconium oxide has the property of generating electromotive force when its both sides are
exposed to oxygen ions of different concentration and the magnitude of this electromotive force
depends on how much the difference is.
0 The front oxygen sensor detects the amount of oxygen in exhaust gases by making use of this
property of the zirconium oxide material.
0 The zirconium oxide material is formed into a closed end tube and its external surface is ex-
posed to exhaust gases with smaller oxygen ion concentration, whereas its internal surface is ex-
posed to atmospheric air. The external surface has a porous platinum coating. The sensor housing
is grounded to the exhaust pipe and the inside is connected to the ECM through the harness to
be able to use the current output from the sensor.
0 The sensor incorporates a ceramic heater to improve its performance at low temperatures.
Y
(3)
1-
I
(4)
S2H1791B
(1) Sensor element

(2) Sensor housing
(3) Protection tube
(4) Gasket
FU-16
0 When rich air-fuel mixture is burnt in the cylinder, the oxygen in the exhaust gases is almost com-
pletely used in the catalytic reaction by the platinum coating on the external surface of the zirconia
tube. This results in a very large difference in the oxygen ion concentration between the inside and
outside of the tube, and the electromotive force generated is large.
0 When a lean air-fuel mixture is burnt in the cylinder, relatively large amount of oxygen remains
in the exhaust gases even after the catalytic action, and this results in a small difference in the oxy-
gen ion concentration between the tube's internal and external surfaces. The electromotive force
in this case is very small.
0 The difference in oxygen concentration changes drastically in the vicinity of the stoichiometric
air-fuel ratio, and hence the change in the electromotive force is also large. By using this informa-
tion, the ECM can determine the air-fuel ratio of the supplied mixture easily. The front oxygen sen-
sor does not generate much electromotive force when the temperature is low. The output charac-
teristics of the sensor stabilize at a temperature of approximately 700°C (1,292"F).
Atmospheric air /- Zro2
Lean - Air-fuel ratio - Rich
Ceramic heater -.J

NF0331
FU-17
B: REAR OXYGEN SENSOR

0 The rear oxygen sensor is used to sense oxygen concentration in the exhaust gas. If the air-fuel
ratio is leaner than the stoichiometric ratio in the mixture (i.e., excessive amount of air), the exhaust
gas contains more oxygen. To the contrary, if the fuel ratio is richer than the stoichiometric ratio,
the exhaust gas contains almost no oxygen.
0 Detecting the oxygen concentration in exhaust gas using the oxygen sensor makes it possible
to determine whether the air-fuel ratio is leaner or richer than the stoichiometry.
0 The rear oxygen sensor has azirconia tube (ceramic) which generates voltage if there is a differ-
ence in oxygen ion concentration between the inside and outside of the tube. Platinum is coated
on the inside and outside of the zirconia tube as a catalysis and electrode material. The sensor
housing is grounded to the exhaust pipe and the inside is connected to the ECM through the har-
ness.
0 A ceramic heater is employed to improve performance at low temperatures.
/ \\ \
(4)
(5)
B2H381OC
(1) Protectiontube (4) Gasket

(2) Ceramic heater (5) Sensor housing
(3) Zirconia tube (6) Harness
FU-18
tube. This results in a very large difference in the oxygen ion concentration between the inside and
0s as rich
s o
-t
C L
Comparison
p sz
.- voltage
-
E% - ~ -
gz%
25
s 4
To be judged
- x o
w o >
Small
C: ENGINE COOLANT TEMPERATURE SENSOR

The engine coolant temperature sensor is located on the engine coolant pipe. The sensor uses
a thermistor whose resistance changes inversely with temperature. Resistance signals as engine
coolant temperature information are transmitted to the ECM to make fuel injection, ignition timing,
purge control solenoid valve and other controls.
1 A
-20 0 20 40 60 80
Temp. "C ( O F )
(-4) (32) (68) (104)(140)(176)
S2H1113B
(1) Connector (2) Thermistor element
FU-19
D: CRANKSHAFT POSITION SENSOR

The crankshaft position sensor is installed on the oil pump which is located in the front center
portion of the cylinder block. The sensor generates a pulse when one of the teeth on the perimeter
of the crankshaft sprocket (rotating together with the crankshaft) passes in front of it. The ECM de-
termines the crankshaft angular position by counting the number of pulses.
The crankshaft position sensor is a molded type which consists of a magnet, core, coil, terminals
and other components as illustrated below.
NF0024
(1) Terminal (4) Coil

(2) Yoke core (5) Core
(3) Magnet (6) Cover
FU-20
0 As the crankshaft rotates, each tooth aligns with the crankshaft position sensor. At that time, the
magnetic flux in the sensor’s coil changes since the air gap between the sensor pickup and the
sprocket changes. This change in magnetic flux induces a voltage pulse in the sensor and the
pulse is transmitted to the ECM.
NF0398
(1) Crankshaft position sensor

(2) Crankshaft sprocket
(3) Crankshaft half rotation
FU-21
E: CAMSHAFT POSITION SENSOR

0 The camshaft position sensor is located on the left-hand camshaft support. It detects the com-
bustion cylinder at any given moment.
0 The sensor generates a pulse when one of the bosses on the back of the left-hand camshaft
drive sprocket passes in front of the sensor. The ECM determines the camshaft angular position
by counting the number of pulses.
Internal construction and the basic operating principle of the camshaft position sensor are similar
to those of the crankshaft position sensor. A total of seven bosses are arranged at equally spaced
four locations (one each at two locations, two at one location, and three at one location) of the
sprocket as shown below.
S2H1813A
(1) Boss (4) Camshaft position sensor

(2) Camshaft sprocket (5) Boss
(3) Airgap (6) Camshaft one rotation (Crankshafttwo rotations)
FU-22
I
F: KNOCK SENSOR
0 The knock sensor is installed on the cylinder block, and senses knocking that occurs in the en-
gine.
0 The sensor is a piezo-electric type which converts vibration resulting from knocking into electric
signals.
0 In addition to a piezo-electric element, the sensor has a weight and case as its components.
If knocking occurs in the engine, the weight in the case moves causing the piezo-electric element
to generate a voltage.
0 The knock sensor harness is connected to the bulkhead harness.
(2)
B2H1998B
(1) Nut A: To knock sensor harness

(2) Weight
(3) Resistor
(4) Housing
(5) Piezo-electric element
FU-23
G: VEHICLE SPEED SENSOR

1. MT VEHICLES
0 The vehicle speed sensor is mounted on the transmission.
0 The vehicle speed sensor generates a 4-pulse signal for every rotation of the front differential
and send it to the ECM and the combination meter.
B2H2458C
(1) Combination meter

(2) ECM
(3) Vehicle speed sensor
(4) Transmission
FU-24
2. AT VEHICLES
and send it to the transmission control module (TCM). The signal sent to the TCM is converted
there into a 4-pulse signal, and then sent to the ECM and the combination meter.
62H24596

(2) ECM
(3) TCM
(5) Transmission
FU-25
CONTROL SYSTEM
5. Control System
A: GENERAL
The ECM receives signals from various sensors, switches, and other control modules. Using these
signals, it determines the engine operating conditions and if necessary, emits signals to one or
more systems to control them for optimum operation.
Major control items of the ECM are as follow:
0 Fuel injection control
0 Ignition system control
0 Idle air control
0 Fuel pump control
0 Canister purge controt*1
0 Radiator fan control**
0 On-board diagnosis function
*I : Canister purge control is described under “EC (SOHC) - Emission Control (Aux. Emission Con-
trol Devices) Evaporative Emission Control System”.
*2: Radiator fan control is described under “CO - Cooling”.
FU-26
CONTROL SYSTEM
B: INPUT AND OUTPUT SIGNALS

~ ~
Signal Unit Function

~~ ~
Intake air temperature and pressure Detects the temperature of intake and amount of intake air (Mea-
sensor sures the absolute pressure).
Detects the amount of intake air (Measure the atmospheric pres-
Atmospheric pressure sensor
sure).
Throttle position sensor Detects the throttle valve position.
Detects the density of oxygen in exhaust gases at the upstream of
Front oxygen (NF) sensor
the front catalytic converter.
Detects the density of oxygen in exhaust gases at the downstream
Rear oxygen sensor
of the front catalytic converter.
Crankshaft position sensor Detects the crankshaft angular position.
Camshaft position sensor Detects the combustion cylinder.
Engine coolant temperature sensor Detects the engine coolant temperature.
Knock sensor Detects engine knocking.
Vehicle speed sensor Detects the vehicle speed.
Ignition switch Detects operation of the ignition switch.
nput signals
Starter switch Detects the condition of engine cranking.
Neutral position switch (MT) Detects that the gear is in neutral.
ParWNeutral position switch (AT) Detects shift positions.
Torque control signal (AT) Controls engine torque.
Heater circuit of front and rear oxy- Detects abnormality in the heater circuit of the front and rear oxygen
gen sensor sensors.
Diagnostics of TCM (AT) Detects the self-diagnostics of the TCM.
N C switch Detects ON-OFF operation of the A/C switch.
Fuel temperature sensor Detects the temperature of the fuel in the fuel tank.
Fuel level sensor Detects the level of the fuel in the fuel tank.
Fuel tank pressure sensor Detects the evaporation gas pressure in the fuel tank.
Small light switch Detects ON-OFF operation of the small light switch.
Blower fan switch Detects ON-OFF operation of the blower fan switch.
Rear defogger switch Detects ON-OFF operation of the rear defogger switch.
~~
Fuel Injector Activates an injector.

Ignition signal Turns the primary ignition current ON or OFF.
~~
Fuel pump relay Turns the fuel pump relay ON or OFF.

~~
N C control relay Turns the N C control relay ON or OFF.

Radiator fan control relay Turns the radiator fan control relay ON or OFF.
Adjusts the amount of air flowing through the bypass line in the
Idle air control solenoid valve
3utput signals throttle body.
Malfunction indicator lamp Indicates existence of abnormality.
Purge control solenoid valve Controls purge of evaporative gas absorbed by the canister.
Power supply Control ON/OFF of the main power supply relay.
Pressure control solenoid valve Controls evaporation gas pressure in the fuel tank.
Closes the evaporation line between the fuel tank and canister to
Drain valve
detect leakage of evaporation gases.
FU-27
CONTROL SYSTEM
C: FUEL INJECTION CONTROL

0 The ECM receives signals from various sensors and based on them, it determines the amount
of fuel injected and the fuel injection timing. It performs the sequential fuel injection control over
the entire engine operating range except during start-up of the engine.
0 The amount of fuel injected depends upon the length of time the injector stays open. The fuel
injection duration is determined according to varying operating condition of the engine. For the
purpose of achieving highly responsive and accurate fuel injection duration control, the ECM per-
forms a new feedback control that incorporates a learning feature as detailed later.
0 The sequential fuel injection control is performed such that fuel is injected accurately at the time
when the maximum air intake efficiency can be achieved for each cylinder (i.e., fuel injection is
completed just before the intake valve begins to open).
1. FUEL INJECTION DURATION

Fuel injection duration is basically determined as indicated below:
0 During engine start-up:
The duration defined below is used.
0 Duration of fuel injection during engine start-up ..... Determined according to the engine cool-
ant temperature detected by the engine coolant temperature sensor.
0 During normal operation:
The duration is determined as follows:
Basic duration of fuel injection x Correction factors + Voltage correction time
0 Basic duration of fuel injection ..... The basic length of time fuel is injected. This is determined
by two factors -the amount of intake air detected by the manifold pressure sensor and the en-
gine speed monitored by the crankshaft position sensor.
0 Correction factors ..... See the next section.
0 Voltage correction time ..... This is added to compensate for the time lag before operation of
injector that results from variation in the battery voltage.
FU-28
CONTROL SYSTEM
2. CORRECTION FACTORS
The following factors are used to correct the basic duration of fuel injection in order to make the
air-fuel ratio meet the requirements of varying engine operating conditions:
0 Air-fuel ratio feedback factor:
This factor is used to correct the basic duration of fuel injection in relation to the actual engine
speed. (See the next section for more detail.)
0 Start increment factor:
This factor is used to increase the fuel injection duration only while the engine is being cranked
to improve its startability.
0 Coolant-temperature-dependent increment factor:
This factor is used to increase the fuel injection duration depending on engine coolant temperature
signals to facilitate cold starting. The lower the coolant temperature, the greater the increment.
0 After-start increment factor:
0 This factor is used to increase the fuel injection duration for a certain period immediately after
start of the engine to stabilize engine operation.
0 The increment depends on the coolant temperature at the start of the engine.
0 Wide-open-throttle increment factor:

This factor is used to increase the fuel injection duration depending on the relationship between
the throttle position sensor signal and manifold pressure sensor signal.
0 Acceleration increment factor:
This factor is used to increase the fuel injection duration to compensate for a time lag between air
flow measurement and fuel injection control for better engine response to driver’s pedal operation
during acceleration.
FU-29
CONTROL SYSTEM
3. AIR-FUEL RATIO FEEDBACK FACTOR

The ECM creates this factor utilizing the front oxygen sensor signal. When the signal voltage is low,
the air-fuel ratio is richer than the stoichiometric ratio. The ECM then makes the fuel injection dura-
tion shorter by modifying the factor. When the voltage is high showing that the mixture is lean, the
ECM modifies the factor to make the injection duration longer. In this way, the air-fuel ratio is main-
tained at a level close to the stoichiometric ratio at which the three-way catalyst acts most effective-
ly.
B2H0989B
(1) Front catalyst A: Injection duration increment signal

(2) Exhaust gas B: Injection duration decrement signal
(3) Front oxygen (NF) sensor C: High oxygen density
(4) Fuel injector D: Low oxygen density
(5) Combustion chamber E: Lean signal
(6) ECM F: Rich signal
4. LEARNING FEATURE
The air-fuel ratio feedback control includes a learning feature which contributes to more accurate
and responsive control.
0 In the air-fuel ratio feedback control, the ECM calculates the necessary amount of correction
based on data from the oxygen sensor and adds the result to the basic duration (which is stored
in the ECM’s memory for each condition defined by the engine speed and various loads.)
0 Without a learning feature, the ECM carries out the above-mentioned process every time. This
means that if the amount of necessary correction is large, the air-fuel ratio feedback control be-
comes less responsive and less accurate.
The learning feature enables the ECM to store the amount of correction into memory and add
it to the basic fuel injection duration to create a new reference fuel injection duration. Using the
reference duration as the basic duration for the injection a few times later, the ECM can reduce
the amount of correction and thus make its feedback control more accurate and responsive to
changes in the air-fuel ratio due to difference in driving condition and sensor/actuator characteris-
tics that may result from unit-to-unit variation or aging over time.
FU-30
CONTROL SYSTEM m
D: IGNITION SYSTEM CONTROL

0 The ECM determines operating condition of the engine based on signals from the pressure sen-
sor, engine coolant temperature sensor, intake air temperature sensor, crankshaft position sensor
and other sources. It then selects the ignition timing most appropriate for the condition thus deter-
mined from those stored in its memory and outputs at that timing a primary current OFF signal to
the ignitor to initiate ignition.
0This control uses a quick-to-response learning feature by which the data stored in the ECM
memory is processed in comparison with information from various sensors and switches.
0 Thus, the ECM can always perform optimum ignition timing taking into account the output, fuel
consumption, exhaust gas, and other factors for every engine operating condition.
0 Ignition control during start-up
Engine speed fluctuates during start of the engine, so the ECM cannot control the ignition timing.
During that period, the ignition timing is fixed at 10" BTDC by using the IO" signal from the crank-
Crankshaft position sensor b
Camshaft position sensor *
Engine coolant temperature sensor *

Atmospheric pressure sensor e
I 1
I
I
Intake air temperature and
pressuresensor
I
ECM Ignitioncoil and
ignitor assembly
Knock sensor b
I
Throttle position sensor
I *
I
I
I
Neutral position switch (MT)
ParWNeutralposition switch (AT)
1
NC switch
1
I
*I - NF0031
FU-31
CONTROL SYSTEM
Ignition control after start of engine

Between the 97" and 65" crank angle signal, the ECM measures the engine speed, and by using
this data it decides the dwell set timing and ignition timing according to the engine condition.
#4 #1 #3 #2 #4
(1)
I I I I I
97" 65" 10" 97" 65" 10" 97" 65" 10" 97" 65" 10"
(2)
I 1 I I I I I I 1 I I I
27.5"
20" 501 [ 20" 20"50" 20"
(6) I #4 i #1 I #3 I #2 I
B2H041OD
(1) Cylinder number (5) Ignition timing at normal condition

(2) Crank angle pulse (BTDC) (6) Burning cylinder
(3) Cam angle pulse (ATDC) (7) Dwellset
(4) Ignition timing at starting (8) Ignite
FU-32
CONTROL SYSTEM
E: IDLE AIR CONTROL

0 The ECM activates the idle air control solenoid valve to control the bypass air flowing through
the bypass passage in the throttle body depending on signalsfrom the crankshaft position sensor,
engine coolant temperature sensor, pressure sensor and A/C switch so that the proper idle speed
for each engine load is achieved.
0 The idle air control solenoid valve uses a duty-ratio-controlled solenoid which can continuously
vary the opening area of the rotary valve. As the ECM increases the duty ratio, opening of the rotary
valve increases so that the bypass air flow increases, and the engine idling speed becomes higher
as a result.
0 The bypass air control is necessary for:
0 Increasing idling speed when the air conditioning system and/or electrical loads are turned
on.
0 Increasing idling speed during early stage of warm up period.
0 Obtaining dashpot function when the throttle valve is quickly closed.
0 Prevention of engine speed variation during idling.
Intake air temperature and pressure sensor
Crankshaft position sensor
Camshaft position sensor
Engine coolant temperature sensor
ECM
Ignition switch

A/C switch
Neutral position switch (MT)

ParWNeutral position switch (AT)
NF0033
F: FUEL PUMP CONTROL

Using the signal from the crankshaft position sensor, the ECM controls operation of the fuel pump
by turning its relay ON or OFF. To improve safety, the fuel pump is stopped if the engine stalls with
the ignition switch ON.
~~~~ ~
Ignition switch ON I Fuel pump relay I Fuel pump I

A certain period of time after ignition switch is turned ON ON Operates
While cranking the engine ON Operates
While engine is operating ON Operates
When enaine stoos OFF Does not operate
FU-33
ON-BOARD DIAGNOSIS SYSTEM
6. On-board Diagnosis System

A: GENERAL
0 The on-board diagnosis system detects and indicates a fault by generating a code correspond-
ing to each fault location. The malfunction indicator lamp (CHECK ENGINE light) on the combina-
tion meter indicates occurrence of a fault or abnormality.
0 When the malfunction indicator lamp comes on as a result of detection of a fault by the ECM,
the corresponding diagnostic trouble code (DTC) and freeze frame engine condition are stored
in the ECM.
0 On the OBD-I1 conformable car, it is necessary to connect the Subaru Select Monitor (SSM) or
General Scan Tool (GST) to the data link connector in order to check the DTC.
0 The SSM and GST can read and erase DTCs. They can also read freeze frame data in addition
to other pieces of engine data.
0 If there is a failure involving sensors which may affect drive control of the vehicle, the fail-safe
function ensures minimum level of driveability.
B: FAIL-SAFE FUNCTION
For a sensor or switch which has been judged faulty in the on-board diagnosis, the ECM, if ap-
propriate, generates an associated pseudo signal to keep the vehicle operational. (The control
becomes degraded .)
FU-34
FUEL INJECTION
(FUEL SYSTEM)
Page
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. .
2. Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.
4.
5.
6.
Fuel Line . . . . . . . . . . . . . .
Sensors and Switches . . . . . . . . . . . .
Control System . . . . .
On-board Diagnosis System . .
...................
...................
.....................
......................
....................
.......................
..........
8a16
. . . . . . . . . . 27
36
GENERAL
1. General
0 The Multipoint Fuel Injection (MFI) system supplies optimum air-fuel mixture under every engine
operating condition through the use of the latest electronic control technology.
This system pressurizes the fuel to a constant pressure and injects it into each intake air port in
the cylinder head. The injection quantity of fuel is controlled by an intermittent injection system
where an electro-magnetic injection valve or injector opens for a short period that is precisely con-
trolled depending on the quantity of air appropriate for each condition of operation. In actual con-
trol, an optimum fuel injection quantity is achieved by varying the duration of an electric pulse ap-
plied to the injector. This way of control enables simple, yet highly precise metering of the fuel.
0 The engine control module (ECM) that controls the fuel injection system corrects the fuel injec-
tion amount depending on the vehicle speed, throttle opening, coolant temperature and other ve-
hicle-operation-related information. The ECM receives the information in the form of electric sig-
nals from the corresponding sensors and switches.
The MFI system also has the following features:
0 Reduced exhaust emissions
0 Reduced fuel consumption
0 Increased engine output
0 Quick response to accelerator and brake pedal operation
0 Superior startability and warm-up performance in cold weather due to corrective controls made
according to coolant and intake air temperatures
FU-2
AIR LINE
2. Air Line
A: GENERAL
The air filtered by the air cleaner enters the throttle body where it is regulated in the volume by the
throttle valve and then enters the intake manifold. It is then distributed to each cylinder where the
air is mixed with fuel injected by the injector. During idling operation, air flows into the cylinder
through the idle air control solenoid valve, bypassing the throttle valve. This enables controlling
the engine idling speed properly.
B: PRESSURE SENSOR
The pressure sensor is attached to the top of the throttle body, and continuously sends to the en-
gine control module (ECM) voltage signals that are proportional to intake manifold absolute pres-
sures. The ECM controls the fuel injection and ignition timing based on the intake manifold abso-
lute pressure signals in addition to other signals from many sensors and other control modules.
Connector
Terminal
BkL
“i# I
I
I Absolute pressure
NF0318
C: THROlTLE BODY
0 In response to operation of the accelerator pedal, the throttle valve in the throttle body opens/
closes to regulate the volume of the air drawn into the combustion chamber.
0 During idling, the throttle valve is almost fully closed and the volume of air passing through the
throttle body is less than that passing through the idle air control solenoid valve.
0 More than half of the air necessary for idling is supplied to the intake manifold via the idle air
control solenoid valve which controls properly the engine idling speed, so the idling speed needs
not be adjusted.
FU-3
AIR LINE
D: THROTTLE POSITION SENSOR

0 The throttle position sensor is mounted in the throttle body and linked to the throttle valve.
0 The throttle position sensor sends the ECM voltage signal corresponding to the opening of the
throttle valve. When the sensor's output voltage exceeds a predetermined level, the ECM inter-
prets it as complete closure of the throttle valve. When the output voltage is at another predeter-
mined level, the ECM recognizes that the throttle valve is at a wide open position. Since the output
characteristics of the sensor change over years, the ECM is provided with a learning function to
be able to interpret signals into throttle valve angles always correctly.
Wave washer
'Connector Return spring
Terminal
I I 1
NF0319
FU-4
AIR LINE
E: IDLE AIR CONTROL SOLENOID VALVE

0 The idle air control solenoid valve is located in the throttle body and regulates the amount of in-
take air that flows bypassing the throttle valve into the intake manifold during engine idling. It is
activated by a signal from the ECM in order to maintain the engine idling speed at a target speed.
0 The idle air control solenoid valve is a solenoid-actuated rotary valve consisting of a coil, rotary
valve, spring and housing. The housing is an integral part of the throttle body and provided with
a bypass air port whose opening area is changed by the rotary valve.
NF0397
(1) Connector (3) Air inlet pori

(2) Air outlet port (4) Terminal
FU-5
AIR LINE
F: MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR

The mass air flow and the intake air temperature sensors are integrated into a single unit. The unit
is mounted on the air cleaner case and measures the amount as well as the temperature of the
intake air.
The measured amount and temperature are converted into electrical signals and sent to the ECM.
The ECM uses these signals to control injection and ignition timing as well as the fuel injection
amount.
NF0321
(1) Mass air flow and the intake air temperature A: Air
sensor unit
(2) Mass air flow sensor
(3) Intake air temperature sensor
FU-6
AIR LINE
G: TUMBLE GENERATOR VALVES

0 A tumble generator valve is provided on each engine bank, between the intake manifold and
intake air ports. The right bank tumble generator valve has butterfly valves for the #I and #3 cylin-
ders and the left bank tumble generator valve has those for the #2 and #4 cylinders. The two butter-
fly valves in each tumble generator valve are fitted on a single shaft that is driven by an actuator.
0 The tumble generator valves are controlled by the ECM according to the coolant temperature
and the time elapsed after start of the engine. When the engine is started, the butterfly valves are
moved to the closing ends. In this state, the intake air flows at very high speeds passing through
narrowed passages in the directions determined by the individual intake air ports in the cylinder
head. This creates tumbling air motions in the cylinders, which enables lean mixtures to be ignited
and thus harmful exhaust emissions to be reduced during engine start. The tumble generator
valves are fully open when the engine is operating at an ordinary driving speed, allowing intake
air to flow without being changed in direction and velocity.
NF0322
(A) Activated
(B) Not activated
(1) Actuator (6) Tumble generating air passage
(2) Tumble generator valve position sensor (7) Intake main air passage
(3) Tumble generator housing (8) Piston
(4) Intake manifold (9) Injector
(5) Tumble generator valve (10) Cylinder head
FU-7
FUEL LINE
3. Fuel Line
A: GENERAL
0 The fuel pressurized by the fuel tank inside pump is delivered to each fuel injector by way of the
fuel pipe and fuel filter. Fuel injection pressure is regulated to an optimum level by the pressure
regulator.
0 Each injector injects fuel into the intake port of the corresponding cylinder where the fuel is
mixed with air. The mixture then enters the cylinder.
Fuel injection amount and timing are regulated by the ECM.
-:A
-: B
NF0428
Purge control solenoid valve Drain filter (21) Fuel tank pressure sensor
Purge valve Shut-off valve (22) Fuel gauge
Pressure regulator Vent valve (23) Combination meter
Throttle body Fuel temperature sensor (24) Fuel injector
Fuel filter Fuel level sensor
Intake manifold Fuel pump A: Fuel line
ECM Jet pump B: Evaporation line
Canister Fuel cut valve
Pressure control solenoid valve Fuel sub level sensor
Drain valve Fuel tank
FU-8
FUEL LINE
B: PRESSURE REGULATOR
The pressure regulator is installed at the injector end of the fuel supply line. It has a fuel chamber
and spring chamber separated by a diaphragm. Fuel chamber is connected to the fuel supply
line and the spring chamber is connected to the intake manifold. Fuel chamber also has a relief
valve connected to the fuel return line through which fuel returns to the fuel tank. When the intake
manifold vacuum increases, the diaphragm is pulled and the relief valve opens to decrease the
fuel supply line pressure (or fuel injection pressure). When the intake manifold vacuum decreases,
the diaphragm is pushed by the spring to increase the fuel supply line pressure. Thus, the differ-
ence between the fuel injection pressure and the intake manifold vacuum is kept at a constant level
of 294 kPa (3.00 kgf/cm2, 43.0 psi) to precisely control the amount of injected fuel.
A
0
NF0387
A: To intake manifold (1) Relief valve

B: Fuel IN (2) Diaphragm
C: FuelOUT
FU-9
FUEL LINE
C: FUEL INJECTORS
0 The MFI system employs top feed type fuel injectors.
0 Each injector is installed in the fuel pipe in such a way that the injector is cooled by fuel.
0 The features of this type of fuel injector are as follows:
1) High heat resistance
2) Low driving noise
3) Easy to service
4) Small size
0 The injector injects fuel according to the valve open signal from the ECM. The needle valve is
lifted by the solenoid which is energized on arrival of the valve open signal.
0 Since the injector’s nozzle hole area, the lift of valve and the fuel pressure are kept constant, the
amount of fuel injected is controlled only by varying the duration of the valve open signal from the
ECM.
0 The multi-hole nozzle makes it possible for the injector to produce fire fuel particles, which en-
hances the combustion efficiency and output performance of the engine.
NF0388
FU-10
FUEL LINE
D: FUEL TANK
The fuel tank utilizes a two-compartment design to ensure sufficient capacity without interfering
with the rear differential. It is provided with a suction jet pump (included in the fuel pump and fuel
level sensor assembly) which transfers fuel from one compartment to the other. Each compartment
has an individual fuel level sensor.
The fuel tank is located under the rear seat and secured with hold-down bands.
NF0473
(1) Fuel pump and fuel level sensor assembly (4) Cushion
(2) Fuel sub level sensor (5) Steel
(3) Band
FU-11
FUEL LINE
Fuel injection (Fuel System)
E: FUEL PUMP AND FUEL LEVEL SENSOR ASSEMBLY

1. FUEL PUMP
The fuel pump consists of a motor, impeller, pump casing, pump cover, check valve and filter. It
is located in the fuel tank and combined with the fuel level sensor into a single unit. The operation
of this impeller type pump is very quiet.
NF0474
Fuel pump (9) Motor armature

Fuel level sensor (IO) Suction
Jet pump (11) Discharge
Mesh filter (12) Vane groove
Fuel temperature sensor
Impeller A: From engine (return line)
Check valve B: From sub tank
Pump casing C: To engine (delivery line)
0 When the ignition switch is turned ON, fuel pump relay is activated. Then the motor operates
to rotate the impeller.
0 As the impeller rotates, fuel in a vane groove of the impeller flows along the fuel passage into
the next vane groove by centrifugal force. When fuel flows from one groove to the next, a pressure
difference occurs due to friction. This creates a pumping effect.
0 The fuel pushed up by rotation of the impeller then passes through the clearance between the
armature and the magnet of the motor and is discharged through the check valve.
0 When the fuel discharge pressure reaches the specified level, the relief valve opens and excess
fuel is released into the fuel tank. In this manner, the relief valve prevents an abnormal increase
in fuel pressure.
0 When the engine and the fuel pump stop, spring force acts on the check valve to close the dis-
charge port, so that the fuel pressure in the fuel delivery line is retained.
FU-12
FUEL LINE
2. FUEL LEVEL SENSOR

The fuel level sensor forms part of the fuel pump and located in the fuel tank. The sensor outputs
an electric resistance signal that varies with movement of its float to indicate the level of the fuel
remaining in the tank.
NF0327
(1) Fuel level sensor

(2) Float
FU-13
FUEL LINE
3. JETPUMP
0 The jet pump utilizes the velocity of fuel returning from the engine to produce negative pressure
in it.
0 Using the pumping effect produced by the negative pressure, the jet pump transfers fuel from
the sub-compartment to the main compartment of the fuel tank.
0 When the return line nozzle is clogged, the fuel sent back through the return line flows back into
the fuel tank via the relief valve.
r i r i
(1 ) Relief valve A: Return line

(2) Nozzle
FU-14
FUEL LINE
F: SUB-COMPARTMENT FUEL LEVEL SENSOR

This sensor detects the level of the fuel in the sub-compartment (the compartment in which the
fuel pump is not located) and acts as part of the fuel transfer line when the jet pump is in operation
to maintain the fuel in both compartments at the same level.
NF0396
(1) Fuel level sensor A: Tojet pump

(2) Float
G: FUEL FILTER
The fuel filter located in the engine compartment is a pressure-withstanding, cartridge type. It has
a filter element in a metal case. The fuel entering the filter flows from the perimeter of the element
to the center of the filter and goes out from there.
NFOOI a
FU-15
4. Sensors and Switches

A: FRONT OXYGEN (NF) SENSOR
0 The front oxygen sensor uses zirconium oxide (Zr02) which is a solid electrolyte, at portions ex-
posed to exhaust gas.
0 The zirconium oxide has the property of generating electromotive force when its both sides are
exposed to oxygen ions of different concentration and the magnitude of this electromotive force
depends on how much the difference is.
0 The front oxygen sensor detects the amount of oxygen in exhaust gases by making use of this
property of the zirconium oxide material.
0 The zirconium oxide material is formed into a closed end tube and its external surface is ex-
posed to exhaust gases with smaller oxygen ion concentration, whereas its internal surface is ex-
posed to atmospheric air. The external surface has a porous platinum coating. The sensor housing
is grounded to the exhaust pipe and the inside is connected to the ECM through the harness to
be able to use the current output from the sensor.
0 The sensor incorporates a ceramic heater to improve its performance at low temperatures.
NF0389
(1) Protectiontube (3) Sensor housing

(2) Gasket (4) Ceramic heater
FU-16
tube. This results in avery large difference in the oxygen ion concentration between the inside and
tion, the ECM can determine the air-fuel ratio of the supplied mixture easily. The front oxygen sen-
sor does not generate much electromotive force when the temperature is low. The output charac-
teristics of the sensor stabilize at a temperature of approximately 700°C (1,292"F).
AtmosDheric air /- Zr02
Lean t-- Air-fuel ratio - Rich
Ceramic heater 1
NF0331
FU-17
B: REAR OXYGEN SENSOR

0 The rear oxygen sensor is used to sense oxygen concentration in the exhaust gas. If the air-fuel
ratio is leaner than the stoichiometric ratio in the mixture (i.e., excessive amount of air), the exhaust
gas contains more oxygen. To the contrary, if the fuel ratio is richer than the stoichiometric ratio,
the exhaust gas contains almost no oxygen.
0 Detecting the oxygen concentration in exhaust gas using the oxygen sensor makes it possible
to determine whether the air-fuel ratio is leaner or richer than the stoichiometry.
0 The rear oxygen sensor has azirconia tube (ceramic) which generates voltage if there is a differ-
ence in oxygen ion concentration between the inside and outside of the tube. Platinum is coated
on the inside and outside of the zirconia tube as a catalysis and electrode material. The sensor
housing is grounded to the exhaust pipe and the inside is connected to the ECM through the har-
ness.
0 A ceramic heater is employed to improve performance at low temperatures
NF0390
(1) Protection tube (4) Ceramic heater

(2) Gasket (5) Zirconia tube
(3) Sensor housing
FU-18
tube. This results in avery large difference in the oxygen ion concentration between the inside and
gen ion concentration between the tube’s internal and external surfaces. The electromotive force
tion, the ECM can determine the air-fuel ratio of the supplied mixture easily. The rear oxygen sensor
does not generate much electromotive force when the temperature is low. The output characteris-
tics of the sensor stabilize at a temperature of approximately 300 to 400°C (572 to 752°F).
Large I Stoichiometric mixture ratio
* \\\I
Exhaust ITo be judged
as lean
Small
Lean -Air-fuel ratio- Rich
NF0333
FU-19
C: ENGINE COOLANT TEMPERATURE SENSOR

The engine coolant temperature sensor is located on the engine coolant pipe. The sensor uses
a thermistor whose resistance changes inversely with temperature. Resistance signals as engine
coolant temperature information are transmitted to the ECM to make fuel injection, ignition timing,
purge control solenoid valve and other controls.
1' I Temp. "C ( O F )

-20 0 20 40 60 80
(-4) (32) (68) (104)(140)(176)
S2H1113B
(1) Connector (2) Thermistor element
D: EXHAUST GAS TEMPERATURE SENSOR

The exhaust gas temperature sensor is located on the joint pipe and used to monitor the condition
of the precatalytic converter.
FU-20
E: CRANKSHAFT POSITION SENSOR

0 The crankshaft position sensor is installed on the oil pump which is located in the front center
portion of the cylinder block. The sensor generates a pulse when one of the teeth on the perimeter
of the crankshaft sprocket (rotating together with the crankshaft) passes in front of it. The ECM de-
termines the crankshaft angular position by counting the number of pulses.
0 The crankshaft position sensor is a molded type which consists of a magnet, core, coil, terminals
and other components as illustrated below.
NF0024
(1) Terminal (4) Coil

(2) Yoke core (5) Core
(3) Magnet (6) Cover
FU-21
0 As the crankshaft rotates, each tooth aligns with the crankshaft position sensor. At that time, the
magnetic flux in the sensor’s coil changes since the air gap between the sensor pickup and the
sprocket changes. This change in magnetic flux induces a voltage pulse in the sensor and the
pulse is transmitted to the ECM.
u u u u u u u u u u u u u u u u
I-
(3)
NF0429

(2) Crankshaft sprocket
(3) Crankshaft half rotation
FU-22
Fuel Injection (Fuel Svstem)
F: CAMSHAFT POSITION SENSOR

0 The camshaft position sensor is located on the left-hand camshaft support. It detects the com-
bustion cylinder at any given moment.
0 The sensor generates a pulse when one of the bosses on the back of the left-hand camshaft
drive sprocket passes in front of the sensor. The ECM determines the camshaft angular position
by counting the number of pulses.
Internal construction and the basic operating principle of the camshaft position sensor are similar
to those of the crankshaft position sensor. Two bosses are provided on the sprocket as shown be-
low.
NF0478
(1) Boss (4) Camshaft position sensor

(2) Camshaft sprocket (5) Camshaft one rotation (Crankshaft two rotations)
(3) Air gap
FU-23
G: KNOCK SENSOR
0 The knock sensor is installed on the cylinder block, and senses knocking that occurs in the en-
gine.
0 The sensor is a piezo-electric type which converts vibration resulting from knocking into electric
signals.
0 In addition to a piezo-electric element, the sensor has a weight and case as its components.
If knocking occurs in the engine, the weight in the case moves causing the piezo-electric element
to generate a voltage.
0 The knock sensor harness is connected to the bulkhead harness.
.)2(
(3)’
NF0391
(1) Nut (4) Housing

(2) Weight (5) Resistor
(3) Piezo-electricelement
FU-24
H: VEHICLE SPEED SENSOR

1. MT VEHICLES
and send it to the ECM and the combination meter.
82H2458C

(2) ECM
(4) Transmission
FU-25
I
2. AT VEHICLES
and send it to the transmission control module (TCM). The signal sent to the TCM is converted
there into a 4-pulse signal, and then sent to the ECM and the combination meter.
62H24596

(2) ECM
(3) TCM
(5) Transmission
FU-26
CONTROL SYSTEM
5. Control System
A: GENERAL
The ECM receives signals from various sensors, switches, and other control modules. Using these
signals, it determines the engine operating conditions and if necessary, emits signals to one or
more systems to control them for optimum operation.
Major control items of the ECM are as follow:
0 Fuel injection control
0 Ignition system control
0 Idle air control
0 Fuel pump control
0 Canister purge control*l
0 Radiator fan control*2
0 On-board diagnosis function
*1: Canister purge control is described under “EC (DOHC TURBO) - Emission Control (Aux. Emis-
sion Control Devices) Evaporative Emission Control System”.
*2: Radiator fan control is described under “CO - Cooling”.
FU-27
CONTROL SYSTEM
B: INPUT AND OUTPUT SIGNALS

Signal Unit Function
Pressure sensor Detects the amount of intake air (Measures the absolute pressure).
Mass air flowand intake air tempera- Detects the temperature and amount of intake air.
ture sensor
I
Throttle position sensor I Detects the throttle valve position.

Detects the density of oxygen in exhaust gases at the upstream of
Front oxygen (NF) sensor
the front catalytic converter.
Rear oxygen sensor Detects the density of oxygen in exhaust gases at the downstream
of the rear catalytic converter.
Exhaust gas temperature sensor I Detects the exhaust gas temperature.
Tumblegenerator valve position sen- Detects the tumble generator valve position.
sor
Crankshaft position sensor Detects the crankshaft angular position.
Camshaft position sensor I Detects the combustion cylinder.
Engine coolant temperature sensor I Detects the engine coolant temperature.
Knock sensor I Detects engine knocking.
Vehicle speed sensor I Detects the vehicle speed.
Input signals
Ignition switch I Detects operation of the ignition switch.
Starter switch I Detects the condition of engine cranking.
Neutral position switch (MT) I Detects that the gear is in neutral.
ParWNeutral position sensor (AT) I Detects shift positions.
Heater circuit of front and rear oxy- Detects the abnormality in heater circuit of front and rear oxygen
gen sensor sensor.
~~
Diagnostics of TCM (AT) Detects the self-diagnostics of the TCM.

Torque control signal (AT) Controls engine torque.
NC switch Detects ON-OFF operation of the N C switch.
Fuel level sensor Detects the level of the fuel in the fuel tank.
Fuel temperature sensor Detects the temperature of the fuel in the fuel tank.
Fuel tank pressure sensor Detects the evaporation gas pressure in the fuel tank.
Small light switch Detects ON-OFF operation of the small light switch.
Blower fan switch Detects ON-OFF operation of the blower fan switch.
Rear defogger switch Detects ON-OFF operation of the rear defogger switch.
FU-28
CONTROL SYSTEM
Signal
Fuel Injector Activates an injector.
lanition signal Turns the primary ignition current ON or OFF.
Fuel pump controller Controls the fuel pump.
A/C control relay Turns the A/C control relay ON or OFF.
Radiator fan control relay Turns the radiator fan control relay ON or OFF.
Adjusts the amount of air flowing through the bypass line in the
throttle body.
3utput signals Tumble generator valve actuator I Operates the tumble generator valve. I
Wastegate control solenoid valve I Controls supercharging pressure. I
Malfunction indicator lamp I Indicates existence of abnormality. I
Purge control solenoid valve I Controls purge of evaporative gas absorbed by the canister. I
Pressure control solenoid valve I Controls evaporation gas pressure in the fuel tank. I
II
~~
Drain valve
Power SUDD~V
I
Close the evaporation line between the fuel tank and canister to de-
tect leakage of evaporation gases.
Controls ON/OFF of the main Dower SUDP~Yrelay.
II
FU-29
CONTROL SYSTEM
C: FUEL INJECTION CONTROL

0 The ECM receives signals from various sensors and based on them, it determines the amount
of fuel injected and the fuel injection timing. It performs the sequential fuel injection control over
the entire engine operating range except during start-up of the engine.
0 The amount of fuel injected depends upon the length of time the injector stays open. The fuel
injection duration is determined according to varying operating condition of the engine. For the
purpose of achieving highly responsive and accurate fuel injection duration control, the ECM per-
forms a new feedback control that incorporates a learning feature as detailed later.
0 The sequential fuel injection control is performed such that fuel is injected accurately at the time
when the maximum air intake efficiency can be achieved for each cylinder (i.e., fuel injection is
completed just before the intake valve begins to open).
1. FUEL INJECTION DURATION

Fuel injection duration is basically determined as indicated below:
During engine start-up:
The duration defined below is used.
0 Duration of fuel injection during engine start-up . . . . . Determined according to the engine cool-
ant temperature detected by the engine coolant temperature sensor.
0 During normal operation:
The duration is determined as follows:
Basic duration of fuel injection x Correction factors + Voltage correction time
Basic duration of fuel injection ..... The basic length of time fuel is injected. This is determined
by two factors -the amount of intake air detected by the manifold pressure sensor and the en-
gine speed monitored by the crankshaft position sensor.
0 Correction factors ..... See the next section.
0 Voltage correction time ..... This is added to compensate for the time lag before operation of
injector that results from variation in the battery voltage.
FU-30
CONTROL SYSTEM
2. CORRECTION FACTORS
The following factors are used to correct the basic duration of fuel injection in order to make the
air-fuel ratio meet the requirements of varying engine operating conditions:
0 Air-fuel ratio feedback factor:
This factor is used to correct the basic duration of fuel injection in relation to the actual engine
speed. (See the next section for more detail.)
0 Start increment factor:
This factor is used to increase the fuel injection duration only while the engine is being cranked
to improve its startability.
0 Coolant-temperature-dependent increment factor:
This factor is used to increase the fuel injection duration depending on engine coolant temperature
signals to facilitate cold starting. The lower the coolant temperature, the greater the increment.
0 After-start increment factor:
0 This factor is used to increase the fuel injection duration for a certain period immediately after
start of the engine to stabilize engine operation.
0 The increment depends on the coolant temperature at the start of the engine.
0 Wide-open-throttle increment factor:

This factor is used to increase the fuel injection duration depending on the relationship between
the throttle position sensor signal and manifold pressure sensor signal.
0 Acceleration increment factor:
This factor is used to increase the fuel injection duration to compensate for a time lag between air
flow measurement and fuel injection control for better engine response to driver’s pedal operation
during acceleration.
FU-31
CONTROL SYSTEM
3. AIR-FUEL RATIO FEEDBACK FACTOR

The ECM creates this factor utilizing the front oxygen sensor signal. When the signal voltage is low,
the air-fuel ratio is richer than the stoichiometric ratio. The ECM then makes the fuel injection dura-
tion shorter by modifying the factor. When the voltage is high showing that the mixture is lean, the
ECM modifies the factor to make the injection duration longer. In this way, the air-fuel ratio is main-
tained at a level close to the stoichiometric ratio at which the three-way catalyst acts most effective-
ly.
I t-------- 1
I
B2H0989B
(1) Front catalyst A: Injection duration increment signal

(2) Exhaust gas B: Injection duration decrement signal
(3) Front oxygen (NF) sensor C: High oxygen density
(4) Fuel injector D: Low oxygen density
(5) Combustion chamber E: Lean signal
(6) ECM F: Rich signal
4. LEARNING FEATURE
The air-fuel ratio feedback control includes a learning feature which contributes to more accurate
and responsive control.
0 In the air-fuel ratio feedback control, the ECM calculates the necessary amount of correction
based on data from the oxygen sensor and adds the result to the basic duration (which is stored
in the ECM’s memory for each condition defined by the engine speed and various loads.)
0 Without a learning feature, the ECM carries out the above-mentioned process every time. This
means that if the amount of necessary correction is large, the air-fuel ratio feedback control be-
comes less responsive and less accurate.
0 The learning feature enables the ECM to store the amount of correction into memory and add
it to the basic fuel injection duration to create a new reference fuel injection duration. Using the
reference duration as the basic duration for the injection a few times later, the ECM can reduce
the amount of correction and thus make its feedback control more accurate and responsive to
changes in the air-fuel ratio due to difference in driving condition and sensor/actuator characteris-
tics that may result from unit-to-unit variation or aging over time.
FU-32
CONTROL SYSTEM
D: IGNITION SYSTEM CONTROL

0 The ECM determines operating condition of the engine based on signals from the pressure sen-
sor, engine coolant temperature sensor, intake air temperature sensor, crankshaft position sensor
and other sources. It then selects the ignition timing most appropriate for the condition thus deter-
mined from those stored in its memory and outputs at that timing a primary current OFF signal to
the ignitor to initiate ignition.
0This control uses a quick-to-response learning feature by which the data stored in the ECM
memory is processed in comparison with information from various sensors and switches.
0 Thus, the ECM can always perform optimum ignition timing taking into account the output, fuel
consumption, exhaust gas, and other factors for every engine operating condition.
0 Ignition control during start-up
Engine speed fluctuates during start of the engine, so the ECM cannot control the ignition timing.
During that period, the ignition timing is fixed at IO" BTDC by using the IO" signal from the crank-
shaft position sensor.
Crankshaft position sensor +
Camshaft position sensor b
plug #2
Ignition coil
Mass air flow and intake air temperature sensor + ECM and ignitor
assembly
-4 Spark
plug #3 I
- NF0432
FU-33
CONTROL SYSTEM
I , h r \ b h , " A \I
(2) l#+i-l-l-l!IIlfl! l ! ! ~ ~ # i ! ! ! ! ! !f i ! !~!!l-Hi!!!!!lIll /!#+++!!I! I' ; I
#3 #2 #4
(3)
#1 #3 #2 #4
(4)
(5) #4 #1 #3 #2
NF0430
(1) Cylinder number (TDC)

(2) Crank angle pulse
(3) Ignition timing at starting
(4) Ignition timing at normal condition
(5) Burning cylinder
FU-34
a
CONTROL SYSTEM
E: IDLE AIR CONTROL

0 The ECM activates the idle air control solenoid valve to control the bypass air flowing through
the bypass passage in the throttle body depending on signals from the crankshaft position sensor,
engine coolant temperature sensor, pressure sensor and A/C switch so that the proper idle speed
for each engine load is achieved.
0 The idle air control solenoid valve uses a duty-ratio-controlled solenoid which can continuously
vary the opening area of the rotary valve. As the ECM increases the duty ratio, opening of the rotary
valve increases so that the bypass air flow increases, and the engine idling speed becomes higher
as a result.
0 The bypass air control is necessary for:
0 Increasing idling speed when the air conditioning system and/or electrical loads are turned
on.
0 Increasing idling speed during early stage of warm up period.
0 Obtaining dashpot function when the throttle valve is quickly closed.
0 Prevention of engine speed variation during idling.
1- Crankshaft position sensor
Camshaft position sensor
ECM
Engine coolant temperature sensor
Vehicle speed sensor

Idle air control
solenoid valve
Ignition switch
N C switch
*Neutral position switch (MT)

*Park/Neutral position switch (AT)
NF0431
Ignition switch ON Fuel pump relay Fuel pump

A certain period of time after ignition switch is turned ON ON Operates
While cranking the engine ON Operates
While engine is operating ON Operates
When engine stops OFF Does not operate
FU-35
ON-BOARD DIAGNOSIS SYSTEM
6. On-board Diagnosis System

A: GENERAL
0 The on-board diagnosis system detects and indicates a fault by generating a code correspond-
ing to each fault location. The malfunction indicator lamp (CHECK ENGINE light) on the combina-
tion meter indicates occurrence of a fault or abnormality.
0 When the malfunction indicator lamp comes on as a result of detection of a fault by the ECM,
the corresponding diagnostic trouble code (DTC) and freeze frame engine condition are stored
in the ECM.
0 On the OBD-II conformable car, it is necessary to connect the Subaru Select Monitor (SSM) or
General Scan Tool (GST) to the data link connector in order to check the DTC.
0 The SSM and GST can read and erase DTCs. They can also read freeze frame data in addition
to other pieces of engine data.
0 If there is a failure involving sensors which may affect drive control of the vehicle, the fail-safe
function ensures minimum level of driveability.
B: FAIL-SAFE FUNCTION
For a sensor or switch which has been judged faulty in the on-board diagnosis, the ECM, if ap-
propriate, generates an associated pseudo signal to keep the vehicle operational. (The control
becomes degraded.)
FU-36
EMISSION CONTROL
(AUX. EMISSION
CONTROL DEVICES) EC (SOHC)
Page
1. System Overview ......................... ........................... 2
2. Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Crankcase Emission Con .................... 6
4. Three-way Catalyst . . . . . . . . . . . . . . ...................................... a
5. A/F Control System ........................... ....................... 9
6. Ignition Control System .
7. Evaporative Emission Co
..................................
m ..........
a. On-board Refueling Vapor Recovery (ORVR) System . . . . . . . . . . . . . .
9. Vacuum Connections ..............................
. . . . . . . . . . . . . . . . . . . 11
lo
20
. . . . . . . . . . . . . . . . . . 22
m
I
SYSTEM OVERVIEW
Emission Control (Aux. Emission Control Devices)
1. System Overview
There are three emission control systems which are as follows:
0 Crankcase emission control system
0 Exhaust emission control system
0 Three-way catalyst system
0 Air/fuel (A/F) control system
0 Ignition control system
0 Evaporative emission control system

0 On-board refueling vapor recovery (ORVR) system
tem I Main components I Function
;rankcase emission control Positive crankcase Draws blow-by gas into intake manifold from crankcase and burns it
system ventilation (PCV) together with air-fuel mixture. Amount of blow-by gas to be drawn in
valve is controlled by intake manifold pressure.
Exhaust I Catalyst I Front Three-way catalyst Oxidizes HC and CO contained in exhaust gases as well as reducing
mission NOx.
:ontrol
system I A/F control Engine control mod- Receives input signals from various sensors, compares signals with
ule (ECM) stored data, and emits a signal for optimal control of air-fuel mixture
ratio.
Front oxygen (NF) Detects quantity of oxygen contained exhaust gases.
sensor
Rear oxygen sensor I Detects density of oxygen contained exhaust gases.
Throttle position
sensor
I Detects throttle position.
Intake air tempera- Detects absolute pressure of intake manifold.

ture and pressure
sensor Detects intake air temperature of intake manifold.
ECM Receives various signals, compares signals with basic data stored in
memory, and emits a signal for optimal control of ignition timing.
Crankshaft position Detects engine speed (Revolution).
sensor
Camshaft position Detects reference signal for combustion cylinder discrimination.
sensor
Engine coolant tern- Detects coolant temperature.
perature sensor
Knock sensor Detects engine knocking.
Evaporative emission control Canister Absorbs evaporative gas which occurs in fuel tank when engine
system stops, and releases it to combustion chambers for a complete burn
when engine is started. This prevents HC from being discharged into
atmosphere.
Purge control Receives a signal from ECM and controls purge of evaporative gas
solenoid valve absorbed by canister.
Pressure control Receives a signal from ECM and controls evaporative gas pressure
solenoid valve in fuel tank.
3RVR system I Ventvalve [Controls evaporation pressure in fuel tank.
I-Drainvalve Closes the evaporation line by receiving a signal from ECM to check
evaporation gas leak.
EC-2
SYSTEM OVERVIEW
MEMO
EC-3
SCHEMATIC DIAGRAMS
2. Schematic Diagrams
I -
L
I
I
I
NF0475
EC-4
SCHEMATIC DIAGRAMS
Engine control module (ECM) Fuel pump relay A/C relay

Ignition coil and ignitor assembly Fuel filter A/C control module
Crankshaft position sensor Front catalytic converter Ignition switch
Camshaft position sensor Rear catalytic converter Transmission control module
(TCM) (AT vehicles only)
Throttle position sensor Radiator fan Vehicle speed sensor
Fuel injectors Radiator fan relay Data link connector
Pressure regulator Air assist injector solenoid valve Fuel tank pressure sensor
Engine coolant temperature Knock sensor Pressure control solenoid valve
sensor
Intake air temperature Front oxygen (NF) sensor Fuel temperature sensor
and pressure sensor
Idle air control solenoid valve Rear oxygen sensor Fuel level sensor
Purge control solenoid valve Atmospheric pressure sensor Drain filter
Fuel pump A/C compressor Vent valve
PCV valve Inhibitor switch (AT vehicles only) Shut-off valve
Air cleaner element Neutral switch (MT vehicles only) Drain valve
Canister CHECK ENGINE malfunction Fuel cut valve
indicator lamp (MIL)
Main relay Tachometer
EC-5
CRANKCASE EMISSION CONTROL SYSTEM
3. Crankcase Emission Control System

0 The positive crankcase ventilation (PCV) system prevents air pollution which will be caused by
blow-by gas being emitted from the crankcase.
The system consists of a sealed oil filler cap, rocker covers with fresh air inlet, connecting hoses,
a PCV valve and an air intake duct.
0 In a part-throttle condition, the blow-by gas in the crankcase flows into the intake manifold
through the connecting hose of crankcase and PCV valve by the strong vacuum created in the
intake manifold. Under this condition, fresh air is introduced into the crankcase through the con-
necting hose of the rocker cover.
0 In a wide-open-throttle condition, a part of blow-by gas flows into the air intake duct through the
connecting hose and is drawn into the throttle chamber, because under this is condition, the intake
manifold vacuum is not strong enough to introduce through the PCV valve all blow-by gases that
increase in the amount with engine speed.
EC-6
CRANKCASE EMISSION CONTROL SYSTEM
B2H3534D
(1) Air cleaner case (6) Crankcase (A) Part-throttle condition

(2) PCVvalve (7) Case (B) Wide-open-throttlecondition
(3) Throttle body (8) Valve C: Fresh air
(4) Intake manifold (9) Spring D: Mixture of air and blow-by gas
(5) Oil filler cap (10) PCV valve E: Blow-by gas
EC-7
THREE-WAY CATALYST
4. Three-way Catalyst
0 The basic material of three-way catalyst is platinum (Pt), rhodium (Rh) and palladium (Pd), and
a thin coat of their mixture is applied onto honeycomb or porous ceramics of an oval shape (carri-
er). To avoid damaging the catalyst, only unleaded gasoline should be used.
0 The catalyst reduces HC, CO and NOx in exhaust gases through chemical reactions (oxidation
and reduction). These harmful components are reduced most efficiently when their concentra-
tions are in a certain balance. These concentrations vary with the air-fuel ratio. The ideal air-fuel
ratio for reduction of these components is the stoichiometric ratio.
0 Therefore, the air-fuel ratio needs to be controlled to around the stoichiometric ratio to purify the
exhaust gases most efficiently.
EC-8
A/F CONTROL SYSTEM
5. A/F Control System

0 The aidfuel (A/F) control system makes a correction to the basic fuel injection duration in accor-
dance with the signal from the front oxygen sensor so that the stoichiometric ratio is maintained,
thus ensuring most effective exhaust gas purification by the three-way catalyst. Different basic fuel
injection durations are preset for various engine speeds and loads, as well as the amount of intake
air.
0 This system also has a “learning” control function which stores the corrected data in relation to
the basic fuel injection in the memory map. This allows an appropriate air-fuel ratio correction to
be added automatically in quick response to any situation that requires such an effect. Thus, the
air-fuel ratio is optimally maintained under various conditions while purifying exhaust gases most
effectively, improving driving performance and compensating for changes in sensors’ perfor-
mance over time.
EC-9
I
IGNITION CONTROL SYSTEM
6. Ignition Control System

0 The ignition system is controlled by the ECM.
The ECM monitors the operating condition of the engine using the signals from the sensors and
switches shown below and determines the ignition timing most appropriate for each engine oper-
ating condition. Then it sends a signal to the ignitor, commanding generation of a spark at that
timing.
0 The ECM uses a preprogrammed map for a “closed-loop” control which provides its ignition tim-
ing control with excellent transient characteristics, i.e., highly responsive ignition timing control.
B2H3536D
(1) Battery (6) Intake air temperature and pressure sensor

(2) Ignition switch (7) Engine coolant temperature sensor
(3) ECM (8) Spark plug
(4) Camshaft position sensor (9) Ignition coil and ignitor assembly
(5) Knock sensor (IO) Crankshaft position sensor
EC-10
EVAPORATIVE EMISSION CONTROL SYSTEM
7. Evaporative Emission Control System

A: GENERAL
0 The evaporative emission control system prevents fuel vapors from escaping into atmosphere.
This system includes a canister, purge control solenoid valve, fuel cut valve, and the lines connect-
ing them.
0 Fuel vapors in the fuel tank is introduced into the canister through the evaporation line, and are
absorbed by activated carbon in it. The fuel cut valve is also incorporated in the fuel tank line.
0 The purge control solenoid valve is controlled optimally by the ECM according to the engine
condition.
0 The pressure control solenoid valve incorporated in the fuel tank evaporation line regulates the
pressure/vacuum in the fuel tank under the control of the ECM which uses the signal from the fuel
tank pressure sensor.
NF0476
(1) Fuel gauge (7) Pressure control solenoid valve (13) Fuel tank
(2) Intake manifold (8) Drain valve (14) Fuel cut valve
(3) Throttle body (9) Drain filter (15) Fuel tank pressure sensor
(4) Purge control solenoid valve (10) Shut-off valve (16) Vent valve
(5) Engine control module (ECM) (11) Fuel temperature sensor
(6) Canister (12) Fuel level sensor
EC-11
B: FUEL CUT VALVE

The fuel cut valve is built onto the evaporation pipe of the fuel tank cap. The rising level of the fuel
in the fuel tank causes the float to move up and close the cap hole so that no fuel can enter the
evaporation I ine.
B1c NF0469
(1) Float A: To canister

B: Valveopen
C: Valve closed
EC-12
C: FUEL TANK CAP

The fuel tank cap has a relief valve which prevents development of vacuum in the fuel tank in the
event of a problem with the fuel vapor line.
When there is no problem with the fuel vapor line, the filler pipe is sealed at the portion (A) and
by the seal pressed against the filler pipe end. If vacuum develops in the fuel tank, the atmospheric
pressure forces the spring down to open the valve; consequently outside air flows into the fuel tank,
thus controlling the inside pressure.
NF0470
(1) Seal
(2) Spring
(3) Valve
(4) Filter
EC-13
D: CANISTER
The charcoal filled in the canister temporarily stores fuel vapors. When the purge control solenoid
valve is opened by a signal from the ECM, the external fresh air entering the canister carries the
fuel vapors into the collector chamber.
H2H3223B
(1) Grid A: To purge control solenoid valve

(2) Filter B: From fuel tank
(3) Charcoal C: Air
(4) Filter
(5) Spring
E: PURGE CONTROL SOLENOID VALVE

The purge control solenoid valve is on the evaporation line between the canister and intake man-
ifold. It is installed at the underside of intake manifold.
B2H0426B
A: To canister
B: To intake manifold
EC-14
F: PRESSURE CONTROL SOLENOID VALVE

The fuel tank pressure control solenoid valve is located in the evaporation line between the shut-off
valve on fuel filler pipe and the fuel tank. It adjusts the fuel tank inside pressure under the control
of the ECM.
When the tank inside pressure becomes higher than the atmospheric pressure, the valve is
opened allowing fuel vapors to be introduced into the canister.
On the other hand, when the tank inside pressure becomes lower than the atmospheric pressure,
external air is taken from the drain valve into the canister.
The pressure control solenoid valve can also be electrically closed for the system diagnosis pur-
poses.
B2H1719C
(1) Filter A: Atmospheric pressure

(2) Coil B: From shut-off valve
(3) Connector terminal C: To fuel tank
(4) Diaphragm
(5) Valve
EC-15
G: DRAIN FILTER
The drain filter is installed at the air inlet port of the vent control solenoid valve. It cleans the air taken
in the canister through the vent control solenoid valve.
A B
S2H0874B
(1) Cap A: To drain valve

(2) Element B: To atmosphere
(3) Case
EC-16
H: VENT VALVE
The vent valve is located on the fuel tank. During filling the fuel tank, fuel vapors are introduced
into the canister through the vent valve.
When the fuel vapor pressure becomes higher than the atmospheric pressure and overcomes the
spring force which is applied to the back side of the diaphragm, the port toward the canister is
opened. The vent valve also has a float which blocks the fuel vapor passage when the tank is filled
up. Increasing fuel level raises the float to close the port toward the canister.
B-
H2H3224B
(1) Spring A: To filler pipe

(2) Diaphragm B: To canister
(3) Plate cover
(4) Packing
(5) Float
(6) Float spring
EC-17
I EVAPORATIVE EMISSION CONTROL SYSTEM
I: SHUT-OFF VALVE
The shut-off valve is located at the top of the fuel filler pipe. When a filler gun is inserted into the
filler pipe, the shut-off valve closes the evaporation line.
A B
B2H1769B
(1) Pin A: To canister

(2) Valve B: To fuel tank
(3) Spring
(4) Plate
(5) Shaft
(6) Pin
EC-18
J: DRAIN VALVE
The drain valve is located on the line connecting the drain filter and canister, just below the drain
filter. The drain valve is forcibly closed by a signal from the ECM while the evaporation system diag-
nosis is being conducted.
. .
B2H1770A
(1) Magnetic plate (6) Valve

(2) Yoke (7) Plate
(3) Packing (8) Retainer
(4) Spring (9) Moving core
(5) Valve seat (IO) Bobin
EC-19
ON-BOARD REFUELING VAPOR RECOVERY (ORVR) SYSTEM
8. On-board Refueling Vapor Recovery (ORVR) System

A: GENERAL
The on-board refueling vapor recovery system allows the fuel vapors in the fuel tank to be
introduced directly into the canister through the vent valve when the fuel tank inside pressure in-
creases as a result of refueling.
The diagnosis of the system is performed by monitoring the fuel tank inside pressure data from
the fuel tank pressure sensor while forcibly closing the drain valve.
B: OPERATION
0 While driving
Since the back side of the diaphragm in the pressure control solenoid valve is open to the atmo-
sphere, the diaphragm is held pressed by the atmospheric pressure in the position where only the
external air is introduced into the canister. When the fuel vapor pressure acting on the other side
of the diaphragm increases and overcomes the atmospheric pressure, it pushes the diaphragm
and opens the port through which the fuel vapors make their way to the canister.
NF0471
(1) Canister (4) Intake manifold

(2) Pressure control solenoid valve (5) Shut-off valve: opened
(3) Purge control solenoid valve
EC-20
0 While refueling
As the fuel enters the fuel tank, the tank inside pressure increases. When the inside pressure be-
comes higher than the atmospheric pressure, the port of the vent valve opens, allowing the fuel
vapors to be introduced into the canister through the vent line. The fuel vapors are absorbed by
charcoal in the canister, so the air discharged from the drain valve contains no fuel. When a filler
gun is inserted, the shut-off valve closes the evaporation line.
NF0472
(1) Canister (4) Shut-off valve: closed

(2) Pressure control solenoid valve (5) Filler gun
(3) Vent valve
EC-21
VACUUM CONNECTIONS
9. Vacuum Connections
The hose and pipe connections of the intake manifold, throttle body and other related parts are
as shown in the illustration.
-:A
-: B
c)
FRONT OF VEHICLE
B2H3540B
(1) Pressure regulator A: HOSE

(2) Throttle body B: PIPE
(3) Purge control solenoid valve C: To canister
(4) Air assist injector solenoid valve
EC-22
EMISSION CONTROL
(AUX. EMISSION
CONTROL DEVICES)
EC (DOHC
TURBO
)
Page
1. System Overview . . . . . . . . . . ................
2. Schematic Diagrams . . . . . . ...............
3. Crankcase Emission Contr
4. Three-way Catalyst . .
5. A/F Control System . . . . . . . . ................ ................
6. Ignition Control System . . .
7. Evaporative Emission Con
8. On-board Refueling Vapor
9. Vacuum Connections . . . . . . . . . ................ ................
I SYSTEM OVERVIEW
1. System Overview
There are three emission control systems which are as follows:
0 Crankcase emission control system
0 Exhaust emission control system
0 Three-way catalyst system
0 Air/fuel (A/F) control system
0 Ignition control system
0 Evaporative emission control system

0 On-board refueling vapor recovery (ORVR) system
tern I Main components Function
:rankcase emission control Positive crankcase Draws blow-by gas into intake manifold from crankcase and burns it
system ventilation (PCV) together with air-fuel mixture. Amount of blow-by gas to be drawn in
valve is controlled by intake manifold pressure.
Exhaust >atalyst Pre Three-way catalyst Oxidizes HC and CO contained in exhaust gases as well as reducing
mission system NOx.
Front
:ontrol
system Rear
WF control Engine control mod- Receives input signals from various sensors, compares signals with
system ule (ECM) stored data, and emits a signal for optimal control of air-fuel mixture
ratio.
Front oxygen (NF) Detects quantity of oxygen contained exhaust gases.
sensor
I Rear oxygen sensor I Detects density of oxygen contained exhaust gases.
Throttle position
sensor
1 Detects throttle position.
Mass air flow sensor Detects amount of intake air.

and intake air tem-
perature sensor Detects.intake air temperature of air cleaner case.
gnition control
system I ECM
Crankshaft position
Receives various signals, compares signals with basic data stored in
memory, and emits a signal for optimal control of ignition timing.
Detects engine speed (Revolution).
sensor
Camshaft position Detects reference signal for combustion cylinder discrimination.
sensor
Engine coolant tem- Detects coolant temperature.
perature sensor
%
l ck sensor 1 Detects engine knocking
Evaporative emission control Canister Absorbs evaporative gas which occurs in fuel tank when engine
system stops, and releases it to combustion chambers for a complete burn
when engine is started. This prevents HC from being discharged into
atmosphere.
Purge control Receives a signal from ECM and controls purge of evaporative gas
solenoid valve absorbed by canister.
3RVR system Vent valve Controls evaporation pressure in fuel tank.
Drain valve Closes the evaporation line by receiving a signal from ECM to check
the evaporation gas leak.
EC-2
SYSTEM OVERVIEW
MEMO
EC-3
SCHEMATIC DIAGRAMS
2. Schematic Diagrams
1 II I
NF0435
EC-4
SCHEMATIC DIAGRAMS
m
Engine control module (ECM) Front catalytic converter Neutral switch (MT vehicles only)
Ignition coil and ignitor assembly Rear catalytic converter CHECK ENGINE malfunction
indicator lamp (MIL)
Crankshaft position sensor Precatalytic converter Tachometer
Camshaft position sensor Exhaust temperature sensor A/C relay
Throttle position sensor Front oxygen (NF) sensor A/C control module
Fuel injectors Rear oxygen sensor Ignitionswitch
Pressure regulator Turbocharger Transmission control module
(TCM) (AT vehicles only)
Engine coolant temperature Wastegate control solenoid valve Vehicle speed sensor
sensor
Pressure sensor Wastegate controller Data link connector
Idle air control solenoid valve Purge valve Fuel tank pressure sensor
Purge control solenoid valve Air bypass valve Pressure control solenoid valve
Fuel pump Intercooler Fuel temperature sensor
Mass air flow and intake air tem- Tumble generator valve position Fuel level sensor
perature sensor sensor
Air cleaner element Tumble generator valve actuator Drain filter
Canister Radiator fan Vent valve
Main relay Radiator fan relay Shut-off valve
Fuel pump relay Knock sensor Drain valve
Fuel filter A/C compressor Fuel cut valve
Fuel pump controller Inhibitorswitch (AT vehicles only)
EC-5
I CRANKCASE EMISSION CONTROL SYSTEM
3. Crankcase Emission Control System

0 The positive crankcase ventilation (PCV) system prevents air pollution which will be caused by
blow-by gas being emitted from the crankcase.
The system consists of a sealed oil filler cap, rocker covers with fresh air inlet, connecting hoses,
a PCV valve and an air intake duct.
0 In a part-throttle condition, the blow-by gas in the crankcase flows into the intake manifold
through the connecting hose of crankcase and PCV valve by the strong vacuum created in the
intake manifold. Under this condition, fresh air is introduced into the crankcase through the con-
necting hose of the rocker cover.
0 In a wide-open-throttle condition, a part of blow-by gas flows into the air intake duct through the
connecting hose and is drawn into the throttle chamber, because under this is condition, the intake
manifold vacuum is not strong enough to introduce through the PCV valve all blow-by gases that
increase in the amount with engine speed.
NF0307
(1) Air intake duct (5) Case A: To intake manifold

(2) PCVvalve (6) Valve
(3) intake manifold (7) Spring
(4) Crankcase (8) PCVvalve
EC-6
THREE-WAY CATALYST
4. Three-way Catalyst
0 The basic material of three-way catalyst is platinum (Pt), rhodium (Rh) and palladium (Pd), and
a thin coat of their mixture is applied onto honeycomb or porous ceramics of an oval shape (carri-
er). To avoid damaging the catalyst, only unleaded gasoline should be used.
0 The catalyst reduces HC, CO and NOx in exhaust gases through chemical reactions (oxidation
and reduction). These harmful components are reduced most efficiently when their concentra-
tions are in a certain balance. These concentrations vary with the air-fuel ratio. The ideal air-fuel
ratio for reduction of these components is the stoichiometric ratio.
0 Therefore, the air-fuel ratio needs to be controlled to around the stoichiometric ratio to purify the
exhaust gases most efficiently.
EC-7
A/F CONTROL SYSTEM
5. NF Control System
0 The aidfuel (A/F) control system makes a correction to the basic fuel injection duration in accor-
dance with the signal from the front oxygen sensor so that the stoichiometric ratio is maintained,
thus ensuring most effective exhaust gas purification by the three-way catalyst. Different basic fuel
injection durations are preset for various engine speeds and loads, as well as the amount of intake
air.
This system also has a “learning” control function which stores the corrected data in relation to
the basic fuel injection in the memory map. This allows an appropriate air-fuel ratio correction to
be added automatically in quick response to any situation that requires such an effect. Thus, the
air-fuel ratio is optimally maintained under various conditions while purifying exhaust gases most
effectively, improving driving performance and compensating for changes in sensors’ perfor-
mance over time.
EC-8
I m
IGNITION CONTROL SYSTEM
6. Ignition Control System

0 The ignition system is controlled by the ECM.
The ECM monitors the operating condition of the engine using the signals from the sensors and
switches shown below and determines the ignition timing most appropriate for each engine oper-
ating condition. Then it sends a signal to the ignitor, commanding generation of a spark at that
timing.
0 The ECM uses a preprogrammed map for a “closed-loop” control which provides its ignition tim-
ing control with excellent transient characteristics, i.e., highly responsive ignition timing control.
NF0308
(1) Battery (6) Ignition coil and ignitor assembly

(2) Ignition switch (7) Knock sensor
(3) ECM (8) Mass air flow and intake air temperature sensor
(4) Camshaft position sensor (9) Engine coolant temperature sensor
EC-9
7. Evaporative Emission Control System

A: GENERAL
0 The evaporative emission control system prevents fuel vapors from escaping into atmosphere.
This system includes a canister, purge control solenoid valve, fuel cut valve, and the lines connect-
ing them.
0 Fuel vapors in the fuel tank is introduced into the canister through the evaporation line, and are
absorbed by activated carbon in it. The fuel cut valve is also incorporated in the fuel tank line.
0 The purge control solenoid valve is controlled optimally by the ECM according to the engine
condition.
0 The pressure control solenoid valve incorporated in the fuel tank evaporation line regulates the
pressurelvacuum in the fuel tank under the control of the ECM which uses the signal from the fuel
tank pressure sensor.
-:A
-: B
NF0428
(1 ) Purge control solenoid valve (11) Drain filter (21) Fuel tank pressure sensor
(2) Purge valve (12) Shut-off valve (22) Fuel gauge
(3) Pressure regulator (13) Vent valve (23) Combination meter
(4) Throttle body (14) Fuel temperature sensor (24) Fuel injector
(5) Fuel filter (15) Fuel level sensor
(6) Intake manifold (16) Fuel pump A: Fuel line
(7) ECM (1 7) Jet pump B: Evaporation line
(8) Canister (18) Fuel cut valve
(9) Pressure control solenoid valve (19) Fuel sub level sensor
(10) Drain valve (20) Fuel tank
EC-10
B: FUEL CUT VALVE

The fuel cut valve is built onto the evaporation pipe of the fuel tank cap. The rising level of the fuel
in the fuel tank causes the float to move up and close the cap hole so that no fuel can enter the
evaporation line.
NF0469
(1) Float A: To canister

B: Valveopen
C: Valve closed
EC-11
C: FUEL TANK CAP

The fuel tank cap has a relief valve which prevents development of vacuum in the fuel tank in the
event of a problem with the fuel vapor line.
When there is no problem with the fuel vapor line, the filler pipe is sealed at the portion (A) and
by the seal pressed against the filler pipe end. If vacuum develops in the fuel tank, the atmospheric
pressure forces the spring down to open the valve; consequently outside air flows into the fuel tank,
thus controlling the inside pressure.
NF0470
(1) Seal
(2) Spring
(3) Valve
(4) Filter
EC-12
D: CANISTER
The charcoal filled in the canister temporarily stores fuel vapors. When the purge control solenoid
valve is opened by a signal from the ECM, the external fresh air entering the canister carries the
fuel vapors into the collector chamber.
H2H3223B
(1) Grid A: To purge control solenoid valve

(2) Filter B: From fuel tank
(3) Charcoal C: Air
(4) Filter
(5) Spring
EC-13
E: PURGE CONTROL SOLENOID VALVE

The purge control solenoid valve is on the evaporation line between the canister and intake man-
ifold. It is installed at the underside of intake manifold.
A B
t t
NF0386
A: To canister
B: To intake manifold
EC-14
a
F: PRESSURE CONTROL SOLENOID VALVE

The fuel tank pressure control solenoid valve is located in the evaporation line between the shut-off
valve on fuel filler pipe and the fuel tank. It adjusts the fuel tank inside pressure under the control
of the ECM.
When the tank inside pressure becomes higher than the atmospheric pressure, the valve is
opened allowing fuel vapors to be introduced into the canister.
On the other hand, when the tank inside pressure becomes lower than the atmospheric pressure,
external air is taken from the drain valve into the canister.
The pressure control solenoid valve can also be electrically closed for the system diagnosis pur-
poses.
B2H1719C
(1) Filter A: Atmospheric pressure

(2) Coil B: From shut-off valve
(3) Connector terminal C: To fuel tank
(4) Diaphragm
(5) Valve
EC-15
Emission Control IAux. Emission Control Devices)
G: DRAIN FILTER
The drain filter is installed at the air inlet port of the vent control solenoid valve. It cleans the air taken
in the canister through the vent control solenoid valve.
S2H0874B
(1) Cap A: To drain valve

(2) Element B: To atmosphere
(3) Case
EC-16
a
Emission Control fAux. Emission Control Devices)
H: VENT VALVE
The vent valve is located on the fuel tank. During filling the fuel tank, fuel vapors are introduced
into the canister through the vent valve.
When the fuel vapor pressure becomes higher than the atmospheric pressure and overcomes the
spring force which is applied to the back side of the diaphragm, the port toward the canister is
opened. The vent valve also has afloat which blocks the fuel vapor passage when the tank is filled
up. Increasing fuel level raises the float to close the port toward the canister.
B-
H2H3224B
(1) Spring A: To filler pipe

(2) Diaphragm B: To canister
(3) Plate cover
(4) Packing
(5) Float
(6) Float spring
EC-17
I: SHUT-OFF VALVE
The shut-off valve is located at the top of the fuel filler pipe. When a filler gun is inserted into the
filler pipe, the shut-off valve closes the evaporation line.
A
\
,(3)
n I
-(4)
B2H1769B
(1) Pin A: To canister

(2) Valve B: To fuel tank
(3) Spring
(4) Plate
(5) Shaft
(6) Pin
EC-18
J: DRAIN VALVE
The drain valve is located on the line connecting the drain filter and canister, just below the drain
filter. The drain valve is forcibly closed by a signal from the ECM while the evaporation system diag-
nosis is being conducted.
B2H1770A
(1) Magnetic plate (6) Valve

(2) Yoke (7) Plate
(3) Packing (8) Retainer
(4) Spring (9) Moving core
(5) Valve seat (10) Bobin
EC-19
8. On-board Refueling Vapor Recovery (ORVR) System

A: GENERAL
The on-board refueling vapor recovery system allows the fuel vapors in the fuel tank to be
introduced directly into the canister through the vent valve when the fuel tank inside pressure in-
creases as a result of refueling.
The diagnosis of the system is performed by monitoring the fuel tank inside pressure data from
the fuel tank pressure sensor while forcibly closing the drain valve.
B: OPERATION
0 While driving
Since the back side of the diaphragm in the pressure control solenoid valve is open to the atmo-
sphere, the diaphragm is held pressed by the atmospheric pressure in the position where only the
external air is introduced into the canister. When the fuel vapor pressure acting on the other side
of the diaphragm increases and overcomes the atmospheric pressure, it pushes the diaphragm
and opens the port through which the fuel vapors make their way to the canister.
I
I
I 111 /
NF0471
(1) Canister (4) Intake manifold

(2) Pressure control solenoid valve (5) Shut-off valve: opened
(3) Purge control solenoid valve
EC-20
0 While refueling
As the fuel enters the fuel tank, the tank inside pressure increases. When the inside pressure be-
comes higher than the atmospheric pressure, the port of the vent valve opens, allowing the fuel
vapors to be introduced into the canister through the vent line. The fuel vapors are absorbed by
charcoal in the canister, so the air discharged from the drain valve contains no fuel. When a filler
gun is inserted, the shut-off valve closes the evaporation line.
W
NF0472
(1) Canister (4) Shut-off valve: closed

(2) Pressure control solenoid valve (5) Filler gun
(3) Vent valve
EC-21
I
VACUUM CONNECTIONS
9. Vacuum Connections
The hose and pipe connections of the intake manifold, throttle body and other related parts are
as shown in the illustration.
A
(1
9D
-
-
: (3)
: (4)
NF0315
(1 ) Pressure regulator A: IN
(2) Purge control solenoid valve B: OUT
(3) Hose C: To canister
(4) Pipe D: Front of vehicle
EC-22
INTAKE (INDUCTION) IN ( s o w
Page
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... . . . . . . . . . . . . . . . . . . 2
GENERAL
Intake (Induction)
1. General
The intake system consists of an air intake duct, a resonator chamber, and an air cleaner element
housed in its case. The resonator, located upstream of the air cleaner case, effectively reduces
the intake noise level.
A
NF0450
(1) Air intake duct A: Fresh air

(2) Resonator chamber B: To throttle body
(3) Air cleaner case
(4) Air cleaner element
IN-2
INTAKE (INDUCTION) IN (%ll;o)
Page
1. Intake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Turbocharger System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INTAKE SYSTEM
Intake (Induction)
1. Intake System
A: GENERAL
The intake system consists of an air intake duct, a resonator chamber, and an air cleaner element
housed in its case. The resonator, located upstream of the air cleaner case, effectively reduces
the intake noise level.
e),
NF0342
(1 ) Air intake duct A: Fresh air

(2) Resonator chamber B: To turbocharger
(3) Air cleaner case
(4) Mass air flow and intake air temperature sensor
(5) Intake boot
(6) Intake duct
IN-2
TURBOCHARGER SYSTEM
Intake (Induction)
2. Turbocharger System
A: GENERAL
0 The turbocharger system consists of a water-cooled turbocharger,air-cooled intercooler,waste-
gate control solenoid valve, etc.
0 The outlet side turbine, rotated by exhaust gas pressure, rotates the inlet side turbine. As a re-
sult, the inlet side turbine compresses the intake air before it is delivered to the intake manifold.
0 The intake air is heated when it passes through the turbocharger unit. The air is cooled as it
passes through the intercooler.
0 This turbocharger system controls the supercharging pressure according to changes in the at-
mospheric pressure. Even at a high altitude, therefore, the system offers stable performance with-
out being affected by variations in atmospheric pressure.
- u u
NF0343
(1) Pressure sensor (9) Wastegate controller

(2) Crankshaft position sensor (10) Wastegate control solenoid valve
(3) Camshaft position sensor (11) Air bypass valve
(4) Throttle position sensor (12) Intercooler
(5) Engine coolant temperature sensor (13) Throttle body
(6) Mass air flow and intake air temperature sensor (14) Intake manifold
(7) Wastegate valve (15) ECM
(8) Turbocharger unit
IN-3
TURBOCHARGER SYSTEM
Intake (Induction)
6: TURBOCHARGER UNIT
The turbocharger is water-cooled. It utilizes a wastegate valve to adjust its supercharging pres-
sure to an optimum level. The turbine is housed in a lightweight, thin-wall, heat-resistant casting.
The compressor housing is made of thin-wall, aluminum alloy casting. The shaft for turbine and
compressor is supported by a full-floating metal bearing system.
E
W
1
A NF0344
(1 ) Wastegate controller A: Lubricating oil outlet E: Lubricating oil inlet

(2) Compressor housing B: Exhaust gas outlet F: Air inlet
(3) Turbine housing C: Air outlet G : Wastegate valve operating pressure
D: Engine coolant inlet
IN-4
TURBOCHARGER SYSTEM
Intake (Induction)
C: LUBRICATION OF TURBOCHARGER
The turbocharger is lubricated by engine oil branched out from the oil pump. To cope with very
high speed of the turbocharger turbine and the compressor shaft which may reach a maximum
of several hundred thousands of rpm, full-floating type bearings are used which can form ade-
quate oil films on their inside and outside during running.
Further the oil supplied to the turbocharger also plays a role of cooling the turbine so that heat from
exhaust gas does not transmitted to the bearings.
NF0345
(1) Compressor housing (3) Turbine housing

(2) Turbine wheel (4) Compressor impeller
D: COOLING OF TURBOCHARGER
The turbocharger unit is cooled by engine coolant, which enhances the reliability and durability
of the unit. The engine coolant from the coolant drain hose located under the cylinder head is led
by a pipe to the coolant passage provided in the turbocharger bearing housing. After cooling the
bearing housing, the engine coolant is led into the coolant filler tank through a pipe.
IN-5
TURBOCHARGER SYSTEM
Intake (Induction)
E: WASTEGATE CONTROL SOLENOID VALVE

The wastegate control solenoid valve switches the intake air pressure passages to the wastegate
controller in response to signals from the ECM. When the solenoid valve is closed, the intake air
pressure upstream of the turbocharger unit is applied to the wastegate controller. When the sole-
noid valve is opened, the intake air pressure downstream of the turbocharger unit (supercharged
air pressure) is applied to the wastegate controller.
NF0346
(1) Coil
IN-6
TURBOCHARGER SYSTEM
Intake (Induction)
F: REGULATION OF SUPERCHARGING PRESSURE

1. BASIC FUNCTION OF THE WASTEGATE VALVE
When the engine speed increases as the throttle valve opens, the amount of exhaust gas in-
creases. This increases the speed of the turbine (approx. 20,000 to 150,000rpm), the supercharg-
ing pressure and the engine output.
If the resultant supercharging pressure is extremely high, however, it may cause knocking and an
excessively high thermal load on such engine components as pistons. In the worst case, the en-
gine may be damaged or broken. To prevent this, the wastegate valve and its controller are pro-
vided. By sensing the supercharging pressure, the wastegate valve controller controls the opera-
tion of the wastegate valve to maintain the supercharging pressure below a predetermined level.
NF0347
(1) Wastegate valve

(2) Turbocharger
(3) Wastegate valve controller
While the supercharging pressure is lower than the predetermined level, the wastegate valve is
closed so that entire exhaust gas is directed to the turbine.
NF0348
IN-7
TURBOCHARGER SYSTEM
Intake (Induction)
When the supercharging pressure reaches the predetermined level, the wastegate controller lets
the supercharging pressure press the diaphragm. This causes the wastegate valve to open
through a linkage. With the wastegate valve open, part of the exhaust gas is allowed to flow into
the exhaust gas pipe that bypasses the passage to the turbine.
This decreases the exhaust gas pressure that rotates the turbine and keeps the supercharging
pressure constant.
0 It means P2 - P1 = constant.
PI: Atmospheric pressure
P2: Supercharging pressure
NF0349
2. CONCEPT OF THE WASTEGATE VALVE CONTROL

At high altitudes, the atmospheric pressure (PI) is low, so that the supercharging pressure (P2)
is also low in a conventional system. The wastegate solenoid valve operates in such a way that
a constant supercharging pressure (P2) is maintained by acting in response to change in the atmo-
spheric pressure.
NF0350
IN-8
TURBOCHARGER SYSTEM
Intake (Induction)
G: INTERCOOLER
0 Since the intake air having passed through the turbocharger unit is heated to avery high temper-
ature, the air itself is expanded, resulting in a lower supercharging charging efficiency. The inter-
cooler is provided just before the throttle body to cool down the intake air and improve the super-
charging efficiency.
0 The intercooler is an air cooled type. The air delivered from the air duct provided at the engine
hood flows through the core and cools the intake air passing through the intercooler.
NF0351
A: From turbocharger
B: To throttle body
IN-9
TURBOCHARGERSYSTEM
Intake (Induction)
H: AIR BYPASS VALVE

When a throttle valve is suddenly closed, low air suction noise may occur due to a sudden rise of
the air pressure in the passage between the turbocharger and throttle body. To prevent this, an
air bypass valve and air passage are provided. The air bypass valve, actuated by the vacuum
created by a sudden closure of the throttle valve, allows the suction air to bypass the turbocharger
and flow directly upstream, thus lowering the pressure in the air passage.
II
:i:
B
NF0393
A: To intake manifold
B: To turbocharger inlet duct
C: From intercooler
IN-I 0
a
MECHANICAL ME ( ~
Page
1. General ............................. ......................................... 2
2. .................................... ........... 3
3. ........................................ 4
4. ..................................... . 6
5. ....................................................... 7
6. .................................... ........... 8
7. ....................................................... 9
0. .................................................. 10
9. Crankshaft ................................... .. ........................... 11
10. Piston ...................... ......................................... .. 12
11. Engine Mounting ...................................... .......................... 13
-. .
I GENERAL
Mechanical
1. General
The engine used in this vehicle is of a horizontally opposed, four-cylinder design. This four-stroke-
cycle, water-cooled, SOHC engine uses a total of 16 valves and its main components are made
of aluminum alloy. It is fueled by a multiple fuel injection system.
The engine’s major structural and functional features are as follows:
0 The cylinder head forms pentroof combustion chambers, each having a spark plug located at
its center and two each of intake and exhaust valves (four valves per cylinder). The intake and ex-
haust ports are located in a cross-flow arrangement.
0 There are a screw and nut at the valve end of each rocker arm. They are used for adjusting the
valve clearance.
0 A single timing belt drives two camshafts on the left and right banks and the engine coolant
pump on the left bank. Belt tension is automatically adjusted by a belt tension adjuster, eliminating
need for a manual adjustment.
0 The crankshaft is supported by five bearings with high rigidity and strength.
0 The cylinder block is an aluminum die casting fitted with iron die-cast cylinder liners.
C. -
NF0039
(1) Camshaft (6) Camshaft cap (11) Exhaust rocker arm

(2) Intake valve (7) Valve rocker cover (12) Exhaust rocker shaft
(3) Cylinder block (8) Cylinder head (13) Intake rocker shaft
(4) Connecting rod (9) Oil pan (14) Intake rocker arm
(5) Spark plug (10) Exhaust valve
ME-2
TIMING BELT a
Mechanical
2. Timing Belt
0 A single timing belt drives two camshafts (one in the left bank and one in the right bank). The
belt also drives the water pump by its non-toothed side.
0 The timing belt teeth have a specially designed round profile which contributes to quiet opera-
tion. The timing belt is made of strong and inflexible core cords, wear-resistant canvas and heat-re-
sistant rubber material.
0 A hydraulic automatic belt tension adjuster always keeps the belt taut to the specified tension.
Any manual belt tension adjustment is unnecessary.
NF0040
(1) Timingindicator(FortimingmarkofcrankshaftpuI1ey) (8) Water pump pulley

(2) *Piston position mark (9) Idler No. 2
(3) Belt tension pulley (10) Timing belt
(4) Automatic belt tension adjuster (11) Crankshaft sprocket

(5) Alignment mark (12) Idler
(6) **Piston position mark (13) Camshaft sprocket RH

(7) Camshaft sprocket LH
NOTE:
*: The #I piston is at TDC when the piston position mark on the crankshaft sprocket is aligned with
the timing mark on the cylinder block.
**: The #I piston is at TDC on the compression stroke when the piston position mark on the cam-
shaft sprocket is aligned with the timing mark on the belt cover.
ME-3
I AUTOMATIC BELT TENSION ADJUSTER
Mechanical
3. Automatic Belt Tension Adjuster

The automatic belt tension adjuster consists of a tensioner unit and a bracket. It maintains the tim-
ing belt tension automatically at a specified level to enable the belt to transmit power correctly,
reduce operating noise and increase the life of the belt.
The cylinder of the tensioner unit incorporates an adjuster rod, wear ring, plunger spring, return
spring, check ball and silicone oil.
The automatic belt tension adjuster gives tension to the belt by a levering action which is produced
by the push force of the tensioner unit’s adjuster rod. It operates in the process detailed below.
--
NF0368
( I ) Oil seal (8) Plunger spring

(2) Wear ring (9) Check ball
(3) Oil reservoir chamber (10) Timing belt
(4) Return spring (11) Belt tension pulley
(5) Adjuster rod (12) Tensioner bracket
(6) Plunger (13) Cylinder
(7) Oil pressure chamber
ME-4
AUTOMATIC BELT TENSION ADJUSTER
Mechanical
Timing belt tensioning action

0
When the belt becomes slack, the adjuster rod is pushed upward by the return spring. The oil in
the reservoir chamber, which is pressurized by the plunger spring to a certain level, pushes open
the check ball and flows into the oil pressure chamber to keep the pressure constant.
The thrust force F resulting from extension of the adjuster rod applies a counterclockwise torque
to the tensioner bracket, which causes the belt tension pulley at its end to turn in the same direc-
tion. This applies tensioning pressure Pb to the timing belt.
0 Timing belt tension balancing action
When the belt tension pulley is pushed against the timing belt with pressure Pb, reaction force Tb
of the timing belt generates the reaction force P at the point on which the adjustor rod force is act-
ing.
This force P pushes the adjuster rod until it balances with the sum of the thrust force F and the
pressure of the oil in the oil pressure chamber. Therefore, the timing belt tension is kept constant.
0 Overtension correction action
If the tension of the timing belt increases excessively, the force P becomes larger than the thrust
force F and silicone oil is returned from the oil pressure chamber to the reservoir chamber little by
little until the force P balances again with the thrust force F. Thus the timing belt tension is main-
tained at the specified level at all times.
r- .
ME-5
I BELT COVER
Mechanical
4. Belt Cover
0 The belt cover is made of lightweight, heat resistant synthetic resin molding. It constitutes a total-
ly enclosed housing with its cylinder block mating edges sealed with rubber gaskets. This effec-
tively protects the inside components from dust and liquid.
0 Rubber seals used between the cylinder block and the belt cover effectively reduces transmis-
sion of noise and vibration.
0 The front belt cover has a line mark for ignition-timing checking.
gkp
gkp’
NF0042
(1) Front belt cover

(2) Belt cover No. 2 (RH)
(3) Belt cover No. 2 (LH)
(4) Belt cover (LH)
ME-6
a
VALVE ROCKER ASSEMBLY
Mechanical
5. Valve Rocker Assembly

0 The intake valve rocker arms and the exhaust valve rocker arms are installed on their own rocker
shafts both of which are retained by the camshaft caps.
0 The valve end of each rocker arm is provided with valve rocker adjusting screw and nut. Turning
of this screw adjusts the valve clearance.
0 The exhaust valve rocker arms are Y-shaped, and each arm operates two exhaust valves simul-
taneously.
0 Each rocker shaft has an oil passage in it.
NF0043
(1) Valve rocker adjusting screw and nut (4) Camshaft cap
(2) Intake valve rocker arm (5) Supporter
(3) Wave washer (6) Exhaust valve rocker arm
ME-7
CAMSHAFT
Mechanical
6. Camshaft
0 The camshaft is supported inside the cylinder head at four journals.
0 The two flanges on each camshaft supports thrust forces to limit the end play of the camshaft
within the tolerance.
0 Each camshaft has an oil passage in it.
U u u
B2H1987B
(1) Journal
(2) Oil passage
(3) Shaft flange
ME-8
9s
CYLINDER HEAD
Mechanical
7. Cylinder Head
0 The cylinder head is made of aluminium die casting.
0 Each combustion chamber in the cylinder head is a compact, pentroof design. The spark plug
is located at the center of the combustion chamber, which contributes to creation of a wide “squish
area” for increased combustion efficiency.
0 The two intake and two exhaust valves are arranged on opposite sides for a cross-flow feature.
0 The cylinder head gasket is a metallic gasket consisting of three layers of the stainless steel
sheets. It is highly resistant to heat and maintains high level of sealing performance for a long peri-
od.
r- .
NF0045
(1) Intake valve (5) Exhaust port

(2) Intake port (6) Exhaust valve
(3) Squish area (7) Spark plug
(4) Combustion chamber
ME-9
I CYLINDER BLOCK
Mechanical
8. Cylinder Block
0 The cylinder block is made of aluminum die casting. Its open-deck design provides it with such
advantageous features as relatively small weight, high rigidity and excellent cooling efficiency.
0 The cylinder liners are made of cast iron. They are dry type which means their outer surfaces
are entirely in contact with the cylinder block.
0 The cylinder block supports the crankshaft at its five journals. The journal supporting portions
are designed such that sufficient stiffness and quiet operation are ensured.
0 The oil pump is located in the front center of the cylinder block and the engine coolant pump
is located at the front of the left-cylinder bank. At the rear of the right-cylinder bank is an oil separa-
tor which removes oil mist contained in blow-by gas.
--
ME-I 0
CRANKSHAFT
m
Mechanical
9. Crankshaft
The crankshaft is supported in the cylinder block by five bearings. Each corner formed by a journal
or pin and a web is finished by fillet-rolling method which increases strength of that area. The five
crankshaft bearings are made of aluminum alloy and the No. 5 bearing is provided with a flanged
metal to support thrust forces.
r.
#5
&v #1
NF0372
ME-I1
PISTON
Mechanical
IO.Piston
0 The pistons are of a slipper skirt design for reduced weight and friction. The oil control ring
groove utilizes a thermal design.
0 The piston pin is offset either downward (Nos. 1 and 3 pistons) or upward (Nos. 2 and 4 pistons).
0 The piston head has recesses to prevent interference with the intake and exhaust valves. It also
has engraved marks to identify the piston size and the direction of installation. All the pistons are
common in their design.
0 Three piston rings are used for each piston - two compression rings and one oil control ring.
The top piston ring has inner bevels and the second piston ring has an interrupt (cut) on the bottom
outside to reduce oil consumption.
NF0449
(1) Location mark (Engine front side) A: Top ring (a) Inner-bevel
(2) Identification mark (Piston size) B: Second ring (b) Interrupt (cut)
(3) Engine capacity (2500 cc) C: Oil ring (c) Upper rail
(d) Spacer
(e) Lower rail
ME-12
ENGINE MOUNTING
Mechanical
11. Engine Mounting
NF0374
( I ) Bracket
(2) Cushion rubber
ME-I3
ENGINE MOUNTING
Mechanical
MEMO
ME-14
MECHANICAL ME (%I::o)
Page
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. ................................................................ 3
3. 4
4. ........................................................ 6
5. Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............. 7
6. ................................................................ 8
7. 9
8. ................................................ 10
9. Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
10. ...................................... 12
I GENERAL
Mechanical
1. General
The engine used in this vehicle is of a horizontally opposed, four-cylinder design. This four-stroke-
cycle, water-cooled, DOHC turbocharged engine uses a total of 16 valves and its main compo-
nents are made of aluminum alloy. It is fueled by a multiple fuel injection system.
The engine’s major structural and functional features are as follows:
0 The cylinder head forms pentroof combustion chambers, each having a spark plug located at
its center and two each of intake and exhaust valves (four valves per cylinder). The intake and ex-
haust ports are located in a cross-flow arrangement.
0 A single timing belt drives four camshafts on the left and right banks and the engine coolant
pump on the left bank. Belt tension is automatically adjusted by a belt tension adjuster, eliminating
need for a manual adjustment.
0 The crankshaft is supported by five bearings with high rigidity and strength.
0 The cylinder block is an aluminum die casting fitted with iron die-cast cylinder liners.
(6)
NF0366
(1) Intake camshaft (5) Crankshaft (9) Cylinder head

(2) Intake valve (6) Connecting rod (IO) Oil pan
(3) Piston (7) Spark plug (11) Exhaust valve
(4) Cylinder block (8) Valve rocker cover (12 ) Exhaust camshaft
ME-2
1
TIMING BELT
Mechanical
2. Timing Belt
0 A single timing belt drives four camshafts (intake and exhaust camshafts on each bank). The
belt also drives the water pump by its non-toothed side.
0 The timing belt teeth have a specially designed round profile which contributes to quiet opera-
tion. The timing belt is made of strong and inflexible core cords, wear-resistant canvas and heat-re-
sistant rubber material.
0 A hydraulic automatic belt tension adjuster always keeps the belt taut to the specified tension.
Any manual belt tension adjustment is unnecessary.
NF0367
Timing indicator (For timing mark of crankshaft pulley) (9) Water pump pulley
*Piston position mark (10) Idler No. 2
Belt tension pulley (11) Timing belt
Automatic belt tension adjuster assembly (12) Crankshaft sprocket
Alignment mark (13) Idler
**Piston position mark (14) Exhaust camshaft sprocket RH
Intake camshaft sprocket LH (15) Intake camshaft sprocket RH
Exhaust camshaft sprocket LH
*: The #I piston is set at the top dead center (TDC) when the piston-position mark on the crankshaft
sprocket is aligned with the mark on cylinder block.
**: The #1 piston is set at TDC on the compression stroke when the piston-position mark on the
camshaft sprocket is facing directly upward.
ME-3
Mechanical
3. Automatic Belt Tension Adjuster

The automatic belt tension adjuster consists of a tensioner unit and a bracket. It maintains the tim-
ing belt tension automatically at a specified level to enable the belt to transmit power correctly,
reduce operating noise and increase the life of the belt.
The cylinder of the tensioner unit incorporates an adjuster rod, wear ring, plunger spring, return
spring, check ball and silicone oil.
The automatic belt tension adjuster gives tension to the belt by a levering action which is produced
by the push force of the tensioner unit’s adjuster rod. It operates in the process detailed below.
NF0368
(1) Oil seal (8) Plunger spring

(2) Wear ring (9) Check ball
(3) Oil reservoir chamber (10) Timing belt
(4) Return spring (11) Belt tension pulley
(5) Adjuster rod (12) Tensioner bracket
(6) Plunger (13) Cylinder
(7) Oil pressure chamber
ME-4
Mechanical
0 Timing belt tensioning action

When the belt becomes slack, the adjuster rod is pushed upward by the return spring. The oil in
the reservoir chamber, which is pressurized by the plunger spring to a certain level, pushes open
the check ball and flows into the oil pressure chamber to keep the pressure constant.
The thrust force F resulting from extension of the adjuster rod applies a counterclockwise torque
to the tensioner bracket, which causes the belt tension pulley at its end to turn in the same direc-
tion. This applies tensioning pressure Pb to the timing belt.
0 Timing belt tension balancing action
When the belt tension pulley is pushed against the timing belt with pressure Pb, reaction force Tb
of the timing belt generates the reaction force P at the point on which the adjustor rod force is act-
ing.
This force P pushes the adjuster rod until it balances with the sum of the thrust force F and the
pressure of the oil in the oil pressure chamber. Therefore, the timing belt tension is kept constant.
0 Overtension correction action
If the tension of the timing belt increases excessively, the force P becomes larger than the thrust
force F and silicone oil is returned from the oil pressure chamber to the reservoir chamber little by
little until the force P balances again with the thrust force F. Thus the timing belt tension is main-
tained at the specified level at all times.
c- -
ME-5
I BELT COVER
Mechanical
4. Belt Cover
0 The belt cover is made of lightweight, heat resistant synthetic resin molding. It constitutes a total-
ly enclosed housing with its cylinder block mating edges sealed with rubber gaskets. This effec-
tively protects the inside components from dust and liquid.
0 Rubber seals used between the cylinder block and the belt cover effectively reduces transmis-
sion of noise and vibration.
0 The front belt cover has a line mark for ignition-timing checking.
e-
NF0369
ME-6
CAMSHAFT
Mechanical
-
v u -
7
V U
-
ml
P L - ’
h --
- n
-
~ -
NF0370
(1 ) Left intake camshaft (4) Left exhaust camshaft

(2) Journal (5) Right intake camshaft
(3) Flange (6) Right exhaust camshaft
ME-7
I CYLINDER HEAD
Mechanical
6. Cylinder Head
0 The cylinder head is made of aluminium die casting.
0 Each combustion chamber in the cylinder head is a compact, pentroof design. The spark plug
is located at the center of the combustion chamber, which contributes to creation of a wide “squish
area” for increased combustion efficiency.
0 The two intake and two exhaust valves are arranged on opposite sides for a cross-flow feature.
0 The cylinder head gasket is a metallic gasket consisting of three layers of the stainless steel
sheets. It is highly resistant to heat and maintains high level of sealing performance for a long peri-
od.
NF0371
(1) Intake valve (5) Exhaust port

(2) Intake port (6) Exhaust valve
(3) Squish area (7) Spark plug
(4) Combustion chamber
ME-8
CYLINDER BLOCK
Mechanical
7. Cylinder Block
0 The cylinder block is made of aluminum die casting. Its open-deck design provides it with such
advantageous features as relatively small weight, high rigidity and excellent cooling efficiency.
0 The cylinder liners are made of cast iron. They are dry type which means their outer surfaces
are entirely in contact with the cylinder block.
0 The cylinder block supports the crankshaft at its five journals. The journal supporting portions
are designed such that sufficient stiffness and quiet operation are ensured.
0 The oil pump is located in the front center of the cylinder block and the engine coolant pump
is located at the front of the left-cylinder bank. At the rear of the right-cylinder bank is an oil separa-
tor which removes oil mist contained in blow-by gas.
ME-9
I CRANKSHAFT
Mechanical
8. Crankshaft
The crankshaft is supported in the cylinder block by five bearings. Each corner formed by a journal
or pin and a web is finished by fillet-rolling method which increases strength of that area. The five
crankshaft bearings are made of aluminum alloy and the No. 5 bearing is provided with a flanged
metal to support thrust forces.
NF0372
ME-I 0
PISTON
Mechanical
9. Piston
0 The pistons are of a slipper skirt design for reduced weight and friction. The oil control ring
groove utilizes a thermal design.
0 The piston pin is offset either downward (Nos. 1 and 3 pistons) or upward (Nos. 2 and 4 pistons).
0 The piston head has recesses to prevent interference with the intake and exhaust valves. It also
has engraved marks to identify the piston size and the direction of installation. All the pistons are
common in their design.
0 Three piston rings are used for each piston - two compression rings and one oil control ring.
The top piston ring has inner bevels and the second piston ring has a cut on the bottom outside
to reduce oil consumption.
NF0373
(1) Identification mark A: Topring (a) Inner-bevel

(2) Location mark (Engine front side) B: Second ring (b) Cut
C: Oil ring (c) Upper rail
(d) Spacer
(e) Lower rail
ME-11
ENGINE MOUNTING
Mechanical
IO.Engine Mounting
NF0374
(1) Bracket
(2) Cushion rubber
ME-12
I
EXHAUST EX (SOHC)
Page
1. General . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL
Exhaust
1. General
0 The exhaust system consists of front exhaust pipes, catalytic converters, a center exhaust pipe,
a rear exhaust pipe and a muffler. The front catalytic converter is located immediately behind the
front exhaust pipe, and the rear catalytic converter is incorporated in the center exhaust pipe.
0 The exhaust system features an improved sound suppression design; the two branches of the
front exhaust pipe join at a point almost equal in distance from the engine’s exhaust ports and the
rear exhaust pipe has resonance chambers in addition to a large capacity muffler.
EX-2
COMPOSITION
Exhaust
2. Composition
NF0441
(1) Right front exhaust pipe (6) Center exhaust pipe
--- (2) Left front exhaust pipe (7) Rear catalytic converter
(8) Resonance chamber
(3) Front catalytic converter
(4) Front oxygen (NF) sensor (9) Rear exhaust pipe
(5) Rear oxygen sensor (IO) Muffler
EX-3
COMPOSITION
Exhaust
-
MEMO
EX-4
I
EXHAUST
Page
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
r- .
I GENERAL
Exhaust
1. General
0 The exhaust system consists of left and right exhaust manifolds, afront joint pipe, a turbocharger
joint pipe, a center exhaust pipe, a rear exhaust pipe and a muffler. The turbocharger joint pipe
incorporates the precatalytic converter, the center exhaust pipe incorporates the front catalytic
converter, and the rear exhaust pipe incorporates the rear catalytic converter.
0 The exhaust system features an improved sound suppression design; the rear exhaust pipe has
a resonance chamber in 'addition to a large capacity muffler.
EX-2
CONSTRUCTION
Exhaust
2. Construction
7
NF0001
Left exhaust manifold (8) Center exhaust pipe

Front joint pipe (9) Rear catalytic converter
Front oxygen (NF)sensor (10) Rear oxygen sensor
Exhaust temperature sensor (11) Chamber
Right exhaust manifold (12) Rear exhaust pipe
Precatalytic converter (13) Muffler
Front catalytic converter (14) Turbocharger joint pipe
EX-3
CONSTRUCTION
Exhaust
MEMO
EX-4
COOLING co Page
1. General ....................... ............................................ 2
2. Cooling Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 3
3. Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................. 5
4. Mechanical Seal _ _ _ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 7
5. Thermostat .................... ............................................ 8
6. Radiator Fan ............................................ .... 9
GENERAL
Cooling
1. General
0 The engine cooling system consists of a down-flow radiator which features high heat-dissipation
performance, an electric-motor-driven fan, a water pump, a thermostat, and an engine coolant
temperature sensor.
0 The engine coolant reservoir tank is designed to minimize the need for replenishing coolant.
0 The ECM controls the operation of the radiator main fan and sub fan depending on the signals
from the engine coolant temperature sensor, vehicle speed sensor and A/C switch.
co-2
i$l
COOLING CIRCUITS
Coolina
2. Cooling Circuits
A: NON-TURBO MODEL
The cooling system operates in three different phases depending on the temperature of the engine
coolant.
0 1st phase (thermostat closed)
When the engine coolant temperature is below 76°C (169"F), the thermostat remains closed. The
coolant flows through the bypass and heater circuits.
This permits the engine to warm up quickly.
0 2nd phase (thermostat open)
When the engine coolant temperature is above 76 - 80°C (169 - 176"F), the thermostat opens.
The coolant flows through the radiator where it is cooled.
0 3rd phase (thermostat open and radiator fan operating)
When the engine coolant temperature sensor sends a signal indicating a temperature above 95°C
(203°F) to the ECM, it causes the radiator fan (or fans) to operate.
p' I
B2H2915C
(1) Radiator (7) Cylinder head RH

(2) Water pump (8) Cylinder jacket RH
(3) Engine coolant reservoir tank (9) Cylinder block RH
(4) Thermostat (IO) Cylinder block LH
(5) Throttle body (11) Cylinder jacket LH
(6) Heater core (12) Cylinder head LH
CO-3
COOLING CIRCUITS
Coolina
B: TURBO MODEL
The cooling system operates in three different phases depending on the temperature of the engine
coolant.
0 1st phase (thermostat closed)
When the engine coolant temperature is below 76°C (169"F), the thermostat remains closed. The
coolant flows through the bypass and heater circuits.
This permits the engine to warm up quickly.
0 2nd phase (thermostat open)
When the engine coolant temperature is above 76 - 80°C (169 - 176"F), the thermostat opens.
The coolant flows through the radiator where it is cooled.
0 3rd phase (thermostat open and radiator fan operating)
When the engine coolant temperature sensor sends a signal indicating a temperature above 95°C
(203°F) to the ECM, it causes the radiator fan (or fans) to operate.
When the engine is stopped after high-speed operation, vapor produced in the turbocharger cool-
ing section flows from the coolant filler tank to the reservoir tank where it condenses back into wa-
ter.
Water is then absorbed by the coolant filler tank as the engine cools down.
C.. . .
T'
I
NF0483
(1) Radiator (8) Oil cooler

(2) Engine coolant reservoir tank (9) Cylinder head RH
(3) Thermostat (10) Cylinder jacket RH
(4) Throttle body (11) Cylinder block RH
(5) Heater core (12) Cylinder block LH
(6) Coolant filler tank (13) Cylinder jacket LH
(7) Turbocharger (14) Cylinder head LH
CO-4
WATER PUMP
3
Cooling
3. Water Pump
The water pump is located in the front portion of the left bank cylinder block and is driven by the
engine through the timing belt. The thermostat is fitted into the coolant inlet at the bottom of the
water pump. When the pump’s impeller rotates, the coolant is drawn into the pump from the lower
pipe (which is connected to the radiator hose) via the thermostat. It then flows along the perimeter
of the impeller and then is discharged for circulation through a circuit depending on the coolant
temperature.
A: NON-TURBO MODEL
--
NF0050
(1) Pulley (3) Mechanical seal (5) Thermostat

(2) Ball bearing (4) Impeller (6) Thermostat case
CO-5
WATER PUMP
Coolina
B: TURBO MODEL
From water tank
From engine
oil cooler
NF0051
(1) Pulley (3) Mechanical seal (5) Thermostat

(2) Ball bearing (4) Impeller (6) Thermostat case
CO-6
MECHANICAL SEAL
Coolina
4. Mechanical Seal
The mechanical seal has its seat tightly fitted on the water pump shaft. Since it is a hermetic seal
forming an integral part of the water pump, the water pump cannot be disassembled.
NF0052
(1) Carbon seal

-- (2) Ceramics seat
(3) Water pump shaft
CO-7
I THERMOSTAT
Cooling
5. Thermostat
The thermostat has a totally-enclosed wax pellet which expands as the coolant temperature in-
creases. It opens and closes accurately at the preset temperatures and features high durability.
NF0053
(1) Valve (4) Piston (7) Stop ring

(2) Spring (5) Guide (8) Wax element
(3) Stopper (6) Rubber packing (9) Jiggle valve
CO-8
RADIATOR FAN
Cooling
6. Radiator Fan
A: DESCRIPTION
Each radiator fan is made of plastic. It is driven by an electric motor which is retained on a shroud.
1. NON-TURBO MODEL
--
NF0054
Radiator (9) Radiator main fan

Radiator sub fan (model with N C ) (10) Radiator main fan motor
Radiator sub fan motor (model with N C ) (11) Lower cushion
Radiator sub fan shroud (model with N C ) (12) Radiator drain plug
Overflow hose (13) Upper bracket
Engine coolant reservoir tank cap (14) Upper cushion
Engine coolant reservoir tank
Radiator main fan shroud N C : Air conditioning system
co-9
RADIATOR FAN
Coolina
2. TURBO MODEL
(18)
NF0437
(1) Radiator lower cushion (7) Engine coolant reservoir tank (13) Radiator main fan
(2) Radiator ( 8 ) Overflow pipe (14) Radiator main fan motor
(3) Radiator upper cushion (9) Sub fan shroud (1 5) Radiator drain plug
(4) Radiator upper bracket (10) Radiator sub fan (16) Engine coolant filler tank
(5) Engine coolant reservoir tank cap (11) Radiator sub fan motor (17) Engine coolant filler tank cap
(6) Overflow hose (12) Main fan shroud (18 ) Engine coolant hose
co-10
RADIATOR FAN
Cooling
Engine coolant temperature

Lower than 95°C (203°F) Between 95 and 99°C Higher than 100°C (212°F)
Vehicle speed
(203 and 210°F)
Operation of radiator fan Operation of radiator fan Operation of radiator fan
Lower than 19 km/h OFF ON ON
(12 MPH)
Between 20 and 69 km/h OFF ON ON
(12 and 43 MPH)
Between 70 and 89 km/h OFF OFF ON
(43 and 55 MPH)
Higher than 90 km/h OFF OFF ON
(56 MPH)
co-11
RADIATOR FAN
Cooling
2. MODELS WITH A/C

On models equipped with an air conditioning system, the ECM receives signals from the engine
coolant temperature sensor, vehicle speed sensor and A/C switch. According to these signals, the
ECM turns ON or OFF the radiator main fan and sub fan simultaneously (and also selects the Hi
or Low fan speed in turbo model).
0 Non-turbo model
I Vehicle speed
A/C com-
pressor
Lower than 95°C
(203°F)
Engine coolant temperature
Between 95 and 99°C
(203 and 210°F)
Higher than 100°C
(212°F)
Operation of radiator fans Operation of radiator fans Operation of radiator fans
I Main fan I sub fan 1 Main fan I sub fan I Main fan I subfan I
(12 MPH)
Between 20 and 69 km/h

(12 and 43 MPH)
f43 and 55 MPH)
(56 MPH)
I
0 Turbo model
I Engine coolant temperature
Lower than 90°C Between 90 and 95°C Higher than 96°C
A/C com- (194°F) (194 and 203°F) (205°F)
Vehicle speed
pressor
Operation of radiator fans Operation of radiator fans Operation of radiator fans
I Main fan I sub fan I Main fan I sub fan I Main fan I sub fan
Lower than 19 km/h OFF OFF OFF OFF OFF Low-speed Low-speed
(12 MPH) ON Low-speed*l Low-speed*l Hi-speed Hi-speed Hi-speed Hi-speed
High-speed*2 High-speed*2
Between 20 and 69 km/h OFF OFF OFF OFF OFF Hi-speed Hi-speed
(12 and 43 MPH)
ON Hi-speed Hi-speed Hi-speed Hi-speed Hi-speed Hi-speed
Between 70 and 105 km/h OFF OFF OFF OFF OFF Hi-speed Hi-speed
(43 and 65 MPH)
ON Low-speed Low-speed Low-speed Low-speed Hi-speed Hi-speed
Higher than 106 km/h OFF OFF OFF OFF OFF Hi-speed Hi-speed
(66 MPH)
ON OFF OFF Low-speed OFF Hi-speed Hi-speed
*1: When the intake air temperature is 76°C (169°F).
*2: When the intake air temperature is 78°C (172°F) or higher, the radiator fans perform “Hi-speed’’ operation for 10 minutes.
co-12
LUBRICAT10N LU
Page
1. General . . . . . . . . . . . . ............................................... 2
2. Engine Oil Flow ................................. ..................... 5
3. Oil Pump . . . . . . . . . . . . . . . . ............................................
........................................... .................. 8
iI Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....................... 11
7. Oil Cooler (Turbo Model Only) ............................................. 12
I GENERAL
Lubrication
1. General
0 The lubrication system force-circulates engine oil throughout the engine using an oil pump. The
oil pressure is regulated by the relief valve built into the oil pump.
0 The oil pump is a thin, large-diameter trochoid rotor type which can accommodate the engine’s
high output. The pump is directly driven by the crankshaft.
0 The engine oil is cleaned by a full-flow, paper element type oil filter. The filter has a bypass valve
which allows the engine oil to flow bypassing the filter if it is clogged.
0 The inside of the oil pan is fitted with a baffle plate which reduces changes in the oil level due
to movement of the vehicle, thus ensuring uninterrupted suction of oil.
0 The engine oil discharged from the oil pump is delivered to the journal bearings, connecting rod
bearings, and other parts requiring lubrication and cooling via the vertical passage in the right
bank of the cylinder block, the oil filter, and the oil galleries in the right and left banks of the cylinder
block.
0 The engine oil is also distributed to each cylinder head valve mechanism at a proper flow rate
achieved by metering by the orifice provided in each oil gallery.
O- -A water-cooled oil cooler is located between the oil filter and cylinder block to keep the engine
oil in an optimum temperature range and prevent degradation of lubrication performance (Turbo
model).
LU-2
GENERAL
Lubrication
A: NON-TURBO MODEL
NF0057
(1) Oil filter (5) Roller

(2) Oil pump (6) Rocker arm
(3) Oil strainer (7) Rocker shaft
(4) Camshaft
(a) Bypass valve opening pressure:
157 kPa (1.6 kgf/cm2,23 psi)
(b) Relief valve opening pressure:
490 kPa (5.0 kgf/cm2,71 psi)
LU-3
GENERAL
Lubrication
B: TURBO MODEL
NF0058
(1) Oil filter (4) Oil strainer

(2) Oil cooler (5) Intake gallery
(3) Oil pump (6) Exhaust gallery
(a) Bypass valve opening pressure:
157 kPa (1.6 kgf/cm2, 23 psi)
(b) Relief valve opening pressure:
588 kPa (6.0 kgf/cm2, 85 psi)
LU-4
ENGINE OIL FLOW
Lubrication
2. Engine Oil Flow

A: NON-TURBO MODEL
4 4
and roller and roller
Intake valve Intake valve
I I
Intake Exhaust Camshaft
I Intake I1 Exhaust I Camshaft I
77
rocker shaft rocker shaft
Camshaft cap Camshaft cap

r.
#1 & # 3 f2 & #4
cylinder head cylinder head
(R.H.)
#-- I I I
#2 & #3
connecting connecting connecting
rod bearing
#3 journal
bearing bearing bearing bearing bearing
(Rear) (Center)
I 1
Cylinder block Cylinder block

main gallery R.H. main gallery L.H.
+ Oil strainer
NF0059
LU-5
ENGINE OIL FLOW
Lubrication
B: TURBO MODEL
Camshaft Camshaft Camshaft

1 Camshaft
I
TIT,
journal journal journal
t
Intake Exhaust
gallery gallery
charger
1
connecting connecting
rod bearing
t- Oil pressure
Cylinder block
(maingallery R.H.
I I
main gallery L.H.
Oil pump rotor

Oil pump i
I
I Oilstrainer I
NF0060
LU-6
OIL PUMP
Lubrication
3. Oil Pump
0 The oil pump is a trochoid rotor type consisting of an inner rotor and outer rotor assembled with
each other in a pump body. When the inner rotor is driven by the crankshaft, the outer rotor is ro-
tated, changing the space between it and the inner rotor. The change in the space occurs because
of the difference in the number of teeth between the rotors.
0 Engine oil is drawn into the large space created near the inlet of the pump. It is then carried to
the discharge port. As the pump rotates, the space carrying the oil becomes smaller, thus the oil
is pressurized and discharged from the outlet port. Oil pressure is regulated by the relief valve built
into the pump. Excess oil is directly returned to the inlet port.
(3)
NF0061
(1) Inner rotor (6) Plug

(2) Outer rotor (7) Gasket
(3) Oilseal (8) Relief valve spring
(4) Oil pump case (9) Relief valve
(5) Oil pump cover
LU-7
I OIL FILTER
Lubrication
4. Oil Filter
The oil filter is a full-flow filtering, cartridge type that utilizes a paper element. It also has a built-in
bypass valve. The filter element has a special pleat design to increase the effective filtering area.
S2H0249B
(1) Oil seal

(2) Filter body
(3) Bypass valve
(4) Pleated element
LU-8
OIL PAN AND OIL STRAINER
3
Lubrication
5. Oil Pan and Oil Strainer

0 The oil pan is attached to the cylinder block using liquid gasket for sealing. The oil strainer is
a metal net type and removes large foreign particles from the engine oil. It is located in the middle
of the oil pan. The pipe from the strainer is connected to the suction port of the oil pump in the left
bank of the cylinder block.
0 There is a baffle plate in the oil pan, near the bottom of the cylinder block. It stabilizes the oil level
and reinforces the oil pan.
A: NON-TURBO MODEL
S2H0852B
(1) Oil strainer (a) LOW level

(2) Level gauge guide (b) FULL level (Engine HOT condition)
(3) Baffle plate (c) FULL level (Engine COLD condition)
(4) Oil level gauge
LU-9
I OIL PAN AND OIL STRAINER
Lubrication
B: TURBO MODEL
(1)
r.
NF0468
(1) Oil strainer (a) LOWlevel

(2) Level gauge guide (b) FULL level (Engine HOT condition)
(3) Baffle plate (c) FULL level (Engine COLD condition)
(4) Oil level gauge
LU-10
OIL PRESSURE SWITCH
Lubrication
6. Oil Pressure Switch

The oil pressure switch is located in the front upper portion of the right cylinder block bank. The
purpose of this switch is to monitor the operation of the oil pump as well as the lubricating oil pres-
sure when the engine is running.
NF0065
r. . (1) Contact point (4) Molded portion

(2) Diaphragm (5) Terminal
(3) Spring
1) When oil pressure does not build up (immediately after ignition switch is turned ON):
The diaphra-gmis pushed toward the cylinder block by the spring force (a force equivalent to the
specified oil pressure).This closes the contact points, causing the oil pressure warning light in the
combination meter to illuminate.
2) When oil pressure reaches the specified value (after engine starts):
After reaching the specified value of 14.7 kPa (0.15 kgf/cm2, 2.1 psi), the oil pressure pushes the
diaphragm overcoming the spring force. This opens the contact points and the oil pressure warn-
ing light goes out.
LU-11
OIL COOLER (TURBO MODEL ONLY)
Lubrication
7. Oil Cooler (Turbo Model Only)

The oil cooler used in models is of a water cooled type. It serves to maintain engine oil in proper
temperature range and so prevent degradation of lubricating oil performance.
r- .
NF0360
(1) Oil cooler (3) Connector

(2) Water pipe (4) Oil filter
LU-12
SPEED CONTROL SYSTEM SP
Page
1. General _ _ . . . . . _ . . . . . . . . . . .
, , , , , , ._....__......___ 2
. ... ., ., ., , . . . . . . . _ _ _ . . . . _ _ _ ... . . _ _ .
I GENERAL
Speed Control System
1. General
The accelerator outer cable is secured to the accelerator pedal bracket rather than to the toe-
board. Securing the outer cable in this way has a merit of making the ratio of throttle valve move-
ment to cable stroke less variable. This arrangement is also effective to prevent unsmooth cable
return movement that may result from deformation of the toeboard or improper installation of the
accelerator pedal and, therefore, to improve safety.
In addition, the floating type casing cap through which the cable is attached to the bracket re-
duces vibration of the pedal, thus improving quietness.
NF0438
(1) Accelerator cable

(2) Casing cap (floating type)
(3) Accelerator pedal
(4) Bracket
(5) Toeboard
(6) Grommet
SP-2
IGNITION /G (SOHC)
Page
*.
1. Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
r.
IGNITION COIL
Ignition
1. Ignition Coil
Ignition coils are made integral with an ignitor.
The ignition system is of a dual-ignition-coil design, each coil causing two plugs to generate
sparks simultaneously. In response to the signal from the ECM, the ignitor supplies current to an
ignition coil and the ignition coil supplies high-voltage current to a pair of spark plugs (#1 and #2
or #3 and #4) simultaneously.
r.
NF0034
(1) Ignition coil and ignitor assembly
IG-2
I IGNITION COIL
Ignition
3
I
NF0035
-- .
(1) ECM (5) Spark plug #2
(2) Ignitor (6) Spark plug #3
(3) Ignition coil (7) Spark plug #4
(4) Spark plug #1 (8) Ignition switch
IG-3
SPARK PLUG
2. Spark Plug
The spark plug’s thread diameter is 14 mm (0.551 in) and the gap is controlled to a value between
1.Oand 1. I mm (0.039 and 0.043 in).
Gap: 1.O - 1 .I mm (0.039 - 0.043in)
NF0036
IG-4
I
Page
1. Ignition Coil ........................................................................... 2
2. Spark Plug ............................................................................ 3
IGNITION COIL
Ignition
1. Ignition Coil
The engine uses a direct ignition system with one ignition coil mounted for each cylinder (or spark
plug).
The secondary terminal of the ignition coil is in contact with the spark plug terminal nut.
Since no spark plug cable is used, secondary voltage drop, leaks, or other problems that are in-
herent in a system using spark plug cables do not occur. The result is high performance and high
reliability.
y n coil
Connector ---
NF0316
IG-2
SPARK PLUG
Ignition
2. Spark Plug
The spark plug has a platinum tipped electrode. The thread diameter is 14 mm (0.551 in) and the
gap is controlled to a value between 0.7 and 0.8 mm (0.028 and 0.031 in).
-&--Gap: 0.7 - 0.8 mm (0.028 - 0.031 in)

NF0317
r.
IG-3
SPARK PLUG
Ignition
MEMO
IG-4
STARTINGICHARG ING sc Page
1. Starter . . . . . . . . . . . .............................................. 2
2. Generator ........................ ...........
................................
STARTER
Starting/C harging
1. Starter
The starter is of a reduction type. Its output is 1.O kW on the MT model and 1.4 kW on the AT model.
Starter switch
1
Pinion
I
I
I I
I
I
I
I
! I
\ I
1
\ I I
r.
-
-
NF0364
sc-2
cil
GENERATOR
Starting/Charging
2. Generator
The generator has a built-in regulator which provides diagnostic functions in addition to a voltage
regulating function as follows:
1) Voltage regulation
The on-off operation of transistor Trl connects and disconnects the field current circuit, providing
a constant level of output voltage.
2) Diagnosis warning
When any of the following problems occur, the charge lamp illuminates.
a. No voltage generation
Brush wear exceeds specified wear limits, field coil circuit is broken, etc.
b. Excessive output
Output voltage is greater than 16 volts (approx).
c. Terminal B disconnection
Harness is disconnected from alternator terminal B.
d. Terminal S disconnection
Harness is disconnected from alternator terminal S. In this case, voltage is slightly greater than
-
specified regulated voltage; however, voltage regulation is still controlled and the battery is
r-
prevented from becoming overcharged.
Trio diode (3 pcs.)

@
Plus diode (3 pcs.)
\
i 4
I
I
I I
I
I
I
I
I
I I
I I
I
Diagnostic Tr2
I
I I
I and warning I
I I
I circuit I
I I
I I
I
I
I
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ - - - - - _ _ J
IC regulator
0 :Alternator terminal
Minus diode (3 pcs.)

0 : Regulator terminal
NF0365
sc-3
BATTERY
Starting/Charging
3. Battery
The battery is located in the left front part of the engine compartment. It is held on a tray by the
battery holder.
sc-4
CONTROL SYSTEM cs Page
1. Gear Shift Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Select Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 . Sift Lock System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
r .
I GEAR SHIFT LEVER
Control Svstem
1. Gear Shift Lever

The manual transmission's gear shift lever system is a parallel link type whose stay is mounted
through a cushion rubber.
NF0103
(1) Knob. (5) Stay

(2) Gear shift lever (6) Bush
(3) Cushion rubber (7) Joint
(4) Boot (8) Rod
cs-2
SELECT LEVER
Control System
2. Select Lever
0 The automatic transmission’s select lever moves through seven positions.
0 The select lever makes shift direction (longitudinal) movements as well as select direction (later-
al) movements. The select lever is guided by a gate to make these movements.
0 To transmit movements of the select lever to the transmission, a push-pull cable is used.
0 The detent arm is a new addition to the select lever mechanism. It ensures more precise posi-
tioning of the select lever.
0 A plastic select lever base plate is used.
V View A @
NFOlO4
(1 ) Push-pullcable (5) Gate

(2) Detent spring (6) Select lever
(3) Base plate (7) Arm
(4) Detent arm
cs-3
SHIFT LOCK SYSTEM
Control System
3. Shift Lock System

A: GENERAL
To increase safety during standing start, the shift lock system prevents movement of the select
lever from the lip’’position to any other position unless the brake pedal is depressed. This system
is also provided with a key interlock function which prevents removal of the ignition key from the
key cylinder unless the selector lever is placed in the “PI’ position.
Shift lock system

Key interlock system
5’
B3H1753B
(1) “P” position switch (4) Key lock solenoid

(2) Key cylinder (5) Brake pedal switch
(3) Shift lock solenoid (6) Integrated module
cs-4
SHIFT LOCK SYSTEM
Control System
B: SHIFT LOCK SYSTEM OPERATION

The shift lock system has a solenoid-operated plunger (1 ). With the select lever in the “P” position,
the plunger remains extended, holding the lock arm (2) in its raised (locking) position. When the
brake pedal is depressed with the ignition switch in either the ON or START position, the solenoid
is energized and the plunger is retracted. This causes the lock arm to tilt forward to the select lever
release position. The select lever now can be moved to any other position.
The “P” position of the select lever is detected by the “P” position switch (3).
r. -
I J
\O /
B3H1754A
(1) Solenoid
(2) Lockarm
(3) “P”position switch
cs-5
I SHIFT LOCK SYSTEM
Control Svstem
C: KEY INTERLOCK FUNCTION

0 When the select lever is at any position other than “P”, the solenoid is energized and its pin is
held extended. Being caused to stay in its upright position by extension of the pin, the interlock
lever interferes with the stopper portion of the rotator which turns together with the ignition key.
Thus, the ignition key cannot be rotated to the “LOCK” position.
C.
Section
S3H0575A
(1) Column cover Interlock position

(2) Key Stopper
(3) Push button ACC
(4) Extended ON
(5) Solenoid pin START
(6) Solenoid unit View B
(7) Lever fulcrum Rotator
(8) Lever spring Key
(9) Interlock lever Interlock lever
(10) Interlock activated Solenoid
(11) LOCK
CS-6
SHIFT LOCK SYSTEM
Control System
0 When the select lever is moved to “P”, the “P” position switch in the select lever assembly oper-
ates, deenergizing the solenoid. As the push force of the solenoid pin is removed, the lever spring
causes the interlock lever to tilt and become clear of the rotator’s stopper. Then the key can be
rotated to the “LOCK” position and removed from the ignition switch.
S3H0576A
(1) Retracted
(2) Interlock deactivated
cs-7
SHIFT LOCK SYSTEM
Control System
MEMO
CS-8
I
AUTOMATIC TRANSMISSION AT a
Page
1. Electrohydraulic Control System ................................................... 2
2. Transmission Control Module (TCM) .............................................. 14
3. On-board Diagnostics System ..................................................... 34
4 . Fail-safe Function .................................................................... 36
5. Transmission Mounting ............................................................. 38
.
ELECTROHYDRAULICCONTROL SYSTEM
Automatic Transmission
1. Electrohydraulic Control System

A: GENERAL
The electrohydraulic control system for the transmission and transfer consists of various sensors
and switches, a transmission control module (TCM) and the hydraulic controlling units including
solenoid valves. The system controls the automatic transmission operation, including gear shift-
ing, lock-up clutch operation, line pressure, automatic control pattern selection (“Base” and “Pow-
er’’), and gear-shift timing. It also controls the operation of the transfer clutch. The TCM determines
vehicle operating conditions from various input signals and controls a total of eight solenoids (shift
solenoids 1 and 2, low clutch timing solenoid, 2-4 brake timing solenoid, line pressure duty sole-
noid, lock-up duty solenoid, transfer duty solenoid, and 2-4 brake duty solenoid) by sending ap-
propriate signals to them.
INPUT OUTPUT
ON-OFF
I
I Throttle position sensor t- Shift solenoid 1

ON-OFF
Shift solenoid 2
Line pressure duty solenoid

I
ECM
4 Dropping resistor A (non-turbo model) I
4 Lock-up duty solenoid I
4 Transfer duty solenoid I
I Inhibitor switch
ECM
t-
n
Ia
tke-
(non-turbo model)
ECM
Mass air flow signal (turbo model) TCM
4 2-4 brake timing solenoid
I FWD switch (non-turbo model) t--. Low clutch timing solenoid

ECM
I Battery voltage -I Torque control signal 1
FCM
I ABS signal k 4 Torque control signal 2
I Brake switch t- 4 AT diagnosis signal
--bFWD indicator light (non-turbo model) ; meter

~
I I
1 - I
ECM I I
I I
I
AT OIL TEMP light I
I I
I
I
I Cruise control signal I--

NF0464
AT-2
ELECTROHYDRAULIC CONTROL SYSTEM
B: INPUT SIGNALS
Signal name Major function
Indicatesthe throttle valve position. This signal is used to determine shift point, line
pressure, and lock-up engaging vehicle speed, which vary with engine load.
Front vehicle speed sensor Indicates the vehicle speed. This signal is used for control of gear shifting, lock-up
(located on transmission case) engaging, line pressure, and transfer clutch operation.
Rear vehicle speed sensor Used to control transfer clutch, and also as backup signal in case of failure of front
(located on extension case) vehicle speed sensor.
Indicates the engine speed. This signal is used for control of lock-up clutch to en-
Engine speed signal
sure smooth engagement.
Used to determine gears and line pressures in each of ranges “P”, “R”, “N”, “D”,
Inhibitor switch “399,“2” and “1 33,
Indicates the ATF temperature. This signal is used for inhibition of lock-up, release
ATF temperature sensor
of OD and determination of ATF temperature.
Used to change the mode from AWD to FWD. Also used to adapt the vehicle to
FWD switch (non-turbo model) FWD tester roller. Changeover from AWD to FWD can be made by inserting a fuse
into the fuse holder.
Used when ABS is operating to optimize ABS control. In this control, transfer
.ABS
. . signal clutch torque load capacity is adjusted to eliminate the influence of engine braking
and reduce the degree of coupling between front and rear wheels.
Indicates operation of cruise control system. It is used to expand “4th” operating
Cruise control signal
range.
Tells the rotation speed of the input shaft. The proportion of this speed to the ve-
Torque converter turbine speed sensor
hicle speed determines whether shifting should be made or not.
Torque control cut signal Sent from engine control module (ECM) to TCM to inhibit the torque control.
Intake manifold pressure signal Used to determine line pressure of gear shifting.
(non-turbo model)
Mass air flow signal (turbo model) Used to determine line pressure of gear shifting.
If this signal is issued during downhill driving, TCM makes shift down control,
Brake switch
causing the vehicle speed to be reduced.
AT-3
I ELECTROHYDRAULIC CONTROL SYSTEM
C: OUTPUT SIGNALS
Signal name Function
Each of these signals controls shift step by turning the corresponding solenoid ON/
Shift solenoid 1, 2
OFF. Activating timing is controlled for each solenoid to reduce shift shock.
Line pressure duty solenoid Regulates the line pressure according to driving conditions.
Regulates the hydraulic pressure of the lock-up clutch to operate it in three modes
Lock-up duty solenoid
(open,
. . smooth and lock-up).
..
Regulates the hydraulic pressure of the transfer clutch to control the driving force to
Transfer duty solenoid
the rear drive shaft.
Causes the light to illuminate when ATF becomes excessively hot (exceeds a set tem-
AT OIL TEMP light
perature level). This light is also used for on-board diagnostics.
2-4 brake duty solenoid I Regulates2-4 brake operating pressure to reduce shifting shocks.
Switches on or off the pressure acting on 2-4 brake timing valve B to control the re-
2-4 brake timing solenoid
lease timing of the 2-4 brake.
Switches on or off the pressure acting on the low clutch timing valve B to control the
release timing of the low clutch.
Low clutch timing solenoid Also switches on or off the pressure acting on the reverse inhibit valve to control the
reverse inhibit function.
Torque control signal 1 Reduces engine torque during range selection and gear change.
Torque control signal 2 Reduces engine torque during range selection and gear change.
AT-4
D: CONTROL ITEMS
2ontrol item Iescription of control
Base shift control
Jpshifting and downshifting are set for each range, gear
0 Base pattern
and pattern according to throttle position and vehicle speed.
0 Power pattern
Gear shift control ABS-in-operation control g a r is locked in 3rd when ABS signal enters.
~~
ATF-low-temperaturecon- Shifting into 4th gear is prevented when ATF temperature is

trol Delow the preset value.
Power pattern is selected when throttle opening is changed
Power pattern control
Automatic pattern at a speed exceeding the preset value.
select control When throttle opening is changed at a speed less than the
Base pattern control
preset value, Base pattern is resumed.
Lock-up ON is set for D-range 4th gear; ON/OFF is set for
all gears (except D-range 4th) and patterns. Lock-up control
Base lock-up control
Transmission Lock-up control is performed according to throttle position and vehicle
control speed. (Basically lock-up is OFF during gear shifting.)
Smooth control Smooth lock-up is performed when lock-up is switched on.
Line pressure is regulated according to throttle position,
Ordinary control
vehicle speed and range signals.
Line pressure con- Shifting control Line pressure is regulated when shifting to lessen shifting
trol shock.
Line pressure is lowered to a minimum so as to reduce en-
Starting control
gine cranking load.
Shift step control ON/OFF timing for shift solenoid is controlled.
Lock-up controt When shifting,-the lock-up clutch is temporarily released.
Shift timing control
When shifting, line pressure is controlled to the optimum
Line pressure control
level so as to reduce shifting shock.
Transfer clutch pressure is regulated according to the
Ordinary transfer control
throttle valve angle and vehicle speed.
1 range control Transfer clutch pressure is increased.
AWD transfer Immediately after detecting a slip, transfer clutch pressure is
clutch control controlled to the same pressure as 1 range. (This control is
Slip control canceled if V 2 60 km/h (37 MPH), or when throttle valve is
(non-turbo
model) closed fully.)
Control in turns Transfer clutch pressure is reduced after detecting a turn.
Transfer clutch pressure is adjusted to a set level immedi-
ABS-in-operation control
ately after reception of ABS signal.
Multi-plate clutch (LSD) pressure is regulated according to
Ordinary transfer control
the torque input to the transfer and the driving condition.
When starting, the LSD pressure is adjusted proportionately
Start control to the throttle value angle.
When the front and rear wheel speed ratio is less than the
Control in turns set value for a vehicle speed, the LSD pressure is de-
AWD multi- creased.
plate clutch
control (LSD) When a front or rear wheel starts slipping, the LSD pressure
Slip control
(turbo model) is decreased.
The LSD pressure is adjusted to the set level immediately
ABS-in-operation control
after reception of ABS signal.
When the brake switch is ON and throttle valve is fully
Base brake control
closed, the LSD pressure is lowered.
1 range control The LSD pressure is increased to improve driveability.
AT-5
E: THROTTLE POSITION SENSOR
The throttle position sensor provides electrical signals corresponding to throttle valve positions.
The throttle valve angular position and accelerator depressing speed are detected by this throttle
position sensor.
F: REAR VEHICLE SPEED SENSOR

1. NON-TURBO MODEL
This vehicle speed sensor (output shaft speed sensor) is externally mounted on the extension
case. It detects the rear wheel speed in terms of the peripheral speed of the transfer clutch drum
and sends sine wave signals (30 pulses per rotation) to the TCM.
r. .
NF0068
(1) Rear vehicle speed sensor
2. TURBO MODEL
This vehicle speed sensor (output shaft speed sensor) is externally mounted on the extension
case. It detects the rear wheel speed in terms of the peripheral speed of the rear drive shaft and
sends sine wave signals (22 pulses per rotation) to the TCM.
d
H3H1818C
(1) Rear vehicle speed sensor
AT-6
G: FRONT VEHICLE SPEED SENSOR

This vehicle speed sensor (output shaft speed sensor) is externally mounted on the transmission
case. It detects the front wheel speed and sends sine wave signals (16 pulses per rotation) to the
TCM.
The TCM converts the signals into pulse signals and outputs them to both the engine control mod-
ule (ECM) and the combination meter.
1. NON-TURBO MODEL
NF0069
(1) Front vehicle speed sensor
2. TURBO MODEL
hJ
H3H1818D
(1) Front vehicle speed sensor
AT-7
ELECTROHYDRAULICCONTROL SYSTEM
H: ATF TEMPERATURE SENSOR

This sensor is located in the hydraulic control valve of the transmission. It detects the temperature
of ATF and outputs it as an electrical resistance signal. The output characteristics of the sensor
are shown below.
t
0)
2
m
4-4
._
(I)
(I)
2
Temperature -
NF0071
--- (1) ATF temperature sensor
I: TORQUE CONVERTER TURBINE SPEED SENSOR

The torque converter turbine speed sensor (output shaft speed sensor) is externally mounted on
the transmission case.
The sensor detects the torque converter turbine speed in terms of the rotation speed of the periph-
ery of the high clutch drum coupled to the input shaft, and sends sine wave signals (32 pulses per
rotation) to the TCM. The TCM calculates the proportion of the input shaft speed to the vehicle
speed and determines whether the shifting is to be made or not.
NF0072
(1 ) Torque converter turbine speed sensor
AT-8
J: INHIBITOR SWITCH
The inhibitor switch assures safety when starting the engine. This switch is mounted on the right
side of the transmission case, and is operated by the selector lever.
When the selector lever is set to P or N, the electrical circuit in the inhibitor switch is closed and
the starter circuit is completed for cranking the engine.
When the selector lever is in the R, D, 3, 2 or 1 range, the electrical circuit in the inhibitor switch
is open. Hence engine cranking is disabled. In the R range, the backup light circuit is completed
in the switch, and the backup lights come on.
In addition to the above function, the inhibitor switch incorporates a circuit for detecting the se-
lected range position and sending the range signal to the TCM.
Inhibitor switch side connector
NF0073
AT-9
I ELECTROHYDRAULICCONTROL SYSTEM
K: SHIFT SOLENOIDS 1 AND 2

These solenoids are located in the transmission hydraulic control valve. They are turned ON or
OFF according to signals from the TCM. The gear positions are changed according to the ON and
OFF condition of these solenoids.
NF0074
C.
(1) Shift solenoid 2
(2) Shift solenoid 1
L: LOW CLUTCH TIMING SOLENOID

This solenoid is located in the transmission hydraulic control valve. It is turned ON r OFF accord-
ing to signals from the TCM. It then controls the low clutch timing valve B and reverse inhibitor
valve.
NF0075
(1) Low clwtch timing solenoid
AT-I 0
M: 2-4 BRAKE TIMING SOLENOID

This solenoid is located in the transmission hydraulic control valve. It is turned ON or OFF accord-
ing to signals from the TCM. It then controls the 2-4 brake timing valve B to decrease the change
gear shock.
NF0076
(1) 2-4 brake timing solenoid

r-
N: LINE PRESSURE DUTY SOLENOID

This solenoid is located in the transmission hydraulic control valve. Its duty ratio is controlled by
signals from the TCM. This solenoid then controls the pressure modifier valve and accumulator
control valve A to adjust the line pressure to an optimum pressure level suitable for operating
conditions.
NF0077
(1) Line pressure duty solenoid
AT-1 1
I ELECTROHYDRAULIC CONTROL SYSTEM
0:LOCK-UP DUTY SOLENOID

signals from the TCM. It then controls the lock-up control valve to provide smooth engagement and
disengagement of the lock-up clutch.
NF0078
(1) Lock-up duty solenoid

r.
P: 2-4 BRAKE DUTY SOLENOID

signals from the TCM. It modulates the 2-4 brake pressure when the 2-4 brake is operated, reduc-
ing shifting shocks.
NF0079
(1) 2-4 brake duty solenoid
AT-12
Q: TRANSFER DUTY SOLENOID

This solenoid is located in the transfer hydraulic pressure control unit on the rear end of transmis-
sion case. Its duty ratio is controlled by signals from the TCM. It then controls the transfer clutch/
control valve to control the pressure applied to the transfer clutch.
1. NON-TURBO MODEL
NF0080
r. - (1) Transfer duty solenoid
2. TURBO MODEL
H3H1929C
(1) Transfer duty solenoid
AT-1 3
TRANSMISSION CONTROL MODULE (TCM)
2. Transmission Control Module (TCM)

The TCM receives various sensor signals and determines the running conditions of the vehicle.
It then sends control signals to each solenoid according to the preset gearshift characteristic data,
lock-up operation data, and transfer clutch torque data (duty ratios).
A: CONTROL SYSTEM
2ontrol item Input signal
Shift control Ordinary shift control Throttle position sensor
Rear vehicle speed sensor
Front vehicle speed sensor
Engine speed
Inhibitor switch
ABS-in-operationcontrol ABS signal
Brake switch
Hydraulic oil temperature control ATF temperature sensor
Reverse inhibiting control Throttle position sensor
Inhibitor switch
Shift pattern (Base/Power)select control Throttle position sensor
Inhibitor switch
Grade control Throttle position sensor
Brake switch
Inhibitor switch
Engine speed
Intake manifold pressure
-ock-up control Ordinary lock-up control Throttle position sensor
Engine speed
Inhibitor switch
Smooth control Throttle position sensor
Hvdraulic oil temDerature control ATF temDerature sensor
AT-14
I Control item Input signal

Oil pressure control 3rdinary pressure control Throttle position sensor
Engine speed
Inhibitor switch
Shifting control Throttle position sensor
Engine speed
Inhibitor switch
Starting control Engine speed
Inhibitor switch
Learning control Shift solenoid A
Shift solenoid B
,.. . .
AWD transfer clutch control Ordinary transfer control Throttle position sensor
(non-turbo model) Rear vehicle speed sensor
Inhibitor switch
FWD switch
1 range control Throttle position sensor
Inhibitor switch
Slip detection control Throttle position sensor
Steering control Throttle position sensor
Brake switch
AT-I 5
;ontrol item Input signal

\WD multi-plate clutch (LSD) Ordinary transfer control Throttle position sensor
:ontrol (turbo model) Rear vehicle speed sensor
Inhibitor switch
1 range control Throttle position sensor
Inhibitor switch
Slip detection control Throttle position sensor
___ ~~~
Steering control Throttle position sensor

Brake switch
Base brake operating control Throttle position sensor
Brake switch
AT-16
I
9: SYSTEM DIAGRAM
ABS signal .------------7 ---_---
I ------) Speedometer circuit
FWD switch (non-turbo model)

.-------- ---. .-----------)
I
I
I I
1
1
( 1 1 1
AT diagnosis signal
Engine speed signal .----------

1 1 1 1
1 1 1 1
I I 1 I I I
1 1 1 1 I I
---------* FWD indicator light (non-turbo model)
Inhibitor switch .--------- 1 1 ~
I I I I
I I I I I
1
I
I
I
I I
I I--------+ ATOILTEMPlight
1 1 1 1 1 1 1 I
r
Cruise control signal .-------. 1
1 1 l 1 1 1 1 1
I I I I I I I I --------)
1 1 1 1 1 1 1 1 1
Torque control signal 1
.- - - - - -
1 1 1 1 1 I I I I I
1 1 1 1 1 1 1 1 1 1
Battery voltage I I I I I I I I I I I I-----* Torque control signal 2
1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1
Torque control cut signal ._____ I II I
t I I I
1 1I I I I I I I I----* Dropping resistor A (non-turbo model)
1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1 1
Intake manifold pressure signal (non-turbo model) .---; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ;--+Dropping resistor 6 (non-turbo model)
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Brake switch "'1 I I I I I I I I I I I I I I I I
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 ~ 1 1 1 1 1 1 1 1
Mass air flow signal (turbo model) "-1 I I 1 I I I I I 1 I I I I 1 I I I
lTVTT7TTVT, 1 1 1 1
I I , 1
1 1 1 1
1 1 1
-- -D : Mechanical signal
I Tires (rear wheels) I
---+
: Electricalsignal
NF0465
AT-17
I TRANSMISSION CONTROL MODULE (TCM)
C: SHIFT CONTROL
The TCM performs gear shifting control according to driving conditions by using the shift point
characteristic data stored in its memory. Appropriate solenoids are operated at the proper timing
corresponding to the shift pattern, throttle position, and vehicle speed for smooth shifting.
NOTE:
When the ATF temperature is below approximately 10°C (50"F), the gear cannot be shifted to the
4th speed.
Large
Solenoid 1 Solenoid 2
1st ON ON
2nd OFF ON
3rd OFF OFF
4th ON OFF
Small
~.- . Low High
Vehicle speed
NF0082
0 The TCM activates both solenoids 1 and 2 in response to throttle and vehicle speed signals.
0 Shift valves move in response to operation of the solenoids, supplying or interrupting the line
pressure to each clutch.
0 A shift to each gear takes place according to ON-OFF operation of both the solenoids as indi-
cated in the table above.
I Shift clutches I
r
I
Solenoi
I
L
i
Throttle position I
Vehicle speed I
Clutch fluid TCM c I
I
I
I
I
NF0083
AT-I 8
D: LOCK-UP CONTROL
0 The TCM has pre-programmed lock-up clutch engagement and disengagement conditions for
each gear and shift pattern. In addition, it specifies engagement of the clutch whenever the 4th
gear is selected in the D range. The engagement and disengagement conditions are defined in
terms of the throttle valve position and vehicle speed.
0 The TCM controls the operation of the lock-up clutch by means of the duty solenoid which in turn
controls the lock-up control valve as described below:
1. NON-LOCK-UP OPERATION
The duty solenoid allows the pilot pressure (supplied from the pilot valve) to be applied to the “dis-
engaging” end of the lock-up control valve spool. The lock-up control valve then opens the clutch
disengaging circuit port to allow the lock-up operating pressure (torque converter clutch regular
pressure) to build up in the circuit. On the other hand, the valve opens the clutch engaging circuit’s
port and allows the fluid in the circuit to flow to the ATF cooler, thus lowering the pressure in the
circuit. As a result, the lock-up clutch is disengaged due to difference in pressure between both
circuits.
This
-
r-
operation is performed for all the speed gears except the 4th gear of the D range.
2. LOCK-UP OPERATION
The duty solenoid allows the pilot pressure to be applied to the “engaging” end of the lock-up con-
trol valve spool. The lock-up control valve then opens the clutch engaging circuit’s port that com-
municates to the torque converter’s impeller chamber, allowing high pressure fluid to flow to the
lock-up clutch. The clutch then engages.
0 The TCM controls the current to the duty solenoid by gradually changing the duty ratio. As a
result, the lock-up control valve also moves gradually, so the clutch engagement pressure in-
creases smoothly. This causes the lock-up clutch to become initially in a half-engaged state and
then in a fully engaged state, thus preventing shock during engagement.
This operation is performed for all the speed gears and always when the 4th gear is selected in
the D range.
AT-I 9
E: LINE-PRESSURE CONTROL
0 The oil pump delivery pressure (line pressure) is regulated to a constant pressure by the pilot
valve. This pressure is used as the pilot pressure for controlling spool valves.
0 The pilot pressure applied to the pressure modifier valve is modulated by the line pressure duty
solenoid into the pressure modifier pressure.
0 The pressure modifier valve is an auxiliary valve for the pressure regulator valve, and it creates
a signal pressure (pressure modifier pressure). The pressure modifier pressure is used to regulate
the line pressure to a level optimum for a particular driving condition.
0 This pressure modifier pressure is applied to the pressure regulator valve which controls the oil
pump delivery pressure.
0The pressure modifier pressure from the pressure modifier valve is cushioned by the pressure
modifier accumulator to remove pulsation of the pressure.
NFOO84
(1) Relief valve (7) Filter (13) Pressure regulator valve

(2) Pilot valve (8) Accumulator (14) Oil pump
(3) Line pressure (9) Pressure modifier valve (15) ON
(4) Pilot pressure (10) To ATF cooler circuit (16) OFF
( 5 ) Filter (11) Accumulator
(6) Line pressure duty solenoid (12) From R range pressure circuit
AT-20
F: LINE-PRESSURE CONTROL DURING SHIFTING

The line pressure which engages shift clutches to create 1st to 4th speeds is controlled by the TCM
to meet varying operating conditions.
During gear shifting, the TCM decreases the line pressure to a level that matches the selected gear
in order to minimize shifting shock loads.
Throttle position,
: Line pressure accelerator pedal
depressing speed,
zp;r; : Pilot pressure etc.
: Line pressure duty pressure
: Modifier pressure
ZZZZ : Accumulator control pressure
NF0085
During gear shifting, the TCM controls the line pressure as follows:
0The TCM receives signals such as throttle position signal and accelerator pedal speed signal.
Based on these input signals, it issues a control signal to the line pressure duty solenoid.
0 The pressure from the line pressure duty solenoid (line pressure duty pressure) is converted by
the pressure modifier valve into a modifier pressure, and the modifier pressure is applied to the
pressure regulator valve.
0The pressure regulator valve adjusts the oil-pump-generated line pressure according to the
modifier pressure to make the line pressure matched to the driving condition.
AT-21
G: SHIFT PAlTERN SELECTION CONTROL

The TCM changes its gear shift control pattern automatically between the Base pattern suitable
for ordinary economy driving and the Power pattern suitable for climbing uphill or rapid accelera-
tion.
In the Power pattern, the downshift point and upshift point are set higher than those of the Base
pattern.
Selector lever position Changeover from Base to Power pattern
D and 3 ranges Performed automatically according to accelerator pedal depression speed.
“D” range (Base pattern) “D” range (Power pattern)

Large Large
Small Small
Low Vehicle speed High Low Vehicle speed
High
H3H1231A
AT-22
H: GRADE CONTROL
While the vehicle is driving up a hill, the gear is fixed to the 3rd to avoid repeated gear shift between
the 3rd and 4th gears.
When the vehicle is descending a steep slope at a speed of approximately 80 km/hour (50 miles/
hour), a 4th to 3rd downshift occurs automatically when the brake pedal is depressed.
This gearshift control is cancelled when the accelerator pedal is depressed.
The TCM performs these controls based mainly on the throttle opening, engine speed and vehicle
speed.
r- - WI
BRAKEPEDAL RE-ACCELERATION
ON
NF0087
“D” range (Base pattern) “D” range (Grade control pattern)

Throttle Throttle
openin( opening
0 Vehicle speed
NF0088
AT-23
I TRANSMISSION CONTROL MODULE (TCM)
I: LEARNING CONTROL
The TCM has a learning control function with which it can adapt gear shift timing optimally to the
current vehicle conditions by updating correction factors in the memory.
For this reason, gear shift shock may become larger after the power supply is interrupted (discon-
nection of battery, flat battery, etc.) or immediately after the ATF is replaced.
Larger gear shift shock after power supply interruption occurs because the correction data is reset
to those for the new vehicle condition.
The TCM starts learning function again as soon as the power supply is restored. After driving for
a while, therefore, the transmission will become able to make gear shifts at the optimum timing.
Larger shift shock immediately after ATF change is caused by change in friction characteristics
of the transmission internal parts. Also in this case, the transmission recovers shockless gear shift-
ing after driving for a while.
--
AT-24
J: REVERSE INHIBITION CONTROL

This control prevents the transmission from shifting into the reverse gear when the select lever is
accidentally placed in the R position, thus protecting the components such as reverse clutch from
being damaged.
If the selector lever is moved to the R position during driving at a speed faster than the predeter-
mined speed, the low clutch timing solenoid is energized. Then, the pilot pressure is supplied to
the reverse inhibitor valve. This causes the reverse inhibitor valve to move downward, closing the
low & reverse brake port.
In this condition, the low & reverse brake does not engage since the ATF flowing from the manual
valve is blocked by the reverse inhibitor valve.
As a result, the transmission is put into the neutral state, and the shifting into the reverse gear is
inhibited.
r. .
NF0089
(1) Line pressure (6) Manual valve (P range) (11) Low & reverse brake (Release)
(2) Pilot pressure (7) Drain (12) Low clutch
(3) 1st reducing valve ( 8 ) Shift valve B (13) 2-4 brake
(4) Shift valve A (9) Low clutch timing solenoid (14) Reverse clutch
(5) ON (IO) Reverse inhibitor valve (15) High clutch
AT-25
K: AWD TRANSFER CLUTCH CONTROL (NON-TURBO MO DEL)

Control item Type of control Gear position Remarks
Normal control
Regulates transfer clutch pressure in re-

1 Basic control sponse to throttle position and vehicle 1st thru 4th and reverse
speed.
Duty ratio
NF036'
Increases transfer clutch pressure above
2 1 range control 1st
basic control pressure.
Increases transfer clutch pressure to the Release:
3 Slipcontrol same level as in the 1 range immediately 1st thru 4th and reverse Nhen running faster than the set ve-
after a slip is detected. iicle speed with fully closed throttle
-
Decreases transfer clutch pressure upon
Turning control 1st thru 4th and reverse
. 4_ detection of a turn.
Regulates to the specified transfer clutch
5 ABS control pressure quickly when the ABS signal is 1st thru 4th and reverse
input.
Regulates to the specified transfer clutch
P and N range con-
6
trol
pressure quickly when shifted to the P or N P and N
range.
-1

(rear wheel rpm)
(front wheel rpm)
I Inhibitor switch
I I I
+l*l
I
I
i
b
I
interface
Input
interface
converter
I
CPU
Memory
c output
interface
circuit
I
I
Transfer
clutch
I circuit
FWD switch
I
Brake switch t
Constant
ABS signal voltage source
I
L
I I
i
NF0466
AT-26
L: AWD CENTER DIFFERENTIAL CONTROL (TURBO MODEL)

1. CONTROL DESCRIPTION
The TCM controls the engagement of the center differential’s multi-plate clutch (LSD) using maps
that are pre-programmed based on the throttle opening and engine speed. It selects a map ac-
cording to driving conditions and use it as the control basis.
2. ORDINARY CONTROL
A specific map is given to each of the 1st to 4th gears and the reverse gear for use by the TCM
to control the torque distribution appropriately during ordinary driving conditions.
The maps are programmed in such a way that the differential action limiting torque decreases as
the throttle valve opening decreases and as the vehicle speed increases. This way of control is
employed in order to reduce internal circulation of torque and also to improve steering perfor-
mance and stability of the vehicle’s behavior when the accelerator pedal is released or when a
downshift is performed, thus upgrading the stability achieved by the AWD system.
3. START CONTROL
When the vehicle speed is 0 km/h (0 MPH), the TCM makes control to generate differential action
,.limiting torque that is proportional to the throttle angle.
This enables the vehicle to start smoothly without swerving even on a slippery road.
4. TURNING CONTROL
The TCM makes a correction such that the input torque to the multi-plate clutch is reduced as the
steering angle increases.
This function is performed to improves turning performance at certain vehicle speed range.
5. SLIP CONTROL
When front or rear wheels start slipping with the vehicle running slower than the predetermined
speed, the TCM makes control to increase the differential action limiting torque.
This function maintains traction and improves driving stability.
Low- Vehicle speed +High
NF0489
AT-27
6. ABS CONTROL
When the TCM receives an ABS operation signal from the ABS unit, it adjusts the differential action
limiting torque to the predetermined level and selects the 3rd gear in which the one-way clutch
is freewheeling.
This function improves ABS control.
7. BASE BRAKE CONTROL
When the brake switch is ON and the throttle valve is fully closed, the TCM makes control to de-
crease the differential action limiting torque. The ABS control has priority over this control.
This function improves stability during braking.
8. 1 RANGE CONTROL
When the 1 range is selected, the TCM makes control to increase the differential action limiting
torque.
This function improves driving performance and traction.
9. CONTROL SYSTEM
The TCM is constantly monitoring the driving conditions of the vehicle using the eleven input sig-
nals. Based on the conditions it has determined, the TCM adjusts the duty ratio of current to the
transfer duty solenoid thus changing the engagement of the multi-plate clutch. The input signals
are used also for automatic transmission control.
----
Sensor
I
TCM
1 Actuator i
'

!
Input
interface
ND
+ converter e I-
Output
interface
solenoid
1
7
L
' I 1
1 I!
' !' II
*u
b
u I
circuit
i
circuit
L-
(rear wheel rpm)
cz Multi-plate
r
Front vehicle speed sensor b
(front wheel rpm)
CPU
Input
interface A
v
circuit
Brake switch
t
Constant
ABS signal b voltage source
NF0493
AT-28
MEMO
r. .
AT-29
M: TRANSFER CONTROL
1. NON-TURBO MODEL
The transfer hydraulic pressure control unit includes a valve body attached to the side of the exten-
sion case through a gasket and separator plate.
The pressurized fluids for the transfer hydraulic pressure control (line pressure and pilot pressure)
are supplied from the oil pump by way of the passages formed in the transmission case and then
the passages in the extension case that lead to the hydraulic circuit in the transfer valve body.
The line pressure is regulated by the transfer control valve whose opening is controlled by the
transfer pressure created by the transfer duty solenoid.
0 The transfer duty solenoid is controlled by the TCM. The TCM changes the solenoid controlling
duty ratio according to the driving conditions.
0 The transfer duty solenoid creates the transfer pressure from the pilot pressure. The transfer
pressure is applied to the transfer control valve and adjusts the valve’s opening.
0 The line pressure directly led to the transfer control valve, on the other hand, is regulated by the
transfer control valve and becomes the transfer clutch pressure.
C.
0 -The transfer clutch pressure is applied to the transfer clutch and engages the clutch to a con-
trolled degree.
In this way, the degree of transfer clutch engagement is varied so that optimum torque is distrib-
uted to the rear wheels according to vehicle driving conditions.
AT-30
NF0091
(1) Transfer control valve (4) Transfer pressure (7) Line pressure
(2) Transfer clutch pressure (5) Filter (8) Oil pump
(3) Transfer duty solenoid (6) Pilot pressure (9) Control valve
AT-31
2. TURBO MODEL
The drive power distribution system includes a valve body attached to the side of the extension
case through a gasket and separator plate.
The pressurized fluids for the drive power distribution system (line pressure and pilot pressure)
are supplied from the oil pump by way of the passages formed in the transmission case and then
the passages in the extension case that lead to the hydraulic circuit in the transfer valve body.
The line pressure is regulated by the transfer control valve whose opening is controlled by the
transfer pressure created by the transfer duty solenoid.
0 The pilot pressure created by passing through the pilot valve in the transmission’s hydraulic con-
trol assembly is further regulated into the transfer pressure by the transfer duty solenoid.
0 The transfer duty solenoid is controlled by the TCM. The TCM changes the solenoid controlling
duty ratio according to driving conditions.
0 The transfer pressure thus created is applied to the transfer control valve and adjusts the valve’s
opening.
0 The line pressure directly led to the transfer control valve, on the other hand, is regulated by the
kansfer control valve and becomes the transfer clutch pressure.
0 The transfer clutch pressure is applied to the multi-plate clutch (LSD) and engages the clutch
to a controlled degree.
In this way, the degree of multi-plate clutch engagement is varied so that optimum torque is distrib-
uted to the rear wheels.
AT-32
II 'I
H3H0759A
(1) Transfer control valve (4) Transfer pressure (7) Line pressure
(2) Transfer clutch pressure (5) Filter (8) Oil pump
(3) Transfer duty solenoid (6) Pilot pressure (9) Control valve
AT-33
ON-BOARD DIAGNOSTICS SYSTEM
3. On-board Diagnostics System

A: FUNCTION
The on-board diagnostics system detects and stores in the form of a code a fault that has occurred
in any of the following input and output signal systems.
I Rear vehicle speed sensor I Transfer duty solenoid I Low clutch timing solenoid I
I Front vehicle speed sensor 1 ATF temperature sensor 1 Torque converter turbine speed sensor I
I Throttle position sensor I Engine speed signal circuit I -
I
I Shift solenoid 1 I Line pressure duty solenoid I -
I
Shift solenoid 2 AT load signal circuit -
2-4 brake timing solenoid Torque control signal circuit -
I Lock-up duty solenoid 1 2-4 brake duty solenoid I -
I
If a fault has been detected, the system tells the fault by causing the AT OIL TEMP warning light
to operate as follows:
0 Repeated flashing at 4 Hz frequency ... Errors such as battery trouble
-o-Repeated flashing at 2 Hz frequency ... No faults in the system
0 Flashing at different intervals and frequencies ... Diagnostic trouble codes of corresponding
faults
0 Continued illumination of light ...Fault in inhibitor switch, idle switch, or wiring
B: OPERATION OF AT OIL TEMP WARNING LIGHT

On starting the engine, the AT OIL TEMP warning light illuminates and then goes out as shown in
the “Normal” diagram below.
If any problem exists, the light continues flashing as shown in the “Abnormal” diagram below.
ON
OFF _ - _ _ _ _ - - 2-secs
_
Abnormal
ON
0.3secs -- 4
- -
4 -
OFF ---_------ 2 secs
Engine starts
- I-
4 0.3secs
-
Flashes
S3H0227B
AT-34
I ON-BOARD DIAGNOSTICS SYSTEM
DTC Faulty component

11 Engine speed signal circuit
23 Mass air flow signal circuit
27 ATF temperature sensor
31 Throttle position sensor
33 Front vehicle speed sensor
36 Torque converter turbine speed sensor
I 38 I Torque control siqnal circuit I
45 Intake manifold pressure signal circuit
71 Shift solenoid 1
72 Shift solenoid 2
73 Low clutch timing solenoid
74 2-4 brake timing solenoid
75 Line pressure duty solenoid
r. - 76 2-4 brake duty solenoid
77 Lock-up duty solenoid
79 Transfer duty solenoid
93 Rear vehicle speed sensor
D: SELEC-TMONITOR
Various sensor and switch data as well as diagnostic trouble codes for faults that are currently
present and occurred in the past can be monitored by connecting the select monitor to the select
monitor terminal located under the instrument panel.
AT-35
FAIL-SAFE FUNCTION
4. Fail-safe Function
The fail-safe control function ensures minimum level of driveability even if a fault should occur in
the vehicle speed sensors, throttle position sensor, inhibitor switch, or any of the solenoids.
0 FRONT AND REAR VEHICLE SPEED SENSORS
A dual speed-sensing system is used. The speed signal is taken from the transmission (by the out-
put shaft speed sensor). Even if one sensor system fails, the vehicle can be controlled normally
with the other normally operating sensor system.
If both the front and rear vehicle speed sensors become faulty, the vehicle is made to operate only
in the 1st and 3rd speeds.
0 THROTTLE POSITION SENSOR
If the throttle position sensor becomes faulty, the throttle opening is fixed at the predetermined
angle.
0 INHIBITOR SWITCH
If the TCM receives different signals simultaneously from a faulty inhibitor switch, it selects a range
in the following priority:
r. -
D>N(P)>R>3>2>1>
0 SHIFT SOLENOID 1 AND 2
If a fault occurs in either of solenoids 1 and 2, both the solenoids are de-energized, and the gear
is held in the 3rd.
If both the solenoids should fail, the TCM invariably selects and keeps the 3rd gear.
0 LINE PRESSURE DUTY SOLENOID
If the line pressure duty solenoid fails, the solenoid is de-energized and the line pressure is raised
to the maximum to enable the vehicle to operate.
In this condition, the usable gears are limited to the 1st and 3rd.
LOCK-UP DUTY SOLENOID
If the lock-up duty solenoid fails, the solenoid is de-energized and the lock-up clutch is disen-
gaged.
0 TRANSFER DUTY SOLENOID
When the transfer duty solenoid becomes faulty, it is de-energized. This causes maximum oil pres-
sure to be applied to the transfer clutch so that the power is always transmitted to the rear axle
(direct-coupled AWD condition).
2-4 BRAKE DUTY SOLENOID
If a fault occurs in the 2-4 brake duty solenoid, the solenoid is de-energized and the usable gears
are limited to the 1st and 3rd.
LOW-CLUTCH TIMING SOLENOID
If a fault occurs in the low clutch timing solenoid, the solenoid is de-energized and the usable
gears are limited to the 1st and 3rd.
AT-36
FAIL-SAFE FUNCTION
a
_ _ _ _
0 2-4 BRAKE TIMING SOLENOID

If a fault occurs in the 2-4 brake timing solenoid, the solenoid is de-energized and the usable gears
are limited to the 1st and 3rd.
0 TORQUE CONVERTOR TURBINE SPEED SENSOR
If a fault occurs in the torque converter turbine speed sensor, the usable gears are limited to the
1st and 3rd.
AT-37
TRANSMISSION MOUNTING
5. Transmission Mounting
B2H31456
(1) Pitching stopper

(2) Cushion rubber
(3) Cross member
AT-38
I
MANUAL TRANSMISSION
AND DIFFERENTIAL MT
1. ......
2. ........................................................ 4
3. ............................. 10
4. Transmission Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
GENERAL
Manual Transmission and Differential
1. General
The Impreza’ssingle-range manual transmission is of a full-time all-wheel-drive design integrating
a transmission assembly, front differential, and transfer gear assembly with center differential into
a single unit. The transmission creates five forward speeds and one reverse using the correspond-
ing gears all provided with inertia lock-key type synchronizers.
The transmission and front differential are housed in an aluminum case which is split into right and
left halves and constitutes also a clutch housing. Located at the rear and joined each other are
the transfer case and extension case which house the transfer gears and center differential as well
as part of the transmission assembly.
The major features of the transmission are as follows:
0 The forward speed gears are helical gears featuring high tooth face strength, large tooth contact
areas, and quiet operation.
0 Reversing rotation is achieved by making a slidable reverse idler gear engage with both the re-
verse drive gear on the mainshaft and the reverse driven gear integral with the 1st-2nd synchroniz-
er hub on the drive pinion shaft.
The center differential compensates for the difference in front and rear axle speeds. It consists of
--a bevel gear set and a viscous coupling located at its rear end which are housed in a single case.
The center differential,together with a pair of transfer gears, transmits the power from the transmis-
sion to the drive pinion shaft (front wheel drive shaft) and the rear drive shaft. The viscous coupling
functions as a differential-action-control element.
MT-2
GENERAL
NFOlll
(1) Mainshaft (6) Transfer driven gear (1 1) Driven shaft (countershaft)

(2) 3rd drive gear (7) Extension case (12) 2nd driven gear
(3) 4th drive gear (8) Transfer drive gear (13) 1st driven gear
(4) 5th drive gear (9) Viscous coupling (14) Drive pinion shaft
(5) Transfer case (10) Center differentialassembly (15) Front differentialassembly
MT-3
REVERSE CHECK MECHANISM
2. Reverse Check Mechanism

Located in the transfer case, the reverse check mechanism prevents a direct 5th-to-reverse shift
by using a selector arm and cam combination which allows the gear to be shifted into the reverse
only after it has been returned once into the neutral.
A: CONSTRUCTION
The construction of the reverse check mechanism is as shown in the drawing on the opposing
page.
The reverse check sleeve is bolted to the transfer case and houses the mechanism’s main compo-
nents.
The reverse accent shaft is slidable inside the reverse check sleeve and its smaller-diameter end
is fitted with the reverse check cam. The cam is rotatable and axially movable on the shaft but its
leftward movement is restricted by a step formed on the sleeve’s inner wall.
The reverse accent shaft has hollows in both ends. In the left end hollow are the 1st return spring
and its cap and in the right end hollow is the reverse return spring which pushes the shaft leftward.
Around the check cam is the reverse check spring whose left end applies simultaneous leftward
and rotational forces to the cam.
Both the reverse check spring and reverse return spring are retained at their right ends by the re-
verse check plate which is held in place by the snap ring.
The reverse accent shaft has a V-groove in which the detent ball is pressed by the reverse accent
spring fitted through the hole in the reverse check sleeve.
The reverse check sleeve and reverse accent shaft have a slot and a notch at their bottoms, re-
spectively, and he selector arm is inserted in the notch through the slot.
MT-4
NF0114
(1) Silect adjust shim (6) Reverse check cam (11) Selector arm
(2) Detent ball (7) Reverse return spring (12) Spring cap
(3) Reverse accent spring (8) Reverse check spring (13) 1st return spring
(4) Reverse check sleeve (9) Snap ring (14) O-ring
(5) Reverse accent shaft (10) Reverse check plate
MT-5
B: OPERATION
The drawing below shows the state of the reverse check mechanism when the selector arm is in
the neutral position. The 1st and 2nd gears will be selected if the selector arm is moved leftward
from this point to a stop and then turned in either way. A rightward movement of the arm to a stop
will enable selection of the 5th and reverse gears. In the neutral position, the selector arm receives
a rightward force (force toward the 5th and reverse gear side) from the 1st return spring and a
leftward force (force toward the 1st and 2nd gear side) from the reverse return spring to stay in
that position.
The following explanation describes how the selector arm and reverse check mechanism operate
when the driver selects the 5th gear and then selects the reverse gear.
NF0115
(1) 1st return spring (3) Reverse accent shaft (5) 5th and reverse gear side
(2) Reverse check sleeve (4) Reverse return spring (6) 1st and 2nd gear side
MT-6
-
1. WHEN SELECTOR ARM IS MOVED TOWARD 5TH AND REVERSE GEAR SIDE
The selector arm moves rightward while pushing both the reverse accent shaft and reverse check
cam simultaneously.
NF0116
(1 ) Reverse check sleeve (3) Reverse check cam (5) Neutral position
(2) Reverse accent shaft (4) Selector arm
2. WHEN SHIFT IS MADE TO 5TH GEAR

The selector arm is turned toward the 5th gear selection direction. When the arm clears the edge
of the reverse check cam as it turns, the cam becomes free of the selector arm's pressure and
returns to its original position by the force of the reverse check spring.
' (4) NF0117
(1) Reverse check sleeve (3) Reverse check cam (5) Reverse check spring
MT-7
3. WHEN A SHIFT FROM 5TH TO REVERSE IS ATTEMPTED

The selector arm turns toward the reverse gear while pushing the reverse accent shaft rightward
and the reverse check cam counterclockwise (as viewed in the direction of arrows A).
The reverse check cam, however, stops to rotate at a point where its stopper hits against the re-
verse check plate (this point corresponds to the neutral position in terms of the angle) and pre-
vents the selector arm from moving toward the reverse gear selection direction. The selector arm
is then axially pushed to the neutral position by the reverse accent shaft which is given a leftward
force by the reverse return spring.
\
I
I
A-A
5th + Neutral Dosition
NF0118
(1) Reverse check sleeve (5) Reverse check plate

(2) Reverse accent shaft ( 6 ) Snap ring
(3) Reverse check cam (7) Selector arm
(4) Reverse return spring
MT-8
i
4. WHEN A SHIFT TO REVERSE IS MADE AFTER RETURN OF SELECTOR ARM TO NEU-

TRAL
As the ends of the reverse accent shaft and the reverse check cam are on the same plane, the
selector arm now can turn toward the reverse gear selection direction after pushing leftward both
the shaft and cam simultaneously.
U
NF0119
(1) Reverse check sleeve (3) Reverse check cam

MT-9
CENTER DIFFERENTIAL
3. Center Differential
A: CONSTRUCTION
The center differential consists of a set of bevel gears and a viscous coupling.
The center differential has the following two functions: distributing the engine torque to the front
and rear wheel drive shafts and absorbing the difference in rotating speed between the front and
rear wheels.
The engine torque enters the center differential case from the transmission’s driven shaft. The
torque is then distributed through the bevel gear set directly to the drive pinion shaft and via the
transfer drive and driven gears to the rear drive shaft.
The viscous coupling limits the bevel gear set’s differential action when either front or rear wheels
spin so that adequate torques are transmitted to the front and rear wheels and proper traction is
obtained.
NF0120
Transfer driven gear (4) Center differential assembly (with viscous coupling)
Transfer drive gear (5) Drive pinion shaft
Viscous coupling (6) Driven shaft
MT-10
CENTER DIFFERENTIAL
B: MECHANISM OF VISCOUS COUPLING

The viscous coupling consists of a number of alternately arranged inner and outer plates and air-
and-silicone oil mixture filled into a sealed space that is formed by the center differential case and
the rear side gear of the differential gear set. The inner plates have their inner perimeters splined
to the side gear and the outer plates have their outer perimeters splined to the center differential
case. The outer plates are held apart by spacer rings. There are no spacer rings between the inner
rings, so the inner rings are movable slightly in axial directions. X-section rings are used to prevent
leakage of silicone oil which would otherwise occur if the oil is pressurized due to large difference
in front and rear axle speeds.
4
1
(1) X-section ring
(2) O-ring
(5) Inner plate
(6) X-section ring
NF0121
(3) Spacer ring (7) Side gear (rear)

(4) Outer plate
MT-I1
CENTER DIFFERENTIAL
1. TORQUE CHARACTERISTICS
When a speed difference occurs between the center differential case and the rear side gear, a
shear force is generated in the silicone oil placed between the outer and inner plates. The torque
is then transmitted by the silicone oil between the center differential case and the rear side gear.
The greater the speed difference, the greater the shear force generated in the silicone oil. The rela-
tionship between the torque transmission and the speed difference is shown in the figure below.
As can be seen from the figure, the smaller the speed difference, the smaller the torque transmis-
sion and the differential action.
4 Speed difference
NF0122
2. HUMP PHENOMENON
Silicone oil is heated and expanded as differential action continues. This causes the pressure of
air inside the viscous coupling to increase and the pressure of oil between plates to decrease. As
a result, the inner and outer plates are pushed together. This direct plate-to-plate contact causes
a non-viscous operation to occur, and this phenomenon is called “hump”.
The hump eliminates the rotating speed difference between the center differential case and the
rear side gear (or locks the differential), so soon after it has occurred, the internal pressure and
temperature drop. The viscous coupling then returns to the normal shear torque transmitting op-
eration. (The hump phenomenon does not occur under normal operating conditions.)
MT-12
CENTER DIFFERENTIAL
C: FUNCTION
When there is no speed difference between the front and rear wheels, the center differential deliv-
ers the engine torque to the front and rear wheels at a ratio of 5050.
When a rotating speed difference occurs between the front and rear wheels, the center differential
operates to absorb it in a controlled way by the function of the viscous coupling.
1. DURING NORMAL DRIVING

During straight-line driving on aflat road at a constant speed, all the four wheels rotate at the same
speed. The center differential delivers engine torque evenly to the front and rear drive axles. The
viscous coupling does not generate shear torque because there is no relative movements be-
tween the inner and outer plates.
(B)
NF0123
(1) Engine torque (A) To front differential (B) To rear differential
2. DURING TURNS AT LOW SPEEDS

During turns at low speeds, rotating speed difference occurs between the front and rear wheels,
as well as between the left and right wheels. More particularly, the front wheels rotate faster than
the rear wheels. The center differential then acts to absorb the speed difference to enable smooth
driving.
Although the speed difference is small under this condition, operation of the viscous coupling
causes more torque to be transmitted to the rear than to the front.
NFO124
MT-13
CENTER DIFFERENTIAL
3. DRIVING ON ROUGH OR SLIPPERY ROADS

0 When front wheels are on a slippery surface
When the front wheels begin to spin, the resulting speed difference between the front and rear
drive shafts causes the viscous coupling to generate significant amount of shear torque. As a re-
sult, the torque distributed to the rear wheels becomes much larger than that distributed to the
spinning front wheels. The traction and driving stability are thus ensured on a rough or slippery
road.
NFO125
0 When rear wheels are on a slippery surface

When the vehicle is accelerated quickly from a standing start with the rear wheels on a slippery
surface, the distribution of the vehicle weight on the front and rear wheels changes and the rear
wheels start spinning. Due to the resulting speed difference between the front and rear drive
shafts, the viscous coupling generates a significant amount of shear torque, now in the direction
opposite to that generated when the front wheels are on a slippery surface. As a result, the torque
distributed to the front wheels becomes much larger than that distributed to the rear wheels.
NF0126
MT-14
4. Transmission Mounting
A: GENERAL
The pitching stopper is made of resin. It is a non-adjusting type and has a slot on the transmission
end as a bolt hole.
NFOI 28
(1) Pitching stopper

(2) Cushion rubber
(3) Cross member
MT-15
MEMO
MT-16
CLUTCH CL
Page
....................................... ................ 2
................................................. 3
3. Cross Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. Flywheel ............................... ........................................
5. Hydraulic Clutch Pedal System . . . . . . . . . . . . . . . . .................... 7
OUTLINE
Clutch
1. Outline
A: NON-TURBO MODEL
0 The clutch control operates the release fork using the hydraulic pressure generated in the mas-
ter cylinder when the pedal is depressed. This ensures smooth and reliable clutch control with
minimum frictional resistance.
0 The clutch itself is a push type clutch. When the clutch pedal is depressed, the self-aligning re-
lease bearing is caused to slide on a guide pressing the center of the diaphragm spring. The
warped diaphragm spring disengages the pressure plate from the clutch disc.
The clutch using a diaphragm spring has the advantage of little variation in push load even when
the clutch disc facing is worn.
The diaphragm spring is located inside the clutch cover.
0 The clutch has a clutch disc between the flywheel and the pressure plate.
0 Inside the clutch cover, there is a diaphragm spring and a pressure plate combined with each
other by means of strap plates, which also serve to prevent the pressure plate from turning.
B: TURBO MODEL
0 The turbo model adopts a hydraulic control which is appropriate for increased clutch load.
0 The clutch control system operates the release fork using the hydraulic pressure that is gener-
ated in the master cylinder when the clutch pedal is depressed.
0 The clutch itself is a pull type clutch. When the clutch pedal is depressed, the self-aligning re-
lease bearing is caused to slide on a guide pulling the center of the diaphragm spring. The warped
diaphragm spring disengages the pressure plate from the clutch disc.
The clutch using a diaphragm spring has the advantage of little variation in push load even when
the clutch disc facing is worn.
The diaphragm spring is located inside the clutch cover.
0 The clutch has a clutch disc between the flywheel and the pressure plate.
0 Inside the clutch cover, there is a diaphragm spring and a pressure plate combined with each
other by means of strap plates, which also serve to prevent the pressure plate from turning with
respect to the clutch cover.
CL-2
OPERATION
Clutch
2. Operation
A: NON-TURBO MODEL
Applying foot pressure to the clutch pedal moves the release lever. This causes the release bear-
ing to slide on the guide, pressing the center of the diaphragm spring. The spring is warped and
the force having pressed the pressure plate is lost. As a result, the flywheel, clutch disc and pres-
sure plate are disengaged, disconnecting the driving power.
The push type clutch has the point of action at the tips of the diaphragm spring fingers, through
which the pressure plate is pressed to the clutch disc. When the power transmission is to be inter-
rupted, the diaphragm spring is forced to warp using the pivots established on the inward side
of the spring finger tips (on the principle of the lever and fulcrum) to disengage the pressure plate
from the clutch disc.
B: TURBO MODEL
Applying foot pressure to the clutch pedal moves the release lever. This causes the release bear-
ing to slide on the guide, pulling the center of the diaphragm spring. The spring is warped and
the force having pressed the pressure plate is lost. As a result, the flywheel, clutch disc and pres-
sure pl$e are disengaged, disconnecting the driving power.
In the pull type clutch, the diaphragm spring has the point of action located inward from the tip,
through which the pressure plate is pressed against the clutch disc. When the power transmission
is to be interrupted, the diaphragm spring is forced to pivot on the tip and warp away from the pres-
sure plate (on the principle of lever and fulcrum).
CL-3
CROSS SECTIONAL VIEW
Clutch
3. Cross Sectional View

A: NON-TURBO MODEL
NF0451
(1) Operating cylinder (4) Clutch cover (7) Ball bearing
(2) Release lever (5) Transmission main shaft ( 8 ) Flywheel
(3) Release bearing (6) Clutch disc
CL-4
CROSS SECTIONAL VIEW
Clutch
B: TURBO MODEL
NF0211
(1) Spring bracket (5) Flywheel (9) Ball bearing

(2) Spring (6) Clutch cover (10) Release bearing
(3) Release lever (7) Clutch disc
(4) Operating cylinder (8) Transmission main shaft
CL-5
FLYWHEEL
Clutch
4. Flywheel
A: OUTLINE
The flywheel is of a flexible type, consisting of a drive plate, reinforcement and mass flywheel.
This type of flywheel is characterized by less vibration and less noise, since it transmits the engine
power from the crankshaft to the clutch disc through the drive plate and mass flywheel.
CL-6
HYDRAULIC CLUTCH PEDAL SYSTEM
Clutch
5. Hydraulic Clutch Pedal System

A: CONSTRUCTION
0 The hydraulic clutch pedal is connected to the master cylinder via a rod.
0 The clutch pedal and brake pedal are mounted on the same bracket.
0 The clutch pedal has a mechanism that reduces the initial force required to depress the clutch
pedal.
NF0213
(1) Clutch pedal

(2) Brake pedal
(3) Brake and clutch pedal bracket
(4) Rod
(5) Lever
B: OPERATION
The clutch pedal used with the hydraulic clutch control system is similar to that for a mechanical
clutch control system except that it has a spring that returns it to the original position.
CL-7
HYDRAULIC CLUTCH PEDAL SYSTEM
Clutch
MEMO
CL-8
FRONT SUSPENSION FS
Page
1. Front Suspension ................................................. . . . . . . . . . . . .. . . . . . . 2
I FRONT SUSPENSION
Front Suspension
1. Front Suspension
A: OUTLINE
The front suspension is a strut-type independent suspension, with cylindrical double-acting, low-
pressure-gas-filled dampers and coil springs. The top of each strut assembly is attached to the
body through a rubber cushion. Used in combination with other rubber cushions, this rubber cush-
ion effectively insulate vibration and shock and thus improves ride comfort. This type also main-
tains a wide distance between the upper and lower supporting points and makes adjustment of
the caster unnecessary.
The transverse link is an “L” shaped arm design to increase steering stability and reduce road
noise. The transverse link has a maintenance-free ball joint fitted by a castle nut at its outer end.
The front of the link’s inner end is fitted to the front crossmember through a rubber cushion and
the rear of the inner end is bolted to the vehicle body through a fluid-filled bushing.
The front crossmember is bolted to the vehicle body.
The stabilizer is attached to the front crossmember through rubber cushions and its right and left
ends are connected to the stabilizer links through rubber bushings.
The lower end of the stabilizer link is connected to the transverse link through rubber bushings.
A cambir angle adjustment mechanism, which uses eccentric bolts, is provided at the joint of the
damper strut and axle housing.
FS-2
FRONT SUSPENSION
Front Suspension
f
t
E
ai
NFO129
(1) Strut mount (5) Stabilizer

t (2) Strut (6) Front crossmember
i (3) Transverse link (7) Sub frame
(4) Stabilizer link
I
I
ii
FS-3
FRONT SUSPENSION
Front Susoension
B: CONSTRUCTION
1. TRANSVERSE LINK
All the Sedans have larger tread than the previous model for enhanced handling stability.
2. STRUTS
0 All models use struts with low-pressure-gas-filled dampers that feature stable shock attenuating
performance. They improve ride quality and reduce vibration and noise.
0 The coil spring of each strut is arranged in an “S” form so that friction generated in the strut is
minimized and riding comfort is improved.
FS-4
REAR SUSPENSION RS
Page
1. Rear Suspension . . . . _ . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2
.
REAR SUSPENSION
Rear Suspension
1. Rear Suspension
A: OUTLINE
The rear suspension is an independent, dual link strut type. The suspension on each side consists
of two parallelly arranged lateral links, a trailing link, and a strut assembly. The strut assembly con-
sists of a cylindrical double-acting low pressure gas- and oil-filled damper and coil spring.
The respective component parts of this suspension are optimally designed to act in response to
vertical, lateral and longitudinal loads transmitted from the tires. Thus, riding comfort and steering
stability are substantially enhanced.
0 Longitudinal loads act on each trailing link.
0 Vertical loads act on each coil spring, strut and rubber mount (which is located on the top of
each strut).
0 Lateral loads act on the two lateral links on each side.
The crossmember is installed on the body frame via bushings. (AWD model)
The stabilizer that extends to the rear of the crossmember, is installed on the body frame via a
bracket and to the wheel side end of each rear lateral link via a stabilizer link.
(1)
/
NF0094
(1) Strut mount (5) Front lateral link

(2) Strut (6) Rear lateral link
(3) Stabilizer (7) Rear crossmember
(4) Trailing link
RS-2
REAR SUSPENSION
Rear Suspension
B: CONSTRUCTION
1. LATERAL LINKS
0 All the Sedans have larger tread than the previous model for enhanced handling stability.
0 Unsprung weight of the lmpreza has been made smaller than the previous model by using a
pair of steel-pipe lateral links on each side. This enhances both handling stability and riding com-
fort.
2. STRUTS
0 The camber angle of the Impreza has been made more negative than in the earlier model to
improve cornering performance.
0 The dampers used in the struts are of a gas-filled type that features stable shock attenuating
performance. They improve ride quality and reduce vibration and noise.
0 Each strut has at its top a new type strut mount. The strut mounts effectively disperse input forces
from coil springs and struts so that vibration and noise are reduced and riding comfort is improved.
The body attaching flange of each strut mount is adequately rigid, which helps improve handling
stab i Iity.
0 The helper made of highly durable urethane enhances handling stability when the vehicle is
loaded. It also satisfies riding comfort and anti-roll rigidity requirements simultaneously.
RS-3
I
REAR SUSPENSION
Rear Suspension
I
I
I
NF0095
(1) Strut mount Dust cover

(2) Helper Rubber seat
(3) Damper strut Coil spring
RS-4
DIFFERENTIALS DI
Page
1. Rear Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Limited Slip Differential (LSD) . . . . . . .. . . . . .. . ... ... ... ... . .. . .. ... . .. . . . . .. . .. .. . . . . 3
REAR DIFFERENTIAL
Differentials
1. Rear Differential
The drive gear is a hypoid gear with a nominal diameter of 160 mm (6.30 in). The drive pinion shaft
is supported by three bearings. The bearing preload is adjusted by selecting a spacer and washer
combination of a proper thickness. The drive pinion height is adjusted by properly selecting the
thickness of the washers located at the drive pinion neck using Dummy Shaft and Gauge.
NFO097
DI-2
E
LIMITED SLIP DIFFERENTIAL (LSD)

Differentials
2. Limited Slip Differential (LSD)

A: OUTLINE
The limited slip differential is of a viscous coupling (V/C) type which automatically limits the differ-
ential action and distributes torque to the left and right wheels adequately to enhance driving sta-
bility when the left and right wheels are rotating at speeds different from each other during driving
on a slippery road (muddy, snow-covered or slushy road) or cornering.
B: STRUCTURE
The V/C type LSD has outer plates and inner plates arranged alternately. Each outer plate is
splined to the inside of the differential case at its outer periphery and each inner plate is splined
to the outer circumference of the left side gear at its inner periphery.
The inner plates are held in position by spacer rings while the outer rings can slide in the axial
direction along the spline teeth.
The mace between the differential case and the left side gear is filled with a mixture of high viscos-
ity siIi’cone oil and air and hermetically sealed with X-rings.
\
(8)
NF0098
(1) Spacer ring (6) Pinion gear

(2) Inner plate (7) Side gear (right)
(3) Outer plate (8) Differential case
(4) X-ring (9) Side gear (left)
(5) Pinion shaft (10) X-ring
DI-3
Differentials
C: OPERATION
1. WHEN RIGHT AND LEFT WHEELS ROTATE AT THE SAME SPEED
During normal straight-ahead driving where the right and left wheels rotate at the same speed,
the differential case and side gears rotate together, just as in conventional differentials. As a result,
driving torque is distributed equally to the right and left side gears.
NF0099
DI-4
Differentials
2. WHEN RIGHT AND LEFT WHEELS ROTATE AT DIFFERENT SPEEDS

When a speed difference occurs between the right and left wheels, the differential case and the
left side gear do not rotate at the same speed any more. The speed difference between them cor-
responds to that between both the wheels. Because of the shear force caused in the silicone oil,
a differential torque is then generated, which limits differential action.
For example, if the left wheel spins due to small road resistance, a speed difference occurs be-
tween the right and left wheels. Since there is the V/C between the differential case and left side
gear, a differential torque corresponding to the speed difference is generated in the V/C. This dif-
ferential torque is transferred from the left wheel to the right wheel. As a result, a greater driving
torque is distributed to the right wheel which is rotating at a lower speed.
When the right wheel spins, the differential torque is transferred from the right wheel to the left
wheel. Also in this case, a torque greater by the differential torque than the torque to the spinning
wheel is transmitted to the wheel rotating at the lower speed.
When left wheel spins
NF0100
DI-5
Differentials
When right wheel spins
NFO101
D: SERVICE PROCEDURES FOR LSD

It is not recommended to disassemble the LSD assembly as component parts of LSD assembly
are not available individually.
DI-6
DRIVE SHAFT SYSTEM DS
L
Page
E 1. Propeller Shaft . . . . . . ........................................... 2
2. Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................... 4
3. Rear Axle.. . . . . . . . . . . . ................................. 6
PROPELLER SHAFT
Drive Shaft Svstem
1. Propeller Shaft
A: NON-TURBO MODELS
The propeller shaft is of a two-piece design that uses three joints.
(A) (B)
NF0150
(1) Center bearing (A) Transmission side

(6) Rear differentialside
DS-2
PROPELLER SHAFT
Drive Shaft System
B: TURBO MODELS
The propeller shaft uses constant velocity joints for quiet operation of the driveline components.
The center joint is a double offset joint (DOJ) type which can extend and retract in the axial direc-
tions.
(B)
NF0149
(1) Center bearing (A) Transmission side
(2) DOJ (B) Rear differentialside
DS-3
FRONT AXLE
Drive Shaft System
2. Front Axle
A: GENERAL
0 The inboard end of the axle shaft is connected to the transmission via a constant velocity joint
(shudder-less freering tripod joint: SFJ) which is flexible in the axial directions, while the outboard
end is connected via a high efficiency compact ball fixed joint (EBJ) to the wheel hub which is sup-
ported by a taper roller bearing located inside the axle housing. The EBJ features a large operating
angle.
Both the constant velocity joints (SFJ and EBJ) ensure smooth, regular rotation of the drive wheels
with minimum vibration.
0The bearing is a preloaded, non-adjustable tapered roller unit bearing
Each hub is fitted in the axle housing via the tapered roller bearing.
0 The EBJ's spindle is splined to the hub and is secured with an axle nut clinched to it.
0 The disc rotor is an external mounting type. It is secured to the disc wheel using hub bolts to
facilitate maintenance of the disc rotor.
-_
NF0151
(1) EBJ (4) Bearing (7) Oil seal

(2) Axle housing (5) Axle nut ( 8 ) Baffle plate
(3) Tone wheel (6) Hub (9) Hub bolt
DS-4
.
I
FRONT AXLE
Drive Shaft System
B: FRONT DRIVE SHAFT

0 A shudder-less freering tripod joint (SFJ) is used on the differential side of each front drive shaft.
The SFJ can be disassembled for maintenance. It provides a maximum operating angle of 25" and
can be moved in the axial directions.
0 A high efficiency compact ball fixed joint (EBJ) is used on the wheel side of each front drive shaft.
The EBJ's maximum operating angle is 46.5".
i
NF0153
(1) SFJ (3) Transmission side

(2) EBJ (4) Wheel side
DS-5
REAR AXLE
Drive Shaft System
3. Rear Axle
A: NON-TURBO MODELS
0The inboard end of each axle shaft is connected to the transmission via a double offset joint:
DOJ which can extend and retract in the axial directions.
0 The outboard end is supported by angular contact ball bearings located inside the axle housing
via a bell joint (BJ) which features a large operating angle. Both the constant velocity joints (DOJ
and BJ) ensure smooth, regular rotation of the drive wheels with minimum vibration.
0The bearing is a preloaded, non-adjustable angular contact ball unit type.
Each hub is fitted in the axle housing via the angular contact ball bearing.
0 The BJ's spindle is splined to the hub and secured with an axle nut clinched to it.
0 The disc rotor or brake drum is held in position by the hub bolts and wheel nuts together with
the wheel. This facilitates removal and installation of the disc rotor or brake drum and thus im-
proves serv ic eabiIity.
S3H0644A
(1) Bearing (5) BJ

(2) Hub (6) Hub bolt
(3) Axle nut (7) Baffle plate
(4) Oil seal
DS-6
REAR AXLE
Drive Shaft System
B: TURBO MODELS
0 The inboard end of each axle shaft is connected to the transmission via a double offset joint
(DOJ) which can extend and retract in the axial directions.
0 The outboard end is supported by taper roller bearings located inside the axle housing via a
high efficiency compact ball fixes joint (EBJ) which features a large operating angle. Both the
constant velocity joint (DOJ and EBJ) ensure smooth, regular rotation of the drive wheels with mini-
mum vibration.
0The bearing is a preloaded, non-adjustable taper roller unit type.
Each hub is fitted in the axle housing via the taper roller bearing.
0 The EBJ’s spindle is splined to the hub and secured with an axle nut clinched to it.
0 The disc rotor is held in position by the hub bolts and wheel nuts together with the wheel. This
facilitates removal and installation of the disc rotor and thus improves serviceability.
S3H0645A
(1 ) Tapered roller bearing (5) EBJ

(2) Hub (6) Hub bolt
(3) Axle nut (7) Baffle plate
(4) Oil seal
DS-7
I REAR AXLE
Drive Shaft System
C: REAR DRIVE SHAFT

1. NON-TURBO MODELS
A double offset joint (DOJ) is used on the differentialside of each rear drive shaft. The DOJ can
be disassembled for maintenance. It provides a maximum operating angle of 23" and can be
moved in the axial directions.
0 A bell joint (BJ) is used on the wheel side of each rear drive shaft. Its maximum operating angle
is 42".
0 (3) (4) 0 NF0156
(1) DOJ
(2) BJ
(3) Differential side
(4) Wheel side
2. TURBO MODELS
0 A double offset joint (DOJ) is used on the differential side of each rear drive shaft. The DOJ can
be disassembled for maintenance. It provides a maximum operating angle of 23" and can be
moved in the axial directions.
0 A high efficiency compact ball fixed joint (EBJ) is used on the wheel side of each rear drive shaft.
Its maximum operating angle is 42".
(3) (4)
NF0157
(1) DOJ
(2) EBJ
(3) Differential side
(4) Wheel side
DS-8
ABS ABS
Page
1. Anti-lock Brake System (ABS) ......................... 2
. . . . . . . . . . . . .. . . . . . . . . . . . . . .
ANTI-LOCK BRAKE SYSTEM (ABS)
ABS
1. Anti-lock Brake System (ABS)

A: FEATURE
0 The 5.3i type ABS used in the lmpreza has a hydraulic control unit, an ABS control module, a
valve relay and a motor relay integrated into a single unit (called “ABSCM & H/U”) for circuit sim-
plicity and reduced weight.
0 The ABS electrically controls the brake fluid pressure to each wheel to prevent the wheel from
locking during braking on slippery road surfaces, thereby enabling the driver to maintain the
directional control.
0 If the ABS becomes inoperative, a fail-safe system is activated to ensure same level of braking
performance as with a conventional brake system. In that case, the warning light comes on to indi-
cate that the ABS is malfunctioning.
0 The ABS is a 4-sensor, 4-channel system; the front wheel system is an independent control de-
sign*’, while the rear wheel system is a select-low control design*2.
*I : A system which controls the front wheel brakes individually.
*2: A system which applies the same fluid pressure to both the rear wheels if either wheel starts
to lock. The pressure is determined based on the lower of the frictional coefficients of both wheels.
NF0197
(1) ABS control module and hydraulic (5) G sensor (9) Wheel cylinder
control unit (ABSCM 8, H/U)
(2) Proportioningvalve (6) ABS warning light (10) Automatic transmission control
module
(3) Diagnosis connector (7) Tone wheel (11) Brake switch
(4) Data link connector ( 8 ) ABS sensor (12) Master cylinder
(for SUBARU select monitor)
ABS-2
ABS
B: FUNCTIONS OF SENSORS AND ACTUATORS

Name Function
4BS control module and ABSCM section 0 It determines the conditions of the wheels and the vehicle body from the
iydraulic control unit wheel speed data and controls the hydraulic unit depending on the re-
:ABSCM & H/U) sult.
0 When the ABS is active, the ABSCM provides the automatic transmis-
sion control module with control signals which are used by the module
for cooperative control of the vehicle with the ABSCM.
0 Whenever the ignition switch is placed at ON, the module performs a
self diagnosis sequence. If anything wrong is detected, the module cuts
off the system.
0 It communicates with the SUBARU select monitor.
HIU section 0 When the ABS is active, the H/U changes fluid passagesto the wheel cylin-
ders in response to commands from the ABSCM.
0 It constitutes the brake fluid passage from the master cylinder to the wheel
cylinders together with the piping.
Valve relay section It serves as a power switch for the solenoid valves and motor relay coil. It
operates in response to a command from the ABSCM.
Motor relay section It serves as a power switch for the pump motor. It operates in response to
a command from the ABSCM.
ABS sensors (wheel speed sensors) They detect the wheel speed in terms of a change in the density of the
magnetic flux passing through them and convert it into an electrical signal.
The electrical signal is sent to the ABSCM.
Tone wheels They give a change in the magnetic flux density by the teeth around them-
selves to let the ABS sensors generate electrical signals.
S sensor It detects a change in acceleration in the longitudinal direction of the ve-
hicle and outputs it to the ABSCM as a voltage signal.
Stop light switch It provides information on whether the brake pedal is depressed or not to
the ABSCM. The ABSCM uses it to determine ABS operation.
ABS warning light It alerts the driver to an ABS fault. When the diagnosis connector and diag-
nosis terminal are connected, the light flashes to indicate a trouble code
stored in the ABSCM.
Automatic transmission control module It provides gear controls (fixing the speed at 3rd or changing power trans-
mission to front and rear wheels) in response to control signals from the
ABSCM.
ABS-3
ABS
-
-L
I I
E A T E R Y 0-
IGN
I I
NF0198
ABS control module and hydraulic (9) Front right outlet solenoid valve ABS warning light
control unit
ABS control module section Rear left inlet solenoid valve Stop light switch
Valve relay Rear left outlet solenoid valve Stop light
Motor relay Rear right inlet solenoid valve G sensor
Motor Rear right outlet solenoid valve Front left ABS sensor
Front left inlet solenoid valve Automatic transmission control Front right ABS sensor
module
Front left outlet solenoid valve Diagnosis connector (23) Rear left ABS sensor
Front right inlet solenoid valve Data link connector (24) Rear right ABS sensor
ABS-4
ABS
C: PRINCIPLE OF ABS CONTROL

When the brake pedal is depressed during driving, the wheel speed decreases and the vehicle
speed does as well. The decrease in the vehicle speed, however, is not always proportional to the
decrease in the wheel speed. The non-correspondence between the wheel speed and vehicle
speed is called “slip” and the magnitude of the slip is expressed by the “slip ratio” which is defined
as follows:
Slip ratio = Vehicle speed - Wheel speedNehicle speed x 100%
When the slip ratio is 0%, the vehicle speed corresponds exactly to the wheel speed; when it is
loo%, the wheels are completely locking (rotating at a zero speed) while the vehicle is moving.
The braking effectiveness is represented by the “coefficient of friction” between the tire and road
surface. The larger the Coefficient, the higher the braking effectiveness. The diagram below shows
the relationship between the coefficient of friction and the slip ratio for two different road surface
conditions (asphalt-paved road and icy road), assuming that the same tires are used for both the
conditions and the vehicles are moving forward. Although the braking effectiveness (coefficient
of friction) depends on the road surface condition as shown and also on the type of the tire, its peak
range generally corresponds to the 8 - 30% range of the slip ratio.
The ABS controls the fluid pressure to each wheel so that a coefficient of friction corresponding
to this dip ratio range is maintained.
Control range by ABS
Asphalt-paved road
Icy road
--
I
0 * loo(%)
Slip ratio
NF0199
ABS-5
ABS
D: ABS SENSORS
Each of the ABS sensors detects the speed of the corresponding wheel. The sensor consists of
a permanent magnet, coil and tone wheel. The magnetic flux produced by the permanent magnet
changes as each tooth of the tone wheel (which rotates together with the wheel) passes in front
of the magnet’s pole piece. The changing magnetic flux induces voltages at a frequency corre-
sponding to the wheel speed.
(A) (B)
(3)
(4) \
+vI /
I
-V
i i NF0200
(A) Front (1) Sensor body (4) Full speed

(B) Rear (2) Pole piece (5) Low speed
(3) Tone wheel (6) Permanent magnet
ABS-6
ABS
E: ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM & H/U)
0 ABS CONTROL MODULE SECTION (ABSCM)
The ABSCM contains two microcontrol modules (MCMs): master and slave. Both the MCMs pro-
cess the same program and each MCM monitors the other’s outputs. If a mismatch occurs be-
tween their outputs, the ABSCM cuts off the system and activate the fail-safe function.
The ABSCM can store a maximum of 3 trouble codes in an EEP ROM. If more than 3 faults have
occurred, only the 3 most recent failures are stored and others are erased. Trouble codes remain
stored until they are internally or externally erased.
The ABSCM has a test routine (sequence control pattern) which facilitates checking of the hydrau-
lic control unit.
0 ABS control
Using primarily the wheel speed data from each ABS sensor and secondarily the vehicle decelera-
tion rate data from the G sensor as parameters, the ABSCM generates a simulated vehicle speed
when there is a risk of wheel lock-up. Using the simulated vehicle speed (called “dummy” vehicle
speed) as a reference, the ABSCM determines the state of the wheel in terms of the tendency to-
ward lock-up. If the result shows that the wheels are about to lock, the ABSCM issues commands
to energize or de-energize the solenoid valves and activate the motor pump of the H/U to modulate
the brake fluid pressures that act on the wheel cylinders, thereby preventing the wheels from lock-
ing.
The ABSCM controls the right and left front wheel fluid pressures independently and the rear wheel
fluid pressures based on the wheel which is the most likely to lock (select-low control).
0 Functions available using SUBARU select monitor
When the SUBARU select monitor is connected, the ABSCM allows it
0 To read out analog data
0 To read out ON/OFF data
0 To read out or erase trouble code
0 To read out data showing conditions under which a trouble code has been stored (Freeze
frame data)
0 To initiate ABS sequence control pattern
0 Indication functions
Under the control of the ABSCM, the ABS warning light provides the following three indication func-
tion:
0 ABS fault alerting
0 Trouble code indication (by flashing in the diagnosis mode)
0 Valve ON/OFF indication (when sequence control pattern is initiated)
ABS-7
ABS
0 HYDRAULIC CONTROL UNIT SECTION (H/U)

The H/U is a fluid pressure controller consisting of, among others, a motor, solenoid valves, a hous-
ing and relays. It also constitutes passage of the two diagonally split brake circuits.
0 The pump motor drives an eccentric cam which in turn moves the plunger pump to generate
hydrauIic pressure.
0 The housing accommodates the pump motor, solenoid valve and reservoir. It also constitutes
a brake fluid passage.
0 The plunger pump, when operated, draws the brake fluid from the reservoir, lets the fluid in a
wheel cylinder drain into the reservoir, and/or forces the fluid into the master cylinder.
0 The outlet solenoid valve is a 2-position type. It opens or closes the brake fluid passage between
a wheel cylinder and the reservoir according to commands from the ABSCM.
0 The inlet solenoid valve is duty-controlled to reduce brake fluid pulsation for minimum ABS op-
eration noise.
0 The reservoir temporarily stores the brake fluid drained from a wheel cylinder when pressure
“decrease” control is performed.
0 The damper chamber suppresses brake fluid pulsation which would occur during pressure “de-
crease” control in the fluid discharged from the plunger pump to minimize kickbacks of the brake
pedal.
0 The valve relay controls power supply to the solenoid valves and motor relay in response to a
command from the ABSCM. In normal (IG ON) condition, the relay is closed to supply power to
the solenoid valves and motor relay. When an error occurs in the system, the valve relay is turned
OFF to keep the fluid pressure circuit in the normal mode (non-ABS mode).
0 The motor relay closes and supplies power to the pump motor in response to a command from
the ABSCM during the ABS drive mode operations.
The H/U has four operating modes; normal mode (non-ABS mode), and three ABS active modes,
i.e., “increase”, “hold” and “decrease” modes.
ABS-8
ABS
MEMO
ABS-9
ABS
1. DURING NORMAL BRAKING (ABS NOT ACTIVE)

Both the inlet and outlet solenoid valves are not energized.
This means that the inlet port of the inlet solenoid valve is open, whereas the outlet port of the outlet
solenoid valve is closed. So the fluid pressure generated in the master cylinder is transmitted to
the wheel cylinder, producing a brake force.
NOTE:
For simplicity of explanation, operation of the hydraulic control unit is represented by operation
of a single wheel circuit.
ABS-10
ABS
(5) [
L
-1
0 v -
0 0
0 0
0 0
n n
NF0201
(1) From master cylinder (8) Wheel cylinder

(2) Damper chamber (9) Outlet solenoid valve
(3) Inlet port open (10) Motor
(4) Inlet solenoid valve (11) Outlet port closed
(5) Check valve (12) De-energized
(6) De-energized (13) Reservoir
17) Pump
ABS-11
ABS
2. PRESSURE “DECREASE” CONTROL (ABS ACTIVE)

Both the inlet and outlet solenoid valves are energized, which means that the inlet port is closed
and the outlet port is open.
In this state, the wheel cylinder is isolated from the master cylinder but open to the reservoir, so
the brake fluid in it can be drained into the reservoir, decreasing its pressure and reducing the
braking force of the wheel.
The brake fluid collected in the reservoir is forced into the master cylinder by the pump.
During this phase of ABS operation, the pump motor continues operating.
NOTE:
ABS-12
ABS
NF0202

(3) Inlet port closed (10) Motor
(4) Inlet solenoid valve (11) Outlet port open
(5) Check valve (12) Energized
(6) Energized (13) Reservoir
(7) Pump
ABS-13
ABS
3. PRESSURE “HOLD” CONTROL (ABS ACTIVE)

The inlet solenoid valve is energized, so the inlet port is closed.
On the other hand, the outlet solenoid valve is de-energized, so the output port is also closed. In
this state, all the passages connecting the wheel cylinder, master cylinder and reservoir are
blocked. As a result, the fluid pressure in the wheel cylinder is held unchanged.
NOTE:
ABS-I 4
ABS
I '
71
NF0203
(1 ) From master cylinder Wheel cylinder

(2) Damper chamber Outlet solenoid valve
(3) Inlet port closed Motor
(4) Inlet solenoid valve Outlet port closed
(5) Check valve De-energized
(6) Energized Reservoir
(7) Pump
ABS-1 5
ABS
4. PRESSURE “INCREASE” CONTROL (ABS ACTIVE)

Both the inlet and outlet solenoid valves are de-energized, which means that the inlet port of the
inlet solenoid valve is open, whereas the outlet port of the outlet solenoid valve is closed. So the
fluid pressure generated in the master cylinder is transmitted to the wheel cylinder and increased
fluid pressure in the wheel cylinder applies the brake with a larger force.
NOTE:
ABS-I 6
ABS
NF0204

(3) Inlet port open (IO) Motor
(4) Inlet solenoid valve (11) Outlet port closed
(5) Check valve (12) De-energized
(6) De-energized (13) Reservoir
(7) Pump
ABS-I 7
ABS
F: ABS CONTROL CYCLE CURVES

Depressing the brake pedal increases the brake fluid pressure in each wheel cylinder, which in
turn decreases the wheel speed (or increases the wheel deceleration rate). When the brake fluid
pressure is increased to a level of point “A” of the brake fluid pressure curve in the diagram below
(at which the wheel deceleration rate exceeds threshold “-bO”), the ABSCM makes a pressure
“hold” control. At the same time, the ABSCM calculates a “dummy” vehicle speed which is a refer-
ence speed it uses in the next stage of control.
When the wheel speed then drops below the slip ratio setting, i.e., a speed lower than the “dummy”
vehicle speed by the predetermined value (at point “B” of the pressure curve), the ABSCM makes
a control to prevent the wheel from locking, or a pressure “decrease” control.
As the wheel cylinder pressure decreases, the wheel speed starts increasing (or the wheel accel-
eration rate starts rising). When the wheel acceleration rate exceeds threshold “+b10” (at point “C”
of the pressure curve), the ABSCM makes a pressure “hold” control. When the wheel acceleration
rate exceeds threshold “+b20” (at point “D” of the pressure curve), the ABSCM recognizes that
wheel lock-up will not occur and then makes a pressure “increase” control.
When the wheel acceleration rate drops below threshold “+b20”, (at point “E” of the pressure
curve), the ABSCM starts pressure “hold” and “increase” control cycles at a given interval.
When the wheel deceleration rate then exceeds threshold “-bo” (at point “F” of the pressure curve),
the ABSCM immediately makes a pressure “decrease” control.
Slip ratio setting
Wheel speed
Vehicle speed
vehicle speed
Speed -- -.
Wheel
acceleration
/deceleration
\
Brake fluid
pressure
Outlet Oh
valve
OFF
Inlet Oh
valve
OFF Time
NF0205
I Brake fluid
Pressure
I Inlet valve I Outlet valve
I
I Increase I OFF I OFF I ’
I Hold I ON I OFF I
I Decrease I ON I ON I
ABS-1 8
ABS
G: ABS WARNING LIGHT

When a fault occurs in the signal transmission system or the ABSCM, the ABS warning light in the
combination meter comes on. At the same time, the current to the hydraulic control unit is inter-
rupted. The brake system then functions in the same manner as a system without ABS. The warn-
ing light utilizes a dual circuit design.
If the warning light comes on, one or more trouble codes should be stored in the control module.
They must be identified using the warning light’s code indicating function.
NF0467
(1) ABS warning light (U.S. spec. vehicles)

(2) ABS warning light (Canada spec. vehicles)
ABS-1 9
! ANTI-LOCK BRAKE SYSTEM (ABS)
ABS
H: G SENSOR
The G sensor detects changes in the vehicle’s acceleration/deceleration rate in the longitudinal
direct ion.
The moving electrode of a capacitor in the sensor moves away from or close to the fixed electrode
as the vehicle accelerates or decelerates and the resulting change in the capacitance of the ca-
pacitor is outputs to the ABSCM as a change in the voltage.
1Front
When vehicle is accelerated (A) When vehicle is cruising (8) When vehicle is decelerated (C)
J! 4 Fixed electrode \
Moving electrode
G sensor output voltage
ow I
I
-1 G: Accelerated OG: Cruising +1G: Decelerated
1 G Sensor Output Characteristics

NF0207
ABS-20
BRAKES
~
BR
Page
1. Front and Rear Disc Brakes ..................................... ................ 2
2. Rear Drum Brakes . . . . . . . . . . . . ............................................
3. Master Cylinder ...................................................................... 6
4. Brake Booster ........................................ ................... 9
5. Proportioning Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FRONT AND REAR DISC BRAKES
Brakes
1. Front and Rear Disc Brakes

0 The disc brakes are of a ventilated disc type which features high heat dissipation and superb
braking stability. In addition, the front brakes quickly restores their original braking performance
even when they get wet.
0 Ventilated discs are used only on the front wheels.
0 Each disc rotor, which is fitted on the outside of the hub, is secured together with the wheel using
the hub bolts. This facilitates its removal and installation.
0 The inner brake pad is provided with a wear indicator.
NF0236
(1) Disc rotor (3) Hub bolt

(2) Caliper body (4) Hub
BR-2
FRONT AND REAR DISC BRAKES
Brakes
A: PAD WEAR INDICATOR

A wear indicator is provided on the inner disc brake pads. When the pad wears down to 1.5 mm
(0.059 in) the tip of the wear indicator comes into contact with the disc rotor, and makes a squeak-
ing sound as the wheel rotates. This alerts the driver to the situation.
(4) 1.5 mm (0.059 in)

NF0237
(1 ) Wear indicator (3) Worn pad

(2) Newpad (4) Disc rotor
B
A
9
A: TURBO MODEL
4
E: NON-TURBO MODEL
B: FRICTIONAL MATERIAL OF BRAKE PADS

NF0460
The brake pads materials do not contain any asbestos which is harmful to human body.
BR-3
REAR DRUM BRAKES
Brakes
2. Rear Drum Brakes

0 The rear drum brakes are of a leading-trailing shoe type. When fluid pressure is applied to each
wheel cylinder, the piston expands the leading and trailing shoes. During expansion of the shoes,
the lower shoe return spring joint acts as a pivot. The shoes come in contact with the inner surface
of the drum, producing braking action.
0 When brakes are applied during the forward movement, the tip of the brake leading shoe lining
is pressed against the inner surface of the drum so as to oppose the drum’s rotating force. This
increases the braking force. The trailing shoe, however, undergoes a force that pushes it back so
that braking force applied to the trailing shoe decreases.
The above shoe actions are reverse while the vehicle is moving backward; the braking force ex-
erted on the trailing shoe is greater than that on the leading shoe. This means that there is no differ-
ence in braking force between when the vehicle is moving forward and when it is reversing.
0 An inspection hole is provided in the backing plate for easier inspection of the linings for wear.
The hole is closed with a rubber cap.
NF0238
(1) Wheel cylinder (4) Trailing shoe

(2) Upper shoe return spring (5) Leading shoe
(3) Adjuster lever (6) Lower shoe return spring
BR-4
REAR DRUM BRAKES
Brakes
A: AUTOMATIC ADJUSTER
The brake lining-to-drum clearance is automatically adjusted by the automatic adjuster. When the
brake shoe is contracting after expansion, the adjuster lever rotates the adjuster assembly’s screw
to lengthen the adjuster assembly so that the clearance is maintained at the specified value.
NF0239
(1) Upper shoe return spring (5) Adjuster lever

(2) Adjuster assembly (6) Parking lever
(3) Leading shoe (7) Lower shoe return spring
(4) Trailing shoe
BR-5
MASTER CYLINDER
Brakes
3. Master Cylinder
0 There is a brake fluid reservoir tank on the master cylinder. The reservoir is completely sealed
for extended service life of the brake fluid.
With ABS model
NF0461
(1) Reservoir tank

(2) Secondary hydraulic chamber (chamber S)
(3) Primary hydraulic chamber (chamber P)
BR-6
MASTER CYLINDER
Brakes
Without ABS model
iu
NF0241
(1) Reservoir tank

(2) Secondary hydraulic chamber (chamber S )
(3) Primary hydraulic chamber (chamber P)
BR-7
MASTER CYLINDER
Brakes
A: BRAKE FLUID LEVEL SWITCH

The brake fluid level switch is located inside the brake fluid reservoir tank and causes the brake
system warning light on the combination meter to come on when the fluid level has dropped below
the predetermined level.
The switch assembly consists of a reed switch (normally open) and a permanent magnet that is
incorporated in a float.
When the brake fluid level is normal, the float is far above the reed switch, so the force of the mag-
net is unable to act on the reed switch. The warning light circuit, therefore, remains open.
When the brake fluid level drops to a level approximately 30 mm (1.I 8 in) below the maximum level
and the float lowers accordingly, the magnet aligns with the reed switch, activating the reed switch
contact. The warning light then comes on to warn the driver of the situation.
The warning light may, although momentarily, illuminate even when the brake fluid level is normal
if the vehicle tilts or swing largely.
Ai-
L ------- -J
NF0242
(1) Warning light (2) Reed switch (3) Permanent magnet
BR-8
BRAKE BOOSTER
Brakes
4. Brake Booster
The brake booster is a tandem type that uses two diaphragms. This design provides high brake
boosting effects in spite of a reduced diameter.
NF0243
(1) Push rod (5) Filter (9) Valve body

(2) Return spring (6) Silencer (1 0) Plunger valve
(3) Reaction disc (7) Operating rod (11 ) Diaphragm plate
(4) Key (8) Poppet valve (1 2) Valve return spring
BR-9
PROPORTIONING VALVE
Brakes
5. Proportioning Valve
The proportioning valve prevents the rear wheels from locking and resultant skidding that would
occur during hard braking due to transfer of vehicle weight toward the front wheels. The valve dis-
tributes a reduced pressure to the rear wheel brakes as compared with the pressure to the front
wheel brakes when a specified master cylinder fluid pressure (called “split point”) is exceeded
as shown in the diagrams below.
\
:A
:B
NF0248
(1) Master cylinder fluid pressure A: Brakes released

(2) Rear wheel cylinder fluid pressure B: Brakes kept applied
(3) Split point
BR-10
PR0PORTlONING VALVE
Brakes
A: OPERATION
1) Operation before the split point
The piston is held pressed toward the left by the spring so that the piston is kept away from its lip
seal.
Under this condition, fluid pressure “P3” to the rear wheel cylinders is equal to fluid pressure “P2”
from the master cylinder.
I
-4
NF0250
(1) To rear wheel cylinder (4) Spring

(2) From master cylinder ( 5 ) Piston
(3) Lip seal
BR-11
PROPORTIONING VALVE
Brakes
2) Operation at the split point pressure

When pressure “P2” increases to the split point pressure, force “f2” is generated. (Piston’s cross
sectional area “A” has been selected so that the force is generated starting with the split point pres-
sure.) The pressure pushes the piston rightward, overcoming spring force “F”. As a result, the pis-
ton moves rightward and comes in contact with the lip seal, blocking the passage toward the rear
wheel cylinders.
I I
f2 F A
NF0251
(1) To rear wheel cylinder (4) Spring

(2) From master cylinder (5) Piston
(3) Lip seal
3) Operation after reaching the split point pressure

Immediately before the fluid passage toward the rear wheel cylinders is closed, pressure “P2” is
slightly higher than pressure “P3”. So the piston can move in the spring force acting direction and
the fluid can flow to the wheel cylinders. However, as soon as pressure ‘iP2” becomes equal to liP3”,
the passage closes.
This cycle is repeated as long as the pedal is depressed further, but pressure increasing rate of
the rear wheel cylinders is smaller than that of the front wheel cylinders.
BR-I 2
PARKING BRAKE PB
Page
1. Parking Brake (Rear Disc Brakes). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
,
2. Parking Brake (Rear Drum Brakes) .................................... . . . . . . . . . . . 5

PARKING BRAKE (REAR DISC BRAKES)
Parking Brake
1. Parking Brake (Rear Disc Brakes)

The parking brake uses a drum housed in the disc rotor of each rear disc brake. The shoes are
mechanically controlled through linkage and cables.
NF0106
PB-2
Parking Brake
A: OPERATION
1. SETTING
When the parking brake lever is pulled, the shoe actuating lever to which the end of the parking
brake cable is connected turns the strut in direction “F” around point “P”.
The strut then presses the brake shoes A and B against the drum. These brake shoes utilize afloat-
ing design and are movably supported by hold-down pins. The force applied to brake shoe A and
the reaction force “F” applied to the brake shoe B via point “P” press them against the brake drum.
NFO107
(1) Parking brake cable (5) Brake shoe B

(2) Lever (6) Shoe return spring
(3) Strut (7) Shoe hold down pin
(4) Brake shoe A (8) Point “P”
PB-3
Parking Brake
2. RELEASING
When the parking brake lever is returned to the release position and the parking brake cables are
slackened, the brake shoes A and B are moved back to their original positions by the tension of
return springs, so that the parking brake is released.
NF0108
(1) Parking brake cable (5) Brake shoe B

(2) Lever (6) Shoe return spring
(3) Strut (7) Shoe hold down pin
(4) Brake shoe A ( 8 ) Point “P”
PB-4
PARKING BRAKE (REAR DRUM BRAKES)
Parking Brake
2. Parking Brake (Rear Drum Brakes)

When the parking brake lever is moved up, the parking lever in each rear drum brake moves
around point “A” so that the trailing shoe expands. The leading shoe also expands by way of the
adjuster assembly. The shoes are thus pressed against the drum to generate a wheel locking
force.
NFO109
(1) Wheel cylinder Lower shoe return spring

(2) Upper shoe return spring Adjuster assembly
(3) Point“A Parking lever
(4) Adjuster lever
(5) Trailing shoe Automatic brake lining clearance adjustment mechanism
(6) Leading shoe Parking brake mechanism
PB-5
PARKING BRAKE (REAR DRUM BRAKES)
Parking Brake
MEMO
PB-6
POWER ASSISTED SYSTEM
(POWER STEERING) PS
Page
1. Tilt Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Power Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TILT STEERING COLUMN
Power Assisted System (Power Steering)
1. Tilt Steering Column

A: TILT MECHANISM
0 The steering wheel vertical position can be adjusted within a 50 mm (1.97 in) range by using
the tilt lever to unlock the steering column and lock it again at the desired position.
-
L aI \ -
\ (2)
40 mm (1.58in)’
NF0279
(1) Tilt steering column

a (2) Tiltlever
PS-2
E

B: ENERGY-ABSORBING MECHANISM
0 To absorb the backward movement energy generated in the engine in the event of a frontal colli-
sion, a cylindrical fitting type steering column pipe has been adopted. When an impact load ex-
ceeding a certain level is applied to the steering column, the shaft moves in the jacket. Since the
shaft is press-fitted in the jacket, friction generated between them during the above-mentioned
movement absorbs impact. The column bending load is supported by the fittings.
0 Another measure to alleviate impact on the driver in the event of a collision is the wire which is
located between the tilt pin and the distance plate attached to the steering support beam. When
a large impact load is applied to the steering column, the wire is deformed progressively.The im-
pact energy is absorbed during this process.
- \
NF0447
(A) Before absorption of impact energy (1) Tilt pin

(B) After absorption of impact energy (2) Wire
(3) Distance plate
(4) Jacket
(5) Shaft
PS-3
C: STEERING SUPPORT BEAM

The steering column is held in position by a support beam which is installed crosswise in the ve-
hicle body at a level close to the steering wheel to reduce the overhang distance of the steering
wheel from the supporting point of the column. The steering shaft upper bearing is also located
close to the steering wheel to increase supporting efficiency as well as to minimize vibration of the
steering wheel.
NF0281
(1 ) Steering support beam
PS-4
POWER STEERING SYSTEM
Power Assisted System (Power Steerina)
2. Power Steering System

A: HYDRAULIC SYSTEM
0 The fluid pump is directly driven by the engine through a belt.
0 When the steering wheel is not being turned, the pressure-sensitive valve in the pump opens
to drain the fluid into the fluid reservoir tank (Turbo model).
0 The fluid pressure is maintained almost constant regardless of change in the engine speed by
the function of the flow control valve. The pressure-regulated fluid is delivered to the control valve
via hose A.
0 When the steering wheel is turned, the rotary control valve connected to the pinion shaft opens
the hydraulic circuit corresponding to the direction in which the steering wheel is turned. The fluid
then flows into chamber A or B via pipe A or B.
0 The fluid pressure in chamber A or B acts on the rack piston in the same direction as that in which
the rack shaft is moved by rotation of the steering wheel. This helps reduce the effort required of
the driver to operate the steering wheel.
0 Movement of the rack piston causes the fluid in the other chamber to return to the reservoir tank
via pipe A or B, control valve, and hose B.
0 As the steering shaft is connected to the pinion shaft mechanically via the rotary control valve,
the steering system can operate as a manual system even if the hydraulic system becomes in-
operative.
0 To control the maximum fluid pressure, a relief valve is built into the fluid pump to prevent build-
up of an excessive fluid pressure.
PS-5
NF0283
Power cylinder Steering shaft

Rack piston Steering wheel
Rack shaft Tank
Pinion shaft Vane pump
Chamber A Hose A
Chamber B Hose B
Pipe A Turbo model: flow control, energy-savingand pressure sensitive
valve assembly
Non-turbo model: flow control and relief valve assembly
Pipe B Fluid pump
Control valve Engine
PS-6
B: GEARBOX ASSEMBLY
1. POWER CYLINDER
The gearbox integrates the control valve and power cylinder into a single unit. The rack shaft
serves as a power cylinder piston. The rotary control valve is located around the pinion shaft.
The rotary control valve and power cylinder are connected to each other by two pipes through
which hydraulic fluid flows.
NF0284
(1) Piston (4) Power cylinder

(2) Rackshaft (5) Pinion shaft
(3) Cylinder (6) Control valve
PS-7
2. ROTARY CONTROL VALVE

The rotary control valve consists of a rotor (which rotates together with the steering shaft), a pinion
(which is connected to the rotor and torsion bar), and a sleeve (which rotates together with the
pinion). The rotor and sleeve have grooves C and D, respectively, which form fluid passages V1
through V4.
The pinion is in mesh with the rotor with adequate clearance, which enable the rack to be moved
manually by rotating the steering shaft (fail-safe feature).
B
NF0286
PS-8
Torsion bar (12) Torsion bar

Sleeve (13) Rotor
Rotor (14) Sleeve
Pinion (15 ) Fluid return line (to reservoir tank)
Pinion-to-rotorengagement (fail-safe feature) (16) Pinion
Fluid passage VI (17) Torsion bar
Fluid passage V2 (18) Rotor
Fluid passage V3
Fluid passage V4 (A) Cross-sectional view A (fluid passage switching circuit)
Groove C (B) Cross-sectional view B (pinion-to-rotor engagement)
Groove D
PS-9
0 Principle of operation
When the torsion bar is twisted by a rotationalforce applied to the steering wheel, the relative posi-
tion between the rotor and sleeve changes. This changes the cross-sectional area of fluid pas-
sages VI , V2, V3 and V4. The fluid passages are thus switched and the fluid pressure is controlled
in accordance with the operation of the steering wheel.
0 When no steering force is applied:
The rotor and sleeve are held at the neutral position. Fluid passages VI, V2, V3 and V4, which
are formed by grooves C and D are open equally. Under this condition, the fluid from the pump
returns to the reservoir tank so that neither fluid pressure builds up nor the rack piston moves
in the power cylinder.
NF0288
(1) ChamberA (7) From fluid pump

(2) ChamberB (8) To A
(3) VI (9) To B
PS-10
0 When steering force is applied:

When the steering wheel is turned to the right, for example, fluid passages V1 and V3 are opened
while fluid passages V2 and V4 are nearly closed.
At this point, the fluid pressure in chamber A of the power cylinder increases depending on the
degree of closure of fluid passages V2 and V4 so that the rack piston moves to the right. The
fluid in chamber B, on the other hand, is drained through fluid passage V3 into the reservoir tank.
NF0290
(1) ChamberA (7) From fluid pump

(2) ChamberB (8) To A
(3) v1 (9) From B
0 Fail-safe feature
If fluid pressure fails to build up due to, for example, a broken fluid pump drive belt, the steering
wheel rotating torque is transmitted from the valve rotor to the pinion through mechanical engage-
ment between them.
PS-11
C: FLUID PUMP AND RESERVOIR TANK

1. NON-TURBO MODEL
The fluid pump is a vane type driven by the engine via belt.
The reservoir tank is mounted on the vehicle body.
The fluid pump incorporates the flow control valve and relief valve, each performing the following
functions:
0 The flow control valve regulates the flow rate of discharged fluid to a constant level irrespective
of the engine speed.
0 The relief valve protects the system from an excessively high pressure which may occur, for ex-
ample, when the steering wheel is turned all the way.
NF0292
(1) Fluid pump

(2) Reservoir tank
PS-12
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
NF0299
(1) Reservoir tank (4) Fluid pump assembly

(2) Flow control and relief valve assembly (5) Steering gearbox
(3) Vanepump
PS-13
0 VANEPUMP
The vane pump consists of a rotor, a cam ring, and ten vanes.
When the rotor rotates, the vane movably fitted in each slot of the rotor is radially moved out by
centrifugal force and pressed against the inside wall of the cam ring. Since the inside of the cam
ring is oval-shaped, the fluid from the suction port is confined and pressurized in the chamber
formed between two adjacent vanes as the rotor rotates and is delivered through the discharge
port. The pressurized fluid circulates through the hydraulic circuit.
(1).
NF0381
(1 ) Discharge (4) Vane

(2) Rotor (5) Cam ring
(3) Suction
0 FLOW CONTROL VALVE

The flow control valve regulates flow rate of fluid which otherwise would increase as pump speed
increases and deliver dangerously high pressure to the gearbox. It consists of orifices 1 and 2,
valve spool, return port and flow control spring. When a pressure difference occurs between the
front and rear of orifice 2 as a result of an increase in discharge rate, the valve spool moves against
the tension of the flow control spring in such a way that the oil flow rate is controlled by opening
and closing of the return port and orifice 2.
NF0382
(1) Pump speed (4) When oil flow is not controlled

(2) Oil flow (5) Low and mid-range speeds
(3) Idling (6) High speeds
PS-14
0 When the pump begins to rotate, pressure P increases, causing the valve spool to move to
the right. If the pump is operating in the A-to-B speed range, the fluid delivered by the pump
is sent to the gear box in its whole amount through orifice 1.
Pump speed range: A to B
r
J
(4)
(1) Oil reservoir tank

(2) Valve spool
(3) Orifice 1
4 NF0448
(4) To gear box
PS-15
Power Assisted Svstem (Power Steerina)
As the pump speed increases, pressure P increases further, pushing the valve spool further
to the right. As a result, orifice 2 opens allowing part of fluid to return to the pump circuit. Accord-
ingly, a constant flow of oil is maintained.
Pump speed range: B to D
NF0384
(1) To gear box

(2) Orifice 1
(3) Valve spool
(4) Orifice 2
0 When the pump speed further increases, the valve spool is pushed fully to the right. Now, ori-
fice 1 is restricted while orifice 2 opens wide. Oil flow to the gear box is thus maintained at a low
rate.
Pump speed range: D to E
NF0385
(1) To gear box

(2) Orifice 1
(3) Orifice 2
PS-16
2. TURBO MODEL
0 The reservoir tank is mounted on the vehicle body.
0 The fluid pump is belt-driven by the engine. The fluid pump for the turbo models is different from
that for the non-turbo models in that it has additionally an energy-saving valve mechanism. This
valve mechanism reduces the rate of fluid recirculation during straight-ahead driving, which helps
reduce engine load.
NF0299
(1) Reservoir tank (4) Fluid pump assembly

(2) Flow control, energy-serving and pressure sensitive (5) Steering gearbox
valve assembly
(3) Vane pump
PS-17
0 VANE PUMP
The vane pump consists of a rotor, a cam ring, and ten vanes.
When the rotor rotates, the vane movably fitted in each slot of the rotor is radially moved out by
centrifugal force and pressed against the inside wall of the cam ring. Since the inside of the cam
ring is oval-shaped, the fluid from the suction port is confined and pressurized in the chamber
formed between two adjacent vanes as the rotor rotates and is delivered through the discharge
port. The pressurized fluid circulates through the hydraulic circuit.
FLOW CONTROL AND ENERGY-SAVING VALVE ASSEMBLY
0 During engine idling
When the engine is idling, the fluid pump speed is low. As the delivery rate of the pump is small,
the metering orifice allows whole fluid to flow passing through it. So, there is no difference in the
fluid pressure between the right and left of the metering orifice. This means that pressure PI act-
ing on the left end of the flow control valve is equal to pressure P2 (pressure of the fluid flowing
through the pressure sensing holes in the valve body) acting on the right end of the valve. As
a result, the flow control valve is held pressed leftward by the force of the control valve spring.
With the flow control valve in this position, the passage to the fluid pump suction port is closed,
so that the whole fluid delivered from the pump flows toward the power steering gear box.
NF0301
(A) From fluid pump delivery port (1) Metering orifice

(E) To steering gear box (2) Flow control valve
(C) To fluid pump suction port (3) Flow control valve spring
(4) Pressure sensing hole in valve body
PS-18
0 During straight-ahead driving

The speed of the fluid pump increases and the fluid pressure becomes high. The metering ori-
fice does not allow whole fluid to pass through it any longer.
Since the amount of the fluid flowing toward the left end of the flow control valve is larger than
the amount of the fluid flowing toward the right end of the valve passing through the pressure
sensing holes, pressure P1 becomes larger than pressure P2.
As a result, pressure P1 overcomes the force of the flow control valve spring and pushes the
valve rightward. This keeps the passage to the fluid pump suction port open, allowing part of
the fluid to return to the pump suction port and thus reducing flow of fluid to the steering gear
box.
The energy-saving valve mechanism reduces the fluid pump delivery pressure in this way when
steering power assistance is unnecessary, thus reducing load on the engine.
I'
NF0302

(B) To steering gear box (2) Flow control valve
(C) To fluid pump suction port (3) Flow control valve spring
PS-19
During a turn
When the steering wheel is turned, the power steering system starts the steering assist function
and the fluid pressure increases.
Although the pressure of the fluid entering chamber B through the pressure sensing holes in the
valve body increases, the pump delivery pressure is still higher than the chamber B pressure.
So, the flow control valve cannot move leftward.
The fluid in chamber B then enters chamber A at the right end of energy-saving valve piston and
increase the pressure of chamber A.
Since the pressure in chambers A and B is higher than the pressure (ambient pressure) in cham-
ber C at the left end of the energy-saving valve piston, the energy-saving valve piston moves
leftward, overcoming the force of the energy-saving valve spring.
Leftward movement of the energy-saving valve piston compresses the flow control valve spring.
The combination of the tension of the spring and the pressure in chamber B now causes the flow
control valve to move leftward, overcoming the fluid pump delivery pressure. As a result,the flow
control valve closes the passage to the fluid pump suction port and the passage in the metering
orifice opens wider. This enables the fluid delivered by the pump to be supplied to the steering
gear box at the same rate as in the system without an energy-saving valve mechanism.
-
(8)
NF0303
(7) Low-pressure hole in energy-sav-

ing valve
(B) To steering gear box (2) Flow control valve (8) Low-pressure hole in valve body
(C) To fluid pump suction port (3) Energy-savingvalve piston (9) ChamberC
(4) Energy-savingvalve spring (10) Chamber B
(5) Pressure sensing hole in piston (11) Pressure sensing holes in the
valve body
(6) ChamberA
PS-20
HVAC SYSTEM
(HEATER, VENTILATOR AND N C ) AC
Page
1. Heater System ...................................... ................................. 2
2. Air Conditioner . . . . . . . . . .. . .. . ... ...... . . . . . . . . . . . . . . . . . . . . .. . .. . .. . .. . . .. .. . .. . .. . . . . 10
HEATER SYSTEM
HVAC Svstem (Heater. Ventilator and NCI
1. Heater System
A: GENERAL
0 The Impreza’s HVAC system uses an integral air conditioning unit with thin-wall, high-perfor-
mance heater core at the front and evaporator core at the rear. Being compact in size, this unit
enables providing sufficient front passenger’s legroom while ensuring a high air-distribution effi-
ciency by minimizing air flow resistance in all air passages. Overall, the system can create com-
fortable interior air conditions quietly and in all seasons by its excellent heating, cooling, ventilat-
ing, and defrosting performances.
0 There are three ventilation grilles in the dashboard; a trapezoidal grille at the center and round
grilles at both sides. The side grilles are rotatable for air flow direction adjustments.
0 To ensure adequate ventilation, large-size air outlets are provided behind the side portions of
the rear bumper where high-level vacuums are generated during driving.
AC-2
HEATER SYSTEM
HVAC System (Heater, Ventilator and N C )
(3)
NF0158
(1) Side defroster (3) Side ventilation grille

(2) Front defroster (4) Center ventilation grille
1. SPECIFICATIONS
AC-3
HEATER SYSTEM
B: AIR FLOW MODES
F?
Side Front
defroster d
1'
>
It/A
Outside air
I
motor
\Evaporator
Position
''
Heater unit door positions
' YY
Rear heater duct
Position Heater unit door positions
Front Front
w 4 3
DEF BILEVEL
Inr" Rear heater duct

Evaporator
w m Rear heater duct
Ev'aporator
Front Front
Side defroster Outside
defroster I 4I air
ti
DEF/HEAT VENT er
w w
r
W W Eva'porator
Rear heater duct Rear heater duct

Evaporator
-his lever allows selecting either cabin-

Front
iir-recirculationor outside-air-introduction
4 :abin air recirculation or outside air

itroduction is selected when the lever
,witch is moved to the corresponding
iosition.
HEAT
p m Eviporator
Rear heater duct

NF0452
AC-4
HEATER SYSTEM
C: CONTROL PANEL
0 The HVAC control panel is incorporated into the center panel.
0 A rear window defogger switch is located in the control panel
1. MODELS WITH AIR CONDITIONER

0 The control panel uses three large-diameter, dial type switches for easy operation and good
visual recognition.
(1) (4) (2) (6) (3)
I I l l I
NF0453
(1) Air flow control dial:

This switch allows selecting any of the five air flow modes.
NF0376
(2) Fan speed control dial:
This switch allows turning on/off the blower and selecting any of the four blower speeds.
0 1 2 3 4 NF0377
(3) Temperature control dial:
This switch allows adjusting the temperature of air delivered through ventilators steplessly.
(4) Rear window defogger switch:
This switch activates the rear defogger. When the switch is left on, a timer keeps the defogger activated
for 15 minutes and then turns it off automatically.
(5) FRESH/RECIRC lever:
This lever allows selecting either cabin-air-recirculation or outside-air-introduction.
(6) Air conditioner switch:
This switch turns on or off the air conditioner compressor.
AC-5
HEATER SYSTEM
HVAC System (Heater. Ventilator and A/C)
D: HEATER AND COOLING UNIT

0 Having an evaporator core at the front and a heater core at the rear, this single unit combines
both heating and cooling functions.
The heater and cooling unit incorDorates doors for creating different air flow modes and a door
for mixing heated air ana outside air.
0 The air flow mode switching doors and air nixing door are moved by cables through corre-
sponding linkages.
NF0454
1. SPECIFICATIONS
AC-6
HEATER SYSTEM
2. DESIGN FEATURES FOR EACH AIR FLOW MODE

1) Ventilation (VENT) mode
0 The passage leading air from the evaporator to the ventilation outlet (VENT) is made straight to
reduce air flow resistance.
0 When the air temperature is necessary to be adjusted, heated air is blown at right angles against
the flow of cool air from the evaporator. This allows the airs to mix thoroughly.
(1) DEF VENT
HEAT
NF0163
(1) Evaporator
(2) Heater core
2) Foot/face (BILEVEL) mode

0 Warm and cool air flows are created by structural means, namely, by forming sealing surface
for air toward leg area on the heated air passage side and that for air toward the ventilation outlet
(VENT) on the cooled air passage side.
To prevent an excessive difference in the temperature between the two air flows, a bypass pas-
sage is provided to allow part of heated air to flow toward the ventilation (VENT) outlet.
VENT
NF0164
(1 ) Evaporator
(2) Bypass passage
(3) Heater core
AC-7
HEATER SYSTEM
3) Heating (HEAT) mode

0 Warm and cool air flows are created by structural means, namely, by forming sealing surface
for air toward leg area on the heated air passage side and that for air toward the defroster (DEF)
outlet on the cooled air passage side.
To prevent an excessive difference in the temperature between the two air flows, a bypass pas-
sage is provided to allow part of heated air to flow toward the ventilation (VENT) outlet.
0 To maintain the passage toward the defroster (DEF) outlet even during the heating mode opera-
tion, the door of the passage toward leg area is fully opened to the make the passage also serve
as a passage toward the defroster (DEF) outlet.
DEF
\
NF0165
(1) Evaporator
(2) Bypass passage
(3) Heater core
4) Defroster (DEF) mode

0 Air passages are designed in such a way that air flow resistance is minimized and defrosting
performance is maximized.
0 The air passages toward the defroster (DEF) outlet is long enough to ensure a same airflow rate
at all defroster outlets.
DEF
NFOl66
(1) Evaporator
(2) Heater core
HEATER SYSTEM
HVAC Svstem (Heater, Ventilator and N C )
E: BLOWER UNIT
0 The blower unit uses a low-noise-type motor.
NF0455
F: DUCTS
0 The ventilation duct and defroster duct are located behind the instrument panel. Both the ducts
have been modified in the shape to reduce air flow resistance.
0 Defrosting air flow is divided at the center, so that air can flow out evenly through a wide center
defroster as well as right and left side defrosters.
NF0457
AC-9
AIR CONDITIONER
2. Air Conditioner
A: GENERAL
The air conditioner has a newly-developed subcool condenser for improved heat-exchange eff i-
ciency.
As with the previous model’s air conditioner, the refrigerant employed is the chlorine-free
HFC-134a (R134a), which does not contribute to ozone-layer damage.
A simple system structure is realized by incorporation of the receiver dryer into the condenser.
1. SPECIFICATIONS
Item Specification Remarks
Air conditioner “Full-air-mix”type
Cooling Cooling capacity (W) 5100
performance
Air flow rate (m3/h) 450
Refrigerant HFC-134a (9) 500 f 50
quantity
Compressor Type Rotary type with vanes Calsonic CR14
Capacity (g/revolution) 144
Maximum permissible 7000
speed (rpm)
Lubricant (amount con- DH-PR
tained in compressor in
9)
Magnetic clutch Type I
Dry, single disc I
Power consumption (w) 47 I I
Pulley ratio 1:I .064 (crankshaft pulley diameter: 133 mm; compressor
pulley diameter: 125 mm)
Belt Polyurethane V-belt with four ribs
Condenser Type Multi-flow type (with built-in liquid tank capatible with sub-
cooling)
Fan Type Electric-motor-drivenaxial flow fan
Fan diameter 320 mm (7+5 blades)
Power 120 x 2 (turbo model), 70 x 2 (non-turbo model)
consumption (W)
Evaporator Type Laminated
Expansion valve External pressure equalizing type
Temperature control Thermistor
sensor
Other controls Fast idle control Performed by engine control module (ECM)
High and low pressure Low-pressure switch:
limit control turns off compressor at a pressure lower than 0.278 MPa
High-pressure switch:
turns off compressor at a pressure lower than 2.8 MPa
High-speed limit control Performed by ECM
Radiator and condenser Performed by ECM
fan control
AC-10
AIR CONDITIONER
B: COMPRESSOR
The rotary type compressor consists of an integrally formed rotor and shaft, five vanes, and a cylin-
der.
As the rotor turns, the vanes that are movally fitted in the rotor slide over the wall of the oval-shaped
cylinder while drawing, compressing, and discharging refrigerant gas.
The compressor shell has at its rear end an oil separator. High-pressure refrigerant gas having
entered this chamber is separated from the oil it contains before flowing out through the compres-
sor’s delivery port.
There is a check valve in the front housing to avoid reverse rotation of the compressor which would
otherwise occur when the compressor is stopped.
NFO170
(1) Oil cut-off valve (9) Shaft

(2) Oil separator chamber (10) Suction port
(3) Shell (11) Cylinder
(4) Discharge (12) Rotor
(5) Rear side plate (13) Vane
(6) Front side plate (14) Discharge valve
(7) Suction (15) Discharge port
(8) Check valve
AC-11
I
I
AIR CONDITIONER
1. PRESSURE RELIEF VALVE

This valve opens if the pressure of the high-pressure refrigerant gas rises to a dangerously high
level to release part of refrigerant into the atmosphere, thus protecting the compressor. The valve
is designed to limit the amount of released gas to the necessary minimum.
Valve opening pressure: 3.72 MPa (38 kgf/cm2)
Valve closing pressure: 1.8 MPa (17.5 kgf/cm2)
NF0380
(1) .Seat rubber

(2) Seat cover
(3) O-ring
Operating characteristic
(elmin)
(B) t
NFOl72
(A) Pressure
(B) Leakage
AC-12
AIR CONDITIONER
C: COOLING UNIT
The heater unit and cooling unit are integrated into a single “heater and cooling unit”.
The cooling section components of this unit include an evaporator, expansion valve, and case.
U
NF0454
1. EVAPORATOR
The evaporator is a laminated type.
When a low-pressure, low-temperature refrigerant is sprayed by the expansion valve into the
evaporator, it evaporates and cools the evaporator surfaces.
The cabin air is drawn by the blower and cooled down as it flows over the evaporator. The cooled
air then flows passing through the heater unit and delivered into the cabin through versions outlets.
NF0174
(A) Flow of refrigerant

(B) Outlet
(C) Inlet
AC-13
AIR CONDITIONER
2. EXPANSION VALVE
The expansion valve regulates the flow of refrigerant such that heat exchange takes place optimal-
ly.
The expansion valve performs two functions; it sprays the high-pressure refrigerant from the con-
denser using a throttle valve, and it regulates the amount of the spray by changing opening of the
throttle valve.
The expansion valve consists of such main components as a heat sensing cylinder, diaphragm,
ball valve, spring, and adjusting screw.
NF0175
(1) Ball valve Flow of refrigerant

(2) Shaft From evaporator (low-pressure side)
(3) Heat sensing part To compressor
(4) Diaphragm From condenser
To evaporator (high-pressure side)
The heat (temperature) sensing cylinder is held in contact with the evaporator outlet pipe so that
a pressure corresponding to the sensed temperature may be applied to the chamber above the
diaphragm. There is a pressure equalizing hole which communicates with the chamber below the
diaphragm to transmit changes in the refrigerant pressure to the chamber. The ball valve is linked
with the diaphragm and moves according to changes in the balance between the force applied
to the diaphragm and the tension of the spring.
AC-14
m
AIR CONDITIONER
D: CONDENSER
The condenser used in the Impreza’sair conditioning system is the newly developed “subcooling
condenser” that integrates a multi-flow type condenser and a modulator (gas-liquid separator)
into a single unit. The condenser has a high heat-exchange efficiency.
NF0177
(1) Liquid tank

(2) Gasket
1. SUBCOOLING CONDENSER
The new subcooling condenser has a subcooling section where part of the refrigerant that remains
in gas form is cooled and reduced into liquid form. This enables almost 100% of the refrigerant
to be requefied.
NF0488
(1) Liquid tank (A) Inlet

( 8 ) Outlet
AC-15
AIR CONDITIONER
HVAC Svstem (Heater, Ventilator and N C )
E: PRESSURE SWITCH
The pressure switch is a high-pressure side component of the refrigeration cycle (cooling cycle).
It consists of a diaphragm that receives refrigerant gas pressure, a snap plate, a rod, and contacts
that open both when the gas pressure is too low and when it is too high.
The pressure switch plays the following roles:
0 Preventing “no-gas’’ operation due to leakage (when gas pressure is too low)
0 Protecting the cooling system against abnormally high refrigerant pressure (when gas pressure
is too high)
NF0378
(1) Snap plate (high pressure) (6) Contact

(2) Disc (7) Snap plate (low pressure)
(3) Rod (8) Diaphragm
(4) Leaf spring (9) Housing
(5) Contact
ON-OFF pressures
NFOl79
(A) Low pressures

(B) High pressures
1. SPECIFICATIONS
AC-16
AIRBAG SYSTEM AB
Page
1. Airbag System ......................................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...................... 5
AIRBAG SYSTEM
Airbag System
1. Airbag System
A: INSTALLATION
NF0224
(1) Front sub sensor (8) 4-pin connector (Yellow)

(2) 7-pin connector (Yellow) (9) Airbag control module
(3) 2-pin connector (Yellow) (10) 28-pin connector (Yellow)
(4) Airbag module (Driver) (11) 2-pin connector (Blue)
(5) 12-pin connector (Yellow) (12) Airbag module (Side)
(6) Airbag module (Passenger) (13) 2-pin connector (Yellow) (To seat belt pretensioner)
(7) Side airbag sensor (14) 2-pin connector (Yellow)
AIRBAG SYSTEM
Airbag System
B: FUNCTION
1. FRONT AIRBAGS
The airbag system is provided as a driver and front passenger restraint system supplementary
to the seat belts. When an impact greater than a set level is applied to the front of the vehicle, the
sensors generate an electrical pulse to inflate the airbags in the airbag modules, thus preventing
the driver’s and passenger’s upper bodies from directly hitting against the steering wheel, instru-
ment panel and/or windshield:
Driver side Passenger side
Safetv sensor and
Collision
Front sub sensor,

electric sensor and
safety sensor detect
7= an impact greater
than the set level.
1
Inflators are ignited.
1
Gas is generated.
1
Airbag inflation
completes.
.1
Gas is discharged.
I I 1
I v
Airbags deflate.
NF0225
AB-3
AIRBAG SYSTEM
Airbaa System
2. SIDE AIRBAGS
The side airbags provide the driver and front passenger with a restraint supplementary to that by
the seat belts in the event of a side-on collision. When an impact greater than the set level is applied
to either side of the vehicle, the relevant side airbag sensor sends an ignition signal to the corre-
sponding airbag control module. The side airbag module operates to inflate the airbag, thus re-
ducing the shock inflicted in the outside upper body (chest) of the driver or front passenger.
Side airbag sensor
Collision
Side airbag sensor detects

an impact greater than the
set level.
1
Inflator is ignited.
L
Gas is generated.
I
Airbag inflation completes.
I
Gas is discharged.
Airbag deflates.
NF0226
lm
CONSTRUCTION
Airbag System
2. Construction
A: GENERAL
0 The airbag system consists of an airbag control module, left and right front sub sensors, an elec-
tric sensor and safety sensor built into the control module, driver’s and passenger’s airbag mod-
ules each containing an inflator and airbag, and side airbag sensors and modules each contain-
ing an inflator and airbag (Side airbag equipped model).
0 FRONT AIRBAG SYSTEM:
A frontal impact exceeding the set level causes the safety sensor, electric sensor and one or both
front sub sensors to input impact signals to the CPU. The CPU determines whether the airbags
should be inflated or not based on these signals.
0 SIDE AIRBAG SYSTEM:
Input of a side impact signal showing shock energy greater than the set level causes the airbag
on the corresponding side to inflate.
Front sub
Front sub
sensor (LH)
, sensor (RH)
Airbag-
control
module
Electric-
sensor
S
,die airbag
Side airbag sensor (RH)
sensor (LH)\
NF0227
AB-5
CONSTRUCTION
Airbag System
B: AIRBAG CONTROL MODULE

The airbag control module is installed in front of the front floor tunnel. It detects the vehicle’s decel-
eration by receiving electrical signals from its inside safety and electric sensors as well as the front
sub sensors and judges whether to inflate the airbags. This control module has a built-in self-diag-
nosis function. If a fault occurs inside the system, it lights up the airbag warning light in the com-
bination meter. The fault data is stored in the module. A back-up power supply is provided for pos-
sible damage to the battery during an accident, and a boosting circuit is built into the module in
case of a battery voltage drop.
NF0228
C: FRONT SUB SENSOR

One front sub sensor is installed on each side, in front of the front wheel apron wall. The front sub
sensor is a pendulum type sensor. If the sensor receives a frontal impact exceeding a certain limit,
the mass in the sensor rotates forward to turn the switch ON.
Mass
0 c3
v
Switch.contacts
NF0229
AB-6
CONSTRUCTION
Airbag System
D: AIRBAG SENSOR
The safety sensor and electric sensor are incorporated into the airbag control module and the side
airbag sensors.
The safety sensor is also a pendulum type sensor. If the sensor receives a frontal or side impact
exceeding a certain limit, the mass in the sensor moves in the direction opposite to the impact
direction to turn the switch ON.
The electric sensor consists of a semiconductor type sensor which senses the deceleration
caused by collision in terms of change in the electrical resistance of the impact sensing circuit.
SAFETY SENSOR
Switch &ntacts
ELECTRIC SENSOR
NF0230
AB-7
CONSTRUCTION
Airbag System
E: AIRBAG MODULE
1. FRONT AIRBAG
The driver's airbag module is located at the center of the steering wheel and the passenger's air-
bag module is located at upper portion of instrument panel. Each module contains an airbag and
an inflator. If a collision occurs, the inflator produces a large volume of gas to inflate the airbag in
a very short time.
Driver's module Passenger's module
NF0231
(1) Airbag (4) Inflator (Passenger)

(2) Inflator (Driver) (5) Steering support beam
(3) Airbag module lid
2. SIDE AIRBAG
A side airbag module is located at the outer side of each front seat backrest, and it contains an
airbag and an inflator.
If a side-on collision occurs, the inflator produces a large volume of gas to inflate the airbag in a
very short time.
/ Airbag
,Seatframe
/
Inflator Section A
NF0232
AB-8
CONSTRUCTION
Airbag System
F: AIRBAG CONNECTORS
1. DESCRIPTION
The airbag system uses connectors with a double lock mechanism and an incomplete coupling
detection mechanism for enhanced reliability. If coupling is incomplete, the airbag warning light
comes on in the combination meter.
AB-9
CONSTRUCTION
Airbag System
2. AIRBAG HARNESS-TO-AIRBAG HARNESS CONNECTOR

Slide lock
I , Lock arm
NF0304
Disconnection:
Step 1:
(1) Push
Step 2:
Slide and hold B
Step 3:
Release
Step 2:
Hold A
Step 2:
(3) Hold
Step 4:
Disconnect
u I
NF0305
Connection:
Insert the male side connector half into the other until a “click” is heard.
AB-1 0
im
CONSTRUCTION
Airbag System
3. AIRBAG HARNESS-TO-BODY HARNESS CONNECTOR

Disconnection:
Hold the slide lock (A) moved in the direction of the arrow, then pull the female connector in the
direction of the arrow.
NFO130
Connection:
Push the connector (A) into the male connector carefully until a click is heard.
NF0131
AB-I1
CONSTRUCTION
Airbaa System
4. FRONT SUB SENSOR AND SIDE AIRBAG SENSOR CONNECTORS

Disconnection:
Holding the outer part (A), pull the connector in the direction of the arrow.
NF0132
Connection:
Holding the inner part, push the connector into the socket carefully until a click is heard.
Do not hold the outer part (A) as it moves back during connection of the connector.
NF0133
AB-I 2
CONSTRUCTION
Airban System
G: STEERING ROLL CONNECTOR

The steering roll connector is located between the steering column and steering wheel. The con-
nector contains a spirally wound flat cable. The cable can follow rotational movements of the steer-
ing wheel and ensures connection between the airbag module in the steering wheel and the air-
bag harness through which electrical signals are transmitted from the airbag control module.
- 7Flat cable
NF0234
H: AIRBAG WARNING LIGHT

The airbag warning light is located inside the combination meter. It illuminates if a poor connection
in the airbag circuit occurs, or if the airbag control module detects an abnormal condition. When
the airbag system is normal, this light comes on when the ignition switch is turned ON and then
goes out about 7 seconds later.
NF0134
I: WIRE HARNESS
The airbag harnesses are integrated into the body harness as follows:
0 Front sub sensor harness: Integrated into the front harness.
0 Airbag main harness: Integrated into the bulkhead harness.
0 Pretensioner and side airbag harnesses: Integrated into the rear harness.
AB-13
CONSTRUCTION
Airbaa Svstem
J: LOCATIONS OF WARNING AND CAUTION LABELS

/
k
d
View A View B View C
View D View F
NF0490
AB-I 4
SEAT BELT SYSTEM SB
Page
1. Seat Belt . . . . . . . . . . . . . . . . . . _ . . . . . . . . . . . . . . . . . . . . . . , . . . . . _ .. . . _ . . . . . ... 2
SEAT BELT
Seat Belt Svstem
1. Seat Belt
A: ADJUSTABLE SHOULDER BELT ANCHOR
1. FRONT
Each front seat belt system has an adjustable shoulder belt anchor which allows the occupant to
select the most appropriate anchor height from among the five positions in a 100 mm (3.94 in)
range.
NF0217
2. REAR
The side rear seat belt system has an adjustable shoulder belt anchor which allows the occupant
to select the most appropriate anchor height from among the three positions in a 36 mm (1.4 in)
range.
NF0459
SB-2
SEAT BELT
Seat Belt System
B: REAR CENTER THREE-POINT TYPE SEAT BELT

1. SEDAN
A three-point type seat belt is available for the center seating position of the rear seat.
The retractor for the seat belt is installed on the luggage shelf behind the seating position.
NF0218
(1) Retractor
SB-3
SEAT BELT
Seat Belt System
2. WAGON
A three-point type seat belt is available for the center seating position of the rear seat.
The retractor is installed inside the right rear quarter panel.
NF0142
(1) Retractor
C: AUTOMATIC RETRACTOR
When the front passenger's seat belt and all the rear seat belts are drawn out completely, their re-
tractors are placed in the automatic locking mode which is used when installing a child restraint
system. In this mode, the belt can be retracted but cannot be extended. When the belt is retracted
to a certain length, this mode is cancelled and normal operation is restored.
- Fully
retracted Normal mode
Belt can be
extended
and retracted.
I
A
Automatic locking mode
Belt can be retracted

but cannot be extended.
Fully
extended
mode to normal automatic locking

mode changeover
NF0219
SB-4
SEAT BELT
Seat Belt System
D: PRETENSIONER
1. CONSTRUCTION
The driver’s and front passenger’s seat belts are equipped with seat belt pretensioners.
The pretensioners use the front sub sensors and the airbag control module inside sensors to con-
trol their operation. If the sensors detect an impact exceeding the predetermined level during a
frontal or front-angled collision, the front seat belts are quickly rewound by the retractors to take
up slacks for maximum restraining of the seat occupants. If the load placed on a seat belt exceeds
the predetermined level, the torsion bar twists to allow the belt to be payed out, thus lessening the
load imposed on the belt wearer’s chest. Once the seat belt pretensioner has been activated, the
seat belt retractor remains locked.
Driver’s pretensioner
The gas generator is activated.
The generated gas pushes the steel balls.
Moving steel balls cause the ring gear to rotate.
NF0481
(1) Tube (5) Spring

(2) Ring gear (6) Gas generator
(3) Pinion (7) Torsion bar
(4) Steel ball
SB-5
SEAT BELT
Seat Belt Svstem
Front passenger’s pretensioner

The strip is wrapped onto the clutch shaft.
The gas generator is activated.
The generated gas pushes the strip.
A pull given at the strip rotates the clutch shaft
I----
// NF0482
(1) Webbing (4) Clutch

(2) Gas generator (5) Torsion bar
(3) Strip
SB-6
SEAT BELT
Seat Belt System
2. FUNCTION
electric sensor
Front sub sensor

Collision occurs.
Front sub sensor, electric

sensor and safety sensor
detect an impact exceeding
predetermined level.
Pretensioner operates.
Completion.
NF0221
SB-7
I SEAT BELT
Seat Belt Svstem
3. PRETENSIONER CONNECTOR
Disconnection:
Hold slide lock (A) moved in the direction of the arrow, then pull the connector (B) in the direction
of the arrow.
NF0135
Connection:
Push the connector (A) into the male connector carefully until a click is heard.
NF0136
SB-8
~~~ ~~~
WIPER AND
WASHER SYSTEMS ww Page
1. Front Wiper and Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Rear Wiper and Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FRONT WIPER AND WASHER
W b e r and Washer Svstems
1. Front Wiper and Washer

A: DESCRIPTION
1. FRONT WIPER
1) The front wiper is of a tandem type featuring wide wiping area. The blade is installed to the arm
by means of U-hook joint to improve serviceability.
2) The front wiper operates in the HI and LOW speed modes and the INTERMITTENT mode.
The operation modes can be selected by turning the wiper switch incorporated in the combination
switch.
3) In the INTERMITTENT mode, the intermittent unit installed behind the combination switch con-
trols the front wiper operation interval.
4) The front wiper system uses a modular construction in which the wiper motor forms an integral
part of the linkage. The motor is installed on the body through rubber mounting.
NF0223
2. FRONT WASHER SYSTEM

1) The washer system consists of a washer tank, a motor and pump unit and a pair of nozzles.
2) The washer tank is installed at the front of the strut mount on the left side of the engine compart-
ment.
3) The washer motor and pump unit is installed at the bottom of the washer tank.
4) The washer nozzles are installed on the hood. Each nozzle has a diffusion jet hole.
5) Each washer nozzle is provided with a check valve which is located just below it.
ww-2
FRONT WIPER AND WASHER
Wiper and Washer Systems
3. SPECIFICATIONS
Washer Tank Capacity I 4.0 liters (4.2 US qt, 3.5 Imp qt) 1
Wiper Motor Rated voltage 112v I
No-loadcurrent 1 4 A or less I
Speed HIGH 66 & 6 rpm
[at 2.0 N m (20 kg-cm, 17 in-lb)] Low 43 f 5 rpm
~~~
Locked rotor charac-

teristics
I LOW
I
Torque
Current
I Torque
I
29.4 N-m (300 kg-cm, 2.2 ft-lb) or more
36.0 A or less
I 34.3 N m (350 kg-cm, 2.5 ft-lb) I
Current 31.5 A or less
Wiper Blade Length Driver side 550 mm (21.65 in)
Passenger side 425 mm (19.69 in)
ww-3
REAR WIPER AND WASHER
Wiper and Washer Systems
2. Rear Wiper and Washer

A: DESCRIPTION
1. REAR WIPER
1) The rear wiper operates intermittently at a 10-second interval
2) The rear wiper operates over a 168-degree angle.
NF0141
3) The wiper blade is attached to the arm by means of a U-hook joint in the same way as with the
front wipers.
2. REAR WASHER SYSTEM

1) The same washer tank is shared by the front and rear washer systems.
2) The washer motor and pump unit is installed at the bottom of the washer tank, adjacent to the
front washer’s unit.
3) The washer nozzle is installed on the upper portion of rear gate panel. The nozzle has two spray
holes.
4) The washer nozzle is provided with a check valve which is located just below it.
3. SPECIFICAT10NS
Wiper Motor I Rated voltage I12v I

I No-load current 1 2 A or less I
I Speed [at 0.5 N m (5 kg-cm, 4.3 in-lb)] I 25 rpm or more I
I Locked rotor current I 13 A or less I
Wiper Blade I Length I 375 mm (14.76 in) I
ww-4
GLASS/WINDOWS/MIRRORS
~~~~ ~ ~
GW
Page
1. Power Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... 2
POWER WINDOW
Glass/Windows/Mirrors
1. Power Window
A: CONSTRUCTION
0 The power window system consists of regulator motors and switches for individual doors, relays
and a circuit breaker unit.
0 Each door window opens/closes by pushing down/pulling up the switch.
0 Only the driver’s door window switch has a 2-stage mechanism:
0 When the switch is pushed lightly and held in the pushed position, the window continues to
lower until the switch is released.
0 When the switch is pushed down fully, the window lowers to the end position automatically.
NOTE:
For the sake of safety, the power window system is designed to operate only when the ignition
switch is in the ON position.
B: CIRCUIT DIAGRAM
NF0222
GW-2
BODY STRUCTURE BS
Page
Refer to G1831BE SUPPLEMENT for this section.
BODY STRUCTURE BS
Page
1. Steering Support Beam ............................................................. 2
2. Quietness ....................... ....... .. 3
3. Body Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..................... 6
5. Anti Chipping Coat (ACC) Application ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6. Stone Guard Coat (SGC) Application . . . . . . . . . . 8
7. Sealer Application .......................... . . . . . . . . . . ............................ . . . 9
8. Anti-rust Wax (Bitumen Wax) Application .. . . . . . . . . . . . 16
9. Polyvinyl Chloride (PVC) Application . . . . . .. . . . . . . . . ............................ . . . 19
10. Hot Wax Application ........................ . . . . . . . . . . . . . 20
11. Galvanized Sheet Metal Application ..... .. . . . . . . . . ............................ . . . 22
12. Aluminium Sheet Metal Application ...... . . . . . . 23
13. Vent ilation .................................... . . . . . . ............................ 24
14. Child Seat Anchors ......................... ...... 25
STEERING SUPPORT BEAM
Bodv Structure
1. Steering Support Beam

A steering support beam is provided between the left and right front pillars for reinforced support
of the steering column. It also minimizes vibration of the steering column and limits its extension
to a minimum in the event of a collision.
NF0498
BS-2
QUIETNESS
Body Structure
2. Quietness
Silencers, dual-wall panels, sound-absorbing materials, etc. are utilized in conjunction with a high-
rigidity and vibrationlnoise-proof body structure in order to ensure quietness of the passenger
compartment.
A: SILENCERS
Silencers (= asphalt sheets) minimize transmission of noiselvibration into the passenger compart-
ment.
NF0527
BS-3
I
QUIETNESS
Body Structure
B: DUAL-WALL TOEBOARD
The toeboard is a dual-wall design consisting of an asphalt sheet placed between two steel panels
to reduce the transmission of noise and vibration from the engine compartment to the passenger
compartment.
NF0499
(1) Dual-wall toeboard
BS-4
BODY SEALING
Body Structure
3. Body Sealing
A: SEALED PARTS
All gauge holes and other holes used during the body manufacturing process are plugged to pre-
vent entry of water and dust.
Any time the vehicle body has been repaired, the affected holes should be properly plugged with
the use of the specified plugs.
BS-5
PAINTING
Body Structure
4. Painting
A: SPECIFICATION
Color name Color code
PURE WHITE 51 E
PREMIUM SILVER (M) 01G
GREEN (M) 07V
RED MICA (M) 94H
DEEP BLUE MICA 95H
BLUE BLACK MICA 08V
WR BLUE MICA 02c
SPORTS YELLOW 797
PURE WHITE I GRAY (M) OG5 (51E 109V)
RED MICA (M) I GRAY (M) OL1 (94H 109V)
I PREMIUM SILVER (M) I GRAY (M) I OT9 (01G I 09V) I

I GREEN (M) I GRAY (M) I OA6 (07V I 09V) I
I BLUE BLACK MICA / GRAY (MI I OA9 (08V 109V) I
(M):Metallic
B: PAINT FILM STRUCTURE

Color name Paint film structure
0 PUREWHITE
0 SPORTS YELLOW Clear coat
Pigment
l o oa E oOo Color base
OOO 0 0 00
Intermediate
paint
NF0521
0 PREMIUM SILVER (M) Aluminum

0 GREEN(M) pigment\ - Clear coat
0 GRAY(M)
0 'A 5 Colorbase
Pigment -o O O o
Intermediate
paint
NF0522
0 REDMlCA(M) Aluminum
0 DEEP BLUE MICA pigment ~-------\ Clear coat
0 BLUE BLACK MICA \
0 WRBLUEMICA Colored mica
0
'J&00 0
2- Colorbase
-
Piament-O OD' o
Intermediate
paint
NF0523
(M): Metallic
BS-6
ANTI CHIPPING COAT (ACC) APPLICATION
Body Structure
5. Anti Chipping Coat (ACC) Application
NF0500
BS-7
STONE GUARD COAT (SGC) APPLICATION
Body Structure
6. Stone Guard Coat (SGC) Application
NF0533
BS-8
a
SEALER APPLICATION
Body Structure
7. Sealer Application
A: ENGINE COMPARTMENT
NF0501
(1) Sealer
B: ENGINE HOOD
NF0502
(1) Sealer
BS-9
.
SEALER APPLICATION
Body Structure
i
C: DOOR
NF0503
(1) Sealer
D: REAR GATE
NF0504
(1) Sealer
E: TRUNK LID
NF0505
(1) Sealer
BS-IO
I
SEALER APPLICATION
Body Structure
F: REAR END (WAGON)
NF0506
(1) Sealer
BS-11
SEALER APPLICATION
Body Structure
G: REAR END (SEDAN)
NF0507
(1) Sealer
H: ROOF PANEL
NF0508
(1) Sealer
BS-12
SEALER APPLICATION
Body Structure
I: FRONT FLOOR
NF0509
(1) Sealer
J: REAR FLOOR (WAGON)
NF0510
(1) Sealer
BS-I 3
SEALER APPLICATION
Body Structure
K: REAR FLOOR (SEDAN)
NF0511
(1) Sealer
L: UNDER BODY
NF0524
(1) Sealer
BS-I 4
SEALER APPLICATION
Bodv Structure
M: FUEL LID (WAGON)
NF0525
(1) Sealer
N: FUEL LID (SEDAN)
NF0526
(1) Sealer
BS-15
ANTI-RUST WAX (BITUMEN WAX) APPLICATION
Body Structure
8. Anti-rust Wax (Bitumen Wax) Application
(1) Front suspension lower bracket (4) Front floor pan

(2) Front side frame (5) Subframe
(3) Toeboard (6) Under cover
BS-16
Body Structure
(J) NF0529
(1) Front side frame (5) Under cover

(2) Rear side frame (6) Toeboard
(3) Subframe (7) Rear wheel apron
(4) Front wheel apron
BS-17
Bodv Structure
NF0532
(1 ) Brake pipe
(2) Filler pipe
BS-I 8
POLYVINYL CHLORIDE (PVC) APPLICATION
Body Structure
9. Polyvinyl Chloride (PVC) Application
A d
NF0514
BS-19
HOT WAX APPLICATION
Body Structure
IO.Hot Wax Application

F
B
V V
NF0515
(1) Front hood panel (5) Front and rear door hinge (a) WAGON
(2) Front hood hinge (6) Rear gate hinge
(3) Side sill (7) Side door panel (include rear door
panel)
(4) Rear gate outer panel
BS-20
HOT WAX APPLICATION
Bodv Structure
NF0516
(1) Trunklid (b) SEDAN
BS-21
GALVANIZED SHEET METAL APPLICATION
Bodv Structure
11. Galvanized Sheet Metal Application
NF0517
BS-22
ALUMINIUM SHEET METAL APPLICATION
Body Structure
12. Aluminium Sheet Metal Application
NF0531
BS-23
I
VENTILATION
Body Structure
13. Ventilation
A: AIR OUTLET PORT
NF0518
(1) Air outlet port

(2) Airflow
BS-24
CHILD SEAT ANCHORS
Body Structure
14.Child Seat Anchors

Child seat anchors are added to the rear floor panel in order to conform with the FMVSS225 (ISO-
FIX) requirements for child restraint anchorage systems.
NF0519
(1) Anchor
BS-25
CHILD SEAT ANCHORS
Body Structure
MEMO
BS-26
INSTRUMENTATlON/DRlVER INFO
_ _ ~
ID/
Page
1. Combination Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Outside Air Temperature Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
COMBINATION METER
lnstrumentation/Driver Info
1. Combination Meter
A: WARNING AND INDICATOR LIGHTS
NF0442
(1) CHECK ENGINE warning light

This light illuminates when a fault occurs in the MFI (Multiple point Fuel Injection) system.
(2) Brake fluid level warning / parking brake indicator light
This light illuminateswhen the fluid level in the brake reservoirtanklowers below the specified level and/or when the parking
brake is applied.
(3) AT oil temperature warning light
This light illuminateswhen the ATF temperature exceeds 150°C (302°F); it blinks when a fault occurs in the AT control sys-
tem.
(4) AIR BAG system warning light
This light illuminates when a fault occurs in the airbag system.
(5) ABS warning light
This light illuminates when a fault occurs in any electrical component of the ABS (Anti-lock Brake System).
(6) Charge indicator light
This light illuminates when a fault occurs in the charging system while the engine is running.
(7) Oil pressure warning light
This light illuminates when the engine oil pressure decreases below 14.7 kPa (0.15 kg/cm2, 2.1 psi).
101-2
COMBINATION METER
Instrumentation/Driver Info
If everything is normal, the warning and indicator lights should be ON or OFF as shown below ac-
cording to ignition switch positions.
Warning/lndicator light I Ignition switch position
ILOCWACC ION I ST I While engine is running
(1) CHECK ENGINE I OFF I ON I ON I OFF
(2) Brake fluid level / parking brake 1 OFF I ON I ON I *3
(3) AT oil temperature I OFF I ON I ON I OFF
(4) AIRBAG OFF *1 *1 *1
(5) ABS OFF ‘2 *2 *2
(6) Charge OFF ON ON OFF
(7) Oil pressure OFF ON ON OFF
*1 :This light comes ON for about 7 seconds, and then goes out.
*2:This light comes ON for about 2 seconds, and then goes out.
*3:This light comes ON when the parking brake is applied.
IDI-3
COMBINATION METER
B: TELLTALE (GRAPHIC MONITOR)
NF0443
(1 ) Turn signal indicator light

This light blinks in unison with the corresponding turn signal lights when ...e turn signal switch is operk2c
(2) Seat belt warning light
This light stays illuminated for about 6 seconds after the ignition switch has been turned ON.
(3) Headlight beam indicator light
This light illuminates when the headlights are in the high-beam position.
(4) Door open warning light
This light illuminates when one or more doors and/or rear gate are not completely closed.
(5) FWD indicator light (non-turbo AT model)
This light illuminates when the drive mode is changed from AWD to FWD (with the fuse installed in the FWD switch).
(6) Security indicator light
This light illuminates when the security system is armed.
(7) AT selector lever position indicator
The light correspondingto the present AT select lever position illuminateswhen the ignition switch is in any position other
than ACC and LOCK.
(8) Low fuel warning light
This light illuminates when the quantity of the fuel remaining in the tank has decreased to about 9 liters (2.4 US gal, 2.0
Imp gal) or smaller.
IDI-4
COMBINATION METER
~~ ~ ~ ~~ ~
If everything is normal, the telltales should be ON, OFF or in other states as shown below according
to ignition switch positions.
Telltale light
LOCWACC ON ST While engine is
running
t
(1) Turn signal OFF Blink Blink Blink
(2) Seat belt OFF *2 *2 *2
I
1 I
I
(3) Headlight beam
I
0 High beam I OFF
I
1 ON 1 ON
I
1 ON
I 10 Lowbeam IOFF I OFF I OFF I OFF
(4) Door or reargate 0 Open ON ON ON ON
0 Shut OFF OFF OFF OFF
I (5’ FWD
(6) Security
10
10
FWD
AWD
1 OFF
I OFF
*3
I ON
I OFF
OFF
1 ON
1 OFF
OFF
1 ON
I OFF
OFF
(7) AT setector lever position OFF ON ON ON
(8) Lowfuel OFF *I *I *I
*I :This light illuminates when quantity of the fuel remaining in the tank has decreased to about 9 liters (2.4 US gal, 2.0 Imp gal) or
smaller.
*2:This light stays illuminated for about 6 seconds after the ignition switch has been turned ON.
*3:This light blinks when the security system is armed.
IDI-5
COMBINATION METER
Instrumentation/DriverInfo
C: SPEEDOMETER
1. DESCRIPTION
0 The speedometer system is an electrical type that uses electric signals from the speed sensor
in the MT model or the transmission control module (TCM) in the AT model.
0 The vehicle speed sensor is installed on the manual transmission.
0 Since the system does not use mechanical components such as rotating cable, there are no
opportunities of occurring such problems as meter needle vibration and cable disconnection.
Also, it does not constitute any means of mechanical noise transmission.
0 The odometer and tripmeter readings appear on a liquid crystal display (LCD).
2. OPERATION
MT model: The vehicle speed sensor sends vehicle speed signals (4 pulses per rotation of speed
sensor’s driven shaft) to the speedometer drive circuit and odometerhipmeter drive circuit in the
speedometer.
AT model: The TCM sends vehicle speed signals (4 pulses per rotation of output shaft) to the
speedometer drive circuit and odometerhripmeter drive circuit in the Speedometer.
NOTE:
Signals from the speed sensor or TCM are also used by the engine control module, automatic
transmission control module, etc.
3. SPECIFICATION
Speedometer I Type ~
1 Electric pulse type. I
Indication Needle points to 60 km/h (37.3 miles) when 2,548 pulses are input per minute.
Odometer Type Pulse count type.
Display LCD/6 digits; 0 to 999,999 km (mile).
Counts up 1 km per 2,548 pulses (1 mile per 4,104 pulses). (Count down is impos-
Indication
sible.)
Tripmeter Type Pulse count type.
Display LCD/4 digits; 0 to 9999 km (mile).
Counts up 1 km per 2,548 pulses (1 mile per 4,104 pulses). (To change the tripme-
Indication ter from A to B or B to A, push the knob momentarily. To return the tripmeter to zero
indication, keep the knob pushed for more than 1 second.)
IDI-6
COMBINATION METER
4. SYSTEM DIAGRAM
NF0484
MT model
AT model
Odometer/tripmeter drive circuit (7) Front wheel
Speedometer movement (8) Speed sensor
Speedometer (9) TCM
Odometer/tripmeter (10) Electromagnetic pick-up
Speedometer drive circuit (11) Gear for the speed sensor
Combination meter (12) Differential
IDI-7
COMBINATION METER
D: VEHICLE SPEED SENSOR

The vehicle speed sensor uses a Hall IC pick-up to generate speed signals. (MT model)
This sensor is installed on the transmission case and detects rotating speed of the transmission
output gear.
The sensor generates 4 pulses per rotation of the speed sensor driven shaft and send them to the
speedometer.
1. CONSTRUCTION
The speed sensor mainly consists of a Hall IC, magnet ring, driven shaft and spring.
NF0267
(1) Upper case (4) Driven key (7) Rivet

(2) O-ring (5) Lowercase (8) Hall IC
(3) Magnet ring (6) Driven shaft
IDI-8
3
COMBINATION METER
2. OPERATION
As the driven key rotates, the magnet turns causing the magnetic field of the Hall IC to change.
The Hall IC generates a signal that corresponds to a change in the magnetic field.
-
One turn of the driven key in the speed sensor sends 4 pulses to the combination meter, engine
control module and cruise control module.
Signal (4 pulses
per revolution)
Low speed
High speed Combination meter
Revolution of
transmission
output gear
+ Speedometer
drive circuit
Vehicle speed
sensor
I IG
Odometer and
A tripmeter drive
circuit
,-I Engine control module

Cruise control module
NF0268
E: TACHOMETER
The tachometer drive circuit is connected to the engine speed sensing circuit in the engine control
module.
When the engine speed increases or decreases, the voltage of the circuit also increases or de-
creases, changing the magnetic force of the tachometer drive coil.
The tachometer needle then moves in accordance with change in the engine speed.
.-.-.-.-. Combination meter
I-- 1
:
Tachometer drive circuit
ECM
--
NF0269
IDI-9
COMBINATION METER
F: WATER TEMPERATURE GAUGE

0 The water temperature gauge is a cross-coil type.
0 The water temperature signal is sent from the thermo gauge located on the engine.
0 The resistance of the thermo gauge changes according to the engine coolant temperature.
Therefore, the current sent to the water temperature gauge also changes according to the engine
coolant temperature. As the change in current causes the magnetic force of the coil to change,
the gauge's needle moves according to the engine coolant temperature.
0 When the coolant is at a normal operating temperature of approx. 70 to 100 "C (158 to 212 OF),
the gauge's needle stays in the middle of the indication range as shown below.
50 65
Temperature (C) -100 120
Combination meter
1
NF0270
IDI-I 0
COMBINATION METER
Instrumentation/Driver info
G: FUEL GAUGE
1. GENERAL
0 The fuel gauge unit consists of a float and a potentiometer whose resistance varies depending
on movement of the float. It is located inside the fuel tank and forms an integral part of the fuel
pump. The fuel gauge indicates the fuel level in the tank even when the ignition switch is in the
LOCK position.
0 All models are equipped with two fuel level sensors. These sensors are installed in the fuel tank,
one on the right side and the other on the left side. Two sensors are necessary because the fuel
tank is divided into main and sub tank compartments.
8
NF0362
(1) Main fuel level sensor

(2) Sub fuel level sensor
(3) Float
IDI-11
COMBINATION METER
2. OPERATION
The low fuel warning light operates as follows:
The combination meter CPU continually monitors the resistance signal from the fuel level sensor.
It turns on the low fuel warning light if a resistance value corresponding to the critical fuel level
(approx. 78 R) is detected successively for about 10 minutes or the period spent for driving a dis-
tance of 10 km.
This monitoring time has been decided to avoid false operation of the warning light which may
happen when a large part of remaining fuel is collected temporarily in the sub tank compartment.
Sub fuel
Main fuel
level sensor
level sensor I
Fuel tank
NF0273
3. SPECIFICATIONS
Main fuel level FULL 0.5-2.5 R

sensor 112 20.7-24.7 R
EMPTY 50.0-52.0 R
Sub fuel level FULL 0.5-2.5 R
sensor
112 19.5-23.5 R
EMPTY 42.0-44.0 R
IDI-I 2
a
COMBINATlON METER
4. CIRCUIT DIAGRAM
NF0485
(1) Combination meter (6) CPU

(2) Ignition (7) Fuel gauge
(3) Low fuel warning light (8) Sub fuel level sensor
(4) Driver (9) Main fuel level sensor
(5) IIF
IDI-13
OUTSIDE AIR TEMPERATURE DISPLAY
InstrumentatiotdDriver Info
2. Outside Air Temperature Display

A: CONSTRUCTION
The outside air temperature display system consists of an ambient sensor, the CUSTOM CPU and
a liquid crystal display installed in the combination meter. The ambient sensor detects the outside
air temperature using the built-in thermistor which varies its resistance according to change in am-
bient temperature, and sends signals to the CUSTOM CPU.
As soon as the ignition switch is turned ON, the CUSTOM CPU compares the temperature data
sent from the ambient sensor with the one that was stored in its memory when the ignition switch
was turned OFF last time and it causes the lower of the temperatures to be displayed. However,
if 60 minutes or more time has passed between the last turning OFF and the next turning ON of
the ignition switch, the temperature that is displayed is a sensor-provided temperature.
When the vehicle is running slowly, the heat released from the engine compartment raises the tem-
perature of the air around the ambient sensor and this affects the temperature data the sensor
sends to the CUSTOM CPU. The CPU then makes a special control using the vehicle speed data,
i.e., when the vehicle is running at a speed slower than 10 km/h, the CPU uses the temperature
that was detected during the most recent vehicle’s movement at a speed exceeding 10 km/h rather
than a temperature currently being provided by the ambient sensor.
NF0140
(1) Ambient sensor

(2) Outside air temperature display
IDI-I 4
B: CIRCUIT DIAGRAM
Outside air
temperature
Ambient display
sensor
q.7
CUSTOM
CPU
Thermistor Combination meter

T
Vehicle Transmission
speed control
sensor module
MTT
NF0275
IDI-I 5
MEMO
IDI-I 6
SEATS SEa
Page
1. Front Seat ... . . . . . . . . . .. . . . .......... .. . . . . . . .......... ... . . . . .. . ....... . . . . . . . . . . . . . . . 2
2. Rear Seat . . . .... . ....... ... . . . . . . . . . . . . .... . . . . . . . . . . . . . . ..... . .... . . . . . . ............. 3
FRONT SEAT
Seats
1. Front Seat
A: ADJUSTMENT
0 The height of each headrest is adjustable to any of the 3 positions available.
0 The angle of each backrest is adjustable to any of the 32 positions available at 2" steps.
0 The front seat can be slid back and forth to one of the 16 positions available at 13.5 mm (0.53
in) steps.
33rd position
1st
16 x 13.5 mm
NF0486
B: HEIGHT ADJUSTER
The driver's seat is provided with a height adjuster. It allows adjusting the seat height within a range
of 50 mm (2 in).
Both the seat cushion and backrest rises every time the lifter lever is pulled up; they lowers every
time the lever is pushed down.
Lifter lever
50 -1
m. 50 mm
NF0146
SE-2
REAR SEAT
Seats
2. Rear Seat
A: OPERATION
1. SEDAN
A trunk-through hatch is provided behind the seatback. It is accessed by folding down the central
portion of the seatback which also serves as an armrest in its down position.
HG1008B
2. WAGON
Unlock the seatback by pulling the release knob and then fold the seatback down.
NF0147
SE-3
REAR SEAT
Seats
MEMO
SE-4
SECURITY AND LOCKS SL
Page
. .
1. Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Power Door Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Keyless Entry System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. Security System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5. Trunk Lid Release Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
IGNITION SWITCH
Securitv and Locks
~~
1. Ignition Switch
A: DESCRIPTION
1. IGNITION SWITCH
0 The ignition switch has a function of giving the driver warning by sound if he or she opens the
door with the key still in the “LOCK” or “ACC” position.
0 The ignition switches on the MT models have a safety mechanism that prevents inadvertent lock-
ing of the steering wheel during driving. The driver cannot turn the ignition key from “ACC” to
“LOCK” unless the key is pushed inward at the “ACC” position (arrow 1 in the drawing below).
NF0491
0 The ignition switches on the AT models have a key interlock mechanism to avoid locking of the
steering wheel during driving. The ignition key can be turned to the “LOCK” position only when
the select lever is in the P position.
NOTE:
Should the key be impossible to turn to “LOCK” when the select lever is in the P position due to
failure of the key interlock mechanism, the interlocking can be cancelled by operating the release
lever located on the underside of the steering column.
Ignitionswitch
\ IgnitiGn key cylinder

Key interlock solenoid (AT)
NF0492
2. KEY REMINDER CHIME

The reminder chime sounds when the driver’s door opens and the ignition key is in the “LOCK”
or “ACC” position. The chime stops when the key is removed from the ignition switch.
SL-2
POWER DOOR LOCK
Security and Locks
2. Power Door Lock

A: CONSTRUCTION
0 The power door lock system consists of an integrated module, driver’s and front passenger’s
door lock switches, a front door lock actuators, rear door lock actuators, and a rear gate lock ac-
tuator.
0 When the driver’s/front passenger’s door is locked or unlocked using the door lock switch, the
other doors and the rear gate are also locked or unlocked automatically.
B: CIRCUIT DIAGRAM
(1)
NF0444
(1) Integrated module (7) Rear LH actuator (13) Lock

(2) Lock output (8) Rear RH actuator (14) Unlock switch
(3) Unlock output (Driver’s door) (9) Rear gate lock actuator (15) Lock switch
(4) Unlock output (Except driver’s door) (10) Front passenger’s door lock switch (16) Battery
(5) Front LH actuator (11) Driver’s door lock switch
(6) Front RH actuator (12) Unlock
SL-3
KEYLESSENTRYSYSTEM
Security and Locks
3. Keyless Entry System

A: CONSTRUCTION
0 The keyless entry system consists of a transmitter, keyless entry control module (with a built-in
antenna), integrated module, door lock actuators, door switches, horn and interior light.
0 The keyless entry system operates on a radio frequency, so its transmitter can be used in almost
all directions relative to the vehicle.
B: FUNCTION
1. DOOR LOCKING
1 ) Push the transmitter’s LOCK button once.
2) All doors are locked.
3) Check that the horn chirps once
2. DOOR UNLOCKING (DRIVER’S DOOR)
1) Push the transmitter’s UNLOCK button once.
2) The driver’s door is unlocked and the interior light turns ON (when the interior light switch is set
at the DOOR position).
NOTE:
The interior light illuminates for 30 seconds and then goes out. (However, if a door locking proce-
dure is performed again during this period, the light will go out immediately.)
3) Check that the horn chirps twice.
3. DOOR UNLOCKING (ALL DOORS)

1) Push the transmitter’s UNLOCK button twice within 5 seconds.
2) All doors are unlocked.
3) No audible or visible sign is given even after all the doors are unlocked.
4. PANIC ALARM SETTING
1 ) Push the transmitter’s LOCK button for more than 2 seconds.
2) The horn sounds continuously. To stop the horn, push any transmitter’s button.
5. ANSWER BACK (HORN SIGNALING) ON/OFF SELECTION

1) Push the transmitter’s UNLOCK button.
2) Push the transmitter’s LOCK and UNLOCK buttons simultaneously for more than 2 seconds to
activate the answer back function and push them again to deactivate it.
3) When the answer back function is activated, the horn will sound once. When it is deactivated,
the horn will sound twice.
6. DOOR OPEN WARNING FUNCTION

The horn sounds three times if the transmitter’s LOCK button is pressed with any door, rear gate
or trunk lid opened.
SL-4
SECURITY SYSTEM
Security and Locks
4. Security System
A: FEATURES
0 The security system protects the vehicle from a theft action (unauthorized entry into the vehicle).
Upon detection of such an action, it gives audible and visible alarms by causing the horn to sound
and the parking lights to flash. It also immobilizes the vehicle by disabling the starter circuit.
0 Unauthorized entry is monitored through the switches on the doors, rear gate and trunk lid. If
one of the switches is turned ON, the system interprets it as an attempt of unauthorized entry and
gives alarms while disabling the starter circuit.
0Unauthorized entry is also monitored by the impact sensor. The system operates in the same
manner as mentioned above whenever the sensor senses an abnormal impact on the vehicle.
1. ALARMS
0 When activated, the security system causes the parking lights to flash and the horn to sound
intermittently. In addition, the security indicator light on combination meter flashes fast and the
starter motor circuit is disabled.
0 The alarms automatically turn OFF after 30 seconds. However, they will be reactivated if the ve-
hicle is tampered with again.
0 The alarms are activated when a door, rear gate or trunk lid is opened without using the keyless
entry transmitter. (When the system is armed, the alarms will be triggered even if a door is opened
by releasing the inside door handle or the trunk lid is opened by operating the trunk lid release
Iever.)
0 They are also activated when an impact on vehicle body is sensed.
2. HOW TO ARM THE SYSTEM

1) Remove the key from the ignition switch.
2) Make sure that the trunk lid is closed
3) Close all the windows. Close and lock all the doors and rear gate.
4) Push the transmitter’s LOCK button.
5) The horn will chirp once and the parking lights will flash once.
NOTE:
The system can be armed even if the windows are open.
6) Confirm that the security indicator light blinks slowly (once every two seconds). If any of the
doors, rear gate or trunk lid is not properly closed, the system warns the driver of this by causing
the horn to chirp three times, the parking lights to flash three times, and the security indicator to
flash rapidly. When the door, rear gate or trunk lid is closed, it will be automatically locked and the
security system starts working. The indicator light blinks every two seconds when the system is
armed and continues to blink until the system is disarmed.
SL-5
SECURITY SYSTEM
Securitv and Locks
3. HOW TO DISARM THE SYSTEM

1) Push keyless entry transmitter’s UNLOCK button.
2) The horn will chirp twice and the parking lights flash twice.
3) The security indicator light turns OFF.
4) The interior light will illuminate for 30 seconds and then turns OFF. (However, if a system arming
procedure is performed during this period, the interior light will turn OFF.)
4. HOW TO STOP ALARMS

Push the transmitter’s UNLOCK button or turn the ignition switch from “LOCK” to “ON” repeatedly
three times at an interval shorter than five seconds.
SL-6
TRUNK LID RELEASE HANDLE
Security and Locks
5. Trunk Lid Release Handle

A: DESCRIPTION
0 The trunk lid release handle is a device designed to open the trunk lid from inside the trunk.
0 In the event children or adults become locked inside the trunk, the handle allows them to open
the lid.
0 The handle is located on the inside of the trunk lid.
0 The handle is made of material that remains luminescent for approximately an hour in the dark
trunk space after it is exposed to ambient light event for a short time.
NF0479
B: OPERATION
To open the trunk lid from inside the trunk, press the yellow handle downward as indicated by the
arrow on the handle, this operation unlocks the trunk lid. Then push up the lid.
NF0480
SL-7
Securitv and Locks
MEMO
SL-8
EXTERIOR/INTERIOR TRIM El
Page
1. Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTRUMENT PANEL
ExteriorAnterior Trim
1. Instrument Panel
0 A cup holder is provided on the dashboard.
0 A coin tray is provided.
0 The vent grills are barrel type.
0 The dashboard lower cover is fitted with a knee cover.
NF0458
(1) Barrel type vent grill (3) Coin tray

(2) Cup holder (4) Glove compartment
El-2
EXTERIOR BODY PANELS EB
Page
1. Door... . . . . . . . . . . . . . . . . . . . , , , , .............., .. ............... ., , .................. . . ... 2
DOOR
Exterior Body Panels
1. Door
A: DOOR CHECKER
The door checkers are of a new type that uses a molded resin part.
NF0216
B: DOOR CONSTRUCTION
0 All the front and rear doors have in their inside side door beams, inner reinforcements and rein-
forcement latches.
0 Tight closure at the bottom of each door is ensured by dual sealing.
' ' Duaisealing

Outer handle bracket
\
Door beam (added)
I Reinforcement plate
\ \
NF0144
EB-2
CRUISE CONTROL SYSTEM
~~
cc Page
1. Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _ . . . 2
I
CRUISE CONTROL
Cruise Control System
1. Cruise Control
A: OPERATION
0 The cruise control system automatically controls the vehicle speed. It allows the vehicle to run
at a constant speed without need for the driver to keep the accelerator pedal depressed.
0 When the driver has activated the system and made a desired speed setting, the cruise control
module compares the actual vehicle speed detected by the speed sensor (MT) or transmission
control module (AT) with the preset speed in the memory, then generates a signal according to
the difference between the two speeds.
This signal is transmitted to the actuator located in the engine compartment.
The actuator operates the throttle cam as necessary to keep the preset vehicle speed.
cc-2
CRUISE CONTROL
B: COMPONENT LOCATION
NF0462
(1) Actuator (5) Clutch switch (MT)

(2) Inhibitor switch (AT) (6) Stop and brake switch
(3) Command switch (cruise control lever) (7) Control module
(4) Main switch
cc-3
CRUISE CONTROL
Cruise Control Svstem
C: CONTROL AND OPERATION

When actual vehicle speed is higher than the “set” speed, the motor in the actuator operates to move the
Constant speed throttle valve in the closing direction by the amount corresponding to the difference between the two speeds.
control When actual driving speed is lower than “set” speed, the motor operates to move the throttle valve in the
opening enabling direction according to the difference in speed.
When SETKOAST switch is pressed with main switch ON while the vehicle is being driven at a speed great-
Speed setting er than 40 km/h (25 MPH), current flows to the actuator. This causes the clutch in the actuator to engage,
control enabling the motor to operate. The motor moves the throttle valve to the position corresponding to the accel-
erator pedal position. The vehicle is driven at the set speed.
When SETKOAST switch is turned ON while the vehicle is cruising at a constant speed, the motor in the
Deceleration actuator rotates to move the throttle valve in the closing direction. This causes the vehicle to coast. When the
control switch is turned OFF, the vehicle speed is stored in memory and the vehicle maintains that speed thereafter.
When RESUME/ACCEL switch is turned ON while the vehicle is cruising at a constant speed, the motor in
Acceleration the actuator rotates to move the throttle valve in the opening direction. This causes the vehicle to accelerate
control by a certain amount. When the switch is turned OFF, the vehicle speed is stored in memory and the vehicle
maintains that speed thereafter.
When RESUME/ACCEL switch is turned ON after the cruise control is temporarily cancelled, vehicle speed
returns to that speed which was stored in memory just before the cruise control is cancelled. This occurs only
when the vehicle is running at a speed greater than 32 km/h (20 MPH).
Resume control In the following cases, however, the set vehicle speed is completely cleared. Therefore, no resume control is
performed.
(1 ) Ignition switch is turned OFF
(2) Main switch is turned OFF
When any of the following signals is entered into the cruise control module, the clutch is disengaged and the
cruise control is deactivated.
Manual cancel (1) Stop light switch ON signal (Brake pedal depressed) (2) Brake switch OFF signal (Brake pedal de-
control pressed) (3) Clutch switch OFF signal (Clutch pedal depressed - MT) (4) Inhibitor switch ON signal (Selector
lever set to “N” - AT) (5) CANCEL switch ON signal (Command switch cruise control lever pulled) (6) Ignition
switch OFF signal (7) Main switch OFF signal
Low speed limit When the vehicle speed drops below 32 km/h (20 MPH), the cruise control is automatically cancelled. Cruise
control control at any speed lower than 40 km/h (25 MPH) cannot be effected.
When the vehicle speed becomes 10 km/h (6 MPH) or more higher than the memorized speed while vehicle
is running utilizing the cruise control (in a downgrade, for example), the actuator’s clutch is turned OFF so
Motor control
that the vehicle decelerates. When the vehicle’s speed becomes 8 km/h (5 MPH) or more lower than the
memorized speed, the clutch is turned ON again so that the cruise control resumes.
cc-4
CRUISE CONTROL
D: SCHEMATIC
To accelerator pedal
Battery
Ciuise control cable
I
Clutch switch (MT) r+
1
ir
-
Ac:tuator
Vehicle speed
sensor
MT
f - - Vehicle 1
speed
Stop and brake switch I I signal
Cruise control RESUMWACCEL

module
=_LI
1 - L
t
Command switch
i-
(cruise control lever)
TCM (AT)
@+-- Inhibitor switch (P and N)
NF0258
cc-5
CRUISE CONTROL
E: SYSTEM CONSTRUCTION
Vehicle
Unit Name Function Set Cancel Resume Coast
speed
Input Supplies battery voltage to control
signal Main switch module after main switch is turned 0 0 0 0 0
(sensors) ON (with ignition switch ON).
COAST
SET/
switch
RESUME/
1 Sends a SET/COAST signal to
control module.
1 - 1
Sends a RESUME/ACCEL signal
to control module.
0
switch
Simultaneously sends SET/
CANCEL COAST and RESUME/ACCEL 0
switch signals to control module.
Brake Disconnects power supply to
switch (NC) clutch and stepping motor.
0 0
Stop light Sends a cancel signal to control
switch (NO) module.
0 0
Clutch
switch (NC) Sends a cancel signal to control
or inhibitor module.
0 0
switch (NO)
Vehicle
speed Detects vehicle speed. 0 0 0 0 0
sensor I I I I I I
Control
section
Built-in relay I A safety device to protect system
from damage. l o l o l o l o / o
output
signal
Stepping
motor
(PULL)
Stepping
motor
II
Controls vehicle speed.
Controls vehicle speed. 1 0 II I o

Io
I o
(RELEASE) I I I I
Clutch I
Cancels cruise control setting. 0 0 0 0 0
NC:Normally close
N0:Normally open
CC-6
CRUISE CONTROL
F: ACTUATOR
In response to a signal from the cruise control module, the clutch in the actuator is turned ON. This
causes the stepping motor to operate, pulling the throttle cam for speed control.
Throttle cam
Pulley /
Gear ‘ Stepping
motor
NF0260
G: MAIN SWITCH
0 The main switch is the main power supply switch of the cruise control module. It has a built-in
power indicator and night illumination light.
0 When the ignition switch is placed in the OFF position with the main switch ON, the main switch
is also turned OFF. Even if the ignition switch is turned ON again, the main switch will stay in the
OFF state.
“ON” indicator
f light
Illumination
light
NF0494
cc-7
CRUISE CONTROL
H: COMMAND SWITCH (CRUISE CONTROL LEVER)

0 When the vehicle is driven with the cruise control activated, the command switch controls its
operation. It inputs SET/COAST signal, ACCEL/RESUME signal or CANCEL signal to the cruise
control module.
Horn Horn
Command
RESUME/ACCEL
module
NF0262
0 The command switch is located on the right side of the steering wheel, so the driver can operate
it without releasing hands from the steering wheel.
0 The command switch is a self-returning lever type.
1. RESUMWACCEL AND SETKOAST SWITCH

Each switch contact is held closed as long as the lever is kept pressed in the relevant direction
and resulting current is applied as a signal to the control module.
2. CANCEL SWITCH
All the switch contacts are closed as long as the lever is pulled toward the CANCEL position (to-
ward the driver). This causes the RESUME/ACCEL and SET/COAST ON signals to be sent to the
control module si mu1taneously.
I: CANCEL SIGNALS
The cancel signal deactivates the cruise control function. Operating any of the following switches
results in generation of the cancel signal. On receiving the signal, the cruise control module can-
cels the cruise control function.
0 Stop light switch
0 Brake switch
0 Clutch switch (MT model)
0 Inhibitor switch (AT model)
0 Main switch
0 Command switch (CANCEL position)
J: VEHICLE SPEED SENSOR

Vehicle speed sensor is installed on the transmission, and sends signal to the cruise control mod-
ule which uses it in controlling the cruise control function (MT model).
CC-8
CRUISE CONTROL
K: ENGINE THROTTLE
0 The throttle body is equipped with two throttle cams. One is used during acceleration and the
other during cruising in order to open or close the throttle valve.
0 These cams operate independently of each other. In other words, when one cam operates, the
other may not.
NF0263

(2) Cruise control cable
(3) Throttle cam
L: CONTROL MODULE
0 Based on signals from the related switches and sensors, the cruise control module controls all
the following control functions:
Constant speed control; speed setting control; deceleration control; acceleration control; resume
control; manual cancel control; low speed limit control; stepping motor control; clutch control
0 The control module (A) is located inside of the front pillar lower portion (driver side).
NF0463
cc-9
CRUISE CONTROL
M: FAIL-SAFE FUNCTION
The cruise control system has a fail-safe function that cancels the cruise control operation when
any of the following conditions occurs.
1. CONFLICT BETWEEN CRUISE CONTROL SWITCHES AND CANCELLATION SIGNAL

GENERATING SWITCHES
1) The cruise control system is deactivated if any of the cruise control switches (SET/COAST,RE-
SUME/ACCEL, and CANCEL switches) is turned ON while any of the cancellation signal generat-
ing switches (brake, stop lamp, clutch, and inhibitor switches) is being operated. The system is
re-activated when the cruise control switch is turned OFF and then turn ON again after the can-
cellation signal generating switch has been returned to its released position.
2) The cruise control system becomes deactivated if the ignition switch is turned ON with any of
the cruise control switches (including the main switch) in the ON position. The system deactivating
function is retained until the main switch is turned OFF.
2. ABNORMALITIES IN ELECTRIC CIRCUITS

The cruise control system is deactivated and the set speed is also canceled if any of the following
abnormalities occurs in the system’s electric circuits.
The system deactivation function is retained until the ignition switch is turned OFF.
1) The stepping motor terminal is grounded; or the stepping motor drive circuit is broken due to
a short- or open-circuit.
2) The stepping motor clutch drive circuit is shorted.
3) Vehicle speed variation in a 350 ms period exceeds flOkm/h.
4) Fusion has occurred in an internal relay and is detected while the vehicle is running with the
cruise control deactivated.
5) The cruise control module becomes inoperative or its operation is faulty.
6) There is discrepancy between the values stored in the two RAMSof the control module.
7) An abnormality is detected as a result of the self-diagnosis performed after turning ON of the
ignition switch.
3. ABNORMALITIES IN STEPPING MOTOR

The cruise control system is deactivated if either of the following abnormalities occurs in the step-
ping motor.
1) The stepping motor does not operate properly.
2) The stepping motor is energized for unduly long period and too frequently.
When the system is deactivated, it cannot be reactivated for 2 - 20 minutes after detection of the
abnormal condition.
cc-10
ENGINE2 SECTION

of SUBARU vehicles.
for maintenance, disassembling, reas-

approval.
FUEL INJECTION (FUEL SYSTEMS)
FU(D0HC TURB0)m
Page
2 . Throttle Body ............................................................................................. 14
3. Intake Manifold .......................................................................................... 15
4 . Engine Coolant Temperature Sensor ........................................................ 29
5. Crankshaft Position Sensor ....................................................................... 30
6 . Camshaft Position Sensor ......................................................................... 31
7 . Knock Sensor ............................................................................................ 32
8. Throttle Position Sensor ............................................................................ 33
9 . Mass Air Flow and Intake Air Temperature Sensor .................................. 34
10. Pressure Sensor ....................................................................................... 35
11. Idle Air Control Solenoid Valve ................................................................. 36
12. Fuel Injector .............................................................................................. 37
13. Tumble Generator Valve Assembly .......................................................... 40
14. Wastegate Control Solenoid Valve ........................................................... 41
15. Front Oxygen (NF) Sensor ....................................................................... 42
16. Rear Oxygen Sensor ................................................................................. 44
17. Exhaust Temperature Sensor ................................................................... 46
18. Engine Control Module.............................................................................. 47
19. Main Relay ................................................................................................ 48
20 . Fuel Pump Relay ....................................................................................... 49
21 . Fuel Pump Controller ................................................................................ 50
22 . Fuel ........................................................................................................... 51
23 . Fuel Tank .................................................................................................. 52
24 . Fuel Filler Pipe .......................................................................................... 55
25 . Fuel Pump ................................................................................................. 60
26 . Fuel Level Sensor ..................................................................................... 62
27 . Fuel Sub Level Sensor .............................................................................. 63
28 . Fuel Filter .................................................................................................. 65
29 . Fuel Cut Valve ........................................................................................... 66
30. Fuel Damper Valve ................................................................................... 67
31 . Fuel Deliverv. Return and Evaporation Lines ............................................
a . 68
32 . Fuel System Trouble in General ............................................................... 71
GENERAL DESCRIPTION
A: SPECIFICATIONS
Capacity 60 8 (15.9 US gal, 13.2 Imp gal)
Location Under rear seat
Type Impeller
Shutoff discharge pressure 450 - 677 kPa (4.59 - 6.9 kg/cm2, 65.27 - 98.2 psi)
Fuel pump
More than 130 8 (34.3 US gal, 28.6 Imp gal)/h
Discharge flow
[12 V at 300 kPa (3.06 kg/cm2,43.5 psi)]
Fuel filter Cartridge type
FU(D0HC TURBO)-2
GENERAL DESCRIPTION
FU(D0HC TURBO)-3
GENERAL DESCRIPTION
B: COMPONENT
1. INTAKE MANIFOLD
EN1135
FU(D0HC TURBO)-4
GENERAL DESCRIPTION
Fuel pipe ASSY Accelerator cable bracket (25) Fuel pipe protector LH
Fuel hose Fuel injector (26) Nipple
Clip Insulator
,
Purge control solenoid valve Fuel injector pipe Tightening torque: N.m (kgf-m, ft-lb)
Vacuum hose Pressure regulator T1: 4.9 (0.5, 3.6)
Vacuum control hose Pressure regulator hose T2: 6.4 (0.65, 4.7)
Purge valve Fuel pipe protector RH T3: 8.25 (0.84, 6.1)
Purge hose Blow-by hose stay T4: 16 (1.6, 11.8)
Intake manifold gasket Intake manifold T5: 17(1.73, 12.5)
Guide pin Solenoid valve cover T6: 19 (1.94, 13.7)
Tumble generator valve ASSY Solenoid valve cover stay T7: 25 (2.5, 18.1)
Tumble generator valve gasket Wastegate control solenoid valve
ASSY
FU(D0HC TURB0)-5
GENERAL DESCRIPTION
2. AIR INTAKE SYSTEM
EN113
~
(1) Gasket (5) Pressure sensor Tightening torque: N.m (kgf-m, ft-lb)
(2) Throttle position sensor (6) Gasket T1: 1.6 (0.16, 1.2)
(3) Idle air control solenoid valve (7) O-ring T2: 2.8 (0.29, 2.1)
(4) Throttle body T3: 22 (2.2, 15.9)
FU(D0HC TURBO)-6
GENERAL DESCRIPTION
3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS
(1) Crankshaft position sensor (3) Camshaft position sensor Tightening torque: N.m (kgf-m, ft-lb)
(2) Knock sensor T1: 6.4 (0.65, 4.7)
T2: 24 (2.4, 17.4)
FU(D0HC TURBO)-7
GENERAL DESCRIPTION
4. FUELTANK
EN1119
FU(D0HC TURBO)-8
I
GENERAL DESCRIPTION
Heat shield cover Evaporation hose C Fuel sub level sensor gasket
Fuel tank band Evaporation hose B Jet pump filter
Protector LH Evaporation hose D Fuel sub level sensor
Protector RH Evaporation hose E Protector cover
Fuel tank Evaporation pipe ASSY Vent valve hose
Canister hose A Retainer Vent valve
Clamp Quick connector Fuel tank pressure sensor
Fuel pump gasket Jet pump hose A Fuel tank pressure sensor hose
Fuel pump ASSY Fuel return hose A Vent valve gasket
Fuel cut valve gasket Fuel pipe ASSY
Fuel cut valve Jet pump hose B Tightening torque: N-m (kgf-m, ft-lb)
Evaporation hose A Fuel return hose B T1: 4.4 (0.45, 3.3)
Clip Evaporation hose F T2: 7.4 (0.75, 5.4)
Joint pipe Evaporation hose G T3: 33 (3.4, 25)
FU(D0HC TURBO)-9
GENERAL DESCRIPTION
FUEL INJECTION(FUEL SYSTEMS)
5. FUELLINE
EN1120
FU(D0HC TURBO)-I 0
GENERAL DESCRIPTION
Clamp Evaporation hose J (25) Canister holder

Fuel delivery hose A Evaporation hose K (26) Evaporation hose L
Fuel filter bracket Joint pipe (27) Pressure control solenoid valve
Fuel filter holder Canister hose A (28) Canister hose B
Fuel filter cup Air filter hose A (29) Canister
Fuel filter Drain valve hose (30) Fuel pipe ASSY
Evaporation hose Air filter hose B
Clip Drain filter Tightening torque: N-m (kgf-m, ft-lb)
Fuel delivery hose B Drain valve T1: 25 (2.5, 18.1)
Fuel return hose A Canister upper bracket T2: 23 (2.3, 16.6)
Fuel return hose B Cushion rubber T3: 1.25 (0.13, 0.94)
Fuel damper Canister lower bracket
FU(D0HC TURBO)-I 1
GENERAL DESCRIPTION
6. FUEL FILLER PIPE
EN1121
(1) Fuel filter pipe ASSY (8) Filler pipe packing (15) Fuel filler pipe protector
(2) Evaporation hose holder (9) Filler ring
-
(3) Clamp (10) Filler cap Tightening torque: N.m (kgf-m, ft-lb)
(4) Clamp (11) Shut valve T1: 4.4 (0.45, 3.3)
(5) Evaporation hose A (12) Evaporation hose 6 T2: 7.5 (0.76, 5.5)
(6) Evaporation pipe (13) Evaporation hose C
(7) Evaporation pipe holder (14) Joint pipe
FU(D0HC TURBO)-I 2
GENERAL DESCRIPTION
C: CAUTION Be careful not to burn your hands, because each

Wear working clothing, including a cap, protec- part On the vehicle is hot after running.
tive goggles, and protective shoes during opera- Be sure to tighten fasteners including bolts and
.
tion.
Remove contamination including dirt and corro-
nuts to the specified torque.
Place shop jacks or Safety stands at the specified
.
sion before removal, installation or disassembly.
Keep the disassembled parts in order and pro-
tect them from dust or dirt.
points.
Before disconnecting electrical COntleCtOrS Of
sensors or units, be sure to disconnect negative
Before removal, installation or disassembly, be terminal from battery.
sure to clarify the failure. Avoid unnecessary re- Place “NO FIRE” signs near the working area.
moval, installation, disassembly, and replacement. Be careful not to Spill fuel on the floor-
D: PREPARATION TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
24082AA150 CARTRIDGE Troubleshooting for electrical system.
(Newly adopted
tool)
B2M3876
22771AA030 SELECT MONI- Troubleshooting for electrical systems.
TOR KIT English: 22771AA030 (Without printer)
German: 22771AA070 (Without printer)
French: 22771AA080 (Without printer)
Spanish: 22771AA090 (Without printer)
FU(D0HC TURBO)-13
THROTTLE BODY
2. Throttle Body 5) Disconnect the engine coolant hoses from the

throttle body.
A: REMOVAL
1) Disconnect the battery ground cable.
6) Remove the bolts which secure the throttle body

to intake manifold.
2) Remove the intercooler. <Ref. to IN(D0HC
TURBO)-10, REMOVAL, Intercooler.>
6: INSTALLATION
3) Disconnect the connector from the throttle posi- Install in the reverse order of removal.
tion sensor (A) and idle air cotrol solenoid valve (B) NOTE:
and pressure sensor (C). Always use a new gasket.
Tightening torque:
22 N-m (2.2 kgf-m, 15.9 M b )
4) Disconnect the accelerator cable.

// EN0785
FU(D0HC TURBO)-14
a
INTAKE MANIFOLD
11) Remove the power steering pump.

3. Intake Manifold (1) Remove the front side V-belt.
A: REMOVAL <Ref. to ME(D0HC TURBO)-44, REMOVAL, V-
1) Release the fuel pressure. <Ref. to FU(D0HC belt.>
TURBO)-51, RELEASING OF FUEL PRESSURE, (2) Disconnect the power steering switch con-
OPERATION, Fuel.> nector.
(3) Remove the bolts which secure the power

3) Lift up the vehicle. steering pipe brackets to the intake manifold.
4) Remove the under cover. NOTE:
5) Drain the coolant about 3.0 0 (3.2 US qt, 2.6 Do not disconnect the power steering hose.
Imp qt).
(4) Remove the bolts which secure the power

6) Remove the air cleaner upper cover and air in- steering pump bracket.
take boot. <Ref. to IN(D0HC TURBO)-7, REMOV-
AL, Air Cleaner.>
7) Remove the air cleaner element.
9) Disconnect the accelerator cable.
10) Remove the coolant filler tank. <Ref. to CO-51,

REMOVAL, Coolant Filler Tank.>
FU(D0HC TURBO)-15
INTAKE MANIFOLD
(5) Remove the power steering tank from the 14) Disconnect the brake booster hose.
bracket by pulling it upward.
(6) Place the power steering pump on the right

side wheel apron.
duct.
- EN0204
15) Disconnect the pressure hose from the intake
16) Disconnect the engine harness connectors

12) Disconnect the emission hose from the PCV from the bulkhead harness connectors.
valve.
13) Disconnect the engine coolant hoses from the

throttle body.
FU(D0HC TURBO)-16
INTAKE MANIFOLD
17) Disconnect the connectors from the engine 21) Disconnect the engine harness fixed by clip (A)
coolant temperature sensor (A), oil pressure switch from the bracket.
(B) and crankshaft position sensor (C).
\\ I II
(6)
S2M2256A
v . 22) Disconnect the fuel delivery hose, return hose
18) Disconnect the knock sensor connector. and evaporation hose.
WARNING:
Catch the fuel from hoses in a container.
S2M1613
19) Disconnect the connector from the camshaft

position sensor.
23) Remove the bolts which secure the intake man-
ifold to the cylinder heads.
20) Disconnect the connector from the ignition coil.
24) Remove the intake manifold.
EN0854
FU(D0HC TURBO)-17
INTAKE MANIFOLD
B: INSTALLATION 4) Connect the connector to the knock sensor.

1) Install the intake manifold onto cylinder heads.
NOTE:
Always use new gaskets.
Tightening torque:
25 N-m (2.5 kgf-m, 18.1 ft-16)
S2M1613
5) Connect the connector to the camshaft position

sensor.
2) Connect the fuel delivery hose, return hose, and

evaporation hose.
6) Connect the connector to the ignition coil.
3) Connect the connector to the oil pressure switch

(B), crankshaft position sensor (C) and engine
coolant temperature sensor (A).
EN0854 I
7) Connect the engine harness with clip (A) to the
bracket.
FU(D0HC TURBO)-I8
INTAKE MANIFOLD
8) Connect the engine harness connector to the 11) Connect the emission hose to the PCV valve.
bulkhead harness connectors.
12) Connect the pressure hose to the intake duct.
EN0787
9) Connect the brake booster vacuum hose. 13) Install the power steering pump.
(1) Install the power steering tank on the brack-
et.
EN0204
10) Connect the engine coolant hoses to the throt- n/

EN0361
tle body.
(2) Connect the connector to the power steering
pump switch.
FU(D0HC TURBO)-19
INTAKE MANIFOLD
(3) Install the power steering pump, and tighten 19) Connect the connector to the fuel pump relay.
the bolts.
Tightening torque:
22 N.m (2.2 kgf-m, 15.9 ff-16)
20) Connect the battery ground cable.

22) Install the under cover.
23) Fill the coolant. <Ref. to CO-25, FILLING OF
(4) Install the power steering pipe brackets on
COOLANT, Engine Coolant.>
the right side intake manifold.
(5) Install the front side V-belt.

<Ref. to ME(D0HC TURBO)-44, REMOVAL, V-
belt.>
14) Install the cooler filler tank. <Ref. to CO-51 IN-
STALLATION, Coolant Filler Tank.>
15) Connect the accelerator cable.
16) Install the intercooler. <Ref. to IN(D0HC TUR-

BO)-11, INSTALLATION, Intercooler.>
17) Install the air cleaner element.
18) Install the air cleaner upper cover and air intake
duct as a unit. <Ref. to IN(D0HC TURBO)-7, IN-
STALLATION, Air Cleaner.>
FU(D0HC TURBO)-20
INTAKE MANIFOLD
C: DISASSEMBLY 4) Disconnect the connector from the throttle posi-

1) Remove the fuel pipe protector LH. tion sensor (A), idle air control solenoid valve (B)
and pressure sensor (C).
5) Disconnect the engine harness fixed by clip (D)
from the intake manifold.
2) Remove the fuel pipe protector RH.
6) Remove the throttle body from the intake mani-

fold.
3) Remove the engine ground terminal from the in-

take manifold.
// . EN0785
7) Disconnect the connector from the fuel injector.
EN0795
I I EN0798
8) Disconnect the connector from the tumble gen-
erator valve actuator.
\ J EN079E
FU(D0HC TURBO)-21
INTAKE MANIFOLD
9) Disconnect the connector from the tumble gen- 13) Disconnect the evaporation hoses from the
erator valve sensor. purge valve.
I EN0800 ---.
I \ \ \ EN0804
10) Disconnect the connector from the purge con- 14) Remove the two bolts which hold the fuel pipes
trol solenoid valve. on the left side of intake manifold.
11) Remove the purge control solenoid valve.
12) Disconnect the evaporation hose from the in-

take manifold.
EN0803
FU(D0HC TURBO)-22
INTAKE MANIFOLD
15) Remove the bolt which hold the fuel injector 16) Remove the fuel injector.
pipe onto intake manifold.
LH SIDE
EN0806 I 17) Remove the harness bracket which hold the

engine harness onto intake manifold.
I
I ’ EN0807
RH SIDE 18) Remove the engine harness from the intake

manifold.
19) Loosen the clamp which holds the front left side
fuel hose to injector pipe and remove the pipe from
clamp.
I EN0808
I II I I\ EN0812
20) Remove the fuel injector pipe LH.

21) Remove the bolts which installs the fuel pipe on
intake manifold.
FU(D0HC TURBO)-23
INTAKE MANIFOLD
22) Remove the fuel pipe assembly and pressure 2) Install the air intake duct to the intake manifold.
regulator, from the intake manifold. Tightening torque:
23) Remove the intake duct from the intake mani- 19 N-m (1.94 kgf-m, 13.7 ft-lb)
fold.
3) Install the fuel pipe assembly and pressure reg-

24) Remove the tumble generator valve assembly
ulator, to the intake manifold.
from the intake manifold.
7 Tightening torque:
4.9 N.m (0.5 kgf-m, 3.6 ft-lb)
EN0815
D: ASSEMBLY
NOTE: 4) Install the fuel injector pipe LH.
5 ) Connect the left side fuel hose to injector pipe,
1) Install the tumble generator valve assembly to and tighten the clamp screw.
the intake manifold.
Tightening torque:
8.25 N.m (0.84 kgf-m, 6.08 ft-lb)
/I I I\ EN081;
6) Install the engine harness to the intake manifold.
FU(D0HC TURBO)-24
m
INTAKE MANIFOLD
_ _ _ _ ~
7) Install the harness bracket which hold the engine

- 9). Tighten
- the bolt which install the fuel injector
harness onto intake manifold. pipe onto intake manifold.
Tightening torque: Tightening torque:
19 N.m (1.94 kgf-m, 13.7 ft-lb) 19 N.m (1.94 kgf-m, 13.7 fi-lb)
LH SIDE
EN0806
8) Install the fuel injector
I
ENO~IO EN0807
RH SIDE
FU(D0HC TURBO)-25
INTAKE MANIFOLD
10) Tighten the two bolts which install the fuel pipes 12) Connect the evaporation hose to the intake
on the left side of intake manifold. manifold.
Tightening torque:
4.9 N-m (0.5 kgf-m, 3.6 ff-lb)
EN080:
13) Install the purge control solenoid valve.

Tightening torque:
11) Connect the evaporation hoses to the purge 16 N-m (1.6 kgf-m, 11.8 ff-lb)
valve.
CAUTION:
Carefully connect the evaporation hoses.
14) Connect the hoses to the purge control sole-

noid valve.
CAUTION:
Carefully connect the evaporation hoses.
(D)---
lJ EN0816
(A) To fuel pipe ASSY

(B) To intake duct (A) To intake manifold
(C) To purge control solenoid valve (B) To purge valve
(D) To intake manifold
FU(D0HC TURBO)-26
INTAKE MANIFOLD
15) Connect the connector to the purge control so- 19) Install the throttle body to the intake manifold.
lenoid valve. NOTE:
Replace gasket with a new one.
Tightening torque:
22 N-m (2.2 kgf-m, 15.9 fl-lb)
16) Connect the connector to the tumble generator

valve sensor.
EN0785
20) Connect the connector to the throttle position

sensor (A), idle air control solenoid valve (B) and
pressure sensor (C).
21) Connect the engine harness with clip (D) to the
intake manifold.
\/ /
EN0800
17) Connect the connector to the tumble generator

valve actuator.
(D, ( D ) S2M2249A
\ J EN0799
18) Connect the connector to the fuel injector.
I I I EN0798
FU(D0HC TURBO)-27
INTAKE MANIFOLD
22) Install the engine ground terminal to the intake E: lNSPECTlON
manifold. Make sure the fuel pipe and fuel hoses are not
Tightening torque: cracked and that connections are tight.
79 N.m (7.94 kgf-m, 73.7 ft-lb)
23) Install the fuel pipe protector RH.

Tightening torque:
79 N-m (7.94 kgf-m, 73.7 ft-lb)
24) Install the fuel pipe protector LH.

Tightening torque:
79 N.m (7.94 kgf-m, 73.7 ft-lb)
FU(D0HC TURBO)-28
ENGINE COOLANT TEMPERATURE SENSOR
4. Engine Coolant Temperature B: INSTALLATION

Install in the reverse order of removal.
Sensor
Tighfening torque:
A: REMOVAL 18 N.m (1.8 kgf-m, 13.3 fi-lb)
2) Remove the generator <Ref. to SC-13, REMOV-

AL, Generator.>
3) Disconnect the connector from the engine cool-
ant temperature sensor.
4) Remove the engine coolant temperature sensor.
FU(D0HC TURBO)-29
I CRANKSHAFT POSITION SENSOR
5. Crankshaft Position Sensor B: INSTALLATION

A: REMOVAL
Tightening torque:
T: 6.4 N.m (0.65 kgf-m, 4.7 ff-lb)
2) Remove the bolt which install the crankshaft po-

sition sensor to cylinder block.
3) Remove the crankshaft position sensor, and dis-

connect the connector from it.
FU(D0HC TURBO)-30
CAMSHAFT POSITION SENSOR
6. Camshaft Position Sensor B: INSTALLATION

A: REMOVAL Tightening torque:
T: 6.4 Nom(0.65 kgf-m, 4.7 ft-lb)
\ \ 1 IG2M0417
2) Disconnect the connector from the camshaft po-
sition sensor.
3) Remove the hcamshaft position sensor from the

camshaft support LH
FU(D0HC TURBO)-31
KNOCK SENSOR
7. Knock Sensor B: INSTALLATION

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

3) Disconnect the knock sensor connector.
~~
(A) Front side
2) Connect the knock sensor connector
4) Remove the knock sensor from the cylinder

block.

FU(D0HC TURBO)-32
THROTTLE POSITION SENSOR
8. Throttle Position Sensor B: INSTALLATION

A: REMOVAL
1) Disconnect the battery ground cable. Tightening torque:
1.6 N.m (0.16 kgf-m, 1.2 ft-lb)
0
3) Disconnect the connector from the throttle posi-
tion sensor.
4) Remove the throttle position sensor holding

screws, and remove it.
FU(D0HC TURBO)-33
MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR
9. Mass Air Flow and Intake Air B: INSTALLATION

Temperature Sensor Install in the reverse order of removal.
Tightening torque:
A: REMOVAL 7.5 N-m (0.76 kgf-m, 5.5 ft-lb)
2) Disconnect the connector mass air flow and in-

take air temperature sensor.
3) Remove the mass air flow and intake air temper-
ature sensor.
FU(D0HC TURBO)-34
#a
PRESSURE SENSOR
1O.Pressure Sensor B: INSTALLATION

A: REMOVAL NOTE:
1) Disconnect the battery ground cable. Replace the O-ring for the pressure sensor with
new ones.
Tightening torque:
1.6 N-m (0.16 kgf-m, 1.2 ft-16)
2) Remove the idle air control solenoid valve. <Ref.

to FU(D0HC TURBO)-36, REMOVAL, Idle Air
Control Solenoid Valve.>
3) Disconnect the connectors from pressure sen-
sor.
4) Remove the pressure sensor from the throttle

body.
FU(D0HC TURBO)-35
IDLE AIR CONTROL SOLENOID VALVE
11.Idle Air Control Solenoid B: INSTALLATION

Valve
NOTE:
A: REMOVAL Always use a new gasket.
Tightening torque:
2.8 N-m (0.29 kgf-m, 2.1 fWb)
2) Disconnect the connector from the idle air con- I
trol solenoid valve.
EN0822
3) Remove the idle air control solenoid valve from

the throttle body.
4) Remove the gasket from throttle body.
FU(DOHC TURB0)-36
FUEL INJECTOR
12.Fuel Injector 5) Remove the fuel injector while lifting up the fuel
injector pipe.
A: REMOVAL
1. RH SIDE
1) Remove the intake manifold. <Ref. to FU(D0HC
TURBO)-15, REMOVAL, Intake Manifold.>
2) Remove the fuel pipe protector RH.
2. LH SIDE
2) Remove the fuel pipe protector LH.
I I

I I I EN0798 1
4) Remove the bolts which hold the injector pipe to
intake manifold.
n n
I I EN0798
EN0808
FU(D0HC TURBO)-37
FUEL INJECTOR
4) Remove the bolts which hold the injector pipe to B: INSTALLATION
intake manifold.
1. RH SIDE
NOTE:
Replace the O-ring and insulators with new ones.
(A) O-ring
(B) Fuel injector
(C) insulator
I
Tightening torque:
EN0807
/
J
19 N-m (1.94 kgf-m, 13.7 ff-lb)
I EN0806 I EN0808
5) Remove the fuel injector while lifting up the fuel Tightening torque:
injector pipe. 19 N.m (1.94 kgf-m, 13.7 ff-lb)
EN0824 EN0809
FU(D0HC TURBO)-38
FUEL INJECTOR

19 N-m (1.94 kgf-m, 13.7 ff-lb) 19 N.m (1.94 kgf-m, 13.7 ft-lb)
EN080E
2. LH SIDE Tightening torque:

19 N.m (1.94 kgf-m, 13.7 ft-lb)
NOTE:
Replace the O-ring and insulators with new ones.
I B
I
EN080:
Tightening torque:
19 N.m (1.94 kgf-m, 13.7 ft-lb)
(A) O-ring
(B) Fuel injector
(C) Insulator
Tightening torque:
4.9 N.m (0.5 kgf-m, 3.6 ff-lb)
FU(D0HC TURBO)-39
TUMBLE GENERATOR VALVE ASSEMBLY
13.Tumble Generator Valve As- 6) Remove the tumble generator valve body from
the intake manifold.
sembly
A: REMOVAL
B: INSTALLATION
NOTE:
2) Remove the intake manifold. <Ref. to FU(D0HC Always use new gaskets.
TURBO)-I 5, REMOVAL, Intake Manifold.>
Tightening torque:
erator valve sensor. 8.25 N.m (0.84 kgf-m, 6.1 ft-lb)
EN0815
EN0800

erator valve actuator.
\ J EN0799
5) Remove the fuel injector. <Ref. to FU(D0HC

TURBO)-37, REMOVAL, Fuel Injector.>
FU(D0HC TURBO)-40
~
WASTEGATE CONTROL SOLENOID VALVE

14.Wastegate Control Solenoid 5) Remove the wastegate control solenoid valve

from the bracket
Valve
A: REMOVAL
B: INSTALLATION
Tightening torque:
2) Remove the solenoid valve cover. 6.4 N.m (0.65 kgf-m, 4.7 ff-lb)
I
I
/ EN0830
3) Disconnect the connector (A) from the waste-

gate control solenoid valve.
4) Disconnect the pressure hoses (B) from the
wastegate control solenoid valve.
I
FU(D0HC TURBO)-41
FRONT OXYGEN (NF)SENSOR
15.Front Oxygen (NF)Sensor 6) Lift-up the vehicle.

7) Remove the service hole cover
A: REMOVAL
I1 EN0832
8) Apply SUBARU CRC or its equivalent to the

threaded portion of front oxygen (NF)sensor, and
2) Remove the solenoid valve cover leave it for one minute or more.
SUBARU CRC (Part No. 004301003)
9) Remove the front oxygen (NF)sensor.
CAUTION:
When removing the oxygen (NF)sensor, wait
until exhaust pipe cools, otherwise it will dam-
age exhaust pipe.
3) Disconnect the connector from the front oxygen

(NF)sensor.
4) Disconnect the engine harness fixed by clip (A)

from the bracket (6).
5 ) Remove the front right side wheel.
FU(D0HC TURBO)-42
FRONT OXYGEN (NF) SENSOR
B: INSTALLATION 7) Connect the connector of front oxygen (NF)sen-

sor.
1) Before installing front oxygen (NF)sensor, apply
the anti-seize compound only to the threaded por-
tion of front oxygen (NF)sensor to make the next
removal easier.
Anti-seize compound:
SS-30 by JET LUBE
CAUTION:
Never apply anti-seize compound to protector
of front oxygen (NF) sensor.
2) Install the front oxygen (NF) sensor.
Tightening torque:
8) Install the solenoid valve cover.
21N.m (2.1 kgf-m, 15.2 ff-lb)
I
I I
3) Install the service hole cover.
n
4) Lower the vehicle.
5) Install the front right side wheel.
I
EN0832
6) Connect the engine harness with clip (A) to the

bracket (B).
FU(D0HC TURBO)-43
REAR OXYGEN SENSOR
16.Rear Oxygen Sensor 6) Remove the rear oxygen sensor.

CAUTION:
A: REMOVAL When removing the oxygen sensor, wait until
1) Disconnect the battery ground cable. exhaust pipe cools, otherwise it will damage ex-
haust pipe.
2) Lift-up the vehicle.

3) Disconnect the connector from the rear oxygen B: INSTALLATION
sensor.
1) Before installing rear oxygen sensor, apply the
anti-seize compound only to the threaded portion of
rear oxygen sensor to make the next removal eas-
ier.
CAUTION:
of rear oxygen sensor.
Anti-seize compound:
SS-30 by JET LUBE
2) Install the rear oxygen sensor.
Tightening torque:
4) Remove the clip by pulling out from the upper
side of crossmember. 21 N.m (2.1 kgf-m, 15.2 W b )
I I S2M2254
5) Apply SUBARU CRC or its equivalent to the 3) Connect the connector to the rear oxygen sen-
threaded portion of rear oxygen sensor, and leave sor.
it for one minute or more.
FU(D0HC TURBO)-44
REAR OXYGEN SENSOR
4) Connect the clip to the crossmember.
S2M2254

FU(D0HC TURBO)-45
EXHAUST TEMPERATURE SENSOR
17.Exhaust Temperature Sensor B: INSTALLATION

1) Before installing exhaust temperature sensor,
A: REMOVAL apply the anti-seize compound only to the threaded
1) Disconnect the battery ground cable. portion of rear oxygen sensor to make the next re-
moval easier.
CAUTION:
of exhaust temperature sensor.
An ti-seize compound:
SS-30 by JET LUBE
2 ) Install the exhaust temperature sensor.
NOTE:
Align the marking (A) of exhaust temperature sen-
sor to the marking (B) of joint pipe, and tighten the
2) Remove the joint pipe. <Ref. to EX(D0HC TUR- screws.
BO)-12, REMOVAL, Joint Pipe.>
3) Apply SUBARU CRC or its equivalent to the Tightening torque:
threaded portion of exhaust temperature sensor, 21 N-m (2.1 kgf-m, 15.2 ft-lb)
and leave it for one minute or more.
4) Remove the exhaust temperature sensor.
CAUTION:
When removing the oxygen sensor, wait until
exhaust pipe cools, otherwise it will damage ex-
haust pipe.
S2M2255A
3) Install the joint pipe <Ref. to EX(D0HC TURBO)-

12, INSTALLATION, Joint Pipe.>.
FU(D0HC TURB0)-46
I
ENGINE CONTROL MODULE
18.Engine Control Module B: INSTALLATION

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

side.
<Ref. to El-46, REMOVAL, Lower Inner Trim.>
3) Detach the floor mat of the front passenger seat.
4) Remove the protect cover.
I EN118E
5) Remove the nuts (A) which hold ECM to the

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

the ECM.
FU(DOHC TURB0)-47
MAIN RELAY
19.Main Relay
A: REMOVAL
2) Remove the passenger’s side front side sill cov-

er.
3) Remove the bolt which holds the main relay
bracket on the body.
4) Disconnect the connectors from the main relay.
B: INSTALLATION
FU(D0HC TURBO)-48
FUEL PUMP RELAY
2O.Fuel Pump Relay

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

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

bracket.
B: INSTALLATION
FU(D0HC TURBO)-49
FUEL PUMP CONTROLLER
21 .Fuel Pump Controller

A: REMOVAL
2) Remove the rear quarter trim. <Ref. to El-47,

REMOVAL, Rear Quarter Trim.>
3) Disconnect the connector from the fuel pump
control unit.
4) Remove the fuel pump control unit.
B: INSTALLATION
FU(D0HC TURBO)-50
FUEL
22.Fuel 3) Lift-up the vehicle.

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

Tightening torquer
26 N-m (2.65 kgf-m, 19.2 ff-lb)
2) Start the engine and run it until it stalls.

3) After the engine stalls, crank it for five more sec-
onds.
4) Turn the ignition switch to OFF.
2. DRAINING FUEL
WARNING:
1) Set the vehicle on the lift.
FU(D0HC TURBO)-51
FUEL TANK
23.Fuel Tank 9) Disconnect the connector from the pressure con-

A: REMOVAL 10) Disconnect the connector from the drain valve.
WARNING:
2) Release the fuel pressure. <Ref. to FU(D0HC
TURBO)-51, RELEASING OF FUEL PRESSURE,
OPERATION, Fuel.>
3) Drain the fuel from the fuel tank. <Ref. to
FU(D0HC TURBO)-51, DRAINING FUEL, OPER-
ATION, Fuel.> B2M174:
4) Remove the rear seat.
5) Disconnect the connector (A) of fuel tank cord to 11) Loosen the clamp and disconnect the fuel filler
the rear harness. hose (A) and air vent hose (B) from fuel filler pipe
6) Push the grommet (B) which holds the fuel tank and air vent pipe.
cord on floor panel into under the body.
S2M0193A
12) Move the clips, and disconnect the quick con-

7) Remove the rear crossmember. <Ref. to RS-19, nector. <Ref. to FU(D0HC TURBO)-68, REMOV-
REMOVAL, Rear Crossmember.> AL, Fuel Delivery, Return and Evaporation Lines.>
8) Move the clamp, and disconnect the evaporation 13) Disconnect the fuel hoses.
hose from canister.
\ I I I
S2M0949j
FU(D0HC TURBO)-52
FUEL TANK
14) Support the fuel tank with transmission jack, re- 4) Connect the fuel hoses, and hold them with clips
move the bolts from bands and dismount the fuel and quick connector. <Ref. to FU(D0HC TURBO)-
tank from vehicle. 69, INSTALLATION, Fuel Delivery, Return and
WARNING: Evaporation Lines.>
A helper is required to perform this work.
5) Connect the connector to the drain valve.

B: INSTALLATION
1) Support the fuel tank with transmission jack and
push the fuel tank harness into the access hole with
grommet.
2) Set the fuel tank and temporarily tighten the bolts
of fuel tank bands.
WARNING:
A helper is required to perform this work.
02M 1743
6) Connect the connector to the pressure control

solenoid valve.
7) Connect the evaporation hose to the canister,
and hold them with clamp.
3) Connect the fuel filler hose and air vent hose.
\ I / I
S2M0949A
S2M0193A
FU(D0HC TURBO)-53
FUEL TANK
8) Tighten the band mounting bolts. C: INSPECTION

Tightening torque: 1) Make sure there are no cracks, holes, or other
33 N-m (3.4 kgf-m, 25 ft-lb) damage on the fuel tank.
2) Make sure that the fuel hoses and fuel pipes are
not cracked and that connections are tight.
2M2246
9) Install the rear crossmember. <Ref. to RS-19,

INSTALLATION, Rear Crossmember.>
10) Connect the connector (A) to the fuel tank cord
and plug the service hole with gromment (B).
EN053i
11) Set the rear seat and floor mat.

12) Connect the connector to the fuel pump relay.
FU(D0HC TURBO)-54
FUEL FILLER PIPE
24.Fuel Filler Pipe 8) Drain the fuel from fuel tank. Set a container un-
der the vehicle and remove the drain plug from fuel
A: REMOVAL tank.
WARNING:
OPERATION, Fuel.>
2) Open the fuel filler flap lid and remove the filler
cap.
9) Tighten the fuel drain plug and then install the

front right side tank cover.
Tightening torque:
26 N-m (2.65 kgf-m, 19.2 ff-lb)
4) Remove the screws holding packing in place.
IO) Remove the fuel filler pipe protector.
’ EN0542

6) Remove the rear right side wheel nuts.
7) Remove the rear right side wheel.
EN0544
11) Separate the evaporation hoses from the clip of

fuel filler pipe.
FU(D0HC TURBO)-55
I
FUEL FILLER PIPE
12) Disconnect the evaporation hoses from the 17) Remove the air vent pipe together with clip from
pipes. the body.
13) Remove the bolts which hold fuel filler pipe B: INSTA LLATlON
bracket on the body. 1) t Ad the fuel filler flap open.
I
2) Set the fuel saucer (A) -with rubber packing (C)
and insert the fuel filler pipe into the hole from the
inner side of apron.
EN1124
14) Loosen the clamp and separate the fuel filler

hose (A) from fuel filler pipe.
15) Move the clip and separate the evaporation
hose (B). 3) Align the holes in fuel filler pipe neck and set the
cup (B), and tighten the screws.
NOTE:
If edges of rubber packing are folded toward the in-
side, straighten it with a screwdriver.
16) Remove the fuel filler pipe to under side of the

vehicle.
FU(D0HC TURBO)-56
FUEL FILLER PIPE
4) Install the evaporation pipes. 7) Insert the air vent hose approximately 25 to 30
mm (0.98 to 1.18 in) into the lower end of air vent
pipe and hold clip.
L = 27.5e.5 mm (1.083fo.098 in)
5) Connect the evaporation hose to pipes.

L
B2M1195A
(1) Hose
(2) Clip
(3) Pipe
8) Tighten the bolt which holds fuel filler pipe brack-

et on the body.
Tightening torque:
Ill EN1123
7.4 N.m (0.75 kgf-m, 5.4 ft-lb)
6) Insert the fuel filler hose (A) approximately 35 to
40 mm (1.38 to 1.57 in) over the lower end of fuel
filler pipe and tighten the clamp.
CAUTION:
Do not allow clips to touch air vent hose (B) and
rear suspension crossmember.
EN1124
9) Tighten the bolts which hold evaporation hoses

onto the clip of fuel filler pipe.
FU(DOHC TURBO)-57
FUEL FILLER PIPE
10) Install the fuel filler pipe protector. C: DISASSEMBLY

1) Move the clip, and disconnect the evaporation
hose from joint pipe.
EN0544
I
11) Install the rear right wheel.

EN112E
2) Remove the bolt which installs the joint pipe on

fuel filler pipe.

13) Tighten the wheel nuts.
14) Connect the connector to the fuel pump relay.
3) Disconnect the evaporation hose from the fuel
filler pipe.
15) Connect the battery ground terminal.
4) Remove the shut valve from the fuel filler pipe.

<Ref. to EC(D0HC TURBO)-16, REMOVAL, Shut
Valve.>
FU(D0HC TURBO)-58
FUEL FILLER PIPE
D: ASSEMBLY
1) Install the shut valve on the fuel filler pipe. <Ref.
to EC(D0HC TURBO)-16, INSTALLATION, Shut
Valve.>
2) Connect the evaporation hose to the fuel filler
pipe.
3) Connect the evaporation hose to the evaporation

pipe.
4) Install the evaporation pipe to the fuel filler pipe.
FU(D0HC TURBO)-59
FUEL PUMP
25.Fuel Pump 6) Tighten the fuel drain plug.

Tightening torque:
A: REMOVAL 26 N.m (2.65 kgf-m, 19.2 ff-lb)
WARNING:
NOTE:
Fuel pump assembly consists of fuel pump and fuel
level sensor.
OPERATION, Fuel.>
2) Open the fuel filler flap lid and remove the fuel
filler cap.
3) Disconnect the battery ground cable. 7) Raise the rear seat and turn the floor mat up.
8) Remove the access hole lid.
I I \ \ I I I 1 I
. EN0552
5) Drain the fuel from fuel tank. Set a container un- 9) Disconnect the connector from the fuel pump.
der the vehicle and remove the drain plug from fuel
tank.
10) Disconnect the quick connector and then dis-

connect the fuel delivery hose (A). <Ref. to
FU(D0HC TURBO)-68, Fuel Delivery, Return and
Evaporation Lines.>
FU(D0HC TURBO)-60
FUEL PUMP
11) Move the clips, and then disconnect the fuel re- B: INSTALLATION
turn hose (6)and jet pump hose (C). Install in the reverse order of removal. Do the fol-
lowing:
(1) Always use new gaskets.
(2) Ensure the sealing portion is free from fuel or
foreign particles before installation.
(3) Tighten the nuts in alphabetical sequence
shown in figure to specified torque.
Tightening torque:
4.4 N.m (0.45 kgf-m, 3.3 ft-lb)
12) Remove the nuts which install the fuel pump

assembly onto fuel tank.
S2M0063A
C: INSPECTION
Connect the lead harness to the connector terminal
of fuel pump and apply battery power supply to
S2M0061 I check whether the pump operate.
13) Take off the fuel pump assembly from the fuel WARNING:
tank. Wipe off the fuel completely.
Keep battery as far apart from fuel pump as
possible.
Be sure to turn the battery supply ON and
OFF on the battery side.
Do not run fuel pump for a long time under
non-load condition.
FU(D0HC TURBO)-61
FUEL LEVEL SENSOR
26.Fuel Level Sensor

A: REMOVAL
WARNING:
NOTE:
Fuel level sensor is built in fuel pump assembly.
1) Remove the fuel pump assembly. <Ref. to
FU(D0HC TURBO)-60, REMOVAL, Fuel Pump.>
2) Disconnect the connector from the fuel pump
bracket.
3) Remove the bolt which installs the fuel level sen-

sor on mounting bracket.
B: INSTALLATION
FU(D0HC TURBO)-62
FUEL SUB LEVEL SENSOR
27.Fuel Sub Level Sensor 6) Remove the service hole cover.
A: REMOVAL
WARNING:
/ G2M0863
7 ) Disconnect the connector from the fuel sub

meter.
8) Disconnect the fuel jet pump hose.

3) Drain the fuel from the fuel tank. Set a container
under the vehicle and remove drain plug from fuel
tank.
// / S2M0151
9) Remove the bolts which install the fuel sub meter

unit on fuel tank.
4) Tighten the fuel drain plug.

Tightening torque:
26 N.m (2.65 kgf-m, 79.2 ft-lb)
10) Remove the fuel sub meter unit.
5) Remove the rear seat.
FU(D0HC TURBO)-63
B: INSTALLATION
Tightening torque:
4.4 N-m (0.45 kgf-m, 3.3 ff-lb)
FU(D0HC TURBO)-64
FUEL FILTER
28. Fuel Filter

A: REMOVAL
WARNING:
OPERATION, Fuel.>
2) Disconnect the fuel delivery hoses from the fuel
filter.
3) Remove the filter from the holder.

B: INSTALLATION
CAUTION:
If fuel hoses are damaged at the connecting
portion, replace it with a new one.
If clamps are badly damaged, replace with
new ones.
2) Tighten the hose clamp screws.
Tightening torque:
1.25 Nom(0.13 kgf-m, 0.94 ft-lb)
17
C: INSPECTION
1) Check the inside of fuel filter for dirt and water
sediment.
2) If it is clogged, or if replacement interval has
been reached, replace it.
3) If water is found in it, shake and expel the water
from the inlet port.
FU(D0HC TURBO)-65
FUEL CUT VALVE
29.Fuel Cut Valve

A: REMOVAL
1) Remove the fuel tank. <Ref. to FU(D0HC TUR-
BO)-52, REMOVAL, Fuel Tank.>
2) Remove the protect cover.
I EN105C
3) Move the clip and disconnect the evaporation

hose from fuel cut valve.
I EN1131 I
4) Remove the bolts which install the fuel cut valve.
B: INSTALLATION
Tightening torque:
4.4 N-m (0.45 kgf-m, 3.3 fWb)
EN1132
FU(DOHC TURB0)-66
FUEL DAMPER VALVE
30.Fuel Damper Valve

A: REMOVAL
OPERATION, Fuel.>
2) Remove the fuel damper valve from the fuel re-
turn line.
B: INSTALLATION
Tightening torque:
1.25 N.m (0.13 kgf-m, 0.94 ft-lb)
FU(D0HC TURBO)-67
FUEL DELIVERY, RETURN AND EVAPORATION LINES
31 .Fuel Delivery, Return and 3) Open the fuel filler flap lid and remove the fuel
filler cap.
Evaporation Lines 4) Remove the floor mat. <Ref. to El-55, REMOV-
AL, Floor Mat.>
A: REMOVAL 5) Remove the fuel delivery pipes and hoses, fuel
1) Set the vehicle on the lift. return pipes and hoses, evaporation pipes and hos-
OPERATION, Fuel.>
EN1133
6) In engine compartment, detach the fuel delivery

hoses, return hoses and evaporation hose.
FU(D0HC TURBO)-68
8) Separate the quick connector on the fuel delivery (1) Set the new retainer (B) to connector (A).
and return line. (2) Push the pipe into the connector completely.
(1) Clean the pipe and connector, if they are NOTE:
covered with dust. At this time, two clicking sounds are heard.
(2) Hold the connector (A) and push retainer (B)
down.
(3) Pull out the connector (A) from retainer (B).
CAUTION:
Replace retainer with new ones.
(C)
I
S2M0230E
(C) (A) Connector

(B) Retainer
(C) Pipe
S2M0228P
CAUTION:
(A) Connector Pull the connector t o ensure it is connected
(6) Retainer securely.
(C) Pipe Ensure the two retainer pawls are engaged in
their mating positions in the connector.
B: INSTALLATION Be sure to inspect hoses and their connec-
1) Connect the quick connector on the fuel delivery tions for any leakage of fuel.
line.
CAUTION:
Always use a new retainer.
Make sure that the connected portion is not
damaged or has dust. If necessary, clean seal
surface of pipe.
(A) Connector
(6) Retainer
(C) Pipe
I S2M0229f
FU(D0HC TURBO)-69
2) Connect the fuel delivery hose to the pipe with an C: INSPECTION

overlap of 20 to 25 mm (0.79 to 0.98 in). 1) Make sure that there are no cracks on the fuel
Type A: When the fitting length is specified. pipes and fuel hoses.
Type B: When the fitting length is not specified. 2) Make sure that the fuel pipe and fuel hose con-
Q :2.5H.5 mm (0.098-M.059 in) nections are tight.
L: 22.5f2.5 mm (0.886M.098in)
*Y B2M1194B
(1) Fitting
(2) Clamp
(3) Hose
3) Connect the return hose and evaporation hose

to the pipe by approx. 15 mm (0.59 in) from the
hose end.
Fuel return hose:
L = 22.532.5 mm (0.885-M.098 in)
Fuel evaporation hose:
L = 17.5f2.5 mm (0.689M.098 in)
CAUTION:
Be sure to inspect hoses and their connections
for any leakage of fuel.
I
B2M1195A
(1) Hose
(2) Clip
(3) Pipe
FU(D0HC TURBO)-7O
FUEL SYSTEM TROUBLE IN GENERAL
32.Fuel System Trouble in Gen-

eral
A: INSPECTION
Trouble and possible cause 1 Corrective action
1. Insufficient fuel supply to the injector
1) Fuel pump will not operate.
Inspect connections, especially ground, and tighten
0 Defective terminal contact.
securely.
0 Trouble in electromaanetic or electronic circuit parts. Replace fuel pump.
2) Lowering of fuel pump function. Replace fuel pump.
3) Clogged dust or water in the fuel filter. Replace fuel filter, clean or replace fuel tank.
4) Clogged or bent fuel pipe or hose. Clean, correct or replace fuel pipe or hose.
5) Air is mixed in the fuel system. Inspect or retighten each connection part.
6) Clogged or bent breather tube or pipe. Clean, correct or replace air breather tube or pipe.
7) Damaaed diaphraam of pressure reaulator. Replace.
2.Fakacle or blow out fuel
1) 1 I Loosened joints of the fuel pipe. I Retightening.
2) I I Cracked fuel pipe, hose and fuel tank. I Replace.
3) Defective welding part on the fuel tank. Replace.
4) Defective drain packing of the fuel tank. Replace.
Clean, correct or replace air breather tube or air vent
5) Clogged or bent air breather tube or air vent tube.
tube.
3. Gasoline smell inside of compartment
1)
2) I
I
1 I
1
Loose joints at air breather tube, air vent tube and fuel
filler Dioe.
I .
I Defective Dackina air tiahtness on the fuel saucer.

I
Retightening,
1 Correct or replace packina.
3) 1- I Cracked fuel separator. I Replace separator.
4) 1 I Inoperative fuel pump modulator or circuit. I Replace.
4. Defective fuel meter indicator
1) Defective operation of fuel level sensor. Replace.
2) Defective operation of fuel meter. Replace.
1-
~~
I r I Larae operation noise or vibration of fuel pump. 1 Replace.
NOTE: ing system. Refueling will also complement the
When the vehicle is left unattended for an ex- effect of anti-freeze solution each time the fuel
tended period of time, water may accumulate in the level drops to about one-half. After the winter
fuel tank. season, drain the water which may have accu-
To prevent water condensation. mulated in the fuel filter and fuel tank in the man-
(1) Top off the fuel tank or drain the fuel com- ner same as that described under Affected
pletely. areas below.
(2) Drain the water condensation from the fuel (4) Affected areas
filter. When the water condensation is notched in the
Refilling the fuel tank. fuel filter, drain the water from both the fuel filter
Refill the fuel tank while there is still some fuel left in and fuel tank or use a water removing agent (or
the tank. anti-freeze solution) in the fuel tank.
Protecting the fuel system against freezing and Observe the instructions, notes, etc., indicated
water condensation. on the label affixed to the anti-freeze solution (wa-
(3) Cold areas ter removing agent) container before use.
In snow-covered areas, mountainous areas, ski-
ing areas, etc. where ambient temperatures
drop below 0°C (32°F) throughout the winter
season, use an anti-freeze solution in the cool-
FU(D0HC TURBO)-71
FUEL SYSTEM TROUBLE IN GENERAL
FU(D0HC TURBO)-72
EMISSION CONTROL
(AUX
. . EMISSION CONTROL DEVICES)
EC(D0HC TURBO)m
Page
2. Front Catalytic Converter ............................................................................ 3
3. Rear Catalytic Converter ............................................................................. 4
4. Precatalytic Converter ................................................................................. 5
5. Canister ....................................................................................................... 6
6. Purge Control Solenoid Valve ..................................................................... 7
7. Main Fuel Level Sensor .............................................................................. 8
8. Fuel Temperature Sensor ........................................................................... 9
9. Fuel Sub Level Sensor .............................................................................. IO
10. Fuel Tank Pressure Sensor ...................................................................... 11
11. Pressure Control Solenoid Valve .............................................................. 12
12. Drain Filter................................................................................................. 14
13. Vent Valve ................................................................................................. 15
14. Shut Valve ................................................................................................. 16
15. Drain Valve ................................................................................................ 17
GENERAL DESCRIPTION
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)
A: CAUTION
Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
Be careful not to burn your hands, because each
part on the vehicle is hot after running.
Be sure to tighten fasteners including bolts and
Place shop jacks or safety stands at the specified
points.
Before disconnecting electrical connectors of
sensors or units, be sure to disconnect the negative
terminal from battery.
EC(D0HC TURBO)-2
I a
FRONT CATALYTIC CONVERTER
2. Front Catalytic Converter

A: REMOVAL
1) Remove the center exhaust pipe. <Ref. to
EX(D0HC TURBO)-8, REMOVAL, Center Exhaust
Pipe.>
2) Separate the front catalytic converter (A) from
rear catalytic converter (B).
EN099:
B: INSTALLATION
NOTE:
Replace the gaskets with new ones.
C: INSPECTION
1) Make sure there are no exhaust leaks from con-
nections and welds.
2) Make sure there are no holes or rusting.
EC(D0HC TURBO)-3
I REAR CATALYTIC CONVERTER
3. Rear Catalytic Converter

A: REMOVAL
Pipe.>
2) Separate the rear catalytic converter (B) from
front catalytic converter (A).
I EN0993
B: INSTALLATION
NOTE:
C: INSPECTION
nections and welds.
EC(D0HC TURBO)-4
PRECATALYTIC CONVERTER
4. Precatalytic Converter
A: REMOVAL
Precatalytic converter (A) is built in the joint pipe.
Refer to the removal of joint pipe for removal
procedure. <Ref. to EX(D0HC TURBO)-12, RE-
MOVAL, Joint Pipe.>
EN0991
B: INSTALLATION
Precatalytic converter is built in the joint pipe. Refer
to the installation of joint pipe for installation proce-
dure. <Ref. to EX(D0HC TURBO)-12, INSTALLA-
TION, Joint Pipe.>
C: INSPECTION
nections and welds.
EC(D0HC TURBO)-5
CANISTER
5. Canister C: INSPECTION
Make sure the canister and canister hoses are not
A: REMOVAL cracked or loose.
2) Loosen the two clamps which hold two canister
hoses, and disconnect the evaporation three hoses
from canister
\ I I / S2M0950
3) Remove the canister from body.
B: INSTALLATION
Tightening torque:
23 N.m (2.3 kgf-m, 17 ff-lb)
EC(D0HC TURBO)-6
PURGE CONTROL SOLENOID VALVE
31
6. Purge Control Solenoid Valve B: INSTALLATION

A: REMOVAL
1) Disconnect the ground terminal from battery.
Tightening torque:
76 N.m (7.6 kgf-m, 7 7.6 ft-16)
9 EN0899
2) Disconnect the connector and hoses from purge
control solenoid valve. CAUTION:
3) Remove the bolt which installs the purge control Carefully connect the evaporation hoses.
solenoid valve onto intake manifold.
EN0899
(A) To intake manifold
(B) To purge value
C: INSPECTION
Make sure the hoses are not cracked or loose.
EC(D0HC TURBO)-7
MAIN FUEL LEVEL SENSOR
7. Main Fuel Level Sensor

A: REMOVAL
For work procedures, refer to “FU” section. <Ref. to
FU(D0HC TURBO)-62, REMOVAL, Fuel Level
Sensor.>
B: INSTALLATION
For work procedures, refer to “FU” section.
<Ref. to FU(D0HC TURBO)-62, INSTALLATION,
Fuel Level Sensor.>
EC(D0HC TURBO)-8
I
FUEL TEMPERATURE SENSOR
a
8. Fuel Temperature Sensor B: INSTALLATION

A: REMOVAL WARNING:
'1 Remove the fuel pump <Ref. to Spark may occur and ignite if fuel is nearby.
FU(D0HC TURBO)-60, REMOVAL, Fuel Pump.>
2) Disconnect the connector from fuel pump brack-
et.
3) Remove the main fuel level sensor from fuel

pump assembly. <Ref. to FU(D0HC TURBO)-62,
REMOVAL, Fuel Level Sensor.>
S2M085E
NOTE:
Fuel temperature sensor is a unit with the fuel
pump. If replacing it, replace as a fuel pump.
EC(D0HC TURBO)-9
la
9. Fuel Sub Level Sensor

A: REMOVAL
For work procedures, refer to “FU(D0HC TURBO)”
section. <Ref. to FU(D0HC TURBO)-63, REMOV-
AL, Fuel Sub Level Sensor.>
B: INSTALLATION
For work procedures, refer to “FU(D0HC TURBO)’’
section. <Ref. to FU(D0HC TURBO)-64, INSTAL-
LATION, Fuel Sub Level Sensor.>
EC(D0HC TURBO)-IO
FUEL TANK PRESSURE SENSOR
10.Fuel Tank Pressure Sensor 6) Disconnect the pressure hose from fuel tank
pressure sensor.
A: REMOVAL
1) Remove the fuel tank. <Ref. to FU(D0HC TUR-
2) Remove the protector cover.
G3 B2M1779
B: INSTALLATION
EN10% Tightening torque:
3) Disconnect the connector from fuel pressure
7.4 N-m (0.75 kgf-m, 5.4 ft-lb)
sensor, then remove the fixing nut.
C: INSPECTION
4) Release the clips which hold fuel pipes onto fuel Make sure the hoses are not cracked or loose.
tank.
I Clip EN1052 I
5) Remove the clip, and disconnect pressure hose
from fuel tank.
EC(D0HC TURBO)-I 1
PRESSURE CONTROL SOLENOID VALVE
11.Pressure Control Solenoid 5 ) Disconnect the connector from pressure control

solenoid valve.
Valve
A: REMOVAL
6) Disconnect the two evaporation hoses from

pressure control solenoid valve.
7) Remove the pressure control solenoid valve with
bracket.
2) Remove the canister. <Ref. to EC(D0HC TUR-
BO)-6, REMOVAL, Canister.>
3) Disconnect the evaporation hoses (A) from joint
pipes.
8) Remove the pressure control solenoid valve

from bracket.
4) Remove the bolt which installs pressure control

solenoid valve holding bracket on body.
>
I B2M1786 I
9) Disconnect the vacuum hose from pressure con-

EC(D0HC TURBO)-I 2
PRESSURE CONTROL SOLENOID VALVE
B: INSTALLATION
Tightening torque:
17.6 N.m (1.8 kgf-m, 13.0 R-lb)
C: INSPECTION
EC(D0HC TURBO)-13
DRAIN FILTER
12.Drain Filter 6) Remove the bolt which installs the drain filter and
drain valve brackets on body, and remove them as
A: REMOVAL a unit.
7) Disconnect the evaporation hoses, and remove

2) Lift-up the vehicle. the drain filter.
4) Disconnect the connector from drain valve.
I B2M 1791C
/
B: INSTALLATION
0 H2M3611
Tightening torque:
5) Disconnector the evaporation hoses (A) from
23 N-m (2.3 kgf-m, 17 ff-lb)
joint pipes.
C: INSPECTION
1) Make sure all hoses are installed correctly.
2) Make sure the hoses are not cracked or loose.
EC(D0HC TURBO)-14
VENT VALVE
13.Vent Valve B: INSTALLATION

A: REMOVAL CAUTION:
1) Remove the fuel tank. <Ref. to FU(D0HC TUR- Replace the rubber seat with a new one.
2) Remove the protector cover. Tightening torque:
T: 4.4 N.m (0.45 kgf-m, 3.3 ft-lb)
I EN1050 I
3) Remove the clips, and disconnect the hoses

from vent valve. C: INSPECTION
4) Remove the nuts which install the vent on fuel

tank.
-I
EC(D0HC TURBO)-15
SHUT VALVE
14.Shut Valve B: INSTALLATION
A: REMOVAL
1) Disconnect the ground terminal from battery. Tightening torque:
4.5 N.m (0.46 kgf-m, 3.3 ft-lb)
EN1 5E
I -
-
2) Drain fuel from the fuel tank. <Ref. to FU(D0HC
TURBO)-52, REMOVAL, Fuel Tank.> C: INSPECTION
3) Remove the fuel filler pipe. <Ref. to FU(D0HC Make sure the hoses are not cracked or loose.
TURBO)-55, REMOVAL, Fuel Filler Pipe.>
4) Disconnect the evaporation hoses from shut
valve.
EN1057
5 ) Remove the shut valve from fuel filler pipe.
I I
EN105.5
EC(D0HC TURBO)-16
m
DRAIN VALVE
15.Drain Valve 6) Remove the bolt which installs the drain filter and
drain valve brackets on body, and remove them as
A: REMOVAL a unit.
7) Remove the drain valve from bracket.

4) Disconnect the connector from drain valve.
EN1055
B: INSTALLATION
/
0 0- H2M3611 Tightening torque:
5) Disconnect the evaporation hoses from drain
23 N-m (2.3 kgf-m, 17 ft-16)
valve.
EN1055
------- H2M3612AI C: INSPECTION

1) Make sure all hoses are installed correctly.
2) Make sure the hoses are not cracked or loose.
EC(D0HC TURBO)-17
DRAIN VALVE
EC(D0HC TURBO)-18
INTAKE (INDUCTION)
IN(D0HC TURBO)
Page
2. Air Cleaner .................................................................................................. 7
3. Air Intake Duct............................................................................................. 8
4. Intake Duct .................................................................................................. 9
5. Intercooler ................................................................................................. 10
6. Turbocharger............................................................................................. 12
7. Air By-pass Valve ...................................................................................... 14
GENERAL DESCRIPTION
INTAKE (INDUCTION)
A: COMPONENT
1. AIR CLEANER
EN117E
(1) Mass air flow sensor (8) Cushion rubber Tightening torque: N.m (kgf-m, ft-lb)
(2) Air cleaner upper cover (9) Air intake duct T1: 7.5 (0.76, 5.5)
(3) Air cleaner element (10 ) Resonator chamber ASSY T2: 33 (3.4,25)
(4) Spacer (1 1) Cushion rubber T3: Z.s(O.25, 1.8)
(5) Bush (12) Clamp T4: 1.7(0.17, 1.2)
(6) Clip (13) Air intake boot
(7) Air cleaner lower case (14) Cushion
IN(D0HC TURBO)-2
GENERAL DESCRIPTION
INTAKE (INDUCTION)
2. INTAKE DUCT
EN1114
(1) Clamp (5) Air by-pass hose D Tightening torque: N.m (kgf-m, ft-lb)
(2) PCV hose ASSY (6) Intake duct T l : l S ( 1 . 6 , 11.7)
(3) Air by-pass hose B (7) Clamp
(4) Air by-pass hose C
IN(D0HC TURBO)-3
I
GENERAL DESCRIPTION
INTAKE (INDUCTION)
3. INTERCOOLER
. /
GL
/
\
EN090,
(1) Intercooler (7) Gasket (13) Clamp

(2) Intercooler bracket RH (8) Clamp
(3) Intercooler bracket LH (9) Air by-pass hose A Tightening torque: N.m (kgf-m, ft-lb)
(4) Clamp (IO) Intercooler duct A T1: 3 (0.22, 1.6)
(5) Air intake duct (11) Intercooler duct B T2: 16 (1.6, 11.71
(6) Air by-pass valve (12) Intercooler duct C
IN(D0HC TURBO)-4
GENERAL DESCRIPTION
INTAKE (INDUCTION)
4. TURBOCHARGER
-
I /
&.-I
EN111E
(1) Oil inlet pipe (8) Oil outlet pipe Tightening torque: N.m (kgf-m, ft-lb)
(2) Metal gasket (9) Clip T l : 4.4 (0.45, 3.3)
(3) Turbocharger (10) Oil outlet hose T2: 4.9 (0.50, 3.6)
(4) Water pipe (1 1) Turbocharger bracket RH T3: 29 (3.0, 21.7)
(5) Clamp (12) Turbocharger bracket LH T4: 30 (3.1,22.4)
(6) Engine coolant hose T5: 33 (3.4,24.6)
(7) Gasket T6: lS(1.6, 11.7)
IN(D0HC TURBO)-5
GENERAL DESCRIPTION
INTAKE (INDUCTION)
B: CAUTION
tion.
points.
sensor or units, be sure to disconnect negative ter-
minal from battery.
IN(D0HC TURBO)-6
AIR CLEANER
INTAKE (INDUCTION)
2. Air Cleaner 7) Remove the air cleaner lower case.
A: REMOVAL
B: INSTALLATION
2) Disconnect the connector from mass air flow

Tightening torque:
sensor. 33 N.m (3.4 kgf-m, 25 ft-lb)
I
3) Loosen the clamp (A) which connects air intake CAUTION:

boot to intake duct. Before installing the air cleaner upper cover,
4) Remove the two clips (B) from air cleaner upper align holes with protruding portions of air
cover. cleaner lower case, then secure the upper cov-
er to lower case.
5) Remove the air cleaner upper cover.

6) Remove the air cleaner element. C: INSPECTION
Replace if excessively damaged or dirty.
IN(D0HC TURBO)-7
AIR INTAKE DUCT
INTAKE (INDUCTION)
3. Air Intake Duct

A: REMOVAL
1) Remove the bolts which install air intake duct on
the front side of body.
B: INSTALLATION
C: INSPECTION
1) Inspect for cracks and loose connections.
2) Inspect that no foreign objects are mixed in the
air intake duct.
IN(D0HC TURBO)-8
INTAKE DUCT
INTAKE (INDUCTION)
4. Intake Duct
A: REMOVAL

3) Remove the sensor, engine harness, and fuel
pipe attached to the intake manifold. <Ref. to
FU(D0HC TURBO)-21, DISASSEMBLY, Intake
Manifold.>
4) Remove the intake duct from intake manifold.
ENIll!
B: INSTALLATION
IN(D0HC TURBO)-9
I INTERCOOLER
INTAKE (INDUCTION)
5. Intercooler 5 ) Separate the intercooler from throttle body.
A: REMOVAL
1) Disconnect the air by-pass hoses from intercool-
er.
2) Separate the air by-pass valve from intercooler.
3) Remove the bolts which secure intercooler to

bracket.
4) Separate the intercooler air duct from turbo-

charger.
IN(D0HC TURBO)-10
INTERCOOLER
INTAKE (INDUCTION)
B: INSTALLATION C: DISASSEMBLY
Install in the reverse order of removal. 1) Loosen the clamps, then remove intercooler
duct.
Tightening torque:
16 N-m (1.6 kgf-m, 11.7 ff-lb)
MI884
2) Remove the intercooler ducts from intercooler.

r
D: ASSEMBLY
'M
Assemble in the reverse order of disassembly.

Tightening torque:
16 N-m (1.6 kgf-m, 11.7 ff-lb)
1
IN(D0HC TUR 30)-I 1

TURBOCHARGER
INTAKE (INDUCTION)
6. Turbocharger 7) Loosen the clamp which secures turbocharger to

air inlet duct.
A: REMOVAL
8) Remove the bolt which secures bracket of oil

pipe to turbocharger.
9) Remove the oil pipe from turbocharger.
Pipe.>
5) Separate the turbocharger joint pipe from turbo-
charger.
10) Remove the turbocharger bracket.
6) Disconnect the engine coolant hose which is

connected to coolant filler tank.
11) Disconnect the oil outlet hose from pipe.
12) Take out the turbocharger from engine com-

partment.
IN(D0HC TURBO)-12
TURBOCHARGER
INTAKE (INDUCTION)
B: INSTALLATION 5 ) Install the turbocharger bracket.

1) Connect the oil outlet hose to outlet pipe.
6) Connect the engine coolant hose which is con-

nected to coolant filler tank.
2) Install the turbocharger to air intake duct.
I .
3) Install the oil pipe to turbocharger
8) Install the center exhaust pipe. <Ref. to
EX(D0HC TURBO)-9, INSTALLATION, Center
Exhaust Pipe.>
/ II /ENOW:
4) Install the joint pipe to turbocharger.

NOTE:
Tightening torque:
30 N.m (3.1 kgf-m, 22.4 ft-lb)
I EN0911
IN(D0HC TURBO)-I 3
AIR BY-PASS VALVE
INTAKE (INDUCTION)
7. Air By-pass Valve B: INSTALLATION

A: REMOVAL
1) Remove the air by-pass valve from intercooler. Tightening torque:
76 N*m (7.6 kgf-m, 7 7.7 fi-lb)
2) Disconnect the air by-pass hoses from air by-

pass valve.
IN(D0HC TURBO)-14
MECHANICAL
ME(D0HC TURBO)
2. Compression ............................................................................................. 22
3. Idle Speed ................................................................................................. 23
4. Ignition Timing ........................................................................................... 24
5. Intake Manifold Vacuum ............................................................................ 25
6. Engine Oil Pressure .................................................................................. 26
7. Fuel Pressure ............................................................................................ 27
8. Valve Clearance ........................................................................................ 28
9. Engine Assembly ...................................................................................... 33
10. Engine Mounting ....................................................................................... 42
11. Preparation for Overhaul ........................................................................... 43
12. V-belt ......................................................................................................... 44
13. Crankshaft Pulley ...................................................................................... 46
14. Belt Cover ................................................................................................. 47
15. Timing Belt Assembly ................................................................................ 48
16. Camshaft Sprocket.................................................................................... 57
17. Crankshaft Sprocket.................................................................................. 58
18. Camshaft ................................................................................................... 59
19. Cylinder Head Assembly ........................................................................... 64
20 . Cylinder Block ........................................................................................... 72
21 . Engine Trouble in General ........................................................................ 91
22 . Engine Noise ............................................................................................. 96
GENERAL DESCRIPTION
MECHANICAL
A: SPECIFICATIONS
Horizontally opposed, liquid cooled, 4-cylinder,
Type 4-stroke aasoline enaine
Valve arrangement I Belt driven, double overhead camshaft, 4-valve/cvlinder
Bore x Stroke mm (in) I 92 x 75 (3.62 x 2.95)
Piston displacement cm3 (cu in\ I 1.994 (1 21.67)
Compression ratio 8.0
Compression pres-
sure (at 200 - 300 kPa (kgf/cm2, psi) 981 - 1,177 (10- 12, 142- 171)
rPm)
Number of piston rings Pressure ring: 2, Oil ring: 1
Opening 10" BTDC
Engine intake valve timing
Closing 50" ABDC
Opening 53" BBDC
Exhaust valve timing
Closing 7" ATDC
Valve clearance
Intake mm (in) I 0.20f0.02 (0.0079kO.0008)
Exhaust mm (in) I 0.25+0.02 (0.0098kO,0008)
750k100 (No load)
MT
800k150 (NC switch ON)
Idling speed [At neutral position] rPm
750k100 (No load)
AT
825k150 (NC switch ON)
Firing order 1+ 3 + 2 3 4
Ignition timing BTDC/rpm 12"k3"/750 rpm
ME(D0HC TURBO)-2
GENERAL DESCRIPTION
MECHANICAL
NOTE:
STD: Standard I.D.: Inner Diameter O.D.: Outer Diameter OS: Oversize US: Undersize
%It ten-
;ion Protrusion of adjuster rod 5.2 - 6.2 mm (0.205 - 0.244 in)
idjuster
Spacer O.D. 17.955 - 17.975 mm (0.7069 - 0.7077 in)
Tensioner bush I.D. 18.0 - 18.08 mm (0.7087 - 0.71 18 in)
3elt ten- STD 0.025 - 0.125 mm (0.0010 - 0.0049 in)
Clearance between spacer and bush
jioner Limit 0.175 mm (0.0069 in)
STD 0.2 - 0.55 mm (0.0079 - 0.0217 in)
Side clearance of spacer
Limit 0.81 mm (0.0319 in)
Bend limit 0.020 mm (0.0079 in)
I STD 0.015 - 0.070 mm (0.0006 - 0.0028 in)
Thrust clearance
I STD 46.25 - 46.35 mm (1.821 - 1.825 in)

Intake
I Limit
I
46.15 mm (1.817 in)

Cam lobe height
STD 46.1 5 - 46.25 mm (1.817 - 1.821 in)
Camshaft Exhaust
Limit 46.05 mm (1.813 in)
Front 37.946 - 37.963 mm (1.4939 - 1.4946 in)
Jounal O.D. STD Center 29.946-29.963" (1.1790-1.1796 in)
rear
Oil clearance
I STD 0.037 - 0.072 mm (0.0015 - 0.0028 in)
I Limit 0.10 mm (0.0039 in)
Surface warpage limit 0.05 mm (0.0020 in)
Cylinder 0.3 mm (0.012 in)
Surface grinding limit
head
Standard height 127.5 mm (5.02 in)
Refacing angle 90"
STD 1.O mm (0.039 in)
Intake Limit
Valve seat I .7 mm (0.067 in)
Contacting width
STD 1.5 mm (0.059 in)
Exhaust
Limit 2.2 mm (0.087 in)
Inner diameter 6.000 - 6.012 mm (0.2362 - 0.2367 in)
Valve guide
Protrusion above head 12.0 - 12.4 mm (0.472 - 0.488 in)
. .
Intake
I STD 1.2 mm (0.047 in)
Limit 0.8 mm (0.031 in)
Head edge thickness
STD 1.5 mm (0.059 in)
Exhaust
Limit 0.8 mm (0.031 in)
I Intake 5.950 - 5.965 mm (0.2343 - 0.2348 in)
Valve
Stem diameter
I Exhaust
I
I 5.945 - 5.960 "(0.2341 - 0.2346 in)
Intake 0.035 - 0.062 mm (0.0014 - 0.0024 in)
STD
Stem oil clearance Exhaust 0.040 - 0.067 mm (0.0016 - 0.0026 in)
Limit - 0.15 mm (0.0059 in)
Intake 104.4 mm (4.1 10 in)
Overall length
Exhaust 104.7 mm (4.122 in)
Free length 44.67 mm (1.7587 in)
Valve Squareness 2.5", 2.0 mm (0.079 in)
spring 220.7k15.7 N (22.5k1.6 kgf, 49.6f3.5 lb)/36.0 mm (1.417 in)
Tensionlspring height
510.9k25.5 N (52.1k2.6 kgf, 114.9k5.7 lb)/26.6 mm (1.0.47 in
ME(D0HC TURBO)-3
GENERAL DESCRIPTION
MECHANICAL
Surface warpage limit (mating with cylinder head) I 0.05 mm (0.0020 in)
Surface grinding limit I 0.1 mm (0.004 in)
A 92.005 - 92.015 mm (3.6222 - 3.6226 in)
Cylinder bore STD
I
B 91.995 - 92.005 mm (3.6218 - 3.6222 in)
STD 0.015 mm (0.0006 in)
Cylinder Taper
Limit 0.050 mm (0.0020 in)
block
STD 0.010 mm (0.0004 in)
Out-of-roundness
Limit 0.050 mm (0.0020 in)
STD 0.010 - 0.030 mm (0.0004 - 0.001 2 in)
Limit 0.050 mm (0.0020 in)
Enlaraina (borina) limit 0.5 mm (0.020 in)
STD
IA I 91.985 - 91.995 mm (3.6214 - 3.6218 in)
IB I 91.975 - 91.985 mm (3.621 1 - 3.6214 in)
0.25 mm (0.0098 in)
Piston Outer diameter 92.225 - 92.235 mm (3.6309 - 3.6313 in)
os
0.50 mm (0.0197 in)
92.475 - 92.485 mm (3.6407 - 3.6411 in)
os
Standard clearance between piston STD 0.004 - 0.008 mm (0.0002 - 0.0003 in)
pin and hole in piston Limit 0.020 mm (0.0008 in)
Piston pin
Degree of fit
STD 0.20 - 0.35 mm (0.0079 - 0.0138 in)

Top ring
Limit I 1.O mm (0.039 in)
Piston ring gap

Second STD I 0.35 - 0.50mm (0.0138 - 0.0197 in)
ring Limit 1.O mm (0.039 in)
STD 0.20 - 0.70 mm (0.0079 - 0.0276 in)
Piston ring Oil ring
Limit 1.5 mm (0.059 in)
STD 1 0.040 - 0.080 mm (0.0016 - 0.0031 in)
Clearance between piston Top ring
ring and piston ring
Limit I 0.15 mm (0.0059 in)
groove Second STD I 0.030 - 0.070 mm (0.0012 - 0.0028 in)
ring Limit I 0.15 mm (0.0059 in)
Connecting
Bend twist per 100 mm (3. 4 in) in
lenath
Limit I 0.10 mm (0.0039 in)
rod STD I 0.070- 0.330 mm (0.0028 - 0.0130 in)

Side clearance
Limit 0.4 mm (0.016 in)
STD 0.020 - 0.046 mm (0.0008 - 0.0018 in)
Oil clearance
Limit 0.05mm (0.0020 in)
STD 1.492 - 1.501 mm (0.0587 - 0.0591 in)
0.03 mm
(0.0012 1.510 - 1.513 mm (0.0594 - 0.0596 in)
Connecting in) US
rod bearing 0.05 mm
Thickness at center portion
(0.0020 1.520 - 1.523 mm (0.0598 - 0.0600 in)
in) US
0.25 mm
(0.0098 1.620 - 1.623 mm (0.0638 - 0.0639 in)
in) US
Connecting Clearance between piston pin and STD 0 - 0.022 mm (0 - 0.0009 in)
rod bushing bushing Limit I 0.030 mm (0.0012 in)
ME(D0HC TURBO)-4
GENERAL DESCRIPTION
MECHANICAL
lend limit 0.035 mm (0.0014 in)

:rank pin and crank jour- Out-of-ro~ndness 0.020 mm (0.0008 in) or less
tal Grinding limit 0.25 mm (0.0098 in)
0.0012 47.954 - 47.970 mm (1.8879 - 1.8886)
;rank pin outer diameter

0.0020 I 47.934 - 47.950 mm (1.8872 - 1.8878)
1.25 mm
0.0098 47.734 - 47.750 mm (1.8793 - 1.8799)
mm
:0.0012
lo3 1 59.962 - 59.978 mm (2.3607- 2.3613 in)
:ranks haft
#1, #3, #5
mm
:0.0020
n) US
1 59.942 - 59.958 mm (2.3599- 2.3605 in)
3.25 mm
(0.0098 59.742 - 59.758 mm (2.3520- 2.3527 in)
:rank journal outer diam- in) US
Bter STD 59.992 - 60.008 mm (2.3619 - 2.3625 in)
0.03 mm
(0.0012 59.962 - 59.978 mm (2.3607- 2.3613 in)
in) US
0.05 mm
#2. #4
(0.0020 59.942 - 59.958 mm (2.3599- 2.3605 in)
0'25 mm
(0.0098
in) US
I 59.742 - 59.758 mm (2.3520- 2.3527 in)
0.030 - 0.1 15 mm (0.0012 - 0.0045 in)

~
STD
Thrust clearance
Limit 0.25 mm (0.0098 in)
STD 0.01 0 - 0.030 mm (0.0004 - 0.0012 in)
Oil clearance
Limit 0.040 mm (0.0016 in)
STD 1.998 - 2.011 mm (0.0787 - 0.0792 in)
0.03 mm
(0.0012 2.017 - 2.020 mm (0.0794- 0.0795 in)
in) US
0.05 mm
#l. #3
(0.0020 2.027 - 2.030 mm (0.0798- 0.0799 in)
Crankshaft Crankshaft bearing thick-

0.25mm
(0.0098
in) US
I 2.127 - 2.130 mm (0.0837- 0.0839 in)
bearing ness STD 2.000 - 2.013 mm (0.0787- 0.0793 in)

~
0.03 mm
(0.0012 2.019 - 2.022 mm (0.0795 - 0.0796 in)
in) US
#2, #4, #5 0.05 mm
(0.0020 2.029 - 2.032 mm (0.0799 - 0.0800 in)
0.25mm
(0.0098 I 2.129 - 2.132 mm (0.0838- 0.0839 in)
ME(D0HC TURBO)-5
GENERAL DESCRIPTION
MECHANICAL
B: COMPONENT
1. TIMING BELT
EN1136
(1) Right-hand belt cover No. 2 (9) Right-hand intake camshaft (17) Right-hand belt cover
(2) Timing belt guide (MT vehicles sprocket (18) Crankshaft pulley
only)
.. (IO) Left-hand intake camshaft
(3) Crankshaft sprocket sprocket Tightening torque: N.m (kgf-m, ff-lb)
(4) Left-hand belt cover No. 2 (11) Left-hand exhaust camshaft T l : 5 (0.5, 3.6)
(5) Tensioner bracket sprocket T2: l O ( 1 . 0 , 7)
(6) Automatic belt tension adjuster (12) Timing belt T3: 25 (2.5, 18.1)
ASSY (13) Belt idler No. 2 T4: 39 (4.0, 28.9)
(7) Belt idler (14) Belt idler T5: 98 (10, 72.4)
(8) Right-hand exhaust camshaft (15) Left-hand belt cover T6: <Ref. to ME(D0HC TURBO)-46,
sprocket (16) Front belt cover INSTALLA TION, Crankshaft
Pullev.>
ME(D0HC TURBO)-6
GENERAL DESCRIPTION
MECHANICAL
ME(D0HC TURBO)-7
GENERAL DESCRIPTION
MECHANICAL
2. CYLINDER HEAD AND CAMSHAFT
S2M1188A
ME(D0HC TURBO)-8
GENERAL DESCRIPTION
MECHANICAL
Rocker cover (RH) Cylinder head (RH) (29) Oil filler cap
Rocker cover gasket (RH) Cylinder head gasket (RH) (30) Gasket
Oil separator cover Cylinder head gasket (LH) (31) Oil filler duct
Gasket Cylinder head (LH) (32) O-ring
Intake camshaft cap (Front RH) Intake camshaft (LH) (33) Stud bolt
Intake camshaft cap (Center RH) Exhaust camshaft (LH)
Intake camshaft cap (Rear RH) Intake camshaft cap (Front LH) Tightening torque: N.m (kgf-m, ft-lb)
Intake camshaft (RH) Intake camshaft cap (Center LH) T l : <Ref, to ME(D0HC TURBO)-64,
Exhaust camshaft cap (Front RH) Intake camshaft cap (Rear LH) INSTALLATION, Cylinder Head
Exhaust camshaft cap (Center Exhaust camshaft (Front LH) Assembly>
RH) (25) Exhaust camshaft cap (Center T2: 5 (0.5, 3.6)
Exhaust camshaft cap (Rear RH) LH) T3: 10 (1.0, 7)
Exhaust camshaft (RH) (26) Exhaust camshaft cap (Rear LH) T4: 6.4 (0.65, 4.7)
Cylinder head bolt (27) Rocker cover gasket (LH)
Oil seal (28) Rocker cover (LH)
ME(D0HC TURBO)-9
I
GENERAL DESCRIPTION
MECHANICAL
3. CYLINDER HEAD AND VALVE ASSEMBLY
(1 o i
S2M1197A
(1) Exhaust valve (6) Valve spring (11) Exhaust valve oil seal
(2) Intake valve (7) Retainer (12) Intake valve guide
(3) Cylinder head (8) Retainer key (13) Exhaust valve guide
(4) Valve spring seat (9) Valve lifter
(5) Intake valve oil seal (IO) Shim
ME(D0HC TURBO)-IO
I
GENERAL DESCRIPTION
MECHANICAL
4. CYLINDER BLOCK
EN0144
Oil pressure switch Oil cooler Tightening torque: N.m (kgf-m, ft-lb)
Cylinder block (RH) Waster by-pass pipe T1: 5 (0.5, 3.6)
Service hole plug Connector T2: 6.4 (0.65, 4.7)
Gasket Oil strainer T3: lO(1.0, 7)
Oil separator cover Gasket T4: 25 (2.5, 18.1)
Water by-pass pipe Oil pan T5: 47 (4.8, 34.7)
Oil pump Drain plug T6: 69 (7.0, 50.6)
Front oil seal Metal gasket T7: First 12 (1.2, 8.7)
Rear oil seal Oil level gauge guide Second 12 (1.2, 8.7)
O-ring Oil filter T8: 16 (1.6, 11.6)
Service hole cover Gasket T9r 44 (4.5, 33)
Cylinder block (LH) Water pump hose TlO: 25 (2.5, 18.1)
Water pump Plug T11: 55 (5.5, 40)
Baffle plate
ME(D0HC TURBO)-I 1
GENERAL DESCRIPTION
MECHANICAL
5. CRANKSHAFT AND PISTON
EN0415
(1) Flywheel (MT vehicles only) (9) Piston pin (17) Crankshaft bearing # I , #3
(2) Ball bearing (MT vehicles only) (IO) Circlip (18) Crankshaft bearing #2, #4
(3) Reinforcement (AT vehicles only) (11) Connecting rod bolt (19) Crankshaft bearing #5
(4) Drive plate (AT vehicles only) (12) Connecting rod
(5) Top ring (13) Connecting rod bearing Tightening torque: N.m (kgf-m, I?-lb)
(6) Second ring (14) Connecting rod cap T1: 44.6 (4.55, 32.9)
(7) Oil ring (15) Crankshaft T2: 72 (7.3, 52.8)
(8) Piston (16) Woodruff key
ME(D0HC TURBO)-12
GENERAL DESCRIPTION
MECHANICAL
6. ENGINE MOUNTING
\
Q
S2M1783A
(1) Hear shield cover (3) Front engine mounting bracket Tightening torque: N.m (kgf-myft-lb)
(2) Front cushion rubber T1: 35 (3.6,25.8)
T2: 42 (4.3, 30.9)
T3: 85 (8.7, 62.7)
ME(D0HC TURBO)-13
GENERAL DESCRIPTION
MECHANICAL
C: CAUTION Rotating parts and sliding parts such as piston,

Wear working clothing, including a cap, protec- bearing and gear should be coated with oil prior to
tive goggles, and protective shoes during opera- assembly.
tion. Be careful not to let oil, grease or coolant contact
Remove contamination including dirt and corro- the timing belt, clutch disc and flywheel.
sion before removal, installation or disassembly. All removed parts, if to be reused, should be re-
Keep the disassembled parts in order and pro- installed in the original positions and directions.
tect them from dust or dirt. Bolts, nuts and washers should be replaced with
Before removal, installation or disassembly, be new ones as required.
sure to clarify the failure. Avoid unnecessary re- Even if necessary inspections have been made
moval, installation, disassembly, and replacement. in advance, proceed with assembly work while
Be careful not to burn your hands, because each making rechecks.
part in the vehicle is hot after running. Remove or install the engine in an area where
Be sure to tighten fasteners including bolts and chain hoists, lifting devices, etc. are available for
nuts to the specified torque. ready use.
Place shop jacks or safety stands at the specified Be sure not to damage coated surfaces of body
points. panels with tools or stain seats and windows with
Before disconnecting electrical connectors of coolant or oil. Place a cover over fenders, as re-
sensors or units, be sure to disconnect the negative quired, for protection.
terminal from battery. Prior to starting work, prepare the following:
All parts should be thoroughly cleaned, paying Service tools, clean cloth, containers to catch cool-
special attention to the engine oil passages, pis- ant and oil, wire ropes, chain hoist, transmission
tons and bearings. jacks, etc.
Lift-up or lower the vehicle when necessary.
Make sure to support the correct positions.
D: PREPARATION TOOL
1. SPECIAL TOOLS
498267600 CYLINDER Used for replacing valve guides.
HEAD TABLE Used for removing and installing valve springs.
EN0147
498457000 ENGINE STAND Used with ENGINE STAND (499817000).
ADAPTER RH
82M3851
ME(D0HC TURBO)-14
GENERAL DESCRIPTION
MECHANICAL

498457100 ENGINE STAND Used with ENGINE STAND (499817000).
ADAPTER LH
498497100 CRANKSHAFT Used for stopping rotation of flywheel when loos-

STOPPER ening and tightening crankshaft pulley bolt, etc.
02M3853
398744300 PISTON GUIDE Used for installing piston in cylinder for 2000 cc
(Newly adopted engine.
tool)
498857100 VALVE OIL SEAL Used for press-fitting of intake and exhaust valve
GUIDE guide oil seals.
02M3855
ME(D0HC TURBO)-15
GENERAL DESCRIPTION
MECHANICAL

499017100 PISTON PIN Used for installing piston pin, piston and connect-
GUIDE ing rod.
B2M3856
499037100 CONNECTING Used for removing and installing connecting rod
ROD BUSHING bushing.
REMOVER &
INSTALLER
B2M3857
499097700 PISTON PIN Used for removing piston pin.
REMOVER
ASSY
B2M3858
499207400 CAMSHAFT Used for removing and installing camshaft
(Newly adopted SPROCKET sprocket.
tool) WRENCH
B2M4158
ME(D0HC TURBO)-16
GENERAL DESCRIPTION
MECHANICAL

499587700 CAMSHAFT OIL Used for installing cylinder head plug for DOHC
(Newly adopted SEAL engine.
tool) INSTALLER
499587200 CRANKSHAFT Used for installing crankshaft oil seal.

OIL SEAL Used with CRANKSHAFT OIL SEAL GUIDE
INSTALLER (499597100).
B2M3861
499597100 CRANKSHAFT m Used for installing crankshaft oil seal.
OIL SEAL GUIDE m Used with CRANKSHAFT OIL SEAL
82M3863
499718000 VALVE SPRING Used for removing and installing valve spring.
REMOVER
B2M3864
ME(D0HC TURBO)-17
GENERAL DESCRIPTION
MECHANICAL
I ILLUSTRATION r o o L NUMBER DESCRIPTION I REMARKS

498267700 IALVE GUIDE Used for installing intake and exhaust valve
(DJUSTER guides.
I B2M3865
499767200 JALVE GUIDE Jsed for removing valve guides.
3EMOVER
499767400 TALVE GUIDE Jsed for reaming valve guides.

3EAMER
t B2M386t
499817000 ENGINE STAND
~~
Stand used for engine disassembly and assem-

bly.
@ Used with ENGINE STAND ADAPTER RH
(498457000) & LH (498457100).
I B2M386!
ME(D0HC TURBO)-18
GENERAL DESCRIPTION
MECHANICAL

~~ ~
499977300 CRANK PULLEY Used for stopping rotation of crankshaft pulley

WRENCH when loosening and tightening crankshaft pulley
301tS.
B2M4157
499987500 CRANKSHAFT Used for rotating crankshaft.
SOCKET
B2M3871
498547000 OIL FILTER Used for removing and installing oil filter.
WRENCH
B2M3872
499587100 OIL SEAL Used for installing oil pump oil seal.
INSTALLER
ME(D0HC TURBO)-19
GENERAL DESCRIPTION
MECHANICAL

499587600 OIL SEAL GUIDE k e d for installing camshaft oil seal for DOHC
(Newly adopted 'ngine.
tool)
SlH0136
499597200 I I L SEAL GUIDE Used for installing camshaft oil seal for DOHC
(Newly adopted mgine.
tool) Used with OIL SEAL GUIDE (499587600).
EN0168
498187200 SHIM Jsed for correct valve clearance.
(Newly adopted 3 EPLACER
tool)
ENOI6E
~
498277200 STOPPER SET Used for installing automatic transmission assem-

bly to engine.
ME(D0HC TURBO)-20
GENERAL DESCRIPTION
MECHANICAL

24082AA150 CARTRIDGE Troubleshootingfor electrical systems.
02M3076
22771AA030 SELECT MONI- Troubleshootingfor electrical systems.
TOR KIT m English: 22771AA030 (Without printer)
* German: 22771AA070 (Without printer)
m French: 22771AA080 (Without printer)
m Spanish: 22771AA090 (Without printer)
2. GENERAL PURPOSE TOOLS
TOOL NAME REMARKS

Compression Gauge Used for measuring compression.
Timing Light Used for measuring ignition timing.
ME(D0HC TURBO)-21
COMPRESSION
MECHANICAL
2. Compression
A: INSPECTION
CAUTION:
After warming-up, engine becomes very hot. Be
careful not to burn yourself during measure-
ment.
1) After warming-up the engine, turn the ignition
switch to OFF.
2) Make sure that the battery is fully charged.
3) Release fuel pressure. <Ref. to FU(D0HC TUR-
BO)-51, RELEASING OF FUEL PRESSURE, OP-
ERATION, Fuel.,
4) Remove all the spark plugs. <Ref. to IG(D0HC
TURBO)-4, REMOVAL, Spark Plug.>
5) Fully open the throttle valve.
6) Check the starter motor for satisfactory perfor-
mance and operation.
7) Hold the compression gauge tight against the
spark plug hole.
CAUTION:
When using a screw-in type compression
gauge, the screw (put into cylinder head spark
plug hole) should be less than 18 mm (0.71 in)
long.
8) Crank the engine by means of the starter motor,
and read the maximum value on the gauge when
the pointer is steady.
9) Perform at least two measurements per cylinder,

and make sure that the values are correct.
Compression (350 rpm and fully open throttle):
Standard;
951- 1,147kPa(9.7- 11.7kgf/cn?, 138-
166 psi)
Limit;
834 kPa (8.5 kgf/cd, 121 psi)
Difference between c linders;
49 kPa (0.5 k g f / c d 7 psi)
ME(D0HC TURBO)-22
IDLE SPEED
MECHANICAL
3. Idle Speed
A: INSPECTION
1) Before checking the idle speed, check the follow-
ing:
(1) Ensure the air cleaner element is free from
clogging, ignition timing is correct, spark plugs
are in good condition, and that hoses are con-
nected properly.
(2) Ensure the malfunction indicator light
(CHECK ENGINE light) does not illuminate.
2) Warm-up the engine.
3) Stop the engine, and turn the ignition switch to
OFF.
4) Insert the cartridge to the SUBARU SELECT
MONITOR.
5) Connect the SUBARU SELECT MONITOR to
the data link connector.
6) Turn the ignition switch to ON, and SUBARU SE-
LECT MONITOR switch to ON.
7) Select (2. Each System Check} in Main Menu.
8) Select {Engine Control System} in Selection
Menu.
9) Select (1. Current Data Display & Save} in En-
gine Control System Diagnosis.
IO) Select (1.12 Data Display} in Data Display
Menu.
11) Start the engine, and read engine idle speed.
12) Check the idle speed when unloaded. (With
headlights, heater fan, rear defroster, radiator fan,
air conditioning, etc. OFF)
Idle speed (No load and gears in neutral:
7502100 rpm
13) Check the idle speed when loaded. (Turn the
air conditioning switch to “ON” and operate the
compressor for at least one minute before mea-
surement.)
Idle speed [A/C“ON”, no load and gears in neu-
tral]:
8002150 rpm (MT model)
8252150 rpm (AT model)
CAUTION:
Never rotate the idle adjusting screw. If the idle
speed is out of specifications, refer to General
On-board Diagnosis Table under “Engine Con-
trol System”. <Ref. to EN(D0HC TURBO)-2, Ba-
sic Diagnostic Procedure.>
ME(D0HC TU RB0)-23
zz1
IGNITION TIMING
MECHANICAL
4. lgnition Timing
A: INSPECTION
1) Before checking the ignition timing speed, check
the following:
(1) Ensure the air cleaner element is free from
clogging, spark plugs are in good condition, and
that hoses are connected properly.
(2) Ensure the malfunction indicator light
(CHECK ENGINE light) does not illuminate.
2) Warm-up the engine.
3) Stop the engine, and turn the ignition switch to
OFF.
4) Insert the cartridge to the SUBARU SELECT
MONIT0R.
5 ) Connect the SUBARU SELECT MONITOR to
the data link connector.
6) Turn the ignition switch to ON, and SUBARU SE-
LECT MONITOR switch to ON.
7) Select (2. Each System Check} in Main Menu.
8) Select {Engine Control System} in Selection
Menu.
9) Select (1. Current Data Display & Save} in En-
gine Control System Diagnosis.
10) Select (1.12 Data Display} in Data Display
Menu.
11) Start the engine, at idle speed and check the ig-
nition timing.
lgnition timing [BTDC/rpm]:
12"23"/750
If the timing is not correct, check the ignition control
system. Refer to Engine Control System. <Ref. to
EN(D0HC TURBO)-2, Basic Diagnostic Proce-
dure.>
ME(D0HC TURBO)-24
INTAKE MANIFOLD VACUUM
MECHANICAL
5. Intake Manifold Vacuum 3) Keep the engine at the idle speed and read the
vacuum gauge indication.
A: INSPECTION By observing the gauge needle movement, the in-
1) Warm-uD the enuine. ternal condition of the engine can be diagnosed as
2) Disconnect the b a k e vacuum hose and install described below.
Vacuum pressure (at idling, A/C “OFF):

Less than -60.0 kPa (-450 mmHg, -1 7.72 in-
I Diagnosis of engine condition by measurement of manifold vacuum

Vacuum gauge indication Possible engine condition
1. Needle is steady but lower than normal position. This ten- Leakage around intake manifold gasket or disconnection or
dencv becomes more evident as enaine temperature rises. damaaed vacuum hose
~
2. When engine speed is reduced slowly from higher speed, Back pressure too high, or exhaust system clogged
needle stops temporarily when it is lowering or becomes
steady above normal position.
3. Needle intermittently drops to position lower than normal Leakage around cylinder
position.
4. Needle drops suddenly and intermittently from normal posi- Sticky valves
Weak or broken valve springs

vibrate rapidly at certain speed, and then vibration increases as
enaine speed increases.
6. Needle vibrates above and below normal position in narrow Defective ignition system or throttle chamber idle adjustment
range.
ME(D0HC TURBO)-25
ENGINE OIL PRESSURE
MECHANICAL
6. Engine Oil Pressure 5) After measuring the oil pressure, install the oil
pressure switch. <Ref. to LU-23, INSTALLATION,
A: INSPECTION Oil Pressure Switch.>
1) Remove the oil pressure switch from engine cyl- Tightening torque:
inder block. <Ref. to LU-22, REMOVAL, Oil Pres- 25 N.m (2.5 kgf-m, 18.I W b )
sure Switch.>
2) Connect the oil pressure gauge hose to cylinder
block.
3) Connect the battery ground terminal to battery.
4) Start the engine, and measure oil pressure.
Oil pressure:
98 kPa (1.0 k g / c d , 14 psi) or more at 800 rpm
294 kPa (3.0 k s / c d , 43 psi) or more at 5,000
rpm
CAUTION:
If the oil pressure is out of specification,
check oil pump, oil filter and lubrication line.
<Ref. to LU-28, INSPECTION, Engine Lubrica-
tion System Trouble in General.>
If the oil pressure warning light is turned ON
and oil pressure is in specification, replace the
oil pressure switch. <Ref. t o LU-28, INSPEC-
TION, Engine Lubrication System Trouble in
General.>
NOTE:
The specified data is based on an engine oil tem-
perature of 80°C (176°F).
ME(D0HC TURBO)-26
FUEL PRESSURE
MECHANICAL
7. Fuel Pressure 4) Connect the connector of fuel pump relay.
A: INSPECTION
WARNING:
Before removing the fuel pressure gauge, re-
lease the fuel pressure.
NOTE:
If out of specification, check or replace the pressure
regulator and pressure regulator vacuum hose.
44
TURBO)-51, RELEASING OF FUEL PRESSURE, I
0PERATION, Fuel.> 5) Start the engine.
2) Open the fuel flap lid, and remove the fuel filler 6) Measure fuel pressure while disconnecting the
cap. pressure regulator vacuum hose from intake man-
ifold.
Fuel pressure:
Standard; 284 - 314 kPa (2.9 - 3.2 kgf/cd,
41 - 46 psi)
3) Disconnect the fuel delivery hoses from fuel fil-

ter, and connect the fuel pressure gauge.
7) Iter connecting the pressure regulator vacuum

hose, measure fuel pressure.
Fuel pressure:
Standard; 230 -260 kPa (2.35 -2.65 kgf/
cm’, 33 - 38 psi)
NOTE:
The fuel pressure gauge registers 10 to 20 kPa (0.1
to 0.2 kgf/cm2, 1 to 3 psi) higher than standard Val-
ues during high-altitude operations.
ME(D0HC TU RB0)-27
VALVE CLEARANCE
MECHANICAL
8. Valve Clearance 10) When inspecting #2 and #4 cylinders:

(1) Disconnect the battery terminal, and then
A: INSPECTION remove the battery and battery carrier.
CAUTION:
Inspection and adjustment of valve clearance
should be performed while engine is cold.
1) Set the vehicle onto the lift.
H6M0426
(2) Remove the bolt which secures the engine

harness bracket onto body.
3) Remove the air intake duct. <Ref. to IN(D0HC

TURBO)-8, REMOVAL, Air Intake Duct.>
4) Remove one bolt which secures the timing belt
cover (RH).
7) Loosen the remaining bolts which secure the -16M0429
timing belt cover (RH), then remove the belt cover.
8) Lower the vehicle. (3) Disconnect the washer motor connectors.
9) When inspecting #1 and #3 cylinders:
(1) Pull out the engine harness connector with
acket from air cleaner upper cover.
(4) Remove the washer tank mounting bolts.
(2) Remove the air cleaner case. <Ref. to

IN(D0HC TURBO)-7, REMOVAL, Air Cleaner.>
(3) Disconnect the spark plug cords from spark
plugs (#1 and #3 cylinders).
(4) Place a suitable container under the vehicle.
(5) Disconnect the PCV hose from rocker cover
(RH).
(6) Remove the bolts, then remove the rocker
cover (RH).
ME(D0HC TURBO)-28
VALVE CLEARANCE
m
MECHANICAL
(5) Move the washer tank upward. NOTE:

If the measured value is not within specification,
take notes of the value in order to adjust the valve
clearance later on.
(6) Disconnect the spark plug cords from spark

plugs (#2 and #4 cylinders).
(7) Place a suitable container under the vehicle.
(8) Disconnect the PCV hose from rocker cover 13) If necessary, adjust the valve clearance. <Ref.
w-0. to ME(D0HC TURBO)-30, ADJUSTMENT, Valve
(9) Remove the bolts, then remove the rocker Clearance.>
cover (LH). 14) Further turn the crankshaft pulley clockwise.
11) Turn the crankshaft pulley clockwise until arrow Using the same procedures described previously,
mark on the camshaft sprocket is set to position then measure valve clearances again.
shown in the figure. (1) Set the arrow mark on camshaft sprocket to
NOTE: position shown in the figure, and measure #2
Turn the crankshaft using ST. cylinder exhaust valve and #3 cylinder intake
ST 499987500 CRANKSHAFT SOCKET valve clearances.
#I IN. #2 EX.
#3 EX. #3 IN.
\J
S2M1192B I
r
S2M1194B I
12) Measure #1 cylinder intake valve and #3 cylin- (2) Set the arrow mark on camshaft sprocket to
der exhaust valve clearance by using thickness position shown in the figure, and measure #2
cylinder intake valve and #4 cylinder exhaust
gauge (A). valve clearances.
CAUTION:
Insert the thickness gauge in as horizontal a
direction as possible with respect to the shim.
Measure the exhaust valve clearances while
lifting-up the vehicle.
Valve clearance:
Intake: 0.20fo.02 mm (0.0079H0008 in)
Exhaust: 0.25fo.02 mm (0.0098M.0008 in)
II #2 IN
#4 EX.
S2M1195B
ME(D0HC TURBO)-29
I VALVE CLEARANCE
MECHANICAL
(3) Set the arrow mark on camshaft sprocket to B: ADJUSTMENT

position shown in the figure, and measure #I
cylinder exhaust valve and #4 cylinder intake CAUTION:
valve clearances. Adjustment of valve clearance should be per-
formed while engine is cold.
1) Measure all valve clearances. <Ref. to
ME(D0HC TURBO)-28, INSPECTION, Valve
Clearance.>
NOTE:
Record each valve clearance after it has been
measured.
#I EX.
#4 IN. S2M 11960
15) After inspection, install the related parts in the

reverse order of removal.
Tightening torques
32 N-m (3.3 kgf-m, 24 ft-lb)
B2M1234
2) Remove the shim from valve lifter.

(1) Prepare the ST.
ST 498187200 SHIM REPLACER
H2M3622
(2) Rotate the notch of the valve lifter outward

by 45".
ME(D0HC TURBO)-30
VALVE CLEARANCE
MECHANICAL
(3) Adjust the SHIM REPLACER notch to valve (6) Insert tweezers into the notch of the valve
lifter and set it. lifter, and take the shim out.
NOTE: NOTE:
When setting, be careful the SHIM REPLACER By using a magnet (A), the shim (B) can be taken
edge does not touch shim. out without dropping it.
(4) Tighten bolt (A) and install it to the cylinder
head.
(5) Tighten bolt (B) and insert the valve lifter.
B)
H2M3624A
3) Measure the thickness of shim with a microme-

ter.
H2M3623A
B2M1240
4) Select a shim of suitable thickness using mea-

sured valve clearance and shim thickness, by refer-
ring to the following table.
5) Set the suitable shim selected in step 4) to valve
lifter.
Unit: mm
Intake valve:S =(V + T)- 0.20
Exhaust valve:S =(V + T)- 0.25
S: Shim thickness to be used
V: Measured valve clearance
T: Shim thickness required
ME(D0HC TURBO)-31
VALVE CLEARANCE
MECHANICAL
13218 AKOlO 2.00 (0.0787)

13218 AK020 2.02 (0.0795)
13218 AK030 2.04 (0.0803)
13218 AK040 2.06 (0.081 1)
13218 AK050 2.08 (0.0819)
13218 AK060 2.10 (0.0827)
I 13218 AK070 I 2.12 (0.0835) 1
13218 AK080
13218 AK100 2.18 (0.0858)
I 13218 AE730 I 2.24 (0.0882) 1

13218 AE750
13218 AE790 2.30 (0.0906)
I 13218 AE850 I 2.36 (0.0929) 1

13218 AE870
13218 AE910 2.42 (0.0953)
I 13218 AE940 I 2.45 (0.0965) 1

13218 AE950
13218 AE970 2.48 (0.0976)
I 132 18 AFOOO I 2.51 (0.0988) 1

13218 AFO10 2.52 (0.0992)
132 18 AF020 2.53 (0.0996)
13218 AF030 2.54 (0.1 000)
13218 AF040 2.55 10.10041
13218 AF050 2.56 (0.1008)
I 13218 AF060 I 2.57 (0.1012) 1
13218 AF070 2.58 (0.1 016)
13218 AF090 2.60 (0.1024)
13218 AF110 2.62 (0.1031)
13218 AF130 2.64 (0.1039)
13218 AFl50 2.66 (0.1 047)
I 13218 AF170 I 2.68 (0.1055) 1
13218 AF190 2.70 (0.1063)
ME(D0HC TURBO)-32
ENGINE ASSEMBLY
MECHANICAL
9. Engine Assembly 9) Collect refrigerant, and remove the pressure

hoses.
A: REMOVAL (1) Place and connect the attachment hose to
1) Set the vehicle on lift arms. the refrigerant recycle system.
2) Open the front hood fully and support with stay. (2) Collect the refrigerant from A/C system.
3) Raise the rear seat, and turn the floor mat up. (3) Disconnect the A/C pressure hoses from A/
4) Release the fuel pressure. C compressor.
(1) Disconnect the fuel pump relay connector.
I 10) Remove the intercooler. <Ref. to IN(D0HC

(2) Start the engine, and run until stalls. TURBO)-10, REMOVAL, Intercooler.>
(3) After the engine stalls, crank it for five sec- 11) Disconnect the following connectors and cable.
onds more. (1) Engine harness connector
(4) Turn the ignition switch to "OFF".
5) Remove the filler cap.
(2) Engine ground terminal
7) Remove the radiator from vehicle. <Ref. to CO-

37, REMOVAL, Radiator.>
8) Remove the coolant filler tank. <Ref. to CO-51,
REMOVAL, Coolant Filler Tank.>
ME(D0HC TURB0)-33
ENGINE ASSEMBLY
MECHANICAL
(3) Engine harness connector 12) Disconnect the following hoses.

(1) Brake booster vacuum hose
I l l '
' S2M1930
(4) Generator connector, terminal and A/C
compressor connectors
-
(2) Heater inlet outlet hose
EN0204
(A) A/C compressor connector

13) Remove the power steering pump from brack-
et.
(B) Generator connector and terminal
(1) Loosen lock bolt and slider bolt, and remove
(5) Accelerator cable the front side V-belt. <Ref. to ME(D0HC TUR-
BO)-44, FRONT SIDE BELT, REMOVAL, V-
belt.>
(2) Disconnect the power steering switch con-
nector.
(6) Clutch release spring
ME(D0HC TURBO)-34
ENGINE ASSEMBLY
MECHANICAL
(3) Remove the pipe with bracket from intake 15) Remove the nuts which hold lower side of
manifold. transmission to engine.
(4) Remove the power steering pump from en- 16) Remove the nuts which install the front cushion
gine. rubber onto front crossmember.
I
(5) Remove the power steering tank from the 17) SeDarate the clutch release fork from release
bracket by pulling it upward. bearing. (MT vehicles)
(1) Remove the clutch operating cylinder from
transmission.
(2) Remove the plug using a 10 mm hexagon
wrench.
I
I I
(6) Place the power steering pump on the right

side wheel apron.
S2M193:

Pipe.>
ME(D0HC TURBO)-35
ENGINE ASSEMBLY
MECHANICAL
(3) Screw the 6 mm dia. bolt into release fork 19) Remove the pitching stopper.
shaft, and remove it.
20) Disconnect the fuel delivery hose, return hose

and evaporation hose.
CAUTION:
Catch fuel from hose into container.
Disconnect the hose with its end wrapped
with cloth to prevent fuel from splashing.
S2M 1936A
(A) Shaft
(6) Bolt
(4) Raise the release fork and unfasten the re-

lease bearing tabs to free release fork. I I ' .
CAUTION: 21) Remove the fuel filter and bracket.
Step (4) is required to prevent interference with
engine when removing the engine from trans-
mission.
18) Separate the torque converter clutch from drive
plate. (AT vehicles)
(1) Lower the vehicle.
(2) Remove the service hole plug.
(3) Remove the bolts which hold torque con-
verter clutch to drive plate.
(4) Remove the other bolts while rotating the
engine using ST.
ST 499977300 CRANK PULLEY WRENCH 22) Support the engine with a lifting device and wire
ropes.
ME(D0HC TURBO)-36
ENGINE ASSEMBLY
MECHANICAL
23) Support the transmission with a garage jack. 25) Remove the engine from vehicle.
CAUTION: (1) Slightly raise the engine.
Before moving the engine away from transmis- (2) Raise the transmission with garage jack.
sion, check to be sure no work has been over- (3) Move the engine horizontally until the main-
looked. Doing this is very important in order to shaft is withdrawn from clutch cover.
facilitate re-installation and because transmis- (4) Slowly move the engine away from engine
sion lowers under its own weight. compartment.
CAUTION:
Be careful not t o damage adjacent parts or
body panels with crank pulley, oil pressure
gauge, etc.
26)Remove the front cushion rubbers.
24) Separation of engine and transmission.

(1) Remove the starter. <Ref. to SC-6, RE-
MOVAL, Starter.>
(2) Install the ST to torque converter clutch
case. (AT vehicles)
ST 498277200 STOPPER SET
(3) Remove the bolts which hold right upper

side of transmission to engine.
B3M2044
ME(D0HC TURBO)-37
I ENGINE ASSEMBLY
MECHANICAL
B: INSTALLATION (4) Apply grease to the specified points.

1) Install the clutch release fork and bearing onto Spline ~ x 2 2 0 0
transmission. (MT vehicles) Shaft SUNLIGHT 2
(1) Remove the release bearing from clutch
cover with flat type screw driver. m \
(2) Install the release bearing on transmission.

(3) Install the release fork into release bearing
tab.
S2M1938A
(A) Spline (FX2200)

(B) Shaft (SUNLIGHT 2)
(5) Insert the release fork shaft into release

S2M1937A
fork.
(A) Release fork CAUTION:
(B) Release bearing Make sure the cutout portion of release fork
shaft contacts spring pin.
(A) Release fork

(B) Release shaft
(C) Spring pin
ME(D0HC TURBO)-38
ENGINE ASSEMBLY
MECHANICAL
(6) Tighten the plug. 6) Remove the garage jack.

Tightening torque:
44 N-m (4.5 kgf-m, 32.5 ff-lb)
7) Install the pitching stopper.

Tightening torques
2) Install the front cushion rubbers to engine. T I : 50 N-m (5.1 kgf-m, 37 ff-lb)
T2: 58 N.m (5.9kgf-m, 43 ff-lb)
Tightening torque:
34 N-m (3.5 kgf-m, 25.3 ft-lb)
3) Install the engine onto transmission.
(1) Position the engine in engine compartment
and align it with transmission.
CAUTION:
Be careful not to damage adjacent parts or
body panels with crank pulley, oil pressure
gauge, etc.
(2) Apply a small amount of grease to splines of
mainshaft. (MT vehicles)
4) Tighten the bolts which hold right upper side of 8) Remove the ST from torque converter clutch
transmission to engine case. (AT vehicles)
Tightening torque: NOTE:
50 N.m (5.1 kgf-m, 36.9 ff-lb) Be careful not to drop the ST into the torque con-
verter clutch case when removing ST.
9) Install the starter. <Ref. to SC-7, INSTALLA-
TION, Starter.>
B2M2791
5 ) Remove the lifting device and wire ropes.
ME(D0HC TURBO)-39
ENGINE ASSEMBLY
MECHANICAL
IO) Install the torque converter clutch onto drive (2) Install the power steering pump.
plate. (AT vehicles)
Tightening torque:
(1) Tighten the bolts which hold torque convert-
er clutch to drive plate.
20.1 N.m (2.05 kgf-m, 14.8 ft-lb)
(2) Tighten other bolts while rotating the engine
by using ST.
CAUTION:
Be careful not to drop bolts into the torque con-
verter clutch housing.
ST 499977300 CRANK PULLEY WRENCH
Tightening torque:
25 N-m (2.5 kgf-m, 18.1 ft-lb)
(3) Install the power steering pipe bracket on

right side intake manifold, and install the spark
plug codes.
(3) Clog the service hole with plug.

11) Install the fuel filter and bracket.
(4) Connect the power steering switch connec-

tor.
12) Install the power steering pump on bracket.

(1) Install the power steering tank on bracket.
(5) Install the front side V-belt, and adjust it.

<Ref. to ME(D0HC TURBO)-44, FRONT SIDE
BELT, INSTALLATION, V-belt.>
n/
EN0361
ME(D0HC TURBO)-40
m
ENGINE ASSEMBLY
MECHANICAL
13) Tighten the nuts which hold lower side of trans- 19) Install the air intake system.
mission to engine. (1) Install the intercooler. <Ref. to IN(D0HC
TURBO)-1 1, INSTALLATION, Intercooler.>
Tightening torque: (2) Install the air cleaner element and air clean-
50 N.m (5.1 kgf-m, 36.9 ft-lb) er upper cover.
(3) Install the engine harness connector brack-
et.
(4) Install the filler hose to air cleaner case.
20) Install the A/C pressure hoses.
CAUTION:
Use new O-rings.
Tightening torque:
25 N-m (2.5 kgf-m, 18.1 ft-lb)
14) Tighten the nuts which install the front cushion

rubber onto crossmember.
Tightening torque:
83 N.m (8.5 kgf-m, 61 ft-lb)
CAUTION:
Make sure the front cushion rubber mounting
bolts (A) and locator (B)are securely installed.
21) Install the radiator. <Ref. to CO-41, INSTALLA-

TION, Radiator.>
22) Install the coolant filler tank. <Ref. to CO-51,
INSTALLATION, Coolant Filler Tank.>
23) Install the window washer tank.
24) Install the battery in the vehicle, and connect
cables.
25) Fill coolant.
<Ref. to CO-25, FILLING OF ENGINE COOLANT,
REPLACEMENT, Engine Coolant.>
15) Install the center exhaust pipe. 26) Charge the A/C system with refrigerant.
<Ref. to EX(D0HC TURBO)-9, INSTALLATION, <Ref. to AC-17, OPERATION, Refrigerant Charg-
Center Exhaust Pipe.> ing Procedure.>
16) Connect the following hoses: 27) Remove the front hood stay, and close the front
(1) Fuel delivery hose, return hose and evapo- hood.
ration hose 28) Take off the vehicle from lift arms.
(2) Heater inlet and outlet hoses
(3) Brake booster vacuum hose
17) Connect the following connectors and termi-
nals:
(1) Engine ground terminal
(2) Engine harness connectors
(3) Generator connector and terminal
(4) A/C compressor connectors
18) Connect the following cables:
(2) Clutch release spring
CAUTION:
After connecting each cable, adjust them.
ME(D0HC TURBO)-41
ENGINE MOUNTING
MECHANICAL
10.Engine Mounting
A: REMOVAL
1) Remove the engine assembly. <Ref. to
ME(D0HC TURBO)-33, REMOVAL, Engine As-
sembly.>
2) Remove the engine mounting from engine as-
sembly.
B: INSTALLATION
Tightening torque:
Engine mounting;
35 N-m (3.6 kgf-m, 25.8 ft-lb)
C: INSPECTION
Make sure there are no cracks or other damage
ME(D0HC TURBO)-42
PREPARATION FOR OVERHAUL
MECHANICAL
11.Preparation for Overhaul

A: PROCEDURE
1) After removing the engine from the body, secure
it in the ST shown below.
ST1 498457000 ENGINE STAND ADAPTER
RH
ST2 498457100 ENGINE STAND ADAPTER
LH
ST3 499817000 ENGINE STAND
2) In this section the procedures described under

each index are all connected and stated in order. It
will be the complete procedure for overhauling of
the engine itself when you go through all steps in
the process.
Therefore, in this section, to conduct the particular
procedure within the flow of a section, you need to
go back and conduct the procedure described pre-
viously in order to do that particular procedure.
ME(D0HC TURBO)-43
V-BELT
MECHANICAL
12.V-belt 4) Remove the A/C belt tensioner.
A: REMOVAL
1. FRONT SIDE BELT
NOTE:
Perform the following procedures 1) to 4) with the
engine installed to the body.
1) Remove the V-belt cover.
\ S2M0113
B: INSTALLATlON
1. FRONT SIDE BELT
CAUTION:
1) Install a belt, and tighten the slider bolt so as to
obtain the specified belt tension <Ref. to
ME(D0HC TURBO)-45, INSPECTION, V-belt.>
2) Loosen the lock bolt (A). 2) Tighten the lock bolt (A)
3) Loosen the slider bolt (B). 3) Tighten the slider bolt (B).
4) Remove the front side belt (C).
Tightening torque:
Lock bolt through bolt:
25 N.m (2.5 kgf-m, 18 ft-lb)
Slider bolt:
8 N.m (0.8 kgf-m, 5.5 ff-lb)
2. REAR SIDE BELT

1) Loosen the lock nut (A).
2 ) Loosen the slider bolt (B).
EN0226
3) Remove the A/Cbelt.
ME(D0HC TURBO)-44
V-BELT
MECHANICAL
2. REAR SIDE BELT C: INSPECTION

1) Install a belt, and tighten the slider bolt (B) so as 1) Replace the belts, if cracks, fraying Or Wear is
to obtain the specified belt tension. <Ref. to found.
ME(D0HC TURBO)-45, INSPECTION, V-belt.> 2) Check the drive belt tension and adjust it if nec-
2) Tighten the lock nut (A). essary by changing generator installing position
and/or idler pulley installing position.
Tightening torque:
Lock nut (A); Belt tension
22.6 Nom(2.3 kgf-m, 16.6 ff-lb) (A)
replaced: 7 - 9 mm (0.276 - 0.354 in)
reused: 9 - 11 mm (0.354 - 0.433 in)
(B)*
replaced: 7.5 - 8.5 mm (0.295 0.335 in) -
reused: 9.0 - 10.0 mm (0.354 - 0.394 in)
*: With Air conditioner
I 98 N (10 kgf, 22 Ib)
C/P Crankshaft pulley

GEN Generator
P/S Power steering oil pump pulley
N C Air conditioning compressor pulley
I/P Idler pulley
ME(D0HC TURBO)-&
CRANKSHAFT PULLEY
MECHANICAL
13.Crankshaft Pulley 3) Confirm that the tightening angle of the crank-

shaft pulley bolt is 45 degrees or more. If not, con-
A: REMOVAL duct the following procedures (1) through (4).
1) Remove the V-belt. <Ref. to ME(D0HC TUR- CAUTION:
BO)-44, REMOVAL, V-belt.> If the tightening angle of crankshaft pulley bolt
2) Remove the crankshaft pulley bolt. To lock is less than 45 degrees, the bolt should be dam-
crankshaft, use ST. aged. In this case, the bolt must be replaced.
ST 499977300 (1) Replace the crankshaft pulley bolts and
CRANKSHAFT PULLEY WRENCH clean them.
Crankshaft pulley bolt:
12369AA011
(2) Clean the crankshaft thread using an air
gun.
(3) Tighten the bolts temporarily with tightening
torque of 44 N.m (4.5 kgf-m, 33 ft-lb).
(4) Tighten the crankshaft pulley bolts keeping
them in an angle between 65 degrees and 75
degrees.
CAUTION:
3) Remove the crankshaft pulley. Conduct the tightening procedures by confirm-
ing the turning angle of the crankshaft pulley
B: INSTALLATION bolt referring to the gauge indicated on the belt
1) Install the crankshaft pulley. cover.
2) Install the pulley bolt. 4) Install the A/C belt tensioner.
To lock the crankshaft, use ST.
ST 499977300 CRANKSHAFT PULLEY
WRENCH
(1) Clean the crankshaft pulley thread using an
air gun.
(2) Apply engine oil to the crankshaft pulley bolt
seat and thread.
(3) Tighten the bolts temporarily with tightening
torque of 44 Nom(4.5 kgf-m, 33 ft-lb).
(4) Tighten the crankshaft pulley bolts.
Tightening torque:
127 N-m (13 kgf-m, 94.0 ft-lb) 5) Install the A/C belt.
C: INSPECTION
1) Make sure the V-belt is not worn or otherwise
damaged.
2) Check the tension of the belt. <Ref. to
ME(D0HC TURBO)-46
BELT COVER
MECHANICAL
14.Belt Cover C: INSPECTION

Make sure the cover is not damaged.
A: REMOVAL
1) Remove the V-belt. <Ref. to ME(D0HC TUR-
BO)-44, REMOVAL, V-belt.>
2) Remove the crankshaft pulley. <Ref. to
ME(D0HC TURBO)-46, REMOVAL, Crankshaft
Pulley.>
3) Remove the left-hand belt cover (A).
4) Remove the right-hand belt cover (B).
5) Remove the front belt cover (C).
B: INSTALLATION
1) Install the front belt cover (C).
Tightening torque:
5 N-m (0.5 kgf-m, 3.6 ff-lb)
2) Install the right-hand belt cover (B).
Tightening torque:
5 N.m (0.5 kgf-m, 3.6 ff-lb)
3) Install the left-hand belt cover (A).
Tightening torque:
5 N-m (0.5 kgf-m, 3.6 ff-lb)
4) Install the crankshaft pulley. <Ref. to ME(D0HC

TURBO)-46, INSTALLATION, Crankshaft Pulley.>
5) Install the V-belt. <Ref. to ME(D0HC TURBO)-
44, INSTALLATION, V-belt.>
ME(D0HC TURBO)-47
TIMING BELT ASSEMBLY
MECHANICAL
15Timing Belt Assembly

A: REMOVAL
1. TIMING BELT
Pulley.>
3) Remove the belt cover. <Ref. to ME(D0HC
TURBO)-47, REMOVAL, Belt Cover.> 5) If the alignment mark and/or arrow mark (which
4) Remove the timing belt guides. (MT vehicle) indicates rotation direction) on timing belt fade
away, put new marks before removing the timing
belt as follows:
(1) Turn the crankshaft using ST, and align
alignment marks on crankshaft sprocket, left-
hand intake camshaft sprocket, left-hand ex-
haust camshaft sprocket, right-hand intake cam-
shaft sprocket and right hand exhaust camshaft
sprocket with notches of belt cover and cylinder
block.
ST 499987500 CRANKSHAFT SOCKET
EN0257
ME(D0HC TURBO)-48
MECHANICAL
(2) Using white paint, put alignment and/or ar- 7 ) Remove the timing belt.
row marks on the timing belts in relation to the CAUTION:
sprockets. After the timing belt has been removed, never
rotate the intake and exhaust, camshaft sprock-
et. If the camshaft sprocket is rotated, the in-
take and exhaust valve heads strike together
and valve stems are bent.
2. BELT IDLER AND AUTOMATIC BELT
TENSION ADJUSTER ASSEMBLY
1) Remove the belt idler (B) and (C).
S2M1226A
2) Remove the belt idler No. 2.
Z,: 54.5 tooth length

Z,: 51 tooth length
Z,: 28 tooth length
3) Remove the automatic belt tension adjuster as-

sembly.
S2M1223A
6) Remove the belt idler (A).
I I I I I I I I J S2M1226A
ME(D0HC TURBO)-49
MECHANICAL
B: INSTALLATION 2) Install the automatic belt tension adjuster as-

sembly.
1. AUTOMATIC BELT TENSION ADJUST-
ER ASSEMBLY AND BELT IDLER Tightening torque:
39 N-m (4.0 kgf-m, 28.9 ft-lb)
1) Preparation for installation of automatic belt ten-
sion adjuster assembly:
CAUTION:
Always use a vertical type pressing tool to
move the adjuster rod down.
Do not use a lateral type vise.
Push the adjuster rod vertically.
Be sure to slowly move the adjuster rod down
applying a pressure of 294 N (30kgf, 66 Ib).
Press-in the push adjuster rod gradually tak-
ing more than three minutes.
Do not allow press pressure to exceed 9,807 3) Install the belt idler No. 2.
N (1,000 kgf, 2,205 Ib).
Press the adjuster rod as far as the end sur- Tightening torque:
face of the cylinder. Do not press the adjuster 39 N.m (4.0 kgf-m, 28.9 ff-lb)
rod into the cylinder. Doing so may damage the
cylinder.
Do not release the press pressure until stop-
per pin is completely inserted.
(1) Attach the automatic belt tension adjuster
assembly to the vertical pressing tool.
(2) Slowly move the adjuster rod down with a
pressure of 294 N (30 kgf, 66 Ib) until the adjust-
er rod is aligned with the stopper pin hole in the
cy1inder.
4) Install the belt idler.

Tightening torque:
39 N.m (4.0 kgf-m, 28.9 ft-lb)
\ I 1 H2M23821
(3) With a 2 mm (0.08 in) dia. stopper pin or a 2

mm (0.08 in) (nominal) dia. hex bar wrench in-
serted into the stopper pin hole in the cylinder,
secure the adjuster rod.
ME(D0HC TURBO)-50
MECHANICAL
2. TIMING BELT (4) Align single line mark (A) on left-hand ex-
haust camshaft sprocket with notch (B) on belt
1) Preparation for installation of automatic belt ten-
cover by turning the sprocket counterclockwise
sion adjuster assembly. <Ref. to ME(D0HC TUR-
s viewed from front of engine).
BO)-50, AUTOMATIC BELT TENSION
ADJUSTER ASSEMBLY AND BELT IDLER, Tim-
ing Belt Assembly.>
2) Crankshaft and camshaft sprocket alignment.
(1) Align mark (A) on the crankshaft sprocket
with mark on the oil pump cover at cylinder
block.
( 5 ) Align single line mark (A) on left-hand intake

camshaft sprocket with notch (B) on belt cover
by turning the sprocket clockwise (as viewed
from front of engine).
Ensure double lines (C) on intake and exhaust
camshaft sprockets are aligned.
(2) Align single line mark (A) on the right-hand
exhaust camshaft sprocket with notch (B) on
beIt cover.
(3) Align single line mark (A) on the right-hand

intake camshaft sprocket with notch (B) on belt
cover.
(Make sure double lines (C) on intake camshaft
and exhaust camshaft sprockets are aligned.)
ME(D0HC TURBO)-51
MECHANICAL
(6) Ensure camshaft and crankshaft sprockets When the timing belts are not installed, four
are positioned properly. camshafts are held at the “zero-lift” position,
CAUTION: where all cams on camshafts do not push the
Intake and exhaust camshafts for this DOHC intake and exhaust valves down. (Under this
engine can be independently rotated with the condition, all valves remain unlifted.)
timing belts removed. As can be seen from the When the camshafts are rotated to install the
figure, if the intake and exhaust valves are lifted timing belts, #2 intake and #4 exhaust cam of
simultaneously, their heads will interfere with left-hand camshafts are held to push their cor-
each other, resulting in bent valves. responding valves down. (Under this condition,
these valves are held lifted.) Right-side cam-
shafts are held so that their cams do not push
valves down.
Left-hand camshafts must be rotated from
the “zero-lift” position to the position where the
timing belt is to be installed at as small an angle
as possible, in order to prevent mutual interfer-
ence of intake and exhaust valve heads.
Do not allow the camshafts to rotate in the di-
rection shown in the figure as this causes both
intake and exhaust valves to lift simultaneous-
ly, resulting in interference with their heads.
I Rotate direction
(B) B2M1392B
(A) Intake camshaft

(B) Exhaust camshaft
S2M1231A
ME(D0HC TURBO)-52
MECHANICAL
3) Installation of timing belt:
S2M0410
Align the alignment mark on the timing belt with marks on the sprockets in the alphabetical order shown in
the figure. While aligning marks, position the timing belt properly.
CAUTION:
Disengagement of more than three timing belt teeth may result in interference between the valve
and piston.
Ensure the belt’s rotating direction is correct.
Arrow mark Timing belt

I /
28 tooth
r
54.5 tooth length
--
51 tooth length
- -_ . 28 tooth
length ength
(E)
/
Install it in the end.
b !I
S2M1232P
I
ME(D0HC TURBO)-53
' TIMING BELT ASSEMBLY
MECHANICAL
4) Install the belt idlers.

Tightening torque:
39 N.m (4.0kgf-m, 28.9 ft-lb)
CAUTION:
Make sure that the marks on the timing belt and
sprockets are aligned.
5) After ensuring that the marks on the timing belt

and sprockets are aligned, remove the stopper pin
from tensioner adjuster.
6) Install the timing belt guide. (MT vehicle)
(1) Temporarily tighten the remaining bolts. (3) Tighten the remaining bolts.
(2) Check and adjust clearance between the
timing belt and timing belt guide. Tightening torque:
9.8 N.m (1.0kgf-m, 7.2 ft-lb)
Clearance:
1.020.5 mm (0.039M.020in)
EN0254
ME(D0HC TURBO)-54
m
MECHANICAL
C: INSPECTION
1. TIMING BELT
1) Check the timing belt teeth for breaks, cracks,
and wear. If any fault is found, replace the belt.
2) Check the condition of back side of belt; if any
crack is found, replace the belt.
CAUTION:
Be careful not to let oil, grease or coolant
contact the belt. Remove quickly and thorough-
ly if this happens.
Do not bend the belt sharply.
Bending radius: h
60 mm (2.36 in) or more
7) Install the belt cover. <Ref. to ME(D0HC TUR-

BO)-47, INSTALLATION, Belt Cover.>
G2M0115
TURBO)-46, REMOVAL, Crankshaft Pulley.>
ME(D0HC TURBO)-55
MECHANICAL
2. AUTOMATIC BELT TENSION ADJUST- 3. BELT TENSION PULLEY

ER 1) Check the mating surfaces of timing belt and
1) Visually check the oil seals for leaks, and rod contact point of adjuster rod for abnormal wear or
ends for abnormal wear or scratches. If necessary, scratches. Replace the belt tension pulley if faulty.
replace the automatic belt tension adjuster assem- 2) Check the belt tension pulley for smooth rotation.
bly. Replace if noise or excessive play is noted.
CAUTION: 3) Check the belt tension pulley for grease leakage.
Slight traces of oil at rod's oil seal does not in- 4. BELTIDLER
dicate the a problem.
1) Check the idler for smooth rotation. Replace if
2) Check that the adjuster rod does not move when noise or excessive play is noted.
a pressure of 294 N (30 kgf, 66 Ib) is applied to it. 2) Check the outer contacting surfaces of idler pul-
This is to check adjuster rod stiffness. ley for abnormal wear and scratches.
3) If the adjuster rod is not stiff and moves freely 3) Check the idler for grease leakage.
when applying 294 N (30 kgf, 66 Ib), check it using
the following procedures:
(1) Slowly press the adjuster rod down to the
end surface of the cylinder. Repeat this motion 2
or 3 times.
(2) With the adjuster rod moved all the way up,
apply a pressure of 294 N (30 kgf, 66 Ib) to it.
Check the adjuster rod stiffness.
(3) If the the adjuster rod is not stiff and moves
down, replace the automatic belt tension adjust-
er assembly with a new one.
CAUTION:
Always use a vertical type pressing tool to
move the adjuster rod down.
Do not use a lateral type vise.
Push the adjuster rod vertically.
Press-in the push adjuster rod gradually tak-
ing more than three minutes.
Do not allow press pressure to exceed 9,807
N (1,000 kgf, 2,205 Ib).
Press the adjuster rod as far as the end sur-
face of the cylinder. Do not press the adjuster
rod into the cylinder. Doing so may damage the
cylinder.
4) Measure the extension of rod beyond the body. If
it is not within specifications, replace with a new
one.
Rod extension: H
5.7fo.5 mm (0.224fo.020in)
ME(D0HC TURBO)-56
m
CAMSHAFT SPROCKET
MECHANICAL
16.Camshaft Sprocket B: INSTALLATION

1) Install the camshaft sprocket No. 1. and No. 2.
A: REMOVAL To lock camshaft, use ST.
1) Remove the V-belt. <Ref. to ME(D0HC TUR- ST 499207100 CAMSHAFT SPROCKET
BO)-44, REMOVAL, V-belt.> WRENCH
ME(D0HC TURBO)-46, REMOVAL, Crankshaft Tightening torque:
Pulley.> 98 N-m (IO kgf-m, 72.4 ft-lb)
3) Remove the belt cover. <Ref. to ME(D0HC CAUTION:
TURBO)-47, REMOVAL, Belt Cover.> Do not confuse left and right side camshaft
4) Remove the timing belt assembly. <Ref. to sprockets during installation. The camshaft
ME(D0HC TURBO)-48, REMOVAL, Timing Belt sprocket No. 2 is identified by a projection used
Assembly.> to monitor camshaft position sensor.
5) Remove the camshaft position sensor. <Ref. to
FU(D0HC TURBO)-31, REMOVAL, Camshaft Po-
sition Sensor.>
6) Remove the camshaft sprockets. To lock the
camshaft, use ST.
ST 499207400 CAMSHAFT SPROCKET
WRENCH
2M1879A
2) Install the camshaft position sensor. <Ref. to

FU(D0HC TURBO)-31, INSTALLATION, Cam-
shaft Position Sensor.>
3) Install the timing belt assembly. <Ref. to
ME(D0HC TURBO)-50, INSTALLATION, Timing
Belt Assembly.>
TURBO)-46, INSTALLATION, Crankshaft Pulley.>
C: INSPECTION
1) Check the sprocket teeth for abnormal wear and
scratches.
2) Make sure there is no free play between sprock-
et and key.
3) Check the crankshaft sprocket notch used for
sensor for damage and contamination of foreign
matter.
ME(D0HC TURBO)-57
CRANKSHAFT SPROCKET
MECHANICAL
17.Crankshaft Sprocket B: INSTALLATION

1) Install the crankshaft sprocket.
A: REMOVAL
PuHey.>
TURBO)-47, REMOVAL, Belt Cover.>
4) Remove the timing belt assembly. <Ref. to
ME(D0HC TURBO)-48, REMOVAL, Timing Belt
Assembly .> EN0263
5) Remove the camshaft sprocket. <Ref. to
2) Install the camshaft sprocket. <Ref. to
ME(D0HC TURBO)-57, REMOVAL, Camshaft
ME(D0HC TURBO)-57, INSTALLATION, Cam-
Sprocket.>
s haft Sprocket.>
6) Remove the crankshaft sprocket.
Belt Assembly.>
TURB0)-46, INSTALLATION, Crankshaft PuIley.>
C: INSPECTION
1) Check the sprocket teeth for abnormal wear and
scratches.
2) Make sure there is no free play between sprock-
et and key.
3) Check the crankshaft sprocket notch used for
sensor for damage and contamination of foreign
matter.
ME(DOHC TU RBO)-58
I
CAMSHAFT
MECHANICAL
18.Camshaft 10) Remove the oil level gauge guide. (LH side
only)
A: REMOVAL 11) Remove the spark plug cord.
I ) Remove the V-belt. <Ref. to ME(D0HC TUR- 12) Remove the rocker cover and gasket.
BO)-44, INSTALLATION, V-belt.> 13) Loosen the intake camshaft cap bolts equally, a
2) Remove the crankshaft pulley. <Ref. to little at a time in alphabetical sequence shown in
ME(D0HC TURBO)-46, REMOVAL, Crankshaft the figure.
Pulley.>
Assembly.>
5 ) Remove the camshaft sprocket. <Ref. to
Sprocket.>
6) Remove the crankshaft sprocket. <Ref. to
U
ME(D0HC TURBO)-58, REMOVAL, Crankshaft L U
S2M1233A
Sprocket.> 14) Remove the camshaft caps and intake cam-
7) Remove the right-hand belt cover No.2. shaft.
15) Loosen the exhaust camshaft cap bolts equally,
a little at a time in alphabetical sequence shown in
the figure.
8) Remove the tensioner bracket.
16) Remove the camshaft caps and exhaust cam-

shaft.
CAUTION:
Arrange camshaft caps in order so that they
can be installed in their original positions.
17) Similarly, remove the right-hand camshafts and
related parts.
9) Remove the left-hand belt cover No. 2.
S2M1162
ME(DOHC TU RBO)-59
I
CAMSHAFT
MECHANICAL
B: INSTALLATION 2) Camshaft cap installation:

1) Camshaft installation: (1) Apply fluid packing sparingly to the cap mat-
Apply engine oil to the cylinder head at camshaft ing surface.
bearing location before installing the camshaft. In- CAUTION:
stall the camshaft so that each valves is close to or Do not apply fluid packing excessively. Failure
in contact with “base circle” of cam lobe. to do so may cause excess packing to come out
CAUTION: and flow toward oil seal, resulting in oil leaks.
When the camshafts are positioned as shown Fluid packing:
in the figure, camshafts need to be rotated at a THREE BOND 1215 or equivalent
minimum to align with the timing belt during in-
stallation.
Right-hand camshaft need not be rotated
when set at the position shown in the figure.
Left-hand intake camshaft: Rotate 80” clock-
wise.
Left-hand exhaust camshaft: Rotate 45” coun-
terclockwise.
A
h
(2) Apply engine oil to cap bearing surface and

install the cap on camshaft as shown by identifi-
cation mark (A).
(3) Gradually tighten the cap in at least two
stages in alphabetical sequence shown in the
figure, and then tighten to specified torque.
Tightening torque:
20 N.m (2.0 kgf-m, 14.5 ft-16)
I U U S2M 1233A
A Left side cylinder head (4) Similarly, tighten the cap on exhaust side.
B Right side cylinder head After tightening the cap, ensure the camshaft ro-
(a) Intake camshaft tates only slightly while holding it at “base” circle.
(b) Exhaust camshaft
Tightening torque:
20 Nom(2.0 kgf-m, 14.5 ft-16)
ME(D0HC TURBO)-60
CAMSHAFT
MECHANICAL
3) Camshaft oil seal installation: 7) Install the right-hand belt cover No. 2.
Apply grease to the new oil seal lips and press onto Tightening torque:
the front end of camshaft by using ST1 and ST2. 5 N-m (0.5 kgf-m, 3.6 ft-lb)
CAUTION:
Use a new oil seal.
ST1 499587600 OIL SEAL INSTALLER
ST2 499597200 OIL SEAL GUIDE
8) Install the tensioner bracket.

Tightening torque:
25 N-m (2.5 kgf-m, 18.1 fWb)
4) Rocker cover installation:
(1) Install the gasket on rocker cover.
Install the peripheral gasket and ignition coil
gasket.
(2) Apply fluid packing to four front open edges
of peripheral gasket.
Fluid packing:
THREE BOND 1215 or equivalent
9) Install the left-hand belt cover No. 2.

Tightening torque:
5 N.m (0.5 kgf-m, 3.6 ft-lb)
(3) Install the rocker cover on cylinder head.

Ensure the gasket is properly positioned during
installation.
5) Install the spark plug cord.
6) Similarly, install the parts on right-hand side. S2M1162
10) Install the crankshaft sprocket. <Ref. to

ME(D0HC TURBO)-58, INSTALLATION, Crank-
shaft Sprocket.>
11) Install the camshaft sprockets. <Ref. to
shaft Sprocket.>
Belt Assembly.>
ME(D0HC TURBO)-61
CAMSHAFT
MECHANICAL
14) Install the crankshaft pulley. <Ref. to C: INSPECTION

ME(DOHC TURBO)-467 INSTALLATION, Crank- 1) Measure the bend, and repair or replace if nec-
shaft Pulley.> essary.
44, INSTALLATION, V-belt.> Limit:
0.020 mm (0.0008 in)
2) Check the journal for damage and wear. Re-

place if faulty.
Front Center, rear
I Standard I 37.946-37.9635 mm 29.946 - 29.963 mm

(1.4939- 1.4946 in) (1.1790- 1.1796 in) I
4) Measurement of the camshaft journal oil clear-
ance:
(1) Clean the bearing caps and camshaft jour-
nals.
(2) Place the camshafts on the cylinder head.
(Without installing the valve rocker.)
(3) Place a plastigauge across each of the cam-
shaft jounals.
(4) Gradually tighten the cap in at least two
stages in alphabetical sequence shown in the
figure, and then tighten to specified torque.
Tightening torque:
20 N-m (2.0 kgf-m, 14.5 ff-lb)
I U U S2M1233A I
CAUTION:
Do not turn the camshaft.
ME(DOHC TU R BO)-62
CAMSHAFT
MECHANICAL
(5) Remove the bearing caps. 6) Measure the thrust clearance of camshaft with
(6) Measure the widest point of the plastigauge dial gauge. If the clearance exceeds the limit, re-
on each journal. place the caps and cylinder head as a set. If neces-
If the oil clearance exceeds the limit, replace the sary replace the camshaft.
camshaft. If necessary, replace the camshaft Standard:
caps and cylinder head as a set. 0.015 - 0.070 mm (0.0006 - 0.0028 in)
Standard: Limit:
0.037 - 0.072 mm (0.0015 - 0.0028 in) 0.1 mm (0.004 in)
Limit:
0.10 mm (0.0039 in)
(7) Completely remove the plastigauge.

5) Check the cam face condition; remove the minor
faults by grinding with oil stone. Measure the cam
height H;replace if the limit has been exceeded.
Cam height: H
Standard:
Intake:
46.25 - 46.35 mm (1.821 - 1.825 in)
Exhaust:
-
46.15 46.25 mm (1.817 - 1.821 in)
Limit:
Intake:
46.15 mm (7.81 7 in)
Exhaust:
46.05 mm (1.813 in)
Cam base circle diameter A:
37.0 mm (1.457 in)
I t
A
B2M1209A
ME(D0HC TURBO)-63
CYLINDER HEAD ASSEMBLY
MECHANICAL
19.Cylinder Head Assembly 10) While tapping the cylinder head with a plastic
hammer, separate it from cylinder block.
A: REMOVAL Remove the bolts (A) and (D) to remove the cylin-
1) Remove the V-belt. <Ref. to ME(D0HC TUR- der head.
BO)-44, REMOVAL, V- belt.>
I n n

PuHey.>
Assembly.>
5 ) Remove the camshaft sprocket. <Ref. to
ME(D0HC TURBO)-57, REMOVAL, Camshaft B2M1397C
Sprocket.> 11) Remove the cylinder head gasket.
TURBO)-15, REMOVAL, Intake Manifold.> CAUTION:
7) Remove the bolt which installs the A/C compres- Do not scratch the mating surface of cylinder
sor bracket on cylinder head. head and cylinder block.
8) Remove the camshaft. <Ref. to ME(D0HC TUR- 12) Similarly, remove the right side cylinder head.
BO)-59, REMOVAL, Camshaft.> B: INSTALLATION
9) Remove the cylinder head bolts in alphabetical
1) Install the cylinder head and gaskets on cylinder
sequence shown in the figure.
block.
CAUTION:
CAUTION:
Leave bolts (A) and (D) engaged by three or
Use new cylinder head gaskets.
four threads to prevent the cylinder head from
falling. Be careful not to scratch the mating surface
of cylinder head and cylinder block.
2) Tighten the cylinder head bolts.
(1) Apply a coat of engine oil to washers and
bolt threads.
(2) Tighten all bolts to 29 N.m (3.0 kgf-m, 22 ft-
Ib) in alphabetical sequence.
Then tighten all bolts to 69 N-m(7.0 kgf-m, 51 ft-
Ib) in alphabetical sequence.
(3) Back off all bolts by 180" first; back them off
by 180" again.
U U B2M1397C (4) Tighten the bolts (A) and (B) to 34 N-m (3.5
kgf-m, 25 ft-lb).
I n n
ME(DOHC TURB0)-64
(5) Tighten the bolts (C), (D), (E) and (F) to 15 C: DISASSEMBLY
N-m (1.5 kgf-m, 11 ft-lb). 1) Remove the valve shims and valve lifters.
n n 2) Compress the valve spring and remove the valve
spring retainer key. Remove each valve and valve
spring.
ST1 498267600 CYLINDER HEAD TABLE
ST2 499718000 VALVE SPRING REMOVER
CAUTION:
Keep the removed parts in order for re-install-
ing in their original positions.
Mark each valve to prevent confusion.
Use extreme care not to damage the lips of
the intake valve oil seals and exhaust valve oil
(6) Tighten all bolts by 80 to 90" in alphabetical seals.
sequence.
CAUTION:
Do not tighten the bolts more than 90".
(7) Further tighten all bolts by 80 to 90" in al-
phabetical sequence.
CAUTION:
Ensure the total "re-tightening angle" [in the
two previous steps] do not exceed 180".
3) Install the camshaft. <Ref. to ME(D0HC TUR-
BO)-60, INSTALLATION, Camshaft.> SZM1881A
4) Install the A/C compressor bracket on cylinder
head.
5) Install the intake manifold. <Ref. to FU(D0HC
TURBO)-18, INSTALLATION, Intake Manifold.>
6) Install the camshaft sprocket. <Ref. to
shaft Sprocket.>
Belt Assembly.>
TU RBO)-46, INSTALLAT10N, Crankshaft PuIley.>
ME(D0HC TURBO)-65
MECHANICAL
D: ASSEMBLY
S2M1197A
(1) Exhaust valve (6) Valve spring (1 1) Exhaust valve oil seal
(2) Intake valve (7) Retainer (1 2) Intake valve guide
(3) Cylinder head (8) Retainer key (13) Exhaust valve guide
(4) Valve spring seat (9) Valve lifter
(5) Intake valve oil seal (10) Shim
ME(D0HC TURBO)-66
m
1) Installation of valve spring and valve: E: INSPECTION

(1) Coat the stem of each valve with engine oil
and insert the valve into valve guide. 1. CYLINDER HEAD
CAUTION: 1) Make sure that no crack or other damage exists.
When inserting the valve into valve guide, use In addition to visual inspection, inspect the impor-
special care not to damage the oil seal lip. tant areas by means of red check.
(2) Set the cylinder head on STI, 2) Measure the warping of the cylinder head sur-
(3) Install the valve spring and retainer using face that mates with crankcase by using a straight
ST2. edge (A) and thickness gauge (B).
ST1 498267600 CYLINDER HEAD TABLE If the warping exceeds 0.05 mm (0.0020 in), re-
grind the surface with a surface grinder.
ST2 499718000 VALVE SPRING REMOVER
CAUTION: Warping limit:
Be sure to install the valve springs with their 0.05 mm (0.0020 in)
close-coiled end facing the seat on the cylinder Grinding limit:
head. 0.3 mm (0.012 in)
Standard height of cylinder head:
127.5 mm (5.02 in)
CAUTION:
Uneven torque for the cylinder head nuts can
cause warping. When reassembling, pay spe-
cial attention to the torque so as to tighten
evenly.
(4) Compress the valve spring and fit the valve

spring retainer key.
(5) After installing, tap the valve spring retainers
lightly with wooden hammer for better seating.
2) Apply oil to the surface of the valve lifter and
valve shim.
3) Install the valve lifter and valve shim.
ME(D0HC TURBO)-67
MECHANICAL
2. VALVESEAT 2) If the clearance between valve guide and stem

Inspect the intake and exhaust valve seats, and exceeds the limit, replace the valve guide or valve
correct the contact surfaces with valve seat cutter if itself whichever shows greater amount of wear.
they are defective or when valve guides are re- See the following procedure for valve guide re-
placed. placement.
Valve seat width: W Valve guide inner diameter:

Intake 6.000 - 6.012 mm (0.2362 - 0.2367 in)
Standard Valve stem outer diameters:
1.0 mm (0.039 in) Intake
Limit 5.950 - 5.965 mm (0.2343 - 0.2348 in)
1.7 mm (0.067 in) Exhaust
Exhaust 5.945 - 5.960 mm (0.2341 - 0.2346 in)
Standard (1) Place the cylinder head on STI with the
1.5 mm (0.059 in) combustion chamber upward so that valve
Limit guides enter the holes in ST1.
2.2 mm (0.087 in) (2) Insert the ST2 into valve guide and press it
down to remove the valve guide.
ST2 499767200 VALVE GUIDE REMOVER
\ ,
G2M0761
3. VALVE GUIDE
1) Check the clearance between valve guide and
stem. The clearance can be checked by measuring
the outside diameter of valve stem and the inside (3) Turn the cylinder head upside down and
diameter of valve guide with outside and inside mi- place ST as shown in the figure.
crometers respectively. ST 498767700 VALVE GUIDE ADJUSTER
Clearance between the valve guide and valve
L
stem:
Standard
Intake
0.035 - 0.062 mm (0.0014 - 0.0024 in)
Exhaust
0.040 - 0.067 mm (0.0016 - 0.0026 in)
Limit
0.15 mm (0.0059 in)
(4) Before installing a new valve guide, make

sure that neither scratches nor damages exist
on the inside surface of the valve guide holes in
cylinder head.
ME(D0HC TURBO)-68
CYLINDER HEAD ASSEMBLY m
MECHANICAL
(5) Put a new valve guide, coated with sufficient 4. INTAKE AND EXHAUST VALVE
oil, in cylinder, and insert ST1 into valve guide.
1) Inspect the flange and stem of valve, and re-
Press in until the valve guide upper end is flush
place if damaged, worn, or deformed, or if “H” is
with the upper surface of ST2.
less than the specified limit.
ST2 498267700 VALVE GUIDE ADJUSTER H:
Intake
Standard
1.2 mm (0.047 in)
Limit
0.8 mm (0.031 in)
Exhaust
Standard
1.5 mm (0.059 in)
Limit
0.8 mm (0.031 in)
S2M1883A
Valve overall length:
(6) Check the valve guide protrusion. Intake
Valve guide protrusion: L 104.4 mm (4.110in)
-
12.0 - 12.4 mm (0.472 0.488 in) Exhaust
104.7 mm (4.122 in)
(7) Ream the inside of valve guide with 3T.
Gently rotate the reamer clockwise while press-
ing it lightly into the valve guide, and return it
also rotating clockwise. After reaming, clean the
valve guide to remove chips.
ST 499767400 VALVE GUIDE REAMER
CAUTION:
Apply engine oil to the reamer when reaming.
If the inner surface of the valve guide is torn,
the edge of the reamer should be slightly
ground with an oil stone.
If the inner surface of the valve guide be-
comes lustrous and the reamer does not chips,
use a new reamer or remedy the reamer.
(8) Recheck the contact condition between
valve and valve seat after replacing the valve
guide.
G2M0153
2) Put a small amount of grinding compound on the

seat surface and lap the valve and seat surface.
Install a new intake valve oil seal after lapping.
ME(D0HC TURBO)-69
I CYLINDER HEAD ASSEMBLY
MECHANICAL
5. VALVE SPRINGS 6. INTAKE AND EXHAUST VALVE OIL

1) Check the valve springs for damage, free length, SEAL
and tension. Replace the valve spring if it is not Replace the oil seal with a new one, if the lip is
within specifications presented in the table. damaged or spring out of place, or when the surfac-
2) To measure the squareness of the valve spring, es of intake valve and valve seat are reconditioned
stand the spring on a surface plate and measure its or intake valve guide is replaced.
deflection at the top using a try square. 1) Place the cylinder head on ST1.
2) Press in the oil seal to the specified dimension
I 1 Valve spring I indicated in the figure by using ST2.
Free length 44.67 mm (1.7587 in)
220.7t15.7 N
(22.5 f 1.6 kgf, 49.6f3.5 lb)/36.0 mm
Tensiontspring (1.417 in) CAUTION:
height 510.9f25.5 N Apply engine oil to oil seal before force-fit-
(52.1f2.6 kgf, 114.9f5.7 lb)/26.6 mm ting.
(1.047 in) Differentiate between the intake valve oil seal
I Squareness I 2.5", 2.0 mm (0.079 in) I and exhaust valve oil seal by noting their differ-
ence in color.
Color of rubber part:
Intake [Black]
Exhaust [Brown]
Color of spring part:
Intake [Silver]
Exhaust [Silver]
S2M1924A
ME(D0HC TURBO)-70
MECHANICAL
7. VALVE LIFTER
1) Check the valve lifter visually.
2) Measure the outer diameter of valve lifter.
Outer diameter:
34.959 - 34.975 mm (1.3763 - 1.3770 in)
02M122;
3) Measure the inner diameter of valve lifter mating

part on cylinder head.
Inner diameter:
34.994 - 35.016 mm (1.3777 - 1.3786 in)
1400
CAUTION:
If difference between outer diameter of valve
lifter and inner diameter of valve lifter mating
part is over the limit, replace the cylinder head.
Standard:
0.019 - 0.057 mm (0.0007 - 0.0022 in)
Limit:
0.100 mm (0.0039 in)
ME(D0HC TURBO)-71
iia
CYLINDER BLOCK
MECHANICAL
2O.Cylinder Block 16) Remove the oil cooler.
A: REMOVAL
NOTE:
Before conducting this procedure, drain the engine
oil completely if applicable.
Pulley.>
Assembly .>
6) Remove the camshaft sprocket. <Ref. to
Sprocket.>
7) Remove the crankshaft sprocket. <Ref. to
Sprocket.>
(a) Gasket
8) Remove the generator and A/C compressor with
their brackets. (b) Oil cooler
9) Remove the cylinder head assembly. <Ref. to (c) Connector
ME(D0HC TURBO)-64, REMOVAL, Cylinder 17) Removal of oil pan:
Head Assembly.> (1) Turn the cylinder block with #2 and #4 piston
10) Remove the clutch disc and cover. (MT vehi- sides facing upward.
cles) <Ref. to CL-11, REMOVAL, Clutch Disc and (2) Remove the bolts which secure oil pan to
Cover.> cylinder block.
11) Remove the flywheel. (MT vehicles) <Ref. to
(3) Insert a oil pan cutter blade between cylin-
CL-14, REMOVAL, Flywheel.>
der block-to-oil pan clearance and remove the
12) Remove the drive plate. (AT vehicles) oil pan.
Using the ST, lock crankshaft.
ST 498497100 CRANKSHAFT STOPPER CAUTION:
Do not use a screwdriver or similar tool in place
of oil pan cutter.
13) Remove the oil separator cover.

14) Remove the water by-pass pipe for heater.
15) Remove the oil filter. 18) Remove the oil strainer stay.
19) Remove the oil strainer.
20) Remove the baffle plate.
21) Remove the water pipes.
22) Remove the water pump.
ME(DOHC TUR BO)-72

CYLINDER BLOCK
MECHANICAL
23) Remove the oil pump from cylinder block.

Use a flat-bladed screwdriver as shown in the fig-
ure when removing the oil pump.
CAUTION:
Be careful not to scratch the mating surface of
cylinder block and oil pump.
\\ \\
S2M1819 I
EN029r
(1) Service hole plug (3) Circlip (5) Service hole cover
(2)
~, Gasket (4) Piston pin (6) O-ring
24) Remove the service hole cover and service 25) Rotate the crankshaft to bring # 1 and #2 pis-
hole plugs using the hexagon wrench [14 mm (0.55 tons to bottom dead center position, then remove
in)]. the piston circlip through service hole of #1 and #2
cylinders.
ME(D0HC TURBO)-73
CYLINDER BLOCK
MECHANICAL
26) Draw out the piston pin from #1 and #2 pistons 27) Similarly remove the piston pins from #3 and #4
using ST. pistons.
ST 499097700 PISTON PIN REMOVER 28) Remove the bolts which connect cylinder block
on the side of #2 and #4 cylinders.
CAUTION:
Be careful not to confuse the original combina- 29) Back off the bolts which connect cylinder block
tion of piston, piston pin and cylinder. on the side of #1 and #3 cylinders two or three
turns.
I I
30) Set up the cylinder block so that #1 and #3 cyl-
inders are on the upper side, then remove the cyl-
inder block connecting bolts.
31) Separate the left-hand and right-hand cylinder
blocks.
CAUTION:
When separating the cylinder block, do not al-
low the connecting rod to fall and damage the
cylinder block.
\ + G2M0166
B2M2408r
(1) Cylinder block (3) Crankshaft (5) Piston

(2) Rear oil seal
\ ,
(4)
. . Crankshaft bearing
32) Remove the rear oil seal. Press the bearing at the end opposite to locking
33) Remove the crankshaft together with connect- lip.
ing rod. 35) Draw out each piston from cylinder block using
34) Remove the crankshaft bearings from cylinder a wooden bar or hammer handle.
block using a hammer handle. CAUTION:
CAUTION: Do not confuse the combination of piston and
Do not confuse the combination of crankshaft cylinder.
bearings.
ME(D0HC TURBO)-74
CYLINDER BLOCK
MECHANICAL
B: INSTALLATION
02M2407E
(1) Crankshaft bearing (4) Rear oil seal Tightening torque: N-m (kgf-m, ft-lb)
(2) Crankshaft T1: 25 (2.5, 78.1)
(3) Cylinder block T2: 47 (4.8, 34.7)
CAUTION:
Remove oil in the mating surface of bearing and
cylinder block before installation. Also apply a
1
coat of engine oil to crankshaft pins.
1) Position the crankshaft on the #2 and #4 cylinder
block.
2) Apply fluid packing to the mating surface of #1
and #3 cylinder block, and position it on #2 and #4
cylinder block.
Fluid packing:
Is !M 1826A
CAUTION:
Do not allow fluid packing to jut into O-ring
grooves, oil passages, bearing grooves, etc.
ME(D0HC TURBO)-75
I CYLINDER BLOCK
MECHANICAL
3) Temporarily tighten the 10 mm cylinder block 6) Install the rear oil seal using ST1 and ST2.
connecting bolts in alphabetical sequence shown in ST1 499597100 OIL SEAL GUIDE
the figure. ST2 499587200 OIL SEAL INSTALLER
I B2M0088D I ' ~ ' S2M1827A
4) Tighten the 10 mm cylinder block connecting

(A) Rear oil seal
bolts in alphabetical sequence.
(B) Flywheel attaching bolt
Tightening torque:
47 N.m (4.8 kgf-m, 34.7 ft-lb) 7) Position the top ring gap at (A) or (B) in the fig-
ure.
180"
(B)
B2M0088D
EN0304
5) Tighten the 8 mm and 6 mm cylinder block con-
necting bolts in alphabetical sequence shown in the 8) Position the second ring gap at 180" on the re-
figure. verse side for the top ring gap.
9) Position the upper rail gap at (C) or (D) in the fig-
Tightening torque: ure.
(A) - (G): 25 N-m (2.5 kgf-m, 18.1 ft-lb)
(H): 6.4 N-m (0.65 kgf-m, 4.7 ft-lb)
EN0305
B2M0089F
10) Position the expander gap at 180" of the re-
verse side for the upper rail gap.
ME(DOHC TURB0)-76
CYLINDER BLOCK
MECHANICAL
11) Position the lower rail gap at (E) or (F)in the fig- CAUTION:
ure. Use new circlips.
CAUTION:
Ensure ring gaps do not face the same direc-
tion.
Ensure ring gaps are not within the piston
skirt area.
Front side #2
B2M1403A
CAUTION:
Piston front mark faces towards the front of the
engine.
EN0305
12) Installing the circlip:

Install the circlips in piston holes located opposite
of the service holes in cylinder block, when posi-
tioning all pistons in the corresponding cylinders.
(A) Front mark
(1) Piston (4) Gasket Tightening torque: N.m (kgf-m, ft-lb)

(2) Piston pin (5) Service hole plug T: 69 (7.0, 50.6)
(3) Circlip
ME(D0HC TURBO)-77
CYLINDER BLOCK
MECHANICAL
13) Installing the piston: (3) Install the circlip.

(1) Turn the cylinder block so that #1 and #2 cyl- CAUTION:
inders face upward. Use new circlips.
(2) Using ST1, turn the crankshaft so that #1
and #2 connecting rods are set at bottom dead
center.
ST1 499987500 CRANKSHAFT SOCKET
(3) Apply a coat of engine oil to the pistons and
cylinders and insert pistons in their cylinders us-
ing ST2.
ST2 498744300 PISTON GUIDE
S2M 1828
(4) Apply fluid packing around the service hole

Plug.
Fluid packing:
14) Installing piston pin:

(1) Insert ST3 into service hole to align piston
pin hole with connecting rod small end.
CAUTION:
Apply a coat of engine oil to ST3 before inser-
tion.
ST3 499017100 PISTON PIN GUIDE B2M2625
( 5 ) Install the service hole plug and gasket.

CAUTION:
Use a new gasket.
(2) Apply a coat of engine oil to the piston pin

and insert piston pin into piston and connecting
rod through service hole.
ME(D0HC TURBO)-78
a
CYLINDER BLOCK
MECHANICAL
(1) Piston (5) Service hole plug Tightening torque: N.m (kgf-m, ft-lb)
(2) Piston pin (6) Service hole cover T1: 6.4 (0.65, 4.7)
(3) Circlip (7) O-ring T2: 69 (7.0, 50.6)
(4) Gasket
(6) Turn the cylinder block so that #3 and #4 cyl- 19) Apply fluid packing to matching surfaces and
inders face upward. Using the same procedures install the oil pan.
as used for #1 and #2 cylinders, install the pis- Fluid packing:
tons and piston pins. THREE BOND 1215 or equivalent
15) Install the water pipe.
16) Install the baffle plate.
Tightening torque:
6.4 N.m (0.65 kgf-m, 4.7 ff-lb)
17) Install the oil strainer and O-ring
Tightening torque:
10 N-m (1.0 kgf-m, 7 ff-lb)
18) Install the oil strainer stay.
S2M 1833A
ME(DOHC TURBO)-79
CYLINDER BLOCK
MECHANICAL
20) Apply fluid packing to matching surfaces and (2) Apply fluid packing to the matching surface
install the oil separator cover. of oil pump.
Fluid packing: Fluid packing:
THREE BOND 1215 or equivalent THREE BOND 1215 or equivalent
S2M1R34A LJLJ B2M03908
21) Install the drive plate. (AT vehicles)

(A) O-ring
To lock the crankshaft, use ST.
ST 498497100 CRANKSHAFT STOPPER (3) Apply a coat of engine oil to the inside of the
Tightening torque: oil seal.
72 N.m (7.3 kgf-m, 52.8 ft-lb) I .I
1
W &
S2M0118B
(4) Install the oil pump on cylinder block. Be

careful not to damage the oil seal during instal-
22) Install the flywheel. (MT vehicles) <Ref. to CL-
lation.
14, INSTALLATION, Flywheel.>
23) Install the clutch disc and cover. (MT vehicles) Tightening torque:
<Ref. to CL-11, INSTALLATION, Clutch Disc and 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
Cover.> CAUTION:
24) Installation of oil pump: Do not forget to install the O-ring and seal
(1) Discard the front oil seal after removal. Re- when installing the oil pump.
place with a new one using ST. Align the flat surface of oil pump's inner rotor
ST 499587100 OIL SEAL INSTALLER with crankshaft before installation.
M0235
ME(D0HC TURBO)-80
II
CYLINDER BLOCK
MECHANICAL
25) Install the water pump and gasket. 29) Install the water by-pass pipe between oil cool-
er and water pump.
Tightening torque:
First; 12 N-m (1.2 kgf-m, 8.7 ft-16)
Second; 12 N.m (1.2 kgf-m, 8.7 ff-16)
CAUTION:
Be sure to use a new gasket.
When installing the water pump, tighten bolts
in two stages in alphabetical sequence as
shown in the figure.
30) Install the water pipe.

NOTE:
Always use a new O-ring.
31) Install the cylinder head assembly. <Ref. to
ME(D0HC TURBO)-64, INSTALLATION, Cylinder
Head Assembly.>
H2M1846D 32) Install the oil level gauge guide and tighten the
26) Install the water by-pass pipe for heater. attaching bolt (left side only).
27) Install the oil cooler. 33) Install the rocker cover.
34) Install the crankshaft sprocket. <Ref. to
Tightening torque: ME(D0HC TURBO)-58, INSTALLATION, Crank-
T I : 55 N-m (5.5 kgf-m, 40 ft-16) shaft Sprocket.>
T2: 69 N-m (7.0 kgf-m, 50.6 ff-16) 35) Install the camshaft sprocket. <Ref. to
ME(DOHC TU RBO)-57, INSTALLATION, Cam-
shaft Sprocket.>
Belt Assembly.>
38) Install the crankshaft pulley. <Ref. to
ME(D0HC TURBO)-46, INSTALLATION, Crank-
shaft Pulley.>
39) Install the generator and A/C compressor
brackets on cylinder head.
44, INSTALLATION,V-belt.>
41) Install the intake manifold. <Ref. to FU(D0HC
TURBO)-15 , REMOVAL, Intake Manifold.>
(A) O-ring
(B) Oil cooler
(C) Connector
28) Install the oil filter using ST.

ME(D0HC TURBO)-81
CYLINDER BLOCK
MECHANICAL
C: DISASSEMBLY
I
B2M13201
(1) Connecting rod cap (3) Top ring (5) Oil ring
(2) Connecting rod bearing (4) Second ring (6) Circlip
1) Remove the connecting rod cap.
2) Remove the connecting rod bearing.
CAUTION:
Arrange the removed connecting rod, connect-
ing rod cap and bearing in order to prevent con-
fusion.
3) Remove the piston rings using the piston ring ex-
pander.
4) Remove the oil ring by hand.
CAUTION:
Arrange the removed piston rings in proper or-
der to prevent confusion.
5) Remove the circlip.
ME(D0HC TURBO)-82
CYLINDER BLOCK
MECHANICAL
D: ASSEMBLY
~~
(1) Connecting rod bearing (5) Second ring Tightening torque: N.m (kgf-m, ft-lb)
(2) Connecting rod (6) Top ring T: 44.6 (4.55, 32.9)
(3) Connecting rod cap (7) Circlip
(4) Oil ring
1) Install the connecting rod bearings on connect- E: INSPECTION
ing rods and connecting rod caps.
1. CYLINDER BLOCK
CAUTION:
Apply oil to the surfaces of the connecting rod 1) Visually check for cracks and damage. Especial-
bearings. ly, inspect the important parts by means of red lead
2) Install the connecting rod on crankshaft. check.
2) Check the oil passages for clogging.
CAUTION: 3) Inspect the crankcase surface that mates with
Position each connecting rod with the side cylinder head for warping by using a straight edge,
marked facing forward. and correct by grinding if necessary.
3) Install the connecting rod cap with connecting
rod nut. Warping limit:
Ensure the arrow on connecting rod cap faces the 0.05 mm (0.0020 in)
front during installation. Grinding limit:
CAUTION: 0.1 mm (0.004 in)
Each the connecting rod has its own mating Standard height of cylinder block:
cap. Make sure that they are assembled cor- 201.0 mm (7.91 in)
rectly by checking their matching number.
When tightening the connecting rod nuts, ap-
ply oil on the threads.
4) Install the oil ring spacer, upper rail and lower rail
in this order by hand. Then install the second ring
and top ring with a piston ring expander.
ME(D0HC TURBO)-83
CYLINDER BLOCK
MECHANICAL
2. CYLINDER AND PISTON 2) How to measure the inner diameter of each cyl-
inder:
1) The cylinder bore size is stamped on the cylinder Measure the inner diameter of each cylinder in both
block’s front upper surface. the thrust and piston pin directions at the heights
CAUTION: shown in the figure, using a cylinder bore gauge.
Measurement should be performed at a temper- CAUTION:
ature of 20°C (68°F). Measurement should be performed at a temper-
NOTE: ature of 20°C (68°F).
Standard sized pistons are classified into two
grades, “ A and “B”. These grades should be used Taper:
as a guide line in selecting a standard piston. Standard
0.015 mm (0.0006 in)
Standard diameter: Limit
A: 92.005 - 92.015 mm (3.6222 - 3.6226 0.050 mm (0.0020 in)
in)
B: 91.995 - 92.005 mm (3.6218 -3.6222 Out-of-roundness:
in) Standard
0.010 mm (0.0004 in)
Limit
0.050 mm (0.0020 in)
FO
l (0.39)
45 (1.77)
80 (3.15)
115 (4.53)
(E)
H2M1732C
W
(A) Main journal size mark
Unit: mm (in)
(B) Cylinder block RH-LH combination mark S2M1821A
(C) #1 cylinder bore size mark

(A) Piston pin direction
(D) #2 cylinder bore size mark
(B) Thrust direction
(E) #3 cylinder bore size mark
(F) #4 cylinder bore size mark 3) When the piston is to be replaced due to general
or cylinder wear, determine a suitable sized piston
by measuring the piston clearance.
ME(D0HC TURBO)-84
CYLINDER BLOCK
MECHANICAL
4) How to measure the outer diameter of each pis- 6) Boring and honing:
ton: (1) If the value of taper, out-of-roundness, or
Measure the outer diameter of each piston at the cylinder-to-piston clearance measured exceeds
height shown in the figure. (Thrust direction) the specified limit or if there is any damage on
the cylinder wall, rebore it to use an oversize pis-
CAUTION:
Measurement should be performed at a temper- ton.
ature of 20°C (68°F). CAUTION:
When any of the cylinders needs reboring, all
Piston grade point H: other cylinders must be bored at the same time,
37.0 mm (1.457 in) and use oversize pistons. Do not perform bor-
Piston outer diameter: ing on one cylinder only, nor use an oversize
Standard piston for one cylinder only.
A: 91.985 - 91.995 mm (2) If the cylinder inner diameter exceeds the
(3.6214 -3.6218 in) limit after boring and honing, replace the crank-
B: 91.975 - 91.985 mm case.
(3.621 1 - 3.6214 in) CAUTION:
0.25 mm (0.0098 in) oversize Immediately after reboring, the cylinder diame-
92.225-92.235" ter may differ from its real diameter due to tem-
(3.6309 - 3.6313 in) perature rise. Thus, pay attention to this when
0.50 mm (0.0197 in) oversize measuring the cylinder diameter.
92.475-92.485"
Limit of cylinder enlarging (boring):
(3.6407 - 3.641 1 in)
0.5 mm (0.020 in)
IJ B2M1305A
5) Calculate the clearance between cylinder and

piston.
CAUTION:
Measurement should be performed at a temper-
ature of 20°C (68°F).
Cylinder to piston clearance at 20°C (68OF):
Standard
0.010 - 0.030 mm (0.0004 - 0.0012 in)
Limit
0.050 mm (0.0020 in)
ME(D0HC TURBO)-85
CYLINDER BLOCK
3. PISTON AND PISTON PIN 4) Check the circlip installation groove on the piston
for burr (A). If necessary, remove burr from the
'1 Check the pistons and piston pins for damage, groove so that the piston pin can lightly move.
cracks, and wear and the piston ring grooves for
wear and damage. Replace if defective.
2) Measure the piston-to-cylinder clearance at
each cylinder. <Ref. to ME(D0HC TURBO)-84,
CYLINDER AND PISTON, INSPECTION, Cylinder
Block.> If any of the clearances is not within speci- (A),
fication, replace the piston or bore the cylinder to
use an oversize piston.
3) Make sure that the piston pin can be inserted into
the piston pin hole with a thumb at 20°C (68°F). Re-
place if defective.
I
B2M0420E
~~ ~
Standard clearance between piston pin and

hole in piston: 5) Check the piston pin circlip for distortion, cracks
and wear.
Standard
0.004 - 0.008 mm (0.0002 - 0.0003 in)
Limit
0.020 mm (0.0008 in)
B2M1401
I
Micrometer
B2M0084A
ME(D0HC TURBO)-86
I CYLINDER BLOCK
MECHANICAL
4. PISTON RING 2) Squarely place the piston ring and oil ring in cyl-
inder, and measure the piston ring gap with a thick-
1) If the piston ring is broken, damaged, or worn, or
ness gauge.
if its tension is insufficient, or when the piston is re-
placed, replace the piston ring with a new one of
the same size as the piston. Standard Limit
CAUTION: 0.20 - 0.35
Top ring 1.O (0.039)
“N” is marked on the end of the top and sec-
ond rings. When installing the rings to the pis- 1.O (0.039)
ton, face this mark upward.
I
3 “N
EN0330
The oil ring is a combined ring consisting of

two rails and a spacer in between. When install-
ing, be careful to assemble correctly. 3) Measure the clearance between piston ring and
piston ring groove with a thickness gauge.
CAUTION:
Before measuring the clearance, clean the pis-
7“N”
ton ring groove and piston ring.
Unit: mm (in)
Standard Limit
between pis-
ton ring and
(A) Top ring groove ring

0.00281
(6) Second ring
(C) Oil ring
(a) Upper rail
(b) Spacer
(c) Lower rail
B2M1402
ME(D0HC TURBO)-87
CYLINDER BLOCK
MECHANICAL
5. CONNECTING ROO 4) Inspect the connecting rod bearing for scar,

peeling, seizure, melting, wear, etc.
1) Replace the connecting rod, if the large or small
5) Measure the oil clearance on individual connect-
end thrust surface is damaged.
ing rod bearings by means of plastigauge. If any oil
2) Check for bend or twist using a connecting rod clearance is not within specification, replace the
aligner. Replace the connecting rod if the bend or defective bearing with a new one of standard size
twist exceeds the limit. or undersize as necessary. (See the table below.)
Limit of bend or twist per 100 mm (3.94 in) in Connecting rod oil clearance:
length:
0.10 mm (0.0039 in) Standard
-
0.020 0.046 mm (0.0008 - 0.0018 in)
Limit
0.05 mm (0.0020 in)
I Unit: mm (in)
I
Bearing size Outer diameter of
I Bearing
(Thickness at cen-
ter)
crank pin
I Standard
1.492 - 1.501 47.984 - 48.000
1.510-1.513 47.954 - 47.970

(0.0012)
n undersize
(0.0020)
undersize
1.520 - 1.523 47.934 - 47.950
1.620 - 1.623 47.734 - 47.750

(0.0098)
undersize
B2M1184B
(A) Thickness gauge

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

crankshaft and measure the side clearance (thrust
clearance). Replace the connecting rod if the side
clearance exceeds the specified limit.
Connecting rod side clearance:
Standard
-
0.070 0.330 mm (0.0028 - 0.0130 in)
Limit
0.4 mm (0.016 in)
ME(DOHC TUR BO)-88

CYLINDER BLOCK
MECHANICAL
6) Inspect the bushing at connecting rod small end, 6. CRANKSHAFT AND CRANKSHAFT
and replace if worn or damaged. Also measure the BEARING
piston pin clearance at the connecting rod small 1) Clean the crankshaft completely and check for
end. cracks by means of red lead check etc., and re-
Clearance between piston pin and bushing: place if defective.
Standard 2) Measure the crankshaft bend, and correct or re-
0 - 0.022 mm (0 - 0.0009 in) place if it exceeds the limit.
Limit CAUTION:
0.030 mm (0.0012 in) If a suitable V-block is not available, install #1
and #5 crankshaft bearing on cylinder block,
position crankshaft on these bearings and mea-
sure the crankshaft bend using a dial gauge.
Crankshaft bend limit:
0.035 mm (0.0014 in)
3) Inspect the crank journal and crank pin for wear.

If they are not within the specifications, replace the
bearing with a suitable (undersize) one, and re-
U place or recondition crankshaft as necessary.
B2M0084 When grinding the crank journal or crank pin, finish
them to the specified dimensions according to the
7) Replacement procedure is as follows: undersize bearing to be used.
(1) Remove the bushing from connecting rod
with ST and press. Crank pin and crank journal:
(2) Press the bushing with ST after applying oil Out-of-roundness
on the periphery of bushing. 0.020 mm (0.0008 in) or less
ST 499037100 CONNECTING ROD BUSH- Taper limit
ING REMOVER AND IN- 0.07 mm (0.0028 in)
STALLER Grinding limit
0.250 mm (0.0098 in)
G2M0179
(3) Make two 3 mm (0.12 in) holes in bushing.
Ream the inside of bushing.
(4) After completion of reaming, clean the bush-
ing to remove chips.
ME(D0HC TURBO)-89
CYLINDER BLOCK
MECHANICAL
Unit: mm (in)
#1, #3, #5 #2, #4

59.992 - 60.008 59.992 - 60.008 47.984 - 48.000
Journal O.D.
(2.3619 - 2.3625) (2.3619 - 2.3625) (1.8891 - 1.8898)
Standard Bearing size
1.998 - 2.01 1 2.000 - 2.013 1.492-1.510
(Thickness at cen-
(0.0787 - 0.0792) (0.0787 - 0.0793) (0.0587 - 0.0591)
ter)
59.962 - 59.978 59.962 - 59.978 47.954 - 47.970
Journal O.D.
(2.3607 - 2.361 3) (2.3607 - 2.361 3) (1.8879 - 1.8886)
0.03 (0.0012)
Bearing size
undersize 2.01 7 - 2.020 2.019 - 2.022 1.510- 1.513
(Thickness at cen-
(0.0794 - 0.0795) (0.0795 - 0.0796) (0.0594 - 0.0596)
ter)
59.942 - 59.958 59.942 - 59.958 47.934 - 47.950
Journal O.D.
(2.3599 - 2.3605) (2.3599 - 2.3605) (1.8872 - 1.8878)
0.05 (0.0020)
Bearing size
undersize 2.027 - 2.030 2.029 - 2.032 1.520 - 1.523
(Thickness at cen-
(0.0798 - 0.0799) (0.0799 - 0.0800) (0.0598 - 0.0600)
ter)
I --
0.25 (0.0098)
Journal O.D.
59.742
(2.3520
59.758
2.3527)
59.742 - 59.758
(2.3520 - 2.3527)
47.734 - 47.750
(1.8793 - 1.8799)
Bearing size
undersize 2.127-2.130 2.129 - 2.132 1.620 - 1.623
(Thickness at cen-
(0.0837 - 0.0839) (0.0838 - 0.0839) (0.0638 - 0.0639)
ter)
O.D.: Outer Diameter
4) Measure the thrust clearance of crankshaft at 6) Measure the oil clearance on each crankshaft
center bearing. If the clearance exceeds the limit, bearing by means of plastigauge. If the measure-
replace the bearing. ment is not within the specification, replace the de-
fective bearing with an undersize one, and replace
Crankshaft thrust clearance:
or recondition the crankshaft as necessary.
Standard
0.030 - 0.115 mm (0.0012 - 0.0045 in) I Unit: mm fin) I
Limit
0.25 mm (0.0098 in) Standard 0.01 0 - 0.030 (0.0004 -
0.001 2)
I Limit I 0.040 (0.0016) I
EN0341 I
5) Inspect individual crankshaft bearings for signs
of flaking, seizure, melting, and wear.
ME(D0HC TURBO)-90
ENGINE TROUBLE IN GENERAL
MECHANICAL
21 .Engine Trouble in General

A: INSPECTION
NOTE: A - Very often
“RANK’ shown in the chart refers to the possibility B - Sometimes
of reason for the trouble in order (“Very often” to C - Rarely
“Rarely”)
TROUBLE PROBLEM PARTS, ETC. I POSSIBLE CAUSE I RANK
1. Engine will not start.
1) Starter does not turn. Starter Defective battery-to-starter harness B
Defective starter switch C
Defective inhibitor switch or neutral switch C
1 Defective starter I B
Battery I Poor terminal connection I A
Run-down battery A
Defective charging system B
Friction Seizure of crankshaft and connecting rod bearing C
Seized camshaft C
I Seized or stuck piston and cylinder I C
~~
2) Initial combustion does Starter 1 Defective starter I C

not occur. Engine control system <Ref. to EN(D0HC TURBO)-2, Basic Diagnostic Procedure.> 1 A
Fuel line Defective fuel pump and relay I A
I
Lack of or insufficient fuel I
I
B
Belt I Defective I B
I Defective timina I B
Compression I Incorrect valve clearance I C
1 Loosened spark plugs or defective gasket I C
Loosened cylinder head bolts or defective gasket C
Improper valve seating C
Defective valve stem C
F W o r n G broken valve sprina I B
I Worn or stuck piston rings, cylinder and piston I C
I Incorrect valve timing I B
I Improper engine oil (low viscosity) B
3) Initial combustion occur. Engine control system <Ref. to EN(D0HC TURBO)-2, Basic Diagnostic Procedure.> A
Intake system Defective intake manifold gasket B
Defective throttle bodv aasket B
I Defective fuel pump and relay
~~
Fuel line I C
1 Clogged fuel line I C
I Lack of or insufficient fuel I B
Belt Defective I B
Defective timina
“ I B
Compression Incorrect valve clearance C
Loosened spark plugs or defective gasket C
I Improper valve seating I C
Worn or broken valve spring B
Worn or stuck piston rinas. cvlinder and piston C
I.lncorrect v a G timina I B
I Improper engine oil (low viscosity) I B
ME(D0HC TURBO)-91
MECHANICAL
TROUBLE PROBLEM PARTS, ETC. I POSSIBLE CAUSE I

RANK
4) Engine stalls after initial Engine control system <Ref. to EN(D0HC TURBO)P, Basic Diagnostic Procedure.> I A
combustion. Intake system Loosened or cracked intake duct B
Loosened or cracked PCV hose C
Loosened or cracked vacuum hose C
I
I
Defective intake manifold aasket I B
I Defective throttle body gasket I B
Dirty air cleaner element C
Fuel line Clogged fuel line C
Lack of or insufficient fuel B
Belt Defective B
Defective timina B
Compression I Incorrect valve clearance I C
I Loosened spark plugs or defective gasket I C
I Loosened cylinder head bolts or defective gasket I C
Improper valve seating I C
Defective valve stem II C
I Worn or broken valve sprina I B
I Worn or stuck piston rings, cylinder and piston I C
I Incorrect valve timing I B
I Improper engine oil (low viscosity) B
2. Rough idle and engine Engine control system <Ref. to EN(D0HC TURBO)-2, Basic Diagnostic Procedure.> A
stall Intake system Loosened or cracked intake duct / A
Loosened or cracked PCV hose / A
I Loosened or cracked vacuum hose I A
I Defective intake manifold gasket I B
Defective throttle body gasket I B
Defective PCV valve I C
Loosened oil filler cap B
Dirty air cleaner element C
Fuel line Defective fuel Dump and relav C
I Clogged fuel line I C
I Lack of or insufficient fuel I B
Belt I Defective timing I C
Compression Incorrect valve clearance B
Loosened spark plugs or defective gasket B
Loosened cvlinder head bolts or defective aasket B
I Improper valve seatina I B
I Defective valve stem I C
1 Worn or broken valve spring I B
I Worn or stuck piston rings, cylinder and piston I B
Incorrect valve timing ] A
ImDroDer enaine oil (low viscositv) I B
Lubrication system I Incorrect oil pressure -1 --B
I Defective rocker cover gasket I C
Cooling system I Overheating I C
Others I Malfunction of evaporative emission control system I A
Stuck or damaged throttle valve B
Accelerator cable out of adjustment C
ME(D0HC TURBO)-92
MECHANICAL
PROBLEM PARTS, ETC. I POSSIBLE CAUSE RANK

Engine control system <Ref. to EN(D0HC TURBO)-2, Basic Diagnostic Procedure.> A
Intake system Loosened or cracked intake duct I A
Loosened or cracked PCV hose / A
FLoosened or cracked vacuum hose I B
I Defective throttle body gasket I B
Defective PCV valve B
Dirty air cleaner element A
Fuel line Defective fuel Dump and relav B
1 Cloaaed fuel line I B
I Lack of or insufficient fuel I C
Belt Defective timing B
Loosened spark plugs or defective gasket B
Loosened cvlinder head bolts or defective aasket B
I Improper valve seating I B
I Defective valve stem I C
Worn or broken valve spring B
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing A
Improper enaine oil (low viscositv) B
~~
~
Lubrication svstem Incorrect oil pressure I B
Cooling system Overheating I C
Over coolina I C
Others I Malfunction of evaporative emission control system A
Engine control system <Ref. to EN(D0HC TURBO)-2, Basic Diagnostic Procedure.> A
Intake system Loosened or cracked intake duct A
Loosened or cracked PCV hose A
I Loosened or cracked vacuum hose I A
Defective throttle body gasket B
Defective PCV valve B
Dirty air cleaner element B
Fuel line Defective fuel pump and relav B
1 Clogged fuel line I B
Lack of or insufficient fuel C
Loosened spark Dluas or defective aasket C
1 Loosened cylinder head bolts or defective gasket I C
I Improper valve seating I C
Defective valve stem
Worn or broken valve spring
Worn or stuck piston rings, cylinder and piston
Improper enaine oil (low viscositv) B
I
~~
Coolina svstem Overheating

Others I Malfunction of evaporative emission control system I C
ME(D0HC TURB0)-93
MECHANICAL
TROUBLE I PROBLEM PARTS, ETC. I POSSIBLE CAUSE RANK I

5. Enaine does not return to I Enaine control svstem <Ref. to EN(D0HC TURBOb2. Basic Diaanostic Procedure.> II A
I idle.
*
Intake system I
, I
Loosened or cracked vacuum hose

*
I A
II II Others 1I Stuck or damaaed
- throttle valve \I A 1
I
I Accelerator cable out of adjustment I B
I
6. Dieseling (Run-on) I
1
Engine control system <Ref. to EN(D0HC TURBO)-2, Basic Diagnostic Procedure.> I A
I
I I Cooling system I Overheating I B I
I Others I1 Malfunction of evaoorative emission control svstem I B 1
7. After burning in exhaust Engine control system <Ref. to EN(D0HC TURBO)-2, Basic Diagnostic Procedure.> A
system Intake system I Loosened or cracked intake duct C
II II II Loosened or cracked PCV hose I
I
C 1I
II II II Loosened or cracked vacuum hose
I I Defective PCV valve
Loosened oil filler cap C
Defective timing B
Incorrect valve clearance B
II II II Loosened spark pluns -
. - or defective nasket I
I
C 1I
II II II Loosened cylinder head bolts or defective gasket I C I
I
II II II Improper valve seating I B 4
I
I I I Defective valve stem I C 1
Worn or broken valve spring C
Worn or stuck piston rings, cylinder and piston C
II II Lubrication system I Incorrect oil pressure I C 1I
I I Cooling system I Over cooling I C 1
I
~~
Others Malfunction of evaporative emission control system C

8. Knocking Engine control system <Ref. to EN(D0HC TURBO)-2, Basic Diagnostic Procedure.> A
Intake system I Loosened oil filler cap B
II II Belt I
I
-
Defective timina I
I
B I
I
Compression Incorrect valve clearance I C
Incorrect valve timing I B
Cooling system Overheating A
9. Excessive engine oil con- Intake system Loosened or cracked PCV hose A
sumption Defective PCV valve B
Loosened oil filler cap I C
Compression Defective valve stem I A
Worn or stuck piston rings, cylinder and piston I A
Lubrication system Loosened oil pump attaching bolts and defective B
gasket
Defective oil filter o-rina B
Defective crankshaft oil seal I B
Defective rocker cover gasket I B
Loosened oil drain plug or defective gasket I B
Loosened oil pan fitting bolts or defective oil pan I B
ME(D0HC TURBO)-94
MECHANICAL
TROUBLE PROBLEM PARTS, ETC. 1 POSSIBLE CAUSE RANK

10. Excessive fuel consump- Engine control system <Ref. to EN(D0HC TURBO)-2, Basic Diagnostic Procedure.> A
I tion I Intake svstem I Dirtv air cleaner element I A I
-
Loosened spark plugs or defective gasket C
Improper valve seating B
Worn or broken valve spring C
Worn or stuck piston rings, cylinder and piston B
Incorrect valve timing 6
Lubrication system Incorrect oil pressure C
Cooling system Over cooling C
Others Accelerator cable out of adjustment B
ME(D0HC TURBO)-95
ENGINE NOISE
MECHANICAL
22.Engine Noise
A: INSPECTION
Type of sound Condition Possible cause
Valve mechanism is defective.
Incorrect valve clearance
Sound increases as engine
Regular clicking sound Worn valve rocker
speed increases.
Worn camshaft
Broken valve sDrina
Worn crankshaft main bearing
Oil pressure is low.
Worn connecting rod bearing (big end)
Heavy and dull clank
Loose flywheel mounting bolts
Oil pressure is normal.
Damaaed enaine mountina ~
~~ ~~
Ignition timing advanced

High-pitchedclank (Spark Sound is noticeable when Accumulation of carbon inside combustion chamber
knock) accelerating with an overload. Wrong spark plug
Improper gasoline
Sound is reduced when fuel Worn crankshaft main bearing
Clank when engine speed is injector connector of noisy cyl- Worn bearing at crankshaft end of connecting rod
medium (1,000 to 2,000 rpm). inder is disconnected.
(NOTE9
Sound is reduced when fuel Worn cylinder liner and piston ring
injector connector of noisy cyl- Broken or stuck piston ring
Knocking sound when engine inder is disconnected. Worn piston pin and hole at piston end of connecting rod
is operating under idling speed (NOTE*)
and engine is warm Sound is not reduced if each Unusually worn valve lifter
fuel injector connector is dis- Worn cam gear
connected in turn. (NOTE*) Worn camshaft journal bore in crankcase
Squeaky sound I - Insufficient generator lubrication
Rubbing sound I - Defective generator brush and rotor contact
Gear scream when starting - Defective ignition starter switch
engine Worn pear and starter pinion
Sound like polishing glass with - Loose drive belt
a dry cloth Defective water pump shaft
Loss of compression
Hissing sound Air leakage in air intake system, hoses, connections or mani-
folds
~
Timing belt noise - Loose timing belt

Belt contacting case/adjacent part
Valve tappet noise Incorrect valve clearance
NOTE*:
When disconnectingthe fuel injector connector, Malfunction Indicator Light (CHECK ENGINE light) illuminates and trouble code
is stored in ECM memory.
Therefore, carry out the CLEAR MEMORY MODE <Ref. to EN(D0HC TURBO)-49, OPERATION, Clear Memory Mode.> and
INSPECTION MODE <Ref. to EN(D0HC TURBO)-46, OPERATION, Inspection Mode.> after connecting the fuel injector con-
nector.
ME(D0HC TURBO)-96
EXHAUST
EX(D0HC TURBO)
Page
2. Front Exhaust Pipe...................................................................................... 6
3. Center Exhaust Pipe ................................................................................... 8
4. Joint Pipe .................................................................................................. 12
3 -
5. Rear Exhaust Pipe .................................................................................... 13

6. Muffler ....................................................................................................... 14
GENERAL DESCRIPTION
EXHAUST
1 General Description
A: COMPONENT
1. FRONT EXHAUST PIPE
EN1183
EX(D0HC TURBO)-2
GENERAL DESCRIPTION
EXHAUST
Gasket Front exhaust pipe lower insulator (21) Turbocharger joint pipe
Upper exhaust manifold cover (RH) (22) Gasket
(RH) Front exhaust pipe lower insulator (23) Front oxygen (NF) sensor
Exhaust manifold (RH) (LH) (24) Precatalytic converter
Lower exhaust manifold cover Front exhaust pipe lower cover (25) Exhaust temperature sensor
(RH) Front exhaust pipe lower clamp
Front exhaust pipe upper clamp Gasket
Front exhaust pipe upper cover Gasket
Front exhaust pipe upper insulator Upper exhaust manifold cover Tightening torque: N.m (kgf-m, ft-lb)
(RH) (LH) T1: 19 (1.9, 13.7)
Front exhaust pipe upper insulator Exhaust manifold (LH) T2: 25 (2.5, 18.1)
(LH) Lower exhaust manifold cover T3: 35 (3.6, 26.0)
Gasket (LH) T4: 40 (4, 28.9)
Front exhaust pipe Gasket
EX(D0HC TURB0)S
GENERAL DESCRIPTION
EXHAUST
2. CENTER AND REAR EXHAUST PIPE, AND MUFFLER
L4
I \
EN1113
Gasket Rear catalytic converter (25) Upper rear exhaust pipe cover
Front catalytic converter Upper clamp (Rear)
Upper center pipe cover (Front) Gasket (26) Gasket
Center exhaust pipe (Front) Rear exhaust pipe (27) Muffler
Lower center pipe cover (Front) Lower rear exhaust pipe cover (28) Cushion
Bracket (Front) (29) Muffler cutter
Gasket Chamber (30) Center exhaust pipe (Rear)
Upper center pipe cover (Rear) Lower rear exhaust pipe cover
Lower center pipe cover (Rear) (Rear) Tightening torque: N.m (kgf-m, ft-lb)
Upper rear catalytic converter Cushion T1: 13 (1.3, 9.6)
cover Spring T2: lS(1.8, 13.0)
Lower clamp Bolt T3: 30 (3.1, 22.4)
Lower rear catalytic converter Upper rear exhaust pipe cover T4: 35 (3.6, 26.0)
cover (Front) T5: 48 (4.9, 35.4)
Rear oxygen sensor
EX(D0HC TURBO)-4
GENERAL DESCRIPTION
EXHAUST
B: CAUTION
tion.
points.
sensors or units, be sure to disconnect the negative
EX(D0HC TURBO)-5
~
FRONT EXHAUST PIPE

EXHAUST
2. Front Exhaust Pipe 10) Separate the front exhaust pipe from exhaust
manifolds.
A: REMOVAL
B: INSTALLATION
CAUTION:
2) Remove the front oxygen (NF) sensor. <Ref. to
FU(D0HC TURBO)-42, REMOVAL, Front Oxygen
(NF) Sensor.> 1) Assemble the front exhaust pipe and exhaust
3) Remove the under cover. manifolds.
4) Remove the lower exhaust manifold cover (RH). Tightening torque:
5) Remove the lower and upper exhaust manifold 35 N.m (3.6 kgf-m, 26.0 ff-lb)
covers (LH).
- G2M0854
2) Install the front exhaust pipe covers.

6) Remove the bolts and nuts which hold the front
exhaust pipe assembly to turbocharger joint pipe. Tightening torque:
7) While holding the front exhaust pipe assembly 25 N.m (2.5 kgf-m, 78.7 ff-lb)
with one hand, remove the nuts which hold the front 3) Install the upper exhaust manifold cover (RH).
exhaust pipe assembly to cylinder head exhaust Tightening torque:
port. 79 N-m (1.9 kgf-m, 73.7 ff-lb)
0
4) Install the front exhaust pipe assembly.
0 0 0 0 Tightening torque:
35 N-m (3.6 kgf-m, 26.0 ff-lb)
8) Remove the front exhaust pipe assembly.

9) Remove the covers from exhaust manifold and
front exhaust pipe.
EX(D0HC TURBO)-6
lls
FRONT EXHAUST PIPE
EXHAUST
5) Connect the exhaust manifold (RH) to turbo-

charger joint pipe.
Tightening torque:
35 N-m (3.6 kgf-m, 26.0 ft-lb)
6) Install the upper and lower exhaust manifold

covers (LH).
Tightening torque:
79 N-m (7.9 kgf-m, 73.7 ff-lb)
7) Install the lower exhaust manifold cover (RH).
Tightening torque:
79 N*m (7.9 kgf-m, 73.7 ft-lb)
8) Install the front oxygen (NF)sensor. <Ref. to

FU(D0HC TURBO)-43, INSTALLATION, Front
Oxygen (NF)Sensor.>
EX(D0HC TURBO)-7
CENTER EXHAUST PIPE
EXHAUST
3. Center Exhaust Pipe 10) Remove the bolts which install the lower upper
side of turbocharger upper cover, and remove it.
A: REMOVAL
4) Remove the intercooler bracket.
11) Separate the center exhaust pipe from turbo-

charger.

6 ) Remove the under cover.
7) Remove the bolts which install the lower side of
turbocharger upper cover.
CAUTION:
Be careful, the turbocharger and exhaust pipe
are hot.
13) Disconnect the connector from rear oxygen
sensor.

9) Remove the turbocharger upper cover.
14) Vertically draw out clip from crossmember.
I S2M2254
EX(D0HC TURBO)-8
CENTER EXHAUST PIPE
m
EXHAUST
15) Separate the center exhaust pipe from rear ex- B: INSTALLATION
haust pipe.
CAUTION:
1) Install the center exhaust pipe and temporarily
tighten the bolt which holds center exhaust pipe to
hanger bracket.
2) Temporarily tighten the bolt which holds the cen-
ter pipe to transmission.
3) Connect the center exhaust pipe to turbocharg-
er.
Tightening torque:
'I \ I G2M085E
35 N-m (3.6 kgf-m, 26.0 ft-lb)
16) Remove the bolt which holds center exhaust
pipe bracket to transmission.
4) Install the center exhaust pipe to rear exhaust

pipe.
17) Remove the intercooler bracket. Tightening torque:
18) Remove the bolt which holds center exhaust
18 N-m (1.8 kgf-m, 13.0 ft-lb)
pipe to hanger bracket.
CAUTION:
Be careful not to pull down the center exhaust
pipe.
I' I G2M0855 I
5 ) Connect the connector to rear oxygen sensor.
19) Remove the center exhaust pipe.
EX(D0HC TURBO)-9
CENTER EXHAUST PIPE
EXHAUST
6) Secure clip on the crossmember. 11) Place the turbocharger lower cover, and tighten
the bolts which install the upper side of lower cover.
Tightening torque:
7.4 N.m (0.75 kgf-m, 5.4 ff-lb)
I I S2M2254
7) Tighten the bolt which holds the center exhaust

pipe bracket to transmission.
Tightening torque:
30 N-m (3.1 kgf-m, 22.4 ff-lb) 12) Place the turbocharger upper cover, and tight-
en the bolts which install the upper side of upper
cover.
Tightening torque:
7.4 Nom(0.75 kgf-m, 5.4 ff-lb)
8) Tighten the bolt which holds the center exhaust

pipe to hanger bracket.
Tightening torque:
35 N-m (3.6 kgf-m, 26.0 ff-lb)
14) Tighten the bolts which install the under side of
turbocharger upper cover.
Tightening torque:
7.4 N-m (0.75 kgf-m, 5.4 ff-lb)
9) Tighten the bolts which hold the intercooler

bracket.
Tightening torque:
35 N-m (3.6 kgf-m, 26.0 ff-lb)
EX(D0HC TURBO)-I 0
CENTER EXHAUST PIPE
EXHAUST
17) Install the intercooler bracket.

EX(D0HC TURBO)-1 1
I
JOINT PIPE
EXHAUST
4. Joint Pipe 6) Remove the lower exhaust manifold cover (RH).
A: REMOVAL
1) Disconnect the ground terminal from battery
7) Remove the nuts which hold the front exhaust

manifold to joint pipe.
2) Remove the solenoid valve cover.

3) Disconnect the exhaust temperature sensor con- Pipe.>
nector. 9) Remove the turbocharger. <Ref. to IN(D0HC
TURBO)-12, REMOVAL, Turbocharger.>
10) Take off the joint pipe in the upward direction.
B: INSTALLATION
Tightening torque:
T: 35 N-m (3.6 kgf-m, 26.0 ff-lb)
4) Remove the front oxygen (NF) sensor. <Ref. to

FU(D0HC TURBO)-42, REMOVAL, Front Oxygen
(NF) Sensor.>
EX(D0HC TURBO)-12
REAR EXHAUST PIPE
EXHAUST
5. Rear Exhaust Pipe B: INSTALLATION

CAUTION:
A: REMOVAL Replace the gaskets with new ones.
1) Install the rear exhaust pipe to muffler.
Tightening torque:
48 N.m (4.9 kgf-m, 35.4 ft-lb)

3) Separate the rear exhaust pipe from center ex-
haust pipe.
CAUTION: 2) Install the rear exhaust pipe to center exhaust
Be careful, the exhaust pipe is hot. pipe.
Tightening torque:
18 N-m (1.8 kgf-m, 13.0 ft-lb)
4) Separate the rear exhaust pipe from muffler.

CAUTION:
Be careful not to pull down the rear exhaust 3) Lower the vehicle.
pipe. 4) Connect the battery ground terminal to battery.
~~
5) Remove the rear exhaust pipe. C: INSPECTION

nections and welds.
3) Make sure the cushion rubber is not worn or
cracked.
EX(D0HC TURBO)-13
MUFFLER
EXHAUST
6. Muffler B: INSTALLATION
A: REMOVAL CAUTION:
1) Separate the muffler from rear exhaust pipe. Replace the gasket with a new one.
CAUTION:
Tightening torque:
Be careful, the exhaust pipe is hot.
48 N.m (4.9 kgf-m, 35.4 ft-lb)
2) Remove the rubber cushions, and detach muf-

fler. C: INSPECTION
CAUTION: nections and welds.
Be careful not to drop the muffler during remov-
al.
3) Make sure the cushion rubber is not worn or
NOTE: cracked.
To facilitate removal, apply a coat of SUBARU
CRC to the mating area of rubber cushions in ad-
vance.
SUBARU CRC (Part No. 00430 1003)
II EN089
EX(D0HC TURBO)-14
IGNITION
IG(D0HC TURBO)
Page
2. Spark Plug................................................................................................... 4
3. Ignition Coil and Ignitor Assembly ............................................................... 8
GENERAL DESCRIPTION
IGNITION
A: SPECIFICATIONS
I / ~ Item I Designation I
I and ignitor
assemblv I Manufacturer DIAMOND
1 TvDe and manufacturer I PFRGG: NGK I

Spark plug Thread size mm 14, P = 1.25
Spark gap mm (in) 0.7 - 0.8 (0.028 - 0.031)
IG(D0HC TURBO)-2
GENERAL DESCRIPTION
IGNITION
B: COMPONENT
El
EN085:
(1) Spark plug Tightening torque: N-m (kgf-m, ft-lb)

(2) Ignition coil and ignitor ASSY T l : 21 (2.1, 15)
T2: 16 (1.6, 11.7)
C: CAUTION Be careful not to burn your hands, because each

Wear working clothing, including a cap, protec- part on the vehicle is hot after running.
tive goggles, and protective shoes during opera- Be sure to tighten fasteners including bolts and
tion. nuts to the specified torque.
Remove contamination including dirt and corro- Place shop jacks or safety stands at the specified
sion before removal, installation or disassembly. points.
Keep the disassembled parts in order and pro- Before disconnecting electrical connectors of
tect them from dust or dirt. sensors or units, be sure to disconnect the negative
Before removal, installation or disassembly, be terminal from battery.
IG(D0HC TURBO)-3
I SPARK PLUG
IGNITION
2. Sparkplug 5) Remove the spark plugs with the spark plug

sockets.
A: REMOVAL
CAUTION:
All spark plugs installed on an engine, must be
of the same heat range.
Spark plug:
NGK: PFRGG
1. RH SIDE
2. LH SIDE
1) Disconnect the battery terminals, and then re-
move the battery and battery carrier.
2) Remove the air cleaner lower case. <Ref. to

IN(D0HC TURBO)-7, REMOVAL, Air Cleaner.>
3) Disconnect the connector from ignition coil.
2) Disconnect the washer motor connector
EN0854
4) Remove the ignition coil.
3) Disconnect the rear window glass washer hose

from washer motor, then plug connection with a
suitable cap.
EN0855I
IG(D0HC TURBO)-4
SPARK PLUG
IGNITION
4) Remove the two bolts which hold the washer B: INSTALLATION

tank, then take the tank away from the working ar-
ea. 1. RH SIDE
Tightening torque (Spark plug):
21 N-m (2.1 kgf-m, 15 ft-lb)
Tightening torque (Ignition coil):
16 N.m (1.63 kgf-m, 11.8 fi-lb)
CAUTION:
The above torque should be only applied to
new spark plugs without oil on their threads.
In case their threads are lubricated, the torque
should be reduced by approximately 1/3 of the
5) Disconnect the connector from ignition coil. specified torque in order to avoid over-stress-
ing.
2. LH SIDE
Tightening torque (Spark plug):
21 N.m (2.1 kgf-m, 15 ft-lb)
Tightening torque (Ignition coil):
16 N-m (1.63 kgf-m, 11.8 ft-lb)
CAUTION:
The above torque should be only applied to
6) Remove the ignition coil. new spark plugs without oil on their threads.
In case their threads are lubricated, the torque
should be reduced by approximately 1/3 of the
specified torque in order to avoid over-stress-
ing.
7) Remove the spark plug with the spark plug sock-

ets.
.
EN0859
IG(D0HC TURBO)+
SPARK PLUG
IGNITION
C: INSPECTION 3) Oil fouled:

Check the electrodes and inner and outer porcelain Wet black deposits show excessive oil entrance
of plugs, noting the type of deposits and the degree into combustion chamber through worn rings and
of electrode erosion. pistons or excessive clearance between valve
guides and stems. If the same condition remains
after repair, use a hotter plug.
(E,
S6M0420A
(A) Electrode gap G6M0089
(B) Carbon accumulation or wear 4) Overheating:

(C) Cracks White or light gray insulator with black or gray
(D) Damage brown spots and bluish burnt electrodes indicate
(E) Damaged gasket engine overheating. Moreover, the appearance re-
sults from incorrect ignition timing, loose spark
1) Normal: plugs, wrong selection of fuel, hotter range plug,
Brown to grayish-tan deposits and slight electrode etc. It is advisable to replace with plugs having
wear indicate correct spark plug heat range. colder heat range.
3M0087 G6M009C
2) Carbon fouled:
Dry fluffy carbon deposits on insulator and elec-
trode are mostly caused by slow speed driving in
city, weak ignition, too rich fuel mixture, dirty air
cleaner, etc.
It is advisable to replace with plugs having hotter
heat range.
IG(D0HC TURBO)-6
SPARK PLUG
IGNITION
D: ADJUSTMENT
Clean the spark plugs in a sand blast type cleaner.
Avoid excessive blasting. Clean and remove the
carbon or oxide deposits, but do not wear away
porcelain.
If deposits are too stubborn, replace the plugs.
After cleaning the spark plugs, reconditionthe firing
surface of electrodes with file. Then correct the
spark plug gap using a gap gauge.
Spark plug gap: L
-
0.7 0.8 mm (0.028 - 0.031 in)
S6M0412A
NOTE:
Replace with a new spark plug if this area is worn to
“ball” shape.
IG(D0HC TURBOJ-7
IGNITION COIL AND IGNITOR ASSEMBLY
IGNITION
3. Ignition Coil and Ignitor As- C: INSPECTION

sembly Ignitor is integrated with the coil. Therefore resis-
tance cannot be measured.
A: REMOVAL
Direct ignition type has been adopted.
Refer to the “Spark Plug Removal” for removal pro-
cedure. <Ref. to IG(D0HC TURBO)-4, REMOV-
AL, Spark Plug.>
B: INSTALLATION
Tightening torque:
76 N-m (7.63 kgf-m, 7 7.8 ft-lb)
IG(D0HC TURBO)-8
ENGINE (DIAGNOSTICS)
EN(D0HC TURBO)
Page
1. Basic Diagnostic Procedure ........................................................................ 2
2. Check List for Interview............................................................................... 4
4. Electrical Components Location.................................................................. 9
5. Engine Control Module (ECM) I/O Signal ................................................. 26
6. Engine Condition Data .............................................................................. 30
7. Transmission Control Module (TCM) I/O Signal ....................................... 32
8. Data Link Connector ................................................................................. 35
9. OBD-ll General Scan Tool ........................................................................ 36
10. Subaru Select Monitor............................................................................... 38
11. Read Diagnostic Trouble Code ................................................................. 45
12. Inspection Mode ........................................................................................ 46
13. Clear Memory Mode.................................................................................. 49
14. Compulsory Valve Operation Check Mode ............................................... 50
15. Engine Malfunction Indicator Lamp (MIL) ................................................. 52
16. Diagnostics for Engine Starting Failure..................................................... 63
17. List of Diagnostic Trouble Code (DTC) ..................................................... 80
18. Diagnostic Procedure with Diagnostic Trouble Code (DTC) ..................... 88
19. General Diagnostic Table ........................................................................ 372
I
BASIC DIAGNOSTIC PROCEDURE
1. Basic Diagnostic Procedure

A: PROCEDURE
1. ENGINE
~
Step Check Yes No

CHECK ENGINE START FAILURE. )oes the engine start? Go to step 2. Inspection using
1)Ask the customer when and how the trouble “Diagnostics for
occurred using the interview check list. <Ref. to Engine Start Fail-
EN(D0HC TURBO)-4, CHECK, Check List for ure”. <Ref. to
Interview.> EN(D0HC
2)Start the engine. TURBO)-63, Diag-
nostics for Engine
Starting Failure.>
I
CHECK ILLUMINATION OF CHECK ENGINE )oes CHECK ENGINE mal- Go to step 3. Inspection using
MALFUNCTION INDICATOR LAMP (MIL). Jnction indicator lamp illumi- “General Diagnos-
late? tics Table”. <Ref.
to EN(D0HC
TURBO)-372,
General Diagnos-
tic Table.>
I CHECK INDICATION OF DTC ON DISPLAY. )oes the Subaru Select Moni- Record the diag- Repair the related
1)Turn the ignition switch to OFF. 3r or OBD-II general scan tool nostic trouble parts.
2)Connect the Subaru Select Monitor or the idicate DTC? code. Repair the NOTE:
OBD-ll general scan tool to data link connec- trouble cause. If DTC is no
tor. <Ref. to EN(D0HC shown on displa!
3)Turn the ignition switch to ON and the Sub- TURBO)-80, List although the MIL il
aru Select Monitor or OBD-I1 general scan tool of Diagnostic Trou- luminates, per
switch to ON. ble Code (DTC).r form diagnostics o
4)Read the DTC on the Subaru Select Monitor Go to step 4. MIL (CHECK EN
or OBD-ll general scan tool. GINE malfunctior
indicator lamp) cir
cuit or combinatior
meter. <Ref. tc
EN(D0HC TUR
BO)-52, Engint
Malfunction Indica
tor Lamp (MIL).>
I PERFORM THE DIAGNOSIS. Ioes the Subaru Select Moni- Inspect using Complete the
1)Perform the clear memory mode. <Ref. to or or OBD-ll general scan tool “Diagnostics Pro- diagnosis.
EN(D0HC TURBO)-49, Clear Memory Mode.: ndicate DTC? cedure with Diag-
2)Perform the inspection mode. <Ref. to nostic Trouble
EN(D0HC TURBO)-46, Inspection Mode.> Code (DTC)”.
<Ref. to EN(D0HC
TURBO)-88, Diag-
nostic Procedure
with Diagnostic
Trouble Code
IDTCb
EN(D0HC TURBO)-2
~ ~
2. AUTOMATIC TRANSMISSION
When the trouble code about automatic transmis-
sion is shown on display, carry out the following ba-
sic check. After that, carry out the replacement or
repair work.
1) ATF level check <Ref. to AT-9, Automatic Trans-
mission Fluid.>
2) Differential gear oil level check <Ref. to AT-11,
Differential Gear Oil.>
3) ATF leak check <Ref. to AT-9, Automatic Trans-
mission Fluid.>
4) Differential gear oil leak check <Ref. to AT-1 1,
Differential Gear Oil.>
5) Stall test <Ref. to AT-13, Stall Test.>
6) Line pressure test <Ref. to AT-16, Line Pressure
Test.>
7) Transfer clutch pressure test <Ref. to AT-18,
Transfer Clutch Pressure Test.>
8) Time lag test <Ref. to AT-15, Time Lag Test.>
9) Road test <Ref. to AT-12, Road Test.>
10) Shift characteristics <Ref. to AT-18, Transfer
Clutch Pressure Test.>
EN(D0HC TURBO)-3
CHECK LIST FOR INTERVIEW
2. Check List for Interview Check the following items when problem has oc-
curred.
A: CHECK NOTE:
1. CHECK LIST NO. 1 Use copies of this page for interviewing customers.
I Customer's name Engine no.

I Date of sale Fuel brand
Odometer reading km
miles
Weather U Fine
0 Cloudy
U Rainy
U Snowy
U Various/Others:
Outdoor temperature
0 Hot
U Warm
0 Cool
U Cold
U Highway
U Suburbs
U Inner city
U Uphill
U Downhill
0 Rough road
U Others:
U Cold
U Warming-up
U After warming-up
0 Any temperature
U Others:
Engine speed
Vehicle speed MPH I
Driving conditions
I Headlight U ON/U OFF Rear defogger U O N D OFF

I Blower Cl ON/U OFF Radio U O N D OFF
U ON/U OFF CD/Cassette U ON/U OFF
U ON/U OFF Car phone CI O N D OFF
Front wiper U ON/R OFF I CB I U O N D OFF
I Rear wiper CI ON/U OFF
EN(D0HC TURBO)-4
ENGINE (DIAGNOSTICSI
2. CHECK LIST NO. 2 NOTE:

Check the following items about the vehicle's state Use copies of this page for interviewing customers.
when MIL turns on,
a) Other warning lights or indicators turn on. CI YesD No
2 Low fuel warning light
;ICharge indicator light
2 AT diagnostics indicator light
3 ABS warning light
3 Engine oil pressure warning light
b) Fuel level
Lack of gasoline: CI YesD No
Indicator Dosition of fuel aauae:
nntentional connectina or disconnectinq of harness connectors or spark plug cords: CI YesD No
What:
d) Intentional connecting or disconnecting of hoses: D YesD No
What:
e) Installing of parts other than genuine parts: CI Yes/CI No
What:
Where:
f) Occurrence of noise: D YesD No
From where:
What kind:
a) Occurrence of smell: CI YesD No
* F r o m where:
What kind:
h) Intrusion of water into engine compartment or passenger compartment: CI YesD No
i) Troubles occurred
Q Engine does not start.
D Engine stalls during idling.
CI Engine stalls while driving.
Q Engine speed decreases.
Q Engine speed does not decrease.
CI Rough idling
0 Poor acceleration
CI Back fire
Q After fire
No shift
CI Excessive shift shock
EN(D0HC TURB0)d
GENERAL DESCRIPTION
3. General Description 8) Use ECM mounting stud bolts at the body head
grounding point when measuring voltage and resis-
A: CAUTION tance inside the passenger compartment.
1) Airbag system wiring harness is routed near the
engine control module (ECM), main relay and fuel
pump relay.
CAUTION:
All Airbag system wiring harness and con-
nectors are colored yellow. Do not use electri-
cal test equipment on these circuit.
Be careful not to damage the Airbag system
wiring harness when servicing the engine con-
trol module (ECM), transmission control mod-
ule (TCM), main relay and fuel pump relay.
2) Never connect the battery in reverse polarity. 9) Use engine grounding terminal or engine proper
The ECM will be destroyed instantly. as the grounding point to the body when measuring
The fuel injector and other part will be damaged voltage and resistance in the engine compartment.
in just a few minutes more.
3) Do not disconnect the battery terminals while the
engine is running.
A large counter electromotiveforce will be gener-
ated in the generator, and this voltage may damage
electronic parts such as ECM, etc.
4) Before disconnecting the connectors of each
sensor and the ECM, be sure to turn OFF the igni-
tion switch.
5) Poor contact has been identified as a primary
cause of this problem. To measure the voltage and/
or resistance of individual sensors or all electrical 10) Use TCM mounting stud bolts at the body head
control modules at the harness side connector, use grounding point when measuring voltage and resis-
a tapered pin with a diameter of less than 0.64 mm tance inside the passenger compartment.
(0.025 in). Do not insert the pin more than 5 mm
(0.20 in) into the part.
6) Before removing the ECM from the located posi-
tion, disconnect two cables on battery.
Otherwise, the the ECM may be damaged.
CAUTION:
When replacing the ECM, be careful not to use
the wrong spec. ECM to avoid any damage on
fuel injection system.
7) The connectors to each sensor in the engine
1666F
compartment and the harness connectors on the.
engine side and body side are all designed to be 11) Every MFI-related part is a precision part. Do
waterproof. However, it is still necessary to take not drop them.
care not to allow water to get into the connectors
when washing the vehicle, or when servicing the
vehicle on a rainy day.
EN(D0HC TURBO)-6
GENERAL DESCRIPTION
12) Observe the following cautions when installing 2. ENGINE GROUNDING

a radio in MFI equipped models. Make sure the engine grounding terminal is proper-
CAUTION: ly connected to the engine.
The antenna must be kept as far apart as pos-
sible from the control unit.
(The ECM is located under the steering column,
inside of the instrument panel lower trim panel.)
The antenna feeder must be placed as far
apart as possible from the ECM and MFI har-
ness.
Carefully adjust the antenna for correct
matching.
When mounting a large power type radio, pay
special attention to the three items above men- 145
tioned.
Incorrect installation of the radio may affect C: NOTE
the operation of the ECM. 1. DESCRIPTION
13) Before disconnecting the fuel hose, disconnect
the fuel pump connector and crank the engine for The on-board diagnostics (OBD) system detects
more than five seconds to release pressure in the and indicates a fault in various inputs and outputs
fuel system. If engine starts during this operation, of the complex electronic control. CHECK ENGINE
run it until it stops. malfunction indicator lamp (MIL) in the combination
14) Problems in the electronic-controlledautomatic meter indicates occurrence of a fault or trouble.
Further, against such a failure or sensors as may
transmission may be caused by failure of the en-
gine, the electronic control system, the transmis- disable the drive, the fail-safe function is provided
sion proper, or by a combination of these. These to ensure the minimal driveability.
three causes must be distinguished clearly when The OBD system incorporated with the vehicles
performing diagnostics. within this engine family complies with Section
15) Diagnostics should be conducted by rotating 1968.1, California Code of Regulations (OBD-ll
with simple, easy operations and proceeding to regulation). The OBD system monitors the compo-
complicated, difficult operations. The most impor- nents and the system malfunction listed in Engine
tant thing in diagnostics is to understand the cus- Section which affects on emissions.
tomer's complaint, and distinguish between the When the system decides that a malfunction oc-
three causes. curs, MIL illuminates. At the same time of the MIL il-
16) On ABS vehicle, when performing driving test lumination or blinking, a diagnostic trouble code
in jacked-up or lifted-up position, sometimes the (DTC) and a freeze frame engine conditions are
warning light may be lit, but this is not a malfunction stored into on-board computer.
of the system. The reason for this is the speed dif- The OBD system stores freeze frame engine
ference between the front and rear wheels. After di- condition data (engine load, engine coolant tem-
agnosis of engine control system, perform the ABS perature, fuel trim, engine speed and vehicle
memory clearance procedure of self-diagnosis sys- speed, etc.) into on-board computer when it detects
tem. a malfunction first.
If the OBD system detects the various malfunc-
B: INSPECTION tions including the fault of fuel trim or misfire, the
Before performing diagnostics, check the following OBD system first stores freeze frame engine condi-
items which might affect engine problems: tions about the fuel trim or misfire.
When the malfunction does not occur again for
1. BATTERY three consecutive driving cycles, MIL is turned off,
1) Measure battery voltage and specific gravity of but DTC remains at on-board computer.
electrolyte. The OBD-ll system is capable of communication
with a general scan tool (OBD-I1 general scan tool)
Standard voltage: 12 V formed by IS0 9141 CARB.
Specific gravity: Above 1.260
2) Check the condition of the main and other fuses,
and harnesses and connectors. Also check for
proper grounding.
EN(D0HC TURBO)-7
I GENERAL DESCRIPTION
The OBD-II diagnostics procedure is different pending on the quantity of air required for one cycle
from the usual diagnostics procedure. When trou- of operation. In actual operation, the injection quan-
bleshooting OBD-ll vehicles, connect Subaru Se- tity is determined by the duration of an electric
lect Monitor or the OBD-ll general scan tool to the pulse applied to the fuel injector and this permits
vehicle. simple, yet highly precise metering of the fuel.
Further, all the operating conditions of the engine
2. ENGINE AND EMISSION CONTROL SYS- are converted into electric signals, and this results
TEM in additional features of the system, such as large
The Multipoint Fuel Injection (MFI) system is a improved adaptability, easier addition of compen-
system that supplies the optimum air-fuel mixture sating element, etc.
to the engine for all the various operating condi- The MFI system also has the following features:
tions through the use of the latest electronic tech- Reduced emission of harmful exhaust gases.
nology. Reduced in fuel consumption.
With this system fuel, which is pressurized at a con- Increased engine output.
stant pressure, is injected into the intake air pas- Superior acceleration and deceleration.
sage of the cylinder head. The injection quantity of Superior startability and warm-up perfor-
fuel is controlled by an intermittent injection system mance in cold weather since compensation is
where the electro-magnetic injection valve (fuel in- made for coolant and intake air temperature.
jector) opens only for a short period of time, de-
D: PREPARATION TOOL
24082AA150 SARTRIDGE Troubleshooting for electrical
(Newly adopted tool) systems.
82M3876
22771AA030 SELECT MONITOR KIT Troubleshooting for electrical
systems.
English: 22771AA030 (With-
out printer)
German: 22771AA070
(Without printer)
French: 22771AA080
(Without printer)
Spanish: 22771AA090
(Without printer)
82M3877
EN(D0HC TURBO)-8
ELECTRICAL COMPONENTS LOCATION
4. Electrical Components Location

A: LOCATION
1. ENGINE
MODULE
(1) Engine control module (ECM) (3) Test mode connector

(2) CHECK ENGINE malfunction indi- (4) Data link connector
cator lamp (MIL)
EN1065
B3M1575A
I
EN(D0HC TURBO)-9
SENSOR
(1) Pressure sensor (4) Knock sensor (8) Tumble generator valve position
(2) Engine coolant temperature sen- (5) Camshaft position sensor sensor
sor (6) Crankshaft position sensor
(3) Throttle position sensor (7) Mass air flow and intake air tem-
perature sensor
EN(D0HC TURBO)-IO
\
EN1012
n
EN1015
EN(D0HC TURBO)-I 1
EN0948
(1) Front oxygen (NF) sensor (3) Exhaust temperature sensor (5) Rear oxygen sensor
(2) Precatalytic converter (4) Front catalytic converter (6) Rear catalytic converter
EN(D0HC TURBO)-12
EN1017
EN(D0HC TURBO)-13
(3) (4)
EN1067
(1) Fuel level sensor (3) Fuel tank pressure sensor

(2) Fuel temperature sensor (4) Fuel sub level sensor
H2M3207A B2M1807A
EN(D0HC TURBO)-14
EN(D0HC TURBO)-15
~
SOLENOID VALVE, ACTUATOR, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM
PARTS
EN0951
(1) Wastegate control solenoid valve (3) Purge control solenoid valve (5) Tumble generator valve actuator
(2) Idle air control solenoid valve (4) Ignition coil
EN(D0HC TURBO)-16
m
(4) EN1024
EN(D0HC TURBO)-17
EN1068
(1) Pressure control solenoid valve (3) Drain valve

(2) Canister (4) Drain filter
SUBARU
-
H2M2444A
EN(D0HC TURBO)-18
EN(D0HC TURBO)-19
(1) Fuel pump (4) Fuel pump controller (7) Radiator sub fan relay 1
(2) Main relay (5) Radiator main fan relay 1 (8) Radiator sub fan relay 2
(3) Fuel pump relay (6) Radiator main fan relay 2 (9) Starter
EN(D0HC TURBO)-20
ENGINE (DIAG NOSTlCS)
EN1191
-(9)
EN1030
EN(D0HC TURBO)-21
3
2. TRANSMISSION
Module
(1) Transmission Control Module (2) AT diagnostic indicator light (for AT

(TCM) (for AT vehicles) vehicles)
EN(DOHC TURB0)-22
a
Sensor
(2) Vehicle speed sensor 2 (for MT vehicles)

(3) Vehicle speed sensor 2 (for AT vehicles)
(4) Torque converter turbine speed sensor (for AT vehicles)
(5) ATF temperature sensor (for AT vehicles)
(6) Brake light switch
EN(D0HC TURBO)-23
Solenoid Valve And Switch (AT Vehicles)
(8) (1’0) 02M2263A 2264A
(1) Dropping resistor

(2) Inhibitor switch
(3) Shift solenoid valve 1
(4) Shift solenoid valve 2
(5) Line pressure duty solenoid
(6) Lock-up duty solenoid
(7) Transfer duty solenoid
(8) 2-4 brake duty solenoid
(9) Low clutch timing solenoid valve
(10) 2-4 brake timing solenoid valve
Solenoid Valve And Switch (MT Vehicles)
(1) Neutral position switch
EN(DOHC TURB0)-24
EN(D0HC TURBO)-25
ENGINE CONTROL MODULE (ECM) I/O SIGNAL
5. Engine Control Module (ECM) I/O Signal

A: ELECTRICAL SPECIFICATION
r
To @ To @ To @
To @ To a
EN0955
I
Signal (V)
Content nector Ignition SW ON Note
nal No. Engine ON (Idling)
Con-
No. Termi- lEnaine OFF)
Crank- Signal (+) 0 -7 - +7 Sensor output waveform
shaft posi- Signal (-) 0 I 0 I -
tion sensor Shield n I 0 I -
Camshaft Signal (+) 0 -7 - +7 Sensor output waveform
position Signal (-) 0 0 -
sensor Shield 0 0 -
Signal B135
Throttle
Power
position B135 5 5
sensor supply
GND(sen-
0 0
sor)
Signal 0 0 - 0.9 -
Rear oxy- n I 0 I -
Shield
gen sen- 1
sor GND(sen-
61 35 19 0 0
sor)
Front oxy- Signal 1 0-1.0 0-1.0
+-
gen (W
sensor Signal 2 B137 5 0- 1.0 0- 1.0
heater
Rear oxygen sensor -
0-1.0 0- 1.0
heater signal
Engine 1.0- 1.4 1.o - 1.4 I After warm-up the engine.
coolant
B135 19 0 0 After warm-up the engine.
“5” and “ 0are repeatedly dis-

Vehicle speed signal Oor5 0 or 5
Dlaved when vehicle is driven.
EN(D0HC TURBO)-26
Signal (V)
‘On- Termi- -
No. (Engine OFF)
Mass air Signal 684 13 - 0.3 - 4.5 -
flow sen- Shield 684 8 0 0 -
sor GND 684 7 0 0 -
#I B136 24 0 13-14 Waveform

Ignition #2 B136 23 0 13-14 Waveform
control #3 6136 22 0 13-14 Waveform
#4 6136 21 0 13-14 Waveform
EN(D0HC TURBO)-27
Con- Signal (V)

Termi-
No. (Engine OFF)
#1 B137 1 10-13 1-14 Waveform
Fuel injec- #2 B136 6 10- 13 1-14 Waveform
I I
~
tor #3 B136 5 10- 13 1-14 Wavef o i

#4 B136 4 10- 13 I 1-14 I Waveform
Idle air
control
Signal B136 10 0 or 13- 14 0 or 13 - 14 Waveform
solenoid
valve
Fuel pump Signal 1 B134 13
controller Signal 2 B136 15
ON: 0.5, or less ON: 0.5, or less -
A/C relay control 8137 27
OFF: 10- 13 OFF: 13- 14
Radiator fan relay 1 ON: 0.5, or less ON: 0.5, or less -
B137 17
control OFF: 10- 13 OFF: 13- 14
Radiator fan relay 2
control
B137 28
ON: 0.5, or less
OFF: 10 - 13
1 ON: 0.5, or less
OFF: 13 - 14
1 With A/C vehicles only
Malfunction indicator - - Light “ON”: 1, or less

B137 15
lamp Liaht “OFF: 10 - 14
Engine speed output B136 9 - I 0- 13, or more I Waveform
Purge control solenoid ON: 1, or less ON: 1, or less -
B137 16
valve OFF: 10 - 13 OFF: 13 - 14
Toraue control 1 sianal B134 19 5 5 -
Toraue control 2 sianal B134 18 5 1 - 5
Torque control cut sig-
nal
Fuel temperature sen-
B136 14 8
I 8
Ambient temperature: 25°C

B135 6 2.5 - 3.8 2.5 - 3.8
sor (75°F)
The value obtained after the
Fuel tank Signal 15 2.3 - 2.7 2.3 - 2.7 fuel filler cap was removed
pressure
sensor - 1I
sor)
B134 19 0 0
once and recapped.
Fuel tank pressure con-

trol solenoid valve
B137 22
ON: 1, or less
OFF: 10 - 13 1 ON: 1, or less
OFF: 13-14 I -
Drain valve
AT diagnosis input sig-

B137 11
ON: 1, or less
OFF: 10- 13
Less than 1 +-+More
I ON: 1, or less
OFF:13-14
Less than 1 ++ More
I -
B135 20 Waveform
nal than 4 than 4
AT load signal B135 28 4.3 - 4.4 I 0.9 - 1.4 I -
Signal B135 8 1.7 - 2.4 I 1.1 -1.6 I
Pressure
sensor
Power
B135 9 5
I
I
5
~
I
I
-
B135 19 0 0
Fuel level sensor B135 25 0.12 - 4.75 0.12 - 4.75 -

ON: 0 ON: 0 -
Small light switch B134 17
OFF: 10 - 13 OFF: 13 - 14
ON: 0 ON: 0 -
Blower fan switch B134 9
OFF: 10- 13 OFF: 13- 14
Rear defogger switch
Power steering oil pres-

B134 3
ON: 0
OFF: 10- 13 I ON: 0
OFF:13-14
ON: 0
I
B135 24 10- 13 -
sure switch OFF: 13 - 14
EN(D0HC TURBO)-28
ENGINE (DIAGNOSTICS1
GND (ignition system) 6136 18 0 0 -

6136 17 0 0 -
GND (power supply) -
6134 22 0 0
6134 7 0 0 -
GND (control systems) -
6134 15 0 0
GND (oxygen sensor -
B137 9 0 0
heater 1)
GND (oxygen sensor -
B137 8 0 0
heater 2)
EN(D0HC TURBO)-29
ENGINE CONDITION DATA
6. Engine Condition Data

Content Specified data
1.6 - 2.9 (%): Idling
Engine load
6.4 - 12.8 (%): 2,500 rpm racing
Measuring condition:
After engine is warmed-up.
Gear position is in neutral position. (MT vehicle)
Gear position is in “N” or “P” position. (AT vehi-
cle)
A/C is turned OFF.
All accessory switches are turned OFF.
EN(D0HC TURBO)-30
ENGINE CONDITION DATA
EN(D0HC TURBO)-31
TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL
7. Transmission Control Module (TCM) I/O Signal

S2M2131
NOTE:
Check with ignition switch ON.
Resistanceto
Content nector Measuring conditions Voltage (V)
nal No. body (ohms)
I
Back-up power supply 856 I 1 lanition switch OFF I 10-13 I -

Ignition power supply
B54 24
Ignition switch ON (with
-
enaine OFF)
Select lever in “ Prange
10-13
Less than 1
l -
“P” range -
855 1 Select lever in any other than
switch More than 8
“P” ranae (exceDt “N” ranae)
Select lever in “N” range I Less than 1 I
“N” range
switch
“N” ranae
- * - (exceDt “P” ranael
\ - I . , I (
1 Morethan8
I
I
-
Select lever in ‘W ranae“ I Less than 1

“R” range -
switch More than 8
“ R ranae
Select lever in “D” range I Less than 1 I
Inhibitor
switch
“D” range
switch
B55 4 Select lever in any other than
“D” ranae
.,
I Morethan 8
I
-
I I
Select lever in “ 3ranae

I
I Less than 1
“3” range -
switch More than 8
“ 3 range
Select lever in “2” range I Less than 1
“2” range
switch
Select lever in any other than
“2” ranae
“
I
I
Morethan 8
I
-
Select lever in “1” ranae I Less than 1

“1” range ~
-
switch
Select lever in any other than
. ranae
“1” .a -
More than 8
I
Brake switch B55 I 12
Brake pedal depressed.
Brake pedal released.
More than 10.5
Less than 1
-
AT OIL TEMP warning light B56 1 11

Light ON
Liaht OFF
Less than 1
More than 9
-
EN(D0HC TURBO)-32
ENGINE (DIAGNOSTlCS)
Termi- Resistance to
nal No. body (ohms)
Throttle position sensor I 854 3

Throttle fully closed.
Throttle fully open.
Approx. 0.5
Approx. 4.3
-
- lanition switch ON (With

Approx . 5.0 -
supply 2 1 - engine OFF) I
ATF temperature 20°C
2.9 - 4.0 2.1 -2.9 k
I 11
\ I

0.5 - 0.8 275 - 375
854
Vehicle stopped.
.. 0
I
Rear vehicle speed sensor 24 Vehicle speed at least 20 More than (AC 450 - 650
I
km/h (12 MPH)
Vehicle stopped. 0
Front vehicle speed sensor 855 18 Vehicle speed at least 20 More than (AC range) 450 - 650
km/h (12 MPH)
Engine idling after warm-up. n
v
Torque converter turbine (D range)
450 - 650
speedsensor - Engine idling after warm-up.
More than 1 (AC range)
(N ranoe) - I
Vehicle speed at most 10 Less than I t

Vehicle speed output signal 17
km/h (6 MPH) +More than 5
0
engine OFF)
Engine speed signal 855 l7
8-11
1
engine
- ON) I
When cruise control is set
Less than 1
fSET lamD ON) -
Cruise set signal 22
When cruise control is not
More than 6.5
set (SET lamD OFF)
Ignition switch ON (with -
Torque control signal 1 5 More than 4.8

Torque control signal 2 14 More than 4.8
engine ON)
Torque control cut signal 10 Ignition switch ON 8 -
1st or 4th gear More than 9
Shift solenoid 1 854 22 - 10-16
2nd or 3rd gear Less than 1
I
~
1st or 2nd gear More than 9

Shift solenoid 2 854 5 ~
10-16
3rd or 4th gear Less than 1
Throttle fully closed (with
1.5 - 5.0
engine OFF) after warm-up.
Line pressure duty solenoid 854 9 2.0 - 4.5
Throttle fully open (with
Less than 0.5
-c
When lock up occurs. More than 8.5
Lock-up duty solenoid 7 10-17
When lock up is released. Less than 0.5
Fuse on FWD switch More than 8.5
Fuse removed from FWD
I
Transfer duty solenoid 6 switch (with throttle fully 10-17
Less than 0.5
open and with select lever in
854 1st gear).
1.5 - 5.0
2-4 brake duty solenoid
I 2.0-4.5
'

Less than 0.5
854 engine OFF) after warm-up.
EN(D0HC TURBO)-33
I TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL
Con-
Termi- Resistance to
nal No. body (ohms)
No.
More than 8.5
engine OFF) after warm-up. a- IIEW;
"I YVT I , w
Less than 0.5
1st gear Less than 1
I
3rd clear
" More than 9
2nd gear Less than 1
Low clutch timing solenoid 854 15 10- 16
4th Clear More than 9
Sensor ground line 1 1 854 1 19 I - 0 I Lessthan 1
Sensor ground line 2 I 855 I 9 1 - 0 I Lessthan 1
856 19
System ground line - 0 Less than 1
854 20
Less than 1 t -
AT diagnosis signal 856 21 Ignition switch ON
+ More than 4
Data link signal (Subaru 15 I - -
EN(D0HC TURBO)-34
DATA LINK CONNECTOR
8. Data Link Connector

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

1 Power supply 9 Blank
2 Blank 10 K line of I S 0 9141 CARB
3 Blank 11 Blank
4 Blank 12 Ground
5 I Blank 13 I Ground
6 I Line end check signal 1 14 I Blank
7 Blank 15 Blank
8 Line end check signal 2 16 Blank
EN(D0HC TURBO)-35
OBD-II GENERAL SCAN TOOL
9. OBD-Il General Scan Tool 3) Using the OBD-II general scan tool, call up diag-
nostic trouble code(s) and freeze frame data.
A: OPERATION OBD-II general scan tool functions consist of:
(1) MODE $01: Current powertrain diagnostic
1. HOW TO USE OBD-II GENERAL SCAN data
TOOL (2) MODE $02: Powertrain freeze frame data
1) Prepare a general scan tool (OBD-II general (3) MODE $03: Emission-related powertrain di-
scan tool) required by SAE J1978. agnostic trouble codes
2) Open the cover and connect the OBD-II general (4) MODE $04: Clear/Reset emission-related
scan tool to the data link connector located in the diagnostic information
lower portion of the instrument panel (on the driv- Read out data according to repair procedures. (For
er's side). detailed operation procedures, refer to the OBD-II
General Scan Tool Operation Manual.)
NOTE:
For details concerning diagnostic trouble codes, re-
fer to the List of Diagnostic Trouble Code (DTC).
<Ref. to EN(D0HC TURBO)-80, List of Diagnostic
Trouble Code (DTC).>
2. MODE $01 (CURRENT POWERTRAIN DIAGNOSTIC DATA)
01 I Number of emission-relatedDowertraintrouble codes and MIL status ONIOFF

I 03 I Fuel svstem control status I - I
04 I Calculated engine load value YO
05 I Engine coolant temperature "C

I 06 I Short term fuel trim I % I
07 I Long term fuel trim %
OB I Intake manifold absolute Dressure kPa
I OC I Enaine revolution I rDm I
I OD I Vehicle speed I kmlh I
OE Ignition timing advance 0
OF Intake air temperature "C

10 Air flow rate from pressure sensor glsec
11 Throttle valve opening angle %
13 Check whether oxvaen sensor is installed. -
Oxygen sensor output voltage and short term fuel trim associated with oxygen sensor-bank
l5 V and Yo
2
24 A/F sensor 1 output voltage and short term fuel trim associated with A/F sensor 1 V and Yo
1C I On-board diagnosis system -
NOTE:
Refer to OBD-II general scan tool manufacturer's instruction manual to access generic OBD-II PlDs (MODE
$01).
EN(D0HC TURBO)-36
OBD-II GENERAL SCAN TOOL
3. MODE $02 (POWERTRAIN FREEZE FRAME DATA)

Refers to data denoting the operating condition when trouble is sensed by the on-board diagnosis system.
A list of the support data and PID (Parameter Identification) codes are shown in the following table.
I PID I Data I Unit of measure I
02 Trouble code that caused CARB required freeze frame data storage -
03 Fuel system control status -
04 Calculated engine load value %
05 Engine coolant temperature "C
06 Short term fuel trim O/O
r-07 I Long term fuel trim I Yo I

OB Intake manifold absolute pressure kPa
OC Engine revolution rPm
OD Vehicle speed km/h
NOTE:
Refer to OBD-II general scan tool manufacturer's instruction manual to access freeze frame data (MODE
$02).
4. MODE $03 (EMISSION-RELATED POWERTRAIN DIAGNOSTIC TROUBLE CODE)
Refer to Read Diagnostic Trouble Code for information about data denoting emission-related powertrain di-
agnostic trouble codes. <Ref. to EN(D0HC TURBO)-45, Read Diagnostic Trouble Code.>
5. MODE $04 (CLEAR/RESET EMISSION-RELATED DIAGNOSTIC INFORMATION)
Refers to the mode used to clear or reset emission-related diagnostic information (OBD-II trouble diagnostic
information).
NOTE:
Refer to OBD-II general scan tool manufacturer's instruction manual to clear or reset emission-related diag-
nostic information (MODE $04).
EN(D0HC TURBO)-37
SUBARU SELECT MONITOR
1O.Subaru Select Monitor (2) Connect the diagnosis cable to data link
connector.
A: OPERATION CAUTION:
1. HOW TO USE SUBARU SELECT MONI- Do not connect scan tools except for Subaru
TOR Select Monitor and OBD-ll general scan tool.
5) Turn the ignition switch to ON (engine OFF) and
1) Prepare the Subaru Select Monitor kit. <Ref. to Subaru Select Monitor switch to ON.
EN(D0HC TURBO)-8, PREPARATION TOOL,
General Description.>
I 52M0288 I
6) Using the Subaru Select Monitor, call up diag-
nostic trouble code(s) and various data, then
2) Connect the diagnosis cable to Subaru Select record them.
Monitor.
3) Insert the cartridge into Subaru Select Monitor. 2. READ DIAGNOSTIC TROUBLE CODE
<Ref. to EN(D0HC TURBO)-8. PREPARATION (DTC) FOR ENGINE. (NORMAL MODE)
TOOL, General Description.> Refer to Read Diagnostic Trouble Code for infor-
mation about how to indicate DTC. <Ref. to
EN(D0HC TURBO)-45, Read Diagnostic Trouble
Code.>
3. READ DIAGNOSTIC TROUBLE CODE
(DTC) FOR ENGINE. (OBD MODE)
Refer to Read Diagnostic Trouble Code for infor-
mation about how to indicate DTC. <Ref. to
EN(D0HC TURBO)-45, Read Diagnostic Trouble
Code.>
4) Connect the Subaru Select Monitor to data link

connector.
( 1 ) Data link connector located in the lower por-
tion of the instrument panel (on the driver's
side).
EN(DOHC TURB0)-38
4. READ CURRENT DATA FOR ENGINE. (NORMAL MODE)

1) On the <<Main Menu,, display screen, select the {Each System Check} and press the [YES] key.
2) On the &ystem Selection Menu), display screen, select the {Engine Control System} and press the [YES]
key.
3) Press the [YES] key after displayed the information of engine type.
4) On the <<Engine Diagnosis), display screen, select the, {Current Data Display & Save} and press the [YES]
key.
5) On the <<Data Display Menu,, display screen, select the {Data Display} and press the [YES] key.
6) Using the scroll key, move the display screen up or down until the desired data is shown.
A list of the support data is shown in the following table.
Contents Display Unit of measure

Battery voltage Battery Voltage V
Vehicle speed Sianal
~~
Vehicle Speed km/h or MPH
Enaine speed sianal 1 Engine Speed I rpm
Engine coolant temperature signal I Coolant Temp. I "C or OF
Ignition timing signal Ignition Timing deg
Throttle position signal Throttle Opening Angle %
Throttle position signal Throttle Sensor Voltage V
Injection pulse width Fuel Injection #I Pulse ms
Idle air control sianal ISC Valve Dutv Ratio %
Fuel pump duty control signal Fuel Pump Duty YO
A/F sensor current A/F Sensor #I Current mA
N F sensor resistance N F Sensor #I Resistance R
Front oxygen (NF) sensor output signal A/F Sensor #I -
Rear oxygen sensor output signal Rear 0 2 Sensor V
Short term fuel trim A/F Correction #I %
1 Knocking Correction I
Knock sensor signal
Atmospheric absolute pressure signal 1 Atmosphere Pressure
1 deg
mmHg or kPa or inHg or
Dsi
Intake manifold relative pressure signal Mani. Relative Pressure
psi
Intake manifold absolute pressure signal 1 Mani. Absolute Pressure 1 mmHg or kPa or inHg or
Dsi
8- ~
A/F correction (short term fuel trim) by rear oxygen sensor A/F Correction #3 YO
Long term whole fuel trim N F Learning #I %

Front oxygen (A/F) sensor heater current A/F Heater Current 1 A
Rear oxvaen sensor heater voltaae Rear 0 2 Heater Voltage V
Canister purge control solenoid valve duty ratio 1 CPC Valve Duty Ratio I %
Primary supercharged pressure control signal 1 Primary Control I Oh
Tumble generator valve position sensor signal (right side) TGV Position Sensor R V
Tumble generator valve position sensor signal (left side) TGV Position Sensor L V
Tumble aenerator valve drive sianal TGV Drive OPEN or CLOSE
I Fuel Level I V
Intake air temperature signal Intake Air Temp. "C or OF
Learned ignition timing Learned Ignition Timing deg
Mass air flow sensor signal Mass Air Flow gls
Mass air flow sensor signal Air Flow Sensor Voltage V
Fuel tank pressure signal Fuel Tank Pressure
psi
Fuel temperature signal Fuel Temp "C or OF
Exhaust gas temperature signal Exhaust Gas Temperature OC or OF
MTIAT identification signal AT Vehicle ID Signal ON or OFF
Fuel Dressure control solenoid valve sianal PCV Solenoid Valve ON or OFF
EN(D0HC TURBO)-39

Drain valve sianal 1 Vent. Solenoid Valve ON or OFF
I Ignition switch signal I Ignition Switch I ON or OFF I
I Test mode connector signal I Test Mode Signal I ON or OFF I
Neutral position switch signal Neutral Position Switch ON or OFF
Air conditioning switch signal N C Switch ON or OFF
Air conditioning signal N C Compressor Signal ON or OFF
Radiator main fan relav sianal Radiator Fan Relav #I ON or OFF
I Fuel pump relay signal I Fuel Pump Relay I ON or OFF I
Knocking signal Knocking Signal ON or OFF
Radiator sub fan relay signal Radiator Fan Relay #2 ON or OFF
Power steering switch signal PIS Switch ON or OFF
Engine torque control signal #I Torque Control Signal #I ON or OFF
Enaine toraue control sianal #2 Toraue Control Sianal #2 ON or OFF
Engine torque control permission signal Torque Permission Signal ON or OFF
Rear oxygen sensor rich signal Rear 0 2 Rich Signal ON or OFF
Starter switch signal Starter Switch ON or OFF
Idle switch signal Idle Switch ON or OFF
Crankshaft position sensor signal Crankshaft Position Sig. ON or OFF
Camshaft position sensor signal Camshaft Position Sig. ON or OFF
Rear defogger switch signal Rear Defogger SW ON or OFF
Blower fan switch signal Blower Fan SW ON or OFF
Small light switch signal Light Switch ON or OFF
Tumble generator valve output signal TGV Output ON or OFF
EN(D0HC TURBO)-40
ENGINE IDIAGNOSTICSI
5. READ CURRENT DATA FOR ENGINE. (OBD MODE)

1) On the ((MainMenu)) display screen, select the {Each System Check} and press the [YES] key.
2) On the ((SystemSelection Menu), display screen, select the {Engine Control System} and press the YES]
key.
4) On the ((Engine Diagnosis), display screen, select the {OSD System} and press the [YES] key.
5) On the <<OBD Menu))display screen, select the {Current Data Display & Save} and press the [YES key.
6) On the ((DataDisplay Menu,, display screen, select the {Data Display} and press the [YES] key.

Number of diagnosis code Number of Diagnosis Code -
Malfunction indicator lamp status MI (MIL) ON or OFF
Monitorina test of misfire Misfire monitoring Complete or incomplete
Monitoring test of fuel system Fuel system monitoring Complete or incomplete
Monitoring test of comprehensive component Component monitoring Complete or incomplete
Test of catalyst Catalyst Diagnosis Complete or incomplete
Test of heated catalyst Heated catalyst No support
Test of evaporative emission purge control system Evaporative purge system Complete or incomplete
Test of secondary air system Secondary air system No support
Test of air conditioning system refrigerant 1 A/C system refrigerant No support
Test of oxygen sensor Oxygen sensor Complete or incomplete
Test of oxygen sensor heater 0 2 Heater Diagnosis Complete or incomplete
Test of EGR system EGR system No support
Air fuel ratio control system for bank 1 Fuel System for Bank 1 -
Engine load data Calculated load value YO
Engine coolant temperature signal Coolant Temp. "C or O F

Short term fuel trim by front oxygen (NF) sensor Short term fuel trim B1 O/O
Long term fuel trim by front oxygen ( N F ) sensor Long term fuel trim B1 YO
Intake manifold absolute pressure signal I

I
Mani. Absolute Pressure
psi I
Enaine meed sianal I Engine Speed rPm
Vehicle speed signal I Vehicle Speed km/h or MPH
Ignition timing advance for #1 cylinder Ignition timing adv. #I 0
Intake air temperature signal Intake Air Temp. "C or OF

Intake air amount Mass Air Flow g/s
Throttle position signal Throttle Opening Angle O/O
A/F sensor sianal NF sensor #11 V

Rear oxvaen sensor outDut sianal I Oxygen Sensor #I 2 V
Air fuel ratio correction by rear oxygen sensor Short term fuel trim #12 YO
On-board diagnostic system OBD System -
NOTE:
For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
EN(D0HC TURBO)-41
6. READ FREEZE FRAME DATA FOR ENGINE. (OBD MODE)

1) On the ((MainMenu,, display screen, select the {Each System Check} and press the [YES] key.
2) On the ((SystemSelection Menu>> display screen, select the {Engine Control System} and press the [YES]
key.
4) On the ((EngineDiagnosis,, display screen, select the {OBD System} and press the [YES] key.
5) On the <<OBD Menu>)display screen, select the {Freeze Frame Data} and press the [YES] key.
I Diagnostic trouble code (DTC) for freeze frame data I Freeze frame data I DTC I
I Air fuel ratio control system for bank 1 I Fuel system for Bank1 I ON or OFF I
Engine load data Calculated load valve %
Engine coolant temperature signal Coolant Temp. "C or OF
Short term fuel trim bv front oxvaen (NF) sensor Short term fuel trim B1 %
I Lonq term fuel trim bv front oxvqen (NF) sensor I I
~~
Lona term fuel trim 81 % I

1
~~
Intake manifold absolute pressure signal 1 Mani. Absolute Pressure I mmHg or kPa or inHg or
mi I
Engine speed signal Engine Speed rPm
Vehicle speed signal Vehicle Speed km/h or MPH
EN(D0HC TURBO)-42
7. LED OPERATION MODE FOR ENGINE

1) On the ((Main Menu,, display screen, select the {Each System Check} and press the [YES] key.
2) On the ((SystemSelection Menu)) display screen, select the {Engine Control System} and press the [YES]
key.
4) On the ((EngineDiagnosis), display screen, select the {Current Data Display & Save} and press the [YES]
key.
5) On the <<DataDisplay Menu))display screen, select the {Data & LED Display} and press the [YES] key.
Contents Display
. - I Message 1 LED "ON" requirements
lanition switch signal Ignition Switch ON or OFF When ignition switch is turned ON.
Test mode connector signal Test Mode Signal ON or OFF When test mode connector is connected.
Neutral position switch signal Neutral Position Switch ON or OFF When neutral position signal is entered.
Air conditioning switch sianal
" I
N C Switch orOFF When air conditioning switch is turned ON.
W.l"., ni-...-.l A /P Cinn-l When air conditioning compressor is in func-
Prrmnrrrr.r.nv
ON or OFF tion,
..
Radiator main fan relay signal Radiator Fan Relay #1 ON or OFF When radiator main fan relay is in function.
Knocking signal Knocking Signal ON or OFF When knocking signal is entered.
Radiator sub fan relay signal Radiator Fan Relay #2 ON or OFF When radiator sub fan relay is in function.
..-.-I u4 T-r-. .- P..-+..nl CL-.nnl u.4
ON Or OFF
When engine torque control signal 1 is
entered.
Engine torque control signal #2
Engine torque control permission

Torque Control Signal #2
1 1
When engine torque control signal 2 is
ON Or OFF entered.
When engine torque control permission sig-
Torque Control Permission ON Or OFF
sianal nal is entered.
When rear oxygen sensor mixture ratio is
Rear oxygen sensor rich signal Rear 0 2 Rich Signal ON or OFF
rich,
Starter switch signal Starter Switch ON or OFF When starter switch signal is entered.
Idle switch signal Idle Switch Signal ON or OFF When idle switch signal is entered.
When crankshaft position sensor signal is
Crankshaft position sensor signal Crankshaft Position Signal ON or OFF entered,
Camshaft position sensor signal 1 Camshaft Position Signal 1 ON or OFF I When camshaft position sensor signal is
entered.
Power steering switch signal PIS Switch ON or OFF When power steering switch is entered.
Rear defogger switch signal Rear Defogger Switch ON or OFF When rear defogger switch is turned ON.
Blower fan switch sianal - I
Blower Fan Switch I
ON or OFF I
When blower fan switch is turned ON.
Liaht switch sianal
~
I LiQht Switch 1 ON or OFF I When small light switch is turned ON.
Tumble generator valve actuator
TGV Output ON or OFF When TGV actuator signal is entered.
signal
Tumble generator valve drive sig- OPEN Or
TGV Drive When TGV moves and valve opens.
nal CLOSE
Fuel pressure control solenoid When fuel pressure control solenoid valve is
valve signal
pcv Solenoid Valve ON Or OFF in function.
Drain valve signal Vent. Solenoid Valve ON or OFF When drain valve is in function.
NOTE:
EN(D0HC TURBO)-43
~
8. READ CURRENT DATA FOR AT

1) On the ((Main Menu)) display screen, select the {Each System Check} and press the [YES] key.
2) On the ((SystemSelection Menu))display screen, select the {Transmission Control System} and press the
[YES] key.
3) Press the [YES] key after displayed the information of transmission type.
4) On the ((TransmissionDiagnosis), display screen, select the {Current-Data Display & Save} and press the
[YES] key.
5) On the ((DataDisplay Menu))display screen, select the {Data Display} and press the [YES] key.
I Contents I Display I Unit of measure
Battery voltage Battery Voltage V
Rear vehicle speed sensor signal Rear Wheel Speed km/h or MPH
Front vehicle speed sensor sianal - Front Wheel Speed km/h or MPH
Automatic transmission fluid temperature signal ATF Temp. "C or OF
I
Mass air flow sensor signal Air Flow Sensor Voltage V
Gear position Gear Position -
Line pressure control dutv ratio Line Pressure Dutv Ratio YO
Transfer clutch control duty ratio Transfer Duty Ratio YO

Power supply for throttle position sensor Throttle Sensor Power V
Torque converter turbine speed signal Turbine Revolution Speed rPm
2-4 brake timing pressure control duty ratio Brake Clutch Duty Ratio YO
Stop lamp switch signal Stop Light Switch ON or OFF
Anti lock brake system sianal ABS Sianal ON or OFF
I Cruise control system signal I Cruise Control Signal I ON or OFF I
NeutraVParking range signal N/P Range Signal ON or OFF
Reverse range signal R Range Signal ON or OFF
Drive range signal D Range Signal ON or OFF
3rd range signal 3rd Range Signal ON or OFF ~
2nd range signal 2nd Range Signal ON or OFF

1st range signal 1st Range Signal ON or OFF
Shift control solenoid A Shift Solenoid #1 ON or OFF
Shift control solenoid B Shift Solenoid #2 ON or OFF
Torque control output signal #1 Torque Control Signal #1 ON or OFF
Torque control output signal #2 Torque Control Signal #2 ON or OFF
Torque control cut signal Torque Control Cut Sig. ON or OFF
2-4 brake timing control solenoid valve 2-4 Brake Timina Sol. ON or OFF
I Low clutch timing control solenoid valve I Low Clutch Timing Sol. I ON or OFF I
EN(D0HC TURBO)-44
I READ DIAGNOSTIC TROUBLE CODE
ENGI NE (DIAGNOSTICS)
11.Read Diagnostic Trouble 3. OBD-ll GENERAL SCAN TOOL

Code Refers to data denoting emission-related power-
train diagnostic trouble codes.
A: OPERATION For details concerning diagnostic trouble codes, re-
fer to the List of Diagnostic Trouble Code (DTC).
1. SUBARU SELECT MONITOR (NORMAL <Ref. to EN(D0HC TURBO)-80, List of Diagnostic
MODE) Trouble Code (DTC).>
1) On the ((Main Menu,, display screen, select the NOTE:
{Each System Check} and press the [YES] key. Refer to OBD-II general scan tool manufacturer's
2) On the <<System Selection Menu)) display instruction manual to access emission-related
screen, select the {Engine Control System} and powertrain diagnostic trouble codes (MODE $03).
press the [YES] key.
3) Press the [YES] key after displayed the informa-
tion of engine type.
4) On the <<EngineDiagnosis,) display screen, se-
lect the {Diagnostic Code@)Display} and press the
[YES] key.
5) On the <<DiagnosticCode(s) Display)) display
screen, select the {Current Diagnostic Code(s)} or
{History Diagnostic Code@)}and press the [YES]
key.
NOTE:
For detailed operation procedure, refer to the
SUBARU SELECT MONITOR OPERATION MAN-
UAL.
For detailed concerning diagnostic trouble
codes, refer to the List of Diagnostic Trouble Code
(DTC). <Ref. to EN(D0HC TURBO)-80, List of Di-
agnostic Trouble Code (DTC).>
2. SUBARU SELECT MONITOR (OBD
MODE)
1) On the <<MainMenu)) display screen, select the
(2. Each System Check} and press the [YES] key.
2) On the <<SystemSelection Menu,, display
screen, select the {Engine Control System} and
4) On the <<EngineDiagnosis,, display screen, se-
lect the {OBD System} and press the [YES] key.
5) On the <<OBDMenu)) display screen, select the
{Diagnosis Code(s) Display} and press the [YES]
key.
6) Make sure that a diagnostic trouble code (DTC)
is shown on the display screen.
NOTE:
UAL.
EN(D0HC TURBO)-45
INSPECTION MODE
12.lnspection Mode 2. SUBARU SELECT MONITOR

After performing diagnostics and clearing the mem-
A: OPERATION ory, check for any remaining unresolved trouble da-
1. PREPARATION FOR THE INSPECTION ta.
MODE 1) Prepare the Subaru Select Monitor kit. <Ref. to
Raise the vehicle using a garage jack and place on General Description.>
safety stands or drive the vehicle onto free rollers.
WARNING:
Before raising the vehicle, ensure parking
brakes are applied.
Do not use a pantograph jack in place of a
safety stand.
Secure a rope or wire t o the front and rear
towing or tie-down hooks to prevent the lateral
runout of front wheels.
Do not abruptly depresshelease the clutch
pedal or accelerator pedal during works even S2M0285
when engine is operating at low speeds since 2) Connect the diagnosis cable to Subaru Select
this may cause the vehicle t o jump off free roll- Monitor.
ers. 3) Insert the cartridge into Subaru Select Monitor.
In order to prevent the vehicle from slipping <Ref. to EN(D0HC TURBO)-8, PREPARATION
due to vibration, do not place any wooden TOOL, General Description.>
blocks or similar items between the safety
stands and the vehicle.
Since the rear wheels will also rotate, do not
place anything near them. Also, make sure that
nobody goes in front of the vehicle.
4) Connect the test mode connector at the lower

portion of instrument panel (on the driver's side), to
the side of the center console box.
Safeystand
02M2969P
EN(D0HC TURBO)-46
INSPECTION MODE
am
5) Connect the Subaru Select Monitor to data link 12) Perform subsequent procedures as instructed
connector. on the display screen.
(1) Connect the Subaru Select Monitor to data If trouble still remains in the memory, the corre-
link connector located in the lower portion of the sponding diagnostic trouble code (DTC) appears
instrument panel (on the driver’s side). on the display screen.
I
NOTE:
UAL.
Release the parking brake.
The speed difference between front and rear
. .
I I wheels may light either the ABS warning light, but
(2) Connect the diagnosis cable to data link this indicates no malfunctions. When engine con-
connector. trol diagnosis is finished, perform the ABS memory
clearance procedure of self-diagnosis system.
CAUTION:
Do not connect scan tools except for Subaru 3. OBD-II GENERAL SCAN TOOL
Select Monitor and OBD-II general scan tool.
After performing the diagnostics and clearing the
6) Turn the ignition switch to ON (engine OFF) and memory, check for any remaining unresolved trou-
Subaru Select Monitor switch to ON. ble data:
1) Connect the test mode connector (A) at the low-
er side of the instrument panel (on the driver’s
side), to the side of the center console box.
. -
S2M0288 I
7) On the ((Main Menu,, display screen, select the
{2. Each System Check} and press the [YES] key.
8) On the ((System Selection Menu,) display
10) On the ((EngineDiagnosis,, display screen, se-
lect the {Dealer Check Mode Procedure} and press
the [YES] key.
11) When the “Perform Inspection (Dealer Check)
Mode?” is shown on the display screen, press the
[YES] key.
EN(D0HC TURBO)-47
INSPECTION MODE
2) Connect the OBD-II general scan tool to its data

link connector in the lower portion of the instrument
panel (on the driver’s side).
CAUTION:
Do not connect scan tools except for Subaru
Select Monitor and OBD-II general scan tool.
3) Start the engine.

NOTE:
Depress the clutch pedal when starting the engine.
4) Using the shift lever, turn the “N” position switch
to ON.
5) Keep the engine speed in the 2,500 - 3,000
rpm range for 40 seconds.
6) Place the shift lever in the “1st” gear and drive
the vehicle at 5 to 10 km/h (3 to 6 MPH).
NOTE:
wheels may light the ABS warning light, but this in-
dicates no malfunctions.When engine control diag-
nosis is finished, perform the ABS memory
7) Using the OBD-II general scan tool, check for di-
agnostic trouble code(s) and record the result(s).
NOTE:
For detailed operation procedures, refer to the
OBD-ll General Scan Tool Instruction Manual.
EN(D0HC TURB0)-48
CLEAR MEMORY MODE
13.Clear Memory Mode

A: OPERATION
1. SUBARU SELECT MONITOR (NORMAL
MODE)
1) On the ((Main Menu)) display screen, select the
2) On the ((System Selection Menu)) display
4) On the ((Engine Diagnosis,) display screen, se-
lect the {Clear Memory} and press the [YES] key.
5) When the 'Done' and 'Turn Ignition Switch OFF'
are shown on the display screen, turn the Subaru
Select Monitor and ignition switch to OFF.
NOTE:
UAL.
2. SUBARU SELECT MONITOR (OBD
MODE)
1) On the ((Main Menu,) display screen, select the
2) On the &ystem Selection Menu), display
4) On the (<EngineDiagnosis,, display screen, se-
lect the {OBD System} and press the [YES] key.
5) On the (<OBDMenu)) display screen, select the
(4. Diagnosis Code(s) Cleared} and press the
[YES] key.
6) When the 'Clear Diagnostic Code?' is shown on
the display screen, press the [YES] key.
7) Turn the Subaru Select Monitor and ignition
switch to OFF.
NOTE:
UAL.
3. OBD-II GENERAL SCAN TOOL
For clear memory procedures using the OBD-II
general scan tool, refer to the OBD-II General Scan
Tool Instruction Manual.
EN(D0HC TURBO)-49
COMPULSORY VALVE OPERATION CHECK MODE
14.Compulsory Valve Operation 5) Connect the Subaru Select Monitor to data link
connector.
Check Mode (1) Connect the Subaru Select Monitor to data
link connector located in the lower portion of the
A: OPERATION instrument panel (on the driver's side).
1) Prepare the Subaru Select Monitor kit. <Ref. to
I I
(2) Connect the diagnosis cable to data link

~
S2M0285 connector.
2) Connect the diagnosis cable to Subaru Select CAUTION:
Monitor. Do not connect scan tools except for Subaru
3) Insert the cartridge into Subaru Select Monitor. Select Monitor and OBD-ll general scan tool.
<Ref. to EN(D0HC TURBO)-8, PREPARATION 6) Turn the ignition switch to ON (engine OFF) and
TOOL, General Description.> Subaru Select Monitor switch to ON.
S2M0286A I S2M0288 I
4) Connect the test mode connector (A) at the low- 7) On the ((Main Menu)) display screen, select the
er portion of instrument panel (on the driver's side), (2.Each System Check} and press the [YES] key.
to the side of the center console box. 8) On the ((System Selection Menu)) display
10) On the ((EngineDiagnosis))display screen, se-
lect the {System Operation Check Mode} and press
the [YES] key.
11) On the ((System Operation Check Mode)) dis-
play screen, select the {Actuator ON/OFF Opera-
tion} and press the [YES] key.
12) Select the desired compulsory actuator on the
((ActuatorON/OFF Operation)) display screen and
13) Pressing the [NO] key completes the compul-
sory operation check mode. The display will then
return to the ((Actuator ON/OFF Operation))
screen.
EN(D0HC TURBO)-50
COMPULSORY VALVE OPERATION CHECK MODE
Contents Display
Compulsory fuel pump relay operation check Fuel Pump Relay
ComDulsorv radiator fan relay oDeration check Radiator Fan Relay
Compulsory air conditioning relay operation check I A/C Compressor Relay I
Compulsory purge control solenoid valve operation check CPC Solenoid Valve
Compulsory fuel pressure control solenoid valve operation check PCV Solenoid Valve
Compulsory drain valve operation check Vent Control Solenoid Valve
Compulsory fuel tank pressure sensor control valve operation check Fuel Tank Sensor Control Valve
Display
EGR Solenoid Valve
ASV Solenoid Valve
m C D Solenoid I
I Pressure Switching Sol. 1 I
I Pressure Switching Sol. 2 I
I AAI Solenoid Valve
EN(D0HC TURBO)-51
ENGINE MALFUNCTION INDICATOR LAMP (MIL)
15.Engine Malfunction Indicator Lamp (MIL)

A: PROCEDURE
1. Activation of check engine malfunction indicator lamp (MIL). <Ref. to EN(D0HC TURBO)-53, ACTIVATION OF CHECK
ENGINE MALFUNCTION INDICATOR LAMP (MIL), Engine Malfunction Indicator Lamp (MIL).>
1
2. Check engine malfunction indicator lamp (MIL) does not come on. <Ref. to EN(D0HC TURBO)-54, CHECK ENGINE MAL-
FUNCTION INDICATOR LAMP (MIL) DOES NOT COME ON., Enaine Malfunction Indicator Lamp (MIL).>
1
3. Check engine malfunction indicator lamp (MIL) does not go off. <Ref. to EN(D0HC TURBO)-56, CHECK ENGINE MAL-
FUNCTION INDICATOR LAMP (MIL) DOES NOT GO OFF., Engine Malfunction Indicator Lamp (MIL).>
1
4. Check engine malfunction indicator lamp (MIL) does not blink at a cycle of 3 Hz. <Ref. to EN(D0HC TURBO)-57, CHECK
ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT BLINK AT A CYCLE OF 3 HZ., Engine Malfunction Indicator
Lamp (MIL).>
1
5. Check engine malfunction indicator lamp (MIL) remains blinking at a cycle of 3 Hz. <Ref. to EN(D0HC TURBO)-60, CHECK
ENGINE MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINKING AT A CYCLE OF 3 HZ., Engine Malfunction Indicator
Lamp (MIL).>
EN(D0HC TURBO)-52
m
B: ACTIVATION OF CHECK ENGINE 4) When the ignition switch is turned to ON (engine

MALFUNCTION INDICATOR off) or to “START” with the test mode connector
connected, the MIL blinks at a cycle of 3 Hz.
LAMP (MIL)
1) When the ignition switch is turned to ON (engine
off), the CHECK ENGINE malfunction indicator
lamp (MIL) in the combination meter illuminates. MIL ON
OFF ,
NOTE:
If the MIL does not illuminate, perform diagnostics
of the CHECK ENGINE light circuit or the combina- r4
1 sec. *
tion meter circuit. <Ref. to EN(D0HC TURBO)-54, Ignition
CHECK ENG INE MALFUNCTlON INDC A T 0R switch
LAMP (MIL) DOES NOT COME ON., Engine Mal- ON
function Indicator Lamp (MIL).> OBD0055P
I FNln74
2) After starting the engine, the MIL goes out. If it

does not, either the engine or the emission control
system is malfunctioning.
b) Trouble occurs.
ON
MIL
OFF Igniiion 1
switch En&e
ON Start OBD0053A
3) If the diagnosis system senses a misfire which

could damage the catalyzer, the MIL will blink at a
cycle of 1 Hz.
ON
MIL
OFF
Ignition
switch ~~g~~~
ON start ~ 1 sec. i
Misfire
start
OBD0054P
EN(D0HC TURBO)-53
C: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT COME

ON.
DIAGNOSIS:
The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted.
TROUBLE SYMPTOM:
When the ignition switch is turned ON (engine OFF), MIL does not come on.
WIRING DIAGRAM:
BATTERY
COMBINATION
METER
C:@ @ ECM
r 1 n i ~n
112 3 1 W 1 4 516 1 1 12131415161718191101
718 9 110111112 13114
L J
Pl?EwEa
10 11 12 13 14 15 16 17 18 19 20
1121314151 16171819110111
12~13~14~15[16~17~18~19~20~21~22~23~24
EN1137
Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage less than 1 V? Go to step 4. Go to step 2.
1)Turnthe ignition switch to ON.
2)Measure the voltage between ECM connec-
tor and chassis ground.
Connector & terminal
(8137) No. 15 (+) - Chassis ground (-):
EN(DOHC TURB0)-54
Step Check Yes No

CHECK POOR CONTACT. ,oes the MIL come on when Tepair poor con- 30 to step 3.
haking or pulling ECM con- x t in ECM con-
ector and harness? lector.
CHECK ECM CONNECTOR. ;the ECM connector correctly leplace the ECM. Repair connection
onnected? :Ref. to FU(D0HC sf ECM connector,
'URB0)-47,
lngine Control
nodule.>
CHECK HARNESS BETWEEN COMBINA- ;the resistance less than 1 ;o to step 5. Repair harness
TION METER AND ECM CONNECTOR. 2? and connector.
1)Turn the ignition switch to OFF. NOTE:
2)Remove the combination meter. <Ref. to In this case, repai
IDI-11, Combination Meter Assembly.> the following:
3)Disconnectthe connector from ECM and Open circuit in
combination meter. harness between
4)Measure the resistance of harness between ECM and combi-
ECM and combination meter connector. nation meter con-
Connector & terminal nector
(8137) No. 15 - (i12) No. 6: 8 Poor contact in
couplingconnect0
CHECK POOR CONTACT. lepair poor con-
;there poor contact in combi- Go to step 6.
Check poor contact in combination meter con- iation meter connector? act in combination
nector. neter connector.
CHECK HARNESS BETWEEN COMBINA- s the voltage more than 10 V? So to step 7. Check the follow-
TION METER AND IGNITION SWITCH CON- ing and repair if
NECTOR. necessary.
1)Turn the ignition switch to ON. NOTE:
2)Measure the voltage between combination * Brokendown
meter connector and chassis ground. ignition relay.
Connector & terminal Blown out fuse
(i10) No. 7 (+) - Chassis ground (-): (No. 5).
If replaced fuse
(No. 5) blows eas-
ily, check the har-
ness for short
circuit of harness
between fuse (No.
5) and ignition
relay connector.
Open or short
circuit in harness
between fuse (No.
5) and battery ter-
minal
Open circuit in
harness between
fuse (No. 5) and
ignition relay con-
nector
Poor contact in
ignition relay con-
nector
Poor contact in
ignition switch cor
nector
I
CHECK LAMP BULB. s the lamp bulb condition OK; 3epair combina- Replace the lamp
Remove the engine malfunction indicator lamp :ion meter connec. bulb.
bulb. :or.
EN(D0HC TURBO)-55
~
D: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT GO

OFF.
DIAGNOSIS:
The CHECK ENGINE malfunction indicator lamp (MIL) circuit is shorted.
TROUBLE SYMPTOM:
Although MIL comes on when the engine runs, trouble code is not shown on the Subaru select monitor
or OBD-ll general scan tool display.
WIRING DIAGRAM:
BATTERY
IGNITION
1
ql
OMBINATION
ETER
A:@
I
C:@
U @ ECM
EN1137
t
Step Check
1 CHECK HARNESS BETWEEN COMBINA- Does the MIL come on?
TlON METER AND ECM CONNECTOR. in harness <Ref. to FU(D0HC
1)Turnthe ignition switch to OFF.
2)Disconnect the connector from ECM.
3)Turn the ignition switch to ON.
EN(D0HC TURBO)-56
E: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT BLINK

AT A CYCLE OF 3 HZ.
DIAGNOSIS:
The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted.
Test mode connector circuit is in open.
TROUBLE SYMPTOM:
When in inspection mode, MIL does not blink at a cycle of 3 Hz.
EN(D0HC TURB0)-57
WIRING DIAGRAM:
IGNITION BATTERY
SBF-4 SBF-1
3 c
COMBINATION
METER
A:@
C:@
EN1138
EN(D0HC TURBO)-58
_____~
Step Check Yes No

CHECK STATUS OF CHECK ENGINE MAL- loes the MIL come on? io to step 2. Repair the MIL cir-
FUNCTION INDICATOR LAMP (MIL). cuit. <Ref. to
1)Turnthe ignition switch to OFF. EN(D0HC
2)Disconnectthe test mode connector. TURBO)-54,
3)Turn the ignition switch to ON. (engine OFF) CHECK ENGINE
MALFUNCTION
INDICATOR
LAMP (MIL)
DOES NOT
COME ON.,
Engine Malfunc-
tion Indicator
Lamp (MIL).>
! CHECK HARNESS BETWEEN COMBINA- loes the MIL come on? 3epair ground Go to step 3.
TlON METER AND ECM CONNECTOR. ;hort circuit in har-
1)Turnthe ignition switch to OFF. less between
2)Disconnectthe connector from ECM. :ombination meter
3)Turn the ignition switch to ON. ind ECM connec-
or.
I CHECK HARNESS BETWEEN TEST MODE s the resistance less than 1 i o to step 4. Repair harness
CONNECTOR AND CHASSIS GROUND. n? and connector.
2)Disconnect the connector from ECM. In this case, repaii
3)Measure the resistance of harness between the following:
test mode connector and chassis ground. Open circuit in
Connector & terminal harness between
(876) No. 1 - Chassis ground: test mode connec-
tor and chassis
ground
I CHECK POOR CONTACT. s there poor contact in ECM 3epair poor con- Go to step 5.
Check poor contact in ECM connector. :onnector? act in ECM con-
lector.
i CHECK HARNESS BETWEEN ECM AND s the resistance less than 1 i o to step 6. Repair open circuit
TEST MODE CONNECTOR. R? in harness
1)Connect the test mode connector. between ECM and
2)Measure the resistance of harness between test mode connec-
ECM and chassis ground. tor.
(8134) No. 14 - Chassis ground:
i CHECK POOR CONTACT. s there poor contact in ECM
Check poor contact in ECM connector. :onnector?
lector. TURBO)-47,
Engine Control
Module.>
EN(D0HC TURBO)-59
F: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINK-

ING AT A CYCLE OF 3 HZ.
DIAGNOSIS:
Test mode connector circuit is shorted.
TROUBLE SYMPTOM:
MIL blinks at a cycle of 3 Hz when the ignition switch is turned to ON.
WIRING DIAGRAM:
IGNITION BATTERY
SBF-4 SBF-1
3 c
METER -1.- r
1121314151 r - l 16171819110111
12~13~14~15~16~17~18~19~20~21~22~23~24
112131415161 171819110111
12~13]14]15~16]17~18~19~20]21]22]23~24
m
EN1138
EN(D0HC TURBO)-60
Step Check Yes No

CHECK TEST MODE CONNECTOR. Does the MIL flash on and off? Go to step 2. System is in good
1)Disconnectthe test mode connector. order.
MIL blinks at a c)
cle of 3 Hz whe
test mode connec
tor is connected.
CHECK HARNESS BETWEEN ECM CON- Is the resistance less than 5 Repair short circuit Replace the ECM.
NECTOR AND ENGINE GROUNDING TER- R? in harness <Ref. to FU(D0HC
MINAL. between ECM and TURBO)-47,
1)Turnthe ignition switch to OFF. test mode connec- Engine Control
2)Disconnectthe connector from ECM. tor. Module.>
3)Measure the resistance of harness between
ECM connector and chassis ground.
EN(D0HC TURBO)-61
EN(D0HC TURBO)-62
DIAGNOSTICS FOR ENGINE STARTING FAILURE
16.Diagnostics for Engine Starting Failure

A: PROCEDURE
1. Inspection of starter motor circuit. <Ref. to EN(D0HC TURBO)-64, STARTER MOTOR CIRCUIT, Diagnostics for Engine
Startina Failure.>
L
2. Inspection of ECM power supply and ground line. <Ref. to EN(D0HC TURBO)-68, CONTROL MODULE POWER SUPPLY
AND GROUND LINE, Diagnostics for Engine Starting Failure.>
L
3. Inspection of ignition control system. <Ref. to EN(D0HC TURBO)-72, IGNITION CONTROL SYSTEM, Diagnostics for
Engine Starting Failure.>
-L
4. Inspection of fuel pump circuit. <Ref. to EN(D0HC TURBO)-76, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Fail-
ure.>
-1
5. Inspection of fuel injector circuit. <Ref. to EN(D0HC TURBO)-78, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Start-
ing Failure.>
EN(D0HC TURBO)-63
B: STARTER MOTOR CIRCUIT

CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN(D0HC TUR-
BO)-49,'Clear Memory Mode.> and-INSPECTION MODE <Ref. to EN(D0HC TURBO)-46, Inspection
Mode.>.
WIRING DIAGRAM:
IGNITION
INTERRUPT
RELAY
I ITO SECURITY SYSTEM I
STARTER
INTER LOCK
RELAY (MT)
STARTER
SWITCH
(MT)
M @ ECM
-
-
7 8 9101112
EN1139
EN(D0HC TURBO)-64
Step Check Yes No

CHECK OPERATION OF STARTER MOTOR Ioes the starter motor operate 30 to step 2. Go to step 3.
vhen the switch starts?
CHECK DTC. s the trouble code stored in 3ecord the DTC. Go to step 3.
<Ref. to EN(D0HC TURBO)-45, OPERATION, nemory? <Ref. to EN(D0HC 3epair the trouble
Read Diagnostic Trouble Code.> -URBO)-80, LIST, List of Diag. :ase. <Ref. to
iostic Trouble Code (DTC).> !N(DOHC
rURBO)-88, Diag-
iostic Procedure
Nith Diagnostic
rrouble Code
DTC).>
CHECK INPUT SIGNAL FOR STARTER MO- s the voltage more than 10 V? 30 to step 4. Go to step 5.
TOR.
2)Disconnectthe connector from starter motor
3)Turn the ignition switch to ST.
4)Measure the power supply voltage between
starter motor connector terminal and engine
ground.
(814) No. 1 (+) - Engine ground (-):
CHECK GROUND CIRCUIT OF STARTER s the resistance less than 5 )heck the starter Repair open circuil
MOTOR. a? notor. <Ref. to of ground cable.
1)Turn the ignition switch to OFF. X - 6 , Starter.>
2)Disconnect the terminal from starter motor.
3)Measure the resistance of ground cable
between ground cable terminal and engine
ground. . I
CHECK HARNESS BETWEEN ECM AND s the resistance less than 1 qepair ground Go to step 6.
STARTER MOTOR CIRCUIT. 2? short circuit.
2)Measure the resistance between starter
motor and ECM.
(814) No. 1 - Engine ground:
CHECK HARNESS BETWEEN ECM AND s the resistance less than 1
STARTER MOTOR CIRCUIT. 3? short circuit.
1)Turnthe ignition switch to START.
2)Measure the resistance of fuse.
(6 14) No. 1 - Engine ground:
CHECK HARNESS BETWEEN BATTERY s the voltage more than 10 V? 30 to step 8. Repair open circuii
AND IGNITION SWITCH CONNECTOR. in harness
1)Turnthe ignition switch to OFF. between ignition
2)Disconnect the connector from ignition switch and battery,
switch.
3)Measure the power supply voltage between
ignition switch the connector and chassis
I
ground.
CHECK HARNESS BETWEEN BATTERY s the voltage more than 10 V? 3epair open circuit Go to step 9.
AND IGNITION SWITCH CONNECTOR. 3etween ignition
1)Connect the connector to ignition switch. ;witch and starter
2)Turn the ignition switch to START. notor circuit.
3)Measure the voltage between ignition switch
and chassis ground.
EN(D0HC TURBO)-65
Step Check Yes No

9 CHECK POOR CONTACT. Is there poor contact in ignition Repair poor con- Replace the igni-
Check poor contact in ignition switch connec- switch connector? tact in ignition tion switch.
tor. switch connector.
EN(D0HC TURBO)-66
EN(D0HC TURBO)-67
C: CONTROL MODULE POWER SUPPLY AND GROUND LINE

CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODEeRef. to EN(D0HC TUR-
BO)-49, Clear Memory Mode.> and INSPECTION MODE. <Ref. to EN(D0HC TURBO)-46, Inspection
Mode.>
WIRING DIAGRAM:
MAIN RELAY
BATTERY
A:@
c:@ ECM
D:@
r 1
EN1171
EN(D0HC TURBO)-68
_ _ _ _ _ ~
Step Check
CHECK MAIN RELAY. s the resistance less than 10
1)Turn the ignition switch to OFF. 2? relay.
2)Remove the main relay.
3)Connect the battery to main relay terminals
No. 1 and No. 2. I
4)Measure the resistance between main relay
terminals.
Terminals
NO. 3 - NO. 5:
NO. 4 - NO. 6:
CHECK GROUND CIRCUIT OF ECM. s the resistance less than 5 i o to step 3. Repair open circuit
1)Disconnect the connector from ECM. 2? in harness
2)Measure the resistance of harness between between ECM
ECM and chassis ground. connector and
Connector & terminal engine grounding
-
(6134) No. 7 Chassis ground: terminal.
-
( 6 134) No. 15 Chassis ground:
(6136) No,8 - Chassis ground:
-
(6136) No. 17 Chassis ground:
(684) No, 1 - Chassis ground: (MT vehi-
cle)
CHECK INPUT VOLTAGE OF ECM. s the voltage more than 10 V? io to step 4. Repair open or
Measure the voltage between ECM connector ground short cir-
and chassis ground. cuit of power sup-
Connector & terminal ply circuit.
(8134) No. 5 (+) - Chassis ground (-): I
CHECK HARNESS BETWEEN ECM AND s the resistance more than 1 i o to step 5. Repair ground
MAIN RELAY CONNECTOR. dnR? short circuit in har.
1)Turn the ignition switch to OFF. ness between
2)Disconnect the connector from ECM. ECM connector
3)Measure the resistance between ECM and and main relay
chassis ground. connector, then
Connector & terminal replace the ECM.
(6134) No. 6 -Chassis ground:
CHECK OUTPUT VOLTAGE FROM ECM. s the voltage more than 10 V? ;o to step 6. Replace the ECM.
1)Connectthe connector to ECM. <Ref. to FU(D0HC
2)Turn the ignition switch to ON. TURBO)-47,
3)Measure the voltage between ECM connec- Engine Control
tor and chassis ground. Module.>
i
CHECK INPUT VOLTAGE OF MAIN RELAY. s the voltage more than 10 V? ;o to step 7. Repair open circuil
Check the voltage between main relay connec- in harness
tor and chassis ground. between ECM
Connector & terminal connector and
(647) No. 2 (+) - Chassis ground (-): main relay connec
tor.
. CHECK GROUND CIRCUIT OF MAIN RE- s the resistance less than 5 ;o to step 8. Repair open circuii
LAY. 2? between main
1)Turnthe ignition switch to OFF. relay and chassis
2)Measure the resistance between main relay ground.
connector and chassis ground.
Connector 81terminal
EN(DOHC TURBO)-69
I
Check Yes No
Is the voltage more than 10 V? Go to step 9. Repair open or
Measure the voltage between main relay con- ground short cir-
nector and chassis ground. cuit in harness of
Connector & terminal power supply cir-
(847) No. 5 (+) - Chassis ground (-): cuit.
CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 10 V? Check ignition Repair open or
1)Connect the main relay connector. control system. ground short cir-
2)Turn the ignition switch to ON. <Ref. to EN(D0HC cuit in harness
3)Measure the voltage between ECM connec- TURBO)-72, IGNI- between ECM
tor and chassis ground. TION CONTROL connector and
Connector & terminal SYSTEM, Diag- main relay connec.
(8137) No. 2 (+) - Chassis ground (-): nostics for Engine tor.
(8137) No. 3 (+) - Chassis ground (-): Starting Failure.>
EN(D0HC TURB0)-70
EN(D0HC TURB0)-71
D: IGNITION CONTROL SYSTEM

CAUTION:
BO)-49, Clear Memory Mode.> and INSPECTION MODE <Ref. to EN(D0HC TURBO)-46, Inspection
Mode.>.
WIRING DIAGRAM:
@ ECM
IGNITION COIL IGNITION COIL IGNITION COIL IGNtTION COIL

No.1 N0.2 N0.3 N0.4
EN1140
EN(D0HC TURBO)-72
ENGINE (D IAGNOSTlCS)
Step Check Yes No

CHECK SPARK PLUG CONDITION. s the spark plug's status OK? Go to step 2. Replace the spark
1)Removethe spark plug. <Ref. to IG(D0HC 3lug.
TURBO)-5, INSTALLATION, Spark Plug.>
2)Check the spark plug condition. <Ref. to
IG(D0HC TURBO)-6, INSPECTION, Spark
Plug.>
! CHECK IGNITION SYSTEM FOR SPARKS. Ioes spark occur at each cyl- Check fuel pump So to step 3.
1)Connectthe spark plug to ignition coil. nder? system. <Ref. to
2)Release the fuel pressure. <Ref. to EN(D0HC
FU(D0HC TURBO)-51, RELEASING OF TURBO)-76,FUEL
FUEL PRESSURE, OPERATION, Fuel.> PUMP CIRCUIT,
3)Contact the spark plug's thread portion on Diagnostics for
engine. Engine Starting
4)While opening the throttle valve fully, crank Failure.>
the engine to check that spark occurs at each
cylinder.
1 CHECK POWER SUPPLY CIRCUIT FOR IG- s the voltage more than 10 V? Go to step 4. Repair harness
NlTlON COIL & IGNITOR ASSEMBLY. 2nd connector.
2)Disconnectthe connector from ignition coil i3 In this case, repai
ignitor assembly. the following:
?)Turn the ignition switch to ON. Open circuit in
4)Measure the power supply voltage between harness between
ignition coil & ignitor assembly connector and ignition coil & igni-
engine ground. tor assembly, and
Connector & terminal ignition switch con
(€31) No. 3 (+) - Engine ground (-): nector
(€32) No. 3 (+) - Engine ground (-): Poor contact in
(E33) No. 3 (+) - Engine groundI)-( coupling connec-
(E34) No. 3 (+) - Engine ground (-): tors
I CHECK HARNESS OF IGNITION COIL & IG. s the resistance between less ;o to step 5. Repair harness
NITOR ASSEMBLY GROUND CIRCUIT. han 5 12? and connector.
1)Turnthe ignition switch to OFF. NOTE:
2)Measure the resistance between ignition coi In this case, repai
& ignitor assembly connector and engine the following:
ground. Open circuit in
(€31) No. 2 - Engine ground: ignition coil & igni-
(E32) No, 2 - Engine ground: tor assembly con-
(E33) No. 2 - Engine ground: nector and engine
(E34) No. 2 - Engine ground: grounding termina
b CHECK HARNESS BETWEEN ECM AND IG s the resistance less than 1 ;o to step 6. Repair harness
NlTlON COIL & IGNITOR ASSEMBLY CON- n? and connector.
NECTOR. NOTE:
1)Turn the ignition switch to OFF. In this case, repai
2)Disconnect the connector from ECM. the following:
3)Disconnectthe connector from ignition coil 8 Open circuit in
ignitor assembly. harness between
4)Measure the resistance of harness between ECM and ignition
ECM and ignition coil & ignitor assembly con- coil & ignitor
nector. assembly connec-
Connector & terminal tor
. (6136) NO. 2 1 - (E34) NO. 1: Poor contact in
(6136) NO. 22 - (€33) NO. 1: coupling connect0
(6136) NO. 23 - (€32) NO. 1:
(6136) NO. 24 - (€31) NO. 1:
EN(D0HC TURBO)-73
~
Step Check Yes No

I CHECK HARNESS BETWEEN ECM AND IG-
NITION COIL & IGNITOR ASSEMBLY CON- Ma? short circuit in har-
NECTOR. nessbetween
Measure the resistance of harness between ECM and ignition
ECM and engine ground. coil i
3 ignitor
Connector a terminal: assembly connec-
(6136) No. 21- Engine ground: tor.
-
(8736) No. 22 Engine ground:
(6736) No. 23- Engine ground:
-
(6136) No. 24 Engine ground:
CHECK POOR CONTACT. Is there poor contact in ECM
Check poor contact in ECM connector. connector?
assembly.
EN(D0HC TURBOk74
I
-
EN(D0HC TURBO)-75
E: FUEL PUMP CIRCUIT

CAUTION:
BO)-49, Clear Memory Mode.> and INSPECTION MODE <Ref. to EN(D0HC TURBO)-46, Inspection
Mode.>.
WIRING DIAGRAM:
BATTERY
SBF-5
3 c
FUEL PUMP
I
FUEL PUMP
CONTROLLER
FUEL
PUMP
EN(DOHC TURB0)-76
-
ENGINE (DIAG NOSTlCSl
Step Check Yes No

1 CHECK OPERATING SOUND OF FUEL Does the fuel pump produce Check the fuel Record the DTC.
PUMP. operating sound? injector circuit. Repair the trouble
Make sure that fuel pump is in operation for <Ref. to EN(D0HC case. <Ref. to
two seconds when turning the ignition switch to TURBO)-78,FUEL EN(D0HC
ON. INJECTOR CIR- TURBO)-88, Diag-
NOTE: CUIT, Diagnostics nostic Procedure
Fuel pump operation can also be executed us- for Engine Start- with Diagnostic
ing Subaru Select Monitor (Function mode: ing Failure.> Trouble Code
FDOI). (DTC).>
For the procedure, refer to “Compulsory Valve
Operation Check Mode”. <Ref. to EN(D0HC
TURBO)-50, Compulsory Valve Operation
Check Mode.>
EN(D0HC TURBO)-77
r
F: FUEL INJECTOR CIRCUIT

CAUTION:
Check or repair only faulty parts.
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN(D0HC
TURBO)-49, Clear Memory Mode.> and INSPECTION MODE. <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>
WIRING DIAGRAM:
I I ' " IC
I .
I
-
FUEL INJECTORS
EN1 142
EN(D0HC TURBO)-78
-
~~~ ~~
Step Check Yes No

CHECK OPERATIONOF EACH FUEL INJEC- ;the fuel injector emits “oper- ;heck the fuel 20 to step 2.
TOR. iting” sound? bressure. <Ref. to
While cranking the engine, check that each AE(D0HC
fuel injector emits “operating” sound. Use a -URBO)-27,
sound scope or attach a screwdriver to the NSPECTION,
injector for this check. -uel Pressure.>
CHECK POWER SUPPLY TO EACH FUEL s the voltage more than 10 V? 20 to step 3. 3epair harness
INJECTOR. ind connector.
1)Turn the ignition switch to OFF. qOTE:
2)Disconnect the connector from #I cylinder n this case, repaii
fuel injector. he following:
3)Turn the ignition switch to ON. 1 Open circuit in
4)Measure the power supply voltage between iarness between
the fuel injector terminal and engine ground. nain relay and fuel
Connector & terminal njector connector
#I (€5) No. 2 (+) - Engine ground (-): 1 Poor contact in
#2 (E 16) No. 2 (+) - Engine ground (-): nain relay connec,

#3 (E6) No. 2 (+) - Engine ground (-): :or
#4 (El 7) No. 2 (+) - Engine ground (-): 1 Poor contact in
:oupling connectol
1 Poor contact in
‘uel injector con-

lector
I CHECK HARNESS BETWEEN ECM AND s the resistance less than 1 30 to step 4. qepair harness
FUEL INJECTOR CONNECTOR. 2? and connector.
1)Disconnect the connector from ECM. MOTE:
2)Measure the resistance of harness between in this case, repai
ECM and fuel injector connector. the following:
Connector & terminal 1 Open circuit in
(8137) NO. 1 - (€5) NO. 1: iarness between

-
(8136) NO. 6 (€16) NO. 1: ECM and fuel
(8136) NO. 5 - (E6) NO. 1: njector connector
(8136) NO. 4 - (€6) NO. 1: 1 Poor contact in
:oupling connect0
I CHECK HARNESS BETWEEN ECM AND s the resistance less than 1 qepair ground So to step 5.
FUEL INJECTOR CONNECTOR. A? short circuit in har-
Measure the resistance of harness between less between
ECM and fuel injector connector. ECM and fuel
Connector & terminal njector connector.
P CHECK EACH FUEL INJECTOR. s the resistance between 5 So to step 6. Replace the faulty
1)Turn the ignition switch to OFF. ind 20 Q? fuel injector.
2)Measure the resistance between each fuel
injector terminals.
Terminals
NO. 1 -NO. 2:
i CHECK POOR CONTACT. s there poor contact in ECM Repair poor con- Inspection using
Check poor contact in ECM connector. :onnector? tact in ECM con- “General Diagnos-
nector. tic Table”. <Ref. to
EN(D0HC
TURBO)-372,
INSPECTION,
General Diagnos-
tic Table.>
EN(D0HC TURBO)-79
LIST OF DIAGNOSTIC TROUBLE CODE (DTC)
17.List of Diagnostic Trouble Code (DTC)

A: LIST
DTC
Item Index
No.
PO031 Front oxygen (NF) sensor heater cir- <Ref. to EN(D0HC TURBO)-88, DTC PO031 - FRONT OXYGEN (NF)
cuit low input SENSOR HEATER CIRCUIT LOW INPUT -, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>
PO032 Front oxygen (NF)sensor heater cir- <Ref. to EN(D0HC TURBO)-92, DTC PO032 - FRONT OXYGEN (NF)
cuit high input SENSOR HEATER CIRCUIT HIGH INPUT -, Diagnostic Procedure with
PO037 Rear oxygen sensor heater circuit <Ref. to EN(D0HC TURBO)-94, DTC PO037 - REAR OXYGEN SENSOR
malfunction HEATER CIRCUIT MALFUNCTION-, Diagnostic Procedure with Diagnos-
tic Trouble Code (DTC).>
PO038 Rear oxygen sensor heater circuit <Ref. to EN(D0HC TURBO)-98, DTC PO038 - REAR OXYGEN SENSOR
high input HEATER CIRCUIT HIGH INPUT -, Diagnostic Procedure with Diagnostic
PO101 Mass air flow sensor circuit range/ <Ref. to EN(D0HC TURBO)-100, DTC PO101 - MASS AIR FLOW SEN-
performance problem (high input) SOR CIRCUIT RANGE/PERFORMANCEPROBLEM (HIGH INPUT) -,
Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO102 Mass air flow sensor circuit low input <Ref. to EN(D0HC TURBO)-102, DTC PO102 - MASS AIR FLOW SEN-
SOR CIRCUIT LOW INPUT -, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
PO103 Mass air flow sensor circuit high <Ref. to EN(D0HC TURBO)-106, DTC PO103 - MASS AIR FLOW SEN-
input SOR CIRCUIT HIGH INPUT -, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
PO106 Pressure sensor circuit range/pedor- <Ref. to EN(D0HC TURBO)-108, DTC PO106 - PRESSURE SENSOR
mance problem (low input) CIRCUIT RANGE/PERFORMANCEPROBLEM (LOW INPUT) -, Diagnos-
tic Procedure with Diagnostic Trouble Code (DTC).>
PO107 Pressure sensor circuit low input <Ref. to EN(D0HC TURBO)-110, DTC PO107 - PRESSURE SENSOR
CIRCUIT LOW INPUT -, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
PO108 Pressure sensor circuit high input <Ref. to EN(D0HC TURBO)-114, DTC PO108 - PRESSURE SENSOR
CIRCUIT HIGH INPUT -, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
PO111 Intake air temperature sensor circuit <Ref. to EN(D0HC TURBO)-118, DTC PO111 - INTAKE AIR TEMPERA-
range/performance problem TURE SENSOR CIRCUIT RANGE/PERFORMANCEPROBLEM -, Diag-
nostic Procedure with Diagnostic Trouble Code (DTC).>
low input TURE SENSOR CIRCUIT LOW INPUT -, Diagnostic Procedure with Diag-
nostic Trouble Code (DTC).>
high input TURE SENSOR CIRCUIT HIGH INPUT -, Diagnostic Procedure with Diag-
PO117 Engine coolant temperature Sensor <Ref. to EN(D0HC TURBO)-126, DTC PO117 - ENGINE COOLANT TEM-
circuit low input PERATURE SENSOR CIRCUIT LOW INPUT -, Diagnostic Procedure with
PO118 Engine coolant temperature sensor <Ref. to EN(D0HC TURBO)-128, DTC PO118 - ENGINE COOLANT TEM-
circuit high input PERATURE SENSOR CIRCUIT HIGH INPUT -, Diagnostic Procedure with
Diaqnostic Trouble Code (DTC).>
PO121 Throttle position sensor circuit range/ <Ref. to EN(D0HC TURBO)-132, DTC PO121 - THROTTLE P O S I T I O F
performance problem (high input) SENSOR CIRCUIT RANGE/PERFORMANCEPROBLEM (HIGH INPUT) -
, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
POI22 Throttle position sensor circuitlow <Ref. to EN(D0HC TURBO)-134, DTC PO122 -THROTTLE POSITION
input SENSOR CIRCUIT LOW INPUT -, Diagnostic Procedure with Diagnostic
EN(D0HC TURBO)-80
-
No.
DTC
PO123
I Item
Throttle position sensor circuit high

Index
<Ref. to EN(D0HC TURBO)-138, DTC PO123 - THROTTLE POSITION

input SENSOR CIRCUIT HIGH INPUT -, Diagnostic Procedure with Diagnostic
PO125 Insufficient coolant temperature for <Ref. to EN(D0HC TURBO)-140, DTC PO125 - INSUFFICIENT COOLANT
closed loop fuel control TEMPERATURE FOR CLOSED LOOP FUEL CONTROL -, Diagnostic
Procedure with Diaanostic Trouble Code ( D T C b
PO128 Thermostat malfunction <Ref. to EN(D0HC TURBO)-142, DTC PO128 - THERMOSTAT MAL-
FUNCTION -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO131 Front oxygen (NF) sensor circuit <Ref. to EN(D0HC TURBO)-143, DTC PO131 - FRONT OXYGEN (NF)
range/performance problem (low SENSOR CIRCUIT RANGE/PERFORMANCEPROBLEM (LOW INPUT) -,
i
inDut) Diaanostic Procedure with Diaanostic Trouble Code (DTC).>
range/performance problem (high SENSOR CIRCUIT RANGE/PERFORMANCEPROBLEM (HIGH INPUT) -
input) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
slow response SENSOR CIRCUIT SLOW RESPONSE -, Diagnostic Procedure with Diag-
PO136 Rear oxygen sensor circuit malfunc- <Ref. to EN(D0HC TURBO)-148, DTC PO136 - REAR OXYGEN SENSOR
tion CIRCUIT MALFUNCTION -, Diagnostic Procedure with Diagnostic Trouble
Code ( D T C b
Rear oxygen sensor circuit slow <Ref. to EN(D0HC TURBO)-150, DTC PO139 - REAR OXYGEN SENSOR
response CIRCUIT SLOW RESPONSE -, Diagnostic Procedure with Diagnostic
+------
PO171 Fuel trim malfunction ( N F too lean) <Ref. to EN(D0HC TURBO)-152, DTC PO171 - FUEL TRIM MALFUNC-
TION (NF TOO LEAN) -, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
PO172 Fuel trim malfunction ( N F too rich) <Ref. to EN(D0HC TURBO)-153, DTC PO172 - FUEL TRIM MALFUNC-
TION (NF TOO RICH) -, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
PO181 Fuel temperature sensor A circuit <Ref. to EN(D0HC TURBO)-156, DTC PO181 - FUEL TEMPERATURE
range/performance problem SENSOR A CIRCUIT RANGE/PERFORMANCEPROBLEM -, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
PO182 Fuel temperature sensor A circuit low <Ref. to EN(D0HC TURBO)-158, DTC PO182 - FUEL TEMPERATURE
input SENSOR A CIRCUIT LOW INPUT -, Diagnostic Procedure with Diagnostic
I Fuel temperature sensor A circuit

high input
<Ref. to EN(D0HC TURBO)-160, DTC PO183 - FUEL TEMPERATURE
SENSOR A CIRCUIT HIGH INPUT -, Diagnostic Procedure with Diagnostic
PO244 Wastegate control solenoid valve <Ref. to EN(D0HC TURBO)-164, DTC PO244 - WASTEGATE CONTROL
malfunction (high input) SOLENOID VALVE MALFUNCTION (HIGH INPUT) -, Diagnostic Proce-
dure with Diagnostic Trouble Code (DTC).>
PO245 Wastegate control solenoid valve cir- <Ref. to EN(D0HC TURBO)-166, DTC PO245 - WASTEGATE CONTROL
cuit low input SOLENOID VALVE CIRCUIT LOW INPUT -, Diagnostic Procedure with
PO246 Wastegate control solenoid valve cir- <Ref. to EN(D0HC TURBO)-170, DTC PO246 - WASTEGATE CONTROL
cuit high input SOLENOID VALVE CIRCUIT HIGH INPUT -, Diagnostic Procedure with
Diaanostic Trouble Code ( D T C b
PO301 Cylinder 1 misfire detected <Ref. to EN(D0HC TURBO)-172, DTC PO301 - CYLINDER 1 MISFIRE
DETECTED -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(D0HC TURBO)-172, DTC PO302 - CYLINDER 2 MISFIRE
DETECTED -. Diaanostic Procedure with Diaanostic Trouble Code (DTC).>
PO303 Cylinder 3 misfire detected <Ref.EEN(DOHC TGRBO)T72, DTC PO303 - CYLINDER 3 MISFIRE
PO304 Cylinder 4 misfire detected <Ref. to EN(D0HC TURBO)-173, DTC PO304 - CYLINDER 4 MISFIRE
I
EN(D0HC TURBO)-81
DTC
Item Index
No.
PO327 Knock sensor circuit low input <Ref. to EN(D0HC TURBO)-182, DTC PO327 - KNOCK SENSOR CIR-
CUIT LOW INPUT -, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
PO328 Knock sensor circuit high input <Ref. to EN(D0HC TURBO)-184, DTC PO328 - KNOCK SENSOR CIR-
CUIT HIGH INPUT -, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
PO335 Crankshaft position sensor circuit <Ref. to EN(D0HC TURBO)-186, DTC PO335 - CRANKSHAFT POSITION
malfunction SENSOR CIRCUIT MALFUNCTION-, Diagnostic Procedure with Diagnos
PO336 Crankshaft position sensor circuit <Ref. to EN(D0HC TURBO)-188, DTC PO336 -Crankshaft Position Sensor
range/performance problem Circuit Range/Performance Problem -, Diagnostic Procedure with Diagnos
PO340 Camshaft position sensor circuit mal- <Ref. to EN(D0HC TURBO)-190, DTC PO340 - CAMSHAFT POSITION
function SENSOR CIRCUIT MALFUNCTION-, Diagnostic Procedure with Diagnos.
PO341 Camshaft position sensor circuit <Ref. to EN(D0HC TURBO)-192, DTC PO341 - CAMSHAFT POSITION
range/performance problem SENSOR CIRCUIT RANGE/PERFORMANCEPROBLEM -, Diagnostic
PO420 Catalyst system efficiency below <Ref. to EN(D0HC TURBO)-196, DTC PO420 - CATALYST SYSTEM
threshold EFFICIENCY BELOW THRESHOLD -, Diagnostic Procedure with Diag-
PO442 Evaporative emission control system <Ref. to EN(D0HC TURBO)-199, DTC PO442 - EVAPORATIVE EMIS-
malfunction SION CONTROL SYSTEM MALFUNCTION -, Diagnostic Procedure with
purge control valve circuit low input SION CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT LOW
~____
INPUT -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
purge control valve circuit high input SION CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH
INPUT -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
vent control low input SION CONTROL SYSTEM VENT CONTROL LOW INPUT -, Diagnostic
vent control high input SION CONTROL SYSTEM VENT CONTROL HIGH INPUT -, Diagnostic
pressure sensor range/performance SION CONTROL SYSTEM PRESSURE SENSOR RANGE/PERFOR-
problem MANCE PROBLEM -, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
pressure sensor low input SION CONTROL SYSTEM PRESSURE SENSOR LOW INPUT -, Diagnos-
'0453 Evaporative emission control system <Ref. to EN(D0HC TURBO)-222, DTC PO453 - EVAPORATIVE EMIS-
pressure sensor high input SION CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT -, Diag-
'0461 Fuel level sensor circuit range/perfor- <Ref. to EN(D0HC TURBO)-225, DTC PO461 - FUEL LEVEL SENSOR
mance problem CIRCUIT RANGE/PERFORMANCE PROBLEM -, Diagnostic Procedure
with Diagnostic Trouble Code (DTC).>
'0462 . Fuel level sensor circuit low input <Ref. to EN(D0HC TURBO)-228, DTC PO462 - FUEL LEVEL SENSOR
Code (DTC).>
'0463 Fuel level sensor circuit high input <Ref. to EN(D0HC TURBO)-232, DTC PO463 - FUEL LEVEL SENSOR
Code (DTC).>
EN(D0HC TURBO)-82
DTC
Item Index
No.
PO464 Fuel level sensor intermittent input <Ref. to EN(D0HC TURBO)-236, DTC PO464 - FUEL LEVEL SENSOR
INTERMITTENT INPUT-, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
PO480 Cooling fan relay 1 circuit low input <Ref. to EN(D0HC TURBO)-239, DTC PO480 - COOLING FAN RELAY 1
Code (DTC).>
PO483 Cooling fan function problem <Ref. to EN(D0HC TURBO)-243, DTC PO483 - COOLING FAN FUNC-
TlON PROBLEM -, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
PO500 Vehicle speed sensor malfunction <Ref. to EN(D0HC TURBO)-246, DTC PO500 -VEHICLE SPEED SEN-
SOR MALFUNCTION-, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
PO506 Idle control system RPM lower than <Ref. to EN(D0HC TURBO)-248, DTC PO506 - IDLE CONTROL SYSTEM
expected RPM LOWER THAN EXPECTED -, Diagnostic Procedure with Diagnostic
PO507 Idle control system RPM higher than <Ref. to EN(D0HC TURBO)-250, DTC PO507 - IDLE CONTROL SYSTEM
expected RPM HIGHER THAN EXPECTED -, Diagnostic Procedure with Diagnostic
PO508 Idle control system circuit low input <Ref. to EN(D0HC TURBO)-252, DTC PO508 - IDLE CONTROL SYSTEM
Code (DTC).>
PO509 Idle control system circuit high input <Ref. to EN(D0HC TURBO)-254, DTC PO509 - IDLE CONTROL SYSTEM
Code (DTC).>
PO512 Starter switch circuit high input <Ref. to EN(D0HC TURBO)-257, DTC PO512 - STARTER SWITCH CIR-
CUlT HIGH INPUT -, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
PO545 Exhaust gas temperature sensor cir- <Ref. to EN(D0HC TURBO)-260, DTC PO545 - EXHAUST GAS TEMPER-
cuit low input ATURE SENSOR CIRCUIT LOW INPUT -, Diagnostic Procedure with
PO546 Exhaust gas temperature sensor cir- <Ref. to EN(D0HC TURBO)-262, DTC PO546 - EXHAUST GAS TEMPER-
cuit high input ATURE SENSOR CIRCUIT HIGH INPUT -, Diagnostic Procedure with
PO604 Internal control module memory <Ref. to EN(D0HC TURBO)-266, DTC PO604 - INTERNAL CONTROL
check sum error MODULE MEMORY CHECK SUM ERROR -, Diagnostic Procedure with
PO703 Brake switch input malfunction <Ref. to EN(D0HC TURBO)-268, DTC PO703 - BRAKE SWITCH INPUT
MALFUNCTION-, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
PO705 Transmission range sensor circuit <Ref. to AT-115, CHECK INHIBITOR SWITCH., Diagnostic Procedure for
malfunction No-Diagnostic Trouble Code (DTC).>
PO710 Transmissionfluid temperature sen- <Ref. to AT-48, DTC 27 ATF TEMPERATURE SENSOR, Diagnostic Proce-
sor circuit malfunction dure with Diagnostic Trouble Code (DTC).>
PO715 Torque converter turbine speed sen- <Ref. to AT-62, DTC 36 TORQUE CONVERTER TURBINE SPEED SEN-
sor circuit malfunction SOR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO720 Output speed sensor (vehicle speed <Ref. to AT-57, DTC 33 FRONT VEHICLE SPEED SENSOR, Diagnostic Pro-
sensor 2) circuit malfunction cedure with Diagnostic Trouble Code (DTC).>
PO725 Engine speed input circuit malfunc- <Ref. to AT-44, DTC 11 ENGINE SPEED SIGNAL, Diagnostic Procedure
tion with Diagnostic Trouble Code (DTC).>
PO731 -. Gear 1 incorrect ratio <Ref. to EN(D0HC TURBO)-270, DTC PO731 - GEAR 1 INCORRECT
RATIO -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO732 Gear 2 incorrect ratio <Ref. to EN(D0HC TURBO)-270, DTC PO732 -GEAR 2 INCORRECT
PO733 Gear 3 incorrect ratio <Ref. to EN(D0HC TURBO)-270, DTC PO733 - GEAR 3 INCORRECT
EN(D0HC TURBO)-83
DTC
Item Index
No.
PO734 Gear 4 incorrect ratio <Ref. to EN(D0HC TURBO)-270, DTC PO734 - GEAR 4 INCORRECT
PO741 Torque converter clutch system mal- <Ref. to EN(D0HC TURBO)-272, DTC PO741 -TORQUE CONVERTER
function CLUTCH SYSTEM MALFUNCTION-, Diagnostic Procedure with Diagnos-
PO743 Torque converter clutch system <Ref. to AT-94, DTC 77 LOCK-UP DUTY SOLENOID, Diagnostic Procedure
(Lock-up duty solenoid) electrical with Diagnostic Trouble Code (DTC).>
PO748 Pressure control solenoid (Line pres- <Ref. to AT-86, DTC 75 LINE PRESSURE DUTY SOLENOID, Diagnostic
sure duty solenoid) electrical Procedure with Diaanostic Trouble Code [ D T C b
PO753 Shift solenoid A (Shift solenoid 1) <Ref. to AT-70, DTC 71 SHIFT SOLENOID 1, Diagnostic Procedure with
electrical Diagnostic Trouble Code (DTC).>
PO758 Shift solenoid B (Shift solenoid 2) <Ref. to AT-74, DTC 72 SHIFT SOLENOID 2, Diagnostic Procedure with
electrical Diagnostic Trouble Code (DTC).>
PO778 2-4 brake pressure control solenoid <Ref. to AT-90, DTC 76 2-4 BRAKE DUTY SOLENOID, Diagnostic Proce-
valve (2-4 brake duty solenoid) circuit dure with Diagnostic Trouble Code (DTC).>
malfunction
PO785 2-4 brake timing control solenoid <Ref. to AT-82, DTC 74 2-4 BRAKE TIMING SOLENOID, Diagnostic Proce-
valve (2-4 brake timing solenoid) cir- dure with Diagnostic Trouble Code (DTC).>
cuit malfunction
P i 086 Tumble generator valve #2 (LH) posi- <Ref. to EN(D0HC TURBO)-274, DTC Pi086 -TUMBLE GENERATOR
tion sensor circuit low input VALVE #2 (LH) POSITION SENSOR CIRCUIT LOW INPUT -, Diagnostic
P1087 Tumble generator valve #2 (LH) posi- <Ref. to EN(D0HC TURBO)-278, DTC Pi087 -TUMBLE GENERATOR
tion sensor circuit high input VALVE #2 (LH) POSITION SENSOR CIRCUIT HIGH INPUT -, Diagnostic
P i 088 Tumble generator valve #I (RH) posi- <Ref. to EN(D0HC TURBO)-280, DTC P1088 - TUMBLE GENERATOR
tion sensor circuit low input VALVE #I (RH) POSITION SENSOR CIRCUIT LOW INPUT -, Diagnostic
P i 089 Tumble generator valve #I (RH) posi- <Ref. to EN(D0HC TURBO)-284, DTC P i 089 - TUMBLE GENERATOR
tion sensor circuit high input VALVE #I (RH) POSITION SENSOR CIRCUIT HIGH INPUT -, Diagnostic
P i 090 Tumble generator valve #I (RH) mal- <Ref. to EN(D0HC TURBO)-286, DTC Pi090 -TUMBLE GENERATOR
function (stuck open) VALVE SYSTEM #I (RH) MALFUNCTION (STUCK OPEN) -, Diagnostic
Pi091 Tumble generator valve #I (RH) mal- <Ref. to EN(D0HC TURBO)-287, DTC Pi091 -TUMBLE GENERATOR
function (stuck close) VALVE SYSTEM #I (RH) MALFUNCTION (STUCK CLOSE) -, Diagnostic
P i 092 Tumble generator valve #2(LH) mal- <Ref. to EN(D0HC TURBO)-288, DTC Pi092 - TUMBLE GENERATOR
function (stuck open) VALVE SYSTEM #2 (LH) MALFUNCTION (STUCK OPEN) -, Diagnostic
P1093 Tumble generator valve #2(LH) mal- <Ref. to EN(D0HC TURBO)-289, DTC Pi093 - TUMBLE GENERATOR
function (stuck close) VALVE SYSTEM #2 (LH) MALFUNCTION (STUCK CLOSE) -, Diagnostic
Pi094 Tumble generator valve circuit #I <Ref. to EN(D0HC TURBO)-290, DTC Pi094 - TUMBLE GENERATOR
(opencircuit) VALVE CIRCUIT #1 (OPEN CIRCUIT) -, Diagnostic Procedure with Diag-
P i 095 Tumble generator valve circuit #I <Ref. to EN(D0HC TURBO)-292, DTC Pi095 - TUMBLE GENERATOR
(overcurrent) VALVE CIRCUIT #I (OVERCURRENT) -, Diagnostic Procedure with Diag-
Pi096 . Tumble generator valve circuit #2 <Ref. to EN(D0HC TURBO)-294, DTC P1096 - TUMBLE GENERATOR
(opencircuit) VALVE CIRCUIT #2 (OPEN CIRCUIT) -, Diagnostic Procedure with Diag-
P i 097 Tumble generator valve circuit #2 <Ref. to EN(D0HC TURBO)-296, DTC Pi097 -TUMBLE GENERATOR
(overcurrent) VALVE CIRCUIT #2 (OVERCURRENT) -, Diagnostic Procedure with Diag-
EN(D0HC TURBO)-84
DTC
Item Index
No.
P1110 Atmospheric pressure sensor low <Ref. to EN(D0HC TURBO)-297, DTC P1110 -ATMOSPHERIC PRES-
input SURE SENSOR CIRCUIT LOW INPUT -, Diagnostic Procedure with Diag-
P1111 Atmospheric pressure sensor high <Ref. to EN(D0HC TURBO)-297, DTC P l l l l -ATMOSPHERIC PRES-
input SURE SENSOR CIRCUIT HIGH INPUT -, Diagnostic Procedure with Diag-
P1112 Atmospheric pressure sensor range/ <Ref. to EN(D0HC TURBO)-298, DTC P1112 - ATMOSPHERIC PRES-
performance problem SURE SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM -, Diag-
P1130 Front oxygen sensor circuit malfunc- <Ref. to EN(D0HC TURBO)-300, DTC P1130 - FRONT OXYGEN (NF)
tion (open circuit) SENSOR CIRCUIT MALFUNCTION (OPEN CIRCUIT) -, Diagnostic Proce-
P1131 Front oxygen sensor circuit malfunc- <Ref. to EN(D0HC TURBO)-302, DTC P1131 - FRONT OXYGEN (NF)
tion (short circuit) SENSOR CIRCUIT MALFUNCTION (SHORT CIRCUIT) -, Diagnostic Pro-
cedure with Diagnostic Trouble Code (DTC).>
P1134 Front oxygen (A/F) sensor micro- <Ref. to EN(D0HC TURBO)-304, DTC P1134 - FRONT OXYGEN (A/F)
computer problem SENSOR MICRO-COMPUTER PROBLEM -, Diagnostic Procedure with
P1139 Front oxygen (A/F) sensor #1 heater <Ref. to EN(D0HC TURBO)-306, DTC P1139 - FRONT OXYGEN (A/F)
circuit perfomancehange problem SENSOR #1 HEATER CIRCUIT RANGE/PERFORMANCE PROBLEM -,
P1141 Mass air flow sensor circuit range/ <Ref. to EN(D0HC TURBO)-308, DTC P1141 - MASS AIR FLOW SEN-
perfomance problem (low input) SOR CIRCUIT RANGE/PERFORMANCEPROBLEM (LOW INPUT) -,
P1142 Throttle position sensor circuit range/ <Ref. to EN(D0HC TURBO)-310, DTC P1142 -THROTTLE POSITION
performance problem (low input) SENSOR CIRCUIT RANGWPERFORMANCEPROBLEM (LOW INPUT) -,
P1146 Pressure sensor circuit range/perfor- <Ref. to EN(D0HC TURBO)-312, DTC P1146 - PRESSURE SENSOR
mance problem (high input) CIRCUIT RANGE/PERFORMANCEPROBLEM (HIGH INPUT) -, Diagnos-
P1230 Fuel pump control unit maifunction <Ref. to EN(D0HC TURBO)-314, DTC P1230 - FUEL PUMP CONTROL-
LER MALFUNCTION -, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P1244 Wastegate control solenoid valve <Ref. to EN(D0HC TURBO)-318, DTC P1244 - WASTEGATE CONTROL
malfunction (low input) SOLENOID VALVE RANGWPERFORMANCEPROBLEM (LOW INPUT) -,
P1245 Wastegate control solenoid valve <Ref. to EN(D0HC TURBO)-320, DTC P1245 - WASTEGATE CONTROL
malfunction (fail-safe) SOLENOID VALVE MALFUNCTION (FAIL-SAFE) -, Diagnostic Procedure
with Diagnostic Trouble Code (DTC).>
P1301 Fire due to increased exhaust tem- <Ref. to EN(D0HC TURBO)-322, DTC P1301 - FIRE DUE TO
perature INCREASED EXHAUST TEMPERATURE -, Diagnostic Procedure with
P1312 Exhaust temperature sensor mal- <Ref. to EN(D0HC TURBO)-324, DTC P1312 - EXHAUST GAS TEMPER-
function ATURE CIRCUIT MALFUNCTION-, Diagnostic Procedure with Diagnostic
Trouble Code ( D T C b
P1400 Fuel tank pressure control solenoid <Ref. to EN(D0HC TURBO)-326, DTC P1400 - FUEL TANK PRESSURE
valve circuit low input CONTROL SOLENOID VALVE CIRCUIT LOW INPUT -, Diagnostic Proce-
P1420 Fuel tank pressure control solenoid <Ref. to EN(D0HC TURBO)-330, DTC P1420 - FUEL TANK PRESSURE
valve circuit high input CONTROL SOLENOID VALVE CIRCUIT HIGH INPUT -, Diagnostic Proce-
P1443 Evaporative emission control system <Ref. to EN(D0HC TURBO)-332, DTC P1443 - EVAPORATIVE EMIS-
vent control function problem SION CONTROL SYSTEM VENT CONTROL FUNCTION PROBLEM -,
Diaanostic Procedure with Diaanostic Trouble Code ( D T C b
P1480 Cooling fan relay 1 circuit high input <Ref. to EN(D0HC TURBO)-335, DTC P1480 - COOLING FAN RELAY 1
Code (DTC).>
EN(D0HC TURBO)-85
ENGINE f DIAGNOSTICS)
DTC
Item Index
No.
P I 507 Idle control system malfunction (fail- <Ref. to EN(D0HC TURBO)-338, DTC P1507 - IDLE CONTROL SYSTEM
safe) MALFUNCTION (FAIL-SAFE) -, Diagnostic Procedure with Diagnostic
PI518 Starter switch circuit low input <Ref. to EN(D0HC TURBO)-341, DTC PI518 - STARTER SWITCH CIR-
CUlT LOW INPUT -, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
PI544 High exhaust temperature detected <Ref. to EN(D0HC TURBO)-344, DTC PI544 - HIGH EXHAUST TEM-
PERATURE DETECTED -, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
PI560 Back-up voltage circuit malfunction <Ref. to EN(D0HC TURBO)-347, DTC PI560 - Back-up Voltage Circuit
~
Malfunction-.>
P I 590 Neutral position switch circuit high <Ref. to EN(D0HC TURBO)-350, DTC PI590 - NEUTRAL POSITION
input SWITCH CIRCUIT HIGH INPUT -, Diagnostic Procedure with Diagnostic
PI591 Neutral position switch circuit low <Ref. to EN(D0HC TURBO)-354, DTC PI591 - NEUTRAL POSITION
input SWITCH CIRCUIT LOW INPUT -, Diagnostic Procedure with Diagnostic
P I 594 Automatic transmission diagnosis <Ref. to EN(D0HC TURBO)-356, DTC P1594 - AUTOMATIC TRANSMIS-
input signal circuit malfunction SION DIAGNOSIS INPUT SIGNAL CIRCUIT MALFUNCTION-, Diagnostic
Procedure with Diaanostic Trouble Code ( D T C b
PI595 Automatic transmission diagnosis <Ref. to EN(D0HC TURBO)-358, DTC PI595 - AUTOMATIC TRANSMIS-
input signal circuit low input SION DIAGNOSIS INPUT SIGNAL CIRCUIT LOW INPUT -, Diagnostic
P I 596 Automatic transmission diagnosis <Ref. to EN(D0HC TURBO)-360, DTC P1596 - AUTOMATIC TRANSMIS-
input signal circuit high input SION DIAGNOSIS INPUT SIGNAL CIRCUIT HIGH INPUT -, Diagnostic
P I 698 Engine torque control cut signal cir- <Ref. to EN(D0HC TURBO)-362, DTC P1698 - ENGINE TORQUE CON-
cuit low input TROL CUT SIGNAL CIRCUIT LOW INPUT -, Diagnostic Procedure with
Diaanostic Trouble Code ( D T C b
PI699 Engine torque control cut signal cir- <Ref. to EN(D0HC TURBO)-364, DTC P1699 - ENGINE TORQUE CON-
cuit high input TROL CUT SIGNAL CIRCUIT HIGH INPUT -, Diagnostic Procedure with
PI700 Throttle position sensor circuit mal- <Ref. to AT-52, DTC 31 THROTTLE POSITION SENSOR, Diagnostic Proce-
function for automatic transmission dure with Diagnostic Trouble Code (DTC).>
P I 701 Cruise control set signal circuit mal- <Ref. to EN(D0HC TURBO)-366, DTC P1701 - CRUISE CONTROL SET
function for automatic transmission SIGNAL CIRCUIT MALFUNCTION FOR AUTOMATIC TRANSMISSION -,
PI703 Low clutch timing control solenoid <Ref. to AT-78, DTC 73 LOW CLUTCH TIMING SOLENOID, Diagnostic Pro-
valve circuit malfunction cedure with Diagnostic Trouble Code (DTC).>
PI711 Engine torque control signal 1 circuit <Ref. to EN(D0HC TURBO)-368, DTC P1711 - ENGINE TORQUE CON-
malfunction TROL SIGNAL 1 CIRCUIT MALFUNCTION-, Diagnostic Procedure with
P1712 Engine torque control signal 2 circuit <Ref. to EN(D0HC TURBO)-370, DTC P1712 - ENGINE TORQUE CON-
malfunction TROL SIGNAL 2 CIRCUIT MALFUNCTION-, Diagnostic Procedure with
EN(D0HC TURBO)-86
EN(D0HC TURBO)-87
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
18.Diagnostic Procedure with Diagnostic Trouble Code (DTC)

A: DTC PO031 - FRONT OXYGEN (NF) SENSOR HEATER CIRCUIT LOW IN-
PUT -
DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:
MAIN RELAY BATTERY

SBF-5
nFRONTOXYGEN
EN1143
EN(D0HC TURBO)-88
Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. )oes the Subaru Select Moni- i o to step 2. Go to step 5.
3r or OBD-II general scan tool
idicate DTC PO031 and
’0037 at the same time?
CHECK POWER SUPPLY TO FRONT OXY- s the voltage more than 10 V? i o to step 3. Repair power sup-
GEN (NF)SENSOR. ply line.
2)Disconnect the connector from front oxygen In this case, repaii
(NF)sensor. the following:
3)Turn the ignition switch to ON. * Open circuit in
4)Measure the voltage between front oxygen harness between
(NF)sensor connector and engine ground. main relay and
Connector & terminal front oxygen (NF)
(818) No. 2 (+) - Engine ground (-): sensor connector
* Poor contact in
front oxygen (NF)
sensor connector
Poor contact in
main relay connec.
tor
CHECK GROUND CIRCUIT OF ECM. s the resistance less than 5 o
; to step 4. Repair harness
Measure the resistance of harness between 2? and connector.
ECM connector and chassis ground. NOTE:
Connector & terminal In this case, repaii
(8137) No. 8 - Chassis ground: the following:
(8137) No. 9 - Chassis ground: Open circuit in
harness between
ECM and engine
ground terminal
9 Poor contact in
ECM connector
Poor contact in
coupling connectoi
CHECK CURRENT DATA. s the value more than 0.2 A? 3epair poor con- Go to step 5.
1)Start the engine. act in connector.
2)Read the data of front oxygen (NF)sensor JOTE:
heater current using Subaru Select Monitor or n this case, repaii
OBD-ll general scan tool. he following:
NOTE: I Poor contact in
*Subaru Select Monitor ront oxygen (NF)
For detailed operation procedure, refer to the jensor connector
“READ CURRENT DATA FOR ENGINE. <Ref. 1 Poor contact in
to EN(D0HC TURBO)-38, Subaru Select Mon ECM connector
itor.>
*OBD-II scan tool
OBD-II General Scan Tool Instruction Manual.
CHECK OUTPUT SIGNAL FROM ECM. s the voltage less than 1.O V? 30 to step 7. Go to step 6.
1)Start and idle the engine.
. (8137) No. 4 (+) - Chassis ground (-):
CHECK OUTPUT SIGNAL FROM ECM. Ioes the voltage change less 3epair poor con- Go to step 7 .
Measure the voltage between ECM connector han 1.O V by shaking harness act in ECM con-
and chassis ground. md connector of ECM while lector.
Connector & terminal nonitoring the value with volt-
(8137) No. 4 (+) - Chassis groundI)-( ige meter?
(8137) No. 5 (+) - Chassis groundI)-(
EN(D0HC TURBO)-89
Step Check Yes No

r
CHECK FRONT OXYGEN (NF) SENSOR. Is the resistance less than 10 Repair harness Replace the front
1)Turn the ignition switch to OFF. R? and connector. oxygen (NF)sen-
2)Measure the resistance between front oxy- NOTE: sor. <Ref. to
gen (NF) sensor connector terminals. In this case, repair FU(D0HC
Terminals the following: TURBO)-42, Front
NO. 2 -NO. 1: Open or ground Oxygen (NF) Sen-
short circuit in har- sor.>
ness between front
oxygen (NF)sen-
sor and ECM con-
nector
Poor contact in
front oxygen (NF)
sensor connector
Poor contact in
ECM connector
EN(D0HC TURBO)-QO
ENG INE (DIAG NOSTlCS)
EN(D0HC TURBO)-91
B: DTC PO032 - FRONT OXYGEN (NF) SENSOR HEATER CIRCUIT HIGH IN-
PUT -
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
MAIN RELAY BATTERY

I
SBF-5
k!
FRONT OXYGEN
EN1143
EN(D0HC TURBO)-92
Step Check Yes No

CHECK OUTPUT SIGNAL FROM ECM. s the voltage more than 8 V? Go to step 3. i o to step 2.
CHECK FRONT OXYGEN ( N F ) SENSOR s the value more than 2.3 A? Replace the ECM. END
HEATER CURRENT. <Ref. to FU(D0HC
1)Turn the ignition switch to OFF. TURBO)-47,
2)Repair the battery short circuit in harness Engine Control
between ECM and front oxygen (NF) sensor Module.>
connector.
4)Read the data of front oxygen (NF) sensor
heater current using Subaru Select Monitor or
the OBD-ll general scan tool.
NOTE:
*Subaru Select Monitor
“READ CURRENT DATA FOR ENGINE. <Ref.
tq EN(D0HC TURBO)-38, Subaru Select Mon-
itor.>
*OED41 general scan tool
CHECK OUTPUT SIGNAL FROM ECM. END
Measure the voltage between ECM connector
and chassis ground.
(8137) No. 4 (+) - Chassis ground (-): ige meter? oxygen (NF)sen-
(8137) No. 5 (+) - Chassis ground (-): sor connector.
EN(DOHC TU RB0)-93
c
C: DTC PO037 - REAR OXYGEN SENSOR HEATER CIRCUIT MALFUNCTION

Two consecutive driving cycles with fault
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
MAIN RELAY
- BATTERY
EN1144
EN(D0HC TURBO)-94
Step Check Yes No

CHECK GROUND CIRCUIT OF ECM. s the resistance less than 5 20 to step 2. Repair harness
1)Turnthe ignition switch to OFF. 2? and connector.
2)Disconnectthe connector from ECM. NOTE:
3)Measure the resistance of harness between In this case, repair
ECM connector and chassis ground. the following:
Connector & terminal Open circuit in
(8137) No. 8 - Chassis ground: harness between
(8137) No. 9 - Chassis ground: ECM and engine
ground terminal
Poor contact in
ECM connector
Poor contact in
coupling connector
! CHECK CURRENT DATA. s the value more than 0.2 A? 3epair the con- Go to step 3.
1)Start the engine.
2)Read the data of rear oxygen sensor heater
current using Subaru Select Monitor or OBD-ll
general scan tool.
NOTE:
“QEAD CURRENT DATA FOR ENGINE”. <Ref.
to EN(D0HC TURBO)-38, Subaru Select Mon-
itor.>
*OBD-I1 scan tool
I CHECK OUTPUT SIGNAL FROM ECM. Go to step 4.
1)Start and idle the engine.
I CHECK OUTPUT SIGNAL FROM ECM. loes the voltage change less Repair poor con- Go to step 5.
Measure the voltage between ECM connector han 1 .O V by shaking harness tact in ECM con-
and chassis ground. ind connector of ECM while nector.
Connector & terminal nonitoring the value with volt-
(8136) No. 13 (+) - Chassis ground (-): ige meter?
1 CHECK OUTPUT SIGNAL FROM ECM. s the voltage less than 1.O V? Replace the ECM. Repair battery
1)Disconnectthe connector from rear oxygen <Ref. to FU(D0HC short circuit in har-
sensor. TURBO)-47, ness between
2)Measure the voltage between ECM connec- Engine Control ECM and rear oxy-
tor and chassis ground. Module.> gen sensor con-
Connector & terminal nector. After
( 8 136) No. 13 (+) - Chassis ground (-): repair, replace the
ECM. <Ref. to
FU(D0HC
TURBO)-47,
Engine Control
Module.>
EN(D0HC TURBO)-95
Step Check Yes No

CHECK POWER SUPPLY TO REAR OXY- ;the voltage more than 10 V? 30 to step 7 . 3epair power sup-
GEN SENSOR. )ly line.
1)Turnthe ignition switch to OFF. IIOTE:
2)Disconnect the connector from rear oxygen n this case, repair
sensor. he following:
3)Turn the ignition switch to ON. Open circuit in
4)Measure the voltage between rear oxygen iarness between
sensor connector and engine ground or chas- nain relay and
sis ground. ear oxygen sen-
Connector & terminal ior connector
(B19) No. 2 (+) - Chassis groundI)-( Poor contact in
ear oxygen sen-
;or connector
Poor contact in
:oupling connectoi
CHECK REAR OXYGEN SENSOR. s the resistance less than 30 Repair harness 3eplace the rear
1)Turnthe ignition switch to OFF. 2? and connector. Ixygen sensor.
2)Measure the resistance between rear oxy- NOTE: :Ref. to FU(D0HC
gen sensor connector terminals. In this case, repair rURBO)-44, Rear
Terminals the following: lxygen Sensor.>
NO. 1 -NO. 2: Open circuit in
harness between
rear oxygen sen-
sor and ECM con-
nector
Poor contact in
rear oxygen sen-
sor connector
Poor contact in
ECM connector
Poor contact in
coupling connectoi
EN(D0HC TURBO)-96
EN(DOHC TURBO)-97
ENGINE lDl AG NOSTICS)
D: DTC PO038 - REAR OXYGEN SENSOR HEATER CIRCUIT HIGH INPUT -

CAUTION:
tion Mode.>.
WIRING DIAGRAM:
MAIN RELAY BATTERY
REAR
1
OXYGEN SENSOR
EN1144
Step Check
1 . CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 8 V?
and chassis ground.
EN(D0HC TURBO)-98
Step Check Yes No

! CHECK CURRENT DATA. Is the value more than 7 A? Replacethe ECM. !ND
1)Turn the ignition switch to OFF. <Ref.to FU(D0HC
2)Repair the battery short circuit in harness TURBO)-47,
between ECM and rear oxygen sensor connec- Engine Control
tor. Module.>
4)Read the data of rear oxygen sensor heater
current using Subaru Select Monitor or the
OBD-II general scan tool.
NOTE:
itor.>
*OBD-II general scan tool
5 CHECK POOR CONTACT. Is there poor contact in ECM Repair poor con- END
Check poor contact in ECM connector. connector? tact in ECM con-
nector.
I
EN(D0HC TURBO)-99
E: DTC PO101 - MASS AIR FLOW SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM (HIGH INPUT) -
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Poor driving performance
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
BATTERY
SBF-5
3 c
1 MASS AIR FLOW AND

INTAKE A I Z E R A T U R E 1
ECM
EN1 145
EN(D0HC TURBO)-I00
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Replace the mass
tor or OBD-II general scan tool PO102 or PO103 air flow and intake
indicate DTC PO102 or PO103? using “Diagnos- air temprature sen,
tics Chart with sor. <Ref. to
Trouble Code”. FU(D0HC
NOTE: TURBO)-34, Mass
In this case, it is Air Flow and
not necessary to intake Air Temper-
inspect DTC ature Sensor.>
PO101.
EN(D0HC TURBO)-101
F: DTC PO102 - MASS AIR FLOW SENSOR CIRCUIT LOW INPUT -

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Poor driving performanc
WIRING DIAGRAM:
MASS AIR FLOW AND

INTAKE AIR TEMPERATURE
EN(D0HC TURBO)-I02
Step Check Yes No

CONNECT SUBARU SELECT MONITOR OR 3 the value equal to or more Even if MIL lights ;o to step 2.
THE OBD-ll GENERAL SCAN TOOL, AND han 1.3 g/sec (0.172 Ib/min)or up, the circuit has
READ DATA. 1.3V and equal to or less than returned to a nor-
1)Turn the ignition switch to OFF. 140 g/sec (32 Ib/min) or 4.58 mal condition at
2)Connect the Subaru Select Monitor or the I? this time. A tempo-
OBD-ll general scan tool to data link connec- rary poor contact
tor. of the connector or
3)Turn the ignition switch to ON and Subaru harness may be
Select Monitor or the OBD-ll general scan tool the cause. Repair
switch to ON. harness or con-
4)Start the engine. nector in the mass
5)Read the data of mass air flow sensor signal air flow sensor.
using Subaru Select Monitor or OBD-II general NOTE:
scan tool. In this case, repaii
NOTE: the following:
*Subaru Select Monitor Open or ground
For detailed operation procedure, refer to the short circuit in har-
“READ CURRENT DATA FOR ENGINE. <Ref. ness between
to EN(D0HC TURBO)-38, Subaru Select Mon mass air flow sen-
itor.> sor and ECM con-
*OBD-ll general scan tool nector
For detailed operation procedures, refer to the w Poor contact in
O b - l I General Scan Tool Instruction Manual. mass air flow sen-

sor or ECM con-
nector
CHECK INPUT SIGNAL FOR ECM. s the voltage less than 0.2 V? Go to step 4. 30 to step 3.
and chassis ground while engine is idling.
(B84) No. 13 (+) - Chassis ground (-):
CHECK INPUT SIGNAL FOR ECM (USING Ioes the voltage change more Repair poor con- ;ontact with SOA
SUBARU SELECT MONITOR). han 0.2 V by shaking harness tact in ECM con- distributor) ser-
Measure the voltage between ECM connector ind connector of ECM while nector. lice.
and chassis ground while engine is idling. nonitoring the value with Sub- \IOTE:
tru select monitor? nspection by DTN
s required, be.
:ause probablc
:ause is deteriora
ion of multiplt
iarts.
CHECK POWER SUPPLY TO MASS AIR s the voltage more than 1OV? Go to step 5. 3epair open circuil
FLOW SENSOR. ietween mass air
1)Turn the ignition switch to OFF. low sensor and
2)Disconnect the connector from mass air flow nain relay
sensor.
4)Measure voltage between mass air flow sen,
sor connector and chassis ground.
(B3) No. 1 (+)- Chassis ground (-):
CHECK HARNESS BETWEEN ECM AND s the resistance less than l R ? Go to step 6. 3epair open circuit
MASS AIR FLOW SENSOR CONNECTOR. ietween ECM and
- 1)Turn the ignition switch to OFF. nass air flow sen-
2)Disconnect the connector from ECM. sor connector.
ECM and mass air flow sensor connector.
-
(B84) NO. 13 (B3) NO. 3:
(8135) NO. 27 - (83) NO. 4:
-
(B 135) NO. 19 (B3) NO. 5:
EN(D0HC TURBO)-IO3
Step Check
CHECK HARNESS BETWEEN ECM AND Is the resistance more than
MASS AIR FLOW SENSOR CONNECTOR 1M a ? short circuit
Measure the resistance of harness between between ECM and
ECM and chassis ground. mass air flow sen-
Connector & terminal sor connector.
( 8 135) No. 19 - Chassis ground:
CHECK POOR CONTACT Is there poor contact in mass Repair poor con- Replace the mass
Check poor contact in mass air flow sensor air flow sensor connector? tact in mass air air flow and intake
connector. flow sensor con- air temperature
nector. sensor. <Ref. to
FU(D0HC
TURBO)-34, Mass
Air Flow and
Intake Air Temper-
ature Sensor.>
EN(D0HC TURBO)-104
EN(D0HC TURBO)-105
ENGI NE (DIAG NOSTlCS)
G: DTC PO103 - MASS AIR FLOW SENSOR CIRCUIT HIGH INPUT -

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
MAIN RELAY
BATTERY
SBF-5
3 c
I MASS AIR FLOW AND

EN(D0HC TURBO)-I06
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLEENG
CODE (DTC)
INE (DIAGNOSTICS)
Step Check Yes No

CONNECT SUBARU SELECT MONITOR OR Is the value equal to or more Even if MIL lights o to step 2.
THE OBD-ll GENERAL SCAN TOOL, AND than 1.3 g/sec (0.172 Ib/min)or up, the circuit has
READ DATA. 0.3 V and equal to or less than returned to a nor-
1)Turnthe ignition switch to OFF. 240 g/sec (32 Ib/min) or 4.58 mal condition at
2)Connect the Subaru Select Monitor or the ? this time.
OBD-ll general scan tool to data link connec-
tor.
3)Turn the ignition switch to ON and Subaru
Select Monitor or the OBD-ll general scan tool
switch to ON.
4)Start the engine.
5) Read the data of mass air flow sensor signal
using Subaru Select Monitor or OBD-ll general
scan tool.
NOTE:
“READ CURRENT DATA FOR ENGINE”. <Ref.
itor.>
*OBD-ll general scan tool
s the value more than 240 g/ Repair battery ieplace the mass
CHECK HARNESS BETWEEN ECM AND
iec (32 Ib/min) or 4.58 V in short circuit in har, .ir flow sensor.
MASS AIR FLOW SENSOR CONNECTOR.
1)Turn the ignition switch to OFF and Subaru unction mode F06? ness between
Select Monitor or the OBD-ll general scan tool mass air flow sen-
switch to OFF. sor and ECM con-
2)Disconnect the connector from mass air flow nector. After
sensor. repair, replace the
3)Turn the ignition switch to ON and Subaru ECM.
Select Monitor or the OBD-ll general scan tool
switch to ON.
4)Read the data of mass air flow sensor signal
using Subaru select monitor or OBD-ll general
scan tool.
NOTE:
to EN(D0HC TURBO)-38, Subaru Select Mon,
itor.>
EN(D0HC TURBO)-107
H: DTC PO106 - PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM (LOW INPUT) -
TROUBLE SYMPTOM:
Failure of engine to start
CAUTION:
tion Mode.>.
I THROTTLE BODY
EN(D0HC TURBO)-I08
~ _ _ _ ~ ~
Step Check Yes No

CHECK IDLE SWITCH SIGNAL. Ioes the LED of {Idle Switch 20 to step 2. Check the throttle
1)Turnthe ignition switch to ON. jignal} come on? position sensor cir,
2)Operate the LED operation mode for engine cuit. <Ref. to
using Subaru Select Monitor. EN(D0HC
NOTE: TURBO)-132,
*Subaru Select Monitor DTC PO121 -
For detailed operation procedure, refer to the THROTTLE POSI-
“LED OPERATION MODE FOR ENGINE. TION SENSOR
<Ref. to EN(D0HC TURBO)-38, Subaru CIRCUIT RANGE/
Select Monitor.> PERFORMANCE
PROBLEM (HIGH
INPUT) -, Diag-
nostic Procedure
with Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it zi
not necessary tc
inspect DTC
PO106.
! CHECK ANY OTHER DTC ON DISPLAY. loes the Subaru Select Moni- nspect DTC Go to step 3.
or or OBD-ll general scan tool ’0107 or PO108
ndicate DTC PO107 or PO1087 Jsing “List of Diag-
iostic Trouble
:ode (DTC)”.
:Ref. to EN(D0HC
TURBO)-80, List
i f Diagnostic Trou-
ile Code (DTC).>
VOTE:
in this case, it is
lot necessary to
nspect DTC
D0106.
1 CHECK CONDITION OF PRESSURE SEN- s the pressure sensor installa- 30 to step 4. iighten pressure
SOR. ion bolt tightened securely? sensor installation
bolt securely.
I CHECK CONDITION OF THROlTLE BODY. s the throttle body installation Replace the pres- Tighten throttle
iolt tightened securely? sure sensor. <Ref. body installation
to FU(D0HC bolt securely.
TURBO)-35, Pres-
sure Sensor.>
EN(D0HC TURBO)-I09
I: DTC PO107 - PRESSURE SENSOR CIRCUIT LOW INPUT -

CAUTION:
tion Mode.>.
WIRING DIAGRAM:
THROTTLE BODY
PRESSURE
I@ ECM
EN(D0HC TURBO)-I 10
Step Check Yes No

CHECK CURRENT DATA. s the value less than -7.2 kPa 20 to step 3. 30 to step 2.
1)Start the engine. -54 mmHg, -2.1 inHg)?
2)Read the data of intake manifold absolute
pressure signal using Subaru Select Monitor or
OBD-ll general scan tool.
NOTE:
OSubaru Select Monitor
to EN(D0HC TURBO)-38, Subaru Select Mon
itor.>
I CHECK POOR CONTACT. s there poor contact in ECM or 3epair poor con- Even if MIL lights
Check poor contact in ECM and pressure sen- )ressure sensor connector? act in ECM or ~ pthe
, circuit has
sor connector. iressure sensor .eturned to a nor-
:onnector. nal condition at
his time.
I CHECK INPUT SIGNAL FOR ECM. s the voltage more than 4.5 V? 30 to step 5. 20 to step 4.
and chassis ground.
CHECK INPUT SIGNAL FOR ECM. loes the voltage change more ’lepair poor con- Zontact with SOA
Measure the voltage between ECM connector han 4.5 V by shaking harness act in ECM con- :distributor) ser-
and chassis ground. ind connector of ECM while lector. {ice.
Connector & terminal nonitoring the value with volt- VOTE:
(6135) No. 9 (+) - Chassis ground (-): ige meter? ‘nspection by DTk
s required, be,
:ause probablc
:ause is deteriora,
:ion of multiplc
Darts.
1 CHECK INPUT SIGNAL FOR ECM. s the voltage less than 0.7 V? 30 to step 6. Zontact with SOA
Measure the voltage between ECM and chas- :distributor) ser-
sis ground. dice.
Connector & terminal VOTE:
(8135) No. 8 (+) - Chassis ground (-): Inspection by DThr
s required, be
zause probablt
zause is deteriora
tion of multiplt
Darts.
i CHECK HARNESS BETWEEN ECM AND s the voltage more than 4.5 VS 30 to step 7. Repair open circuii
PRESSURE SENSOR CONNECTOR. n harness
1)Turnthe ignition switch to OFF. Detween ECM and
2)Disconnectthe connector from pressure Dressure sensor
sensor. zonnector.
4)Measure the voltage between pressure sen-
sor connector and engine ground.
. Connector & terminal
(E21) No. 3 (+) - Engine ground (-):
EN(D0HC TURBO)-1 11
~ ~ ~~ ~ ~ ~ ~ ~ _ _ _ _ _ _ _
Step Check Yes No

7 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 8. Repair open circuit
PRESSURE SENSOR CONNECTOR. R? in harness
1)Turn the ignition switch to OFF. between ECM and
2)Disconnect the connector from ECM. pressure sensor
3)Measure the resistance of harness between connector.
ECM and pressure sensor connector.
-
(8135) NO. 19 (E21) NO. 2:
8 CHECK HARNESS BETWEEN ECM AND Is the resistance more than 1 Go to step 9. Repair ground
PRESSURE SENSOR CONNECTOR. Ma? short circuit in har-
Measure the resistance of harness between ness between
pressure sensor connector and engine ground. ECM and pressure
Connector & terminal sensor connector.
(E21) No. 1 - Engine ground:
9 CHECK POOR CONTACT. Is there poor contact in pres- Repair poor con- Replace the pres-
Check poor contact in pressure sensor con- sure sensor connector? tact in pressure sure sensor. <Ref.
nector. sensor connector. to FU(D0HC
TURBO)-35, Pres-
sure Sensor.>
EN(D0HC TURBO)-1 12
EN(D0HC TURBO)-I 13
J: DTC PO108 - PRESSURE SENSOR CIRCUIT HIGH INPUT -

CAUTION:
tion Mode.>.
WIRING DIAGRAM:
THROTTLE BODY
PRESSURE SE
EN(D0HC TURBO)-114
Step Check Yes No

CHECK CURRENT DATA. s the value more than 282 kPa 20 to step 9. Go to step 2.
1)Start the engine. 2121 mmHg, 83.50 inHg)?
pressure signal using Subaru Select Monitor or
NOTE:
Gubaru Select Monitor I
itor.>
CHECK INPUT SIGNAL FOR ECM. s the voltage more than 4.5 V?
and chassis ground.
(8135) No. 9 (+)- Chassis ground (-):
, CHECK INPUT SIGNAL FOR ECM. Ioes the voltage change more 3epair poor con- Contact with SOA
Measure the voltage between ECM connector han 4.5 V by shaking harness act in ECM con- (distributor) ser-
gnd chassis ground. n d connector of ECM while lector. vice.
Connector & terminal nonitoring the value with volt- NOTE:
(8135) No. 9 (+)- Chassis ground (-): tge meter? Inspection by DTk
is required, be
cause probable
cause is deteriora
tion of multiple
parts.
1 CHECK INPUT SIGNAL FOR ECM. s the voltage less than 0.7 V? 30 to step 5. Contact with SOA
Measure the voltage between ECM connector (distributor) ser-
and chassis ground. vice.
Connector & terminal NOTE:
(8135) No. 8 (+) - Chassis ground (-): Inspection by DTk
is required, be
cause probablt
cause is deteriora
tion of multiplt
parts.
I CHECK HARNESS BETWEEN ECM AND s the voltage more than 4.5 VS 30 to step 6. Repair open circuil
PRESSURE SENSOR CONNECTOR. in harness
1)Turnthe ignition switch to OFF. between ECM and
2)Disconnectthe connector from pressure pressure sensor
sensor. connector.
4)Measure the voltage between pressure sen-
sor connector and engine ground.
(E21) No. 3 (+)- Engine ground (-):
i CHECK HARNESS BETWEEN ECM AND s the resistance less than 1 30 to step 7. Repair open circuil
PRESSURE SENSOR CONNECTOR. 2? in harness
1)Turnthe ignition switch to OFF. between ECM and
. 2)Disconnect the connector from ECM. pressure sensor
ECM and pressure sensor connector.
(8135) NO. 8 - (E21) NO. 1:
EN(D0HC TURBO)-115
Step Check Yes No

r CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 8. 3epair open circuit
PRESSURE SENSOR CONNECTOR. a? n harness
Measure the resistance of harness between letween ECM and
ECM and pressure sensor connector. lressure sensor
Connector & terminal :onnector.
(8135) NO. 19 - (E21) NO.2:
I CHECK POOR CONTACT. Is there poor contact in pres- Repair poor con- 3eplace the pres-
Check poor contact in pressure sensor con- sure sensor connector? tact in pressure iure sensor. <Ref.
nector. sensor connector. o FU(D0HC
rURBO)-35, Pres-
iure Sensor.>
CHECK HARNESS BETWEEN ECM AND Is the value more than 282 kPa Repair battery 3eplace the pres-
PRESSURE SENSOR CONNECTOR. (2121 mmHg, 83.50 inHg)? short circuit in har- ure sensor. <Ref.
1)Turnthe ignition switch to OFF and Subaru ness between o FU(D0HC
Select Monitor or the OBD-II general scan tool ECM and pressure rURBO)-35, Pres-
switch to OFF. sensor connector. ;ure Sensor.>
2)Disconnect the connector from pressure
sensor.
3)Turn the ignition switch to ON and Subaru
Select Monitor or the OBD-II general scan tool
switch to ON.
iressure signal using Subaru Select Monitor or
NOTE:
itor.>
EN(D0HC TURBO)-I 16
EN(D0HC TURBO)-I 17
ENGINE [DIAGNOSTICS)
K: DTC PO111 - INTAKE AIR TEMPERATURE SENSOR CIRCUIT RANGE/PER-

FORMANCE PROBLEM -
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
IAIN RELAY
BATTERY
SBF-5
MASS AIR FLOW AND

ECM
@
EN1145
EN(D0HC TURBO)-I 18
Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. loes the Subaru Select Moni- Inspect DTC Go to step 2.
or or OBD-ll general scan toolPOI 12, PO113,
ndicate DTC PO112, PO113, PO117, PO118 or
’0117, PO118 or P0125? PO125 using “List
of Diagnostic Trou-
ble Code (DTC)”.
<Ref. to EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0111.
CHECK ENGINE COOLANT TEMPERA- s the engine coolant tempera- Replace the mass Inspect DTC
TURE. ure between 75°C (167°F) and air flow and intake PO125 using “List
1)Start the engine and warm it up completely. )5”C (203”F)? air temperature of Diagnostic Trow
2)Measure the engine coolant temperature sensor. <Ref. to ble Code (DTC)”.
using Subaru Select Monitor or OBD-11general FU(D0HC <Ref. to EN(D0HC
scan tool. TURBO)-34, Mass TURBO)-80, List
NOTE: Air Flow and of Diagnostic Trow
*Subaru Select Monitor Intake Air Temper- ble Code (DTC).>
For detailed operation procedure, refer to the ature Sensor.>
itor.> I
EN(D0HC TURBO)-I 19
L: DTC PO112 - INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW INPUT

7

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
RATTFRY
MASS AIR FLOW AND

ECM
E:
EN1 145
EN(D0HC TURBO)-120
Step Check Yes No

CHECK CURRENT DATA. s the value greater than 55°C 30 to step 2. 3epair poor con-
1)Start the engine. 131OF)? 3Ct.
2)Read the data of intake air temperature sen- JOTE:
sor signal using Subaru Select Monitor or the n this case, repai
OBD-ll general scan tool. he following:
NOTE: Poor contact
Gubaru Select Monitor nass air flow and
For detailed operation procedure, refer to the itake air tempera.
“READ CURRENT DATA FOR ENGINE”. <Ref. ure sensor
to EN(D0HC TURBO)-38, Subaru Select Mon- Poor contact in
itor.> iCM
*OBD-II general scan tool Poor contact in
For detailed operation procedure, refer to the Ynt connector
CHECK HARNESS BETWEEN MASS AIR s the value less than -36°C (- 3eplace the mass 3epair ground
FLOW AND INTAKE AIR TEMPERATURE )7”F)? air flow and intake ihort circuit in har.
SENSOR AND ECM CONNECTOR. air temperature less between
1)Turn the ignition switch to OFF. sensor. <Ref. to nass air flow and
2)Disconnect the connector from mass air flow ‘U( DOHC itake air tempera.
and intake air temperature sensor. TURBO)-34, Mass ure sensor and
3)Turn the ignition switch to ON. 4ir Flow and iCM connector.
4)Read the data of intake air temperature sen- ntake Air Temper-
sor signal using Subaru Select Monitor or the ature Sensor.>
NOTE:
itor.>
EN(D0HC TURBO)-121
M: DTC PO113 - INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH INPUT

-
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
MAIN RELAY
I MASS AIR FLOW AND

ECM
EN1145
EN(D0HC TURBO)-122
Step Check Yes No

I CHECK CURRENT DATA. Repair poor con-
1)Start the engine. 17”F)? tact.
2)Read the data of intake air temperature sen- NOTE:
sor signal using Subaru Select Monitor or the In this case, repaii
OBD-I1 general scan tool. the following:
NOTE: Poor contact in
*Subaru Select Monitor mass air flow and
For detailed operation procedure, refer to the intake air tempera-
“READ CURRENT DATA FOR ENGINE”. <Ref. ture sensor
to EN(D0HC TURBO)-38, Subaru Select Mom * Poor contact in
itor.> ECM
*OBD-ll general scan tool Poor contact in
For detailed operation procedure, refer to the ioint connector
! CHECK HARNESS BETWEEN MASS AIR ;the voltage more than 10 V? Repair battery Go to step 3.
FLOW AND INTAKE AIR TEMPERATURE short circuit in har-
SENSOR AND ECM CONNECTOR. ness between
1)Turn the ignition switch to OFF. mass air flow and
2)Disconnect the connector from mass air flow intake air tempera-
and intake air temperature sensor. ture sensor and
3)Measure the voltage between mass air flow ECM connector.
?nd intake air temperature sensor connector
and engine ground.
(63)No. 2 (+) - Engine ground (-):
I CHECK HARNESS BETWEEN INTAKE AIR s the voltage more than 10 V? Repair battery Go to step 4.
TEMPERATURE AND PRESSURE SENSOR short circuit in har-
AND ECM CONNECTOR. ness between
1)Turnthe ignition switch to ON. mass air flow and
2)Measure the voltage between mass air flow intake air tempera-
and intake air temperature sensor connector ture sensor and
and engine ground. ECM connector.
(63)No. 2 (+) - Engine ground (-):
I CHECK HARNESS BETWEEN MASS AIR s the voltage more than 3 V? Go to step 5. Repair harness
FLOW AND INTAKE AIR TEMPERATURE and connector.
SENSOR AND ECM CONNECTOR. NOTE:
Measure the voltage between mass air flow In this case, repaii
and intake air temperature sensor and pres- the following:
sure sensor connector and engine ground. Open circuit in
(63)No. 2 (+) - Engine groundI)-( mass air flow and
intake air tempera
ture sensor and
ECM connector
* Poor contact in
mass air flow and
intake air tempera-
ture sensor
Poor contact in
ECM
Poor contact in
joint connector
EN(D0HC TURBO)-123
-
Step Check Yes No

# CHECK HARNESS BETWEEN MASS AIR Is the resistance less than 5 Replace the mass Repair harness
FLOW AND INTAKE AIR TEMPERATURE R? air flow and intake and connector.
SENSOR AND ECM CONNECTOR. air temperature NOTE:
1)Turn the ignition switch to OFF. sensor. <Ref. to In this case, repaii
2)Measure the resistance of harness between FU(D0HC the following:
mass air flow and intake air temperature sen- TURBO)-34, Mass Open circuit in
sor and engine ground. Air Flow and nessbetween
Connector & terminal Intake Air Temper- mass air flow and
(83)No. 5 -Engine ground: ature Sensor.> intake air tempera-
ture sensor and
ECM connector
Poor contact in
mass air flow and
intake air tempera.
ture sensor
Poor contact in
ECM
Poor contact in
ioint connector
EN(D0HC TURBO)-124
EN(D0HC TURBO)-I25
N: DTC PO117 - ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW

INPUT -
TROUBLE SYMPTOM:
Hard to start
Erroneous idling
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
I ENGINE
COOLANT
TEMPERATURE
SENSOR
EN114;
EN(D0HC TURBO)-I26
Step Check Yes No

CHECK CURRENT DATA. s the value greater than i50°C Go to step 2. Repair poor con-
1)Start the engine. 302”F)? tact.
2)Read the data of engine coolant temperature NOTE:
sensor signal using Subaru Select Monitor or In this case, repai
OBD-II general scan tool. the following:
*Subaru Select Monitor engine coolant
For detailed operation procedure, refer to the temperature sen-
“READ CURRENT DATA FOR ENGINE”. <Ref. sor
to EN(D0HC TURBO)-38, Subaru Select Mon- Poor contact in
itor.> ECM
For detailed operation procedures, refer to the coupling connect0
OBD-ll General Scan Tool Instruction Manual. Poor contact in
joint connector
CHECK HARNESS BETWEEN ENGINE s the value less than -40°C (- Replace the Repair ground
COOLANT TEMPERATURE SENSOR AND IO’F)? engine coolant short circuit in har.
ECM CONNECTOR. temperature sen- ness between
1)Turnthe ignition switch to OFF. sor. <Ref. to engine coolant
2)Disconnectthe connector from engine cocl- FU(D0HC temperature sen-
ant temperature sensor. TURBO)-29, sor and ECM con-
3)Turn the ignition switch to ON. Engine Coolant nector.
4)Read the data of engine coolant temperature Temperature Sen-
sensor signal using Subaru Select Monitor or sor.>
NOTE:
itor.>
EN(D0HC TURBO)-127
ENG INE (DIAGNOSTICS)
0:DTC PO118 - ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT HIGH

INPUT -
TROUBLE SYMPTOM:
Hard to start
Erroneous idling
CAUTION:
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURB0)46, Inspec-
tion Mode.>.
WIRING DIAGRAM:
1 ENGINE
COOLANT
TEMPERATURE
SENSOR
U
@ECM
EN1147
EN(D0HC TURBO)-128
Step Check Yes No

CHECK CURRENT DATA. I Is the value less than -40°C (- I Go to step 2. Repair poor con-
1)Start the engine. 40°F)? tact.
2)Read the data of engine coolant temperature NOTE:
sensor signal using Subaru Select Monitor or In this case, repai
m Poor contact in
NOTE:
OSubaru Select Monitor engine coolant
For detailed operation procedure, refer to the temperature sen-
“READ CURRENT DATA FOR ENGINE”. <Ref. sor
to EN(D0HC TURBO)-38, Subaru Select Mom * Poor contact in
itor.> ECM
For detailed operation procedures, refer to the coupling connect0
OBD-ll General Scan Tool Instruction Manual. m Poor contact in
joint connector
! CHECK HARNESS BETWEEN ENGINE Is the voltage more than 10 V? Repair battery Go to step 3.
COOLANT TEMPERATURE SENSOR AND short circuit in har-
ECM CONNECTOR. ness between
1)Turnthe ignition switch to OFF. ECM and engine
2)Disconnect the connector from engine cool- coolant tempera-
ant temperature sensor. ture sensor con-
3)Measure the voltage between engine coolant nector.
temperature sensor connector and engine
ground.
1 CHECK HARNESS BETWEEN ENGINE Is the voltage more than 10 V? Repair battery Go to step 4.
COOLANT TEMPERATURE SENSOR AND short circuit in har-
ECM CONNECTOR. ness between
1)Turn the ignition switch to ON. ECM and engine
2)Measure the voltage between engine coolant coolant tempera-
temperature sensor connector and engine ture sensor con-
ground. nector.
I CHECK HARNESS BETWEEN ENGINE Is the voltage more than 4 V? Go to step 5. Repair harness
COOLANT TEMPERATURE SENSOR AND and connector.
NOTE:
In this case, repai
the following:
Open circuit in
harness between
ECM and engine
coolant tempera-
ture sensor con-
nector
Poor contact in
engine coolant
temperature sen-
sor connector
9 Poor contact in
ECM connector
Poor contact in
coupling connecta
Poor contact in
joint connector
EN(D0HC TURBO)-129
Step Check Yes No

I CHECK HARNESS BETWEEN ENGINE Is the resistance less than 5 Replace the Repair harness
COOLANT TEMPERATURE SENSOR AND n? engine coolant and connector.
ECM CONNECTOR. temperature sen- NOTE:
1)Turnthe ignition switch to OFF. sor. <Ref. to In this case, repair
2)Measure the resistance of harness between FU(D0HC the following:
engine coolant temperature sensor connector TURBO)-29, Open circuit in
and engine ground. Engine Coolant harness between
Connector & terminal Temperature Sen- ECM and engine
(E8) No. 7 - Engine ground: sor.> coolant tempera-
ture sensor con-
nector
Poor contact in
engine coolant
temperature sen-
sor connector
Poor contact in
ECM connector
Poor contact in
coupling connector
Poor contact in
joint connector
EN(D0HC TURBO)-130
I
t
EN(D0HC TURBO)-I31
P: DTC PO121 - THROTTLE POSITION SENSOR CIRCUIT RANGE/PERFOR-

MANCE PROBLEM (HIGH INPUT) -
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Fuel is cut.
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
THROTTLE
POSITION
SENSOR
c
li
EN1148
EN(D0HC TURBO)-I 32
I
~
Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. Ioes the Subaru Select Moni- Inspect DTC Replace the throt-
or or OBD-I1general scan tool P0122, PO123 or !le position sen-
ndicate DTC PO1 22, PO123 or P I 507 using " List ;or. <Ref. to
'1 507? of Diagnostic Trou- FU(D0HC
ble Code (DTC)". TURBO)-33,
<Ref. to EN(D0HC Throttle Position
TURBO)-80, List Sensor.>
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0121.
EN(D0HC TURBO)-133
Q: DTC PO122 -THROTTLE POSITION SENSOR CIRCUIT LOW INPUT -

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
THROTTLE
POSITION
SENSOR
EN1148
EN(D0HC TURBO)-134
ENGINE IDIAGNOSTICS)
Step Check Yes No

CHECK CURRENT DATA. s the value less than 0.1 V? 30 to step 2. Even if MIL lights
1)Start the engine. up, the circuit has
2)Read the data of throttle position sensor sig- returned to a nor-
nal using Subaru Select Monitor or OBD-ll mal condition at
general scan tool. this time. A tempo
NOTE: rary poor contact
*Subaru Select Monitor of the connector
For detailed operation procedure, refer to the may be the cause
“READ CURRENT DATA FOR ENGINE. <Ref. NOTE:
to EN(D0HC TURBO)-38, Subaru Select Mon- In this case, repar
itor.> the following:
For detailed operation procedures, refer to the throttle position
OBD-II General Scan Tool Instruction Manual. sensor connector
Poor contact in
ECM connector
Poor contact in
coupling connectc
! CHECK INPUT SIGNAL FOR ECM. s the voltage more than 4.5 V‘ 30 to step 4. Go to step 3.
and chassis ground while throttle valve is fully
closed.
(6135) No. 9 (+) -Chassis ground (-):
I CHECK JNPUT SIGNAL FOR ECM. Ioes the voltage change more 3epair poor con- Contact with SOA
Measure the voltage between ECM connector han 4.5 V by shaking harness act in ECM con- (distributor) ser-
and chassis ground. ind connector of ECM while lector. vice.
(6135) No. 9 (+) -Chassis ground (-): ige meter? Inspection by DTL
is required, be
cause probabll
cause is deteriora
tion of multipll
parts.
I CHECK INPUT SIGNAL FOR ECM. s the voltage less than 0.1 V?
and chassis ground.
(8135) No. 7 (+) -Chassis ground (-):
1 CHECK INPUT SIGNAL FOR ECM. (USING joes the voltage change more
SUBARU SELECT MONITOR.) han 0.1 V by shaking harness act in ECM con-
Measure the voltage between ECM connector md connector of ECM while lector.
and chassis ground. nonitoring the value with Sub-
kru Select Monitor?
EN(D0HC TURB0)-135
Step Check Yes No

CHECK HARNESS BETWEEN ECM AND s the voltage more than 4.5 V' 30 to step 7. Repair harness
THROTTLE POSITION SENSOR CONNEC- and connector.
TOR. NOTE:
1)Turn the ignition switch to OFF. In this case, repaii
2)Disconnectthe connectors from throttle posi- the following:
tion sensor. Open circuit in
3)Turn the ignition switch to ON. harness between
4)Measure the voltage between throttle posi- throttle position
tion sensor connector and engine ground. sensor and ECM
Connector & terminal connector
(€13) No. 1 (+) - Engine ground (-): Poor contact in
throttle position
sensor connector
Poor contact in
ECM connector
Poor contact in
coupling connectoi
Poor contact in
joint connector
CHECK HARNESS BETWEEN ECM AND s the resistance less than 1 30 to step 8. Repair harness
THROTTLE POSITION SENSOR CONNEC- 2? and connector.
TOR. NOTE:
'1)Turn the ignition switch to OFF. In this case, repaii
ECM connector and throttle position sensor Open circuit in
connector. harness between
Connector & terminal throttle position
(8135) NO. 7 - (E13) NO. 3: sensor and ECM
connector
Poor contact in
ECM connector
Poor contact in
throttle position
sensor connector
Poor contact in
coupling connectoi
I CHECK HARNESS BETWEEN ECM AND s the resistance less than 10 3epair ground Go to step 9.
THROlTLE POSITION SENSOR CONNEC- 3? short circuit in har-
TOR. less between
Measure the resistance of harness between hrottle position
throttle position sensor connector and engine sensor and ECM
ground. :onnector.
1 CHECK POOR CONTACT. s there poor contact in throttle 3epair poor con- Replace the throt-
Check poor contact in throttle position sensor iosition sensor connector? act in throttle posi, tle position sen-
connector. ion sensor sor. <Ref. to
:onnector. FU(D0HC
TURBO)-33,
Throttle Position
Sensor.>
EN(D0HC TURBO)-136
-
EN(D0HC TURBO)-I37
R: DTC PO123 - THROTTLE POSITION SENSOR CIRCUIT HIGH INPUT -

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Poor driving performance -
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
THROTTLE
POSITION
SENSOR
I -
EN1148
EN(D0HC TURBO)-138
~~
Step Check Yes No

CHECK CURRENT DATA. ;the value more than 4.9 V? i o to step 2. Even if MIL lights
2)Read the data of throttle position sensor sig. returned to a nor-
nal using Subaru Select Monitor or OBD-ll mal condition at
general scan tool. this time. A tempo-
For detailed operation procedure, refer to the may be the cause.
“READ CURRENT DATA FOR ENGINE. <Ref. NOTE:
to EN(D0HC TURBO)-38, Subaru Select Mon In this case, repair
OBD-ll General Scan Tool Instruction Manual. sensor connector
Poor contact in
ECM connector
Poor contact in
coupling connector
CHECK HARNESS BETWEEN THROlTLE 5 the resistance less than 5 Go to step 3. Repair harness
POSITION SENSOR AND ECM CONNEC- l? and connector.
TOR. NOTE:
2)Disconnect the connector from throttle posi- the following:
tion sensor. Open circuit in
3)Measure the resistance of harness between harness between
throttle position sensor connector and engine throttle position
ground. sensor and ECM
(E 13) No. 2 - Engine ground: Poor contact in
coupling connectot
Poor contact in
joint connector
CHECK HARNESS BETWEEN THROTTLE s h e voltage more than 4.9 b Aepair battery Replace the throt-
POSITION SENSOR AND ECM CONNEC- short circuit in har- tle position sen-
TOR. ness between sor. <Ref. to
1)Turn the ignition switch to ON. throttle position FU(D0HC
2)Measure the voltage between throttle posi- sensor and ECM TURBO)-33,
tion sensor connector and engine ground. connector. After Throttle Position
Connector & terminal repair, replace the Sensor.>
(E13) No. 3 (+) -Engine ground (-): ECM. <Ref. to
FU(D0HC
TURBO)-47,
Engine Control
Module.>
EN(D0HC TURBO)-139
S: DTC PO125 - INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED

LOOP FUEL CONTROL -
TROUBLE SYMPTOM:
Engine would not return to idling.
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
ENGINE
COOLANT
TEMPERATURE
SENSOR
IC
I
c
-
EN(D0HC TURBO)-140
ENGINE [DIAGNOSTICSI
Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- I Inspect DTC I Go to step 2.
tor or OBD-ll general scan tool PO117 or PO118
indicate DTC PO117 or PO118? using “List of Diag.
nostic Trouble
Code (DTC)”.
<Ref. to EN(D0HC
TURBO)-80, List
of Diagnostic Trow
ble Code (DTC).>
NOTE:
In this case, it is
not necessary tc
inspect DTC
PO125.
! CHECK ENGINE COOLING SYSTEM. Is there a fault in engine cool- Replace the ther- rleplace the
NOTE: ing system? mostat. <Ref. to engine coolant
Check the following items. CO-35, Thermo- temperature sen-
*Thermostat open stuck stat.> sor. <Ref. to
*Coolant level FU(D0HC
Coolant freeze TURBO)-29,
*Tire diameter Engine Coolant
Temperature Sen-
sor.>
EN(D0HC TURBO)-141
T: DTC PO128 - THERMOSTAT MALFUNCTION -

TROUBLE SYMPTOM:
Thermostat remains open.
CAUTION:
tion Mode.>.
Step Check Yes No

CHECK VEHICLE CONDITION. Has engine operated at idle or In this case, it is Go to step 2.
has vehicle been driven with not necessary to
part of engine submerged inspect DTC
under water? P0128.
CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Go to step 3. Inspect DTC
tor or OBD-II general scan tool PO125, P0301,
indicate DTC PO125, P0301, P0302, P0303,
P0302, P0303, P0304, PO305 P0304, PO305 and
and PO306 at same time? PO306 using “List
of Diagnostic Trou-
ble Code (DTC)”.
<Ref. to EN(D0HC
TURBO)SO, List
of Diagnostic Trou-
ble Code (DTC).>
CHECK ENGINE COOLANT. Are coolant level and mixture Go to step 4. Replace the
ratio of cooling water to anti- engine coolant.
freeze solution correct? <Ref. to CO-25,
REPLACEMENT,
Engine Coolant.>
CHECK RADIATOR FAN. Does the radiator fan continu- Repair radiator fan Replace the ther-
1)Start the engine. ously rotate for more than 3 Zircuit. <Ref. to mostat. <Ref. to
2)Check radiator fan operation. minutes during idling? EO-46, Radiator GO-35, Thermo-
Main Fan and Fan stat.>
Motor.> and <Ref.
to CO-48, Radiator
Sub Fan and Fan
Motor.>
EN(D0HC TURBO)-142
1
-
U: DTC PO131 - FRONT OXYGEN (NF) SENSOR CIRCUIT RANGUPERFOR-

MANCE PROBLEM (LOW INPUT) -
NOTE:
I For the diagnostic procedure, refer to DTC P0132. <Ref. to EN(D0HC TURBO)-144, DTC PO132 - FRONT
OXYGEN (NF)SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT) -, Diagnostic
EN(D0HC TURBO)-143
-
V: DTC PO132 - FRONT OXYGEN (NF) SENSOR CIRCUIT RANGWPERFOR-

MANCE PROBLEM (HIGH INPUT) -
CAUTION:
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:
EN1143
EN(D0HC TURBO)-I44
ENGl N E (DIAGNOSTICS)
~
Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. loes the Subaru Select Moni- nspect DTC Go to step 2.
or or OBD-ll general scan tool J0031, P0032,
ndicate DTC P0031, P0032, J1131, P1134or
J1131. Pi134or P1139? J1 139 using “List
if Diagnostic Trou-
)le Code
DTC)”.<Ref. to
!N(DOHC
rURBO)-80, List
ile Code (DTC).>
CHECK FRONT (NF) OXYGEN SENSOR DA- s the value equal to or more 20 to step 3. Go to step 4.
TA. han 0.85 and equal to less
1)Start the engine. han 1.15 in idling?
2)While observing the Subaru Select Monitor
or OBD-ll general scan tool screen, warm-up
the engine until coolant temperature is above
70°C (158°F).
If the engine is already warmed-up, operate at
idle speed for at least 1 minute.
3)Read the data of front oxygen (NF) sensor
signal using Subaru Select Monitor or OBD-ll
general scan tool.
NOTE:
*Subam Select Monitor
itor.>
CHECK REAR OXYGEN SENSOR SIGNAL. loes the LED of {Rear 0 2 3epair poor con- Check rear oxyger
1)Race the engine at speeds from idling to 3ich Signal} blink? act in front oxygen sensor circuit.
5,000 rpm for a total of 5 cycles. N F ) sensor and <Ref. to FU(D0HC
NOTE: ‘ear oxygen sen- TURBO)-44, Rear
To increase engine speed to 5,000 rpm, slowly ;or connector. Oxygen Sensor.>
depress accelerator pedal, taking approximate-
ly 5 seconds, and quickly release accelerator
pedal to decrease engine speed.
2)Operate the LED operation mode for engine.
NOTE:
“LED OPERATION MODE FOR ENGINE.
<Ref. to EN(D0HC TURBO)-38, Subaru
Select Monitor.>
CHECK EXHAUST SYSTEM. s there a fault in exhaust sys- 3epair or replace Replace the front
Check exhaust system parts. em? aulty parts. oxygen (NF) sen-
NOTE: sor. <Ref. to
Check the following items. FU(D0HC
*Loose installation of portions TURBO)-42, Fron
. *Damage (crack, hole etc.) of parts Oxygen (NF)Sen
*Looseness of front oxygen (NF) sensor sor.>
*Looseness and ill fitting of parts between front
oxygen (NF) sensor and rear oxygen sensor
1
EN(D0HC TURBO)-145
W: DTC PO133 - FRONT OXYGEN (NF)SENSOR CIRCUIT SLOW RESPONSE

-
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
AIN RELAY BATTERY
RFRONTOXYGEN
EN1143
EN(D0HC TURBO)-146
Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. Ioes the Subaru Select Moni- Inspect DTC I Go to step 2.
or or OBD-ll general scan tool P0031, P0032,
idicate DTC P0031, P0032, PO131, PO132,
)0131, PO132, P1130, P1131, P1130, P1131,
V134 or P1139? P1134or P1139
using “List of Diag-
nostic Trouble
Code (DTC)”.
<Ref. to EN(D0HC
TURBO)-80, List
of Diagnostic Trow
ble Code (DTC).>
NOTE:
In this case, it i$
not necessary tc
inspect DTC
PO133.
! CHECK EXHAUST SYSTEM. s there a fault in exhaust sys- Repair exhaust Replace the front
NOTE: em? system. oxygen (NF) sen-
Check the following items. sor. <Ref. to
*Loose installation of front portion of exhaust FU(D0HC
pipe onto cylinder heads TURBO)-42, Front
*Loose connection between front exhaust pipe Oxygen (NF) Sen-
and front catalytic converter sor.>
*Damage of exhaust pipe resulting in a hole
EN(D0HC TURBO)-147
r
ENGINE DlAG NOSTICS)
X: DTC PO136 - REAR OXYGEN SENSOR CIRCUIT MALFUNCTION -

CAUTION:
tion Mode.>.
WIRING DIAGRAM:
AIN RELAY BATTERY
OXYGEN SENSOR
3:@
EN1144
Step Check
1 . CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni-
tor or OBD-II general scan tool
indicate DTC PO131 or PO132? I I
EN(D0HC TURBO)-148
Step Check Yes No

CHECK FAILURE CAUSE OF PO131 or ;the failure cause of PO131 or ;heck fuel system. ;o to step 3.
PO132. ‘0132 in the fuel system? \IOTE:
Inspect DTC PO131 or PO132 using “List of n this case, it is
Diagnostic Trouble Code (DTC)”. <Ref. to lot necessary to
EN(D0HC TURBO)-80, List of Diagnostic nspect DTC
Trouble Code (DTC).> ’01 36.
CHECK REAR OXYGEN SENSOR DATA. boes the value fluctuate? 30 to step 7 . io to step 4.
1)Warm-upthe engine until engine coolant
temperature is above 70°C (158”F), and keep
the engine speed at 2,000 rpm to 3,000 rpm for
two minutes.
2)Read the data of rear oxygen sensor signal
scan tool.
NOTE:
OSubaru Select Monitor
“READ CURRENT DATA SHOWN ON DIS-
PLAY FOR ENGINE”. <Ref. to EN(D0HC
TURBO)-38, Subaru Select Monitor.>
.OBD-ll general scan tool
OBD-I1 General Scan Tool Instruction Manual.
CHECKREAROXYGENSENSORDATA. s the value fixed between 0.2 30 to step 5. 3eplace the rear
Read the data of rear oxygen sensor signal Ind 0.4 V? )xygen sensor.
using Subaru Select Monitor or OBD-II Gen- :Ref. to FU(D0HC
eral Scan Tool. rURBO)-44, Rear
lxygen Sensor.>
CHECK HARNESS BETWEEN ECM AND ;the resistance more than 3 Repair open circuit 30 to step 6.
REAROXYGENSENSORCONNECTOR. 2? n harness
1)Turn the ignition switch to OFF. Detween ECM and
2)Disconnectthe connectors from ECM and rear oxygen sen-
rear oxygen sensor. sor connector.
ECM and rear oxygen sensor connector.
(6135) NO. 26 - (B19) NO. 4:
CHECKHARNESSBETWEENREAROXY- 5 the voltage more than 0.2 V I Replace the rear 3epair harness
GEN SENSOR AND ECM CONNECTOR. oxygen sensor. md connector.
1)Turn the ignition switch to OFF. <Ref. to FU(D0HC \IOTE:
2)Disconnect the connector from rear oxygen TURBO)-44, Rear n this case, repai
sensor. Oxygen Sensor.> he following:
3)Turn the ignition switch to ON. 1 Open circuit in
4)Measure voltage between rear oxygen sen- iarness between
sor harness connector and engine ground or ‘ear oxygen sen-
chassis ground. ;or and ECM con-
Connector & terminal lector
(B19) No. 3 (+) - Engine ground (-): 1 Poor contact in
‘ear oxygen sen-
jot‘ connector
1 Poor contact in
X M connector
- CHECK EXHAUST SYSTEM. s there a fault in exhaust sys- Repair or replace 3eplace the rear
Check exhaust system parts. em? faulty parts. ixygen sensor.
NOTE: :Ref. to FU(D0HC
Check the following items. TURBO)-44, Rear
*Loose installation of portions 3xygen Sensor.>
.Damage (crack, hole etc.) of parts
.Looseness and ill fitting of parts between front
oxygen (NF) sensor and rear oxygen sensor
EN(D0HC TURBO)-I49
Y: DTC PO139 - REAR OXYGEN SENSOR CIRCUIT SLOW RESPONSE -

CAUTION:
tion Mode.>.
WIRING DIAGRAM:
41N RELAY BATTERY
EN1144
EN(D0HC TURBO)-150
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Replace the rear
tor or OBD-ll general scan tool PO136 using “List oxygen sensor.
indicate DTC PO136? of Diagnostic Trou- <Ref. to FU(D0HC
ble Code (DTC)”. TURBO)-44, Rear
<Ref. to EN(D0HC Oxygen Sensor.>
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
PO1 39.
EN(D0HC TURBO)-151
m
I
~~ ~
2: DTC PO171 - FUEL TRIM MALFUNCTION ( N F TOO LEAN) -

NOTE:
For the diagnostic procedure, refer to DTC P0172. <Ref. to EN(D0HC TURBO)-153, DTC PO172 - FUEL
TRIM MALFUNCTION (NF TOO RICH) -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(D0HC TURBO)-152
~
AA:DTC PO172 - FUEL TRIM MALFUNCTION ( N F TOO RICH) -

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
tion Mode.>.
Step Check Yes No

CHECK EXHAUST SYSTEM. 4re there holes or loose bolts Repair exhaust Go to step 2.
i n exhaust system? system.
! CHECK AIR INTAKE SYSTEM. 4re there holes, loose bolts or Repair air intake Go to step 3.
lisconnection of hose on air system.
ntake system?
I CHECK FUEL PRESSURE. s fuel pressure between 284 Go to step 4. Repair the follow-
Warning: md 314 kPa (2.9 - 3.2 kgl ing items.
+lace “NO FIRE” signs near the working :m2, 41 - 46 psi)? Fuel pressure too
area. high
*Be careful not to spill fuel on the floor. Clogged fuel
1)Release fuel pressure. return line or bent
(1) Disconnect the connector from fuel hose
pump relay. Fuel pressure too
(2) Start the engine and run it until it stalls. low
(3) After the engine stalls, crank it for five Improper fuel
more seconds. pump discharge
(4) Turn the ignition switch to OFF. Clogged fuel
2)Connect the connector to fuel pump relay.
3)Disconnect the fuel delivery hose from fuel
filter, and connect fuel pressure gauge.
4)lnstall the fuel filler cap.
5)Start the engine and idle while gear position
is neutral.
6)Measure the fuel pressure while disconnect-
ing pressure regulator vacuum hose from
intake manifold.
Warning:
Before removing the fuel pressure gauge,
release fuel pressure.
NOTE:
If fuel pressure does not increase, squeeze fue
return hose 2 to 3 times, then measure fue
Dressure aaain.
EN(D0HC TURBO)-I53
Step Check Yes No

CHECK FUEL PRESSURE. ; fuel pressure between 206 io to step 5. 3epair the follow-
After connecting the pressure regulator vac- nd 235 kPa (2.1 - 2.4 kg/ ng items.
uum hose, measure fuel pressure. n2,30 - 34 psi)? :uel pressuretoa
iigh
Warning:
Before removing the fuel pressure gauge Faulty pressure
release fuel pressure. egulator
Clogged fuel
NOTE:
*If fuel pressure does not increase, squeeze 'eturn line or bent
fuel return hose 2 to 3 times, then measure lose
fuel pressure again. 'uel pressure toc
*If out of specificationas measured at this step, ow
check or replace pressure regulator and pres- 1 Faulty pressure
sure regulator vacuum hose. 'egulator
1 Improper fuel
lump discharge
1 Clogged fuel
supply line
CHECK ENGINE COOLANT TEMPERATURE j temperature greater than io to step 6. 3eplace the
SENSOR. 0°C (140"F)? mgine coolant
1)Start the engine and warm-up completely. emperature sen-
2)Read the data of engine coolant temperature sor. <Ref. to
sensor signal using Subaru Select Monitor or 'U( DOHC
~ B D - Igeneral
I scan tool. rURBO)-29,
Engine Coolant
NOTE:
*Subaru Select Monitor remperature Sen-
For detailed operation procedure, refer to the ;or.>
"READ CURRENT DATA FOR ENGINE. <Ref.
itor.>
CHECK PRESSURE SENSOR. jthe value within the specifi- i o to step 7. Replace the mass
1)Start the engine and warm-up engine until ations? 3ir flow and pres-
coolant temperature is greater than 60°C sure sensor. <Ref
(140°F). to FU(D0HC
2)Place the shift lever in neutral position. TURBO)-34, Mas!
3)Turn the A/C switch to OF!? Air Flow and
4)Turn all accessory switches to OFF. Intake Air Temper
5)Read the data of pressure sensor signal ature Sensor.>
using Subaru Select Monitor or OBD-ll genera
scan tool.
NOTE:
"READ CURRENT DATA FOR ENGINE. <Ref
itor.>
Specification:
. *Intake manifold absolute pressure
Ignition ON
73.3 - 106.6 kPa (550 -800 mmHg,
21.65 - 31.50 inHg)
Idling
-
24.0 - 41.3 kPa (180 310 mmHg,
7.09 - 12.20 inHg)
EN(D0HC TURBO)-154
~~
Step Check Yes No

CHECK INTAKE AIR TEMPERATURE SEN- s value obtained when ambi- Contact with SOA Check mass air
SOR. ?nttemperature is subtracted (distributor) ser- flow and intake air
1)Start the engine and warm-up engine until rom intake air temperature vice. temperature sen-
coolant temperature is greater than 60°C jreater than -10°C (14°F) and NOTE: sor. <Ref. to
(140°F). ess than 50°C (122”F)? Inspection by DTM FU(D0HC
2)Place the shift lever in neutral position. is required, be- TURBO)-34, Mass
3)Turn the A/C switch to OFF. cause probable Air Flow and
4)Turn all accessory switches to OFF. cause is deteriora- Intake Air Temper-
5)Open the front hood. tion of multiple ature Sensor.>
6)Measure the ambient temperature. parts,
7)Read the data of pressure sensor signal
scan tool.
NOTE:
I
“READ CURRENT DATA FOR ENGINE”. <Ref. I
itor.>
*OBD-I1 general scan tool
OBD-I1 General Scan Tool Instruction Manual.
EN(D0HC TURBO)-I55
1
ENG INE (DIAGNOSTICS)
AB:DTC PO181 - FUEL TEMPERATURE SENSOR A CIRCUIT RANGE/PERFOR-

MANCE PROBLEM -
CAUTION:
I tion Mode.>.
WIRING DIAGRAM:
FUEL TANK
/riiNIOgl
I
FUEL TEMPERATURE
F A: @ ECM
I U
B: @
m m
6 7 8 9 10 11 12
m6 7 8 9 10 11 12
FN11A!
EN(D0HC TURBO)-I 56
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. >oesthe Subaru Select Moni- Inspect DTC Replace the fuel
or or OBD-ll general scan tool PO182 or PO183 temperature sen-
ndicate DTC PO182 or PO183? using “List of Diag- sor. <Ref. to
nostic Trouble EC(D0HC
Code (DTC)”. TURBO)-9, Fuel
<Ref. to EN(D0HC Temperature Sen-
TURBO)SO, List sor.>
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
PO181.
EN(D0HC TURBO)-157
AC:DTC PO182 - FUEL TEMPERATURE SENSOR A CIRCUIT LOW INPUT -

CAUTION:
-
tion Mode.>.
WIRING DIAGRAM:
FUEL TANK
II
FUEL TEMPERATURE
SENSOR 1
I H
4 5 6
EN1149
I
EN(D0HC TURBO)-158
Step Check
CHECK CURRENT DATA. s the value greater than 120°C
1)Start the engine. 248"F)? up, the circuit has
2)Read the data of fuel temperature sensor returned to a nor-
signal using Subaru Select Monitor or OBD-ll mal condition at
general scan tool. this time.
NOTE:
itor.>
CHECK CURRENT DATA. s the value less than -40°C 3eplace the fuel Repair ground
1)Turn the ignition switch to OFF. -4O"F)? emperature sen- short circuit in har-
2)Remove the access hole lid. ;or. <Ref. to ness between fuel
3)Disconnect the connector from fuel pump. X(DOHC pump and ECM
4)Turn the ignition switch to ON. rURBO)-9, Fuel connector.
5)Read the data of fuel temperature sensor remperature Sen-
signal using Subaru Select Monitor or the ;or.>
N~TE:
itor.>
EN(D0HC TURBO)-159
AD:DTC PO183 - FUEL TEMPERATURE SENSOR A CIRCUIT HIGH INPUT -

CAUTION:
tion Mode.>.
WIRING DIAGRAM:
FUEL TANK
I
I FUEL TEMPERATURE
SENSOR
EN(D0HC TURBO)-I60
Step Check Yes No

CHECK CURRENT DATA. Is the value less than -40°C \Go to step 2. 3epair poor con-
1)Start the engine. (-40"F)? act.
2)Read the data of fuel temperature sensor 4OTE:
signal using Subaru Select Monitor or OBD-II n this case, repaii
general scan tool. he following:
*Subaru Select Monitor uel pump connec-
For detailed operation procedure, refer to the or
"READ CURRENT DATA FOR ENGINE". <Ref. Poor contact in
to EN(D0HC TURBO)-38, Subaru Select Mom ICM connector
itor.> ' Poor contact in
*OBD-II general scan tool :oupling connec-
For detailed operation procedures, refer to the ors
OBD-ll General Scan Tool Instruction Manual. Poor contact in
oint connector
CHECK HARNESS BETWEEN FUEL TEM- I Is the voltage more than 10 V? I fiepair battery 30 to step 3.
PERATURE SENSOR AND ECM CONNEC- short circuit in har.
TOR. ness between
1)Turnthe ignition switch to OFF. ECM and fuel
2)Remove the access hole lid. pump connector.
3)Disconnect the connector from fuel pump.
4)Measure the voltage between fuel pump
tonnector and chassis ground.
(R58) No. 5 (+) - Chassis ground (-):
CHECK HARNESS BETWEEN FUEL TEM- Is the voltage more than 10 V? 30 to step 4.
PERATURE SENSOR AND ECM CONNEC- short circuit in har,
TOR. ness between
1)Turn the ignition switch to ON. ECM and fuel
2)Measure the voltage between fuel pump pump connector.
(R58)No. 5 (+) - Chassis ground (-):
I CHECK HARNESS BETWEEN FUEL TEM- Is the voltage more than 4 V? 3epair harness
PERATURE SENSOR AND ECM CONNEC- ind connector.
TOR. \IOTE:
Measure the voltage between fuel pump con- n this case, repaii
nector and chassis ground. :he following:
Connector & terminal 1 Open circuit in
(R58) No. 5 (+) - Chassis ground (-): iarness between
ECM and fuel
x m p connector
1 Poor contact in
'uel pump connec-

:or
1 Poor contact in
X M connector
1 Poor contact in
:oupling connec-
:ors
EN(D0HC TURBO)-I61
Step Check Yes No

CHECK HARNESS BETWEEN FUEL TEM- s the resistance less than 5 Replace the fuel Repair harness
PERATURE SENSOR AND ECM CONNEC- 2? temperature sen- and connector.
TOR. sor. <Ref. to NOTE:
1)Turn the ignition switch to OFF. EC(D0HC In this case, repai
2)Measure the resistance of harness between TURBO)-9, Fuel the following:
fuel pump connector and chassis ground. Temperature Sen- Open circuit in
Connector & terminal so r.> harness between
(R58)No. 4 - Chassis ground: ECM and fuel
pump connector
Poor contact in
fuel pump connec-
tor
Poor contact in
ECM connector
Poor contact in
coupling connec-
tors
Poor contact in
joint connector
EN(D0HC TURBO)-162
EN(D0HC TURBO)-1 63
AE:DTC PO244 - WASTEGATE CONTROL SOLENOID VALVE MALFUNCTION

(HIGH INPUT) -
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
MAIN RELAY
BATTERY
n
n
5 6
@ ECM
t 71
1 1
WASTE
CONTROL
VALVE
ITE
LENOID
I
EN1150
EN(D0HC TURBO)-I64
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Replace the
tor or OBD-II general scan tool PO245 or PO246 wastegate control
indicate DTC PO245 or P0246? using “List of Diag- solenoid valve.
nostic Trouble <Ref. to FU(D0HC
Code (DTC)”. TURBO)-41,
<Ref.to EN(D0HC Wastegate Con-
TURBO)-80, List trol Solenoid
of Diagnostic Trou- Valve.>
ble Code (DTC).>
NOTE:
In this case, it is
not necessary tc
inspect DTC
P0244.
EN(D0HC TURBO)-165
-
AF:DTC PO245 - WASTEGATE CONTROL SOLENOID VALVE CIRCUIT LOW

INPUT -
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
MAIN RELAY
f
l
u & BATTERY
SBF 5
3 c
. @
I
f
WASTEGATE
CONTROL SOLENOID
VALVE
-
EN(D0HC TURBO)-166
- ~~
Step Check Yes No

CHECK OUTPUT SIGNAL FROM ECM. s the voltage more than 10 V? Even if MIL lights 20 to step 2.
1)Turn the ignition switch to ON. JP,the circuit has
2)Measure the voltage between ECM and ,eturnedto a nor-
chassis ground. nal condition at
Connector & terminal his time. Contact
(6137) No, 24 (+) - Chassis ground (-): with SOA (distribu-
or) service.
UOTE:
nspection by DTM
s required, be-
:ause probable
:ause is deteriora-
:ion of multiple
Darts.
CHECK HARNESS BETWEEN WASTEGATE s the resistance less than 10 3epair ground 30 to step 3.
CONTROL SOLENOID VALVE AND ECM 3? short circuit in har-
CONNECTOR. less between
1)Turn the ignition switch to OFF: ECM and waste-
2)Disconnect the connectors from wastegate aate control sole-
control solenoid valve and ECM. ioid valve
3)Measure the resistance of harness between Zonnector.
wastegate control solenoid valve connector
atid engine ground.
-
(8127) No, 1 Engine ground:
CHECK HARNESS BETWEEN WASTEGATE s the resistance less than 1 %loto step 4. Repair open circuij
CONTROL SOLENOID VALVE AND ECM n? in harness
CONNECTOR. between ECM and
Measure the resistance of harness between wastegate control
ECM and wastegate control solenoid valve of solenoid valve
harness connector. connector.
(8137) NO. 24 - (8127) NO. 1: In this case, repai
the following:
Open circuit in
harness between
ECM and waste-
gate control sole-
noid valve
connector
CHECK WASTEGATE CONTROL SOLE- Is the resistance between 30 Go to step 5. Replace the
NOID VALVE. m d 34 R? wastegate control
1)Remove the purge control solenoid valve. solenoid valve.
2)Measure the resistance between purge con- <Ref. to FU(D0HC
trol solenoid valve terminals. TURBO)-41,
Terminals Wastegate Con-
NO. 1 -NO. 2: trol Solenoid
Valve.>
CHECK POWER SUPPLY TO WASTEGATE Is the voltage more than 10 V? Go to step 6. Repair open circui
CONTROL SOLENOID VALVE. in harness
1)Turn the ignition switch to ON. between main
2)Measure the voltage between wastegate relay and waste-
. control solenoid valve and engine ground. gate control sole-
Connector & terminal noid valve
-
(8127) No. 2 (+) Engine ground (-): connector.
EN(D0HC TURBO)-167
I
Step Check Yes No

6 CHECK POOR CONTACT. Is there poor contact in waste- Repair poor con- Contact with SOA
Check poor contact in wastegate control sole- gate control solenoid valve tact in wastegate (distributor) ser-
connector? control solenoid vice.
valve connector. NOTE:
Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
EN(D0HC TURBO)-168
EN(D0HC TURBO)-I69
AG:DTC PO246 - WASTEGATE CONTROL SOLENOID VALVE CIRCUIT HIGH

INPUT -
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
AIN RELAY
. @
&@ ECM
WASTEGATE I
CONTROL SOLENOID
VALVE
EN(D0HC TURBO)-170
Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 10 V? Go to step 3. Go to step 2.
2)Measure the voltage between ECM and
chassis ground.
2 CHECK POOR CONTACT. Is there poor contact in ECM Repair poor con- Replace the ECM.
Check poor contact in ECM connector. connector? tact in ECM con- <Ref. to FU(D0HC
nector. TURBO)-47,
Engine Control
Module.>
3 CHECK HARNESS BETWEEN WASTEGATE Is the voltage more than 10 V? Repair battery Go to step 4.
CONTROL SOLENOID VALVE AND ECM short circuit in har-
CONNECTOR. ness between
1)Turn the ignition switch to OFF. ECM and waste-
2)Disconnect the connector from wastegate gate control sole-
control solenoid valve. noid valve
3)Turn the ignition switch to ON. connector. After
4)Measure the voltage between ECM and repair, replace the
chassis ground. ECM. <Ref. to
Connector & terminal FU(D0HC
(8137) No. 24 (+) - Chassis ground (-): TURBO)-47,
Engine Control
Module.>
4 CHECK WASTEGATE CONTROL SOLE- Is the resistance less than 1 Replace the Go to step 5.
NOlD VALVE. a? wastegate control
1)Turnthe ignition switch to OFF. solenoid valve
2)Measure the resistance between wastegate <Ref. to FU(D0HC
control solenoid valve terminals. TURBO)-41,
Terminals Wastegate Con-
NO. 1 -NO. 2: trol Solenoid
Valve.> and ECM
<Ref. to FU(D0HC
TURBO)-47,
Engine Control
Module.>
5 CHECK POOR CONTACT. Is there poor contact in ECM Repair poor con- Replace the ECM.
Check poor contact in ECM connector. connector? tact in ECM con- <Ref. to FU(D0HC
nector. TURBO)-47,
Engine Control
Module.>
EN(D0HC TURBO)-I71
AH:DTC PO301 - CYLINDER 1 MISFIRE DETECTED -

NOTE:
For the diagnostic procedure, refer to DTC P0304. <Ref. to EN(D0HC TURBO)-173, DTC PO304 - CYLIN-
DER 4 MISFIRE DETECTED -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AI: DTC PO302 - CYLINDER 2 MISFIRE DETECTED -

NOTE:
AJ:DTC PO303 - CYLINDER 3 MISFIRE DETECTED -

NOTE:
EN(D0HC TURBO)-172
-
AK:DTC PO304 - CYLINDER 4 MISFIRE DETECTED -

Immediately at fault recognition (A misfire which could damage catalyst occurs.)
TROUBLE SYMPTOM:
Engine stalls.
Erroneous idling
Rough driving
CAUTION:
tion Mode.>.
EN(D0HC TURBO)-173
WIRING DIAGRAM:
MAIN RELAY
SBF-5
3 c
FUEL INJECTORS
M
EN1142
EN(D0HC TURBO)-174
Step Check Yes No
Does the Subaru Select Moni- Inspect DTC Go to step 2.
CHECK ANY OTHER DTC ON DISPLAY.
tor or OBD-II general scan tool P0106, P0107,
indicate DTC P0106, P0107, P0108, P0117,
PO108, PO117, PO118 or PO118 or PO125
PO125? using “List of Diag.
nostic Trouble
Code (DTC)”.
<Ref. to EN(D0HC
TURBO)-80, List
of Diagnostic Trou,
ble Code (DTC).>
NOTE:
In this case, it i!
not necessary c t
inspect DT(
P0301, PO302
PO303 and PO304
Is the voltage more than 10 V? Go to step 7. ;o to step 3.
CHECK OUTPUT SIGNAL FROM ECM.
tor and chassis ground on faulty cylinders.
#1 (6137) No. 1 (+) - Chassis
ground (-):
#2 (6136) No,6 (+) - Chassis
ground (-):
#3 (8136) No. 5 (+) - Chassis
ground (-):
#4 (6136) No. 4 (+) - Chassis
I .,
around (-1:
3epair ground 30 to step 4.
CHECK HARNESS BETWEEN FUEL INJEC- Is the resistance less than 10
TOR AND ECM CONNECTOR. R? ;hort circuit in ha1
less between fue
1)Turn the ignition switch to OFF.
njector and ECM
2)Disconnect the connector from fuel injector
:onnector.
on faulty cylinders.
3)Disconnect the connector from ECM.
tor and engine ground on faulty cylinders.
-
#1 (€5) No. 1 (+) Engine ground (-):
#2 (€16) No. 1 (+) - Engine ground (-):
#3 (E6) No. 1 (+) - Engine ground (-):
#4 (El 7) No. 1 (+) - Engine ground (-):
Is the resistance less than 1 Go to step 5. Repair harness
I CHECK HARNESS BETWEEN FUEL INJEC-
Q? and connector.
TOR AND ECM CONNECTOR.
Measure the resistance of harness connector NOTE:
In this case, rep?
between ECM connector and fuel injector on
the following:
faulty cylinders.
Open circuit in
harness between
#1 (6137) NO. 1 -(E5) NO. 1:
ECM and fuel
#2 (8136) NO. 6 - (E16) NO. 1:
injector connect0
#3 (8136) NO. 5 - (E6) NO. 1:
Poor contact in
#4 (6136) NO. 4 - (E17) NO. 1:
coupling connect
Is the resistance between 5 Go to step 6. Replace the faulty
5 CHECK FUEL INJECTOR. fuel injector. <Ref.
Measure the resistance between fuel injector and 20 R?
to FU(D0HC
terminals on faulty cylinder.
TURBO)-37, Fuel
Terminals
Injector.>
NO. 1 - NO. 2: 1
EN(D0HC TURBO)-175
Step Check Yes No

I CHECK POWER SUPPLY LINE. Is the voltage more than 10 V? 3epair poor con- Repair harness
1)Turnthe ignition switch to ON. act in all connec- and connector.
ors in fuel injector NOTE:
:ircuit. In this case, repa
the following:
Open circuit in
harness between
main relay and fue
injector connector
on faulty cylinders
Poor contact in
coupling connectc
Poor contact in
main relay connec
tor
Poor contact in
fuel injector con-
nector on faulty
cylinders
CHECK HARNESS BETWEEN FUEL INJEC- Is the voltage more than 10 V? 3epair battery Go to step 8.
TOR AND ECM CONNECTOR. ;hort circuit in har-
1)Turn the ignition switch to OFF. less between
2)Disconnect the connector from fuel injector ICM and fuel
on faulty cylinder. njector. After
3)Turn the ignition switch to ON. epair, replace the
4)Measure the voltage between ECM connec- ICM. <Ref. to
tor and chassis ground on faulty cylinders. W(D0HC
Connector & terminal rURBO)-47,
#1 (8137) No. 1 (+) - Chassis Ingine Control
groundI)-( vlodu1e.B
#2 (8136) No. 6 (+) - Chassis
ground (-):
#3 (8136) No. 5 (+) - Chassis
ground (-):
#4 (8136) NO. 4 (+) - Chassis
ground (-):
I CHECK FUEL INJECTOR. 3eplace the faulty Go to step 9.
Is the resistance less than 1
1)Turn the ignition switch to OFF. R? uel injector <Ref.
2)Measure the resistance between fuel injector o FU(D0HC
terminals on faulty cylinder. rURBO)-37, Fuel
Terminals njector.> and
NO. 1 -NO. 2: ICM <Ref. to
W(D0HC
rURBO)-47,
Ingine Control
vlodule.>
1 CHECK INSTALLATION OF CAMSHAFT PO- Is the camshaft position sensor righten camshaft Go to step 10.
SlTlON SENSOWCRANKSHAFTPOSITION or crankshaft position sensor iosition sensor or
SENSOR. loosely installed? :rankshaft posi-
ion sensor.
10 CHECK CRANKSHAFT SPROCKET. Is the crankshaft sprocket 3eplace the crank- Go to step 11.
Remove the timing belt cover. rusted or does it have broken ;haft sprocket.
teeth? :Ref. to
vlE(D0HC
rURBO)-58,
;rankshaft
Sprocket.>
EN(D0HC TURBO)-I76
m
~
Step Check Yes No

1 CHECK INSTALLATION CONDITION OF 5 the timing belt dislocated Repair installation 30 to step 12.
TIMING BELT. rom its proper position? condition of timing
Turn the crankshaft using ST, and align align- belt. <Ref. to
ment mark on crankshaft sprocket with align- ME(D0HC
ment mark on cylinder block. TURBO)-48, Tim-
ST 499987500 CRANKSHAFT SOCKET ing Belt Assem-
bly.>
2 CHECK FUEL LEVEL. s the fuel meter indication Go to step 13. Replenish fuel so
bigher than the “Lower” level? bel meter indica-
tion is higher than
the “Lower” level.
After replenishing
fuel, Go to step 13
3 CHECK STATUS OF CHECK ENGINE MAL- s the MIL coming on or blink- Go to step 15. So to step 14.
FUNCTION INDICATOR LAMP (MIL). ng?
1)Clear the memory using Subaru Select Mon-
itor.
<Ref. to EN(D0HC TURBO)-49, Clear Mem-
ory Mode.>
2)Start the engine, and drive the vehicle more
than 10 minutes.
4 CHECK CAUSE OF MISFIRE DIAGNOSED. Mas the cause of misfire diag- Finish diagnostics Repair poor con-
iosed when the engine is run- operation, if the tact.
ling? engine has no NOTE:
abnormality. In this case, repai
NOTE: the following:
Ex. Remove the Poor contact in
spark plug cord, ignitor connector
etc. Poor contact in
ignition coil con-
nector
Poor contact in
fuel injector con-
nector on faulty
cylinders
Poor contact in
ECM connector
Poor contact in
coupling connectc
5 CHECK AIR INTAKE SYSTEM. s there a fault in air intake sys Repair air intake Go to step 16.
em? system.
NOTE:
Check the follow.
ing items:
Are there air
leaks or air suction
caused by loose or
dislocated nuts
and bolts?
Are there cracks
or any disconnec-
tion of hoses?
EN(D0HC TURBO)-177
Step Check Yes No

6 CHECK MISFIRE SYMPTOM. 30 to step 17.
1)Turn the ignition switch to ON. tor or OBD-ll general scan tool
2)Read the diagnostic trouble code (DTC). indicate only one DTC?
<Ref. to EN(D0HC TURBO)-38, Subaru
Select Monitor.>
OBD-ll General Scan Tool Operation Manual.
NOTE:
Perform diagnosis according to the items listec
below.
7 CHECK DIAGNOSTIC TROUBLE CODE Does the Subaru Select Moni- Go to step 22. 30 to step 18.
(DTC) ON DISPLAY. tor or OBD-ll general scan tool
indicate DTC PO301 and
P0302?
(DTC) ON DISPLAY. tor or OBD-II general scan tool
P0304?
(DTC) ON DISPLAY. tor or OBD-ll general scan tool
P0303?
(DTC) ON DISPLAY. tor or OBD-I1 general scan tool
P0304?
1 ONLY ONE CYLINDER Is there a fault in that cylinder? Repair or replace 30 to DTC PO171
faulty parts. md P0172. <Ref.
NOTE: o EN(D0HC
Check the follow- rURBO)-152,
ing items. ITC PO171 -
Spark plug 'UEL TRIM MAL-
Spark plug cord UNCTION (NF
Fuel injector '00 LEAN) -,
Compression Iiagnostic Proce-
ratio lure with Diagnos
ic Trouble Code
DTC).>
EN(D0HC TURBO)-178
a
Step Check Yes No

!2 GROUP OF #1 AND #2 CYLINDERS 4re there faults in #1 and #2 Repair or replace Go to DTC PO171
:ylinders? faulty parts. and P0172. <Ref.
NOTE: to EN(D0HC
Check the fol- TURBO)-152,
lowing items. DTC PO171 -
Spark plugs FUEL TRIM MAL-
Fuel injectors FUNCTION ( N F
Ignition coil TOO LEAN) -,
Compres- Diagnostic Proce-
sion ratio dure with Diagnos-
If no abnormal is tic Trouble Code
discovered, check (DTC).>
for “IGNITION
CONTROL SYS-
TEM” of #1 and #2
cylinders side.
<Ref. to EN(D0HC
TURBO)-72, IGNI-
TION CONTROL
SYSTEM, Diag-
nostics for Engine
Starting Failure.>
23 GROUP OF #3 AND #4 CYLINDERS Ire there faults in #3 and #4 Repair or replace Go to DTC PO171
:ylinders? faulty parts. and P0172. <Ref.
NOTE: to EN(D0HC
Check the fol- TURBO)-152,
lowing items. DTC PO171 -
Fuel injectors FUNCTION (NF
Ignition coil TOO LEAN) -,
If no abnormal is Diagnostic Proce-
discovered, check dure with Diagnos-
for “IGNITION tic Trouble Code
CONTROL SYS- (DTC).>
TEM” of #3 and #4
cylinders side.
<Ref. to EN(D0HC
TURBO)-72, IGNI-
TION CONTROL
SYSTEM, Diag-
nostics for Engine
Starting Failure.>
24 GROUP OF #1 AND #3 CYLINDERS 4re there faults in #1 and #3 Repair or replace Go to DTC PO171
:ylinders? faulty parts. and PO172. <Ref.
NOTE: to EN(D0HC
Check the follow- TURBO)-152,
ing items. DTC PO171 -
Skipping timing TOO LEAN) -,
belt teeth Diagnostic Proce-
dure with Diagnos
tic Trouble Code
(DTCb
EN(D0HC TURBO)-I79
Step Check Yes No

!5 GROUP OF #2 AND #4 CYLINDERS Are there faults in #2 and #4 Repair or replace Go to DTC PO171
cylinders? faulty parts. and P0172. <Ref.
NOTE: to EN(D0HC
Check the follow- TURBO)-152,
ing items. DTC PO171 -
Compression TOO LEAN) -,
ratio Diagnostic Proce-
Skipping timing dure with Diagnos-
belt teeth tic Trouble Code
(DTC).>
!6 CYLINDER AT RANDOM Is the engine idle rough? Go to DTC PO171 Repair or replace
and P0172. <Ref. faulty parts.
to EN(D0HC NOTE:
TURBO)-152, Check the follow.
DTC PO171 - ing items.
FUEL TRIM MAL- Spark plugs
FUNCTION ( N F Fuel injectors
TOO LEAN) -, Compression
Diagnostic Proce- ratio
dure with Diagnos-
tic Trouble Code
(DTC).>
EN(D0HC TURBO)-I80
EN(D0HC TURBO)-181
ENGlNE (DIAGNOSTICS)
AL:DTC PO327 - KNOCK SENSOR CIRCUIT LOW INPUT -

TROUBLE SYMPTOM:
Knocking occurs.
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
KNOCK
SENSOR
,I,I-
c -1
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
t
I
L:
I
-
4
I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I
t
h @ECM
EN0975
EN(D0HC TURBO)-182
~ ~~
Step Check Yes No

CHECK HARNESS BETWEEN KNOCK SEN- s the resistance more than 20 to step 2. Repair harness
SOR AND ECM CONNECTOR. 700 kR? and connector.
2)Disconnect the connector from ECM. In this case, repaii
3)Measure the resistance between ECM har- the following:
ness connector and chassis ground. Open circuit in
(8135) No. 4 - Chassis ground: knock sensor and
ECM connector
Poor contact in
knock sensor con-
nector
Poor contact in
coupling connectoi
! CHECK KNOCK SENSOR. s the resistance more than 30 to step 3. Repair harness
1)Disconnectthe connector from knock sensor 700 kR? and connector.
2)Measure the resistance between knock sen- NOTE:
sor connector terminal and engine ground. In this case, repai
Terminal the following:
No. 2 - €ngine ground: Open circuit in
harness between
knock sensor and
ECM connector
Poor contact in
knock sensor con-
nector
Poor contact in
coupling connect0
I CHECK CONDITION OF KNOCK SENSOR Is the knock sensor installation 3eplace the knock Tighten knock sen
INSTALLATION. solt tightened securely? sensor. <Ref. to sor installation bolt
W(D0HC securely.
TURBO)-32,
h o c k Sensor.>
EN(D0HC TURBO)-I83
~ ~~
AM:DTC PO328 - KNOCK SENSOR CIRCUIT HIGH INPUT -

TROUBLE SYMPTOM:
Knocking occurs.
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
KNOCK
SENSOR
I@
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I
I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I
I
i
@ECM
EN0975
EN(D0HC TURBO)-184
I
Step Check
CHECK HARNESS BETWEEN KNOCK SEN- Is the resistance less than 400
SOR AND ECM CONNECTOR. kR?
Measure the resistance of harness between
! CHECK KNOCK SENSOR. Is the resistance less than 400 Replace the knock Repair ground
1)Disconnectthe connector from knock sensor. kR? sensor. <Ref. to short circuit in har
FU(D0HC ness between
TURBO)-32, knock sensor con-
Knock Sensor.> nector and ECM
connector.
NOTE:
The harness be
tween both con
nectors i!
shielded. Repai
short circuit of har
ness together witt
shield.
I CHECK INPUT SIGNAL FOR ECM. s the voltage more than 2 V? Even if MIL lights Repair poor con-
1)Connect the connectors to ECM and knock up, the circuit has tact in ECM con-
sensor. returned to a nor- nector.
chassis ground.
EN(D0HC TURBO)-185
I
AN:DTC PO335 - CRANKSHAFT POSITION SENSOR CIRCUIT MALFUNCTION

-
immediately at fault recognition
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
n
CRANKSHAFT
E
POSITION
SENSOR
c
I
I
I
I
I
I
I
I
t
I
F
I
I
I
I
I
I
t
IC
0@ECM
EN097f
EN(D0HC TURBO)-186
Step Check Yes No

CHECK HARNESS BETWEEN CRANK- s the resistance more than Repair harness 30 to step 2.
SHAFT POSITION SENSOR AND ECM CON- 100 kR? and connector.
NECTOR. NOTE:
2)Disconnect the connector from crankshaft the following:
position sensor. Open circuit in
crankshaft position sensor connector and crankshaft posi-
engine ground. tion sensor and
Connector & terminal ECM connector
(E10) No. 1 - Engine ground: Poor contact in
ECM connector
Poor contact in
coupling connectoi
CHECK HARNESS BETWEEN CRANK- s the resistance less than 10 Repair ground 30 to step 3.
SHAFT POSITION SENSOR AND ECM CON- 2? short circuit in har-
NECTOR. ness between
Measure the resistance of harness between crankshaft posi-
crankshaft position sensor connector and tion sensor and
engine ground. ECM connector.
(€10) No. 1 - Engine ground: The harness be-
tween both con-
nectors are
shielded. Repaii
ground short circuii
in harness togeth-
er with shield.
CHECK HARNESS BETWEEN CRANK- s the resistance less than 5 Go to step 4. 3epair harness
SHAFT POSITION SENSOR AND ECM CON- 2? 2nd connector.
NECTOR. IOTE:
Measure the resistance of harness between n this case, repaii
crankshaft position sensor connector and he following:
engine ground. I Open circuit in
Connector & terminal iarness between
(E10) No. 2 - Engine ground: :rankshaft posi-
ion sensor and
ICM connector
1 Poor contact in
ECM connector
1 Poor contact in
:oupling connectoi
CHECK CONDITION OF CRANKSHAFT PO- s the crankshaft position sen- Go to step 5. righten the crank-
SITION SENSOR. ;or installation bolt tightened ;haft position sen-
securely? ;or installation bolt
securely.
I CHECK CRANKSHAFT POSITION SENSOR. 3eplace the crank.
1)Remove the crankshaft position sensor. 2nd 4 kR? tact in crankshaft ;haft position sen-
2)Measure the resistance between connector position sensor ;or. <Ref. to
terminals of crankshaft position sensor. connector. U(D0HC
Terminals rURBO)-30,
NO. 1 -NO. 2: 2 rankshaft Posi-
I ion Sensor.>
EN(D0HC TURBO)-187
A0:DTC PO336 - CRANKSHAFT POSITION SENSOR CIRCUIT RANGE/PER-

FORMANCE PROBLEM -
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
CRANKSHAFT
POSITION
SENSOR
I
I I
EN097(
EN(D0HC TURBO)-I88
Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Go to step 2.
tor or OBD-ll general scan tool PO335 using “List
indicate DTC P0335? of Diagnostic Trou-
ble Code (DTC)”.
<Ref.to EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
I
CHECK CONDITION OF CRANKSHAFT PO- Is the crankshaft position sen- Go to step 3. Tighten crank-
SITION SENSOR. sor installation bolt tightened shaft position sen-
Turn the ignition switch to OFF. securely? sor installation bolt
securely.
I CHECK CRANKSHAFT SPROCKET. Are crankshaft sprocket teeth Replace the crank- Go to step 4.
Remove the front belt cover. cracked or damaged? shaft sprocket.
<Ref. to FU(D0HC
TURBO)-30,
Crankshaft Posi-
tion Sensor.>
I CHECK INSTALLATION CONDITION OF Is the timing belt dislocated Repair installation Replace the crank-
TIMING BELT. from its proper position? condition of timing shaft position sen-
Turn the crankshaft using ST, and align align- belt. <Ref. to sor. <Ref. to
ment mark on crankshaft sprocket with align- ME(D0HC FU(D0HC
ment mark on cylinder block. TURBO)-48, Tim- TURBO)-30,
ST 499987500 CRANKSHAFT SOCKET ing Belt Assem- Crankshaft Posi-
bly.> tion Sensor.>
EN(D0HC TURBO)-189
AP:DTC PO340 - CAMSHAFT POSITION SENSOR CIRCUIT MALFUNCTION -

TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
nCAMSHAFT
POSITION
tr
SENSOR
j@
F I
I I
I I
I I
I I
I I
I I
I I
I I
t
1
I
F I
I
I I
I I
I I
\
I I
I I
t
F
U@ECM
EN097
EN(D0HC TURBO)-190
Step Check Yes No

CHECK HARNESS BETWEEN CAMSHAFT ;the resistance more than Repair harness Go to step 2.
POSITION SENSOR AND ECM CONNEC- 00 kR? and connector.
TOR. NOTE:
1)Turn the ignition switch to OFF. In this case, repair
2)Disconnect the connector from camshaft the following:
position sensor. * Open circuit in
camshaft position sensor connector and camshaft position
engine ground. sensor and ECM
(€15) No. 1 - Engine ground: * Poor contact in
ECM connector
Poor contact in
coupling connector
! CHECK HARNESS BETWEEN CAMSHAFT s the resistance less than 10 Repair ground Go to step 3.
POSITION SENSOR AND ECM CONNEC- L?
TOR.
camshaft position sensor connector and
engine ground.
I CHECK HARNESS BETWEEN CAMSHAFT s the resistance less than 5 Go to step 4. Repair harness
POSITION SENSOR AND ECM CONNEC- 2? and connector.
TOR. NOTE:
Measure the resistance of harness between In this case, repai
camshaft position sensor connector and the following:
engine ground. Open circuit in
(E15) No. 2 - Engine ground: camshaft position
sensor and ECM
connector
Poor contact in
ECM connector
Poor contact in
coupling connect0
1 CHECK CONDITION OF CAMSHAFT POSI- s the camshaft position sensor Go to step 5. Tighten camshaft
TION SENSOR. nstallation bolt tightened position sensor
jecurely? installation bolt
securely.
5 CHECK CAMSHAFT POSITION SENSOR. s the resistance between 1 Repair poor con- Replace the cam-
1)Remove the camshaft position sensor. md 4 kR? tact in camshaft shaft position sen.
2)Measure the resistance between connector position sensor sor. <Ref. to
terminals of camshaft position sensor. connector. FU(D0HC
Terminals TURBO)-31, Cam
NO. 1 - NO. 2: shaft Position Sen
sor.>
EN(D0HC TURBO)-191
a
AQ:DTC PO341 - CAMSHAFT POSITION SENSOR CIRCUIT RANGE/PERFOR-

MANCE PROBLEM -
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
CAMSHAFT
POSITION
SENSOR
h
E
I
I
I
I
I
I
I
I
t
1
F
I
I
I
I
I
I
t
IC
I@ECM
ENO97;
EN(D0HC TURBO)-I92
ENGINE ID1AGNOSTICS)
Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Go to step 2.
tor or OBD-I1 general scan tool PO340 using “List
ble Code (DTC)”.
<Ref. to EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
CHECK HARNESS BETWEEN CAMSHAFT 1 Is the resistance more than Repair harness Go to step 3.
POSITION SENSOR AND ECM CONNEC- 100 kR? and connector.
TOR. NOTE:
1)Turnthe ignition switch to OFF. In this case, repair
2)Disconnect the connector from camshaft the following:
position sensor. Open circuit in
+
camshaft position sensor connector and camshaft position
engine ground. sensor and ECM
(€15) No. 1 - Engine ground: Poor contact in
ECM connector
Poor contact in
coupling connector
I CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than 10 Repair ground Go to step 4.
POSITION SENSOR AND ECM CONNEC- short circuit in har-
TOR. ness between
Measure the resistance of harness between camshaft position
camshaft position sensor connector and sensor and ECM
engine ground. connector.
(€75) No, 1 - Engine ground: I The harness be-
tween both con-
nectors are
shielded. Repair
ground short circuit
in harness togeth-
er with shield.
I CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than 5 Go to step 5. Repair harness
POSITION SENSOR AND ECM CONNEC- Q? and connector.
NOTE:
In this case, repai
the following:
Open circuit in
harness between
camshaft position
sensor and ECM
connector
Poor contact in
ECM connector
Poor contact in
coupling
. - connect0
securely? installation bolt

securely.
EN(D0HC TURBO)-I93
i DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
Step Check Yes No

CHECK CAMSHAFT POSITION SENSOR. Is the resistance between 1 Go to step 7. Replace the cam-
1)Remove the camshaft position sensor. and 4 kR? shaft position sen-
2)Measure the resistance between connector sor. <Ref. to
terminals of camshaft position sensor. FU(D0HC
Terminals TURBO)-31, Cam-
NO. 1 -NO. 2: shaft Position Sen-
sor.>
CHECK CONDITION OF CAMSHAFT POSI- Is the camshaft position sensor Go to step 8. Tighten camshaft
TlON SENSOR. installation bolt tightened position sensor
Turn the ignition switch to OFF. securely? installation bolt
securely.
CHECK CAMSHAFT SPROCKET. Are camshaft sprocket teeth Replace the cam- Go to step 9.
Remove the front belt cover. <Ref. to cracked or damaged? shaft sprocket.
ME(S0HC)-46, Belt Cover.> <Ref. to
ME(D0HC
TURBO)-57, Cam-
shaft Sprocket.>
CHECK INSTALLATION CONDITION OF Is the timing belt dislocated Repair installation Replace the cam-
TIMING BELT. from its proper position? condition of timing shaft position sen-
Turn the camshaft using ST, and align align- belt. <Ref. to sor. <Ref. to
ment mark on camshaft sprocket with align- ME(D0HC FU(D0HC
ment mark on timing belt cover LH. TURBO)-48, Tim- TURBO)-31, Cam-
ST 499207100 CAMSHAFT SPROCKET ing Belt Assem- shaft Position Sen-
WRENCH bly.> sor.>
EN(D0HC TURBO)-I 94
EN(D0HC TURBO)-I95
AR:DTC PO420 - CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD -

TROUBLE SYMPTOM:
Engine stalls.
Idle mixture is out of specifications.
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
I T
43
F
1
0 :o0
8: 8135 C 8136 D: 8137 ECM
I
EN1151
EN(D0HC TURBO)-I96
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. )oes the Subaru Select Moni- nspect the rele- 20 to step 2.
i r or OBD-ll general scan tool rant DTC using
idicate DTC P0031, P0032, List of Diagnostic
'0131, P0132, P0133, P1130, rrouble Code
'1 131, P1134, P1139, P0037, DTC)". <Ref. to
'0038, PO136 and PO139? EN(D0HC
rURBO)-80, List
If Diagnostic Trou-
)le Code (DTC).>
\IOTE:
n this case, it is
lot necessary to
nspect DTC
'0420.
2 CHECK EXHAUST SYSTEM. s there a fault in exhaust sys- 3epair or replace ;o to step 3.
Check for gas leaks or air suction caused by em? he exhaust sys-
loose or dislocated nuts and bolts, and open em. <Ref. to
hole at exhaust pipes. IX(D0HC
NOTE: rURBO)-2, Gen-
Check the following positions. ?ral Description.>
*Between cylinder head and front exhaust pipe
*Between front exhaust pipe and front catalytic
converter
*Between front catalytic converter and rear cat-
alytic converter
3 CHECK REAR CATALYTIC CONVERTER. s there damage at rear face of 3eplace the front o
; to step 4.
Separate rear catalytic converter from rear ear catalyst? :atalytic converter
<Ref.to EC(D0HC
TURBO)-3, Front
Satalytic Con-
terter.> and rear
:atalytic converter
<Ref.to EC(D0HC
TURBO)-4, Rear
Catalytic Con-
werter.>
4 CHECK FRONT CATALYTIC CONVERTER. s there damage at rear face or Replace the front Contact with SOA
Remove the front catalytic converter. ront face of front catalyst? catalytic con- (distributor) ser-
verter. <Ref. to vice.
EC(D0HC NOTE:
TURBO)-3, Front Inspection by DTL
Catalytic Con- is required, be
ve rter.z cause probabl,
cause is deteriora
tion of multipl'
parts.
EN(D0HC TURBO)-197
a
EN(D0HC TURBO)-I98
ls
AS:DTC PO442 - EVAPORATIVE EMISSION CONTROL SYSTEM MALFUNC-

TION -
TROUBLE SYMPTOM:
Gasoline smell
There is a hole of more than 1 .O mm (0.04 in) dia. in evaporation system or fuel tank.
CAUTION:
49,Operation.> OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-
46, Inspection Mode.>.
EN(D0HC TURBO)-I 99
I
WIRING DIAGRAM:
-
- - -
-
Ln
A
00
E134 B B137 ENGINECONTROLMODULE
m
6 7 8 9 10 11 12
EN1152
EN(D0HC TURBO)-200
m
Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. IS there any other DTC on dis- nspect the rele- 30 to step 2.
,lay? /ant DTC using
‘List of Diagnostic
rrouble Code
DTC)”. <Ref. to
IN(D0HC
rURBO)-80, List
i f Diagnostic Trou.
ile Code (DTC).>
CHECK FUEL FILLER CAP. Is the fuel filler cap tightened 30 to step 3. Tighten fuel filler
1)Turn the ignition switch to OFF. securely? cap securely.
2)Check the fuel filler cap.
NOTE:
The DTC code is stored in memory if fuel filler
cap is or was loose or if the cap chain was
caught while tightening.
CHECK FUEL FILLER PIPE PACKING. Is there any damage to the 3epair or replace Go to step 4.
seal between fuel filler cap and he fuel filler cap
fuel filler pipe? m d fuel filler pipe.
:Ref. to FU(D0HC
TURBO)-55, Fuel
-.
-iller Pipe.>
CHECK DRAIN VALVE. Does the drain valve produce 30 to step 5. Replace the drain
1)Connect the test mode connector. operating sound? valve. <Ref. to
2)Turn the ignition switch to ON. EC(D0HC
3)Operate the drain valve. TURBO)-17, Drair
NOTE: Valve.>
Drain valve operation can also be executed us-
ing Subaru Select Monitor. For the procedure.
refer to “Compulsory Valve Operation Check
Mode”. <Ref. to EN(D0HC TURBO)-50, Com-
pulsory Valve Operation Check Mode.>
CHECK PURGE CONTROL SOLENOID Does the purge control sole- So to step 6. Replace the purge
VALVE. noid valve produce operating control solenoid
Operate the purge control solenoid valve. sound? valve. <Ref. to
NOTE: EC(D0HC
Purge control solenoid valve operation can alsc TURBO)-7, Purge
be executed using Subaru Select Monitor. Foi Control Solenoid
the procedure, refer to “Compulsory Valve Op. Valve.>
eration Check Mode”. <Ref. to EN(D0HC TUR-
BO)-50, Compulsory Valve Operation Check
Mode.>
CHECK PRESSURE CONTROL SOLENOID Does the pressure control Go to step 7. Replace the pres-
VALVE. solenoid valve produce operat- sure control sole-
Operate the pressure control solenoid valve. ing sound? noid valve. <Ref.
NOTE: to EC(D0HC
Pressure control solenoid valve operation car TURBO)-I2, Pres
also be executed using Subaru Select Monitor sure Control Sole-
For the procedure, refer to “Compulsory Valve noid Valve.>
Operation Check Mode”. <Ref. to EN(D0HC
TURBO)-50, Compulsory Valve Operatior
Check Mode.>
CHECK EVAPORATIVE EMISSION CON- IS there a hole of more than 1.O Repair or replace Go to step 8.
TROL SYSTEM LINE. mm (0.04 in) dia. on fuel line? the fuel line. <Ref.
Turn the ignition switch to OFF. to FU(D0HC
TURBO)-68, Fuel
Delivery, Return
and Evaporation
Lines.>
EN(DOHC TU R BO)-201
Step Check Yes No

8 CHECK CANISTER. Is the canister damaged or is
Repair or replace Go to step 9.
there a hole of more than 1.O
the canister. <Ref.
mm (0.04 in) dia. in it? to EC(D0HC
TURBO)B, Canis-
ter.>
9 CHECK FUEL TANK. Is the fuel tank damaged or is Repair or replace Go to step 10.
Remove the fuel tank. <Ref. to FU(D0HC there a hole of more than 1.O the fuel tank. <Ref.
TURBO)-52, Fuel Tank.> mm (0.04 in) dia. in it? to FU(D0HC
TURBO)-52, Fuel
Tank.>
10 CHECK ANY OTHER MECHANICAL TROU- Are there holes of more than Repair or replace Contact with SOA
BLE IN EVAPORATIVE EMISSION CON- 1.O mm (0.04 in) dia., cracks, the hoses or pipes. (distributor) ser-
TROL SYSTEM. clogging or disconnections of vice.
hoses or pipes in evaporative NOTE:
emission control system? Inspection by DTN
is required, be.
cause probable
cause is deteriora-
tion of multiple
parts.
EN(D0HC TURBO)-202
EN(D0HC TURBO)-203
AT:DTC PO444 - EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON-

TROL VALVE CIRCUIT LOW INPUT -
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
41N RELAY
SBF-5
BATTERY
3 c
" 5 6
U
PURGE CONTROL
SOLENOID VALVE
EN1 153
EN(DOHC TURB0)-204
ENGI NE (DIAG NOSTlCS)
Step Check Yes No

CHECK OUTPUT SIGNAL FROM ECM. 5 the voltage more than 10 V? Even if MIL lights So to step 2.
1)Turn the ignition switch to ON. up, the circuit has
2)Measure the voltage between ECM and returned to a nor-
chassis ground. mal condition at
Connector & terminal this time. Contact
(B 137) No. 16 (+) - Chassis ground (-): with SOA (distribu-
tor) service.
NOTE:
Inspection by DTW
is required, be.
cause probable
cause is deteriora,
tion of multiple
parts.
! CHECK HARNESS BETWEEN PURGE CON. s the resistance less than 10 Repair ground 20 to step 3.
TROL SOLENOID VALVE AND ECM CON- 2? short circuit in har-
1)Turn the ignition switch to OFF. ECM and purge
2)Disconnect the connectors from purge con- control solenoid
trol solenoid valve and ECM. valve connector.
purge control solenoid valve connector and
engine ground.
1 CHECK HARNESS BETWEEN PURGE CON, s the resistance less than 1 Go to step 4. 3epair open circuit
TROL SOLENOID VALVE AND ECM CON- 2? n harness
NECTOR. letween ECM and
Measure the resistance of harness between )urge control sole-
ECM and purge control solenoid valve of har- ioid valve connec-
ness connector. or.
Connector & terminal rlOTE:
(6137) NO. 16 - (E4) NO. 2: n this case, repair
he following:
Open circuit in
iarness between
X M and purge
:ontrol solenoid
ialve connector
Poor contact in
:oupling connectoi
I CHECK PURGE CONTROL SOLENOID s the resistance between 10 20 to step 5. 3eplace the purge
VALVE. 2nd 100 Q? :ontrol solenoid
1)Remove the purge control solenoid valve. ialve. <Ref. to
2)Measure the resistance between purge con- IC(D0HC
trol solenoid valve terminals. TURBO)--/, Purge
Terminals 2ontrol Solenoid
NO. 1 -NO. 2: Jake.>
> CHECK POWER SUPPLY TO PURGE CON- s the voltage more than 10 V? ;o to step 6. 3epair open circuit
TROL SOLENOID VALVE. n harness
1)Turn the ignition switch to ON. letween main
2)Measure the voltage between purge control 'elay and purge
solenoid valve and engine ground. :ontrol solenoid
Connector & terminal ialve connector.
EN(D0HC TURBO)-205
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
Step Check Yes

6 CHECK POOR CONTACT. Repair poor con-
Check poor contact in purge control solenoid control solenoid valve connec- tact in purge con- (distributor) ser-
tor? trol solenoid valve vice.
connector. NOTE:
Inspection by DTN
is required, be.
cause probablc
cause is deteriora
tion of multiple
Darts.
EN(D0HC TURBO)-206
m
EN(D0HC TURBO)-207
AU:DTC PO445 - EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON-

TROL VALVE CIRCUIT HIGH INPUT -
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
MAIN RELAY
SBF-5
BATTERY
3 c " 5 6
n@ ECM
PURGE CONTROL
SOLENOID VALVE
EN1 153
EN(D0HC TURBO)-208
Step Check No
CHECK OUTPUT SIGNAL FROM ECM. Even if MIL light
1)Turn the ignition switch to OFF. )etween 0 and 10 V? up, the circuit has
2)Connect the test mode connector at the returned to a nor-
lower portion of instrument panel (on the mal condition at
driver’s side), to the side of the center console this time. In this
box. case, repair poor
3)Turn the ignition switch to ON. :ontact in ECM
4)While operating the purge control solenoid sonnector.
valve, measure voltage between ECM and
chassis ground.
NOTE:
Purge control solenoid valve operation can be
executed using Subaru Select Monitor. For pro-
cedure, refer to “Compulsory Valve Operation
Check Mode”. <Ref. to EN(D0HC TURBO)-50,
Compulsory Valve Operation Check Mode.>
CHECK OUTPUT SIGNAL FROM ECM.
-----I-
s the voltage more than 10 V? Go to step 4. Go to step 3.
chassis ground.
CHECK POOR CONTACT. s there poor contact in ECM Repair poor con- Replace the ECM.
Check poor contact in ECM connector. :onnector? tact in ECM con- <Ref. to FU(D0HC
nector. TURBO)-47,
Engine Control
Module.>
CHECK HARNESS BETWEEN PURGE CON- s the voltage more than 10 V? Repair battery Go to step 5.
TROL SOLENOID VALVE AND ECM CON- short circuit in har,
1)Turn the ignition switch to OFF. ECM and purge
2)Disconnectthe connector from purge control control solenoid
solenoid valve. valve connector.
3)Turn the ignition switch to ON. After repair,
4)Measure the voltage between ECM and replace the ECM.
chassis ground. <Ref. to FU(D0HC
Connector & terminal TURBO)-47,
(6137) No. 16 (+) - Chassis ground (-): Engine Control
Module.>
CHECK PURGE CONTROL SOLENOID s the resistance less than 1 Replace the purge Go to step 6.
VALVE. n? control solenoid
1)Turn the ignition switch to OFF. valve <Ref. to
2)Measure the resistance between purge con- EC(D0HC
trol solenoid valve terminals. TURBO)-7, Purge
Terminals Control Solenoid
NO. 1 -NO. 2: Valve.> and ECM
<Ref. to FU(D0HC
TURBO)-47,
Engine Control
Module.>
CHECK POOR CONTACT. s there poor contact in ECM Repair poor con- Replace the ECM.
nector. TURBO)-47,
Engine Control
Module.>
EN(D0HC TURBO)-209
AV:DTC PO447 - EVAPORATIVE EMISSION CONTROL SYSTEM VENT CON-

TROL LOW INPUT -
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
41N RELAY BATTERY

n
SBF-5
'3
3 c q-
A:@ B:@ ECM I I
EN1154
Step Check Yes No

chassis ground.
EN(D0HC TURBO)-210
m
Step Check Yes No

CHECK POOR CONTACT. there poor contact in ECM lepair poor con- Even if MIL lights
Check poor contact in ECM connector. mnector? ict in ECM con- up, the circuit has
ector. returned to a nor-
mal condition at
this time. (How-
ever, the possibilit)
of poor contact stil
remains.)
NOTE:
In this case, repai
the following:
Poor contact in
drain valve con-
nector
Poor contact in
ECM connector
Poor contact in
coupling connec-
tors
CHECK HARNESS BETWEEN DRAIN ; the resistance less than 10 lepair ground Go to step 4.
VALVE AND ECM CONNECTOR. !? hort circuit in har-
1)Turnthe ignition switch to OFF. ess between
2)Disconnect the connectors from drain valve iCM and drain
and ECM. alve connector.
drain valve connector and chassis ground.
(R69) No. 2 - Chassis ground:
CHECK HARNESS BETWEEN DRAIN ;the voltage less than 1 R? i o to step 5. Repair harness
VALVE AND ECM CONNECTOR. and connector.
Measure the resistance of harness between NOTE:
ECM and drain valve connector. In this case, repa
Connector & terminal the following:
(8137) NO. 11 - (R69) NO. 2: Open circuit in
harness between
ECM and drain
valve connector
Poor contact in
coupling connec-
tors
CHECK DRAIN VALVE. 5the resistance between 10 ;o to step 6. Replace the drain
Measure the resistance between drain valve .nd 100 a? valve. <Ref. to
terminals. EC(D0HC
Terminals TURBO)-I 7, Draii
NO. 1 - NO. 2: Valve.>
CHECK POWER SUPPLY TO DRAIN VALVE 5 the voltage more than 10 V' o
1)Turn the ignition switch to ON. and connector.
2)Measure the voltage between drain valve NOTE:
and chassis ground. In this case, repa
Connector & terminal the following:
(R69) No. 1 (+) - Chassis ground (-): Open circuit in
harness between
main relay and
drain valve
Poor contact in
coupling connec-
EN(D0HC TURBO)-21 1
Step Check Yes No

7 CHECK POOR CONTACT. Is there poor contact in drain Repair poor con- Contact with SOA
Check poor contact in drain valve connector. valve connector? tact in drain valve (distributor) ser-
connector. vice.
NOTE:
Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
Darts.
EN(D0HC TURBO)-212
ENGINE IDlAGNOSTlCSl
EN(D0HC TURBO)-213
AW:DTC PO448 - EVAPORATIVE EMISSION CONTROL SYSTEM VENT CON-

TROL HIGH INPUT -
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
4IN RELAY BATTERY
€3
SBF-5
1CANISTER
I A:@ B:@ ECM
- I I
EN1154
EN(D0HC TURBO)-214
Step Check Yes No

I CHECK OUTPUT SIGNAL FROM ECM. Ioes the voltage change Go to step 2. Even if MIL lights
1)Turn the ignition switch to OFF. letween 0 and 10 V? up, the circuit has
2)Connect the test mode connector at the returned to a nor-
lower portion of instrument panel (on the mal condition at
driver’s side), to the side of the center console this time. In this
box. case, repair poor
3)Turn the ignition switch to ON. contact in ECM
4)While operating the drain valve, measure connector.
voltage between ECM and chassis ground.
NOTE:
Drain valve operation can be excecuted using
c
Subaru Select Monitor. For procedure, refer to
“Compulsory Valve Operation Check Mode”.
<Ref. to EN(D0HC TURBO)dO, Compulsory
Valve Operation Check Mode.>
! CHECK OUTPUT SIGNAL FROM ECM. s the voltage more than 10 V? Go to step 4. Go to step 3.
chassis ground.
j CHECK POOR CONTACT. s there poor contact in ECM Repair poor con- Replace the ECM.
nector. TURBO)-47,
Engine Control
Module.>
I CHECK HARNESS BETWEEN DRAIN s the voltage more than 10 V? Repair battery Go to step 5.
VALVE AND ECM CONNECTOR. short circuit in har-
2)Disconnect the connector from drain valve. ECM and drain
3)Turn the ignition switch to ON. valve connector.
4)Measure the voltage between ECM and After repair,
chassis ground. replace the ECM.
Connector & terminal <Ref. to FU(D0HC
(B137) No. 11 (+) - Chassis ground (-): TURBO)-47,
Engine Control
Module.>
i CHECK DRAIN VALVE. s the resistance less than 1 Replace the drain Go to step 6.
1)Turn the ignition switch to OFF. 2? valve <Ref. to
2)Measure the resistance between drain valve EC(D0HC
terminals. TURBO)-I 7, Drain
Terminals Valve.> and ECM
NO. 1 - NO.2: <Ref. to FU(D0HC
TURBO)-47,
Engine Control
Module.>
i CHECK POOR CONTACT. s there poor contact in ECM Repair poor con- Replace the ECM.
nector. TURBO)-47,
Engine Control
Module.>
EN(D0HC TURBO)-215
AX:DTC PO451 - EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE

SENSOR RANGE/PERFORMANCE PROBLEM -
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
1
JEL TANK
3ESSURE
;ENSOR
#
I
[,I-
=-I
@
EN(D0HC TURBO)-216
m
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Is there any DTC on display? Inspect the rele- Go to step 2.
vant DTC using
“List of Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
2 CHECK FUEL FILLER CAP. Is the fuel filler cap tightened Go to step 3. Tighten fuel filler
1)Turnthe ignition switch to OFF. securely? cap securely.
2)Open the fuel flap.
3 CHECK PRESSURENACUUM LINE. Is there a fault in pressurehac- Repair or replace Replace the fuel
NOTE: uum line? the hoses and tank pressure sen-
Check the following items. pipes. sor. <Ref. to
*Disconnection, leakage and clogging of the EC(D0HC
vacuum hoses and pipes between fuel tank TURBO)-I 1 , Fuel
pressure sensor and fuel tank Tank Pressure
*Disconnection, leakage and clogging of air Sensor.>
ventilation hoses and pipes between fuel filler
DiDe and fuel tank
EN(D0HC TURBO)-217
AY:DTC PO452 -
EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE
SENSOR LOW INPUT -
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
IEL TAN1
IESSURI
,ENSOR
EN1155
EN(D0HC TURBO)-21 8
EiN
~~
Step Check Yes No

CHECK CURRENT DATA. s the value less than -2.8 kPa IGo to step 2. Even if MIL lights
1)Turn the ignition switch to OFF. -21 .O mmHg, -0.827 inHg)? JP,the circuit has
2)Remove the fuel filler cap. ,eturned to a nor-
3)lnstall the fuel filler cap. nal condition at
4)Turn the ignition switch to ON. his time.
5)Read the data of fuel tank pressure sensor
signal using Subaru Select Monitor or the
NOTE:

Fordetailed operation procedure, refer to the
to EN(D0HC TURBO)-38, Subaru Select Mon.
itor.>
CHECK POWER SUPPLY TO FUEL TANK s the voltage more than 4.5 V? Go to step 4. 30 to step 3.
PRESSURE SENSOR.
and chassis ground.
I
CHECK POWER SUPPLY TO FUEL TANK loes the voltage change more Repair poor con- ;ontact with SOA
PRESSURE SENSOR. han 4.5 V by shaking harness tact in ECM con- distributor) ser-
Measure the voltage between ECM connector ind connector of ECM while nector. lice.
and chassis ground. nonitoring the value with volt- \JOTE:
Connector i? terminal ige meter? nspection by DTL
(B 135) No. 9 (+) - Chassis ground (-): s required, be
:ause probablc
:ause is deteriora
ion of multipli
)arts.
CHECK INPUT SIGNAL FOR ECM. s the voltage less than 0.2 V? Go to step 6. 30 to step 5.
Measure the voltage between ECM and chas-
sis ground.
CHECK INPUT SIGNAL FOR ECM. (USING loes the value change more Repair poor con- 30 to step 6.
SUBARU SELECT MONITOR.) han -2.8 kPa (-21 .O mmHg, - tact in ECM con-
Read the data of fuel tank pressure sensor sig. 1.827 inHg) by shaking har- nector.
nal using Subaru Select Monitor. less and connector of ECM
NOTE: while monitoring the value with
*Subaru Select Monitor Subaru Select Monitor?
itor.>
EN(D0HC TURBO)-219
Step Check Yes No

CHECK HARNESS BETWEEN ECM AND j the voltage more than 4.5 V? o
; to step 7. 3epair harness
COUPLING CONNECTOR IN REAR WIRING and connector.
HARNESS. UOTE:
1)Turn the ignition switch to OFF. n this case, repair
2)Remove the rear seat cushion (Sedan) or he following:
move rear seat cushion (Wagon). 1 Open circuit in
3)Separate rear wiring harness and fuel tank iarness between
cord. X M and rear wir-
4)Turn the ignition switch to ON. ng harness con-
5)Measure the voltage between rear wiring lector
harness connector and chassis ground. 1 Poor contact in
Connector & terminal :oupling connector

CHECK HARNESS BETWEEN ECM AND s the resistance less than 1 20 to step 0. 3epair harness
COUPLING CONNECTOR IN REAR WIRING 2? 3nd connector.
HARNESS. VOTE:
1)Turn the ignition switch to OFF. In this case, repair
2)Disconnect the connector from ECM. :he following:
3)Measure the resistance of harness between 1 Open circuit in
ECM and rear wiring harness connector. iarness between

Connector & terminal ECM and rear wir-
(6135) NO. 19 - (R15) NO. 11: ng harness con-
lector
1 Poor contact in
2oupling connector
Poor contact in
loint connector
CHECK HARNESS BETWEEN ECM AND s the resistance more than 30 to step 9. Repair ground
COUPLING CONNECTOR IN REAR WIRING 500 kR? short circuit in har-
HARNESS. ness between
Measure the resistance of harness between ECM and rear wir-
rear wiring harness connector and chassis ing harness con-
ground. nector.
3 CHECK FUEL TANK CORD. s the resistance less than 1 30 to step 10. Repair open circuit
1)Disconnectthe connector from fuel tank 2? in fuel tank cord.
pressure sensor.
2)Measure the resistance of fuel tank cord.
(R57) NO. 9 - (R47) NO. 3:
IO CHECK FUEL TANK CORD. s the resistance less than 1 So to step 11. Repair open circuit
Measure the resistance of fuel tank cord. 3? in fuel tank cord.
(R57) NO. 11 - (R47) NO. 1:
I1 CHECK FUEL TANK CORD. s the resistance more than Go to step 12. Repair ground
Measure the resistance of harness between 500 kR? short circuit in fuel
fuel tank pressure sensor connector and chas tank cord.
sis ground.
12 CHECK POOR CONTACT. s there poor contact in fuel Repair poor con- Replace the fuel
Check poor contact in fuel tank pressure sen- ank pressure sensor connec- tact in fuel tank tank pressure sen.
sor connector. or? pressure sensor sor. <Ref. to
connector. EC(D0HC
TURBO)-11, Fuel
Tank Pressure
Sensor.>
EN(D0HC TURBO)-220
EN(D0HC TURBO)-221
AZ:DTC PO453 - EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE

SENSOR HIGH INPUT -
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
EN1155
EN(D0HC TURBO)-222
~
Step Check Yes No

CHECK CURRENT DATA. s the value more than 2.8 kPa 20 to step 12. 30 to step 2.
1)Turn the ignition switch to OFF. 21 .O mmHg, 0.827 inHg)?
2)Remove the fuel filler cap.
3)lnstall the fuel filler cap.
signal using Subaru Select Monitor or OBD-ll
general scan tool.
NOTE:
4ubaru Select Monitor
itor.>
CHECK POWER SUPPLY TO FUEL TANK s the voltage more than 4.5 V? 30 to step 4. 30 to step 3.
PRESSURE SENSOR.
and chassis ground.
CHECK POWER SUPPLY TO FUEL TANK Does the voltage change more 3epair poor con- Replace the ECM.
PRESSURE SENSOR. ;han 4.5 V by shaking harness act in ECM con- <Ref.to FU(D0HC
Measure the voltage between ECM connector and connector of ECM while lector. TURBO)-47,
and chassis ground. nonitoring the value with volt- Engine Control
Connector & terminal 3ge meter? Module.>
CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 0.2 V? 20 to step 6. So to step 5.
Measure the voltage between ECM and chas-
sis ground.
CHECK INPUT SIGNAL FOR ECM. (USING Does the value change more 3epair poor con- So to step 6.
SUBARU SELECT MONITOR.) than -2.8 kPa (-21 .O mmHg, :act in ECM con-
Read the data of fuel tank pressure sensor sig -0.827 inHg) by shaking har- lector.
nal using Subaru Select Monitor. ness and connector of ECM
NOTE: while monitoring the value with
Gubaru Select Monitor Subaru Select Monitor?
itor.>
CHECK HARNESS BETWEEN ECM AND Is the voltage more than 4.5 VS 30 to step 7. Repair harness
COUPLING CONNECTOR IN REAR WIRING and connector.
HARNESS. NOTE:
2)Remove the rear seat cushion (Sedan) or the following:
move rear seat cushion (Wagon). a Open circuit in
3)Separate rear wiring harness and fuel tank harness between

cord. ECM and rear wir.
4)Turn the ignition switch to ON. ing harness con-
5)Measure the voltage between rear wiring nector
harness connector and chassis ground. Poor contact in
Connector & terminal coupling connectc
EN(D0HC TURBO)-223
~~
Step Check Yes No

CHECK HARNESS BETWEEN ECM AND j the resistance less than 1 30 to step 8. 3epair harness
COUPLING CONNECTOR IN REAR WIRING I? md connector.
HARNESS. \IOTE:
1)Turnthe ignition switch to OFF. n this case, repaii
2)Disconnect the connector from ECM. he following:
3)Measure the resistance of harness between Open circuit in
ECM and rear wiring harness connector. iarness between
Connector & terminal X M and rear wir-
(6135) NO. 15 - (R 15) NO. 10: ng harness con-
lector
Poor contact in
:oupling connectoi
CHECK HARNESS BETWEEN ECM AND ;the resistance less than 1 30 to step 9. 3epair ground
COUPLING CONNECTOR IN REAR WIRING 2? ;hort circuit in har-
HARNESS. less between
Measure the resistance of harness between X M and rear wir-
rear wiring harness connector and chassis ng harness con-
ground. lector.
(8135) NO. 9 - (R15) NO. 9:
I CHECK FUEL TANK CORD. j the resistance less than 1 So to step 10. 3epair open circuit
1)Disconnectthe connector from fuel tank 1? n fuel tank cord.
pressure sensor.
2)Measure the resistance of fuel tank cord.
(R57) NO. 11 - (R47) NO. 2:
0 CHECK FUEL TANK CORD. ;the resistance less than 1 Go to step 11. 3epair open circuit
Measure the resistance of fuel tank cord. I? n fuel tank cord.
(R57) NO. 10 - (R47) NO. 1:
1 CHECK POOR CONTACT. ;there poor contact in fuel Repair poor con- 3eplace the fuel
Check poor contact in fuel tank pressure sen- snk pressure sensor connec- tact in fuel tank ank pressure sen-
sor connector. x? pressure sensor ;or. <Ref. to
connector. X(DOHC
rURBO)-I 1, Fuel
rank Pressure
Sensor.>
I2 CHECK HARNESS BETWEEN ECM AND s the value more than 2.8 kPa Repair battery 3eplace the fuel
FUEL TANK PRESSURE SENSOR CONNEC, 21 .O mmHg, 0.827 inHg)? short circuit in har :ank pressure sen.
TOR. ness between ;or. <<Ref. to
1)Turn the ignition switch to OFF. ECM and fuel tank EC(D0HC
2)Disconnect the connector from fuel tank pressure sensor rURBO)-I 1, Fuel
pressure sensor. connector. rank Pressure
3)Turn the ignition switch to ON. Sensor.>
signal using Subaru Select Monitor or the
NOTE:
Gubaru Select Monitor
itor.>
-0BD-II general scan tool
EN(D0HC TURBO)-224
m
BA:DTC PO461 - FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM -
CAUTION:
tion Mode.>.
EN(D0HC TURBO)-225
WIRING DIAGRAM:
I 1
EN1156
EN(DOHC TURB0)-226
a
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. loes the Subaru Select Moni- Inspect DTC Replace the fuel
or or OED-ll general scan tool PO462 or PO463 level sensor <Ref.
ndicate DTC PO462 or P0463? using “List of Diag- to FU(D0HC
nostic Trouble TURBO)-62, Fuel
Code (DTC)”. Level Sensor.>
<Ref. to EN(D0HC and fuel sub level
TURBO)-80, List sensor <Ref. to
of Diagnostic Trou- FU(D0HC
ble Code (DTC).s TURBO)-63, Fuel
NOTE: Sub Level Sen-
In this case, it is sor.>
not necessary tc
inspect this trou-
ble.
EN(D0HC TURBO)-227
~
BB:DTC PO462 - FUEL LEVEL SENSOR CIRCUIT LOW INPUT -

CAUTION:
tion Mode.>.
WIRING DIAGRAM:
I
No 13
=&%-=-
IGNITION SWITCH
@
SBF-4 SBF-1
-
3 c
I 1
@
FUEL SUB FUEL LEVEL
LEVEL SEI SENSOR
-@-
a
112131415161 n 171819110111
a
1121314151 n 16171819110111
EN1156
m
Step Check Yes No

CHECK SPEEDOMETER AND TACHOME- >oesthe speedometer and i o to step 2. Repair or replace
TER OPERATION IN COMBINATION achometer operate normally? !he combination
METER. meter. <Ref. to
IDI-4, Combina-
tion Meter Sys-
tem.>
CHECK INPUT SIGNAL FOR ECM. s the voltage less than 0.12 i o to step 6. So to step 3.
1)Turn the ignition switch to ON. (Engine OFF) I?
(6135) No, 25 (+) - Chassis groundI)-(
CHECK INPUT SIGNAL FOR ECM. (USING Toes the value change less jepair poor con- Even if MIL lights
SUBARU SELECT MONITOR.) han 0.12 V by shaking har- act in ECM con- up, the circuit has
Read the data of fuel level sensor signal using less and connector of ECM lector. returned to a nor-
Subaru Select Monitor. vhile monitoring the value with mal condition at
jubaru Select Monitor? this time. A tempo-
NOTE:
Gubaru Select Monitor rary poor contact
For detailed operation procedure, refer to the of the connector
“READ CURRENT DATA FOR ENGINE”. <Ref. may be the cause.
to EN(D0HC TURBO)-38, Subaru Select Mon- NOTE:
itor.> In this case, repaii
the following:
Poor contact in
combination meter
connector
Poor contact in
ECM connector
Poor contact in
coupling connec-
tors
CHECK INPUT VOLTAGE OF ECM. s the voltage more than 0.12 30 to step 4. Go to step 7.
1)Turn the ignition switch to OFF. d?
2)Separate fuel tank cord connector (R57) and
rear wiring harness connector (R15).
4)Measure the voltage of harness between
CHECK HARNESS BETWEEN ECM AND s the resistance more than 1 io to step 6. 3epair ground
COMBINATION METER. An? short circuit in har-
2)Disconnect the connector from connector I C M and combi-
(ilo), (i12) and ECM connector. iation meter con-
3)Measure the resistance between ECM and lector.
chassis ground.
CHECK HARNESS BETWEEN ECM AND s the resistance less than 10 iepair or replace Repair open circuit
COMBINATION METER. L? l e combination oetween ECM and
Measure the resistance between ECM and ieter. <Ref. to :ombination meter
combination meter connector. DI-4, Combina- :onnector.
Connector & terminal on Meter Sys- NOTE:
(6135) No. 25 - (i12) No. 2: 3m.> In this case, repaii
the following:
Poor contact in
coupling connectot
EN(D0HC TURBO)-229
Step Check Yes No

r CHECK FUEL TANK CORD. Is the resistance more than 1 Go to step 8. Repair ground
1)Turn the ignition switch to OFF. MR? short circuit in fuel
2)Disconnect the connector from fuel sub level tank cord.
sensor.
3)Measure the resistance between fuel sub
level sensor and chassis ground.
5 CHECK FUEL TANK CORD. Is the resistance more than 1 Go to step 9. Repair ground
1)Disconnectthe connector from fuel pump MR? short circuit in fuel
assembly. tank cord.
2)Measure the resistance between fuel pump
assembly and chassis ground.
b CHECK FUEL LEVEL SENSOR. Is the resistance between 0.5 Go to step 10. Replace the fuel
1)Remove the fuel pump assembly. <Ref. to and 2.5 R? level sensor.
FU(D0HC TURBO)-60, Fuel Pump.>
2)Measure the resistance between fuel level
sensor and terminals with its float set to the full
position.
Terminals
NO. 2 - NO. 3:
IO CHECK FUEL SUB LEVEL SENSOR. Is the resistance between 0.5 Repair poor con- Replace the fuel
1)Remove the fuel sub level sensor. <Ref. to and 2.5 R? tact in harness sub level sensor.
FU(D0HC TURBO)-63, Fuel Sub Level Sen- between ECM and
sor.> combination meter
2)Measure the resistance between fuel sub connector.
level sensor and terminals with its float set to
the full position.
Terminals
NO. 1 -NO. 2:
EN(D0HC TURBO)-230
im
EN(D0HC TURBO)-231
I
BC:DTC PO463 - FUEL LEVEL SENSOR CIRCUIT HIGH INPUT -

CAUTION:
tion Mode.>.
WIRING DIAGRAM:
No.13 SBF-4 SBF-1
I IGNITION SWITCH
@
COMBINATION
FUEL LEVEL
LEVEL SENSOR SENSOR
EN(DOHC TU RB0)-232
I a
~~ ~
Step Check Yes No

CHECK SPEEDOMETER AND TACHOME- Ioes the speedometer and i o to step 2. Repair or replace
TER OPERATION IN COMBINATION achometer operate normally? the combination
METER. meter. <Ref. to
IDI-4, Combina-
tion Meter Sys-
tem.>
! CHECK INPUT SIGNAL FOR ECM. s the voltage more than 4.75 ;o to step 3. Even if MIL lights
1)Turnthe ignition switch to ON. (Engine OFF) I? dp, the circuit has
2)Measure the voltage between ECM connec- returned to a nor-
tor and chassis ground. mal condition at
Connector & terminal this time. A tempo-
(8135) No. 25 (+) - Chassis ground (-): rary poor contact
3f the connector
may be the cause.
NOTE:
In this case, repait
the following:
Poor contact in
fuel pump connec-
tor
Poor contact in
coupling connectoi
3 CHECK INPUT VOLTAGE OF ECM. s the voltage more than 4.75 20 to step 4. Repair battery
1)Turnthe ignition switch to OFF. I? short circuit
2)Disconnect the combination meter connector between ECM and
(i10) and ECM connector. combination meter
3)Turn the ignition switch to ON. connector.
4)Measure the voltage of harness between
ECM and chassis ground.
1 CHECK HARNESS BETWEEN ECM AND s the resistance less than 5 i o to step 5. Repair open circuit
FUEL TANK CORD. 3? between ECM and
1)Turn the ignition switch to OFF. fuel tank cord.
2)Separate fuel tank cord connector (R57) and
rear wiring harness connector (R15).
3)Measure the resistance between ECM and
fuel tank cord.
(8135) NO. 25 - (R15) NO. 2:
> CHECK HARNESS BETWEEN FUEL TANK s the resistance less than 5 30 to step 6. Repairopen circuit
CORD AND CHASSIS GROUND. n? between fuel tank
Measure the resistance between fuel tank cord cord and chassis
and chassis ground. ground.
(R15) No. 8 - Chassis ground: In this case, repaii
the following:
Poor contact in
coupling connec-
tors
5 CHECK FUEL TANK CORD. s the resistance less than 10 o
; to step 7. Repair open circuit
1)Disconnectthe connector from fuel level sen. n? between coupling
sor. connector and fuel
2)Measure the resistance between fuel level level sensor.
sensor and coupling connector.
(R57)NO. 8 - (R58)NO. 2:
EN(D0HC TURBO)-233
Step Check
I
CHECK FUEL TANK CORD. the resistance less than 10
1)Disconnectthe connector from fuel sub level ? between fuel level
sensor. sensor and fuel
2)Measure the resistance between fuel level sub level sensor.
sensor and fuel sub level sensor.
-
(R58) NO. 3 (R59) NO. 2:
I CHECK FUEL TANK CORD. the resistance less than 10 Go to step 9. Repair open circuit
Measure the resistance between fuel sub level ? between coupling
sensor and coupling connector. connector and fuel
Connector & terminal sub level sensor.
-
(R57) NO. 3 (R59) NO. 1:
1 CHECK FUEL LEVEL SENSOR. the resistance more than 53 Replace the fuel Go to step 10.
1)Remove the fuel pump assembly. <Ref. to ? level sensor. <Ref.
FU(D0HC TURBO)-60, Fuel Pump.> to FU(D0HC
2)While moving the fuel level sensor float up TURBO)-62, Fuel
and down, measure resistance between fuel Level Sensor.>
level sensor terminals.
Terminals
NO. 2 - NO. 3:
IO CHECK FUEL SUB LEVEL SENSOR. the resistance more than 45 Replace the fuel Replace the com-
1)Remove the fuel sub level sensor. <Ref. to ? sub level sensor. bination meter.
FU(D0HC TURBO)-63, Fuel Sub Level Sen- <Ref. to FU(D0HC <Ref. to IDI-11,
sor.> TURBO)-63, Fuel Combination
2)While moving the fuel sub level sensor float Sub Level Sen- Meter Assembly.>
up and down, measure resistance between s0r.z
fuel sub level sensor terminals.
Terminals
NO. 1 - NO. 2:
EN(D0HC TURBO)-234
EN(D0HC TURBO)-235
BD:DTC PO464 - FUEL LEVEL SENSOR INTERMITTENT INPUT-

* DTC DETECTING CONDITION:
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
I -
e-N0.13
IGNITION SWITCH
SBF-4 SBF-1
-ac
COMBINATION
METER
GAUGE
' A
EN1 156
EN(D0HC TURBO)-236
Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- nspect DTC Go to step 2.
tor or OBD-II general scan tool ’0462 or PO463
indicate DTC PO462 or P0463? ising “List of Diag-
iostic Trouble
;ode (DTC)”.
:Ref. to EN(D0HC
TURBO)-~O, List
)le Code (DTC).>
! CHECK FUEL LEVEL SENSOR. Does the resistance change 30 to step 3. Replace the fuel
1)Remove the fuel pump assembly. <Ref. to smoothly between approx. 0.5 level sensor. <Ref.
FU(D0HC TURBO)-60, Fuel Pump.> R and approx. 52 R? to FU(D0HC
2)While moving the fuel level sensor float up TURBO)-62, Fuel
and down, make sure that the resistance Level Sensor.>
between fuel level sensor terminals changes
smoothly.
Terminals
NO. 2 - NO. 3:
I CHECK FUEL SUB LEVEL SENSOR. Does the resistance change 3epair poor con- Replace the fuel
1)Remove the fuel sub level sensor. <Ref. to smoothly between approx. 0.5 act in ECM, com- sub level sensor.
FU(D0HC TURBO)-63, Fuel Sub Level Sen- Q and approx. 44 SZ? iination meter and <Ref. to FU(D0HC
sor.> :oupling connec- TURBO)-63, Fuel
2)While moving the fuel sub level sensor float ors. Sub Level Sen-
up and down, make sure that the resistance sor.>
between fuel level sensor terminals changes
smoothly.
Terminals
NO. 1 - NO. 2:
EN(D0HC TURBO)-237
EN(DOHC TU RB0)-238
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) m
BE:DTC PO480 - COOLING FAN RELAY 1 CIRCUIT LOW INPUT-

TROUBLE SYMPTOM:
Radiator fan does not operate properly.
Overheating
CAUTION:
tion Mode.>.
EN(D0HC TURBO)-239
WIRING DIAGRAM:
SBF-1
3 e-- T
7
N0.17
EN1157
EN(D0HC TURBO)-240
im
Step Check Yes No

CHECK OUTPUT SIGNAL FROM ECM. Ioes the voltage change lepair poor con- ;o to step 2.
1)Turn the ignition switch to OFF. tetween 0 and 10 V? 3ct in ECM con-
2)Connect the test mode connector at the lector.
lower portion of instrument panel (on the
driver’s side), to the side of the center console
box.
4)While operating the radiator fan relay, mea-
sure voltage between ECM terminal and
ground.
NOTE:
Radiator fan relay operation can be executed
using Subaru Select Monitor. For procedure,
Mode”.<Ref. to EN(D0HC TURBO)-38, Subaru
Select Monitor.>
? CHECK GROUND SHORT CIRCUIT IN RADI- s the resistance less than 10 lepair ground 20 to step 3.
ATOR MAIN FAN RELAY CONTROL CIR- 2? ihort circuit in
CUIT. adiator main fan
1)Turn the ignition switch to OFF. elay control cir-
2)Disconnect the connectors from ECM. uit.
% CHECK POWER SUPPLY FOR RELAY. s the voltage more than 10 V? ;o to step 4. qepair open circui
1)Removethe main fan relay 1 and 2 from A/C n harness
relay holder. ietween ignition
2)Turn the ignition switch to ON. ;witch and fuse
3)Measure the voltage between fuse and relay md relay box (F/B:
box (F/B) connector and chassis ground. :onnector.
(F66) No. 27 (+) - Chassis ground (-):
3 CHECK MAIN FAN RELAY. s the resistance between 87 o
; to step 5. 3eplace the main
1)Turnthe ignition switch to OFF. and 107 Q? an relay.
2)Measure the resistance between main fan
relay terminals.
Terminal
No. 27 - No. 28:(Main fan relay 1)
No. 22 - No. 21:(Main fan relay 2)
5 CHECK OPEN CIRCUIT IN MAIN FAN RE- s the resistance less than 1 20 to step 6. 3epair harness
LAY CONTROL CIRCUIT. n? and connector.
Measure the resistance of harness between VOTE:
ECM and main fan relay connector. n this case, repai
Connector & terminal :he following:
(8137) NO. 17 - (F66) NO. 28: 1 Open circuit in
(8137) NO. 28 - (F30) NO. 21: iarness between

ECM and main far
’elay connector
1 Poor contact in
:oupling connectc
5 CHECK POOR CONTACT. s there poor contact in ECM of 3epair poor con- 2ontact with SOA
Check poor contact in ECM or main fan relay nain fan relay connector? act in ECM or [distributor) ser-
connector. nain fan relay con ice.
lector.
EN(D0HC TURBO)-241
EN(D0HC TURBO)-242
II
BF:DTC PO483 - COOLING FAN FUNCTION PROBLEM -

TROUBLE SYMPTOM:
Occurrence of noise
Overheating
CAUTION:
After repair or replacement of faulty parts, conwct Clear llemory Mode <Re to EN(D0HC TURBO)-
tion Mode.>.
NOTE:
If the vehicle, with the engine idling, is placed very close to a wall or another vehicle, preventing normal cool-
ing function, the OBD system may detect malfunction.
EN(D0HC TURBO)-243
WIRING DIAGRAM:
SBF-1
3 e m
T
L”r”l
N0.17
I @ECM
I
1
-I T-
0 0 0
I SUB FAN
RELAY2
SUB FAN
RELAY1
MAIN FAN MAIN FAN
RELAY2 RELAY1
SUB FAN
MOTOR AIR CONDITIONING RELAY HOLDER
EN1157
EN(D0HC TURBO)-244
a
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Is there any other DTC on dis- Inspect the rele- Check radiator fan,
play? vant DTC using fan motor and ther-
“List of Diagnostic mostat. <Ref. to
Trouble Code CO-9, Radiator
(DTC)”. <Ref. to Main Fan Sys-
EN(D0HC tem.> and <Ref. to
TURBO)-80, List CO-17, Radiator
of Diagnostic Trou- Sub Fan Sys-
ble Code (DTC).> tem.> If thermostat
is stuck, replace
thermostat.
EN(D0HC TURBO)-245
BG:DTC PO500 - VEHICLE SPEED SENSOR MALFUNCTION -

CAUTION:
tion Mode.>.
WIRING DIAGRAM:
Fa
r
IGNITION
RELAY BATTERY
-
-
m
@: AT VEHICLES
@: MT VEHICLES
VEHICLE
SPEED
SENSOR
COMBINATION
METER
F
@ECM I& EN1158
Step Check Yes No

1 CHECK TRANSMISSION TYPE. Is the transmission type AT? Go to step 2. Go to step 3.
EN(DOHC TU R BO)-246
Step Check Yes No

CHECK DTC PO720 ON DISPLAY. Does the Subaru Select Moni- Check front vehi- Go to step 3.
tor or OBD-ll general scan tool cle speed sensor
indicate DTC P0720? signal circuit. <Ref.
to AT-57, DTC 33
FRONT VEHICLE
SPEED SENSOR,
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
1 CHECK SPEEDOMETER OPERATION IN Does speedometer operate Go to step 4. Check speedome-
COMBINATION METER. normally? ter and vehicle
speed sensor.
<Ref. to IDI-13,
Speedometer.>
and <Ref. to AT-32,
Front Vehicle
Speed Sensor.>
I CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10 Repair poor con- Repair harness
COMBINATION METER CONNECTOR. Q? tact in ECM con- and connector.
nector. NOTE:
In this case, repai
the following:
Open circuit in
harness between
ECM and combi-
nation meter con-
nector
Poor contact in
ECM connector
Poor contact in
combination meter
connector
Poor contact in
coupling connect0
EN(D0HC TURBO)-247
BH:DTC PO506 - IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED -

TROUBLE SYMPTOM:
Engine is difficult to start.
Engine does not start.
Erroneous idling
Engine stalls.
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
MAIN RELAY
BATTERY
SBF-5
3 c 5 6 7 8
AIR CONTROL
SOLENOID
VALVE
@ ECM
EN1160
EN(D0HC TURBO)-248
ENGINE fDIAGNOSTICS)
Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. Ioes the Subaru Select Moni- Inspect DTC 20 to step 2.
or or OBD-ll general scan tool PO505 or P I 505
ndicate DTC PO508 or P509? using “List of Diag-
nostic Trouble
Code (DTC)”.
<Ref. to EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0506.
CHECK IDLE AIR CONTROL SOLENOID Ioes air flow out? Go to step 4. 3eplace the idle
VALVE. iir control solenoid
1)Turn the ignition switch to OFF. ialve. <Ref. to
2)Remove the idle air control solenoid valve -U(DOHC
from throttle body. <Ref. to FU(D0HC rURBO)-36, Idle
TURBO)-36, REMOVAL, Idle Air Control Sole. 4ir Control Sole-
noid Valve.> ioid Valve.> After
3)Using an air gun, force air into the idle air .eplace,Go to step
control solenoid valve by-pass air inlet. Con- 5.
firm that forced air subsequently escapes from
both main air passage and assist air passage.
CHECK IDLE AIR CONTROL SOLENOID s the value more than 60%? Go to step 4. END.
VALVE DUTY RATIO.
2)Start the engine, and warm-up the engine.
3)Turn all accessory switches to OFF.
4)Read the data of idle air control solenoid
valve duty ratio using Subaru Select Monitor 01
NOTE:
Gubaru Select Monitor
itor.>
1 CHECK BY-PASS AIR LINE. loes air flow out? Replace the idle 3eplace the throt-
1)Turn the ignition switch to OFF. air control solenoid le body. <Ref. to
2)Remove the idle air control solenoid valve valve. <Ref. to ‘U(D0HC
from throttle body. <Ref. to FU(D0HC FU(D0HC rURBO)-14,
TURBO)-36, REMOVAL, Idle Air Control Sole, TURBO)-36, Idle Throttle Body.>
noid Valve.> Air Control Sole-
3)Remove the throttle body to intake manifold. noid Valve.>
<Ref. to FU(D0HC TURBO)-14, REMOVAL,
Throttle Body.>
4)Using an air gun, force air into the solenoid
valve installation area and throttle valve inte-
rior. Confirm that forced air subsequently I
escapes from both these areas.
EN(D0HC TURBO)-249
BI: DTC PO507 - IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED -
. Two consecutive driving cycles with fault

TROUBLE SYMPTOM:
Engine keeps running at higher revolution than specified idling revolution.
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
MAIN RELAY
m SBF-5
BATTERY
(3c 5 6 7 8
-1 AIR CONTROL
SOLENOID
IgI
I
- EN116(
EN(D0HC TURBO)-250
51
__
Step Check Yes No

I CHECK ANY OTHER DTC ON DISPLAY. loes the Subaru Select Moni- Inspect DTC 20 to step 2.
or or OBD-ll general scan tool PO508 or PO509
ndicate DTC PO508 or P0509? Jsing “List of Diag-
iostic Trouble
:ode (DTC)”.
<Ref.to EN(D0HC
TURBO)-80, List
Df Diagnostic Trou-
de Code (DTC).>
NOTE:
In this case, it is
l o t necessary tc
inspect DTC
P0507.
2 CHECK THROTTLE CABLE. loes the throttle cable have Go to step 3. 4djust throttle
,lay for adjustment? :able. <Ref. to
SP-7, INSTALLA-
TION, Accelerator
2ontrol Cable.>
3 CHECK AIR INTAKE SYSTEM. s there a fault in air intake sys- Repair air suction 3eplace the idle
1)Turnthe ignition switch to ON. em? and leaks. iir control solenoid
2)Start the engine, and idle it. ialve. <Ref. to
3)Check the following items. -U(DOHC
*Loose installation of intake manifold, idle air rURBO)-36, Idle
control solenoid valve and throttle body 4ir Control Sole-
Cracks of intake manifold gasket, idle air con- ioid Valve.>
trol solenoid valve gasket and throttle body
gasket
*Disconnections of vacuum hoses
EN(DOHC TU RB0)-251
BJ:DTC PO508 - IDLE CONTROL SYSTEM CIRCUIT LOW INPUT -

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Engine breathing
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
MAIN RELAY
BATTERY
SBF-5
5 6 7 8
1-111 I
AIR CONTROL
SOLENOID
VALVE
EN(D0HC TURBO)-252
~~ ~
Step Check Yes No

CHECK OUTPUT SIGNAL FROM ECM. s the voltage more than 3 V? 3epair poor con- Go to step 2.
1)Turn the ignition switch to ON. act in ECM con-
2)Measure the voltage between ECM and lector.
chassis ground.
! CHECK POWER SUPPLY TO IDLE AIR CON- s the voltage more than 10 V? o
TROL SOLENOID VALVE. and connector.
2)Disconnectthe connector from idle air con- In this case, repair
trol solenoid valve. the following:
3)Turn the ignition switch to ON. Open circuit in
4)Measure the voltage between idle air control harness between
solenoid valve and engine ground. idle air control
Connector & terminal solenoid valve and
(E7) No. 2 (+) - Engine groundI)-( main relay connec-
tor
Poor contact in
coupling connector
I CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 20 to step 4. Repair harness
IDLE AIR CONTROL SOLENOID VALVE Q? and connector.
NOTE:
In this case, repair
the following:
Open circuit in
harness between
ECM and idle air
control solenoid
valve connector
Poor contact in
coupling connector
I CHECK HARNESS BETWEEN ECM AND IS the resistance less than 10 3epair ground Go to step 5.
IDLE AIR CONTROL SOLENOID VALVE a? short circuit in har-
Measure the resistance of harness between X M and idle air
ECM and chassis ground. :ontrol solenoid
Connector & terminal /alve connector.
I CHECK GROUND CIRCUIT OF IDLE AIR Is the resistance less than 5 20 to step 6. Repair open circuit
CONTROL SOLENOID VALVE. Q? in harness
Measure the resistance of harness between between idle air
idle air control solenoid valve connector and control solenoid
engine ground. valve connector
Connector & terminal and engine ground
(E7) No. 3 - Engine ground: terminal.
i CHECK POOR CONTACT. Is there poor contact in ECM 3epair poor con- Replace the idle
Check poor contact in ECM and idle air control and idle air control solenoid :act in ECM and air control solenoid
solenoid valve connectors. valve connectors? dle air control valve. <Ref. to
;olenoid valve FU(D0HC
:onnectors. TURBO)-36, Idle
Air Control Sole-
noid Valve.>
EN(DOHC TURB0)-253
BK:DTC PO509 - IDLE CONTROL SYSTEM CIRCUIT HIGH INPUT -

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Engine breathing
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
MAIN RELAY
BATTERY
SBF-5
AIR CONTROL
SOLENOID
VALVE
lrOl
a-
%
@!
H
EN1160
EN(D0HC TURBO)-254
Step No
CHECK THROTTLE CABLE. Adjust throttle
'lay for adjustment? :able. <Ref. to
SP-7, INSTALLA-
TION, Accelerator
Control Cable.>
! CHECK OUTPUT SIGNAL FROM ECM. Go to step 4.
chassis ground.
I CHECK OUTPUT SIGNAL FROM ECM. s the voltage more than 10 V? Repair battery Replace the idle
1)Turn the ignition switch to OFF. short circuit in har- air control solenoic
2)Disconnect the connector from idle air con- ness between valve <Ref. to
trol solenoid valve. ECM and idle air FU(D0HC
3)Turn the ignition switch to ON. control solenoid TURBO)-36, Idle
4)Measure the voltage between ECM and valve connector. Air Control Sole-
chassis ground. After repair, noid Valve.> and
Connector & terminal replace the ECM. ECM <Ref. to
(6136) No. 10 (+) - Chassis ground (-): <Ref. to FU(D0HC FU(D0HC
TURBO)-47, TURBO)-47,
Engine Control Engine Control
Module.> Module.>.
I CHECK OUTPUT SIGNAL FROM ECM. Ioes the voltage change more Repair battery Contact with SOA
Measure the voltage between ECM and chas- han 10 V by shaking harness short circuit in har- (distributor) ser-
sis ground. ind connector of ECM while ness between vice.
Connector & terminal nonitoring the value with volt- ECM and idle air NOTE:
(6136) No. 10 (+) -Chassis ground (-): kge meter? control solenoid lnsepction by DTL
valve connector. is required, be
After repair, cause probablc
replace the ECM. cause is deteriora
<Ref. to FU(D0HC tion of multiplf
TU RB0)-47, parts.
Engine Control
Module.>
EN(D0HC TURBO)-255
EN(D0HC TURBO)-256
~ ~ ~ ~
~ ~ ~
BL:DTC PO512 - STARTER SWITCH CIRCUIT HIGH INPUT -

TROUBLE SYMPTOM:
CAUTION:
tion Mode.>.
EN(D0HC TURBO)-257
WIRING DIAGRAM:
IGNITION
SWITCH
INTERRUPT
RELAY El AT : AT VEHICLES
ITO SECURITY SYSTEM]
RE LAY(MT)
STARTER
SWITCH
(MT)
B U @ ECM
7 8 9 10 11 12
EN1139
EN(D0HC TURBO)-258
Step Check Yes No

1 CHECK OPERATION OF STARTER MOTOR. Does the starter motor operate Repair battery Check starter
NOTE: when ignition switch to “ON”? short circuit in motor circuit.
Place the inhibitor switch in each position. starter motor cir- <Ref. to EN(D0HC
cuit. After repair, TURBO)-64,
replace the ECM. STARTER
<Ref. to FU(D0HC MOTOR CIR-
TURBO)-47, CUIT, Diagnostics
Engine Control for Engine Start-
Module.> ing Failure.>
EN(D0HC TURB0)-259
lill
BM:DTC PO545 - EXHAUST GAS TEMPERATURE SENSOR CIRCUIT LOW IN-

PUT -
TROUBLE SYMPTOM:
Hard to start
Erroneous idling
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
EXHAUSTGAS
TEMPERATURE
SENSOR
IC
F
EN1161
EN(D0HC TURBO)-260
Em
Step Check Yes No

I CHECK CURRENT DATA. s the value greater than Go to step 2. Repair poor con-
1)Start the engine. 1200°C (2192”F)? tact.
2)Read the data of exhaust gas temperature NOTE:
sensor signal using Subaru Select Monitor or In this case, repaii
*Subaru Select Monitor exhaust gas tem-
For detailed operation procedure, refer to the perature sensor
“READ CURRENT DATA FOR ENGINE”. <Ref. Poor contact in
to EN(D0HC TURBO)-38, Subaru Select Mon- ECM
itor., Poor contact in
*OBD-II general scan tool joint connector
! CHECK HARNESS BETWEEN EXHAUST s the value less than 372°C Replace the Repair ground
GAS TEMPERATURE SENSOR AND ECM 702”F)? exhaust gas tem- short circuit in har-
CONNECTOR. perature sensor. ness between
1)Turn the ignition switch to OFF. <Ref. to FU(D0HC exhaust gas tem-
2)Disconnect the connector from exhaust gas TURBO)-46, perature sensor
temperature sensor. Exhaust Tempera- and ECM connec-
3)Turn the ignition switch to ON. ture Sensor.> tor.
4)Read the data of exhaust gas temperature
sensor signal using Subaru Select Monitor or
NOTE:
itor.>
EN(D0HC TURBO)-261
BN:DTC PO546 - EXHAUST GAS TEMPERATURE SENSOR CIRCUIT HIGH IN-

PUT -
TROUBLE SYMPTOM:
Hard to start
Erroneous idling
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
EXHAUST GAS
TEMPERATURE
SENSOR
10
F
I @ECM
EN1 I61
EN(D0HC TURBO)-262
p19
Step Check Yes No

CHECK CURRENT DATA. ;the value less than 372°C 20 to step 2. lepair poor con-
1)Start the engine. 702”F)? act.
2)Read the data of exhaust gas temperature JOTE:
sensor signal using Subaru Select Monitor or n this case, repair
OBD-II general scan tool. he following:
*Subaru Select Monitor !xhaust gas tem-
For detailed operation procedure, refer to the )erature sensor
“READ CURRENT DATA FOR ENGINE”. <Ref. Poor contact in
to EN(D0HC TURBO)-38, Subaru Select Mon- iCM
itor.> Poor contact in
*OBD-ll general scan tool Dint connector
! CHECK HARNESS BETWEEN EXHAUST s the voltage more than 10 V? 3epair battery ;o to step 3.
GAS TEMPERATURE SENSOR AND ECM short circuit in har-
1)Turnthe ignition switch to OFF. ECM and exhaust
2)Disconnect the connector from exhaust gas jas temperature
temperature sensor. sensor connector.
3)Measure the voltage between exhaust gas
temperature sensor connector and engine
ground.
(8279) No. 1 (+) - Engine ground (-):
I CHECKHARNESSBETWEENEXHAUST s the voltage more than 10 V? ?epair battery 30 to step 4.
GAS TEMPERATURE SENSOR AND ECM ;hort circuit in har-
1)Turnthe ignition switch to ON. ECM and exhaust
2)Measure the voltage between exhaust gas gas temperature
temperature sensor connector and engine ;ensor connector.
ground.
(8279) No. 1 (+) - Engine ground (-):
I CHECK HARNESS BETWEEN EXHAUST s the voltage more than 4 V? 30 to step 5. lepair harness
GAS TEMPERATURE SENSOR AND ECM ind connector.
CONNECTOR. 4OTE:
Measure the voltage between exhaust gas n this case, repaii
temperature sensor connector and engine he following:
Connector & terminal iarness between
(8279) No. 1 (+) - Engine ground (-): X M and exhaust
jas temperature
;ensor connector
Poor contact in
?xhaustgas tem-
ierature sensor
:onnector
Poor contact in
X M connector
1 Poor contact in
oint connector
EN(D0HC TURBO)-263
Step Check Yes No

CHECK HARNESS BETWEEN EXHAUST s the resistance less than 5 3eplace the Repair harness
GAS TEMPERATURE SENSOR AND ECM n? ?xhaustgas tem- and connector.
CONNECTOR. Ierature sensor. NOTE:
1)Turn the ignition switch to OFF. :Ref. to FU(D0HC In this case, repair
exhaust gas temperature sensor connector
and engine ground.
rURBO)-46,
Exhaust Tempera-
ure
.
the following:
Open circuit in
harness between
Connector & terminal ECM and exhaust
-
(B279) No. 2 Engine ground: gas temperature
sensor connector
I
Poor contact in
exhaust gas tem-
perature sensor
connector
Poor contact in
ECM connector
Poor contact in
joint connector
EN(DOHC TURB0)-264
a
EN(D0HC TURBO)-265
B0:DTC PO604 - INTERNAL CONTROL MODULE MEMORY CHECK SUM ER-

ROR -
TROUBLE SYMPTOM:
Engine does not start.
Engine stalls.
CAUTION:
tion Mode.>.
EN(D0HC TURBO)-266
WIRING DIAGRAM:
M A I N RELAY
FRONT OXYGEN(A/F) SENSOIR -
IGNITION
SWITCH BATTERY
No.11 SBF-4 SBF-1
EN1171
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Replace the ECM. It is not necessary
tor or OBD-ll general scan tool <Ref. to FU(D0HC to inspect DTC
indicate DTC P0604? TURBO)-47, P0604.
Engine Control
Module.>
EN(DOHC TURB0)-267
BP:DTC PO703 - BRAKE SWITCH INPUT MALFUNCTION -

CAUTION:
tion Mode.>.
WIRING DIAGRAM:
BATTERY
n
r
I2 BRAKE LIGHT
Ip,
0
z
i I I T 0 STOP LIGHTS1
TCM
B2M4366
Step Check Yes No

1 CHECK OPERATION OF BRAKE LIGHT. Does the brake light come on Go to step 2. Repair or replace
when depressing the brake the brake light cir-
pedal? cuit.
EN(DOHC TURB0)-268
U
Step Check Yes No

CHECK HARNESS BETWEEN TCM AND Is the resistance less than 1 20 to step 3. Repair or replace
BRAKE LIGHT SWITCH CONNECTOR. R? the harness and
1)Disconnectthe connectors from TCM and connector.
brake light switch. NOTE:
2)Measure the resistance of harness between In this case, repai
TCM and brake light switch connector. the following:
Connector & terminal Open circuit in
-
(B55) NO. 12 (965) NO. 3: harness between
TCM and brake
light switch con-
nector
Poor contact in
TCM connector
Poor contact in
brake light switch
connector
I CHECK HARNESS BETWEEN TCM AND Is the resistance more than 1 30 to step 4. Repair ground
BRAKE LIGHT SWITCH CONNECTOR. MR? short circuit in har.
TCM and chassis ground. TCM and brake
Connector & terminal light switch con-
(B55) No. 12 - Chassis ground: nector.
1 CHECK INPUT SIGNAL FOR TCM. Is the voltage less than 1 V 30 to step 5. Adjust or replace
1)Connect the connectors to TCM and brake when releasing the brake the brake light
light switch. pedal? switch. <Ref. to LI.
2)Measure the voltage between TCM and 7, STOP LIGHT
chassis ground. SWITCH,
Connector & terminal INSPECTION,
(B55) No. 12 (+) - Chassis ground (-): Stop Light Sys-
tem.>
B CHECK INPUT SIGNAL FOR TCM. Is the voltage more than 10 V 30 to step 6. Adjust or replace
Measure the voltage between TCM and chas- when depressing the brake the brake light
sis ground. pedal? switch. <Ref. to LI-
Connector & terminal 7, STOP LIGHT
(955) No. 12 (+) - Chassis ground (-): SWITCH,
INSPECTION,
Stop Light Sys-
tem.>
i CHECK POOR CONTACT. Is there poor contact in TCM 3epair poor con- Replace the TCM.
Check poor contact in TCM connector. connector? act in TCM con- <Ref. to AT-45,
lector. Transmission Con,
trol Module
(TCM).>
EN(D0HC TURBO)-269
BQ:DTC PO731 - GEAR 1 INCORRECT RATIO -

NOTE:
For the diagnostic procedure, refer to DTC P0734. <Ref. to EN(D0HC TURBO)-270, DTC PO734 - GEAR
4 INCORRECT RATIO -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
BR:DTC PO732 - GEAR 2 INCORRECT RATIO -

NOTE:
BS:DTC PO733 - GEAR 3 INCORRECT RATIO -

NOTE:
BT:DTC PO734 - GEAR 4 INCORRECT RATIO -

TROUBLE SYMPTOM:
Shift point too high or too low; engine brake not effective in “3’ range; excessive shift shock; excessive
tight corner “braking”
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Is there any other DTC on dis- Inspect relevant Go to step 2.
play? DTC using “List of
Diagnostic Trou-
ble Code (DTC)”.
<Ref. to EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
2 CHECK THROTTLE POSITION SENSOR Is there any trouble in throttle Repair or replace Go to step 3.
CIRCUIT. position sensor circuit? the throttle posi-
Check throttle position sensor circuit. <Ref. to tion sensor circuit.
AT-52, DTC 31 THROTTLE POSITION SEN-
SOR, Diagnostic Procedure with Diagnostic
3 CHECK FRONT VEHICLE SPEED SENSOR Is there any trouble in vehicle Repair or replace Go to step 4.
CIRCUIT. speed sensor 2 circuit? the vehicle speed
Check front vehicle speed sensor circuit. <Ref. sensor 2 circuit.
to AT-57, DTC 33 FRONT VEHICLE SPEED
SENSOR, Diagnostic Procedure with Diagnos-
tic Trouble Code (DTC).> I
1 CHECK TORQUE CONVERTER TURBINE Is there any trouble in torque

SPEED SENSOR CIRCUIT. converter turbine speed sensor the torque con-
Check torque converter turbine speed sensor circuit? verter turbine
circuit. <Ref. to AT-62, DTC 36 TORQUE CON- speed sensor cir-
VERTER TURBINE SPEED SENSOR, Diag-
nostic Procedure with Diagnostic Trouble Code
(DTC).>
EN(DOHC TU RB0)-270
Step Check Yes No

5 CHECK POOR CONTACT. Is there poor contact in TCM Repair poor con- Go to step 6.
Check poor contact in TCM connector. connector? tact in TCM con-
nector.
6 CHECK MECHANICAL TROUBLE. Is there any mechanicaltrouble Repair or replace Replace the TCM.
Check mechanical trouble in automatic trans- in automatic transmission? the automatic <Ref. to AT-45,
mission. transmission. Transmission Con-
<Ref. to AT-12, trol Module
INSPECTION, (TCM).>
Road Test.>
EN(D0HC TURB0)-271
-
BU:DTC PO741 - TORQUE CONVERTER CLUTCH SYSTEM MALFUNCTION -

TROUBLE SYMPTOM:
No lock-up (after engine warm-up)
No shift or excessive tight corner “braking”
CAUTION:
tion Mode.>.
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Is there any other DTC on dis- Inspect the rele- Go to step 2.
play? vant DTC using
Trouble Code
(DTC)”. <Ref. to
EN(D0HC
TURBO)-80, List
of Diagnostic Trou,
ble Code (DTC).>
2 CHECK LOCK-UP DUTY SOLENOID CIR- Is there any trouble in lock-up Repair or replace Go to step 3.
CUIT. duty solenoid circuit? the lock-up duty
Check lock-up duty solenoid circuit. <Ref. to solenoid circuit.
AT-94, DTC 77 LOCK-UP DUTY SOLENOID,
Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
3 CHECK THROTTLE POSITION SENSOR Is there any trouble in throttle Repair or replace Go to step 4.
CIRCUIT. position sensor circuit? the throttle posi-
Check throttle position sensor circuit. <Ref. to tion sensor circuit.
AT-52, DTC 31 THROTTLE POSITION SEN-
4 CHECK TORQUE CONVERTER TURBINE Is there any trouble in torque Repair or replace Go to step 5.
SPEED SENSOR CIRCUIT. converter turbine speed sensor the torque con-
Check torque converter turbine speed sensor circuit? verter turbine
circuit. <Ref. to AT-62, DTC 36 TORQUE CON. speed sensor cir-
VERTER TURBINE SPEED SENSOR, Diag- cuit.
(DTC).>
5 CHECK ENGINE SPEED INPUT CIRCUIT. Is there any trouble in engine Repair or replace Go to step 6.
Check engine speed input circuit. <Ref. to AT- speed input circuit? the engine speed
44, DTC 11 ENGINE SPEED SIGNAL, Diag- input circuit.
(DTC).>
6 CHECK INHIBITOR SWITCH CIRCUIT. Is there any trouble in inhibitor Repair or replace Go to step 7.
Check inhibitor switch circuit. <Ref. to AT-1 15, switch circuit? the inhibitor switch
CHECK INHIBITOR SWITCH., Diagnostic Pro. circuit.
cedure for No-DiagnosticTrouble Code
(DTC).>
7 CHECK BRAKE LIGHT SWITCH CIRCUIT. Go to step 8.
- Check brake light switch circuit. <Ref. to AT- light switch circuit? the brake light
112, CHECK BRAKE SWITCH., Diagnostic switch circuit.
Procedure for No-DiagnosticTrouble Code
(DTC).>
EN(D0HC TURBO)-272
Step Check Yes No

8 CHECK ATF TEMPERATURE SENSOR CIR- Is there any trouble in ATF tem- Repair or replace Go to step 9.
CUIT. perature sensor circuit? the ATF tempera-
Check ATF temperature sensor circuit. <Ref. to ture sensor circuit.
AT-48, DTC 27 ATF TEMPERATURE SEN-
9 CHECK POOR CONTACT. Is there poor contact in TCM Repair poor con- Go to step 10.
Check poor contact in TCM connector. connector? tact in TCM con-
nector.
Is there any mechanicaltrouble Repair or replace Replace the TCM.
Check mechanical trouble in automatic trans- in automatic transmission? the automatic <Ref. to AT-45,
mission. transmission. Transmission Con-
<Ref. to AT-12, trol Module
INSPECTION, (TCM).>
Road Test.>
EN(D0HC TURBO)-273
BV: DTC PI086 - TUMBLE GENERATOR VALVE #2 (LH) POSITION SENSOR

CIRCUIT LOW INPUT -
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
TUMBLE GENERATOR VALVE

POSITION SENSOR
" -
EN(DOHC TURB0)-274
Step Check Yes No

CHECK CURRENT DATA. s the value less than 0.1 V? 30 to step 2. Even if MIL lights
2)Read the data of tumble generator valve returned to a nor-
position sensor signal using Subaru Select mal condition at
Monitor or OBD-ll general scan tool. this time. A tempo.
“READ CURRENT DATA FOR ENGINE”. <Ref. NOTE:
to EN(D0HC TURBO)-38, Subaru Select Mon- In this case, repaii
OBD-II General Scan Tool Instruction Manual. sensor connector
Poor contact in
ECM connector
Poor contact in
coupling connect0
! CHECK INPUT SIGNAL FOR ECM. s the voltage more than 4.5 V? 20 to step 4. Go to step 3.
and chassis ground while tumble generator
valve is fully closed.
‘Connector & terminal
I CHECK INPUT SIGNAL FOR ECM. loes the voltage change more 3epair poor con- Contact with SOA
Measure the voltage between ECM connector han 4.5 V by shaking harness act in ECM con- (distributor)ser-
and chassis ground. md connector of ECM while lector. vice.
(8135) No. 9 (+) - Chassis ground (-): ige meter? Inspection by DTk
is required, be
cause probable
cause is deteriora
tion of multiple
parts.
I CHECK INPUT SIGNAL FOR ECM. s the voltage less than 0.1 V? 30 to step 6. Go to step 5.
and chassis ground.
I CHECK INPUT SIGNAL FOR ECM. (USING loes the voltage change more 3epair poor con- Go to step 6.
SUBARU SELECT MONITOR.) han 0.1 V by shaking harness :act in ECM con-
Measure the voltage between ECM connector md connector of ECM while lector.
and chassis ground. nonitoring the value with Sub-
3ru Select Monitor?
EN(D0HC TURBO)-275
Step Check Yes No

6 CHECK HARNESS BETWEEN ECM AND s the voltage more than 4.5 V' 20 to step 7. Repair harness
TUMBLE GENERATOR VALVE POSITION and connector.
SENSOR CONNECTOR. NOTE:
2)Disconnectthe connectors from tumble gen- the following:
erator valve position sensor. Open circuit in
4)Measure voltage between tumble generator tumble generator
valve position sensor connector and engine valve position sen
ground. sor and ECM con-
Connector & terminal nector
(E50) No. 1 (+)- Engine ground (-): Poor contact in
tumble generator
valve position sen
sor connector
Poor contact in
ECM connector
Poor contact in
coupling conneck
Poor contact in
joint connector
7 CHECK HARNESS BETWEEN ECM AND s the resistance less than 1 20 to step 8. Repair harness
TUMBLE GENERATOR VALVE POSITION 2? and connector.
SENSORCONNECTOR. NOTE:
1)Turn the ignition switch to OFF. In this case, repa
ECM connector and tumble generator valve Open circuit in
position sensor connector. harness between
Connector & terminal tumble generator
(8135) NO. 13 - (E50) NO. 3: valve position sen
sor and ECM con-
nector
Poor contact in
ECM connector
Poor contact in
tumble generator
valve position sen
sor connector
Poor contact in
coupling connectc
8 CHECK HARNESS BETWEEN ECM AND s the resistance less than 10 3epair ground Go to step 9.
TUMBLE GENERATOR VALVE POSITION 2? short circuit in har-
SENSOR CONNECTOR. less between tum-
Measure the resistance of harness between )le generator valve
tumble generator valve position sensor con- losition sensor
nector and engine ground. and ECM connec-
Connector & terminal or.
(€50) No. 3 - Engine ground:
9 CHECK POOR CONTACT. s there poor contact in tumble 3epair poor con- Replace the tum-
Check poor contact in tumble generator valve lenerator valve position sensoi act in tumble gen- ble generator valvc
position sensor connector. :onnector? ?ratorvalve assembly. <Ref. tc
iosition sensor FU(D0HC
:onnector. TURBO)-40, Tum-
ble Generator
Valve Assembly.>
EN(D0HC TURBO)-276
EN(D0HC TURBO)-277
BW:DTC PI087 -TUMBLE GENERATOR VALVE #2 (LH) POSITION SENSOR

CIRCUIT HIGH INPUT -
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
tion Mode.>.
WIRING DIAGRAM:

POSITION SENSOR
U@ECM
EN1162
EN(DOHC TURB0)-278
~~
Step Check Yes No

CHECK CURRENT DATA. s the value more than 4.9 V? Go to step 2. Even if MIL lights
Monitor or OBD-ll general scan tool. this time. A tempo-
*Subaru Select Monitor Df the connector
to EN(D0HC TURBO)-38, Subaru Select Mon- In this case, repair
*OBD-ll general scan tool b Poor contact in
For detailed operation procedures, refer to the tumble generator
OBD-II General Scan Tool Instruction Manual. valve position sen-
sor connector
b Poor contact in
ECM connector
Poor contact in
soupling connectot
! CHECK HARNESS BETWEEN TUMBLE s the resistance less than 5 Go to step 3. Repair harness
GENERATOR VALVE POSITION SENSOR 3? and connector.
4ND ECM CONNECTOR. NOTE:
1)Turnthe ignition switch to OFF. In this case, repair
2)Disconnect the connector from tumble gen- the following:
erator valve position sensor. b Open circuit in

throttle position sensor connector and engine tumble generator
ground. valve position sen-
Connector & terminal sor and ECM con-
(€50) No. 2 - Engine ground: nector
b Poor contact in
soupling connector
b Poor contact in
ioint connector
I CHECK HARNESS BETWEEN TUMBLE Replace the tum-
GENERATOR VALVE POSITION SENSOR short circuit in har- ble generator valve
AND ECM CONNECTOR. ness between tum- assembly. <Ref. to
1)Turn the ignition switch to ON. ble generator valve FU(D0HC
2)Measure the voltage between throttle posi- position sensor TURBO)-40, Tum-
tion sensor connector and engine ground. and ECM connec- ble Generator
Connector & terminal tor. After repair, Valve Assembly.>
(€50) No. 3 (+) - Engine ground (-): replace the ECM.
<Ref. to FU(D0HC
TURBO)-47,
Engine Control
Module.>
EN(D0HC TURBO)-279
ENG I N E (DIAGNOSTICS)
BX: DTC PI088 -TUMBLE GENERATOR VALVE #I(RH) POSITION SENSOR

CIRCUIT LOW INPUT -
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
tion Mode.>.
WIRING DIAGRAM:

POSITION SENSOR
EN1163
EN(D0HC TURBO)-280
Step Check Yes No

I CHECK CURRENT DATA. the value less than 0.1 V? 20 to step 2. Even if MIL lights
Monitor or OBD-II general scan tool. this time. A tempo-
“READ CURRENT DATA FOR ENGINE”. <Ref NOTE:
to EN(D0HC TURBO)-38, Subaru Select Mon In this case, repaii
OBD-II General Scan Tool Instruction Manual. valve position sen-
sor connector
8 Poor contact in
-
ECM connector
Poor contact in
coupling connectoi
! CHECK INPUT SIGNAL FOR ECM. the voltage more than 4.5 V? 30 to step 4. Go to step 3.
and chassis ground while throttle valve is fully
clised.
I CHECK INPUT SIGNAL FOR ECM. )es the voltage change more 3epair poor con- Contact with SOA
Measure the voltage between ECM connector %n4.5 V by shaking harness act in ECM con- (distributor) ser-
and chassis ground. d connector of ECM while lector. vice.
Connector & terminal mitoring the value with volt- NOTE:
(6135) No. 9 (+) - Chassis ground (-): e meter? Inspection by DTM
is required, be.
cause probable
cause is deteriora.
tion of multiple
parts.
I CHECK INPUT SIGNAL FOR ECM. the voltage less than 0.1 V? ;o to step 6. Go to step 5.
and chassis ground.
1 CHECK INPUT SIGNAL FOR ECM. (USING )es the voltage change more 3epair poor con- Go to step 6.
SUBARU SELECT MONITOR.) %n0.1 V by shaking harness act in ECM con-
Measure the voltage between ECM connector d connector of ECM while lector.
and chassis ground. mitoring the value with Sub-
J Select Monitor?
EN(D0HC TURBO)-281
Step Check Yes No

CHECK HARNESS BETWEEN ECM AND I Is the voltage more than 4.5 VI; 30 to step 7. Repair harness
TUMBLE GENERATOR VALVE POSITION and connector.
1)Turnthe ignition switch to OFF. In this case, repai
2)Disconnect the connectors from tumble gen- the following:
4)Measure the voltage between throttle posi- tumble generator
tion sensor connector and engine ground. valve position sen-
(E54) No. 1 (+) - Engine ground (-): nector
Poor contact in
tumble generator
valve position sen-
sor connector
Poor contact in
ECM connector
Poor contact in
coupling connect0
Poor contact in
joint connector
resistance less than 1 20 to step 8. Repair harness
and connector.
1)Turnthe ignition switch to OFF. In this case, repai
ECM connector and tumble generator valve Open circuit in
position sensor connector. harness between
Connector & terminal tumble generator
(8135) NO. 23 - (E54) NO. 3: valve position sen-
sor and ECM con-
nector
Poor contact in
ECM connector
Poor contact in
tumble generator
valve position sen-
sor connector
Poor contact in
coupling connectoi
CHECK HARNESS BETWEEN ECM AND IS the resistance less than 10 3epair ground Go to step 9.
THROlTLE POSITION SENSOR CONNEC- Q? ;hort circuit in har-
TOR. less between tum-
Measure the resistance of harness between ile generator valve
tumble generator valve position sensor con- iosition sensor
nector and engine ground. and ECM connec-
CHECK POOR CONTACT. Is there poor contact in tumble 3epair poor con- Replace the tum-
Check poor contact in tumble generator valve generator valve position sensor act in tumble gen- ble generator valve
position sensor connector. connector? ?ratorvalve assembly. <Ref. to
iosition sensor FU(D0HC
:onnector. TURBO)-40, Tum-
ble Generator
Valve Assembly.>
EN(D0HC TURBO)-282
EN(D0HC TURBO)-283
~~
BY:DTC PI089 - TUMBLE GENERATOR VALVE #I(RH) POSITION SENSOR

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
tion Mode.>.
WIRING DIAGRAM:

POSITION SENSOR
" -
U@ECM
EN(DOHC TURB0)-284
Step Check Yes No

I CHECK CURRENT DATA. s the value more than 4.9 V? 20 to step 2. Even if MIL lights
Monitor or OBD-ll general scan tool. this time. A tempo
Gubaru Select Monitor of the connector
For detailed operation procedure, refer to the may be the cause
to EN(D0HC TURBO)-38, Subaru Select Mon In this case, repai
OBD-II General Scan Tool Instruction Manual. valve position sen
sor connector
Poor contact in
ECM connector
Poor contact in
coupling connectc
2 CHECK HARNESS BETWEEN TUMBLE s the resistance less than 5 30 to step 3. Repair harness
GENERATOR VALVE POSITION SENSOR 2? and connector.
AND ECM CONNECTOR. NOTE:
1 !Turn the ignition switch to OFF. In this case, repai
2)Disconnect the connector from tumble gen- the following:
tumble generator valve position sensor con- tumble generator
nector and engine ground. valve position sen.
(E54) No. 2 - Engine ground: nector
8 Poor contact in
coupling connect0
Poor contact in
joint connector
B CHECK HARNESS BETWEEN TUMBLE s the voltage more than 4.9 V? 3epair battery Replace the tum-
GENERATOR VALVE POSITION SENSOR ;hort circuit in har- ble generator valve
AND ECM CONNECTOR. less between tum- assembly. <Ref. tc
1)Turn the ignition switch to ON. )le generator valve FU(D0HC
2)Measure the voltage between tumble gener- )osition sensor TURBO)-40, Tum-
ator valve position sensor connector and ind ECM connec- ble Generator
engine ground. or. After repair, Valve Assembly.>
Connector & terminal eplace the ECM.
(E54) No. 3 (+) - Engine ground (-): :Ref. to FU(D0HC
-URBO)-47,
ingine Control
Aodule.>
EN(DOHC TURBO)-285
BZ:DTC P1090 -TUMBLE GENERATOR VALVE SYSTEM #1 (RH) MALFUNC-

TION (STUCK OPEN) -
CAUTION:
tion Mode.>.
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Go to step 2.
tor or OBD-ll general scan tool
P1088, P1089,
indicate P1088, P1089, P1094 PI094 or PI095
or P I 095? using List of Diag-
nostic Trouble
Code (DTC) <Ref.
to EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
2 FHECK TUMBLE GENERATOR VALVE RH Does the tumble generator Replace the tum- Clean tumble gen-
1)Removethe tumble generator valve assem- valve move smoothly? (No dirt ble generator valve erator valve.
bly. or foreign materials clogged) assembly. <Ref. to
2)Check tumble generator valve body. FU(D0HC
TURBO)-40, Tum-
ble Generator
Valve Assembly.>
EN(D0HC TURBO)-286
CA:DTC PI091 -TUMBLE GENERATOR VALVE SYSTEM #I(RH) MALFUNC-

TION (STUCK CLOSE) -
CAUTION:
tion Mode.>.
Step Check Yes No

tor or OBD-ll general scan tool
P I 088, P I 089,
P I094 or P I 095
indicate P I 088, P I 089, P I 094
or P1095? using List of Diag-
nostic Trouble
Code (DTC) <Ref.
to EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
2 CHECK TUMBLE GENERATOR VALVE RH Does the tumble generator Replace the tum- Clean tumble gen-
1)Remove the tumble generator valve assem- valve move smoothly? (No dirt ble generator valve erator valve.
2)Check tumble generator valve body. FU(DOHC
TURBO)-40, Tum-
ble Generator
Valve Assemblw
EN(DOHC TURB0)-287
CB:DTC PI092 -TUMBLE GENERATOR VALVE SYSTEM #2 (LH) MALFUNC-

TION (STUCK OPEN) -
CAUTION:
tion Mode.>.
Step Check Yes No

tor or OBD-ll general scan toolP1086, P1087,
indicate P1086, P1087, P1096 P1096 or P I 097
or P1097? using List of Diag-
nostic Trouble
Code (DTC) <Ref.
to EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
2 CHECK TUMBLE GENERATOR VALVE RH Does the tumble generator Replace the tum- :lean tumble gen-
‘1)Remove the tumble generator valve assem- valve move smoothly? (No dirt ble generator valve srator valve.
TURBO)-40, Tum-
ble Generator
Valve Assembly.>
EN(D0HC TURBO)-288
CC:DTC PI093 -TUMBLE GENERATOR VALVE SYSTEM #2 (LH) MALFUNC-

TION (STUCK CLOSE) -
CAUTION:
tion Mode.>.
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. 3oes the Subaru Select Moni- Inspect DTC Go to step 2.
:or or OBD-II general scan tool
P1086, P1087,
ndicate P1086, P1087, P1096 P1096 or P1097
3r P1097? using List of Diag-
nostic Trouble
Code (DTC) <Ref.
to EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
2 CHECK TUMBLE GENERATOR VALVE RH Does the tumble generator Replace the tum- Clean tumble gen-
1)Remove the tumble generator valve assem- valve move smoothly? (No dirt ble generator valve erator valve.
bly. 3r foreign materials clogged) assembly. <Ref. to
TURBO)-40, Tum-
ble Generator
Valve Assembly.>
EN(D0HC TURBO)-289
CD:DTC PI094 - TUMBLE GENERATOR VALVE CIRCUIT #I(OPEN CIRCUIT)

-
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
TUMBLE
GENERATOR VALVE
ACTUATOR RH
EN(D0HC TURBO)-290
Step Check Yes No

CHECK HARNESS BETWEEN ECM AND s the resistance less than 1Q? I Go to step 2. Repair open circuit
TUMBLE GENERATOR VALVE ACTUATOR between ECM and
CONNECTOR. tumble generator
1)Turnthe ignition switch to OFF. valve connector.
2)Disconnectthe connector from tumble gen- NOTE:
erator valve and ECM connector. In this case, repaii
3)Measure the resistance between tumble the following:
generator valve actuator and ECM connector. Open circuit in
(E55) NO. 1 - (B84) N0.4: ECM and tumble
(E55) NO. 2 - (B84) NO.5: generator valve
actuator connec-
tor.
Poor contact in
coupling connec-
tor.
! CHECK POOR CONTACT. s there poor contact in tumble rlepair poor con- Replace the tum-
Check poor contact in tumble generator valve jenerator valve actuator contact in tumble gen- ble generator valve
actuator connector. lector. erator valve assembly. <Ref. to
actuator connec- FU(D0HC
tor. TURBO)-40, Tum-
ble Generator
Valve Assembly.>
EN(D0HC TURBO)-291
CE:DTC PI095 -TUMBLE GENERATOR VALVE CIRCUIT #I (OVERCURRENT)

CAUTION:
tion Mode.>.
WIRING DIAGRAM:
TUMBLE
GENERATOR VALVE
ACTUATORRH
EN116r
EN(D0HC TURB0)-292
I
Step Check Yes No

1 CHECK HARNESS BETWEEN ECM AND Is the voltage less than 5V? Replace the tum- Repair battery
TUMBLE GENERATOR VALVE ACTUATOR ble generator valve short circuit
CONNECTOR. assembly. <Ref. to between ECM and
1)Turn the ignition switch to OFF. FU(D0HC tumble generator
2)Disconnect the connector from tumble gen- TURBO)-40, Tum- valve actuator.
erator valve connector. ble Generator
3)Measure the voltage between tumble gener- Valve Assembly.>
ator valve actuator and chassis ground.
(E55) No. 1 (+) - Chassis ground (-):
(€55) No. 2 1+J - Chassis around (4:
EN(D0HC TURBO)-293
CF:DTC PI096 - TUMBLE GENERATOR VALVE CIRCUIT #2 (OPEN CIRCUIT)

-
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
TUMBLE
GENERATOR VALVE
ACTUATOR LH
EN1165
EN(D0HC TURBO)-294
Step Check Yes No

I CHECK HARNESS BETWEEN ECM AND s the resistance less than 1a? Go to step 2. Repair open circuit
TUMBLE GENERATOR VALVE ACTUATOR between ECM and
CONNECTOR. tumble generator
1)Turn the ignition switch to OFF. valve connector.
2)Disconnect the connector from tumble gen- NOTE:
erator valve and ECM connector. In this case, repaii
3)Measure the resistance between tumble the following:
generator valve actuator and ECM connector. Open circuit in
(E5l) NO. 1 - (884)NO. 10: ECM and tumble
(E5l) NO. 2 - (884)NO. 11: generator valve
actuator connec-
tor.
Poor contact in
coupling connec-
tor.
2 CHECK POOR CONTACT. s there poor contact in tumble Repair poor con- Replace the tum-
Check poor contact in tumble generator valve jenerator valve actuator contact in tumble gen- ble generator valve
actuator connector. lector. erator valve assembly. <Ref. to
actuator connec- FU(D0HC
tor. TURBO)-40, Tum-
ble Generator
Valve Assembly.>
EN(D0HC TURBO)-295
CG:DTC PI097 -TUMBLE GENERATOR VALVE ClRCUlT#2 (OVERCURRENT)

CAUTION:
tion Mode.>.
WIRING DIAGRAM:
TUMBLE
GENERATOR VALVE
ACTUATOR LH
EN1165
EN(D0HC TURBO)-296
Step Check Yes No

1 CHECK HARNESS BETWEEN ECM AND Is the voltage less than 5V? Replace the tum- Repair battery
TUMBLE GENERATOR VALVE ACTUATOR ble generator valve short circuit
CONNECTOR. assembly. <Ref. to between ECM and
1)Turn the ignition switch to OFF. FU(D0HC tumble generator
2)Disconnect the connector from tumble gen- TURBO)-40, Tum- valve actuator.
erator valve connector. ble Generator
3)Measure the voltage between tumble gener- Valve Assembly.>
ator valve actuator and chassis ground.
(€51) No. 1 (+) - Chassis ground (-):
(E51) No. 2 (+) - Chassis ground (-):
CH:DTC PI110 - ATMOSPHERIC PRESSURE SENSOR CIRCUIT LOW INPUT

CAUTION:
Step Check Yes No

tor or OBD-ll general scan tool <Ref. to FU(D0HC to inspect DTC
indicate DTC P11l o ? TURBO)-47, P1110.
Engine Control
Module.>
NOTE:
Atmospheric pres-
sure sensor is buili
into ECM.
CI: DTC P I 111 - ATMOSPHERIC PRESSURE SENSOR CIRCUIT HIGH INPUT

CAUTION:
tion Mode.>.
Step Check Yes No

tor or OBD-II general scan tool <Ref. to FU(D0HC to inspect DTC
indicate DTC P111l ? TURBO)-47, P1111.
Engine Control
Module.>
NOTE:
Atmospheric pres-
sure sensor is built
into ECM.
EN(DOHC TURB0)-297
~
-
CJ:DTC P I 112 ATMOSPHERIC PRESSURE SENSOR CIRCUIT RANGWPER-
FORMANCE PROBLEM -
CAUTION:
tion Mode.>.
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Replace the ECM.
tor or OED-ll general scan tool PO106, PO107, <Ref. to FU(D0HC
indicate DTC PO106, PO107, PO108, P1110 or TURBO)-47,
P0108, P1110 or P111I ? P I 111 using “List Engine Control
of Diagnostic Trou- Module.>
ble Code NOTE:
(DTC)”.<Ref. to Atmospheric pres
EN(D0HC sure sensor is buill
TURBO)-80, List into ECM.
of Diagnostic Trou-
ble Code (DTC).>
EN(D0HC TURBO)-298
EN(D0HC TURBO)-299
CK: DTC P I 130 - FRONT OXYGEN (NF)SENSOR CIRCUIT MALFUNCTION

(OPEN CIRCUIT) -
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
-
FN1143
EN(D0HC TURBO)-300
Step Check Yes No

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 2. Repair harness
FRONT OXYGEN ( N F ) SENSOR CONNEC- a? and connector.
TOR. NOTE:
2)Disconnect the connectors from ECM and the following:
front oxygen (NF) sensor connector. Open circuit in
ECM and front oxygen (NF) sensor connector. ECM and front
Connector & terminal oxygen (NF)sen-
(8137) NO. 29 - (818) NO. 3: sor connector
(8137) NO. 19 - (818) NO. 4: Poor contact in
front oxygen (NF)
sensor connector
9 Poor contact in
ECM connector
CHECK POOR CONTACT. Is there poor contact in front 3epair poor con- Replace the front
Check poor contact in front oxygen (NF) sen- oxygen (NF) sensor connec- act in front oxygen oxygen (NF) sen-
sor connector. tor? N F ) sensor con- sor. <Ref. to
lector. FU(D0HC
TURBO)-42, Front
Oxygen (NF) Sen,
sor.>
EN(D0HC TURBO)-301
CL: DTC P I 131 - FRONT OXYGEN (NF) SENSOR CIRCUIT MALFUNCTION

(SHORT CIRCUIT) -
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
MAIN RELAY BATTERY

SBF-5
3 c
EN1143
EN(D0HC TURBO)-302
Step Check Yes No

CHECK HARNESS BETWEEN ECM AND the resistance more than 10 Go to step 2. Repair ground
FRONT OXYGEN (NF) SENSOR CONNEC- ? short circuit in har
TOR. ness between
1)Turnthe ignition switch to OFF. ECM and front
2)Disconnect the connector from ECM. oxygen (NF) sen-
3)Measure the resistance of harness between sor connector.
CHECK HARNESS BETWEEN ECM AND the resistance more than 10 Go to step 3. Repair ground
FRONT OXYGEN ( A F ) SENSOR CONNEC- ? short circuit in har
TOR. ness between
Measure the resistance of harness between ECM and front
ECM connector and chassis ground. oxygen (NF) sen-
Connector & terminal sor connector.
CHECK OUTPUT SIGNAL FOR ECM. the voltage more than 4.5 V? Go to step 4. Go to step 5.
1)Connect the connector to ECM.
CHECK OUTPUT SIGNAL FOR ECM. the voltage more than 10 V? Repair battery Repair poor con-
Measure the voltage between ECM connector short circuit in har- tact in ECM con-
and chassis ground. ness between nector.
Connector & terminal ECM and front
(8137) No. 19 (+) - Chassis ground (-): oxygen (NF) sen-
sor connector.
CHECK OUTPUT SIGNAL FOR ECM. the voltage more than 4.95 Go to step 6. Replace the front
Measure the voltage between ECM connector b
oxygen (NF) sen-
and chassis ground. sor. <Ref. to
(6137) No. 29 (+) - Chassis ground (-): TURBO)-42, Froni
Oxygen (NF) Sen
sor.>
CHECK OUTPUT SIGNAL FOR ECM. the voltage more than 10 V? Repair battery Repair poor con-
Measure the voltage between ECM connector short circuit in har- tact in ECM con-
and chassis ground. nessbetween nector.
Connector & terminal ECM and front
(8137) No. 29 (+) - Chassis ground (-): oxygen (NF) sen-
sor connector.
EN(D0HC TURBO)-303
CM:DTC PI134 - FRONT OXYGEN (NF)SENSOR MICRO-COMPUTER PROB-

LEM -
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Replace the ECM. I It is not necessarv
’
tor or OBD-II general scan tool <Ref. to FU(DOHC to inspect DTC
indicate DTC P1134? TURBO)-47, P1134.
Engine Control
Module.>
EN(D0HC TURBO)-304
EN(D0HC TURBO)-305
CN: DTC P I 139 - FRONT OXYGEN (NF) SENSOR #IHEATER CIRCUIT

RANGUPERFORMANCE PROBLEM -
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
w
FRONTOXYGEN
EN(D0HC TURBO)-306
Step Check
CHECK HARNESS BETWEEN ECM AND s the resistance less than 1
FRONT OXYGEN (NF) SENSOR CONNEC- L? in harness
TOR. between ECM and
1)Start the engine, and warm-up the engine. front oxygen (NF)
2)Turn the ignition switch to OFF. I
sensor connector.
3)Disconnect the connectors from ECM and
front oxygen (NF) sensor.
ECM and front oxygen (NF) sensor connector.
-
(8137) NO. 5 (818) NO. 1:
-
(8137) NO. 4 (818) NO. 1:
I
CHECK HARNESS BETWEEN ECM AND s the resistance less than 1 30 to step 3. Repair open circuit
FRONT OXYGEN ( N F ) SENSOR CONNEC- 2? in harness
Measure the resistance of harness between front oxygen (NF)
ECM and front oxygen (NF) sensor connector. sensor connector.
(8137) NO. 19 - (818) NO. 4:
(8137) NO. 29 - (818) NO. 3:
I CHECK HARNESS BETWEEN ECM AND s the resistance less than 1 30 to step 4. Repair open circuil
FRONT OXYGEN ( N F ) SENSOR CONNEC- 2? in harness
Measure the resistance of harness between front oxygen (NF)
main relay and front oxygen (NF) sensor con- sensor connector.
nector.
(847) NO. 4 - (818) NO. 2:
I CHECK FRONT OXYGEN (NF)SENSOR. s the resistance less than 5 30 to step 5. Replace the front
Measure the resistance between front oxygen 2? oxygen (NF) sen-
(NF) sensor connector terminals. sor. <Ref. to
Terminals FU(DOHC
NO. 2 -NO. 1: TURBO)-42, Front
Oxygen (NF) Sen
sor.>
i CHECK POOR CONTACT. s there poor contact in ECM or Repair poor con- Replace the front
Check poor contact in ECM and front oxygen ront oxygen (NF) sensor contact in ECM or oxygen (NF) sen-
(NF) sensor connector. lector? iront oxygen (NF) sor. <Ref. to
sensor connector. FU(D0HC
TURBO)-42, Fronl
Oxygen (NF) Sen
sor.>
EN(D0HC TURBO)-307
C0:DTC P I 141 - MASS AIR FLOW SENSOR CIRCUIT RANGWPERFORMANCE

PROBLEM (LOW INPUT) -
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
IAlN RELAY
BATTERY
SBF-5
MASS AIR FLOW AND

4
ECM
EN(D0HC TU R BO)-308
Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. I Does Subaru select monitor orInspect DTC Replace the mass
OBD-II general scan tool indi- PO102 or PO103 air flow and intake
cate DTC PO1 02 or PO103? using “Diagnos- air temperature
tics Chart with sensor.
Trouble Code”
<Ref. to EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary tc
inspect DTC
P I 141.
EN(D0HC TURBO)-309
CP:DTC P I 142 - THROTTLE POSITION SENSOR CIRCUIT RANGUPERFOR-

MANCE PROBLEM (LOW INPUT) -
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
THROTTLE
POSITION
SENSOR
[
1
ml
5 6 7 8
I
I
II
0@ECM
EN1166
EN(D0HC TURBO)-310
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Replace the throt-
tor or OBD-II general scan tool PO122 or PO123 tle position sen-
indicate DTC PO122 or P0123? using “List of Diag- sor. <Ref. to
nostic Trouble FU(D0HC
Code (DTC)”. TURBO)-33,
<Ref. to EN(D0HC Throttle Position
TURBO)-80, List Sensor.>
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P1142.
EN(D0HC TURBO)-31 1
ENG IN E (DIAGNOSTICS)
~
CQ:DTC P1146 - PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM (HIGH INPUT) -
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
THROTTLE BODY
U@ ECM
EN1146
EN(D0HC TURBO)-312
Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. loes the Subaru Select Moni- Inspect DTC 30 to step 2.
NOTE: or or OBD-ll general scan tool PO107, PO108 or
In this case, it is not necessary to inspect DTC ndicate DTC PO107, PO108 or P1112 using “List
PO106. ’1 112? of Diagnostic Trou
ble Code (DTC)”.
<Ref. to EN(D0HC
TURBO)-80, List
of Diagnostic Trou
ble Code (DTC).>
CHECK AIR INTAKE SYSTEM. 4re there holes, loose bolts or Repair air intake 30 to step 3.
lisconnection of hose on air system.
ntake system?
CHECK PRESSURE SENSOR. s the value within the specifi- Go to step 4. 3eplace the pres-
1)Start the engine and warm-up engine until iure sensor. <Ref.
coolant temperature is greater than 60°C o FU(D0HC
(140°F). rURBO)-35, Pres.
2)Place the shift lever in the selector lever in ;ure Sensor.>
“N” or “ P position.
3)Turn the N C switch to OFF.
4)Turn all accessory switches to OFF.
5)Read the data of pressure sensor signal
scan tool.
NOTE:
to EN(D0HC TURBO)-38, Subaru Select Mom
itor.>
Specification:
*Intake manifold absolute pressure
Ignition ON
73.3 - 106.6 kPa (550 - 800 mmHg,
21.65 - 31.50 inHg)
idling
20.0 - 46.7 kPa (150 - 350 mmHg,
5.91 - 13.78 inHg)
CHECK THROTTLE POSITION. s the throttle positioning ratio Go to step 5. idjust or replace
Read the data of throttle position signal using he throttle posi-
Subaru Select Monitor or OBD-ll general scan ion sensor. <Ref.
tool. o FU(D0HC
NOTE: -URBO)-33,
*Subaru Select Monitor -hrottle Position
For detailed operation procedure, refer to the ;ensor.>
itor.>
CHECK THROTTLE POSITION. s the throttle positioning ratio Replace the pres- Ieplace the throt-
?qualto or more than 85% sure sensor. <Ref. le position sen-
vhen throttle is fully open? to FU(D0HC ;or. <Ref. to
TURBO)-35, Pres- ’U(D0HC
sure Sensor.> -URB0)-33,
-hrottle Position
;ensor.>
EN(D0HC TURBO)-313
CR:DTC P1230 - FUEL PUMP CONTROLLER MALFUNCTION -

CAUTION:
tion Mode.>.
WIRING DIAGRAM:
FUEL PUMP
CONTROLLER
ECM
A: @
C :@
EN1141
EN(D0HC TURBO)-314
Step Check Yes No

CHECK POWER SUPPLY CIRCUIT TO FUEL the voltage more than 1OV? i o to step 2. Repair power sup-
PUMP CONTROLLER. ply circuit.
2)Disconnect the connector from fuel pump In this case repair
controller. the following:
3)Turn the ignition switch to ON. Open or ground
4)Measure the voltage between fuel pump short circuit in har-
controller and chassis ground. ness between fuel
Connector & terminal pump relay and
(R122) No. 10 (+)- Chassis ground (-): fuel pump control-
ler.
Poor contact in
fuel pump control-
ler connector.
Poor contact in
fuel pump relay
connector.
CHECK GROUND CIRCUIT OF FUEL PUMP the resistance less than 5 ;o to step 3. Repair harness
CONTROLLER. ? and connector.
2)Measure the resistance of harness between In this case, repair
fuel pump controller and chassis ground. the following:
Connector & terminal Open circuit
(R122) No. 5 - Chassis ground: between fuel pump
controller and
chassis ground.
Poor contact in
fuel pump control-
ler connector.
CHECK HARNESS BETWEEN FUEL PUMP the resistance less than 1 i o to step 4. Repair open circuit
CONTROLLER AND FUEL PUMP CONNEC- ? betweenfuel pump
TOR. controller and fuel
1)Disconnect the connector from fuel pump.
fuel pump controller and fuel pump connector.
(R122) NO. 7 - (R58) NO. 2:
-
(R122) NO. 6 (R58) NO. 1:
CHECK HARNESS BETWEEN FUEL PUMP the resistance more than 1M
CONTROLLER AND FUEL PUMP CONNEC- ? short circuit
TOR. betweenfuel pump
Measure the resistance of harness between controller and fuel
fuel pump controller and chassis ground.
CHECK HARNESS BETWEEN FUEL PUMP the resistance less than 1 i o to step 6. Repair harness
CONTROLLER AND ECM CONNECTOR. ? and connector.
2)Disconnect the connector from ECM. In this case, repair
fuel pump controller and ECM connector. Open circuit
. Connector & terminal betweenfuel pump
-
(R122) NO. 9 (8134) NO. 13: controller and
(R122) NO. 8 - (8136) NO. 16: ECM.
Poor contact in
fuel pump control-
ler and ECM con-
nector.
EN(D0HC TURBO)-315
Step Check Yes No

5 CHECK HARNESS BETWEEN FUEL PUMP Is the resistance more than 1M Go to step 7. Repair ground
CONTROLLER AND ECM CONNECTOR. R? short circuit
Measure the resistance of harness between betweenfuel pump
fuel pump controller and chassis ground. controller and
Connector & terminal ECM.
7 CHECK POOR CONTACT. Is there poor contact in ECM Repair poor con- Replace the fuel
Check poor contact in ECM and fuel pump and fuel pump controller contact in ECM and pump controller.
controller connector. nector. fuel pump control- <Ref. to FU(D0HC
ler. TURBO)-50, Fuel
Pump Controller.>
EN(D0HC TURBO)-316
EN(D0HC TURBO)-317
CS:DTC PI244 - WASTEGATE CONTROL SOLENOID VALVE RANGWPER-

FORMANCE PROBLEM (LOW INPUT) -
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
MAIN RELAY
BATTERY
SBF-5
I
WASTEGATE
CONTROL SOLENOID
VALVE
EN1150
EN(D0HC TURBO)-318
Step Check Yes No

I CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Replace the
tor or OBD-ll general scan tool PO245 or PO246 wastegate control
indicate DTC PO245 or P0246? using “List of Diag- solenoid valve.
<Ref. to FU(D0HC
TURBO)-41,
Wastegate Con-
trol Solenoid
Valve.>
EN(D0HC TURBO)-31 9
CT:DTC PI245 - WASTEGATE CONTROL SOLENOID VALVE MALFUNCTION

(FAIL-SAFE) -
CAUTION:
49,Operation.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
@ ECM
.
WAS TE
CONTRO LENOID
VALVE
EN1150
EN(D0HC TURBO)-320
ENGINE I DIAGNOSTICS)
Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Replace the
tor or OBD-II general scan tool P0244, P0245, wastegate control
indicate DTC P0244, P0245, PO246 or P1244 solenoid valve.
PO246 or P1244? using “List of Diag- <Ref. to FU(D0HC
nostic Trouble TURBO)-41,
Code (DTC)”. Wastegate Con-
<Ref. to EN(D0HC trol Solenoid
TURBO)SO, List Valve.>
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P1245.
EN(DOHC TU RB0)-321
CU:DTC PI301 - FIRE DUE TO INCREASED EXHAUST TEMPERATURE -

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
EXHAUSTGAS
TEMPERATURE
SENSOR
@ECM
EN1 161
EN(D0HC TURBO)-322
Step Check Yes No

1 CHECK ANY OTHER DTC. Does failure for repair or Repair or replace Contact with SOA
Conduct the troubleshooting for all DTC replacement exist? failure, then (distributor) ser-
P0301, P0302, PO303 and P0304. <Ref. to replace the precat- vice.
EN(D0HC TURBO)-80, List of Diagnostic alytic converter. NOTE:
Trouble Code (DTC).> Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
EN(D0HC TURBO)-323
CV:DTC PI312 - EXHAUST GAS TEMPERATURE CIRCUIT MALFUNCTION -

CAUTION:
tion Mode.>.
WIRING DIAGRAM:
EXHAUSTGAS
TEMPERATURE
SENSOR
_I
EN1161
EN(DOHC TURB0)-324
ENGINE (DlAG NOSTlCS)
Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Replace the
tor or OBD-ll general scan tool P0545, PO546 or exhaust gas tem-
indicate DTC P0545, PO546 or P1544 using “List perature sensor.
P1544? of Diagnostic Trou- <Ref. to FU(D0HC
ble Code (DTC)”. TURBO)-46,
<Ref. to EN(D0HC Exhaust Tempera-
TURBO)-80, List ture Sensor.>
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary tc
inspect DTC
P1312.
EN(D0HC TURBO)-325
CW:DTC PI400 - FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIR-

CUIT LOW INPUT -
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
BATTERY
MAIN RELAY SBF-5
3 c
I PRESSURE
I CONTROL
SOLENOID
1 IA:@
D:@
ECM
Step Check Yes No

chassis ground.
EN(D0HC TURBO)-326
Step Check Yes No

CHECK POOR CONTACT. s there poor contact in ECM lepair poor con- Contact with SOA
Check poor contact in ECM connector. :onnector? act in ECM con- (distributor) ser-
'ector. vice.
NOTE:
Inspection by DTk
is required, be,
cause probable
cause is deteriora,
tion of multiple
parts.
CHECK HARNESS BETWEEN FUEL TANK s the resistance less than 10 iepair ground Go to step 4.
PRESSURE CONTROL SOLENOID VALVE 2? hort circuit in har-
AND ECM CONNECTOR. less between
1)Turn the ignition switch to OFF. C M and fuel tank
2)Disconnect the connectors from fuel tank lressure control
pressure control solenoid valve and ECM. olenoid valve
3)Measure the resistance of harness between onnector.
fuel tank pressure control solenoid valve con-
nector and chassis ground.
CHECK HARNESS BETWEEN FUEL TANK s the voltage less than 1 R? ;o to step 5. Repair harness
PRESSURE CONTROL SOLENOID VALVE and connector.
AND ECM CONNECTOR. NOTE:
Measure the resistance of harness between In this case, repai
ECM and fuel tank pressure control solenoid the following:
valve connector. Open circuit in
(8137) NO. 22 - (R68) NO. 2: ECM and fuel tank
pressure control
solenoid valve
connector
Poor contact in
coupling connec-
tors
CHECK FUEL TANK PRESSURE CONTROL s the resistance between 10 i o to step 6. Replace the fuel
SOLENOID VALVE. md 100 R? tank pressure con.
Measure the resistance between fuel tank trol solenoid valve.
pressure control solenoid valve terminals. <Ref. to EC(D0HC
Terminals TURBO)-12, Pres.
NO. 1 -NO. 2: sure Control Sole-
noid Valve.>
CHECK POWER SUPPLY TO FUEL TANK s the voltage more than 10 V? i o to step 7. Repair harness
PRESSURE CONTROL SOLENOID VALVE. and connector.
2)Measure the voltage between fuel tank pres In this case, repai
sure control solenoid valve and chassis the following:
(R68) No. 1 (+) - Chassis ground (-): main relay and fuel
tank pressure con,
trol solenoid valve
connector
Poor contact in
coupling connec-
tors
Poor contact in
main relay connec
tor
EN(D0HC TURBO)-327
Step Check Yes No

7 CHECK POOR CONTACT. Is there poor contact in fuel Repair poor con- Contact with SOA
Check poor contact in fuel tank pressure con- tank pressure control solenoid tact in fuel tank (distributor) ser-
trol solenoid valve connector. valve connector? pressure control vice.
solenoid valve NOTE:
Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
EN(D0HC TURBO)-328
EN(D0HC TURBO)-329
CX:DTC PI420 - FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIR-

CUIT HIGH INPUT -
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
BATTERY
MAIN RELAY SBF-5
3 c I
FUEL TANK
I PRESSURE
C0NT R 0L
1
I
SOLENOID
VALVE
EN(D0HC TURBO)-330
Step Check Yes No

CHECK OUTPUT SIGNAL FROM ECM. )oes voltage change between I Go to step 2. 3 e n if MIL lights
1)Turn the ignition switch to OFF. 1 and 10 V? rp, the circuit has
2)Connect the test mode connector at the eturned to a nor-
lower portion of instrument panel (on the nal condition at
driver’s side), to the side of the center console his time. In this
box. :ase, repair poor
4)While operating the fuel tank pressure con- :onnector.
trol solenoid valve, measure voltage between
NOTE:
Fuel tank pressure control solenoid valve oper.
ation can be executed using Subaru Seleci
Monitor. For procedure, refer to “Compulsor)
Valve Operation Check Mode”. <Ref. tc
EN(D0HC TURBO)-50, Compulsory Valve O p
eration Check Mode.>
! CHECK OUTPUT SIGNAL FROM ECM. s the voltage more than 10 V? So to step 4. 20 to step 3.
chassis ground.
1 CHECK POOR CONTACT. 3eplace the ECM.
Check poor contact in ECM connector. onnector? tact in ECM con- :Ref. to FU(D0HC
nector. ruRBO)-47,
Engine Control
dodule.>
CHECK HARNESS BETWEEN FUEL TANK s the voltage more than 10 V? Repair battery 20 to step 5.
PRESSURE CONTROL SOLENOID VALVE short circuit in har.
AND ECM CONNECTOR. ness between
1)Turn the ignition switch to OFF. ECM and fuel tank
2)Disconnect the connector from fuel tank pressure control
pressure control solenoid valve. solenoid valve
(8137) No. 22 (+) - Chassis ground (-): TURBO)-47,
Engine Control
Module.>
1 CHECK FUEL TANK PRESSURE CONTROL s the resistance less than 1 Replace the fuel 20 to step 6.
SOLENOID VALVE. 2? tank pressure con,
1)Turnthe ignition switch to OFF. trot solenoid valve
2)Measure the resistance between fuel tank <Ref.to EC(D0HC
pressure control solenoid valve terminals. TURBO)-12, Pres
Terminals sure Control Sole-
NO. 1 -NO. 2: noid Valve.> and
ECM <Ref. to
FU(D0HC
TURBO)-47,
Engine Control
Module.>
i CHECK POOR CONTACT. s there poor contact in ECM Repair poor con- 3eplace the ECM.
Check poor contact in ECM connector. :onnector? tact in ECM con- :Ref. to FU(D0HC
nector. TURBO)-47,
Engine Control
I vlodule.>
EN(D0HC TURBO)-331
CY:DTC PI443 - EVAPORATIVE EMISSION CONTROL SYSTEM VENT CON-

TROL FUNCTION PROBLEM -
Immediately after fault occurrence
TROUBLE SYMPTOM:
Improper fuel supply
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
BATTERY
MAIN RELAY SBF-5
I --
3 c
I
I I
EN(D0HC TURBO)-332
Step Check Yes No

I CHECK ANY OTHER DTC ON DISPLAY. Is there any other DTC on dis- Inspect the rele- 30 to step 2.
play? vant DTC using
Trouble Code
(DTC)”. <Ref. to
EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
! CHECK VENT LINE HOSES. Is there a fault in vent line? Repair or replace 20 to step 3.
Check the following items. the faulty part.
Clogging of vent hoses between canister and
drain valve
Clogging of vent hose between drain valve
and air filter
Clogging of drain filter
b CHECK DRAIN VALVE OPERATION. Does the drain valve produce Contact with SOA 3eplace the drain
1)Turn the ignition switch to OFF. operating sound? (distributor) ser- ialve. <Ref. to
2)Connect the test mode connector at the vice. iC(D0HC
lower portion of instrument panel (on the NOTE: rURBO)-17, Drain
driver’s side), to the side of the center console Inspection by DTM Ja1ve.b
box. is required, be-
Spurn the ignition switch to ON. cause probable
4)Operate the drain valve. cause is deteriora-
NOTE: tion of multiple
Drain valve operation can also be executed us- parts.
ing Subaru Select Monitor. For the procedure,
refer to the “Compulsory Valve Operation
Check Mode”. <Ref. to EN(D0HC TURBO)-50,
Compulsory Valve Operation Check Mode.>
EN(D0HC TURBO)-333
EN(D0HC TURBO)-334
CZ:DTC PI480 - COOLING FAN RELAY 1 CIRCUIT HIGH INPUT -

TROUBLE SYMPTOM:
Radiator fan does not operate properly.
Overheating
CAUTION:
49, Operation.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspection Mode.>.
EN(D0HC TURBO)-335
WIRING DIAGRAM:
BATTERY
SBF-l
3 -
e a
I
1
[i
I
-1
cSI
h
4N
IR
MI
EN1157
EN(D0HC TURBO)-336
Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. )oes the voltage change Iven if MIL lights io to step 2.
1)Turnthe ignition switch to OFF. letween 0 and 10 V? ip, the circuit has
2)Connect the test mode connector at the eturned to a nor-
lower portion of instrument panel (on the nal condition at
driver’s side), to the side of the center console his time. In this
box. :ase, repair poor
4)While operating the radiator fan relay, mea- :onnector.
sure voltage between ECM and chassis
ground.
NOTE:
Radiator fan relay operation can be executed
using Subaru Select Monitor. For procedure,
Mode”.<Ref. to EN(D0HC TURBO)-50, Com-
pulsory Valve Operation Check Mode.>
2 CHECK SHORT CIRCUIT IN RADIATOR FAN s the voltage more than 10 V? 3epair battery io to step 3.
RELAY CONTROL CIRCUIT. ;hort circuit in
1)Turn the ignition switch to OFF. adiator fan relay
2)Remove the main fan relay and sub fan relay. :ontrol circuit.
(with A/C models) After repair,
3)Disconnect the test mode connector. eplace the ECM.
4)Turn the ignition switch to ON. :Ref. to FU(D0HC
5)Measure the voltage between ECM and ruRBO)-47,
chassis ground. hgine Control
Connector & terminal dodule.>
3 CHECK MAIN FAN RELAY. s the resistance less than 1 3eplace the main i o to step 4.
1)Turn the ignition switch to OFF. 2? an relay and
2)Remove the main fan relay I and 2. ICM. <Ref. to
3)Measure the resistance between main fan W(DOHC
relay terminals. rURBO)-47,
Terminal Engine Control
No. 25 - No. 26 (Main fan relay 1) dodule.>
No. 23 - No. 24 (Main fan relay 2)
4 CHECK SUB FAN RELAY. s the resistance less than 1 3eplace the sub i o to step 5.
1)Remove the sub fan relay. 2? an relay and
2)Measure the resistance between sub fan X M . <Ref. to
relay terminals. -U(DOHC
Terminal rURBO)-47,
No. 7 - No. 8 (Sub fan relay 1) Engine Control
No. 17 - No. 18 (Sub fan relay 2) dodule.>
5 CHECK POOR CONTACT. s there poor contact in ECM 3epair poor con- leplace the ECM.
Check poor contact in ECM connector. :onnector? act in ECM con- :Ref. to FU(D0HC
lector. -URBO)-47,
ingine Control
Aodu1e.i
EN(DOHC TU RB0)-337
DA:DTC PI507 - IDLE CONTROL SYSTEM MALFUNCTION (FAIL-SAFE) -

TROUBLE SYMPTOM:
Engine keeps running at higher revolution than specified idling revolution.
Fuel is cut according to fail-safe function.
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
MAIN RELAY
BATTERY
SBF-5
IDLE
41R CONTROL
SOLENOID
VALVE
@ECM I
EN1160
EN(D0HC TURBO)-338
Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. >oesthe Subaru Select Moni- Inspect DTC- Go to step 2.
ndicate DTC P0506, P0507, P0508, PO509 or
’0508, PO509 or P1142? P1142 using “List
of Diagnostic Trou-
ble Code (DTC)”.
<Ref. to EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P1507.
CHECK AIR INTAKE SYSTEM. s there a fault in air intake sys- Repair air suction Go to step 3.
1)Turnthe ignition switch to ON. em? and leaks.
2)Start the engine, and idle it.
3)Check the following items.
*Loose installation of intake manifold, idle air
control solenoid valve and throttle body
*Cracks of intake manifold gasket, idle air con-
fro1 solenoid valve gasket and throttle body
gasket
*Disconnections of vacuum hoses
CHECK THROlTLE CABLE. >oesthe throttle cable have
)lay for adjustment? cable. <Ref. to
SP-7, INSTALLA-
TION, Accelerator
Control Cable.>
CHECK AIR BV-PASS LINE. ire foreign particles in by-pass Remove foreign Replace the idle
1)Turn the ignition switch to OFF. tir line? particles from by- air control solenoid
2)Remove the idle air control solenoid valve pass air line. valve. <Ref. to
from throttle body. <Ref. to FU(D0HC FU(DOHC
TURBO)-36, Idle Air Control Solenoid Valve.> TURBO)-36, Idle
3)Confirm that there are no foreign particles in Air Control Sole-
bV-DaSS air line. noid Valve.>
EN(D0HC TURBO)-339
EN(D0HC TURBO)-340
DB:DTC P1518 - STARTER SWITCH CIRCUIT LOW INPUT -

TROUBLE SYMPTOM:
CAUTION:
tion Mode.>.
EN(D0HC TURBO)-341
WIRING DIAGRAM:
EN1139
EN(D0HC TURBO)-342
Step Check Yes No

1 CHECK OPERATION OF STARTER MOTOR, Does the starter motor operate Repair harness Check starter
when ignition switch to “ST”? and connector. motor circuit. <Ref.
NOTE: to EN(D0HC
In this case, repair TURBO)-64,
the following: STARTER
Open or ground MOTOR CIR-
short circuit in har- CUIT, Diagnostics
ness between for Engine Start-
ECM and starter ing Failure.>
motor connector.
Poor contact in
ECM connector.
EN(D0HC TURBO)-343
DC:DTC PI544 - HIGH EXHAUST TEMPERATURE DETECTED -

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
EXHAUST GAS
TEMPERATURE
SENSOR
IC
F
I @ECM
EN1161
EN(DOHC TURB0)-344
FNGINE (DIAGNOSTICS)
Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. Ioes the Subaru Select Moni- Inspect DTC ;o to step 2.
ndicate DTC P0335, P0336, P0340, P0341,
'0340, P0341, P0545, P0546, P0545, P0546,
'1312, P0102, P0103, P0101, P1312, P0102,
'1 141, P0301, P0302, P0303, PO103, P0101,
'0304, P1301, P0171, P0133, P1141, P0301,
'1 134, PO131, P0132, P1130, P0302, P0303,
'1 131, P1139, P0031, P0032, P0304, P1301,
'01 39, PO136, PO039 or PO171, PO133,
'0037? P1134, PO131,
PO132, P1130,
P1131, P1139,
P0031, P0032,
PO139, PO136,
PO039 or PO037
using List of Diag-
nostic Trouble
Code (DTC). <Ref.
to EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P1544.
I CHECK EXHAUST SYSTEM. s there a fault in exhaust sys- Repair or replace ;ontact with SOA
Check exhaust system parts. em? failure, then distributor) ser-
NOTE: replace the precat- ice.
Check the following items. alytic converter. JOTE:
*Loose installation of exhaust manifold nspection by DTM
*Cracks or hole of exhaust manifold j required, be-
*Loose installation of front oxygen (NF)senso I
:ause probable
:ause is deteriora-
tion of multiple
Darts.
EN(D0HC TURBO)-345
R!
EN(D0HC TURBO)-346
~~~
DD:DTC PI560 - BACK-UP VOLTAGE CIRCUIT MALFUNCTION -

CAUTION:
tion Mode.>.
EN(DOHC TURB0)-347
WIRING DIAGRAM:
EN1171
Step Check Yes No

1 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 10 V? Repair poor con- Go to step 2.
1)Turn the ignition switch to OFF. tact in ECM con-
2)Measure the voltage between ECM and nector.
chassis ground.
EN(D0HC TURBO)-348
I
Step Check Yes No

! CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10 Repair ground Go to step 3.
MAIN FUSE BOX CONNECTOR. R? short circuit in har-
1)Disconnect the connector from ECM. ness between
2)Measure the resistance of harness between ECM connector
ECM and chassis ground. and battery termi-
Connector & terminal nal.
I CHECK FUSE SBFQ. Is fuse blown? Replace the fuse. Repair harness
and connector.
NOTE:
In this case, repai
the following:
Open circuit in
harness between
ECM and battery
Poor contact in
ECM connector
Poor contact in
battery terminal
EN(D0HC TURBO)-349
DE:DTC P1590 - NEUTRAL POSITION SWITCH CIRCUIT HIGH INPUT -

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
10
INHIBKOR SWKCH
@a a
I STAFiTER MOTOF
B2M437(
EN(DOHC TURBO)-350
-
step Check Yes No

I CHECK DTC PO705 ON DISPLAY. 3oes the Subaru Select Moni- Inspect DTC Go to step 2.
:or or OBD-II general scan tool PO705 using “List
ndicate DTC P0705? of Diagnostic Trou-
ble Code (DTC)”.
<Ref. to EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
! CHECK INPUT SIGNAL FOR ECM. s the voltage less than 1 V? Go to step 3. Go to step 5.
chassis ground in selector lever “ N and “ P
positions.
i
1 CHECK INPUT SIGNAL FOR ECM. s the voltage between 4.5 and Go to step 4. Go to step 5.
Measure the voltage between ECM and chas- 5.5 V?
sis ground in selector lever except for “N” and
“ P positions.
Connector L? terminal
I CHECK POOR CONTACT. s there poor contact in ECM Repair poor con- Contact with SOA
Check poor contact in ECM connector. :onnector? tact in ECM con- (distributor)ser-
nector. vice.
NOTE:
Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
i CHECK INPUT SIGNAL FOR ECM. s the voltage more than 10 V? Repair battery Go to step 6.
Measure the voltage between ECM and chas- short circuit in har-
sis ground. ness between
Connector & terminal ECM and inhibitor
(8134) No. 8 (+) - Chassis ground (-): switch connector.
i CHECK HARNESS BETWEEN ECM AND IN- s the resistance less than 1 Go to step 7. Repair harness
HIBITOR SWITCH CONNECTOR. 2? and connector.
2)Disconnect the connectors from ECM and In this case, repaii
inhibitor switch. the following:
3)Measure the resistance of harness between b Open circuit in
ECM and inhibitor switch connector. harness between

Connector & terminal ECM and inhibitor
(8134) NO. 8 - (T7) NO. 12: switch connector
b Poor contact in
zoupling connector
Poor contact in
inhibitor switch
Zonnector
b Poor contact in
ECM connector
EN(D0HC TURBO)-351
Step Check Yes No

CHECK INHIBITOR SWITCH GROUND LINE. s the resistance less than 5 20 to step 8. Repair open circuit
Measure the resistance of harness between 2? in harness
inhibitor switch connector and engine ground. between inhibitor
Connector & terminal switch connector
(T7) No. 7 - Engine ground: and starter motor
ground line.
NOTE:
In this case, repai,
the following:
Open circuit in
harness between
inhibitor switch
connector and
starter motor
ground line
Poor contact in
starter motor con-
nector
Poor contact in
starter motor
ground
Starter motor
CHECK INHIBITOR SWITCH. s the resistance less than 1 30 to step 9. Replace the inhibi,
Measure the resistance between inhibitor 2? tor switch. <Ref. to
switch connector receptacle’sterminals in AT-28, Inhibitor
selector lever “N” and “ P positions. Switch.>
Terminals
NO. 7 - NO. 12:
CHECK SELECTOR CABLE CONNECTION. s there any fault in selector 3epair selector Contact with SOA
:able connection to inhibitor :able connection. (distributor) ser-
;witch? <Ref.to CS-27, vice.
INSPECTION, NOTE:
Select Cable.> Inspection by DTL
is required, be
cause probablc
cause is deteriora
tion of multiplf
parts.
EN(D0HC TURBO)-352
EN(D0HC TURBO)-353
DF:DTC PI591 - NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT -

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
B2M437(
EN(DOHC TURB0)-354
Step Check Yes No

CHECK DTC PO705 ON DISPLAY. Does the Subaru Select Moni- Inspect DTC 20 to step 2.
tor or OBD-ll general scan tool PO705 using “List
ble Code (DTC)”.
<Ref. to EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
CHECK INPUT SIGNAL FOR ECM. Is the voltage between 4.5 and Even if MIL lights so to step 3.
1)Turn the ignition switch to ON. 5.5 V at except “ N and “ P up, the circuit has
2)Measure the voltage between ECM and positions? returned to a nor-
chassis ground. mal condition at
Connector & terminal this time.
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10 Repair ground i o to step 4.
TRANSMISSION HARNESS CONNECTOR. R? short circuit in har-
2)Disconnect the connectors from ECM and ECM and trans-
transmission harness connector (T3). mission harness
CHECK TRANSMISSION HARNESS CON- Is the resistance less than 10 Repair ground $0to step 5.
NECTOR. R? short circuit in har-
1)Disconnect the connector from inhibitor ness between
switch. transmission har-
2)Measure the resistance of harness between ness and inhibitor
transmission harness connector and engine switch connector.
ground.
(T3) No. 12 - Engine ground:
CHECK INHIBITOR SWITCH. Is the resistance more than 1 Go to step 6. Ieplace the inhibi.
Measure the resistance between inhibitor M a at except “N” and “ P posi- or switch. <Ref. to
switch connector receptacle’sterminals in tions? 4l-28, Inhibitor
selector lever except for “N” position. ;witch.>
Terminals
NO. 7 - no. 12:
CHECK SELECTOR CABLE CONNECTION. Is there any fault in selector Repair selector :ontact with SOA
cable connection to inhibitor cable connection. distributor) ser-
switch? <Ref. to CS-27, ice.
INSPECTION, JOTE:
Select Cable.> nspection by DTk
; required, be
:ause probablc
:ause is deteriora
ion of multiplc
,arts.
EN(DOHC TURB0)-355
DG:DTC P I 594 - AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL

CIRCUIT MALFUNCTION -
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
r @ TCM
02M4371
Step Check Yes No

1 CHECK DRIVING CONDITION. Is the AT shift control function- Go to step 2. Replace the TCM.
1)Start and warm-up the engine until the radia- ing properly? <Ref. to AT-45,
tor fan makes one complete rotation. Transmission Con-
2)Drive the vehicle. trol Module
(TCM).>
EN(D0HC TURBO)-356
Step Check Yes No
2 CHECK ACCESSORY. Are car phone and/or CB Repair grounding Replace the TCM.
I installed on vehicle? line of car phone <Ref. to AT-45,
or CB system. Transmission Con-
trol Module
(TCM).>
EN(D0HC TURB0)957
DH:DTC P I 595 - AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL

CIRCUIT LOW INPUT -
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
n@TCM
IC 71
F7
B2M4371
EN(D0HC TURBO)-358
Step Check Yes No

CHECK HARNESS BETWEEN ECM AND Is the voltage less than 1 V? 30 to step 2. Even if MIL lights
TCM CONNECTOR. ~ pthe, circuit has
1)Turnthe ignition switch to ON. eturned to a nor-
2)Measure the voltage between ECM and nal condition at
chassis ground. his time.
Connector & terminal \IOTE:
(6135) No. 20 (+) - Chassis ground (-): n this case, repaii
he following:
' Poor contact in
X M connector
' Poor contact in
TCM connector
! CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10 3epair ground 30 to step 3.
TCM CONNECTOR. R? ;hort circuit in har-
2)Disconnect the connector from ECM and ICM and TCM
TCM. :onnector.
I CHECK OUTPUT SIGNAL FOR ECM. Is the voltage more than 5 V? i o to step 4. 3epair poor con-
1)Connect the connector to ECM. act in ECM con-
2)Turn the ignition switch to ON. lector.
chassis ground.
I CHECK TROUBLE CODE FOR AUTOMATIC Does the trouble code appear nspect trouble 3eplace the TCM.
TRANSMISSION. for automatic transmission? :ode for automatic :Ref. to AT-45,
Read the trouble code for automatic transmis- ransmission. rransmission Con-
sion. <Ref. to AT-24, Read Diagnostic Trouble :Ref. to AT-44, rol Module
Code (DTC).> liagnostic Proce- TCM).>
jure with Diagnos-
ic Trouble Code
DTC).>
EN(D0HC TURBO)-359
-
DI: DTC P I 596 AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
n
IC
@TCY
82M4371
EN(D0HC TURBO)-360
Step Check Yes No

CHECK HARNESS BETWEEN ECM AND s the voltage more than 10 V? Repair battery Go to step 2.
TCM CONNECTOR. short circuit in har-
1)Turn the ignition switch to ON. less between
2)Measure the voltage between ECM and ECM and TCM
chassis ground. zonnector. After
Connector & terminal repair, replace the
(8135) No. 20 (+) - Chassis ground (-): ECM. <Ref. to
FU(D0HC
TURBO)-47,
Engine Control
Module.>
! CHECK HARNESS BETWEEN ECM AND s the voltage more than 4 V? Go to step 5. Go to step 3.
TCM CONNECTOR.
and chassis ground.
CHECK HARNESS BETWEEN ECM AND s the voltage less than 1 V? Repair poor con- Go to step 4.
TCM CONNECTOR. tact in ECM con-
Measure the voltage between ECM connector nector.
and chassis ground.
a
I CHECK OUTPUT SIGNAL FROM ECM. Ioes the voltage change from Even if MIL lights Contact with SOA
Measure the voltage between ECM and chas- V to 4 V while monitoring the up, the circuit has (distributor) ser-
sis ground. falue with voltage meter? returned to a nor- vice.
Connector & terminal mal condition at NOTE:
(8135) No. 20 (+) - Chassis ground (-): this time. Inspection by DTN
NOTE: is required, b e
In this case, repaii cause probable
the following: cause is deteriora.
Poor contact in tion of multiple
ECM connector parts.
Poor contact in
TCM connector
i CHECK HARNESS BETWEEN ECM AND s the voltage more than 4 V? Go to step 6. Repair open circuit
TCM CONNECTOR. in harness
Measure the voltage between TCM and chas- between ECM and
sis ground. TCM connector.
(B54) No, 20 (+) - Chassis ground (-):
i CHECK POOR CONTACT. s there poor contact in TCM Repair poor con- Check TCM power
Check poor contact in TCM connector. :onnector? tact in TCM con- supply line and
nector. aroundina line.
EN(D0HC TURBO)-361
ENGINE lDlAGNOSTlCSl
DJ:DTC PI698 - ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT LOW IN-
PUT -
CAUTION:
After repair or replacement of faulty parts, condut Clear Memory Mode <Ref. to EN(D0HC TURBO)-
tion Mode.>.
WIRING DIAGRAM:
IC i
c II
I @ .
EN(D0HC TURBO)-362
Step Check Yes No

CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 3 V? Repair poor con- So to step 2.
1)Start the engine, and warm-up the engine. tact in ECM con-
2)Turn the ignition switch to OFF. nector.
chassis ground.
(B 136) No. 14 (+) - Chassis ground (-):
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10 Repair ground Go to step 3.
TCM CONNECTOR. R? short circuit in har-
1)Turn the ignition switch to OFF. nessbetween
2)Disconnect the connectors from ECM and ECM and TCM
TCM. connector.
-
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Repair poor con- Repair open circuit
TCM CONNECTOR. R? tact in ECM or in harness
Measure the resistance of harness between TCM connector. between ECM and
ECM and TCM connector. TCM connector.
-
(8136) NO. 14 (BSS) NO. 20:
EN(D0HC TURBO)-363
DK:DTC P1699 - ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT HIGH IN-
PUT -
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
F
IC
@TCM
EN(D0HC TURBO)-364
Step Check Yes No

I CHECK OUTPUT SIGNAL FROM ECM. Is the voltage less than 3 V? 30 to step 2. Repair battery
1)Start the engine, and warm-up the engine. short circuit in har-
3)Disconnect the connector from TCM. ECM and TCM
(B 136) No. 14 (+)- Chassis ground (-): TURBO)-47,
Engine Control
Module.>
2 CHECK HARNESS BETWEEN ECM AND Does the voltage change more qepair battery Contact with SOA
TCM CONNECTOR. than 10 V by shaking harness short circuit in har- (distributor) ser-
1)Turnthe ignition switch to OFF. and connector of ECM while less between vice.
2)Measure the voltage between ECM and monitoring the value with volt- ECM and TCM NOTE:
chassis ground. age meter? :onnector. After Inspection by DTM
Connector & terminal ,epair, replace the is required, be-
(B 136) No. 14 (+) - Chassis ground (-): ECM. <Ref. to cause probable
FU(D0HC cause is deteriora.
TURBO)-47, tion of multiple
Engine Control parts.
Module.>
EN(D0HC TURBO)-365
-
~
-
DL:DTC PI 701 CRUISE CONTROL SET SIGNAL CIRCUIT MALFUNCTION
FOR AUTOMATIC TRANSMISSION -
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
D 71
EN1170
EN(D0HC TURBO)-366
Step Check Yes No

I CHECK HARNESS BETWEEN TCM AND Is the resistance less than 1 20 to step 2. Repair open circuit
CCM CONNECTOR. R? in harness
1)Turn the ignition switch to OFF. between TCM and
2)Disconnect the connectors from TCM and CCM connector.
CCM.
TCM and CCM connector.
(655)NO. 22 - (694) NO.3 :
! CHECK HARNESS BETWEEN TCM AND Is the resistance less than 10 3epair short circuit Go to step 3.
CCM CONNECTOR. n? n harness
Measure the resistance of harness between letween TCM and
TCM and chassis ground. X M connector.
CHECK INPUT SIGNAL FOR TCM. Is the resistance less than 1 V’ 20 to step 4. Check cruise con-
1)Connect the connector to TCM and CCM. trol command
2)Lift-up the vehicle or set the vehicle on free switch circuit.
rollers. <Ref. to CC-7,
CAUTION: INSPECTION,
On AWD models, raise all wheels off Cruise Control
ground. Command
3)Start the engine. Switch.>
4)Turn the cruise control main switch to ON.
5)Move selector lever to “ D and slowly
increase vehicle speed to 50 km/h (31 MPH).
6)Turn the cruise control command switch to
ON.
7)Measure the voltage between TCM and
chassis ground.
I CHECK POOR CONTACT. I S there
poor contact in TCM 3epair poor con- Replace the TCM.
Check poor contact in TCM connector. Zonnector? act in TCM con- <Ref. to AT-45,
lector. Transmission Con-
trol Module
I
(TCM).>
EN(D0HC TURBO)-367
DM:DTC PI711 - ENGINE TORQUE CONTROL SIGNAL 1 CIRCUIT MALFUNC-

TION -
TROUBLE SYMPTOM:
Excessive shift shock
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
El@ TCM
71
B2M4374
EN(D0HC TURBO)-368
Step Check Yes No

CHECK INPUT SIGNAL FOR ECM. ;the voltage more than 4.5 V? ;o to step 2. Go to step 4.
chassis ground.
! CHECK INPUT SIGNAL FOR ECM. ;the voltage more than 10 V? qepair battery Go to step 3.
Measure the voltage between ECM and chas- ;hort circuit in har-
sis ground. less between
Connector & terminal X M and TCM
(8135) No. 19 (+) - Chassis ground (-): :onnector.
1 CHECK POOR CONTACT. s there poor contact in ECM 3epair poor con- Replace the ECM.
Check poor contact in ECM connector. :onnector? act in ECM con- <Ref. to FU(D0HC
lector. TURBO)-47,
Engine Control
Module.>
I CHECK HARNESS BETWEEN ECM AND s the resistance less than 1 30 to step 5. Repair open circuit
TCM CONNECTOR. 2? in harness
1)Turn the ignition switch to OFF. between ECM and
2)Disconnect the connectors from ECM and TCM connector.
TCM.
ECM and TCM connector.
-
(8135) NO. 19 (854) NO. 13:
i CHECK HARNESS BETWEEN ECM AND s the resistance less than 10 3epair ground Go to step 6.
TCM CONNECTOR. 2? short circuit in har-
Measure the resistance of harness between less between
ECM and chassis ground. :CM and TCM
i CHECK POOR CONTACT. s there poor contact in TCM 3epair poor con- Replace the TCM.
Check poor contact in TCM connector. :onnector? :act in TCM con- <Ref. to AT-45,
lector. Transmission Con.
trol Module
(TCM).>
EN(DOHC TU RB0)-369
DN:DTC PI712 - ENGINE TORQUE CONTROL SIGNAL 2 CIRCUIT MALFUNC-

TION -
TROUBLE SYMPTOM:
Excessive shift shock
CAUTION:
tion Mode.>.
WIRING DIAGRAM:
B2M437E
EN(D0HC TURBO)-370
Step Check Yes No

CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 4.5 V? Go to step 2. 30 to step 4.
chassis ground.
CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 10 V? Repair battery 30 to step 3.
Measure the voltage between ECM and chas- short circuit in har-
sis ground. ness between
Connector & terminal ECM and TCM
(8134) No. 18 (+) - Chassis ground (-): connector.
CHECK POOR CONTACT. Is there poor contact in ECM Repair poor con- 3eplace the ECM.
Check poor contact in ECM connector. Zonnector? tact in ECM con- :Ref. to FU(D0HC
nector. rURBO)-47,
Engine Control
Module.>
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 5. 3epair open circuii
TCM CONNECTOR. n? n harness
1)Turnthe ignition switch to OFF. ietween ECM and
2)Disconnect the connectors from ECM and TCM connector.
TCM.
ECM and TCM connector.
i
( 8 134) NO. 18 - (856) NO. 4:
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10 Repair ground 30 to step 6.
TCM CONNECTOR. n? short circuit in har-
ECM and chassis ground. ECM and TCM
Connector & terminal connector.
CHECK POOR CONTACT. Is there poor contact in TCM Repair poor con- 3eplace the TCM.
Check poor contact in TCM connector. connector? tact in TCM con- :Ref. to AT-45,
nector. rransmission Con-
:rol Module
:TCM).>
EN(D0HC TURBO)-371
GENERAL DIAGNOSTIC TABLE
19.General Diagnostic Table

A: INSPECTION
1. ENGINE
NOTE:
Malfunction of parts other than those listed is also possible. <Ref. to ME(D0HC TURBO)-91, Engine Trouble
in General.>
SvmDtom Problem parts

1) Idle air control solenoid valve
2) Pressure sensor
3) Mass air flow and intake temperature sensor
4) Ignition parts (*I)
1. Engine stalls during idling.
5) Engine coolant temperature sensor (*2)
6) Crankshaft position sensor ('3)
7) Camshaft position sensor (*3)
8) Fuel injection parts (*4)
2) Pressure sensor
6) Air intake system (*5)
2. Rough idling
8) Throttle position sensor
9) Crankshaft position sensor (*3)
IO) Camshaft position sensor (*3)
11) Oxygen sensor
12) Fuel pump and fuel pump relay
2) Engine coolant temperature sensor
3) Accelerator cable ("6)
3. Engine does not return to idle.
5) Pressure sensor
6) Mass air flow sensor
1) Pressure sensor
5 ) Fuel pump and fuel pump relay
4. Poor acceleration 6) Engine coolant temperature sensor (*2)
8) Camshaft position sensor (*3)
9) A/C switch and A/C cut relay
10) Engine torque control signal circuit
1) Pressure sensor
5. Engine stalls or engine sags or hesitates at
5 ) Camshaft position sensor (*3)
acceleration.
6) Purge control solenoid valve
7) Fuel injection parts ('4)
EN(D0HC TURBO)-372
SvmDtom Problem parts

1) Pressure sensor
6. Surge
5 ) Camshaft position sensor (*3)
1) Pressure sensor
3) Engine coolant temperature sensor
7. Spark knock
4) Knock sensor
5 ) Fuel injection parts (*4)
1) Pressure sensor
8. After burning in exhaust system 3) Engine coolant temperature sensor (*2)
5 ) Fuel pump and fuel pump relay
*1: Check ignition coil & ignitor assembly and spark plug.
*2: Indicate the symptom occurring only in cold temperatures.
*3:Ensure the secure installation.
*4: Check fuel injector, fuel pressure regulator and fuel filter.
*5:Inspect air leak in air intake system.
*6: Adjust accelerator cable.
EN(DOHC TURB0)-373
EN(D0HC TURBO)-374
I
~
TRANSMISSION SECTION

of SUBARU vehicles.
c- - for maintenance, disassembling, reas-

approval.

1
CONTROL SYSTEMS
CSr
Page
2. Electrical Component .................................................................................. 6
3. AT Shift Lock System .................................................................................. 8
4. Select Lever .............................................................................................. 23
5. Select Cable .............................................................................................. 26
6. AT Shift Lock Solenoid and “P” Position Switch ........................................ 29
7. Integrated Module ..................................................................................... 31
8. MT Gear Shift Lever .................................................................................. 32
9. General Diagostic...................................................................................... 38
c- .
GENERAL DESCRIPTION
I
CONTROL SYSTEMS
A: SPECIFICATIONS
I Item I Specification -1
I Vibration torque of rod against lever N.m (kgf-m, ft-lb) I 0.7 (0.07, 0.5) or less
cs-2
GENERAL DESCRIPTION
I
CONTROL SYSTEMS
B: COMPONENT
1. AT SELECT LEVER
.‘
‘-
.‘
‘ I
I
. .‘ ‘-A ‘
TR054t
Indicator light bulb Cushion (25) Slider

Detent arm Guide plate (26) Clip
Detent spring Snap pin (27) “P” position switch
Select lever Outer cable (28) Spring
Spring pin Inner cable (29) Button
Arm Nut B
Pin Nut A Tightening torque: N.m (kgf-m, fi-lb)
Plate Clip T1: 7.5 (0.76, 5.5)
Grommet Lock plate T2: 13 (1.3, 9.4)
Packing Shift lock solenoid T3: l S ( 1 . 8 , 13.0)
Grip Clamp T4: 33 (3.4,25)
Indicator cover Cover
cs-3
I CONTROL SYSTEMS
GENERAL DESCRIPTION
2. MT GEAR SHIFT LEVER
TI30594
(1) Gear shift knob (IO) O-ring A (19) Stay

(2) Console boot (11) O-ring B (20) Spacer
(3) Plate complete (12) BushA
(4) Lever (13) Cushion rubber Tightening torque: N-m (kgf-m, ft-lb)
(5) Bush (14) Bush6 T1: 7.5 (0.76, 5.5)
(6) Bush (15 ) Joint T2: 12 (1.2, 8.7)
(7) Locking wire (16) Rod T3: lS(1.8, 13.0)
(8) Boot (17) Bracket
(9) Snap ring (18) Washer
cs-4
CONTROL SYSTEMS
C: CAUTION
tion.
Use SUBARU genuine grease etc. or the equiv-
alent. Do not mix grease etc. with that of another
grade or from other manufacturers.
points.
Apply grease onto sliding or revolution surfaces
before installation.
c. Before installing O-rings or snap rings, apply suf-
ficient amount of grease to avoid damage and de-
formation.
Before securing a part on a vice, place cushion-
ing material such as wood blocks, aluminum plate,
or shop cloth between the part and the vice.
Before disconnecting electrical connectors, be
sure to disconnect the negative terminal from bat-
tery.
cs-5
I ELECTRICAL COMPONENT
CONTROL SYSTEMS
2. Electrical Component
A: LOCATION
(1) Inhibitor switch (4) Key warning switch (7) Key lock solenoid
(2) Integrated module (5) Shift lock solenoid
(3) Stop light switch (6) “P” position switch
CS-6
ELECTRICAL COMPONENT
I
CONTROL SYSTEMS
(2)
\ \o\ ' B2M2246E TR0548
TR0549
cs-7
I
AT SHIFT LOCK SYSTEM
CONTROL SYSTEMS
3. AT Shift Lock System

10 9 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 20 19 18 17 16 15 14 13 12 11
I BO031 1
InpuVOutput signal
Contents Connector No. Terminal No.
Measured value and measuring conditions
Battery power supply 8281 2 9-16V
Ignition power supply B280 19 10 - 15 V when ignition switch is at ON or START.
Ignition power supply 8280 10 10 - 15 V when ignition switch is at ACC.
0 V when select lever is in “ P position.
Inhibitor Switch (“P” position) 8280 5 9 - 16 V when select lever is in other positions than “ P
oosition.
Stop light switch I B280 I 9

9 - 16 V when stop light switch is ON.
0 V when stop light switch is OFF.
I “P” position switch I B280

0 V when select lever is in “ P position.
9 - 16 V when select lever is in other positions than “P”
position.
8.5 - 16 V when shift lock is released.
Shift lock solenoid signal 8281 9
0 V when shift lock is oPeratina.
I
9 - 16 V when key is inserted.

Key warning switch signal 6280 20
0 V when key is removed.
7.5 - 16 V when turning ignition switch to ON, select
Key lock solenoid signal 8281 3 lever is in “P” position and brake switch is ON.
0 V at other conditions than above. .
Ground B281 4 -
Ground B281 13 -
CS-8
I
CONTROL SYSTEMS
B: SCHEMATIC
OQ
(2)
0
0 c----
L
(4)
(1) Ignition switch (4) integrated module (7) Shift lock solenoid
(2) Stop light switch (5) Inhibitor switch (8) “P” position switch
(3) Key warning switch (6) Key lock solenoid (9) Battery
cs-9
CONTROL SYSTEMS
C: INSPECTION
Step Check Yes NO
CHECK SHIFT LOCK. While brake pedal is Go to step 2. Inspect “SELECT
1)Turn the ignition switch ON. depressed, can select lever LEVER CANNOT
2)Move the select lever to “P” position. move from “ P range to other BE SHIFT
positions? LOCKED. <Ref.
to CS-I4, SELECT
LEVER CANNOT
BE SHIFT
LOCKED,
INSPECTION, AT
Shift Lock Sys-
tem.>
! CHECK SHIFT LOCK. While brake pedal is not Inspect “SELECT Go to step 3.
depressed, can select lever LEVER SHIFT
move from “P” range to other LOCK CANNOT
positions? BE RELEASED.
<Ref. to CS-16,
SELECT LEVER
SHIFT LOCK
CANNOT BE
RELEASED,
INSPECTION, AT
Shift Lock Sys-
tem.>
I CHECK KEY INTERLOCK. When select lever is in other Inspect “KEY 4T shift lock sys-
than “P” position, does ignition INTERLOCK em is normal.
switch turn to “LOCK position? DOES NOT BE
Or when select lever is in “ P LOCKED OR
position, does ignition switch RELEASED. <Ref.
turn to “LOCK position? to CS-20, KEY
INTERLOCK
DOES NOT LOCK
OR RELEASE,
INSPECTION, AT
Shift Lock Sys-
tem.>
cs-10
CONTROL SYSTEMS
cs-11
CONTROL SYSTEMS
1. INTEGRATED MODULE POWER SUPPLY AND GROUND LINE

WIRING DIAGRAM:
r 0
P 0
z
I
A: @
I I
-
-
TR0551
cs-12
AT SHIFT LOCK SYSTEM 1
CONTROL SYSTEMS
~
Step Check Yes No

CHECK FUSE (No. 3 , 4 and 11). s the fuse (No. 3,4 or 11) 3eplace the fuse So to step 2.
1)Aemove the fuse (No. 3 , 4 and 11). )lawn out? :No. 3, 4 or 11). If
he replaced fuse
:No. 3,4 or 11)
ias blown out eas
ly, repair short cir-
:uit in harness
letween fuse and
ntegrated module.
! CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 30 to step 3. Repair open circuit
INTEGRATED MODULE AND BODY 2? in harness
GROUND. between inte-
1)Turn the ignition switch to OFF. grated module and
2)Measure the resistance of harness between body ground.
integrated module and chassis ground.
-
I CHECK BATTERY POWER SUPPLY. s the voltage more than 9 V? 30 to step 4. Repair open circuit
1)Turn the ignition switch to ON (engine OFF). harness between
2)Measure the voltages between integrated battery and inte-
module and chassis ground. grated module,
Connector & terminal and poor contact
(8281) No. 1 (+) - Chassis ground (-): in coupling con-
nector.
I CHECK IGNITION POWER SUPPLY CIR- s the voltage more than 9 V? So to step 5. Repair open circuit
CUIT. harness between
1)Tufn the ignition switch to ACC. battery and inte-
2)Measure the voltage between integrated grated module,
module and chassis ground. and poor contact
Connector & terminal in coupling con-
(8280) No. 10 (+) - Chassis ground (-): nector.
> CHECK IGNITION POWER SUPPLY CIR- s the voltage more than 9 V? Go to step 6. Repair open circuit
CUIT. harness between
1)Turn the ignition switch to ON (engine OFF). battery and inte-
2)Measure the voltage between integrated grated module,
module and chassis ground. and poor contact
Connector & terminal in coupling con-
(8281) No. 19 (+) - Chassis ground (-): nector.
i CHECK POOR CONTACT. s there poor contact in power Repair poor con- Replace the inte-
;upply and ground line circuit? tact. grated module.
CS-13
CONTROL SYSTEMS
2. SELECT LEVER CANNOT BE SHIFT LOCKED

WIRING DIAGRAM:
SBF-1
STOP LIGHT
A: @
B: @ INTEGRATED MODULE
I la1
I
1I SHIFT LOCK
I SOLENOID
Is
OC :WITHOUT CRUISE CONTROL MODEL
WC :WITH CRUISE CONTROL MODEL
TR0552
cs-14
CONTROL SYSTEMS
Step Check Yes No

I CHECK STOP LIGHT SWITCH. Does the stop light turn ON? Go to step 2. Inspect the stop
Depress the brake pedal. light system.
2 CHECK HARNESS BETWEEN STOP LIGHT Is the resistance more than 1 Repair open circuit So to step 3.
SWITCH AND INTEGRATED MODULE. MR? in harness
1)Turn the ignition switch to OFF. between inte-
2)Disconnect the integrated and stoplight grated module and
switch connector. stop light switch.
stop light switch and integrated module.
Without cruise control model
(864) NO. 1 - (B280) NO. 9:
(B65) NO. 3 - (8280) NO. 9:
3 CHECK HARNESS BETWEEN STOP LIGHT Is the resistance less than 1 Repair short circuit Go to step 4.
SWITCH AND INTEGRATED MODULE. n? in harness
Measure the resistance of harness between between inte-
stop light switch and chassis ground. grated module and
Connector & terminal stop light switch.
(B64) No. 1 - Chassis ground:
4 CHECK HARNESS BETWEENINTEGRATED Is the resistance more than 1 Repair open circuit Go to step 5.
MODULE AND SHIFT LOCK SOLENOID. MR? in harness
1)Disconnect the shift lock solenoid connector between inte-
2)Measure the resistance of harness between grated module and
integrated module and shift lock solenoid.. shift lock solenoid.
(B116) NO. 4 - (8281) NO. 9:
5 CHECK HARNESSBETWEENINTEGRATED Is the resistance less than 1 Repair short circuit Go to step 6.
MODULE AND SHIFT LOCK SOLENOID. Q? in harness
shift lock solenoid and chassis ground. grated module and
Connector & terminal shift lock solenoid.
( B l l 6 ) No. 4 - Chassis ground:
6 CHECK HARNESS BETWEEN SHIFT LOCK Is the resistance more than 1 Repair open circuit Go to step 7.
SOLENOID AND CHASSIS GROUND. MR? in harness
Measure the resistance of harness between between shift lock
shift lock solenoid and chassis ground. solenoid and body
Connector & terminal ground.
7 CHECK SHIFT LOCK SOLENOID. Is the resistance between 10 Go to step 8. Replace the shift
Measure the resistance of shift lock solenoid and 20 R? lock solenoid.
connector terminals.
Terminal
NO. 4 -NO. 5:
8 CHECK SHIFT LOCK SOLENOID. Does the shift lock solenoid Go to step 9. Replace the shift
Connect the battery with shift lock solenoid operate properly? lock solenoid.
connector terminal and operate solenoid.
Terminal
-
NO. 4 (+) NO. 5 (--)I
9 CHECK POOR CONTACT. Is there poor contact in key Repair poor con- Replace the inte-
lock circuit? tact. grated module.
CS-15
CONTROL SYSTEMS
3. SELECT LEVER SHIFT LOCK CANNOT BE RELEASED

WIRING DIAGRAM:
INHIBITOR STOP LIGHT

SWITCH SWITCH
I
A: @
B: @ INTEGRATED MODULE
I SHIFT LOCK
~
I SOLENOID
B
m n
11213]4]516171819110
11~12~13~14]15]16~17~18~19~20
9 10 11 12
TR0553
CS-16
AT SHIFT LOCK SYSTEM I
CONTROL SYSTEMS
~ ~
Step Check Yes No

CHECK INHIBITOR SWITCH. ;ombination meter indicator Go to step 2. 4djust inhibitor
1)Turn the ignition switch to ON (engine OFF). amp and select lever “ P , “R”, ;witch and select
2)Move the select lever from “P”to “1” range. IN”, “ 3 , “ 2 and “1” are cor- :able.
.ectly matched?
CHECK HARNESS BETWEEN INHIBITOR s the resistance less than 1 Repair short circuit 30 to step 3.
SWITCH AND INTEGRATED MODULE. n? in harness
2)Disconnect the connector transmission har- grated module and
ness and intgrated module. transmission con-
3)Measure the resistance of harness between nector.
integrated module and chassis ground.
CHECK HARNESS BETWEEN INHIBITOR s the resistance more than 1 Repair open circuit 30 to step 4.
SWITCH AND INTEGRATED MODULE. WR? in harness
integrated module and inhibitor switch. grated module and
Connector & terminal transmission con-
(612) NO. 3 - (6280) NO. 5: nector
CHECK HARNESS BETWEEN INHIBITOR s the resistance less than 1 Go to step 5. Sepair open circuii
SWITCH AND CHASSIS GROUND. n? n harness
Measure the resistance of harness between 2etween inte-
integrated module and chassis ground. Jrated module and
Connector & terminal :hassis ground.
(612) No. 4- Chassis ground:
CHECK INHIBITOR SWITCH. s the resistance more than 1 Repair or replace 30 to step 6.
1)Move the select lever to “ P position. wn? inhibitor switch.
2)Measure the resistance of transmission har-
ness connector terminals.
(T3) NO. 3 - NO. 4:
CHECK OUTPUT SIGNAL FOR INTEGRAT- Is the voltage between 9 and Go to step 7. 30 to step 15.
ED MODULE. 16 V?
1)Connect all connectors.
3)Measure the voltage between integrated
module and chassis ground.
CHECK STOP LIGHT SWITCH. Does the stop light turn on? Go to step 8. Inspect stop light
Depress the brake pedal. iystem.
CHECK HARNESS BETWEEN STOP LIGHT Is the voltage more than 9 V? Go to step 9. Repair open or
SWITCH AND AT SHIFT LOCK CONTROL short circuit in har,
MODULE. ness between inte
1)Depress the brake pedal. grated module ana
2)Measure the voltage between integrated itop light switch.
CHECK HARNESS BETWEENINTEGRATED Is the resistance more than 1 Repair open circuit Go to step 10.
MODULE AND SHIFT LOCK SOLENOID. MR? in harness
2)Disconnect the connector from shift lock grated module and
solenoid and integrated module. shift lock solenoid.
integrated module and shift lock solenoid.
(6281) NO. 9 - (61161 NO. 4:
CS-17
I AT SHIFT LOCK SYSTEM
CONTROL SYSTEMS
Step Check Yes No

IO CHECK HARNESS BETWEENINTEGRATEC Is the resistance less than 10 Go to step 11. Repair short circui
MODULE AND SHIFT LOCK SOLENOID. R? in harness
shift lock solenoid and chassis ground. grated module an(
Connector & terminal shift lock solenoid
I1 CHECK HARNESS BETWEEN SHIFT LOCK Is the resistance less than 1 Go to step 12. Repair open circui
SOLENOID AND CHASSIS GROUND. n? in harness
Measure the resistance of harness between between shift lock
shift lock solenoid and chassis ground. solenoid and chas
Connector & terminal sis ground.
( 6 1 16) No. 5 - Chassis ground:
12 CHECK SHIFT LOCK SOLENOID. Is the resistance between 10 Go to step 13. Replace the shift
Measure the resistance of shift lock solenoid and 20 R? lock solenoid.
Terminal
NO. 4 - NO. 5:
13 CHECK SHIFT LOCK SOLENOID. Is shift lock solenoid operating So to step 14. Replace the shift
Connect the battery with shift lock solenoid properly? lock solenoid.
connector terminal and operate solenoid.
Terminal
-... . NO. 4 (+) - NO. 5I)-(
14 CHECK OUTPUT SIGNAL FOR AT SHIFT Is the voltage more than 8.5 V? 30 to step 15. Replace the inte-
LOCK CONTROL MODULE. grated module.
1)Turnthe ignition switch to ON (engine OFF).
5 CHECK POOR CONTACT. Is there poor contact in key 3epair poor con- Replace the inte-
lock circuit? act. grated module.
CS-18
AT SHIFT LOCK SYSTEM I
CONTROL SYSTEMS
cs-19
CONTROL SYSTEMS
4. KEY INTERLOCK DOES NOT LOCK OR RELEASE

WIRING DIAGRAM:
(D
>
a
si E
$ 0
c.
TR0554
cs-20
I AT SHIFT LOCK SYSTEM
I
CONTROL SYSTEMS
Step Check Yes No

CHECK HARNESS BETWEEN BATTERY s the voltage between 9 and 30 to step 2. 3epair open or
AND KEY WARNING SWITCH. I6 V? short circuit in har-
1)Disconnectthe connector key warning less between bat-
switch. :ery and key
2)Measure the voltage of harness between key Narning switch.
warning switch and chassis ground.
CHECK KEY WARNING SWITCH. Is the resistance more than 1 3eplace key warn- 30 to step 4.
Measure the resistance of stop light switch WR? ng switch.
Terminal
NO. 1 - NO. 2:
CHECK KEY WARNING SWITCH. Is the resistance more than 1 30 to step 4. Replace key warn-
1)Remove the key. MR? ing switch.
2)Measure the resistance of stop light switch
Terminal
NO. 1 - NO. 2:
CHECK HARNESS BETWEEN AT SHIFT Is the resistance more than 9 30 to step 5. Repair open circuit
LOCK CONTROL MODULE AND KEY V? in harness
WARNING SWITCH. between inte-
1)Disconnectthe integrated module connector. grated module and
2)Measure the voltage of harness integrated key warning
module and chassis ground. switch.
CHECK HARNESS BETWEENINTEGRATED Is the resistance more than 1 Repair open circuit Go to step 6.
MODULE AND KEY LOCK SOLENOID. MR? n harness
1)Disconnectthe connector key lock solenoid. setween inte-
2)Measure the resistance of harness between grated module and
integrated module and key lock solenoid. cey lock solenoid.
(873) NO. 2 - (8281) NO. 3:
CHECK HARNESS BETWEEN INTEGRATED Is the resistance more than 1 Go to step 7. Repair short circuit
MODULE AND KEY LOCK SOLENOID. R? in harness
integrated module and chassis ground. grated module and
Connector & terminal key lock solenoid.
CHECK HARNESS BETWEEN KEY LOCK Is the resistance less than 10 Go to step 8. Repair open circuit
SOLENOID AND CHASSIS GROUND. a? in harness
Measure the resistance of harness between between key lock
key lock solenoid and chassis ground. solenoid and chas
Connector & terminal sis ground.
CHECK KEY LOCK SOLENOID. Is the resistance between 4 Go to step 14. Replace the key
Measure the resistance of key lock solenoid and 8 R? lock solenoid.
(873) NO. 1 -NO. 2:
CHECK HARNESS BETWEEN “P” POSI- Is the resistance less than 1 Go to step 10. Repair short circuil
TION SWITCH AND CHASSIS GROUND. R? in harness
Measure the resistance of harness between between “P” posi-
“ P position switch and chassis ground. tion switch and
Connector & terminal integrated module
cs-21
CONTROL SYSTEMS
Step Check Yes No

IO CHECK HARNESS BETWEEN AT SHIFT s the resistance more than 1 Repair open circuit Go to step 11.
LOCK CONTROL MODULE AND “P” POSI- AQ? in harness
TION SWITCH. between inte-
1)Disconnectthe connector from “ P position grated module and
switch. “P” position switch.
integrated module and “ P position switch.
(B116) NO. 2 - (8280) NO. 6:
I1 CHECK HARNESS BETWEEN “P” POSI- s the resistance more than 1 IGo to step 12. Repair open circuit
TlON SWITCH AND CHASSIS GROUND. JIR? in harness
Measure the resistance of harness “P”position between “P” posi-
switch and chassis ground. tion switch and
Connector & terminal shassis ground.
( B l l 6 ) No. 6 - Chassis ground:
I2 CHECK “P” POSITION SWITCH. s the resistance less than 1 Go to step 13. Replace the “P”
1)Move the select lever to “P” position. 2? aosition switch.
2)Measure resistance between “ P position
switch connector terminals.
Terminal
NO. 2 - NO. 6:
k . CHECK “P” POSITION SWITCH. s the resistance more than 1 Go to step 14. Replace the “P”
1)Move the select lever to other than “P” posi- JIQ? position switch.
tion.
Terminal
NO. 2 - NO. 6:
4 CHECK OUTPUT SIGNAL FOR INTEGRAT- s the voltage 7.5 and 16 V? 30 to step 15. Replace the inte-
ED MODULE. grated module.
2)Turn the ignition switch to ON (engine OFF).
3)Move the select lever to “P” position.
4)Press the brake pedal.
module connector and chassis ground.
I5 CHECK POOR CONTACT. s there poor contact in AT shift Repair poor con- Replace the inte-
x k circuit? tact. grated module.
cs-22
SELECT LEVER
I
CONTROL SYSTEMS
4. Select Lever B: INSTALLATION

1) Mount the select lever onto the vehicle body.
A: REMOVAL 2) Tighten the four bolts to install the select lever to
1) Set the vehicle on the lift. the vehicle body, then connect the connector.
Tightening torque:
3) Move the select lever to the “N” position.
13 N.m (1.3 kgf-m, 9.4 ft-lb)
5) Remove the rear exhaust pipe and muffler.
6) Remove the heat shield cover. (If equipped)
7) Disconnect the cable from select lever and then
remove the cable bracket.
3) Install the console box. <Ref. to El-39, INSTAL-

LATION, Glove Box.>
4) Set the location of select lever at ‘IN” position.
6) Set the location of range select lever to “N” posi-
(A) Adjusting nuts tion.
(B) Cable bracket 7) Insert the thread portion of the other inner cable
and into the connector hole of the select lever, and
8) Lower the vehicle. fix the other outer cable end to the bracket.
9) Remove the console box. <Ref. to El-41, RE- 8) Adjust the select cable position. <Ref. to CS-27,
MOVAL, Console Box.> ADJUSTMENT, Select Cable.>
10) Disconnect the connectors, then remove the 9) After completion of fitting, make sure that the se-
four bolts to take out the select lever assembly from lect lever operates smoothly all across the operat-
the body. ing range.
10) Inspect the following items. If the following in-
spection reveals problems, adjust the select cable
and inhibitor switch. <Ref. to CS-27, ADJUST-
MENT, Select Cable.> and <Ref. to AT-28, AD-
JUSTMENT, Inhibitor Switch.>
(1) The engine starts operating when select le-
ver is in position “P”,but not in other positions.
(2) The back-up light is lit when the select lever
is in position ‘W, but not in other positions.
(3) Select lever and indicator positions are
I1510
matched.
11) Check the shift-lock system.
(1) Ensure the ignition switch rotates from
“ACC” to “LOCK when the select lever is set at
“P”. Also check that ignition key can be removed
only from the “LOCK position.
(2) Ensure the select lever moves from “P” to
any other position when the brake pedal is de-
pressed with ignition key set at “ON” or
“START.
12) Install heat shield cover. (If equipped)
13) Install rear exhaust pipe and muffler.
CS-23
SELECT LEVER
I
CONTROL SYSTEMS
C: DISASSEMBLY 6) Remove the lock plate.

1) Remove the grip.
2) Remove the indicator light and then remove the n
indicator cover.
NOTE:
Be careful not to break the indicator light during re-
moval.
v
TR0556
7) Remove the pattern plate.
B3M1511A
(A) Grip
c. ~ (B) Indicator cover
(C) indicator light
3) Remove the slider. TR0557

4) Remove the clips and then remove the guide
8) Remove the clip and remove the “P” position
plate. switch.
I
I B3M2177A
(A) Clips
(A) Clip
(B) Guide plate
(B) “P” position switch
5) Remove the clamp, and shift lock solenoid. 9) Remove the cap and then extract straight pin.
I TR0555
B3M1797A
(A) Clamp
(A) Straight pin
(B) Shift lock solenoid
(B) Select lever lower
CS-24
I
SELECT LEVER
CONTROL SYSTEMS
10)Remove the select lever lower then take away

the select lever upper from plate.
dA’ B3M1848A
(A) Select lever lower

(B) Select lever upper
(C) Plate
1 1 ) Remove the spring and remove the detent arm.
(A) Detent arm

(B) Spring
12)Remove the cushion.

D: ASSEMBLY
1) Clean all parts before assembly.
2) Apply grease [NIGTIGHT LYW No. 2 or equiva-
lent] to each parts. <Ref. to CS-3, AT Select Le-
ver.>
3) Assembly is in the reverse order of disassembly.
4) After completion of fitting, transfer the select le-
ver to range “P” - “l”, then check whether the in-
dicator and select lever agree, whether the pointer
and position mark agree and what the operating
force is.
E: INSPECTION
1) Inspect the removed parts by comparing with
new ones for deformation, damage and wear. Cor-
rect or replace if defective.
2) Confirm the following parts for operating condi-
tion before assembly. Moving condition of the se-
lector lever upper, it should move smoothly.
CS-25
I I
SELECT CABLE
CONTROL SYSTEMS
5. Select Cable 10) Disconnect the cable from select lever and then
remove the cable bracket.
A: REMOVAL
3) Prior to removal, set the lever to “N” position.
5) Remove the front and center exhaust pipe. (Non-
turbo model) <Ref. to EX(S0HC)-5, REMOVAL,
Front Exhaust Pipe.>
CAUTION:
When removing the exhaust pipes, be careful
each exhaust pipe does not drop out.
6) Remove the center exhaust pipe. (Turbo model) (A) Adjusting nuts
<Ref. to EX(D0HC TURBO)-8, REMOVAL, Center (B) Cable bracket
Exhaust Pipe.>
7) Remove’ the heat shield cover. (If equipped) 11) Remove the select cable from plate assembly.
8) Remove the snap pin from range select lever.
(A) Range select lever

(B) Snap pin
(C) Select cable
(D) Clamp
9) Remove the plate assembly from transmission
case
(A) Select cable

(B) Plate ASSY
(C) Clamp
CS-26
I SELECT CABLE
I
CONTROL SYSTEMS
1) Install the select cable to plate assembly. Check the removed cable and replace if damaged,
rusty, or malfunctioning.
Tightening torque:
1) Check for smooth operation of the cable.
32 N.m (3.3 kgf-m, 24 fi-lb)
2) Check the inner cable for damage and rust.
2) Install the select cable to range select lever. 3) Check the outer cable for damage, bends, and
3) Install the plate assembly to transmission. cracks.
Tightening torque: 4) Check the boot for damage, cracks, and deterio-
T: 24.5 N-m (2.5 kgf-m, 18.1 ft-lb) ration.
5) Move the select lever from “P” position to “1” po-
sition. You should be able to feel the detentes in
each position. If the detentes cannot be felt or the
position pointer is improperly aligned, adjust the ca-
ble.
D: ADJUSTMENT
3) Set the lever to “N” position.
c.
(A) Select cable 6) Remove the heat shield cover. (If equipped)
(B) Plate ASSY 7) Loosen the adjusting nut on each side.
4) Install the snap pin to range select lever
I / 03M1792A
(A) Adjusting nut A

(B) Adjusting nut B
(A) Range select lever
(B) Snap pin
(C) Select cable
(D) Clamp
5) Move the select lever to the “N” position, then ad-

just the select cable position. <Ref. to CS-27, AD-
JUSTMENT, Select Cable.>
6) Install the heat shield cover. (If equipped)
7) Install the front and center exhaust pipe. (Non-
turbo model) <Ref. to EX(S0HC)-6, INSTALLA-
TION, Front Exhaust Pipe.>
8) Install the center exhaust pipe. (Turbo model)
<Ref. to EX(D0HC TURBO)-9, INSTALLATION,
Center Exhaust Pipe.>
CS-27
I SELECT CABLE
CONTROL SYSTEMS
8) Turn the adjusting nut B until it lightly touches the

connector.
(A) Front side

(B) Select lever
(C) Connector
(D) Adjusting nut B
(E) Contact point
(F) Adjusting nut A
S).While preventing the adjusting nut B from mov-

ing with a wrench, tighten adjusting nut A.
Tightening torque:
7.5 N.m (0.76 kgf-m, 5.5 ft-lb)
(A) Adjusting nut A

(B) Adjusting nut B
10) After completion of fitting, make sure that the

select lever operates smoothly all across the oper-
ating range.
CS-28
AT SHIFT LOCK SOLENOID AND “P” POSITION SWITCH I
CONTROL SYSTEMS
6. AT Shift Lock Solenoid and 6 : INSTALLATION

“P” Position Switch Install in the reverse order of removal.
A: REMOVAL
2) Remove the console box. <Ref. to El-41, RE-
MOVAL, Console Box.>
3) Disconnect the connector.
4) Remove the grip.
5 ) Remove the indicator cover.
6) Remove the slider.

7) Remove the cushion.
8) Remove the clip and remove the “P” position
switch.
(A) Clip
(B) “ P position switch
9) Remove the clamp and remove the shift lock so-

lenoid.
(A) Clamp
(B) Shift lock solenoid
CS-29
I AT SHIFT LOCK SOLENOID AND “P” POSITION SWITCH
CONTROL SYSTEMS
C: INSPECTION
Step Check
1 CHECK SHIFT LOCK SOLENOID.
Measure the resistance of shift lock solenoid and 20 R? lock solenoid and
connector terminals. “ P position switch
Terminal assembly.
NO. 4 - NO. 5
2 CHECK SHIFT LOCK SOLENOID. Is the shift lock solenoid oper- Go to step 3. Replace the shift
Connect the battery with shift lock solenoid ating properly? lock solenoid and
connector terminal, operate solenoid. “ P position switch
Terminal assembly.
NO. 4 (+) - NO. 5 (-)
3 CHECK “P” POSITION SWITCH. Is the resistance less than 1 Go to step 4. Replace the “ P
1)Move the select lever to “ Pposition. n? position switch.
4 CHECK “P” POSITION SWITCH. Is the resistance more than 1 Normal Replace the “P”
1)Move the select lever to other than “P” posi- MR? position switch.
tion.
2)Measure resistance between “P” position
CS-30
INTEGRATED MODULE
I
CONTROL SYSTEMS
7. Integrated Module B: INSTALLATION

A: REMOVAL
1 ) Disconnect the ground terminal from battery.
2 ) Remove the lower cover.
3) Remove the knee bolster.
4) Disconnect the connector from integrated mod-

ule.
5) Remove the integrated module.
CS-31
I MT GEAR SHIFT LEVER
I
CONTROL SYSTEMS
8. MT Gear Shift Lever 11) Remove the cushion rubber from body.
A: REMOVAL
2) Remove the gear shift knob.
5) Remove the boot plate from body.
(A) Stay
(B) Cushion rubber
12) Remove the joint and then extract the spring
pin.
@.Lift-up the vehicle.

9) Remove the stay from transmission bracket.
(A) Joint
(B) Spring pin

14) Remove the gear shift lever
(A) Stay
(B) Transmission bracket
10) Remove the rod from joint.
CS-32
MT GEAR SHIFT LEVER
I
CONTROL SYSTEMS
B: INSTALLATION 7) Connect the rod to the joint.

1) Install the joint to the transmission and secure Tightening torque:
with the straight pin. 18 N.m (1.8 kgf-m, 73.0 ff-lb)
2) Insert the gear shift lever from room side.
NOTE:
After inserting the rod and stay, temporarily put
them onto transmission mount.
(A) Stay
(B) Rod
8) Connect the stay to transmission bracket.

3) Lift-up the vehicle. Tightening torque:
c4) Install the joint to shifter arm.
.
18 N-m (1.8 kgf-m, 13.0 ff-lb)
5) Insert the spring pin.
(A) Stay
(A) Joint
(B) Transmission bracket
(B) Spring pin
6) Mount the cushion rubber on the body. IO) Install the rear exhaust pipe and muffler.
Tightening torque: 1 1 ) Lower the vehicle.
18 N-m (1.8 kgf-m, 13.0 ff-lb) 12) Install the boot plate to body.
Tightening torque:
7.5 N.m (0.76 kgf-m, 5.5 ff-lb)
13) Install the consol box. <Ref. to El-41, INSTAL-
LATION, Console Box.>
(A) Stay
(B) Cushion rubber
cs-33
I
CONTROL SYSTEMS
C: DISASSEMBLY 5) Remove the bush and cushion rubber from stay.

1) Disassemble the locking wire.
B3M08300
' ' B3M0617C

(A) Bushing
(A) Locking wire (B) Stay
(B) Stay (C) Cushion rubber
2) Remove the rod from gear shift lever. 6) Remove the O-ring, then disconnect the bush D.
- B3M1828A
(A) Rod (A) O-ring B

(B) Gear shift lever (B) O-ring A
(C) Stay (C) Bushing B
3) Remove the snap ring from bush B, then discon- 7) Draw out the spring pin, then remove the bush C
nect the stay. from gear shift lever.
B3M0619B 83M0621B
(A) Snap ring (A) Spring pin

(B) Bushing B (B) BushingA
(C) Boot
4) Remove the boot from gear shift lever.
cs-34
MT GEAR SHIFT LEVER
I
CONTROL SYSTEMS
D: ASSEMBLY 4) Insert the gear shift lever into the boot hole.
1) Clean all parts before assembly. 5) Install the snap ring and stay to the bushing B.
2) Mount the bushing B and cushion rubber on the
stay.
B3M0619C
B3M0830C
(A) Snap ring
(6) Bushing B
(A) Bushing
6) Tighten with locking wire to the extent that the
(6) Cushion rubber boot will not come off.
3) Mount each part; boot, O-ring, bush, spacer, CAUTION:
bush A, bush B and straight pin on the gear shift le- Always use new locking wire.
..-
-
ver.
CAUTION:
Always use new O-rings.
Apply grease [DNIGTIGHT LYW No. 2 or
equivalent] to the inner and side surfaces of the
bushing when installing the spacer.
L(A)
(6)
(C)
(D)
(E)
(F)
Boot
O-ring B
Bushing
Spacer
BushingA
Bushing E3
B3M0623C
(A) Locking wire
(6) Stay
7) Insert the rod into the boot hole.

8) Connect the rod to gear shift lever.
Tightening torque:
11.8 N.m (1.2 kgf-m, 8.7 fi-lb)
n
(G) Spring pin
(H) O-ring A
(A) Rod
(6) Shift lever
(C) Stay
cs-35
CONTROL SYSTEMS
9) Check the swing torque of the rod in relation to E: INSPECTION

the gear shift lever. 1) Check each part (bushing, cushion rubber, spac-
If the torque exceeds the specification, replace the er, boot, stay and rod, etc.) for deformation, dam-
bushing or retighten nuts. age and wear. Repair or replace any defective part.
Rocking torque: Determine defective parts by comparing with new
0.7 N.m (0.07 kgf-m, 0.5 ft-lb) or less parts.
(A) Center of rotation

(6) Swing torque
70) Check that there is no excessive play and that

parts move smoothly.
B3M7 765A
(A) Bushing
(6) Cushion rubber
(C) Spacer
(D) Boot
(E) Stay
(F) Rod
CS-36
MT GEAR SHIFT LEVER 3
CONTROL SYSTEMS
2) Check the swing torque of the rod in relation of

the gear shift lever.
If the torque exceeds the specification, replace the
bushing or retighten nuts.
Rocking torque:
0.7 N-m (0.07 kgf-m, 0.5 ff-lb) or less
(6)
B3M1829C
(A) Center of rotation

(B) Swing torque
cs-37
GENERAL DlAGOSTlC
CONTROL SYSTEMS
9. General Diagostic
A: INSPECTION
Symptom Problem Darts
Stop light switch
Shift lock does not function. Shift lock solenoid
Integrated module
Stop light switch
Shift lock solenoid
Shift lock cannot be released.
Integrated module
Inhibitor switch
Key warning switch
“ P position switch
Key interlock does not function.
Key lock solenoid
Integrated module
Key warning switch
“ P position switch
Key interlock cannot be released.
Key lock solenoid
Integrated module
Inhibitor switch
Starter does not run. Select cable
Starter circuit
Inhibitor switch
Back-up light does not light up. Select cable
Back-up light circuit
CS-38
I
AUTOMATIC TRANSMISSION
AT
1.
Page
General Description .................................................................................... 2
a
2. Automatic Transmission Fluid ..................................................................... 9
3. Differential Gear Oil ................................................................................... 11
4. Road Test .................................................................................................. 12
5. Stall Test ................................................................................................... 13
6. Time Lag Test ........................................................................................... 15
7. Line Pressure Test .................................................................................... 16
8. Transfer Clutch Pressure Test .................................................................. 18
9. Automatic Transmission Assembly ........................................................... 19
C. . 10. Transmission Mounting System ................................................................ 25
11. Extension Case Oil Seal ........................................................................... 27
12. Inhibitor Switch .......................................................................................... 28
13. Front Vehicle Speed Sensor ..................................................................... 32
14. Rear Vehicle Speed Sensor ...................................................................... 35
15. Torque Converter Turbine Speed Sensor ................................................. 36
16. Control Vatve Body ................................................................................... 37
17. Shift Solenoids. Duty Solenoids and ATF Temperature Sensor ...............39
18. ATF Filter .................................................................................................. 44
19. Transmission Control Module (TCM) ........................................................ 45
20 . Dropping Resistor ..................................................................................... 46
21. ATF Cooler Pipe and Hose ....................................................................... 47
I
1. General Description 4. TRANSMISSION GEAR RATIO
A: SPECIFICATIONS Model I Sedan non-turbo

I Except sedan
non-turbo I
1. TORQUE CONVERTER CLUTCH 1st I 3.027 I 2.785 I
Model Non-turbo Turbo
2nd I 1.619 I 1.545 I
3rd 1.ooo
Symmetric, 3 element, single stage, 2 phase
Type 4th 0.694
torwe converter
ratio torque I 1.9 - 2.1 I 1.85-2.15

5. PLANETARY GEAR AND PLATE
Nominal
diameter I 246 mm (9.69 in)
1-1
speed
(at sea level)
2,100 - 2,600 rpm 1 2,600 - 3,300 rpm
Model
I “ 1
Turbo
One-way
clutch
1 Sprague type one-way clutch
Front sun gear number of
teeth
33
Front pinion number of teeth I 21

2. OILPUMP Front internal gear number
75
of teeth
I Type I Pracoid constant-displacementpump I Rear sun gear number of
37 42
LDriving method I Driven by engine teeth
Inner rotor 9 Rear pinion number of teeth I 19 I 17
3. TRANSMISSION CONTROL ELEMENT Drive & driven plate number

4 5
of high clutch
4-forward, 1-reverse, double-row plane- Drive & driven plate number
Type 6 7
tary gears of low clutch
I I
Multi-Dlate clutch 3 sets
I Multi-plate brake I
One-way clutch
(sprague type)
2 sets
1 sets
I
Drive & driven plate number
of 2-4 brake
Drive & driven plate number
of low & reverse brake
1
AT-2
6. SELECTOR POSITION 8. COOLING AND HARNESS
P (Park)
Transmission in neutral, output member immov.
able, and engine start possible
Cooling system
I Liquid-cooledcooler incorpo-
rated in radiator I
Transmission in reverse for backing
(Reverse) I Transmission harness I 20 poles I
tral) 9. TRANSFER
Automatic gear change 1st e + 2nd +_) 3rd
D (Drive) Model Non-turbo Turbo
+ 4th
Multi-plate Variable torque

Automatic gear change 1st e + 2nd +_)3rd t Transfer type transfer distribution
4th (MPT) (VTD)
2nd gear locked (Deceleration possible 2nd t Drive & driven plate
2 (2nd)
3rd c 4th)
1 (1st)
1 1st gear locked (Deceleration possible 1st t
2nd c 3rd t 4th)
number of transfer
clutch
5
I Electronic, hydraulic type

3
Control method I
Control
method I Hydraulic remote control
Lubricant
The same Automatic transmission
fluid used in automatic transmis-
sion
7. HYDRAULIC CONTROL AND LUBRICA- Ist reduction Clear ratio I I.OOO ( 5 ~ 5 3 ) I
JlON
forward speed changes by electri-

cal signals of vehicle speed and
accelerator (throttle) opening]
Fluid
mission fluid
9.3 - 9.6 8 (9.8 - 10.1 US qt,
Fluid capacity
7.4 - 7.7 Imp qt)
Forced feed lubricationwith oil
Lubrication system
,DUmD
,
Automatic transmission fluid
Oil
(above mentioned)
10.FlNAL REDUCTION
I Model Sedan non-turbo Except sedan non-turbo

Front final gear ratio 4.444 (4019) 4.1 11 (37/91
ITEM
Front differential gear oil
API Classification
GL - 5
SAE Viscosity No. and Applicable Temperature
Lubricationoil ("C) -30 -26 -15 -5 0 15 2530
H3M1235A
Front differential oil capacity 1.2 8 (1.3 US qt, 1.1 Imp qt)
AT-3
GENERAL DESCRIPTION
I
B: COMPONENT
NOTE:
For information about other transmission mounting components, refer to “AUTOMATIC TRANSMISSION”
<Pub. No. G0853ZE> a separate publication.
1. TRANSMISSION MOUNTING
’1I
P
t
(1) Pitching stopper Tightening torque: N.m (kgf-m, ft-lb)

(2) Rear cushion rubber T1: 35 (3.6, 26)
(3) Crossmember T2: 39 (4.0,29)
(4) Stopper T3: 50 (5.1, 37)
T4: 58 (5.9, 43)
T5: 70 (7.1, 51)
AT-4
C: CAUTION Use SUBARU genuine gear oil, grease etc. or

Wear working clothing, including a cap, protec- the equivalent. Do not mix gear oil, grease etc. with
tive goggles, and protective shoes during opera- that of another grade or from other manufacturers.
tion. Be sure to tighten fasteners including bolts and
Remove contamination including dirt and corro- nuts to the specified torque.
sion before removal, installation, and disassembly. Place shop jacks or safety stands at the specified
Keep the disassembled parts in order and pro- points.
tect them from dust or dirt. Apply gear oil onto sliding or revolution surfaces
Until the oil pan is removed, do not place with the before installation.
oil pan side facing up to prevent foreign matter from Replace deformed or otherwise damaged snap
entering the valve body. rings with new ones.
Before removal, installation or disassembly, be Before installing O-rings or oil seals, apply suffi-
sure to clarify the failure. Avoid unnecessary re- cient amount of ATF fluid to avoid damage and de-
moval, installation, disassembly and replacement. formation.
When disassembling the-case and other light al- Be careful not to incorrectly install or fail to install
loy parts, use a plastic hammer to force it apart. Do O-rings, snap rings and other such parts.
not pry it apart with a screwdriver or other tool. Before securing a part on a vice, place cushion-
Be careful not to burn your hands, because each ing material such as wood blocks, aluminum plate,
part on the vehicle is hot after running. or shop cloth between the part and the vice.
Avoid damaging the mating surface of the case.
~ . ..
Before applying sealant, completely remove the
old seal.
D: PREPARATION TOOL
1. SPECIAL TOOLS
~

398527700 PULLER ASSY Used for removing and installing extension case
roller bearing.
Used for installing extension oil seal.
AT-5
3
I---
498575400 OIL PRESSURE Used for measuring oil pressure.
GAUGE ASSY
I B3M204C
498897200 4DAPTER Used for oil pump housing when measuring
reverse clutch pressure and line pressure.
I B3M2041
498545400 -ILTER WRENCH Jsed for removing and installing ATF filter.
498277200 ;TOPPER SET Jsed for removing and installing automatic trans.
nission assembly to engine.
I B3M2043
AT-6
ILLUSTRATION I TOOLNUMBER DESCRIPTION REMARKS

41099AA020 NGINE SUPPORT Used for supporting engine.
B3M1976 ~
I 41099AA010 INGINE SUPPORT Jsed for supporting engine.

3RACKET
B3M1975
Turbo model :RANK PULLEY Used for removing and installing bolts which hold
499977300 WRENCH torque converter clutch and drive plate.
Non-turbo model
499977100
B2M4157
I 24082AA150
(Newly adopted tool
CARTRIDGE Troubleshooting for electrical systems.
B2M3876
AT-7
GENERAL DESCRIPTION
I

22771AA030 SELECT MONITOR Troubleshooting for electrical systems.
KIT English:
22771AA030 (Without printer)
German:
French:
Spanish:
B2M3877
499267300 STOPPER PIN Used for installing and adjusting inhibitor switch.
B3M2008
TOOL NAME REMARKS
AT-8
AUTOMATIC TRANSMISSION FLUID I
2. Automatic Transmission (4) Fluid temperature rising speed:

By idling the engine
Fluid Time for temperature rise to 60°C (140°F) with at-
A: INSPECTION mospheric temperature of 0°C (32°F): More than
25 minutes
1) Check the level of the ATF.
<Reference>
(1) Raise the ATF temperature to 60 to 80°C
Time for temperature rise to 30°C (86°F) with atmo-
(140 to 176°F) from 40 to 60°C (104 to 140°F)
spheric temperature of 0°C (32°F): Approx. 8 min-
(when cold) by driving a distance of 5 to 10 km (3
utes
to 6 miles).
By running the vehicle
NOTE: Time for temperature rise to 60°C (140°F) with at-
The level of ATF varies with fluid temperature. Pay mospheric temperature of 0°C (32°F): More than
attention to the fluid temperature when checking oil 10 minutes
level. (5) Method for checking fluid level upon delivery
or at periodic inspection:
Check fluid level after a warm-up run of approx.
10 minutes. During the warm-up period, the au-
tomatic transmission functions can also be
checked.
2) Check the fluid for leaks.
Check for leaks in the transmission. If there are
leaks, it is necessary to repair or replace gasket, oil
seals, plugs or other parts.
B3M1020B B: REPLACEMENT
(A) ATF level gauge 2) Drain the ATF completely.
(B) Upper level CAUTION:
(C) Lower level Directly after the engine has been running, the
(2) Make sure the vehicle is level. After select- ATF is hot. Be careful not to burn yourself.
ing all positions (P, R, N, D, 3, 2, l ) , set the se- NOTE:
lect leveler in “P” range. Measure fluid level with Tighten the ATF drain plug after draining the ATF.
the engine idling. Tightening torque:
NOTE: 25 N-m (2.5 kgf-m, 18.1 ft-lb)
After running, idle the engine for one or two min-
utes before measurement.
(3) If the fluid level is below the center between
upper and lower marks, add the recommended
ATF until the fluid level is found within the spec-
ified range (above the center between upper
and lower marks). When the transmission is hot,
the level should be above the center of upper
and lower marks, and when it is cold, the level
should be found below the center of these two
marks.
CAUTION:
Use care not to exceed the upper limit level. (A) Oil pan
ATF level varies with temperature. Remem- (B) Drain plug
ber that the addition of fluid to the upper limit (C) Differential oil drain plug
mark when the transmission is cold will result 3) Lower the vehicle.
in overfilling of fluid.
AT-9
I AUTOMATIC TRANSMISSION FLUID
I
4) Pour ATF into the oil charge pipe.

Recommended fluid:
Dexron Ill type automatic transmission fluid
Capacity:
Fill the same amount of fluid drained from the
drain plug hole.
Capacity when transmission is overhauled:
9.3-9.6 8 (9.8- 10.1 USqt, 8.2-8.4Imp
qt)
5) Check the level and leaks of the ATF.
<Ref. to AT-9, INSPECTION, Automatic Transmis-
sion Fluid.>
AT-I 0
DIFFERENTIAL GEAR OIL I
3. Differential Gear Oil B: REPLACEMENT

A: INSPECTION 2) Drain the differential gear oil completely.
1) Park the vehicle on a level surface. CAUTION:
2) Remove the oil level gauge and wipe it clean. Directly after the engine has been running, the
3) Reinsert the level gauge all the way. Be sure that differential gear oil is hot. Be careful not to burn
the level gauge is correctly inserted and in the yourself.
proper orientation.
4) Remove it again and note the reading. If the dif- NOTE:
ferential gear oil level is below the “L” line, add oil to Tighten the differential gear oil drain plug after
bring the level up to the “F’ line. draining the differential gear oil.
5) To prevent overfilling the differential gear oil, do Tightening torque:
not add oil above the ‘IF line. 44 N.m (4.5 kgf-m, 32.5 ff-16)
c. .
I s3M0478A
(A) Upper level (A) Oil pan

(B) Lower level (B) Drain plug
(C) Differential oil drain plug

4) Pour gear oil into the gauge hole.
Recommended fluid:
Use GL-5 or equivalent.
Gear oil capacity:
1.2 8 (1.3 US qt, 1.1 Imp qt)
5) Check the level of the differential gear oil.
<Ref. to AT-1 1, INSPECTION, Differential Gear
Oil.>
AT-I 1
ROAD TEST
4. RoadTest
A: INSPECTION
1. GENERAL PRECAUTION
Road tests should be conducted to properly diag-
nose the condition of the automatic transmission.
CAUTION:
When performing the test, do not exceed post-
ed speed limit.
2. D RANGE SHIFT FUNCTION
Check shifting between 1st a 2nd w 3rd a 4th
while driving on normal city streets.
3. D RANGE SHIFT SHOCK
Check the shock level when shifting up during nor-
mal driving.
4. KICK-DOWN FUNCTION
Check kick-down for each gear. Also check the
krick-down shock level.
between D -
5. ENGINE BRAKE OPERATION
Check the 3rd gear engine brake when shifting
3rd range while driving in 4th gear of
D range [50 to 60 km/h (31 to 37 MPH)].
Check the 2nd gear engine brake when shifting
between 3 2 range while driving in the 3 range
3rd gear [40 to 50 km/h (25 to 31 MPH)].
Check the 1st gear engine brake when shifting
between 2 -1 range while driving in the 2 range
2nd gear [20 to 30 km/h (12 to 19 MPH)].
6. LOCK-UP FUNCTION
Check that rpm does not change sharply when the
axle pedal is lightly depressed when driving on flat
roads at normal speed in the lock-up range.
7. P RANGE OPERATION
Stop the vehicle on an uphill grade of 5% or more
and shift to “P” range. Check that the vehicle does
not move when the parking brake is released.
8. UNUSUAL SOUNDS AND VIBRATION
Check for unusual sounds and vibration while driv-
ing and during shifting.
9. CLIMBING CONTROL FUNCTION
Check that the gear remains in 3rd when going
up a grade.
Check that the gear remains in 3rd when apply-
ing the brakes while going down a grade.
10.01L LEAKS
After the driving test, inspect for oil leaks.
AT-I 2
I STALL TEST
I
5. Stall Test 7) Shift the select lever to Neutral, and cool down
the engine by idling it for more than one minute.
A: INSPECTION 8) Record the stall speed.
9) If the stall speed in “2” range is higher than spec-
1. GENERAL INFORMATION ifications, low clutch slipping and “2-4 brake slip-
The stall test is of extreme importance in diagnos- ping” may occur. To identify it, conduct the same
ing the condition of the automatic transmission and test as above in D range.
the engine. It should be conducted to measure the 10) Perform the stall tests with the select lever in
engine stall speeds in “R” and “2” ranges. the R range.
Purposes of the stall test: NOTE:
1) To check the operation of the automatic trans- Do not continue the stall test for MORE THAN
mission clutch. FIVE SECONDS at a time (from closed throttle, ful-
2) To check the operation of the torque converter ly open throttle to stall speed reading). Failure to
clutch. follow this instruction causes the engine oil and
3) To check engine performance. ATF to deteriorate and the clutch and brake to be
adversely affected.
2. TEST METHODS
Be sure to cool down the engine for at least one
1) Preparations before test: minute after each stall test with the select lever set
(1) Check that the throttle valve opens fully. in the “P’ or ‘IN” range and with the idle speed lower
(2) Check that the engine oil level is correct. than 1,200 rpm.
c _ . (3) Check that the coolant level is correct. If the stall speed is higher than the specified
(4) Check that the ATF level is correct. range, attempt to finish the stall test in as short a
(5) Check that the differential gear oil level is time as possible, in order to prevent the automatic
correct. transmission from sustaining damage.
(6) Increase ATF temperature to 50 to 80°C Stall speed (at sea level):
(122 to 176°F) by idling the engine for approxi- Non-turbo model: 2,100 -2,600 rpm
mately 30 minutes (with select lever set to “N” or Turbo model: 2,600 - 3,300 rpm
lip”).
2) Install an engine tachometer at a location visible
from the driver’s compartment and mark the stall
speed range on the tachometer scale.
3) Place the wheel chocks at the front and rear of all
wheels and engage the parking brake.
4) Move the manual linkage to ensure it operates
properly, and shift the select lever to the “2” range.
5) While forcibly depressing the foot brake pedal,
gradually depress the accelerator pedal until the
engine operates at full throttle.
03M1589E
(A) Brake pedal

(B) Accelerator pedal
6) When the engine speed is stabilized, read that

speed quickly and release the accelerator pedal.
AT-1 3
I
STALL TEST
3. EVALUATION
Stall speed (at sea level) Position Cause
Less than specifications Erroneous engine operation

Torque converter clutch's one-way clutch slipping
Line pressure too low
Low clutch slipping
~
One-wav clutch malfunctionim -
Greater than specifications R Reverse clutch slipping
Low & reverse brake slipping
2 Low clutch slipping
I 2-4 brake slipping
AT-I 4
TIME LAG TEST
I
6. Time Lag Test

A: INSPECTION
1. GENERAL INFORMATION
If the select lever is shifted while the engine is
idling, there will be a certain time elapse or lag be-
fore the shock can be felt. This is used for checking
the condition of the low clutch, reverse clutch, low &
reverse brake and one-way clutch.
CAUTION:
Perform the test at normal operation fluid
temperature 60 to 80°C (140 to 176°F).
Be sure to allow a one minute interval be-
tween tests.
Make three measurements and take the aver-
age value.
2. TEST METHODS
1) Fully apply the parking brake.
-2.)Start the engine.
3) Check the idling speed (NC OFF).
4) Shift the select lever from “N” to “D” range.
Using a stop watch, measure the time it takes from
shifting the lever until the shock is felt.
Time lag: Less than 1.2 seconds
5 ) In the same manner, measure the time lag for
“N” + “R”.
Time lag: Less than 1.5 seconds
3. EVALUATION
1) If “N” + ‘ID time lag is longer than specified:
Low clutch worn
One-way clutch not operating properly
2) If “N” + “R” time lag is longer than specified:
Reverse clutch worn
Low & reverse brake worn
AT-I 5
I LINE PRESSURE TEST
7. Line Pressure Test 2. TEST METHODS

1) Temporarily attach the ST to a suitable place in
A: MEASUREMENT the driver’s compartment, remove the blind plug lo-
1. GENERAL INFORMATION cated in front of the toe board and pass the hose of
the ST to the engine compartment.
If the clutch or the brake shows a sign of slippage or ST 498575400 OIL PRESSURE GAUGE
shifting sensation is not correct, the line pressure ASSY
should be checked.
Excessive shocks during upshifting or shifting
takes place at a higher point than under normal cir-
cumstances, may be due to the line pressure being
too high.
Slippage or inability to operate the vehicle may,
in most cases, be due to loss of oil pressure for the
operation of the clutch, brake or control valve.
1) Line pressure measurement (under no load):
CAUTION:
Before measuring line pressure, jack-up all
wheels.
Maintain temperature of ATF at approximate- (A) Pressure gauge hose
ly 50°C (122°F) during measurement. (B) Hole in toe board (blind plug hole)
(ATF will reach the above temperature after (C) Brake pedal
idling the engine for approximately 30 minutes
with select lever in “N” or “P”.) 2) Remove the test plug and install the ST instead.
2) Line pressure measurement (under heavy load):
ST 498897200 OIL PRESSURE GAUGE
ADAPTER
CAUTION:
Before measuring line pressure, apply both
foot and parking brakes with all wheels
chocked (Same as for “stall” test conditions).
Measure the line pressure when the select le-
ver is in “R”, “2” with engine under stall condi-
tions.
Measure the line pressure within 5 the sec-
onds after shifting the select lever to each posi-
tion. (If the line pressure needs to be measured
again, allow the engine to idle and then stop.
Wait for at least one minute before measure-
ment.) (A) Test plug
Maintain the temperature of ATF at approxi-
mately 50°C (122°F) during measurement. (ATF 3) Connect ST1 with ST2.
will reach the above temperature after idling the ST1 498897200 OIL PRESSURE GAUGE
engine for approximately 30 minutes with the ADAPTER
select lever in “N” or “P”.) ST2 498575400 OIL PRESSURE GAUGE
ASSY
AT-16
LINE PRESSURE TEST
I
4) Check for duty ratio changes by opening and

closing the throttle valve using the Subaru Select
Monitor.
(1) Insert the cartridge to the Subaru Select
Monitor. <Ref. to AT-5, PREPARATION TOOL,
(2) Connect the Subaru Select Monitor to data

link connector.
5 ) Check the line pressure in accordance with the
following chart.
3. EVALUATION
Standard line Dressure 1
Range Line pres- Throttle Line pressure
posi- sure duty position kPa (kgkm’, psi)
tion ratio (Yo)
1,128-1,304
Full open (11.5 - 13.3,
164- 189)
1,520 - 1,716
Full open (15.5 - 17.5,
220 - 249)
304 - 412
D 100 Full closed
(3.1 - 4.2, 44 - 60)
AT-I 7
I TRANSFERCLUTCHPRESSURETEST
8. Transfer Clutch Pressure 2. EVALUATION

Test MTP model
A: INSPECTION NOTE:
If the oil pressure is not produced or if it does not
1. TEST METHODS change in the AWD mode, the transfer duty sole-
noid or transfer valve assembly may be malfunc-
MPT model tioning. If the oil pressure is produced in the FWD
Check the transfer clutch pressure in accordance mode, the problem is similar to that in the AWD
with the following chart in the same manner as with mode.
line pressure. <Ref. to AT-16, Line Pressure Test.>
ST 498897700 OIL PRESSURE ADAPTER Standard transfer clutch Dressure kPa (ka/cm2. Dsi)
SET Duty ratio Throttle
AWD mode
FWD
ST 498575400 OIL PRESSURE GAUGE (%) position mode
ASSY 932 - 1,089
AWD mode: “D” range (9.5-11.1,
closed
FWD mode: “P”range, engine speed 2,000 rpm
2/3 t hrot- 216 - 294
CAUTION: tle (2.2 - 3.0, 31 - 43)
Before setting in FWD mode, install the spare
fuse on FWD mode switch.
c. ~ t 1
Duty ratio Throttle Standard transfer clutch pressure

(Yo) position kPa (kg/cm2,psi)
Full 932 - 1,089
5
closed (9.5-11.1, 135-158)
2/3 throt- 216-294
60
tle (2.2 - 3.0, 31 - 43)
(A) Test plug
VTD model
Check the transfer clutch pressure in accordance
with the following chart in the same manner as with
line pressure.
ST 498897700 OIL PRESSURE ADAPTER
SET
ST 498575400 OIL PRESSURE GAUGE
ASSY
7
H3M18408
(A) Test plug
AT-I 8
AUTOMATIC TRANSMISSION ASSEMBLY
I
9. Automatic Transmission As- 10) Disconnect the following connectors:

(1) Transmission harness connector
sembly
A: REMOVAL
2) Open the front hood fully, and support it with
stay.
4) Remove the air intake duct. (Non-turbo model)
<Ref. to IN(S0HC)-7, REMOVAL, Air Intake Duct.>
5 ) Remove the air cleaner case. (Non-turbo model)
<Ref. to IN(S0HC)-6, REMOVAL, Air Cleaner
Case.>
6) Remove the air cleaner case stay. (Non-turbo (2) Transmission ground terminal
model) 11) Remove the starter. <Ref. to SC-6, REMOVAL,
Starter.>
12) Install the ST to torque converter clutch case.
7) Remove the intercooler. (Turbo model) <Ref. to

IN(D0HC TURBO)-10, REMOVAL, Intercooler.>
8) Remove the front, center, rear exhaust pipe and
muffler. (Non-turbo model) 13) Remove the pitching stopper.
<Ref. to EX(S0HC)-5, REMOVAL, Front Exhaust
Pipe.>, <Ref. to EX(S0HC)-9, REMOVAL, Rear
Exhaust Pipe.> and <Ref. to EX(S0HC)-1 1, RE-
MOVAL, Muffler.>
9) Remove the center, rear exhaust pipe and
muffer. (Turbo model) <Ref. to EX(D0HC TUR-
BO)-8, REMOVAL, Center Exhaust Pipe.>, <Ref.
to EX(D0HC TURBO)-13, REMOVAL, Rear Ex-
haust Pipe.> and <Ref. to EX(D0HC TURBO)-14,
REMOVAL, Muffler.>
14) Separate the torque converter clutch from drive

plate.
(1) Remove the service hole plug.
(2) Remove the bolts which hold torque con-
verter clutch to drive plate.
(3) While rotating the engine, remove the other
bolts using ST.
CAUTION:
Be careful not to drop bolts into the torque con-
verter clutch housing.
AT-I 9
I
Turbo model 17) Remove the bolt which holds right upper side of
ST 499977300 CRANK PULLEY WRENCH transmission to engine.
Non-turbo model
B3M2044

15) Remove the ATF level gauge. 20) Remove the heat shield cover. (If equipped)
CAUTION: 21) Drain the ATF to remove the ATF drain plug.
Plug the opening to prevent entry of foreign
particles into transmission fluid.
(A) Oil pan

(6) Drain plug
16) Set the ST.
22) Disconnect the ATF cooler hoses from pipes of
NOTE: transmission side, and remove the ATF level gauge
Also is available Part No. 41099AA010. guide.
ST 41 099AA020 ENGINE SUPPORT ASSY
23) Remove the propeller shaft.

<Ref. to DS-14, REMOVAL, Propeller Shaft.>
24) Remove the shift select cable. <Ref. to CS-26,
REMOVAL, Select Cable.>
25) Disconnect the stabilizer link from transverse
link.
AT-20
I
26) Remove the bolt securing ball joint of trans- 30) Remove the transmission rear crossmember
verse link to housing. from vehicle.
S4M0090
27) Remove the spring pins and separate front 31) Remove the transmission.
drive shafts from each side of the transmission. CAUTION:
Move the transmission and torque converter as
a unit away from engine.
Remove the nuts which hold lower side of

transmission to engine.
I 32) Separate transmission assembly and rear
cushion rubber.
v
B3M2047
29) Place the transmission jack under transmis-

sion.
CAUTION:
Make sure that the support plates of trans-
mission jack don't touch the oil pan.
AT-2 1
I AUTOMATIC TRANSMISSION ASSEMBLY
I
B: INSTALLATION 6) Tighten the nuts and bolts which hold lower side
1) Install the rear cushion rubber to transmission of transmission to engine.
assembly. Tightening torque:
Tightening torque: 50 N-m (5.1 kgf-m, 36.9 ft-lb)
39 N.m (4.0 kgf-m, 29 ft-lb)
2) Install the ST to torque converter clutch case.

8) Connect the engine and transmission.
(1) Remove the ST from torque converter clutch
3) Install the transmission onto engine. case.
-_. (1) Gradually raise the transmission with trans- NOTE:
Be careful not to drop the ST into the torque con-
mission jack.
verter clutch case when removing the ST.
(2) Install the starter.
<Ref. to SC-7, INSTALLATION, Starter.>
(3) Tighten the bolt which holds right upper side
of transmission to engine.
Tightening torque:
50 N.m (5.1 kgf-m, 36.9 ft-lb)
(2) Engage them at splines.

4) Install the transmission rear crossmember.
Tightening torque:
T1: 35 N-m (3.6 kgf-m, 26 ft-lb)
T2: 70 Nom(7.1 kgf-m, 51.4 ft-lb)
03M2044
5) Take off the transmission jack.
AT-22
1
9) Install the torque converter clutch to drive plate. 12) Lift-up the vehicle.
(1) Tighten the bolts which hold torque convert- Install the front drive shafts into transmission.
er clutch to drive plate. (1) Lift-up the vehicle.
(2) Tighten the other bolts while rotating the en- (2) Install the front drive shaft into transmission.
gine by using ST. (3) Drive the spring pin into chamfered hole of
CAUTION: drive shaft.
Be careful not to drop bolts into the torque con- CAUTION:
verter clutch housing. Always use a new spring pin.
Turbo model
Non-turbo model
Tightening torque:
25 N.m (2.5 kgf-m, 18.1 ft-lb)
13) Install the ball joint into housing.

14) Connect the stabilizer link to transverse link,
and temporarily tighten the bolts.
CAUTION:
Discard the loosened self-locking nut and re-
place with a new one.
(3) Clog the service hole with a plug. Tightening torque:
10) Remove the ST. T1: 30 N.m (3.1 kgf-m, 22.4 ft-lb)
T2: 50 N-m (5.1 kgf-m, 37 ft-lb)

Tightening torque: 15) Install the shift select cable onto select lever.
T1: 50 N.m (5.1 kgf-m, 37 ft-lb) <Ref. to CS-27, INSTALLATION, Select Cable.>
T2: 58 N.m (5.9 kgf-m, 43 ft-lb) 16) Install the ATF level gauge guide, and connect
the ATF cooler hoses to pipe.
AT-23
1
17) Install the propeller shaft. 32) Check the select lever operation.
<Ref. to DS-15, INSTALLATION, Propeller Shaft.> <Ref. to AT-28, INSPECTION, Inhibitor Switch.>
18) Install the heat shield cover. (If equipped) 33) Check the ATF level. <Ref. to AT-9, Automatic
19) Install the front, center, rear exhaust pipes and Transmission Fluid.>
muffler. (Non-turbo model) 34) Check the vehicle on the road tester.
<Ref. to EX(S0HC)-6, INSTALLATION, Front Ex- <Ref. to AT-12, Road Test.>
haust Pipe.>, <Ref. to EX(S0HC)-9, INSTALLA-
TION, Rear Exhaust Pipe.> and <Ref. to
EX(S0HC)-11, INSTALLATION, Muffler.>
20) Install the center, rear exhaust pipes and muf-
fler. (Turbo model) <Ref. to EX(D0HC TURBO)-9,
INSTALLATION, Center Exhaust Pipe.>, <Ref. to
EX(D0HC TURBO)-13, INSTALLATION, Rear Ex-
haust Pipe.>, <Ref. to EX(D0HC TURBO)-14, IN-
STALLATION, Muff ler.>
23) Install the ATF level gauge.
c. .
24) Connect the following connectors:

(1) Transmission harness connectors
(2) Transmission ground terminal
25) Install the air cleaner case stay. (Non-turbo
model)
Tightening torque:
16 N.m (1.6 kgf-m, 11.6 ft-16)
26) Install the air cleaner case. (Non-turbo model)
<Ref. to IN(S0HC)-6, INSTALLATION, Air Cleaner
Case.>
27) Install the air intake duct. (Non-turbo model)
<Ref. to IN(S0HC)-7, INSTALLATION, Air Intake
Duct.>
28) Install the intercooler. (Turbo model) <Ref. to
IN(D0HC TURBO)-1 1, INSTALLATION, Intercool-
er.>
30) Fill ATF up to the middle of the “COLD” side on
level gauge by using the gauge hole.
Recommended fluid:
Dexron Ill type automatic transmission fluid
Fluid capacity:
9.3-9.6 0 (9.8-10.1 USqt, 7.4-7.7lmp
qt)
31) Take off the vehicle from lift arms.
AT-24
TRANSMISSION MOUNTING SYSTEM
I
1O.Transmission Mounting Sys- 6) Set the transmission jack under the transmis-
sion.
tem CAUTION:
A: REMOVAL Make sure that the support plates of trans-
mission jack don't touch the oil pan.
1. PITCHING STOPPER 7) Remove the crossmember.
2) Remove the air intake duct. (Non-turbo model)
3) Remove the air cleaner case. (Non-turbo model)
Case.>
5) Remove the pitching stopper.
8) Remove the rear cushion rubber.

B: INSTALLATION
1. PITCHING STOPPER
Tightening torque:
T I : 50 N.m (5.1 kgf-m, 37 ff-lb)
T2: 58 N.m (5.9 kgf-m, 43 ft-lb)
2. CROSSMEMBER AND CUSHION RUB-
BER
2) Jack-up the vehicle and support it with sturdy
racks.
3) Remove the front, center, rear exhaust pipes
and muffler. (Non-turbo model)
Exhaust Pipe.> and <Ref. to EX(S0HC)-11, RE-
MOVAL, Muffler.>
4) Remove the center, rear exhaust pipes and muf- 2) Install the air intake duct and cleaner case. (Non-
fler. (Turbo model) <Ref. to EX(D0HC TURBO)-8, turbo model) <Ref. to IN(S0HC)-7, REMOVAL, Air
REMOVAL, Center Exhaust Pipe.>, <Ref. to Intake Duct.>, <Ref. to IN(S0HC)-6, REMOVAL,
EX(D0HC TURBO)-13, REMOVAL, Rear Exhaust Air Cleaner Case.>
Pipe.>, <Ref. to EX(D0HC TURBO)-14, REMOV- 3) Install the intercooler. (Turbo model) <Ref. to
AL, Muffler.> IN(D0HC TURBO)-10, REMOVAL, Intercooler.>
CAUTION:
When removing the exhaust pipes, be careful
each exhaust pipe does not drop out.
AT-25
I TRANSMISSION MOUNTING SYSTEM
2. CROSSMEMBER AND CUSHION RUB- C: INSPECTION

BER Repair or replace parts if the results of the inspec-
1) Install the rear cushion rubber. tion below are not satisfactory.
Tightening torque: 1. PITCHING STOPPER
39 N.m (4.0 kgf-m, 29 ff-lb) Make sure that the pitching stopper is not bent or
2 ) Install the crossmember. damaged. Make sure that the rubber is not stiff,
cracked, or otherwise damaged.
Tightening torque:
T I : 35 N-m (3.6 kgf-m, 26 ft-lb) 2. CROSSMEMBER AND CUSHION RUB-
T2: 70 N.m (7.1 kgf-m, 51.4 ff-lb) BER
Make sure that the crossmember is not bent or
damaged. Make sure that the cushion rubber is not
stiff, cracked, or otherwise damaged.
c.
3) Remove the transmission jack.

5 ) Install the front, center, rear exhaust pipes and
the muffler. (Non-turbo model)
<Ref. to EX(S0HC)-6, INSTALLATION, Front Ex-
haust Pipe.>, <Ref. to EX(S0HC)-9, INSTALLA-
TION, Rear Exhaust Pipe.> and <Ref. to
6) Install the center, rear exhaust pipes and muffler.
(Turbo model) <Ref. to EX(D0HC TURBO)-14, IN-
STALLATION, Muffler.>, <Ref. to EX(D0HC TUR-
BO)-13, INSTALLATION, Rear Exhaust Pipe.>,
AT-26
EXTENSION CASE OIL SEAL
11.Extension Case Oil Seal 13) Install the rear exhaust pipe and muffler.
Non-turbo model
A: INSPECTION <Ref. to EX(S0HC)-9, INSTALLATION, Rear Ex-
Make sure that the ATF does not leak from the joint haust Pipe.> and <Ref. to EX(S0HC)-11, INSTAL-
of the transmission and propeller shaft. If so, re- LATION, Muffler.>
place the oil seal. <Ref. to AT-27, REPLACE- Turbo model
MENT, Extension Case Oil Seal.> <Ref. to EX(D0HC TURBO)-14, INSTALLATION,
Muffler.>, <Ref. to EX(D0HC TURBO)-13, IN-
B: REPLACEMENT STALLATION, Rear Exhaust Pipe.>
1) Set the vehicle on the lift. 14) Pour ATF and check the ATF level. <Ref. to AT-
2) Disconnect the ground terminal from battery. 9, Automatic Transmission Fluid.>
4) Clean the transmission exterior.
5 ) Drain the ATF completely.
NOTE:
Tighten the ATF drain plug after draining the ATF.
Tightening torque:
25 N-m (2.5 kgf-m, 18.1 ft-lb)
(A) Oil pan

(B) Drain plug
(C) Differentialoil drain plug

Non-turbo model
<Ref. to EX(S0HC)-9, REMOVAL, Rear Exhaust
Pipe.> and <Ref. to EX(S0HC)-11, REMOVAL,
Muffler.>
Turbo model
<Ref. to EX(D0HC TURBO)-13, REMOVAL, Rear
Exhaust Pipe.>, <Ref. to EX(D0HC TURBO)-14,
REMOVAL, Muffler.>
8) Remove the propeller shaft. <Ref. to DS-14, RE-
MOVAL, Propeller Shaft.>
9) Using the ST, remove the oil seal.
ST 398527700 PULLER ASSY
10) Using the ST, install the oil seal.
ST 498057300 INSTALLER
11) Install the propeller shaft. <Ref. to DS-15, IN-
STALLATION, Prope1ler Shaft.>
AT-27
I INHIBITOR SWITCH
3) Check if there is continuity at equal points when
the select lever is turned 1.5" in both directions
from the N range.
If there is continuity in one direction and the conti-
nuity in the other or if there is continuity at unequal
points, adjust the inhibitor switch.<Ref. to AT-28,
ADJUSTMENT, Inhibitor Switch.>
I f-----3
Position Pin No. (A) Continuity does not exist.

P 4-3 (B) Continuity exists.
-. R 4-2 (C) 1.5"
I
N 4-1
Signal sent to TCM
D 4-8 4) Repeat the above checks. If there are abnormal-
3 4-7 ities, adjust the select cable. <Ref. to CS-27, AD-
2 4-6 JUSTMENT, Select Cable.>
I 1 I 4-5 I B: ADJUSTMENT
Starter circuit PIN 12-11 1) Shift the select lever to the N range.
Back-up light circuit R 10-9 2) Loosen the three inhibitor switch securing bolts.
3) Insert the ST as vertical as possible into the
holes in the inhibitor switch lever and switch body.
Inhibitor switch side connector ST 499267300 STOPPER PIN
B3H0016e
4) Tighten the three inhibitor switch bolts.

Tightening torque:
3.4 N.m (0.35 kgf-m, 2.5 ft-lb)
5 ) Repeat the above checks. If the inhibitor switch
is determined to be "faulty", replace it.
AT-28
INHI BI T 0R SWITCH
I
C: REMOVAL 11) Remove the plate assembly from transmission

1) Set up the vehicle on the lift. case.
2) Move the select lever to neutral position.
Case.>
5) Disconnect the inhibitor switch connector.
(A) Select cable

(B) Plate ASSY
12) Remove the bolts.
c-
(A) Inhibitor switch
6) Remove the inhibitor switch connector from stay.

8) Remove the front exhaust pipe with center ex-
haust pipe. (Non-turbo model)
Pipe.>
9) Remove the center exhaust pipe. (Turbo model)
<Ref. to EX(D0HC TURBO)-8, REMOVAL, Center
Exhaust Pipe.> 13) Move the range select lever to parking position
10) Remove the snap pin from range select lever. (left side).
(A) Snap pin (A) Range select lever

(B) Select cable
(C) Range select lever
AT-29
I INHIBITOR SWITCH
14) Remove the inhibitor switch from transmission. 6) Install the plate assembly to transmission.
Tightening torque:
T: 24.5 N.m (2.50 kgf-m, 18.1 ff-16)
15) Disconnect the inhibitor switch harness from in-

hibitor switch. (A) Select cable
(B) Plate ASSY
D: INSTALLATION
1) Connect the inhibitor switch harness to inhibitor 7 ) Install the snap pin to range select lever
switch.
2) Install the inhibitor switch to transmission case.
c.
(A) Snap ring

(B) Select cable
(A) Inhibitor switch (C) Range select lever
3) Move the range select lever to neutral position. 8) Install the front exhaust pipe with center exhaust
4) Using the ST, tighten bolts of inhibitor switch. pipe. (Non-turbo model)
ST 499267300 STOPPER PIN <Ref. to EX(S0HC)-6, INSTALLATION, Front Ex-
haust Pipe.>
Tightening torque:
3.4 N-m (0.35 kgf-m, 2.5 ff-16)
11) Install the inhibitor switch connector from stay.

(B) Range select lever
5) Install the select cable to range select lever.
AT-30
INHIBITOR SWITCH
1
12) Connect the inhibitor switch connector.
13) Install the air cleaner case. (Non-turbo model)

<Ref. to IN(S0HC)-6, INSTALLATION,Air Cleaner
Case.>
14) Install the intercooler. (Turbo model)
<Ref. to IN(D0HC TURBO)-11, INSTALLATION,
Intercooler.>
1 5 ) Inspect the inhibitor switch. <Ref. to AT-28, IN-
SPECTION, Inhibitor Switch.>
AT-31
I FRONT VEHICLE SPEED SENSOR
AUTOMATIC TRANSM ISSlON
13.Front Vehicle Speed Sensor 9) Drain the ATF completely.

NOTE:
A: REMOVAL Tighten the ATF drain plug after draining the ATF.
1) Set up the vehicle on the lift.
2) Disconnect the ground terminal from battery. Tightening torque:
25 N-m (2.5 kgf-m, 18.1 ft-lb)

<Ref. to IN(SOHC)-6, REMOVAL, Air Cleaner (A) Oil pan
Case.> (B) Drain plug
4) Remove the intercooler. (Turbo model) <Ref. to (C) Differential oil drain plug
W(DOHC TURBO)-10, REMOVAL, Intercooler.>
5) Disconnect the transmission connector. IO) Remove the front, center, rear, exhaust pipes
and muffler.
Exhaust Pipe.> and <Ref. to EX(S0HC)-11, RE-
MOVAL, Muffler.>
11) Remove the center, rear exhaust pipes and
muffler. (Turbo model) <Ref. to EX(D0HC TUR-
BO)-8, REMOVAL, Center Exhaust Pipe.>, <Ref.
to EX(D0HC TURBO)-13, REMOVAL, Rear Ex-
haust Pipe.>, <Ref. to EX(D0HC TURBO)-14, RE-
MOVAL, Muffler.>
12) Remove the shield cover.
(A) Transmission connector 13) Remove the propeller shaft. <Ref. to DS-14,
REMOVAL, Propeller Shaft.>
6) Remove the transmission connector from stay. 14) Place the transmission jack under crossmem-
7) Lift-up the vehicle. ber.
NOTE:
Place a shop cloth or equivalent between the
crossmember and transmission.
15) Remove the transmission rear crossmember
bolts.
AT-32
FRONT VEHICLE SPEED SENSOR I
16) Lower the AT jack. 20) Disconnect the duty solenoids and ATF tem-
NOTE: perature sensor connectors. Remove the connec-
Do not separate the AT jack and transmission. tors from clip and disconnect the connectors.
17) Remove the oil cooler outlet pipe.
CAUTION:
When removing the outlet pipe, be careful not
to lose the balls and springs used with retain-
ing screws.
18) Remove the front and rear vehicle speed sen-
sor and torque converter turbine speed sensor.
Front vehicle speed sensor and torque
converter turbine speed sensor
(A) Lock-up duty solenoid (Blue)

(B) Low clutch timing solenoid (Gray)
(C) Line pressure duty solenoid (Red)
(D) Shift solenoid 2 (Yellow)
(E) Shift solenoid 1 (Green)
(F) 2-4 brake timing solenoid (Black)
(G) 2-4 brake duty solenoid (Red)
(H) ATF temperature sensor
(I) Transfer duty solenoid (Brown)
(J) Transmission ground
(A) Front vehicle speed sensor
(B) Torque converter turbine speed sensor 21) Remove the harness assembly.
Rear vehicle speed sensor B: INSTALLATION
1) Pass the harness assembly through the hole in
the transmission case.
(A) Rear vehicle speed sensor

(B) Front vehicle speed sensor
19) Remove the oil pan.
AT-33
I FRONT VEHICLE SPEED SENSOR
2) Connect the harness connectors. 6) Install the oil cooler outlet pipe.
Connect the connectors of same color, and secure CAUTION:
the connectors to valve body sing clips. Be sure to use a new aluminum washer.
Tightening torque (Transmission ground termi- Tightening torque:
nal): 25 N-m (2.5 kgf-m, 18.1 ft-lb)
8 N-m (0.8 kgf-m, 5.8 ft-lb) 7) Install the transmission rear crossmember bolts.
Tightening torque:
75 Nom(7.6 kgf-m, 55 ft-lb)
8 ) Install the propeller shaft. <Ref. to DS-15, IN-
STALLATION, PropeIler Shaft.>
9) Install the shield cover. (If equipped)
10) Install the front, center, rear exhaust pipes and
muffler. (Non-turbo model)
haust Pipe.> and <Ref. to EX(S0HC)-9, INSTAL-
B2M22631 LATION, Rear Exhaust Pipe.> and <Ref. to
(A) Lock-up duty solenoid (Blue) 11) Install the center, rear exhaust pipes and muf-
(B) Low clutch timing solenoid (Gray) fler. (Turbo model) <Ref. to EX(D0HC TURBO)-
Line pressure duty solenoid (Red) 14, INSTALLATION, Muffler.>, <Ref. to EX(D0HC
Shift solenoid 2 (Yellow) TURBO)-13, INSTALLATION, Rear Exhaust
Shift solenoid 1 (Green) Pipe.>, <Ref. to EX(D0HC TURBO)-9, INSTALLA-
2-4 brake timing solenoid (Black) TION, Center Exhaust Pipe.>
2-4 brake duty solenoid (Red) 12) Lower the vehicle.
ATF temperature sensor 13) Install the transmission connector to the stay.
Transfer duty solenoid (Brown) 14) Install the air cleaner case. (Non-turbo model)
Transmission ground
Case.>
3) Apply proper amount of liquid gasket to the en- 15) Install the intercooler. (Turbo model). <Ref. to
tire oil pan mating surface. IN(D0HC TURBO)-11, INSTALLATION, Intercool-
Fluid packing: er.>
Three Bond 12176
I B3M1040
4) Install the oil pan.

Tightening torque:
25 N-m (2.5 kgf-m, 18.1 ff-lb)
5) Install the front and rear vehicle speed sensor,
and also the torque converter turbine speed sen-
sor, and then fasten the harness.
Tightening torque:
7 N-m (0.7 kgf-m, 5. 1 ft-lb)
AT-34
REAR VEHICLE SPEED SENSOR
14.Rear Vehicle Speed Sensor

A: REMOVAL
When removing the rear vehicle speed sensor, re-
fer to “Front Vehicle Speed Sensor.” <Ref. to AT-
32, REMOVAL, Front Vehicle Speed Sensor.>
B: INSTALLATION
When installing the rear vehicle speed sensor, refer
to “Front Vehicle Speed Sensor.” <Ref. to AT-33,
INSTALLATION, Front Vehicle Speed Sensor.>
AT-35
I TORQUE CONVERTER TURBINE SPEED SENSOR
I
15.Torque Converter Turbine

Speed Sensor
A: REMOVAL
When removing the torque converter turbine speed
sensor, refer to “Front Vehicle Speed Sensor.’’
<Ref. to AT-32, REMOVAL, Front Vehicle Speed
Sensor.>
B: INSTALLATION
When installing the torque converter turbine speed
sensor, refer to “Front Vehicle Speed Sensor.”
<Ref. to AT-33, INSTALLATION, Front Vehicle
Speed Sensor.>
AT-36
CONTROL VALVE BODY
I
5) Disconnect the duty solenoids and ATF temper-

16.Control Valve Body ature sensor connectors. Remove the connectors
A: REMOVAL from clip and disconnect the connectors.
3) Drain the ATF completely.
NOTE:
Tightening torque:
25 N.m (2.5 kgf-m, 18.7 ff-16)
B2M2269
(A) Lock-up duty solenoid (Blue)

(A) Oil pan (I) Transfer duty solenoid (Brown)
(B) Drain plug
(C) Differential oil drain plug 6) Remove the control valve. When removing the
control valve body, be careful not to interfere with
4) Remove the oil pan. transfer duty solenoid wiring.
NOTE:
Remove and clean the magnet.
Remove the old gasket on the oil pan and trans-
mission case completely.
I103;
AT-37
I CONTROL VALVE BODY
I
B: INSTALLATION 5) Apply proper amount of liquid gasket to the en-

1) Set the range select lever in ‘IN” position. tire oil pan mating surface.
2) Install the control valve and ground earth con- Fluid packing:
nectors. Tree Bond 12178
Tightening torque:
8 N.m (0.8 kgf-m, 5.8 ft-lb)
B3M1040

Tightening torque:
4.9 N-m (0.5 kgf-m, 3.6 ft-16)
(A) Short bolts 7 ) Pour ATF into the oil charge pipe. <Ref. to AT-9,
(B) Long bolts Automatic Transmission Fluid.>
ij Connect all connector. 8) Check the level of the ATF.
<Ref. to AT-9, Automatic Transmission Fluid.>
C: DISASSEMBLY
Refer to “AUTOMATIC TRANSMISSION” <Pub.
No. G0853ZE> a separate publication.
D: ASSEMBLY
E: INSPECTION
Lock-up duty solenoid (Blue)
Low clutch timing solenoid (Gray)
Line pressure duty solenoid (Red)
Shift solenoid 2 (Yellow)
Shift solenoid 1 (Green)
2-4 brake timing solenoid (Black)
2-4 brake duty solenoid (Red)
Transfer duty solenoid (Brown)
4) Attach the magnet at the specified position.
AT-38
SHIFT SOLENOIDS, DUTY SOLENOIDS AND ATF TEMPERATURE SENSOR I
17.Shift Solenoids, Duty Sole- 8) Remove the solenoids, duty solenoids and ATF
temperature sensor.
noids and ATF Temperature
Sensor
A: REMOVAL
5) Drain the ATF completely.
NOTE:
Tightening torque: (A) Lock-up duty solenoid (Blue)
25 Nom(2.5 kgf-m, 18.1 ff-lb) (B) Low clutch timing solenoid (Gray)
c- . (G) 2-4 brake duty solenoid (Red)
1. TRANSFER DUTY SOLENOID AND

TRANSFER VALVE BODY
1) Set up the vehicle on the lift.
(A) Oil pan 3) Remove the air intake duct. <Ref. to IN(S0HC)-
(B) Drain plug 7, REMOVAL, Air Intake Duct.>
4) Remove the air cleaner case. <Ref. to IN(S0-
6) Remove the oil pan. HC)-6, REMOVAL, Air Cleaner Case.>
7) Disconnect the solenoid and sensor connectors. 5 ) Remove the intercooler. (Turbo model) <Ref. to
Remove the connectors from clip and disconnect IN(D0HC TURBO)-10, REMOVAL, Intercooler.>
the connectors. 6) Remove the pitching stopper.
I
(G) (F) B2M2263J
Lock-up duty solenoid (Blue) 7) Remove the front exhaust pipe with center ex-
Low clutch timing solenoid (Gray) haust pipe. (Non-turbo model)
Line pressure duty solenoid (Red) With OBD
Pipe.>
8) Remove the center exhaust pipe. (Turbo model)
2-4 brake timing solenoid (Black) <Ref. to EX(D0HC TURBO)-8, REMOVAL, Center
2-4 brake duty solenoid (Red) Exhaust Pipe.>
AT-39
I SHIFT SOLENOIDS, DUTY SOLENOIDS AND ATF TEMPERATURE SENSOR I
9) Raise the vehicle and drain the ATF 14) Remove the select cable nut.
G3M0308
(A) Oil pan

15) Move the gear select cable so that extension
bolts can be removed.
(B) Drain plug
16) Remove the bolts.
(C) Defferential oil drain plug
17) Remove the extension case.
10) Remove the heat shield cover. (If equipped) NOTE:
11) Remove the propeller shaft. <Ref. to DS-14, Use a container to catch oil flowing from extension.
12) Remove the rear crossmember.
-_.(1) Support the transmission using a transmis-
sion jack and raise slightly.
(2) Remove the bolts and nuts as shown in the
figure.
18) Disconnect the transfer duty solenoid connec-

tor.
19) Remove the transfer duty solenoid and transfer
valve body.
13) Remove the rear vehicle speed sensor
B3M1045F
(A) Transfer valve body

(B) Transfer duty solenoid connector
(C) Transfer duty solenoid
AT-40
SHIFT SOLENOIDS, DUTY SOLENOIDS AND ATF TEMPERATURE SENSOR
B: INSTALLATION 3) Apply proper amount of liquid gasket to the en-

1) Install the solenoids and ATF temperature sen- tire oil pan mating surface.
sor. Fluid packing:
Tree Bond 12178
Tightening torque:
T: 8 N-m (0.8 kgf-m, 5.8 ft-lb)
I
B3M 1040

Tightening torque:
(A) Lock-up duty solenoid (Blue) 4.9 N.m (0.50 kgf-m, 3.6 ft-lb)
c- - (D) Shift solenoid 2 (Yellow)
2) Connect the harness connectors.

Connect the connectors of same color, and secure
the connectors to valve body using clips.
(A) Oil pan

(B) Drain plug
5 ) Fill ATF up to the middle of the “COLD” side on

level gauge by using the gauge hole. <Ref. to AT-9,
Automatic Transmission Fluid.>
6) Check the ATF level. <Ref. to AT-9, Automatic
Transmission Fluid.>
(G, CF, B2M2263J
Lock-up duty solenoid (Blue)

Low clutch timing solenoid (Gray)
Line pressure duty solenoid (Red)
2-4 brake timing solenoid (Black)
2-4 brake duty solenoid (Red)
AT-4 1
I SHIFT SOLENOIDS, DUTY SOLENOIDS AND ATF TEMPERATURE SENSOR
e
1. TRANSFER DUTY SOLENOID AND 4) Install the rear crossmember.

TRANSFER VALVE BODY (1) Tighten the bolts.
1) Install the transfer duty solenoid and transfer Tightening torque:
valve body. T I : 35 N-m (3.6 kgf-m, 26 ft-lb)
(1) Install the transfer duty solenoid and trans- T2: 70 N.m (7.1 kgf-m, 51.4 ft-lb)
fer valve body.
Tightening torque:
T: 8 N-m (0.8 kgf-m, 5.8 ft-lb)
(2) Connect the transfer duty solenoid connec-
tor.
(2) Lower and remove the transmission jack.

STALLATION, Propeller Shaft.>
6) Install the front exhaust pipe and center exhaust
c.
pipe.
7) Lower and remove the jack.
(A) Transfer valve body 8) Connect the transmission harness connector.
(B) Transfer duty solenoid connector
(C) Transfer duty solenoid
2) Install the extension case to transmission case.

(1) Tighten eleven bolts.
Tightening torque:
25 N-m (2.5 kgf-m, 18.1 ft-lb)
(2) Adjust the select cable. <Ref. to CS-27, AD-
JUSTMENT, Select Cable.>
3) Install the rear vehicle speed sensor.
Tightening torque: 9) Install the pitching stopper.
T: 7 N.m (0.7 kgf-m, 5. t ft-lb)
Tightening torque:
T1: 50 N.m (5.1 kgf-m, 37 ft-lb)
T2: 58 N.m (5.9 kgf-m, 43 ft-lb)
IO) Install the air cleaner case and duct.
AT-42
I SHIFT SOLENOIDS, DUTY SOLENOIDS AND ATF TEMPERATURE SENSOR
I
11) Fill ATF up to the middle of the "COLD" side on

level gauge by using the gauge hole. <Ref. to AT-9,
Automatic Transmission Fluid.>
12) Check the ATF level. <Ref. to AT-9, Automatic
Transmission Fluid.>
AT-43
ATF FILTER
18.ATF Filter C: INSPECTION

Replace the part if any defect is found from the in-
A: REMOVAL spection.
NOTE: Check for rust, hole, ATF leaks, and other damage.
The ATF filter is maintenance free.
2) Using the ST, remove the ATF filter.
Torque wrench length Tightening torque

mm (in) N.m (kgf-m, ft-lb)
100 (3.94) 6 (0.6, 4.3)
150 (5.91) 5 (0.5, 3.6)
200 (7.87) 4 (0.4, 2.9)
250 (9.841 3 (0.3. 2.2)
CAUTION:
Align the ST with torque wrench while tighten-
ing the ATF filter.
3) Add ATF.
4) Inspect the level of ATF. <Ref. to AT-9, Automat-
ic Transmission Fluid.>
AT-44
I
19.Transmission Control Mod- B: INSTALLATION

1) Install the transmission control module.
ule (TCM)
Tightening torque:
A: REMOVAL 7.5 N-m (0.76 kgf-m, 5.5 ft-lb)
(A) Transmission control module

2) Remove the lower cover and then disconnect the
connector. (B) Brake pedal bracket
2) Connect the connectors to transmission control

c- . module.
3) Disconnect the connectors from transmission

control module.
(A) Transmission control module

(B) Brake pedal bracket
4) Remove the transmission control module.
AT-45
DROPPING RESISTOR
20.Dropping Resistor B: INSTALLATION

A: REMOVAL
Tightening torque:
NOTE: 6.4 N.m (0.65 kgf-m, 4.7 fWb)
The dropping resister is only equipped to Non-turbo
models.
(A
03M2170A
(A) Dropping resistor
2) Remove the air intake duct. <Ref. to IN(S0HC)-

6, REMOVAL, Air Cleaner Case.>
3)Disconnect the connector from dropping resistor.
4) Remove the dropping resistor.
J/
\
i::
I '
(A) Dropping resistor
C: INSPECTION
~~
B3M2170A
Step Check Yes No

1 CHECK RESISTOR. Is the resistance between 9 Go to step 2. Replace the drop-
1)Turn the ignition switch to OFF. and 15 a? ping resistor. <Ref.
2)Disconnect the connector from dropping to AT-46, Dropping
resistor.
3)Measure the resistance between dropping
resistor terminal.
Terminals
NO. 1 - NO. 2:
2 CHECK RESISTOR. Is the resistance between 9 Dropping resistor Replace the drop-
Measure the resistance between dropping and 15 a? is normal. ping resistor.
resistor terminal. <Ref. to AT-46,
Terminals Dropping Resis-
NO. 3 - NO. 4: tor.>
AT-46
ATF COOLER PIPE AND HOSE I
21 .ATF Cooler Pipe and Hose 6) Remove the ATF cooler pipe from cylinder head.
A: REMOVAL
1. NON-TURBO MODEL
4) Disconnect the ATF cooler hose from radiator.
NOTE:
Do not remove with a screwdriver or other point-
ed tools.
When the hose is difficult to remove, wrap a shop 7) Remove the oil cooler inlet and outlet pipes.
cloth around the hose to protect it. Turn it with pli- CAUTION:
ers, and then pull directly out with your hand. When removing the outlet pipe, be careful not
to lose the ball and spring used with retaining
screw.
c-
S2M0895
5) Disconnect the ATF cooler hoses from pipes.

NOTE:
Do not remove with a screwdriver or other point- (A) Inlet pipe
ed tools. (B) Outlet pipe
When the hose is difficult to remove, wrap a shop
cloth around the hose to protect it. Turn it with pli-
ers, and then pull directly out with your hand.
AT-47
I ATF COOLER PIPE AND HOSE
I
2. TURBO MODEL 8) Remove the ATF cooler pipe from frame.

2) Remove the battery and washer tank.
5) Remove the radiator under cover.
EN1063
sconnect the ATF cooler hose from radiator

NOTE:
:- Do not remove with a screwdriver or other point-
ed tools. I'
When the hose is difficult to remove, wrap a shop TR0331
cloth around the hose to protect it. Turn it with pli-
9) Remove the oil cooler inlet and outlet pipes.
CAUTION:
When removing the outlet pipe, be careful not
to lose the ball and spring used with retaining
screw.
-I TR0329
7) Disconnect the ATF cooler hoses from pipes.

NOTE:
Do not remove with a screwdriver or other point-
ed tools.
When the hose is difficult to remove, wrap a shop (A) Inlet pipe
cloth around the hose to protect it. Turn it with pli- (B) Outlet pipe
AT-48
ATF COOLER PIPE AND HOSE
I
B: INSTALLATION 3) Connect the ATF cooler hose to pipe transmis-

sion side.
1. NON-TURBO MODEL NOTE:
1) Install the oil cooler outlet and inlet pipes. Install so that the hose is not folded over, exces-
CAUTION: sively bent, or twisted.
Be sure to use a new aluminum washer. Be careful to insert the hose to the specified po-
sition.
Tightening torque:
T1: 44 N-m (4.5 kgf-m, 32.5 ff-lb)
T2: 25 N-m (2.5 kgf-m, 18.1 ff-lb)
4) Connect the ATF cooler hose to pipe of radiator

side.
NOTE:
(A) Inlet pipe Install so that the hose is not folded over, exces-
(B) Outlet pipe sively bent, or twisted.
Be careful to insert the hose to the specified po-
2) Install the ATF cooler pipe to cylinder head. sition.
Tightening torque:
7.35 N-m (0.75 kgf-m, 5.42 ft-lb)
S2M0895
5) istall the under cover.

6) Fill ATF. <Ref. to AT-9, Automatic Transmission
Fluid.>
NOTE:
Make sure there are no ATF leaks in joints between
the transmission, radiator, pipes, and hoses.
AT-49
I ATF COOLER PIPE AND HOSE
I
2. TURBO MODEL 3) Connect the ATF cooler hose to pipe transmis-

sion side.
1) Install the oil cooler outlet and inlet pipes.
NOTE:
CAUTION: Install so that the hose is not folded over, exces-
Be sure to use a new aluminum washer. sively bent, or twisted.
Tightening torque: Be careful to insert the hose to the specified po-
T l : 44 N.m (4.5 kgf-m, 32.5 ft-lb) sition.
T2: 25 N-m (2.5 kgf-m, 18.1 ft-lb)
4) Connect the ATF cooler hose to pipe of radiator

-- . (A) Inlet pipe
side.
NOTE:
(B) Outlet pipe
Install so that the hose is not folded over, exces-
2) Install the ATF cooler pipe to frame. sively bent, or twisted.
Be careful to insert the hose to the specified po-
sition.
L
TR0329
5) Install the radiator under cover.

Tightening torque:
4.9 N.m (0.5 kgf-m, 3.6 ft-lb)
TR0331
EN106:

7) Install the battery and washer tank.
AT-50
I
8) Fill ATF. <Ref. to AT-9, Automatic Transmission C: INSPECTION

Fluid.> Repair or replace any defective hoses, pipes,
NOTE: clamps, and washers found from the inspection be-
Make sure there are no ATF leaks in joints between low.
the transmission, radiator, pipes, and hoses. 1) Check for ATF leaks in joints between the trans-
mission, radiator, pipes, and hoses.
2) Check for deformed clamps.
3) Lightly bend the hose and check for cracks in the
surface and other damage.
4) Pinch the hose with your fingers and check for
poor elasticity. Also check for poor elasticity in the
parts where the clamp was installed by pressing
with your fingernail.
5 ) Check for peeling, cracks, and deformation at
the tip of the hose.
c- .
AT-51
I
AT-52
(DIAGNOSTICS)
Page
2. Check List for Interview ............................................................................... 4
5. Transmission Control Module (TCM) I/O Signal ....................................... 11
7. Read Diagnostic Trouble Code (DTC) ...................................................... 24
8. Inspection Mode ........................................................................................ 26
c- . 10. AT OIL TEMP Warning Light Display ........................................................ 28
12. Diagnostic Procedure for AT OIL TEMP Warning Light ............................ 31
13. Diagnostic Procedure for Select Monitor Communication......................... 39
14. Diagnostic Procedure with Diagnostic Trouble Code (DTC) ..................... 44
15. Diagnostic Procedure for No-Diagnostic Trouble Code (DTC) ...............108
16. Symptom Related Diagnostic .................................................................. 127
I BASIC DIAGNOSTIC PROCEDURE
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

A: PROCEDURE
Step Check Yes No
CHECK PRE-INSPECTION. j the unit that might influence ;o to step 2. 3epair or replace
1)Ask the customer when and how the trouble l e AT problem normal? ?achitem.
occurred using the interview checklist. <Ref. to
AT-4, Check List for Interview.>
2)Before performing diagnosis, inspect the fol-
lowing items which might influence the AT
problems.
*General inspection <Ref. to AT-5, INSPEC-
TION, General Description.>
*Oil leak
*Stall speed test <Ref. to AT-I 3, Stall Test.>
*Line pressure test <Ref. to AT-16, Line Pres-
sure Test.>
*Transfer clutch pressure test <Ref. to AT-I 8,
Transfer Clutch Pressure Test.>
*Time lag test <Ref. to AT-15, Time Lag Test.>
*Road test <Ref. to AT-12, Road Test.>
*Inhibitor switch <Ref. to AT-28, Inhibitor
Switch.>
CHECK AT OIL TEMP WARNING LIGHT. )oes not the AT OIL TEMP $0 to step 3. 30 to step 4.
Turn the ignition switch to ON. iarning light light up?
CHECK AT OIL TEMP WARNING LIGHT. j the AT OIL TEMP warning $0 to step 4. 30 to step 5.
1)Turn the ignition switch to OFF. ght flashing?
2)Repair the AT OIL TEMP warning light circuit
or power supply and ground line circuit.
<Ref. to AT-31, Diagnostic Procedure for AT
OIL TEMP Warning Light.>
CHECK INDICATION OF DTC. j the diagnostic trouble code 20 to step 6. 30 to step 5.
Calling up the diagnostic trouble code (DTC). DTC) displayed? JOTE:
Without SUBARU SELECT MONITOR 3ecord all diag
<Ref. to AT-24, WITHOUT SUBARU SELECT iostic trouble code
MONITOR, Read Diagnostic Trouble Code DTC).
(DTC).>
With SUBARU SELECT MONITOR
<Ref. to AT-25, WITH SUBARU SELECT
MONITOR, Read Diagnostic Trouble Code
(DTC).>
NOTE:
If the communication function of the selec
monitor cannot be executed normally, check
the communication circuit. <Ref. to AT-39
COMMUNICATION FOR INITIALIZING IM.
POSSIBLE, Diagnostic Procedure for Selec
Monitor Communication.>
AT-2
I
Step Check Yes No

5 PERFORM THE GENERAL DIAGNOSTICS. Is the diagnostic trouble code io to step 6. iomplete the
1NnsDect usina the “Diaqnostic Procedure for (DTC) displayed? iagnosis.
No-Diagnostictrouble Code”.<Ref. to AT-108,
Diagnostic Procedure for No-Diagnostic Trou-
ble Code (DTC).>
2)lnspect using the “Symptom Related Diag-
nostic’’. <Ref. to AT-127, Symptom Related
Diagnostic.>
3)Perform the clear memory mode.
MONITOR, Clear Memory Mode.>
Without SUBARU SELECT MONITOR
<Ref. to AT-27, WITHOUT SUBARU SELECT
4)Perform the inspection mode. <Ref. to AT-26,
Inspection Mode.>
Calling up the diagnostic trouble code (DTC).
MONITOR, Read Diagnostic Trouble Code
(DTC).>
MONITOR, OPERATION, Read Diagnostic
6 PERFORM THE DIAGNOSIS. 5 the diagnostic trouble code nspect using the :omplete the
1)lnspect using the “Diagnostics Chart with DTC) displayed? Diagnostics Chart hagnosis.
Diahnostic Trouble Code”.<Ref. to AT-44, Diag- vith Diagnostic
nostic Procedure with Diagnostic Trouble Code 2onnector”. <Ref.
(DTC).> o AT-44, Diagnos-
NOTE: ic Procedure with
For trouble code table, refer to the “List of Diag. liagnostic Trou-
nostic Trouble Code”.<Ref. to AT-29, List of Di. ,le Code (DTC).>
2)Repair the trouble cause.
3)Perform the clear memory mode.
MONITOR, OPERATION, Clear Memory
Mode.>
4)Perform the inspection mode. <Ref. to AT-26,
Inspection Mode.>
5)Calling up the diagnostic trouble code (DTC)
Trouble Code ( D T C b
AT-3
I
2. Check List for Interview NOTE:

Use copies of this page for interviewing customers.
A: CHECK
Check the following items when problem has oc-
curred.
Customer's name I
Data vehicle brought in
Data of repair
Trans. model TRANSMISSION I VIN
Odometer reading km/h or mile
Freauencv D Continuous U Intermittent ( times a day)
~~
Weather CI Fine CI Cloudy U Rainy U Snowy

CI Various/Others
( 1
Place U High 0 Suburbs U Inner city CI Uphill U Rough road
U Others
( 1
Outdoor temperature 0 Hot U Warm c3 Cool U Cold
Vehicle speed km/h (MPH:
Malfunction indicator lamp (MIL) U Continuously lit ] U Not lit
Select lever Dosition CIP UR UN UD C13 U 2 U1
Driving condition U Not affected U At starting CI While idling
U At racing U While accelerating U While cruising
0 While decelerating U While turning (URH/CI
I LH)
SvmDtoms
, * I U No up-shift
I Q No down-shift
CI No kick down
CI Vehicle does not move (UAny position U Particular position)
CI Lock-uD malfunction
I U Noise or vibration
I 0 Shift shock or sliD
I U Select lever does not move
AT-4
GENERAL DESCRIPTION
I
3. General Description 3. ATFLEVEL

Make sure the ATF level is in the specification.
A: CAUTION
Supplemental Restraint System “Airbag”
The airbag system wiring harness is routed near
the transmission control module (TCM).
CAUTION:
All airbag system wiring harness and con-
cal test equipment on these circuit.
Be careful not to damage the airbag system
wiring harness when performing diagnostics
and servicing the TCM. B3M0173B
Measurement
When measuring the voltage and resistance of the (A) Upper level
ECM, TCM or each sensor, use a tapered pin with (B) Lower level
a diameter of less than 0.64 mm (0.025 in) in order
to avoid poor contact. Do not insert the pin more 4. FRONT DIFFERENTIAL OIL LEVEL
than 6.5 mm (0.256 in). Make sure the front differential oil level is in the
a:INSPECTION specification.
1. BATTERY
Measure the battery voltage and specific gravity of
electrolyte.
Standard voltage: 12V or more
2. TRANSMISSION GROUND
Make sure that the ground terminal bolt is tightened B3M01748
securely.
Chassis side (A) Upper level
Tightening torque: (B) Lower level
13 N.m (1.3 kgf-m, 9.4 ff-lb)
5. OPERATION OF SHIFT SELECT LEVER
Make sure there is no abnormal noise, dragging or
contact pattern in each select lever range.
WARNING:
Stop the engine while checking operation of the
selector lever.
TR0373
AT-5
GENERAL DESCRIPTION
I
C: PREPARATION TOOL
1. SPECIAL TOOLS
I
ILLUSTRATION TOOLNUMBER I
I
DESCRIPTION REMARKS
Troubleshooting for electrical systems.
(Newly adopted tool)
02M3876
22771AA030 SELECT MONITOR Troubleshootingfor electrical systems.
KIT * English:
German:
French:
Spanish:
B2M3877
TOOL NAME REMARKS

Circuit Tester Used for measuring resistance, voltage and ampere.
Oscilloscope Used for measuring sensor.
AT-6
4. Electrical Components Loca-

tion
A: LOCATION
1. CONTROL MODULE
(1) Engine control module (ECM) (3) Transmission control module (TCM)
(2) ATF temperature warning light (AT diagnostic indicator (4) Data link connector
light)
B3M1575A
TR0563 TR0382
AT-7
I
2. SENSOR
TR0565
(1) Throttle position sensor (4) Rear vehicle speed sensor (6) ATF temperature sensor
(2) Front vehicle speed sensor (5) Torque converter turbine speed (7) Dropping resistor (Non-turbo
(3) Inhibitor switch sensor model)
AT-8
I
don-turbo model
--/
S2M0262B TR0387
Turbo model
_J
TR0592
\\ol (3) ' TR0388
(6)
I , ,
TR0390 TR0389
TR0593
AT-9
3. SOLENOID
B3M 1 186A
(1) Solenoid 1 (4) Low clutch timing solenoid (7) 2-4 brake timing solenoid
(2) Solenoid 2 (5) Lock-up duty solenoid (8) Transfer duty solenoid
(3) Line pressure duty solenoid (6) 2-4 brake duty solenoid
.-,
B2M2264E
AT-10
I
5. Transmission Control Mod-

ule (TCM) I/O Signal
1. NON-TURBO MODEL
to @ to @

Con- Resistanceto
Termi-
nal No. body (ohms)
No.
Back-up power supply B55 6 lanition switch OFF I 10-13 I -
854
B54
23
24
-
enaine OFF)
Select lever in “ P range
10 - 13
Less than 1
l -
“ P range -
switch More than 8
“ P ranae (except “N” ranae)
Select lever in “N” range I Less than 1 I
“ N range
switch
“N” ranae lexceDt “ P ranae)
- “ % I “ I
1
,
Morethan8 1
I
-
“R” range
Select lever in ‘W ranae - I Less than 1
-
switch More than 8
“R” range
Select lever in “D” range I Less than 1 I
Inhibitor
switch
“ D range
switch
“D ranae I
I
I
More than8 1
I
-
Select lever in “ 3 ranae I

I
Less than 1
“ 3 range 1
-
switch More than 8
“3”ranae
Select lever in “2” range I Less than 1
“ 2 range
switch
“ 2 ranae
I More than8 I -
“ I ” range
Select lever in “1”ranae I Less than 1 I
654 1 Select lever in any other than -
switch More than 8
“1” range
AT-1 1
I
Termi- Resistanceto
nal No. body (ohms)
No.
Brake pedal depressed. More than 10.5 -
Brake switch B55 24
Brake pedal released. Less than 1
ABS switch ON Less than 1 -
ABS signal B54 19
ABS switch OFF More than 6.5
Light ON Less than 1 -
AT OIL TEMP light B54 3
+
Light OFF More than 9
I Throttle fully closed.
Throttle position sensor B55 2 Approx. 0.5 -
Throttle fullv open. Approx. 4.3
Throttle position sensor power Ignition switch ON (With -
4.8 - 5.3
SUDDlV engine OFF)
1.6 - 2.0 2.1 - 2.9 k
(68°F)
ATF temperature sensor B55 11
0.4 - 0.9 275 - 375
(176°F)
Vehicle stopped. I 0 I
Rear vehicle speed sensor Vehicle speed at least 20 More than (AC range) 450 - 650
km/h (12 MPH)
..
Vehicle stowed 0
Front vehicle speed sensor Vehicle speed at least 20 450 - 650
More than (Ac
km/h (12 MPH)
Engine idling after warm-up I n
u I
Torque converter turbine (D range)
B55 12 450 - 650
speed sensor Engine idling after warm-up
More than (AC
(N range)
Vehicle speed at most 10 Less than I t -
Vehicle speed output signal 855 13
0
engine OFF) -
Engine speed signal B55 4
0 - 13 or more
engine ON)
Less than 1
(SET liaht ON)
Cruise set signal 854 11 ~~

More than 6.5
set (SET light OFF)
Torque control signal 1 More than 4.8 -
enaine
" ON)
Torque control signal 2 More than 4.8
enaine ON)
I
~
Toraue control cut simal 854 2 Ignition switch ON I a I -

Intake manifold pressure sig-
Engine idling after warm-up. I .2 - 1.a
nal
1st gear More than 9
Shift solenoid 1 10-16
3rd aear Less than 1
2nd gear More than 9
Shift solenoid 2
4th gear Less than 1
4
1.5 - 5.0
Line pressure duty solenoid B54 2.0 - 4.5
Less than 1
AT-I 2
TRANSMISSION CONTROL MODULE (TCM) 1/0 SIGNAL I
I I
'On-
Termi- Resistanceto
Content Measuring conditions Voltage (V) body (ohms)
nal NO.
No.
More than 8.5
Dropping resistor 854 18
enaine
a -~OFF) after warm-uD.
I
1 Less than 0.5
I
9- 15

Lock-up duty solenoid B54 16 10- 17
Fuse on FWD switch More than 8.5
~

Transfer duty solenoid 854 15 switch (with throttle fully 10- 17
Less than 0.5
open and with select lever in
1st gear).
1.5 - 5.0
2-4 brake duty solenoid B54 8 2.0 - 4.5
Less than 1
enaine OFF) after warm-uD.
d

More than 8.5
--2-4 brake dropping resistor B54 17 9-16 "
Less than 0.5
2-4 brake timing solenoid B54 5 10- 16
3rd gear More than 9
Low clutch timing solenoid B54 14 10- 16
4th gear More than 9
Sensor ground line 1 855 10 - 0 Less than 1
Sensor ground line 2 855 21 - 0 Less than 1
9 -
System ground line 0 Less than 1
B55 19
Fuse removed. More than 9 -
FWD switch B55 14
Fuse installed. Less than 1
Fuse ONFWD switch Less than 1
I FWD indicator light

I B54 I l2
switch
More than 9
Less than I t
-
-
AT diagnosis signal B54 4 Ignition switch ON
-+More than 4
Data link signal (Subaru Select
B55 7
Monitor) 16
AT-I 3
2. TURBO MODEL
to @
n n n
I TR0532
Check with ianition switch ON.

Con- Resistance
Content nector Terminal No. Measuring conditions Voltage (V) to body
No. (ohms)
Back-up power supply 856 1 Ignition switch OFF IO- 13 -
B54 23 Ignition switch ON (with IO- 13 -
B54 24 engine OFF)
1
I I I I
I Select lever in “ P range I Less than 1

“ P range Select lever in any other
1
switch than “P” range (except “N” More than 8
range)
Select lever in “N” range Less than 1
“N” range Select lever in any other
14
switch than “N” range (except “P” More than 8
range)
“R” range
I Select lever in “R” ranae
“ I Less than 1 t
3 Select lever in any other
switch More than 8
than “R” ranae
I
Inhibitor I I
switch “D” range
I Select lever in “D” range
- Less than 1 I
B55 4 Select lever in any other -
switch More than 8
I I
than “D” ranae“ I I
I
“ 3 range
switch
B55 I 5
I Select lever in “ 3ranae
“
Select lever in any other
than “ 3 range
I Less than 1
More than 8
-
“ 2 range
I I Select lever in “2” range
- I Less than 1 I
switch
B55 I
I
6
I
I
Select lever in any other
than “2” ranae”
Select lever in “1” range
I
I
More than 8
Less than 1
I
-
“1” range
switch
7
1 Select lever in any other
than “1” range
1 More than 8
-
Brake switch B55 I 12

Brake pedal depressed.
Brake Dedal released.
I
I
More than 10.5
Less than 1
-
Light ON Less than 1 -
AT OIL TEMP warning light 856 10
Liaht OFF More than 9
AT-I 4
TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL I
I Check with ianition switch ON.

Con- Resistance
No. (ohms)
Throttle fully closed. Approx. 0.5 -
Throttle position sensor 654 3
Throttle fullv- open.
. Auprox.
.. 4.3
654 2 Ignition switch ON (With Approx. 5.0 -
engine OFF)
1.6 - 2.0 2.1 k - 2.9 k
(68°F)
ATF temperature sensor 654 11
0.4 - 0.9 275 - 375
(176°F)
I Vehicle stopped.
. . I 0 I
Rear vehicle speed sensor 655 24 Vehicle speed at least 20 More than (Ac range) 450 - 650
km/h (12 MPH)
Vehicle stotmed.
,. 0
Front vehicle speed sensor 655 18 Vehicle speed at least 20 More than (AC range) 450 - 650
km/h (12 MPH)
I Engine idling after warm- I n
V
I
Torque converter turbine - up. (D-range)
655 8 450 - 650
speedsensor Engine idling after warm-
More than 1 (AC range)
UP. (N ranae)
~
Vehicle speed at most 10 Less than I t -

Vehicle speed output signal 656 17
0
engine OFF) -
Engine speed signal 655 17
0- 13 or more
engine ON)
Less than 1
(SET lamp ON) -
Cruise set signal 655 22
More than 6.5
set (SET lamp OFF)
I Torque control signal 1 656

~~
5
engine ON)
More than 4 -
Torque control signal 2 656 14 Ignition switch ON (with More than 4 -

enaine ON)
655 10 lanition switch ON 8 -
654 1
I Engine idling after warm-
UD.
--r
0.5 - 1.2
l -
I Shift solenoid 1 654 22 -
1st or 4th gear
2nd or 3rd gear
1st or 2nd gear
More than 9
Less than 1
More than 9
10-16
Shift solenoid 2 654 5 ' 10-16

-
3rd or 4th gear Less than 1
engine OFF)
1.5 - 5.0
Throttle fully closed after
warm-up.
Line pressure duty solenoid 654 9 2.0 - 4.5
engine OFF) Less than 1
Throttle fully open after
warm-up.
Lock-up duty solenoid 654 7 10-17
- More than 8.5
Transfer duty solenoid 654 6 Throttle fully open and with 10 - 17
Less than 0.5
select lever in 1st gear.
AT-15
Check wi I ignition switch ON.

Con- Resistance
No. (ohms)
engine OFF) after warm- 1.5 - 5.0
2-4 brake duty solenoid B54 18 UP.
2.0 - 4.5
engine OFF) after warm- Less than 1
UP.
2-4 brake timing solenoid 854 16 10-16
3rd gear More than 9
-ow clutch timing solenoid 854 15 10-16
4th gear More than 9
ABS switch ON Less than 1
4BS signal 855 21
ABS switch OFF More than 6.5
Sensor around line 1 854 20 Less than 1
Sensor ground line 2 B55 9 - 0 Less than 1
B56 19 I
-
System ground line
B54 21
-
I
I
0 Less than 1
:.ensor ground line 3 854 10 0 Less than 1

Sensor ground line 4 B54 19 - I 0 Less than 1
Less than 1 t
AT diagnosis signal B56 21 Ignition switch ON
+ More than 4
lata link signal (Subaru 15
856
Select Monitor) 6
AT-I 6
AT-1 7
TRANSMISSION CONTROL MODULE (TCM) I10 SIGNAL I
B: SCHEMATIC
1. NON-TURBO MODEL
I
TR0566
AT-I 8
TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL E
Transmission control module “ 2 range indicator light ATF temperature sensor

Data link connector ”1” range indicator light Torque converter turbine speed
Cruise set switch “ P range switch sensor
ABS control module “R” range switch Front vehicle speed sensor
Ignition switch “N” range switch Rear vehicle speed sensor
Brake switch “ D range switch Shift solenoid 1
Brake light “ 3 range switch Shift solenoid 2
Battery “ 2 range switch 2-4 brake timing solenoid
Combination meter “1” range switch Line pressure duty solenoid
AT OIL TEMP warning light Throttle position sensor Line pressure dropping resistor
FWD indicator light Engine speed signal 2-4 brake duty solenoid
FWD switch Torque control cut signal 2-4 brake dropping resistor
“ P range indicator light Torque control signal 2 Lock-up duty solenoid
“R” range indicator light Torque control signal 1 Low clutch timing solenoid
“N” range indicator light AT load signal Transfer duty solenoid
“ D range indicator light AT diagnostics signal
“ 3 range indicator light Engine control module
AT-19
I TRANSMISSION CONTROL MODULE (TCM) I10 SIGNAL I
2. TURBO MODEL
r-
r"" 1 -
(4)
c- "
m
(9)
TR0567
AT-20
Transmission control module (16) “ D range indicator light Engine control module
Cruise control module (17) “ D range switch ATF temperature sensor
ABS control module (18) “ 3 range indicator light Torque converter turbine speed
Ignition switch (19) “ 3 range switch sensor
Brake switch (20) “2” range indicator light Rear vehicle speed sensor
Brake light (21) “ 2 range switch Front vehicle speed sensor
Battery (22) “1” range indicator light Shift solenoid 1
Combination meter (Speedome- (23) “1” range switch Shift solenoid 2
ter circuit) (24) Data link connector 2-4 brake timing solenoid
AT OIL TEMP light (25) Throttle position sensor Line pressure duty solenoid
“ P range indicator light (26) Engine speed signal 2-4 brake duty solenoid
“P” range switch (27) Torque control cut signal Lock-up duty solenoid
“R” range indicator light (28) Torque control signal 2 Low clutch timing solenoid
“R” range switch (29) Torque control signal 1 Transfer duty solenoid
“N” range indicator light (30) Mass air flow signal
“N” range switch (31) AT diagnostics signal
AT-21
I SUBARU SELECT MONITOR
6. Subaru Select Monitor (2) Connect the diagnosis cable to data link
connector.
A: OPERATION CAUTION:
1. READ DIAGNOSTIC TROUBLE CODE Do not connect scan tools except for Subaru
Select Monitor and OBD-ll general scan tool.
(DTC)
5) Turn the ignition switch to ON (engine OFF) and
1) Prepare the Subaru Select Monitor kit. Subaru Select Monitor switch to ON.
.
I S2M0285
2) Connect the diagnosis cable to Subaru Select

Monitor.
3 Insert the cartridge into Subaru Select Monitor.
<Ref. to AT-6, PREPARATION TOOL, General De-
scription.>
(A) Power switch
’’ S2M0288C

{Each System Check} and press the [YES] key.
7) On the ((System Selection Menu,, display
screen, select the {Transmission Control System}
and press the [YES] key.
tion of transmission type.
9) On the ((Transmission Diagnosis)) display
screen, select the {Diagnostic Code@) Display}
10) On the ((Diagnostic Code(s) Display)) display
screen, select the {Latest Diagnostic Code(s)} or
{Memorized Diagnostic Code(s)} and press the
1 S2M028E
[YES] key.
4) Connect the Subaru Select Monitor to dati link NOTE:
connector. For detailed operation procedure, refer to the
(1) Data link connector located in the lower por- SUBARU SELECT MONITOR OPERATION MAN-
tion of the instrument panel (on the driver’s UAL.
side). For detailed concerning diagnostic trouble
codes, refer to the DIAGNOSTIC TROUBLE CODE
LIST (DTC). <Ref. to AT-29, List of Diagnostic
2. READ CURRENT DATA
(A) Data link connector
4) On the ((Transmission Diagnosis,, display
screen, select the {Current Data Display & Save}
AT-22

Batterv voltaae I Batterv Voltaae V
I Rear vehicle speed sensor signal 1 Rear Wheel Speed I km/h or MPH I
I Front vehicle speed sensor signal I Front Wheel Speed I km/h or MPH I
Automatic transmission fluid temperature signal ATF Temp. "Cor OF
Gear Dosition Gear Position -
I &ne pressure control dutv ratio 1 Line Pressure Dutv Ratio I YO I
I Lock up clutch control duty ratio I Lock Up Duty Ratio I O/O I
I Transfer clutch control duty ratio 1 Transfer Duty Ratio I % I
Power supply for throttle position sensor Throttle Sensor Power V
Torque converter turbine speed signal Turbine Revolution Speed rPm
2-4 brake timina Dressure control dutv ratio Brake Clutch Dutv Ratio - -
YO
-
IMass air flow sensor sianal (Turbo model) I Air Flow Sensor Voltaae -1 V -1
-4 -Intake manifold pressure sensor voltage (Non-turbo model) I Mani. Pressure Voltage I V I
I 2 wheel drive switch signal (Non-turbo model) 1 FWD Switch I ON or OFF I
-Stop lamp switch signal Stop Light Switch ON or OFF
Anti lock brake system signal ABS Signal ON or OFF
Cruise control system signal Cruise Control Signal ON or OFF
NeutraVParkina ranae sianal N/P RanQeSianal ON or OFF
I Reverse range signal I R Range Signal I ON or OFF I
I Drive range signal 1 D Range Signal I ON or OFF I
3rd range signal 3rd Range Signal ON or OFF
2nd range signal 2nd Range Signal ON or OFF
1st range signal 1st Range Signal ON or OFF
Shift control solenoid A Shift Solenoid #1 ON or OFF
Shift control solenoid B Shift Solenoid #2 ON or OFF
Torque control output signal #I Torque Control Signal 1 ON or OFF
Torque control output signal #2 Torque Control Signal 2 ON or OFF
Torque control cut signal Torque Control Cut Sig. ON or OFF
2-4 brake timing control solenoid valve 2-4 Brake Timing Sol. ON or OFF
Low clutch timing control solenoid valve Low Clutch Timing Sol. ON or OFF
Automatic transmission diagnosis indicator lamp Diagnosis Lamp ON or OFF
3. CLEAR MEMORY MODE NOTE:

For detailed operation procedure, refer to the SUB-
1) On the ((Main Menu)) display screen, select the ARU SELECT MONITOR OPERATION MANUAL.
12.Each System Check} and press the [YES] key.
2) On the ((System Selection Menu), display
4) On the ((Transmission Diagnosis)) display
screen, select the {Clear Memory} and press the
[YES] key.
AT-23
I READ DIAGNOSTIC TROUBLE CODE (DTC)
7. Read Diagnostic Trouble

Code (DTC)
A: OPERATION
1. WITHOUT SUBARU SELECT MONITOR
~~
Step Check Yes No

PERFORM READ DIAGNOSTIC TROUBLE Does the indicator light blink at Repair power sup- 30 to step 2.
CODE. 4-Hz intervals? NOTE: Blinks ply and ground cir-
1)Warm-up the engine. every 0.125 (1/8) seconds cuit.<Ref. to AT-36,
2)Turn the ignition switch to OFF. (until ignition switch is turned CHECK POWER
3)Turn the ignition switch to ON. OFF). SUPPLY AND
4)Start the engine. GROUND LINE,
5)Drive the vehicle at speeds greater than 20 Diagnostic Proce-
km/h (12 MPH). dure for AT OIL
6)Stop the vehicle. TEMP Warning
7)Brake pedal depressed and move the select Light.>
lever to 1 range.
1O)Move the select lever 2 range.
11)Move the select lever 1 range.
12)Movethe select lever 2 range.
13)Movethe select lever 3 range.
14)Move the select lever D range.
CHECK INDICATOR LIGHT. Does the indicator light blink at AT system is nor- 30 to step 3.
2-Hz intervals? NOTE: Blinks mal.
every 0.25 (1/4) seconds (until
ignition switch is turned OFF).
CHECK INDICATOR LIGHT. Is a trouble code outputted? Inspect the prob- 30 to step 4.
lem correspond-
ing with diagnostic
trouble code
(DTC).
NOTE:
Record all diag-
iostic trouble code
(DTC).
CHECK INDICATOR LIGHT. Does the indicator light remain Repair the AT OIL 2alling up the
illuminated? TEMP warning liagnostic trouble
ight circuit <Ref. :ode (DTC) again.
to AT-31, Diagnos-
:ic Procedure for
4T OIL TEMP
Uarning Light.>,
3r Inspect inhibitor
switch, wiring,
TCM, etc.
AT-24
READ DIAGNOSTIC TROUBLE CODE (DTC) I
AUTOMATIC TRANSMISSION [DIAGNOSTICS)
The AT OIL TEMP warning light flashes the code corresponding to the faulty part.
The long segment (1.2 sec on) indicates a “ten”, and the short segment (0.2 sec on) signifies a “one”
Normal code
0.25
DTC 11
0.3 0.2
\ /
Unit: Seconds
TR056!
2. WITH SUBARU SELECT MONITOR

Refer to SUBARU SELECT MONITOR for informa-
tion about how to obtain and understand trouble
codes. <Ref. to AT-22, OPERATION, Subaru Se-
lect Monitor.>
AT-25
I INSPECTION MODE
~~
8. Inspection Mode
A: OPERATION
Raise the vehicle using a garage jack and place on
safety stands or drive the vehicle onto free rollers.
WARNING:
Before raising the vehicle, ensure parking
brakes are applied.
Do not use a pantograph jack in place of a
safety stand.
Secure a rope or wire to the front and rear
towing or tie-down hooks to prevent the lateral
runout of front wheels.
Do not abruptly depresshelease clutch pedal
or accelerator pedal during works even when
the engine is operating at low speeds since this
may cause vehicle to jump off free rollers.
In order to prevent the vehicle from slipping
due to vibration, do not place any wooden
blocks or similar items between the safety
%landsand the vehicle.
Since the rear wheels will also rotate, do not
place anything near them. Also, make sure that
nobody goes in front of the vehicle.
(B)
B2M2969C
(A) Safety stand

(B) Free rollers
AT-26
CLEAR MEMORY MODE I
9. Clear Memory Mode

A: OPERATION
Current trouble codes shown on the display are
cleared by turning the ignition switch OFF after
conducting the on-board diagnostics operation.
Previous trouble codes, however, cannot be
cleared since they are stored in the TCM memory
which is operating on the back-up power supply.
These trouble codes can be cleared by removing
the specified fuse (located under the light or left
lower position of the instrument panel).
CLEAR MEMORY:
Removal of No. 4 fuse (for at least one
minute)
The No. 4 fuse is located in the line to the mem-
ory back-up power supply of the TCM. Removal of
this fuse clears the previous trouble codes stored in
-+he TCM memory.
Be sure to remove the No. 4 fuse for at least the
specified length of time. Otherwise, trouble codes
may not be cleared.
Refer to SUBARU SELECT MONITOR for informa-
tion about how to clear trouble codes.
<Ref. to AT-23, CLEAR MEMORY MODE, OPER-
ATION, Subaru Select Monitor.>
AT-27
AT OIL TEMP WARNING LIGHT DISPLAY
I
10.AT OIL TEMP Warning Light determined by a trouble code during the on-board
diagnostics operation. Problems which occurred
Display previously can also be identified through the mem-
ory function. If the AT OIL TEMP warning does not
A: INSPECTION show a problem (although a problem is occurring),
When any on-board diagnostics item is malfunc- the problem can be determined by checking the
tioning, the display on the Power indicator light performance characteristics of each sensor using
blinks from the time the malfunction is detected af- the selectmonitor. indicator signal is as shown in
ter starting the engine until the ignition switch iS the figure.
turned OFF. The malfunctioning part or unit can be
Normal
ON
2 secs
I .
OFF -
ON
-_ -_ -
0.25 secs
_ _
2 secs
OFF -- _ _ _ _ __
Normal (power switch ON)
I I-
Blink
I
Power indicator light ON
S3M0062A
AT-28
I
11.List of Diagnostic Trouble

Code (DTC)
A: LIST
DTC No. Item Content of diagnosis Index
<Ref. to AT-44, DTC 11 ENGINE SPEED SIGNAL,
Detects open or shorted input
11 Engine speed signal Diagnostic Procedure with Diagnostic Trouble
signal circuit.
Code (DTC).>
<Ref. to AT-46, DTC 23 MASS AIR FROW SIG-
Detects Open Or shorted input
23 Mass air flow signal NAL, Diagnostic Procedure with Diagnostic Trou-
signal circuit.
ble Code (DTC).>
<Ref. to AT-48, DTC 27 ATF TEMPERATURE
27 ATF temperature sensor signal
Detectscircuit,
Open Or shorted input SENSOR, Diagnostic Procedure with Diagnostic
<Ref. to AT-52, DTC 31 THROTTLE POSITION
31 Throttle position sensor signal
Detectscircuit,
Open Or shorted input SENSOR, Diagnostic Procedure with Diagnostic
<Ref. to AT-57, DTC 33 FRONT VEHICLE SPEED
Front vehicle speed Detects Open Or shorted input
33 SENSOR, Diagnostic Procedure with Diagnostic
sensor signal circuit.
<Ref. to AT-62, DTC 36 TORQUE CONVERTER
Torque converter tur- Detects Open Or shorted input
36 TURBINE SPEED SENSOR, Diagnostic Proce-
bine speed sensor signal circuit.
<Ref. to AT-66, DTC 38 TORQUE CONTROL SIG,
38 Torque control signal Detects Open Or shorted input NAL, Diagnostic Procedure with Diagnostic Trou-
signal circuit.
ble Code (DTC).>
~
Intake manifold pres-

<Ref. to AT-68, DTC 45 INTAKE MANIFOLD
sure Detects open or shorted input
45 PRESSURE SIGNAL, Diagnostic Procedure with
signal (Non-turbo signal circuit.
model)
<Ref. to AT-70, DTC 71 SHIFT SOLENOID 1,
Detects open or shorted out-
71 Shift solenoid 1 Diagnostic Procedure with Diagnostic Trouble
put signal circuit.
Code (DTC).>
<Ref. to AT-74, DTC 72 SHIFT SOLENOID 2,
72 Shift solenoid 2 Diagnostic Procedure with Diagnostic Trouble
put signal circuit.
Code (DTC).>
<Ref. to AT-78, DTC 73 LOW CLUTCH TIMING
Low clutch timing sole- Detects open or shorted out-
73 SOLENOID, Diagnostic Procedure with Diagnostic
noid put signal circuit.
<Ref. to AT-82, DTC 74 2-4 BRAKE TIMING
2-4 brake timing sole- Detects open or shorted out-
Trouble
_ _ _
Code
~
(DT
~ ~
Cb
<Ref. to AT-86, DTC 75 LINE PRESSURE DUTY
Line pressure duty sole- Detects open or shorted out-
<Ref. to AT-90, DTC 76 2-4 BRAKE DUTY SOLE-
76 2-4 brake duty solenoid NOID, Diagnostic Procedure with Diagnostic Trou.
put signal circuit.
ble Code (DTC).>
<Ref. to AT-94, DTC 77 LOCK-UP DUTY SOLE-
77 Lock-up duty solenoid NOID, Diagnostic Procedure with Diagnostic Trou,
put signal circuit.
ble Code ( D T C b
~~
<Ref. to AT-100, DTC 79 TRANSFER DUTY

79 Transfer duty solenoid SOLENOID, Diagnostic Procedure with Diagnostic
put signal circuit.
<Ref. to AT-104, DTC 93 REAR VEHICLE SPEED
Rear vehicle speed Detects open or shorted input
93 SENSOR, Diagnostic Procedure with Diagnostic
sensor signal circuit.
AT-29
r.
AT-30
DIAGNOSTIC PROCEDURE FOR AT OIL TEMP WARNING LIGHT
a
12.Diagnostic Procedure for AT OIL TEMP Warning Light

A: AT OIL TEMP WARNING LIGHT DOES NOT COME ON OR GO OFF
DIAGNOSIS:
The AT OIL TEMP warning light circuit is open or shorted.
TROUBLE SYMPTOM:
When the ignition switch is turned to ON (engine OFF), AT OIL TEMP warning light does not illuminate.
When the on-board diagnostics is performed, AT OIL TEMP warning light remains illuminated.
--
AT-31
I
WIRING DIAGRAM:
IGNITION
SWITCH
SBF-1 SBF-4
I i
COMBINATION
METER
B AT OIL
INHIBITOR SWITCH
r- ~
3 3
I A: @
3
B: @ TCM
7 8 9101112
dR\
9 101112
A: @ B: @
TR0570
AT-32
1
~~~ ~
Step Check Yes No

CHECK AT OIL TEMP WARNING LIGHT. )oes the AT OIL TEMP warn- Go to step 3. 30 to step 2.
Turn the ignition switch to ON (engine OFF). i g light illuminate?
CHECK AT OIL TEMP WARNING LIGHT. ;the AT OIL TEMP warning Go to step 4. 3eplace the AT
1)Turn the ignition switch to OFF. ght bulb OK? 31L TEMP warn-
2)Remove the combination meter. ng light bulb.
3)Remove the ATF temp warning light bulb
from combination meter.
CHECK AT OIL TEMP WARNING LIGHT. )oes the AT OIL TEMP warn- A temporary poor 30 to step 10.
Perform “Read Diagnostic Trouble Code”. i g light blink? contact of the con-
<Ref. to AT-24, WITHOUT SUBARU SELECT nector or harness
MONITOR, OPERATION, Read Diagnostic may be the cause.
Trouble Code (DTC).> Repair the har-
ness or connector
in TCM, inhibitor
switch and combi-
nation meter.
CHECK FUSE (No. 13). 5 the fuse (No. 13) blown out? Replace the fuse 30 to step 5.
Remove the fuse (No. 13). (No. 13). If the
replaced fuse (No.
13) is blown out
easily, repair short
circuit in harness
between fuse (No.
13) and combina-
tion meter.
CHECK HARNESSCONNECTOR BETWEEN 5 the voltage more than 9 V? Go to step 6. 3epair open or
COMBINATION METER AND IGNITION short circuit in har-
SWITCH. less between
1)Turnthe ignition switch to ON (engine OFF). :ombination meter
2)Measure the voltage between combination md battery.
meter connector and chassis ground.
(il0) No. 7 (+) - Chassis ground (-):
CHECK COMBINATION METER. 3 the voltage less than 1 V? Go to step 7 . 3epair the combi-
Measure the voltage between combination iation meter.
meter connector and chassis ground. :Ref. to IDI-11,
Connector & terminal zombination
( i l l ) No. 5 (+) - Chassis ground (-): Meter Assembly.>
CHECK OPEN CIRCUIT OF HARNESS. s the resistance less than 1 Go to step 8. 3epair open circuit
1)Turn the ignition switch to OFF. l? n harness
2)Disconnect the connector from combination ietween TCM and
meter connector. :ombination
3)Measure the resistance of harness between neter, and poor
combination meter. :ontact in cou-
Connector & terminal iling connector.
Non-turbo model
(854) NO. 3 - ( i l l ) NO. 5:
Turbo model
(856) NO. 11 - ( i l l ) NO. 5:
AT-33
I DIAGNOSTIC PROCEDURE FOR AT OIL TEMP WARNING LIGHT
Step Check Yes No

I CHECK INPUT SIGNAL FOR TCM. 5 the voltage less than 1 V? Even if the AT OIL Replace the TCM.
1)Connectthe connector to TCM and combina- TEMP warning <Ref. to AT-45,
tion meter. lights up, the cir- Transmission Con-
2)Turn the ignition switch to ON (engine OFF). cuit has returned trol Module
3)Measure the voltage between TCM connec- to a normal condi- (TCM).>
tor and chassis ground. tion at this time. A
Connector & terminal temporary poor
Non-turbo model contact of the con-
-
(B54)No. 3 (+) Chassis ground (-): nector or harness
Turbo model may be the cause.
(B56)No. 11 (+) - Chassis ground (-): Repair the har-
ness or connector
in TCM.
1 CHECK SUBARU SELECT MONITOR. 10 you have a SUBARU Go to step 10. Go to step 11.
SELECT MONITOR?
0 CHECK INHIBITOR SWITCH. Vhen each range is selected, Go to step 11. Check the inhibi-
1)Connect the Subaru Select Monitor to data loes the LED of Subaru Seleci tor switch circuit.
link connector. Aonitor light up? <Ref. to AT-115,
2)Turn the ignition switch to ON. CHECK INHIBI-
3)Subaru Select Monitor to ON. TOR SWITCH.,
4)Read the data of range switch using Subaru Diagnostic Proce-
._ Select Monitor. dure for No-Diag-
*Range switch is indicated in ON w OFF. nostic Trouble
Code (DTC).>
1 CHECK SHORT CIRCUIT OF HARNESS. s the resistance less than 1 Replace the TCM. Repair short circuil
1)Disconnectthe connector from TCM. AR? <Ref. to AT-45, in harness
2)Remove the combination meter. Transmission Con- between combina-
3)Disconnect the connector from combination trol Module tion meter connec.
meter. (TCM).> tor and TCM
4)Measure the resistance of harness connec- connector.
tor between TCM and chassis ground.
Connector & terminauspecified resistance
Non-turbo model
(854)No. 3 (+) - Chassis ground (-):
Turbo model
(B56)No. 11 (+) - Chassis ground (-):
AT-34
I DIAGNOSTIC PROCEDURE FOR AT OIL TEMP WARNING LIGHT
I
AT-35
I I
B: CHECK POWER SUPPLY AND GROUND LINE

WIRING DIAGRAM:
BATTERY
n
I -
i
m
(I)
INITION DATALINK
NITCH CONNECTOR
by
TB
m,@ : NON-TURBO MODEL
m, :TURBO MODEL
9 110 11 111211 311 411 511 6
112131415] 16171819110111
1211311411511 611 711 8119120121122123124
TR0571
AT-36
I DIAGNOSTIC PROCEDURE FOR AT OIL TEMP WARNING LIGHT I
AUTOMATIC TRANSMISSION (DIAGNOSTICSI
Step Check Yes No

1 CHECK IGNITION SWITCH. Is the ignition switch ON? Go to step 2. Turn the ignition
switch ON.
2 CHECK GENERATOR. Is the voltage between 10 and Go to step 3. Repair the genera
1)Start the engine. 15 V? tor. <Ref. to SC-
2)ldle the engine. 13, Generator.>
3)Measure the voltage between generator and
chassis ground.
Terminal
Generator B terminal (+) - Chassis
ground (-):
3 CHECK BATTERY TERMINAL. Is there poor contact at battery Repair the battery Go to step 4.
Turn the ignition switch to OFF. terminal? terminal.
I CHECK POWER SUPPLY OF TCM. Is the voltage between 10 and Go to step 6. Go to step 5.
1)Disconnectthe connector from TCM. 15 V?
3)Measure the voltage between TCM connec-
Non-turbo model
Turbo model
5 CHECK FUSE (NO. 4). Is the fuse (No. 4) blown out? Replace the fuse Repair open circuii
Remove fuse (No. 4). (No. 4). If the in harness
replaced fuse (No. between fuse (No.
4) has blown out 4) and TCM, or
easily, repair short fuse (No. 4) and
circuit in harness battery, and poor
between fuse (No. sontact in cou-
4) and TCM. pling connector.
5 CHECK IGNITION POWER SUPPLY CIR- Is the voltage more than 10 V? Go to step 8. Go to step 7.
CUIT.
2)Measure the ignition power supply voltage
between TCM connector and chassis ground.
(654) No. 24 (+)- - Chassis ground (-):
7 CHECK FUSE (NO. 11). Is the fuse (No. 11) blown out? Replace the fuse Repair open circuii
Remove the fuse (No. 11). (No. 11). If the in harness
replaced fuse (No. Detween fuse (No.
11) has blown out 4) and TCM, or
easily, repair short fuse (No. 4) and
circuit in harness Dattery, and poor
between fuse (No. :ontact in cou-
11) and TCM. Dling connector.
3 CHECK HARNESSCONNECTOR BETWEEN Is the resistance less than 1 Go to step 9. Repair open circuii
TCM AND TRANSMISSION. n? n harness
1)Turn the ignition switch to OFF: Detween TCM,
2)Disconnect the connector from TCM and ransmission har-
transmission. less connector,
3)Measure the resistance of harness between and poor contact
TCM and transmission connector. n coupling con-
Connector & terminal lector.
Non-turbo model
(B55) NO. 9 - (B1 1) NO. 16
(B55) NO. 19 - (Bl 1) NO. 16
Turbo model
(B56) NO. 19 - ( B l l ) NO. 16
(654) NO.21 - (611) NO. 16
AT-37
I
Step Check Yes No

9 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 30 to step 10. Repair open circuit
TRANSMISSION AND TRANSMISSION n? in harness
GROUND. between transmis-
Measure the resistance of harness between sion and transmis-
transmission and transmission ground. sion ground.
(T4) No. 16 - Transmission ground:
10 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in control Repair the con- Replace the TCM.
module power supply, ground lector. <Ref. to AT-45,
line and data link connector? Transmission Con-
trol Module
(TCM).>
AT-38
I DIAGNOSTIC PROCEDURE FOR SELECT MONITOR COMMUNICATION
E
13.Diagnostic Procedure for Select Monitor Communication

A: COMMUNICATION FOR INITIALIZING IMPOSSIBLE
DIAGNOSIS:
Faulty harness connector
TROUBLE SYMPTOM:
Select the monitor communication failure
AT-39
DIAGNOSTIC PROCEDURE FOR SELECT MONITOR COMMUNICATION
I
WIRING DIAGRAM:
BATTERY
P
0
5 DATALINK
=
12
CONNECTOR
-
13
r- ~
1 A:@ B:@
m
2 2
m *
9 2
C @ : m
*
TCM
TRANSMISSION
m,@ : NON-TURBO MODEL
TR0571
AT-40
I
~~
Step Check Yes No

CHECK SUBARU SELECT MONITOR POW- s the voltage more than lOV? 30 to step 2. 3epair harness
ER SUPPLY CIRCUIT. and connector
Measure the voltage between data link con- 3etween battery
nector and chassis ground. and data link con-
Connector & terminal lector, and poor
(840) No. 1 - Chassis ground: :ontact in cou-
Dling connector.
CHECK SUBARU SELECT MONITOR Is the resistance less than In? 30 to step 3. Repair open circuii
GROUND CIRCUIT. in harness
Measure the resistance of harness between between data link
data link connector and chassis ground. sonnector and
Connector & terminal ground terminal,
(840) No. 12 - Chassis ground: and poor contact
(840) No. 13 - Chassis ground: in coupling con-
nector.
CHECK COMMUNICATIONOF SELECT Are the name and year of the 30 to step 8. Go to step 4.
MONITOR. system displayed on the select
1)Turn the ignition switch to ON. monitor?
2)Using the select monitor, check whether
communication to other systems (such as
engine, ABS etc.) can be executed normally.
CHECK COMMUNlCATtON OF SELECT Are the name and year of the So to step 10. Go to step 5.
1)Turn the ignition switch to OFF. monitor?
2)Disconnect the TCM connector.
3)Check whether communication to other sys-
tems (such as ABS etc.) can be executed nor-
mally.
CHECK COMMUNICATIONOF SELECT Are the name and year of the Inspect the ECM. Go to step 6.
MONIT0R . system displayed on the select
1)Turnthe ignition switch to OFF. monitor?
2)Connect the TCM connector.
3)Disconnect the ECM connector.
tems (such as ABS etc.) can be executed nor-
mally.
CHECK COMMUNICATIONOF SELECT Are the name and year of the Inspect the Go to step 7.
MONITOR. system displayed on the select ABSCM&H/U.
2)Connect the ECM connector.
3)Disconnect the ABSCM&H/U connector.
tems (such as engine etc.) can be executed
normally.
CHECK COMMUNICATIONOF SELECT Are the name and year of the Inspect the cruise Go to step 8.
MONITOR. system displayed on the select control module.
2)Connect the ABSCM&H/U module connec-
tor.
3)Disconnect the cruise control module con-
nector.
normally.
NOTE:
If the vehicle is not equipped with cruise contro
Go to step 8.
AT-41
I DIAGNOSTIC PROCEDURE FOR SELECT MONITOR COMMUNICATION
Step Check
R? and connector
between each con.
trol module and
data link connec-
tor.
(840) No. 4-Chassis ground:

I CHECK OUTPUT SIGNAL FOR TCM. Is the voltage more than 1 V? 3epair harness A temporary poor
ind connector contact or har-
letween each con- ness may be the
rol module and case. Repair har-
jata link connec- ness or connector
or. in the select moni-
tor communication
circuit.
0 CHECK HARNESSKONNECTORBETWEEN Is the resistance less than 0.5 i o to step 11. Repair harness
TCM AND DATA LINK CONNECTOR. R? and connector
Measure the resistance between TCM connec- between TCM and
tor and data link connector. data link connec-
Connector & terminal tor.
Non-turbo model
-
(855) NO. 7 (840) NO. 5:
(855) NO. 16 - (840) NO. 4:
Turbo model
(856) NO. 6 - (840) NO. 5:
(856) NO. 15 - (840) NO. 4:
1 CHECK INSTALLATION OF TCM CONNEC- Is TCM connector inserted into i o to step 12. Insert the TCM
TOR. TCM? connector into
Turn the ignition switch to OFF. TCM.
2 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in control 3epair the poor Replace the TCM.
module and data link connec- :ontact. <Ref. to AT-45,
tor? Transmission Con-
trol Module
(TCM).>
AT-42
AT-43
I
14.Diagnostic Procedure with Diagnostic Trouble Code (DTC)

A: DTC 11 ENGINE SPEED SIGNAL
DIAGNOSIS:
Engine speed input signal circuit is open or shorted.
TROUBLE SYMPTOM:
No lock-up (after engine warm-up).
AT OIL TEMP warning light remains on when the vehicle speed is ''0'.
WIRING DIAGRAM:
1
@TCM
: NON-TURBO MODEL
: TURBO MODEL
I ECM I
TR0572
AT-44
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) I
Step Check Yes No

CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 io to step 2. 3epair open circuit
TCM AND ECM. 2? n harness
1)Turn the ignition switch to OFF. letween TCM and
2)Disconnect the connectors from TCM and X M connector.
ECM.
TCM and ECM connector.
Non-turbo model
(B55) NO. 4 - (8134) NO. 30:
Turbo model
(B55) NO. 17 - (8136) NO. 9:
CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 i o to step 3. 3epair short circuit
TCM AND ECM. VlR? n harness
Measure the resistance of harness between ietween TCM and
TCM connector and chassis ground. ICM connector.
Non-turbo model
Turbo model
PREPARE SUBARU SELECT MONITOR. l o you have a Subaru Select i o to step 5. 30 to step 4.
Vlonitor?
CHECK INPUT SIGNAL FOR TCM. s the voltage 0 V? gven if the AT OIL 30 to step 6.
1)Connect the connectors to TCM and ECM. rEMP warning
2)Turn the ignition switch to ON (engine OFF). ights up, the cir-
3)Measure the voltage between TCM connec- :uit has returned
tor and chassis ground. o a normal condi-
Connector & terminal ion at this time. A
Non-turbo model emporary poor
(B55) No. 4 (+) - Chassis ground (-): :ontact of the con
Turbo model lector or harness
(B55) No. 17 (+) - Chassis ground (-): nay be the cause
3epair harness or
:onnector in the
E M and ECM.
I CHECK INPUT SIGNAL FOR TCM USING Is the revolution value the Iven if the AT OIL 30 to step 6.
SUBARU SELECT.MONITOR. same as the tachometer read- rEMP warning
1)Connect the connectors to TCM and ECM. ng shown on the combination ights up, the cir-
2)Connect the Subaru Select Monitor to data neter? x i t has returned
link connector. o a normal condi.
3)Start the engine, and turn the Subaru Select ion at this time. A
Monitor switch to ON. emporary poor
4)Warm-up the engine until engine coolant :ontact of the con
temperature is above 80°C (176°F). lector or harness
5)Engine idling. nay be the cause
6)Read the data of engine speed using the qepair harness or
Subaru Select Monitor. :onnector in the
-Display shows engine speed signal value sent TCM and ECM.
from ECM.
i CHECK POOR CONTACT. Is there poor contact in engine qepair poor con- Go to step 7.
speed signal circuit? :act.
I CONFIRM DTC 11. Replace the ECM with a new Replace the TCM. Replace the ECM.
one. Does the trouble code <Ref. to AT-45,
appear again, after the mem- Transmission Con
ory has been cleared? :rol Module
[TCM).>
AT-45
B: DTC 23 MASS AIR FROW SIGNAL

DIAGNOSIS:
Input signal circuit of TCM from ECM is open or shorted.
TROUBLE SYMPTOM:
Excessive shift shock.
WIRING DIAGRAM:
TR0573
Step Check Yes No

Repair ground ter- Go to step 2.
I
I GROUND CIRCUIT OF ECM minal and/or
<Ref. to AT-52, DTC 31 THROTTLE POSITION ground circuit of
SENSOR, Diagnostic Procedure with Diagnos- ECM.
2 CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 Go to step 3. Repair open circuit
TCM AND ECM. n? in harness
2)Disconnect the connectors from TCM and ECM connector.
~ ECM.
(B54) NO. 1 - (8135) NO. 28:
3 CHECKHARNESSCONNECTORBETWEEN s the resistance more than 1 Go to step 4. Repair short circuit
TCM AND ECM. M1R? in harness
Measure the resistance of harness between between TCM and
TCM connector and chassis ground. ECM connector.
4 PREPARE SUBARU SELECT MONITOR. l o you have a Subaru Select Go to step 6. Go to step 5.
vlonitor?
AT-46
Step Check Yes No

1 CHECK INPUT SIGNAL FOR TCM. s the voltage between 0.4 and Even if the AT OIL ;o to step 7.
1)Connect the connectors to TCM and ECM. I .8 V? TEMP warning
2)Start the engine, and warm-up the transmis- lights up, the cir-
sion until ATF temperature is above 80°C cuit has returned
(176°F). to a normal condi-
NOTE: tion at this time. A
If ambient temperature is below 0°C (32°F) temporary poor
drive the vehicle until the ATF reaches its oper contact of the con-
ating temperature. nector or harness
3)Engine idling. may be the cause.
4)Measure the voltage between TCM connec- Repair harness or
tor and chassis ground. connector in the
Connector & terminal TCM and ECM.
i CHECK INPUT SIGNAL FOR TCM USING s the value between 0.4 and Even if the AT OIL 30 to step 7.
SUBARU SELECT MONITOR. 1.8 V? TEMP warning
1)Connect the connectors to TCM and ECM. lights up, the cir-
2)Connect the Subaru Select Monitor to data cuit has returned
link connector. to a normal condi-
3)Start the engine, and turn the Subaru Seleci tion at this time. A
monitor switch to ON. temporary poor
4)Warm-upthe engine until the engine coolani contact of the con-
temperature is above 80°C (176°F). nector or harness
6)Read the data of intake manifold pressure Repair harness or
signal using Subaru Select Monitor. connector in the
*Display shows the intake manifold pressure TCM and ECM.
signal value sent from ECM.
r CHECK POOR CONTACT. s there poor contact in intake Repair the poor 3eplace the TCM.
nanifold pressure signal cir- contact. :Ref. to AT-45,
rransmission Con-
rot Module
'TCMb
AT-47
I
C: DTC 27 ATF TEMPERATURE SENSOR

DIAGNOSIS:
Input signal circuit of TCM to ATF temperature sensor is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
TCM
w o
a m
w w
:TURBO MODEL
LL
+
4:
TRANSMISSION
TR0574
AT-48
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) 1
~~~ ~
Step Check Yes No

CHECK HARNESSCONNECTOR BETWEEN ;the resistance less than 1 io to step 2. Repair open circuit
TCM AND ATF TEMPERATURE SENSOR. 1? in harness
2)Disconnect the connector from transmission transmission con-
and TCM. nector.
TCM and transmission connector.
Non-turbo model
(655) NO. 10 - (61 1) NO. 12:
Turbo mode
(654) NO.20 - ( 6 1 1) NO. 12:
CHECK HARNESSCONNECTOR BETWEEN 3 the resistance less than 1 io to step 3. Repair open circuit
TCM AND ATF TEMPERATURE SENSOR. I? in harness
TCM and transmission connector. transmission con-
Connector & terminal nector.
Non-turbo model
(655) No. 11 - (611) NO. 11:
Turbo mode
(654) NO. 11 - (611) NO. 11:
c .- CHECK HARNESSCONNECTOR BETWEEN ;the resistance more than 1 io to step 4. Repair short circuit
TCM AND ATF TEMPERATURE SENSOR. AR? in harness
TCM connector and chassis ground. transmission con-
Non-turbo model
Turbo mode
I CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 So to step 5. Repair short circuil
TCM AND ATF TEMPERATURE SENSOR. An? in harness
TCM connector and chassis ground. transmission con-
Non-turbo model
Turbo mode
1 CHECK ATF TEMPERATURE SENSOR. s the resistance between 275 So to step 6. Go to step 11.
1)Turn the ignition switch to OFF. md 375 n?
2)Connect the connectors to transmission and
TCM.
3)Turn the ignition switch to ON and start
engine.
4)Warm-up the transmission until the ATF tern
perature reaches to 80°C (176°F).
NOTE:
If ambient temperature is below 0°C (32°F)
drive the vehicle until the ATF reaches its oper
ating temperature.
5)Disconnect the connector from transmission
6)Measure the resistance between transmis-
sion connector terminals.
(T4) NO. 11 - NO. 12:
AT-49
~~
Step Check Yes No

6 CHECK ATF TEMPERATURE SENSOR. Does the resistance value Go to step 7. So to step 11.
1)Turn the ignition switch to ON (engine OFF). ncrease while the ATF temper
2)Measure the resistance between transmis- 3ture decreases?
sion connector terminals.
(T4) NO. 11 - NO. 12:
7 PREPARE SUBARU SELECT MONITOR. 30 you have a Subaru Select Go to step 9. 30 to step 8.
Monitor?
CHECK INPUT SIGNAL FOR TCM. s the voltage between 0.4 and Even if the AT OIL 30 to step 10.
1)Connect the connector to transmission. 1.9 V? TEMP warning
2)Warm-up the transmission until the ATF tem- lights up, the cir-
perature is about 80°C (176°F). cuit has returned
NOTE: to a normal condi-
If ambient temperature is below 0°C (32°F) tion at this time.
drive the vehicle until the ATF reaches its oper. Temporary poor
ating temperature. :ontact of the con.
3)Measure the voltage between TCM connec- lector or harness
tor terminal. nay be the case.
Connector & terminal Repair harness or
Non-turbo model :ontact in the ATF
(B55)NO. 11 (+) - NO. 10 (-): :emperatwe sen-
r. ~ Turbo model ;or and transmis-
(B54) NO. 11 (+) - NO. 20 (-): sion connector.
9 CHECK INPUT SIGNAL FOR TCM USING 1oes the ATF temperature Even if the AT OIL 50 to step 10.
SUBARU SELECT MONITOR. jradually decrease? rEMP warning
1)Connect the connector to transmission. ights up, the cir-
2)Turn the ignition switch to ON (engine OFF). :uit has returned
o a normal condi-
ion at this time.
remporary poor
:ontact of the con-
lector or harness
nay be the case.
3epair harness or
:ontact in the ATF
emperature sen-
ior and transmis-
;ion connector.
3 there poor contact in ATF Iepair poor con- ieplace the TCM.
smperature sensor circuit? act. :Ref. to AT-45,
tansmission Con-
'01 Module
TCM).>
AT-50
Step Check Yes No

I1 CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 ;o to step 12. lepair open circuit
TRANSMISSION AND ATF TEMPERATURE 2? 1 harness
SENSOR. letween ATF tem-
1)Turnthe ignition switch to OFF. lerature sensor
2)Disconnect the connector from transmission. .nd transmission
3)Remove the transmission connector from onnector.
bracket.
4)Lift-up the vehicle and place safety stand.
CAUTION:
On AWD models, raise all wheels off
ground.
5)Drain the automatic transmission fluid.
CAUTION:
Do not drain the automatic transmission flu.
id until it cools down.
6)Remove the oil pan, and disconnect the con-
nector from ATF temperature sensor connec-
tor.
ATF temperature sensor and transmission con.
nector. I

(T4) NO. 11 - (AT1) NO. 2:
12 CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 50 to step 13. iepair open circuit
TRANSMISSION AND ATF TEMPERATURE n? iharness
SENSOR. letween ATF tem-
Measure the resistance of harness between Ierature sensor
ATF-temperaturesensor and transmission con. ind transmission
nector. :onnector.
(T4) NO. 12 - (ATl) NO. 1:
13 CHECK HARNESSCONNECTOR BETWEEN Is the resistance more than 1 20 to step 14. iepair short circuit
TRANSMISSION AND ATF TEMPERATURE Ma? iharness
SENSOR. jetween ATF tem-
Measure the resistance of harness between erature sensor
transmission connector and transmission nd transmission
ground. onnector.
(T4) No. 11 - Transmissionground:
4 CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 leplace the ATF lepair short circuit
TRANSMISSION AND ATF TEMPERATURE An? mperature sen- 1 harness
SENSOR. ,or. <Ref. to AT- etween ATF tem-
Measure the resistance of harness between 19,Shift Sole- erature sensor
transmission connector and transmission ioids, Duty Sole- nd transmission
ground. ioids and ATF onnector.
Connector & terminal emperature Sen-
-
(T4) No. 12 Transmissionground: ,or.>
AT-51
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) I
D: DTC 31 THROTTLE POSITION SENSOR

DIAGNOSIS:
Input signal circuit of throttle position sensor is open or shorted.
TROUBLE SYMPTOM:
Shift point too high or too low; excessive shift shock; excessive tight corner “braking”.
WIRING DIAGRAM:
NON-TURBO MODEL
@ TCM 000
A. 6134 B 8135 C 6136 ECM
L
THROTTLE
POSITION SENSOR
SHIELD AND
SENSOR GROUND
JOINT CONNECTOR
AT-52
I
TURBO MODEL
@ TCM
A: 8134
C:@
'O
B 6135
D:@
ECM
I
I I
r. .
SHIELD AND
THROTTLE SENSORGROUND
POSITION SENSOR JOINT CONNECTOR
TR0576
AT-53
Step Check Yes No

I CHECK ENGINE GROUND TERMINALS. -lave engine ground terminals 20 to step 2. righten the engine
ieen tightened? ground terminals.
! CHECK GROUND CIRCUIT OF ECM. s the resistance less than 5 :o to step 3. 3epair open circuit
1)Turn the ignition switch to OFF. 3? n harness
2)Disconnect the connector from ECM. letween ECM
3)Measure the resistance of harness between :onnector and
ECM and engine ground. mgine grounding
Connector & terminal erminal.
Non-turbo model
( 6 134)No. 8 - Engine ground:
(6136) No. 21 -Engine ground:
Turbo model
_I
~

t CHECK THROTTLE POSITION SENSOR. s the resistance between 3.0 20 to step 4. 3eplace the throt-
1)Disconnect the connector from throttle posi- 2nd 4.2 kfi? le position sensor.
tion sensor.
2)Measure the resistance between throttle
position sensor connector receptacle's termi-
nals.
Terminals
Non-turbo model
NO. 4 - NO. 2:
Turbo model
NO. 1 - NO. 2:
I CHECK THROTTLE POSITION SENSOR. s the resistance between 0.35 ;o to step 5. 3eplace the throt-
Measure the resistance between throttle posi- md 0.5 kR? le position sensor.
tion sensor connector receptacle's terminals.
Terminals
NO. 2 - NO. 3:
> CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 20 to step 6. 3epair open circuit
TCM AND THROTTLE POSITION SENSOR. n? n harness
1)Disconnect the connector from TCM. ietween TCM and
2)Measure the resistance of harness between hrottle position
TCM and throttle position sensor connector. sensor connector,
Connector & terminal 3nd poor contact
Non-turbo model n coupling con-
-
(655) NO. 2 (€13) NO. 3: lector.
Turbo model
-
(B54) NO. 3 (E13) NO. 3:
i CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 ;o to step 7. 3epair open circuit
TCM AND THROlTLE POSITION SENSOR. n? n harness
TCM and throttle position sensor connector. hrottle position
Connector & terminal sensor connector,
Non-turbo model md poor contact
-
(655) NO. 1 (€13) NO. 4: n coupling con-
Turbo model lector.
-
(654) NO. 2 (€13) NO. 4:
AT-54
I
Step Check Yes No

CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 o step 8. Repair short circuit
TCM AND THROTTLE POSITION SENSOR. An? n harness
Measure the resistance of harness between Detween TCM and
TCM connector and chassis ground. throttle position
Non-turbo model
Turbo model
CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 o step 9. Repair short circuit
TCM AND THROTTLE POSITION SENSOR. dR? in harness
TCM connector and chassis ground. throttle position
Non-turbo model
Turbo model
I CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 o step 10. Repair open circuit
TCM AND ECM. 2? in harness
TCM and ECM connector. ECM connector.
Non-turbo model
(655) NO.2 - (6136) NO. 17:
Turbo model
(654) NO. 3 - (6135) NO. 7:
0 CHECK HARNESSCONNECTOR BETWEEN Is the resistance less than 1 to step 11. Repair open circuit
TCM and ECM connector. ECM connector.
Non-turbo model
(655) NO. 1 - (6136) NO. 15:
Turbo model
(654) NO. 2 - (6135) NO. 9:
I1 PREPARE SUBARU SELECT MONITOR. Do you have a Subaru Select to step 14. Go to step 12.
Monitor?
12 CHECK INPUT SIGNAL FOR TCM. Is the voltage between approx. to step 13. Go to step 18.
1)Connect the connectors to TCM, throttle 0.5 V in throttle fully closed?
position sensor and ECM.
2)Turn the ignition switch to ON (engine OFF)
3)Close the throttle completely.
Non-turbo model
Turbo model
13 CHECK INPUT SIGNAL FOR TCM. Is the voltage between approx. to step 16.
1)Open the throttle completely. 4.3 V with throttle fully open?
Non-turbo model
Turbo model
AT-55
AUTOMATIC TRANSMISSION [DIAGNOSTICS)
Step Check Yes No

4 CHECK INPUT SIGNAL FOR TCM USING s the value voltage between 30 to step 15. 20 to step 18.
SUBARU SELECT MONITOR. ipprox. 0.5 V?
1)Connect the connectors to TCM, throttle
position sensor and ECM.
2)Connect the Subaru Select Monitor to data
link connector.
4)Turn the Subaru Select Monitor switch to ON.
5)Throttle fully closed.
6)Read the data of throttle position sensor
using Subaru Select Monitor.
*Throttle position sensor input signal is indi-
cated.
5 CHECK INPUT SIGNAL FOR TCM USING s the value voltage between 30 to step 17. i o to step 18.
SUBARU SELECT MONITOR. ipprox. 4.3 V?
Throttle fully open.
NOTE:
Must be changed correspondingly with acceler-
ator pedal operation (from “released” to “de-
pressed” position).
6 CHECK INPUT SIGNAL FOR TCM (THROT- s the voltage between 4.8 and Even if the AT OIL i o to step 18.
.- TLE POSITION SENSOR POWER SUPPLY). i.3 V? rEMP warning
Measure the voltage between TCM connector ights up, the cir-
and chassis ground. :uit has returned
Connector & terminal o a normal condi-
Non-turbo model ion at this time. A
(855)No. 1 (+) - Chassis ground (-): emporary poor
Turbo model :ontact of the con-
(B54) No. 2 (+) - Chassis ground (-): lector or harness
nay be the cause.
3epair harness or
:onnector in throt-
le position sensor
:ircuit.
7 CHECK INPUT SIGNAL FOR TCM USING s the value voltage between Even if the AT OIL i o to step 18.
SUBARU SELECT MONITOR (THROTTLE ..8 and 5.3 V? rEMP warning
POSITION SENSOR POWER SUPPLY). ights up, the cir-
Read the data of throttle position sensor power :uit has returned
supply using Subaru Select Monitor. o a normal condi-
*Throttle position sensor power supply voltage ion at this time. A
is indicated. emporary poor
:ontact of the con-
lector or harness
nay be the cause.
3epair harness or
:onnector in throt-
le position sensor
:ircuit.
8 CHECK POOR CONTACT. s there poor contact in throttle
losition sensor circuit? :ontact. <Ref. to AT-45,
Transmission Con-
trol Module
AT-56
3
E: DTC 33 FRONT VEHICLE SPEED SENSOR

DIAGNOSIS:
The vehicle speed signal is abnormal.
The circuit in combination meter is faulty.
The harness connector between TCM and vehicle speed sensor is in short or open.
TROUBLE SYMPTOM:
Erroneous idling.
Engine stalls.
Poor driving performance.
--
AT-57
I
WIRING DIAGRAM:
TCM
SHIELD AND
SENSORGROUND
JOINT CONNECTOR
I
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I I
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..
I I
I I
I I
I
I I
1
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I
JI
I I
I I
I I
I I
I I
I I
I
r *I
(I II COMBINATON FRONT
VEHICLE SPEED
SENSOR
A: a
TR0577
AT-58
I
Step Check Yes No

CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 20 to step 2. Repair open circuit
TCM AND TRANSMISSION. R? in harness
2)Disconnect the connector from TCM and transmission con-
transmission. nector.
Non-turbo model
(B55) NO. 5 - (B11)NO. 17:
Turbo model
(B55) NO. 18 - (B11)NO. 17:
CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 30 to step 3. Repair open circuit
TCM AND TRANSMISSION. R? in harness
Connector & terminal nector, and poor
Non-turbo model contact in cou-
(B55) NO. 21 - (Bll)NO. 18: pling connector.
Turbo model
(854) NO. 10 - (B 1 1) NO. 18:
1 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 30 to step 4. Repair short circuit
TCM AND TRANSMISSION. MR? in harness
Non-turbo model
Turbo model
(854) No, 10 - Chassis ground:
CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 30 to step 5. Repair short circuit
TCM AND TRANSMISSION. MR? in harness
(B55) No. 5 - Chassis ground: pling connector.
Turbo model
I CHECK FRONT VEHICLE SPEED SENSOR. Is the resistance between 450 30 to step 6. Replace the front
Measure the resistance between transmission and 650 R? vehicle speed sen.
connector receptacle's terminals. sor. <Ref. to AT-32,
'
Connector & terminal Front Vehicle

(T4) NO. 17- NO. 18: Speed Sensor.>
i PREPARE OSCILLOSCOPE. Do you have an oscilloscope? 30 to step 9. Go to step 7.
I PREPARE SUBARU SELECT MONITOR. Do you have a Subaru Select 30 to step 10. Go to step 8.
Monitor?
AT-59
Step Check Yes No

CHECK INPUT SIGNAL FOR TCM. Is the voltage more than AC 1 %en if the AT OIL 20 to step 11.
1)Connect all connectors. V? rEMP warning
2)Lift-up or raise the vehicle and place safety ights up, the cir-
stands. :uit has returned
CAUTION: o a normal condi-
On AWD models, raise all wheels off floor. ion at this time. A
3)Start the engine and set the vehicle in 20 km emporary poor
h (12 MPH) condition. :ontactor or har-
less may be the
NOTE:
The speed difference between front and real :ase. Repair har-
wheels may light the ABS warning light, but thk less or connector
indicates no malfunction. When the AT contro n the front vehicle
diagnosis is finished, perform the ABS memorq ;peed sensor cir-
clearance procedure of on-board diagnostic5 :uit.
system. <Ref. to ABS-22, Clear Memor)
Mode.>
tor terminals.
i
Non-turbo model
(655) NO. 5 (+) - (654) NO. 21 (-):
Turbo model
(655) NO. 18 (+) - (654) NO. 10 (-):
CHECK FRONT VEHICLE SPEED SENSOR s the voltage more than AC 4 h e n if the AT OIL ;o to step 11.
USING OSCILLOSCOPE. J? rEMP warning
1)Connect all connectors. ights up, the cir-
2)Lift-up the vehicle and place safety stands. :uit has returned
CAUTION: o a normal condi-
On AWD models, raise all wheels off ion at this time. A
ground. emporary poor
3)Set the oscilloscope to TCM connector ter- :ontactor or har-
minals. less may be the
Non-turbo model :ase. Repair har-
Positive probe; (855) No. 18 less or connector
Earth lead; (B54) No. 10 Ithe front vehicle
Turbo model ;peed sensor cir-
Positive probe; (855) No. 5 :uit.
Earth lead; (854) No. 21
4)Start the engine, and drive the wheels slowly,
NOTE:
The speed difference between front and real
wheels may light the ABS warning light, but this
indicates no malfunctions.When the AT control
diagnosis is finished, perform the ABS memory
<Ref. to ABS-22, Clear Memory Mode.>
5)Measure the signal voltage indicated on
oscilloscope.
AT-60
I
Step Check Yes No

0 CHECK INPUT SIGNAL FOR TCM USING Does the speedometer indica- Even if the AT OIL ;o to step 11.
SUBARU SELECT MONITOR. tion increase as the Subaru TEMP warning
1)Connect all connectors. Select Monitor data increases? lights up, the cir-
3)Lift-up or raise the vehicle and place safety tion at this time. A
stands. temporary poor
CAUTION: connector or har-
On AWD models, raise all wheels off floor. ness may be the
4)Turn the ignition switch to ON and turn the case. Repair har-
Subaru Select Monitor switch to ON. ness or connector
5)Start the engine. in the front vehicle
6)Read the data of vehicle speed using Subaru speed sensor cir-
Select Monitor. cuit.
Compare the speedometer with Subaru
Select Monitor indications.
*Vehicle speed is indicated in “km/h” or “MPH”.
1)Slowly increase the vehicle speed to 60 km/h
or 37 MPH.
NOTE:
indicates no malfunction. When the AT control
clearance procedure of on-board diagnostics
system. <Ref. to ABS-22, Clear Memory
Mode.>
1 CHECK POOR CONTACT. IS there poor contact in front Repair poor con- Replace the TCM.
vehicle speed sensor circuit? tact. <Ref. to AT-45,
Transmission Con-
trol Module
(TCM).>
AT-61
I
DIAGNOSTIC P 3OCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSI( IN (DIAGNOSTICS)
F: DTC 36 TORQUE CONVERTER TURBINE SPEED SENSOR

DIAGNOSIS:
Input signal circuit of TCM is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
: NON-TURBO MODEL
: TURBO MODEL
SHIELD AND
SENSOR GROUND
JOINT CONNECTOR
r.
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t
*a
4
la
1I
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\
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-
I
TORQUE
CONVERTER
TURBINE SPEED
SENSOR
TRQ570
AT-62
I
Step Check Yes No

I CHECK TORQUE CONVERTER TURBINE Is the resistance between 450 ;o to step 2. Replace the tur-
SPEED SENSOR. and 650 Q? bine speed sensor.
1)Turn the ignition switch to OFF. <Ref. to AT-36,
2)Disconnect the connector from transmission. Torque Converter
3)Measure the resistance between transmis- Turbine Speed
sion connector receptacle's terminals. Sensor.>
(T4) NO. 14 - NO. 15:
! CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 ;o to step 3. Repair open circuit
TCM AND TRANSMISSION. Q? in harness
1)Disconnectthe connector from TCM. between TCM and
2)Measure the resistance of harness between transmission con-
TCM and transmission connector. nector.
Non-turbo model
(B55) NO. 12 - (Bll)NO. 14:
Turbo model
-
(B55) NO. 8 (Bll)NO. 14:
t CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 $0 to step 4. Repair open circuit
TCM AND TRANSMISSION. Q? in harness
(B55) NO. 21 - (Bll)NO. 15: pling connector.
Turbo model
(B55) NO. 9 - (B11) NO. 15:
I CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 ;o to step 5. Repair short circuit
TCM AND TRANSMISSION. MQ? in harness
TCM and chassis ground. transmission con-
Non-turbo model
Turbo model
I CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 20 to step 6. Repair short circuit
TCM AND TRANSMISSION. MQ? in harness
(B55) No. 12 - Chassis ground: pling connector.
Turbo model
5 PREPARE OSCILLOSCOPE. Do you have an oscilloscope? ;o to step 10. Go to step 7.
7 PREPARE SUBARU SELECT MONITOR. Do you have a Subaru Select o
; to step 9. Go to step 8.
Monitor?
AT-63
Step Check Yes f

8 CHECK INPUT SIGNAL FOR TCM. s the voltage more than AC 1 Even if the AT OIL 20 to stc
1)Connect the connectors to TCM and trans- I? TEMP warning
mission. lights up, the cir-
2)Start the engine and move select lever to “P” cuit has returned
or “N” range. to a normal condi-
3)Measure the voltage between TCM connection at this time. A
tor terminals. temporary poor
Connector & terminal contact of the con-
Non-turbo model nector or harness
(855) NO. 12 (+) - NO. 21 (-): may be the cause.
Turbo model Repair harness or
(855) NO. 8 (+) - NO. 9 (-): connector in the
TCM and trans-
mission.
9 CHECK INPUT SIGNAL FOR TCM USING s the revolution value same as Even if the AT OIL 20 to ste
SUBARU SELECT MONITOR. he tachometer reading shown TEMP warning
1)Connect the connectors to TCM and trans- In the combination meter? lights up, the cir-
mission. cuit has returned
2)Connect the Subaru Select Monitor to data to a normal condi-
link connector. tion at this time. A
3)Turn the ignition switch to ON and turn the temporary poor
r. - Subaru Select Monitor switch to ON. contact of the con-
4)Start the engine. nector or harness
5)Move the select lever to “P” or “N” range. may be the cause.
6)Read the data of turbine speed using Subaru Repair harness or
Select Monitor. connector in the
Compare the tachometer with Subaru Select TCM and trans-
Monitor indications. mission.
10 CHECK INPUT SIGNAL FOR TCM USING s the signal voltage more than Even if the AT OIL 30 to stt
OSCILLOSCOPE. 4c 1 V? TEMP warning
1)Connect the connectors to TCM and trans- lights up, the cir-
mission. cuit has returned
2)Set the oscilloscope to TCM connector ter- to a normal condi-
minals. tion at this time. A
Turbo model temporary poor
Positive probe; (B55) No. 8 contact of the con-
Earth lead; (B55) No. 9 nector or harness
Non-turbo model may be the cause.
Positive probe; (B55) No. 12 Repair harness or
Earth lead; (B55) No. 21 connector in the
3)Start the engine and move the select lever to TCM and trans-
“P” or “N” range. mission.
11 CHECK POOR CONTACT. s there poor contact in torque Repair poor con- z$5EG
:onverter turbine speed sensor tact. :Ref. to
:ircuit? rransmi:
rol Modi
I I TCM).>
AT-64
I
AT-65
G: DTC 38 TORQUE CONTROL SIGNAL

DIAGNOSIS:
The signal circuit is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
I : NON-TURBO MODEL
.TURBO MODEL
I TR0579
1
TCM AND ECM.
Step

2)Disconnect the connectors from TCM and
ECM.
Check
CHECK HARNESSCONNECTOR BETWEEN I Is the resistance less than 1
t
Go to step 2. Repair open circuit
in harness
between TCM and
ECM connector.
Non-turbo model
(854) NO. 21 - (8134) NO. 17:
(854) NO. 13 - (8134) NO. 16:1
Turbo model
(B56) NO. 14 - (8135) NO. 18:
(856) NO. 5 -(8135) NO. 19:
AT-66
I
Step Check Yes No

CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 Go to step 3. 3epair short circuit
TCM AND ECM. An? I harness
TCM connector and chassis ground. ICM connector.
Non-turbo model
Turbo model
CHECK OUTPUT SIGNAL EMITTED FROM s the voltage more than 4.8 V' Even if the AT OIL ;o to step 4.
TCM. TEMP warning
2)Turn the ignition switch to ON (engine OFF). cuit has returned
3)Measure the voltage between TCM connec- to a normal condi-
tor terminals. tion at this time. A
Non-turbo model contact of the con-
(B54) No. 21 (+) - Chassis ground (-): nector or harness
(B54) No. 13 (+) - Chassis ground (-): may be the cause.
Turbo model Repair harness or
(B56) No. 14 (+) - Chassis ground (-): connector in the
(B56) No. 5 (+) - Chassis ground (-): TCM and ECM.
I CHECK POOR CONTACT. s there poor contact in torque Repair poor con- ;o to step 5.
:ontrol signal circuit? tact.
1 CHECK GROUND LINE BETWEEN TRANS- s there any dirt or rust at Remove dirt and ;o to step 6.
MISSION AND BODY. lround line installing point? rust.
Check the installing condition of ground line in
transmission and body.
i CHECK GROUND LINE BETWEEN TRANS- s the tightening torque value Go to step 7. 7ghten to speci-
MISSION AND BODY. vithin specification? ied torque.
Check the installing condition of ground line in
transmission and body.
Tightening torque:
13f3 N.m (1.3i0.3 kgf-m, 9.4i9.2 ft-lb)
, CHECK GROUND LINE INSIDE TRANSMIS- s the tightening torque value Go to step 9. 7ghten to speci-
SION. vithin specification? ied torque.
1)Drain the AT fluid and remove the oil pan.
2)Check the tightening torque value of ground
line installing bolt.
Tightening torque:
T: Bfl N-m (O.BiO.l kgf-m, 5.8i0.7 ft-lb)
I CHECK GROUND CIRCUIT OF ECM. s there any trouble? Repair ground ter- So to step 9.
<Ref. to AT-52, DTC 31 THROTTLE POSITION minal and/or
SENSOR, Diagnostic Procedure with Diagnos, ground circuit of
tic Trouble Code (DTC).> ECM.
1 RECHECK OUTPUT SIGNAL EMITTED s each voltage more than 4.8 Replace the TCM. 3eplace the ECM.
FROM TCM. I? <Ref. to AT-45,
Measure the voltage between TCM connector Transmission Con-
and chassis ground. trol Module
Connector & terminal (TCM).>
Non-turbo model
Turbo model
AT-67
I
H: DTC 45 INTAKE MANIFOLD PRESSURE SIGNAL

DIAGNOSIS:
Input signal circuit of TCM from ECM is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
TR0580
~~
Step Check Yes No

1 CHECK ENGINE GROUND TERMINALSAND Is there any trouble? Repair ground ter- Go to step 2.
GROUND CIRCUIT OF ECM minal and/or
<Ref. to AT-52, DTC 31 THROTTLE POSITION ground circuit of
SENSOR, Diagnostic Procedure with Diagnos- ECM.
2 CHECK HARNESSCONNECTOR BETWEEN Is the resistance less than 1 Go to step 3. Repair open circuit
2)Disconnect the connectors from TCM and
ECM.
(B55)NO. 20 -(8136) NO. 11:
3 CHECK HARNESSCONNECTOR BETWEEN
TCM AND ECM. in harness
TCM connector and chassis ground. ECM connector.
(B55)No. 20 - Chassis ground:
1 PREPARE SUBARU SELECT MONITOR. Do you have a Subaru Select Go to step 6. Go to step 5.
Monitor?
AT-68
Step Check Yes No

CHECK INPUT SIGNAL FOR TCM. s the voltage between 1.2 and Even if the AT OIL 30 to step 7.
1)Connect the connectors to TCM and ECM. i.8 V? TEMP warning
2)Start the engine, and warm-up the transmis- lights up, the cir-
sion until the ATF temperature is above 80°C cuit has returned
(176°F). to a normal condi-
NOTE: tion at this time. A
If ambient temperature is below 0°C (32"F), temporary poor
drive the vehicle until the ATF reaches its oper- contact of the con-
ating temperature. nector or harness
4)Measure the voltage between TCM connec- Repair harness or
tor and chassis ground. connector in the
Connector & terminal TCM and ECM.
CHECK INPUT SIGNAL FOR TCM USING s the value between 1.2 and Even if the AT OIL o ; to step 7.
SUBARU SELECT MONITOR. 1.8 V? TEMP warning
3)Start the engine, and turn the Subaru Select tion at this time. A
monitor switch to ON. temporary poor
4)Warm-up the engine until the engine coolant contact of the con-
temperature is above 80°C (176°F). nector or harness
6)Read the data of intake manifold pressure Repair harness or
signal using Subaru Select Monitor. connector in the
*Display shows the intake manifold pressure TCM and ECM.
signal value sent from ECM.
CHECK POOR CONTACT.
<Ref. to AT-45,
%it? Transmission Con-
trol Module
AT-69
I
I: DTC 71 SHIFT SOLENOID 1

DIAGNOSIS:
Output signal circuit of shift solenoid 1 is open or shorted.
TROUBLE SYMPTOM:
Does not shift.
WIRING DIAGRAM:
TRANSMISSION
TR0581
AT-70
I
Step Check Yes No

CHECK HARNESS CONNECTOR BETWEEN j the resistance less than 1 ;o to step 2. iepair open circuit
TCM AND TRANSMISSION. 1? 1 harness
2)Disconnect the connector from TCM and *ansmissioncon-
transmission. lector.
TCM and shift solenoid 1 connector.
Non-turbo model
(854) NO. 7 - (B 1 1) NO. 1:
Turbo model
(B54) NO.22 - (B1 1) NO. 1:
CHECK HARNESS CONNECTOR BETWEEN 3 the resistance more than 1 ;o to step 3. iepair short circuit
TCM AND TRANSMISSION. An? i harness
TCM connector and chassis ground. ransmission con-
Non-turbo model
Turbo model
b CHECK SHIFT SOLENOID 1. s the resistance between 10 30 to step 4. ;o to step 7.
Measure the resistance between transmission ind 16 Q?
(T4) NO. 1 - NO. 16:
I CHECK OUTPUT SIGNAL EMITTED FROM s the voltage more than 9V? 30 to step 5. ;o to step 6.
TChk
1)Connect the connectors to TCM and trans-
mission.
3)Move the select lever to “ D range.
Non-turbo model
Turbo model
1 CHECK OUTPUT SIGNAL EMIlTED FROM s the voltage less than l V ? Even if the AT OIL 20 to step 6.
TCM. rEMP warning
1)Move the select lever to “ 2 range. ights up, the cir-
2)Measure the voltage between TCM connec- :uit has returned
tor and chassis ground. :o a normal condi-
Connector & terminal :ion at this time. A
Non-turbo model :emporary poor
(854) No. 7 (+) - Chassis ground (-): :ontact of the con.
Turbo model lector or harness
(B54) No. 22 (+) - Chassis ground (-): nay be the cause.
qepair harness or
:ontact in the
TCM.
i CHECK POOR CONTACT. s there poor contact in shift Repair poor con- 3eplace the TCM.
;olenoid 1 circuit? :act. :Ref. to AT-45,
rransmission Con,
rol Module
TCM).>
AT-71
AUTOMATIC TRANSMISSION [DIAGNOSTICSI
Step Check Yes No

r CHECK SHIFT SOLENOID 1 (IN TRANSMIS- s the resistance between 10 Go to step 8. 3eplace the shift
SION). ind 16 Q? ;olenoid 1. <Ref.
1)Remove the transmission connector from o AT-39, Shift
bracket. Solenoids, Duty
2)Lift-up or raise the vehicle and support with Solenoids and ATF
safety stand. remperature Sen-
CAUTION: ior.>
ground.
CAUTION:
Do not drain the automatic transmission flu-
nector from shift solenoid 1.
5)Measure the resistance between shift sole-
noid 1 connector and transmission ground.
Terminal
No. 1 - Transmissionground:
I CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 [Go to step 9. 3epair open circuit
SHIFT SOLENOID 1 AND TRANSMISSION. 2? n harness
.. Measure the resistance of harness between )etween shift sole-
shift solenoid 1 and transmission connector. ioid 1 and trans-
Connector & terminal nission connector.
(AT5) NO. 1 - (T4) NO. 1:
1 CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 Even if the AT OIL 3epair short circuit
SHIFT SOLENOID 1 AND TRANSMISSION. An? TEMP warning iarness between
Measure the resistance of harness between lights up, the cir- ;hift solenoid 1
shift solenoid 1 connector and transmission cuit has returned ind transmission
ground. to a normal condi- :onnector.
Connector & terminal tion at this time. A
(T4) No. 1 - Transmissionground: temporary poor
contact of the con-
nector or harness
may be the cause.
Repair harness or
connector in shift
solenoid 1 and
transmission.
AT-72
r.
AT-73
J: DTC 72 SHIFT SOLENOID 2

DIAGNOSIS:
Output signal circuit of shift solenoid 2 is open or shorted.
TROUBLE SYMPTOM:
Does not shift.
WIRING DIAGRAM:
<
z (D
m v)
I-
TR0582
AT-74
1
~~
Step Check Yes No

CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 ;o to step 2. 3epair open circuit
TCM AND TRANSMISSION. l? n harness
2)Disconnect the connector from TCM and ransmission con-
TCM and shift solenoid 2 connector.
Non-turbo model
(654) NO. 6 - (611) NO. 2:
Turbo model
(B54) NO. 5 - (611) NO. 2:
! CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 30 to step 3. 3epair short circuit
TCM AND TRANSMISSION. VlQ? n harness
TCM connector and chassis ground. ransmission con-
Non-turbo model
Turbo model
1- CHECK SHIFT SOLENOID 2. s the resistance between 10 30 to step 4. 30 to step 6.
Measure the resistance between transmission ind 16 Q?
connector & terminal
(T4) NO.2 - NO. 16:
AT-75
~~
Step Check Yes No

I CHECK OUTPUT SIGNAL EMITTED FROM I Is the voltage less than 1 V? Even if the AT OIL 30 to step 5.
TCM. TEMP warning
1)Connect the connectors to TCM and trans- lights up, the cir-
mission. suit has returned
2)Lift-up or raise the vehicle and support with to a normal condi-
safety stand. tion at this time. A
CAUTION: temporary poor
On AWD models, raise all wheels off :ontact of the con-
ground. lector or harness
3)Start the engine and warm-up the transmis- nay be the cause.
sion until the ATF temperature is above 80°C 3epair harness or
(176°F). :onnector in the
NOTE: TCM and trans-
If the ambient temperature is below 0°C (32°F) nission.
ating temperature.
4)Move the selector lever to “D”, and slowly
increase the vehicle speed to 50 km/h (31
MPH).
NOTE:
wheels may light the ABS warning light, but thi:
indicates no malfunction. When the AT contro
diagnosis is finished, perform the ABS memo0
Mode.>
Non-turbo model
Turbo model
CHECK POOR CONTACT. IS there poor contact in shift 3eoair Door con-
-3.- I----- denlace the TCM
I. . - ~ .
solenoid 2 circuit? act. <Ref. to AT-45,
Transmission Con.
trol Module
(TCM).>
CHECK SHIFT SOLENOID 2 (IN TRANSMIS- Is the resistance between 10 $0to step 7. Replace the shift
SION). and 16 !2? solenoid 2 assem-
1)Remove the transmission connector from bly. <Ref. to AT-39
bracket. Shift Solenoids,
2)Drain the automatic transmission fluid. Duty Solenoids
CAUTION: and ATF Tempera-
Do not drain the automatic transmission flu- ture Sensor.>
nector from shift solenoid 2.
4)Measure the resistance between shift sole-
noid 2 connector and transmission ground.
CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1
SHIFT SOLENOID 2 AND TRANSMISSION. R? in harness
Measure the resistance of harness between between shift sole.
shift solenoid 2 and transmission connector. noid 2 and trans-
Connector & terminal mission connector,
(AT6) NO. 1 - (T4) NO.2:
AT-76
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) I
Step Check Yes

I CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 Even if the AT OIL
SHIFT SOLENOID 2 AND TRANSMISSION. An? TEMP warning harness between
Measure the resistance of harness between lights up, the cir- shift solenoid 2
shift solenoid 2 connector and transmission cuit has returned and transmission
ground. to a normal condi- connector.
i tion at this time. A
(T4) No. 2 - Transmissionground: temporary poor
contact of the con-
nector or harness
may be the cause.
Repair harness or
connector in shift
solenoid 2 and
transmission.
-. .
AT-77
K: DTC 73 LOW CLUTCH TIMING SOLENOID

DIAGNOSIS:
Output signal circuit of low clutch timing solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
TCM
I
LOW CLUTCH
TIMING
SOLENOID
TRANSMISSION
AT-78
~
Step Check Yes No

CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 o
; to step 2. 3epair open circuit
TCM AND TRANSMISSION. 2? n harness
1)Turn the ignition switch to OFF ietween TCM and
2)Disconnect the connector from TCM and .ransmissioncon-
Non-turbo model
(954) NO. 14 - (91 1) NO. 3:
Turbo model
(954) NO. 15 - (91 1) NO. 3:
CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 30 to step 3. 3epair short circuit
TCM AND TRANSMISSION. MR? n harness
Measure the resistance of harness between 3etween TCM and
TCM connector and transmission ground. transmission con-
Non-turbo model
Turbo model
CHECK LOW CLUTCH TIMING SOLENOID. Is the resistance between 10 30 to step 4. Go to step 7.
Measure the resistance between transmission and 16 R?
(T4) NO. 3 - NO. 16:
CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage more than 9V? 30 to step 5. Go to step 6.
TCM.
mission.
3)Move the select lever to “ D range.
Non-turbo model
Turbo model
CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage less than 1V? Even if the AT OIL Go to step 6.
TCM. TEMP warning
1)Move the select lever to “ 2 range. lights up, the cir-
2)Measure the voltage between TCM connec- cuit has returned
tor and chassis ground. to a normal condi-
Connector & terminal tion at this time. A
Non-turbo model temporary poor
(954) No. 14 (+) - Chassis ground (-): contact of the con-
Turbo model nector or harness
(954) No. 15 (+) - Chassis ground (-): may be the cause.
Repair harness or
contact in the TCM
and transmission.
1 CHECK POOR CONTACT. Is there poor contact in low Repair poor con- Replace the TCM.
clutch timing solenoid circuit? tact. <Ref. to AT-45,
Transmission Con
trol Module
(TCM).>
AT-79
Step Check Yes No

r CHECK LOW CLUTCH TIMING SOLENOID s the resistance between 10 i o to step 8. 3eplace the low
(IN TRANSMISSION). md 16 R? :lutch timing sole-
1)Remove the transmission connector from ioid. <Ref. to AT-
bracket. 39,Shift Sole-
2)Lift-up or raise the vehicle and support with ioids, Duty Sole-
safety stands. ioids and ATF
CAUTION: remperature Sen-
On AWD models, raise all wheels off ior.>
ground.
CAUTION:
Do not drain the automatic transmission flu-
nector from low clutch timing solenoid.
5)Measure the resistance between low clutch
timing solenoid connector and transmission
ground.
Terminal
No. 1 - Transmission ground:
I CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 i o to step 9. 3epair open circuit
LOW CLUTCH TIMING SOLENOID AND 2? n harness
TRANSMISSION. )etween low clutch
Measure the resistance of harness between iming solenoid
low clutch timing solenoid and transmission md transmission
connector. :onnector.
(ATS) NO. 7 - (T4) NO. 3:
1 CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 hen if the AT OIL 3epair short circuit
LOW CLUTCH TIMING SOLENOID AND dR? -EMP warning iarness between
TRANSMISSION. ghts up, the cir- OW clutch timing
Measure the resistance of harness between :uit has returned ;olenoid and
low clutch timing solenoid connector and trans- 3 a normal condi- ransmission con-
mission ground. ion at this time. A lector.
Connector & terminal smporary poor
(T4) No. 3 - Transmission ground: :ontact of the con-
iector or harness
nay be the cause.
lepair harness or
:onnector in low
:lutchtiming sole-
ioid and transmis-
,ion.
AT-80
r.
AT-81
L: DTC 74 2-4 BRAKE TIMING SOLENOID

DIAGNOSIS:
Output signal circuit of 2-4 brake timing solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
I
2-4 BRAKE
TIMING
SOLENOID
TRANSMISSION
TR0584
AT-82
I
Step Check
CHECK HARNESSCONNECTOR BETWEEN Is the resistance less than 1 ) to step 2.
in harness
between TCM and
transmission con-
2)Disconnect the connector from TCM and
nector.
transmission.
Non-turbo model
(B54) NO. 5- (B11) NO. 4:
Turbo model
(854) NO. 16 - (81I ) NO. 4:
CHECK HARNESSCONNECTOR BETWEEN Is the resistance more than 1
MQ? in harness
TCM AND TRANSMISSION.
between TCM and
+---
transmission con-
TCM connector and transmission ground.
nector.
Non-turbo model
Turbo model
Is the resistance between 10 o to step 4. Go to step 7.
CHECK 2-4 BRAKE TIMING SOLENOID.
Measure the resistance between transmission and 16 Q?
CHECK OUTPUT SIGNAL EMllTED FROM 1 Is the voltage less than 1 V?

TCM.
mission.
2)Lift-up or raise the vehicle and support with
safety stands.
CAUTION:
ground.
3)Start the engine and warm-up the transmis-
sion until the ATF temperature is above 80°C
(176°F).
NOTE:
If the ambient temperature is below 0°C (32°F)
drive the vehicle until the ATF reaches its oper,
ating temperature.
4)Move the select lever to “l”,and slowly
increase vehicle speed to 10 km/h (6 MPH).
NOTE:
The speed difference between front and rea
wheels may light the ABS warning light, but thi!
indicates no malfunction. When the AT contrc
diagnosis is finished, perform the ABS memo?
clearance procedure of on-board diagnostic!
system. <Ref. to ABS-22, Clear Memor
Mode.>
Non-turbo model
Turbo model
AT-83
Step Check Yes No

1 CHECK OUTPUT SIGNAL EMITTED FROM I Is the voltage more than 9 V? Zven if the AT OIL 30 to step 6.
TCM. rEMP warning
1)Move the select lever to “D”, and slowly ights up, the cir-
increase vehicle speed to 65 km/h (40 MPH). :uit has returned
NOTE: o a normal condi-
The speed difference between front and rear ion at this time. A
wheels may light the ABS warning light, but this emporary poor
indicates no malfunction. When the AT control :ontact of the con-
diagnosis is finished, perform the ABS memory lector or harness
clearance procedure of on-board diagnostics nay be the cause.
system. <Ref. to ABS-22, Clear Memory qepair harness or
Mode.> :ontact in the
2)Measure the voltage between TCM connec- ransmission.
Non-turbo model
Turbo model
I CHECK POOR CONTACT. Is there poor contact in 2-4 3epair poor con- Replace the TCM.
brake timing solenoid circuit? act. <Ref. to AT-45,
Transmission Con.
trol Module
(TCM).>
I
CHECK 2-4 BRAKE TIMING SOLENOID (IN I Is the resistance between 10 30 to step 8. Replace the 2-4
TRANSMISSION). and 16 R? brake timing sole-
1)Remove the transmission connector from noid. <Ref. to AT-
‘20 ChiH Crrln.
bracket.
2)Lift-up or raise the vehicle and support with noids, Duty Sole-
safety stands. noids and ATF
CAUTION: Temperature Sen-
On AWD models, raise all wheels off sor.>
ground.
3)Drain the automatic transmission fluid. I
CAUTION:
Do not drain the automatic transmission flu,
4)Remove the oil pan,.and disconnect the con-
nector from 2-4 brake timing solenoid.
5)Measure the resistance between 2-4 brake
timing solenoid connector and transmission
ground.
Terminal
I CHECK HARNESSCONNECTOR BETWEEN Is the resistance less than 1 30 to step 9. Repair open circuit
2-4 BRAKE TIMING SOLENOID AND R? in harness
TRANSMISSION. between 2-4 brake
Measure the resistance of harness between 2- timing solenoid
4 brake timing solenoid and transmission con- and transmission
nector. connector.
(AT8) NO. 1 - (T4) NO. 4:
AT-84
Step Check Yes No

9 CHECK HARNESSCONNECTOR BETWEEN Is the resistance more than 1 Even if the AT OIL Repair short circuit
2-4 BRAKE TIMING SOLENOID AND MR? TEMP warning harness between
TRANSMISSION. lights up, the cir- 2-4 brake timing
Measure the resistance of harness between 2- cuit has returned solenoid and
4 brake timing solenoid connector and trans- to a normal condi- transmission con-
mission ground. tion at this time. A nector.
(T4) No. 4 - Transmissionground: contact of the con-
nector or harness
may be the cause.
Repair harness or
connector in 2-4
brake timing sole-
noid and transmis-
sion.
AT-85
I
M: DTC 75 LINE PRESSURE DUTY SOLENOID

DIAGNOSIS:
Output signal circuit of line pressure duty solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
: NON-TURBO MODEL
U
DROPPING
RESISTOR
Ir""lB L
TRANSMISSION
TR0585
Step Check Yes No

I CHECK VEHICLE. - I
Go to step 7.
! CHECK RESISTOR. s the resistance between 9 I Go to step 3. Replace the drop-
1)Turn the ignition switch to OFF. ping resistor. <Ref.
resistor. Resistor.>
resistor terminal.
Terminals
NO. 1 -NO. 2:
AT-86
Step Check Yes No

3 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 i o to step 4. Repair open circuit
TCM AND DROPPING RESISTOR. n? in harness
2)Measure the resistance of harness between dropping resistor
TCM connector and dropping resistor connec- connector.
tor.
(B54) NO. 18 - (84) NO. 1:
4 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 ;o to step 5. Repair short circuit
TCM AND DROPPING RESISTOR. MR? in harness
dropping resistor connector and chassis dropping resistor
ground. connector.
5 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 ;o to step 6. Repair open circuit
TRANSMISSION AND DROPPING RESIS- Q? in harness
TOR. between dropping
1 )Disconnect the connector from transmission. resistor and trans-
2)Measure the resistance of harness between mission connector.
transmission and dropping resistor connector.
(B4) NO. 2 - ( B l l ) NO. 5:
6 CHECK HARNESSCONNECTOR BETWEEN Is the resistance more than 1 ;o to step 7. Repair short circuit
TRANSMISSION AND DROPPING RESIS- MQ? in harness
Measure the resistance of harness between resistor and trans-
dropping resistor connector and chassis mission connector.
I
ground.
7 CHECK HARNESSCONNECTOR BETWEEN Is the resistance less than 1 i o to step 8. Repair open circuit
TCM AND TRANSMISSION. n? in harness
and TCM. nector.
-
(B54) NO. 9 (B1 1) NO. 5:
8 CHECK HARNESSCONNECTOR BETWEEN Is the resistance more than 1 ;o to step 9. Repair short circuit
TCM AND CHASSIS GROUND. MR? in harness
9 CHECK LINE PRESSURE DUTY SOLENOID. Is the resistance between 2.0 20 to step 10. Go to step 16.
Measure the resistance between transmission and 4.5 R?
connector receptacle's terminals.
Terminal
(T4) NO. 5 - NO. 16:
10 PREPARE SUBARU SELECT MONITOR. Do you have a Subaru Select ;o to step 13. Go to step 11.
Monitor?
AT-87
Step Check Yes No

1 CHECK OUTPUT SIGNAL EMITTED FROM s the voltage between 1.5 and Go to step 12. ;o to step 15.
TCM.
(176°F).
NOTE:
If the ambient temperature is below 0°C (32°F:
drive the vehicle until the ATF reaches its ope1
ating temperature.
4)Move the select lever to “N”.
-
2 CHECK OUTPUT SIGNAL EMITTED FROM s the voltage less than 1 V Even if the AT OIL ;o to step 15.
TCM. iith throttle fully open? TEMP warning
Measure the voltage between TCM connector lights up, the cir-
and chassis ground. cuit has returned
Connector & terminal to a normal condi-
.. ~
(B54) No. 9 (+) - Chassis ground (-): tion at this time. A
temporary poor
contact of the con-
nector or harness
may be the cause.
Repair harness or
connector in trans-
mission.
3 CHECK OUTPUT SIGNAL EMITTED FROM j the value 1OO%? Go to step 14. io to step 15.
TCM USING SUBARU SELECT MONITOR.
mission.
link connector.
3)Start the engine, and turn the Subaru Select
Monitor switch to ON.
4)Warm-up the transmission until the ATF tem.
perature is above 80°C (176°F).
NOTE:
ating temperature.
5)Stop the engine and turn the ignition switch
to ON (engine OFF).
6)Move the select lever to “N”.
7)Read the data of line pressure duty solenoid
*Line pressure duty solenoid is indicated in
“o/o”,
1)Throttle is fully closed.
AT-88
I
Step Check Yes No

4 CHECK OUTPUT SIGNAL EMITTED FROM s the value less than 25%? lven if the AT OIL ;o to step 15.
TCM USING SUBARU SELECT MONITOR. 'EMP warning
1)Turnthe ignition switch to ON (Engine OFF). ghts up, the cir-
2)Throttle is fully open. uit has returned
3 a normal condi-
on at this time. A
zmporary poor
ontact of the con-
lector or harness
lay be the cause.
iepair harness or
onnector in trans-
nission.
5 CHECK POOR CONTACT. s there poor contact in line Iepair poor con- 3eplace the TCM.
)ressure duty solenoid circuit? act. :Ref. to AT-45,
rransmissionCon-
rol Module
TCM).>
6 CHECK LINE PRESSURE DUTY SOLENOID s the resistance between 2.0 io to step 17. 3eplace the line
(IN TRANSMISSION). ind 4.5 Q? )ressure duty
1)Remove the transmission connector from ;olenoid. <Ref. to
bracket. 4T-39, Shift Sole-
2)Drain the automatic transmission fluid. ioids, Duty Sole-
CAUTION: \aids and ATF
Do not drain the automatic transmission flu- Temperature Sen-
id until it cools down. ;or.>
nector from line pressure duty solenoid.
4)Measure the resistance between line pres-
sure duty solenoid connector and transmission
ground.
Terminal
17 CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 ;o to step 18. 3epair open circuit
TRANSMISSION AND LINE PRESSURE a? n harness
DUTY SOLENOID. )etween line pres-
Measure the resistance of harness between jure duty solenoid
line pressure duty solenoid and transmission md transmission
(T4) NO. 5 - (AT2) NO. 1:
18 CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 iven if the AT OIL 3epair short circuit
TRANSMISSION AND LINE PRESSURE dQ? -EMP warning n harness
DUTY SOLENOID. ghts up, the cir- jetween line pres-
Measure the resistance of harness between :uit has returned ;ure duty solenoid
transmission connector and transmission D a normal condi- ind transmission
ground. ion at this time. A :onnector.
Connector & terminal emporary poor
(T4) No. 5 - Transmissionground: :ontact of the con-
lector or harness
nay be the cause.
3epair harness or
:onnector in line
)ressure duty
;olenoid and
ransmission.
AT-89
N: DTC 76 2-4 BRAKE DUTY SOLENOID

DIAGNOSIS:
Output signal circuit of 2-4 brake duty solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
$ m
I-
m a
2
Ey*-
_.
SOLENOID
~
TI30586
Step Check Yes No

1 CHECK VEHICLE. Is the target non-turbo model? Go to step 2. Go to step 7.
2 CHECK RESISTOR. Is the resistance between 9 Go to step 3. Replace the drop-
1)Turnthe ignition switch to OFF. and 15 Q? ping resistor. <Ref.
resistor. Resistor.>
resistor terminal.
Terminals
NO. 3 - NO. 4:
AT-90
I
~~~ ~~
Step Check Yes No

CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 Go to step 4. Repair open circuit
TCM AND DROPPING RESISTOR. 2? in harness
2)Measure the resistance of harness between dropping resistor
TCM connector and dropping resistor connec- connector.
tor.
(B54) NO. 17 - (B4) NO. 3:
CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 Go to step 5. Repair short circuit
TCM AND DROPPING RESISTOR. VlQ? in harness
dropping resistor connector and chassis dropping resistor
ground. connector.
CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 Go to step 6. Repair open circuit
TRANSMISSION AND DROPPING RESIS- n? in harness
1)Disconnect the connector from transmission. resistor and trans-
2)Measure the resistance of harness between mission connector.
transmission and dropping resistor connector.
(B4) NO. 4 - ( B l l ) NO. 9:
CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 Go to step 7. Repair short circuit
TRANSMISSION AND DROPPING RESIS- Ua? in harness
Measure the resistance of harness between resistor and trans-
dropping resistor connector and chassis mission connector.
ground.
CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 Go to step 8. Repair open circuit
TCM AND TRANSMISSION. n? in harness
1)Turnthe ignition switch to OFF. between TCM and
and TCM. nector.
Non-turbo model
(B54) NO. 8 - ( B l l ) NO. 9:
Turbo model
(B54) NO. 18 - ( B l l ) NO. 9:
CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 Go to step 9. Repair short circuii
TCM AND CHASSIS GROUND. Ma? in harness
Non-turbo model
Turbo model
CHECK 2-4 BRAKE DUTY SOLENOID. Is the resistance between 2.0 Go to step 10. Go to step 16.
Measure the resistance between transmission and 4.5 R?
Terminal
(T4) NO. 16 - NO. 9:
I PREPARE SUBARU SELECT MONITOR. Do you have a Subaru Select Go to step 13. Go to step 11.
Monitor?
AT-9 1
~~
Step Check Yes No

1 CHECK OUTPUT SIGNAL EMITTED FROM ;the voltage between 1.5 and 30 to step 12. i o to step 15.
TCM. i.0 V with throttle fully closed?
(176°F).
NOTE:
If the ambient temperature is below 0°C (32"F),
drive the vehicle until the ATF reaches its oper-
ating temperature.
4)Move the select lever to "N".
Non-turbo model
(B54) No. 8 (+) - Chassis groundI)-(
Turbo model
2 CHECK OUTPUT SIGNAL EMITTED FROM s the voltage less than 1 V Even if the AT OIL io to step 15.
TCM. with throttle fully open? rEMP warning
._ Measure the voltage between TCM connector ights up, the cir-
(B54) No. 8 (+) - Chassis ground (-): emporary poor
Non-turbo model :ontact of the con-
(B54) No. 18 (+) - Chassis ground (-): lector or harness
nay be the cause.
3epair harness or
:onnector in TCM
2nd transmission.
3 CHECK OUTPUT SIGNAL EMIlTED FROM s the value 1OO%? 30 to step 14. ;o to step 15.
link connector.
4)Warm-up the transmission until the ATF tem-
perature is above 80°C (176°F).
NOTE:
If the ambient temperature is below 0°C (32"F),
drive the vehicle until the ATF reaches its oper-
ating temperature.
5)Stop the engine and turn the ignition switch
to ON (engine OFF).
6)Move the select lever to "N".
7)Read the data of 2-4 brake duty solenoid
*2-4 brake duty solenoid is indicated in "%".
AT-92
I
Step- Check Yes No
5 CHECK POOR CONTACT. Is there poor contact in 2-4 3epair poor con- Heplace the TCM.
brake duty solenoid circuit? act. <Ref. to AT-45,
Transmission Con-
trol Module
(TCM).>
6 CHECK 2-4 BRAKE DUTY SOLENOID (IN Is the resistance between 2.0 30 to step 17. Replace the 2-4
TRANSMISSION). and 4.5 R? brake duty sole-
1)Remove the transmission connector from noid. <Ref. to AT-
bracket. 39, Shift Sole-
2)Drain the automatic transmission fluid. . noids, Duty Sole-
CAUTION: noids and ATF
Do not drain the automatic transmission flu- Temperature Sen-
id until it cools down. sor.>
3)Remove the oil pan, and disconnect the con.
nector from 2-4 brake duty solenoid.
4)Measure the resistance between 2-4 brake
duty solenoid connector and transmission
ground.
Terminal
7 CHECK HARNESS CONNECTOR BETWEEN IS the resistance less than 1 30 to step 18. Repair open circuil
TRANSMISSION AND 2-4 BRAKE DUTY SO- Q? in harness
LENOID. between 2-4 brake
Measure the resistance of harness between 2- duty solenoid and
4 brake duty solenoid and transmission con- transmission con-
nector. nector.
(T4) NO. 9 - (AT7) NO. 1:
8 CHECK HARNESSCONNECTOR BETWEEN Is the resistance more than 1 Even if the AT OIL Repair short circuil
TRANSMISSION AND 2-4 BRAKE DUTY SO- MQ? rEMP warning in harness
LENOID. ights up, the cir- between 2-4 brake
Measure the resistance of harness between :uit has returned duty solenoid and
transmission connector and transmission o a normal condi- transmission con-
ground. ion at this time. A nector.
(T4) No. 9 - Transmissionground: :ontact of the con-
lector or harness
nay be the cause.
3epair harness or
:onnector in line
3ressure duty
solenoid and
ransmission.
AT-93
0:DTC 77 LOCK-UP DUTY SOLENOID

DIAGNOSIS:
Output signal circuit of lock-up duty solenoid is open or shorted.
TROUBLE SYMPTOM:
No “lock-up” (after engine warm-up).
WIRING DIAGRAM:
@ TCM
TRANSMISSION
TR0587
AT-94
I
Step Check Yes No

I CHECK DTC. l o multiple trouble codes So to another trou- Go to step 2.
ippear in the on-board diag- )le code.
iostics test mode?
! CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 o
; to step 3. Repair open circui
TCM AND TRANSMISSION. 2? in harness
1)Turn the ignition switch to OFF. between TCM anc
Non-turbo model
(654) NO. 16 - (61 1) NO. 13:
Turbo model
(654) NO. 7 - (61 1) NO. 13:
i CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 ;o to step 4. Repair short circui
TCM AND TRANSMISSION. fin? in harness
Measure the resistance of harness connector between TCM anc
between TCM and chassis ground. transmission con-
Non-turbo model
Turbo model
I CHECK LOCK-UP DUTY SOLENOID. s the resistance between 10 ;o to step 5. Go to step 11.
Measure the resistance between transmission 2nd 17 Q?
(T4) NO. 13 - NO. 16:
) PREPARE SUBARU SELECT MONITOR. l o you have a Subaru Select ;o to step 8. Go to step 6.
donitor?
AT-95
I
Step Check Yes

, CHECK OUTPUT SIGNAL EMITTED FROM j the voltage more than 8.5 V? 30 to step 7.
TCM.
mission.
CAUTION:
ground.
(176°F).
NOTE:
drive the vehicle until the ATF reaches its oper.
ating temperature.
4)Move the select lever to “D” and slowly
MPH). Wheels will lock-up.
NOTE:
.. wheels may light the ABS warning light, but thiz
diagnosis is finished, perform the ABS memoq
clearance procedure of on-board diagnostic:
system. <Ref. to ABS-22, Clear Memoq
Mode.>
Non-turbo model
(B54)No. 16 (+) - Chassis ground (-):
Turbo model
CHECK OUTPUT SIGNAL EMITTED FROM s the voltage less than 0.5 V? :veri if the AT OIL
TCM. rEMP warning
1)Return the engine to idling speed and move ights up, the cir-
the select lever to “N”. :uit has returned
2)Measure the voltage between TCM connec- o a normal condi-
tor and chassis ground. ion at this time. A
Non-turbo model :ontact of the con-
(854)No. 16 (+) - Chassis ground (-): lector or harness
Turbo model nay be the cause.
(B54)No. 7 (+) - Chassis ground (-): 3epair harness or
:onnector in TCM
and transmission.
AT-96
I
Step Check Yes No

CHECK OUTPUT SIGNAL EMllTED FROM Is the value 95%? 30 to step 9. 30 to step 10.
mission.
CAUTION:
ground.
link connector.
(176°F).
NOTE:
drive the vehicle until the ATF reaches its oper.
ating temperature.
6)Read the data of lock-up duty solenoid using
Subaru Select Monitor.
*Lock-up duty solenoid is indicated in “Yo”.
1)Move the select lever to “ D and slowly
MPH). Wheels will lock-up.
NOTE:
diagnosis is finished, perform the ABS memor)
system. <Ref. to ABS-22, Clear Memor),
Mode.>
CHECK OUTPUT SIGNAL EMllTED FROM Is the value 5%? Even if the AT OIL 30 to step 10.
TCM USING SUBARU SELECT MONITOR. TEMP warning
Return the engine to idling speed and move lights up, the cir-
the select lever to “N”. cuit has returned
NOTE: to a normal condi-
The speed difference between front and real tion at this time. A
wheels may light the ABS warning light, but this temporary poor
indicates no malfunction. When AT control di- contact of the con-
agnosis is finished, perform the ABS memor) nector or harness
clearance procedure of on-board diagnostics may be the cause.
system. <Ref. to ABS-22, Clear Memor) Repair harness or
Mode.> connector in TCM
and transmission.
CHECK POOR CONTACT. Is there poor contact in lock-up Repair poor con- 3eplace the TCM.
duty solenoid circuit? tact. :Ref. to AT-45,
rransmission Con-
rol Module
I I
TCM).>
AT-97
I
Step No
CHECK LOCK-UP DUTY SOLENOID (IN Replace the lock-
TRANSMISSION). ind 17 R? up duty solenoid.
1)Remove the transmission connector from <Ref. to AT-39,
bracket. Shift Solenoids,
2)Drain the automatic transmission fluid. Duty Solenoids
CAUTION: and ATF Tempera-
Do not drain the automatic transmission flu- ture Sensor.>
nector from lock-up duty solenoid.
4)Measure the resistance between lock-up
ground.
Terminal
CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 IGo to step 13. Repair open circuit
LOCK-UP DUTY SOLENOID AND TRANS- 2? in harness
MISSION. between TCM and
Measure the resistance of harness between transmission con-
lock-up duty solenoid and transmission connector.
nector.
(T4) NO. 13 - (AT3) NO. 1:
CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 Even if the AT OIL Repair short circuit
LOCK-UP DUTY SOLENOID AND TRANS- dR? TEMP warning in harness
MISSION. lights up, the cir- between lock-up
Measure the resistance of harness between cuit has returned duty solenoid and
transmission connector and transmission to a normal condi- transmission con-
ground. tion at this time. A nector.
(T4) No. 13 - Transmission ground: contact of the con.
nector or harness
may be the cause.
Repair harness or
connector in lock-
up duty solenoid
and transmission.
AT-98
r- .
AT-99
P: DTC 79 TRANSFER DUTY SOLENOID

DIAGNOSIS:
Output signal circuit of transfer duty solenoid is open or shorted.
TROUBLE SYMPTOM:
Excessive “braking” in tight corners.
WIRING DIAGRAM:
@ TCM
I -
-
TRANSMISSION
TR0588
AT-I 00
I
Step Check Yes No

1 CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 i o to step 2. 3epair open circuit
TCM AND TRANSMISSION. 2? n harness
1)Turn the ignition switch to OFF. setween TCM and
2)Disconnect the connector from TCM and [ransmissioncon-
Non-turbo model
-
(B54) NO. 15 (Bl 1) NO. 6:
Turbo model
(B54) NO. 6 - (811) NO. 6:
2 CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 i o to step 3. Repair short circuii
TCM AND TRANSMISSION. An? in harness
Measure the resistance harness connector between TCM and
between TCM and chassis ground. transmission con-
Non-turbo model
-
Turbo model
.3 CHECK TRANSFER DUTY SOLENOID. s the resistance between 10 ;o to step 4. Go to step 13.
Measure the resistance between transmission ind 17 R?
connector and transmission terminals.
(T4) NO. 6- NO. 16:
4 PREPARE SUBARU SELECT MONITOR. 10 you have a Subaru Select ;o to step 7 . Go to step 5.
A o nito r?
CHECK OUTPUT SIGNAL EMITTED FROM s the voltage less than 1 V in ;o to step 6. Go to step 12.
TCM. P” range?
mission.
Non-turbo model
Turbo model
CHECK OUTPUT SIGNAL EMITTED FROM s the voltage between 5 and 7 iven if the AT OIL Go to step 12.
TCM. J in “D” range? -EMP warning
Measure the voltage between TCM connector ights up, the cir-
(854) No. 15 (+) - Chassis ground (-): emporary poor
Turbo model :ontact of the con.
(854) No. 6 (+) - Chassis ground (-): rector or harness
nay be the cause.
Iepair harness or
:onnector in the
TCM and trans-
nission.
7 CHECK VEHICLE s the taraet non-turbo model S o
; to step 8. Go to step 10.
AT-I 01
Step Check Yes No

CHECK OUTPUT SIGNAL EMITTED FROM s the value between 5 and Go to step 9. 30 to step 12.
TCM USING SUBARU SELECT MONITOR. I O%?
mission.
link connector.
3)Turn the ignition switch to ON (engine OFF)
and turn the Subaru Select Monitor switch to
ON.
4)Move the select lever to “D” with throttle fully
open (vehicle speed 0 km/h or 0 MPH).
5)Read the data of transfer duty solenoid using
*Transfer duty solenoid is indicated in “ O h ” .
CHECK OUTPUT SIGNAL EMITTED FROM s the value between approx. Even if the AT OIL 30 to step 12.
TCM USING SUBARU SELECT MONITOR. SO% and approx. 70%? TEMP warning
1)Move the select lever to “D” with throttle fully lights up, the cir-
closed (vehicle speed 0 km/h or 0 MPH). cuit has returned
2)Rear the data of transfer duty solenoid using to a normal condi-
Subaru Select Monitor. tion at this time. A
*Transfer duty solenoid is indicated in “%”. temporary poor
contact of the con-
nector or harness
may be the cause.
Repair harness or
connector in the
TCM and trans-
mission.
I CHECK OUTPUT SIGNAL EMITTED FROM s the value between 80 and Go to step 11. 30 to step 12.
TCM USING SUBARU SELECT MONITOR. )5%?
1)Connect connectors to TCM and transmis-
sion.
2)Connect Subaru Select Monitor to data link
connector.
3)Turn ignition switch to ON (engine OFF) and
turn Subaru Select Monitor switch to ON.
4)Move select lever to “ D with throttle fully
open (vehicle speed 0 km/h or 0 MPH).
5)Read data of transfer duty solenoid using
*Transfer duty solenoid is indicated in ‘Yo”.
CHECK OUTPUT SIGNAL EMllTED FROM s the value approx. 40%? Even if the AT OIL 30 to step 12.
TCM USING SUBARU SELECT MONITOR. TEMP warning
1)Move select lever to “N” with throttle fully lights up, the cir-
close (vehicle speed 0 km/h or 0 MPH). cuit has returned
2)Rear data of transfer duty solenoid using to a normal condi-
Subaru Select Monitor. tion at this time. A
*Transfer duty solenoid is indicated in “Yo”. temporary poor
contact of the con-
nector or harness
may be the cause.
Repair harness or
connector in the
transfer duty sole-
noid and TCM
connector.
AT-I 02
Step Check Yes No

2 CHECK POOR CONTACT. Is there poor contact in transfer lepair poor con- 3eplace the TCM.
duty solenoid circuit? act. :Ref. to AT-45,
rransmission Con-
rol Module
'TCM).r
3 CHECK TRANSFER DUTY SOLENOID (IN Is the resistance between 10 ;o to step 14. 3eplace the trans-
TRANSMISSION). and 17 Q? er duty solenoid.
CAUTION:
ground.
CAUTION:
Do not drain the automatic transmission flu.
3)Remove the extension case, and disconnect
the connector from transfer duty solenoid.
4)Measure the resistance between transfer
ground.
(AT4) No. 1 - Transmissionground:
4 CHECK HARNESS CONNECTOR BETWEEN IS the resistance less than 1 o; to step 15. 3epair open circuit
TRANSFER DUTY SOLENOID AND TRANS- Q? n harness
MISSION. ietween transfer
Measure the resistance of harness between juty solenoid and
transfer duty solenoid and transmission con- ransmission con-
nector. lector.
(T4) NO. 6 - (AT4) NO. 1:
5 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 %en if the AT OIL 3epair short circuit
TRANSFER DUTY SOLENOID AND TRANS- MQ? rEMP warning n harness
MISSION. ights up, the cir- ietween transfer
Measure the resistance of harness between :uit has returned luty solenoid and
transmission connector and transmission o a normal condi- ransmission con-
ground. ion at this time. A lector.
(T4) No. 6 - Transmissionground: :ontact of the con,
lector or harness
nay be the cause.
3epair harness or
:ontact in the
ransfer duty sole-
ioid and transmis.
;ion.
AT-I 03
I
Q: DTC 93 REAR VEHICLE SPEED SENSOR

DIAGNOSIS:
Input signal circuit of TCM is open or shorted.
TROUBLE SYMPTOM:
No lock-up or excessive tight corner “braking”
WIRING DIAGRAM:
: NON-TURBO MODEL
: TURBO MODEL
REAR VEHICLE
SPEED SENSOR
TR0589
AT-I 04
Step Check Yes No

CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 20 to step 2. Repair open circuit
Non-turbo model
(B55)NO. 3 - (B11)NO. 19:
Turbo model
(B55)NO.24 - (B11)NO. 19:
CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 o
; to step 3. Repair open circuit
TCM and transmission connector. transmission, and
Connector & terminal poor contact in
Non-turbo model coupling connec-
(B55)NO.21 - (B11)NO.20: tor.
Turbo model
(B54)NO. 19 - ( 6 1 1) NO. 20:
CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 30 to step 4. Repair short circuit
TCM AND TRANSMISSION. Uln? in harness
Non-turbo model
Turbo model
(655)No. 24 - Chassis ground:
CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 30 to step 5. Repair short circuit
TCM AND TRANSMISSION. wn? in harness
Non-turbo model
Turbo model
CHECK REAR VEHICLE SPEED SENSOR. s the resistance between 450 30 to step 6. Replace the rear
Measure the resistance between transmission and 650 Q? vehicle speed sen.
connector receptacle'sterminals. sor. <Ref. to AT-
Connector & terminal 35, Rear Vehicle
(T4) NO. 19 - NO.20: Speed Sensor.>
PREPARE OSCILLOSCOPE. l o you have an oscilloscope? 30 to step 10. Go to step 7.
PREPARE SUBARU SELECT MONITOR. 30 you have a Subaru Select 30 to step 9. Go to step 8.
Monitor?
AT-I 05
Step Check Yes No

CHECK INPUT SIGNAL FOR TCM. s the voltage more than AC 1 Even if the AT OIL 30 to step 11.
1)Connect the connectors to TCM and trans- /? TEMP warning
mission. ights up, the cir-
2)Lift-up or raise the vehicle and place safety :uit has returned
stands. :o a normal condi-
CAUTION: :ion at this time. A
On AWD models, raise all wheels off floor. :emporary poor
3)Start the engine and set vehicle in 20 km/h :ontact of the con-
(12 MPH) condition. lector or harness
NOTE: nay be the cause.
The speed difference between front and rea 3epair harness or
wheels may light the ABS warning light, but thi: :onnector in the
indicates no malfunction. When the AT contro TCM and trans-
diagnosis is finished, perform the ABS memor) nission.
clearance procedure of on-board diagnostic5
Mode.>
tor terminals.
Non-turbo model
(655) NO. 3 (+) - (654) NO. 21 (-):
Turbo model
(655) NO.24 (+) - (654) NO. 19 (-):
CHECK INPUT SIGNAL FOR TCM USING )oes the speedometer indica- Even if the AT OIL i o to step 11.
SUBARU SELECT MONITOR. on increase as the Subaru rEMP warning
1)Connect the connectors to TCM and trans- ielect Monitor data increases? ights up, the cir-
mission. :uit has returned
2)Connect the Subaru Select Monitor to data o a normal condi-
link connector. ion at this time. A
3)Lift-up or raise the vehicle and place safety emporary poor
stands. :ontact of the con-
CAUTION: lector or harness
Raise all wheels off floor. nay be the cause.
4)Turn the ignition switch to ON and turn the 3epair harness or
Subaru Select Monitor switch to ON. :onnector in the
5)Start the engine. T M and trans-
6)Read the data of vehicle speed using Subaru nission.
Select Monitor.
Compare the speedometer with Subaru
Select Monitor indications.
*Vehicle speed is indicated in “km/h” or “MPH”.
1)Slowly increase the vehicle speed to 60 km/h
or 37 MPH.
NOTE:
indicates no malfunction. When the AT control
Mode.>
AT-106
~ ~
Step Check Yes No

IO CHECK INPUT SIGNAL FOR TCM USING s the signal voltage more than Even if the AT OIL 30 to step 11.
OSCILLOSCOPE. 4c 1 V? rEMP warning
1)Connect the connectors to TCM and trans- ights up, the cir-
mission. :uit has returned
2)Lift-up or raise the vehicle and place safety o a normal condi-
stands. ion at this time. A
CAUTION: emporary poor
Raise all wheels off floor. :ontact of the con-
3)Set the oscilloscope to TCM connector ter- lector or harness
minals. nay be the cause.
Turbo model 3epair harness or
Positive probe; (655) No. 24 :onnector in the
Earth lead; (855) No. 19 TCM and trans-
Non-turbo model nission.
Positive probe; (B55) No. 3
Earth lead; (B55) No. 21
4)Start the engine and set the vehicle in 20 km,
h (12 MPH) condition.
NOTE:
diagnosis is finished, perform the ABS memoq
clearance procedure of on-board diagnostic:
system. <Ref. to ABS-22, Clear Memoq
Mode.>
5)Measure the signal voltage indicated on
oscilbscope.
I1 CHECK POOR CONTACT. s there poor contact in rear 3epair poor con- 3eplace the TCM.
iehicle speed sensor circuit? act. :Ref. to AT-45,
rransmission Con-
rol Module
'TCM).>
AT-1 07
I DIAGNOSTIC PROCEDURE FOR NO-DIAGNOSTIC TROUBLE CODE (DTC)
15.Diagnostic Procedure for No-Diagnostic Trouble Code (DTC)

A: CHECK GEAR POSITION.
Step Check Yes No
CHECK GEAR POSITION. Does the transmission gear 30 to step 2. Check shift sole-
1)Lift-up the vehicle and place safety stand. correspond to the gear which noid 1 and shift
CAUTION: is shown on display? solenoid 2 signal
On AWD models, raise all wheels off circuit. <Ref. to AT-
ground. 70, DTC 71 SHIFT
2)Start the engine. SOLENOID 1,
3)Move the select lever to “D”, and drive the Diagnostic Proce-
vehicle. dure with Diagnos-
4)Read the data of gear position using Subaru tic Trouble Code
Select Monitor. (DTC).> and <Ref.
*Gear position is indicated. to AT-74, DTC 72
SHIFT SOLE-
NOTE:
The speed difference between front and rear NOID 2, Diagnos-
wheels may light the ABS warning light, but this tic Procedure with
indicates no malfunction. When the AT control Diagnostic Trou-
diagnosis is finished, perform the ABS memory ble Code (DTC).>
Mode.>
I CHECK VEHICLE. s the target no6turbo model? 30 to step CHECK Go to step CHECK
=WD BRAKE SWITCH.
;WITCH.<Ref. to <Ref. to AT-1 12,
4T-110, CHECK CHECK BRAKE
IWD SWITCH., SWITCH., Diag-
liagnostic Proce- nostic Procedure
lure for No-Diag- for No-Diagnostic
iostic Trouble Trouble Code
;ode (DTC).> (DTC).>
AT-I 08
DIAGNOSTIC PROCEDURE FOR NO-DIAGNOSTIC TROUBLE CODE (DTC)
ALJTOMATIC TRANSMISSION (DIAGNOSTICS)
AT-I 09
I
B: CHECK FWD SWITCH.

DIAGNOSIS:
LED does not come on even if FWD switch is ON.
FWD switch circuit is open or short.
WIRING DIAGRAM:
2
z
0
- 0
IGNITION
SWITCH
0
SBF-4 SEF-1
BATTERY
3 0
1
I
-
E
FWD SWITCH
COMBINATION
METER
) FWD
r.
A: @
B:@
B:@ A:@
4- 8 11 12 16 19 20 24 27 28 30
TI30590
AT-I 10
DIAGNOSTIC PROCEDURE FOR NO-DIAGNOSTIC TROUBLE CODE (DTC) 1
~~
Step Check Yes No

I CHECK FWD SWITCH. When the fuse is inserted to Go to step CHECK Go to step 2.
FWD switch, does the LED BRAKE
light up? SWITCH.<Ref. to
AT-1 12, CHECK
BRAKE SWITCH.,
Diagnostic Proce-
dure for No-Diag-
nostic Trouble
Code (DTC).>
! CHECK FWD INDICATOR LIGHT. Is the FWD indicator light bulb Go to step 3. Replace the FWD
1)Turnthe ignition switch to OFF. indicator light bulb.
2)Remove the combination meter. <Ref. to IDI-11,
3)Remove the FWD indicator light bulb from Combination
I
combination meter.
TCM AND FWD SWITCH.

r---f-
CHECK HARNESSCONNECTOR BETWEEN Is the resistance less than 1 Go to step 4.
Meter Assembly.>
Repair open circuit
in harness
2)Disconnect the connector from TCM and FWD switch con-
FWD switch. nector.
I
TCM and FWD switch connector.
-
(B55) NO. 14 (F67) NO. 30:
I CHECK HARNESSCONNECTOR BETWEEN Is the resistance less than 1 Go to step 5. Repair open circuit
FWD SWITCH AND CHASSIS GROUND. D? in harness
Measure the resistance of harness between between FWD
FWD switch and chassis ground. switch connector
Connector & terminal and chassis
-
(F67) No. 29 Chassis ground: ground.
CHECKHARNESSCONNECTORBETWEEN Is the resistance more than 1 1 Go to step 6. Repair short circuit
TCM AND FWD SWITCH. MQ? in harness
Measure the resistance of harness connector between TCM and
between TCM and body to make sure that cir- FWD switch con-
cuit does not short. nector.
-
(B55) No. 14 Chassis ground:
i CHECK INPUT SIGNAL FOR TCM. Go to step 12.
1)Turn the ignition switch to OFF. FWD switch while installing?
2)Connect the connector to TCM and FWD
switch.
4)Measure the signal voltage for TCM while
installing the fuse to FWD switch connector.
r CHECK INPUT SIGNAL FOR TCM. Replace the TCM.
Measure the signal voltage for TCM while FWD switch while removing? <Ref. to AT-45,
removing the fuse from FWD switch connector. Transmission Con-
I
TCM AND COMBINATION METER.

7j--
CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Go to step 9.
trol Module
(TCM).>
Repair open circuit
in harness
between TCM and
2)Disconnect the connector from TCM and combination meter
combination meter. and poor contact
3)Measure the resistance of harness between in coupling con-
TCM and diagnosis connector. nector.
-
(B54) No. 12 ( i l l ) No. 4:
~~ ~
Step Check Yes No

9 CHECK HARNESS CONNECTOR BETWEEN the resistance more than 1 30 to step 1Q. Repair short circuii
TCM AND COMBINATION METER. n? ,n harness
Measure the resistance of harness connector between TCM and
between TCM and chassis ground to make :ombination meter
sure that circuit does not short. zonnector.
-
10 CHECK OUTPUT SIGNAL EMITTED FROM the voltage less than 1 V in 30 to step 11. So to step 12.
TCM. YD switch while installing?
2)Connect the connector to TCM and combina-
tion meter.
4)Measure the signal voltage for TCM while
installing and removing the fuse to FWD switch
connector.
11 CHECK OUTPUT SIGNAL EMITTED FROM the voltage more than 9 V in 30 to step 12. Replace the TCM.
TCM. 'VDswitch while removing? <Ref. to AT-45,
Measure the signal voltage for TCM while Transmission Con.
_.. removing the fuse from FWD switch connector. trol Module
Connector & terminal [TCM).>
-
12 CHECK POOR CONTACT. there poor contact in FWD 3epair poor con- Replacethe TCM.
[itch circuit? act. <Ref. to AT-45,
Transmission Con.
trol Module
(TCM).>
C: CHECK BRAKE SWITCH.
I
Check Yes No
CHECK BRAKE SWITCH. When the brake pedal is Go to step CHECK Check the brake
depressed, does the LED light ABS SWITCH. switch circuit.
up? <Ref. to AT-113,
CHECK ABS
SWITCH., Diag-
nostic Procedure
for No-Diagnostic
Trouble Code
(DTC).>
AT-1 12
DIAGNOSTIC PROCEDURE FOR NO-DIAGNOSTIC TROUBLE CODE (DTC) I
D: CHECK ABS SWITCH.

Step Check Yes No
Go to step CHECK
1 light up? [switch circuit. CRUISE CON-
<Ref. to ABS1 38, TROL SWITCH.
DTC 44 ABS-AT <Ref. to AT-113,
CONTROL (NON CHECK CRUISE
CONTROLLED), CONTROL
Diagnostics Chart SWITCH., Diag-
with Subaru Select nostic Procedure
Monitor.> and for No-Diagnostic
<Ref. to ABS-140, Trouble Code
DTC 44 ABS-AT (DTC).>
CONTROL (CON-
TROLLED), Diag-
nostics Chart with
Subaru Select
Monitor.>
E: CHECK CRUISE CONTROL

r- SWITCH.
~
Step Check Yes No

1 CHECK CRUISE CONTROL SWITCH. When cruise control is set, Go to step CHECK Check the cruise
does the LED light up? INHIBITOR control. <Ref. to
SWITCH. <Ref. to CC-28, Diagnos-
AT-1 15, CHECK tics Chart with
INHIBITOR Diagnostic Trou-
SWITCH., Diag- ble Code.>
nostic Procedure
for No-Diagnostic
Trouble Code
(DTC).>
AT-I 13
I
r. .
AT-I 14
F: CHECK INHIBITOR SWITCH.

DIAGNOSIS:
Input signal circuit of inhibitor switch is open or shorted.
TROUBLE SYMPTOM:
Shift characteristics are erroneous.
Engine brake is not effected when selector lever is in “ 3 range.
Engine brake is not effected when selector lever is in “2” range.
Engine brake is not effected when selector lever is in “1” range.
AT-1 15
WIRING DIAGRAM:
IGNITION
SWITCH
SBF-1 SBF-4 0 No 13
0 c
COMBINATION
METER
I - A@
I @" C@
TR0591
AT-I 16
DIAGNOSTIC PROCEDURE FOR NO-DIAGNOSTIC TROUBLE CODE (DTC) 3
Step Check Yes No

CHECK “P” RANGE SWITCH. When “ P range is selected, i o to step 2. 20 to step 22.
loes the LED light up?
CHECK INDICATOR LIGHT. >oes the combination meter ;o to step 3. o
; to step 26.
P” range indicator illuminate?
CHECK “P” RANGE SWITCH. When the “R” range is io to step 28. o
; to step 4.
;elected, does the “ P range
.ED light up?
CHECK “R” RANGE SWITCH. Nhen the “R” range is ;o to step 5. 30 to step 29.
;elected, does the LED light
lp?
CHECK INDICATOR LIGHT. loes the combination meter ;o to step 6. 30 to step 32.
R” range indicator illuminate?
CHECK “R” RANGE SWITCH. Nhen the “N” range is 20 to step 34. 30 to step 7.
;elected, does the “R” range
-ED light up?
CHECK “N” RANGE SWITCH. Nhen the “N” range is 30 to step 8. 30 to step 35.
;elected, does the LED light
JP?
CHECK INDICATOR LIGHT. loes the combination meter 30 to step 9. 30 to step 38.
‘N” range indicator illuminate?
CHECK “N” RANGE SWITCH. Nhen the “ D range is o
; to step 40. 30 to step 10.
selected, does the “N” range
-ED light up?
1 CHECK “D” RANGE SWITCH. Nhen the “D” range is o; to step 11. 30 to step 41.
selected, does the LED light
Jp?
I CHECK INDICATOR LIGHT. I o e s the combination meter 30 to step 12. 30 to step 44.
‘D” range indicator illuminate?
? CHECK “D” RANGE SWITCH. Nhen the “ 3 range is selected, 30 to step 46. 30 to step 13.
joes the “D” range LED light
Jp?
3 CHECK “3” RANGE SWITCH. When the “ 3 range is selected, 30 to step 14. 30 to step 47.
joes the LED light up?
I CHECK INDICATOR LIGHT. Does the combination meter 30 to step 15. Go to step 50.
‘3” range indicator illuminate?
> CHECK “3” RANGE SWITCH. When the “ 2 range is selected, 30 to step 52. Go to step 16.
does the “ 3 range LED light
up?
5 CHECK “2” RANGE SWITCH. When the “2” range is selected, 30 to step 17. Go to step 53.
does the LED light up?
7 CHECK INDICATOR LIGHT. Does the combination meter 30 to step 18. Go to step 56.
“2” range indicator illuminate?
3 CHECK “2” RANGE SWITCH. When the “1” range is selected, So to step 58. Go to step 19.
does the “2” range LED light
up?
9 CHECK “1” RANGE SWITCH. When the “ I ” range is selected, Go to step 20. Go to step 59.
does the LED light up?
D CHECK INDICATOR LIGHT. Does the combination meter Go to step 21. Go to step 62.
“1” range indicator illuminate?
1 CHECK “1” RANGE SWITCH. When the “P” range is Go to step 64. Go to step Symp-
selected, does the “1” range tom Related Diag-
LED light UP? nostic. <Ref. to A1
127, Symptom
Related Diagnos-
tic.>
AT-I 17
Step Check Yes No

2 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Go to step 23. Repair open circui
INHIBITOR SWITCH AND CHASSIS R? in harness
GROUND. between inhibitor
1)Turn the ignition switch to OFF. switch connector
2)Disconnect the connector from inhibitor and chassis
switch. ground, and poor
3)Measure the resistance of harness between contact in cou-
inhibitor switch and chassis ground. pling connector.
(T7) No. 5 - Chassis ground:
3 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Go to step 24. Repair open circuil
TCM AND INHIBITOR SWITCH. R? in harness
2)Disconnect the connectors from TCM and inhibitor switch
inhibitor switch. connector, and
3)Measure the resistance of harness between poor contact in
TCM and inhibitor switch connector. coupling connec-
Non-turbo model
(655) NO. 23 - (T7) NO. 9
Turbo model
._ (655) NO. 1 - (T?’) NO. 9
4 CHECK INPUT SIGNAL FOR TCM. Is the voltage less than 1 V in Go to step 25. Go to step 65.
1)Turnthe ignition switch to OFF. ‘P” range?
2)Connect the connector to TCM and inhibitor
switch.
chassis ground.
Non-turbo model
Turbo model
5 CHECK INPUT SIGNAL FOR TCM. Is the voltage more than 8 V in Go to step 65. Replace the TCM.
Measure the voltage between TCM and chas- 2ther ranges? <Ref. to AT-45,
sis ground. Transmission Con-
Connector & terminal :rol Module
Non-turbo model :TCM).>
Turbo model
6 CHECK “P” RANGE INDICATOR LIGHT s the “ P range indicator light Go to step 27. qeplace the “ P
BULB. iulb OK? ange indicator
1)Turn the ignition switch to OFF. ight bulb. <Ref. to
2)Remove the combination meter. DI-11, Combina-
3)Remove the “ P range indicator light bulb ion Meter Assem-
from combination meter. ilY.>
7 CHECKHARNESSCONNECTORBETWEEN s the resistance more than 1 Go to step 65. 3epair open circuit
TCM AND COMBINATION METER. n? n harness
1)Disconnectthe connectors from TCM and ietween TCM con.
combination meter. lector and combi-
2)Measure the resistance of harness between iation meter, and
TCM and combination meter. ioor contact in
Connector & terminal :oupling connec-
Non-turbo model or.
(655) NO.23 -(112) NO. 14:
Turbo model
(655) NO. 1 - (i12) NO. 14:
AT-I 18
Step Check Yes No

CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 30 to step 29. lepair ground
TCM AND INHIBITOR SWITCH. AR? ,hart circuit in “ P
1)Turn the ignition switch to OFF. ange circuit.
2)Disconnect the connectors from TCM, inhibi.
tor switch and combination meter.
TCM and chassis ground.
Non-turbo model
-
(B55) No. 23 Chassis ground:
Turbo model
CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 30 to step 30. lepair open circui
TCM AND INHIBITOR SWITCH. 2? I harness
1)Turn the ignition switch to OFF. between TCM anc
2)Disconnect the connectors from TCM and ihibitor switch
inhibitor switch. :onnector,and
3)Measure the resistance of harness between ioor contact in
TCM and inhibitor switch connector. :oupling connec-
Connector & terminal Dr.
Non-turbo model
(B55) NO. 17 - (V) NO. 8:
Turbo model
(B55) NO. 3- (V) NO. 8:
CHECK INPUT SIGNAL FOR TCM. s the voltage less than 1 V in 30 to step 31. ;o to step 65.
1)Turn the ignition switch to OFF. R” range?
switch.
chassis ground.
Non-turbo model
Turbo model
CHECK INPUT SIGNAL FOR TCM. s the voltage more than 8 V in 30 to step 65. leplace the TCM.
Measure the voltage between TCM and chas- )ther ranges? :Ref. to AT-45,
sis ground. -ransmissionCon
Connector & terminal rol Module
Non-turbo model TCM).>
Turbo model
CHECK “R” RANGE INDICATOR LIGHT s the “R” range indicator light 30 to step 33. leplace the “R”
BULB. )ulb OK? ange indicator
1)Turn the ignition switch to OFF. ght bulb. <Ref. tc
3)Remove the “R” range indicator light bulb ion Meter Assem,
from combination meter. )lY.>
AT-I 19
~ ~~ ~~~~
Step Check Yes No

3 CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 30 to step 65. Repair open circuii
TCM AND COMBINATION METER. 2? in harness
1)Disconnectthe connectors from TCM and between TCM con
combination meter. nector and combi-
2)Measure the resistance of harness between nation meter, and
TCM and combination meter. poor contact in
Connector & terminal TCM connector.
Non-turbo model
(B55) NO. 17 - (i12) NO. 13:
Turbo model
(B55) NO. 3 - (i12) NO. 13:
4 CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 30 to step 35. Repair ground
TCM AND INHIBITOR SWITCH. AR? short circuit in “R”
1)Turn the ignition switch to OFF. range circuit.
2)Disconnect the connectors from TCM, inhibi.
Non-turbo model
._ .. Turbo model
5 CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 30 to step 36. Repair open circuit
TCM AND INHIBITOR SWITCH. 2? in harness
TCM and inhibitor switch connector, coupling connec-
Non-turbo model
(B55) NO. 22 - (T?) NO. IO:
Turbo model
(B55) NO. 14 - (T7) NO. 10:
6 CHECK INPUT SIGNAL FOR TCM. 5 the voltage less than 1 V in 20 to step 37. Go to step 65.
1)Turn the ignition switch to OFF. N” range?
switch.
chassis ground.
Non-turbo model
Turbo model
7 CHECK INPUT SIGNAL FOR TCM. 5 the voltage more than 8 V in 20 to step 65. Replace the TCM.
Measure the voltage between TCM and chas- ither ranges? <Ref. to AT-45,
Connector & terminal trol Module
Non-turbo model (TCM).>
Turbo model
AT-I 20
I
Step Check Yes No

8 CHECK “N” RANGE INDICATOR LIGHT s the “N” range indicator light i o to step 39. Replace the “N”
BULB. wlb OK? range indicator
1)Turn the ignition switch to OFF. light bulb. <Ref. to
2)Remove the combination meter. IDI-11, Combina-
3)Remove the “N” range indicator light bulb tion Meter Assem-
from combination meter. bly.>
9 CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 i o to step 65. Repair open circuit
1)Disconnect the connectors from TCM and between TCM con-
Non-turbo model
(B55) NO.22 - (i12) NO. 12:
Turbo model
(B55) NO. 14 - (i12) NO. 12:
0 CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 30 to step 41. Repair ground
TCM AND INHIBITOR SWITCH. dQ? short circuit in “N”
1)Turnthe ignition switch to OFF. range circuit.
2)Disconnect the connectors from TCM, inhibi-
Non-turbo model
Turbo model
,1 CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 i o to step 42. Repair open circuit
TCM AND INHIBITOR SWITCH. n? in harness
Non-turbo model
(B55) NO. 8 - (T7) NO. 3:
Turbo model
(B55) NO. 4 - (T7) NO. 3:
12 CHECK INPUT SIGNAL FOR TCM. Is the voltage less than 1 V in 30 to step 43. Go to step 65.
1)Turn the ignition switch to OFF. ‘ D range?
switch.
chassis ground.
Non-turbo model
Turbo model
AT-I 21
Step Check Yes No

CHECK INPUT SIGNAL FOR TCM. s the voltage more than 8 V in I Go to step 65. 3eplace the TCM.
Measure the voltage between TCM and chas- Ither ranges? :Ref. to AT-45,
sis ground. rransmission Con-
Connector & terminal ro1 Module
Turbo model
CHECK “D” RANGE INDICATOR LIGHT s the “ D range indicator light ;o to step 45. 3eplace the “ D
BULB. lulb OK? ange indicator
1)Turnthe ignition switch to OFF. ight bulb. <Ref. to
3)Remove the “ D range indicator light bulb ion Meter Assem-
from combination meter. llY.>
TCM AND COMBINATION METER. 2? n harness
1)Disconnectthe connectors from TCM and letween TCM con-
combination meter. lector and combi-
2)Measure the resistance of harness between ration meter, and
TCM and combination meter. TCM connector.
Non-turbo model
(B55) NO. 8 - (i12) NO. 11:
Turbo model
(B55) NO. 4 - (i12) NO. 11:
CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 20 to step 47. 3epair ground
TCM AND INHIBITOR SWITCH. dQ? ;hort circuit in “ D
1)Turnthe ignition switch to OFF. ange circuit.
Non-turbo model
Turbo model
TCM AND INHIBITOR SWITCH. 2? n harness
2)Disconnect the connector from TCM and nhibitor switch
inhibitor switch. :onnector, and
3)Measure the resistance of harness between loor contact in
Non-turbo model
(655) NO. 18 - (P) NO. 11:
Turbo model
(655) NO. 5 - (R) NO. 1 1:
AT-I 22
I
3
Step Check
18 CHECK INPUT SIGNAL FOR TCM. s the voltage less than 1 V in 30 to step 49. Go to step 65.
1)Turn the ignition switch to OFF. 3 range?
switch.
chassis ground.
Non-turbo model
Turbo model
I9 CHECK INPUT SIGNAL FOR TCM. s the voltage more than 8 V in 30 to step 65. Replace the TCM.
Measure the hvoltage between TCM and chas- )ther ranges? <Ref. to AT-45,
Turbo model
io CHECK “3” RANGE INDICATOR LIGHT s the “3” range indicator light 30 to step 51. Replace the “ 3
BULB. ulb OK? range indicator
3)Remove the “ 3 range indicator light bulb tion Meter Assem-
il CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 30 to step 65. Repair open circuii
1)Disconnectthe connectors from TCM and between TCM con
Non-turbo model
(B55) NO. 18 - (i12) NO. 10:
Turbo model
(B55) NO. 5 - (i12) NO. 10:
i2 CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 30 to step 53. Repair ground
TCM AND INHIBITOR SWITCH. del? short circuit in “ 3
Non-turbo model
Turbo model
AT-I 23
Step Check Yes No

13 CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 30 to step 54. 3epair open circuit
TCM AND INHIBITOR SWITCH. n? n harness
2)Disconnect the connector from TCM and nhibitor switch
inhibitor switch. :onnector, and
3)Measure the resistance of harness between ioor contact in
Connector & terminal ‘or.
Non-turbo model
(854) NO. 10 - (T7) NO. 4:
Turbo model
(B55) NO. 6 - (T7) NO. 4:
14 CHECK INPUT SIGNAL FOR TCM. s the voltage less than 1 V in o
1)Turn the ignition switch to OFF. ‘2” range?
switch.
chassis ground.
Non-turbo model
.. .. (854) No. 10 (+) - Chassis groundI)-(
Turbo model
5 CHECK INPUT SIGNAL FOR TCM. s the voltage more than 8 V in 30 to step 65. 3eplace the TCM.
Measure the voltage between TCM and chas- ither ranges? :Ref. to AT-45,
sis ground. rransmission Con-
Connector & terminal rol Module
Turbo model
8
6 CHECK “2” RANGE INDICATOR LIGHT s the “2” range indicator light 30 to step 57. 3eplace the “ 2
BULB. iulb OK? ‘ange indicator
1)Turn the ignition switch to OFF. ight bulb. <Ref. to
3)Remove the “2” range indicator light bulb ion Meter Assem-
from combination met,er. ilY.>
7 CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 ;o to step 65. 3epair open circuit
TCM AND COMBINATION METER. 2? n harness
1)Disconnectthe connectors from TCM and letween TCM and
combination meter. :ombination
2)Measure the resistance of harness between neter, and poor
TCM and combination meter. :ontact in TCM
Non-turbo model
(854) No. 10 - (i12) No. 4:
Turbo model
(B55) No. 6 - (i12) No. 4:
AT-I 24
I
~ ~~
Step Check Yes No

3 CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 ;o to step 59. Repair ground
TCM AND INHIBITOR SWITCH. do? short circuit in “ 2
2)Disconnect the connectors from TCM, inhibi
Non-turbo model
Turbo model
3 CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 ;o to step 60. Repair open circuit
TCM AND INHIBITOR SWITCH. 1? in harness
Non-turbo model
(854) NO. 1 - (P) NO. 6:
Turbo model
(B55) NO. 7 - (P) NO. 6:
3 CHECK INPUT SIGNAL FOR TCM. s the voltage less than 1 V in 30 to step 61. Go to step 65.
1)Turnthe ignition switch to OFF. 1” range?
switch.
chassis ground.
Non-turbo model
Turbo model
-
(B55) No. 7 (+) Chassis ground (-):
1 CHECK INPUT SIGNAL FOR TCM. s the voltage more than 8 V in ;o to step 65. Replace the TCM.
Measure the voltage between TCM and chas- ither ranges? <Ref. to AT-45,
-
(854) No. 1 (+) Chassis ground (-):
Turbo model
-
2 CHECK “1” RANGE INDICATOR LIGHT s the “1” range indicator light 20 to step 63. Replace the “1”
BULB. iulb OK? range indicator
3)Remove the “1” range indicator light bulb tion Meter Assem-
AT-1 25
Step Check Yes No

i3 CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1RS i o to step 65. Repair open circuit
TCM AND COMBINATION METER. in harnes between
1)Disconnectthe connectors from TCM and TCM and combi-
combination meter. nation meter, poor
2)Measure the resistance of harness between contact in TCM
TCM and combination meter. connector.
Non-turbo model
(B54) No. 1 - (i12) No. 5:
Turbo model
(B55) No. 7 - (i12) No. 5:
i4 CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 ;o to step 65. Repair ground
TCM AND INHIBITOR SWITCH. dsz? short circuit in “1”
Non-turbo model
-. Turbo model
i5 CHECK POOR CONTACT. s there poor contact in inhibi- 3epair poor con- Adjust the inhibi-
or switch circuit? act. tor switch and
select cable. <Ref.
to AT-28, ADJUST-
MENT, Inhibitor
Switch.> and
<Ref. to CS-26,
Select Cable.>
AT-I 26
I
SYMPTOM RELATED DIAGNOSTIC
16.Symptom Related Diagnostic

A: INSPECTION
Svmptom Problem parts I
Inhibitor switch
Starter does not rotate when the select lever is in “P” or “N”; Select cable
starter rotates when the select lever is in “R”, “D”, “ 3 or “ 2 . Select lever
Starter motor and harness
~~
Strainer
Abnormal noise when the select lever is in “ P or “N” Oil pump
Drive plate
ATF level too high or too low
Strainer
Hissing noise occurs during standing start.
ATF level too high or too low
Noise occurs while driving in “Dl”. Final gear
Planetary gear
Noise occurs while driving in “ 0 2 . Reduction gear
Differential gear oil level too high or too low
Final gear
Low & reverse brake
Noise occurs while driving in “ D 3
Reduction gear
Final gear
Low & reverse brake
Noise occurs while driving in ‘ID4 Planetary gear
Reduction gear
Control valve
Lock-up damper
Engine stalls while shifting from one range to another.
Engine performance
Input shaft
TCM
Vehicle moves when the select lever is in “N”.
Low clutch
TCM
Harness
Shock occurs when the select lever is moved from “N” to “ D .
Control valve
ATF deterioration
Control valve
Low clutch
Excessive time lag occurs when the select lever is moved from
“N” to “ D .
Seal ring
Front gasket transmission case
TCM
Harness
Shock occurs when the select lever is moved from “N” to “R”.
Control valve
ATF deterioration
Control valve
Low & reverse clutch
Excessive time lag occurs when the select lever is moved from Reverse clutch
“N” to “R”. Line pressure duty solenoid
Seal ring
Parking brake mechanism
Vehicle does not start in any shift range (engine stalls).
Planetarv aear
AT-127
I
~~
Symptom ’roblem parts

Strainer
1 Line pressure duty solenoid
I Control valve
1 Drive pinion
1 Hypoid gear
1 Axle shaft
1 Differential gear
Vehicle does not start in any shift range (engine revving up).
1 Oil pump
1 Input shaft
b Output shaft
b Planetary gear
b Drive plate
b ATF level too low
b Front gasket transmission case

b Select cable
Vehicle does not start in “R” range only (engine rewing up).
b
.Select lever
Control valve
b
.Low & reverse clutch

Reverse clutch
,Vehicle does not start in “R” range only (engine stalls).

..
Low clutch
2-4 brake
.
-
Planetary gear
Parking brake mechanism
Low clutch
Vehicle does not start in “D”, “ 3 range only (engine rewing up).
* One-wav clutch
Vehicle does not start in “D”, “ 3or “2” range only (engine rev- Low clutch
vina up).
Vehicle does not start in “D”, “ 3 or “ 2 range only (engine
stalls).
.Reverse clutch
Vehicle starts in “R” range only (engine revving up). Control valve
Control valve
Low clutch
Reverse clutch
Acceleration during standing starts is poor (high stall rpm).
ATF level too low
Oil pump
Acceleration during standing starts is poor (low stall rpm). Torque converter one-way clutch
Engine performance
TCM
Control valve
Acceleration is poor when the select lever is in “D”, “ 3 or “ 2
High clutch
range (normal stall rpm).
2-4 brake
Planetary gear
I
Control valve
Acceleration is poor when the select lever is in “R” (normal stall High clutch
rpm). 2-4 brake
Planetary gear
TCM
No shift occurs from 1st to 2nd gear. Throttle position sensor
Shift solenoid 1
Control valve
2-4 brake
TCM
Control valve
No shift occurs from 2nd to 3rd gear.
High clutch
Shift solenoid 2
I
Problem parts
TCM
B Shift solenoid 1
No shift occurs from 3rd to 4th gear. B ATF temperature sensor
r
Control valve
B 2-4 brake
B Inhibitor switch
Engine brake is not effected when the select lever is in “ 3 TCM
range. * Throttle position sensor
* Control valve
‘Engine brake is not effected when the select lever is in “ 3 or “2” 0 Control valve
range.
Engine brake is not effected when the select lever is in “1” * Control valve
range. Low & reverse brake
Inhibitor switch
TCM
Shift characteristics are erroneous. Rear vehicle speed sensor
Control valve
Ground earth
TCM
Control valve
Lock-up facing
Engine speed signal
m n u brake is not effected. Select cable
Select lever
Shift lever cannot be moved or is hard to move from “P” range. Parkinu mechanism
ATF spurts out. ATF level too high
Differential oil swrts out. Differential gear oil too high
Seal pipe
Differential oil level changes excessively.
Double oil seal
High clutch
2-4 brake
Low & reverse clutch
Odor is produced from ATF supply pipe.
Reverse clutch
Lock-up facing
ATF deterioration
TCM
Shock occurs from 1st to 2nd gear.
Control valve
2-4 brake
ATF deterioration
Engine performance
TCM
Control valve
2-4 brake
Hiah clutch
I
Symptom Problem parts

TCM
Shock occurs from 2nd to 3rd gear. Control valve
High clutch
2-4 brake
r
ATF deterioration
Engine performance
TCM
Slippage occurs from 2nd to 3rd gear. Line pressure duty solenoid
Control valve
High clutch
2-4 brake
TCM
Control valve
2-4 brake
ATF deterioration
Engine performance
Low clutch timing solenoid
Low clutch
TCM
Slippage occurs from 3rd to 4th gear. Line pressure duty solenoid
Control valve
2-4 brake
TCM
Shock occurs when the select lever is moved from “ 3 to “ 2 Control valve
2-4 brake
ATF deterioration
TCM
I Shock occurs when the select lever is moved from “ 0to “1” Line pressure duty solenoid
Control valve
range. ATF deterioration
Low clutch timinu solenoid
AT-I 30
3vmPtom Problem parts

TCM
Shock occurs when the select lever is moved from “2” to “1” Control valve
.ange. Low & reverse clutch
ATF deterioration
TCM
Shock occurs when the accelerator pedal is released at Control valve
nedium speeds. Lock-up damper
Engine performance
TCM
Lock-up duty solenoid
Vibration occurs during straight-forwardoperation.
Lock-up facing
Lock-up damper
TCM
Vibration occurs during turns (tight corner “braking” phenome- ATF temperature sensor
non). Transfer clutch
Transfer valve
ATF deterioration
Harness
TCM
Front wheel slippage occurs during standing starts. Control valve
Transfer clutch
Transfer valve
Transfer pipe
Transfer dutv solenoid
TCM
Transfer clutch
Vehicle is not set in FWD mode.
Transfer valve
Select cable
Select lever
Select lever is hard to move.
Detent spring
Manual date
Detent spring
Select lever is too high to move (unreasonable resistance).
Manual plate
Select cable
Select lever slips out of operation during acceleration or while Select lever
driving on rough terrain. Detent spring
Manual plate
AT-1 31
I SYMPTOM RELATED DIAGNOSTIC
I
AT-I 32
MANUAL TRANSMISSION AND
DIFFERENTIAL
MT
Page
2. Transmission Gear Oil .............................................................................. 26
3. Manual Transmission Assembly ............................................................... 27
4. Transmission Mounting System ................................................................ 34
5. Oil Seal ...................................................................................................... 36
6. Switches and Harness .............................................................................. 37
7. Vehicle Speed Sensor ............................................................................... 39
8. Preparation for Overhaul ........................................................................... 40
9. Transfer Case and Extension Case Assembly .......................................... 41
r . 10. Transfer Drive Gear .................................................................................. 45
11. Transfer Driven Gear ................................................................................ 47
12. Center Differential ..................................................................................... 49
13. Reverse Check Sleeve .............................................................................. 50
14. Transmission Case ................................................................................... 54
15. Main Shaft Assembly for Single-Range .................................................... 57
16. Drive Pinion Shaft Assembly ..................................................................... 63
17. Front Differential Assembly ....................................................................... 71
18. Speedometer Gear .................................................................................... 77
19. Reverse Idler Gear .................................................................................... 78
20. Shifter Fork and Rod ................................................................................. 80
21 . General Diagnostic.................................................................................... 84
GENERAL DESCRIPTION
3
MANUAL TRANSMISSION AND DIFFERENTIAL
A: SPECIFICATIONS
1. MANUAL TRANSMISSION AND DIFFERENTIAL
Sedan Wagon
Type 5-forward speeds with synchromesh and 1-reverse
1st 3.454 3.454
2nd 2.062 1.947
3rd 1.448 1.366
Transmission gear ratio
F I 1.088 I 0.972
15th I 0.780 I 0.738
I Reverse I 3.333
Type of gear Hypoid
Gear ratio 4.1 11 I
3.900
Type of gear Helical
Transfer
Gear ratio 1.ooo 1.100
Rear reduction gear
C. ~
Type of gear Hypoid
Final
Gear ratio 4.1 11 3.900 3.545
Front differential 1 Type and number of gear Straight bevel gear (Bevel pinion: 2, Bevel gear: 2)
Center differential I Type and number of gear

I Straight bevel gear
(Bevel Dinion: 2, Bevel aear: 2 and viscous couplina)
Transmission aear
" .
oil I
GL-5
Transmission aear oil caeacitv I 3.5 8 (3.7 US qt, 3.1 Imp qt)
2. TRANSMISSION GEAR OIL

Recommended oil
Transmission gear oil

API Classification
SAE Viscosity No and Applicable Temperature
(OF) -22 -15
MT-2
GENERAL DESCRIPTION
3
3. TRANSMISSION CASE ASSEMBLY 4. DRIVE PINION ASSEMBLY

Drive pinion shim adjustment Preload adjustment of thrust bearing
Hypoid gear backlash Starting torque
0.13 - 0.18 mm (0.0051 - 0.0071 in) 0.3 - 0.8 N-m (0.03 - 0.08 kgf-m, 0.2 - 0.6 ft-
Drive pinion shim Ib)
Part No.
Thickness
mm (in)
1 Part No.
mm (in) Part No. Thickness mm (in)
32295AA031
I 803025052 I 3.950 (0.1555) I
0.275 803025053
32295AA041
32295AA051 803025055
(0.0079) (0.01 18)
32295AA061 I 32295AAlOl
Selection of main shaft rear plate

I Main shaft rear date I
bimension"Amm (in) I Part No. I Mark I 803025059 3.850 (0.1516)
. . 4.00-4.13
32294AA041 1
(0.1575 - 0.1626)
3.87 - 3.99
32294AA051 2 5. MAIN SHAFT
(0.1524 - 0.1571)
Input shaft holder adjustment Snap ring (Outer-25) to synchronizer hub clear-
ance
I Dimension " D mm (in) I Number of shim I 0.060 - 0.100 mm (0.0024 - 0.0039 in)
52.50 - 53.1 1
(2.0669 - 2.0909)
- I SnaD rina (Outer-25) 1
Thickness Part No, Thickness
52.00 - 52.49 Part No.
1 mm (in) mm (in)
(2.0472 - 2.0665)
- 805025051 2.42 (0.0953) 805025055 2.62 (0.1031)
51.26 - 51.99
2 805025052 2.47 (0.0972) 805025056 2.67 (0.1051)
(2.0181 - 2.0468)
805025053
_________- - - (0.0992)
2.52 ,- ,
805025057 2.72 (0.1071)
1
I
I
- - - - I
805025054 I 2.57 (0.1012) I 805025058 I 2.37 (0.0933)
MT-3
GENERAL DESCRIPTION
I
6. REVERSE IDLER GEAR 7. SHIFTER FORK AND ROD

Adjustment of reverse idler gear position Select suitable shifter forks so that both coupling
Reverse idler gear to transmission case (LH) wall sleeve and reverse driven gear are positioned in
clearance the center of their synchromesh mechanisms.
6.0 - 7.5 mm (0.236 - 0.295 in) Rod end clearance
A: 1st-2nd - 3rd-4th
0.4 - 1.4 mm (0.016 - 0.055 in)
Part No. Mark Remarks
B: 3rd-4th - 5th
0.5 - 1.3 mm (0.020 - 0.051 in)
I 32820AA080 I 8 I Standard I
I 32820AA090 I 9 I Closer to the case wall I I 1st-2nd shifter fork I
I Part No. I Mark I Remarks I
After installing a suitable reverse shifter lever, ad-
just reverse idler gear to transmission case wall I 32804AA060 1 Approach to 1st gear
by 0.2 mm (0.008 in)
clearance to within 0 to 0.5 mm (0 to 0.020 in) using 32804AA070 I No mark I Standard
1
washers.
I
I 32804AA080 I 3 I Approach to 2nd gear
by 0.2 mm (0.008 in) I
I Part No.
I Thickness
mm (in)
I
Washer (20.5 x 26 x t)
Part No, I
y; : ;T I
I
803020151 0.4 (0.016) 803020154 1.9 (0.075) Part No. Mark Remarks
--803020152 1.1 (0.043) 803020155 2.3 (0.091) Approach to 4th gear
32810AA061 1
803020153 1.5 (0.059) - - bv 0.2 mm (0.008 in)
I 32810AA071 I No mark I Standard I
I 32810AA101 I 3 I Approach to 3rd gear
bv 0.2 mm (0.008 in)
I 5th shifter fork (Non-turbo)

I 32812AA201 I 4 I
Approach to 5th gear
bv 0.2 mm (0.008 in) I
Become distant from
32812AA221 5th gear by 0.2 mm
(0.008 in)
I 32812AA231 I ' 1 Approach to 5th gear

by 0.2 mm (0.008 in) I
32812AA241 No mark Standard
Become distant from
32812AA251 9 5th gear by 0.2 mm
(0.008 in)
MT-4
GENERAL DESCRIPTION
8. TRANSFER CASE 9. EXTENSION ASSEMBLY

Neutral position adjustment Thrust washer (50 x 61 x t) to taper roller bearing
table outer race side clearance
0.2 - 0.3 mm T (0.0008 - 0.012 in T)
Part No. Thickness mm (in)
32190AA000 0.15 (0.0059) NOTE:
T: Tight
I 32190AA010 I 0.30 (0.0118) I

Part No. Mark Remarks 803050060 0.50 (0.0197)
Neutral position is 803050061 0.55 (0.0217)
32188AA090 3
closer to 1st.
I 803050062 I 0.60 (0.0236) I
I 32188AA100 I 0 I Standard I 803050063 0.65 (0.0256)
I 32188AA110 I 1 I Neutral position is
closer to reverse aear. I 803050064
803050065
0.70 (0.0276)
0.75 (0.0295)
Reverse check plate adjustment 803050066 0.80 (0.0315)
803050067 0.85 (0.0335)
I -
Reverse check plate I
I Part No. Mark1 Angle
e I I
Remarks
I I
803050068
803050069 I
0.90 (0.0354)
0.95 (0.0374) I
.-.. Arm stops closer to I 803050070 I 1.OO (0.0394) I
32189AA000 0 803050071 1.05 (0.0413)
I I I
280
I
-
5th qear.
I
Arm stops closer to 803050072 1.10 (0.0433)
32189AA010 1
31" 5th gear. 803050073 1.15 (0.0453)
Arm stops in the cen- 803050074 1.20 (0.0472)
33189AA020 2
340 ter. I 803050075 I 1.25 (0.0492) I
Arm stops closer to I 803050076 I 1.30 (0.0512) I
32189AA030 3
370 reverse gear. 803050077 1.35 (0.0531)
I 32189AA040 I 4 I 40" I Arm stops closer to
reverse aear. I 803050078
803050079
1.40 (0.0551)
1.45 (0.0571)

I 803036050 I 0.9 (0.035) I
803036054 1.O (0.039)
803036051 1.1 (0.043)
803036055 1.2 (0.047)
803036052 1.3 (0.051 )
803036056 1.4 (0.055)
803036053 1.5 (0.059)
I 803036057 I 1.6 (0.063) I
803036058 1.7 (0.067)
MT-5
GENERAL DESCRIPTION
1O.FRONT DIFFERENTIAL 11.TRANSFER DRIVE GEAR
Snap ring (Outer-30)

Washer (38.1 x 50 x t)
Thickness Part No, Thickness
Part No. 805030041 1.53 (0.0602)
mm (in) mm (in)
0.925 - 1.025 - 805030042 1.65 (0.0650)
I I 0.0374) I I 0.0413) I
I
I 803038022
I
I
0.975-
l.ooo
(0.0384-
I
I
- 1
I
- II
Thickness Part No. Thickness

Part No.
mm (in) mm (in)
805028011 I 1.05 (0.0413) 1 805028012 I 1.20 (0.0472)
MT-6
GENERAL DESCRIPTION
I
B: COMPONENT
1. TRANSMISSION CASE
(1) Transmission case ASSY (7) Speedometer shaft (13) Oil level gauge (Non-turbo model)
(2) Gasket (8) Snap ring (Outer) (14) Oil level gauge (Turbo model)
(3) Drain plug (9) Oil seal
(4) Snap ring (Outer) (10) Clamp Tightening torque: N.m (kgf-m, ff-lb)
(5) Speedometer driven gear (11) Pitching stopper bracket T: 44 (4.5, 32.5)
(6) Washer (12) Clip
Size All models Tightening torque: N.m (kgf-m, ft-lb)

8 mm bolt <5> - <I 5> 25 (2.5, 18.1)
< I > - <4>
10 mm bolt 39 (4.0, 28.9)
<16> - <17>
MT-7
2. DRIVE PINION ASSEMBLY
/
/’
/
/’
S3M0423B
(1) Drive pinion shaft (15) Baulk ring (29) Locknut

(2) Roller bearing (16) 1st-2nd synchronizer hub (30) Washer
(3) Washer (17) Insert key (31) Thrust bearing
(4) Thrust bearing (18) Reverse driven gear (32) Differential bevel gear sleeve
(5) Needle bearing (19) Outer baulk ring (33) Washer
(6) Driven shaft (20) Synchro cone (34) Lock washer
(7) Key (21) Inner baulk ring (35) Locknut
(8) Woodruff key (22) 2nd driven gear
(9) Drive pinion collar (23) 2nd driven gear bush Tightening torque: N.m (kgf-m, ft-lb)
(10) Needle bearing (24) 3rd-4th driven gear T1: 29 (3.0, 21.7)
(11) Snap ring (Outer) (25) Driven pinion shim T2: 118 (12.0, 86.8)
(12) Washer (26) Roller bearing T3: 265 (27, 195)
(13) Subgear (27) 5th driven gear
(14) 1st driven gear (28) Lock washer
MT-8
3. MAIN SHAFT ASSEMBLY
Oil seal Needle bearing Ball bearing

Needle bearing 4th gear thrust washer Synchro cone stopper
Transmission main shaft Ball bearing Snap ring
Needle bearing 5th gear thrust washer Lock washer
3rd drive gear 5th needle bearing race Lock nut
Inner baulk ring Needle bearing Reverse idler gear shaft
Synchro cone (3rd) Main shaft rear plate Straight pin
Outer baulk ring 5th drive gear Reverse idler gear
Coupling sleeve (3rd-4th) 5th baulk ring Washer
Synchronizer hub (3rd-4th) Shifting insert key (5th-Rev)
Shifting insert key (3rd-4th) Synchronizer hub (5th-Rev) Tightening torque: N.m (kgf-m, ft-lb)
4th baulk ring Coupling sleeve (5th-Rev) T: 118 (12.0, 86.8)
4th drive gear Rev baulk ring
4th needle bearing race Synchro cone (Rev)
MT-9
I
4. SHIFTER FORK AND SHIFTER ROD
r-
(1) Shifter arm (9) 3rd-4th fork rod (17) Reverse fork rod arm
(2) 5th shifter fork (10) Interlock plunger (18) Reverse shifter lever
(3) Straight pin (1 1) 1st-2nd fork rod
(4) Reverse fork rod (12) 3rd-4th shifter fork Tightening torque: N-m (kgf-m, ft-lb)
(5) Checking ball plug (13) 1st-2nd shifter fork T: 19.6(2.0, 14.5)
(6) Gasket (14) Ball
(7) Checking ball spring (15) Spring
(8) Ball (16) Snap ring (Outer)
MT-10
GENERAL DESCRIPTION
I
5. TRANSFER CASE AND EXTENSION

I .
TROOO
Oil guide Return spring (31) Transfer drive gear

Gasket O-ring (32) Ball bearing
Transfer case Adjusting select shim (33) Extension
Ball Reverse check sleeve (34) Oil seal
Reverse accent spring Gasket (35) Dust cover
Gasket Neutral switch (36) Shift bracket
Plug Gasket (37) Snap ring
Oil seal Back-up light switch
Snap ring (Inner) Roller bearing Tightening torque: N.m (kgf-myft-lb)
Reverse check plate Transfer driven gear T1: 6.4 (0.65, 4.7)
Reverse check spring Roller bearing T2: lO(1.0, 7.2)
Reverse return spring Adjusting washer T3: 25 (2.5, 18.1)
Reverse check cam Ball bearing T4: 26 (2.7, 20)
Reverse accent shaft Center differential T5: 40 (4.1, 29.7)
Return spring cap Adjusting washer
MT-11
I GENERAL DESCRIPTION I
6. FRONT DIFFERENTIAL
H3M1967A
(1) Drive pinion shaft (8) Snap ring (Outer) (15) Retainer lock plate
(2) Hypoid driven gear (9) Roller bearing
(3) Pinion shaft (10) Differentialcase Tightening torque: N.m (kgf-m, ft-lb)
(4) Straight pin (1 1) Oil seal T1: 25(2.5, 18.1)
(5) Washer (12) Differential side retainer T2: 62 (6.3, 45.6)
(6) Differential bevel gear (13) O-ring
(7) Differential bevel pinion (14) Axle drive shaft
MT-12
7. TRANSMISSION MOUNTING
“i, @
I
’\
TROOl:
(1) Pitching stopper (8) Cushion D Tightening torque: N.m (kgf-m, ft-lb)
(2) Spacer (9) Center crossmember T l : 7.5 (0.76, 5.5)
(3) Cushion C (10) Rear plate T2: 35 (3.6,26)
(4) Front plate (1 1) Front crossmember T3: 50 (5.1, 37)
(5) Damper T4: 58 (5.9, 43)
(6) Rear cushion rubber T5: 70 (7.1, 51)
(7) Rear crossmember T6: 140(14.3, 103)
MT-13
C: CAUTION Be sure to tighten fasteners including bolts and

Wear working clothing, including a cap, protec- nuts to the specified torque.
tive goggles, and protective shoes during opera- Place shop jacks or safety stands at the specified
tion. points.
Remove contamination including dirt and corro- Apply gear oil onto sliding or revolution surfaces
sion before removal, installation, and disassembly. before installation.
Keep the disassembled parts in order and pro- Replace deformed or otherwise damaged snap
tect them from dust or dirt. rings with new ones.
Before removal, installation or disassembly, be Before installing O-rings or oil seals, apply suffi-
sure to clarify the failure. Avoid unnecessary re- cient amount of gear oil to avoid damage and defor-
moval, installation, disassembly and replacement. mation.
When disassembling the case and other light al- Be careful not to incorrectly install or fail to install
loy parts, use a plastic hammer to force it apart. Do O-rings, snap rings and other such parts.
not pry it apart with a screwdriver or other tool. Before securing a part on a vice, place cushion-
Be careful not to burn your hands, because each ing material such as wood blocks, aluminum plate,
part on the vehicle is hot after running. or shop cloth between the part and the vice.
Use SUBARU genuine gear oil, grease etc. or Avoid damaging the mating surface of the case.
the equivalent. Do not mix gear oil, grease etc. with Before applying sealant, completely remove the
that of another grade or from other manufacturers. old seal.
D: PREPARATION TOOL
r. ~
1. SPECIAL TOOLS

398791700 REMOVER Used for removing and installing spring pin (6
mm).
B3M1938
39941 1700 ACCENT BALL Used for installing reverse shifter rail arm.
INSTALLER
B3M1939
MT-14
GENERAL DESCRIPTION 1
--t ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

399527700 'ULLER SET k e d for removing and installing roller bearing
Differential).
1) BOLT (899521412)
2) PULLER (399527702)
3) HOLDER (399527703)
4) ADAPTER (398497701)
5 ) BOLT (899520107)
6) NUT (021008000)
I B3M1940A
399780104 VEIGHT Jsed for measuring preload on roller bearing.
I B3M1941
498077000 3EMOVER Used for removing roller bearing of drive pinion
shaft.
I B3M194;
498077300 CENTER DIFFER- Used for removing the center differential cover
ENTIAL BEARING ball bearing.
REMOVER
I B3M194:
MT-15

498147000 DEPTH GAUGE Used for adjusting main shaft axial end play.
~~
498247001 MAGNET BASE Used for measuring backlash between side

gear and pinion, and hypoid gear.
Used with DIAL GAUGE (498247100).
-t B3M1945
498247100 31AL GAUGE m Used for measuring backlash between side
.
Used with MAGNET BASE (498247001).
r--- B3M1946
498427100 STOPPER Jsed for securing the drive pinion shaft assem-
3ly and driven gear assembly when removing the
jrive pinion shaft assembly lock nut.
I B3M1947
MT-16
GENERAL DESCRIPTION 3
ILLUSTRATION TOOL NUMBER DESCRIPTION

_ _ _- I REMARKS
498787100 JlAlN SHAFT Used for removing and installing transmission
;TOPPER main shaft lock nut.
B3M1948
498937000 rRANSMlSSlON Jsed for removing and installing transmission
i0LDER nain shaft lock nut.
B3M1945
499277100 BUSH 1-2 1 Used for installing 1st driven gear thrust plate
INSTALLER and 1st-2nd driven gear bush.
1 Used for installing roller bearing outer races to
jifferential case.
B3M195l
499277200 INSTALLER Used for press-fittingthe 2nd driven gear, roller
bearings, and 5th driven gear onto the driven
shaft.
B3M195
MT-17
GENERAL DESCRIPTION

499757002 INSTALLER Used for installing snap ring (OUT 25), and
ball bearing (25 x 26 x 17).
Used for installing bearing cone of transfer
driven gear (extension core side).
B3M1952
499787000 NRENCH ASSY Used for removing and installing differential side
retainer.
B3M1953
499827000 WESS Used for installing speedometer oil seal when
Installing speedometer cable to transmission.
B3M1954
499857000 jTH DRIVEN GEAR Jsed for removing 5th driven gear.
3EMOVER
B3M1955
MT-18
IL
TOOL NUMBER DESCRIPTION L
REMARKS
499877000 3ACE 4-5 1 Used for installing 4th needle bearing race and
NSTALLER ,all bearing onto transmission main shaft.
1 Used with REMOVER (8997141IO).
I
B3M1956
499917500 ]RIVE PINION Used for adjusting drive pinion shim.
3AUGE ASSY
+ B3M1957
499927100 HANDLE Used for fitting transmission main shaft.
I B3M1958
~
499937100 TRANSMISSION Stand used for transmission disassembly and

STAND SET assembly.
I B3M1959
MT-19

499987003 SOCKET WRENCH Used for removing and installing driven pinion
(35) lock nut and main shaft lock nut.
B3M1960
499987300 SOCKET WRENCH Used for removing and installing driven gear
(50) assembly lock nut.
...
B3M1961
8997141 10 REMOVER Used for fixing transmission main shaft, drive
pinion, rear drive shaft.
B3M1962
899864100 REMOVER Used for removing parts on transmission main
shaft and drive pinion.
B3M1963
MT-20

899884100 iOLDER Jsed for tightening lock nut on sleeve.
B3M1964
899904100 3 EMOVER Used for removing and installing straight pin.
B3M1965
899988608 SOCKET WRENCH Used for removing and installing drive pinion lock
?7) nut.
B3M1966
398497701 ADAPTER Used for installing roller bearing onto differen-
tial case.
Used with INSTALLER (499277100).
B3M1967
MT-21
GENERAL DESCRIPTION

499587000 INSTALLER Used for installing driven gears to driven shaft.
B3M1968
899824100 PRESS Used for installing speedometer shaft oil seal.
B3M1969
499987100 SOCKET WRENCH Llsed for removing and installing drive pinion lock
(35) IUt.
B3M1970
899984103 SOCKET WRENCH Jsed for removing and installing drive pinion lock
(35) IUt.
B3M1971
MT-22
GENERAL DESCRIPTION
I

498057300 NSTALLER Jsed for installing extension oil seal.
B3M1972
498255400 'LATE Used for measuring backlash.
B3M1973
498077400 REMOVER Used for removing synchronizer cone of main
shaft.
Used for removing 5th driven gear of drive pin-
ion shaft.
B3M1974
41099AA010 ENGINE SUPPORT Used for supporting engine.
BRACKET
B3M1975
MT-23
GENERAL DESCRIPTION
I
r------
ILLUSTRATION TOOL NUMBER
41099AA020
DESC R IPTION
ENGINE SUPPORT
REMARKS
Jsed for supporting engine.
398527700 PULLER ASSY Jsed for removing and installing extension case
*oiler bearing.
I-
B3M1977
398643600 GAUGE Jsed for measuring total end play, extension end
2lay and drive pinion height.
I B3M1978
38177700 INSTALLER 1 Used for installing bearing cone of transfer
driven gear (transfer case side).

1 Used for installing ball bearing of transfer drive
gear.
B3M1905
MT-24
GENERAL DESCRIPTION
1
TOOL NAME REMARKS

MT-25
I TRANSMISSION GEAR OIL
2. Transmission Gear Oil B: REPLACEMENT

1) Pull out oil level gauge.
A: INSPECTION 2) Lift-up the vehicle.
1) Park vehicle on a level surface. 3) Drain the transmission gear oil completely.
2) Turn the ignition switch to OFF, and wait until the
CAUTION:
engine cools. Directly after the engine has been running, the
3) Remove the oil level gauge and wipe it clean. transmission gear oil is hot. Be careful not to
4) Reinsert the level gauge all the way. Be sure burn yourself.
that the level gauge is correctly inserted and in the
proper direction. NOTE:
5) Pull out the oil level gauge again and check the Tighten the transmission gear oil drain plug after
oil level on it. If it is below the lower level, add oil draining transmission gear oil.
through the oil level gauge hole to bring the level up Tightening torque:
to the upper level. 44 N.m (4.5 kgf-m, 325 ft-lb)
e' A S3M0470A
(A) Drain plug

(B) Gasket

5 ) Pour the gear oil into the gauge hole.
Recommended gear oil:
Use GL-5 or equivalent.
Gear oil capacity:
3.5 0 (3.7 US 9t, 3.1 Imp 9t)
6 ) Check the level of the transmission gear oil.
CAUTION:
When inserting the level gauge into transmis-
sion gear, align the protrusion on the side of
the top part of the level gauge with the notch in
the gauge hole.
NOTE:
The level should be within the specified range
marked on the gauge.
MT-26
I
MANUAL TRANSMISSION ASSEMBLY
3. Manual Transmission As- (3) Vehicle speed sensor

sembly
A: REMOVAL
1) Open the front hood fully, and support with stay.
2) Disconnect the battery ground terminal.
3) Remove the air intake duct and cleaner case.
(Non-turbo model) <Ref. to IN(S0HC)-7, REMOV-
AL, Air Intake Duct.> and <Ref. to IN(S0HC)-6,
REMOVAL, Air Cleaner Case.>
4) Remove the air cleaner case stay. (Non-turbo
model)
7) Remove the starter. <Ref. to SC-6, REMOVAL,
Starter.>
8) Remove the operating cylinder from the trans-
mission.
Non-turbo model
5 ) Remove the intercooler (Turbo model) <Ref. to

6) Disconnect the following connectors.
(1) Neutral position switch connector
(2) Back-up light switch connector
Non-turbo model Turbo model
9) Remove the pitching stopper.

(A) Neutral switch (Brown)
(B) Back-up light switch (Gray)
Turbo model
MT-27
I MANUAL TRANSMISSION ASSEMBLY
10) Separate the clutch release fork from the re- 11) Set ST.
lease bearing. (Turbo model) NOTE:
(1) Remove the clutch operating cylinder from Also is available Part No. 927670000.
the transmission.
ST 41099AA020 ENGINE SUPPORT ASSY
(2) Remove the plug using 10 mm hexagon
wrench.
S2M1935 I 12) Remove the bolt which holds right upper side of
transmission to the engine.
(3) Screw the 6 mm dia. bolt into the release
fork shaft, and remove it.
B2M2791
13) Remove the front and center exhaust pipes.

(Non-turbo model) with OBD <Ref. to EX(S0HC)-
5, REMOVAL, Front Exhaust Pipe.>
14) Remove the center exhaust pipe. (Turbo mod-
el). <Ref. to EX(D0HC TURBO)-8, REMOVAL,
CAUTION:
When removing exhaust pipes, be careful each
exhaust pipe does not drop out.
S2M1936A 17) Remove the hanger bracket from right side of
transmission.
(A) Shaft
(B) Bolt I I W ' I
(4) Raise the release fork and unfasten the re-

lease bearing tabs to free release fork.
CAUTION:
Step (4) is required to prevent interference with
engine when removing engine from transmis-
sion.
I rJl \\ 0 B2M0032
18) Remove the propeller shaft. <Ref. to DS-14,

MT-28
1
19) Remove the gear shift rod and stay from trans- 22) Remove the spring pins and separate front
mission. drive shafts from each side of the transmission.
(1) Disconnect the stay from the transmission. CAUTION:
(2) Disconnect the rod from the transmission. Discard removing spring pin. Replace with a
new one.
2M0325
(4 Stay
(6) Rod 23) Remove the nuts which hold lower side of
transmission to the engine.
20) Disconnect the stabilizer link from the trans-
verse link.
2 1 ) Remove the bolt securing ball joint of trans-
verse link to housing.
Except sedan turbo model
B2M2790
24) Place the transmission jack under transmis-

sion.
CAUTION:
G4M0491 Always support transmission case with a trans-
mission jack.
Sedan turbo model
u
G2M0326
MT-29
I
25) Remove the transmission rear crossmember 6) Tighten the nuts which hold lower side of trans-
from the vehicle. mission to the engine.
Tightening torque:
50 N.m (5.1 kgf-m, 36.9 ft-lb)
26) Remove the transmission.

CAUTION: I 82M2790
Move transmission jack toward rear until main 7) Connect the engine and transmission.
shaft is withdrawn from clutch cover. (1) Install the starter.
27) Separate the transmission assembly and rear <Ref. to SC-7, INSTALLATION, Starter.>
cushion rubber. (2) Tighten the bolt which holds right upper side
of transmission to the engine.
B-:INSTALLATION
1) Install the rear cushion rubber to the transmis- Tightening torque:
sion assembly. 50 N.m (5.1 kgf-m, 36.9 ft-lb)
Tightening torque: I
35 N.m (3.6 kgf-m, 26.3 ft-lb)
2) Install the clutch release lever and bearing onto
the transmission. (Turbo model) <Ref. to CL-15,
INSTALLATION, Release Bearing and Lever.>
3) Install the transmission onto the engine.
(1) Gradually raise the transmission with trans-
mission jack.
(2) Engage them at splines.
CAUTION: B2M2791
Be careful not to strike main shaft against 8) Remove ST.

clutch cover.
4) Install the transmission rear crossmember.
Tightening torque:
T1: 70 N-m (7.1 kgf-m, 51 ft-lb)
T2: 140 N.m (14.3 kgf-m, 103 ft-lb)
5) Take off the transmission jack.
MT-30
I
9) Push the clutch release lever to fit bearing into 14) Drive the spring
. - .pin into the chamfered hole of
clutch cover. drive shaft.

CAUTION:
Always use a new spring pin.
/
H2M1818
10) Install the plug.

Tightening torque:
44 N.m (4.5 kgf-m, 32.5 ft-lb) 15) Install the ball joints of lower arm into knuckle
arm of housing, and tighten the installing bolts.
Tightening torque:
49 N-m (5.0 kgf-m, 36 ft-lb)
(4 Plug
(B) Transmission ASSY
- B2M3402A
Tightening torque: (A) Transverse link
T7: 50 Nom(5.7 kgf-m, 37 ft-lb) (B) Ball joint
T2: 58 N.m (5.9 kgf-m, 43 ft-lb)

13) Install the front drive shaft into the transmis-
sion.
MT-31
16) Install the stabilizer link from the transverse (2) Connect the stay to the transmission brack-
link. et.
Except sedan turbo model Tighfening torque:
Tightening torque: 18 N.m (1.8 kgf-m, 13.0 ft-lb)
30 N.m (3.1 kgf-m, 22.1 ft-lb)
(A) Stay
Sedan turbo model (B) Transmission bracket
Tightening torque:
45 N-m (4.6 kgf-m, 33.2 ft-lb)
20) Install the rear exhaust pipe and muffler.
21) Install the hanger bracket on the right side of
transmission.
17) Install the gear shift rod and stay.

(1) Connect the rod to the joint.
Tightening torque: (4, B2M0032
18 N-m (1.8 kgf-m, 13.0 ft-lb)
Install the front exhaust .pipe
. and center ex-
haust pipe. (Non-turbo model)
haust Pipe.>
24) install the under cover.
MT-32
I MANUAL TRANSMISSION ASSEMBLY 1
25) Install the operating cylinder.

Tightening torque:
37 N-m (3.8 kgf-m, 27.5 ft-lb)
Non-turbo model
Turbo model
26) Connect the following connectors.

(1) Transmission ground terminal
Tightening torque:
73 N-m (7.3 kgf-m, 9.4 ft-lb)
(2) Vehicle speed sensor connector
(3) Neutral position switch connector
(4) Back-up light switch connector
27) Install the air cleaner case stay.
Tightening torque:
76 N-m (7.6 kgf-m, 7 7.6 ft-lb)
28) Install the air cleaner case and intake duct.
(Non-turbo model) <Ref. to IN(S0HC)-6, INSTAL-
LATION, Air Cleaner Case.> and <Ref. to IN(S0-
HC)-7, INSTALLATION, Air Intake Duct.>
<Ref. to IN(D0HC TURBO)-1 1, INSTALLATION,
I ntercooler.>
31) Take off the vehicle from lift arms.
MT-33
I TRANSMISSION MOUNTING SYSTEM
I
4. Transmission Mounting Sys- 8) Remove the rear crossmember.

tem
A: REMOVAL
1. PITCHING STOPPER
3) Remove the air intake duct (Non-turbo model).
4) Remove the air cleaner case (Non-turbo model).
7 C J \ ' G2M0831
Case.> 9) Remove the rear cushion rubber.

5) Remove the inter cooler (Turbo model). <Ref. to
B: INSTALLATION
6) Remove the pitching stopper. 1. PITCHING STOPPER
Tightening torque:
T1: 50 N-m (5.1 kgf-m, 37 ff-lb)
T2: 58 N.m (5.9 kgf-m, 43 ff-lb)
2. CROSSMEMBER AND CUSHION RUB-

BER
racks.
2) Install the air intake duct and cleaner case. (Non-
3) Remove the front, center exhaust pipes. (Non-
turbo model)
turbo model)
Case.> and <Ref. to IN(S0HC)-7, INSTALLATION,
Pipe.>
Air Intake Duct.>
CAUTION: 3) Install the intercooler. (Turbo model)
When removing exhaust pipes, be careful each <Ref. to IN(D0HC TURBO)-11, INSTALLATION,
exhaust pipe does not drop out. Intercooler.>
4) Remove the center exhaust pipe. (Turbo model) 4) Connect the battery ground terminal.
<Ref. to EX(D0HC TURBO)-8, REMOVAL, Center
Exhaust Pipe.>
7) Set the transmissionjack under the transmission
body.
CAUTION:
Always support transmission case with a trans-
mission jack.
MT-34
TRANSMISSION MOUNTING SYSTEM
I
2. CROSSMEMBER AND CUSHION RUB- C: INSPECTION

BER Repair or replace parts if the results of the inspec-
1) Install for rear cushion rubber. tion below are not satisfactory.
Tighfening torque: 1. PITCHING STOPPER
35 N-m (3.6 kgf-m, 26 ff-lb) Make sure that the pitching stopper is not bent or
2 ) Install the crossmember. damaged. Make sure that the rubber is not stiff,
cracked, or otherwise damaged.
Tighfening torque:
T I : 70 N.m (7.1 kgf-m, 51 ff-lb) 2. CROSSMEMBER AND CUSHION RUB-
T2: 140 N-m (14.3 kgf-m, 103 ff-lb) BER
Make sure that the crossmember is not bent or
damaged. Make sure that the cushion rubber is not
stiff, cracked, or otherwise damaged.
3) Remove the transmission jack.

5) Install the front and center exhaust pipes. (Non-
turbo model)
<Ref. to EX(-S0HC)-6, INSTALLATION, Front Ex-
haust Pipe.>
MT-35
I OIL SEAL
I
5. Oil Seal 7 ) Using ST, install the oil seal.

ST 4$8057300 INSTALLER
A: INSPECTION
Inspect for oil leakage from the oil seal. Replace
the oil seal if the lips is deformed, hardened, dam-
aged, worn or defective if any.
B: REPLACEMENT
2) Drain the gear oil completely.
NOTE:
Tighten the drain plug after draining gear oil.
\ B3M1982
Tightening torque:
44 N.m (4.5 kgf-m, 32.5 ff-lb) 8) Install the propeller shaft. <Ref. to DS-15, IN-
11) Pour the gear oil and check the oil level. <Ref.
to MT-26, Transmission Gear Oil.>
1 g B3M0037
3) Remove the rear exhaust pipe and muffler,

5) Remove the propeller shaft. <Ref. to DS-14, RE-
MOVAL, Propeller Shaft.>
6) Using ST, remove the oil seal.
B3M2135A
(A) Oilseal
MT-36
SWITCHES AND HARNESS
I
6. Switches and Harness 6) Remove the back-up light switch and neutral po-
sition switch with harness.
A: REMOVAL
1. BACK-UP LIGHT AND NEUTRAL POSI-
TION SWITCH
1) Disconnect the connector battery ground termi-
nal.
AL, Air Cleaner Case.> and <Ref. to IN(S0HC)-7,
REMOVAL, Air Intake Duct.>
3) Remove the intercooler (Turbo model). <Ref. to
IN(D0HC TURBO)-I0, REMOVAL, Intercooler.>
(A) Neutral switch (Brown connector)
4) Disconnect the connector back-up light switch
and neutral position switch. (B) Back-up light switch (Gray connector)
Non-turbo model
(A) Neutral switch (Brown)

(B) Back-up light switch (Gray)
Turbo model
MT-37
I SWITCHES AND HARNESS
1. BACK-UP LIGHT SWITCH AND NEU- 1. BACK-UP LIGHT SWITCH
TRAL POSITION SWITCH Inspect the back-up light switch. <Ref. to LI-6, IN-
1) Install the back-up light switch and neutral posi- SPECTION, Back-up Light System.>
tion switch with harness.
2. NEUTRAL POSITION SWITCH
Tightening torque: 1) Turn the ignition switch to OFF.
24.5 N.m (2.5 kgf-m, 18.1 fi-lb)
2) Disconnect the connector neutral position
switch.
3) Measure the resistance between neutral position
switch terminal.
Non-turbo model
I Gear shift position I Terminal No. I Specified resistance I
Neutral position Less than 1R
1 and2 .
Other positions More than 1MR
Gear shift position Terminal No. Specified resistance

--- (A) Neutral switch
Neutral position
1 and 3
Less than 1R
Other positions More than 1MR
(B) Back-up light switch
2) Connect the connector of back-up light switch

and neutral position switch.
3) Install the air intake duct and cleaner case. (Non-
turbo model) <Ref. to IN(S0HC)-6, INSTALLA-
TION, Air Cleaner Case.> and <Ref. to IN(S0HC)-
7, INSTALLATION, Air Intake Duct.>
<Ref. to IN(D0HC TURBO)-I 1, INSTALLATION,
Intercooler.>
5 ) Connect the battery ground terminal.
Turbo model
TROlOl
4) Replace defective parts.
MT-38
VEHICLE SPEED SENSOR I
7. Vehicle Speed Sensor

A: REMOVAL
3) Remove the front and center exhaust pipes.
4) Disconnect the connector from vehicle speed
sensor.
5 ) Turn and remove the vehicle speed sensor.
-8: INSTALLATION
NOTE:
Discard the vehicle speed sensor and after re-
moval, replace with a new one.
Ensure the sensor mounting hole is clean and
free of foreign matter.
Align the tip end of key with key groove on the
end of speedometer shaft during installation.
1) Hand tighten the vehicle speed sensor.
2) Tighten the vehicle speed sensor using suitable
tool.
Tightening torque:
5.9 N-m (0.6 kgf-m, 4.3 ff-lb)
3) Connect the connector to vehicle speed sensor.
4) Install the front and center exhaust pipes.
5 ) Lower the vehicle.
C: INSPECTION
Inspect the vehicle speed sensor.
Non-Turbo model
<Ref. to EN(S0HC)-238, DTC PO500 - VEHICLE
SPEED SENSOR MALFUNCTION -, Diagnostic
Turbo model
<Ref. to EN(D0HC TURBO)-246, DTC PO500 -
VEHICLE SPEED SENSOR MALFUNCTION -,
Code (DTC).>
MT-39
I PREPARATION FOR OVERHAUL
I
8. Preparation for Overhaul

A: PROCEDURE
1) Clean the oil, grease, dirt and dust from trans-
mission.
2) Remove the drain plug to drain oil. After draining,
retighten it as before.
CAUTION:
Tightening torque:
44 N.m (4.5 kgf-m, 32.5 ft-lb)
3) Attach the transmission to ST.

ST 499937100 TRANSMISSION STAND
j G3M0517
4) Rotating parts should be coated with oil prior to

assembly.
5) All disassembled parts, if to be reused, should
be reinstalled in the original positions and direc-
tions.
6) Gaskets, lock washers and lock nut must be re-
placed with new ones.
7) Liquid gasket should be used where specified to
prevent leakage.
MT-40
TRANSFER CASE AND EXTENSION CASE ASSEMBLY
I
2j Remove the bearing cone from the extension

9. Transfer Case and Extension case assemblv, and install to taper roller bearing of
Case Assembly the transfer d h e n gear.
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle. <Ref. to MT-27, REMOVAL, Manual
Transmission Assembly.>
2) Remove the back-up light switch and neutral po-
sition switch. <Ref. to MT-37, REMOVAL, Switches
and Harness.>
3) Remove the transfer case with extension case
assembly.
(A) Bearing cone (Extensioncase)

(B) Extension case
3) While pressing the bearing cone horizontally,

turn the driven shaft ten rotations.
4) Measure the height “W’ between transfer case
and taper roller bearing on the transfer driven gear.
4) Remove the shifter arm.

5) Remove the extension case assembly.
5 ) Measure the depth “X’.

NOTE:
Measure with bearing cone and thrust washer re-
B3M1374 I moved.
B INSTALLATION
1) Install the center differential and transfer driven
gear into transfer case.
6) Calculate space “t” using the following equation:

t = X - W + 0.2 to 0.3 mm (0.008 to 0.012 in)
MT-41
TRANSFER CASE AND EXTENSION CASE ASSEMBLY
I
7) Select the nearest washer in the following table: 10) Measure the depth “T” between extension case
and transfer drive gear.
-
Standard clearance between thrust washer and
taper roller bearing: ST 398643600 GAUGE
0.2 - 0.3 mm T (0.008 - 0.012 in T)
NOTE:
T: Tight
I Thrust washer (50 x 61 x t) I
I Part No. I Thickness” (in) I
803050060 0.50 (0.01 97)
803050061 0.55 (0.0217)
803050062 0.60 (0.0236)
803050063 0.65 (0.0256) 3951
I 803050064 I 0.70 (0.0276) I 11) Calculate the space “U” using the following
803050065
equation: U = S - T
12) Select the suitable washer in the following ta-
803050067 ble:
Standard clearance:
I. 803050070 I 1.OO (0.0394) -10.15 - 0.35 mm (0.0059 - 0.0138 in)
803050071 1.05 (0.041 3) I Thrust washer I
803050072 1.10 (0.0433) Part No. Thickness mm (in)
803050073 1.15 (0.0453) 803036050 0.9 (0.035)
803050074 1.20 (0.0472) 803036054 1.O (0.039)
803050075 1.25 (0.0492) 803036051 1.1 (0.043)
803050076 1.30 (0.0512) 803036055 1.2 (0.047)
I 803050077 I 1.35 (0.0531) 1 803036052 1.3 (0.051)
803050078 1.40 (0.0551) I 803036056 I 1.4 (0.055) ~ -1
803050079 1.45 (0.0571) 803036053 1.5 (0.059)
803036057 1.6 (0.063)
803036058 1.7 (0.067)
407A
-
MT-42
I TRANSFER CASE AND EXTENSION CASE ASSEMBLY I
16) Install the extension assembly into the transfer C: DISASSEMBLY

case.
1. TRANSFER CASE
Tightening torque:
40N.m (4.1 kgf-m, 29.7 ff-lb) 1) Remove the reverse check assembly. <Ref. to
MT-50, REMOVAL, Reverse Check Sleeve.>
r 2) Remove the oil guide.
B3M 1374
17) Install the shifter arm to the transfer case. 83M1378

I
2. EXTENSION CASE
1) Remove the transfer drive gear assembly. <Ref.
to MT-45, REMOVAL, Transfer Drive Gear.>
2) Remove the shift bracket.
- w
B3M1396
18) Hang the shifter arm on the 3rd-4th fork rod.
B3M1381
3) Remove the oil seal from the extension case.

<Ref. to MT-36, OIL SEAL, .>
I B3M1397B I
19) Install the transfer case with extension case as-
sembly to the transmission case.
Tightening torque:
25N-m (2.5 kgf-m, 18.1 ff-lb)
/ B3M 1373
MT-43
I TRANSFER CASE AND EXTENSION CASE ASSEMBLY
D: ASSEMBLY
1. EXTENSION CASE
1) Using ST, install the oil seal to the extension
case. <Ref. to MT-36, Oil Seal.>
CAUTION:
Use new oil seal.
2) Install the shift bracket to the extension case.
Tightening torque:
25 N-m (2.5 kgf-m, 18.1 ff-lb)
3) Install the transfer drive gear to the extension

case. <Ref. to MT-45, INSTALLATION, Transfer
Drive Gear.>
2. TRANSFER CASE
1) Install the oil guide to the transfer case.
Tightening torque:
6.4 Nom(0.65 kgf-m, 4.7 ff-lb)
B3M137E
2) Install the reverse check sleeve assembly to the

transfer case. <Ref. to MT-50, INSTALLATION,
Reverse Check Sleeve.>
MT-44
TRANSFER DRIVE GEAR I
1O.Transfer Drive Gear C: DISASSEMBLY

1) Remove the snap ring.
A: REMOVAL
@
from vehicle. <Ref. to MT-27, REMOVAL, Manual C
and Harness.>
3) Remove the transfer case with extension case C
assembly. <Ref. to MT-41, REMOVAL, Transfer
Case and Extension Case Assembly.>
4) Remove the extension case assembly. B3M 198E
5) Remove the transfer driven gear.
2) Remove the ball bearing.
6) Remove the transfer drive gear.
B3M1986
INSTALLATION D: ASSEMBLY
1) Set the ST applying to inner race of bearing and
1) Install the transfer drive gear.
instal to drive shaft.
Tightening torque: ST 398177700 INSTALLER
26 N.m (2.7 kgf-m, 20 fi-lb) CAUTION:
Do not apply pressure in excess of 10 kN (1 ton,
1.1 US ton, 1.O Imp ton)
B3M198E
2) Install the transfer driven gear.

3) Install the extension case assembly.
4) Install the transfer case and extension case as- 2) Install the snap ring on transfer drive shaft.
sembly. <Ref. to MT-41, INSTALLATION, Transfer 3) Inspect the clearance between snap ring and in-
Case and Extension Case Assembly.> ner race of ball bearing. <Ref. to MT-46, INSPEC-
5 ) Install the back-up light switch and neutral posi- TION, Transfer Drive Gear.>
tion switch. <Ref. to MT-38, INSTALLATION,
Switches and Harness.>
6) Install the manual transmission assembly from
vehicle. <Ref. to MT-30, INSTALLATION, Manual
MT-45
I TRANSFER DRIVE GEAR
E: INSPECTION
1) Bearings
Replace bearings in the following cases:
Broken or rusty bearings
Worn or damaged
Bearings that fail to turn smoothly or make ab-
normal noise when turned after gear oil lubrication.
2) Drive gear
Replace drive gear in the following cases:
If their tooth surfaces and shaft are excessively
broken or damaged.
3) Measure the clearance between snap ring and
inner race of ball bearing with a thickness gauge.
Clearance:
0.0 1 - 0.15 mm (0.0004 - 0.0059 in)
B3M1991
If the measurement is not within the specification,

select suitable snap ring.
I Snap ring (Outer-30) I
805030041 1.53 (0.0602)
805030042 1.65 (0.0650)
805030043 1.77 (0.0697)
MT-46
TRANSFER DRIVEN GEAR I
11.Transfer Driven Gear B: INSTALLATION

1) Install the bearing cup to extension case and
A: REMOVAL transfer case.
and Harness.>
4) Remove the extension case assembly.
5) Remove the transfer driven gear.
6) Remove the bearing cup from extension case

and transfer-case. (A) Bearing cup
(B) Bearing cup
(C) Transfer case
(D) Extension case
2) Install the transfer driven gear.
3) Install the transfer case and extension case as-

sembly.<Ref. to MT-41, INSTALLATION, Transfer
4) Install the back-up light switch and neutral posi-
5) Install the manual transmission assembly to ve-
(A) Bearing cup (transfer case) hicle. <Ref. to MT-30, INSTALLATION, Manual
(B) Bearing cup (extension case) Transmission Assembly.>
MT-47
I TRANSFER DRIVEN GEAR
C: DISASSEMBLY D: ASSEMBLY
1) Using ST, remove the roller bearing (extension 1) Using ST, install the roller bearing (extension
case side). case side).
ST 498077000 REMOVER ST1 398177700 INSTALLER
ST2 899864100 REMOVER
CAUTION:
1.1 US ton, 1.0 Imp ton)
(A) Roller bearing
2) Using ST1 and ST2, remove the roller be&,ing

(transfer case side).
ST1 498077000 REMOVER
sJ2 899864100 REMOVER (A) Roller bearing
2) Using ST, install the roller bearing (transfer case

side).
CAUTION:
1.1 US ton, 1.O Imp ton)
(A) Roller bearing
(A) Roller bearing
E: INSPECTION
1) Bearings
Replace the bearings in the following cases:
Worn or damaged
2) Driven gear
Replace drive gear in the following cases:
If their tooth surfaces and shaft are excessively
broken or damaged.
MT-48
CENTER DIFFERENTIAL I
12.Center Differential C: DISASSEMBLY

NOTE:
A: REMOVAL Do not disassemble center differential because it is
1) Remove the manual transmission assembly a non-disassemble part.
Transmission Assembly.> Remove ball bearing using ST.
2) Remove the transfer case with extension case CAUTION:
assembly.<Ref. to MT-41, REMOVAL, Transfer Do not reuse ball bearing.
Case and Extension Case Assembly.> ST 498077300 CENTER DIFFERENTIAL
3) Remove the extension case assembly. <Ref. to BEARING REMOVER
MT-41, REMOVAL, Transfer Case and Extension 1
Case Assembly.>
4) Remove the transfer driven gear. <Ref. to MT-
47, REMOVAL, Transfer Driven Gear.>
5) Remove the center differential.
B: INSTALLATION
1) Install the center differential into transfer case.
2) Install the transfer driven gear. <Ref. to MT-47,
INSTALLATION, Transfer Driven Gear.>
3) Install the extension case assembly. <Ref. to
“MT-41, INSTALLATION,Transfer Case and Exten-
sion Case Assembly.> D: ASSEMBLY
4) Install the transfer case with extension case as- Install the ball bearing to center differential assem-
sembly. <Ref. to MT-41, REMOVAL, Transfer bly.
Case and Extension Case Assembly.> CAUTION:
5) Install the back-up light switch and neutral posi- Do not apply pressure in excess of 10 kN (1 ton,
tion switch. <Ref. to MT-37, REMOVAL, Switches 1.1 US ton, 1.O Imp ton).
and Harness.>
I
hicle. <Ref. to MT-30, INSTALLATION, Manual
B3M13998
(A) Ball bearing
E: INSPECTION
1) Bearings
Worn or damaged
Bearings having other defects
2) Center differential
Replace the center differential assembly in the fol-
lowing case:
Worn or damaged
MT-49
I REVERSE CHECK SLEEVE
I
13.Reverse Check Sleeve B: INSTALLATION

1) Install the reverse check sleeve.
A: REMOVAL
1) Remove the manual transmission assembly Tightening torque:
from vehicle. <Ref. to MT-27, REMOVAL, Manual 6.4 N-m (0.65 kgf-m, 4.7 ff-16)
3) Remove the shifter arm.
4) Remove the plug, spring washer and reverse
check ball.
B3M 1377 I
2) Install the ball, spring, washer and plug to trans-

fer case.
Tightening torque:
10 N-m (1.0 kgf-m, 7.2 ff-16)
5) Remove the reverse check sleeve.
3) Install the shifter arm to transfer case assembly.

I
. .
B3M1377 I
sembly. <Ref. to MT-41, INSTALLATION,Transfer
MT-50
REVERSE CHECK SLEEVE I
1) Cover the reverse check sleeve with a rag, and 1) Install the return spring (lst-2nd), return spring
remove snap ring using a screwdriver. cap, reverse accent shaft, check cam, return spring
NOTE: and check spring onto reverse check sleeve.
Replace the snap ring with a new one if deformed NOTE:
or weakened. Be sure the bent section of reverse check spring is
positioned in the groove in check cam.
B3M1383C
I B3M 1384A
(A) Snap ring
(A) Reverse check spring
2) Remove the reverse check plate, reverse check (B) Reverse check cam
‘spring, reverse check cam, return spring (5th-Rev), (C) Return spring (5th-Rev)
reverse accent shaft, return spring cap and return
(D) Reverse accent shaft
spring (1st-2nd).
(E) Return spring cap
I 1 (F) Return spring (1st-2nd)
(G) Reverse check sleeve
2) Hook the bent section of reverse check spring

over reverse check plate.
3) Rotate the cam so that the protrusion of reverse
check cam is at the opening in plate.
4) With cam held in that position, install plate onto
reverse check sleeve and hold with snap ring.
5) Position O-ring in groove in sleeve.
I B3M1384A I
(A) Reverse check plate
(8) Reverse check spring
(C) Return spring (5th-Rev)
(D) Reverse check cam
(E) Reverse accent shaft
(F) Return spring cap
(G) Return spring (1st-2nd)
3) Remove O-ring.
NOTE:
Reverse check sleeve assembly uses an O-ring
which should not be scratched.
Be careful not to break adjustment shim placed
between reverse check sleeve assembly and case.
MT-51
I REVERSE CHECK SLEEVE
E: INSPECTION F: ADJUSTMENT
Make sure the cutout section of reverse accent
shaft is aligned with the opening in reverse check 1. NEUTRAL POSITION ADJUSTMENT
sleeve. 1) Shift the gear into 3rd gear position.
Spin cam by hand for smooth rotation. 2) Shifter arm turns lightly toward the lst/2nd gear
Move cam and shaft all the way toward plate and side but heavily toward the reverse gear side be-
release. cause of the function of the return spring, until arm
If the cam does not return properly, replace reverse contacts the stopper.
check spring; if the shaft does not, check for 3) Make adjustment so that the heavy stroke (re-
scratches on the inner surface of sleeve. If the verse side) is a little more than the light stroke (lst/
sleeve is in good order, replace spring. 2nd side).
4) To adjust, remove bolts holding reverse check
sleeve assembly to the case, move sleeve assem-
bly outward, and place adjustment shim (0 to 1 ea.)
between sleeve assembly and case to adjust the
clearance.
CAUTION:
Be careful not to break O-ring when placing
shim(s).
NOTE:
r. - , B3M0048D
When the shim is removed, the neutral position
will move closer to reverse; when the shim is add-
(A) Snap ring ed, the neutral position will move closer to 1st gear.
If the shims alone cannot adjust the clearance,
(6) Reverse check plate
(C) Check spring
replace the reverse accent shaft and re-adjust.
(D) Checkcam
Select a suitable reverse accent shaft and re- Part No. Thickness mm (in)
verse check plate.<Ref. to MT-52, ADJUSTMENT, I 32190AA000 I 0.15 (0.0059) I
Reverse Check Sleeve.> I 32190AA010 I 0.30 (0.0118) I

Neutral position is closer to 1st
32188AA090 3
gear.
-
I 32188AA100 I 0 1 Standard I
1 32188AA110 I 1 I Neutral position is closer to
reverse aear. I
MT-52
REVERSE CHECK SLEEVE I
2. REVERSE CHECK PLATE ADJUST-

MENT
1) Shift the shifter arm to “5th” and then to reverse
to see if reverse check mechanism operates prop-
erly.
2) Also check to see if the arm returns to neutral
when released from the reverse position. If the arm
does not return properly, replace reverse check
plate.
Reverse check plate I
I Part No. (A):
No.
Angle
0
Remarks
Arm stops closer to

32189AA000 0 280
5th gear.
Arm stops closer to
32189AA010 1 310
5th gear.
Arm stops in the cen-
32 189AA020 2 340
ter.
Arm stops closer to
32189AA030 3 370
reverse gear.
Arm stops closer to
32 189AA040 4 400
reverse gear.
B3M00540
MT-53
I TRANSMISSION CASE I
14.Transmission Case 7) Separate the transmission case into the right

and left cases by loosening coupling bolts and nuts.
A: REMOVAL
2) Remove the clutch release lever. <Ref. to CL-
15, REMOVAL, Release Bearing and Lever.>
4) Remove the bearing mounting bolts.
1 03M 1359
8) Remove the drive pinion shaft assembly from left

side transmission case.
NOTE:
Use a hammer handle, etc. to remove if too tight.
5 ) Remove the main shaft rear plate.
(A) Main shaft assembly

(B) Drive pinion shaft assembly
9) Remove the main shaft assembly.
10) Remove the differential assembly.
I I S3M0100C CAUTION:
Be careful not to confuse right and left roller
(A) Main shaft rear plate bearing outer races.
6) Put the vinyl tape around splines of the right and Be careful not to damage retainer oil seal.
left axle drive shafts to prevent damage to oil seal.
I I I \\ \
B3M14050
(A) Vinyl tape
MT-54
TRANSMISSION CASE
I
B: INSTALLATION 8) Backlash adjustment of hypoid gear and preload

1) Wipe off grease, oil and dust on the mating sur- adjustment of roller bearing
faces of transmission cases with white gasoline. NOTE:
2) Install the front differential assembly. Support the drive pinion assembly with ST. (AWD
3) Install the main shaft assembly. model)
Install the needle bearing knock pin hole into trans- ST 4984271 00 STOPPER
mission case knock pin.
4) Install the drive pinion shaft assembly.
Install the roller bearing knock pin hole into trans-
mission case knock pin.
5) Apply the liquid gasket, and then put the case
right side and left side together.
Liquid gasket:
6) Tighten seventeen bolts with bracket, clip, etc.
as shown in the figure. L - I
B3M1362A
NOTE:
Insert the bolts from the bottom and tighten nuts 9) Place the transmission with case left side facing
at the top. downward and put ST1 on bearing cup.
- 0 - Put the cases together so that the drive pinion
10) Screw the retainer assembly into left case from
shim and input shaft holder shim are not caught up the bottom with ST2. Fit ST3 on the transmission
in between. main shaft. Shift gear into 4th or 5th and turn the
Confirm that speedometer gear is meshed. shaft several times. Screw in the retainer while
turning ST3 until a slight resistance is felt on ST2.
Tightening torque: This is the contact point of hypoid gear and drive
8 mm bolt pinion shaft. Repeat the above sequence several
25 Nom(2.5 kgf-m, 18.1 ft-16) times to ensure the contact point.
*10 mm bolt
39 N.m (4.0 kgf-m, 28.9 ft-lb)
ST1 399780104 WEIGHT
ST2 499787000 WRENCH ASSY
ST3 4999271 00 HANDLE
03M1361A
7) Tighten the ball bearing attachment bolts.
Tightening torque:
29 N-m (3.0 kgf-m, 21.7 ft-16)
MT-55
I TRANSMISSION CASE
11) Remove weight and screw in retainer without 17) After checking the tooth contact of hypoid
O-ring on the upper side and stop at the point gears, remove the lock plate. Then loosen the re-
where slight resistance is felt. tainer until the O-ring groove appears. Fit O-ring
NOTE: into the groove and tighten the retainer into the po-
At this point, the backlash between the hypoid gear sition where retainer has been tightened in.
and drive pinion shaft is zero. Tighten the lock plate.
ST 499787000 WRENCH ASSY NOTE:
Carry out this job on both upper and lower retain-
ers.
Tightening torque:
T: 25 N-m (2.5 kgf-m, 18.1 fi-lb)
12) Fit lock plate. Loosen the retainer on the lower

side by 1-112 notches of lock plate and turn in the
6tainer on the upper side by the same amount in
order to obtain the backlash. S3M0014C
NOTE: 18) Selecting of main shaft rear plate <Ref. to MT-

The notch on the lock plate moves by 1/2 notch if 62, ADJUSTMENT, Main Shaft Assembly for Sin-
the plate is turned upside down. gle-Range.>
13) Turn in the retainer on the upper side addtion- 19) Install the clutch release lever and bearing.
ally by 1 notch in order to apply preload on taper <Ref. to CL-15, INSTALLATION, Release Bearing
roller bearing. and Lever.>
14) Tighten temporarily both the upper and lower 20) Install the transfer case with extension case as-
lock plates and mark both holder and lock plate for sembly. <Ref. to MT-41, INSTALLATION, Transfer
later readjustment. Case and Extension Case Assembly.>
15) Turn the transmission main shaft several times 21) Install the manual transmission assembly into
while tapping around retainer lightly with plastic the vehicle.<Ref. to MT-30, INSTALLATION, Man-
hammer. ual Transmission Assembly.>
16) Inspect and adjust backlash and tooth contact C: INSPECTION
of hypoid gear. <Ref. to MT-74, INSPECTION,
Front Differential Assembly.> Check the transmission case for cracks, damage,
and oil leaks.
MT-56
MAIN SHAFT ASSEMBLY FOR SINGLE-RANGE
I
15.Main Shaft Assembly for Sin- C: DISASSEMBLY

1) Put the vinyl tape around main shaft splines to
gle-Range protet oil seal from damage. Then pull out the oil
A: REMOVAL seal and needle bearing by hand.
1) Remove the manual transmission assembly 2) Remove the lock nut from transmission main
from vehicle. <Ref. to MT-27, REMOVAL, Manual shaft assembly.
Transmission Assembly.> NOTE:
2) Remove the transfer case with extension case Remove the caulking before off lock nut.
assembly. <Ref. to MT-41, REMOVAL, Transfer ST1 499987000 TRANSMISSION HOLDER
Case and Extension Case Assembly.> ST2 498937003 SOCKET WRENCH (35)
3) Remove the transmission case. <Ref. to MT-41,
REMOVAL, Transfer Case and Extension Case
Assembly.>
4) Remove the drive pinion shaft assembly. <Ref.
to MT-63, REMOVAL, Drive Pinion Shaft Assem-
bly.>
B: INSTALLATION
1) Install the needle bearing and oil seal onto the
front of transmission main shaft assembly.
r.
CAUTION:
Wrap clutch splined section with vinyl tape to 3) Remove the 5th-Rev sleeve and hub assembly,
prevent damage to oil seal. baulk ring, 5th drive gear and needle bearing.
Apply grease (Unilube #2 or equivalent) to the
sealing lip of oil seal.
Use a new one. )
2) Install the needle bearing outer race knock pin
hole into transmission case knock pin.
NOTE:
Align the end face of seal with surface (A) when in-
stalling oil seal.
I
A// / 03MQ4378
(A) 5th-Rev sleeve and hub ASSY

(B) Baulk ring
(C) 5th drive gear
4) Remove the snap ring and synchro cone stopper

from 5th-Rev sleeve and hub assembly.
B3M0528A
3) Install the drive pinion assembly. <Ref. to MT-63,

INSTALLATION, Drive Pinion Shaft Assembly.>
4) Install the transmission case. <Ref. to MT-55, IN-
STALLATION, Transmission Case.>
sembly. <Ref. to MT-41, INSTALLATION, Transfer
6) Install the manual transmission assembly to ve- w B3M0435E
Transmission Assembly.> (A) Synchro cone stopper
(B) Snap ring
MT-57
I MAIN SHAFT ASSEMBLY FOR SINGLE-RANGE
5) Using ST1, ST2 and a press, remove the ball 6) Using ST1 and ST2, remove the rest of parts.
bearing, synchro cone and baulk ring (Rev). NOTE:
NOTE: Replace sleeve and hub with new ones. Do not at-
Replace the sleeve and hub with new ones. Do tempt to disassemble because they must engage
not attempt to disassemble because they must en- at a specified point. If they should be disassem-
gage at a specified point. If they should be disas- bled, marking engagement point on splines before-
sembled, mark engagement point on the splines hand.
beforehand. ST1 899864100 REMOVER
Do not reuse the ball bearing. ST2 8997141 10 REMOVER
ST1 499757002 INSTALLER
ST2 498077400 SYNCHRO CONE REMOV- Press
ER n
fl
(A) Ball bearing
(B) Synchro cone
(C) Baulk ring
03MQ035A
MT-58
I
D: ASSEMBLY 3) Install the 4th needle bearing race onto transmis-

1) Assemble each sleeve and hub assembly. sion main shaft using ST1, ST2 and a press.
NOTE: CAUTION:
Position open ends of spring 120" apart. Do not apply pressure in excess of 10 kN (1 ton,
1.1 US ton, 1.0 Imp ton).
3rd-4th hub ASSY ST1 8997141 10 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
3rd gear
5th-Rev hub ASSY
- vyY//-'/ B3M0543C
(A) 4th needle bearing race
4) Install the baulk ring, needle bearing, 4th drive

gear and 4th gear thrust washer to the transmission
main shaft.
NOTE:
Align the baulk ring and gear & hub assembly with
B3M1366A
key groove.
2) Install the 3rd drive gear, outer baulk ring, syn-
chro cone, inner baulk ring, sleeve and hub assem-
bly for 3rd needle bearing on the transmission main
shaft.
NOTE:
Align the groove in baulk ring with shifting insert.
S3M0045P
(A) Groove
7 d-r- (B) 4th gear side
(A) 3rd needle bearing

(B) 3rd drive gear
(C) Inner baulk ring
(D) Synchro cone
(E) Outer baulk ring
(F) Sleeve and hub ASSY
MT-59
5) Drive the ball bearing onto the rear section of 7) Install the bearing onto synchro cone.
transmission main shaft using ST1, ST2 and a 8) Install the baulk ring and synchro cone onto 5th-
press. Rev sleeve and hub assembly using ST and a
CAUTION: press.
Do not apply pressure in excess of 10 kN (1 ton, CAUTION:
1.1 US ton, 1.O Imp ton). Do not apply pressure in excess of 10 kN (1 ton,
ST1 8997141 10 REMOVER 1.1 US ton, 1.0 Imp ton).
ST2 499877000 RACE 4-5 INSTALLER NOTE:
Use new ball bearing.
After press fitting, make sure synchro cone ro-
tates freely.
6) Using ST1 and ST2, install the 5th gear thrus

iasher and 5th needle bearing race onto the rear
section of transmission main shaft.
CAUTION:
Do not apply pressure in excess of 10 kN (1 ton, (A) Baulk ring
1.1 US ton, 1.O Imp ton).
(B) Synchro cone
NOTE: (C) Ball bearing
Face the thrust washer in the correct direction.
ST1 8997141 10 REMOVER 9) Install the synchro cone stopper and snap ring to
ST2 499877000 RACE 4-5 INSTALLER 5th-Rev sleeve and hub assembly.
B3M0091D u B3M04358
(A) Face this surface to 5th gear side. (A) Synchro cone stopper
(B) Snap ring
MT-60
1
10) Install the rest parts to the rear section of trans- E: INSPECTION
mission main shaft. Disassembled parts should be washed clean first
NOTE: and then inspected carefully.
Align the groove in baulk ring with shifting insert. 1) Bearings
Bearings whose balls, outer races and inner rac-
es are broken or rusty.
Worn bearings
2) Bushing (each gear)
Replace the bushing in the following cases:
When the sliding surface is damaged or abnor-
mally worn.
When the inner wall is abnormally worn.
(A) Needle bearing 3) Gears
(B) 5th drive gear Replace the gears with new ones if their tooth
(C) Baulk ring surfaces are broken, damaged, or excessively
(D) 5th-Rev sleeve and hub ASSY worn.
r. (E) Lock washer Correct or replace if the cone that contacts the
(F) Lock nuts baulk ring is rough or damaged.
Correct or replace if the inner surface or end face
11) Tighten the lock nuts to the specified torque us- is damaged.
ing ST1 and ST2. 4) Baulk ring
NOTE: Replace the ring in the following cases:
Secure the lock nuts in two places after tightening. When the inner surface and end face are dam-
ST1 499987003 SOCKET WRENCH aged.
ST2 498937000 TRANSMISSION HOLDER When the ring inner surface is abnormally or par-
tially worn down.
Tightening torque: When the contact surface of the synchronizer
118 N.m (12.0 kgf-m, 86.8 ff-lb) ring insert is scored or abnormally worn down.
5) Shifting insert key
Replace the insert if deformed, excessively worn,
or defective in any way.
&
S3M0189
6) Oil seal
Replace the oil seal if the lip is deformed, hard-
ened, damaged, worn, or defective in any way.
7) O-ring
Replace the O-ring if the sealing face is deformed,
hardened, damaged, worn, or defective in any way.
MT-61
8) Gearshift mechanism
Repair or replace the gearshift mechanism if ex-
cessively worn, bent, or defective in any way.
F: ADJUSTMENT
Selection of main shaft rear plate
Using ST, measure the amount (A) of ball bearing
protrusion from transmission main case surface
and select the proper plate in the following table:
NOTE:
Before measuring, tap the end of main shaft with a
plastic hammer lightly in order to make the clear-
ance zero between the main case surface and the
moving flange of bearing.
ST 498147000 DEPTH GAUGE
~ _ _ _ _~
Dimension (A)
Part No. Mark
mm (in)
4.00 - 4.13
I
e*
(0.1575 -
0.1626)
3.87- 3.99
I 32294AA041 I 1
(0.1524 - 32294AA051 2
0.1571)
MT-62
DRIVE PINION SHAFT ASSEMBLY 3
16.Drive Pinion Shaft Assembly 4) Inspection and adjustment of ST

NOTE:
A: REMOVAL Loosen the two bolts and adjust so that the scale
1) Remove the manual transmission assembly indicates 0.5 correctly when the plate end and the
from vehicle. <Ref. to MT-27, REMOVAL, Manual scale end are on the same level.
Transmission Assembly.> Tighten the two bolts.
2) Remove the transfer case with extension case ST 499917500 DRIVE PINION GAUGE
assembly. <Ref. to MT-41, REMOVAL, Transfer ASSY
3) Remove transmission case. <Ref. to MT-54, RE-
MOVAL, Transmission Case.>
4) Remove the drive pinion shaft assembly.
NOTE:
Use a hammer handle, etc. to remove if too tight.
*- (A) Plate
(B) Scale
5 ) Position the ST by inserting the knock pin of ST

into the knock hole in the transmission case.
ST 49991 7500 DRIVE PINION GAUGE
ASSY
(A) Main shaft assembly
6) Slide the drive pinion gauge scale with finger tip
(B) Drive pinion shaft assembly
and read the value at the point where it matches
with the end face of drive pinion.
B: INSTALLATION ST 499917500 DRIVE PINION GAUGE
1) Remove the differential assembly. ASSY
2) Alignment markshumbers on hypoid gear set
The upper number on driven pinion is the match
number for combining it with hypoid driven gear.
The lower number is for shim adjustment. If no low-
er number is shown, the value is zero. The number
on hypoid driven gear indicates a number for com-
bination with drive pinion.
11. B3M0065C I
(A) Adjust clearance to zero without shim.
7) The thickness of shim shall be determined by

adding the value indicated on drive pinion to the
value indicated on the ST. (Add if the number on
G3M0554 drive pinion is prefixed by + and subtract if the num-
ber is prefixed by -.)
3) Place the drive pinion shaft assembly on right
ST 499917500 DRIVE PINION GAUGE
hand transmission main case without shim and
ASSY
tighten the bearing mounting bolts.
MT-63
I DRIVE PINION SHAFT ASSEMBLY
I
8) Select one to three shims from the next table for C: DISASSEMBLY
the value determined as described above and take
a shim thickness which is closest to the said value. CAUTION:
Attach a cloth to the end of driven shaft (on the
frictional side of thrust needle bearing) during
Part No. Thickness mm (in) disassembly or reassembly to prevent damage.
I 32295AA031 I 0.1 50 (0.0059) 1) Straighten the lock nut at staked portion. Re-
I 32295AA041 I 0.175 (0.0069) move the lock nut using S T l , ST2 and ST3.
32295AA051 0.200 (0.0079) ST1 899884100 HOLDER
32295AA061 0.225 (0.0089) ST2 4984271 00 STOPPER
32295AA071 0.250 (0.0098) ST3 899988608 SOCKET WRENCH (27)
32295AA081 0.275 (0.0108)
I 32295AA091 I 0.300 (0.0118)
I 32295AA101 I 0.500 (0.0197)
9) Install the differential assembly. <Ref. to MT-71,

INSTALLATION, Front Differential Assembly.>
10) Set the transmission main shaft assembly and
drive pinion assembly in position. (So there is no
clearance between the two when moved all the way
to the front). Inspect the suitable 1st - 2nd, 3rd -
4th and 5th shifter fork so that the coupling sleeve G3M0595
and reverse driven gear are positioned in the cen- 2) Withdraw the drive pinion from driven shaft.
ter of their cynchronizing mechanisms. <Ref. to
Remove the differential bevel gear sleeve, adjust-
MT-68, INSPECTION, Drive Pinion Shaft Assem-
ing washer No. 1, adjusting washer No. 2, thrust
bly.> bearing, needle bearing, drive pinion collar, needle
11) Install the transmission case. <Ref. to MT-55, bearing and thrust bearing.
INSTALLATION, Transmission Case.>
hicle.<Ref. to MT-27, Manual Transmission As-
sembly.>
Differential bevel gear sleeve

Washer No. 1 (25 x 37.5 x t)
Thrust bearing (25 x 37.5 x 3)
Washer No. 2 (25 x 37.5 x 4)
Needle bearing (25 x 30 x 20)
Drive pinion collar
Needle bearing (30 x 37 x 23)
Thrust bearing (33 x 50 x 3)
MT-64
DRIVE PINION SHAFT ASSEMBLY
I
3) Remove the roller bearing and washer using ST 7) Remove the roller bearing, 3rd-4th driven gear
and press. using ST1 and ST2.
CAUTION: ST1 499757002 INSTALLER
Do not reuse roller bearing. ST2 8997141 10 REMOVER
ST 498077000 REMOVER
I
G3M060; 8) Remove the key.

9) Remove the 2nd driven gear, inner baulk ring,
4) Straighten the lock nut at staked portion. Re-
synchro cone and outer baulk ring.
move the lock nut using ST1 and ST2.
ST1 499987300 SOCKET WRENCH (50)
ST2 899884100 HOLDER
c.
(A) 2nd driven gear

(B) Inner baulk ring
5) Remove the 5th driven gear using ST. (C) Synchro cone
ST 499857000 5TH DRIVEN GEAR REMOV- (D) Outer baulk ring
ER
10) Remove the 1st driven gear, 2nd gear bushing,
gear and hub using ST1 and ST2.
NOTE:
Replace the gear and hub if necessary. Do not at-
tempt to disassemble if at all possible because they
must engage at a specified point. If they have to be
disassembled, mark the engaging point before-
hand.
STl 499757002 INSTALLER
ST2 8997141 10 REMOVER
6) Remove the woodruff key.
G3M0611
MT-65
11) Remove the sub gear for 1st driven gear. ST1 499277200 INSTALLER
D: ASSEMBLY
1) Install the sleeve and assembly by matching
alignment marks.
NOTE:
Use the new gear and hub assembly, if the gear
or hub have been replaced.
5) Install the 2nd driven gear, inner baulk ring, syn-

chro cone, outer baulk ring and insert onto driven
shaft.
B3M0077E n n
(A) 1st gear side
-+ (B) 2nd gear side
(C) Flush surface
(D) Stepped surface
2) Install the washer, snap ring and sub gear to 1st

driven gear. ( ) ( S3M0445A
3) Install the 1st driven gear, 1st baulk ring, gear
and hub assembly onto driven shaft.
(A) 2nd driven gear
NOTE: (B) Inner baulk ring
Take care to install gear and hub assembly in (C) Synchro cone
proper direction. (D) Outer baulk ring
Align the baulk ring and gear & hub assembly
with key groove. 6) After installing key on driven shaft, install the
4) Install the 2nd driven gear bushing onto driven 3rd-4th driven gear using ST and press.
shaft using ST1, ST2 and press. CAUTION:
CAUTION: Do not apply pressure in excess of 10 kN (1 ton,
Attach a cloth to the end of driven shaft to 1.1 US ton, 1.0 Imp ton).
prevent damage. NOTE:
Do not apply pressure in excess of 10 kN (1 Align the groove in baulk ring with insert.
ton, 1.1 US ton, 1.0 Imp ton). ST 499277200 INSTALLER
NOTE:
When press fitting, align the oil holes of shaft and
bush.
G3M061.5
MT-66
DRIVE PINION SHAFT ASSEMBLY il
7) Install a set of roller bearings onto the driven NOTE:

shaft using ST and press. Stake the lock nut at two points.
CAUTION: Using spring balancer, check that starting torque
Do not apply pressure in excess of 10 kN (1 ton, of roller bearing is 0.1 to 1.5 N (0.01 to 0.15 kgf,
1.1 US ton, 1.O Imp ton). 0.02 to 0.33ft).
I I
G3M0616 10) Install the roller bearing onto drive pinion.

8) Position the woodruff key in groove on the rear of NOTE:
driven shaft. Install 5th driven gear onto drive shaft When installing roller bearing, note its directions
using ST and press. (front and rear) because the knock pin hole in outer
r.
CAUTION: race is offset.

1.1 US ton, 1.O Imp ton).
' \
(B) B3M1661A
(A) Roller bearing

(B) Knock pin hole
G3M0617
9) Install the lock washer. Install lock nut and tight- 11) Install the washer using STI, ST2 and press.
en to the specified torque using ST. CAUTION:
ST 499987300 SOCKET WRENCH (50) Discard old lock nuts, replace with new ones.
Tightening torque: Secure lock nut in four places.
265 N.m (27 kgf-m, 195 ff-lb) STI 4992771 00 BUSH 1-2 INSTALLER
I .
(A) Washer
MT-67
12) Install the thrust bearing and needle bearing. The ball bearing on the rear side of the drive pin-
Install the driven shaft assembly. ion shaft should be checked for smooth rotation be-
fore the drive pinion assembly is disassembled. In
this case, because a preload is working on the
r-:-- bearing, its rotation feels like it is slightly dragging

unlike the other bearings.
B3M0082
13) Install the drive pinion collar, needle bearing,

adjusting washer No. 2, thrust bearing, adjusting
washer No. 1 and differential bevel gear sleeve in
B3M0038E
that order.
NOTE: (A) Drive pinion shaft
Be careful because the spacer must be installed in (B) Ball bearing
proper direction.
r- - I
2) Bushing (each gear)
Replace the bushing in the following cases:
When the sliding surface is damaged or abnor-
mally worn.
When the inner wall is abnormally worn.
3) Gears
Replace gears with new ones if their tooth sur-
faces are broken, damaged, or excessively worn.
Correct or replace if the cone that contacts the
baulk ring is rough or damaged.
Correct or replace if the inner surface or end face
(A) Driven shaft is damaged.
(B) Drive shaft 4) Baulk ring
(C) Drive pinion collar Replace the ring in the following cases:
(D) Needle bearing (25 x 30 x 20) When the inner surface and end face are dam-
(E) Washer No. 2 (25 x 36 x 4) aged.
(F) Thrust bearing (25 x 37.5 x 3) When the ring inner surface is abnormally or par-
(G) Washer No. 1 (25 x 36 x t) tially worn down.
(H) Differential bevel gear sleeve
If the gap between the end faces of the ring and
the gear splined part is excessively small when the
E: INSPECTION ring is pressed against the cone.
Disassembled parts should be washed clean first Clearance (A):
and then inspected carefully. 0.5 - 1.0 mm (0.020 - 0.040 in)
1) Bearings
Replace bearings in the following cases:
Bearings whose balls, outer races and inner rac-
es are broken or rusty.
Worn bearings
/I \

I
S3M0188A
MT-68
DRIVE PINION SHAFT ASSEMBLY I
When the contact surface of the synchronizer 2) Using ST1, ST2 and ST3, tighten the lock nut to
ring insert is scored or abnormally worn down. the specified torque.
5) Shifting insert key ST1 899884100 HOLDER
Replace the insert if deformed, excessively worn, ST2 498427100 STOPPER
or defective in any way. ST3 899988608 SOCKET WRENCH (27)
7- I Tightening torque:
118 N.m (12 kgf-m, 86.8 ft-16)
6) Oil seal
Replace the oil seal if the lip is deformed, hard- G3M0626
ened, damaged, worn, or defective in any way.
3) After removing ST2, measure the starting torque
7) O-ring
using torque driver.
&place the O-ring if the sealing face is deformed,
ST1 899884100 HOLDER
hardened, damaged, worn, or defective in any way.
ST3 899988608 SOCKET WRENCH (27)
F: ADJUSTMENT Starting torque:
1. THRUST BEARING PRELOAD 0.3 - 0.8 N-m
(0.03 - 0.08 kgf-m, 0.2 - 0.6 ft-16)
1) After completing the preceding steps 1) through
3), select adjusting washer No. 1 so that the dimen-
sion (H) is zero through visual check. Position
washer (18.3 x 30 x 4) and lock washer (18 x 30 x
2) and install lock nut (18 x 13.5).
4) If starting torque is not within specified limit, se-

lect new adjusting washer No. 1 and recheck start-
ing torque.
\-,
B3M05361
(A) Adjusting washer No.1

(B) Adjusting washer No.2
MT-69
DRIVE PINION SHAFT ASSEMBLY
I
I Adjusting washer No. 1 I

Part No.
803025052 3.950 (0.1555)
803025055 4.025 (0.1585)

803025056 4.050 (0.1594)
803025057 4.075 (0.1604)
I B3M05361
(A) Adjusting washer No. 1

(B) Adjusting washer No. 2
I Starting torque I Dimension H I Washer No. 2 1

I Low I Small I Select thicker one. I
I Part No. I Thickness mm

I 803025059 I 3.850 (0.1516) I
803025054 4.000 (0.1575)
803025058 4.150 (0.1634)
MT-70
FRONT DIFFERENTIAL ASSEMBLY
1
17.Front Differential Assembly B: INSTALLATION

1) Install the differential side retainers using ST.
A: REMOVAL ST 499787000 WRENCH ASSY
1) Remove the manual transmission assembly 2) Install the differential assembly.
Be careful not to fold the sealing lip of oil seal.
assembly. <Ref. to MT-41, REMOVAL, Transfer NOTE:
Case and Extension Case Assembly.> Wrap the left and right splines sections of axle shaft
3) Remove the transmission case. <Ref. to MT-54, with vinyl tape to prevent scratches.
REMOVAL, Transmission Case.>
4) Removes the drive pinion shaft assembly. <Ref.
bly.>
<Ref. to MT-57, REMOVAL, Main Shaft Assembly
for Single-Range.>
6) Remove the differential assembly.
CAUTION:
Be careful not to confuse right and left roller
-bearing outer races.
Be careful not to damage retainer oil seal. 3) Install the main shaft assembly. <Ref. to MT-57,
INSTALLATION, Main Shaft Assembly for Single-
Range.>
4) Install the drive pinion assembly. <Ref. to MT-63,
INSTALLATION, Drive Pinion Shaft Assembly.>
STALLATION, Transmission Case.>
7) Remove the differential side retainers using ST.
ST 499787000 WRENCH ASSY
MT-71
I FRONT DIFFERENTIAL ASSEMBLY
C: DISASSEMBLY 4) Pull out the pinion shaft, and remove the differ-
1) Remove the right and left snap rings from differential bevel pinion and gear and washer.
ential, and then remove the two axle drive shafts.
NOTE:
During reassembly, reinstall each axle drive shaft
in the same place from which it was removed.
2) Loosen the twelve bolts and remove hypoid driv-
en gear.
(A) Pinion shaft

(B) Bevel pinion
(C) Bevel gear
(D) Washer
5) Remove the roller bearing using ST.

ST 399527700 PULLER SET
G3M0668
(A) Snap ring D: ASSEMBLY

(B) Axle drive shaft
1) Install the bevel gear and bevel pinion together
(C) Hypoid driven gear with washers, and insert pinion shaft.
3) Drive out the straight pin from differential assem- NOTE:
bly toward hypoid driven gear. Face the chamfered side of washer toward gear.
+I
A'L G3M0667
(A) Bevel pinion
(B) Bevel gear
(C) Pinion shaft
MT-72
FRONT DIFFERENTIAL ASSEMBLY 1
2) Measure the backlash between bevel gear and 4) Install the roller bearing to differential case.
pinion. If it is not within specifications, install a suit- CAUTION:
able washer to adjust it. <Ref. to MT-75, ADJUST- Do not apply pressure in excess of 10 kN (1 ton,
MENT, Front Differential Assembly.> 1.1 US ton, 1.O Imp ton).
NOTE: NOTE:
Be sure the pinion gear tooth contacts adjacent Be careful because roller bearing outer races are
gear teeth during measurement. used as a set.
STl 498247001 MAGNET BASE STl 499277100 BUSH 1-2 INSTALLER
ST2 4982471 00 DIAL GAUGE ST2 398497701 ADAPTER
Standard backlash:
0.73 - 0.78 mm (0.0057 - 0.0077 in)
I I
\- / I
I ST2 y
G3M0671
5) Install the hypoid driven gear to differential case

G3M0670 using twelve bolts.
3) Align the pinion shaft and differential case at Tightening torque:
their holes, and drive straight pin into holes from T: 62 N.m (6.3 kgf-m, 45.6 ft-lb)
the hypoid driven gear side, using ST.
I
NOTE:
Lock the straight pin after installing.
. .
B3M0554C
(A) Hypoid driven gear

(B) Differential case
B3M0609C
(A) Pinion shaft

(B) Differential case
(C) Straight pin
MT-73
E: INSPECTION 1. BEVEL PINION GEAR BACKLASH

Repair or replace the differential gear in the follow- Measure the backlash between bevel gear and pin-
ing cases: ion. If it is not within specifications, install a suitable
The hypoid drive gear and drive pinion shaft washer to adjust it.
tooth surface are damaged, excessively worn, or
NOTE:
seized.
Be sure the pinion gear tooth contacts adjacent
The roller bearing on the drive pinion shaft has a
gear teeth during measurement.
worn or damaged roller path.
There is damage, wear, or seizure of the differ- ST1 498247001 MAGNET BASE
ential bevel pinion, differential bevel gear, washer, ST2 498247100 DIAL GAUGE
pinion shaft, and straight pin. Standard backlash:
The differential case has worn or damaged slid-
ing surfaces.
0.13 - 0.18 mm (0.0051 - 0.0071 in)
2. HYPOID GEAR BACKLASH

Set the STI, ST2 and ST3. Insert the needle
through transmission oil drain plug hole so that the
needle comes in contact with the tooth surface at a
right angle and check the backlash.
STI 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
ST3 498255400 PLATE
Backlash:
B3M0558C
0.13 - 0.18 mm (0.0051 - 0.0071 in)
(A) Drive pinion shaft
(6) Hypoid driven gear
(C) Pinion shaft
(D) Straight pin
(E) Washer
(F) Differential bevel gear
(G) Differential bevel pinion
(H) Snap ring
(I) Roller bearing
(J) Differential case
NOTE:
If the backlash is outside specified range, adjust it
by turning holder in right side case.
MT-74
FRONT DIFFERENTIAL ASSEMBLY I
3. TOOTH CONTACT OF HYPOID GEAR

Check tooth contact of hypoid gear as follows: Ap-
ply a uniform thin coat of red lead on both tooth sur-
faces of 3 or 4 teeth of the hypoid gear. Move the
hypoid gear back and forth by turning the transmis-
sion main shaft until a definite contact pattern is de-
veloped on hypoid gear, and judge whether face
contact is correct. If it is inaccurate, make adjust-
ment. <Ref. to MT-75, ADJUSTMENT, Front Differ- Thickness mm (in)
Part No.
ential Assembly.>
Tooth contact is correct. I 803038021
1 0.925- 0.950
(0.0364
~~-
\ -
- 0.0374)
~~
0.975- I .OOO
I
803038022
(0.0384- 0.0394)
1.025- 1.050
803038023
(0.0404- 0.0413)
3) Adjust until the specified value is obtained.

Standard backlash:
-
0.13 0.18 mm (0.0051 - 0.0071 in)
2. HYPOID GEAR BACKLASH
Adjust the backlash by turning holder in right side
(A) Toe case.
(B) Coast side
ST 499787000 WRENCH ASSY
(C) Heel I
(D) Drive side
NOTE:
Each time holder rotates one tooth, backlash
changes by 0.05 mm (0.020 in).
MT-75
3. TOOTH CONTACT OF HYPOID GEAR The drive pinion shim selected before is too thin.
Increase its thickness.
Adjust until the teeth contact is correct.
Backlash is excessive.
To reduce backlash, loosen holder on the upper
side (case right side) and turn in the holder on the
lower side (case left side) by the same amount.
B3MOQ74
Backlash is insufficient.
To increase backlash, loosen holder on the lower
side (case left side) and turn in the holder on the
upper side (case right side) by the same amount.
B3MQO72
The drive pinion shim selected before is too

thick.
Reduce its thickness.
03M0073
MT-76
SPEEDOMETER GEAR I
18.Speedometer Gear B: INSTALLATION

1) Install the washer and speedometer shaft, and
A: REMOVAL press fit oil seal with ST.
1) Remove the manual transmission assembly CAUTION:
from vehicle. <Ref. to MT-27, REMOVAL, Manual Use new oil seal, if it has been removed.
2) Remove the back-up light switch and neutral po- ST 899824100 or 499827000PRESS
sition switch. <Ref. to MT-37, REMOVAL, Switches 2) Install the vehicle speed sensor. <Ref. to MT-39,
and Harness.> INSTALLATION, Vehicle Speed Sensor.>
3) Remove the transfer case with extension case 3) Install the speedometer driven gear and snap
assembly. <Ref. to MT-41, REMOVAL, Transfer ring.
Case and Extension Case Assembly.> CAUTION:
4) Remove the transmission case. <Ref. to MT-54, Use new snap ring, if it has been removed.
5) Remove the vehicle speed sensor. <Ref. to MT-
39, REMOVAL, Vehicle Speed Sensor.>
6) Remove the outer snap ring and pull out the
speedometer driven gear. Next, remove the oil
seal, speedometer shaft and washer.
r.
/ (A) Outer snap ring

(B) Speedometer driven gear

B3M0525C STALLATION, Transmission Case.>
(A) Outer snap ring sembly. <Ref. to MT-41, INSTALLATION, Transfer
(B) Speedometer driven gear Case and Extension Case Assembly.>
hicle.<Ref. to MT-30, INSTALLATION, Manual
C: INSPECTION
Check the speedometer gear, oil seal and speed-
ometer shaft for damage. Replace if damaged.
MT-77
REVERSE IDLER GEAR
19.Reverse Idler Gear B: INSTALLATION

1) Install the reverse shifter lever, reverse idler gear
A: REMOVAL and reverse idler gear shaft, and secure with
1) Remove the manual transmission assembly straight pin.
from vehicle. <Ref. to MT-27, REMOVAL, Manual NOTE:
Transmission Assembly .> Be sure to install the reverse idler shaft from the
2) Remove the back-up light switch and neutral po- rear side.
and Harness.>
REMOVAL, Drive Pinion Shaft Assembly.>
5) Remove the drive pinion shaft assembly. <Ref.
bly.>
6) Remove the main shaft assembly. M0526C
for Single-Range.> (A) Reverse shifter lever
7) Remove the differential assembly. <Ref. to MT- (B) Reverse idler gear
A , REMOVAL, Front Differential Assembly.>
(C) Reverse idler gear shaft
8) Remove the shifter forks and rods. <Ref. to MT-
(D) Straight pin
80, REMOVAL, Shifter Fork and Rod.>
9) Pull out the straight pin, and remove the idler 2) Inspect and adjust the clearance between re-
gear shaft, reverse idler gear and washer. verse idler gear and transmission case wall. <Ref.
to MT-78, INSTALLATION, Reverse Idler Gear.>
and <Ref. to MT-79, ADJUSTMENT, Reverse Idler
Gear.>
3) Install the shifter forks and rods. <Ref. to MT-80,
INSTALLATION,Shifter Fork and Rod.>
4) Install the differential assembly. <Ref. to MT-71,
INSTALLATION, Front Differential Assembly.>
5) Install the main shaft assembly.
<Ref. to MT-57, INSTALLATION, Main Shaft As-
sembly for Single-Range.>
6) Install the drive pinion shaft assembly. <Ref. to
MT-63, INSTALLATION, Drive Pinion Shaft As-
(A) Straight pin sembly.>
(8) Idler gear shaft 7) Install the transmission case. <Ref. to MT-55, IN-
(C) Idler gear STALLATION, Transmission Case.>
(D) Washer 8) Install the transfer case with extension case as-
IO) Remove the reverse shifter lever. Case and Extension Case Assembly.>
IO) Install the manual transmission assembly to ve-
MT-78
REVERSE IDLER GEAR I
C: INSPECTION D: ADJUSTMENT
1) Move the reverse shifter rod toward the reverse 1) Select the appropriate reverse shifter lever from
side. Inspect the clearance between reverse idler the table below, and adjust until the gap between
gear and transmission case wall. the reverse idler gear and transmission case wall is
If out of specification, select the appropriate re- within specification.
verse shifter lever and adjust.
Clearance A:
Clearance A: 6.0 - 7.5 mm (0.236 - 0.295 in)
6.0 - 7.5 mm (0.236 - 0.295 in)
2) After installing a suitable reverse shifter lever,

“shift into neutral. Inspect the clearance between re-
32820AA070 7 Further from case wall
verse idler gear and transmission case wall.
If out of specification, select the appropriate washer 32820AA080 8 Standard
and adjust. 32820AA090 9 Closer to case wall
Clearance:
0 - 0.5 mm (0 - 0.020 in)
3) Check the reverse idler gear and shaft for dam-

age. Replace if damaged.

803020151 0.4 (0.016)
803020152 1.1 (0.043)
803020153 1.5 (0.059)
803020154 1.9 (0.075)
803020155 2.3 (0.091)
MT-79
I MANUAL TRANSMISSION AND DIFFERENTIAL
SHIFTER FORK AND ROD
20.Shifter Fork and Rod 10) Drive out the straight pin, and pull out 3-4 fork
rod and shifter fork.
A: REMOVAL NOTE:
1) Remove the manual transmission assembly When removing rod, keep other rods in neutral. Al-
from vehicle. <Ref. to MT-27, REMOVAL, Manual so, when pulling out straight pin, remove it toward
Transmission Assembly.> the inside of the case so that it does not hit against
2) Remove the back-up light switch and neutral po- the case.
and Harness.>
5) Removes the drive pinion shaft assembly. <Ref.
bly.>
for Single-Range.> (A) Straight pin
7) Remove the differential assembly. <Ref. to MT- (B) 3-4 fork rod
7.4,~REMOVAL, Front Differential Assembly.> (C) Shifter fork
8) Drive out the straight pin with ST, and 5th shifter
fork. 11) Drive out the straight pin, and pull out the 1-2
ST 398791700 STRAIGHT PIN REMOVER fork rod and shifter fork.
12) Remove the outer snap ring, and pull out re-
verse shifter rod arm from reverse fork rod. Then
take out the ball, spring and interlock plunger from
rod. And then remove the rod.
NOTE:
When pulling out reverse shifter rod arm, be careful
not to let ball pop out of arm.
13) Remove the reverse shifter lever.
( B: INSTALLATION
B3M03331 1) Install the reverse arm fork spring, ball and inter-
lock plunger to reverse fork rod arm. Insert the re-
(A) Straight pin verse fork rod into hole in reverse fork rod arm, and
(6) 5th shifter fork hold it with outer snap ring using ST.
9) Remove the plugs, springs and checking balls. CAUTION:
Apply grease to plunger to prevent it from fall-
ing.
ST 39941 1700 ACCENT BALL INSTALLER
2) Position the ball, spring and gasket in reverse
shifter rod hole, on left side transmission case, and
tighten the checking ball plug.
CAUTION:
3) Install the 1-2 fork rod into 1-2 shifter fork via the
hole on the rear of the transmission case.
MT-80
SHIFTER FORK AND ROD I
4) Align the holes in rod and fork, and drive straight 9) Position the balls, checking ball springs and gas-
pin into these holes using ST. kets into 3-4 and 1-2 rod holes, and install plugs.
CAUTION: CAUTION:
Replace straight pin with a new one. Replace gasket with a new one.
NOTE:
Set other rods to neutral.
Make sure interlock plunger is on the 3-4 fork rod
side.
ST 398791700 STRAIGHT PIN REMOVER
5) Install the interlock plunger onto 3-4 fork rod.
CAUTION:
Apply a coat of grease to plunger to prevent it
from falling.
6) Install the 3-4 fork rod into 3-4 shifter fork via the 33J
hole on the rear of transmission case.
7) Align the holes in rod and fork, and drive straight (A) 5th shifter fork
pin into these holes. (B) Reverse fork rod
(C) Straight pin
CAUTION:
Replace straight pin with a new one. 10) Install the differential assembly. <Ref. to MT-
** NOTE: 1
71 INSTALLATION, Front Differential Assembly.>
Set the reverse fork rod to neutral. 11) Install the main shaft assembly.
Make sure the interlock plunger (installing be- Single-range model:
fore) is on the reverse fork rod side. <Ref. to MT-57, INSTALLATION, Main Shaft As-
ST 398791700 STRAIGHT PIN REMOVER sembly for Single-Range.>
8) Install the 5th shifter fork onto the rear of reverse 12) Install the drive pinion shaft assembly. <Ref. to
fork rod. Align the holes in the two parts and drive MT-63, INSTALLATION, Drive Pinion Shaft As-
straight pin into place. sembly.>
13) Install the transmission case. <Ref. to MT-55,
CAUTION: INSTALLATION, Transmission Case.>
Replace straight pin with a new one. 14) Install the transfer case with extension case as-
ST 398791700 STRAIGHT PIN REMOVER sembly. <Ref. to MT-41, INSTALLATION, Transfer
15) Install the back-up light switch and neutral po-
( sition switch. <Ref. to MT-38, INSTALLATION,
B3M0333J
(A) 5th shifter fork

(B) Reverse fork rod
(C) Straight pin
MT-81
C: INSPECTION 4) Inspect the clearance between 3rd, 4th drive

1) Check the shift shaft and shift rod for damage. gear and coupling sleeve. If any clearance is not
Replace if damaged. within specifications, replace shifter fork as re-
2) Gearshift mechanism quired.
Repair or replace the gearshift mechanism if ex- Clearance (a) and (b):
cessively worn, bent, or defective in any way. 9.3 mm (0.366 in)
3) Inspect the clearance between lst, 2nd driven
gear and reverse driven gear. If any clearance is
not within specifications, replace the shifter fork as
required.
Clearance (a) and (b):
9.5 mm (0.374 in)
B3M1411A
(A) 3rd drive gear

(B) Coupling sleeve
(C) 4th drive gear
L I
I 3rd-4th shifter fork
I Part No. I Mark I Remarks
(A) 1st driven gear
(B) Reverse driven gear
I 32810AA061 I Approach to 4th gear
by 0.2 mm (0.008 in).
(C) 2nd driven gear 3281OAA071 - Standard
Become distant from
3281OAAI 01 3 3rd gear by 0.2 mm
(0.008 in).
I 32804AA060 I 1 I Approach to 1st gear

by 0.2 mm (0.008 in). I
32804AA070 - Standard
Become distant from
32804AA080 3 2nd gear by 0.2 mm
(0.008 in).
MT-82
I
5) Inspect the clearance between 5th drive gear 6) Inspect the rod end clearances (A) and (B). If any
and coupling sleeve. If any clearance is not within clearance is not within specifications, replace the
specifications, replace shifter fork as required. rod or fork as required.
Clearance (a): Clearance (A):
9.3 mm (0.366 in) 1st -2nd to 3rd - 4th:
0.4 - 1.4 "(0.016 - 0.055 in)
Clearance (B):
3rd - 4th to 5th:
0.5 - 1.3 "(0.020 - 0.051 in)
r
(A) 5th drive gear
S3M0191A
(B) Coupling sleeve

W
B3M0530A
-4- - 5th shifter fork (Non-turbo) I
I 32812AA201 I 4 I Approach to 5th gear
bv 0.2 mm 10.008 ink I
32812AA211 5 Standard
Become distant from
32812AA221 6 5th gear by 0.2 mm
I (0.068 in).- I
I 32812AA231 1 7 I Approach to 5th gear

by 0.2 mm (0.008 in). I
32812AA241 - Standard
Become distant from
32812AA251 9 5th gear by 0.2 mm
(0.008 in).
MT-83
I GENERAL DIAGNOSTIC
I
21 .General Diagnostic
A: INSPECTION
1. MANUAL TRANSMISSION
Symptom Possible cause ~~

Remedv
1. Gears are difficult to intermesh. (a) Worn, damaged or burred chamfer of Replace.
VOTE: internal spline of sleeve and reverse
The cause for difficulty in shifting gears driven gear
:an be classified into two kinds: one is (b) Worn, damaged or burred chamfer of Replace.
malfunction of the gear shift system and spline of gears
:he other is malfunction of the transmis- Redace.
(c) Worn or scratched bushinas
sion. However, if the operation is heavy
and engagement of the gears is difficult, (d) Incorrect contact between synchro- Correct or replace.
jefective clutch disengagement may also nizer ring and gear cone or wear
De responsible. Check whether the clutch
s correctly functioning, before checking
the gear shift system and transmission.
2. Gear slips out. (a) Defective pitching stopper adjustment Adjust.
Gear slips out when coasting on rough (b) Loose engine mounting bolts Tiahten
u or redace.
.-
road.
Gear slips out during acceleration.
(c) Worn fork shifter, broken shifter fork
rail spring
Replace.
Id) Worn or damaaed ball bearina Replace.

(e) Excessive clearance between splines Replace.
of synchronizer hub and synchronizer
sleeve
(f) Worn tooth step of synchronizer hub Replace.
(resDonsible for slipout of 3rd clear)
(9) Worn 1st driven gear, needle bearing Replace.
and race
(h) Worn 2nd driven gear, needle bearing Replace.
and race
Ii) Worn 3rd drive aear and bushinn Replace.
(i) Worn 4th drive gear and bushing Replace.
(k) Worn reverse idler gear and bushing Replace.
3. Unusual noise comes from transmis- (a) Insufficient or improper lubrication Lubricate or replace with specified oil.
sion. (b) Worn or damaged gears and bearings Replace.
NOTE: NOTE:
If an unusual noise is heard when the ve- If the trouble is only wear of the tooth sur-
hicle is parked with its engine idling and if faces, merely a high roaring noise will oc-
the noise ceases when the clutch is disen- cur at high speeds, but if any part is
gaged, it may be considered that the broken, rhythmical knocking sound will be
noise comes from the transmission. heard even at low speeds.
MT-84
GENERAL DIAGNOSTIC
I
2. DIFFERENTIAL
Symptom Possible cause Remedy

1 . Broken differential (case, gear, bear- (a) Insufficient or improper oil 3isassemble differential and replace bro-
ng, etc.) ten components and at the same time
VOTE: :heck other components for any trouble,
4bnormal noise will develop and finally it 3nd replace if necessary.
Mill become impossible to continue to run (b) useof vehicle under Severe con& Readjust bearing preload and backlash
h e to broken pieces obstructing the gear tions such as load and m d face contact of gears.
,evolution. improper use of clutch
(c) Improper adjustment of taper roller 4djust.
bearing
(d) Improper adjustment of drive pinion 4djust.
and hvlsoid driven aear
(e) Excessive backlash due to worn dif- 4dd recommended oil to specified level.
ferential side gear, washer or differential Do not use vehicle under severe operat-
pinion vehicle under severe operating ng conditions.
conditions
2. Differential and hypoid gear noises

I (f) Loose hypoid driven gear clamping
bolts
(a) Insufficient oil
Tighten.
-ubricate.
r
b u b l e s of the differential and hYPoid (b) Improper adjustment of hypoid driven :heck tooth contact.
p a r always appear as nOiSe problems. sear and drive Dinion
rherefore noise is the first indication of I vi I iypuiu ui ivci I ycai ai iu Replace as a set.
:he trouble. However noises from the Readjust bearing preload.
mgine, muffler, tire, exhaust gas, bear-
,e roller bearing Readjust hypoid driven gear to drive pin-
ng, body, etc. are easily mistaken for the
on backlash and check tooth contact.
jifferential noise. Pay special attention to
:he hypoid gear noise because it is easily (e) Distorted hypoid driven gear or differ- Replace.
:onfused with other gear noises. There ential case
we the following four kinds of noises. (f) Worn washer and differential pinion Replace.
1 Gear noise when driving: If noise shaft
ncreases as vehicle speed increases it
nay be due to insufficient gear oil, incor-
Oect gear engagement, damaged gears,
2tc.
1 Gear noise when coasting: Damaged
jears due to maladjusted bearings and

ncorrect shim adjustment
1 Bearing noise when driving or when
:oasting: Cracked, broken or damaged

3earings
1 Noise which mainly occurs when turn-
ng: Unusual noise from differential side

jear, differential pinion, differential pinion
;haft. etc.
MT-85
I GENERAL DIAGNOSTIC
MT-86
a
CLUTCH SYSTEM
CL
Page
2. Clutch Disc and Cover .............................................................................. i1
3. Flywheel .................................................................................................... 14
4. Release Bearing and Lever ....................................................................... 15
5. Operating Cylinder .................................................................................... 18
6. Master Cylinder ......................................................................................... 20
7. Clutch Pipe and Hose ............................................................................... 22
8. Clutch Fluid ............................................................................................... 23
9. Clutch Fluid Air Bleeding ........................................................................... 24
... 10. Clutch Pedal .............................................................................................. 26
11. Clutch Switch ............................................................................................ 30
12. General Diagnostic Table .......................................................................... 31
CLUTCH SYSTEM
A: SPECIFICATIONS
Model NON-TURBO TURBO
Clutch cover Type Push type Pull type
Diaphraam set load ka Ob) 580 (1 -279) 830 (1,830)
Clutch disk I Facinq material I Woven (Non asbestos)
O.D. x I.D. x thickness mm (in) 225 x 150 x 3.5 230 x 150 x 3.5
(8.86 x 5.91 x 0.138) (9.06 x 5.91 x 0.138)
Spline O.D. mm (in) 25.2 (0.992), (No. of teeth: 24)
Clutch release lever ratio 1.6 1.7
I Release bearina Grease-Dacked self-alianina
I Clutch Dedal
I
II Full stroke . ,I
mm (in) 130 - 135 (5.12 - 5.31) I
I Free play mm (in) 1 10 - 20 (0.39 - 0.79) 3 - 13 (0.12 - 0.51)
1
Clutch disk Depth of rivet head mm (in) Standard 1.3 - 1.9 (0.051 - 0.075)
Limit of 0.3 (0.012)
sinking
I Limit for deflection mm (in) I 1.0 (0.039) at R = 107 (4.21) 1 0.8 (0.031) at R = 110 (4.33) I
13.: Inner diameter
O.D.: Outer diameter
cL-2
I
GENERAL DESCRIPTION
CLUTCH SYSTEM
B: COMPONENT
1. CLUTCH ASSEMBLY FOR NON-TURBO MODEL
TR0533
(1) Clutch release lever sealing (6) Release bearing Tightening torque: N.m (kgf-m, ft-lb)
(2) Retainer spring (7) Clutch cover T1: 15.7(1.6, 11.6)
(3) Pivot (8) Clutch disc T2: 72 (7.3, 52.8)
(4) Release lever (9) Flywheel
(5) Clip
cL-3
GENERAL DESCRIPTION
CLUTCH SYSTEM
2. CLUTCH ASSEMBLY FOR TURBO MODEL
(8) TR0534
(1) Clutch release lever sealing (6) Clutch cover Tightening torque: N-m (kgf-m, ft-lb)
(2) Release lever shaft (7) Clutch disc T1: 15.7(1.6, 11.6)
(3) Plug (8) Flywheel T2: 44 (4.5, 32.5)
(4) Release lever (9) Spring
(5) Release bearing (10) Bracket
cL-4
GENERAL DESCRIPTION
I
CLUTCH SYSTEM
3. CLUTCH PIPE AND HOSE FOR NON-TURBO MODEL
(1)’ I
TR0535
(1) Operating cylinder (6) Pipe Tightening torque: N.m (kgf-m, ft-lb)
(2) Washer (7) Master cylinder ASSY T I : 8 (0.8, 5.8)
(3) Clutch hose (8) Clevis pin T2: 15 (1.5, 11)
(4) Bracket (9) Snap pin T3: 18 (1.8, 13.0)
(5) Clip (IO) Lever T4: 37 (3.8,27.5)
CL-5
CLUTCH SYSTEM
4. CLUTCH PIPE AND HOSE FOR TURBO MODEL
TR0536
(1) Operating cylinder (6) Pipe Tightening torque: N.m (kgf-m, ft-lb)
(2) Washer (7) Master cylinder ASSY T I : 8 (0.8, 5.8)
(3) Clutch hose (8) Clevis pin TZ: lS(1.5, 1 1 )
(4) Bracket (9) Snap pin T3: 18 (1.8, 13.0)
(5) Clip (10) Lever T4: 37 (3.8,27.5)
CL-6
I
GENERAL DESCRIPTION
CLUTCH SYSTEM
5. MASTER CYLINDER
NON-TURBO MODEL
TR0431
(1) Reservoir cap (7) Diaphragm spring Tightening torque: N-m (kgf-m, ft-lb)
(2) Reservoir tank (8) Gasket T I : 10 (1.0, 7)
(3) Oil seal (9) Return spring T2: 46.6 (4.75, 34.4)
(4) Straight pin (10) Piston
(5) Master cylinder (11) Push rod
(6) Seat (12) Piston stop ring
cL-7
GENERAL DESCRIPTION
I
CLUTCH SYSTEM
TURBO MODEL
TR054!
(1) Reservoir cap (6) Seat Tightening torque: N.m (kgf-m, ft-lb)
(2) Reservoir tank (7) Return spring T: 10 (1.0, 7)
(3) Oil seal (8) Piston
(4) Straight pin (9) Push rod
(5) Master cylinder (10) Piston stop ring
CL-8
I I
GENERAL DESCRIPTION
6. CLUTCH PEDAL
TR0537
(1) Stopper (12) Clutch clevis pin (23) Clutch switch (With cruise control)
(2) Bushing (13) Assist rod A (24) Stop light switch
(3) Spring pin (14) Clip (25) Pedal bracket
(4) Snap pin (15) Assist spring (26) Clutch master cylinder bracket
(5) Brake pedal pad (16) Assist bushing (27) Lever
(6) Brake pedal (17) Assist rod B (28) Clutch switch (Starter interlock)
(7) Clevis pin (18) Spring S
(8) Brake pedal spring (19) Rods Tightening torque: N-m (kgf-m, ft-lb)
(9) Clutch pedal pad (20) Bushing S T1: 8 (0.8, 5.8)
(IO) Clutch pedal (21) O-ring T2: lS(1.8, 13.0)
(11) Bushing C (22) Clip T3: 30 (3.1,22.4)
cL-9
GENERAL DESCRIPTION
CLUTCH SYSTEM
C: CAUTION Be sure to tighten fasteners including bolts and

Wear working clothing, including a cap, protec- nuts to the specified torque.
tive goggles, and protective shoes during opera- Place shop jacks or safety stands at the specified
tion. points.
Remove contamination including dirt and corro- Apply grease onto sliding or revolution surfaces
sion before removal, installation or disassembly. before installation.
Keep the disassembled parts in order and pro- Before installing O-rings or snap rings, apply suf-
tect them from dust or dirt. ficient amount of fluid to avoid damage and defor-
Before removal, installation or disassembly, be mation.
sure to clarify the failure. Avoid unnecessary re- Before securing a part on a vice, place cushion-
moval, installation, disassembly, and replacement. ing material such as wood blocks, aluminum plate,
Be careful not to burn your hands, because each or shop cloth between the part and the vice.
part on the vehicle is hot after running. Keep fluid away from the vehicle body. If any flu-
Use SUBARU genuine fluid, grease etc. or the id contacts the vehicle body, immediately flush the
equivalent. Do not mix fluid, grease etc. with that of area with water.
another grade or from other manufacturers.
D: PREPARATION TOOL
1. SPECIAL TOOLS
TOOL NUMBER DESCRlPTtON REMARKS

498497100 CRANKSHAFT Used for stopping rotation of flywheel when Ioos.
STOPPER eninghightening bolt, etc.
I B2M3853
499747100 CLUTCH DISC Used when installing clutch disc to flywheel.
GUIDE
B2M4112
TOOL NAME REMARKS I

Dial Gauge Used for measuring clutch disk run-out.
CL-10
CLUTCH DISC AND COVER
1
CLUTCH SYSTEM
2. Clutch Disc and Cover 2) Install the clutch cover on flywheel and tighten
bolts to the specified torque.
A: REMOVAL NOTE:
1) Remove the transmission assembly from vehicle When installing the clutch cover on the flywheel,
body. <Ref. to MT-27, REMOVAL, Manual Trans- position the clutch cover so that there is a gap of
mission Assembly.> 120” or more between “0’marks on the flywheel
2) Install the ST on flywheel. and clutch cover. ( “ 0 marks indicate the directions
ST 499747100 CLUTCH DISC GUIDE of residual unbalance.)
Note the front and rear of the clutch disc when in-
stalling.
Temporarily tighten the bolts by hand. Each bolt
should be tightened to the specified torque in a
crisscross method.
Tightening torque:
15.7 N-m (1.6 kgf-m, 11.6 ft-lb)
I I1 1‘ 1
(A) Clutch cover
-. - .
3) Remove the clutch cover and clutch disc.

CAUTION:
Take care not to allow oil on the clutch disc
facing.
Do not disassemble either the clutch cover or
clutch disc.
B: INSTALLATION
1) Insert the ST into the clutch disc and install them
on the flywheel by inserting the ST end into the pi-
lot bearing.
ST 499747100 CLUTCH DISC GUIDE
B2M 1I0118
- -
(A) “ 0marks
3) Remove the ST.

ST 499747100 CLUTCH DISC GUIDE
4) Install the transmission assembly. <Ref. to MT-
G2M0253 30, INSTALLATION, Manual Transmission Assem-
bly.>
CL-11
I CLUTCH DISC AND COVER
1
CLUTCH SYSTEM
C: INSPECTION 4) Deflection on facing:

If deflection exceeds the specified value at the out-
1. CLUTCH DISC er circumference of facing, repair or replace.
1) Facing wear: ST 499747100 CLUTCH DISC GUIDE
Measure the depth of rivet head from the surface of Limit for deflection:
facing. Replace if the facings are worn locally or Non-turbo model:
worn down to less than the specified value. 1.0 mm (0.039 in) at R = 107 mm (4.21 in)
Depth of rivet head: Turbo model:
Limit of sinking 0.8 mm (0.031 in) at R = 110 mm (4.33 in)
0.3 mm (0.012 in)
CAUTION:
Do not wash the clutch disc with any cleaning
fluid.
5) Worn spline, loose rivets and torsion spring fail-

ure:
Replace defective parts.
2) Hardened facing:
Correct by using emery paper or replace.
3) Oil soakage on facing:
Replace the clutch disc and inspect transmission
front oil seal, transmission case mating surface,
engine rear oil seal and other points for oil leakage.
(A) Spline
(B) Rivet
(C) Torsion spring
(A) Facing
CL-12
CLUTCH DISC AND COVER
I
CLUTCH SYSTEM
2. CLUTCH COVER
NOTE:
Visually check for the following items without disas-
sembling, and replace or repair if defective.
1) Loose thrust rivet.
2) Damaged or worn bearing contact area at the
center of diaphragm spring.
(Bf
(A) Thrust rivet

c.
(B) Diaphragm spring
3) Damaged or worn disc contact surface of pres-

sure plate.
4) Loose strap plate setting bolt.
5) Worn diaphragm sliding surface.
(A) Pressure plate

(B) Strap plate
CL-13
I FLYWHEEL
CLUTCH SYSTEM
3. Flywheel 2) Tighten the flywheel attaching bolts to the spec-

ified torque.
A: REMOVAL NOTE:
1) Remove the transmission assembly. <Ref. to Tighten the flywheel installing bolts gradually. Each
MT-27, REMOVAL, Manual Transmission Assem- bolt should be tightened to the specified torque in
bly.> a crisscross method.
2) Remove the clutch cover and clutch disc. <Ref.
to CL-11, REMOVAL, Clutch Disc and Cover.> Tightening torque:
72 N-m (7.3 kgf-m, 52.8 ft-lb)
CAUTION:
Take care not to allow oil on the clutch disc
facing.
Do not disassemble either the clutch cover or
clutch disc.
3) Using ST, remove the flywheel.
ST 498497100 CRANKSHAFT STOPPER
r.
3) Install the clutch disc and cover. <Ref. to CL-11,
INSTALLATION, INSTALLATION, Clutch Disc and
Cover.>
4) Install the transmission assembly. <Ref. to MT-
30, INSTALLATION, Manual Transmission Assem-
- .
' B2M0332B bly.>
C: INSPECTION
(A) Flywheel
CAUTION:
B: INSTALLATION Since this bearing is grease sealed and is of a
1) Install the flywheel and ST. non-lubrication type, do not wash with gaso-
line or any solvent.
ST 498497100 CRANKSHAFT STOPPER
1) Damage of facing and ring gear:
If defective, replace the flywheel.
(A) Flywheel
(B) Ring gear
2) Smoothness of rotation:
Rotate the ball bearing applying pressure in thrust
direction.
3) If noise or excessive play is noted, replace the
flywheel.
CL-14
RELEASE BEARING AND LEVER
I
CLUTCH SYSTEM
4. Release Bearing and Lever 4) Remove the clutch release bearing from clutch
cover using a flat-type screwdriver.
A: REMOVAL
1. NON-TURBO MODEL
1) Remove the transmission assembly from vehicle
body.
<Ref. to MT-27, REMOVAL, Manual Transmission
Assembly.>
2) Remove the two clips from clutch release lever
and remove the release bearing.
CAUTION:
Be careful not to deform the clips.
3) Remove the release lever seal. (A) Clutch release bearing
B: INSTALLATION
1. NON-TURBO MODEL
CAUTION:
Before or during assembling, lubricate the fol-
lowing points with a light coat of grease.
Contact surface of lever and pivot
Contact surface of lever and bearing
Transmission main shaft spline (Use grease
containing molybdenum disulphide.)
(A) Clutch release lever
Contact surface of lever and operating cylin-
der
(B) Release lever seal
1) While pushing the release lever to pivot and
4) Remove the release lever retainer spring from twisting it to both sides, fit the retainer spring onto
release lever pivot with a screwdriver by accessing the constricted portion of pivot.
it through the clutch housing release lever hole. NOTE:
Then remove the release lever. Apply grease (SUNLIGHT 2: P/N 003602010) to
the contact point of release lever and operating cyl-
inder.
Confirm that the retainer spring is securely fitted
by observing it through the main case hole.

(B) Screwdriver
2. TURBO MODEL
1) Remove the transmission assembly from vehicle (A) Release lever
body. <Ref. to MT-27, REMOVAL, Manual Trans-
mission Assembly.> 2) Install the release bearing and fasten it with two
2) Remove the clutch release lever from transmis- clips.
sion.
3) Put the clutch release bearing in engine side.
CL-15
I RELEASE BEARING AND LEVER
CLUTCH SYSTEM
3) Install the release lever seal. 3) Apply grease to the specified points:
Spline FX2200
Shaft SUNLIGHT 2
(A) Release lever

(6) Release lever seal
4) Install the transmission assembly.
<Ref. to MT-30, INSTALLATION, Manual Tran
mission Assembly.>
2. TURBO MODEL
#) Install the release bearing on transmission.
2) Insert the release fork into release bearing tab.
S2M1938A
(A) Spline (FX2200)

(6) Shaft (SUNLIGHT 2)
4) Insert the release fork shaft into release fork.

CAUTION:
Make sure the cutout portion of the release fork
S2M1937A shaft contacts spring pin.
(A) Release fork

(6) Release bearing
1845A
(A) Release fork

(B) Release shaft
(C) Spring pin
5 ) Install the transmission assembly. <Ref. to MT-

30, INSTALLATION, Manual Transmission Assem-
bly.>
CL-16
RELEASE BEARING AND LEVER I
CLUTCH SYSTEM
C: INSPECTION 2. RELEASE LEVER

1. RELEASE BEARING 1) Check the lever pivot portion and the point of
contact with release bearing case for wear.
CAUTION:
Since this bearing is grease sealed and is of a
non-lubrication type, do not wash with gaso-
line or any solvent when servicing the clutch.
1) Check the bearing for smooth movement by ap-
plying force in the radial direction.
Radial direction stroke:
1.4 mm (0.055 in)
S2M1102E

(B) Pivot
(C) Clutch release bearing
(A) Bearing case
2) Check the bearing for smooth rotation by apply-

ing pressure in the thrust direction.
(A) Bearing case
3) Check wear and damage of bearing case sur-

face contacting with lever.
CL-17
I OPERATING CYLINDER I
CLUTCH SYSTEM
5. Operating Cylinder 4) Remove the operating cylinder from transmis-

sion.
A: REMOVAL Non-turbo model
1) Remove the air cleaner case and air intake duct
(Non-turbo model). <Ref. to IN(S0HC)-6, REMOV-
3) Remove the clutch hose from operating cylinder.
CAUTION:
Cover the hose joint to prevent clutch fluid from
flowing out.
Non-turbo model
Turbo model
-.
179J
-
(A) Clutch hose
(B) Operating cylinder
Turbo model
(A) Clutch hose

(6) Operating cylinder
CL-18
OPERATING CYLINDER I
CLUTCH SYSTEM
B: INSTALLATION 2) After bleeding air from the operating cylinder, en-

1) Install in the reverse order of removal. sure that the clutch operates properly.
<Ref. to CL-24, Clutch Fluid Air Bleeding.>
NOTE:
Before installing the operating cylinder, apply C: INSPECTION
grease (SUNLIGHT 2: P/N 003602010) to the con- 1) Check the operating cylinder for damage. If the
tact point of release lever and operating cylinder. operating cylinder is damaged, replace it.
Tightening torque: 2) Check the operating cylinder for fluid leakage or
T1: 18 N.m (1.8 kgf-m, 13.0 ft-lb) damage on boot. If any leakage or damage is
T2: 37 N-m (3.8 kgf-m, 27.5 ft-lb) found, replace the operating cylinder.
Non-turbo model
c. .
Turbo model
NOTE:
Be sure to install the clutch hose with the mark
side facing upward.
Be careful not to twist the clutch hose during in-
stallation.
(A) Marking
(B) Clutch hose
(C) Operating cylinder
CL-19
I I
MASTER CYLINDER
CLUTCH SYSTEM
6. Master Cylinder B: INSTALLATION

1) Install the master cylinder to body, and install the
A: REMOVAL clutch pipe to master cylinder.
1) Thoroughly drain the brake fluid from reservoir CAUTION:
tank. Check that the pipe is routed properly.
2) Remove the snap pin, clevis pin and separate
the push rod of master cylinder from clutch pedal. Tightening torque:
T1: 15 N.m (1.5 kgf-m, 10.8 ff-lb)
T2: 18 N.m (1.8 kgf-m, 13.0 ff-lb)
B4M1189E
(A) Clevis pin

(B) Snap pin 2) Connect the push rod of master cylinder to clutch
-* (C) Push rod pedal, and install the clevis pin and snap pin.
(D) Locknut
NOTE:
3) Remove the air cleaner case and air intake duct Apply grease to the clevis pin.
(Non-turbo model). <Ref. to IN(S0HC)-6, RE-
MOVAL, Air Cleaner Case.> and <Ref. to IN(S0-
HC)-7, REMOVAL, Air Intake Duct.>
5) Remove the clutch pipe from master cylinder.
6) Remove the master cylinder with reservoir tank.
CAUTION:
Be extremely careful not to spill the brake fluid.
Brake fluid spilt on the vehicle body will harm / B4M1189C
the paint surface; wipe it off quickly if spilt.
(A) Clevis pin
(B) Snap pin
(C) Push rod
3) After bleeding air from the system, ensure that

the clutch operates properly.
<Ref. to CL-24, Clutch Fluid Air Bleeding.>
4) Install the air cleaner case and air intake duct
(Non-turbo model). <Ref. to IN(S0HC)-6, INSTAL-
LATION, Air Cleaner Case.> and <Ref. to IN(S0-
HC)-7, INSTALLATION, Air Intake Duct.>
5) Install the intercooler (Turbo model). <Ref. to
(A) Master cylinder IN(D0HC TURBO)-11, INSTALLATION, Intercool-
(B) Clutch pipe er.>
CL-20
MASTER CYLINDER I
CLUTCH SYSTEM
1) Remove the straight pin and reservoir tank. 1) Install the clutch damper. (Non-turbo model)
Tightening torque:
46.6 N.m (4.75 kgf-m, 34.4 ft-lb)
2) Apply a coat of grease to the contacting surfaces
of the push rod and piston before installation.
Grease:
SILICONE GREASE G40M (Part No.
004404003)
(A) Reservoir tank

(B) Straight pin
2) Remove the oil seal.
3) To assemble the master cylinder, reverse the se-

quence of disassembly procedure.
Tightening torque:
10 N-m (1.0 kgf-m, 7 ft-lb)
E: INSPECTION
If any damage, deformation, wear, swelling, rust or
other faults are found on the cylinder, piston, push
(A) Oil seal rod, fluid reservoir, return spring, gasket, clutch
(B) Master cylinder damper and hose replace the faulty part.
3) Move the cylinder boot backward.
TR0475
(A) Master cylinder body

(B) Return spring
(A) Cylinder boot
(C) Piston
(B) Master cylinder
(D) Stop ring
4) Remove the stop ring. (E) Rod ASSY
CAUTION: (F) Clutch damper (Non-turbo model)
Be careful when removing the snap ring to pre-
vent the rod, washer, piston and return spring
from flying out.
5) Remove the clutch damper. (Non-turbo model)
CL-21
I CLUTCH PIPE AND HOSE
CLUTCH SYSTEM
7. Clutch Pipe and Hose B: INSTALLATION

A: REMOVAL NOTE:
1) Remove the air cleaner case. (Non-turbo model) Bleed the clutch fluid. <Ref. to CL-24, Clutch Fluid
<Ref. to IN(S0HC)-6, REMOVAL, Air Cleaner Air Bleeding.>
Case.>
2) Remove the intercooler. (Turbo model) <Ref. to Tightening torque:
IN(D0HC TURBO)-IO, REMOVAL, Intercooler.> T1: 15 N.m (1.5 kgf-m, 10.8 ft-lb)
3) Drain the clutch fluid. <Ref. to CL-23, Clutch Flu- T2: 18 N-m (1.8 kgf-m, 13.0 ft-16)
id.> T3: 25 N-m (2.5 kgf-m, 18.1 ft-16)
4) Remove the clutch pipe from the clutch hose and
master cylinder.
5) Pull out the clamp, then remove the clutch hose
from bracket I
'\
'\
(A) Clamp
(B) Clutch hose
6) Remove the hose from operating cylinder.
7) Remove the bracket.
(A) Clutch pipe

(B) Clip
(C) Clutch hose
C: INSPECTION
Check pipes and hoses for cracks, breakage or
damage. Check joints for fluid leakage. If any
cracks, breakage, damage or leakage is found, re-
pair or replace the applicable pipe or hose.
CL-22
CLUTCH FLUID I
CLUTCH SYSTEM
8. Clutch Fluid B: REPLACEMENT

CAUTION:
A: INSPECTION The FMVSS No. 116, fresh DOT3 or 4 brake
1) Park the vehicle on a level surface. fluid must be used.
2) Inspect the fluid level using the scale on the out- Cover the bleeder with waste cloth, when
side of the reservoir tank. If the level is below “MIN”, loosening it, to prevent brake fluid from being
add fluid to bring it up to “MAX, and also inspect for splashed over surrounding parts.
leakage. Avoid mixing different brands of brake fluid
to prevent degrading the quality of the fluid.
Be careful not to allow dirt or dust to get into
the reservoir tank.
NOTE:
During bleeding operation, keep the clutch reser-
voir tank filled with brake fluid to eliminate entry of
air.
Clutch pedal operating must be very slow.
For convenience and safety, it is advisable to
e have two men working.
(A) Max. level mately 70 m f2 (2.4 US fl 02, 2.5 Imp fl 02) for total
c.
(B) Min. level clutch system.
(C) Reservoir tank 1) Remove the air cleaner case and air duct.
2) Either jack-up the vehicle and place a safety
stand under it, or lift-up the vehicle.
3) Draw out the brake fluid from reservoir tank with
syringe.
4) Refill the reservoir tank with recommended
brake fluid.
Recommended brake fluid:
FM VSS No. 1 16, fresh DOT3 or 4 brake fluid
5) Drain fluid in the same method as the air bleed-
ing.
6) Refill the brake fluid before reservoir tank be-
comes empty, and drain the contaminated fluid
again.
7) Repeat the above procedure until the contami-
nated fluid is completely drained.
CL-23
I CLUTCH FLUID AIR BLEEDING I
CLUTCH SYSTEM
9. Clutch Fluid Air Bleeding 4) Slowly depress the clutch pedal and keep it de-
pressed. Then open the air bleeder to discharge air
A: PROCEDURE together with the fluid.
Release the air bleeder for 1 or 2 seconds. Next,
NOTE:
with the bleeder closed, slowly release the clutch
Bleed air from the oil line with the help of a co-work-
pedal,
er.
1) Remove the air cleaner case and air intake duct.
3) Fit one end of a vinyl tube into the air bleeder of
operating cylinder and put the other end into a
brake fluid container.
(A) Operating cylinder

(B) Vinyl tube
5 ) Repeat these steps until there are no more air

bubbles in the vinyl tube.
CAUTION:
Cover the bleeder with waste cloth when loos-
ening it, to prevent brake fluid from being
splashed over surrounding parts.
(A) Clutch hose
(B) Air bleeder
(C) Operating cylinder
CL-24
CLUTCH FLUID AIR BLEEDING I
CLUTCH SYSTEM
6) Tighten the air bleeder.

Tightening torque:
T: 8 N.m (0.8 kgf-m, 5.8 ff-lb)
7) Repeat steps 2) through 4) using the air bleeder

on operating cylinder.
8) Tighten the air bleeder.
Tightening torque:
8 N-m (0.8 kgf-m, 5.8 ff-lb)
9) After depressing the clutch pedal, make sure
that there are no leaks evident in the entire system.
10) After bleeding air from the system, ensure that
the clutch operates properly.
CL-25
I CLUTCH PEDAL I
CLUTCH SYSTEM
1O.Clutch Pedal B: INSTALLATION

A: REMOVAL
CAUTION:
1) Remove the steering column. <Ref. to PS-23,
REMOVAL, Tilt Steering Column.>
If the cable clamp is damaged, replace it with
a new one.
2) Disconnect the connectors from stop light and Never fail to cover outer cable end with boot.
clutch switches. Be careful not to kink the accelerator cable.
3) Remove the snap pins which secure lever to
push rod and operating rod. Always use a new clevis pins.
4) Remove the clevis pins which secure lever to 2) Adjust the clutch pedal after installation.<Ref. to
push rod and operating rod. CL-27, ADJUSTMENT, Clutch Pedal.>
C: DISASSEMBLY
1) Remove the clutch switches.
2) Remove the clips, assist spring, rod and bush-
ing.
(A) Operating rod

(B) Push rod
(C) Snap pin
02M4115A
(D) Clevis pin
(A) Clip
5 ) Remove the air cleaner case and intake duct.
(Non-turbo model) <Ref. to IN(S0HC)-6, REMOV- (B) Assist spring
AL, Air Cleaner Case.> and <Ref. to IN(S0HC)-7, (C) Assist rod
REMOVAL, Air Intake Duct.> (D) Bushing
6) Remove intercooler. (Turbo model) <Ref. to (E) Clevis pin
7) Remove the nut which secures clutch master 3) Remove the spring pin and lever.
cylinder.
(A) Pin
8) Remove the bolts and nuts which secure brake (B) Lever
and clutch pedals, and remove pedal assembly.
CL-26
CLUTCH PEDAL I
CLUTCH SYSTEM
4) Remove the clutch pedal and bushings. E: INSPECTION

Move the clutch pedal pads in the lateral direction
with a force of approximately 10 N (1 kgf, 2 Ib) to
ensure the pedal deflection is in specified range.
CAUTION:
If excessive deflection is noted, replace the
bushings with new ones.
Deflection of clutch pedal:
Service limit
5.0 mm (0.197 in) or less
B2M4117A
(A) Clutch pedal

(B) Bushing
5 ) Remove the stopper, clip, O-ring, rod S, and

then remove the spring and bushing S.
(A) Clutch pedal

(B) Brake pedal
F: ADJUSTMENT
1) Turn the lock nuts until clutch pedal full stroke
length is within specifications.
(A) Clip CAUTION:
(B) O-ring Do not attempt to turn the clutch switch to ad-
(C) Bushings just clutch pedal full stroke length.
(D) Spring S NOTE:
(E) Rod S If the lock nuts cannot adjust the clutch pedal full
(F) Stopper stroke length to specifications, turn the master cyl-
inder push rod to adjust it.
6) Remove the stoppers from clutch pedal.
7) Remove the clutch pedal pad. (Non-turbo model) Specified clutch pedal full stroke: A
130 - 135 mm (5.12 - 5.31 in)
D: ASSEMBLY Tightening torque (Clutch switch lock nut):
1) Attach the clutch switch, etc. to pedal bracket T: 8 N.m (0.8 kgf-m, 5.8 ft-16)
temporarily.
2) Clean the inside of bores of clutch pedal and
brake pedal, apply grease, and set bushings into
bores.
3) Align the bores of pedal bracket, clutch pedal
and brake pedal, attach brake pedal return spring,
assist rods, and spring, and bushing.
NOTE:
Clean up inside of bushings and apply grease be-
fore installing the spacer.
CL-27
CLUTCH PEDAL
CLUTCH SYSTEM
2) Turn the master cylinder push rod so that the cle- 6) Push the release lever until operating cylinder
vis pin moves to the left and then to the right. Clevis push rod retracts. Ensure that the clutch fluid level
pin must move without resistance while it is rattling. in reservoir tank increases. If the clutch fluid level
increases, hydraulic clutch is properly adjusted; if
Tightening torque (Push rod lock nut):
fluid level does not increase or push rod does not
T: 10 N.m (1.0 kgf-m, 7 fWb) retract, replace the master cylinder with a new
one.<Ref. to CL-20, Master Cylinder.>
B4M1189G
1918
(A) Clevis pin
(B) Snap pin (1) Push rod
(C) Push rod (2) Release lever
*. (D) Locknut (3) Operating cylinder
3) Depress and release the clutch pedal 2 to 3 7) Push the release lever until operating cylinder
times to ensure that the clutch pedal and release push rod retracts. Check that the clutch fluid level in
fork operates smoothly. If the clutch pedal and re- reservoir tank increases.
lease fork do not operate smoothly, bleed air from
the clutch hydraulic system. <Ref. to CL-24, Clutch
Fluid Air Bleeding.>
4) Measure the clutch pedal full stroke length again
to ensure that it is within specifications. If it is not,
repeat adjustment procedures again from the be-
ginning.
Specified clutch pedal full stroke:
130 - 135 mm (5.12 - 5.31 in)
5) Move the clevis pin to the left and then to the
right. It should move without resistance while it is 1918
rattling. If resistance is felt, repeat adjustment pro-

cedures again from the beginning. (1) Push rod
(2) Release lever
(3) Operating cylinder
8) If the clutch fluid level increases, hydraulic clutch

play is correct.
9) If the clutch fluid level does not increase or push
rod does not retract, clutch pedal must be readjust-
ed.
CL-28
CLUTCH PEDAL
I
CLUTCH SYSTEM
10) Check the fluid level on the outside of the res-

ervoir tank. If the level is below “MIN”, add clutch
fluid to bring it up to “MAX.
Recommended clutch fluid:
FMVSS No. 116, fresh DOT 3 or DOT 4 brake
fluid
(A) Max. level

(B) Min. level
c. ~ (C) Reservoir tank
CL-29
I CLUTCH SWITCH
CLUTCH SYSTEM
11.Clutch Switch 2) Check the clutch switch continuity. If continuity is

not as specified, replace the switch.
A: REMOVAL (1) Disconnect the clutch switch connector.
1) Disconnect the ground terminal from battery. (2) Measure the resistance between 1 and 2 of
2) Disconnect the connector from clutch switch. clutch switch terminal.
3) Remove the clutch switch. Terminals/Specified resistance
B: INSTALLATION When clutch pedal depressed:
1) Move the clevis pin of the push rod right and left 1 - ZLess than 1 0
and hold where it moves smoothly, then measure TerminaWSpecified resistance
stroke of clutch pedal. When clutch pedal not depressed:
Specified clutch pedal full stroke:A 1 - ZMore than lMSZ
130 -135 mm (5.12 - 5.31 in) Clutch switch (Starter interlock)
Tightening torque:
T: 8 N-m (0.8 kgf-m, 5.8 ft-lb)
Clutch switch (With cruise control)

04M 119OC
2) If the clutch pedal stroke is out of specification,

adjust the stroke. <Ref. to CL-27, ADJUSTMENT,
Clutch Pedal.>
3) Connect the clutch switch connector.
C: INSPECTION
1) If the clutch switch does not operate properly (or
if it does not stop at the specified position), replace
with a new one.
TR0541
Specified position: L
(3) If not as specified, replace the clutch switch.
P'.5/omm(0.079+0.059/0
in)
I L
G4M0327
CL-30
I
CLUTCH SYSTEM
12.General Diagnostic Table

A: INSPECTION
1. CLUTCH
I Symptom Possible cause Corrective

1. Clutch slippage. (a) Clutch facing smeared by oil Replace.
It is hard to perceive clutch slippage in (bl Worn clutch facina Replace.
the early stage, but pay attention to the (c) Deteriorated diaphragm spring Replace.
following symptoms
(d) Distorted pressure plate or flywheel Sorrect or replace.
Engine speeds up when shifting.
High speeds driving is impossible; (e) Defective release bearing holder Sorrect or replace.
especially rapid acceleration impossible
and vehicle speed does not increase in
proportion to an increase in engine
speed.
Power falls, particularly when ascend-
ing a slope, and there is a smell of burn-
ing of the clutch facing.
Method of testing: Put the vehicle in a
stationary condition with parking brake
.fully applied. Disengage the clutch and
shift the transmission gear into the first.
Gradually allow the clutch to engage
while gradually increasing the engine
speed. The clutch function is satisfactory
if the engine stalls. However, the clutch is
slipping if the vehicle does not start off
and the engine does not stall.
2. Clutch drags. (a) Worn or rusty clutch disc hub spline ReDlaCe clutch disc.
As a symptom of this trouble, a harsh (b) Excessive deflection of clutch disc Correct or replace.
scratching noise develops and control facina
becomes quite difficult when shifting (c) Seized crankshaft pilot needle bear- Replace.
gears. The symptom becomes more inn
apparent when shifting into the first gear.
(d) Cracked clutch disc facing ReDlace.
However, because much trouble of this
sort is due to defective synchronization (e) Sticked clutch disc (smeared by oil or Replace.
mechanism, carry out the test as water)
described after.
Method of testing: <Ref. to CL-32,
DIAGNOSTIC DIAGRAM OF CLUTCH
DRAG, INSPECTION, General Diagnos-
tic Table.>
It may be judged as insufficient disen-
gagement of clutch if any noise occurs
during this test.
3. Clutch chatters. (a) Adhesion of oil on the facing Replace clutch disc.
Clutch chattering is an unpleasant vibra- (bl Weak or broken torsion spring Replace clutch disc.
tion to the whole body when the vehicle is (c) Defective facing contact or excessive Replace clutch disc defection.
just started with clutch partially engaged. disc
(d) Warped pressure plate or flywheel Correct or replace.
(e) Loose disc rivets Replace clutch disc.
(fl Loose enaine mountina Retiahten or replace mounting.
(9) Improper adjustment of pitching stop- Adjustment.
per
CL-31
I
CLUTCH SYSTEM
Symptom Possible cause Corrective

4. Noisy clutch (a) Broken, worn or unlubricated release Replace release bearing.
Examine whether the noise is generated bearing
when the clutch is disengaged, engaged, (b) Insufficient lubrication of pilot bearing Apply grease.
or partially engaged. (c) Loose clutch disc hub Replace clutch disc.
I (d) Loose torsion spring retainer I Replace clutch disc.
(e) Deteriorated or broken torsion spring Replace clutch disc.
5. Clutch grabs. (a) Grease or oil on facing Replace clutch disc.
When starting the vehicle with the clutch (b) Deteriorated cushioning spring Replace clutch disc.
partially the clutch engages (c) Worn or rusted spline of clutch disc or Take off rust, apply grease or replace
suddenly and the vehicle jumps instead main shaft clutch disc or main shaft.
of making a smooth start.
(d) Deteriorated or broken torsion spring Replace clutch disc.
(e) Loose engine mounting Retighten or replace mounting.
(f) Deteriorated diaphragm spring Replace.
2. CLUTCH PEDAL
Trouble Corrective action

Insufficient pedal play Adjust pedal play.
Clutch pedal free play insufficient Adjust pedal free play.
Excessively worn and damaged pedal shaft and/or bushing Replace bushing and/or shaft with new one.
3. DIAGNOSTIC DIAGRAM OF CLUTCH DRAG
Step No
CHECK GEAR NOISE. Clutch is normal.
1)Start the engine. rom the transmission gear?
2)Disengage the clutch and shift quickly from
neutral to reverse in idling condition.
! CHECK GEAR NOISE. Defective trans-
Disengage the clutch at idle and shift from neu- rom the transmission gear? mission or exces-
tral to reverse within 0.5 - 1.O seconds. sive clutch drag
torque.
Inspect Pilot bear-
ing, clutch disc,
transmission and
clutch disc hub
spline.
I CHECK GEAR NOISE. Clutch and fly-
1)Disengage the clutch at idle and shift from wheel seizure.
neutral to reverse within 0.5 - 1.O seconds. Inspect clutch disc, Inspect clutch disc,
2)With the clutch disengaged, shift from N to clutch cover, clutch spline of clutch
R. R to N several times. release, and clutch disc hub.
pedal free play.
CL-32
I a
~~
CHASSIS SECTION

of SUBARU vehicles.
c- .

approval.
FUJI HEAVY INDUSTRIES LTD. G18306E5

FRONT SUSPENSION
FSr
2. Wheel Alignment ......................................................................................... 8
3. Sub Frame ................................................................................................ 16
4. Front Transverse Link ............................................................................... 17
5. Front Ball Joint .......................................................................................... 19
6. Front Strut ................................................................................................. 20
7. Front Stabilizer .......................................................................................... 24
8. Front Crossmember .................................................................................. 25
9. General Diagnostic Table.......................................................................... 26
c- .
FRONT SUSPENSION
A: SPECIFICATIONS
1. STABILIZER
Model Bar diameter.
ALL MODEL 20 mm (0.79 in)
2. WHEEL ALIGNMENT
Sedan Wagon
Model
Caster (common difference: f0'45') 3'35' I

I
3'25' I
I
3'35' I 3'25'
I
II 3'25'
. ~-
0+3 mm (Of0.12 in)

Toe-in
Each toe anale: kO"O7'30 (Total toe anale: fO"15')
I Kingpin angle (tolerance: +0"45') I 14"35' I 14"20' I 13"45' I 13"30' I 13'20'
Wheel arch height 396 mm 406 mm 387 mm 397 mm 402 mm
[tolerance: f 1 2 mm (f0.47 in)] (15.59 in) (15.98 in) (15.24 in) (15.63 in) (15.83 in)
AOTE:
Front and rear toe-ins and front camber can be
adjusted. If the toe-in or camber tolerance exceeds
specifications,adjust toe-in and camber to the mid-
dle value of specification.
The other items indicated in the specification ta-
ble cannot be adjusted. If the other items exceeds
specifications, check suspension parts and con-
nections for deformities; replace with new ones as
required.
B4M2250B
(1) Front
A - B = Positive: Toe-in, Negative: Toe-out
a = Each toe angle
FS-2
FRONT SUSPENSION
c- .
FS-3
GENERAL DESCRIPTION
FRONT SUSPENSION
B: COMPONENT
FS-4
GENERAL DESCRIPTION
FRONT SUSPENSION
Front crossmember (17 )Dust seal Tightening torque: N.m (kgf-m, ft-lb)
Bolt ASSY (18) Strut mount T I : ZO(2.0, 14.5)
Housing (19) Spacer T2: 25 (2.5, 18.1) 1
Washer (20) Upper spring seat T3: 30 (3.1,22)

Stopper rubber (Rear) (21) Rubber seat T4: 34 (3.5,25)
Rear bushing (22) Dust cover T5: 40 (4.1, 30)
Stopper rubber (Front) (23) Helper T6: 45 (4.6, 33)
Ball joint (24) Coil spring T7: 50 (5.1, 37)
Transverse link (25) Damper strut T8: 55 (5.6, 41)
Cotter pin (26) Adjusting bolt T9: 71 (7.2, 52)
Front bushing (27) Castle nut T10: 100 (10.2, 74)
Stabilizer link (Except sedan turbo (28) Self-locking nut T11: <Ref. to FS-17, INSPECTION,
model) (29) Sub frame Sub Frame.>
Clamp (30) Cover T12: 175 (17.8, 129)
Bushing (311 Clip T13: 190(19.4, 140)
Stabilizer (32) Stabilizer link (Sedan turbo model) T14: 250 (25.5, 184)
Jack-up plate
.-
FS-5
GENERAL DESCRIPTION
FRONT SUSPENSION
C: CAUTION
tion.
points.
c-- Before installing O-rings or snap rings, apply suf-
formation.
FS-6
GENERAL DESCRIPTION
FRONT SUSPENSION
D: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION TOOL NUMBER REMARKS

927380002 sed as an adapter for camber & caster gauge
,hen measuring camber and caster.
I ) 28199AC000 PLATE
2) 28199AC010 BOLT
927680000 NSTALLER & Jsed for replacing transverse link bushing.

3EMOVER SET
84M2385
927760000 STRUT MOUNT Used for disassembling and assembling strut
SOCKET and shock mount.
TOOL NAME REMARKS

Alignment gauge Used for wheel alignment measurement.
Turning radius gauge Used for wheel alignment measurement.
Toe-in gauge Used for toe-in measurement.
Dial gauge Used for damper strut measurement.
FS-7
I
WHEEL ALIGNMENT
FRONT SUSPENSION
2. Wheel Alignment
A: INSPECTION
Check, adjust and/or measure wheel alignment in accordance with procedures indicated in figure:
WHEEL ARCH HEIGHT (FRONT AND REAR)
1
CAMBER (FRONT AND REAR)
FRONT TOE-IN
REAR TOE-IN
THRUST ANGLE (REAR)
WHEEL STEERING ANGLE
B4M1OBBA
FS-8
I WHEEL ALIGNMENT I
FRONT SUSPENSION
1. WHEEL ARCH HEIGHT

1) Adjust the tire pressure to specifications.
2) Set the vehicle under “curb weight” conditions. (Empty luggage compartment, install spare tire, jack, ser-
vice tools, and top up fuel tank.)
3) Set the steering wheel in a wheel-forward position.
4) Suspend a thread from wheel arch (point “ A in figure below) to determine the point directly above center
of spindle.
5 ) Measure the distance between measuring point “ A and center of spindle.
E t
m
.-
a,
a,
.-m
a,
..c
c c
c E
2 m
.-c
2 a,
-a, m
a, .c
a, 2
m
c c
3
c
5
L
-a,a,
C m
e aa,
LL f
7 End of spindle;,y//,/
suo009
~
Model
Front
I Turbo ~~
396k12 mm (15.59k0.47in)
Specified wheel arch height
Non-turbo
406kl2 mm (15.98k0.47in)
Sedan
Rear 376k12 mm (14.80k0.47in) 381532 mm (15.0k0.47in)
Front 387k12 mm (15.24k0.47in) 397k12 mm (1 5.63k0.47in)
Wagon
Rear 376+12 mm (14.80k0.47in) 381332 mm (15.0k0.47in)
Front - 402k12 mm (15.83k0.47in)
OUTBACK
I Rear - 386k12 mm (15.20k0.47in)
FS-9
I WHEEL ALIGNMENT
FRONT SUSPENSION
2. CAMBER 2) Turn the camber adjusting bolt so that the cam-

ber is set at the specification.
Inspection
NOTE:
1) Place the front wheel on turning radius gauge. Moving the adjusting bolt by one scale graduation
Make sure the ground contacting surfaces of front changes the camber by approximately 0’10’.
and rear wheels are set at the same height.
2) Set the ST into the center of the wheel, and then
install the wheel alignment gauge.
ST 927380002 ADAPTER
c- ~ (1) Alignment gauge

(2) Turning radius gauge
NOTE:
Refer to the ‘SPECIFICATIONS” for the camber
va Iues.
Front: <Ref. to FS-2, SPECIFICATIONS, General J
Description.>
Rear: <Ref. to RS-2, SPECIFICATIONS, General (1) Strut
Description.> (2) Adjusting bolt
Front camber adjustment (3) Housing
(4) Outer
1) Loosen the two self-locking nuts located at the
(5) Inner
lower front portion of strut.
(6) Camber is increased.
CAUTION: (7) Camber is decreased.
When the adjusting bolt needs to be loos-
ened or tightened, hold its head with a wrench
and turn the self-locking nut.
FS-10
I WHEEL ALIGNMENT I
FRONT SUSPENSION
Left side Right side
Camber is increased.
J @) I
;hte counterclock-
@ Rotate clockwise.
u 04M0190 B4M03Gn
Camber is decreased. @ Rotate clockwise.

@
‘
I
;?:e counterclock-
W
B4M0350 B4M0190
3 ) Tighten the two self-locking nuts. 4. FRONT WHEEL TOE-IN

--Tightening torque: Inspection
175 N.m (1 7.8 kgf-m, 129 ft-lb) 1) Using a toe gauge, measure the front wheel toe-
3. CASTER in.
Inspection Toe-in:
Of3 mm (OdU. 12 in)
1) Place the front wheel on turning radius gauge.
Make sure the ground contacting surfaces of front 2) Mark the rear sides of left and right tires at height
and rear wheels are set at the same height. corresponding to the center of spindles and mea-
2) Set the ST into the center of the wheel, and then sure distance “ A between marks.
install the wheel alignment gauge. 3) Move the vehicle forward so that the marks line
ST 927380002 ADAPTER up with front sides at height corresponding to the
center of spindles.
4) Measure the distance “ 6 between left and the
right marks. Toe-in can then be obtained by the fol-
lowing equation:
A - B = Toe-in
B A
(1) Alignment gauge i i

(2) Turning radius gauge
NOTE:
Refer to the ‘SPECIFICATIONS’ for the caster val-
ues. <Ref. to FS-2, SPECIFICATIONS, General Adjustment
Description.> 1) Loosen the left and right side steering tie-rods
lock nuts.
FS-11
I WHEEL ALIGNMENT
FRONT SUSPENSION
2) Turn the left and right tie rods equal amounts un- 4) Measure the distance “B” between left and right
til the toe-in is at the specification. marks. Toe-in can then be obtained by the follow-
Both the left and right tie-rods are right-hand ing equation:
threaded. To increase toe-in, turn both tie-rods A - B = Toe-in
clockwise equal amounts (as viewed from the in-
side of the vehicle). I
S4M0348A Adjustment
1) Loosen the self-locking nut on inner side of link
(1) Lock nut
rear.
3) Tighten the tie-rod lock nut. CAUTION:
Tightening torque: When loosening or tightening the adjusting
83 N-m (8.5kgf-m, 61.5 ff-lb) bolt, hold the bolt head and turn self-locking
nut.
CAUTION: Discard the loosened self-locking nut and re-
Correct the tie-rod boot, if it is twisted. place with a new one.
NOTE:
Check that the left and right wheel steering angle is
5. REAR WHEEL TOE-IN
Inspection
1) Using a toe-in gauge, measure the rear wheel
toe-in.
Toe-in:
-132 mm (-0.039fo.079 in)
2) Mark the rear sides of left and right tires at height
corresponding to the center of spindles and mea- (1) Adjusting bolt
sure distance “A” between marks. (2) Link rear
3) Move the vehicle forward so the that marks line
up with front sides at height corresponding to the 2) Turn the adjusting bolt head until toe-in is at the
specification.
center of spindles.
FS-12
WHEEL ALIGNMENT I
FRONT SUSPENSION
NOTE:
When the left and right wheels are adjusted for toe-in at the same time, the movement of one scale gradu-
ation changes toe-in by approximately 1.5 mm (0.12 in).
Left side Right side

~~
Rotate counterclock-
Toe-in is increased. Rotate clockwise.
wise.
B4M0192 B4M0352
~~
c Rotate counterclock-
Toe-in is decreased. Rotate clockwise.
wise.
B4M0352 84M0192
1) Tighten the self-locking nut. Adjus ment

Tightening torque: Turn the tie-rod to adjust the steering angle of both
100 N-m (10.2 kgf-m, 74 ft-lb) inner and outer wheels.
6. STEERING ANGLE CAUTION:
Check the toe-in.
Inspection Correct the boot if it is twisted.
1) Place the vehicle on a turning radius gauge.
2) While depressing the brake pedal, turn the steer-
ing wheel fully to the left and right. With the steer-
ing wheel held at each fully turned position,
-
measure both the inner and outer wheel steering
angle.
Steering angle:
Turbo,sedan and
Model Others
OUTBACK
S4M0348A
I
~~
Outerwheel I 29"35"f1.5" 31"35Y1.5"

(1) Locknut
FS-13
I WHEEL ALIGNMENT
FRONT SUSPENSION
7. THRUST ANGLE 3) When the left and right adjusting bolts are turned
incrementally by one graduation in the same direc-
Inspection
tion, the thrust angle will change approximately 16’
1) Position the vehicle on a level surface. [‘I“ is almost equal to 12 mm (0.472 in)].
2) Move the vehicle 3 to 4 meters directly forward.
Thrust angle:
3) Determine the locus of both front and rear axles.
4) Measure the distance “L” between center line of O”f20’
loci of the axles.
Thrust angle:
Less than 20‘ when “L” is equal to or less
than 15 mm (59 in).
c- .
M S4M0350B
(1) Center line of loci (front axle)

(2) Center line of loci (rear axle)
T S4M0350B NOTE:
Thrust angle refers to a mean value of left and right
(1) Center line of loci (front axle) rear wheel toe angles in relation to the vehicle
(2) Center line of loci (rear axle) body center line. Vehicle is driven straight in the
thrust angle direction while swinging in the oblique
Adjustment direction depending on the degree of the mean
1) Make the thrust angle adjustments by turning thrust angle.
toe-in adjusting bolts of rear suspension equally in (11
the same direction.
2) When one rear wheel is adjusted in a toe-in di-
t
rection, adjust the other rear wheel equally in toe-
out direction, in order to make the thrust angle ad-
justment.
(1) Front
(2) Thrust angle
(3) Body center line
FS-14
I WHEEL ALIGNMENT I
FRONT SUSPENSION
Thrust angle: r = (a- p)/2

a: Right rear wheel toe-in angle
p: Left rear wheel toe-in angle
NOTE:
Here, use only positive toe-in values from each
wheel to substitute for a and p in the equation.
B4M01948
(1) Front
(2) Body center line
c.
FS-15
SUB FRAME
FRONT SUSPENSION
3. Sub Frame B: INSTALLATION

A: REMOVAL
NOTE:
Replace the M12 bolt with a new one.
3) Remove the bolt cover. Tightening torque:
T1: 34 N.m (3.5 kgf-m, 25 ff-lb)
T2: 55 N-m (5.6 kgf-m, 41 ff-lb)
T3: 71 N.m (7.2 kgf-m, 52 ff-lb)
T4: 105 N-m (10.7 kgf-m, 77 ff-lb)
4) Remove the clip.
(1) M8 bolt
(2) M12 bolt (with max)
(3) M12 bolt (with oil)
(4) M10 bolt
5) Remove the sub frame.

NOTE:
Loosen bolt (1) and leave a few threads caught,
then remove the bolts in the order of (2),(3), (4),
(51,and (6).
FS-16
SUB FRAME
FRONT SUSPENSION
C: INSPECTION
1) Check that there is no damage and distortion at
the sub frame.
2) Check that the bolts are tightened with the spec-
ified torque. If there is looseness, tighten to the
specified torque.
NOTE:
The tightening torque differs by the color for bolt
(3). Always verify the bolt color before checking
tightening torque.
Tightening torque:
T I : 34 N-m (3.5 kgf-m, 25 ff-lb)
T2: 55 N.m (5.6 kgf-m, 41 ff-lb)
T3: 71 N-m (7.2 kgf-m, 52 ff-lb)
T4: Dark green bolt
105 Nom(10.7 kgf-m, 77 ff-lb)
T4: Except dark green bolt
55 N-m (5.6 kgf-m, 41 ff-lb)
FS-17
SUB FRAME
FRONT SUSPENSION
3. Sub Frame B: INSTALLATION

A: REMOVAL
NOTE:
Replace the M12 bolt with a new one.
3) Remove the bolt cover. Tightening torque:
T1: 34 N-m (3.5 kgf-my25 ft-16)
T2: 55 N-m (5.6 kgf-my41 ft-16)
T3: 71 N-m (7.2 kgf-my52 ft-16)
4) Remove the clip.
(1) M8 bolt
(2) M12 bolt
(3) MlO bolt
C: INSPECTION
Check that there is no damage and distortion at the
sub frame.
5 ) Remove the sub frame.

NOTE:
Loosen bolt (1) and leave a few threads caught,
then remove the bolts in the order of (2),(3), (4),
(5),and (6).
FS-16
I
FRONT TRANSVERSE LINK
FRONT SUSPENSION
4. Front Transverse Link B: INSTALLATION

1) Temporarily tighten the two bolts used to secure
A: REMOVAL the rear bushing of the transverse link to body.
1) Set the vehicle on the lift. NOTE:
2) Disconnect the ground terminal from battery. These bolts should be tightened to such an extent
3) Lift-up the vehicle and remove the wheel. that they can still move back and forth in the oblong
4) Remove the sub frame. <Ref. to FS-16, RE- shaped hole in the bracket (which holds the bush-
MOVAL, Sub Frame.> ing).
5) Disconnect the stabilizer link from transverse
2) Install the bolts used to connect the transverse
link. link to crossmember and temporarily tighten with
6) Remove the bolt securing the ball joint of trans- nut.
verse link to housing.
CAUTION:
3) Insert the ball joint into housing.
4) Connect the stabilizer link to transverse link, and
temporarily tighten bolts.
CAUTION:
c.
S4MOO9(
7) Remove the nut (do not remove bolt.) securing

the transverse link to crossmember.
8) Remove the two bolts securing the bushing
bracket of transverse link to vehicle body at rear
bushing location.
" S4M0090
5) Tighten the following points in the order shown

below when the wheels are in full contact with the
ground and vehicle is curb weight.
(1) Transverse link and stabilizer
Tightening torque:
Sedan Turbo model:
45 N.m (4.6 kgf-m, 33 ft-lb)
9) Extract the ball joint from housing. Except sedan Turbo model:
10) Remove the bolt securing the transverse link to 30 N m (3.1 kgf-m, 22 ft-lb)
crossmember and extract the transverse link from
crossmember. (2) Transverse link and crossmember
Tightening torque:
100 N-m (10.2 kgf-m, 74 ft-lb)
(3) Transverse link rear bushing and body
Tightening torque:
250 N-m (25.5 kgf-m, 184 ff-16)
FS-17
I FRONT TRANSVERSE LINK
FRONT SUSPENSION
NOTE: D: ASSEMBLY
Move the rear bushing back and forth until trans-
verse link-to-rear bushing clearance is established 1. FRONT BUSHING
(as indicated in figure.) before tightening. To reassemble, reverse disassembly procedures.
Unit: mm (in) CAUTION:
Install the front bushing in correct direction, as
.059) shown in the figure.
(1) Rear bushing
6) Install the sub frame. <Ref. to FS-16, INSTALLA- S4M0351A

TION, Sub Frame.>
7) Inspect the wheel alignment and adjust if neces- (1) Face bushing toward center of ball joint
sary. <Ref. to FS-8, Wheel Alignment.> (2) Ball joint
C: DISASSEMBLY 2. REAR BUSHING

1. FRONT BUSHING 1) Install the rear bushing to transverse link and
align the aligning marks scribed on the two.
Using ST, press the front bushing out of place. 2) Tighten the self-locking nut.
ST 927680000 INSTALLER & REMOVER
SET CAUTION:
While holding the rear bushing so as not to
change position of aligning marks, tighten the
self-locking nut.
Tightening torque:
190 N-m (19.4 kgf-m, 140 ff-lb)
E: INSPECTION
1) Check the transverse link for wear, damage and
G4M0494 cracks, and correct or replace if defective.
2) Check the bushings for cracks, fatigue or dam-
2. REAR BUSHING
age.
1) Scribe an aligning mark on the transverse link 3) Check the rear bushing for oil leaks.
and rear bushing.
2) Loosen the nut and remove the rear bushing.
G4M0495 I
FS-18
I
FRONT BALL JOINT
FRONT SUSPENSION
5. Front Ball Joint C: INSPECTION

1) Measure the play of ball joint by the following
A: REMOVAL procedures. Replace with a new one when the play
1) Remove the front wheel. exceeds the specified value.
2) Pull out the cotter pin from the ball stud, remove (1) With 686 N (70 kgf, 154 Ib) loaded in the di-
the castle nut, and extract the ball stud from the rection shown in the figure, measure dimension
transverse link. e 1.
3) Remove the bolt securing the ball joint to the
housing.
--4)-€xtract the ball joint from the housing.

\
G4M0499
- G4M0500
(2) With 686 N (70 kgf, 154 Ib) loaded in the op-
posite direction shown in the figure, measure di-
mension e,.
B: INSTALLATION
1) Install the ball joint onto the housing. I 4
Torque (Bolt):
50 N-m (5-7 kgf-m, 37 ft-lb)
CAUTION:
Do not apply grease to the tapered portion of
ball stud.
2) Connect the ball joint to transverse link.
Torque (Castle nut): G4M0501
Sedan turbo model: (3) Calculate plays from the following formula.
30 N-m (3.7 kgf-m, 22ft-lb) S= Q2 - 0 1
Except sedan turbo model: (4) When plays are larger than the following val-
45 N.m (4.6 kgf-m, 33ft-lb) ue, replace with a new one.
3) Retighten the castle nut further within 60" until a FRONT BALL JOINT
slot in castle nut is aligned with the hole in ball stud Specified play for replacement: S
end, then insert the new cotter pin and bend it
Less than 0.3 mm (0.012 in)
around castle nut.
4) Install the front wheel. 2) When the play is smaller than the specified val-
ue, visually inspect the dust cover.
3) The ball joint and cover that have been removed
must be checked for wear, damage or cracks, and
any defective part must be replaced.
4) If the dust cover is damaged, replace with a new
ball joint.
FS-19
I FRONT STRUT
FRONT SUSPENSION
6. Front Strut 6) Remove the three nuts securing strut mount to

body.
A: REMOVAL
1) Remove the front wheel.
2) Remove the bolt securing brake hose from strut.
R4Mi78A
3) Scribe an alignment mark on the camber adjust-

ing bolt which secures strut to housing.
4) Remove the bolt securing the ABS sensor har-
ness.
suo011
5 ) Remove the two bolts securing housing to strut.

CAUTION:
While holding the head of adjusting bolt, loosen
self-locking nut.
FS-20
I FRONT STRUT
I
FRONT SUSPENSION
B: INSTALLATION C: DISASSEMBLY
1) Install the strut mount at upper side of strut to 1) Using a coil spring compressor, compress the
body and tighten with nuts. coil spring.
Tightening torque:
20 N-m (2.0 kgf-m, 74.5 ft-lb)
2) Position the aligning mark on camber adjustment
bolt with aligning mark on lower side of strut.
CAUTION:
While holding the head of adjusting bolt,
tighten self-locking nut.
Be sure to use a new self-locking nut.
Tightening torque: S4M0095
775 N-m (77.8 kgf-m, 729 ft-lb)
3 ) Install the ABS sensor harness to strut. 2) Using the ST, remove the self-locking nut.
ST 927760000 STRUT MOUNT SOCKET
Tightening torque:
33 N.m (3.4 kgf-m, 24.3 ft-lb)
4) Install bolts which secure the brake hose to strut.
-_Tightening torque:
33 N-m (3.4 kgf-m, 24.3 ft-lb)
5 ) Install the front wheels.
NOTE:
Check wheel alignment and adjust if necessary.
3) Remove the strut mount, upper spring seat and

rubber seat from strut.
4) Gradually decreasing the compression force,
and remove the coil spring.
5 ) Remove the dust cover and helper spring.
FS-21
I FRONT STRUT
FRONT SUSPENSION
D: ASSEMBLY 5) Set the coil spring correctly so that its end face
1) Before installing the coil spring, strut mount, etc., fits well into the spring seat as shown.
on the strut, check for the presence of air in the
dampening force generating mechanism of the
strut since air prevents proper dampening force
from being produced.
2) Checking for the presence of air:
(1) Place the strut vertically with the piston rod
facing up.
(2) Move the piston rod to the center of its entire
stroke.
(3) While holding the piston rod end with finger-
tips, move the rod up and down. I S4M0353A
(4) If the piston rod moves at least 10 mm (0.39 6) Install the helper and dust cover to the piston
in) in the former step, purge air from the strut. rod.
3) Air purging procedure: 7) Pull the piston rod fully upward, and install the
(1) Place the strut vertically with the piston rod rubber seat and spring seat.
facing up. NOTE:
(2) Fully extend the piston rod. Ensure the upper spring seat is positioned as
(3) With the piston rod fully extended, place the shown in the figure.
-- -piston rod side down. The strut must stand ver-
tically.
(4) Fully contract the piston rod.
(5) Repeat 3 or 4 times from the first step.
NOTE:
After completely purging air from the strut, be sure
to place the strut with the piston rod facing up. If it
is laid down, check for entry of air in the strut as
outlined under “Checking for the presence of air”.
4) Using a coil spring compressor, compress the
coil spring.
4 (1)
S4M0097B
NOTE: (1) Outside of body

Make sure that the vertical installing direction of coil
spring is as shown in the figure. 8) Install the strut mount to the piston rod, and tight-
en the self-locking nut temporarily.
CAUTION:
(2 Be sure to use a new self-locking nut.
9) Using a hexagon wrench to prevent strut rod
from turning, tighten self-locking nut with ST.
ST 927760000 STRUT MOUNT SOCKET
Tightening torque:
55 N.m (5.6 kgf-m, 41 ft-lb)
I B4M0568B I
(1) Fiat (top side)
(2) identificationpaint
(3) inclined (bottom side)
FS-22
I
FRONT STRUT
FRONT SUSPENSION
10) Loosen the coil spring carefully. 5. HELPER

E: INSPECTION Replace it with a new one if cracked or damaged.
Check the disassembled parts for cracks, damage F: DISPOSAL
and wear, and replace with new parts if defective.
CAUTION:
1. DAMPER STRUT On struts which have “GAS FILLED” marked
1) Check for oil leakage. on the outer housing under spring seat, com-
2) Move the piston rod up and down to check that it pletely discharge the gas before disposing, fol-
operates smoothly without any binding. lowing the methods below.
3) Play of piston rod Do not disassemblethe strut damper or place
Measure the play as follows: into a fire.
Fix the outer shell and fully extend the rod. Set a Drill holes before disposing of gas filled
dial gauge at the end of the rod: L [ l o mm (0.39 struts.
in)], then apply a force of W [20 N (2 kgf, 4 Ib)] to Before handling gas filled struts, be sure to
threaded portion. With the force of 20 N (2 kgf, 4 Ib) wear goggles to protect eyes from gas, oil and/
applied, read the dial gauge indication: PI. Apply a or filings.
force of 20 N (2 kgf, 4 Ib) in the opposite direction
of “W”, then read the dial gauge indication: P.,
GAS FILLED
DO NOT OPEN
DO NOT HEAT
I B4M1201
1) Place the gas filled strut on a flat and level sur-

face with piston rod fully extended.
The free play is determined by the following equa- 2) Using a 2 to 3 mm (0.08 to 0.12 in) dia. drill,
tion: make holes in areas shown in the figure.
Play = PI, P2
Limit of play: I piston rod ,-Strut
Less than 0.8 mm (0.031 in)

If the play is greater, replace the strut.
2. STRUT MOUNT
Check the rubber part for creep, cracks and deteri-
oration, and replace it with a new one if defective.
M (1.57 in)
3. DUSTCOVER B4M1202P
If any cracks or damage are found, replace it with a
new one.
4. COIL SPRING
One having permanent strain should be replaced
with a new one. When the vehicle posture is un-
even, although there are no considerable reasons
like tire puncture, uneven loading, etc., check the
coil spring for its free length referring to specifica-
tions, cracks, etc., and replace it with a new one if
defective.
FS-23
I FRONT STABILIZER
FRONT SUSPENSION
7. Front Stabilizer B: INSTALLATION

A: REMOVAL NOTE:
Jack-up the front part Of the vehicleand Install the bushing (on front crossmember side)
it with safety stands (rigid racks). while aligning it with paint mark on stabilizer.
2, Remove the j a c k w plate from lowerpart Of Ensure the bushing and stabilizer have the Same
crossmember. identification colors when installing.
3) Remove the sub frame. <Ref. to FS-16,RE-
LbVAL, Sub Frame.>
4) Remove the bolt and nut which secure the stabi-
lizer to crossmember.
'' suo012
(1) Mark stamped on stabilizer

c- -
(2) Bushing identification color
5 ) Remove the bolts which Secure the stabilizer link 2)Always tighten the rubber bushing location when
to front transverse link. wheels are in full contact with the ground and ve-
hicle is curb weight.
Tightening torque (Sedan turbo model):
Jack-up plate to crossmember:
20 Nom(2.0 kgf-m, 14.5 ft-lb)
Stabilizer link to front transverse link:
45 N-m (4.6 kgf-m, 33 ft-lb)
Stabilizer to crossmember:
25 N.m (2.5 kgf-m, 18.1 ft-lb)
Tightening torque (Except sedan turbo model):
Jack-up plate to crossmember:
20 N.m (2.0 kgf-m, 14.5 ft-lb)
Stabilizer link to front transverse link:
30 N.m (3.1 kgf-m, 22 ft-lb)
Stabilizer to crossmember:
25 N-m (2.5 kgf-m, 18.1 ft-lb)
3) Install the sub frame. <Ref. to FS-16, INSTALLA-
TION, Sub Frame.>
C: INSPECTION
1) Check the bushing for cracks, fatigue or dam-
age.
2) Check the stabilizer link for deformities, cracks
or damage, and bushing for protrusions from the
hole of stabilizer link.
FS-24
FRONT CROSSMEMBER
FRONT SUSPENSION
8. Front Crossmember 12) Support the crossmember with a jack, remove

the nuts securing crossmember to body and lower
A: REMOVAL crossmember gradually along with the steering
1) Disconnect the ground terminal from battery. gearbox.
2) Lift-up the vehicle and remove the front tires and CAUTION:
wheels. When removing the crossmember downward,
3) Remove the sub frame. <Ref. to FS-16, RE- be careful that the tie-rod end does not inter-
MOVAL, Sub Frame.> fere with SFJ boot.
4) Remove both stabilizer and jack-up plate. 13) Remove the steering gearbox from crossmem-
ber.
B: INSTALLATION
CAUTION:
Always tighten the rubber bushing when
wheels are in full contact with the ground and
vehicle is curb weight.
Tightening torque:
Transverse link bushing to crossmember:
c.
100 N.m (10.2 kgf-m, 74 ft-lb)
(1) Front stabilizer Stabilizer to bushing:
(2) Front crossmember 25 N.m (2.5 kgf-m, 18.1 ft-lb)
Tie-rod end to housing:
5) Disconnect the tie-rod end from housing. 27.0 N-m (2.75 kgf-m, 19.9 ft-lb)
6) Remove the front exhaust pipe. (Non-turbo mod- Front cushion rubber to crossmember:
el) <Ref. to. EX(S0HC)-5, REMOVAL, Front Ex- 85 N.m (8.7 kgf-m, 62.7 ft-lb)
haust Pipe.> Universal joint to pinion shaft:
7 ) Remove the front transverse link from front 24 N-m (2.4 kgf-m, 17.4 ff-16)
crossmember and body. Crossmember to body:
100 N-m (10.2 kgf-m, 74 ft-lb)
2) Purge air from the power steering system.
NOTE:
Check the wheel alignment and adjust if necessary.
C: INSPECTION
Check the crossmember for wear, damage and
cracks, and correct or replace if defective.
8) Remove the nuts attaching engine mount cush-

ion rubber to crossmember.
9) Remove the steering universaljoint. <Ref. to PS-
26, REMOVAL, Steering Gearbox.>
10) Disconnect the power steering pipe from steer-
ing gear box.
11) Lift the engine by approx. 10 mm (0.39 in) by
using a chain block.
FS-25
I
FRONT SUSPENSION
9. General Diagnostic Table

A: INSPECTION
1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT
Possible causes Countermeasures
(2) Unsmooth operation of damper strut and/or shock absorber Replace.

(3) Installation of wrong strut and/or shock absorber Replace with proper parts.
(4) Installation of wrong coil spring Replace with proper parts.
ning over bump and/or hump.

1) Large rebound shock
3) Large shock in bumping
I Replace.
(1) Breakage of coil spring
(2) Overinflation pressure of tire
I (3) Improper wheel arch height
I Adjust.
I Adjust or replace coil springs with new ones.
I
I
(4) Fault in operation of damper strut and/or shock absorber Replace.
*(5)Damage or deformation of strut mount and/or shock absorber mount Replace.
(6) Unsuitability of maximum and/or minimum length of damper strut and/or Replace with proper parts.
shock absorber
I ( 7 ) Deformation or loss of bushing I Replace. I
(8) Deformationor damage of helper in strut assembly and/or shock Replace.
absorber
(9) Oil leakaae of damDer strut and/or shock absorber Replace.

(1 ) Wear or damage of damper strut and/or shock absorber component Replace.
parts
(2) Loosenina of suspension link installing bolt I Retighten to the specified torque. I
(3) Deformation or loss of bushing 1 Replace. I
shock absorber
(5) Breakaae of coil sprina Replace.
I (6) Wear or damaae of ball ioint I Replace. I
I (7) Deformation of stabilizer clamp I Replace. I
FS-26
REAR SUSPENSION
RS
a
.
Page
2. Wheel Alignment ......................................................................................... 9
3. Rear Stabilizer........................................................................................... 10
4. Rear Trailing Link ...................................................................................... 11
5. Rear Strut .................................................................................................. 15
6. Lateral link ................................................................................................. 16
7. Rear Crossmember ................................................................................... 19
I
GENERAL DESCRIPTION
REAR SUSPENSION
A: SPECIFICATIONS
Sedan Wagon
Item OUTBACK
Turbo I Non-turbo 1 Turbo 1 Non-turbo
I Camber (tolerance: fO"45') I -1"30' I -1"25' I -1'20' I -1'15' I -1"10' I
- I f 2 mm (-0.039k0.079 in)
Toe-in
Each toe-in angle: fO"07'30 (Total toe-in angle 0"+15')
Wheel arch height 376 m m 381 mm 376 m m 381 m m 386 m m
[tolerance:k12 mm (k0.47 in)l (14.80 in) (15.0 in) (14.80 in) (15.0 in) (15.20 in)
I Thrust angle I O"f20' I
20 mm 1 3 mm 17 mm 13mm
Diameter of stabilizer
(0.79 in) (0.51 in) (0.67 in) (0.51 in)
NOTE:
Front and rear toe-ins and front camber can be
adjusted. If the toe-in or camber tolerance exceeds
specifications, adjust the toe-in and camber to the
middle value of specification.
The other items indicated in the specification ta-
%le cannot be adjusted. If the other items exceeds
specifications, check the suspension parts and
connections for deformities; replace with new ones
as required.
B4M2250C
(1) Front
A - B = Positive: Toe-in, Negative: Toe-out
al, a2: Each toe-in angle
RS-2
3
GENERAL DESCRIPTION
REAR SUSPENSION
c.
RS-3
I
REAR SUSPENSION
B: COMPONENT
P I
SI
RS-4
GENERAL DESCRIPTION
REAR SUSPENSION
Stabilizer Trailing link bracket Tightening torque: N-m (kgf-m, ft-lb)

Stabilizer bracket Cap (Protection) T1: 20(2.0, 14.5)
Stabilizer bushing Washer T2: 25 (2.5, 18.1)
Clamp Rear crossmember T3: 45 (4.6, 33.2)
Floating bushing Strut mount cap T4: 55 (5.6, 4 1)
Stopper Strut mount T5: 70 (7.1, 52)
Stabilizer link Rubber seat upper T6: 90 (9.2, 66)
Rear lateral link Dust cover T7: 100 (10.2, 74)
Bushing (C) Coil spring T8: 115(11.7, 85)
Bushing (A) Helper T9: 130 (13.3, 96)
Front lateral link Rubber seat lower TlO: 135(13.8, 100)
Bushing (B) Damper strut T11: 220(22.4, 162)
Trailing link rear bushing Self-locking nut
Trailing link Rear differential member rear
Trailing link front bushing
c.
RS-5
REAR SUSPENSION
C: CAUTION
tion.
points.
-0 Before installing O-rings or snap rings, apply suf-
formation.
Before disposing shock absorbers, be sure to
bleed gas completely. Also, do not throw away in
fire.
RS-6
I
GENERAL DESCRIPTION
REAR SUSPENSION
D: PREPARATION TOOL
1. SPECIAL TOOLS
I ILLUSTRATION TOOL NUMBER DESCRIPTlON REMARKS

927380002 rDAPTER Jsed as an adapter for camber & caster gauge
vhen measuring camber and caster.
1) 28199ACOOO PLATE
2) 28199AC010 BOLT
1 B4M2378A
927720000 NSTALLER &
3EMOVER
Jsed for replacing front bushing.
I suo014
927730000 NSTALLER & Used for replacing rear bushing.
3EMOVER
I SUOOI!
28099PA100 REMOVER Used for removing DOJ.
RS-7
I
GENERAL DESCRIPTION
REAR SUSPENSION

92770000 INSTALLER & Used for replacing lateral link bushing.
REMOVER
SUO015
927690000 HELPER SOCKET Used for replacing lateral link bushing.
WRENCH
SUO015
TOOL NAME REMARKS

Alignment gauge Used for wheel alignment measurement.
Turnina radius aauae Used for wheel alianment measurement.
IToe-in aauae I Used for toe-in measurement. I
I Transmission iack I Used for suspension assembly/disassembly. I
I Bearing puller I Used for removing bushings.
RS-8
I
WHEEL ALIGNMENT
REAR SUSPENSION
2. Wheel Alignment
A: INSPECTION
NOTE:
The front and rear wheel alignment must be mea-
sured and/or adjusted at once to obtain accuracy.
Measure and/or adjust the rear wheel alignment to-
gether with the front. Follow the procedure in "FS"
section "Wheel Alignment" for measurement and/or
adjustment of wheel alignment. <Ref. to FS-8, IN-
SPECTION, Wheel Alignment.>
RS-9
I REAR STABILIZER
REAR SUSPENSION
3. Rear Stabilizer B: INSTALLATION

A: REMOVAL NOTE:
1) Jack-up the rear part of the vehicle, support it Install the bushing while aligning it with paint
with safety stands (rigid racks). mark on stabilizer.
2) Remove the bolts which secure stabilizer link to Ensure that the bushing and stabilizer have the
rear lateral link. same identification colors when installing.
3) Remove the bolt which secures stabilizer to sta-

bilizer bracket. (1) Mark stamped on stabilizer
c- - (2) Bushing identification color
2) Always tighten the rubber bushing location when

wheels are in full contact with the ground and vehi-
cle is curb weight.
Tightening torque:
Stabilizer link to rear lateral link
45 N-m (4.6 kgf-m, 33.2 ft-lb)
Stabilizer to stabilizer bracket
25 N.m (2.5 kgf-m, 18.1 ft-lb)
C: INSPECTION
1) Check the bushing for cracks, fatigue or dam-
age.
2) Check the stabilizer links for deformities, cracks,
or damage, and bushing for protrusions from the
hole of stabilizer link.
RS-10
REAR TRAILING LINK
1
REAR SUSPENSION
4. Rear Trailing Link B: INSTALLATION

A: REMOVAL CAUTION:
1) Loosen the rear wheel nuts. Always tighten the .rubber bushing location
2)Jack-up the vehicle, SUPPofl it with safety stands when wheels are in full contact with the ground
(rigid racks) and remove the rear wheels. and vehicle is at curb weight condition.
3) Remove both rear parking brake clamp and ABS
sensor harness. (Models equipped with ABS) NOTE:
4) R~~~~~ the bolt which Secures trailing link to Check the wheel alignment and adjust if necessary.
trailing link bracket.
(1) Trailing link
5 ) Remove the bolt which secures trailing link to

rear housing.
RS-11
REAR TRAILING LINK
REAR SUSPENSION
C: DISASSEMBLY 2. REAR BUSHING

1. FRONT BUSHING 1) Remove the housing. <Ref. to DS-23, REMOV-
AL, Rear Axle.>
Using ST, press the front bushing out of place. 2) Using ST, press the rear bushing out of place.
ST 927720000 INSTALLER & REMOVER ST 927730000 INSTALLER &-REMOVER
SET SET
c- -
(1) Press (1) Press

(2) Trailing link (2) Housing
RS-12
REAR TRAILING LINK I
REAR SUSPENSION
D: ASSEMBLY 2. REAR BUSHING

1) Using ST, press the bushing into trailing link.
1. FRONT BUSHING
Using ST, press the bushing into trailing link. SET
NOTE:
SET
If it is difficult to press the bushing into trailing link,
CAUTION: apply water-diluted TIRE LUBE to the inner surface
When installing the bushing, turn ST plunger of ST as a lubricant.
upside down and press it until plunger end sur-
face contacts trailing link end surface. SPE ClFlED lubricant:
TIRE LUBE :water = 1 :3
‘ir
(2)
\
c-
(3)
\
S4M0360E
(1) Press
(1) Press
(2) Front bushing
(3) Trailing link
CAUTION:
Install the front bushing in proper direction, as
shown in the figure.
I
S4M0361A
(1) Front
RS-13
REAR TRAILING LINK
REAR SUSPENSION
2) Press the ST pluger until bushing flange pro- 3) Turn the trailing link upside down. Press the ST
trudes beyond trailing link. plunger in the direction opposite that outlines in the
ST 927730000 INSTALLER & REMOVER former procedure until bushing is correctly posi-
SET tioned in trailing link.
SET
r. .
( 1 ) Plunger
(2) Flange
( 1 ) Press
(2) Plunger
4) Install the housing. <Ref. to DS-26, INSTALLA-

TION, Rear Axle.>
E: INSPECTION
Check the trailing links for bends, corrosion or dam-
age.
RS-14
I REAR STRUT I
REAR SUSPENSION
5. Rear Strut B: INSTALLATION

1) Tighten the self-locking nut used to secure strut
A: REMOVAL mount to car body.
1) Remove the rear seat cushion and backrest. CAUTION:
(Sedan model) Discard the loosened self-locking nut, and re-
2) Remove the strut cap of quarter trim. (Wagon place with a new one.
model)
3) Loosen the rear wheel nuts. Tightening torque:
4) Jack-up the vehicle, support it with safety stands 20 Nom(2.0 kgf-m, 14.5 ft-lb)
(rigid racks) and remove the rear wheels. 2) Tighten the bolts which secure rear strut to hous-
5 ) Remove the brake hose clip and remove the ing.
brake hose from rear strut.
Tightening torque:
220 N.m (22.4 kgf-m, 162 ft-lb)
CAUTION:
Discard the loosened self-locking nut, and re-
3) Install the brake hose to lower side of strut, then
insert brake hose clip.
CAUTION:
Check that the hose clip is positioned proper-
ly-
Check the brake hose for twisting, or exces-
sive tension.
(1) Brake hose clip
(Model equipped with ABS)
(2) Brake hose
Do not subject the ABS sensor harness to exc-
6) Remove -the bolts which secure rear strut to es-sive tension.
housing. 4) Lower the vehicle and tighten wheel nut.
Tightening torque:
90 N-m (9.2 kgf-m, 66 ft-lb)
5 ) Sedan model:
Install the rear seat backrest and rear seat cushion.
Wagon model:
Install the strut cap to rear quarter trim.
NOTE:
Check wheel alignment and adjust if necessary.
C: DISASSEMBLY
For disassembly of rear strut, refer to procedures
7) Remove the nuts securing strut mount to body. outlined under front strut as a guide. <Ref. to FS-
21, DISASSEMBLY, Front Strut.>
D: ASSEMBLY
Refer to Front Strut as a guide for assembly proce-
dures.
<Ref. to FS-22, ASSEMBLY, Front Strut.>
E: INSPECTION
Refer to Front Strut as a guide for inspection proce-
dures.
<Ref. to FS-23, INSPECTION, Front Strut.>
F: DISPOSAL
Refer to Front Strut as a guide for disposal proce-
dures.<Ref. to FS-23, DISPOSAL, Front Strut.>
RS-15
LATERAL LINK
REAR SUSPENSION
6. Lateral link
A: REMOVAL
1) Loosen the wheel nuts. Lift-up the vehicle and
remove wheel.
2) Remove the stabilizers. (Turbo model)
3) Remove the ABS sensor harness from trailing
link.
(Models eqipped with ABS)
4) Remove the bolt securing trailing link to housing.
r.
(1) Rear housing

(2) Trailing link
5) Remove the bolts which secure lateral link as-

sembly to rear housing.
6) Remove the DOJ from rear differential using ST.
ST 28099PA100 DRIVE SHAFT REMOVER
NOTE:
The side spline shaft circlip comes out together
with the shaft.
Bushing ST:INSTALLER & REMOVER SET
Bushing A 927700000
Bushina B 927690000
I BushinaC I 927700000 I
(1) Bolt
(2) DOJ
CAUTION:
Be careful not to damage the side bearing re-
tainer. Always use bolt shown in figure, as sup-
porting point for ST during removal.
7) Scribe an alignment mark on the rear lateral link
adjusting bolt and crossmember.
RS-16
LATERAL LINK
REAR SUSPENSION
D: ASSEMBLY
1) Using ST, press the bushing into place.
CAUTION:
Select the ST according to the type of bushings
used.
NOTE:
Use the same ST as that used during disassem-
bly.
If it is difficult to press the bushing into trailing
link, apply water-diluted TIRE LUBE to the inner
surface of ST as a lubricant.
Specified lubricant:
TIRE LUBE :water = 1 :3
S4MQIQQ
(1) Bushing A
(2) Bushing B
(3) Bushing C
(4) Front
(5) Outside of body
(1) Press
(2) Bushing
(3) Lateral link
S4MQ365
(1) Press
(2) Lateral link
RS-17
I LATERAL LINK
REAR SUSPENSION
2) Press the ST plunger until bushing flange pro- 3) Turn the lateral link upside down. Press the ST
trudes beyond lateral link. plunger in the direction opposite that outlined in the
NOTE: former procedure until bushing is correctly posi-
Use the same ST as that used during disassembly. tioned in trailing link.
NOTE:
Using the same ST as that used during dissassem-
bly.
c. .
(1) Press
(2) Plunger
(3) Lateral link
(4) Flange (1) Press
(2) Plunger
(3) Lateral link
E: INSPECTION
Visually check the lateral links for damage or
bends.
RS-18
I REAR CROSSMEMBER I
REAR SUSPENSION
7. Rear Crossmember B: INSTALLATION

A: REMOVAL 2) For installation and tightning torque of rear differ-
CAUTION: ential:
Do not subject the ABS sensor harness to ex- <Ref. to DI-20, INSTALLATION, Rear Differential.>
cessive tension. (Models equipped with ABS) 3) Always tighten the rubber bushing when wheels
1) Separate the front exhaust pipe and rear ex- are in full contact with the ground and vehicle is
haust pipe. curb weight.
2) Remove the rear exhaust pipe and muffler. NOTE:
3) Remove the rear differential. Check the wheel alignment and adjust if necessary.
<Ref. to DI-19, REMOVAL, Rear Differential.>
4) Place a transmission jack under rear crossmem-
C: INSPECTION
ber. Check the removed parts for wear, damage and
cracks, and correct or replace if defective.
5) Remove the bolts securing crossmember to ve-

hicle body, and remove the crossmember.
6) Scribe an alignment mark on the rear lateral link

cam bolt and crossmember.
7) Remove the front and rear lateral links by loos-
ening nuts.
RS-19
I
REAR SUSPENSION

A: INSPECTION
1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT
(1) Permanent distortion or breakage of coil spring Replace.
(2) Unsmooth operation of damper strut and/or shock absorber Replace.
I (3) Installation of wrong strut and/or shock absorber I Replace with proper parts. I
I (4) Installation of wrong coil spring I Replace with proper parts. I
2. POOR RIDE COMFORT
1) Large rebound shock
2) Rocking of vehicle continues too long after running over bump and/or hump.
3) Large shock in bumping
I (1) Breakage of coil spring I Replace.

I (2) Overinflation Dressure of tire I Adiust.
(3) Improper wheel arch height I
Adjust or replace coil springs with new ones.
44)Fault in operation of damper strut and/or shock absorber
\ ,
II Replace.
'
t(5) Damaae or deformation of strut mount and/or shock absorber mount I Replace.
(6) Unsuitabilityof maximum and/or minimum length of damper strut and/or Replace with proper parts.
shock absorber
(7) Deformation or loss of bushing Replace.
(8) Deformation or damage of helper in strut assembly and/or shock Replace.
absorber
I (9) Oil leakage of damper strut and/or shock absorber 1 Replace.
3. NOISE
(1) Wear or damage of damper strut and/or shock absorber component Replace.
parts
(2) Loosening of suspension link installing bolt I Retighten to the specified torque. I
(3) Deformation or loss of bushing I Replace. I
shock absorber
(5)Breakaae of coil sprina Replace.
(6) Wear or damage of ball ioint I Replace. I
I (7) Deformationof stabilizer clamp I Replace. I
RS-20
WHEEL AND TIRE SYSTEM
WT
page
~~ ~

2. Tire .............................................................................................................. 4
3. Steel Wheel ................................................................................................. 5
4. Aluminum Wheel ......................................................................................... 6
5. Wheel Balancing ......................................................................................... 7
6. “T-type” Tire ................................................................................................ 8
7. Full Wheel Cap ............................................................................................ 9
8. General Diagnostics Table ........................................................................ 10
I
GENERAL DESCRIPTION
~ ~
A: SPECIFICATIONS
S4M0367A
I I P195/60R1587H I 15x6JJ I I I
Front and rear P205/55 R16 89V 16 x 6 1/2JJ 55 (2.17)
.
100 (3.94) Dia.
-*
215/45 R17 87W 17 x 7JJ
T-Type tire T I 35/70 D16 1OOM 16 x 4T 50 (1.97)
Tire size Tire inflation pressure kPa (kg/cm2,psi)

Fr: 220 (2.2, 32)
P I95/60 R15 87H
Rr: 200 (2.0, 29)
Front and rear
P205155 R16 89V Fr: 220 (2.2, 32) Fir: 200 (2.0, 29)
215/45 R17 87W Fr: 230 (2.3, 33) Rr: 220 (2.2, 32)
T-Type tire T135ffO D16 100M 420 (4.2, 60)
WT-2
1. SERVICE DATA B: PREPARATION TOOL

I
~
Item I Axial runout I Radial runout 1 1. GENERAL PURPOSE TOOLS
Steel wheel 1.5 mm (0.059 in)
1.O mm (0.039 in) TOOL NAME REMARKS
Aluminum wheel
Air pressure gauge Used for measuring tire air pressure.
2. ADJUSTING PARTS Dial gauge Used for measuring wheel runout.
I n a m F iunbalance I Less than 5 g (0.18 02) I

Balance weight part number
Weight
I 723141320 I 20 g (0.71 02) I

723141330
723141350
723241380
723241590

Weight
(For aluminum wheel)
23141GA462
23141GA482
r 23141GA512 I 30 g (1.06 02) I

I 23141GA522 -I 35 g (1.23 02) I
23141GA532 40 g (1.41 02)
231
~- 41GA542 45 a (15 9 02)
" >
23141GA552 50 g (I.76 02)

- 55 g (1.94 0 2 )
23141GA572 60 g (2.12 02)
WT-3
I TIRE
2. Tire
A: INSPECTION
1) Take stone, glass, nail etc. off the tread groove.
2) Replace the tire:
CAUTION:
When replacing a tire, make sure to use only
the same size, construction and load range as
originally installed.
Avoid mixing radial, belted bias or bias tires
on the vehicle.
(1) when large crack on side wall, damage or
crack on tread is found.
(2) when the “tread wear indicator” appears as
a solid band across the tread.
r. . -
I S4M0377A
(1 ) Tread wear indicator

(2) Tire tread
1. TIRE ROTATION
If tires are maintained at the same positions for a
long period of time, uneven wear results. There-
fore, they should be periodically rotated.
This lengthens service life of tires.
CAUTION:
When rotating tires, replace unevenly worn or
damaged tires with new ones.
WT-4
I STEEL WHEEL I
3. Steel Wheel C: INSPECTION

1) Deformation or damage on the rim can cause air
A: REMOVAL leakage. Check the rim flange for deformation,
1) Apply the parking brake, and position select le- crack or damage, and repair or replace as neces-
ver to “P” or “LOW”. sary.
2) Set the shop jacks or a lift to the specified point, 2) Jack-up the vehicle until wheels clear the floor.
and support the vehicle with its wheels slightly con- 3) Slowly rotate the wheel to check rim “runout” us-
tacting the floor. ing a dial gauge.
3) Loosen the wheel nuts.
4) Raise the vehicle until its wheels take off the
ground using a jack or a lift.
5) Remove the wheel nuts and wheels.
NOTE:
While removing the wheels, prevent hub bolts
from damage.
NOTE:
Place the wheels with their outer sides facing up-
ward to prevent wheels from damage.
/ G4M029E
B: INSTALLATION
--I ) Attach the wheel to the hub by aligning the wheel I-1.5 mm (0.059 in) I
bolt hole with the hub bolt. ~
2) Temporarily attach the wheel nuts to the hub

bolts. (In the case of aluminum wheel, use SUBA-
RU genuine wheel nut for aluminum wheel.)
3) Manually tighten the nuts making sure the wheel
hub hole is aligned correctly to the guide portion of
hub.
4) Tighten the wheel nuts in a diagonal selection to
APP
the specified torque. Use a wheel nut wrench.
Wheel nut tightening torque:
90 N.m (9. I kgf-m, 65.7 ff-lb)
CAUTION: G4M0299
Tighten the wheel nuts in two or three steps
by gradually increasing the torque and working 4) If the rim runout exceeds specifications, remove
diagonally, until the specified torque is the tire from rim and check runout while attaching
reached. For drum brake models, excess tight- dial gauge to positions shown in figure.
ening of wheel nuts may cause wheels to “jud- 5) If the measured runout still exceeds specifica-
der”. tions, replace the wheel.
Do not depress the wrench with a foot; Al-
ways use both hands when tightening.
Make sure the bolt, nut and the nut seating
surface of the wheel are free from oils.
5) If a wheel is removed for replacement or for re-
pair of a puncture, retighten the wheel nuts to the
specified torque after running 1,000 km (600
miles).
WT-5
I ALUMINUM WHEEL
4. Aluminum Wheel
A: REMOVAL
Refer to Steel Wheel for removal procedure of a h -
minum wheels. <Ref. to WT-5, REMOVAL, Steel
Wheel.>
B: INSTALLATION
Refer to Steel Wheel for installation procedure of
aluminum wheels.cRef. to WT-5, INSTALLATION,
Steel Wheel.>
C: INSPECTION
Refer to Steel Wheel for inspection procedure of
aluminum wheels. <Ref. to WT-5, INSPECTION,
Steel Wheel.>
Rim runout:
I Axial runout limit I Radial runout limit I
1.O mm (0.039 in)
D: -CAUTION
Aluminum wheels are easily scratched. To main-
tain their appearance and safety, do the following:
1) Do not damage the aluminum wheels during re-
moval, disassembly, installation, wheel balancing,
etc. After removing the aluminum wheels, place
them on a rubber mat, etc.
2) While the vehicle is being driven, be careful not
to ride over sharp obstacles or allow aluminum
wheels to contact the shoulder of the road.
3) When installing a tire chain, be sure to install it
properly not to have a slack; otherwise it may hit
the wheel while driving.
4) When washing the aluminum wheel, use neutral
synthetic detergent and water. Avoid using the
cleanser including abrasive, hard brushes or an
automatic car washer.
WT-6
WHEEL BALANCING
I
5. Wheel Balancing B: INSPECTION

1) Proper wheel balance may be lost if the tire is re-
A: REPLACEMENT paired or if it wears. Check the tire for dynamic bal-
1) Remove the balance weights. ance, and repair as necessary.
2) Using the dynamic balancing, measure wheel 2) To check for dynamic balance, use a dynamic
balance. balancer. Drive in the balance weight on both the
3) Select a weight close to the value measured by top and rear sides of the rim.
dynamic balancing. 3) Some types of balancer can cause damage to
the wheel. Use an appropriate balancer when ad-
I Balance weight part number
(For steel wheel)
Weight justing the wheel balance.
4) Use genuine balance weights.
I 723141300 I 10 g (0.35 02) I CAUTION:
I 723141310 I 15 g (0.53 02) I 55 g (1.94 02) weight used with aluminum
723141320 20 g (0.71 02) wheel is not available.
723141330 25 g (0.88 02)
Balance weights are available for use with
any of 14- to 16-inch wheels.
723141340 30 g (1.06 02)
723141350 35 CI (1.23 oz)
I 723141360 I 40 g (1.41 02) I
I 723141370 I 45 g (1.59 02) I
c- ~ 723241380 50 g (1.76 02)
723241580 55 g (1.94 02)
723241590 60 g (2.12 02)

Weight
(For aluminum wheel)
23 14 1GA462 5 g (0.18 02).
23141GA472 10 a (0.35 02)
r - 23141GA492 I 20 CI (0.71 02) I

I 23141GA502 I 25 g (0.88 02) I
I 23141GA512 I 30 g (1.06 02) I
23141GA522 35 g (1.23 02)
23141GA532 40 g (1.41 02)
23141GA542 45 g (1.59 02)
23141GA552 50 Q (1.76 02)
I - I 55 g (1.94 02) I B4M0053B
23141GA572 60 g (2.12 02)
(1) Weight for aluminum wheel
(2) Weight for steel wheel
Service limit: A
Weight for steel wheel;
2.16 mm (0.085 in)
Weight for aluminum wheel;
4.5 mm (0.177 in)
WT-7
I “T-TYPE” TIRE
6. “T-type” Tire
A: NOTE
“T-type” tire for temporary use is prepared as a
spare tire.
CAUTION:
Do not use a tire chain with the “T-type” tire.
Because of the smaller tire size, a tire chain will
not fit properly and will result in damage to the
vehicle and the tire.
Do not drive at a speed greater than 80 km/h
(50 MPH).
Drive as slowly as possible and avoid pass-
ing over bumps.
B: REPLACEMENT
Refer to Removal and Installation of Steel Wheel
for removaVinstallation of “T-type” tires. <Ref. to
WT-5, Steel Wheel.>
CAUTION:
Tiepiace with a conventional tire as soon as
possible since the “T-type” tire is only for tem-
porary use.
C: INSPECTION
1) Check the tire inflation pressure.
Specification:
420 kPa (4.2 kg/cn?, 60 psi)
2) Take the stones, glass, nails, etc. out of the tread
groove.
3) Check the tires for deformation, cracks, partial
wear, or wear.
CAUTION:
Replace the tire with a new one.
WT-8
FULL WHEEL CAP I
7. Full Wheel Cap

A: REMOVAL
Pry off the full wheel cap with a wheel cap remover
inserted between openings in the cap.
B: INSTALLATION
Align the valve hole in the wheel cap with the valve
on the wheel and secure the wheel cap by tapping
*.- . points by hand.
four
C: INSPECTION
1) Check the wheels for missing wheel caps.
2) Check the pawls of wheel caps for damage or
bend.
3) Check the wheel caps for cracks.
WT-9
3
GENERAL DIAGNOSTICS TABLE
8. General Diagnostics Table

A: INSPECTION
I I Replace
II
Front wheel shimmy
Abnormal tire wear

I
I
Worn or improperly inflated of tire.
Wheel is out of balance.
Improperly inflated of tire.
I Adjustment
I Replace
I
I
I
Sways/pitches Worn or improperly inflated of tire. Replace
Wander/pulls Worn or improperly inflated of tire. Replace
WT-10
E
DIFFERENTIALS
~~~~~~~~
Dl ~
Page
1. General Description .... ..................................................................... ...........2
2. Differential Gear Oil ................................................................................... 17
3. Front Differential........................................................................................ 18
4. Rear Differential ........................................................................................ 19
5. Rear Differential Front Oil Seal ...................................... .... .......................35
6. Rear Differential Side Oil Seal .................................................................. 37
7. Rear Differential Member .......................................................................... 40
I
GENERAL DESCRIPTION
DIFFERENTIALS
A: SPECIFICATIONS
II MODEL
I
Waaon Sedan
Non-Turbo
Waaon Sedan
I
MT
Turbo
AT I
Type of gear Hypoid gear
Gear ratio (Number of gear
3.900 (39/10) 4.1 11 (37/9) 4.444 (40/9) 3.545 (39/11) 4.1 11 (37/9)
teeth)
Oil capacity 0.8 0 (0.8 US qt, 0.7 Imp qt)
Rear differential gear oil GL-5
causes the drive line and tires to "drag" or emit

ITEM
abnormal noise when AWD is selected. Rear differential gear oil
API Classification
I \ I tiL-5
SAE Viscosity No. and Application Temperature
("C) -30 -26 -15 -5 0 15 25 30
( O F ) -22 -15 5 23 32 59 77 86
I I I I L ' I
1-2 75W-90
I I I I I I I
f= H3M1272A
DROOOI
1. SERVICE DATA
Front and rear bearing preload at companion New bearing 19.6 - 28.4 (2.0 - 2.9, 4.4 - 6.4)
flange bolt hole N (kgf, Ib) Used bearing 8.34-16.67(0.85-1.7, 1.87-3.75)
Side aear backlash mm (in) 0.10 - 0.20 (0.0039 - 0.0079)
I Side bearina standard width mm (in) I 20.00 (0.7874) I
I Crown gear to drive pinion backlash mm (in) I 0.10 - 0.20 (0.0039 - 0.0079) I
I Crown gear runout on its back surface mm (in) I Less than 0.05 (0.0020) I
2. ADJUSTING PARTS
19.6 - 28.4 N
New bearing
Front and rear bearing preload at com- (2.0 - 2.9 kgf, 4.4 - 6.4 Ib)
panion flange bolt hole 8.34 - 16.67 N
Used bearing
(0.85 - 1.7 kgf, 1.87 - 3.75 Ib)
Part No. Lenath
I 383695201 I 56.2 mm (2.213 in)
I 383695202 I 56.4 mm (2.220 in)
Preload adjusting spacer 383695203 56.6 mm (2.228 in)
383695204 56.8 mm (2.236 in)
383695205 57.0 mm (2.244 in)
383695206 57.2 mm (2.252 in)
DI-2
GENERAL DESCRIPTION
DIFFERENTIALS
Part No. Length

383705200 2.59 mm (0.1020 in)
383715200 2.57 mm (0.1012 in)
I 383725200 I 2.55 mm (0.1004 in) I
I Preload adjusting washer
..
383575200 3.33 mm (0.131 1 in)

Pinion height adjusting shim 383585200 3.36 mm (0.1323 in)
383595200 3.39 mm (0.1335 in)
383605200 3.42 mm (0.1346 in)
383615200 3.45 mm (0.1358 in)
383625200 3.48 mm (0.1370 in)
383635200 3.51 mm (0.1382 in)
383645200 3.54 mm (0.1394 in)
383655200 3.57 mm (0.1406 in)
383665200 3.60 mm (0.141 7 in)
383675200 3.63 mm (0.1429 in)
383685200 3.66 mm (0.1441 in)
Side gear backlash 0.1 - 0.2 mm (0.0039 - 0.0079 in)
Part No. Thickness
t
I
Side gear thrust washer 383445201 II 0.75 - 0.80 mm (0.0295 - 0.0315 in)
(Non-Turbo model) t 383445202 I 0.80 - 0.85 mm (0.0315 - 0.0335 in)
Side bearina standard width - 20.00 mm (0.7874 in)

Part No. Thickness
383475201 0.20 mm (0.0079 in)
383475202 0.25 mm (0.0098 in)
I Side bearing retainer shim 383475203 0.30 mm (0.0118 in)
~
-1 383475204 I 0.40 mm (0.0157 in) I

I 383475205 I 0.50 mm (0.0197 in) I
&own gear to drive pinion backlash 0.10 - 0.20 mm (0.0039 - 0.0079 in)
Limit
Crown gear runout on its back sunface 0.05 mm (0.0020 in)
DI-3
I I
GENERAL DESCRIPTION
DIFFERENTIALS
B: COMPONENT
1. REAR DIFFERENTIAL WITHOUT LSD
(1) Pinion crown gear set (13) Side bearing (25) Air breather cap
(2) Pinion height adjusting washer (14) O-ring (26) Stud bolt
(3) Rear bearing (15) Side bearing retainer shim (27) Oil filler plug
(4) Bearing preload adjusting spacer (16) Side bearing retainer (28) Oil drain plug
(5) Bearing preload adjusting washer (17) Side oil seal (29) Rear cover
.,
(6) Differentialcarrier (18) .. thrust washer
. , Side aear (301 Differentialcase
\ I
(7) Front bearing (19) Side gear Tightening torque: N-m (kgf-m, ft-lb)
(8) Spacer (20) Pinion mate gear T1: 10.3 (1.05, 7.6)
(9) Pilot bearing (21) Pinion mate gear washer T2: 29.4 (3.00,21.7)
(IO) Front oil seal (22) Pinion shaft lock pin T3: 49.0 (5.0, 36.2)
(11) Companion flange (23) Circlip T4: 103.0 (10.50, 75.9)
(12) Self-locking nut (24) Pinion mate shaft T5: 181.4 (18.50, 133.8)
DI-4
I
GENERAL DESCRIPTION
DIFFERENTIALS
2. REAR DIFFERENTIAL WITH LSD
(1) Pinion crown gear set (12) Self-locking nut (23) Oil filler plug
(2) Pinion height adjusting shim (13) Side bearing (24) Oil drain plug
Rear bearing O-ring
Bearing preload adjusting spacer Side bearing retainer shim Tightening torque: N.m (kgf-m, ft-lb)
Bearing preload adjusting washer Side bearing retainer T1: 10.3 (1.05, 7.6)
Differentialcarrier Side oil seal TZ: 29.4 (3.00,21.7)
Front bearing Gasket T3: 49.0 (5.00, 36.2)
Collar Differential case T4: 103.0 (10.50, 75.9)
Pilot bearing Rear cover T5: 181.4 (18.50, 133.8)
Front oil seal Air breather cap
Companion flange Stud bolt
DI-5
I I
GENERAL DESCRIPTION
DIFFERENTIALS
3. REAR DIFFERENTIAL MOUNTING SYSTEM
DR0002
(1) Differentialfront member (7) Stopper Tightening torque: N-m (kgf-m, ft-I&)
(2) Plate (8) Dynamic damper T1: 20(2.0, 14.5)
(3) Crossmember (9) Differential mount bracket T2: 33 (3.4, 24.3)
(4) Differential rear member (10 ) Differential mount front cover T3: 65 (6.6, 47.9)
(5) Differential mount lower bracket T4: 70 (7.1, 51.6)
(TURBO model) T5: 90 (9.2, 66.4)
(6) Differential mount lower bracket T6: 100 (10.2, 73.8)
(Non-turbo model)
DI-6
GENERAL DESCRIPTION
DIFFERENTIALS
C: CAUTION
tion.
Use SUBARU genuine gear oil, grease etc. or
the equivalent. Do not mix gear oil, grease etc. with
that of another grade or from other manufacturers.
points.
--a- Apply gear oil onto sliding or revolution surfaces
Before installing O-rings or snap rings, apply suf-
ficient amount of gear oil to avoid damage and de-
formation.
Avoid damaging the mating face of the case.
DI-7
GENERAL DESCRIPTION
DIFFERENTIALS
D: PREPARATION TOOL
1. SPECIAL TOOLS

398477701 HANDLE Used for installing front and rear bearing cone.
B3M1893
398477702 DRIFT Used for press-fitting the bearing cone of differ-
ential carrier (rear).
B3M1894
398217700 ATTACHMENT SET Stand for rear differential carrier disassembly
and assembly.
B3M1895
498447120 DRIFT Used for installing front oil seal.
B3M1896
DI-8
DIFFERENTIALS
ILLUSTRATION TOOL NUMBER DESCRIPTION IEMARKS

98427200 LANGE WRENCH k e d for stopping rotation of companion flange
vhen loosening and tightening self-lock nut.
B3M1897
I98467700 )RIFT Jsed for removing pinion, pilot bearing and front
iearing cone.
B3M189e ~
a7801 04 VEIGHT Used for installing front bearing cone, pilot bear-
ing companion flange.
B3M189(
899580100 NSTALLER Used for press-fittingthe front bearing cone, pilo
bearing.
B3M190
DI-9
I
GENERAL DESCRIPTION
DIFFERENTIALS

899904100 STRAIGHT PIN Used for driving out differential pinion shaft lock
REMOVER Din.
B3M1901
498247001 MAGNET BASE 1 Used for measuring backlash between side
jear and pinion, and hypoid gear.

1 Used with DIAL GAUGE (498247100).
B3M1902
498247100 DIAL GAUGE 1 Used for measurng backlash between side

1 Used with MAGNET BASE (498247001).
03M1903
398507704 BLOCK Jsed for adjusting pinion height and preload.
B3M1904
DI-I 0
3
DIFFERENTIALS
ILLUSTRATION TOOL NUMBER DESCRIPTION 3EMARKS

%98177700 VSTALLER Used for installing rear bearing cone.
B3M1905
398457700 UTACHMENT I Used for removing side bearing retainer.
6=:p
B3M1906
398477703 ]RIFT2 1 Used for press-fitting the bearing race (rear) of
differential carrier.
B3M190i
398437700 DRIFT Used for installing side oil seal.
B3M1901
DI-11
GENERAL DESCRIPTION
DIFFERENTIALS
I ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

398507702 DUMMY SHAFT Used for adjusting pinion height and preload.
398507703 3UMMY COLLAR Used for adjusting pinion height and preload.
I B3M1910
39851 7700 3EPLACER Used for removing rear bearing cone.
398487700 )RIFT 1 Used for press-fitting the side bearing cone.
DI-I 2
I I
GENERAL DESCRIPTION
DIFFERENTIALS

398507701 DIFFERENTIAL Used for adjusting pinion height.
CARRIER GAUGE
B3M1913
398527700 PULLEY ASSY Used for removing front oil seal.
Used for removing side bearing cup. (T-type)
B3M1914
399527700 PULLER SET Used for extracting side bearing cone.
(1)BOLT (899521412)
(2)PULLER (399527702)
(3)HOLDER (399527703)
(4)ADAPTER (398497701)
(5)BOLT (899520107)
(6)NUT (021008000)
B3M1915A
398227700 WEIGHT . Used for installing side bearing.
B3M1916
DI-I 3
GENERAL DESCRIPTION
DIFFERENTIALS

28099PA090 OIL SEAL PROTEC- Used for installing rear drive shaft into rear dif-
TOR ferential.
For protecting oil seal.
B3M1917
398237700 GAUGE Used for installing side bearing.
I------
B3M1918
28099PA100 DRIVE SHAFT Used for removing rear drive shaft from rear
REMOVER differential.
399703602 WLLEY ASSY Used for removing companion flange
I B3M1930
DI-I 4
I I
GENERAL DESCRIPTION DIFFERENTIALS

399874100 INSTALLER 1Used for installing companion flange.
B3M193
DI-I 5
GENERAL DESCRIPTION
DIFFERENTIALS
I TOOL NAME I REMARKS I

I Transmission jack 1 Used for assembly/disassembly of rear differential. I
Puller Used for removal of side bearing retainer.
Thickness gauge Used for measuring clearance.
DI-16
I DIFFERENTIAL GEAR OIL 1
DIFFERENTIALS
2. Differential Gear Oil 5 ) Fill differential carrier with gear oil to the upper
plug level.
A: INSPECTION CAUTION:
1) Take out the filler plug, and replace gear oil if it is Carefully refill oil while watching the level. Ex-
contaminated or deteriorated. <Ref. to DI-17, RE- cess or insufficient oil must be avoided.
PLACEMENT, Differential Gear Oil.>
2) Check gear oil level is up to the bottom part of fill- Oil capacity:
er bolt. If the level is low, refill up to the bottom of 0.8 Q (0.8 US qf, 0.7 Imp qt)
filler bolt.
I 1
I . . , . . . , I I
1
DUO017 I (A) Filler plug
.
r-
(A) Filler plug ( 6 ) Drain plug
( 6 ) Drain plug
6) Install the filler plug.
B: REPLACEMENT NOTE:
Apply fluid packing to the filler plug.
2) Jack-up the vehicle and support it with sturdy Fluid packing:
racks. THREE BOND 1105 or equivalent
3) Remove the oil drain plug and filler plug, and Tightening torque:
drain the gear oil.
49.0 N.m (5.0 kgf-m, 36.2 ff-lb)
CAUTION:
Be careful not to burn your hands, because
gear oil becomes extremely hot after running.
(A) Filler plug

(B) Drain plug
4) Tighten the oil drain plug.

NOTE:
Apply fluid packing to the drain plug.
Fluid packing:
THREE BOND I105 or equivalent
Tightening torque:
49.0 N.m (5.0 kgf-m, 36.2 ff-lb)
DI-17
FRONT DIFFERENTIAL
DIFFERENTIALS
3. Front Differential
A: NOTE
1. AT MODEL
Refer to AUTOMATIC TRANSMISSION in sepa-
rate publication “AUTOMATIC TRANSMISSION”
for Front Differential. <Pub. No. G0853ZE>
2. MTMODEL
For front differential of manual transmission, refer
to “MT” section. <Ref. to MT-71, Front Differential
Assembly.>
DI-18
REAR DIFFERENTIAL I
DIFFERENTIALS
4. Rear Differential 14) Remove the DOJ of rear drive shaft from rear
differential using ST. <Ref. to DI-37, REPLACE-
A: REMOVAL MENT, Rear Differential Side Oil Seal.>
1) Set the vehicle on the lift. ST 28099PA100 DRIVE SHAFT REMOVER
3) Move the select lever or gear shift lever to “N”.
4) Release the parking brake.
racks.
7) Remove the wheels.
Non-turbo model:
Muffler.>
(A) Bolt
Turbo model:
<Ref. to EX(D0HC TURBO)-13, REMOVAL, Rear 15) Secure the rear drive shaft to rear crossmem-
Exhaust
- PiDe.> and <Ref. to EX(D0HC TURBO)- ber using wire.
14, REMOVAL, Muffler.>
r9) Remove the rear differential protector. (If
.
equipped)
10) Remove the front cover of rear differential
mount.
S3M0500
16) Remove the lower differential bracket.
11) Remove the propeller shaft. <Ref. to DS-14,

12) Remove the heat shield cover.
13) Remove the clamps and bracket of parking
brake cable.
0
S3M0529
17) Support the rear differential with transmission

jack.
DI-I 9
I REAR DIFFERENTIAL
DIFFERENTIALS
18) Remove the self-locking nuts and bolts. 22) Remove the rear differential from front mem-
ber, and remove rear member.
G3M1030
19) Remove the bolts which secure rear differential
front member to body. B: INSTALLATION
Loosen bolt A first, then remove bolts B. To install, reverse the removal sequence.
NOTE: 1) Install the air breather cap tapping with a plastic
Support the front member with the use of a helper hammer.
to prevent it from dropping. CAUTION:
Be sure to install a new air breather cap.
- 2) Position the front member on body by passing it
c- - under parking brake cable and securing to rear dif-
ferential.
NOTE:
\ When installing the rear differential front member,
do not confuse the installation sequence of the up-
per and lower stoppers.
3) Install the DOJ of drive shaft into rear differen-
\ ' 'B3M0657C 1 tial.<Ref. to DI-37, REPLACEMENT, Rear Differ-
ential Side Oil Seal.>
(A) Bolt A ST 28099PA090 SIDE OIL SEAL PROTEC-
(B) Bolt B TOR
20) Remove bolt A.
21) While slowly lowering the transmission jack,
move rear differential forward and remove front
member and rear differential from body.

5 ) After installation, fill the differential carrier with
gear oil to the filler plug level. <Ref. to DI-17, Differ-
. . I
' G3M1029
ential Gear Oil.>
DI-20
REAR DIFFERENTIAL
DIFFERENTIALS
C: DISASSEMBLY 4) Remove the rear cover by loosening retaining

To detect the real cause of trouble, inspect the fol- bolts.
lowing items before disassembling.
Tooth contact of crown gear and pinion, and
I
backlash
Runout of crown gear at its back surface
Turning resistance of drive pinion
1) Set the ST on vise and install the differential as-
sembly to ST.
ST 398217700 ATTACHMENT
I
(A) Rear cover

(B) Differential carrier
5) Make right and left side bearing retainers in or-

der to identify them at reassembly. Remove the
- ST I
G3M1031 1
side bearing retainer attaching bolts, set the ST to
differential case, and extract right and left side
bearing retainers with a puller.
2) Drain the gear oil by removing plug. CAUTION:
3) Remove the air breather cap. Each shim, which is installed to adjust the side
NOTE: bearing preload, should be kept together with
Do not attempt to replace the air breather cap units mating retainer.
less necessary. ST 398457700 ATTACHMENT
S3M0530A
6) Pull out the differential case assembly from dif-

(A) Air breather cap ferential carrier.
(B) Rear cover
CAUTION:
Be careful not to hit the teeth against the case.
S3M0533
DI-21
I I
REAR DIFFERENTIAL
DIFFERENTIALS
7) When replacing the side bearing, pull the bear- 10) Drive out the pinion shaft lock pin from crown
ing cup from side bearing retainer using ST. gear side. (Without LSD)
ST 398527700 PULLER ASSY NOTE:
The lock pin is staked at the pin hole end on the dif-
ferential carrier; do not drive it out forcibly before
unstaking it.
ST 899904100 STRAIGHT PIN REMOVER
,
S3M05341:
8) Extract the bearing cone with ST.

CAUTION:
Do not attempt to disassemble the parts unless
necessary.
NOTE: 11) Draw out the pinion mate shaft and remove pin-
Set the puller so that its claws catch the edge of ion mate gears, side gears and thrust washers.
+he bearing cone. (Without LSD)
Never mix up the right and left hand bearing rac- NOTE:
es and cones. The gears as well as thrust washers should be
ST 398527700 PULLER SET marked or kept separated right and left, and front
and rear.
(C)
S3M051OP
9) Remove the crown gear by loosening crown
gear bolts.
(A) Sidegear
CAUTION: (B) Pinion mate gear
Further disassembling is not allowed. (C) Thrust washer
(D) Differential case
(E) Pinion mate shaft
S3M0509
DI-22
I I
REAR DIFFERENTIAL
DIFFERENTIALS
12) Hold the companion flange with ST and remove 15) Remove the rear bearing cone from drive pin-
drive pinion nut. ion by supporting cone with ST.
ST 498427200 FLANGE WRENCH NOTE:
Place the replacer so that its center-recessed side
faces the pinion gear.
ST 398517700 REPLACER
13) Extract the companion flange with a puller.

S3MOS
16) Remove the front oil seal from differential carri-

er using ST.
14) Press the end of drive pinion shaft and extract it

together with rear bearing cone, preload adjusting
spacer and washer.
NOTE: S3M0513
Hold the drive pinion so as not to drop it.
ST 398467700 DRIFT 17) Remove the pilot bearing together with front
bearing cone using ST.
ST 398467700 DRIFT
G3M0078
S3M0514A
(A) Pinion bearing

(B) Front bearing
(C) Rear bearing cup
DI-23
I
I REAR DIFFERENTIAL
DIFFERENTIALS
18) When replacing the bearings, tap front bearing D: ASSEMBLY

cup and rear bearing cup in this order out of case 1) Precautions for assembling:
by using a brass bar. Assemble in the reverse order of disassembling.
Check and adjust each part during assembly.
Keep the shims and washers in order, so that
they are not misinstalled.
Thoroughly clean the surfaces on which the
shims, washers and bearings are to be installed.
Apply gear oil when installing the bearings and
thrust washers.
Be careful not to mix up the right and left hand
races of the bearings.
Replace the oil seal with a new one at every dis-
assembly. Apply chassis grease between the lips
when installing the oil seal.
(A) 2 cutouts along diagonal lines
(6) Tap alternately with brass bar.
c.
2) Adjusting preload for front and rear bearings:

Adjust the bearing preload with spacer and washer
between front and rear bearings. Pinion height ad-
justing washer are not affected by this adjustment.
The adjustment must be carried out without oil seal
inserted.
m
(1) Press the rear bearing race into differential
carrier with STI and ST2.
ST1 398477701 HANDLE
ST2 398477703 DRIFT 2
G3M1037
(2) Insert the ST1 into carrier with pinion height

adjusting washer and rear bearing cone fitted
onto it.
CAUTION:
Re-use the used washer if not deformed.
Use a new rear bearing cone.
DI-24
REAR DIFFERENTIAL I
DIFFERENTIALS
(3) Then install the preload adjusting spacer Front and rear bearing preload
and washer, front bearing cone, ST2, compan-
For new bearing:
ion flange, and washer and drive pinion nut. 19.6- 28.4N (2.0- 2.9kgf, 4.4- 6.4Ib)
ST1 398507702 DUMMY SHAFT at companion flange bolt hole
ST2 398507703 DUMMY COLLAR For used bearing:
8.34- 16.67N (0.85- 1.7 kgf, 1.87- 3.75Ib)
at cotmanion flanae bolt hole
S3M0516A
(A) Pinion height adjusting shim

(8) Preload adjusting spacer
---
(C) Preload adjusting washer
(4) Turn the STI with hand to make it seated,
1 Part NO. 1 Thickyiy mm
. . II
I
and tighten the drive pinion nut while measuring 383705200 I 2.59 (0.1020)
the preload with spring balance. Select the pre- 383715200 [ 2.57(0.1012)
load adjusting washer and spacer so that the 383725200 I 2.55(0.1004)
specified preload is obtained when nut is tight- 383735200 1 2.53 10.0996) I
ened to the specified torque.
CAUTION: 383755200
Use a new lock nut. ’reload adjusting
Masher
1
I
NOTE: 383775200 1 2.45 (0.0965)

f
Be careful not to give excessive preload. 383785200 2.43 (0.0957)
When tightening the drive pinion nut, lock ST1 383795200 2.41 (0.0949)
with ST2 as shown in the figure. 383805200 2.39(0.0941)
ST1 398507704 BLOCK 383815200 2.37 (0.0933)
ST2 398507702 DUMMY SHAFT 383825200 2.35(0.0925)
Tightening torque:
r- 383835200 I 2.33(0.0917) I
181 N.m (18.5 kgf-m, 134 ft-lb)
I 383845200 I 2.31 (0.0909) I
Part No.
383695202 56.4(2.2201
Preload adjusting
383695203 56.6(2.228)
spacer
383695204 56.8 (2.236)
383695205 1 57.0(2.244)
383695206 I 57.2 (2.252)
U
G3M1038
DI-25
I REAR DIFFERENTIAL
DIFFERENTIALS
3) Adjusting drive pinion height: (2) Measure the clearance N between the end
Adjust the drive pinion height with shim installed of ST2 and the end surface of STI by using a
between rear bearing cone and the back of pinion thickness gauge.
gear. NOTE:
(1) Install STl, ST2 and ST3, as shown in the Make sure there is no clearance between the case
figure, and apply the specified preload on the and ST2.
bearings.
ST1 398507702 DUMMY SHAFT
Front and rear bearing preload ST2 398507701 DIFFERENTIAL CARRIER
For new bearing: GAUGE
19.6 - 28.4 N (2.0 - 2.9 kgf, 4.4 - 6.4 Ib)
at companion flange bolt hole
For used bearing:
8.34-l6.67N(0.85-l1.7kgf, 1.87-3.75Ib)
at companion flange bolt hole
Adjusting preload for front and rear bearings:

NOTE:
At this time, install a pinion height adjusting shim
which is temporarily selected or the same as that
used before. Measure and record the thickness. H3M1309B
ST1
.
398507702 DUMMY SHAFT
c-
ST2 398507701 DIFFERENTIAL CARRIER (3) Obtain the thickness of pinion height adjust-
GAUGE ing shim to be inserted from the following formu-
ST3 398507703 DUMMY COLLAR la, and replace the temporarily installed shim
with this one.
T = To + N - (H x 0.01) - 0.20 mm (0.0079 in)
NOTE:
-I Use copies of this page.
T Thickness of shim temporarily inserted
mm (in)
To Thickness of pinion height adjusting
I shim mm (in) I
N I
Reading of thickness gauge mm (in) I
S3M0518B
H I Figure marked on drive pinion head I
Memo:
(A) Pinion height adjusting shim
(Example of calculation)
To = 2.20 + 1.20 = 3.40 mm
N = 0.23 mm H = + 1,
T = 3.40 + 0.23 - 0.01 - 0.20 = 3.42
Result: Thickness = 3.42 mm
Therefore use the shim 383605200.
DI-26
I REAR DIFFERENTIAL
DIFFERENTIALS
5) Insert the drive pinion into differential carrier, in-

I Pinion height adjusting shim i stall the previously selected bearing preload adjust-
ing spacer and washer.
383495200
I
3.15 (0.1240)
383525200 3.18 (0.1 252)
383545200 3.24 (0.1276)

383555200 3.27 (0.1287)
383565200 3.30 (0.1299)
383575200 3.33 (0.1311)
383585200 3.36 (0.1323)
383595200 3.39 (0.1335)
383605200 3.42 (0.1346)
(A) Drive pinion
383615200 3.45 (0.1358)
(B) Bearing adjusting spacer
383625200 3.48 (0.1370)
(C) Washer
383635200 3.51 (0.1382)
(D) Differential carrier
383645200 3.54 (0.1394)
383655200 3.57 (0.1 406) 6) Press-fit the front bearing cone into case with
c- - ST1, ST2 and ST3.
383665200 3.60 (0.1417)
383675200 3.63 (0.1429) ST1 398507703 DUMMY COLLAR
383685200 3.66 (0.1441) ST2 399780104 WEIGHT
7) Insert the spacer, then press-fit pilot bearing with

ST1 and ST2.
S3M0519A
DI-27
I REAR DIFFERENTIAL
DIFFERENTIALS
8) Fit a new oil seal with ST. 11) Assembling differential case:
NOTE: Install the side gears and pinion mate gears, with
Press-fit until end of oil seal is 1 mm (0.04 in) in- their thrust washers and pinion mate shaft, into dif-
ward from end of carrier. ferential case. (Without LSD)
Apply grease between the oil seal lips. CAUTION:
ST 498447120 DRIFT Apply gear oil on both sides of the washer
and on the side gear shaft before installing.
Insert the pinion mate shaft into the differen-
tial case by aligning the lock pin holes.
9) Press-fit the companion flange with ST1 and

ST2.
GAUTION:
Be careful not to damage the bearing.
G3M0089
(1) Measure the side gear backlash.

Side gear back clearance:
S3M0521A 0.10 - 0.20 mm (0.0039 - 0.0079 in)
10) Install the self-locking nut. Then tighten it with
ST.
ST 498427200 FLANGE WRENCH
Tightening torque:
181 N-m (18.5 kgf-m, 134 fWb)
DI-28
1
REAR DIFFERENTIAL
DIFFERENTIALS
14) Adjusting the side bearing retainer shims:

(1) The driven gear backlash and side bearing
preload can be determined by the side bearing
retainer shim thickness.
(2) Installthe differential case assembly into dif-
I 383445201 I 0.75- 0.80(0.0295- 0.0315) I ferential carrier in the reverse order of disas-
383445202 0.80- 0.85(0.0315 - 0.0335) sembly.
383445203 0.85- 0.90(0.0335- 0.0354)
(3) Install the side retainer shims and O-rings to

the left and right retainers from which they were
removed.
NOTE:
Replace the broken or cracked O-ring with a new
one.
Replace the broken or corroded side retainer
shim with a new one of same thickness.

383475201 0.20 (0.0079)
I 383475202 I 0.25(0.0098) I
383475203 0.30(0.0118)
383475204 0.40(0.0157)
3a3475205 0.50(0.0197)
S3M0509 I
- cone onto differential
13) Press the side bearing
case with ST.
ST 398487700 DRIFT
w
(A) Arrow mark
01-29
I REAR DIFFERENTIAL
DIFFERENTIALS
(5) Tighten the side bearing retainer bolts. 15) Recheck the crown gear-to-pinion backlash.
CAUTION: Backlash:
Before tightening the two side bearing retainer 0.10 - 0.20 mm (0.0039 - 0.0079 in)
bolts, apply Lock Tite to bolt threads.
+Lock Tite:
-
THREE BOND 1 105 or equivalent
Tightening torque:
10.3 N.m (1.05 kgf-m, 7.6 ft-16)
G3M1047
16) Check the crown uear runout on its back sur-

face, and make sure pinion and crown gear rotates
smoothIy .
Limit of runout:
S3M0173 Less than 0.05 mm (0.0020 in)
(6) Measure the crown gear-to-drive pinion
backlash. Set the magnet base on differential
carrier. Align the contact point of dial gauge with
tooth face of crown gear, and move crown gear
while holding drive pinion still. Read the value in-
dicated on dial gauge.
Backlash:
0.10 - 0.20 mm (0.0039 - 0.0079 in)
1 1 4 S3M0525
17) Checking and adjusting the tooth contact of

crown gear:
(1) Apply an even coat of red lead on both sides
of three or four teeth on the the crown gear.
Check the contact pattern after rotating the
crown gear several revolutions back and forth
until a definite contact pattern appears on the
G3M1047
crown gear.
(2) When the contact pattern is incorrect, read-
(7) At the same time, measure the turning resis- just according to the instructions given in
tance of drive pinion. Compared with the resis- “TOOTH CONTACT PATTERN”.
tance when differential case is not installed, if
the increase of the resistance is not within the NOTE:
specified range, readjust side bearing retainer Be sure to wipe off red lead completely after adjust-
shims. ment is completed.
Turning resistance increase:

2 . 9 - l 0 . 8 N ( 0 . 3 - l 1 . 1 kgf,O.7-2.4Ib)
DI-30
I REAR DIFFERENTIAL
DIFFERENTIALS
18) If proper tooth contact is not obtained, once Where:

again adjust the drive pinion height changing RH T = Thickness of pinion height adjusting shim
and LH side bearing retainer shims and the hypoid (">
gear
- backlash. To = Thickness of shim temDorarilv inserted
(1) Drive pinion height
STl 398507702 DUMMY SHAFT N = Reading of thickness gauge (mm)
ST2 398507701 DIFFERENTIAL CARRIER H = Figure marked on drive pinion head
GAUGE (2) Hyp6id gear backlash
Backlash:
0.10 -
0.20 mm (0.0039 - 0.0079 in)
H3M13098
T = To + N - (H x 0.01) - 0.20 (mm)

) G3M104i
TOOTH CONTACT PATTERN

Condition Contact pattern Adjustment
Correct tooth contact
Tooth contact pattern slightly shifted
towards toe under no load rotation.
-
(When loaded, contact pattern moves
toward heel.)
Heel side
G3M0098A
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.
Flank contact
- G3M0098B
This may cause noise and stepped wear
V
G3M0098F
Reduce thickness of drive pinion height
Backlash is too small. on surfaces. adjusting shim in order to move drive pin-
ion away from crown gear.
- G3M0098C G3M0098G
DI-31
I I
REAR DIFFERENTIAL
DIFFERENTIALS
TOOTH CONTACT PATTERN

Condition Contact pattern Adjustment
Toe contact rhis may cause chipping at toe ends. Adjust as for flank contact.
Contact area is small.
I
G3M0098D G3M0098G
Heel contact rhis may cause chipping at heel ends. Adjust as for face contact.
Contact area is small.
V
G3M0098E G3M0098F
I): Adjusting direction of drive pinion
: Adjusting direction of crown gear
DI-32
REAR DIFFERENTIAL
DIFFERENTIALS
19) Install the rear cover and tighten bolts to spec- 1. SIDE GEAR BACKLASH
ified torque. Using a dial gauge, check the backlash of the side
CAUTION: gear.
Securely connect the ground terminal of rear
differential temperature sensor. Side gear backlash:
0.1 - 0.2 mm (0.004 - 0.008 in)
Tightening torque: If the side gear backlash is not within the specifica-
29 N-m (3.0 kgf-m, 2 1.7 ff-lb) tion, adjust clearance as specified by selecting side
gear thrust washer.
1934
E: INSPECTION
‘-Wash all the disassembled parts clean, and exam- 2. CROWN GEAR BACKLASH
ine them for wear, damage or other defects. Repair
Using a dial gauge, check the backlash of the
or replace defective parts as necessary.
crown gear.
1) Crown gear and drive pinion:
If abnormal tooth contact is evident, find out the Crown gear backlash:
cause and adjust to give correct tooth contact at as- 0.1 - 0.2 mm (0.004 - 0.008 in)
sembly. Replace the gear if excessively worn or in- If the crown gear backlash is not within the specifi-
capable of adjustment. cation, adjust the side bearing preload or repair if
If crack, score or seizure is evident, replace as a necessary.
set. Slight damage of tooth can be corrected by oil
stone or the like.
2) Side gear and pinion mate gear:
Replace if crack, score or other defects are evi-
dent on tooth surface.
Replace if thrust washer contacting surface is
worn or seized. Slight damage of the surface can
be corrected by oil stone or the like.
3) Bearing:
Replace if seizure, peeling, wear, rust, dragging
during rotation, abnormal noise or other defect is I G3M1047
evident.
4) Thrust washers of side gear and pinion mate
gear:
Replace if seizure, flaw, abnormal wear or other
defect is evident.
5) Oil seal:
Replace if deformed or damaged, and at every dis-
assembling.
6) Differential carrier:
Replace if the bearing bores are worn or damaged.
7) Differential case:
Replace if its sliding surfaces are worn or cracked.
8) Companion flange:
Replace if the oil seal lip contacting surfaces have
flaws.
DI-33
I
REAR DIFFERENTIAL
DIFFERENTIALS
3. CROWN GEAR RUNOUT F: ADJUSTMENT

Using a dial gauge, check the crown gear runout. 1. SIDE GEAR BACKLASH
Crown gear runout: Adjust the side gear backlash.
Less than 0.05 mm (0.0020 in) <Ref. to DI-24, ASSEMBLY, Rear Differential.>
If the crown gear runout exceeds 0.05 mm (0.0020
in), replace the crown gear. 2. CROWN GEAR BACKLASH
Adjust the crown gear backlash.
<Ref. to DI-24, ASSEMBLY, Rear Differential.>
3. TOOTH CONTACT BETWEEN CROWN
GEAR AND DRIVE PINION
Adjust the tooth contact between crown gear and
drive pinion gear.
-9
4. TOOTH CONTACT BETWEEN CROWN
S3M0525
4. TOTAL PRELOAD
Adjust the side bearing shim.
GEAR AND DRIVE PINION
r.
Inspect the tooth contact between crown gear and

driven pinion. <Ref. to DI-24, ASSEMBLY, Rear
Differential.>
5. TOTAL PRELOAD
Using a gauge, check the turning resistance in-
crease.
Total preload:
2.9-l0.8N.m(0.3-l1.1 kgf,O.7-2.4Ib)
If the increase of the resistance is not within the
specification, adjust the side bearing retainer
shims.
B3M 1935
DI-34
I
REAR DIFFERENTIAL FRONT OIL SEAL
DIFFERENTIALS
5. Rear Differential Front Oil 11) Extract the companion flange using ST.
ST 399703602 PULLEY ASSY
Seal
.
A: INSPECTION
Make sure that there is no oil leakage from front oil
seal.
If there is any oil leakage, replace the oil seal.
B: REPLACEMENT
1 ) Set the vehicle on the lift.
6448
5) Remove the oil drain plug, and drain gear oil. 12) Remove the oil seal using ST.
--- .
/
(A) Filler plug
DR0003
i: B3M1609B
13) Fit a new oil seal using ST

(B) Drain plug
ST 498447120 DRIFT
6) Install the oil drain plug.
NOTE:
Apply fluid packing to drain plug.
Tightening torque:
49 N.m (5.0 kgf-m, 36.2 ft-lb)
8) Remove the rear differential protector. (If
equipped)
9) Remove the propeller shaft from body. <Ref. to
DS-14, REMOVAL, Propeller Shaft.> G3M0037
IO) Remove the self-locking nut while holding com- 14) Install the companion flange.
panion flange with ST.
ST 498427200 FLANGE WRENCH NOTE:
Use a plastic hammer to install companion flange.
I / / \ \ G3M0034
DI-35
I
REAR DIFFERENTIAL FRONT OIL SEAL
DIFFERENTIALS
15) Tighten the self-locking nut within the specified

torque range so that the turning resistance of com-
panion flange becomes the same as that before re-
placing oil seal.
ST 498427200 FLANGE WRENCH
NOTE:
Use a new self-locking nut.
Tightening torque:
181.4 N-m (18.50 kgf-m, 133.8 ff-lb)
r. .
\ \ G3M0034
16) Reassembling procedure hereafter is the re-

verse of the disassembling.
17) Fill the differential carrier with gear oil to the fill-
er plug level. <Ref. to DI-17, Differential Gear Oil.>
DI-36
1
REAR DIFFERENTIAL SIDE OIL SEAL
DIFFERENTIALS
6. Rear Differential Side Oil Seal (3) Remove the ABS sensor cable clamp and
parking brake cable guide from the trailing link.
A: INSPECTION
Make sure that there is no oil leakage from side oil
seal.
If there is any oil leakage, replace the oil seal.
B: REPLACEMENT
4) Loosen both wheel nuts.
5 ) Jack-up the vehicle and support it with rigid
racks.
6) Remove the wheels. (A) ABS sensor cable clamp
7) Remove the rear exhaust pipe and muffler. (B) Parking brake cable guide
Non-turbo model:
<Ref. to EX(S0HC)-9, REMOVAL, Rear Exhaust (4) Remove the rear stabilizer link.
-
Muffler.>
Turbo model:
*<Ref. to EX(D0HC TURBO)-13, REMOVAL, Rear
Exhaust Pipe.> and <Ref. to EX(D0HC TURBO)-
14, REMOVAL, Muffler.>
8) Remove the DOJ of rear drive shaft from rear dif-
ferential.
(1) Remove the ABS sensor cable clamp and
parking brake cable clamp from bracket.
17
(5) Remove the bolts which secure the trailing

link to the housing.
(A) ABS sensor cable clamp

(B) Parking brake cable guide \\ G3M0042
(2) Remove the ABS sensor cable clamp from (6) Remove the bolts which secure the front
the trailing link. and rear lateral link to the rear housing.
DI-37
I REAR DIFFERENTIAL SIDE OIL SEAL
DIFFERENTIALS
(7) Remove the DOJ from the rear differential 10) Remove the nut of protector.
by using ST. ST 398527700 PULLER ASSY
CAUTION:
When removing the DOJ from the rear differen-
tial, fit ST to the bolts as shown in figure so as
not to damage the side bearing retainer.
G3M1023
11) Drive in a new side oil seal with ST.

CAUTION:
Apply chassis grease between the oil seal lips.
ST 398437700 DRIFT
I
1024
DR0006
12) Insert the DOJ into rear differential.
(A) Bolt
(1) Install the ST to rear differential.
, I
ST 28099PA090 SIDE OIL SEAL PROTEC-

9) Remove the rear drive shaft to rear crossmem- TOR
ber using wire.
S3M050C
DI-38
1
REAR DIFFERENTIAL SIDE OIL SEAL
DIFFERENTIALS
_ _ _ ~ ~
(2) Install the spline shaft until the spline portion

is inside the side oil seal using ST.
TOR
(3) Remove ST.

TOR
13) Hereafter, reassemble in the reverse order of
disassembly.
-44)-Fill differential carrier with gear oil to the filler
plug level. <Ref. to DI-17, Differential Gear Oil.>
DI-39
I REAR DIFFERENTIAL MEMBER
DIFFERENTIALS
7. Rear Differential Member B: INSTALLATION

To install, reverse the removal sequence.
A: REMOVAL 1) Position the front member on body by passing it
1) Set the vehicle on the lift. under parking brake cable and securing to rear dif-
2) Disconnect the ground terminal from battery. ferential.
3) Move the selector lever or gear shift lever to “N”. NOTE:
4) Release the parking brake. When installing the rear differential front member,
5) Loosen the wheel nuts. do not confuse the installation seqence of the stop-
6) Jack-up the vehicle and support it with study per.
racks.
7) Remove the wheels.
Non-turbo model:
Muffler.>
Turbo model:
<Ref. to EX(D0HC TURBO)-13, REMOVAL, Rear
Exhaust Pipe.> and <Ref. to EX(D0HC TURBO)-
14, REMOVAL, Muffler.> I I
’ G3M1029
9). Remove the rear differential protector. (If
r-
equipped) 2) Insert the DOJ of rear drive shaft into rear differ-
10) Remove the rear differential front member. ential.<Ref. to DI-37, REPLACEMENT, Rear Dif-
ferential Side Oil Seal.>
NOTE:
When removing the rear differential front member, CAUTION:
work the removal procedure as rear differential. Before inserting, replace the differential side oil
<Ref. to DI-19, REMOVAL, Rear Differential.> seal with a new one.
11) Remove the differential rear member. ST 28099PA090 SIDE OIL SEAL PROTEX-
TOR
1026
3) Installing procedure hereafter is in the reverse

order of removal.
C: INSPECTION
1) Check the rear differential member for damage,
bend or corrosion.
If damage, bend or corrosion is excessive, replace
the rear differential member.
2) Check bushings of rear differential member for
cracking, hardening or damage.
If cracking, hardening or damage is excessive, re-
place rear differential member.
DI-40
I GENERAL DIAGNOSTIC TABLE
DIFFERENTIALS

A: INSPECTION
Symptom or trouble Possible cause Remedy
1. Oil leakage (1) Worn, scratched, or incorrectly seated Repair or replace.
front or side oil seal. Scored, battered or
excessively worn sliding surface of com-
panion flange.
(2) Clogged or damaged air breather. Clean, repair or replace.
(3) Loose bolts on differential spindle or Tighten bolts to specified torque. Replace
side retainer or incorrectlv fitted 0-rina. 0-rina.
(4) Loose rear cover attaching bolts or
damaged gasket.
(5) Loose oil filler or drain plug.
1 Tighten bolts to specified torque. Replace
gasket and apply liquid packing.
Retighten and apply liquid packing.
(6) Wear, damage or incorrectly fitting for Repair or replace.
sDindle. side retainer and oil seal.
2. Seizure (1) Insufficient backlash for hypoid gear. Readjust or replace.
NOTE: (2) Excessive preload for side, rear or Readjust or replace.
Seized or damaged parts should be re- front bearing,
placed, and Other parts should be
(3) insufficient or improper oil used, Replace seized part and fill with specified
thoroughly checked for any defect and
oil to specified level.
should be repaired or replaced as re-
quired.
3. Damage (1) Improper backlash for hypoid gear. Replace.
NOTE: (2) Insufficient or excessive preload for Readjust or replace.
Damaged Parts should be replaced, and side. rear or front bearina.
1
Other parts should be thoroughly (3) Excessive backlash f& differential
checked for any defect and should be re- ycai.
~~~"
I
Replace gear or thrust washer.
paired or replaced as required.
(4) Loose bolts and nuts such as crown I Retighten.
gear bolt.
(5) Damage due to overloading. Replace.
4. Noises when starting or shifting (1) Excessive backlash for hypoid gear. Readjust.
gears (2) Excessive backlash for differential Replace gear or thrust washer.
NOTE:
Noises may be caused by differential 1 near
a---..
as- (3) Insufficient preload for front or rear
sembly, universal joint, wheel bearing, cIU---:--
~dlIlly.
Readjust.
etc. Find out what is-actuallymaking noise
before disassemblv. (4) Loose drive pinion nut. Tighten to specified torque.
(5) Loose bolts and nuts such as side Tighten to specified torque.
bearing retainer attaching bolt.
5. Noises when cornering (1) Damaged differential gear. Replace.
(2) Excessive wear or damage of thrust Replace.
washer.
(31Broken Dinion mate shaft. Redace.
1 (4) Seized or damaaed side bearing. I Replace.
DI-41
I GENERAL DIAGNOSTIC TABLE
DIFFERENTIALS
I SvmDtom or trouble
6. Gear noises (1) Improper tooth contact of hypoid gear. I Readjust or replace hypoid gear set.
NOTE: (2) Improper backlash for hypoid gear. I Readiust.
Since noises from engine, muffler, trans-
(3) Scored or chipped teeth of hypoid Replace hypoid gear set.
mission, propeller shaft, wheel bearings,
gear.
tires, and body are sometimes mistaken
for noises from differential assembly, be (4) Seized hypoid gear. Replace hypoid gear set.
careful in checking them. Inspection (5) Improper preload for front or rear Readjust.
methods to locate noises include coast- bearings.
ing, accelerating, cruising, and jacking-up (6) Seized, scored or chipped front or Replace.
all four wheels. Perform these inspections rear bearing.
according to condition of trouble. When (7) Seized, scored or chipped side bear- Replace.
listening to noises, shift gears into four ina.
wheel drive and fourth speed position, try-
ing to pick up only differential noise.
(8) Vibrating differential carrier. I Replace. I
DI-42
TRANSFER CASE
TC
Page
2. Transfer Case and Extension for MT .......................................................... 3
3. Transfer Clutch and Extension for AT ......................................................... 4
4. Oil Seal ........................................................................................................ 5
5. Transfer Drive Gear (MT) ............................................................................ 6
6. Transfer Driven Gear (MT) .......................................................................... 7
7. Reduction Drive Gear without VTD ............................................................. 8
8. Reduction Drive Gear with VTD .................................................................. 9
9. Reduction Driven Gear without VTD ......................................................... 10
.
c 10. Reduction Driven Gear with VTD .............................................................. 11
11. Center Differential ..................................................................................... 12
12. Transfer Clutch Pressure Test .................................................................. 13
13. Transfer Duty Solenoid and Valve Body ................................................... 14
TRANSFERCASE
A: NOTE
For removal, installation and inspection work, refer
to “AT” or “MT” section.
AT model:
<Ref. to AT-2, General Description.>
MT model:
<Ref. to MT-2, General Description.>
TC-2
I
TRANSFER CASE AND EXTENSION FOR MT
TRANSFERCASE
2. Transfer Case and Extension

for MT
A: NOTE
to “MT” section. <Ref. to MT-41, Transfer Case and
Extension Case Assembly.>
c.
TC-3
I
TRANSFER CLUTCH AND EXTENSION FOR AT
TRANSFERCASE
3. Transfer Clutch and Exten-

sion for AT
A: NOTE
to “AUTOMATIC TRANSMISSION’’ (a separate
publication: Pub. No. G0853ZE).
TC-4
I OIL SEAL
TRANSFERCASE
4. Oil Seal
A: NOTE
to “AT” or “MT” section.
AT model:
<Ref. to AT-27, Extension Case Oil Seal.>
MT model:
<Ref. to MT-36, Oil Seal.>
TC-5
TRANSFER DRIVE GEAR (MT)
TRANSFERCASE
5. Transfer Drive Gear (MT)

A: NOTE
to “MT” section. <Ref. to MT-45, Transfer Drive
Gear.>
TC-6
I TRANSFER DRIVEN GEAR (MT)
TRANSFERCASE
6. Transfer Driven Gear (MT)

A: NOTE
to "MT" section. <Ref. to MT-47, Transfer Driven
Gear.>
TC-7
I REDUCTION DRIVE GEAR WITHOUT VTD
TRANSFERCASE
7. Reduction Drive Gear without

VTD
A: NOTE
to “AUTOMATIC TRANSMISSION” (a separate
TC-8
I REDUCTION DRIVE GEAR WITH VTD
TRANSFERCASE
8. Reduction Drive Gear with

VTD
A: NOTE
publication: Pub. No. G0853ZE)
TC-9
I REDUCTION DRIVEN GEAR WITHOUT VTD
TRANSFERCASE
9. Reduction Driven Gear with-

out VTD
A: NOTE
TC-10
I REDUCTION DRIVEN GEAR WITH VTD
TRANSFERCASE
1O.Reduction Driven Gear with

VTD
A: NOTE
to “AUTOMATIC TRANSMISSION” (a separate
publication: Pub. No. G0853ZE)
TC-11
CENTER DIFFERENTIAL
TRANSFERCASE
11.Center Differential
A: NOTE
publication) or “MT” section.
AT model:
Pub No. G0853ZE
MT model:
<Ref. to MT-49, Center Differential.=.
TC-12
I TRANSFERCLUTCHPRESSURETEST
TRANSFERCASE
12.Transfer Clutch Pressure

Test
A: NOTE
For inspection work, refer to “AT” section. <Ref. to
AT-18, Transfer Clutch Pressure Test.>
TC-13
I I
TRANSFER DUTY SOLENOID AND VALVE BODY
TRANSFERCASE
13.Transfer Duty Solenoid and

Valve Body
A: NOTE
publication: Pub. No. G0853ZE) or “AT” section.
<Ref. to AT-39, Shift Solenoids, Duty Solenoids
and ATF Temperature Sensor.>
r. .
TC-14
DRIVE SHAFT SYSTEM
DS
Page
2. Propeller Shaft .......................................................................................... 14
3. Front Axle .................................................................................................. 17
4. Rear Axle .................................................................................................. 23
5. Front Drive Shaft ....................................................................................... 32
6. Front Drive Shaft Boots ............................................................................. 38
7. Rear Drive Shaft........................................................................................ 39
8. Rear Drive Shaft Boots ............................................................................. 44
9. General Diagnostic Table.......................................................................... 46
GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM
~ ~ ~~
A: SPECIFICATIONS
1. PROPELLER SHAFT
[ Model I Turbo I Non-turbo I

Propeller shaft type DOJ type UJ type
AT 579 (22.79) 584 (22.99)
Front propeller shaft Joint-to-jointlength: L1 mm (in)
MT 638 (25.12) 643 (25.32)
Rear propeller shaft Joint-to-jointlength: L, mm (in) 713 (28.07) 708 (27.87)
D1 63.5 (2.500)
Outside diameter of tube: mm (in)
D2 57.0 (2.244)
Di D2
Di Dz
DR0008
(A) UJtYPe (B) DOJ type
DS-2
a
GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM
2. FRONT DRIVE SHAFT ASSEMBLY
2 ,
Except turbo MT model 26 mm (1.02 in)

EBJ87+SFJ82
Ttirbo MT model 28 mm (1.10 in)
B4M2218l
(A) EBJ87+SFJ82 (B) Measuring point
DS-3
GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM
3. REAR DRIVE SHAFT ASSEMBLY
Type of drive shaft assembly Model No. of identification L1 +D

protrusion on shaft (") (") ,
EBJ8WDOJ82 RH 2 (Two) 363 24

Sedan Turbo
EBJ8WDOJ82 LH 1 (One) 353 24
BJ79/DOJ79 RH 2 (Two) 368 23
Sedan Non-turbo
BJ79/DOJ79 LH I . ,
1 (One) 358 23
EBJ8WDOJ82 RH 2 (Two) 353 24
Wagon Turbo
EBJ82/DOJ82 LH 1 (One) 343 24
BJ79/DOJ79 RH 2 (Two) 358 23
Wagon Non-turbo
BJ79/DOJ79 LH 1 (One) 348 23
I DR0013
11) Identification protrusion
DS-4
GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM
B: COMPONENT
1. PROPELLER SHAFT
DROOlk
(1) Propeller shaft (Turbo model) (4) Bush Tightening torque: N.m (kgf-m, ft-lb)
(2) Propeller shaft (Non-Turbo model) (5) Bush T I : 31 (3.2,23.1)
(3) Rear differential T2: 52 (5.3, 38.3)
DS-5
I
GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM
2. FRONTAXLE
04M2213A
(1) Baffle plate (SFJ) (9) Boot (SFJ) (17) Housing

(2) Spring pin (10) Boot (EBJ) (18) Oil seal (OUT)
(3) Outer race (SFJ) (11) EBJASSY (19) Hub bolt
(4) Snap ring (12) Tone wheel (With ABS) (20) Hub
(5) Trunnion (13) Baffle plate (21) Axle nut
(6) Free ring . . Oil seal (IN)
(14) ~I
(7) Circlip (15) Snap ring Tightening torque: N-m (kgf-m,

. - ft-lb)
(8) Boot band (16) Bearing T: l S S ( 1 9 , 137)
DS-6
GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM
3. REARAXLE
Baffle plate (DOJ) Baffle plate Tightening torque: N.m (kgf-m, ft-lb)
Outer race (DOJ) Oil seal (IN. No. 2) T1: 13 (1.3, 9.4)
Snap ring Oil seal (IN. No. 3) 12: lSS(19, 137)
Inner race Housing
Ball Bearing ASSY * Non-Turbo model: BJ
Cage Snap ring Turbo model: EBJ
Circlip Oil seal (OUT)
Boot band Tone wheel (With ABS)
Boot (DOJ) Hub bolt
Boot (*) Hub
Non-Turbo: BJ ASSY Axle nut
Turbo: EBJ ASSY
DS-7
GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM
C: CAUTION
tion.
points.
formation.
DS-8
GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM
D: PREPARATION TOOL
1. SPECIAL TOOLS

122431000 4XLE SHAFT 1 Used for installing axle shaft into housing.
NSTALLER 1 Used with ADAPTER (927390000).
B4M2386
325091000 3ANDTIGHTENING Used for tightening boot band. (Except front
rooL axle housing side)
(A) Jig for band
(B) Ratchet wrench
B4N2387P
326470000 AXLE SHAFT Used for removing axle shaft.
PULLER
B4M238f
927060000 HUB REMOVER Used for removing front hub.
Used with HUB STAND (927080000).
B4M238!
DS-9
GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM

927420000 HUB REMOVER Used for removing rear hub.
Used with HUB STAND (927080000).
H5M0981
927080000 HUB STAND Used for disassembling and assembling hub bolt
in hub.
B4M2390
927100000 3EARING PULLER Used for disassembling and assembling front
housing bearing.
Used with HOUSING STAND (927400000).
B4M2391
927140000 4XLE SHAFT Same as plate 2 included in AXLE SHAFT
WLLER PLATE PULLER (926470000).
B4M2392
DS-10
GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM
t
)27390000
I B4M2393
327400000 -1OUSING STAND Used for disassembling and assembling front
housing bearing.
Used with BEARING PULLER (927100000).
04M2394
327410000 OIL SEAL Used for installing oil seal into front housing.
INSTALLER Used with HOUSING STAND (927400000).
r B4M2395
927430000 HOUSING STAND Used for disasembling and assembling rear
housing bearing.
Used with BEARING PULLER (927440000).
H5M098;
DS-11
DRIVE SHAFT SYSTEM

927120000 HUB INSTALLER Used for installing hub.
927440000 BEARING * Used for disassembling and assembling rear

REMOVER housing bearing.
Used with HOUSING STAND (927430000).
927460000 31L SEAL 1 Used for installing outer bearing and sub bear-
NSTALLER ng into houding.
1 Used with HOUSING STAND (927430000).
I H5M0984
327450000 W B INSTALLER 1Used for installing hub unit into hub ASSY.
1Used with BEARING SPACER (28499AE000)
md HUB STAND (927080000).
DS-12
GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM

28OBPAO90 OIL SEAL PROTEC- Used for installing rear drive shaft into rear dif-
TOR ferential.
For potecting oil seal.
B4M2401
28099PA100 DRIVE SHAFT Used for removing rear drive shaft from rear dif-
REMOVER ferential.
B4M2402
28099ACOOO BOOT BAND PLI- Used for tightening front EBJ boot band. (Front
ERS axle housing side)
84M2403
TOOL NAME REMERKS

Puller Used for removing ball joint from knuckle arm.
Dial aauae Used for insDectinQ DroDeller shaft run-out.
lSnaD riniiliers ~
I Used for installing and removing snap ring. I
DS-13
PROPELLER SHAFT
DRIVE SHAFT SYSTEM
2. Propeller Shaft 9) Remove the four bolts which hold propeller shaft
to rear differential.
A: REMOVAL NOTE:
NOTE: Put matching mark on affected parts before re-
Before removing propeller shaft, wrap metal moval.
parts with a cloth or rubber material. Remove all but one bolt.
In case of DOJ type, before removing propeller
shaft, wrap metal parts (installed at the rubber boot
of center DOJ) with a cloth or rubber material, as
shown in the figure. Rubber boot may be damaged
due to interference with adjacent metal parts while
bending the DOJ during removal.
(A) Matching mark
10) Remove the two bolts which hold center bear-

lt3“‘ ing to the vehicle body.
S3M0030
1) Set the vehicle on a lift.

5) Jack-up the vehicle and support it with the safety
stands. (rigid racks)
7) Remove the rear differential protector.
(If equipped) I S3M0028
8) Remove the differential mount front cover.
I S3M0026
DS-14
PROPELLER SHAFT
DRIVE SHAFT SYSTEM
11) Remove the propeller shaft from the transmis- B: INSTALLATION

sion. 1) Insert the sleeve yoke into the transmission and
CAUTION: attach center bearing to body.
not to damage oil seals and frictional surface Tightening torque:
of sleeve yoke. 52 N-m (5.3 kgf-m, 38.3 ff-lb)
Cover the center exhaust pipe with a cloth to
keep off any ATF or oil spilled from transmis-
sion when removing propeller shaft.
NOTE:
Be sure to use an empty oil can to catch oil flow-
ing out when removing propeller shaft.
Be sure to plug the opening in transmission after
removal of propeller shaft.
, ... i'
-
S3M0028
2) Align the matching marks and connect the flange

yoke and rear differential.
Tightening torque:
37 N-m (3.2 kgf-m, 23.7 ff-lb)
12) Install the extension cap to transmission.

NOTE:
If extension cap is not available, place vinyl bag
over opening and fasten with string to prevent gear
oil or ATF from leaking.
(A) Matching mark
3) Install the differential mount front cover.

Tightening torque:
88 N.m (9.0kgf-m, 65 ff-lb)
(A) Extension cap
S3MO026
4) Install the rear differential protector. (If equipped)

DS-15
PROPELLER SHAFT
DRIVE SHAFT SYSTEM
C: INSPECTION 3. RUNOUT OF PROPELLER SHAFT

NOTE: 1) Remove the rear exhaust pipe and muffler.
Do not disassemble propeller shaft. Check the fol- 2) Remove the heat shield cover. (If equipped)
lowing and replace if necessary. 3) Turn the rear wheels by hand to check for
1) Tube surfaces for dents or cracks “runout” of propeller shaft.
2) Splines for deformation or abnormal wear NOTE:
3) Joints for non-smooth operation or abnormal Measure runout with a dial gauge at the center of
noise front and rear propeller shaft tubes.
4) Center bearing for free play, noise or non-
Runout:
smooth operation
Limit 0.6 mm (0.024 in)
5 ) Oil seals for abnormal wear or damage
6) Center bearing for breakage
Check the following points with propeller shaft in-
stalled in vehicle.
1. JOINTS AND CONNECTIONS
1) Remove the rear exhaust pipes and muffler.
3) Check for any looseness of yoke flange connect-
ing bolts and center bearing retaining bolts.
2. SPLINES AND BEARING LOCATIONS
1) Remove the rear exhaust pipe and muffler. (A) Propeller shaft
2) Remove the heat shield cover. (If equipped) (B) Dial gauge
3) Turn the propeller shaft by hand to see if abnor-
mal free play exists at splines. Also move yokes to 4. CENTER BEARING FREE PLAY
see if the abnormal free play exists at spiders and
bearings. 1) Remove the rear exhaust pipe and muffler.
3) While holding propeller shaft near center bearing
with your hand, move it up and down, and left and
right to check for any abnormal bearing free play.
B3M1604
DS-16
FRONT AXLE
DRIVE SHAFT SYSTEM
7) Remove the front drive shaft assembly from the

3. Front Axle hub. If it is hard to remove, use STs.
A: REMOVAL ST1 926470000 AXLE SHAFT PULLER
1) Disconnect the ground cable from battery. ST2 927140000 AXLE SHAFT PULLER
PLATE
2) Jack-up the vehicle, support it with safety
stands, and remove the front wheels. CAUTION:
3) Unlock the axle nut. Be careful not to damage oil seal lip when re-
moving front drive shaft.
When replacing front drive shaft, also replace
inner oil seal.
14
4) Remove the axle nut using a socket wrench.

CAUTION:
Be sure to loose and retighten axle nut after re-
moving wheel from vehicle. Failure to follow 8) Remove the disc rotor from the hub.
this rule may damage wheel bearings. If disc rotor seizes up within hub, drive disc rotor out
by installing an 8-mm bolt in screw hole on the ro-
5) Remove the stabilizer link.
tor.
G4M0215
6) Remove the disc brake caliper from the housing,

u B4M 1670
9) Remove the cotter pin and castle nut which se-

and suspend it from strut using a wire.
cure tie-rod end to housing knuckle arm.
(A) Cotterpin
(B) Castle nut
(C) Tie-rod
DS-17
FRONT AXLE
DRIVE SHAFT SYSTEM
10) Using a puller, remove the tie-rod ball joint from B: INSTALLATION
the knuckle arm. 1) Install the transverse link ball joint to the hous-
ing.
Tightening torque:
49 N-m (5.0 kgf-m, 36 ft-lb)
2) While aligning alignment mark on camber adjust-
ing bolt head, connect the housing and strut.
CAUTION:
Tightening torque:
152 N-m (15.5 kgf-m, 112 ft-lb)
11) On ABS equipped models, remove the ABS 3) Install the ABS sensor on the housing (only ve-
sensor assembly and harness in advance. hicle equipped with ABS).
Tightening torque:
32 N-m (3.3 kgf-m, 24 ft-lb)
4 ) Install the disc rotor on the hub.
5) Install the disc brake caliper on the housing.
Tightening torque:
78 N.m (8 kgf-m, 57.9 ft-lb)
6) Install the front drive shaft. <Ref. to DS-32, IN-
STALLATION, Front Drive Shaft.>
7) Connect the stabilizer link.
8) Connect the tie-rod end ball joint and knuckle
12) Remove the transverse link ball joint from the arm with a castle nut, and insert the cotter pin into
housing. the tie-rod end.
Castle nut tightening torque:
Tighten to 27.0 N-m (2.75 kgf-m, 19.9 ft-lb),
and tighten further within 60" until cotter pin
hole is aligned with a slot in the nut.
CAUTION:
When connecting, do not hit cap at the bottom
of tie-rod end with hammer.
13) After scribing an alignment mark on camber ad-

justing bolt head, remove bolts which connect
housing and strut, and disconnect the housing from
the strut.
(A) Cotter pin

(B) Castle nut
(C) Tie-rod
1970
-
DS-18
FRONT AXLE 1
DRIVE SHAFT SYSTEM
9) While depressing brake pedal, tighten the axle C: DISASSEMBLY

nut and lock it securely. 1) Using ST1, support housing and hub securely.
Tightening torque: 2) Attach ST2 to housing and drive hub out.
186 N-m (19 kgf-m, 137 ft-lb) ST1 927060000 HUB REMOVER
ST2 927080000 HUB STAND
CAUTION:
Use a new axle nut.
Always tighten axle nut before installing
wheel on vehicle. If wheel is installed and
comes in contact with ground when axle nut is
loose, wheel bearings may be damaged.
Be sure to tighten axle nut to specified
torque. Do not overtighten it as this may dam-
age wheel bearing.
10) After tightening the axle nut, lock it securely.
I
I G4M0238 1 v
11) Install the wheel and tighten the wheel nuts to G4M0223
specified torque.
If inner bearing race remains in the hub, remove it
Tightening torque: with a suitable tool (commercially available).
90 N.m (9.2 kgf-m, 66.5 ft-lb)
CAUTION:
Be careful not to scratch polished area of
hub.
Be sure to install inner race on the side of
outer race from which it was removed.
DS-19
Y
FRONT AXLE
DRIVE SHAFT SYSTEM
3) Remove the disc cover from the housing. 8) Using ST and a hydraulic press, drive hub bolts
out.
ST 927080000 HUB STAND
CAUTION:
Be careful not to hammer the hub bolts. This
may deform hub.
G4M0225
4) Using a standard screwdriver, remove the outer

and inner oil seals.
CAUTION:
Do not use old oil seals.
G4M0228
5) Using flat bladed screwdriver, remove the snap
ring.
CAUTION:
Be careful not to damage housing at removal.
H4M1001
6) Using STl , support housing securely.

7) Using ST2, press inner race to drive out outer
bearing.
ST1 927400000 HOUSING STAND
ST2 927100000 BEARING PULLER
CAUTION:
Do not remove outer race unless it is faulty.
Discard outer race after removal.
Do not replace inner or outer race separately;
always replace as a unit.
DS-20
I
FRONT AXLE
DRIVE SHAFT SYSTEM
D: ASSEMBLY 5) Using pliers, install the snap ring in its groove.

1) Attach the hub to ST securely. CAUTION:
ST 927080000 HUB STAND Make sure to install it firmly to groove.
G4M0230
2) Using a hydraulic press, press the new hub bolts 6) Using ST1 and ST2, press the outer oil seal until
into place. it contacts the bottom of housing.
CAUTION: ST1 927410000 OIL SEAL INSTALLER
Be sure to press hub bolts until their seating ST2 927400000 HOUSING STAND
surfaces contact the hub. CAUTION:
NOTE: Do not apply pressure more than 3.92 kN (0.4
Use 12 mm (0.47 in) dia. holes in HUB STAND to ton, 0.4 US ton, 0.4 Imp ton).
prevent bolts from tilting.
3) Clean the dust or foreign particles from inside
the housing.
4) Using ST1 and ST2, press a new bearing into
place.
ST2 927100000 BEARING PULLER
CAUTION:
Always press outer race when installing bear-
ing.
Be careful not to remove the plastic lock from
inner race when installing bearing. 7) Using ST1 and ST2, press the inner oil seal until
Charge bearing with new grease when outer it contacts circlip.
race is not removed. ST1 927410000 OIL SEAL INSTALLER
Do not apply pressure more than 30 kN (3.1 ST2 927400000 HOUSING STAND
ton, 2.8 US ton, 3.1 Imp ton). CAUTION:
Specified grease: Do not apply pressure more than 3.92 kN (0.4
ton, 0.4 US ton, 0.4 Imp ton).
SHELL 6459N
G4M0234
8) Invert the ST and housing.

ST 927400000 HOUSING STAND
DS-21
FRONT AXLE
DRIVE SHAFT SYSTEM
9) Apply the sufficient grease to oil seal lip. E: INSPECTION

Specified grease 1) Inspect the rattle of bearing, give the tires a
SHELL 6459N shake with grasping both the upper and lower sides
of the tire. And also inspect to rotate the wheel
CAUTION: smoothly.
If specified grease is not available, remove
bearing grease and apply Auto Rex A instead.
Do not mix different types of grease.
10) Install the disc cover to housing the three bolts.
Tightening torque:
18 N-m (1.8 kgf-m, 13.0 ft-lb)
11) Attach the hub to ST1 securely.
12) Clean the dust or foreign particles from the pol-
ished surface of hub.
13) Using ST2, press the bearing into hub by driv-
ing inner race.
STI 927080000 HUB STAND 2) Inspect the lean of axis direction using a dial
ST2 927120000 HUB INSTALLER gauge. Replace the hub bearing if the load range
exceed the limitation.
CAUTION:
Do not apply pressure more than 25 kN (2.5 ton, Limit:
2.3 US ton, 2.5 Imp ton). Maximum: 0.05" (0.0020in)
G4M0235
3) Inspect the removed parts for wear and damage.

If defective, replace with new ones.
CAUTION:
If bearing is faulty, replace it as the bearing
set.
Be sure to replace oil seal at every overhaul.
L (A) Replace as a set.

H4M1002C
DS-22
REAR AXLE I
DRIVE SHAFT SYSTEM
4. Rear Axle 8) Disconnect the parking brake cable end
A: REMOVAL
1. DISC BRAKE
1) Disconnect the ground cable from battery.
2) Jack-up the vehicle, and remove the rear wheel
cap and wheels.
CAUTION:
Be sure to loosen and retighten the axle nut af-
ter removing wheel from vehicle. Failure to fol-
low this rule may damage wheel bearings.
3) Unlock the axle nut. 9) Disconnect the rear stabilizer from rear lateral
4) Remove the axle nut using a socket wrench. link.
5) Return the parking brake lever and loosen the 10) Remove the bolts which secure trailing link as-
adjusting nut. sembly to the rear housing.
CAUTION:
Discard old self-locking nut. Relpace with a
new one.
(1) Parking brake lever

(2) Lock nut S4M0109
(3) Adjusting nut
11) Remove the bolts which secure lateral assem-
6) Remove the disc brake caliper from the back bly to the rear housing.
plate, and suspend it from strut using a piece of CAUTION:
wire. Discard old self-locking nut. Relpace with a
new one.
7) Remove the disc rotor from the hub.

NOTE:
If disc rotor seizes up within hub, drive it out by in-
stalling an 8-mm bolt into bolt hole in disc rotor.
DS-23
REAR AXLE
DRIVE SHAFT SYSTEM
12) Disengage the BJ from the housing splines, 2. DRUMBRAKE

and remove the rear drive shaft assembly.
If it is hard to remove, use STs.
2) Jack-up the vehicle, and remove the rear wheel
STI 926470000 AXLE SHAFT PULLER
cap and wheels.
ST2 927140000 AXLE SHAFT PULLER
PLATE CAUTION:
Be sure to loosen and retighten the axle nut af-
CAUTION: ter removing wheel from vehicle. Failure to fol-
Be careful not to damage the oil seal lip when low this rule may damage wheel bearings.
removing rear drive shaft.
When rear drive shaft is to be replaced, also 3) Unlock the axle nut.
replace inner oil seal with a new one. 4) Remove the axle nut using a socket wrench.
I
5) Return the parking brake lever and loosen the
adjusting nut.
N G4M0247
13) Remove the rear ABS sensor from the back

plate (only vehicle equipped with ABS).
(2) Locknut
(3) Adjusting nut
6) Remove the brake drum from hub.

7) If it is difficult to remove brake drum, remove the
adjusting hole cover from the back plate, and then
turn the adjusting screw using a slot-type screw-
driver until the brake shoe separates from the
drum.
(1) ABS sensor
14) Remove the bolts which secure rear housing to

strut, and separate the two.
(1) Back plate

(2) Wheel cylinder
(3) Adjuster ASSY pawls
(4) Adjusting lever
(5) Tightening direction
(6) Push
DS-24
REAR AXLE
DRIVE SHAFT SYSTEM
NOTE: 11) Remove the bolts which secure trailing link as-
If brake drum is difficult to remove, drive it out by in- sembly to the rear housing.
stalling an 8-mm bolt into bolt hole in brake drum. CAUTION:
I Discard old self-locking nut. Replace with a
new one.
I G4M0243 1
8) Using a flare-net wrench, disconnect the brake

hose from the wheel cylinder. S4M0109 I
CAUTION: 12) Remove the bolts which secure lateral link as-
Cover open end of wheel cylinder to prevent en- sembly to the rear housing.
try of foreign particles. CAUTION:
Discard old self-locking nut. Replace with a
new one.
9) Disconnect the parking brake cable end.
13) Disengage the BJ from the housing splines,

and remove the rear drive shaft assembly.
If it is hard to remove, use STs.
PLATE
CAUTION:
Be careful not to damage the oil seal lip when
removing rear drive shaft.
I \
When rear drive shaft is to be replaced, also
(1) Cable end replace inner oil seal with a new one.
I
10) Disconnect the rear stabilizer from the rear lat-
eral link.
I
// U
G4M0247
DS-25
I REAR AXLE
DRIVE SHAFT SYSTEM
14) Remove the rear ABS sensor from the back B: INSTALLATION
plate (only vehicle equipped with ABS).
1. DISC BRAKE
1) Connect the rear housing assembly and strut as-
sembly.
CAUTION:
Tightening torque:
196 N-m (20 kgf-m, 145 ft-16)
2) Fit the BJ (bell joint) to the rear housing splines.
CAUTION:
Be careful not to damage inner oil seal lip.
(1) ABS sensor 3) Connect the rear housing assembly to the lateral
link assembly.
15) Remove the bolts which secure rear housing to
strut, and separate the two. CAUTION:
Tightening torque:
137 N-m (14 kgf-m, 101 ft-16)
4) Connect the rear housing assembly to the trail-

ing link assembly.
CAUTION:
Tightening torque:
113 N-m (1 1.5 kgf-m, 83 ft-16)
S4M0109
5) Connect the rear stabilizer to the rear lateral link.

CAUTION:
Tightening torque:
44 N-m (4.5 kgf-m, 32.5 ft-lb)
DS-26
REAR AXLE
DRIVE SHAFT SYSTEM
6) Connect the parking brake cable to the parking 13) Install the wheel and tighten the wheel nuts to
brake. specified torque.
7) Install the disc rotor on the rear housing assem- Tightening torque:
bly. 88 N-m (9 kgf-m, 65 ft-lb)
8) Install the disc brake caliper on the back plate.
Tightening torque:
2. DRUMBRAKE
52 N.m (5.3 kgf-m, 38.3 ft-lb) 1) Connect the rear housing assembly and strut as-
sembly.
CAUTION:
Tightening torque:
196 N-m (20 kgf-m, 745 ff-lb)
2) Fit the BJ (bell joint) to rear housing splines.
CAUTION:
Be careful not to damage inner oil seal lip.
3) Connect the rear housing assembly to the lateral
link assembly.
9) Install the rear ABS sensor and brake cable CAUTION:
bracket (only vehicle equipped with ABS). Use a new self-locking nut.
Tightening torque:
137 N.m (74 kgf-m, 101 ff-lb)
(1) ABS sensor
10) Bleed air from brake system. <Ref. to BR-44,

REPLACEMENT, Brake FIuid.>
11) Adjust the parking brake lever stroke by turning
adjuster.
12) Move the brake lever back to apply brakes.
While depressing brake pedal, tighten the axle nut
using a socket wrench. Lock the axle nut after tight-
I.
4) Connect the rear housing assembly to the trail-
ing link assembly.
CAUTION:
Tightening torque:
173 N.m (1 7.5 kgf-m, 83 ff-lb)
ening.
Tightening torque:
786 N-m (79 kgf-m, 737 ft-lb)
CAUTION:
Use a new axle nut.
torque. Do not overtighten it as this may dam- S4M0109
age wheel bearing.
DS-27
I REAR AXLE
DRIVE SHAFT SYSTEM
5) Connect the rear stabilizer to the rear lateral link. C: DISASSEMBLY

CAUTION: 1) Using STI and ST2, remove the hub from the
Use a new self-locking nut. rear housing.
ST 927080000 HUB STAND
Tightening torque:
ST 927420000 HUB REMOVER
44 N-m (4.5 kgf-m, 32.5 ft-lb)
6) Connect the parking brake cable to the parking
brake. I I
7) Clean the brake pipe connection. Using a flare-
nut wrench, connect the brake pipe to the wheel
cylinder.
8) Connect the rear ABS sensor to the back plate
(only vehicle equipped with ABS).
G4M02501
2) Remove the back plate from the rear housing

3) Using a standard screwdriver, remove the outer
and inner oil seals.
CAUTION:
Use new oil seals.
4) Using flat bladed screwdriver, remove the snap
ring.
(1) ABS sensor CAUTION:
Be careful not to damage housing at removal.
9) Connect the parking brake cable to the lever.
IO) Install the brake drum on the rear housing as-
sembly.
11) Bleed air from brake system. <Ref. to BR-44,
REPLACEMENT, Brake FIuid.>
12) Adjust the parking brake lever stroke by turning
adjuster.
13) Move the brake lever back to apply brakes.
While depressing brake pedal, tighten the axle nut
using a socket wrench. Lock the axle nut after tight-
0
ening. H4M1003
Tightening torque: 5 ) Using STI and ST2, remove the bearing by

186 N-m (19 kgf-m, 137 ft-lb) pressing inner race.
CAUTION: STI 927430000 HOUSING STAND
Use a new axle nut. ST2 927440000 BEARING REMOVER
Always tighten axle nut before installing CAUTION:
wheel on vehicle. If wheel is installed and Do not remove bearing unless damaged.
comes in contact with ground when axle nut is Do not re-use bearing after removal.
age wheel bearing.
14) Install the wheel and tighten the wheel nuts to
specified torque.
Tightening torque:
90 Nom(9.2 kgf-m, 66.5 ft-lb)
U
G4M0252
DS-28
REAR AXLE
DRIVE SHAFT SYSTEM
6) Remove the tone wheel bolts and remove the D: ASSEMBLY

tone wheel from the hub (only vehicle equipped 1) Using ST, press the new hub bolt into place.
with ABS).
7 ) Using ST, press the hub bolt out. CAUTION:
ST 927080000 HUB STAND Ensure hub bolt closely contacts hub.
Use a 12 mm (0.47 in) hole in the ST to pre-
CAUTION: vent hub bolt from tilting during installation.
Be careful not to hammer the hub bolts. This ST 927080000 HUB STAND
may deform hub.
30
-
G4M0221
2) Remove the foreign particles (dust, rust, etc.)
from the mating surfaces of hub tone wheel, and in-
stall the tone wheel to hub (only vehicle equipped
with ABS).
CAUTION:
Ensure tone wheel closely contacts hub.
Be careful not to damage tone wheel teeth.
(1)
S4M0370P
(1) Tone wheel
DS-29
REAR AXLE
DRIVE SHAFT SYSTEM
3) Clean the housing interior completely. Using 5) Using ST1 and ST2, press the outer oil seal unit
STI and ST2, press the bearing into the housing. it comes in contact with snap ring.
ST1 927430000 HOUSING STAND STI 927430000 HOUSING STAND
ST2 927440000 BEARING REMOVER ST2 927460000 OIL SEAL INSTALLER
CAUTION: CAUTION:
Always press iouter race when installing Do not apply pressure more than 3.92 kN (0.4
bearing. ton, 0.4 US ton, 0.4 Imp ton).
Be careful not to remove plastic lock from in-
ner race when installing bearing.
Charge bearing with new grease when outer
race is not removed.
Do not apply pressure more than 30 kN (3.1
S4M0267E
(1) Snap ring
6) Invert both ST1 and housing.

7) Using ST2, press the inner oil seal into the hous-
I S4M0266A
ing until it touches bottom.
4) Using plier, install the snap ring. ST2 927460000 OIL SEAL INSTALLER
CAUTION: CAUTION:
Ensure snap ring fits in groove properly. Do not apply pressure more than 3.92 kN (0.4
ton, 0.4 US ton, 0.4 ImD ton).
(1) Plier
DS-30
REAR AXLE 1
DRIVE SHAFT SYSTEM
8) Using ST1 and ST2, press the sub seal into E: INSPECTION
place. 1) Inspect the rattle and lean of axis direction of the
ST1 927430000 HOUSING STAND removed parts as the same procedure of Front Axle
ST2 927460000 OIL SEAL INSTALLER <Ref. to DS-22, INSPECTION, Front Axle.>
CAUTION: The lean of axis direction
Do not apply pressure more than 3.92 kN (0.4 Maximum: 0.05" (0.0020in)
2) Inspect the removed parts for wear and damage.
If defective, replace with a new one.
CAUTION:
If a bearing is faulty, replace it as the bearing
set.
Be sure to replace oil seal at every overhaul.
S4M0269A
9) Apply the sufficient grease to oil seal lip.

Specified grease:
SHELL 6459N
CAUTION:
H4M1002C
If specification grease is not available, re-
move bearing grease and apply Auto Rex A in-
(A) Replace as a set.
stead.
Do not mix different types of grease.
10) Install back plate to rear housing.
Tightening torque:
52 N.m (5.3 kgf-m, 38 ft-16)
11) Using ST1 and ST2, press the baring into hub.
ST1 927080000 HUB STAND
ST2 927450000 HUB INSTALLER
CAUTION:
Do not apply pressure more than 25 kN (2.5 ton,
2.3 US ton, 2.5 Imp ton).
DS-31
FRONT DRIVE SHAFT
DRIVE SHAFT SYSTEM
5. Front Drive Shaft 6 : INSTALLATION

1) Insert the BJ into hub splines.
A: REMOVAL
CAUTION:
Be careful not to damage inner oil seal lip and
2) Jack-up the vehicle, support it with safety stands tone wheel.
(rigid racks), and remove the front wheel cap and
wheels. 2) Using STI and ST2, pull the drive shaft into
3) Unlock the axle nut. place.
4) Depress the brake pedal and remove the axle STI 922431000 AXLE SHAFT INSTALLER
nut using a socket wrench. ST2 927390000 ADAPTER
CAUTION: CAUTION:
Be sure to loosen and retighten axle nut after Do not hammer drive shaft when installing it.
removing wheel from vehicle. Failure to follow
this rule may damage wheel bearings.
5 ) Remove the stabilizer link from the transverse
link.
6) Disconnect the transverse link from the housing.
7) Remove the spring pin which secures transmis-
sion spindle to SFJ.
CAUTION:
Use a new spring pin.
3) Tighten the axle nut temporarily.

4) Install the SFJ on transmission spindle and drive
spring pin into place.
CAUTION:
8) Remove the front drive shaft assembly. If it is

hard to remove, use STI and ST2.
STI 926470000 AXLE SHAFT PULLER
PLATE
CAUTION:
Be careful not to damage the oil seal lip and
tone wheel when removing front drive shaft. 5 ) Connect the transverse link to the housing.
When front drive shaft is to be replaced, also Tightening torque (self-locking nut):
replace inner oil seal. 49 N-m (5.0 kgf-m, 36 ft-lb)
CAUTION:
6) Install the stabilizer bracket.
DS-32
a
FRONT DRIVE SHAFT
DRIVE SHAFT SYSTEM
7) While depressing brake pedal, tighten the axle C: DISASSEMBLY - /
nut to the specified torque. 1) Place alignment marks on the shaft and outer
Tightening torque: race.
186 N.m (1 9 kgf-m, 137 fi-lb)
CAUTION:
Use a new axle nut.
age wheel bearing. 04M0774
I
8) After tightening axle nut, lock it securely.
2) Remove the SFJ boot band and boot.
CAUTION:
Be careful not to damage boot.
B4M0775 1
3) Remove the circlip from SFJ outer race using
screwdriver.
04M0776
4) Remove the SFJ outer race from shaft assem-

bly.
5 ) Wipe off grease.
CAUTION:
The grease is a special grease. Do not confuse
with other greases.
DS-33
I FRONT DRIVE SHAFT
I
DRIVE SHAFT SYSTEM
6) Place alignment mark on free ring and trunnion. 1 1 ) Place the drive shaft in a vise between wooden
bIocks.
CAUTION:
Do not place drive shaft directly in the vise; use
wooden block.
12)Raise the boot band claws by means of screw-
driver and hammer
04M0777
7) Remove the free ring from trunnion.

CAUTION:
Be careful with the free ring position.
8) Place alignment mark on trunnion and shaft.
04M2220B
(A) Boot band claws
13)Cut and remove the boot.

CAUTION:
The boot must be replaced with a new one
whenever it is removed.
04M0778
9) Remove the snap ring and trunnion.
W 14)Thus, disassembly of axle is completed, but BJ

cannot be disassembled.
B4M0779
CAUTION:
Be sure to wrap shaft splines with vinyl tape to
prevent boot from scratches.
IO) Remove the SFJ boot.
DS-34
FRONT DRIVE SHAFT
DRIVE SHAFT SYSTEM
D: ASSEMBLY 7) Install the boot projecting portion to shaft groove.

CAUTION:
Use specified grease.
,C)
EBJ side:
NTG2218 (Part No. 28093AA000)
SFJ side:
SSG6003 (Part No. 28093TAOOO)
1) Place the EBJ boot and small boot band on the
BJ side of shaft.
CAUTION:
N B4M 1297C
prevent boot from scratches. (A) Boot

2) Place the drive shaft in a vise. (6) Small boot band
(C) Shaft
CAUTION:
Do not place drive shaft directly in the vise; use
wooden blocks.
3) Apply a coat of specified grease [60 to 70 g (2.12
to 2.47 oz)] to EBJ.
4) Apply an even coat of specified grease [20 to 30
g (0.71 to 1.06 oz)] to the entire inner surface of
boot. Also apply the grease to the shaft.
NOTE:
The inside of the larger end of BJ boot and the boot
qroove shall be cleaned so as to be free from
irease and other substances.
5) Install the boot projecting portion to the EBJ
groove.
(A) EBJ
(6) Lorge boot band
(C) Boot
6) Set the large boot band in place.
DS-35
I FRONT DRIVE SHAFT
DRIVE SHAFT SYSTEM
8) Tighten the boot bands using ST, torque wrench 14) Align alignment marks on free ring and trunnion
and socket flex handle. and install the free ring.
ST 28099AC000 BOOT BAND PLlER CAUTION:
Be careful with the free ring position.
(A) Large boot band

(B) Boot
(C) Torque wrench
(D) Socket flex handle
(E) BJ
Tightening torque:
Large boot band
157 N-m (16.0 kgf-m, 116 ff-lb) or more
Small boot band
733 N.m (73.6 kgf-m, 98 ff-lb) or more
84M0777
9) Place the SFJ boot at the center of shaft.
10) Align alignment marks and install the trunnion 15) A g n alignment marks on shaft and outer race,
on the shaft. and install outer race.
I 04M0778 I 04MQ774
11) Install the snap ring to the shaft. 16) Install the circlip in the groove on the SFJ outer
race.
CAUTION:
Confirm that the snap ring is completely fitted CAUTION:
in the shaft groove. Pull the shaft lightly and assure that the circlip
12) Fill 100 to 110 g (3.53 to 3.88 oz) of specified i s completely fitted in the groove.
grease into the interior of SFJ outer race. 17) Apply an even coat of the specified grease 30
13) Apply a coat of specified grease to the free ring to 40 g (1.06 to 1.41 oz) to the entire inner surface
and trunnion. of boot.
18) Install the SFJ boot taking care not to twist it.
CAUTION:
The inside of the larger end of SFJ boot and
the boot groove shall be cleaned so as to be
free from grease and other substances.
When installing SFJ boot, position outer race
of SFJ at center of its travel.
DS-36
FRONT DRIVE SHAFT
DRIVE SHAFT SYSTEM
19) Put a band through the clip and wind twice in E: INSPECTION
alignment with band groove of boot. Check the removed parts for damage, wear, corro-
CAUTION: sion etc. If faulty, repair or replace.
Use a new band. 1) SFJ (Shudder-less Freering tripod Joint)
20) Pinch the end of band with pliers. Hold the clip Check seizure, corrosion, damage and excessive
and tighten securely. Play.
2) Shaft
NOTE: Check excessive bending, twisting, damage and
When tightening boot, exercise care so that the air wear.
within the boot is appropriate. 3) EBJ (Bell Joint)
21) Tighten the band by using ST. Check seizure, corrosion, damage and excessive
ST 925091000 BAND TIGHTENING TOOL Play.
NOTE: 4) Boot
Tighten the band until it cannot be moved by hand. Check for wear, warping, breakage or scratches.
5) Grease
Check for discoloration or fluidity.
22) Tap on the clip with the punch provided at the

end of ST.
ST 925091000 BAND TIGHTENING TOOL
CAUTION:
Tap to an extent that the boot underneath is not
damaged.
G4M029C
23) Cut off band with an allowance of about 10 mm

(0.39 in) left from the clip and bend this allowance
over the clip.
CAUTION:
Be careful so that the end of the band is in close
contact with clip.
24) Fix up boot on the EBJ in the same manner.
NOTE:
Extend and retract the SFJ to provide equal grease
coating.
DS-37
FRONT DRIVE SHAFT BOOTS
DRIVE SHAFT SYSTEM
6. Front Drive Shaft Boots

A: INSPECTION
Inspect the wear, warping, breakage or scratches
for boot. If faulty, repair or replace.
B: REPLACEMENT
2) Jack-up the vehicle, support it with safety stands
(rigid racks), and remove the front wheel cap and
wheels.
NOTE:
Do not remove the axle nut.
3) Remove the stabilizer link.
4) Disconnect the transverse link from the housing.
5) Remove the spring pin which secures transmis-
sion spindle to the SFJ.
CAUTION:
Use a new spring pin.
6) Remove the EBJ and SFJ boots from the drive

shaft. <Ref. to DS-33, DISASSEMBLY, Front Drive
Shaft.>
7) Install the EBJ and SFJ boots to the drive shaft.
<Ref. to DS-35, ASSEMBLY, Front Drive Shaft.>
8) Install the SFJ on transmission spindle and drive
spring pin into the place.
CAUTION:
9) Connect the transverse link to the housing.

10) Install the stabilizer link.
DS-38
REAR DRIVE SHAFT
1
DRIVE SHAFT SYSTEM
7. Rear Drive Shaft 5) Remove the axle nut and drive shaft. If it is hard
to remove, use ST1 and ST2.
A: REMOVAL ST1 926470000 AXLE SHAFT PULLER
1) Disconnect the ground cable from battery. ST2 927140000 AXLE SHAFT PULLER
2) Lift-up the vehicle, and remove the rear wheel PLATE
cap and wheels. CAUTION:
CAUTION: Be careful not to damage tone wheel when re-
Be sure to loosen and retighten axle nut after moving rear drive shaft.
removing wheel from vehicle. Failure to follow
this rule may damage wheel bearings.
3) Unlock the axle nut.
4) Remove the DOJ from rear differential using ST.
NOTE:
The side spline shaft circlip comes out together
with the shaft.
(1) Bolt
(2) DOJ
CAUTION:
tainer. Always use bolt as shown in figure, as
supporting point for ST during removal.
(1) Side bearing retainer
DS-39
REAR DRIVE SHAFT
DRIVE SHAFT SYSTEM
B: INSTALLATION 6) Align the DOJ and differential splines.

1) Insert the BJ or EBJ into the rear hub splines. 7) Push the housing to insert DOJ into the differen-
tial.
CAUTION:
Be careful not to damage tone wheel. NOTE:
Make sure the DOJ is inserted properly.
2) Using ST1 and ST2, pull the drive shaft into the
place.
ST1 922431000 AXLE SHAFT INSTALLER
ST2 927390000 ADAPTER
CAUTION:
Do not hammer drive shaft when installing it.
G3M0050
CAUTION:
new one.
8) While depressing brake pedal, tighten the axle
B4M1690A nut using a socket wrench.
3) Tighten the axle nut temporarily. Tightening torque:
4) Usina ST, install the DOJ into differential. 235 N-m (24 kgf-m, 174 ft-lb)
ST 28099PA090 SIDE OIL SEAL PROTEC- CAUTION:
TOR Use a new axle nut for rear use only.
age wheel bearing.
9) After tightening axle nut, lock it securely.
5) Insert the DOJ spline end into the bore of side oil
seal, and remove ST.
CAUTION:
Do not allow DOJ splines to damage side oil
seal.
TOR
DS-40
REAR DRIVE SHAFT
DRIVE SHAFT SYSTEM
C: DISASSEMBLY 7) Wipe off the grease and take out balls.

1) Straighten the bent claw of larger end of DOJ CAUTION:
boot. The grease is a special grease (grease for con-
2) Loosen the band by means of screwdriver or pli- stant velocity joint). Do not confuse with other
ers with care of not damaging boot. greases.
NOTE:
Disassemble exercising care not to lose balls (6
PCS).
3) Remove the boot band on the small end of DOJ

boot in the same manner.
4) Remove the larger end of DOJ boot from DOJ 27E
outer race.
5 ) Pry and remove the round circlip located at the (A) Outer race
neck of DOJ outer race with a screwdriver. (6) Grease
8) To remove the cage from the inner race, turn the
cage by a half pitch to the track groove of the inner
race and shift the cage.
9) Remove snap ring, which fixes inner race to
shaft, by using pliers.
IO) Take out the DOJ inner race.
11) Take off the DOJ cage from shaft and remove
DOJ boot.
CAUTION:
G4M0282 I Be sure to wrap shaft splines with vinyl tape to
6) Take out the DOJ outer race from shaft assem-
bly. 12) Remove the BJ or EBJ boot in the same proce-
dure as DOJ boot.
13) Thus, disassembly of axle is completed, but BJ
or EBJ is unable to be disassembled.
DS-41
REAR DRIVE SHAFT
DRIVE SHAFT SYSTEM
D: ASSEMBLY 5) Install the cage, which was previously fitted, to

inner race fixed upon shaft.
CAUTION:
Use specified grease. NOTE:
Fit the cage with the protruded part aligned with the
BJ side (Non-turbo model): track on the inner race and then turn by a half pitch.
Molylex No. 2 (Part No. 723223010)
EBJ side (Turbo model):
NTG 2218 (Part No. 28093AA000)
DOJ side:
VU-3A702 (Yellow) (Part No. 23223GA050)
1) Install the BJ or EBJ boot in specified position,
and fill it with 60 to 70 g (2.12 to 2.47 oz) of speci-
fied grease.
2) Place the DOJ boot at the center of shaft.
B4M0228E
CAUTION:
(A) inner race
(B) Cage
3) Insert the DOJ cage onto shaft.
NOTE: 6) Fill 80 to 90 g (2.82 to 3.17 oz) of specified
Insert the cage with the cut-out portion facing the grease into the interior of DOJ outer race.
shaft end, since the cage has an orientation. 7) Apply a coat of specified grease to the cage
pocket and six balls.
8) Insert six balls into the cage pocket.
9) Align the outer race track and ball positions and
place in the part where shaft, inner race, cage and
balls are previously installed, and then fit outer
race.
6, S4M0376B
(A) Cage
(B) Cut-out portion ~~~
-_
4) Install the DOJ inner race on shaft and fit snap
ring with pliers. B4M0227E
NOTE:
Confirm that the snap ring is completely fitted in the (A) Outer race
shaft groove. (B) Grease
I G4M0285
DS-42
I
REAR DRIVE SHAFT
DRIVE SHAFT SYSTEM
10) Install the circlip in the groove on the DOJ outer 16) Tap on the clip with the punch provided at the
race. end of ST.
NOTE: ST 925091000 BAND TIGHTENING TOOL
Assure that the balls, cage and inner race are CAUTION:
completely fitted in the outer race of DOJ. Tap to an extent that the boot underneath is not
Exercise care not to place the matched position damaged.
of circlip in the ball groove of outer race.
Pull the shaft lightly and assure that the circlip is
completely fitted in the groove.
G4M0290
17) Cut off the band with an allowance of about 10

4 mm (0.39 in) left from the clip and bend this allow-
G4M0282
ance over the clip.
11) Apply an even coat of the specified grease [20 CAUTION:
to 30 g (0.71 to 1.06 oz)] to the entire inner surface Be careful so that the end of the band is in close
of boot. Also apply grease to shaft. contact with clip.
12) Install the DOJ boot taking care not to twist it.
18) Fix up the boot on the BJ or EBJ in the same
NOTE: manner.
The inside of the larger end of DOJ boot and the
NOTE:
boot groove shall be cleaned so as to be free from
Extend and retract the DOJ to provide equal grease
grease and other substances.
coating.
When installing DOJ boot, position outer race of
DOJ at center of its travel. E: INSPECTION
13) Put a band through the clip and wind twice in Check the removed parts for damage, wear, corro-
alignment with band groove of boot. sion etc. If faulty, repair or replace.
CAUTION: 1) DOJ (Double Offset Joint)
Use a new band. Check seizure, corrosion, damage, wear and ex-
cessive play.
14) Pinch the end of band with pliers. Hold the clip
and tighten securely. 2) Shaft
Check excessive bending, twisting, damage and
NOTE: wear.
When tightening boot, exercise care so that the air 3) BJ (Bell Joint) and EBJ (Eightball Bell Joint)
within the boot is appropriate. Check seizure, corrosion, damage and excessive
15) Tighten the band by using ST. Play.
ST 925091000 BAND TIGHTENING TOOL 4) Boot
NOTE: Check for wear, warping, breakage or scratches.
Tighten the band until it cannot be moved by hand. 5) Grease
Check for discoloration or fluidity.
G4M0289
REAR DRIVE SHAFT BOOTS
DRIVE SHAFT SYSTEM
~ __
8. Rear Drive Shaft Boots 7) Remove the DOJ from rear differential using ST.
A: INSPECTION NOTE:
Inspect the wear, warping, breakage or scratches The side spline shaft circlip comes out together
for boot. If faulty, repair or replace. with the shaft.
B: REPLACEMENT
2) Lift-up the vehicle, and remove the rear wheel
cap and wheels.
NOTE:
Axle nut need not be removed.
3) Remove the ABS sensor clamps and parking
brake cable bracket.
4) Disconnect the stabilizer link from the lateral link.
5) Remove the bolts which secure lateral link as-
sembly to the rear housing.
6) Remove the bolts which secure trailing link as- (1) Bolt
sembly to the rear housing. (2) DOJ
CAUTION:
tainer. Always use bolt as shown in figure, as
supporting point for ST during removal.
(1) Side bearing retainer
8) Remove the DOJ and BJ or EBJ boots from the

drive shaft. <Ref. to DS-41, DISASSEMBLY, Rear
Drive Shaft.>
9) Install the DOJ and BJ or EBJ boots to the drive
shaft. <Ref. to DS-42, ASSEMBLY, Rear Drive
Shaft.>
DS-44
REAR DRIVE SHAFT BOOTS
DRIVE SHAFT SYSTEM
10) Using ST, install the DOJ into differential. 14) Connect the rear housing assembly to the trail-
ST 28099PA090 SIDE OIL SEAL PROTEC- ing link assembly, and tighten the self-locking nut.
TOR 15) Connect the rear housing assembly to the lat-
era1 link assembly, and tighten the self-locking nut.
16) Connect the stabilizer link to the lateral link.
17) Install the ABS sensor clamps and parking
brake cable bracket.
11) Insert the DOJ spline end into the bore of side
oil seal, and remove ST.
CAUTION:
Do not allow DOJ splines to damage side oil
seal.
TOR
12) Align the DOJ and differential splines.

13) Push the housing to insert DOJ into the differ-
ential.
NOTE:
Make sure the DOJ is inserted properly.
I G3M005C
CAUTION:
new one.
DS-45
DRIVE SHAFT SYSTEM

A:INSPECTION
NOTE:
Vibration while cruising may be caused by an unbalanced tire, improper tire inflation pressure, improper
wheel alignment, etc.
Symptom Possible cause Remedy

1. Vibration of propeller shaft (1) Worn or damaged universal joint. Replace.
NOTE: (2) Unbalanced propeller shaft due to Replace.
Vibration is caused by propeller shaft dur- bend or dent,
ing operation and is transferred to vehicle
(3)Loose installation of propeller shaft, Retighten.
body. Generally vibration increase in pro-
portion to vehicle speed. (4) Worn or damaged center bearing and Replace.
damaaed center mountina
I " rubber.
2. Tapping when starting and noise (1) Worn or damaged universal joint. Replace.
while cruising, Cawed by Propeller (2) Worn spline of sleeve yoke. Replace.
-
shaft. (3) Loose installation of propeller shaft. Retighten.
(4) Loose installation of joint. Replace.
(5) Worn or damaged center bearing and Replace.
damaged center mounting rubber.
3. Front wheel shimmy (1) Worn or damaged hub bearing Repair or replace.
4. Wander or pulling (1) Worn or damaged hub bearing Repair or replace.
DS-46
ABS
ABS
Page
2. ABS Control Module and Hydraulic Control Unit (ABSCM&H/U)................7
3. ABS Sequence Control ............................................................................. 11
4. Front ABS Sensor ..................................................................................... 14
5. Rear ABS Sensor ...................................................................................... 18
6. Front Tone Wheel ..................................................................................... 21
7. Rear Tone Wheel ...................................................................................... 22
8. G Sensor ................................................................................................... 23
GENERAL DESCRIPTION
ABS
A: SPECIFICATIONS
Item Standard or remarks
Front 0.3 - 0.8 mm (0.012 - 0.031 in)
ABS sensor gap
Rear 0.7 - 1.2 mm (0.028- 0.047 in)
ABS sensor resistance

I Front I 1.25k0.25 kR I
ABS sensor
I Rear I 1.Of0.2 k!2 I
RH White
Front
- LH Yellow
Marks of the harness
RH Light blue
Rear
LH Brown
ABS control module and hydraulic control unit (ABSCM&H/U) AT cc

marks MT CD
ABS-2
GENERAL DESCRIPTION
ABS
B: COMPONENT
1. SENSOR
El
/-----Q
BROOOl
(1) G sensor (4) Rear ABS sensor LH Tightening torque: N.m (kgf-m, fi-lb)
(2) Rear ABS sensor RH (5) Front ABS sensor LH T1: 7.4 (0.75, 5.4)
(3) ABS spacer (6) Front ABS sensor RH T2: 32 (3.3,24)
ABS-3
I
GENERAL DESCRIPTION
ABS
2. ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
(1) Stud bolt (6) Front-RH outlet Tightening torque: N.m (kgf-m, ft-lb)
(2) Damper (7) Primary inlet T1: lS(1.8, 13.0)
(3) ABS control module and hydraulic (8) Rear-LH outlet T2: 29 (3.0, 21.7)
control unit (9) Rear-RH outlet T3: 32 (3.3.24)
(4) Front-LH outlet (10) Bracket
(5) Secondary inlet
ABS-4
GENERAL DESCRIPTION
1
ABS
C: CAUTION
tion.
part in the vehicle is hot after running.
points.
sensors or units, be sure to disconnect negative
ABS-5
GENERAL DESCRIPTION
ABS
D: PREPARATION TOOL
1. SPECIAL TOOLS

24082AA150 ;ARTRIDGE rroubleshootingfor electrical systems.
(New apopted tool)
02M3876
<IT b English: 22771AA030 (Without printer)
German: 22771AA070 (Without printer)
French: 22771AA080 (Without printer)
Spanish: 22771AA090 (Without printer)
02M3877
TOOL NAME REMARKS

Circuit tester Used for measuring resistance, voltage and ampere.
Pressure gauge Used for measuring oil pressure.
Oscilloscope Used for measuring sensor.
ABS-6
I ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
ta
ABS
2. ABS Control Module and Hy- 8) Remove the ABSCM&H/U from engine compart-
ment.
draulic Control Unit (AB- CAUTION:
SCM&H/U) ABSCM&H/U cannot be disassembled. Do
not attempt to loosen the bolts and nuts.
A: REMOVAL Do not drop or bump the ABSCM&H/U.
1) Disconnect the ground terminal from battery. Do not turn the ABSCM&H/U upside down or
2) Remove the air intake duct from engine compart- place it on its side.
ment to facilitate removal of ABSCM&H/U. Be careful to prevent foreign particles from
3) Use an air gun to get rid of water around the AB- getting into the ABSCM&H/U.
SCM&H/U. Apply a coat of rust-preventive wax (Nippeco
CAUTION: LT or GB) to bracket attaching bolt after tight-
The contact will be insufficient if the terminal ening.
gets wet. Do not pull the harness when disconnecting
4) Pull off the lock of the ABSCM&H/U connector to connector.
remove it.
/- B4M1222
5) Disconnect the connector from ABSCM&H/U.

CAUTION:
Be careful not to let water or other foreign mat-
ter contact the ABSCM&H/U terminal.
6) Unlock the cable clip.
7) Disconnect the brake pipes from ABSCM&H/U.
CAUTION:
Wrap the brake pipes with vinyl bag to avoid
spilling brake fluid on vehicle body.
ABS-7
ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
ABS
B: INSTALLATION
1) Install the ABSCM&H/U bracket.
Tightening torque:
32 N-m (3.3 kgf-m, 24 ff-16)
2) Install the ABSCM&H/U.
Mark Model
CAUTION:
Confirm that the specifications of the AB- cc AT
SCM&H/U conforms to the vehicle specifica- I CD I MT I
tions.
Tightening torque:
18 N.m (1.8 kgf-m, 13.0 ff-16)
(1) Mark
I /- 04M1222
1. CHECKING THE HYDRAULIC UNIT ABS
3) Connect the brake pipes to their correct AB- OPERATION BY PRESSURE GAUGE
SCM&H/U connections.
1) Lift-up the vehicle and remove wheels.
Tightening torque: 2) Disconnect the air bleeder screws from the FL
15 N.m (1.5 kgf-m, 10.8 ft-lb) and FR caliper bodies.
4) Using cable clip, secure the ABSCM&H/U har- 3) Connect two pressure gauges to the FL and FR
ness to bracket. caliper bodies.
5 ) Connect the connector to the ABSCM&H/U. CAUTION:
CAUTION: Pressure gauges used exclusively for brake
Be sure to remove all foreign matter from in- fluid must be used.
side the connector before connecting. Do not employ the pressure gauge previously
Ensure that the ABSCM&H/U connector is se- used for transmission since the piston seal is
curely locked. expanded and may lead to malfunction of the
6) Install the air intake duct. brake.
Non-turbo model: NOTE:
<Ref. to IN(S0HC)-7, INSTALLATION, Air Intake Wrap a sealing tape around the pressure gauge.
Duct.>
Turbo model:
<Ref. to IN(D0HC TURBO)-8, INSTALLATION, Air
Intake Duct.>
7) Bleed air from the brake system. <Ref. to BR-46,
Air Bleeding.>
I R4M 1797
ABS-8
I
ABS
2. CHECKING THE HYDRAULIC UNIT ABS

OPERATION WITH BRAKE TESTER
1) In the case of AWD AT Non-turbo vehicles, in-
stall a spare fuse with the FWD connector in the
main fuse box to simulate FWD vehicles.
Front wheel Rear wheel

3,432 kPa 3,432 kPa
Initial value (35 kgf/cm2,498 (35 kgf/cm2,498
Psi) Psi)
When 490 kPa 490 kPa
decom- (5 kgf/cm2, 71 psi) (5 kgf/cm2,71 psi) (1) Main fuse box
pressed or less or less (2) FWD connector
3,432 kPa 3,432 kPa
2) Prepare for operating the ABS sequence control.
When (35 kgf/cm2,498 (35 kgf/cm2,498
compressed Psi)
<Ref. to ABS-I 1, ABS Sequence Control.>
Psi)
or more or more 3) Set the front wheels or rear wheels on the brake
~
tester and set the select lever’s position at “neu-

8) Remove the pressure gauges from FL and FR t ral”.
caliper bodies.
9 ) Remove the air bleeder screws from the RL and
RR caliper bodies.
10) Connect the air bleeder screws to the FL and
FR caliper bodies.
11) Connect two pressure gauges to the RL and
RR caliper bodies.
12) Bleed air from the pressure gauges and the FL
and FR caliper bodies.
13) Perform the ABS sequence control.
14) When the hydraulic unit begins to work, at first
the RR side performs decompression, holding, and
compression, and then the RL side performs de-
compression, holding, and compression.
15) Read the values indicated on the pressure
gauges and check if they meet the standard value.
16) After checking, remove the pressure gauges
from caliper bodies.
17) Connect the air bleeder screws to RL and RR
caliper bodies.
18) Bleed air from the brake line.
(1) Brake tester
4) Operate the brake tester.

5) Perform ABS sequence control.
<Ref. to ABS-1 1, ABS Sequence Control.>
ABS-9
ABS
6) Hydraulic unit begins to work; and check the fol-

lowing working sequence.
(1) The FL wheel performs decompression,
holding, and compression in sequence, and
subsequently the FR wheel repeats the cycle.
(2) The RR wheel performs decompression,
holding, and compression in sequence, and
subsequently the RL wheel repeats the cycle.
7) Read the values indicated on the brake tester
and check if the fluctuation of values, when decom-
pressed and compressed, meet the standard val-
ues.
Front wheel Rear wheel
981 N 981 N
Initial value
(100 kgf, 221 Ib)
1 I I
(100 kgf, 221 Ib)
I Empressed
When
(50 ~ ~ 0 l y O l b ) 5
or less
981 N
(0:;1yO
or less
981 N
Ib)
(100 kgf, 221 Ib) (100 kgf, 221 Ib)

compressed
or more or more
8 ) After checking, also check if any irregular brake

pedal tightness is felt.
ABS-1 0
ABS SEQUENCE CONTROL m
ABS
3. ABS Sequence Control 2. ABS SEQUENCE CONTROL WITH SE-

LECT MONITOR
A: OPERATION
NOTE:
1) Under the ABS sequence control, after the hy-
In the event of any trouble, the sequence control
draulic unit solenoid valve is driven, the operation
of the hydraulic unit can be checked by means of may not be operative. In such a case, activate the
sequence control, referring to “ABS SEQUENCE
the brake tester or pressure gauge.
CONTROL WITH DIAGNOSIS CONNECTOR’’.
2) ABS sequence control can be started by diagno-
<Ref. to ABS-11, ABS SEQUENCE CONTROL
sis connector or select monitor.
WITH DIAGNOSIS CONNECTOR, ABS Sequence
1. ABS SEQUENCE CONTROL WITH DIAG- Control.>
NOSIS CONNECTOR When the diagnosis terminal is connected to the
diagnosis connector, the sequence control will not
1) Connect the diagnosis terminals to terminals No.
operate.
3 and No. 6 of the diagnosis connector beside driv-
er’s seat heater unit. 1) Connect the select monitor to data link connector
under the driver’s seat instrument panel lower cov-
er.
2) Turn the ignition switch ON.
3) Turn the select monitor switch ON.
4) Put the select monitor to “BRAKE CONTROL”
mode.
5 ) When “Function check sequence’’ is selected,
‘ABS sequence control’ will start.
6) The message ’Press Brake Pedal Firmly’ is dis-
played as follows:
& (1) When using the brake tester, depress the
BR0094
brake pedal with braking force of 981 N (100 kgf,
(1) Diagnosis connector 221 Ib).
(2) Diagnosis terminals (2) When using the pressure gauge, depress
’ (3) 3 terminal the brake pedal so as to make the pressure
(4) 6 terminal
gauge indicate 3,432 kPa (35 kg/cm2, 498 psi).
CAUTION:
2) Set the speed of all wheels at 4 km/h (2 MPH) or Do not depress the clutch pedal.
less.
7) When the message “Press YES’’ is displayed,
3) Turn the ignition switch OFF. press the YES key.
4) Within 0.5 seconds after the ABS warning light 8) Operation points will be displayed on the select
goes out, depress the brake pedal and hold it im- monitor.
mediately after the ignition switch is turned to ON.
CAUTION:
Do not depress the clutch pedal.
NOTE:
When the ignition switch is set to on, the brake
pedal must not be depressed.
Engine must not operate.
5 ) After completion of ABS sequence control, turn
the ignition switch OFF.
ABS-1 1
ABS SEQUENCE CONTROL
ABS
3. CONDITIONS FOR ABS SEQUENCE CONTROL
4 km/h Unit: second
- 10 km/h (6 MPH) or less
Speed of all wheels
Terminal No.3 and No.6

Operational LOW I I I
guide line of ON
sequence
control
Ignition key switch
OFF J 1.5 _IA j
I
j 1.5 1.4
w-v
i 1.0 i 1.4 Ljl
-1-
0.6
I
I
I
ABS warning light I
I
I ' I 1 I I 1 I
HIGH
Stop light switch
LOW
I
;
Withinm j I
I
!
I
1
!
1
1
!
I
I
!
I , I
I 1 I
AT ABS signal I1 1
I 1I
I I 1 I I 1 I I
I 1 I I
I I
I 1 I
I 1 I
II 1
1 I
OFF ! I 1 I
I 1 I
FL inlet valve ON j I1 1
1
I
OFF
Operational FR outlet valve ON j I
I
1
1
I
I
OFF' 1
I
I 1 I
.I 1. I
pattern of ON I I
I
1
1
I 1 I I I
I
I 1 I
FR inlet valve
sequence
control
I
I
I 1
1
I
I
1
1
I
I I 1
I
I I
I
I
I
RR outlet valve ON
OFF
j I
I
1
1
I
I
l
1
l
1
I
I
I
1I .
; 1 1 I 1 I
I
I 1
,
I I
RR inlet valve ON I I
I
1
1
I
I
1
1
I
I
I
I
I , Point A ~
I*
I 1
I
I
I
1
1
I
I
I
1
I
I
I
1
I
1
1
1
1
1
I
I
I
I
I
I
I
. .
I
I
I
I
I
I
I
1
1
1
1
1
1
1
I
I
I
I
I
I
I
I
I
I
I
I
I
I
n
I
Operational Pressure of master cylinder !

pressure of Pressure of FL wheel cylinder !
Pressure of FR wheel cvlinder !
sequence Pressure of RR wheel c h d e r l !
control IPressure of RL wheel cilinderl j / II
I
I
,
I
I .I
.I ,
I
I
I
. I
W
L
I I I
I
1
1
I
I
1
1
I
I
I
I
1
,
I
I i I B4M1001A
NOTE:
When the select monitor is used, control operation starts at point A. The patterns from IGN key ON to the
point A show that operation is started by diagnosis connector.
HIGH means high voltage.
LOW means low voltage.
ABS-I 2
ABS
~~ ~
4. CONDITIONS FOR COMPLETION OF

When the following conditions develop, the ABS
sequence control stops and ABS operation is re-
turned to the normal control mode.
1) When the speed of at least one wheel reaches
10 km/h (6 MPH).
2) When terminal No. 3 or No. 6 are separated from
diagnosis terminals. (When the select monitor is
not used.)
3) When the brake pedal is released during se-
quence control and the braking lamp switch is set
to OFF.
4) When the brake pedal is depressed after the ig-
nition key is turned to ON, and before ABS warning
light goes out. (When the select monitor is not
used.)
5 ) When the brake pedal is not depressed after the
ignition key is turned to ON, and within 0.5 seconds
after ABS warning light goes out. (When the select
monitor is not used.)
6) After completion of the sequence control.
7) When malfunction is detected. (When the select
monitor is used.)
ABS-1 3
FRONT ABS SENSOR
ABS
4. Front ABS Sensor 6) Remove the bolts which secure front ABS sen-
sor to housing, and remove the front ABS sensor.
A: REMOVAL CAUTION:
1) Disconnect the ground terminal from battery. Be careful not to damage the pole piece locat-
2) Jack-up the vehicle, support it with rigid racks, ed at tip of the sensor and teeth faces during re-
and remove the wheel. moval.
3) Disconnect the front ABS sensor connector lo- Do not pull the sensor harness during remov-
cated next to the front strut mounting house in en- ai.
gine compartment.
4) Remove the bolts which secure sensor harness
to strut.
B4M2209
5 ) Remove the bolts which secure sensor harness

to body.
(1) To front ABS sensor connector

(2) Bracket
ABS-14
FRONT ABS SENSOR 1
ABS
B: INSTALLATION 3) Place a thickness gauge between the ABS sen-

sor's and tone wheel's tooth face. After standard
1) Temporarily install the front ABS sensor on
clearance is obtained over the entire perimeter,
housing.
tighten the ABS sensor on housing to specified
CAUTION: torque.
Be careful not to strike the ABS sensor's pole
piece and tone wheel's teeth against adjacent ABS sensor standard clearance:
metal parts during installation. 0.3 - 0.8 mm (0.012 -
0.031 in)
Tightening torque:
32 N-m (3.3 kgf-m, 24 ft-16)
1
84M220E
2) Install the front ABS sensor on strut and wheel

apron bracket.
Tightening torque: CAUTION:
32 N-m (3.3 kgf-m, 24 ft-16) Check the marks on the harness to make sure
that no distortion exists.
RH: White
LH: Yellow
NOTE:
If the clearance is outside specifications, readjust.
4) After confirmation of the ABS sensor clearance,
connect the connector to ABS sensor.
5) Install the wheel.
1728C
I
(1) To front ABS sensor connector

(2) Bracket
ABS-15
FRONT ABS SENSOR
ABS
C: INSPECTION 2) Measure the distance “B” between the surface

where front axle housing meets the ABS sensor,
1. ABS SENSOR and the tone wheel.
1) Check the pole piece of the ABS sensor for for- NOTE:
eign particles or damage. If necessary, clean the Measure so that the gauge touches the tone wheel
pole piece or replace the ABS sensor. teeth top.
2) Measure the ABS sensor resistance.
B4M0248
(1) Axle housing
Terminal No. Standard (2) Tone wheel
1 and2 1.25f0.25 kQ
3) Find the gap between the ABS sensor pole face
and the surface of the tone wheel teeth by putting
the measured values in the formula below and cal-
culating.
ABS sensor clearance = B - A
ABS sensor standard clearance:
0.3 - 0.8 mm (0.012 - 0.031 in)
NOTE:
A
A
B4M2482A
ABS-I 6
1
FRONT ABS SENSOR
ABS
3. OUTPUT VOLTAGE D: ADJUSTMENT

Adjust the gap using spacer (Part No. 26755A000).
Output voltage can be checked by the following
method. Install a resistor and condenser, then ro-
tate the wheel about 2.75 km/h (2 MPH) or equiva-
lent.
NOTE:
Regarding terminal No., please refer to item 1. ABS
SENSOR.
+60 mV
-60
Standard output voltage:

0.12 - 1 v
(When it is 20 Hz) 1
Oscilloscope
_-
_-
LL --
--
r
ABS-1 7
REAR ABS SENSOR
ABS
5. Rear ABS Sensor B: INSTALLATION

1) Temporarily install the rear ABS sensor on back
A: REMOVAL plate.
1) Disconnect the ground terminal from battery. CAUTION:
2) Jack-up the vehicle, suppofl it with rigid racks, Be careful not to strike the ABS sensor's pole
and remove the wheel. piece and tone wheel's teeth against adjacent
3) Remove the rear seat and disconnect the rear metal parts during installation.
ABS sensor connector.
4) Remove the rear sensor harness bracket from
rear trailing link and bracket.
5) Remove the rear ABS sensor from back plate.
(1) Rear ABS sensor
link.
(1) Rear ABS sensor
Tightening torque:
32 N-m (3.3 kgf-m, 24 ff-lb)
(1) Rear sensor harness

(2) Trailing link
ABS-I 8
REAR ABS SENSOR
ia
ABS
3) Place a thickness gauge between the ABS sen- C: INSPECTION

sor’s and tone wheel’s tooth face. After standard
clearance is obtained over the entire perimeter, 1. ABS SENSOR
tighten the ABS sensor on rear arm to specified 1) Check the pole piece of the ABS sensor for for-
torque. eign particles or damage. If necessary, clean the
ABS sensor standard clearance: pole piece or replace the ABS sensor.
0.7- f.2mm(0.028-00.047in) 2) Measure the ABS sensor resistance.
Tightening torque:
32 N.m (3.3 kgf-m, 24 ff-lb) I
CAUTION:
Check the marks on the harness to make sure
RH: White
LH: Yellow
NOTE:
4) After confirmation of the ABS sensor clearance,
connect the connector to ABS sensor. Terminal No. Standard
~~~~ ~
CAUTION:
If resistance is outside the standard value, re-
place the ABS sensor with a new one.
Check the marks on the harness to make sure
RH: Light blue
LH: Brown
NOTE:
Check the ABS sensor cable for discontinuity. If
necessary, replace with a new one.
ABS-I 9
REAR ABS SENSOR
2. SENSORGAP 3. OUTPUT VOLTAGE

Clearances (sensor gaps) should be measured one Output voltage can be checked by the following
by one to ensure the tone wheel and speed sensor method. Install a resistor and condenser, then ro-
are installed correctly. tate the wheel about 2.75 km/h (2 MPH) or equiva-
NOTE: lent.
If clearance is narrow, adjust by using the spacer NOTE:
(Part No. 26755AA000). Regarding terminal No., please refer to item 1. ABS
If clearance is wide, check the outputted voltage SENSOR.
then replace the ABS sensor or tone wheel if the
outputted voltage is outside the specification. +60 mV
ABS sensor clearance:

0.7 -7.2 mm (0.028 - 0.047 in) -60 mV
Tone wheel 1 Standard output voltage:

0.12 - 1 v
--E=
(When it is 20 Hz)
Oscilloscope
%nsor gap BR0002 To terminal
To terminal
H4M1141P
D: ADJUSTMENT
Adjust the gap using spacer (Part No.
26755AA000).
ABS-20
FRONT TONE WHEEL
PI
ABS
6. Front Tone Wheel

A: REMOVAL
Refer to Front Drive Shaft, because the front tone
wheel is integrated with front drive shaft.
<Ref. to DS-32, REMOVAL, Front Drive Shaft.>
B: INSTALLATION
Refer to Front Drive Shaft, because the front tone
wheel is integrated with front drive shaft.
<Ref. to DS-32, INSTALLATION, Front Drive
Shaft.>
C: INSPECTION
Visually check the tone wheels teeth (44 pieces) for
cracks or dents. If necessary, replace the tone
wheel with a new one.
NOTE:
Replace the BJ assembly with a new one as a sin-
gle unit if there is any defect found on the tone
wheel, since it is unitized with the BJ assembly of
drive shaft.
ABS-21
REAR TONE WHEEL
ABS
7. Rear Tone Wheel

A: REMOVAL
Refer to Rear Drive Shaft, because the rear tone
wheel is integrated with hub.
<Ref. to DS-23, REMOVAL, Rear Axle.>
B: INSTALLATION
Refer to Rear Drive Shaft, because the rear tone
wheel is integrated with hub.
<Ref. to DS-26, INSTALLATION, Rear Axle.>
C: INSPECTION
Visually check the tone wheels teeth (44 pieces) for
cracks or dents. If necessary, replace the tone
wheel with a new one.
ABS-22
1
G SENSOR
ABS
8. GSensor B: INSTALLATION
A: REMOVAL CAUTION:
1) Disconnect the ground terminal from battery. Do not drop or bump the G sensor.
Tightening torque (G sensor):
32 N.m (3.3 kgf-m, 24 ft-lb)
2) Remove the console cover.

<Ref. to El-41, Console Box.>
3) Disconnect the connector from G sensor.
4) Remove the G sensor from body.
CAUTION:
Do not drop or bump the G sensor.
ABS-23
G SENSOR
ABS
C: INSPECTION
Step Check Yes No
CHECK SUBARU SELECT MONITOR. Do you have the SUBARU 30 to step 5. Go to step 2.
SELECT MONITOR?
I CHECK G SENSOR. Is the voltage 2.3k0.2 V when 30 to step 3. Replace G sensor.
1)Turn the ignition switch to OFF. G sensor is horizontal?
2)Remove the G sensor from vehicle.
3)Connect the connector to G sensor.
5)Measure the voltage between G sensor con-
nector terminals.
Connector & terminal:
(8292) NO.2 (+) - NO. 3 (-)
I CHECK G SENSOR. Is the voltage 3.9k0.2 V when
Measure the voltage between G sensor con- G sensor is inclined forwards
nector terminals. to go"?
(8292) NO.2 (+) - NO. 3 (-)
I CHECK G SENSOR.
Measure the voltage between G sensor con-
nector terminals.
G sensor is inclined backwards
to go"?
nd/
Is the voltage 0.7f0.2 V when 3 sensor is nor- Replace G sensor.

(8292) NO.2 (+) - NO. 3 (-)
I CHECK G SENSOR. Is the indicated reading 30 to step 6. Replace G sensor.
1)Turn the ignition switch to OFF. 2.3f0.2 V when the vehicle is
2)Connect the select monitor connector to data in horizontal position?
link connector.
3)Turn the select monitor into (BRAKE CON-
TROL} mode.
4)Set the display in the {Current Data Display
& Save} mode.
5)Read the G sensor output voltage.
I CHECK G SENSOR. Is the indicated reading
1)Remove the console box. 3.9f0.2 V when G sensor is
2)Remove the G sensor from vehicle. (Do not inclined forwards to go"?
disconnect connector.)
3)Read the select monitor display.
CHECK G SENSOR. Is the indicated reading 3 sensor is nor- Replace G sensor.
Read the select monitor display. 0.7k0.2 V when G sensor is nal.
inclined backwards to go"?
ABS-24
ABS (DIAGNOSTICS)
ABS
Page
4. Electrical Components Location................................................................ 12
5. Control Module I/O Signal ......................................................................... 14
7. Read Diagnostic Trouble Code (DTC) ...................................................... 20
8. Inspection Mode ........................................................................................ 21
10. ABS Warning Light Illumination Pattern .................................................... 23
11. List of Diagnostics Trouble Code (DTC) ................................................... 24
12. Diagnostics Chart with Diagnosis Connector ............................................ 29
13. Diagnostics Chart with Subaru Select Monitor .......................................... 96
14. General Diagnostics Table ...................................................................... 183
ABS (DIAGNOSTICS)

A: PROCEDURE
CAUTION:
Remove foreign matter (dust, water, etc.) from the ABSCM&H/U connector during removal and instal-
lation.
NOTE:
To check harness for broken wires or short circuits, shake it while holding it or the connector.
When the ABS warning light illuminates, read and record the diagnostic trouble code (DTC) indicated by
ABS warning light.
Step Check Yes No

I CHECK PRE-INSPECTION. Is unit that might influence the Go to step 2. Repair or replace
1)Ask the customer when and how the trouble ABS problem normal? each unit.
occurred using interview checklist. <Ref. to
ABS-6, Check List for Interview.>
2)Before performing diagnosis, inspect the unit
which might influence the ABS problem. <Ref.
to ABS-9, INSPECTION, General Descrip-
tion.>
! CHECK INDICATION OF DIAGNOSTIC Is the diagnostic trouble code Go to step 3. Inspect using diag
TROUBLE CODE (DTC). nostic chart for
Calling up diagnostic trouble code (DTC). ABS warning light
<Ref. to ABS-20, Read Diagnostic Trouble failure.cRef. to
Code (DTC).> ABS-29, Diagnos-
tics Chart with
Diagnosis Con-
nector.>
NOTE:
Call up diagnostic
trouble code (DTC]
again after inspect.
ing ABS warnins
light. <Ref. to ABS.
20, Read Diagnos
tic Trouble Code
(DTC).>
I CHECK DIAGNOSTIC TROUBLE CODE Is only the start code issued? Go to step 4. Go to step 5.
(DTC).
NOTE:
Record all diagnostic trouble codes (DTC).
I PERFORM THE GENERAL DIAGNOSTICS. Is only the start code issued? IComplete the Go to step 5.
1)Inspect using “General Diagnostics Table”. diagnosis.
<Ref. to ABS-I 83, General DiagnosticsTable.>
2)Perform the clear memory mode. <Ref. to
ABS-22, WITHOUT SUBARU SELECT MONI-
TOR, OPERATION, Clear Memory Mode.>
3)Perform the inspection mode. <Ref. to ABS-
21, Inspection Mode.>
Calling up the diagnostic trouble code (DTC).
<Ref. to ABS-20, Read Diagnostic Trouble
Code (DTC).>
ABS-2
m
ii
ABS (DIAGNOSTICS)
Step Check Yes No

) PERFORM THE DIAGNOSIS. Is only the start code issued? 2omplete the Inspect using
1)lnspect using “Diagnostics Chart with Diag- iiagnosis. “DiagnosticsChart
nostic Connectof.<Ref. to ABS-29, Diagnos- with Diagnostic
tics Chart with Diagnosis Connector.> Connectof. <Ref.
NOTE: to ABS-29, Diag-
For diagnostic trouble code (DTC) list, refer tc nostics Chart with
“List of DiagnosticsTrouble Code (DTC)”.<Ref. Diagnosis Con-
to ABS-24, WITHOUT SUBARU SELECT nector.>
MONITOR, LIST, List of Diagnostics Trouble
Code (DTC).>
2)Repair the trouble cause.
ABS-22, WITHOUT SUBARU SELECT MONI-
TOR, OPERATION, Clear Memory Mode.>
I
5)Calling up the diagnostic trouble code (DTC).
I
<Ref. to ABS-20, Read Diagnostic Trouble
Code (DTC).>
ABS-3
ABS (DIAGNOSTICS)

CAUTION:
Remove foreign matter (dust, water, etc.) from the ABSCM&H/U connector during removal and instal-
lation.
NOTE:
To check harness for broken wires or short circuits, shake it while holding it or the connector.
Check the list for interview. <Ref. to ABS-26, WITH SUBARU SELECT MONITOR, LIST, List of Diagnos-
tics Trouble Code (DTC).>
Step Check Yes No

CHECK PRE-INSPECTION. Is unit that might influence the o
; to step 2. lepair or replace
1)Ask the customer when and how the trouble ABS problem normal? !ach unit.
occurred using interview checklist. <Ref. to
ABS-6, Check List for Interview.>
2)Before performing diagnosis, inspect the unit
which might influence the ABS problem. <Ref.
to ABS-9, INSPECTION, General Descrip-
tion.>
CHECK INDICATION OF TROUBLE CODE Is the corresponding trouble 30 to step 3. ;o to step 4.
DISPLAY. encoding?
2)Connect the SUBARU SELECT MONITOR
to data link connector.
3)Turn the ignition switch to ON and SUBARU
SELECT MONITOR to ON.
NOTE:
If the communication function of the selec
monitor cannot be executed normally, check
the communication circuit. <Ref. to ABS-96
COMMUNICATION FOR INITIALIZING IM.
POSSIBLE, Diagnostics Chart with Subaru Se,
lect Monitor.>
4)Read the diagnostic trouble code (DTC).
<Ref. to ABS-19, READ CURRENT DATA,
OPERATION, Subaru Select Monitor.>
5)Record all diagnostic trouble codes (DTC)
and frame data.
PERFORM THE GENERAL DIAGNOSTICS. IS no diagnostic trouble code 2omplete the ;o to step 4.
1)lnspect using “General Diagnostics Table”. :DTC) designated and ABS liagnosis.
<Ref. to ABS-183, General DiagnosticsTable.> Narning light goes out after
2)Perform the clear memory mode. <Ref. to :urning on?
ABS-19, CLEAR MEMORY MODE, OPERA-
TION, Subaru Select Monitor.>
4)Calling up the diagnostic trouble code (DTC).
<Ref. to ABS-I 8, READ DIAGNOSTIC TROU-
BLE CODE (DTC), OPERATION, Subaru
Select Monitor.>
ABS-4
1
ABS (DIAGNOSTICS)
Step Check Yes No

I PERFORM THE DIAGNOSIS. Is no diagnostic trouble code Complete the Inspect using
1)lnspect using “Diagnostics Chart with Sub- (DTC) designated and does diagnosis. “DiagnosticsChart
aru Select Monitor”.<Ref. to ABS-96, Diagnos- ABS warning light go out after with Subaru Select
tics Chart with Subaru Select Monitor.> turning on? Monitor”. <Ref. to
NOTE: ABS-96, Diagnos-
tics Chart with
Subaru Select
Monitor.>
ABS-5
ABS (DIAGNOSTICS)
2. Check List for Interview

A: CHECK
Check the following items about the vehicle's state.
1. STATE OF ABS WARNING LIGHT
ABS warning light 0 Always
comes on. CI Sometimes
U Only once
CI Does not come on
When / how long does it come on?:
Ignition key position CI LOCK
CI ACC
CI ON (before starting engine)
CI START
CI On after starting (Engine is running)
0 On after starting (Engine is stop)
Timing CI Immediately after ignition is ON.
Q Immediately after ignition starts.
CI When advancing km/h to km/b
MPHto MPF
0 While traveling at a constant speed km/h I MPF
Q When decelerating km/h to km/b
MPHto MPF
Steering time : sec

Q When turning to left Steering angle : deg
1 Steering time : sec
Parts name :
Operating condition :
ABS-6
ABS (DIAGNOSTICS)
2. SYMPTOMS
4BS operating condi-
tion c1 Operates only when abruptly applying brakes.
*How to steD on brake pedal

Vehicle speed :
t km/h
MPH
a) Operating time : sec
What kind of noise? D Knock

D Gong gong
D Bong
D Buzz
D Gong gong buzz
D Others :
D Stick
D Press down once with a clunk
c1 Press and released
D Others :
Behavior of vehicle a) Directional stability cannot be obtained or steering arm refuses to work when applying brakes :
D Yes/ D No
When : I D Vehicle turns to right
When : D Vehicle turns to right

c1 Vehicle turns to left
CI Spins
D Others :
What : 0 Braking distance is long

D Brakes lock or drag
D Pedal stroke is long
c1 Pedal sticks
D Others :
What : c1 Fails to accelerate

D Engine stalls
D Others :
Where
What kind :
f) Occurrence of abnormal noise : P Yes / D No
Where
What kind :
a) Occurrence of other Dhenomena : D Yes / D No
What kind :
ABS-7
ABS (DIAGNOSTICS)
3. CONDITIONS UNDER WHICH TROUBLE OCCURS

:nvironment a) Weather 3 Fine
Ll Cloudy
CI Rainy
U Snowy
U Various/Others :
b) Ambient temperature OF ("C)
c) Road F u r b a n area
0 Suburbs
U Highway
U General road
U Ascending slope
U Descending slope
U Paved road
U Gravel road
U Muddy road
U Sandy place
U Others :
d) Road surface U Dry
CI Wet
U New-fallen snow
U Compressed snow
U Frozen slope
U Others :
2ondition a) Brakes Deceleration : g
U Continuous / U Intermittent
b) Accelerator Acceleration : 9
D Continuous / U Intermittent
c) Vehicle speed km/h I MPH
U Advancing
U Accelerating
U Reducing speed
CI Low speed
CI Turning
U Others :
d) Tire inflation pressure Front RH tire : kPa
Front LH tire : kPa
Rear RH tire : kPa
Rear LH tire : kPa
e) Degree of wear Front RH tire
Front LH tire :
Rear RH tire :
Rear LH tire :
f) Genuine parts are used. : 0 Yes / U No
g) Chain is passed around tires. : U Yes / U No
h) T tire is used. : U Yes / Q No
i) Condition of suspension alignment :
j) Loading state :
k) Repair parts are used. : U Yes / Q No
What :
I) Others :
ABS-8
GENERAL DESCRIPTION a
ABS (DIAGNOSTICS)
3. General Description B: INSPECTION

Before performing diagnostics, check the following
A: CAUTION items which might affect ABS problems:
1. SUPPLEMENTAL RESTRAINT SYSTEM 1. BATTERY
“AIR BAG” Measure the battery voltage and specific gravity of
The airbag system wiring harness is routed near electrolyte.
the ABS sensor, ABS control module and hydraulic
control unit. Standard voltage: 12 V, or more
CAUTION: Specific gravity: Above 1.260

All Airbag system wiring harness and con- 2. BRAKE FLUID
cal test equipment on these circuit. 1) Check the brake fluid level.
Be careful not to damage the Airbag system 2) Check for brake fluid leakage.
wiring harness when servicing the ABS sensor, 3. HYDRAULIC UNIT
ABS control module and hydraulic control unit.
Check the hydraulic unit.
With brake tester <Ref. to ABS-9, CHECKING
THE HYDRAULIC UNIT ABS OPERATION WITH
BRAKE TESTER, INSPECTION, ABS Control
Module and Hydraulic Control Unit (ABSCM&H/
U).>
Without brake tester <Ref. to ABS-8, CHECK-
ING THE HYDRAULIC UNIT ABS OPERATION
BY PRESSURE GAUGE, INSPECTION, ABS
Control Module and Hydraulic Control Unit (AB-
SCM&H/U).>
4. BRAKEDRAG
Check for brake drag.
5. BRAKE PAD AND ROTOR
Check the brake pad and rotor.
Front <Ref. to BR-17, INSPECTION, Front
Brake Pad.> and <Ref. to BR-18, INSPECTION,
Front Disc Rotor.>
Rear <Ref. to BR-24, INSPECTION, Rear
Brake Pad.> and <Ref. to BR-26, INSPECTION,
Rear Disc Rotor.> or <Ref. to BR-31, INSPEC-
TION, Rear Drum Brake Shoe.> and <Ref. to BR-
32, INSPECTION, Rear Drum Brake Drum.>
6. TIRE
Check the tire specifications, tire wear and air pres-
sure. <Ref. to WT-2, SPECIFICATIONS, General
Description.>
GENERAL DESCRIPTION
ABS (DIAGNOSTICS)
C: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION I TOOL NUMBER DESCRIPTION REMARKS

24082AA150 CARTRIDGE Troubleshooting for electrical systems.
B2M3876
KIT 1 English: 22771AA030 (Without printer)
1 German: 22771AA070 (Without printer)
1 French: 22771AA080 (Without printer)

1 Spanish: 22771AA090 (Without printer)
B2M3877
I TOOL NAME I REMARKS I

Circuit tester 1 Used for measuring resistance, voltage and ampere.
Oscilloscope I Used for measuring sensor.
ABS-I 0
GENERAL DESCRIPTION
ABS (DIAGNOSTICS)
ABS-I 1
ABS (DIAGNOSTICS)

A: LOCATION
(1) ABS control module and hydraulic (5) Data link connector (for Subaru (8) ABS sensor
control unit (ABSCM&H/U) select monitor) (9) Wheel cylinder
(2) Proportioning valve (6) Transmission control module (only (10) G sensor
(3) Diagnosis connector AT vehicle) (1 1) Stop light switch
(4) ABS warning light (7) Tone wheel (12) Master cylinder
ABS-12
ABS IDIAGNOSTICS)
(4 BR0079
64M1226B
\I - I
BR0056
REAR
(7)
ABS-I 3
CONTROL MODULE I/O SIGNAL
ABS (DIAGNOSTICS)
5. Control Module I/O Signal

ABS control module and

hydraulic control unit connector
I
Connector switch
B4M1220A
NOTE:
The terminal numbers in the ABS control module and hydraulic control unit connector are as shown in the
figure.
When the connector is removed from the ABSCM&H/U, the connector switch closes the circuit between
terminal No. 22 and No. 23. The ABS warning light illuminates.
ABS-14
a
ABS (DIAGNOSTICS)
Terminal No. InputlOutput signal

Contents
(+)-(-) Measured value and measuring conditions
Front left wheel 9-1 0
ABS sensor*2 Front right wheel 11-12 0.12- 1 v
(Wheel speed sensor) Rear left wheel 7-8 (When it is 20 Hz.)
I Rear rightwheel 14-1 5
Valve relay power supply 24-23 10-15V
Motor relay power supply 25-23 10-15V
power supply 30-28 4.75 - 5.25 V
G sensor*2 ground 28 -
output 6-28 2.3f0.2 V when the vehicle is in horizontal position.
Less than 1.5 V when the stop light is OFF and, 10 - 15 V
Stop light switch*l 2-23
. liaht
when the stoD * is ON.
Less than 1.5 V during 1.5 seconds when ignition switch is ON,
ABS warning light*2 22-23
and 10 - 15 V after 1.5 seconds.
AT ABS signal*2 Less than 1.5 V when the ABS control still operates and more
31-23
(AT model only) than 5.5 V when ABS does not operate.
Less than 1.5 V when the ABS control still operates and more
ABS operation signal monitor*2 3-23
than 5.5 V when ABS does not operate.
Data is received. 20-23 Less than 1.5 V when no data is received.
Select monitor*2
Data is sent. 5-23 4.75 - 5.25 V when no data is sent.
ABS diagnosis connec- Terminal No. 3 29-23 10 - 15 V when the ignition switch is ON.
tor*2 Terminal No. 6 4-23 10 - 15 V when the ignition switch is ON.
Power supply*l 1-23 10 - 15 V when the ignition switch is ON.
Grounding line 23 -
Grounding line 26 -
ABS-I 5
ABS (DIAGNOSTICS)
B: SCHEMATIC
BR0108
ABS control module and hydraulic (9) Front right outlet solenoid valve (17) ABS warning light
control unit (ABSCM&H/U) (10 ) Rear left inlet solenoid valve (18) Stop light switch
ABS control module area (11) Rear left outlet solenoid valve (19) Stop light
Valve relay (12) Rear right inlet solenoid valve (20) G sensor
Motor relay (13) Rear right outlet solenoid valve (21) Front left ABS sensor
Motor (14) Transmissioncontrol module (only (22) Front right ABS sensor
Front left inlet solenoid valve AT model) (23) Rear left ABS sensor
Front left outlet solenoid valve (15 ) Diagnosis connector (24) Rear right ABS sensor
Front right inlet solenoid valve (16) Data link connector
ABS-I 6
CONTROL MODULE I/O SIGNAL ABS (DIAGNOSTICS)
C: WAVEFORM
ABS sensor
[VI
Terminal NO.
9 - 10 Standard output
11 - 1 2 voltage at 20 Hz:
7 - 8 0.12 - 1 v
14 - 15
B4M2526A
ABS-I 7
ABS (DIAGNOSTICS)
6. Subaru Select Monitor 5) Turn the ignition switch to ON (engine OFF) and
Subaru Select Monitor switch to ON.
A: OPERATION
1. READ DIAGNOSTIC TROUBLE CODE
WC)
1) Prepare the Subaru Select Monitor kit.
” S2M0288D
(1) Power switch
6) On the ((Main Menu)) display screen, select the

2) Connect the diagnosis cable to Subaru Select screen, select the {Brake Control System} and
Monitor. press the [YES] key.
3) Insert the cartridge into Subaru Select Monitor. 8) Press the [YES] key after displayed the informa-
<Ref. to ABS-IO, SPECIAL TOOLS, PREPARA- tion of engine type.
TION TOOL, General Description.> 9) On the ((ABS Diagnosis))display screen, select
the {Diagnostic Code(s) Display} and press the
[YES] key.
10) On the ((Diagnostic Code@) Display)) display
screen, select the {Current Diagnostic Code(s)} or
{History Diagnostic Code(s)} and press the [YES]
key.
NOTE:
UAL.
S2M0286 For detailed concerning diagnostic trouble codes
4) Connect the Subaru Select Monitor to data link (DTC), refer to the LIST OF DIAGNOSTICSTROU-
connector. BLE CODE (DTC). <Ref. to ABS-24, List of Diag-
(1) Data link connector is located in the lower nostics Trouble Code (DTC).>
portion of the instrument panel (on the driver’s
side).
I
(2) Connect the diagnosis cable to data link

connector.
ABS-18
FR Wheel Speed Wheel speed detected by the Front Right ABS sensor is displayed km/h or MPH
FL Wheel Speed Wheel speed detected by the Front Left ABS sensor is displayed km/h or MPH
RR Wheel Speed Wheel speed detected by the Rear Right ABS sensor is displayed km/h or MPH
RL Wheel Speed Wheel speed detected by the Rear Left ABS sensor is displayed km/h or MPH
Stop Light Switch Stop light switch signal ON or OFF
Stop Light Switch Stop light switch monitor voltage is displayed. V
Refers to vehicle acceleration detecting by the analog G sensor. It
G sensor output Signal V
appears on the select monitor display in volts.
ON or OFF
Valve Relay Signal Valve Relay Signal
I e I a v Signal 1 Motor Relay Signal I ON or OFF I

I ABS Signal to TCM 1 ABS operation signal from ABS control module to TCM
I ON or OFF
ABS Warning Lamp ON operation of the ABS warning light is displayed. ON or OFF
Motor Relay Monitor Operating condition of the motor relay is displayed. ON or OFF
ON or OFF
Valve Relay Monitor Operating condition of the valve relay is displayed.
ON or OFF
CCM Signal ABS operation signal from ABS control module to TCM
I I I 1
NOTE:
3. CLEAR MEMORY MODE
1) On the ((Main Menu. display screen, select the {2. Each System Check} and press the ((YES))key.
2) On the ((SystemSelect Menu))display screen, select {Brake System} and press the ((YES))key.
3) Press the ((YES))key after displayed the information of engine type.
4) On the (<BrakeControl Diagnosis,) display screen, select the {Clear Memory} and press the ((YES), key.
5 ) When the “Done” and “turn ignition switch O F F are shown on the display screen, turn the Subaru Select
Monitor and ignition switch to OFF.
NOTE:
ABS-1 9
READ DIAGNOSTIC TROUBLE CODE (DTC)
ABS (DIAGNOSTICS)
7. Read Diagnostic Trouble 2) Turn the ignition switch OFF.

3) Connect the diagnosis connector terminal 6 to
Code (DTC) diagnosis terminal.
A: OPERATION 4) Turn the ignition switch ON.
5) ABS warning light is set in the diagnostic mode
1. WITHOUT SUBARU SELECT MONITOR and blinks to identify diagnostic trouble code
(DTC).
1) Take out the diagnosis connector from side of
driver's seat heater unit. 6) After the start code (1 1) is shown, the diagnostic
trouble code (DTC) will be shown in order of the last
information first.
These repeat for a maximum of 3 minutes.
NOTE:
When there are no diagnostic trouble code
(DTC) in memory, only the start code (1 1) is shown.
When on-board diagnosis of the ABS control
module detects a problem, the information (up to a
maximum of three) will be stored in the EEP ROM
as a diagnostic trouble code (DTC). When there
BRO110 are more than three, the most recent three will be
stored. (Stored codes will stay in memory until they
(1) Diagnosis connector are cleared.)
(2) Diagnosis terminals
(3) 3 terminal
(4) 6 terminal
Example of DTC indication
DTC: 21
^.. 1 1 2 1 1 1 2 1
k-! 0.3 sec 0.3 sec \L 0.3 sec

DTC: 21 Start code DTC: 21
I DTC: 22,31
1 1 2 2 3 1 1 1
Start code DTC: 22 DTC: 31 Start code
BR0081

Refer to SUBARU SELECT MONITOR for information about how to obtain and understand the diagnostic
trouble code (DTC). <Ref. to ABS-18, Subaru Select Monitor.>
ABS-20
INSPECTION MODE I
ABS (DIAGNOSTICS)
8. Inspection Mode
A: OPERATION
Reproduce the condition under which the problem
has occurred as much as possible.
Drive the vehicle at a speed more than 40 km/h (25
MPH) for at least one minute.
ABS-21
CLEAR MEMORY MODE
ABS (DIAGNOSTICS)
9. Clear Memory Mode

A: OPERATION
1) After calling up a diagnostic trouble code (DTC),
disconnect the diagnosis connector terminal 6 from
diagnosis terminal.
(1) Diagnosis connector

(2) Diagnosis terminals
(3) 3 terminal
(4) 6 terminal
2) Repeat 3 times within approx. 12 seconds; connecting and disconnecting terminal 6 and diagnosis termi-
nal for at least 0.2 seconds each time.
Diagnostic trouble code (DTC) indicatione mode

-- a
Memory erase mode
GND(Low level) GND open (High level)

Terminal 8
0.2 sec 0.2 sec or more

or more
12 sec or less
BR0082
NOTE:
After diagnostics is completed, make sure to clear memory. Make sure only start code (1 1) is shown after
memory is cleared.
Refer to SUBARU SELECT MONITOR for information about how to clear the diagnostic trouble code (DTC).
<Ref. to ABS-18, Subaru Select Monitor.>
ABS-22
ABS WARNING LIGHT ILLUMINATION PATTERN
ABS (DIAGNOSTICS)
1O.ABS Warning Light Illumination Pattern

A: INSPECTION
START
Ignition key switch

OFF '-I
Goes out. Goes out.

ABS warning light
1.5 s
~ 4 ~ 0 7A8 1
1) When the ABS warning light does not illuminate in accordance with this illumination pattern, there must be
an electrical malfunction.
2) When the ABS warning light remains constantly OFF, repair the ABS warning light circuit or diagnosis cir-
cuit. <Ref. to ABS-29, Diagnostics Chart with Diagnosis Connector.>
NOTE:
Even though the ABS warning light does not go out 1.5 seconds after it illuminates, the ABS system operates
normally when the warning light goes out while driving at approximately 12 km/h (7 MPH). However, the Anti-
lock brakes do not work while the ABS warning light is illuminated.
ABS-23
LIST OF DIAGNOSTICS TROUBLE CODE (DTC)
ABS (DIAGNOSTICS)
11.List of Diagnostics Trouble Code (DTC)

A: LIST
3TC No Contents of diagnosis Index No.
Start code
11 DTC is shown after start code. -
Only start code is shown in normal condition.
<Ref. to ABS-40, DTC 21 ABNORMAL ABS SENSOR (OPEN CIR-
21 Front right ABS sensor CUIT OR INPUT VOLTAGE TOO HIGH) (FRONT RH), Diagnostics
Chart with Diagnosis Connector.>
23 Front left ABS sensor CUIT OR INPUT VOLTAGE TOO HIGH) (FRONT LH), Diagnostics
Abnormal ABS sensor Chart with Diagnosis Connector.>
(Open circuit or input
voltage too high) <Ref. to ABS-40, DTC 25 ABNORMAL ABS SENSOR (OPEN CIR-
25 Rear right ABS sensor CUIT OR INPUT VOLTAGE TOO HIGH) (REAR RH), Diagnostics
27 Rear left ABS sensor CUIT OR INPUT VOLTAGE TOO HIGH) (REAR LH), Diagnostics
Chart with Diaanosis Connector.>
s
<Ref. to ABS-46, DTC 22 ABNORMAL ABS SENSOR (FRONT RH),

22 Front right ABS sensor
Diagnostics Chart with Diagnosis Connector.>
~
24 Front left ABS sensor I <Ref. to ABS-46, DTC 24 ABNORMAL ABS SENSOR (FRONT LH),
Diaanostics
u Chart with Diaanosis Connector.>
I
Abnormal ABS sensor <Ref to ABS-46, DTC 26 ABNORMAL ABS SENSOR (REAR RH),
26 Rear r'ght ABS
(Abnormal ABS sen- Diaanostics Chart with Diaanosis Connector.>
sor signal) <Ref. to ABS-47, DTC 28 ABNORMAL ABS SENSOR (REAR LH),
28 Rear left ABS sensor
<Ref. to ABS-53, DTC 29 ABNORMAL ABS SENSOR SIGNAL
29 Any one of four (ANY ONE OF FOUR), Diagnostics Chart with Diagnosis Connec-
tor.>
<Ref. to ABS-57, DTC 31 ABNORMAL INLET SOLENOID VALVE
31 Front right inlet valve ClRCUIT(S) IN ABSCM&H/U (FRONT RH), Diagnostics Chart with
Diagnosis Connector.>
<Ref. to ABS-61, DTC 32 ABNORMAL OUTLET SOLENOID VALVE
32 Front right outlet valve CIRCUIT(S) IN ABSCM&H/U (FRONT RH), Diagnostics Chart with
33 Front left inlet valve CIRCUIT(S) IN ABSCM&H/U (FRONT LH), Diagnostics Chart with
1 <Ref. to ABS-61, DTC 34 ABNORMAL OUTLET SOLENOID VALVE
34 Abnormal solenoid Front left outlet valve CIRCUIT(S) IN ABSCM&H/U (FRONT LH), Diagnostics Chart with
valve circuit(s) in ABS Diagnosis Connector.>
control module and <Ref. to ABS-57, DTC 35 ABNORMAL INLET SOLENOID VALVE
35 hydraulic unit Rear right inlet valve CIRCUIT(S) IN ABSCM&H/U (REAR RH), Diagnostics Chart with
36 Rear right outlet valve CIRCUIT(S) IN ABSCM&H/U (REAR RH), Diagnostics Chart with
37 Rear left inlet valve CIRCUIT(S) IN ABSCM&H/U (REAR LH), Diagnostics Chart with
38 Rear left outlet valve ClRCUIT(S) IN ABSCM&H/U (REAR LH), Diagnostics Chart with
ABS-24
ABS (DIAGNOSTICS)
DTC No. Contents of diagnosis Index No.

<Ref. to ABS-66, DTC 41 ABNORMAL ABS CONTROL MODULE,
41 Abnormal ABS control module
<Ref. to ABS-69, DTC 42 SOURCE VOLTAGE IS ABNORMAL.,
42 Source voltage is abnormal.
<Ref. to ABS-74, DTC 44 A COMBINATION OF AT CONTROL
44 A combination of AT control abnormal
ABNORMAL, Diagnostics Chart with Diagnosis Connector.>
<Ref. to ABS-77, DTC 51 ABNORMAL VALVE RELAY, Diagnostics
51 Abnormal valve relay
<Ref. to ABS-81, DTC 52 ABNORMAL MOTOR AND/OR MOTOR
52 Abnormal motor and/or motor relay
RELAY, Diagnostics Chart with Diagnosis Connector.>
<Ref. to ABS-86, DTC 54 ABNORMAL STOP LIGHT SWITCH,
54 Abnormal stop light switch
<Ref. to ABS-89, DTC 56 ABNORMAL G SENSOR OUTPUT VOLT-
56 Abnormal G sensor output voltage
AGE. Diaanostics Chart with Diaanosis Connector.>
ABS-25
ABS (DIAGNOSTICS)

DTC
Display screen Contents of diagnosis Index No.
No.
- Communication for ini- Select monitor commu- <Ref. to ABS-96, COMMUNICATION FOR INITIALIZING IMPOSSI-
tializing impossible nication failure BLE, Diagnostics Chart with Subaru Select Monitor.>
- I No trouble code
Although no trouble
code appears on the
select monitor display,
the ABS warning light
remains on.
<Ref. to ABS-101, NO TROUBLE CODE, Diagnostics Chart with
Subaru Select Monitor.>
Open or short circuit in Open or short circuit in <Ref. to ABS-104, DTC 21 OPEN OR SHORT CIRCUIT IN FRONT
21 front right ABS sensor front right ABS sensor RIGHT ABS SENSOR CIRCUIT, Diagnostics Chart with Subaru
circuit circuit Select Monitor.>
Front right ABS sensor Front right ABS sensor <Ref. to ABS-110, DTC 22 FRONT RIGHT ABNORMAL ABS SEN-
22
abnormal signal abnormal signal SOR SIGNAL, Diagnostics Chart with Subaru Select Monitor.>
Open or short circuit in Open or short circuit in <Ref. to ABS-104, DTC 23 OPEN OR SHORT CIRCUIT IN FRONT
23 front left ABS sensor front left ABS sensor LEFT ABS SENSOR CIRCUIT, DiagnosticsChart with Subaru Select
circuit circuit Monitor.>
Front left ABS sensor Front left ABS sensor <Ref. to ABS-110, DTC 24 FRONT LEFT ABNORMAL ABS SEN-
24
Open or short circuit in Open or short circuit in <Ref. to ABS-104, DTC 25 OPEN OR SHORT CIRCUIT IN REAR
25 rear right ABS sensor rear right ABS sensor RIGHT ABS SENSOR CIRCUIT, Diagnostics Chart with Subaru
circuit circuit Select Monitor.>
Rear right ABS sensor Rear right ABS sensor <Ref. to ABS-1 10, DTC 26 REAR RIGHT ABNORMAL ABS SEN-
26
Open or short circuit in Open or short circuit in <Ref. to ABS-105, DTC 27 OPEN OR SHORT CIRCUIT IN REAR
27 rear left ABS sensor rear left ABS sensor LEFT ABS SENSOR CIRCUIT, DiagnosticsChart with Subaru Select
circuit circuit Monitor.>
Rear left ABS sensor Rear left ABS sensor <Ref. to ABS-1 11, DTC 28 REAR LEFT ABNORMAL ABS SENSOR
28
abnormal signal abnormal signal SIGNAL, Diagnostics Chart with Subaru Select Monitor.>
Abnormal ABS sensor Abnormal ABS sensor <Ref. to ABS-117, DTC 29 ABNORMAL ABS SENSOR SIGNAL ON
29 signal on any one of signal on any one of ANY ONE OF FOUR SENSOR, Diagnostics Chart with Subaru
four sensor four Select Monitor.>
Front right inlet valve Front right inlet valve <Ref. to ABS-121, DTC 31 FRONT RIGHT INLET VALVE MAL-
31
malfunction malfunction FUNCTION, Diagnostics Chart with Subaru Select Monitor.>
Front right outlet valve Front right outlet valve <Ref. to ABS-125, DTC 32 FRONT RIGHT OUTLET VALVE MAL-
32
malfunction malfunction FUNCTION, Diagnostics Chart with Subaru Select Monitor.> '
Front left inlet valve Front left inlet valve <Ref. to ABS-121, DTC 33 FRONT LEFT INLET VALVE MALFUNC-
33
malfunction malfunction TION, Diagnostics Chart with Subaru Select Monitor.>
Front left outlet valve Front left outlet valve <Ref. to ABS-125, DTC 34 FRONT LEFT OUTLET VALVE MAL-
34
Rear right inlet valve Rear right inlet valve <Ref. to ABS-121, DTC 35 REAR RIGHT INLET VALVE MALFUNC-
35
Rear right outlet valve Rear right outlet valve <Ref. to ABS-125, DTC 36 REAR RIGHT OUTLET VALVE MAL-
36
Rear left inlet valve Rear left inlet valve <Ref. to ABS-121, DTC 37 REAR LEFT INLET VALVE MALFUNC-
37
Rear left outlet valve Rear left outlet valve <Ref. to ABS-125, DTC 38 REAR LEFT OUTLET VALVE MALFUNC-
38
1
1
i 1I A D C A--4"-l --A..l-
MPO l.UIIlIUI IIIUUUIG
malfunction
I ABS controlmodule I Cnel. LO H nD m3 - I dl0, DTC 41 ABS CONTROL MODULE MALFUNC-
and hydraulic control
unit malfunction
I .n-S I- A 4-
TION, Diagnostic:s Chart with Subaru Select Monitor.>

Power supply voltage Power supply voltage <Ref. to ABS-132, DTC 42 POWER SUPPLY VOLTAGE TOO LOW,
42
too low too low Diagnostics Chart with Subaru Select Monitor.>
Power supply voltage Power supply voltage <Ref. to ABS-134, DTC 42 POWER SUPPLY VOLTAGE TOO HIGH,
42
too high too high Diagnostics Chart with Subaru Select Monitor.>
ABS-26
a
ABS (DIAGNOSTICS)
' L'
Display screen Contents of diagnosis Index No.
No.
ABS-AT control (Non ABS-AT control (Non <Ref. to ABS-138, DTC 44 ABS-AT CONTROL (NON CON-
44
Controlled) Controlled) TROLLED), Diagnostics Chart with Subaru Select Monitor.>
ABS-AT control (Con- ABS-AT control (Con- <Ref. to ABS-I 40, DTC 44 ABS-AT CONTROL (CONTROLLED),
44
trolled) trolled) Diagnostics Chart with Subaru Select Monitor.>
<Ref. to ABS-143, DTC 51 VALVE RELAY MALFUNCTION, Diag-
51 Valve relay malfunction Valve relay malfunction
I
nostics Chart with Subaru Select Monitor,>
<Ref. to ABS-I 47, DTC 51 VALVE RELAY ON FAILURE, Diagnos-
51 Valve relay ON failure Valve relay ON failure
tics Chart with Subaru Select Monitor.>
Open circuit in motor Open circuit in motor <Ref. to ABS-151, DTC 52 OPEN CIRCUIT IN MOTOR RELAY CIR-
52
relay circuit relay circuit CUIT, Diagnostics Chart with Subaru Select Monitor.>
<Ref. to ABS-I 55, DTC 52 MOTOR RELAY ON FAILURE, Diagnos-
52 Motor relay ON failure Motor relay ON failure
tics Chart with Subaru Select Monitor.r
<Ref. to ABS-159, DTC 52 MOTOR MALFUNCTION, Diagnostics
52 Motor malfunction Motor malfunction
Chart with Subaru Select Monitor.>
Stop light switch signal Stop light switch signal <Ref. to ABS-162, DTC 54 STOP LIGHT SWITCH SIGNAL CIRCUIT
54
circuit malfunction circuit malfunction MALFUNCTION, Diagnostics Chart with Subaru Select Monitor.>
Open or short circuit in Open or short circuit in <Ref. to ABS-165, DTC 56 OPEN OR SHORT CIRCUIT IN G SEN-
56
G sensor circuit G sensor circuit SOR CIRCUIT, Diagnostics Chart with Subaru Select Monitor.>
Battery short in G sen- Battery short in G sen- <Ref. to ABS-169, DTC 56 BATTERY SHORT IN G SENSOR CIR-
56
sor circuit sor circuit CUIT, Diagnostics Chart with Subaru Select Monitor.>
Abnormal G sensor Abnormal G sensor <Ref. to ABS-175, DTC 56 ABNORMAL G SENSOR HIGH M OUT-
56
high output high p output PUT, Diagnostics Chart with Subaru Select Monitor.>
Detection of G sensor Detection of G sensor <Ref. to ABS-179, DTC 56 DETECTION OF G SENSOR STICK,
56
stick stick Diagnostics Chart with Subaru Select Monitor.>
ABS-27
I LIST OF DIAGNOSTICS TROUBLE CODE (DTC)
ABS (DIAGNOSTICS)
ABS-28
I
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)
12.Diagnostics Chart with Diagnosis Connector

A: ABS WARNING LIGHT DOES NOT COME ON.
DIAGNOSIS:
ABS warning light circuit is open or shorted.
TROUBLE SYMPTOM:
When the ignition switch is turned ON (engine OFF), ABS warning light does not come on.
ABS-29
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
BATTERY
SBF-3 SBF-1
3 c
t
1
m
RELAY HOLDER
BROO83
ABS-30
ABS IDIAGNOSTICS)
Step Check Yes No

I CHECK IF OTHER WARNING LIGHTS TURN )o other warning lights turn io to step 2. 3epair the combi-
ON. In? iation meter.
Turn the ignition switch to ON (engine OFF). cRef. to IDI-11,
Zombination
Weter Assembly.>
2 CHECK ABS WARNING LIGHT BULB. s the ABS warning light bulb i o to step 3. Replace the ABS
1)Turn the ignition switch to OFF. IK? Narning light bulb.
2)Remove the combination meter. <Ref. to IDI-11,
3)Remove the ABS warning light bulb from Zombination
combination meter. Weter Assembly.>
3 CHECK BATTERY SHORT OF ABS WARN- s the voltage less than 3 V? ;o to step 4. Repair the warning
ING LIGHT HARNESS. light harness.
1)Disconnectthe connector (B200) from con-
nector (F74).
2)Measure the voltage between connector
(8200) and chassis ground.
S CHECK BATTERY SHORT OF ABS WARN- s the voltage less than 3 V? i o to step 5. Repairthe warning
ING LIGHT HARNESS. light harness.
(8200) and chassis ground.
5 CHECK WIRING HARNESS. s the voltage between 10 and ;o to step 6. Repair the wiring
1)Turn the ignition switch to OFF. 5 V? harness.
2)lnstall the ABS warning light bulb from com-
bination meter.
3)lnstall the combination meter.
(B200) and chassis ground.
6 CHECK BATTERY SHORT OF ABS WARN- s the voltage less than 3 V? ;o to step 7. Repair the wiring
ING LIGHT HARNESS. harness.
(F74) and chassis ground.
7 CHECK BATTERY SHORT OF ABS WARN- s the voltage less than 3 V? ;o to step 8. Repair the wiring
ING LIGHT HARNESS. harness.
8 CHECK GROUND CIRCUIT OF ABSCM&HIU s the resistance less than 0.5 ;o to step 9. Repair the
Measure the resistance between ABSCM&HlU 2? ABSCM&HlU
and chassis ground. ground harness.
(F49) NO. 23 - GND:
9 CHECK WIRING HARNESS. s the resistance less than 0.5 20 to step 10. Repair the har-
Measure the resistance between connector n? nesslconnector.
ABS-31
ABS (DIAGNOSTICS)
Step Check Yes No

10 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the con- Replace the
Turn the ignition switch to OFF. nectors between combination nector. ABSCM&H/U.
meter and ABSCM&H/U? <Ref. to ABS-7,
ABS Control Mod-
I
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
ABS-32
ii
ABS (DIAGNOSTICS)
B: ABS WARNING LIGHT DOES NOT GO OFF.

DIAGNOSIS:
ABS warning light circuit is open or shorted.
TROUBLE SYMPTOM:
When starting the engine and while the ABS warning light is kept ON.
ABS-33
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
BATTERY
SBF-3 SBF-1
C
m
RELAY HOLDER
BR0083
ABS-34
1
ABS (DIAGNOSTICS)
Step Check Yes No

I CHECK INSTALLATION OF ABSCM&H/U ;the ABSCM&H/U connector io to step 2. nsert ABSCM&H/
CONNECTOR. iserted into ABSCM until the J connector into
Turn the ignition switch to OFF. lamp locks onto it? 4BSCM&H/U until
he clamp locks
into it.
! CHECK DIAGNOSIS TERMINAL. ;the resistance less than 0.5 io to step 3. 3epalr the diagno-
Measure the resistance between diagnosis ter- I? ;is terminal har-
minals (B81) and chassis ground. less.
Terminals
Diagnosis terminal (A) - Chassis
ground:
Diagnosis terminal (B) - Chassis
ground:
3 CHECK DIAGNOSIS LINE. s the resistance less than 0.5 YO to step 4. qepair harness
1)Turn the ignition switch to OFF. 2? :onnector
2)Connect the diagnosis terminal (881) to Detween
diagnosis connector (B82) No. 6. \BSCM&H/U and
3)Disconnect the connector from ABSCM& jiagnosis connec-
H/U. tor.
4)Measure the resistance between
ABSCM&H/U connector and chassis ground.
(F49) No. 4 - Chassis ground:
1 CHECK GENERATOR. s the voltage between 10 and 50 to step 5. Repair the genera
2)ldle the engine. 13. Generator.>
3)Measure the voltage between generator and
chassis ground.
Terminal
Generator B terminal (+) - Chassis
ground (-):
5 CHECK BAlTERY TERMINAL. s there poor contact at battery 3epair the battery Go to step 6.
Turn the ignition switch to OFF. erminal? erminal.
6 CHECK POWER SUPPLY OF ABSCM. s the voltage between 10 and ;o to step 7. Repair the
1)Disconnectthe connector from ABSCM& I5 V? ABSCM&H/U
H/U. power supply cir-
2)Start the engine. cuit.
3)ldle the engine.
4)Measure the voltage between ABSCM&H/U
7 CHECK WIRING HARNESS. loes the ABS warning light i o to step 8. Repair the front
1)Disconnectthe connector (F74) from con- ,emain off? wiring harness.
nector (8200).
8 CHECK PROJECTION AT ABSCM&H/U. 9re the projection broken? i o to step 9. Replace the
1)Turn the ignition switch to OFF. ABSCM&H/U.
2)Check for broken projection at the <Ref. to ABS-7,
ABSCM&H/U terminal. ABS Control Mod.
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
ABS-35
ABS (DIAGNOSTICS)
Step Check Yes No

I CHECK ABSCM&H/U. Is the resistance more than 1 Go to step 10. Replace the
Measure the resistance between ABSCM&H/U MR? ABSCM&H/U.
terminals. <Ref. to ABS-7,
Terminal ABS Control Mod-
NO.22 - NO. 23: ule and Hydraulic
Control Unit
(ABSCM&H/U).>
0 CHECK WIRING HARNESS. Is the resistance less than 0.5 Go to step 11. Repair the har-
Measure the resistance between connector Q? ness.
-
(F74) No. 20 Chassis ground: I
1 CHECK WIRING HARNESS. Is the resistance more than 1 Go to step 12. I Repair the har-
1)Connect the connector to ABSCM&H/U. MR? ness.
2)Measure the resistance between connector
(F74)No. 20 - Chassis ground:
2 CHECK POOR CONTACT IN ABSCM&H/U Is there poor contact in Repair the con- Replace the
CONNECTOR. ABSCM&H/U connector? nector. ABSCM&H/U.
<Ref. to ABS-7,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
ABS-36
ABS (DIAGNOSTICS)
C: DIAGNOSTIC TROUBLE CODE (DTC) DOES NOT APPEAR.

DIAGNOSIS:
Diagnosis circuit is open.
TROUBLE SYMPTOM:
The ABS warning light turns on or off normally but the start code cannot be read out in the diagnostic mode.
ABS-37
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
BATTERY
DIAGNOSIS
m
RELAY HOLDER
BR0083
ABS-38
ABS (DIAGNOSTICS)
!-
Step Check
1 CHECK DIAGNOSIS TERMINAL. Is the resistance less than 0.5 So to step 2. Repair the diagno-
1)Turn the ignition switch to OFF. n? sis terminal har-
2)Measure the resistance between diagnosis ness.
terminals (881) and chassis ground.
Terminals
Diagnosis terminal (A) - Chassis
ground:
Diagnosis terminal (B) - Chassis
ground:
2 CHECK DIAGNOSIS LINE. Is the resistance less than 0.5
1)Turn the ignition switch to OFF. Q? connector
2)Connect the diagnosis terminal (B81) to between
diagnosis connector (B82) No. 6. ABSCM&H/U and
3)Disconnect the connector from ABSCM& diagnosis connec-
HIU. tor.
i
<Ref. to ABS-7,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
ABS-39
1
ABS (DIAGNOSTICS)
D: DTC21
ABNORMAL ABS SENSOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO
HIGH) (FRONT RH)
NOTE:
For the diagnostic procedure, refer to DTC 27. <Ref. to ABS-41, DTC 27 ABNORMAL ABS SENSOR (OPEN
CIRCUIT OR INPUT VOLTAGE TOO HIGH) (REAR LH), Diagnostics Chart with Diagnosis Connector.>
E: DTC23
HIGH) (FRONT LH)
NOTE:
F: DTC25
HIGH) (REAR RH)
NOTE:
ABS-40
fa
ABS (DIAGNOSTICS)
_ _ _ _ ~
G: DTC27
HIGH) (REAR LH)
DIAGNOSIS:
Faulty ABS sensor (Broken wire, input voltage too high)
TROUBLE SYMPTOM:
ABS does not operate.
ABS41
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
@ ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT
1.
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ABS REAR REAR
SENSOR LH SENSOR RH ABS ABS
SENSOR LH SENSOR RH
BR0084
ABS-42
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR Is
ABS (DIAGNOSTICS)
Step Check Yes No

CHECK ABS SENSOR. s the resistance between 1 20 to step 2. 3eplace the ABS
1)Turn the ignition switch to OFF. ind 1.5 kR? sensor. Front:
2)Disconnect the connector from ABS sensor. :Ref. to ABS-I 4,
3)Measure the resistance of ABS sensor con- 7ont ABS Sen-
nector terminals. ;or.> Rear: <Ref.
Terminal :o ABS-18, Rear
Front RH No. 1 - No. 2: 4BS Sensor.>
-
Front LH No. 1 No. 2:
Rear RH No. 1 -No. 2:
-
Rear LH No. 1 No. 2:
CHECK BATTERY SHORT OF ABS SEN- s the voltage less than 1 V? 20 to step 3. 3eplace the ABS
SOR. sensor. Front:
1)Disconnect the connector from ABSCM& :Ref. to ABS-14,
H/U. 3ont ABS Sen-
2)Measure the voltage between ABS sensor :or.> Rear: <Ref.
and chassis ground. :o ABS-18, Rear
Terminal 4BS Sensor.>
Front RH No. 1 (+) - Chassis ground (-):
Front LH No. 1 (+) - Chassis ground (-):
Rear RH No. 2 (+) - Chassis ground (-):
Rear LH No. 2 (+) - Chassis ground (-):
I CHECK BATTERY SHORT OF ABS SEN- s the voltage less than 1 V? 30 to step 4. Replace the ABS
SOR. sensor. Front:
1)Turn the ignition switch to ON. <Ref. to ABS-14,
2)Measure the voltage between ABS sensor Front ABS Sen-
and chassis ground. :or.> Rear: <Ref.
Terminal to ABS-I 8, Rear
Front RH No. 1 (+) - Chassis ground (-): ABS Sensor.>
Front LH No. 1 (+) - Chassis ground (-):
Rear LH No, 2 (+) - Chassis ground (-):
I CHECK HARNESS/CONNECTOR BETWEEN Is the resistance between 1 20 to step 5. Repair harness/
ABSCM&H/U AND ABS SENSOR. and 1.5 kR? connector
1)Turnthe ignition switch to OFF. between
2)Connect the connector to ABS sensor. ABSCM&H/U and
3)Measure the resistance between ABS sensor.
ABSCM&H/U connector terminals.
DTC 21 / (F49) NO. 11 - NO. 12:
DTC 23 / (F49) NO. 9 - NO. 10:
DTC 25 / (F49) NO. 14 - NO. 15:
DTC 27 / (F49) NO. 7 - NO. 8:
b CHECK BAlTERY SHORT OF HARNESS. Is the voltage less than 1 V? 30 to step 6. Repair harness
Measure the voltage between ABSCM&H/U between
connector and chassis ground. ABSCM&H/U and
Connector i? terminal ABS sensor.
-
DTC 21 / (F49) No. 11 (+) Chassis
ground (-):
-
DTC 23 / (F49) No. 9 (+) Chassis
ground (-):
DTC 25 / (F49) No. 14 (+) - Chassis
ground (-):
DTC 2 7 / (F49) No. 7 (+) - Chassis
ground 6):
ABS-43
ABS (DIAGNOSTICS)
Step Check Yes No

i CHECK BAlTERY SHORT OF HARNESS. s the voltage less than 1 V? ;o to step 7. Repair harness
1)Turn the ignition switch to ON. between
2)Measure the voltage between ABSCM&H/U ABSCM&H/U and
connector and chassis ground. ABS sensor.
DTC 21 /(F49) No. 11 (+) - Chassis
ground (-):
DTC 23 / (F49) No. 9 (+) - Chassis
ground (-):
DTC 25 / (F49) No. 14 (+) - Chassis
ground (-):
DTC 27/ (F49) No. 7 (+) - Chassis
ground (-):
r CHECK INSTALLATION OF ABS SENSOR. Are the ABS sensor installation 20 to step 8. Tighten the ABS
Turn the ignition switch to OFF. Iolts tightened securely? sensor installation
Tightening torque: bolts securely.
32 N.m (3.3 kgf-m, 24 ft-lb)
$ CHECK ABS SENSOR GAP. s the gap within the specifica- 20 to step 9. Adjust the gap.
Measure the tone wheel to ABS sensor piece ions? NOTE:
gap over entire perimeter of the wheel. Adjust the gap u s
Front wheel ing spacers (Par
0.3 - 0.8 mm (0.012 - 0.031 in) No. 26755AA000)
Rear wheel If spacers canno
0.7 - 1.2 mm (0.028 - 0.047 in) correct the gap, re.
place worn sensoi
or worn tone
wheel.
b CHECK TONE WHEEL RUNOUT. s the runout less than 0.05 20 to step 10. Replace the tone
Measure the tone wheel runout. nm (0.0020 in)? wheel. Front:
<Ref. to ABS-21,
Front Tone
Wheel.> Rear:
<Ref. to ABS-22,
Rear Tone
Wheel.>
10 CHECK GROUND SHORT OF ABS SENSOR. s the resistance more than 1 20 to step 11. Replace the ABS
1)Turnthe ignition switch to ON. dR? sensor and
2)Measure the resistance between ABS sen- ABSCM&H/U.
sor and chassis ground. Front: <Ref. to
Terminal ABS-14, Front
Front RH No. 1 - Chassis ground: ABS Sensor.>
Front LH No. 1 - Chassis ground: Rear: <Ref. to
Rear RH No. 1 - Chassis ground: ABS-18, Rear
Rear LH No. 1 - Chassis ground: ABS Sensor.>
and <Ref. to
ABS-7, ABS Con-
trol Module and
Hydraulic Control
Unit (ABSCM&H/
U).>
ABS-44
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR m
ABS (DIAGNOSTICS)
Step Check No
11 CHECK GROUND SHORT OF HARNESS. Repair harness
1)Turnthe ignition switch to OFF: between
ABSCM&H/U connector terminal and chassis Replace
ground. ABSCM&H/U.
Connector & terminal <Ref. to ABS-7,
DTC 21 / (F49) No. 11 - Chassis ground: ABS Control Mod-
DTC 23 / (F49) No. 9- Chassis ground: ule and Hydraulic
DTC 25 / (F49) No. 14 - Chassis ground: Control Unit
-
DTC 27/(F49) No. 7 Chassis ground: (ABSCM&H/U).>
12 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the con- Go to step 13.
nectors between ABSCM&H/U nector.
and ABS sensor?
13 CHECK ABSCM&H/U. Is the same diagnostic trouble Replace the Go to step 14.
1)Connect all connectors. :ode as in the current diagno- ABSCM&H/U.
2)Erase the memory. sis still being output? <Ref. to ABS-7,
3)Perform the inspection mode. ABS Control Mod-
4)Read out the diagnostic trouble code. ule and Hydraulic
Control Unit
(ABSCM&H/U).>
14 CHECK ANY OTHER DIAGNOSTIC TROU- Are other diagnostic trouble Proceed with the A temporary poor
BLE CODES APPEARANCE. codes being output? diagnosis corre- contact.
sponding to the NOTE:
diagnostic trouble Check harnes:
code. and connector:
between AB,
SCM&H/U anc
ABS sensor.
ABS-45
I la
ABS (DIAGNOSTICS)
H: DTC22
ABNORMAL ABS SENSOR (FRONT RH)
NOTE:
For the diagnostic procedure, refer to DTC 28. <Ref. to ABS-47, DTC 28 ABNORMAL ABS SENSOR (REAR
LH), Diagnostics Chart with Diagnosis Connector.>
I: DTC24
ABNORMAL ABS SENSOR (FRONT LH)
NOTE:
J: DTC26
ABNORMAL ABS SENSOR (REAR RH)
NOTE:
ABS-46
ia
ABS (DIAGNOSTICS)
K: DTC28
ABNORMAL ABS SENSOR (REAR LH)
DIAGNOSIS:
Faulty ABS sensor signal (noise, irregular signal, etc.)
Faulty harnesskonnector
TROUBLE SYMPTOM:
ABS-47
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT
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ABS ABS REAR REAR
SENSOR LH SENSOR RH
BR0084
ABS-48
m
ABS (DIAGNOSTICS)
Step Check Yes No

CHECK INSTALLATION OF ABS SENSOR. Are the ABS sensor installation 30 to step 2. 7ghten the ABS
Turn the ignition switch to OFF. bolts tightened securely? iensor installation
Tightening torque: lolts securely.
32 N.m (3.3 kgf-m, 24 ft-lb)
I CHECK ABS SENSOR GAP. Is the gap within the specifica- 30 to step 3. idjust the gap.
Measure the tone wheel to ABS sensor piece tions? JOTE:
gap over entire perimeter of the wheel. idjust the gap us
Front wheel 'lg spacer (Par
0.3 - 0.8 mm (0.012 - 0.031 in) do. 26755AA000)
f spacers canno
:orrect the gap, re
)lace worn senso
)r worn tonc
vheel.
I PREPARE OSCILLOSCOPE. Is an oscilloscope available? 30 to step 4. io to step 5.
I CHECK ABS SENSOR SIGNAL. Is the oscilloscope pattern 30 to step 8. 20 to step 7.
1)Raise all four wheels off ground. smooth, as shown in the fig-
2)Turn the ignition switch OFF. ure?
3)Connect the oscilloscope to the connector.
4)Turn the ignition switch ON.
5)Rotate the wheels and measure voltage at
specified frequency. <Ref. to ABS-17, WAVE-
FORM, Control Module I/O Signal.>
NOTE:
When this inspection is completed, the ABS
control module sometimes stores the DTC 29.
DTC 22 /
(F95) NO. 1 (+) - NO. 2 (-):
DTC 24 /
(F94) NO. 1 (+) - NO. 2 (-):
DTC26/
(699) NO. 9 (+) - NO. 10 (-):
DTC28/
(699) NO. 4 (+) - NO. 5 (-):
CHECK CONTAMINATION OF ABS SENSOR Is the ABS sensor piece or the rhoroughly io to step 6.
OR TONE WHEEL. tone wheel contaminated by 'emove dirt or
Remove the disc rotor or drum from hub in dirt or other foreign matter? ither foreign mat-
accordance with diagnostic trouble code. er.
i CHECK DAMAGE OF ABS SENSOR OR Are there broken or damaged 3eplace the ABS 30 to step 7.
TONE WHEEL. in the ABS sensor piece or the sensor or tone
tone wheel? Nheel. Front: <Ref.
:o ABS-14, Front
4BS Sensor.>
3ear: <Ref. to
46s-18, Rear
4BS Sensor.> and
Front: <Ref. to
46s-21, Front
Tone Wheel.>
?ear: <Ref. to
465-22, Rear
Tone Wheel.>
ABS-49
ABS (DIAGNOSTICS)
~ ~ _ _ _ ~ ~~
Step Check Yes No

I CHECK TONE WHEEL RUNOUT. s the runout less than 0.05 So to step 8. Replace the tone
<Ref. to ABS-21,
Front Tone
Wheel.> Rear:
<Ref. to ABS-22,
Rear Tone
Wheel.>
1 CHECK RESISTANCE OF ABS SENSOR. s the resistance between 1 So to step 9. Replace the ABS
1)Turn the ignition switch OFF. ind 1.5 kR? sensor. Front:
2)Disconnect the connector from ABS sensor. <Ref. to ABS-14,
3)Measure the resistance between ABS sen- Front ABS Sen-
sor connector terminals. sor.> Rear: <Ref.
Terminal to ABS-18, Rear
Front RH No. 1 - No. 2: ABS Sensor.>
Front LH No. 1 -No. 2:
-
Rear RH No. 1 No. 2:
-
CHECK GROUND SHORT OF ABS SENSOR. s the resistance more than 1 So to step 10. Replace the ABS
Measure the resistance between ABS sensor dR? sensor. Front:
and chassis ground. <Ref. to ABS-14,
Terminal Front ABS Sen-
-
Front RH No. 1 Chassis ground: sor.> Rear: <Ref.
Front LH No. 1 - Chassis ground: to ABS-18, Rear
Rear RH No. 1 - Chassis ground: ABS Sensor.>
-
Rear LH No. 1 Chassis ground:
IO CHECK HARNESWCONNECTOR BETWEEN s the resistance between 1 So to step 11. Repair harness1
ABSCM&HIU AND ABS SENSOR. md 1.5 kR? connector
1)Connect the connector to ABS sensor. between
2)Disconnect the connector from ABSCM& ABSCM&H/U and
H/U. ABS sensor.
3)Measure the resistance at ABSCM&HIU
-
DTC 22 / (F49) NO. 11 NO. 12:
DTC 24 / (F49) NO. 9 - NO. 10:
-
DTC 26 /(F49) NO. 14 NO. 15:
-
DTC 28 / (F49) NO. 7 NO. 8:
I1 CHECK GROUND SHORT OF HARNESS. s the resistance more than 1 i o to step 12. Repair harness/
Measure the resistance between ABSCM&H/U dQ? connector
connector and chassis ground. between
Connector & terminal ABSCM&H/U and
-
DTC 22 / (F49) No. 11 Chassis ground: ABS sensor.
DTC 24 / (F49) No. 9 - Chassis ground:
-
DTC 26 / (F49) No. 14 Chassis ground:
-
12 CHECK GROUND CIRCUIT OF ABSCM&H/U. s the resistance less than 0.5 So to step 13. Repair the
Measure the resistance between ABSCM&H/U 2? ABSCM&H/U
and chassis ground. ground harness.
(F49) NO. 23 - GND:
13 CHECK POOR CONTACT IN CONNECTORS. s there poor contact in con- lepair the con- Go to step 14.
lectors between ABSCM&H/L lector.
md ABS sensor?
14 CHECK SOURCES OF SIGNAL NOISE. s the car telephone or the So to step 15. Properly install the
vireless transmitter properly car telephone or
nstalled? the wireless trans-
mitter.
ABS-50
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR a
ABS (DIAGNOSTICS)
Step Check Yes No

5 CHECK SOURCES OF SIGNAL NOISE. Are noise sources (such as an nstall the noise ;o to step 16.
antenna) installed near the sources apart from
sensor harness? he sensor har-
less.
6 CHECK SHIELD CIRCUIT. Is the resistance less than 0.5 30 to step 17. 3epair the shield
1)Connect all connectors. Q? iarness.
2)Measure the resistance between shield con-
-
DTC 26 / (6200) No. 1 1 Chassis
ground:
DTC 28 / (6200) No. 3 - Chassis ground
NOTE:
For the DTC 22 and 24:
Go to step 17.
I7 CHECK ABSCM&H/U. Is the same diagnostic trouble 3eplace the 20 to step 18.
1)Connect all connectors. code as in the current diagno- 4BSCM&H/U.
2)Erase the memory. sis still being output? :Ref. to ABS-7,
3)Perform the inspection mode. 4BS Control Mod-
4)Read out the diagnostic trouble code. Jle and Hydraulic
Zontrol Unit
:ABSCM&H/U).>
18 CHECK ANY OTHER DIAGNOSTIC TROU- Are other diagnostic trouble Proceed with the 4 temporary noise
BLE CODES APPEARANCE. codes being output? jiagnosis corre- nterference.
sponding to the
%agnostictrouble
:ode.
I
ABS-51
ABS-52
ABS (DIAGNOSTICS)
~~
L: DTC29
ABNORMAL ABS SENSOR SIGNAL (ANY ONE OF FOUR)
DIAGNOSIS:
Faulty tone wheel
Wheels turning freely for a long time
TROUBLE SYMPTOM:
ABS-53
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
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FRONT FRONT
ABS ABS REAR REAR
SENSOR LH SENSOR RH
BR0084
ABS-54
ABS (DIAGNOSTICS)
Step Check Yes No

CHECK IF THE WHEELS HAVE TURNED :heck if the wheels have been lThe ABS is nor- /Go to step 2.
FREELY FOR A LONG TIME. urned freely for more than one mal. Erase the
ninute, such as when the vehi- diagnostic trouble
:le is jacked-up, under full-lock code.
:ornering or when tire is not in NOTE:
:ontact with road surface. When the wheels
turn freely for a
long time, such as
when the vehicle is
towed or jacked-
up, or when steer-
ing wheel is contin-
uously turned all
the way, this trou-
ble code may
sometimes occur.
! CHECK TIRE SPECIFICATIONS. 4re the tire specifications cor- Go to step 3. Replace the tire.
Turn the ignition switch to OFF. ect?
1 CHECK WEAR OF TIRE. s the tire worn excessively? Replace the tire. Go to step 4.
I CHECK TIRE PRESSURE. s the tire pressure correct? Go to step 5. Adjust the tire
pressure.
CHECK INSTALLATION OF ABS SENSOR. 4re the ABS sensor installation Go to step 6. Tighten the ABS
Tightening torque: iolts tightened securely? sensor installation
32 N.m (3.3 kgf-m, 24 ft-lb) bolts securely.
i CHECK ABS SENSOR GAP. s the gap within the specifica- Go to step 7. Adjust the gap.
gap over entire perimeter of the wheel. Adjust the gap us,
Specifications ing spacer (Part
Front wheel No. 26755AAOOO).
0.3 - 0.8 mm (0.012 - 0.031 in) If spacers cannot
Rear wheel correct the gap, re-
0.7 - 1.2 mm (0.028 - 0.047 in) place worn sensor
or worn tone
wheel.
PREPARE OSCILLOSCOPE. s an oscilloscope available? Go to step 8. Go to step 9.
I CHECK ABS SENSOR SIGNAL. s the oscilloscope pattern Go to ster, 12. Go to step 9.
1)Raise all four wheels off ground. imooth, as shown in figure?
2)Turn the ignition switch OFF.
NOTE:
When this inspection is completed, the AB
SCM&H/U sometimes stores the DTC 29.
Front RH
(F95) NO. 1 (+) - NO. 2 (-):
Front LH
(F94) NO. 1 (+) - NO.2 (-):
Rear RH
(B99) NO. 9 (+) - NO. 10 (-):
Rear LH
(B99) NO. 4 (+) - NO. 5 (-):
ABS55
~
ABS (DIAGNOSTICS)
Step Check Yes No

3 CHECK CONTAMINATION OF ABS SENSOR s the ABS sensor piece or the Thoroughly 30 to step 10.
OR TONE WHEEL. one wheel contaminated by remove dirt or
Remove the disc rotor from hub. lirt or other foreign matter? other foreign mat-
ter.
IO CHECK DAMAGE OF ABS SENSOR OR 4re there broken or damaged Replace the ABS 30 to step 11.
TONE WHEEL. eeth in the ABS sensor piece sensor or tone
)r the tone wheel? wheel. Front: <Ref.
to ABS-14, Front
ABS Sensor.>
Rear: <Ref. to
ABS-18, Rear
ABS Sensor.>
and Front: <Ref.
to ABS-21, Front
Tone Wheel.>
Rear: <Ref. to
ABS-22, Rear
Tone Wheel.>
I1 CHECK TONE WHEEL RUNOUT. s the runout less than 0.05 Go to step 12. 3eplace the tone
Measure the tone wheel runout. nm (0.0020 in)? Nheel. Front:
:Ref. to ABS-21,
3ont Tone
Nhee1.z Rear:
:Ref. to ABS-22,
3ear Tone
Nheeb
12 CHECK ABSCM&H/U . s the same diagnostic trouble Replace the 30 to step 13.
1)Turn the ignition switch to OFF. ;ode as in the current diagno- ABSCM&H/U.
2)Connect all connectors. ;is still being output? <Ref. to ABS-7,
3)Erase the memory. ABS Control Mod-
4)Perform the inspection mode. ule and Hydraulic
5)Read out the diagnostic trouble code. Sontrol Unit
[ABSCM&H/U).>
13 CHECK ANY OTHER DIAGNOSTIC TROU- 4re other diagnostic trouble Proceed with the 4 temporary poor
BLE CODES APPEARANCE. ;odes being output? diagnosis corre- :ontact.
sponding to the
diagnostic trouble
:ode.
ABS-56
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR I
ABS (DIAGNOSTICS)
~~
M: DTC31
ABNORMAL INLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (FRONT
RH)
NOTE:
For the diagnostic procedure, refer to DTC 37. <Ref. to ABS-57, DTC 37 ABNORMAL INLET SOLENOID
VALVE CIRCUIT(S) IN ABSCM&H/U (REAR LH), Diagnostics Chart with Diagnosis Connector.>
N: DTC33
ABNORMAL INLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (FRONT
LH)
NOTE:
0: DTC35
ABNORMAL INLET SOLENOID VALVE ClRCUIT(S) IN ABSCM&H/U (REAR
RH)
NOTE:
P: DTC37
ABNORMAL INLET SOLENOID VALVE ClRCUIT(S) IN ABSCM&H/U (REAR
LH)
DIAGNOSIS:
Faulty harness/connector
Faulty inlet solenoid valve in ABSCM&H/U
TROUBLE SYMPTOM:
ABS-57
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
BATTERY
n
RELAY
HOLDER
ABS
RELAY
BR0005
ABS-58
9
ABS (DIAGNOSTICS)
~
Step Check Yes No

I CHECK INPUT VOLTAGE OF RELAY HOLD- s the voltage more than 10 V? Go to step 2. Repair open circuit
ER. in harness
1)Turn the ignition switch to OFF. between battery
2)Remove the fuse. m d Relay holder
3)Measure the voltage between ABS relay Zonnector.
2 CHECK RELAY HOLDER. Is the fuse blown out? IReplace the fuse. Go to step 3.
3 CHECK INPUT VOLTAGE OF ABS RELAY. Is the voltage more than 10 V? Go to step 4. Repair open circuit
1)lnstall the fuse. in harness
2)Remove the ABS relay. between battery
3)Turn the ignition switch to ON. and Relay holder
4)Measure the voltage between ABS relay connector.
k
4 CHECK INPUT VOLTAGE OF ABS RELAY. IS the voltage more than 10 V? Go to step 5. Repair harness
Measure the voltage between ABS relay con- connector
nector and chassis ground. between battery,
Connector & terminal ignition switch and
(8264) No. 1 (+) - Chassis ground (-): ABS relay.
5 CHECK GROUND CIRCUIT OF ABS RELAY. Is the resistance less than 5 Go to step 6. Repair open circuit
1)Turn the ignition switch to OFF. n? between ABS
2)Measure the resistance between ABS relay relay and chassis
connector and chassis ground. ground.
(8264) No. 3 (+) - Chassis ground:
6 CHECK the ABS RELAY. Is the resistance less than 10 Go to step 7. Replace the ABS
1)Connect the battery to ABS relay terminal n? relay.
No. 1 and 3.
2)Measure the resistance between ABS relay
terminals.
7 CHECK INPUT VOLTAGE OF ABSCM&H/U. Repair harness
1)Disconnectthe connector from ABSCM& 15 V? connector
H/U. between ABS
2)Run the engine at idle. relay and
3)Measure the voltage between ABSCM&H/U ABSCM&H/U.
7-j-
0 CHECK GROUND CIRCUIT OF ABSCM&H/U. Is the resistance less than 0.5 Go to step 9. Repair the
1)Turn the ignition switch to OFF. ABSCM&H/U
2)Measure the resistance between ground harness.
-
(F49) No. 23 Chassis ground:
nectors between generator, nector.
battery and ABSCM&H/U?
10 CHECK ABSCM&H/U. Is the same diagnositc trouble Replace the Go to step 11.
1)Connect all connectors. code as in the current diagno- ABSCM&H/U.
Control Unit
(ABSCM&H/U).>
ABS-59
ABS (DIAGNOSTICS)
Step Check
11 CHECK ANY OTHER DIAGNOSTIC TROU- Are other diagnostic trouble
BLE CODES APPEARANCE. codes being output?
sponding to the
diagnostic trouble
code.
ABS-60
a
ABS (DIAGNOSTICS)
Q: DTC32
ABNORMAL OUTLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U
(FRONT RH)
NOTE:
For the diagnostic procedure, refer to DTC 38. <Ref. to ABS-61, DTC 38 ABNORMAL OUTLET SOLENOID
R: DTC34
(FRONT LH)
NOTE:
S: DTC36
(REAR RH)
NOTE:
T: DTC38
(REAR LH)
DIAGNOSIS:
Faulty harnesdconnector
Faulty outlet solenoid valve in ABSCM&H/U
TROUBLE SYMPTOM:
ABS-61
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
BATTERY
RELAY
HOLDER
ABS
RELAY
I @ ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT

I
I
ABS-62
m
ABS (DIAGNOSTICS)
~~
Step Check Yes No

I CHECK INPUT VOLTAGE OF RELAY HOLD- j the voltage more than 10 V? Go to step 2. 3epair open circuit
ER. n harness
1)Turn the ignition switch to OFF. 2etween battery
2)Remove the fuse. 2nd Relay holder
3)Measure the voltage between ABS relay :onnector.
2 CHECK RELAY HOLDER. s the fuse blown out? Replace the fuse. 30 to step 3.
3 CHECK INPUT VOLTAGE OF ABS RELAY. s the voltage more than 10 V? Go to step 4. Repair open circuit
1)lnstall the fuse. n harness
2)Remove the ABS relay. Detween battery
3)Turn the ignition switch to ON. 2nd Relay holder
1 CHECK INPUT VOLTAGE OF ABS RELAY. s the voltage more than 10 V? Go to step 5. Repair harness
Measure the voltage between ABS relay con- :onnector
nector and chassis ground. Detween battery,
5 CHECK GROUND CIRCUIT OF ABS RELAY, s the resistance less than 5 Go to step 6. Repair open circuit
1)Turnthe ignition switch to OFF. 2? between ABS
(8264) No. 3 (+)- Chassis ground:
6 . CHECK ABS RELAY. s the resistance less than 10 Go to step 7. Replace the ABS
1)Connect the battery to ABS relay terminal L? relay.
No. 1 and 3.
terminals.
7 CHECK INPUT VOLTAGE OF ABSCM&H/U. s the voltage between 10 and Go to step 8. Repair harness
H/U. between battery,
2)Run the engine at idle. ignition switch and
B CHECK GROUND CIRCUIT OF ABSCM&H/U s the resistance less than 0.5 Go to step 9. Repair the
1)Turn the ignition switch to OFF. l? ABSCM&H/U
9 CHECK POOR CONTACT IN CONNECTORS s there poor contact in con- Repair the con- Go to step 10.
lectors between generator, nector.
Iattery and ABSCM&H/U?
10 CHECK ABSCM&HN. s the same diagnostic trouble Replace the Go to step 11.
2)Erase the memory. ;is still being output? <Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
ABS-63
ABS (DIAGNOSTICS)
Step Check Yes No

sponding to the
diagnostic trouble
code.
ABS-64
ABS (DIAGNOSTICS)
ABS-65
a
ABS (DIAGNOSTICS)
U: DTC41
ABNORMAL ABS CONTROL MODULE
DIAGNOSIS:
Faulty ABSCM&H/U.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
-
-
B4M145i
ABS-66
3
ABS (DIAGNOSTICS)
7
Step Check Yes
I CHECK GROUND CIRCUIT OF ABSCM&H/U. s the resistance less than 0.5 Go to step 2. 3epair the
1)Turn the ignition switch to OFF. 2? 4BSCM&H/U
I
2)Disconnect the connector from ABSCM& jround harness.
H/U.
I
ABSCM&H/U and chassis ground.
---
! CHECK POOR CONTACT IN CONNECTORS. s there poor contact in con- Repair the con- 30 to step 3.
lectors between battery, igni- nector.
ion switch and ABSCM&H/U? I
i CHECK SOURCES OF SIGNAL NOISE. s the car telephone or the Go to step 4. >roperlyinstall the
vireless transmitter properly :ar telephone or
nstalled? he wireless trans-
nitter.
I CHECK SOURCES OF SIGNAL NOISE. 4re noise sources (such as an Install the noise 30 to step 5.
mtenna) installed near the sources apart from
;ensor harness? the sensor har-
ness.
I CHECK ABSCM&H/U. s the same diagnostic trouble Replace the 30 to step 6.
2) Erase the memory. ;is still being output? <Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
5 CHECK ANY OTHER DIAGNOSTICTROU- 4re other diagnostic trouble Proceed with the
BLE CODES APPEARANCE. :odes being output? diagnosis corre- :ontact.
sponding to the
diagnostic trouble
code.
ABS-67
ABS (DIAGNOSTICS)
ABS-68
ABS (DIAGNOSTICS)
V: DTC42
SOURCE VOLTAGE IS ABNORMAL
DIAGNOSIS:
Power source voltage of the ABSCM&H/U is low or high.
TROUBLE SYMPTOM:
ABS-69
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
RELAY
HOLDER
ABS
RELAY
516171819
BR0085
ABS-70
a
ABS (DIAGNOSTICS)
Step Check Yes No

CHECKGENERATOR. s the voltage between 10 and 30 to step 2. qepair the genera-
1)Start the engine. 7 V? :or. <Ref. to SC-
2)ldling after warm-up. 13, Generator.>
3)Measure the voltage between generator B
terminal and chassis ground.
Terminal
Generator 8 terminal - Chassis ground:
CHECK BATTERY TERMINAL. ire the positive and negative 30 to step 3. Tighten the clamp
Turn the ignition switch to OFF. battery terminals tightly 2f terminal.
ilamped?
CHECK INPUT VOLTAGE OF RELAY HOLD- s the voltage more than 10 V? 30 to step 4. Repair open circuit
ER. n harness
1)Turn the ignition switch to OFF. 3etween battery
2)Remove the fuse. and Relay holder
CHECK RELAY HOLDER. s the fuse blown out? 3eplace the fuse. Go to step 5.
CHECK INPUT VOLTAGE OF ABS RELAY. s the voltage more than 10 V? 30 to step 6. Repair open circuit
CHECK INPUT VOLTAGE OF ABS RELAY. s the voltage more than 10 V? 30 to step 7. Repair harness
CHECK GROUND CIRCUIT OF ABS RELAY. s the resistance less than 5 30 to step 8. Repair open circuit
1)Turnthe ignition switch to OFF. 2? between ABS
CHECK ABS RELAY. s the resistance less than 10 30 to step 9. Replace the ABS
1)Connect the battery to ABS relay terminal a? relay.
No. 1 and 3.
terminals.
CHECK INPUT VOLTAGE OF ABSCM&H/U. s the voltage between 10 and So to step 10. Repair harness
1)Disconnectthe connector from ABSCM& I7 V? connector
2)Run the engine at idle. ignition switch and
connector and chassis grou.nd.
1 CHECK GROUND CIRCUIT OF ABSCM&H/U. s the resistance less than 0.5 Go to step 11. Repair the
1)Turnthe ignition switch to OFF. 3? ABSCM&H/U
ABS-71
I
ABS (DIAGNOSTICS)
Step Check Yes No

Control Unit
(ABSCM&H/U).>
3 CHECK ANY OTHER DIAGNOSTIC TROW Are other diagnostic trouble Proceed with the A temporary poor
sponding to the
diagnostic trouble
code.
ABS-72
ABS (DIAGNOSTICS)
ABS-73
ABS (DIAGNOSTICS)
W: DTC44
A COMBINATION OF AT CONTROL ABNORMAL
DIAGNOSIS:
Combination of AT control faults
TROUBLE SYMPTOM:
WIRING DIAGRAM:
I @ ABS CONTROL MODULE AND

HYDRAULIC CONTROL UNIT
I
1 1
: TURBO ENGINE MODEL
I
I 6: 655
A : 8
TCM
BR0086
ABS-74
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ii
ABS (DIAGNOSTICS)
Step Check Yes No

1 CHECK SPECIFICATIONS OF THE AB- Is an ABSCM&H/U for AT 3eplace the Go to step 2.
SCM&H/U. model installed on a MT 4BSCM&H/U.
Check specifications of the mark to the nodel? :Ref. to ABS-7,
ABSCM&H/U. 9BS Control Mod-
CC: AT de and Hydraulic
CD: MT 2ontrol Unit
:ABSCM&H/U).>
2 CHECK GROUND SHORT OF HARNESS. Is the resistance more than 1 30 to step 3. Repair harness
1)Turn the ignition switch to OFF. MQ? between TCM and
2)Disconnect two connectors from TCM. ABSCM&H/U.
3)Disconnect the connector from ABSCM&
H/U.
3 CHECK BATTERY SHORT OF HARNESS. Is the voltage less than 1 V? 30 to step 4. Repair harness
Measure the voltage between ABSCM&H/U between TCM and
connector and chassis ground. ABSCM&H/U.
(F49) No. 3 (+)- Chassis ground (-):
4 CHECK BATTERY SHORT OF HARNESS. Is the voltage less than 1 V? 30 to step 5. Repair harness
1)Turnthe ignition switch to ON. between TCM and
(F49) No, 3 (+) - Chassis ground (-):
5 CHECK TCM. Is the voltage between 10 and Go to step 7. Go to step 6.
1)Turn the ignition switch to OFF. 15 V?
2)Connect all connectors to TCM.
tor terminal and chassis ground.
NON-TURBO MODEL
TURBO MODEL
6 CHECK AT. Is the AT functioning normally? Replace the TCM. Repair the AT.
7 CHECK OPEN CIRCUIT OF HARNESS. Is the voltage between 10 and Go to step 8. Repair harness/
Measure the voltage between ABSCM&H/U 15 V? connector
connector and chassis ground. between TCM and
Connector & terminal ABSCM&H/U.
-
(F49) No. 3 (+) Chassis ground (-):
8 CHECK POOR CONTACT IN CONNECTORS Is there poor contact in con- Repair the con- Go to step 9.
nectors between TCM and nector.
ABSCM&H/U?
1)Turn the ignition switch to OFF. code as in the current diagno- ABSCM&H/U.
2)Connect all connectors. sis still being output? <Ref. to ABS-7,
5)Read out the diagnostic trouble code. Control Unit
(ABSCM&H/U).r
ABS-75
ABS (DIAGNOSTICS)
Step No
10 CHECK ANY OTHER DIAGNOSTIC TROU- A temporary poor
sponding to the
diagnostic trouble
code.
ABS-76
ABS (DIAGNOSTICS)
X: DTC51
ABNORMAL VALVE RELAY
DIAGNOSIS:
Faulty valve relay
TROUBLE SYMPTOM:
ABS-??
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
RELAY
I 11
I
1-1
r
I
m
N
$
I
ABS CONTROL MODULE AND

HYDRAULIC CONTROL UNIT 'I
a
I
3
a
<A - I f
RELAY MOTOR RELAY
B
m
BR0087
ABS-78
m
ABS (DIAGNOSTICS)
~~~ ~
Step Check Yes No

ER. in harness
2)Remove the fuse. and relay holder
3)Measure the voltage between ABS relay Connector.
-
! CHECK RELAY HOLDER. s the fuse blown out? 3eplace fuse. Go to step 3.
I CHECK INPUT VOLTAGE OF ABS RELAY. s the voltage more than 10 V? 30 to step 4. Repair open circuit
3)Turn the ignition switch to ON. and relay holder
I CHECK INPUT VOLTAGE OF ABS RELAY. s the voltage more than 10 V? 30 to step 5. Repair harness
(6264) No. 1 (+)- Chassis ground (-): ABS relay.
CHECK GROUND CIRCUIT OF ABS RELAY. s the resistance less than 5 30 to step 6. Repair open circuit
1)Turn the ignition switch to OFF. 2? between ABS
i CHECK ABS RELAY. s the resistance less than 10 30 to step 7 . Replace the ABS
1)Connect the battery to ABS relay terminal 2? relay.
No. 1 and 3.
terminals.
? CHECK INPUT VOLTAGE OF ABSCM&HIU. s the voltage between 10 and 30 to step 8. Repair harness
1)Turn the ignition switch to OFF. I5 V? connector
2)Disconnect the connector from ABSCM& between battery,
H/U. ABS relay and
3)Run the engine at idle. ABSCM&H/U.
5 CHECK GROUND CIRCUIT OF ABSCM&H/U. s the resistance less than 0.5 Go to step 9. Repair the
1)Turn the ignition switch to OFF. ;2? ABSCM&H/U
3 CHECK VALVE RELAY IN ABSCM&H/U. s the resistance more than 1 Go to step 10. Replace the
Measure the resistance between ABSCM&H/U VlQ? ABSCM&H/U.
and terminals. <Ref. to ABS-7,
Terminals ABS Control Mod-
NO.23 (+) - NO. 24 (-): ule and Hydraulic
Control Unit
(ABSCM&H/U).>
IO CHECK POOR CONTACT IN CONNECTORS. s there poor contact in con- Repair the con- Go to step 11.
lectors between generator, nector.
iattery and ABSCM&H/U?
ABS-79
ABS (DIAGNOSTICS)
~ ~~ ~
Step Check Yes No

I1 CHECK ABSCM&H/U. Is the same diagnostic trouble Replace the IGo to step 12.
Control Unit
(ABSCM&H/U).>
sponding to the
diagnostic trouble
code.
ABS-80
I
ABS (DIAGNOSTICS)
~~ ~
Y: DTC 52
ABNORMAL MOTOR AND/OR MOTOR RELAY
DIAGNOSIS:
Faulty motor
Faulty motor relay
TROUBLE SYMPTOM:
ABS-81
ABS (DIAGNOSTICS)
~ - I
WIRING DIAGRAM:
BATTERY
ZJ
ABS RELAY 6 2 2 5
r 1
VALVE RELAY
BR0088
ABS-82
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR II
ABS (DIAGNOSTICS)
Step Check Yes No

CHECK INPUT VOLTAGE OF ABSCM&H/U. the voltage between 10 and ;o to step 2. Repair harness/
1)Turn the ignition switch to OFF. 5 V? connector
2)Disconnect the connector from ABSCM& between battery
HIU. and ABSCM&H/U
3)Turn the ignition switch to ON. and check fuse
4)Measure the voltage between ABSCM&H/U SBF-holder.
CHECK GROUND CIRCUIT OF MOTOR. ;the resistance less than 0.5 30 to step 3. Repair the
1)Turn the ignition switch to OFF. !? ABSCM&H/U
CHECK INPUT VOLTAGE OF RELAY HOLD, ;the voltage more than 10 V? 30 to step 4.
ER. in harness
CHECKRELAYHOLDER. s the fuse blown out? Replace the fuse. Go to step 5.
CHECK INPUT VOLTAGE OF ABS RELAY. j the voltage more than 10 V? Go to step 6. Repair open circui
CHECK INPUT VOLTAGE OF ABS RELAY. ;the voltage more than 10 V? 30 to step 7 . Repair harness
CHECK GROUND CIRCUIT OF ABS RELAY j the resistance less than 5 So to step 8. Repair open circuP
1)Turn the ignition switch to OFF. 2? between ABS
CHECK ABS RELAY. s the resistance less than 10 Go to step 9. Replace the ABS
1)Connect the battery to ABS relay terminal 2? relay.
No. 1 and 3.
terminals.
CHECK INPUT VOLTAGE OF ABSCM&H/U. s the voltage between 10 and Go to step 10.
1)Run the engine at idle. I5 V? connector
2)Measure the voltage between ABSCM&H/U between battery,
connector and chassis ground. ignition switch an(
ABS-83
ABS (DIAGNOSTICS)
Step Check Yes No

IO CHECK GROUND CIRCUIT OF ABSCM&H/U. Is the resistance less than 0.5 ;o to step 11. 3epair the
1)Turn the ignition switch to OFF. n? 4BSCM&H/U
2)Measure the resistance between jround harness.
I1 CHECK MOTOR OPERATION. Can motor revolution noise 30 to step 12. 3eplace the
Operate the sequence control. <Ref. to ABS- (buzz) be heard when carrying 4BSCM&H/U.
11, ABS Sequence Control.> out the sequence control? :Ref. to ABS-7,
NOTE: ABS Control Mod-
Use the diagnosis connector to operate the se- de and Hydraulic
quence control. >ontrol Unit
ABSCM&H/U).>
12 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- lepair the con- 30 to step 13.
Turn the ignition switch to OFF. nector between generator, bat- lector.
tery and ABSCM&H/U?
13 CHECK ABSCM&H/U. Is the same diagnostic trouble leplace the 30 to step 14.
1)Connect all connectors. code as in the current diagno- \BSCM&H/U.
4)Read out the diagnostic trouble code. ile and Hydraulic
:ontrol Unit
ABSCM&H/U).>
14 CHECK ANY OTHER DIAGNOSTIC TROU- Are other diagnostic trouble 'roceed with the 4 temporary poor
BLE CODES APPEARANCE. :odes being output? liagnosis corre- :ontact.
iponding to the
liagnostic trouble
:ode.
ABS-84
ABS (DIAGNOSTICS)
ABS-85
ABS (DIAGNOSTICSI
2: DTC54
ABNORMAL STOP LIGHT SWITCH
DIAGNOSIS:
Faulty stop light switch
TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
n
STOP LIGHl
SWITCH
1
11 m
I N
m
: WITHOUT CRUISE
CONTROL
: WITH CRUISE
CONTROL
__
I 24 I 25 I
~ ~
2 7 1 2 8 1 2 9 1 3 0 1 3 1 1 23 26
BR0089
ABS-86
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR M
ABS (DIAGNOSTICS)
Step Check Yes No

I CHECK STOP LIGHTS COME ON. Do the stop lights come on? Go to step 2. Repair the stop
Depress the brake pedal. lights circuit.
! CHECK OPEN CIRCUIT IN HARNESS. Is the voltage between 10 and Go to step 3. Repair harness
1)Turn the ignition switch to OFF. 15 V? between stop light
2)Disconnect the connector from ABSCM& switch and
H/U. ABSCM&H/U.
3)Depress the brake pedal.
3 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con-
nector between stop light nector.
switch and ABSCM&H/U?
1 CHECK ABSCM&WU. Is the same diagnostic trouble Replace the Go to step 5.
Control Unit
(ABSCM&H/U).>
sponding to the
diagnostic trouble
code.
ABS-87
ABS (DIAGNOSTICS)
ABS-88
a
ABS (DIAGNOSTICS)
AA:DTC 56
ABNORMAL G SENSOR OUTPUT VOLTAGE
DIAGNOSIS:
Faulty G sensor output voltage
TROUBLE SYMPTOM:
ABS-89
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
SHIELD JOINT
CONNECTOR
7 -
$E 8200
L
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
t :
,@
1
ABS
G SENSOR
BR0090
ABS-90
9
ABS (DIAGNOSTICS)
Step Check Yes No

CHECK ALL FOUR WHEELS FOR FREE iave the wheels been turned -he ABS is nor- 20 to step 2.
TURNING. reely such as when the vehicle nal. Erase the
s lifted up, or operated on a liagnostic trouble
,oiling road? :ode.
CHECK SPECIFICATIONS OF ABSCM&H/U. Ioes the vehicle specification 3eplace the 30 to step 3.
Check specifications of the mark to the 2nd the ABSCM&H/U specifi- 4BSCM&H/U.
ABSCM&H/U. :ation match? :Ref. to ABS-7,
CC: AT 4BS Control Mod-
CD: MT ile and Hydraulic
2ontrol Unit
ABSCM&H/U).>
2AUTION:
3e sure to turn ig-
iition switch to
3FF when remov-
ng ABSCM&H/U.
CHECK INPUT VOLTAGE OF G SENSOR. IS the voltage between 4.75 30 to step 4. Repair harness/
1)Turn the ignition switch to OFF. and 5.25 V? :onnector
2)Remove the console box. Detween G senso
3)Disconnect the G sensor from body. (Do not and ABSCM&H/U
disconnect the connector.)
nector terminals.
(6292) NO. 1 (+) - NO. 3 (-):
CHECK OPEN CIRCUIT IN G SENSOR OUT, Is the resistance between 4.3 30 to step 5. Repair harness/
PUT HARNESS AND GROUND HARNESS. and 4.9 kR? connector
1)Turnthe ignition switch to OFF. between G senso
2)Disconnect the connector from ABSCM& and ABSCM&H/U
H/U.
-
(F49) NO. 6 NO.28:
CHECK GROUND SHORT IN G SENSOR Is the resistance more than 1 Go to step 6. Repair harness
OUTPUT HARNESS. MR? between G sensor
1)Disconnectthe connector from G sensor. and ABSCM&H/U.
CHECK BATTERY SHORT OF HARNESS. Is the voltage less than 1 V? Go to step 7. Repair harness
Measure the voltage between ABSCM&H/U between G sensor
connector and chassis ground. and ABSCM&H/U.
CHECK BATTERY SHORT OF HARNESS. Is the voltage less than 1 V? Go to step 8. Repair harness
1)Turn the ignition switch to ON. between G sensor
2)Measure the voltage between ABSCM&H/U and ABSCM&H/U.
-
ABS-91
I
ABS (DIAGNOSTICS)
Step Check Yes No

I CHECK GROUND SHORT OF HARNESS. Is the resistance more than 1 30 to step 9. Repair harness
Measure the resistance between ABSCM&H/U MR? between G sensor
connector and chassis ground. and ABSCM&H/U.
Connector & terminal Replace the
(F49) No. 28 - Chassis ground: ABSCM&H/U.
<Ref. to ABS-7,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
I CHECK G SENSOR. Is the voltage between 2.1 and 30 to step 10. Replace the G
1)Turn the ignition switch to OFF. 2.4 V when G sensor is hori- sensor. <Ref. to
2)Remove the G sensor from vehicle. zontal? ABS-23, G Sen-
3)Connect the connector to G sensor. sor.>
4)Connect the connector to ABSCM&H/U.
nector terminals.
(B292) NO. 2 (+) - NO. 3 (-):
0 CHECK G SENSOR. Is the voltage between 3.7 and o
; to step 11. Replace the G
Measure the voltage between G sensor con- 4.1 V when G sensor is sensor. <Ref. to
nector terminals. inclined forwards to go"? ABS-23, G Sen-
Connector & terminal sor.>
(B292) NO. 2 (+) - NO. 3 (-):
1 CHECK G SENSOR. Is the voltage between 0.5and o
; to step 12. Replace the G
Measure the voltage between G sensor con- 0.9 V'when G sensor is sensor. <Ref. to
nector terminals. inclined backwards to 90°? ABS-23, G Sen-
(8292) NO. 2 (+) - NO. 3 (-):
2 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- 3epair connector. Go to step 13.
nector between ABSCM&H/U
and G sensor?
3 CHECK ABSC M&H/U. Is the same diagnostic trouble 3eplace the Go to step 14.
:ontrol Unit
ABSCM&H/U).>
4 CHECK ANY OTHER DIAGNOSTIC TROU- Are other diagnostic trouble 'roceed with the A temporary poor
BLE CODES APPEARANCE. codes being output? liagnosis corre- contact.
iponding to the
liagnostic trouble
:ode.
ABS-92
ABS (DIAGNOSTICS)
AB :SELECT MONIT0R AE:ANALOG DATA ARE DIS-

Applicable cartridge of select monitor: <Ref. to PLAYED.
ABS-10, SPECIAL TOOLS, PREPARATION
TOOL, General Description.> DisDlav screen I Contents to be monitored 1
Wheel speed detected by the Front Right
NOTE: FR wheel speed ABS sensor is displayed in km/h or mile/
For basic handling of the select monitor, refer to its h.
Operation Manual. Wheel speed detected by the Front Left
FL wheel speed ABS sensor is displayed in km/h or mile/
AC:DIAGNOSTIC TROUBLE CODES h.
(DTC) ARE DISPLAYED. Wheel speed detected by the Rear Right
A maximum of 3 diagnostic trouble codes (DTC) RR wheel speed ABS sensor is displayed in km/h or mile/
are displayed in order of occurrence. h.
If a particular diagnostic trouble code (DTC) is Wheel speed detected by the Rear Left
not properly stored in memory (due to a drop in AB- RL wheel speed ABS sensor is displayed in km/h or mile/
SCM&H/U power supply, etc.) when a problem oc- h. -
curs, the diagnostic trouble code (DTC), followed Stop light switch monitor voltage is dis-
Stop light switch
by a question mark appears on the select mon-
‘I?”, played.
itor display. This shows it may be an unreliable Refers to vehicle acceleration detecting
Output
reading. voltage
by the analog G sensor. It appears on
the select monitor display in volts.
AF:ON/OFF DATA ARE DISPLAYED.

21 Front Right ABS Sensor Circuit
Display screen Contents to be monitored
Open or Shorted Battery Stop light switch Stop light switch signal
(*a*)/? Valve relav siqnal Valve relay siqnal
u
Motor relay signal I Motor relay signal I
t t 1
ABS signal to TCM
ABS operation signal from ABS con-
trol module to TCM
ABS warning light
I
S4M0076A ABS warning light
Valve relay monitor Valve relay operation monitor signal
*a* refers to the troubles in order of occurrence
Motor relav monitor Motor relay operation monitor signal
(Latest, Old, Older and Reference).
DisDlav screen I Contents to be monitored
CCM signal
ABS operation signal from ABS con-
trol module to TCM I
The most recent diagnostic trouble code
Latest (DTC) appears on the select monitor dis- AG:ABS SEQUENCE CONTROL
The second most recent diagnostic trou-
ble code (DTC) appears on the select
1 I Contents to be monitored I IndexNo.
monitor display.
The third most recent diagnostic trouble sequence
Older code (DTC) appears on the select moni- control
Reference diagnostic trouble code (DTC) appears
AD:CLEAR MEMORY
Function of clearing diagnostic trouble
Clear memory?
code (DTC) and freeze frame data.
ABS-93
ABS (DIAGNOSTICS)
AH:FREEZE FRAME DATA

NOTE:
Data stored at the time of trouble occurrence is
shown on display.
Each time trouble occurs, the latest information
is stored in the freeze frame data in memory.
Freeze frame data will be memorized maximum
to three.
If freeze frame data is not properly stored in
memory (due to a drop in ABSCM power supply,
etc.), a diagnostic trouble code (DTC), preceded by
a question mark "?", appears on the select monitor
display. This shows it may be an unreliable read-
ing.
Wheel speed detected by the Front Right
FR wheel speed ABS sensor is displayed in km/h or mile/
h.
Wheel speed detected by the Front Left
Wheel speed detected by the Rear Right
Wheel speed detected by the Rear Left

RL wheel speed ABS sensor is displayed in km/h or mile/
Ih.
ABSCM power
voltage IPower (in volts) supplied to ABSCM&H/U
appears on the select monitor display.
Refers to vehicle acceleration detected
G sensor output
by the analog G sensor. It appears on
voltage
the select monitor disDlav in volts.
Motor relay mon-
itor
IMotor relay operation monitor signal
Stop light switch Stop light switch signal
ABS signal to ABS operation signal from ABS control
TCM module to TCM
ABS operation signal from ABS control
ABS-AT control module to TCM
ABS 'peration
sianal
I ABS operation signal
ABS-94
\
I ABS (DIAGNOSTICS)
ABS-95
DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)
13.Diagnostics Chart with Subaru Select Monitor

A: COMMUNICATION FOR INITIALIZING IMPOSSIBLE
DIAGNOSIS:
TROUBLE SYMPTOM:
ABS warning light remains on.
WIRING DIAGRAM:
P B
DATA LINK
CONNECTOR
RELAY
HOLDER
ABS
RELAY
+ @ ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT I
m
BR0091
ABS-96
3

ABS (DIAGNOSTICS)
Step Check Yes No

CHECK IGNITION SWITCH. Is the ignition switch ON? 30 to step 2. Turn the ignition
switch to ON, and
select ABS mode
using the select
monitor.
CHECK BATTERY. Is the voltage more than 11 V? 30 to step 3. Charge or replace
1)Turn the ignition switch to OFF. bettery.
2)Measure the battery voltage.
CHECK BAlTERY TERMINAL. Is there poor contact at battery Repair or tighten Go to step 4.
terminal? the battery termi-
181.
CHECK COMMUNICATION OF SELECT Are the name and year of the So to step 10. Go to step 5.
2)Using the select monitor, check whether
communication to other system (such as
engine, TCM, etc.) can be executed normally.
CHECK COMMUNICATION OF SELECT Are the name and year of the Go to step 10. Go to step 6.
€‘)Disconnect the ABSCM&H/U connector.
tems (such as TCM, engine etc.) can be exe-
cuted normally.
CHECK COMMUNICATION OF SELECT Are the name and year of the Inspect the ECM. Go to step 7 .
2)Connect the ABSCM&H/U connector.
3)Disconnect the ECM connector.
tems (such as TCM, engine etc.) can be exe-
cuted normally.
CHECK COMMUNICATION OF SELECT Are the name and year of the Inspect the TCM. Go to step 8.
2)Connect the ECM connector.
3)Disconnect the TCM connector.
normally.
, CHECK COMMUNICATION OF SELECT Are the name and year of the Inspect the cruise Go to step 9.
MONITOR. system displayed on the select control module.
2)Connect the TCM connector.
3)Disconnect the cruise control module con-
nector.
tems (such as engine, TCM etc.) can be exe-
cuted normally.
NOTE:
If the vehicle is not equipped with cruise control
- Go to ster, 9.
ABS-97
ABS (DIAGNOSTICS)
Step Check Yes No

3 CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 30 to step 10. 3epair harness
EACH CONTROL MODULE AND DATA LINK 2? and connector
CONNECTOR. letween each con,
1)Turnthe ignition switch to OFF. :rol module and
2)Disconnect the TCM, ECM, ABSCM&H/U, lata link connec-
and, cruise control module connectors. :or.
IO CHECK OUTPUT SIGNAL FOR ABSCM&H/ s the voltage more than 1 V? 3epair harness 20 to step 11.
U. and connector
1)Turn the ignition switch to ON. letween each con
2)Measure the voltage between ABSCM&H/U rol module and
and chassis ground. jata link connec-
I1 CHECK HARNESWCONNECTOR BETWEEN s the resistance less than 0.5 3epair harness 30 to step 12.
ABSCM&H/U AND DATA LINK CONNEC- 2? ind connector
TOR. letween
Measure the resistance between ABSCM&H/U iBSCM&H/U and
connector and data link connector. jata link connec-
-
(F49) NO. 20 (840) NO. 5:
(F49) NO. 5 - (840) NO. 4:
12 CHECK INSTALLATION OF ABSCM&HN s the ABSCM&H/U connector 20 to step 13. nsert ABSCM&H/
CONNECTOR. iserted into ABSCM&H/U until J connector into
Turn the ignition switch to OFF. he clamp locks onto it? 4BSCM&H/U.
13 CHECK INPUT VOLTAGE OF RELAY HOLD- s the voltage more than 10 V? 20 to step 14. 3epair open circuit
ER. n harness
1)Turn the ignition switch to OFF. letween battery
14 CHECK RELAY HOLDER. s the fuse blown out? 3eplace the fuse. 20 to step 15.
15 CHECK INPUT VOLTAGE OF ABS RELAY. s the voltage more than 10 V? 20 to step 16. 3epair open circuit
1)lnstall the fuse. n harness
2)Remove the ABS relay. letween battery
3)Turn the ignition switch to ON. md Relay holder
16 CHECK INPUT VOLTAGE OF ABS RELAY. s the voltage more than 10 V? 20 to step 17. 3epair harness
Measure the voltage between ABS relay con- :onnector
nector and chassis ground. letween battery,
Connector & terminal gnition switch and
(8264) No. 1 (+) - Chassis ground (-): 4BS relay.
17 CHECK GROUND CIRCUIT OF ABS RELAY. s the resistance less 5 R? 20 to step 18. 3epair open circuit
1)Turn the ignition switch to OFF. letween ABS
2)Measure the resistance between ABS relay 'elay and chassis
ABS-98
ABS (DIAGNOSTICS)
Step Check Yes No

8 CHECK ABS RELAY. Is the resistance less than 10 Go to step 19. Replace the ABS
1)Connect the battery to ABS relay terminal Q? relay.
No. 1 and 3.
terminals.
9 CHECK POWER SUPPLY CIRCUIT. Is the voltage more than 10 V? Go to step 20. Repair open circuit
1)Turnthe ignition switch to ON (engine OFF). in harness
2)Measure the ignition power supply voltage between
ABSCM&H/U and
battery.
!O CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Go to step 21. Repair open circuit
ABSCM&H/U AND CHASSIS GROUND. Q? in harness
1)Turn the ignition switch to OFF. between
2)Disconnect the connector from ABSCM&H/U ABSCM&H/U and
and transmission. inhibitor side con-
3)Measure the resistance of harness between nector, and poor
ABSCM&H/U and chassis ground. contact in cou-
Connector & terminal pling connector.
(F49) No. 23- Chassis ground:
!1 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in control Repair the con- Replace the
module power supply, ground nector. ABSCM&H/U.
line and data link connector? <Ref. to ABS-7,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
ABS-99
ABS (DIAGNOSTICS)
ABS-I 00
I I

ABS (DIAGNOSTICS)
B: NO TROUBLE CODE
DIAGNOSIS:
ABS warning light circuit is shorted.
TROUBLE SYMPTOM:
ABS warning light remains on.
NO TROUBLE CODE displayed on the select monitor.
NOTE:
When the ABS warning light is OFF and “NO TROUBLE CODE” is displayed on the select monitor, the sys-
tem is in normal condition.
ABS-I 01
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
BATTERY
SBF-3 SBF-1
3 c
U
IGNITION
SWITCH
?
z
RELAY HOLDER
BR0083
ABS-1 02
m

ABS IDIAGNOSTICS)
Step Check Yes No

1 CHECK WIRING HARNESS. Does the ABS warning light Go to step 2. Repair the front
1)Turn the ignition switch to OFF. remain off? wiring harness.
2)Disconnect the connector (F74) from con-
nector (8200).
2 CHECK PROJECTIONAT ABSCM&H/U. Are the projection broken? Go to step 3. Replace the
1)Turn the ignition switch to OFF. ABSCM&H/U.
2)Disconnect the connector from ABSCM& <Ref. to ABS-7,
H/U. ABS Control Mod-
,
3)Check for broken projection at the ule and Hydraulic
ABSCM&H/U terminal. Control Unit
(ABSCM&H/U).>
3 CHECK ABSCM&H/U. Replace the
Measure the resistance between ABSCM&H/U MR? ABSCM&H/U.
terminals. <Ref. to ABS-7,
Terminals ABS Control Mod-
NO. 22 - NO. 23: ule and Hydraulic
Control Unit
(ABSCM&H/U).>
1 CHECK WIRING HARNESS. Is the resistance less than 0.5 Go to step 5. Repair the har-
Measure the resistance between connector R? ness.
5 CHECK WIRING HARNESS. Is the resistance more than 1 Go to step 6. Repair the har-
1)Connect the connector to ABSCM&H/U. ness.
I
-
<Ref. to ABS-7,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
ABS-103
ABS (DIAGNOSTICS)
C: DTC21
OPEN OR SHORT CIRCUIT IN FRONT RIGHT ABS SENSOR CIRCUIT
NOTE:
For the diagnostic procedure, refer to DTC 27. <Ref. to ABS-I 05, DTC 27 OPEN OR SHORT CIRCUIT IN
REAR LEFT ABS SENSOR CIRCUIT, Diagnostics Chart with Subaru Select Monitor.>
D: DTC23
OPEN OR SHORT CIRCUIT IN FRONT LEFT ABS SENSOR CIRCUIT
NOTE:
For the diagnostic procedure, refer to DTC 27. <Ref. to ABS-I 05, DTC 27 OPEN OR SHORT CIRCUIT IN
E: DTC25
OPEN OR SHORT CIRCUIT IN REAR RIGHT ABS SENSOR CIRCUIT
NOTE:
For the diagnostic procedure, refer to DTC 27. <Ref. to ABS-105, DTC 27 OPEN OR SHORT CIRCUIT IN
ABS-I 04
ABS (DIAGNOSTICS)
F: DTC27
OPEN OR SHORT CIRCUIT IN REAR LEFT ABS SENSOR CIRCUIT
DIAGNOSIS:
Faulty ABS sensor (Broken wire, input voltage too high)
TROUBLE SYMPTOM:
ABS-I 05
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT I
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7 r' r'
1
FRONT FRONT
ABS ABS REAR REAR
SENSOR LH SENSOR RH
BROOM
ABS-I 06
3

ABS (DIAGNOSTICS)
Step Check Yes No

CHECK OUTPUT OF ABS SENSOR USING Ioes the speed indicated on 30 to step 2. Go to step 8.
SELECT MONITOR. he display change in response
1)Select “Current data display & Save” on the 3 the speedometer reading
select monitor. luring acceleration/decelera-
2)Read the ABS sensor output corresponding ion when the steering wheel is
to the faulty system in the select monitor data I the straight-ahead position?
display mode.
CHECK INSTALLATION OF ABS SENSOR. ire the ABS sensor installation 30 to step 3. Tighten the ABS
Tightening torque: ,olts tightened securely? sensor installation
32 N.m (3.3 kgf-m, 24 ft-lb) bolts securely.
CHECK ABS SENSOR GAP. s the gap within the specifica- 30 to step 4. Adjust the gap.
gap over entire perimeter of the wheel. Adjust the gap us
front wheel ing spacers (Pal
-
0.3 - 0.8 mm (0.012 0.031 in) No. 26755AA000:
Rear wheel If spacers cannc
-
0.7 - 1.2 mm (0.028 0.047 in) correct the gap, re
place the wori
sensor or wori
tone wheel.
.CHECK TONE WHEEL RUNOUT. s the runout less than 0.05 30 to step 5. Replace the tone
<Ref. to ABS-21,
Front Tone
Wheel.> Rear:
<Ref. to ABS-22,
Rear Tone
Wheel.>
CHECK POOR CONTACT IN CONNECTORS. s there poor contact in con- 3epair the con- Go to step 6.
Turn the ignition switch to OFF. lectors between ABSCM&H/U lector.
ind ABS sensor?
CHECK ABSCM&HN. s the same diagnostic trouble 3eplace the Go to step 7.
1)Connect all connectors. :ode as in the current diagno- SBSCM&H/U.
2)Erase the memory. ;is still being output? :Ref. to ABS-7,
4)Read out the diagnostic trouble code. Ae and Hydraulic
2ontrol Unit
ABSCM&H/U).>
CHECK ANY OTHER DIAGNOSTICTROU- ire other diagnostic trouble ’roceed with the A temporary poor
BLE CODES APPEARANCE. :odes being output? jiagnosis corre- contact.
liagnostic trouble Check harnes
:ode. and connector
between AE
SCM&H/U an
ABS sensor.
I CHECK ABS SENSOR. s the resistance between 1 30 to step 9. Replace the ABS
1)Turn the ignition switch to OFF. ind 1.5 kR? sensor. Front:
2)Disconnect the connector from ABS sensor. <Ref. to ABS-14,
3)Measure the resistance of ABS sensor con- Front ABS Sen-
nector terminals. sor.> Rear: <Ref.
Terminal to ABS-18, Rear
front RH No. 1 -No. 2: ABS Sensor.>
front LH No. 1 -No. 2:
Rear RH No. 1 - No. 2:
-
ABS-I 07
ABS (DIAGNOSTICS)
Step Check Yes No

9 CHECK BATTERY SHORT OF ABS SEN- s the voltage less than 1 V? i o to step 10. Replace the ABS
SOR. sensor. Front:
1)Disconnect the connector from ABSCM& <Ref. to ABS-14,
H/U. Front ABS Sen-
2)Measure the voltage between ABS sensor sor.> Rear: <Ref.
and chassis ground. to ABS-I 8, Rear
Terminal ABS Sensor.>
Front RH No. 1 (+) - Chassis ground (-)
Front LH No. 1 (+) - Chassis ground (-)
IO CHECK BAlTERY SHORT OF ABS SEN- s the voltage less than 1 V? ;o to step 11. Replace the ABS
SOR. sensor. Front:
1)Turnthe ignition switch to ON. <Ref. to ABS-14,
2)Measure the voltage between ABS sensor Front ABS Sen-
and chassis ground. sor.> Rear: <Ref.
Terminal to ABS-I 8, Rear
Front RH No. 1 (+) - Chassis ground (-) ABS Sensor.>
Front LH No. 1 (+) - Chassis ground (-)
I1 CHECK HARNESSKONNECTOR BETWEEN s the resistance between 1 ;o to step 12. Repair harness/
'nBSCM&HlU AND ABS SENSOR. ind 1.5 kR? sonnector
1)Turnthe ignition switch to OFF. Detween
2)Connect the connector to ABS sensor. 4BSCM&H/U and
3)Measure the resistance between 4BS sensor.
DTC 21 / (F49) NO. 11 - NO. 12:
DTC 23 / (F49) NO. 9 - NO. 10:
DTC 25 / (F49) NO. 14 - NO. 15:
DTC 2 7 / (F49) NO. 7 - NO. 8:
12 CHECK BAlTERY SHORT OF HARNESS. s the voltage less than 1 V? i o to step 13. Repair harness
Measure the voltage between ABSCM&H/U 3etween
connector and chassis ground. 4BSCM&H/U and
Connector & terminal 4BS sensor.
DTC 21 /(F49) No. 11 (+) - Chassis
ground (-):
DTC 23 / (F49) No. 9 (+) - Chassis
ground (-):
DTC 25 / (F49) No. 14 (+) - Chassis
ground (-):
DTC 27 / (F49) No. 7 (+) - Chassis
ground (-):
13 CHECK BAlTERY SHORT OF HARNESS. s the voltage less than 1 V? i o to step 14. 3epair harness
1)Turn the ignition switch to ON. ietween
2)Measure the voltage between ABSCM&H/U 4BSCM&H/U and
connector and chassis ground. 4BS sensor.
DTC 21 /(F49) No. 11 (+) - Chassis
ground (-):
DTC 23 / (F49) No. 9 (+) - Chassis
ground (-):
DTC 25 / (F49) No. 14 (+) - Chassis
groundI)-(
DTC 2 7 / (F49) No. 7 (+) - Chassis
ground (-):
14 CHECK INSTALLATION OF ABS SENSOR. Ire the ABS sensor installation io to step 15. righten the ABS
32 N.m (3.3 kgf-m, 24 ft-lb) iolts securely.
ABS-I 08
ABS (DIAGNOSTICS)
Step Check Yes No

CHECK ABS SENSOR GAP. ;the gap within the specifica- io to step 16. Adjust the gap.
Measure the tone wheel to ABS sensor piece ons? NOTE:
gap over entire perimeter of the wheel. Adjust the gap us.
front wheel ing spacers (Pad
-
0.3 - 0.8 mm (0.012 0.031 in) No. 26755AAOOO).
Rear wheel If spacers cannol
0.7- 1.2 mm (0.028 - 0.047 in) correct the gap, re-
place the worr
sensor or wow
tone wheel.
CHECK TONE WHEEL RUNOUT. 3 therunout less than 0.05 20 to step 17. Replace the tone
<Ref. to ABS-21,
Front Tone
Wheel.> Rear:
<Ref. to ABS-22,
Rear Tone
Wheel.>
CHECK GROUND SHORT OF ABS SENSOR s the resistance more than 1 20 to step 18. Replace the ABS
1)Turn the ignition switch to ON. An? sensor and
2)Measure the resistance between ABS sen- ABSCM&H/U.
sor and chassis ground. Front: <Ref. to
Terminal ABS-14, Front
Front RH No. 1 - Chassis ground: ABS Sensor.>
Front LH No. 1 - Chassis ground: Rear: <Ref. to
Rear RH No. 1 - Chassis ground: ABS-18, Rear
Rear LH No. 1 - Chassis ground: ABS Sensor.>
and <Ref. to
ABS-7, ABS Con-
trol Module and
Hydraulic Control
Unit (ABSCM&H/
U).>
CHECK GROUND SHORT OF HARNESS. s the resistance more than 1 30 to step 19. Repair harness
1)Turnthe ignition switch to OFF. nn? between
ABSCM&H/U connector terminal and chassis And replace the
ground. ABSCM&H/U.
Connector & terminal <Ref. to ABS-7,
DTC 21 /(F49) No. 11 - Chassis ground ABS Control Mod-
DTC 23 / (F49) No. 9 - Chassis ground: ule and Hydraulic
DTC 25 / (F49) No. 14 - Chassis ground Control Unit
DTC 27/(F49) No. 7 - Chassis ground: (ABSCM&H/U).>
CHECK POOR CONTACT IN CONNECTORS s there poor contact in con- 3epair the con- Go to step 20.
lectors between ABSCM&H/U lector.
md ABS sensor?
CHECK ABSCM&H/U. s the same diagnostic trouble 3eplace the Go to step 21.
1)Connect all connectors. ;ode as in the current diagno- 4BSCM&H/U.
2)Erase the memory. ;is still being output?
3)Perform the inspection mode.
4)Read out the diagnostic trouble code.
~
CHECK ANY OTHER DIAGNOSTIC TROU- 4re other diagnostic trouble Droceed with the A temporary poor
BLE CODES APPEARANCE. :odes being output? diagnosis corre- contact.
jiagnostic trouble Check harnes!
:ode. and connector!
between AB
SCM&H/U anc
ABS sensor.
ABS-I 09
ABS (DIAGNOSTICS)
G: DTC22
FRONT RIGHT ABNORMAL ABS SENSOR SIGNAL
NOTE:
For the diagnostic procedure, refer to DTC 28. <Ref. to ABS-111, DTC 28 REAR LEFT ABNORMAL ABS
SENSOR SIGNAL, Diagnostics Chart with Subaru Select Monitor.>
H: DTC24
FRONT LEFT ABNORMAL ABS SENSOR SIGNAL
NOTE:
For the diagnostic procedure, refer to DTC 28. <Ref. to ABS-111, DTC 28 REAR LEFT ABNORMAL ABS
I: DTC26
REAR RIGHT ABNORMAL ABS SENSOR SIGNAL
NOTE:
For the diagnostic procedure, refer to DTC 28. <Ref. to ABS-1 11, DTC 28 REAR LEFT ABNORMAL ABS
ABS-I 10
I m
ABS (DIAGNOSTICS)
_ _ _ _ _ ~
J: DTC28
REAR LEFT ABNORMAL ABS SENSOR SIGNAL
DIAGNOSIS:
1 TROUBLE SYMPTOM:
1
t ABS does not operate.

i
ABS-1 11
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
1
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FRONT U U
FRONT
ABS ABS REAR REAR
SENSOR LH SENSOR RH
BR0084
ABS-I 12
ABS (DIAGNOSTICS)
~~
~
Step Check Yes No

CHECK OUTPUT OF ABS SENSOR USING Ioes the speed indicated on io to step 2. i o to step 8.
SELECT MONITOR. he display change in response
1)Select "Current data display & Save" on the o the speedometer reading
select monitor. luring acceleration/decelera-
2)Read the ABS sensor output corresponding ion when the steering wheel is
to the faulty system in the select monitor data n the straight-ahead position?
display mode.
CHECK POOR CONTACT IN CONNECTORS. s there poor contact in con- iepair the con- So to step 3.
Turn the ignition switch to OFF. lectors between ABSCM&H/U lector.
ind ABS sensor?
1 CHECK SOURCES OF SIGNAL NOISE. s the car telephone or the i o to step 4. 'roperly install the
vireless transmitter properly :ar telephone or
nstalled? he wireless trans-
nitter.
CHECK SOURCES OF SIGNAL NOISE. 4re noise sources (such as an istall the noise ;o to step 5.
mtenna) installed near the 8ourcesapart from
iensor harness? l e sensor har-
less.
I CHECK SHIELD CIRCUIT. s the resistance less than 0.5 So to step 6. 3epair the shield
1)Turnthe ignition switch to OFF. 3? iarness.
02)Connectall connectors.
DTC 26 / (B200) No. 11 - Chassis
ground:
DTC 28 / (8200) No. 3 - Chassis ground.
NOTE:
Go to step 6.
i CHECK ABSCM&HIU. s the same diagnostic trouble 3eplace the 30 to step 7.
1)Connect all connectors. :ode as in the current diagno- 4BSCM&H/U.
4)Read out the diagnostic trouble code. rle and Hydraulic
2ontrol Unit
ABSCM&H/U).>
r CHECK ANY OTHER DIAGNOSTICTROU- 4re other diagnostic trouble 'roceed with the 1 temporary noise
BLE CODES APPEARANCE. :odes being output? iiagnosis corre- nterference.
;ponding to the
iiagnostic trouble
:ode.
I CHECK INSTALLATIONOF ABS SENSOR. 4re the ABS sensor installation o
; to step 9. righten the ABS
32 N.m (3.3 kgf-m, 24 ft-lb) iolts securely.
3 CHECK ABS SENSOR GAP. Is the gap within the specifica- o; to step 10. 4djust the gap.
Measure the tone wheel to ABS sensor piece !ions? VOTE:
gap over entire perimeter of the wheel. 4djust the gap us.
Front wheel ng spacer (Par
0.3 - 0.8 mm (0.012 - 0.031 in) 10. 26755AA000)
. Rearwheel f spacers canno
0.7- 1.2" (0.028-0.047in) :orrect the gap, re-
ilace the worn
sensor or worn
:one wheel.
IO PREPARE OSCILLOSCOPE. Is an oscilloscope available? 30 to step 11.
ABS-I 13
ABS (DIAGNOSTICS)
Step Check Yes No

1 CHECK ABS SENSOR SIGNAL. s the oscilloscope pattern $0to step 15. So to step 12.
1)Raise all four wheels of ground. mooth, as shown in the fig-
2)Turn the ignition switch OFF. Ire?
specified frequency. <Ref. to ABS-I 7,WAVE-
FORM, Control Module 110 Signal.>
NOTE:
DTC 22 /(F95) NO. 1 (+) - NO. 2 (-):
DTC 24 / (F94) NO. 1 (+) - NO.2 (-):
DTC 26/(899) NO. 9 (+) - NO. 70 (-):
DTC 28 / (899) NO. 4 (+)- NO. 5 (-):
2 CHECK CONTAMINATION OF ABS SENSOR s the ABS sensor piece or the -horoughly 30 to step 13.
OR TONE WHEEL. one wheel contaminated by emove dirt or
Remove the disc rotor or drum from hub in lirt or other foreign matter? Ither foreign mat-
accordance with diagnostic trouble code. e r.
3 CHECK DAMAGE OF ABS SENSOR OR Ire there broken or damaged leplace the ABS $0to step 14.
TONE WHEEL. n the ABS sensor piece or the iensor or tone
one wheel? vheel. Front: <Ref.
3 ABS-14, Front
iBS Sensor.>
lear: <Ref. to
iBS-18, Rear
\BS Sensor.>
ind Front: <Ref.
3 ABS-21, Front
one Wheel.>
lear: <Ref. to
rBS-22, Rear
one Wheel.>
4 CHECK TONE WHEEL RUNOUT. s the runout less than 0.05 ;o to step 15. leplace the tone
Measure the tone wheel runout. nm (0.0020 in)? vheel. Front:
:Ref. to ABS-21,
:rant Tone
Yheel.> Rear:
:Ref. to ABS-22,
lear Tone
Yheel.>
5 CHECK RESISTANCE OF ABS SENSOR. s the resistance between 1 i o to step 16. leplace the ABS
1)Turn the ignition switch OFF. n d 1.5 kR? lensor. Front:
2)Disconnect the connector from ABS sensor. :Ref. to ABS-14,
3)Measure the resistance between ABS sen- :rant ABS Sen-
sor connector terminals. ;or.> Rear: <Ref.
Terminal Q ABS-18, Rear
Front RH No. 1 -No. 2: iBS Sensor.>
Front LH No. 1 -No. 2:
-
Rear RH No. 1 No. 2:
Rear LH No. 1 - No. 2:
6 CHECK GROUND SHORT OF ABS SENSOR s the resistance more than 1 i o to step 17. leplace the ABS
Measure the resistance between ABS sensor VIR? ;ensor. Front:
and chassis ground. :Ref. to ABS-I 4,
Terminal :rant ABS Sen-
-
Front RH No. 1 Chassis ground: ,or.> Rear: <Ref.
-
Front LH No. 1 Chassis ground: 3 ABS-I 8, Rear
-
Rear RH No. 1 Chassis ground: iBS Sensor.>
-
Rem LH No. 1 Chassis ground:
ABS-I 14
ABS /DIAGNOSTICS)
Step Check Yes No

7 CHECK HARNESS/CONNECTOR BETWEEN s the resistance between 1 io to step 18. iepair harness/
ABSCM&H/U AND ABS SENSOR. 3nd 1.5 kR? onnector
1)Connect the connector to ABS sensor. letween
2)Disconnect the connector from ABSCM& rBSCM&H/U and
H/U. rBS sensor.
3)Measure the resistance at ABSCM&H/U
-
DTC 22/(F49) NO. 11 NO. 12:
-
DTC 24 / (F49) No. 9 No. 10:
DTC 26 / (F49) NO. 14 - NO. 15:
-
DTC 28 / (F49) NO. 7 NO. 8:
8 CHECK GROUND SHORT OF HARNESS. s the resistance more than 1 io to step 19. iepair harness/
Measure the resistance between ABSCM&H/U WR? onnector
connector and chassis ground. letween
Connector & terminal rBSCM&H/U and
DTC 22 / (F49) No. 11 - Chassis ground: iBS sensor.
-
-
DTC 28 / (F49) No. 7 - Chassis ground:
9 CHECK GROUND CIRCUIT OF ABSCM&H/U. Is the resistance less than 0.5 i o to step 20. iepair the
Measure the resistance between ABSCM&H/U D? \BSCM&H/U
And chassis ground. iround harness.
(F49) NO. 23- GND:
0 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- iepair the con- io to step 21.
nectors between ABSCM&H/U lector.
and ABS sensor?
1 CHECK SOURCES OF SIGNAL NOISE. Is the car telephone or the i o to step 22. 'roperly install the
vvireless transmitter properly :ar telephone or
installed? he wireless trans-
nitter.
2 CHECK SOURCES OF SIGNAL NOISE. Are noise sources (such as an istall the noise $0to step 23.
antenna) installed near the ources apart from
sensor harness? l e sensor har-
less.
13 CHECK SHIELD CIRCUIT. Is the resistance less than 0.5 i o to step 24. 3epair the shield
1)Connect all connectors. n? tarness.
DTC 26 / (6200) No. 11 - Chassis
ground:
DTC 28 / (8200) No. 3 - Chassis ground:
NOTE:
Go to step 24.
!4 CHECK ABSCM&HN. Is the same diagnostic trouble ieplace the 20 to step 25.
1)Connect all connectors. code as in the current diagno- \BSCM&H/U.
3)Perform the inspection mode. IBS Control Mod-
:ontrol Unit
ABSCM&H/U).>
15 CHECK ANY OTHER DIAGNOSTICTROU- Are other diagnostic trouble 'roceed with the 4 temporary noise
BLE CODES APPEARANCE. codes being output? liagnosis corre- nterference.
,pending to the
liagnostic trouble
:ode.
ABS-I 15
ABS (DIAGNOSTICS)
ABS-I 16
3
ABS (DIAGNOSTICS)
K: DTC29
ABNORMAL ABS SENSOR SIGNAL ON ANY ONE OF FOUR SENSOR
DIAGNOSIS:
Faulty tone wheel
Wheels turning freely for a long time
TROUBLE SYMPTOM:
ABS-I 17
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
\
E
I
I
I
I
I
I
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ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT
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FRONT
ABS REAR REAR
SENSOR LH SENSOR RH
0R0084
ABS-I 18
ABS (DIAGNOSTICS)
Step Check Yes No

CHECK IF THE WHEELS HAVE TURNED Check if the wheels have been The ABS is nor- 30 to step 2.
FREELY FOR A LONG TIME. turned freely for more than onemal. Erase the
minute, such as when the vehi- diagnostic trouble
code.
cle is jacked-up, under full-lock
cornering or when tire is not in
NOTE:
contact with road surface. When the wheels
tum freely for a
long time, such as
when the vehicle is
towed or jacked-
up, or when steer-
ing wheel is contin-
uously turned all
the way, this diag-
nostic trouble code
may sometimes
occur.
I CHECK TIRE SPECIFICATIONS. Are the tire specifications cor- Go to step 3. Replace the tire.
Turn the ignition switch to OFF. rect?
I CHECK WEAR OF TIRE. Is the tire worn excessively? Replace the tire. Go to step 4.
I CHECK TIRE PRESSURE. Is the tire pressure correct? Go to step 5. Adjust the tire
pressure.
I CHECK INSTALLATION OF ABS SENSOR. Are the ABS sensor installation Go to step 6. Tighten the ABS
Tightening torque: bolts tightened securely? sensor installation
32 N.m (3.3 kgf-m, 24 fl-lb) bolts securely.
i CHECK ABS SENSOR GAP. Is the gap within the specifica- Go to step 7. Adjust the gap.
Measure the tone wheel to ABS sensor piece tions? NOTE:
gap over entire perimeter of the wheel. Adjust the gap us
Front wheel ing spacer (Par
- -
0.3 0.8 mm (0.012 0.031 in) No. 26755AAOOO)
Rear wheel If spacers canno
0.7 - 1.2 mm (0.028 - 0.047 in) correct the gap, re
place the won
sensor or wori
tone wheel.
? PREPARE OSCILLOSCOPE. Is an oscilloscope available? Go to step 8. Go to step 9.
ABS-1 19
ABS (DIAGNOSTICS)
~~ ~~ ~ ~~~~ ~~~
Step No
I CHECK ABS SENSOR SIGNAL. o
; to step 9.
1)Raise all four wheels of ground. 3s shown in the figure?
3)Connect the oscilloscope to the connector
(B99), (F95) or (F94) in accordance with trou-
ble code.
NOTE:
Front RH
(F95) NO. 1 (+) - NO. 2 (-):
Front LH
(F94) NO. 1 (+) - NO. 2I)-(
Rear RH
(699) NO. 9 (+)- NO. 10I)-(
Rear LH
(699) NO. 4 (+) - NO. 5 (-):
I CHECK CONTAMINATIONOF ABS SENSOR s the ABS sensor piece or the Thoroughly 30 to step 10.
OR TONE WHEEL. one wheel contaminated by remove dirt or
Remove the disc rotor from hub. lirt or other foreign matter? other foreign mat-
ter.
0 CHECK DAMAGE OF ABS SENSOR OR 4re there broken or damaged Replace the ABS so to step 11.
TONE WHEEL. eeth in the ABS sensor piece sensor or tone
i r the tone wheel? wheel. Front: <Ref.
to ABS-14, Front
ABS Sensor.>
Rear: <Ref. to
ABS-18, Rear
ABS Sensor.>
and Front: <Ref.
to ABS-21, Front
Tone Wheel.>
Rear: <Ref. to
ABS-22, Rear
Tone Wheel.>
I
1 CHECK TONE WHEEL RUNOUT.
<Ref. to ABS-21,
Front Tone
Wheel.> Rear:
<Ref. to ABS-22,
Rear Tone
Wheel.>
2 CHECK ABSCM&H/U. s the same diagnostic trouble Replace the Go to step 13.
1)Turn the ignition switch to OFF. :ode as in the current diagno- ABSCM&H/U.
2)Connect all connectors. ;is still being output? <Ref. to ABS-7,
~ 5)Read out the diagnostic trouble code. Control Unit
(ABSCM&H/U).>
3 CHECK ANY OTHER DIAGNOSTICTROU- ire other diagnostic trouble Proceed with the A temporary poor
BLE CODES APPEARANCE. :odes being output? diagnosis corre- contact.
sponding to the
diagnostic trouble
code.
I
ABS (DIAGNOSTICS)
L: DTC31
FRONT RIGHT INLET VALVE MALFUNCTION
NOTE:
For the diagnostic procedure, refer to DTC 37. <Ref. to ABS-121, DTC 37 REAR LEFT INLET VALVE MAL-
FUNCTION, Diagnostics Chart with Subaru Select Monitor.>
M: DTC33
FRONT LEFT INLET VALVE MALFUNCTION
NOTE:
N: DTC35
REAR RIGHT INLET VALVE MALFUNCTION
NOTE:
0: DTC37
REAR LEFT INLET VALVE MALFUNCTION
DIAGNOSIS:
Faulty inlet solenoid valve
TROUBLE SYMPTOM:
ABS-I 21
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
BATTERY
ABS-I 22
m
ABS (DIAGNOSTICS)
Step Check Yes No

I CHECK INPUT VOLTAGE OF RELAY HOLD Is the voltage more than 10 V? 30 to step 2. Repair open circuit
ER. in harness
1)Turn the ignition switch to OFF. setween battery
2)Remove the fuse. snd relay holder
3)Measure the voltage between ABS relay sonnector.
2 CHECK RELAY HOLDER. Is the fuse blown out? 3eplace the fuse. Go to step 3.
3 CHECK INPUT VOLTAGE OF ABS RELAY. Is the voltage more than 10 V? 30 to step 4. Repair open circuit
1 CHECK INPUT VOLTAGE OF ABS RELAY. Is the voltage more than 10 V? 30 to step 5. Repair harness
5 CHECK GROUND CIRCUIT OF ABS RELAY Is the resistance less than 5 30 to step 6. Repair open circuit
1)Turn the ignition switch to OFF. a? between ABS
6 CHECK ABS RELAY. Is the resistance less than 10 30 to step 7. Replace the ABS
No. 1 and 3.
terminals.
7 CHECK INPUT VOLTAGE OF ABSCM&WU. Is the voltage between 10 and Go to step 8. Repair harness
H/U. ignition switch and
B CHECK GROUND CIRCUIT OF ABSCM&H/U Is the resistance less than 0.5 Go to step 9. Repair the
1)Turn the ignition switch to OFF. Q? ABSCM&H/U
9 CHECK POOR CONTACT IN CONNECTORS Isthere poorcontact in con- Repair the con- Go to step 10.
lo ~
CHECK ABSCM&WU. Is the same diagnostic trouble Replace the Go to step 11.
Control Unit
(ABSCM&H/U).>
ABS-I 23
ABS (DIAGNOSTICS)
Step Check Yes No

sponding to the
diagnostic trouble
code.
ABS-124
m

ABS (DIAGNOSTICS)
P: DTC32
FRONT RIGHT OUTLET VALVE MALFUNCTION
NOTE:
For the diagnostic procedure, refer to DTC 38. <Ref. to ABS-125, DTC 38 REAR LEFT OUTLET VALVE
MALFUNCTION, Diagnostics Chart with Subaru Select Monitor.>
Q: DTC34
FRONT LEFT OUTLET VALVE MALFUNCTION
NOTE:
R: DTC36
REAR RIGHT OUTLET VALVE MALFUNCTION
NOTE:
S: DTC38
REAR LEFT OUTLET VALVE MALFUNCTION
DIAGNOSIS:
Faulty outlet solenoid valve
TROUBLE SYMPTOM:
ABS-I 25
n
ABS IDIAGNOSTICS)
WIRING DIAGRAM:
BATTERY
RELAY
HOLDER
ABS
RELAY
I @ ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT I

I
n I516171819
B 11213141
I
10111112113114 15 116117118119120
BR0085
ABS-126
ABS (DIAGNOSTICS)
Step Check Yes No

CHECK INPUT VOLTAGE OF RELAY HOLD s the voltage more than 10 V? Go to step 2. Repair open circuit
ER. in harness
1)Turnthe ignition switch to OFF. between battery
2)Remove the fuse. and relay holder
CHECK RELAY HOLDER. Is the fuse blown out? Replace the fuse. Go to step 3.
CHECK INPUT VOLTAGE OF ABS RELAY. Is the voltage more than 10 V? Go to step 4. Repair open circuit
CHECK INPUT VOLTAGE OF ABS RELAY. Is the voltage more than 10 V? Go to step 5. Repair harness
. (6264) No. 1 (+) - Chassis ground (-): ABS relay.
CHECK GROUND CIRCUIT OF ABS RELAY Is the resistance less than 5 Go to step 6. Repair open circuii
1)Turn the ignition switch to OFF. n? between ABS
CHECK ABS RELAY. Is the resistance less than 10 Go to step 7. Replace the ABS
1)Connectthe battery to ABS relay terminal n? relay.
No. 1 and 3.
terminals.
CHECK INPUT VOLTAGE OF ABSCM&WU. Is the voltage between 10 and Go to step 0. Repair harness
H/U. ignition switch and
CHECK GROUND CIRCUIT OF ABSCM&H/U Is the resistance less than 0.5
1)Turn the ignition switch to OFF. n? ABSCM&H/U
Connector & terminel
-
CHECK POOR CONTACT IN CONNECTORS Is there poor contact in con- Repair the con- Go to step 10.
I ~ CHECK ABSCM&W. Is the same diagnostic trouble Replace the Go to step 11.
Control Unit
(ABSCM&H/U).>
ABS-I 27
ABS (DIAGNOSTICS)
Check

sponding to the
diagnostic trouble
code.
ABS-1 28
ABS (DIAGNOSTICS)
ABS-I 29
ABS (DIAGNOSTICS)
T: DTC41
ABS CONTROL MODULE MALFUNCTION
DIAGNOSIS:
Faulty ABSCM&H/U
TROUBLE SYMPTOM:
WIRING DIAGRAM:

I
II I
B4M1457
ABS-I 30
3

ABS ( DIAG NOSTlCS)
Step Check Yes No

I CHECK GROUND CIRCUIT OF ABSCM&H/U Is the resistance less than 0.5 $0to step 2. Repair the
1)Turn the ignition switch to OFF. R? ABSCM&H/U
2)Disconnect the connector from ABSCM& ground harness.
H/U.
ABSCM&H/U and chassis ground.
2 CHECK POOR CONTACT IN CONNECTORS Is there poor contact in con- 3epair the con- Go to step 3.
nectors between battery, igni- lector.
tion switch and ABSCM&H/U?
3 CHECK SOURCES OF SIGNAL NOISE. Is the car telephone or the ;o to step 4. Properly install the
wireless transmitter properly car telephone or
installed? the wireless trans-
mitter.
1 CHECK SOURCES OF SIGNAL NOISE. Are noise sources (such as an nstall the noise Go to step 5.
antenna) installed near the ;ources apart from
sensor harness? he sensor har-
less.
~
5 CHECK ABSCM&WU. Is the same diagnostic trouble qeplace the Go to step 6.

01)Turnthe ignition switch to OFF. code as in the current diagno- iBSCM&H/U.
2)Connect all connectors. sis still being output? :Ref. to ABS-7,
3)Erase the memory. 4BS Control Mod-
4)Perform the inspection mode. ile and Hydraulic
5)Read out the diagnostic trouble code. ;ontrol Unit
ABSCM&H/U).>
6 CHECK ANY OTHER DIAGNOSTICTROU- Are other diagnostic trouble Voceed with the A temporary poor
BLE CODES APPEARANCE. codes being output? liagnosis corre- contact.
iponding to the
liagnostic trouble
:ode.
ABS-1 31
ABS (DIAGNOSTICS)
U: DTC42
POWER SUPPLY VOLTAGE TOO LOW
DIAGNOSIS:
Power source voltage of the ABSCM&H/U is low.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
R E LAY
HOLDER
ABS
RELAY
BR0085
ABS-I 32
ABS (DIAGNOSTICS)
Step Check Yes No

I CHECK GENERATOR. s the voltage between 10 and ;o to step 2. Repair the genera
1)Start the engine. I5 V? tor. <Ref. to SC-
Terminal
-
Generator B terminal Chassis ground
! CHECK BATTERY TERMINAL. \re the positive and negative 30 to step 3. Tighten the clamp
Turn the ignition switch to OFF. iattery terminals tightly of terminal.
Aamped?
I CHECK INPUT VOLTAGE OF ABSCM&H/U. s the voltage between 10 and o
1)Disconnect the connector from ABSCM& I5 V? connector
2)Run the engine at idle. ignition switch anc
-
I CHECK GROUND CIRCUIT OF ABSCM&H/U s the resistance less than 0.5 i o to step 5. Repair the
1)Turnthe ignition switch to OFF. n? ABSCM&H/U
i
-
b CHECK POOR CONTACT IN CONNECTORS s there poor contact in con- 3epair the con- Go to step 6.
lectors between generator, lector.
iattery and ABSCM&H/U?
i CHECK ABSCM&H/U. s the same diagnostic trouble 3eplace the Go to step 7.
2)Erase the memory. ;is still being output? :Ref. to ABS-7,
;ontrol Unit
ABSCM&H/U).>
? CHECK ANY OTHER DIAGNOSTIC TROU- \re other diagnostic trouble 'roceed with the A temporary poor
BLE CODES APPEARANCE. :odes being output? jiagnosis corre- contact.
iponding to the
iiagnostic trouble
:ode.
ABS-I 33
ABS (DIAGNOSTICS)
V: DTC42
POWER SUPPLY VOLTAGE TOO HIGH
DIAGNOSIS:
Power source voltage of the ABSCM&H/U is high.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
RELAY
HOLDER
ABS
RELAY
I ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT

I
il21314l n 1 516171819
101111121131 14 I 15 116117]18]19]20
0R0005
ABS-134
ABS (DIAGNOSTICS)
Step Check Yes No

CHECK GENERATOR. s the voltage between 10 and 30 to step 2. Repair the genera
Terminal
Generator 6 terminal - Chassis ground:
CHECK BATTERY TERMINAL. ire the positive and negative 30 to step 3. Tighten the clamp
Turn the ignition switch to OFF. Iattery terminals tightly of terminal.
:lamped?
ER. in harness
1)Turnthe ignition switch to OFF. between battery
I CHECK RELAY HOLDER. s the fuse blown out? 3eplace the fuse. Go to step 5.
I CHECK INPUT VOLTAGE OF ABS RELAY. s the voltage more than 10 V? So to step 6. Repair open circuil
i CHECK INPUT VOLTAGE OF ABS RELAY. s the voltage more than 10 V? So to step 7. Repair harness
I
CHECK GROUND CIRCUIT OF ABS RELAY. s the resistance less than 5 Go to step 8. Repair open circui'
1)Turnthe ignition switch to OFF. R? between ABS
I CHECK ABS RELAY. s the resistance less than 10 Go to step 9. Replace the ABS
1)Connect the battery to ABS relay terminal R? relay.
No. 1 and 3.
terminals.
3 CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage between 10 and Go to step 10. Repair harness
HIU. between battery,
2)Run the engine at idle. ignition switch anc
CHECK GROUND CIRCUIT OF ABSCM&H/U Is the resistance less than 0.5 Go to step 11. Repair the
lo
ABSCM&H/U
~
1)Turn the ignition switch to OFF. R?

1F49)No. 23 - Chassis around:
ABS-1 35
ABS (DIAGNOSTICS)
Step Check Yes No

2) Erase the memory. sis still being output? <Ref. to ABS-7,
Control Unit
(ABSCM&H/U).>
sponding to the
diagnostic trouble
code.
ABS-I 36
ABS (DIAGNOSTICS)
ABS-I 37
ABS (DIAGNOSTICS)
W: DTC44
ABS-AT CONTROL (NON CONTROLLED)
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
I
Ic
TI
NA : NON-TURBO ENGINE MODEL
A:
8
854
8 : 655 TCM
BR008f
ABS-I 38
ABS (DIAGNOSTICS)
Step Check Yes No

1 CHECK SPECIFICATIONSOF THE AB- s an ABSCM&H/U for AT Replace the Go to step 2.
SCM&H/U. model installed on a MT ABSCM&H/U.
Check specifications of the mark to the nodel? <Ref. to ABS-7,
ABSCM&H/U. ABS Control Mod-
CC: AT ule and Hydraulic
CD: MT Control Unit
(ABSCM&H/U).>
2 CHECK GROUND SHORT OF HARNESS. Is the resistance more than 1 Go to step 3. Repair harness
1)Turn the ignition switch to OFF. MQ? between TCM and
H/U.
3 CHECK TCM. Is the voltage between 10 and Go to step 5. Go to step 4.
1)Connect all connectors to TCM. 15 V?
,tor terminal and chassis ground.
NON-TURBO MODEL:
TURBO MODEL:
-
4 CHECK AT. Is the AT functioning normally? Replace the TCM. Repair the AT.
5 CHECK OPEN CIRCUIT OF HARNESS. Is the voltage more than IO V? Go to step 6. Repair harness/
Measure the voltage between ABSCM&H/U connector
connector and chassis ground. between TCM and
-
(F49)No. 3 (+) Chassis ground (-):
(F49)No. 31 (+) - Chassis ground (-):
nectors between TCM and nector.
ABSCM&H/U?
7 CHECK ABSCM&HN. Is the same diagnostic trouble Replace the Go to step 8.
Control Unit
(ABSCM&H/U).>
8 CHECK ANY OTHER DIAGNOSTICTROU- Are other diagnostic trouble Proceed with the A temporary poor
sponding to the
diagnostic trouble
code.
ABS-I 39
ABS (DIAGNOSTICSI
X: DTC44
ABS-AT CONTROL (CONTROLLED)
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
: TURBO ENGINE MODEL
m
a 7
z a
m T
+ (u
m
BR0086
ABS-I 40
ABS (DIAGNOSTICS)
Step Check Yes No

t CHECK BATTERY SHORT OF HARNESS. Is the voltage less than 1 V? Go to step 2. Repair harness
1)Turnthe ignition switch to OFF. between TCM and
HIU.
2 CHECK BAlTERY SHORT OF HARNESS. Is the voltage less than 1 V? Go to step 3. Repair harness
1)Turn the ignition switch to ON. between TCM and
3 CHECK OPEN CIRCUIT OF HARNESS. Is the voltage between 10 and Go to step 4. Repair harness/
2)Connect all connectors to TCM. between TCM and
3)Turn the ignition switch to ON. ABSCM&H/U.
-
Q CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the con- Go to step 5.
Turn the ignition switch to OFF. nectors between TCM and qector.
ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
diagnositc trouble
code.
ABS-1 41
ABS (DIAGNOSTICS)
ABS-142
3
ABS (DIAGNOSTICS)
Y: DTC51
VALVE RELAY MALFUNCTION
DIAGNOSIS:
Faulty valve relay
i TROUBLE SYMPTOM:
ABS-143
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
BATTERY
SBF-1
(3c
r
t
U.
m
m
0
z r 1
PI
IGNITION
SWITCH
RELAY
-
ABS RELAY@
rl
r!l
- @
(u l
I
I '
tIIIIIIIII II I

BR0087
ABS-1 44
3

ABS (DIAGNOSTICS)
~~ ~
Step Check Yes No

I CHECK INPUT VOLTAGE OF RELAY HOLD- Is the voltage more than 10 V? 30 to step 2. 3epair open circuit
ER. n harness
1)Turnthe ignition switch to OFF. ietween battery
2)Remode the fuse. 3nd Relay holder
2 CHECK RELAY HOLDER. Is the fuse blown out? 3eplace the fuse. So to step 3.
3 CHECK INPUT VOLTAGE OF ABS RELAY. Is the voltage more than 10 V? 30 to step 4. Repair open circuit
3)Turn the ignition switch to ON. snd Relay holder
1 CHECK INPUT VOLTAGE OF ABS RELAY. Is the voltage more than 10 V? 30 to step 5. Repair harness
. (6264)No. 1 (+) - Chassis ground (-): ABS relay.
Repair open circuit
5 CHECK GROUND CIRCUIT OF ABS RELAY. Is the resistance less than 5 So to step 6.
1)Turnthe ignition switch to OFF. a? between ABS
(6264)No. 3 (+) - Chassis ground:
6 CHECK ABS RELAY. Is the resistance less than 10 So to step 7. Replace the ABS
No. 1 and 3.
terminals.
7 CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage between 10 and Go to step 8. Repair harness
1)Turnthe ignition switch to OFF. 15 V? connector
HIU. and ABSCM&H/U.
3)Run the engine at idle.
-
(F49)No. 24 (+) Chassis ground (-):
B CHECK GROUND CIRCUIT OF ABSCM&H/U Is the resistance less than 0.5 Go to step 9. Repair the
1)Turnthe ignition switch to OFF. Q? ABSCM&H/U
Control Unit
(ABSCM&H/U).>
ABS-I 45
ABS IDIAGNOSTICS)
Step
11 CHECK ANY OTHER DIAGNOSTIC TROU-
sponding to the
diagnostic trouble
code.
ABS-1 46
I
ABS (DIAGNOSTICS)
Z: DTC 51
VALVE RELAY ON FAILURE
DIAGNOSIS:
Faulty valve relay
TROUBLE SYMPTOM:
ABS-I 47
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
RATTFRY
SBF-3
-
T
SBF-1
RELAY
HOLDER
i IGNITION
SWITCH

I I
M-
-
BR0087
ABS-148
-
ABS IDIAGNOSTICS)
~~
~
Step Check Yes No

I CHECK VALVE RELAY IN ABSCM&HIU. ,sthe resistance more than 1 Go to step 2. 3eplace the
Measure the resistance between ABSCM&H/U wn? 4BSCM&H/U.
terminals. :Ref. to ABS-7,
Terminals 9BS Control Mod-
NO. 23 (+) - NO. 24 (-): Jle and Hydraulic
Zontrol Unit
:ABSCM&H/U).>
2 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the con- 30 to step 3.
3 CHECK ABSCM&H/U. Is the same diagnostic trouble Replace the 30 to step 4.
Control Unit
(ABSCM&H/U).>
I CHECK ANY OTHER DIAGNOSTICTROU- Are other diagnostic trouble Proceed with the A temporary poor
sponding to the
diagnostic trouble
code.
ABS-I 49
I DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICSI
ABS-I 50
=
ABS (DIAGNOSTICS)
AA:DTC 52
OPEN CIRCUIT IN MOTOR RELAY CIRCUIT
DIAGNOSIS:
Faulty motor
Faulty motor relay
TROUBLE SYMPTOM:
ABS-I 51
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
BATTERY
SBF-l
a
, 1)
m
=
ABS RELAY 8225

ABS-I 52
I

ABS (DIAGNOSTICS)
~~ ~
Step Check Yes No

1 CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage between 10 and 30 to step 2. Repair harness/
1)Turnthe ignition switch to OFF. 13 V? connector
H/U. and ABSCM&H/U
4)Measure the voltage between ABSCM&H/U SBFG.
2 CHECK GROUND CIRCUIT OF MOTOR. Is the resistance less than 0.5 Go to step 3. Repair the
1)Turn the ignition switch to OFF. Q? ABSCM&H/U
-
3 CHECK MOTOR OPERATION. Can the motor revolution noise Go to step 4. Replace the
Operate the sequence control. <Ref. to ABS- (buzz) be heard when carrying ABSCM&H/U.
11, ABS Sequence Control.> out the check sequence? <Ref. to ABS-7,
Use the diagnosis connector to operate the se, ule and Hydraulic
quence control. Control Unit
(ABSCM&H/U).>
4 %HECK POOR CONTACT IN CONNECTORS Is there poor contact in con- Repair the con- Go to step 5.
Turn the ignition switch to OFF. nector between hydraulic unit, nector.
relay box and ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
diagnostic trouble
code.
ABS-I 53
ABS (DIAGNOSTICS)
ABS-I 54
E DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
I
ABS (DIAGNOSTICS)
AB:DTC 52
MOTOR RELAY ON FAILURE
DIAGNOSIS:
Faulty motor
Faulty motor relay
f TROUBLE SYMPTOM:
I
1 ABS does not operate.
ABS-155
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
-
a
SBF-1
3 c
-
I II
n
r
VALVE RELAY
L
MOTOR RELAY
'd
k!3
a
1
ABS-I 56
m
ABS (DIAGNOSTICS)
Step Check No
I CHECK MOTOR RELAY IN ABSCM&H/U. ?eplace the
Measure the resistance between ABSCM&H/U 4BSCM&H/U.
terminals. :Ref. to ABS-7,
Terminals 4BS Control Mod-
NO. 25 - NO. 26: Jle and Hydraulic
Zontrol Unit
:ABSCM&H/U).>
2 CHECK MOTOR OPERATION. Replace the
Operate the sequence control. <Ref. to ABS- (buzz) be heard when carrying 4BSCM&H/U.
11, ABS Sequence Control.> out the sequence control? <Ref. to ABS-7,
NOTE: 4BS Control Mod-
Use the diagnosis connector to operate the se de and Hydraulic
quence control. Zontrol Unit
(ABSCM&H/U).>
Turn the ignition switch to OFF. nector between hydraulic unit, nector.
relay box and ABSCM&H/U?
1 CHECK ABSCM&HN. Is the same diagnostic trouble Replace the Go to step 5.
Control Unit
(ABSCM&H/U).>
sponding to the
diagnostic trouble
code.
ABS-I 57
1 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)
ABS-I 58
I I

ABS (DIAGNOSTICS)
AC:DTC 52
MOTOR MALFUNCTION
DIAGNOSIS:
Faulty motor
Faulty motor relay
r TROUBLE SYMPTOM:
i
t
ABS-159
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
-
BATTERY
SBF-1
3 c
!
T
I
9
0
U
W
I
m
I
II I II
T
'Q
I d
--
VALVE RELAY MOTOR RELAY I
3
a
I
I 1
11213141 n I 516171819
I
10]11]121131 14 15
ABS-I 60
ABS (DIAGNOSTICS)
~~ ~~
Step Check Yes NO

CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage between 10 and to step 2. Repair harness/
H/U. and ABSCM&H/U
4)Measure the voltage between ABSCM&H/U SBFG.
CHECK GROUND CIRCUIT OF MOTOR. Is the resistance less than 0.5 to step 3. Repair the
-
CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage between 10 and to step 4. Repair harness
1)Run the engine at idle. 15 V? connector
2)Measure the voltage between ABSCM&H/U between battery,
connector and chassis ground. ignition switch and
(F49) No, 1 (+) - Chassis ground (-):
.CHECK GROUND CIRCUIT OF ABSCM&H/U. Is the resistance less than 0.5 to step 5. Repair the
CHECK MOTOR OPERATION. Can the motor revolution noise to step 6. Replace the
Operate the sequence control. <Ref. to ABS- (buzz) be heard when carrying ABSCM&H/U.
11, ABS Sequence Control.> out the sequence control? <Ref. to ABS-7,
Use the diagnosis connector to operate the se. ule and Hydraulic
quence control. Control Unit
(ABSCM&H/U).>
CHECK POOR CONTACT IN CONNECTORS, Is there poor contact in con- Dair the con- Go to step 7.
Turn the ignition switch to OFF. nector between generator, bat- :tor.
tery and ABSCM&H/U?
CHECK ABSCM&H/U. Is the same diagnostic trouble Aace the Go to step 8.
1)Connect all connectors. code as in the current diagno- SCM&H/U.
2)Erase the memory. sis still being output? ef. to ABS-7,
3)Perform the inspection mode. S Control Mod-
4)Read out the diagnostic trouble code. and Hydraulic
itrol Unit
ECM&H/U).>
CHECK ANY OTHER DIAGNOSTIC TROU- Are other diagnostic trouble ceed with the A temporary poor
BLE CODES APPEARANCE. codes being output? gnosis corre- contact.
mding to the
gnostic trouble
le.
ABS-I 61
ABS (DIAGNOSTICS)
AD:DTC 54
STOP LIGHT SWITCH SIGNAL CIRCUIT MALFUNCTION
DIAGNOSIS:
Faulty stop light switch
TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
+=L I
STOP LIGHT
SWITCH

m il213ITl nI 516171819
101111121131 14 I 15 ]16117118]19120
BR0089
ABS-1 62
ABS (DIAG NOSTlCS)
Step Check Yes No

I CHECK OUTPUT OF STOP LIGHT SWITCH Is the reading indicated on Go to step 2. 30 to step 3.
USING SELECT MONITOR. monitor display less than 1.5
1)Select “Current data display & Save” on the V?
select monitor.
2)Release the brake pedal.
3)Read the stop light switch output in the
select monitor data display.
2 CHECK OUTPUT OF STOP LIGHT SWITCH Is the reading indicated on Go to step 5. 30 to step 3.
USING SELECT MONITOR. monitor display between 10
1)Depress the brake pedal. and 15 V?
2)Read the stop light switch output in the
select monitor data display.
3 CHECK IF STOP LIGHTS COME ON. Do stop lights turn on? Go to step 4. 3epair the stop
Depress the brake pedal. ights circuit.
I CHECK OPEN CIRCUIT IN HARNESS. Is the voltage between 10 and Go to step 5. 3epair harness
1)Turnthe ignition switch to OFF. 15 V? Detween stop light
2)Disconnectthe connector from ABSCM& switch and
H/U. 4BSCM&H/U con-
3)Depress the brake pedal. lector.
.connector and chassis ground.
-
5 CHECK POOR CONTACT IN CONNECTORS Is there poor contact in con- Repair the con- 30 to step 6.
nector between stop light nector.
switch and ABSCM&H/U?
5 CHECK ABSCM&HRI. Is the same diagnostic trouble Replace the 30 to step 7.
Control Unit
(ABSCM&H/U).>
r CHECK ANY OTHER DIAGNOSTICTROU- Are other diagnostic trouble Proceed with the 4 temporary poor
BLE CODES APPEARANCE. codes being output? diagnosis corre- :ontact.
sponding to the
diagnostic trouble
code.
ABS-1 63
ABS (DIAGNOSTICS)
ABS-I 64
ABS (DIAGNOSTICS)
AE:DTC 56
OPEN OR SHORT CIRCUIT IN G SENSOR CIRCUIT
DIAGNOSIS:
TROUBLE SYMPTOM:
ABS-I 65
ABS (DIAGNOSTICSI
WIRING DIAGRAM:
\
@ ABS CONTROL MODULE AND
SHIELD JOINT
CONNECTOR
I
I
I
I
1
7 -
~
I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
t 2
ABS
G SENSOR
BR0090
ABS-1 66
ABS (DIAGNOSTICS)
Step Check Yes No

CHECK OUTPUT OF G SENSOR USING SE- Is the G sensor output on the $0to step 2. Go to step 5.
LECT MONITOR. monitor display between 2.1
1)Select “Current data display & Save” on the and 2.5 V when the G sensor
select monitor. is in horizontal position?
2)Read the G sensor output in select monitor
data display.
! CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Iepair the con- Go to step 3.
nectar between ABSCM&H/U lector.
and G sensor?
I CHECK ABSCM&H/U. Is the same diagnostic trouble 3eplace the Go to step 4.
:ontrol Unit
ABSCM&H/U).>
I CHECK ANY OTHER DIAGNOSTICTROU- Are other diagnostic trouble ’roceed with the A temporary poor
BLE CODES APPEARANCE. codes being output? fiagnosis corre- contact.
iponding to the
iiagnostic trouble
:ode.
i CHECK INPUT VOLTAGE OF G SENSOR. Is the voltage between 4.75 30 to step 6. Repair harness/
1)Turnthe ignition switch to OFF. and 5.25 V? connector
2)Remove the console box. between G sensoi
3)Disconnect the G sensor from body. (Do not and ABSCM&H/U
nector terminals.
(8292) NO. 1 (+)- NO. 3 (-):
i CHECK OPEN CIRCUIT IN G SENSOR OUT- Is the resistance between 4.3 30 to step 7. Repair harness/
1)Turn the ignition switch to OFF. between G sensoi
2)Disconnect the connector from ABSCM& and ABSCM&H/U
H/U.
(F49) NO. 6 - NO. 28:
T CHECK GROUND SHORT IN G SENSOR IS the resistance more than 1 30 to step 8. Repair harness
OUTPUT HARNESS. MR? between G sensoi
1)Disconnectthe connector from G sensor. and ABSCM&H/U
j CHECK G SENSOR. Is the voltage between 2.1 and 30 to step 9. Replace the G
1)Connect the connector to G sensor. 2.5 V when G sensor is hori- sensor. <Ref. to
2)Connect the connector to ABSCM&H/U. zontal? ABS-23, G Sen-
3)Turn the ignition switch to ON. sor.>
. 4)Measure the voltage between G sensor con-
nector terminals.
(8292) NO. 2 (+)- NO. 3 (-):
ABS-I 67
ABS (DIAGNOSTICS)
Step Check Yes No

9 CHECK G SENSOR. Is the voltage between 3.7 and Go to step 10. Replace the G
nector terminals. inclined forwards to go"? ABS-23, G Sen-
Connector & terminal so r.>
(6292) NO. 2 (+) - NO. 3I)-(
nector terminals. inclined backwards to go"? ABS-23, G Sen-
(6292) NO. 2 (+) - NO. 3 (-):
Turn the ignition switch to OFF. nector between ABSCM&H/U nector.
and G sensor?
Control Unit
(ABSCM&H/U).>
. BLE CODES APPEARANCE. codes being output? diagnosis corre-
sponding to the
contact.
diagnostic trouble
I
code.
ABS-1 68
ABS (DIAGNOSTICS)
~
AF:DTC 56
BATTERY SHORT IN G SENSOR CIRCUIT
DIAGNOSIS:
TROUBLE SYMPTOM:
ABS-I 69
ABS (DIAGNOSTICS)
WIRING DIAGRAM:

SHIELD JOINT
CONNECTOR
+g 8200
L
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
t 3
P
U
BS
0 NSOR
11213141 nI 5 16 17 18 19
101111121131 14 I 15 116117[18119120
BR0090
ABS-I 70
ABS (DIAGNOSTICS)
~~ ~
Step Check Yes No

CHECK OUTPUT OF G SENSOR USING SE- 5 the G sensor output on the ;o to step 2. Go to step 5.
LECT MONITOR. ionitor display between 2.1
1)Select “Current data display & Save” on the n d 2.5 V when the G sensor
select monitor. j in horizontal position?
2)Read the G sensor output in select monitor

data display.
! CHECK POOR CONTACT IN CONNECTORS, 5 there poor contact in con- 3epair the con- Go to step 3.
lector between ABSCM&H/U lector.
ind G sensor?
I CHECK ABSCM&H/U. 3 the same diagnostic trouble 3eplace the Go to step 4.
2)Erase the memory. #isstill being output? :Ref. to ABS-7,
2ontrol Unit
ABSCM&H/U).>
I CHECK ANY OTHER DIAGNOSTICTROU- ire other diagnostic trouble ’roceed with the A temporary poor
BLE CODES APPEARANCE. :odes being output? iiagnosis corre- contact.
iponding to the
liagnostic trouble
:ode.
i CHECK FREEZE FRAME DATA. s the front right wheel speed 50 to step 6. Go to step 16.
1)Select “Freeze frame data” on the select In monitor display 0 km?
monitor.
2)Read the front right wheel speed on the
select monitor display.
i CHECK FREEZE FRAME DATA. s the front left wheel speed on 50 to step 7. Go to step 16.
Read the front left wheel speed on the select nonitor display 0 km?
monitor display.
T CHECK FREEZE FRAME DATA. s the rear right wheel speed 30 to step 8. Go to step 16.
Read the rear right wheel speed on the select )n monitor display 0 km?
monitor display.
5 CHECK FREEZE FRAME DATA. s the rear left wheel speed on 30 to step 9. Go to step 16.
Read the rear left wheel speed on the select nonitor display 0 km?
monitor display.
B CHECK FREEZE FRAME DATA. s the G sensor output on mon- 20 to step 10. Go to step 16.
Read the G sensor output on the select monitor display more than 3.65 V?
tor display.
IO CHECK OPEN CIRCUIT IN G SENSOR OUT. s the resistance between 4.3 20 to step 11. Repair harness/
PUT HARNESS AND GROUND HARNESS. ind 4.9 w1? connector
1)Turn the ignition switch to OFF. between G sensoi
2)Disconnectthe connector from ABSCM8 and ABSCM&H/U
H/U.
-
(F49)NO. 6 NO. 28:
I1 CHECK BATTERY SHORT OF HARNESS. s the voltage less than 1 V? 30 to step 12. Repair harness
1)Turn the ignition switch to OFF. between G senso
2)Remove the console box. and ABSCM&H/U
3)Disconnect the connector from G sensor.
~ 4)Disconnect the connector from ABSCM&
H/U.
5)Measure the voltage between ABSCM&
H/U connector and chassis ground.
ABS-171
ABS (DIAGNOSTICS)
~~ ~
Step Check Yes No

12 CHECK BATTERY SHORT OF HARNESS. Is the voltage less than 1 V? Go to step 13. Repair harness
1)Turnthe ignition switch to ON. between G sensor
2)Measure the voltage between ABSCM&H/U and ABSCM&H/U.
nector between ABSCM&H/U nector.
and G sensor?
Control Unit
(ABSCM&H/U).>
sponding to the
diagnostic trouble
code.
16 CHECK INPUT VOLTAGE OF G SENSOR. Is the voltage between 4.75 Go to step 17. Repair harness/
1)Turnthe ignition switch to OFF. and 5.25 V? connector
2)Remove the console box. between G sensor
3)Disconnect the G sensor from body. (Do not and ABSCM&H/U.
nector terminals.
(6292)NO. 1 (+) - NO. 3 (-):
17 CHECK OPEN CIRCUIT IN G SENSOR OUT- Is the resistance between 4.3 Go to step 18. Repair harness/
PUT HARNESS AND GROUND HARNESS. and 4.9 kn? connector
1)Turn the ignition switch to OFF. between G sensor
2)Disconnect the connector from ABSCM& and ABSCM&H/U.
H/U.
(F49)NO. 6 - NO. 28:
1)Connect the connector to G sensor. 2.5 V when G sensor is hori- sensor. <Ref. to
2)Connect the connector to ABSCM&H/U. zontal? ABS-23, G Sen-
3)Turn the ignition switch to ON. sor.>
nector terminals.
(6292)NO. 2 (+) -NO. 3 (-):
19 CHECK G SENSOR. Is the voltage between 3.7and Go to step 20. Replace the G
nector terminals. nclined forwards to 90°? ABS-23, G Sen-
(6292)NO. 2 (+) - NO. 3 (-):
!O CHECK G SENSOR. s the voltage between 0.5 and Go to step 21. Replace the G
nector terminals. nclined backwards to go"? ABS-23, G Sen-
(6292)NO. 2 (+) - NO. 3 (-):
ABS-I 72
ABS (DIAGNOSTICS)
Step I Check Yes No

Turn the ignition switch to OFF. nector between ABSCM&H/U nector.
and G sensor?
Control Unit
(ABSCM&H/U).>
sponding to the
diagnostic trouble
code.
ABS-I73
ABS (DIAGNOSTICS)
ABS-1 74
I
ABS (DIAGNOSTICS)
AG:DTC 56
ABNORMAL G SENSOR HIGH p OUTPUT
DIAGNOSIS:
TROUBLE SYMPTOM:
Y
ABS (DIAGNOSTICS)
AH:DTC 56
DETECTION OF G SENSOR STICK
DIAGNOSIS:
TROUBLE SYMPTOM:
ABS-I 79
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
@ ABS CONTROL MODULE AND

SHIELD JOINT
CONNECTOR
f
I
JI
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
t 7
ABS
G SENSOR
BR0090
ABS-I 80
ABS (DIAGNOSTICS)
-
Step Check Yes No
I CHECK ALL FOUR WHEELS FOR FREE lave the wheels been turned The ABS is nor- 30 to step 2.
TURNING. ireely such as when the vehicle nal. Erase the
s lifted up, or operated on a jiagnostic trouble
rolling road? :ode.
! CHECK OUTPUT OF G SENSOR USING SE- Is the G sensor output on the 30 to step 3. 30 to step 8.
LECT MONITOR. monitor display between 2.1
1)Select ”Current data display 8 Save” on the 2nd 2.5 V when the vehicle is
select monitor. in horizontal position?
5 CHECK OUTPUT OF G SENSOR USING SE- Is the G sensor output on the 30 to step 4. 3eplace the G
LECT MONITOR. monitor display between 3.7 sensor. <Ref. to
1)Turn the ignition switch to OFF. and 4.1 V when G sensor is 465-23, G Sen-
2)Remove the console box. inclined forwards to go”? sor.>
3)Remove the G sensor from vehicle. (Do not
5)Select “Current data display & Save” on the
select monitor.
1 CHECK OUTPUT OF G SENSOR USING SE- Is the G sensor output on the 20 to step 5. Replace the G
LECT MONITOR. monitor display between 0.5 sensor. <Ref. to
Read the select monitor display. and 0.9 V when G sensor is ABS-23, G Sen-
inclined backwards to go“? sor.>
5 CHECK POOR CONTACT IN CONNECTORS, Is there poor contact in con- Repair the con- Go to step 6.
Turn the ignition switch to OFF. nector between ABSCM&H/U lector.
and G sensor?
6 CHECK ABSCM&H/U. ISthe same diagnostic trouble Replace the Go to step 7 .
Control Unit
(ABSCM&H/U).>
sponding to the
diagnostic trouble
code.
B CHECK OPEN CIRCUIT IN G SENSOR OUT- Is the resistance between 4.3 Go to step 9. Repair harness/
1)Turnthe ignition switch to OFF. between G sensor
2)Disconnect the connector from ABSCM& and ABSCM&H/U.
H/U.
(F49) NO. 6 - NO. 28:
1)Remove the console box. 2.5 V when G sensor is hori- sensor. <Ref. to
2)Remove the G sensor from vehicle. zontal? ABS-23, G Sen-
~
3)Connect the connector to G sensor. sor.>

4)Connect the connector to ABSCM&H/U.
nector terminals.
(8292) NO. 2 (+) - NO. 3I)-(
ABS-I 81
ABS (DIAGNOSTICS)
Step Check Yes

10 CHECK G SENSOR. Is the voltage between 3.7 and Go to step 11.
nector terminals. inclined forwards to 90°? ABS-23, G Sen-
11
(8292) NO. 2 (+) - NO. 3 (-):
CHECK G SENSOR. Is the voltage between 0.5 and Go to step 12.
sor.>
I
nector terminals. inclined backwards to 90°? ABS-23, G Sen-
-
(8292) NO. 2 (+) NO. 3 (-):
12 CHECK ABSCM&W. Is the same diagnostic trouble Replace the Go to step 13.
1)Turn the ignition switch to OFF. code as in the current diagno- ABSCM&H/U.
2)Connect all connectors. sis still being output? <Ref. to ABS-7,
5)Read out the diagnostic trouble code. Control Unit
(ABSCM&H/U).>
sponding to the
diagnostic trouble
code.
ABS-I 82
ABS (DIAGNOSTICS)
14.General Diagnostics Table

A: INSPECTION
Symptom Probable faulty units/parts
-~
ABSCM&H/U (solenoid valve)
9 ABS sensor
Brake (caliper & piston, pads)
Vehicle pulls to either side. Wheel alignment
Tire specifications, tire wear and air pressures
Incorrect wiring or piping connections
dehicle instability during braking Road surface (uneven, camber)
ABS sensor
Vehicle spins. Brake (pads)
Tire specifications,tire wear and air pressures
Incorrect wiring or Piping connections
~~

Brake (pads)
Long brakinglstopping distance Air in brake line
Tire specifications,tire wear and air pressures
ABSCM&H/U (solenoid valve, motor)
Wheel locks. ABS sensor
9 ABSCM&H/U (solenoid valve)
ABS sensor
Master cylinder
Brake dragging Brake (caliper & piston)
Parking brake
Poor braking 9 Axle & wheels
Brake pedal play

9 Air in brake line
Long brake pedal stroke
Brake Pedal Play
*-Suspension play or fatigue (reduced damping)
Vehicle pitching Incorrect wiring or piping connections
* Road surface (uneven)
9 ABSCM&H/U (solenoid valve)
ABS sensor
9 Brake (caliper & piston, pads)
Unstable or uneven braking
9 Tire specifications, tire wear and air pressures
9 Incorrect wiring or piping connections

Road surface (uneven)
ABS-I83
ABS (DIAGNOSTICS)
Symptom Probable faulty unitslparts

Excessive pedal vibration
Road surface (uneven)
ABSCM&H/U (mount bushing)
Noise from ABSCM&H/U ABS sensor
Brake piping
ABSCM&H/U (mount bushing)
ABS sensor
Master cylinder
Vibration and/or noise
Noise from front of vehicle Brake (caliper & piston, pads, rotor)
(while driving on slippery roads)
Brake piping
Brake booster & check valve
Suspension play or fatigue
ABS sensor
Brake (caliper & piston, pads, rotor)
Noise from rear of vehicle Parking brake
Brake piping
Suspension play or fatigue
ABS-I 84
GENERAL DESCRIPTION
BRAKE
7. BRAKE BOOSTER
(1) Push rod (5) Filter (9) Valve body

(2) Return spring (6) Silencer (10) Plunger valve
(3) Reaction disc (7) Operating rod (1 1) Diaphragm plate
(4) Key (8) Poppet valve (12) Valve return spring
BR-I 1
GENERAL DESCRIPTION
BRAKE
8. BRAKE PEDAL
MT Model
B4M2345A
(1) Stopper (12) Clutch clevis pin (23) Clutch switch (Starter interlock)
(2) Bushing (13) Assist rod A (24) Clutch switch (With cruise control)
(3) Spring pin (14) Clip (25) Stop light switch
(4) Snap pin (15) Assist spring (26) Pedal bracket
(5) Brake pedal pad (16) Assist bushing (27) Clutch master cylinder bracket
(6) Brake pedal (17) Assist rod B (28) Lever
(7) Clevis pin (18) Spring S
(8) Brake pedal spring (19) Rod S Tightening torque: N-m (kgf-m, ff-lb)
(9) Clutch pedal pad (20) Bushing S T1: 8 (0.8, 5.8)
(10) Clutch pedal (21) O-ring T2: lS(1.8, 13.0)
(11) Bushing C (22) Clip
BR-12
GENERAL DESCRIPTION
BRAKE
AT Model
BR000;
(1) Stopper (6) Brake pedal pad Tightening torque: N.m (kgf-m, ft-lb)
(2) Bushing (7) Brake pedal T1: 8 (0.8, 5.8)
(3) Pedal bracket (8) Clevis pin T2: lS(1.8, 13.0)
(4) Stop light switch (9) Brake pedal spring T3: 29 (3.0,21.7)
(5) Snap pin
BR-13
GENERAL DESCRIPTION
BRAKE
C: CAUTION
tion.
part in the vehicle is hot after running.
points.
formation.
Do not put fluid on body. If the body is tainted,
wash away with water.
BR-14
GENERAL DESCRIPTION
BRAKE
D: PREPARATION TOOL
1. SPECIAL TOOLS

926460000 NHEEL CYLINDER Jsed for installing cup onto wheel cylinder piston
3/4”ADAPTER :Size 11/16 in).
B4M2
-
6
TOOL NAME REMARKS

SNAP RING PLIERS Used for removing and installing snap ring.
BR-15
BRAKE BOOSTER
BRAKE
12.Brake Booster CAUTION:

If external force is applied from above when
A: REMOVAL brake booster is placed in this position, the res-
1) Remove or disconnect the following parts at en- in portion as indicated by “P”, may be dam-
gine compartment. aged.
(1) Disconnect the connector for brake fluid lev-
el indicator.
(2) Remove the brake pipes from master cylin-
der.
(3) Remove the master cylinder installing nuts.
(4) Disconnect the vacuum hose from brake
booster.
2) Remove the following parts from the pedal
bracket.
(1) Snap pin and clevis pin
(2) Four brake booster installing nuts S4M0464A
3) Remove the brake booster while shunning brake

pipes. (1) Force
NOTE:
Be careful not to drop the brake booster. Brake
booster should be discarded if it has been dropped.
Use special care when handling the operating
rod.
If excessive force is applied to operating rod, suffi-
cient to cause a change in the angle in excess of
f3”,it may result in damage to the power piston cyl-
inder.
Use care when placing the brake booster on the
floor.
Do not change the push rod length. If it has been
changed, reset the projected length “L” to the stan-
dard length.
Standard:
L = 10.4 mm (0.41 in)
G4M0424
BR-38
I
BRAKE BOOSTER
BRAKE
B: INSTALLATION 7) Adjust the operating rod of brake booster.

1) Mount the brake booster in position. Standard: L
2) Connect the operating rod to brake pedal with LHD model:
clevis pin and snap pin. 144.6 mm (5.69 in)
RHD model:
7 73.2 mm (6.82 in)
If it is not in specified value, adjust it by adjusting
the brake booster operating rod.
L
k
MM0616P
8) Measure the clearance between threaded end of

stop light switch and stopper.
If it is not in specified value, adjust it by adjusting
the position of stop light switch.
CAUTION:
B4M0117C Be careful not to rotate the stop light switch.
Stop ljght switch clearance: A
(1) Nuts
0.3 mm (0.012 in)
(2) Clevis pin
(3) Snap pin
(4) Operating rod
3) Connect the vacuum hose to brake booster.

A
u- B4M0617H
9) Apply grease to operating rod connecting pin to

prevent it from wearing.
10) Bleed air from the brake system.
Tightening torque (Air bleeder screw):
4) Mount the master cylinder onto brake booster. 8 N.m (0.8 kgf-m, 5.8 ft-16)
5)Connect the brake pipes to master cylinder. 11) Conduct road tests to ensure brakes do not
6) Connect the electric connector for brake fluid drag.
level indicator.
BR-39
BRAKE BOOSTER
BRAKE
C: INSPECTION Operation check

1. OPERATION CHECK (WITHOUT GAUG- 1) With the engine off, depress the brake pedal
several times applying the same pedal force and
ES) make sure that the pedal height does not vary with
CAUTION: each depression of the pedal.
When checking operation, be sure to securely
apply the hand brake.
Checking without gauges
This method cannot determine the exact portion
which has failed, but it can provide a rough under-
standing of the nature of the failure if checking is
conducted in accordance with the following proce-
dures.
Air tightness check
Start the engine, and run it for 1 to 2 minutes, then S4M0466A
turn it off. Depress the brake pedal several times
applying the same pedal force as that used in ordi- (1) When engine is stopped
nary braking operations. The pedal stroke should (2) When engine is started
be greatest on the 1st depression, and it should be-
come smaller with each successive depression. If 2) With the brake pedal depressed, start the en-
no change occurs in the pedal height while in a de- gine.
pressed state, the brake booster is faulty. 3) As engine starts, the brake pedal should move
slightly toward the floor. If no change occurs in the
pedal height, the brake booster is faulty.
NOTE:
If faulty, check precisely with gauges.
Loaded air tightness check
Depress the brake pedal while engine is running,
and turn off the engine while the pedal is still de-
pressed. Keep the pedal depressed for 30 sec-
onds; if no change occurs in the pedal height, the
S4M0465A
brake booster is functioning normally; if the pedal
height increases, it is faulty.
(1) OK NOTE:
(2) NOTOK If faulty, check precisely with gauges.
(3) 1st
(4) 2nd
(5) 3rd
NOTE:
In the event of defective operation, inspect the
condition of the check valve and vacuum hose.
Replace them if faulty and conduct the test
again.
If no improvement is observed, check precisely
with gauges.
BR-40
BRAKE BOOSTER
BRAKE
2. OPERATION CHECK (WITH GAUGES) Leak from the shell jointed portion or stud bolt
welded portion
CAUTION: Damaged diaphragm
When checking operation, be sure to securely Leak from valve body seal and bearing portion
apply the hand brake. Leak from plate and seal assembly portion
Checking with gauges Leak from poppet valve assembly portion
Connect gauges as shown in the figure. After Loaded air tightness check
bleeding air from pressure gauges, proceed to 1) Start the engine and depress the brake pedal
each check. with pedal force of 196 N (20 kgf, 44 Ib). Keep the
engine running until a vacuum of 66.7 kPa (500
mmHg, 19.69 inHg) = point B is indicated on vacu-
um gauge while the pedal is still depressed.
,B
(1 )- Pressure gauge
(2) Vacuum gauge S4M0469A I
(3) Adapter hose
(4) Vacuum hose (1) Pressure gauge
(5) Pedal force gauge (2) Vacuum gauge
(3) Pedal force gauge
Air tightness check (4) Depress
1) Start the engine and keep it running until a vac-
uum of 66.7 kPa (500 mmHg, 19.69 inHg) = point A 2) Stop the engine and watch vacuum gauge.
is indicated on vacuum gauge. Do not depress the If the vacuum drop range is less than 3.3 kPa (25
brake pedal. mmHg, 0.98 inHg) within 15 seconds after stopping
the engine, brake booster is functioning properly.
If defective, refer to “AIR TIGHTNESS CHECK’.
<Ref. to BR-40, INSPECTION, Brake Booster.>
Lack of boosting action check
Turn off the engine, and set the vacuum gauge
reading at “0”. Then, check the fluid pressure when
brake pedal is depressed. The pressure must be
greater than the standard value listed.
Brake pedal 147 N 294 N
force (1 5 kgf, 33 Ib) (30 kgf, 66 Ib)
588 kPa 1,471 kPa
Fluid pressure
(1) Pressure gauge (6 kcdcm’, 85 psi) (15 kg/cm2,213 psi)
(2) Vacuum gauge
2) Stop the engine and watch the gauge. If the vac-

uum drop range is less than 3.3 kPa (25 mmHg,
0.98 inHg) within 15 seconds after stopping the en-
gine, the brake booster is functioning properly.
If defective, the cause may be one of those listed
below.
Check valve malfunction
Leak from vacuum hose
BR-41
BRAKE FLUID
BRAKE
14.Brake Fluid 5) Install one end of a vinyl tube onto the air bleeder
and insert the other end of the tube into a container
A: INSPECTION to collect the brake fluid.
1) Check that the brake fluid level remains between
“MIN” and “MAX’. If out of the specified range, refill
or drain fluid. If fluid level becomes close to “MIN”,
refill fluid.
2) Check the fluid for discoloration. If fluid color has
excessively changed, drain the fluid and refill with
new fluid.
B: REPLACEMENT
CAUTION:
To always maintain the brake fluid character-
istics, replace the brake fluid according to
maintenance schedule or earlier than that when Am Air bleeder screw
used in severe condition.
The FMVSS No. 116, fresh DOT3 or 4 brake
fluid must be used.
Cover the bleeder with waste cloth, when
loosening it, to prevent brake fluid from being
Avoid mixing different brands of brake fluid
Be careful not to allow dirt or dust to get into
the reservoir tank.
CAUTION:
NOTE: Brake fluid replacement sequence; (A) Front
During bleeding operation, keep the brake reser- right -+(8) Rear left + (C) Front left + (D) Rear
voir tank filled with brake fluid to eliminate entry of right
air.
Brake pedal operating must be very slow.
For convenience and safety, two people should
- r
do the work.
mately 500 m 0 (16.9 US fl oz, 17.6 Imp fl oz) for to-
tal brake system.
1) Either jack-up the vehicle and place a safety
stand under it, or lift up the vehicle.
2) Remove both front and rear wheels.
3) Draw out the brake fluid from master cylinder I S4M0475A
with syringe.
4) Refill the reservoir tank with recommended (1 ) Master cylinder
brake fluid. (2) Hydraulic unit
Recommended brake fluid: (3) Proportioning valve
FMVSS No. 116, fresh DOT3 or 4 brake fluid 6) Instruct your co-worker to depress the brake
pedal slowly two or three times and then hold it de-
pressed.
7) Loosen the bleeder screw approximately 1/4 turn
until a small amount of brake fluid drains into the
container, and then quickly tighten the screw.
BR-44
Pls
BRAKE FLUID
BRAKE
8) Repeat steps 6) and 7) above until there are no

air bubbles in drained brake fluid and new fluid
flows through vinyl tube.
NOTE:
Add brake fluid as necessary while performing the
air bleed operation, in order to prevent the tank
from running short of brake fluid.
9 ) After completing the bleeding operation, hold the
brake pedal depressed and tighten the screw and
install bleeder cap.
Tightening torque (Bleeder screw):
8 N-m (0.8 kgf-m, 5.8 fi-lb)
10) Bleed air from each wheel cylinder using the
same procedures as described in steps 6) through
7) above.
11) Depress the brake pedal with a force of approx-
imately 294 N (30 kgf, 66 Ib) and hold it there for ap-
proximately 20 seconds. At this time check the
pedal to see if it shows any unusual movement.
Visually inspect the bleeder screws and brake pipe
joints to make sure that there is no fluid leakage.
12) Install the wheels, and drive vehicle for a short
distance between 2 to 3 km (1 to 2 miles) to make
sure that brakes are operating properly.
BR-45
AIR BLEEDING
BRAKE
15.Air Bleeding 4) Close the outlet plug with your finger, and re-
lease the brake pedal.
A: PROCEDURE
CAUTION:
The FMVSS No. 116, fresh DOT3 or 4 brake
fluid must be used.
Cover the bleeder with waste cloth when
loosening it to prevent brake fluid from being
Avoid mixing different brands of brake fluid
Be careful not to allow dirt or dust to get into I S4M0541
the reservoir tank.
NOTE: 5) Repeat the above step3) and 4) until brake fluid
Start with the brakes (wheels) connected to the is completey bled from outlet plug.
secondary chamber of the master cylinder. 6) Remove the vinyl bag, then connect the brake
The time interval between two brake pedal oper- pipe to master cylinder.
ations (from the time when the pedal is released to Tightening torque:
the time when it is depressed another time) shall be 8 N-m (0.8 kgf-m, 5.8 ff-lb)
approximately 3 seconds. 7) Using water, wash off the spilt brake fluid at the
The air bleeder on each brake shall be released master cylinder surrounding, then wipe up the wa-
for 1 to 2 seconds. ter.
1. MASTER CYLINDER 8) Bleed air from the brake line. <Ref. to BR-46,
BRAKE LINE, PROCEDURE, Air Bleeding.>
NOTE:
If the master cylinder is disassembled or reser- 2. BRAKE LINE
voir tank is empty, bleed the master cylinder. NOTE:
During the bleeding operation, keep the brake During the bleeding operation, keep the brake
reservoir tank filled with brake fluid to eliminate en- reservoir tank filled with brake fluid to eliminate en-
try of air. try of air.
Brake pedal operating must be very slow. Brake pedal operating must be very slow.
For convenience and safety, two people should For convenience and safety, two people should
do the work. do the work.
1) Disconnect the brake line at primary and sec- 1) Make sure that there is no leak from joints and
ondary sides. connections of the brake system.
2) Cover the master cylinder with vinyl bag. 2) Fit one end of vinyl tube into the air bleeder and
3) Carefully depress and hold the brake pedal. put the other end into a brake fluid container.
S4M0.540
W S4M0246
BR-46
is
AIR BLEEDING
BRAKE
CAUTION: 6) Check the pedal stroke.

Brake fluid replacement sequence; (A) Front While the engine is idling, depress the brake pedal
right (6) Rear left + (C) Front left + (D) Rear with a 490 N (50 kgf, 110 Ib) load and measure the
right 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.
I S4M0475A
(1) Master cylinder

(2) Hydraulic unit \
S4M0476A
(3) Proportioning valve
3) Slowly depress the brake pedal and keep it de- (1) Steering wheel
pressed. Then, open the air bleeder to discharge (2) Toe board
air together with the fluid.
Release the air bleeder for 1 to 2 seconds. Specified pedal stroke:
Next, with the bleeder closed, slowly release the Without ABS
brake pedal. 90 mm (3.54 in)
Repeat these steps until there is no more air bub- With ABS
bles in the vinyl tube. 95 mm (3.74 in)
Allow 3 to 4 seconds between two brake pedal op- When depressing brake pedal with a 490 N
erations. (50 kg, 110 lb) load.
CAUTION: 7) If the distance is more than specified, there is a
Cover the bleeder with waste cloth, when loos- possibility that air is in the brake line. Bleed the
ening it, to prevent brake fluid from being brake line until pedal stroke meets the specifica-
splashed over surrounding parts. tion.
8) Operate the hydraulic control unit in the se-
NOTE:
quence control mode. (With ABS)
Brake pedal operating must be very slow.
4) Tighten the air bleeder securely when no air bub- 9) Recheck the brake stroke.
bles are visible. 10) If the distance is more than specified, there is a
Air bleeder tightening torque: possibility air is in the inside of the hydraulic unit.
8 N.m (0.8 kgf-m, 5.8 ft-lb) Repeat above steps 2) to 9) until pedal stroke
5 ) Perform these steps for the brakes connecting to meets the specification.
the secondary chamber of master cylinder, first, 11) Add brake fluid to the required level (MAX. lev-
and then for the ones connecting to primary cham- el) of reservoir tank.
ber. With all procedures completed, fully depress 12) As a final step, test run the vehicle at low speed
the brake pedal and keep it in that position for ap- and apply brakes relatively hard 2 to 3 times to en-
proximately 20 seconds to make sure that there is sure that brakes provide normal braking action on
no leak evident in the entire system. all four wheels without dragging and uneven brak-
ing.
BR-47
BRAKE HOSE
BRAKE
16.Brake Hose B: INSTALLATION

A: REMOVAL 1. FRONT BRAKE HOSE
1) Route the end of brake hose (on caliper side)
1. FRONT BRAKE HOSE
through hole in brake hose bracket at strut location.
1) Separate the brake pipe from brake hose. 2) Tighten the end of brake hose at caliper using a
(Always use flare nut wrench and be careful not to union bolt.
deform flare nut.)
Tightening torque (Union bolt):
18 N.m (1.8 kgf-m, 13.0 ff-lb)
18438
-
(1) Brake hose I1844
(2) Brake pipe 3) Secure the middle fitting of brake hose to bracket
at strut location using a clamp.
2) Pull out the clamp to remove the brake hose. 4) Position the disc in straight-forwarddirection and
3) Remove the bolt at strut and union bolt. route the brake hose through hole in bracket on
2. REAR BRAKE HOSE wheel apron side.
1) Separate the brake pipe from brake hose. CAUTION:
Be sure the brake hose is not twisted.
NOTE:
Always use flare nut wrench and be careful not to 5) Temporarily tighten the flare nut to connect
deform flare nut. brake pipe and hose.
6) Fix the brake hose with clamp at wheel apron
bracket.
7) While holding the hexagonal part of brake hose
fitting with a wrench, tighten the flare nut to the
specified torque.
Tightening torque (Brake pipe flare nut):
15 N-m (1.5 kgf-m, 10.8 ff-lb)
8 ) Bleed air from the brake system. <Ref. to BR-46,
Air Bleeding.>
(1) Brake hose clip

(2) Brake hose
(3) Brake pipe
2) Unscrew the brake hose flare nut, and discon-

nect the brake hose.
3) Pull out the clamp to remove the brake hose.
BR-48
ia
BRAKE HOSE
BRAKE
2. REAR BRAKE HOSE C: INSPECTION

1) Pass the brake hose through the hole of bracket, Ensure there are no cracks, breakage, or damage
and lightly tighten the flare nut to connect brake on hoses. Check the Joints for fluid leakage. If any
hose. cracks, breakage, damage or leakage is found, re-
2) Insert the clamp upward to fix brake hose. pair or replace the hose.
3) While holding the hexagonal part of brake hose
fitting with a wrench, tighten the flare nut to the
specified torque.
Tightening torque (Brake pipe flare nut):
75 N*m (7.5 kgf-m, 70.8 ft-lb)
(1) Brake hose clip

(2) Brake hose
(3) Brake pipe
4) Bleed air from the brake system. <Ref. to BR-46,

Air Bleeding.>
BR-49
BRAKE PIPE
BRAKE
17.Brake Pipe C: INSPECTION

Ensure there are no cracks, breakage, or damage
A: REMOVAL on pipes. Check the joints for fluid leakage. If any
NOTE: cracks, breakage, damage or leakage is found, re-
Airbag system wiring harness is routed near the pair or replace the pipe.
center brake pipe. NOTE:
CAUTION: Use a mirror when inspecting the low-visible part or
All Airbag system wiring harness and con- back side.
cal test equipment on these circuits.
wiring harness when servicing the center brake
pipe.
When removing the brake pipe, make sure
that it is not bent.
B: INSTALLATION
NOTE:
Airbag system wiring harness is routed near the
center brake pipe.
CAUTION:
wiring harness when servicing the center brake
pipe.
When installing the brake pipe, make sure
that it is not bent.
After installing the brake pipe and hose,
bleed the air.
After installing the brake hose, make sure
that it does not touch the tire or suspension as-
sembly, etc.
Brake pipe tightening torque:
15 N*m (1.5 kgf-m, 10.8 ft-lb)
BR-50
1
BRAKE PEDAL
BRAKE
18.Brake Pedal B: INSTALLATION

1 ) Install in the reverse order of removal.
A: REMOVAL CAUTION:
1. MT MODEL If the cable clamp is damaged, replace it with
a new one.
1) Remove the steering bolts. Never fail to cover the outer cable end with
2) Raise the vehicle on hoist and remove the two
bolts which secure steering unit to underside of
body.
.
boot.
Be careful not to kink the accelerator cable.
Always use new clevis pins.
3) Lower the vehicle to floor.
4) Remove the instrument panel lower cover from 2) Adjust the clutch pedal <Ref. to CL-27, ADJUST-
instrument panel. MENT, Clutch Pedal.>
5) Disconnect the following parts from pedal bra&- 3) Inspect after pedal installation <Ref. to BR-53,
et. INSPECTION, Brake Pedal.>
Operating rod of brake booster
Electrical connectors (for stop light switch, etc.)
6) Remove the clevis pin which secures lever to
push rod.
7) Remove the nut which secures clutch master
cylinder.
8) Remove the steering assembly.
9) Remove the accelerator pedal.
10) Remove the bolts and nuts which secure pedal
bracket.
2. ATMODEL
1 ) Disconnect the ground cable from battery.
2) Remove the instrument panel lower cover from
instrument panel.
3) Remove the clevis pin which secures brake ped-
al to brake booster operating rod. Also disconnect
the stop light switch connector.
4) Remove the two bolts and four nuts which se-
cure brake pedal to pedal.
BR-51
BRAKE PEDAL
BRAKE
C: DISASSEMBLY 2. ATMODEL
1. MT MODEL 1) Remove the brake switch.
2) Unbolt, and then remove the brake pedal.
1) Remove the brake switch.
<Ref. to BR-55, REMOVAL, Stop Light Switch.>
2) Remove the clutch pedal.
<Ref. to CL-26, DISASSEMBLY, Clutch Pedal.>
3) Remove the clutch master cylinder bracket.
3) Remove the bush, spacer and spring.
4) Remove the bush, spring and stopper.
(1) Plug
(2) Stopper
(3) Brake pedal
\) B4M2350A (4) Brake pedal spring
(1) Stopper 4) Remove the brake pedal pad.

(2) Bushing
(3) Brake pedal
(4) Brake pedal spring
5) Remove the brake pedal pad.
BR-52
1
BRAKE PEDAL
BRAKE
D: ASSEMBLY E: INSPECTION
1) Attach the stop light switch, etc. to pedal bracket 1) Move the brake and clutch pedal pads in the lat-
temporarily. eral direction with a force of approximately 10 N (1
2) Clean the inside of bores of clutch pedal and kgf, 2 Ib) to ensure pedal deflection is in specified
brake pedal, apply grease, and set bushings into range.
bores. CAUTION:
3) Align bores of pedal bracket, clutch pedal and If excessive deflection is noted, replace the
brake pedal, attach brake pedal return spring and bushings with new ones.
clutch pedal effort reducing spring (vehicle with hill
holder), and then install the pedal bolt. Deflection of brake and clutch pedal:
Service limit
NOTE: 5.0 mm (0.197 in) or less
Clean up inside of bushings and apply grease be-
fore installing the spacer.
Tightening torque:
T: 29 Nom(3.0 kgf-m, 21.7 ft-lb)
(1) Clutch pedal

(2) Brake pedal
4) Set the brake pedal position by adjusting the po-

sition of stop light switch.
-
Pedal position: L
125.9 mm (4.96 in)
Tightening torque:
T: 8 N.m (0.8 kgf-m, 5.8 ft-lb)
&g F::
G4M0326
BR-53
BRAKE PEDAL
BRAKE
2) Check the position of pedal pad.

Pedal height: L
148 mm (5.83 in)
Brake pedal free play: A
1 -3 mm (0.04 - 0.12 in) [Depress brake
pedal pad with a force of less than 10 N (1 kgf,
2 lb).]
B4M03668
(1) Stop light switch

(2) Mat
(3) Toe board
(4) Brake booster operating rod
3) If it is not in specified value, adjust it by adjusting

the brake booster operating rod length.
BR-54
STOP LIGHT SWITCH Is
BRAKE
19.Stop Light Switch C: INSPECTION

1) If the stop light switch does not operate properly
A: REMOVAL (or if it does not stop at the specified position), re-
1) Disconnect the ground terminal from battery. place with a new one.
2) Disconnect the stop light switch connector.
3) Loosen the nuts, and unscrew stop light switch Specified position: L
to remove. 2 mm (0.079 in)
7
A+-
I G4M0327
2) Measure the clearance between threaded end of

(1) Stop light switch stop light switch and stopper.
CAUTION:
B: INSTALLATION Be careful not to rotate the stop light switch.
1) Screw the stop light switch onto a bracket and
secure it temporarily with a nut. Stop light switch clearance: A
2) Adjust the stop light switch position, and then 0.3 mm (0.012 in)
tighten the nut.
<Ref. to BR-56, ADJUSTMENT, Stop Light
Switch.>
Tightening torque:
8 N.m (0.8 kgf-m, 5.8 ft-lb)
(,,--p3)
B4M0617E
(1) Stop light switch

(2) Stopper
(3) Brake pedal
3) If it is not in specified value, adjust it by adjusting

the position of stop light switch.
CAUTION:
Be careful not to rotate the stop light switch.
BR-55
STOP LIGHT SWITCH
BRAKE
D: ADJUSTMENT
Loosen the lock nut, and adjust the stop light switch
position until the clearance between threaded end
of the stop light switch and the stopper becomes
0.3 mm (0.012 in). Then, tighten the lock nut.
Ir' B4M0617E
BR-56
GENERAL DIAGNOSTICS
BRAKE
20.General Diagnostics
A: INSPECTION
Trouble and possible cause Corrective action
1. Insufficient braking (1) Fluid leakage from the hydraulic mechanism Repair or replace (cup, piston seal, piston boot,
master cylinder piston kit, pipe or hose).
(2) Entry of air into the hydraulic mechanism 1 Bleed the air.
(3) Excessively wide shoe clearance ] Adjust the clearance.
(4) Wear, deteriorated surface material, adhering Replace, grind or clean.
water or fluid on the lining
(5) Improper operation of master cylinder, disc cal- Correct or replace.
iDer, brake booster or check valve
2. Unstable or uneven (1) Fluid on the lining, drum or rotor Eliminate cause of fluid leakage, clean, or replace.
braking (2) Drum or rotor eccentricity Correct or replace the drum or rotor.
(3) Worn brake drum, or damage to the drum Correct by grinding, or replace.
caused by sand
(4) Improper lining contact, deteriorated surface Correct by grinding, or replace.
material, improper inferior material, or wear
(5) Deformed back plate Correct or replace.
(6) Improper tire inflation Inflate to correct pressure.
(7) Disordered wheel alignment Adjust alignment.
(8) Loosened back plate or the support installing Retighten.
bolts
(9) Loosened wheel bearing I Retighten to normal tightening torque or replace.
(10) Trouble in the hydraulic system 1
Replace the cylinder, brake pipe or hose.
(11) Uneven effect of the parking brake 1
Check, adjust, or replace the rear brake and cable
I
system.
3. Excessive pedal (1) Entrv of air into the hvdraulic mechanism 1 Bleed the air.
stroke (2) Excessive play in the master cylinder push rod 1 Adjust.
(3) Fluid leakage from the hydraulic mechanism Repair or replace (cup, piston seal, piston boot,
master cylinder piston kit, pipe or hose).
(4) Improperly adjusted shoe clearance Adjust.
(5) ImDroDer linina contact or worn linina Correct or replace.
4. Brake dragging or
improper brake return (2) Improper master cylinder return 1 Clean or replace the cylinder.
(3) Clogged hydraulic system Replace.
(4) Improper return or adjustment of parking brake Correct or adjust.
(5) Weakened spring tension or breakage of shoe Replace the spring.
return sDrina
I Adiust the clearance.
~~~~~ ~ ~
(6) Excessively narrow shoe clearance

( 7 ) lmprouer disc caliper operation 1 Correct or replace.
(8) Improper adjusted wheel bearing Adjust or replace.
5. Brake noise (1) (1) Hardened or deteriorated lining Replace the shoe assembly or pad.
(creak sound) (2) Worn lining Replace the shoe assembly or pad.
(3) Loosened back plate or the support installing Retighten.
bolts
(4) Loose wheel bearing I Retighten to normal tightening torque.
(5) Dirty drum or rotor Clean the drum or rotor, or clean and replace the
brake assembly.
6. Brake noise (2) (1) Worn lining Replace the shoe assembly or pad.
(hissing sound) (2) ImDroDer installed shoe or Dad Correct or replace the shoe assembly or pad.
(3) Loose or bent drum or rotor I Retighten or replace.
BR-57
GENERAL DIAGNOSTICS
BRAKE
Trouble and possible cause Corrective action

7. Brake noise (3) In the case of the disc brake:
(click sound) (1) Excessively worn pad or the support I Replace the pad or the support.
In the case of the drum brake:
(1) Excessively worn shoe ridge Replace the back plate.
(2) Lack of oil on the shoe ridge surface and Add more grease.
I
anchor
BR-58
PARKING BRAKE
~~ ~
PB
Page
2. Parking Brake Lever.................................................................................... 6
3. Parking Brake Cable ................................................................................... 8
4. Parking Brake Assembly (Rear Disc Brake) ............................................. 10
GENERAL DESCRIPTION
PARKING BRAKE
1 General Description
A: SPECIFICATIONS
Type
Model Rear drum brake Rear disc brake
Mechanical on rear brakes, drum in disc
1
Effective drum diameter mm (in) 228.6 (9) 170 (6.69)
Lining dimensions 21 9.3x 35.0x 4.1 163.1 x 30.0x 3.2
mm (in)
(length x width x thickness) (8.63x 1.378x 0.161) (6.42x 1.181x 0.126)
Clearance adjustment Automatic adjustment Manual adjustment
Lever stroke notches/N (kgf, Ib) 7 to 8/196(20,44)
PB-2
GENERAL DESCRIPTION
PARKING BRAKE
B: COMPONENT
(1) Back plate (10) Primary return spring Tightening torque: N-m (kgf-m, ft-lb)
(2) Retainer (11) Secondary return spring T: 53 (5.4, 39)
(3) Spring washer (12) Adjusting spring
(4) Lever (13) Adjuster
(5) Parking brake shoe (Primary) (14) Shoe hold-down cup
(6) Parking brake shoe (Secondary) (15) Shoe hold down spring
(7) Strut spring (16) Shoe hold down pin
(8) Strut (17) Adjusting hole cover
(9) Shoe guide plate
PB-3
GENERAL DESCRIPTION
PARKING BRAKE
2. PARKING BRAKE CABLE
(1 i
B4M0705B
(1) Parking brake lever (7) Clamp Tightening torque: N.m (kgf-m, ft-lb)
(2) Parking brake switch (8) Parking brake cable RH T1: 6 (0.6, 4.4)
(3) Lock nut (9) Cable guide T2: lS(1.8, 13.0)
(4) Adjusting nut (IO) Clamp (Rear disc brake model T3: 33 (3.4,24)
(5) Equalizer only)
(6) Bracket (11) Parking brake cable LH
PB-4
GENERAL DESCRIPTION is
PARKING BRAKE
C: CAUTION
tion.
points.
formation.
Keep grease etc. away from parking brake
shoes.
PB-5
PARKING BRAKE LEVER
PARKING BRAKE
2. Parking Brake Lever 8) Unbend the parking brake lever pawls and re-
move cable.
A: REMOVAL
1) Move the select lever to “P” position or gear shift
lever to 1st gear, then block the wheels.
2) Disconnect the battery ground terminal from bat-
tery.
4) Disconnect the connector of parking brake
switch.
5 ) Loosen the parking cable adjusting nut and con-
sole bracket.
6) Remove the parking brake lever.
(2) Cable
B: INSTALLATION
Tightening torque:
Parking brake lever;
18 N.m (1.8 kgf-m, 13.0 ft-lb)
Adjusting nut;
6 N-m (0.6 kgf-m, 4.4 ft-lb)
NOTE:
7) Remove the inner cable end from equalizer. Be sure to pass the cable through the guide in-
side tunnel.
Be sure to adjust the lever stroke. <Ref. to PB-7,
ADJUSTMENT, Parking Brake Lever.>
-
(1) Equalizer
(2) Inner cable end
S4M0473A
PB-6
PARKING BRAKE LEVER 1
PARKING B R M F
~~~ ~
-
C: INSPECTION D: ADJUSTMENT
While pulling the parking brake lever upward, count 1) Remove the console box. <Ref. to El-41, RE-
the notches. MOVAL, Console Box.>
2) Forcibly pull the parking brake lever 3 to 5 times.
Lever stroke:
3) Adjust the parking brake lever by turning adjust-
7t0 8notches when with a force Of
er until the parking brake lever stroke is set at 7 to
N (20 kgf, 44 lb) 8 notches with an operating force of 196 N (20 kgf,
If incorrect, adjust the parking brake. 44 Ib).
<Ref. to PB-12, ADJUSTMENT, Parking Brake AS- 4) Tighten the lock nut.
sembly (Rear Disc Brake).>
Lever stroke:
7 to 8 notches when pulled with a force of 796
N (20 kgc 44 lb)
5.9 N-m (0.6 kgf-m, 4.3 ft-lb)

(2) Locknut
(3) Adjusting nut
5 ) Install the console box. <Ref. to El-41, INSTAL-

LATION, Console Box.>
PB-7
I PARKING BRAKE CABLE
PARKING BRAKE
3. Parking Brake Cable 10) Pull out the parking brake cable from rear
brake.
A: REMOVAL Disc brake
1) Lift-up the vehicle. <Ref. to PB-10, REMOVAL, Parking Brake As-
2) Remove the rear tires and wheels. sembly (Rear Disc Brake).>
3) Remove the rear cushion. Drum brake
4) Remove the console box. <Ref. to El-41, RE- <Ref. to BR-33, Rear Drum Brake Assembly.>
MOVAL, Console Box.> 11) Pull out the clamp from rear brake.
5) Loosen the parking cable adjusting nut and con- 12) Remove the bolt and bracket from trailing link
sole bracket. bracket.
6) Remove the parking brake lever. 13) Remove the bolt and clamp from rear floor.
S4M0474A
7) Roll up the floor mat and remove clamps. (1) Grommet

(2) Parking brake cable
14) Detach the grommet from rear floor.

15) Remove the cable assembly from cabin by forc-
ibly pulling it backward.
16) Detach the parking brake cable from cable
guide at rear trailing link.
0R0030
8) Remove the equalizer cover.

9) Remove the inner cable end from equalizer.
2)
S4M0473A
(1) Equalizer
(2) Inner cable end
PB-8
PARKING BRAKE CABLE a
PARKING BRAKE
Install the (new) parking brake assembly in the re- Check the removed cable and replace if damaged,
verse order of removal. rusty or malfunctioning.
NOTE: 1) Check for smooth operation of the cable.
Be sure to pass the cable through the cable 2) Check the inner cable for damage and rust.
guide inside tunnel. 3) Check the outer cable for damage, bends, and
Be sure to adjust the lever stroke. <Ref. to PB-7, cracks.
ADJUSTMENT, Parking Brake Lever.> 4) Check the boot for damage, cracks, and deterio-
ration.
PB-9
PARKING BRAKE ASSEMBLY (REAR DISC BRAKE)
PARKING BRAKE
4. Parking Brake Assembly (2) If the disc rotor seizes up within the hub,
drive the disc rotor out by installing an 8-mm bolt
(Rear Disc Brake) in holes B on the rotor.
A: REMOVAL
1)Set the vehicle on a lift.
4) Jack-up the vehicle, and remove wheel.
5) Remove the two mounting bolts and remove the
disc brake assembly.
G4M0383
9) Remove the primary and secondary return

spring from parking brake assembly.
IO) Remove the front shoe hold down spring and
pin with pliers.
(1) Disc brake ASSY
6) Suspend the disc brake assembly so that the

hose is not stretched.
7) Pull down and release the parking brake.
8) Remove the disc rotor.
NOTE:
If the disc rotor is difficult to remove try the following 11) Remove the strut and strut spring.
two methods in order. 12) Remove the rear shoe hold-down spring and
(1) Turn the adjusting screw using a slot-type pin with pliers.
screwdriver until the brake shoe gets away 13) Remove the adjuster assembly and adjusting
enough from the disc rotor. spring from parking brake assembly.
14) Remove the parking cable from parking lever.
15) Remove the brake shoe.
S4M0569A
(1) Adjusting screw

(2) Cover (rubber)
(3) Slot-type screwdriver (1) Parking brake cable
(4) Back plate (2) Parking brake lever
16) Using a standard screwdriver, raise the retain-

er. Remove the parking lever and washer from
brake shoe.
PB-10
-
PARKING BRAKE
B: INSTALLATION NOTE:
Ensure that the shoe return spring is installed as
CAUTION:
shown in Figure.
Be sure the lining surface is free from oil con-
tamination.
Brake grease:
Dow Corning Molykote No. 7439 (Part No.
I
72579 1460)
1) Apply brake grease to the following places.
Six contact surfaces of shoe rim and back plate
packing
Contact surface of shoe wave and anchor pin
Contact surface of lever and strut
Contact surface of shoe wave and adjuster as- S4M0462A
sembly
Contact surface of shoe wave and strut (1) Back plate
Contact surface of lever and shoe wave (2) Shoe guide plate
2) Install in the reverse order of removal. (3) Retainer
(4) Spring washer
CAUTION:
Use new retainers and clinch them when in- (5) Lever
stalling the brake shoes to levers. (6) Primary shoe return spring (Blue)
Ensure that the parking lever moves smooth- (7) Secondary shoe return spring (Yellow)
ly- (8) Parking brake shoe (Primary)
e Do not confuse the left parking lever with (9) Parking brake shoe (Secondary)
right one.
Do not confuse the left strut with right one. 3) Adjust the parking brakes. <Ref. to PB-12, AD-
JUSTMENT, Parking Brake Assembly (Rear Disc
NOTE: Brake).>
Ensure that the adjuster assembly is securely in-
stalled with the screw in the left side, facing vehicle CAUTION:
front. After replacing the parking brake lining, be sure
to drive the vehicle for “break-in” purposes.
(1) Drive the vehicle at about 35 km/h (22 MPH).
(2) With the parking brake release button
pushed in, pull the parking brake lever gently.
(3) Drive the vehicle for about 200 meter (0.12
mile) in this condition.
(4) Wait 5 to 10 minutes for the parking brake to
cool down. Repeat this procedure once more.
(5) After breaking-in, re-adjust the parking
brakes.
S4M0461A
(1) LEFT
PB-11
PARKING BRAKE
C: INSPECTION 2. LEVER STROKE

1) Measure the brake disc inside diameter. If the 1) Remove the console box lid.
disc is scored or worn, replace the brake disc. 2) Forcibly pull the parking brake lever 3 to 5 times.
Disc inside diameter: 3) Adjust the parking brake lever by turning adjust-
Standard er until the parking brake lever stroke is set at 6
170 mm (6.69 in) notches with operating force of 196 N (20 kgf, 44
Service limit Ib).
171 mm (6.73 in)
2) Measure the lining thickness. If it exceeds the
limit, replace shoe assembly.
Lining thickness:
Standard
3.2 mm (0.126 in)
Service limit
1.5 mm (0.059 in)
CAUTION:
BR0054
Replace the brake shoes on the right and left
brake assembly at the same time.
D: ADJUSTMENT (2) Locknut
(3) Adjusting nut
1. SHOE CLEARANCE
1) Remove the adjusting hole cover from back 4) Tighten the lock nut.
plate. 5) Install the console box lid.
2) Turn the adjusting screw using a slot-type screw- Lever stroke:
driver until the brake shoe is in close contact with 7 to 8 notches when pulled with a force of 196
disc rotor. N (20 kgf, 44 16)
Tightening torque (Adjuster lock nut):
6 N-m (0.6 kgf-m, 4.4 ft-16)
S4M0463A I
(1) Adjusting screw
(2) Cover (rubber)
(3) Slot-type screwdriver
(4) Back plate
3) Turn back (downward) the adjusting screw 3 or 4

notches.
4) Install the adjusting hole cover to back plate.
PB-I 2
PARKING BRAKE

A: INSPECTION
Possible cause Remedy
Parking brake lever is maladjusted. Adjustment.
Parkina brake cable does not move. Repair or replace.
Brake drag
Parkina brake shoe clearance is maladiusted. 1 Adjustment. I
Return spring is faulty. I Replace. I
Return spring is faulty. Replace.
Noise from brake
Shoe hold down spring is faulty. Replace.
PB-13
PARKING BRAKE
PB-14
POWER ASSISTED SYSTEM
(POWER STEERING)
Page
2. Steering Wheel .......................................................................................... 19
3. Universal Joint ........................................................................................... 20
4. Tilt Steering Column.................................................................................. 23
5. Steering Gearbox ...................................................................................... 26
6. Pipe Assembly .......................................................................................... 47
7. Oil Pump ................................................................................................... 55
8. Reservoir Tank .......................................................................................... 70
9. Power Steering Fluid................................................................................. 72
GENERAL DESCRIPTION
POWER ASSISTED SYSTEM (POWER STEERING)
A: SPECIFICATIONS
Non-TURBO
Model Sedan and TURBO
Others
OUTBACK
Minimum turning radius m (ft) 5.1 (16.7) 5.4(17.7)
Steering angle (Inside-Outside) 36'55' - 31 "35' 34'05' - 29'35'
Whole
Steering wheel diameter mm (in) 385 (15.16)
svstem
Overall gear ratio (Turns, lock to lock
- - -.. -box)
Gear
Type
-.. I 3.22
I
3.02
Rack and pinion, Integral
Gearbox Backlash 0 (Automatically adjustable)
Valve (Power steerina svsteml Rotary valve
1 TvDe I Vane pump
Oil tank Installed on body
output cm3 (cu in)/rev. 7.8(0.476) 7.2 (0.439)
Pump 7,164- 7,840 7,350- 8,036(75- 82,
Relief pressure kPa (kg/cm2, psi) (73- 80.1,040- 1,165) 1,067- 1,165)
(Power
steering 1 Hvdraulic fluid control I Dropping in response to increased engine revolutions
1
system)
Hydraulic fluid
Range of revolution
Q (US qt, Imp qt)
rPm
1,000rpm: 7 (7.4,
6.2)
3,000rpm: 5 (5.3,
4.4)
700 - 9,000
I
I
7.5(7.9,
7 (7.4,
I .
6.6)"
6.2)'*
I
Revolvina direction Clockwise

Working Name ATF DEXRON Ill
fluid Oil tank 0.3(0.3,0.3)
(Power Capacity
steering Q (US qt, Imp qt) Total 0.7(0.7,0.6)
system)
PS-2
GENERAL DESCRIPTION
Steering wheel Free play mm (in) 17 (0.67)

Inner tire & TURBO, OUTBACK, Non-TURBO sedan 34"05'+1.5"
wheel other 36"55'+1.5"
Turning angle
Outer tire & TURBO, OUTBACK, Non-TURBO sedan 29"35'+1.5"
wheel I other I 31"35'+1.5" I
Steering shaft
Clearance between steering wheel and
column
- - .-. . ... . cover
- - ..
mm (in) I 3.0 (0.1 18)
Sliding resistance N (kgf, Ib) 340 (35, 76) or less

~
Steering gear-
Rack shaft I Horizontal movement: I
play in radial 0.15 (0.0059) or less
box direction Left-turn steering mm (in)
Vertical movement:
(Power steer- 0.3 (0.012) or less
ing system)
Input shaft In radial direction mm (in) 0.18 (0.0071) or less
Play In axial direction mm (in) 0.5 (0.020) or less
Turning resistance N (kgf, Ib) Maximum allowable value: 12 (1.2, 2.7)
Radial play mm (in) I 0.4 (0.016) or less
I Non-TURBO mm (in) I 0.4 (0.016) or less
Pulley shaft
IAxial play I TURBO mm
I
(in) I
I ,
0.8 (0.031) or less I

I I
I
\ I ,
Oil pump I Ditch deflection mm (in) I 1.O (0.039) or less

(Power steer- Pulley
I s t a n c e torotation N (kqf, Ib) I 9.22 (0.94, 2.07) or less I
ing system)
Regular pressure kPa (kg/cm2,psi) 981 (IO,142) or less
Relief pres- "+TURBO kPa (kg/cm2, psi) 7,355 (75, 1,067)
sure TURBO kPa (kg/cm2, psi) 7,845 (80, 1,138)
Steeringwheel At standstill with engine idling on a con- 31.4 (3.2, 7.1) or less
crete road N (kgf, Ib)
effort
(Power steer- At standstill with engine stalled on a
N (kgf, Ib) 294.2 (30, 66.2) or less
ing system) concrete road
Recommended power steering fluid
ATF DEXRON Ill

La CALTEX
MOBIL
TEXACO
PS-3
GENERAL DESCRIPTION
CAUTION:
This table lists various clearances that must be correctly adjusted to ensure normal vehicle driving
without interfering noise, or any other faults.
Location Minimum allowance

(1) Crossmember - Pipe 5 mm (0.20 in)
(2) DOJ - Shaft or joint 14 mm (0.55 in)
(3) DOJ - Valve housing 11 mm (0.43 in)
(4) Pipe - Pipe 2 mm (0.08 in)
(5) Stabilizer - Pipe 5 mm (0.20 in)
(6) Exhaust pipe - Pipe 11 mm (0.43 in)
(7) Exhaust pipe - Gearbox bolt 15 mm (0.59 in)
(8) Side frame - Hose A and B 10 mm (0.39 in)
(9) Cruise control Dump - Hose A and B 15 mm (0.59 in)
(IO)Pipe portion of hose A - Pipe portion of hose B 1.5 mm (0.059 in)
(1 1) AT cooling hose - Joint 20 mm (0.79 in)
ST0081
PS-4
GENERAL DESCRIPTION
B: COMPONENT
1. STEERING WHEEL AND COLUMN
STO10'
(1) Bushing (6) Steering wheel Tightening torque: N.m (kgf-m, ft-lb)
(2) Knee protector (7) Airbag module T1: 1.2 (0.72, 0.9)
(3) Steering shaft (8) Lower steering wheel cover T2: 3.4 (0.35, 2.5)
(4) Steering roll connector T3: 25 (2.5, 18.1)
(5) Column cover T4: 44 (4.5, 32.5)
PS-5
GENERAL DESCRIPTION
2. POWER ASSISTED SYSTEM
I TURBOMODEL
I I
STOlO2
PS-6
GENERAL DESCRIPTION
(1) Eye bolt (27) Pinion and valve ASSY (53) Rack
(2) Pipe C (28) Oil seal (54) Rack bushing
(3) Gasket (29) Back-up washer (55) Rack stopper
(4) Clip (30) Ball bearing (56) Circlip
(5) Pipe D (31) Snap ring (57) Suction hose
(6) Clamp E (32) Locknut (58) Tie-rod end plate
(7) O-ring (33) Adjusting screw (59) Clamp plate
(8) Cap (34) Spring
(9) Reservoir tank (35) Sleeve Tightening torque: N-m (kgf-m, ff-lb)
Reservoir tank bracket Adapter T1: 6 (0.6, 4.3)
Pulley Clamp T2: 7.4 (0.75, 5.4)
Oil pump Cotter pin T3: 8 (0.8, 5.8)
Bracket Castle nut T4: 13 (1.3, 9.4)
Belt tension nut Dust cover T5: 15(1.5, 10.8)
Bush Clip T6: 15(1.5, 10.8)
Belt cover Tie-rod end T7: 15.7(1.6, 11.6)
Pipe E Clip T8: 22 (2.2, 15.9)
Pipe F Boot T9: 24 (2.4, 17.4)
Clamp plate Band T10: 25 (2.5, 18.1)
Universal joint Tie-rod T11: 25 (2.5, 18.1)
Dust seal Lock washer T12: 27(2.75, 19.9)
Valve housing Pipe B T13: 37.3 (3.8,27.5)
Gasket Pipe A T14: 39 (4.0,28.9)
Oil seal Steering body T15: 59 (6.0, 43)
Ball bearing Oil seal T16: 78 (8.0, 58)
Seal ring Piston ring T17: 83 (8.5, 61.5)
T18: 25 (2.5, 18.1)
PS-7
GENERAL DESCRIPTION
3. OILPUMP
NON-TURBO MODEL
(1) Pulley (10) Pressure switch (19) O-ring

(2) Oil seal (11) O-ring (20) Rear cover
(3) Shaft (12) O-ring (21) Suction connector
(4) Connector (13) Pressure plate
(5) O-ring (14) Straight pin Tightening torque: N.m (kgf-m, ft-lb)
(6) Spool valve (15) Vane T1: 21 (2.14, 15.5)
(7) Spring (16) Rotor T2: 49 (5.0, 36.2)
(8) O-ring (17) Cam ring T3: 52 (5.3, 38)
(9) Front casing (18) Retaining ring
PS-8
GENERAL DESCRIPTION
TURBO MODEL
STOOOl
Lead wire Front casing (17) O-ring

Pump switch Flow control spring
Rear cover Flow control valve Tightening torque: N.m (kgf-m, ft-lb)
O-ring Pulley T1: 9.8 (1.0, 7.2)
Cam Oil seal T2: 27 (2.75, 19.9)
Pressure plate Suction connector T3: 27.4 (2.8,20.3)
O-ring O-ring T4: 59 (6.0, 43)
Front casing Retaining ring T5: 11.8 (1.2, 8.7)
PS-9
I
GENERAL DESCRIPTION
C: CAUTION
tion.
moval, installation, disassembly and replacement.
Use SUBARU genuine steering fluid, grease etc.
or the equivalent. Do not mix steering fluid, grease
etc. with that of another grade or from other manu-
fact urers.
points.
Apply steering fluid onto sliding or revolution sur-
faces before installation.
ficient amount of steering fluid to avoid damage
and deformation.
PS-10
1
GENERAL DESCRIPTION
D: PREPARATION TOOL
1. SPECIAL TOOLS

I25700000 VRENCH Used for removing and installing tie-rod.
Apply this tool to rack.
B4M2411
325711000 'RESSURE Used for measuring oil pump pressure.
3AUGE
84M241: ~
926200000 STAND Used when inspecting characteristic of gearbox

assembly and disassembling it.
B4M241
34099AC010 ADAPTER HOSE A 1 Used with PRESSURE GAUGE (925711000).
PS-11
GENERAL DESCRIPTION

34099FA100 STAND BASE Used for assembling power steering gearbox.
For LHD model.
r G1H0273
34099AC020 ADAPTER HOSE B Used with PRESSURE GAUGE (925711000).
r 04M2415
326230000 SPANNER For the lock nut when adjusting backlash of
gearbox.
04M2416
~
34099PA100 SPANNER Measurement of rotating resistance of gear-

box assembly.
I ST0047
PS-12
GENERAL DESCRIPTION
ILLUSTRATION I TOOLNUMBER
134199AE020
For TURBO model.
B4M247 7
14199AE030 NSTALLER Jsed for installing oil seal into oil pump.
34199AE040 31L CHARGE K e d for charging power steering oil.

SUIDE
B4M241$
927640000 INSTALLER B Used for installing ball bearing into housing.
B4M242
PS-13
GENERAL DESCRIPTION

926370000 INSTALLER A Used for installing valve assembly into valve
housing assembly.
Used with STAND BASE (927630000).
84M2421
~~~ ~
926390001 COVER & Used for assembling rack assembly.

REMOVER ASSY
84M2422
926420000 PLUG When oil leaks from pinion side of gearbox
assembly, remove pipe B from valve housing,
attach this tool and check oil leaking points.
04M2423
926400000 GUIDE Right side of rack when installing rack bush.
Used with GUIDE (927660000).
84M2424
PS-14
GENERAL DESCRIPTION
ILLUSTRATION TOOL NUMBFR

-. . DESCRIPTION REMARKS
927660000 GUIDE Right side of rack when installing rack bush.
Used with GUIDE (926400000).
B4M242!
~
927620000 INSTALLER B b Used for installing oil seal of valve housing.

b Used with INSTALLER A (926360000).
B4M242E
326360000 INSTALLER A ' Used as a guide to install oil seal.
1 Used with INSTALLER B (927620000).
04M2420
INSTALLER Jsed for installing oil seal.
B4M2429
PS-15
GENERAL DESCRIPTION

34099FA120 INSTALLER AND Used for installing and removing valve housing
REMOVER SEAL oil seal.
SI H0030
34099FA130 INSTALLER SEAL Used for installing valve housing oil seal.
Used with INSTALLERAND REMOVER SEAL
(34099FA120).
ST0007
34199AE050 REMOVER OIL Used for removing back-up ring and oil seal.
SEAL
84M2432
34099AC030 INSTALLER A Used for installing retaining ring.
Used with INSTALLER B (34099AC040).
For non-turbo model.
H4M1408
PS-16
GENERAL DESCRIPTION
TOOL NUMBER DESCRIPTION REMARKS

ILLUSTRATION
34099AC040 INSTALLER B Used for installing retaining ring.
Used with INSTALLER A (34099AC030).
For non-turbo model.
H4M140E
PS-17
GENERAL DESCRIPTION
~ -
Spring scale Used for measuring tightening torque.

Snap ring pliers Used for removina and installina snaD rina.
. . . I
I
I
I
Dial gauge I Used for measuring steering gearbox.
PS-18
I
STEERING WHEEL
2. Steering Wheel B: INSTALLATION

1) Align the center of roll connector. <Ref. to AB-17,
A: REMOVAL ADJUSTMENT, Roll Connector.>
1) Disconnect the ground terminal from battery. 2) Install in the reverse order of removal.
2) Set the tires to straight-ahead position. NOTE:
3) Remove the airbag module. <Ref. to AB-12, RE- Align the matching marks on the steering wheel
MOVAL, Driver’s Airbag Module.> and steering column.
WARNING:
Tightening torque:
Always refer to “Air Bag System” before per-
44 N.m (4.5 kgf-m, 32.5 ft-lb)
forming airbag module service. <Ref. to AB-12,
CAUTION, Driver’s Airbag Module.> Column cover-to-steering wheel clearance:
4) Remove the steering wheel nut, and then draw -
2 - 4 mm (0.08 0.16 in)
out the steering wheel from the shaft using steering WARNING:
puller. Always refer to “Air Bag System” before per-
NOTE: forming airbag module service. <Ref. to AB-12,
Make the matching marks on the steering wheel CAUTION, Driver’s Airbag Module.>
and steering column in advance. CAUTION:
Insert the roll connector guide pin into the
guide hole on lower end of surface of steering
wheel to prevent damage. Draw out the airbag
system connector, horn connector and cruise
control connectors from the guide hole of
steering wheel lower end.
C: INSPECTION
1) Check the steering wheel for deformation. If the
deformation is excessive, replace the steering
wheel.
2) Check the splines on the steering wheel for dam-
(1) Matching mark age. If the damage is excessive, replace the steer-
ing wheel.
PS-19
UNIVERSAL JOINT
3. Universal Joint B: INSTALLATION

1) Install the universal joint.
A: REMOVAL (1) Align the cutout at serrated section of the
1) Remove the steering wheel. <Ref. to PS-19, RE- column shaft and yoke, then insert the universal
MOVAL, Steering Wheel.>
2) Remove the universal joint bolts and then re-
move the universal joint.
CAUTION:
Scribe alignment marks on universal joint so
that it can be reassembled at the original serra-
tion.
(1) cutout
(2) Yoke
(3) Column shaft
(4) Column shaft side
(5) Gearbox side
(2) Align the bolt hole on the gearbox side of

universal joint with the cutout at the serrated
section of gearbox assembly. Lower the univer-
sal joint completely.
(3) Temporarily tighten the bolt on the gearbox
side. Raise the universal joint to make sure the
bolt is properly passing through the cutout at the
serrated section.
(4) Tighten the bolt.
Tightening torque:
24 N-m (2.4 kgf-m, 17.4 ff-lb)
CAUTION:
Make sure that universal joint bolt is tight-
ened through notch in shaft serration.
Excessively large tightening torque of uni-
versal joint bolts may lead to heavy steering
wheel operation.
Standard clearance between gearbox to DOJ:
Over 14 mm (0.55 in)
PS-20
UNIVERSAL JOINT I
2) Align the center of roll connector. <Ref. to AB-1 7,

ADJUSTMENT, Roll Connector.>
CAUTION:
Ensure that front wheel are set straight forward
direction.
3) Install the steering wheel and airbag module.
<Ref. to PS-19, INSTALLATION, Steering Wheel.>
WARNING:
CAUTION, Driver’s Airbag Module.> and <Ref.
to AB-12, INSTALLATION, Driver‘s Airbag Mod-
ule.>
PS-21
UNIVERSAL JOINT
C: INSPECTION
Clean the disassembled parts with a cloth, and check for wear, damage, or any other faults. If necessary, re-
pair or replace faulty parts.
Inspection Corrective action

Free play
Swinging torque
Yawing torque
Looseness
1 Yawing torque
Replace if faulty.
Looseness
G4M0089
Standard value of universal joint free play: 0 mm (0 in)

Max. value of universal joint swinging torque: 0.3 N.m (0.03 kgf-m, 0.2 ft-lb)
Measurement of folding torque of universal joint is Service limit:
as shown in the figures. Maximum load; 7.3 N (0.74 kgf, 1.64 lb) or less
Service limit:
Maximum load; 7.3 N (0.74 kgc 1.64 lb) or less
S4M0445A
(1) Yoke (Steering column side)

S4M0443A
Service limit:
(1) Yoke (gearbox side)
Maximum load; 7.3 N (0.74 kgf, 1.64 lb) or less
Service limit:
Maximum load; 7.3 N (0.74 kgf, 1.64 lb) or less
S4M0446A
. ,, .
S4M0444A
(1) Yoke (Steering column side)
(1) Yoke (gearbox side)
PS-22
TILT STEERING COLUMN I
4. Tilt Steering Column

A: REMOVAL
ST0022
(1) Tilt steering column Tightening torque: N.m (kgf-m, ft-lb)

(2) Universal joint T1: 24 (2.4, 17.4)
12: 25 (2.5, 18.1)
1) Set the vehicle on the lift. 5 ) Remove the universal joint. .=Ref.to PS-20, RE-
2) Disconnect the battery ground terminal. MOVAL, Universal Joint.>
3) Remove the airbag module. <Ref. to AB-12, RE- 6) Remove the trim panel under instrument panel.
MOVAL, Driver’s Airbag Module.>
WARNING:
CAUTION, Driver’s Airbag Module.>
4) Remove the steering wheel. <Ref. to PS-19, RE-
MOVAL, Steering Wheel.>
PS-23
I TILT STEERING COLUMN
7) Remove the screw securing lower steering col- B: INSTALLATION

umn cover. 1) Set the grommet to the toe board.
1654
- w // B4M1656
8) Remove the knee bolster 2) Insert the end of steering shaft into the toe board
grommet.
3) Tighten the steering shaft mounting bolts under
instrument panel.
Tightening torque:
25 N-m (2.5 kgf-m, 78.7 fWb)
4) Install the knee bolster.
9) Remove all connectors from the steering col-

umn.
10) Remove the two bolts under instrument panel
securing steering column.
5) Connect all connectors under instrument panel.

6) Connect the airbag system connector at the har-
ness spool.
NOTE:
Make sure to apply double lock.
7) Install the lower column cover with tilt lever held
in the lowered position.
8) Install the universal joint. <Ref. to PS-20, IN-
11) Pull out the steering shaft assembly from the STALLATION, Universal Joint.>
hole on toe board. 9) Align the center of roll connector. <Ref. to AB-17,
CAUTION: ADJUSTMENT, Roll Connector.>
Be sure to remove the universal joint before re- CAUTION:
moving steering shaft assembly installingbolts Ensure that front wheels are set in straight for-
when removing steering shaft assembly or ward direction.
when lowering it for servicing of other parts.
PS-24
TILT STEERING COLUMN I
10) Install the steering wheel. <Ref. to PS-19, IN- C: DISASSEMBLY

STALLATION, Steering Wheel.> Remove the two screws securing upper steering
Set the steering wheel to neutral and install it onto column covers, and the two screws securing com-
steering shaft. bination switch, then remove the related parts.
CAUTION:
Insert roll connector guide pin into guide hole
D: ASSEMBLY
on lower end of surface of steering wheel to 1) Insert the combination switch to the upper col-
prevent damage. Draw out airbag system con- umn shaft, and install the upper column cover.
nector, horn connector and cruise control con- Then route the ignition key harness and combina-
nectors from guide hole of steering wheel lower tion switch harness between column cover mount-
end. ing bosses.
11) Install the airbag module to the steering wheel. Tightening torque:
WARNING: 1.2 N.m (0.12 kgf-m, 0.9 ft-lb)
Always refer to “Air Bag System” before per- CAUTION:
forming the service operation. <Ref. to AB-12, Don’t overtorque the screw.
CAUTION, Driver’s Airbag Module.>
E: INSPECTION
1. BASIC INSPECTION
Clean the disassembled parts with a cloth, and check d r wear, damage, or any other faults. necessary, re-
pair or replace faulty parts.
Inspection Corrective action

Overall length of steering column
Measure overall length of steering column.
Standard overall length of steering column:
Replace steering col-

umn assembly.
825.7f1.5” (32.51+0.059in)
ST0024
2. AIRBAG MODEL INSPECTION

WARNING:
For airbag model inspection procedures, refer
to “Air Bag System”. <Ref. to AB-12, CAUTION,
Driver’s Airbag Module.> and <Ref. to AB-12,
INSPECTION, Driver’s Airbag Module.>
PS-25
STEERING GEARBOX
5. Steering Gearbox 10) Remove the one pipe joint at the center of gear-
box, and connect the vinyl hose to the pipe and
A: REMOVAL joint. Discharge the fluid by turning steering wheel
1) Set the vehicle on the lift. fully clockwise and counterclockwise. Discharge
2) Disconnect the battery ground terminal. the fluid similarly from the other pipe.
3) Loosen the front wheel nuts.
4) Lift the vehicle and remove the front wheels.
6) Remove the sub frame. <Ref. to FS-16, RE-
MOVAL, Sub Frame.>
7) Remove the front exhaust pipe assembly. (Non-
TURBO model)
Pipe.>
WARNING:
Be careful, exhaust pipe is hot.
8) Using a puller, remove the tie-rod end from the (1) PipeA
knuckle arm after pulling off cotter pin and remov- (2) Pipe B
ing castle nut.
11) Remove the universal joint. <Ref. to PS-20,
REMOVAL, Universal Joint.>
12) Disconnect the pipes C and D from the pipe of
gearbox.
CAUTION:
Be careful not to damage these pipes.
NOTE:
Disconnect the upper pipe D first, and lower pipe C
second.
(1) Castle nut

(2) Tie-rod end
(3) Knuckle arm
9) Remove the jack-up plate and front stabilizer.
(1) Pipe C
(2) Pipe D
(1) Jack-up plate
PS-26
STEERING GEARBOX 9
13) Remove the clamp bolts securing gearbox to (2) Connect the pipes C and D to the gearbox.
the crossmember, and remove the gearbox. Connect the upper pipe D first, and lower pipe C
second.
Tightening torque:
15 N.m (1.5 kgf-m, 10.8 ft-16)
(1) Clamp
B: INSTALLATION
1) Insert the gearbox into the crossmember, being
(1) Pipe C
careful not to damage gearbox boot.
(2) Pipe D
2) Tighten the gearbox to the crossmember bracket
via clamp with bolt to the specified torque. 4) Install the universal joint. <Ref. to PS-20, IN-
Tightening torque: STALLATION, Universal Joint.>
59 N-m (6.0 kgf-m, 43 ff-16) 5 ) Connect the tie-rod end and knuckle arm, and
tighten with castle nut. Fit the cotter pin into the nut
and bend the pin to lock.
Castle nut tightening torque:
Tighten to 27.0 N.m (2.75 kgf-m, 19.9 ft-lb),
and tighten further within 60" until cotter pin
hole is aligned with a slot in the nut.
CAUTION:
When connecting, do not hit cap at the bottom
of tie-rod end with hammer.
(1) Clamp
3) Install the four pipes on the gearbox.

(1) Connect the pipes A and B to the four pipe
joints of gearbox. Connect the upper pipe B first,
and lower pipe A.
Tightening torque:
13 N.m (1.3 kgf-m, 9.4 ft-16) /, S4M0379A
(1) Castle nut

(2) Tie-rod end
(3) Knuckle arm
6) Install the front stabilizer to vehicle.

7) Install the front exhaust pipe assembly.
8) Install the sub frame. <Ref. to FS-16, INSTALLA-
TION, Sub Frame.>
PS-27
STEERING GEARBOX
9) Align the center of roll connector. <Ref. to AB-17, 1. RACK HOUSING ASSEMBLY
ADJUSTMENT, Roll Connector.>
1) Disconnect the four pipes from the gearbox.
CAUTION:
NOTE:
Ensure that front wheels are set in straight for-
Remove the pipes E and F as a single unit being
ward direction.
fixed at the clamp plate.
10) Install the steering wheel. <Ref. to PS-19, IN-
STALLATION, Steering Wheel.> 2) Secure the gearbox removed from the vehicle in
vice using ST.
11) Install the tires.
ST 926200000 STAND
12) Tighten the wheel nuts to the specified torque.
CAUTION:
Tightening torque: Secure the gearbox in a vice using the ST as
90 N-m (9.7 kgf-m, 66 ff-lb) shown. Do not attempt to secure it without this
13) Connect the ground terminal to battery. ST.
14) Pour the fluid into the oil tank, and bleed air.
<Ref. to PS-72, Power Steering Fluid.>
15) Check for fluid leaks.
16) Install the jack-up plate.
18) Check the fluid level in oil tank.
19) After adjusting toe-in and steering angle, tight-
en the lock nut on tie-rod end.
Tightening torque:
83 N-m (8.5 kgf-m, 61.5 ff-lb)
S4M0143A
CAUTION:
When adjusting toe-in, hold the boot as shown 3) Remove the tie-rod end plate.
to prevent it from being rotated or twisted. If
twisted, straighten it.
I ST0084
4) Remove the tie-rod end and lock nut from the

G4M0132 gearbox.
5 ) Remove the small clip from the boot using pliers,
C: DISASSEMBLY and move the boot to the tie-rod end side.
NOTE:
Parts requiring replacement are described in the
smallest unit of spare parts including damaged
parts and spare parts damaged. In actual disas-
sembly work, accidental damage as well as inevita-
ble damage to some related parts must be taken
into account, and spare parts for them must also be
prepared. However, it is essential to pinpoint the
cause of trouble, and limit the number of replace-
ment parts as much as possible.
I S4M01448
(1) Clip
PS-28
1
STEERING GEARBOX
6) Using standard screwdriver, remove the band 9) Tighten the adjusting screw until it no longer
from the boot. tightens.
S4M0145C S4M0140
10) Using a wrench [32mm (1.26in) width across

(1) Band flats] or adjustable wrench, remove the tie-rod.
7) Extend the rack approximately 40 mm (1.57in) CAUTION:
out. Unlock the lock wire at lock washer on each Check ball joint for free play, and tie-rod for
side of tie-rod end using a standard screwdriver. bends. Replace if necessary.
CAUTION: Check dust seals used with tie-rod end ball
Be careful not to scratch rack surface as oil joint for damage or deterioration. Replace if
leaks may result. necessary.
-
40 mm (1.57 in)
S4M0146C
11) Loosen the adjusting screw and remove the
(1) Lock washer spring and sleeve.
8) Usina ST. loosen the lock nut. CAUTION:
ST 9F6230OOO SPANNER Replace spring and/or sleeve if damaged.
12)Remove the two bolts securing valve assembly.
S4M0147C
S4M0154
PS-29
I STEERING GEARBOX
a
13) Carefully draw out the input shaft and remove 16) Remove the rack bushing and rack stopper
the valve assembly. from the rack assembly.
CAUTION:
Do not reuse removed rack bushing and circlip.
17) Remove the oil seal from rack.
18) Insert ST from the pinion housing side and re-
move the oil seal using a press.
ST 34099FA110 INSTALLER
14) Using a sharp pointed pliers, rotate the rack

stopper in the direction of the arrow until the end of
the circlip comes out of the stopper. Rotate the cir-
clip in the opposite direction and pull it out.
(1) Rack stopper

L A S4M01638
15) Pull the rack assembly from the cylinder side,
and draw out the rack bushing and rack stopper to- (1) Press
gether with the rack assembly. (2) Oil seal
CAUTION:
NOTE:
Be careful not to contact rack to inner wall of
cylinder when drawing out. Any scratch on cyl- Discard the removed the oil seal.
inder inner wall will cause oil leakage.
(3)
S4M0402A
(1) Rack bushing

(2) RackASSY
(3) Rack stopper
PS-30
1
STEERING GEARBOX
2. CONTROL VALVE 5) Loosen the adjusting screw and remove the

spring and sleeve.
1) Disconnect the four pipes from the gearbox.
CAUTION:
NOTE:
Replace the spring and/or sleeve if damaged.
Remove the pipes E and F as a single unit being
fixed at the clamp plate. 6) Remove the two bolts securing valve assembly.
2) Secure the gearbox removed from the vehicle in
vice using ST.
ST 926200000 STAND
CAUTION:
Secure the gearbox in a vice using the ST as
shown. Do not attempt to secure it without this
ST.
I S4M0154 I
7) Carefully draw out the input shaft and remove

the valve assembly.
S4M0143P
3) Usina ST, loosen the lock nut.

8) Slide the dust cover out.
T008!
4) Tighten the adjusting screw until it no longer

tightens.
S4M01568
(1) Dust cover
PS-31
I STEERING GEARBOX
9) Using a press remove pinion and valve assem- 11) Remove the snap ring using snap ring pliers.
bly from the valve housing. CAUTION:
Do not reuse removed snap ring.
Be careful not to scratch pinion and valve as-
sembly.
(3)-
S4M01578
(1) Valve ASSY

(2) Valve housing
(3) Cloth
12) Press out the bearing together with the back up
10) Using ST and press, remove the dust seal, oil washer using pipe of I.D. 38.5 to 39.5 mm (1.516 to
seal and special bearing from the valve housing. 1.555 in) and press.
ST 34099FA120 INSTALLER & REMOVER
SEAL CAUTION:
Do not reuse removed bearing.
CAUTION:
Do not apply a force to end surface of valve
housing.
Do not reuse oil seal after removal.
S4M0159B
(1) Oil seal

(2) Special bearing
S4M0403A
(1) Bearing
(2) Backing washer
(3) Oil seal
(4) Pipe
13) Remove the oil seal.

CAUTION:
Do not reuse removed oil seal.
PS-32
m
STEERING GEARBOX
D: ASSEMBLY Do not apply grease to threaded portion at

end of rack shaft.
1. RACK HOUSING ASSEMBLY Move rack shaft to stroke end two (2) or three
CAUTION: (3) times to squeeze grease which accumulates
on both ends. Remove grease to prevent it from
Use only SUBARU genuine grease for gearbox.
choking air passage hole.
Specified grease for gearbox: 4) Apply grease to the sleeve insertion hole.
VALIANT GREASE M2 (Part No. 003608001) 5) Apply grease to the dust seal insertion hole.
1) Clean all parts and tools before reassembling. CAUTION:
2) Force-fit oil seal using ST. Apply clean grease with clean hands. If material
ST 34099FA110 INSTALLER having a sharp edge is used for applying
CAUTION: grease, oil seal at the inside might be damaged.
Be careful not to damage or scratch cylinder in- 6) Fixing rack housing
ner wall. Fix the rack housing in vice using ST.
NOTE: ST 926200000 STAND
Apply specified power steering fluid to oil seal. CAUTION:
Pay special attention not to install oil seal in When fixing rack housing in vice, be sure to
wrong direction. use this special tool. Do not fix rack housing in
Push oil seal until the stepped portion of A con- vice using pad such as aluminum plates, etc.
tacts end face of B. When using old rack housing, be sure to
clean and remove rust before assembling.
Check pinion housing bushing carefully.
7) Install the oil seal to rack.
8) Fit ST over toothed portion of rack assembly,
and check for binding or unsmooth insertion. If any
deformation is noted on flats at the end of rack,
shape bv using file, and wash with cleaning fluid.
ST 926390061
' COVER & REMOVER
(1)
S4M0406A
(1) Rack ASSY

S4M01648
9) Apply genuine grease to the teeth of thoroughly
washed rack assembly, and fit ST over the toothed
(1) Press
portion.
(2) Oil seal
CAUTION:
3) Apply grease to the teeth of rack so that the Be careful not to block air passage with
grease applied is about as high as teeth, and also grease. Remove excessive grease.
apply a thin film of grease to the sliding portion of After fitting cover, check air passage hole for
rack shaft. clogging. If clogged, open by removing grease
CAUTION: from the hole.
When moving rack to stroke end without tie- Check rack shaft for damage.
rod attached, prevent shocks from being ap- Apply specified power steering fluid to this
plied at the end. ST and surface of piston ring to prevent seal
from being damaged.
PS-33
STEERING GEARBOX
10) Insert the rack assembly into the rack housing 13) Insert the rack stopper into the rack housing,
from cylinder side, and remove ST after it has and wrap the circlip using a sharp pointed pliers to
passed completely through oil seal. secure the rack stopper in position.
NOTE: CAUTION:
Before inserting rack assembly, apply a coat of Be careful not to scratch rack while winding cir-
specified power steering fluid to surfaces of ST and clip.
rack piston. NOTE:
ST 926390001 COVER & REMOVER Rotate the wrench another 90 to 180" after the end
11) Fit ST1 and ST2 over the end of rack, and in- of circlip has been wrapped in.
stall rack bushing.
STl 926400000 GUIDE
ST2 927660000 GUIDE
CAUTION:
If burrs, or nicks are found on this guide and
rack shaft portion, remove by filing.
Dip rack bushing in specified power steering
fluid before installing, and pay attention not to
damage O-ring and oil seal.
S4M0167
14) Fit the mounting rubber onto the rack housing.

15) Apply the specified grease to the dust cover.
(1) Rack bushing ASSY
12) Insert the rack stopper into the cylinder tube un-
til internal groove (on cylinder side) is aligned with I S4M0166A I
external groove (on rack stopper). Turn the rack 16) Install the dust cover on the valve assembly.
stopper with ST so that the rack stopper hole is 17) Apply genuine grease to the pinion gear and
seen through cylinder slits. bearing of valve assembly.
G4M0158
PS-34
STEERING GEARBOX
9
18) Install the gasket on the valve assembly. Insert 21) Install the lock washers and tighten the left and
the valve assembly into the place while facing rack right tie-rods into the rack ends.
teeth toward pinion.
On condition
CAUTION: L: Approximately 40 mm (1.57 in)
Be sure to use a new gasket.
Tightening torque:
NOTE: 78 N-m (8.0 kgf-m, 58 ft-16)
Do not allow packing to be caught when installing
valve assembly.
S4M01.508
. S4M0155 (1) Tie-rod

19) Tighten the bolts alternately to secure the valve 22) Bend the lock washer using a chisel.
assembly.
CAUTION:
Tightening torque: Be careful not to scratch rack when bending
25 N.m (2.5 kgf-m, 18.1 ft-16) lock washer.
CAUTION:
Be sure to alternately tighten bolts.
20) Apply grease to the sliding surface of sleeve
and spring seat, then insert the sleeve into the pin-
ion housing. Fit the spring into the sleeve screw,
pack grease inside of screw, then install the screw. r
' S4M0384A
(1) Lock washer
B4M1129B
(1) Adjusting screw

(2) Spring
(3) Sleeve
PS-35
STEERING GEARBOX
23) Rack and pinion backlash adjustment (7) Install the lock nut. While holding adjusting
(1) Loosen the adjusting screw. screw with a wrench, tighten the lock nut using
(2) Rotate the input shaft so that the rack is in ST.
the straight ahead direction. ST 926230000 SPANNER
(3) Apply grease to the sleeve. Tightening torque (Lock nut):
39 N-m (4.0 kgf-m, 29 f?-lb)
I I NOTE:
P- Hold the adjusting screw with a wrench to pre-
vent it from turning while tightening lock nut.
Make adjustment so that the steering wheel can
be rotated fully from lock to lock without binding.
24) Check for service limit as per article of “Service
limit”.cRef. to PS-42, INSPECTION, Steering
Gearbox.> Make replacement and adjustment if
I B4M1130B necessary.
25) Install the boot to the housing.
(1) Adjusting screw NOTE:
(2) Lock nut Before installing boot, be sure to apply grease to
(3) Spring the groove of tie-rod.
(4) Sleeve Install fitting portions of boots to the following
portions in both sides of assembled steering gear-
(4) Tighten the adjusting screw by two threads. box.
I I The groove on gearbox
The groove on the rod
Make sure that the boot is installed without un-
usual inflation or deflation.
G4M0121
(5) Apply liquid packing to at least 1/3 of entire

perimeter of adjusting screw thread.
Liquid packing:
S4M0151A
THREE BOND 1141
I S4M0385A

perimeter.
(6) Tighten the adjusting screw to 7.4 N.m (0.75

kgf-m, 5.4 ft-lb) and back off 25”.
PS-36
STEERING GEARBOX
il
26) Using a screwdriver, tighten the screw until the 28) If the tie-rod end was removed, screw in lock
ends “ A and “6”of the band come into contact with nut and tie-rod end to the screwed portion of tie-
each other. rod, and tighten the lock nut temporarily in a posi-
CAUTION: tion as shown in figure.
Use a new band. Installed tie-rod length: L
NOTE: 15 mm (0.59 in)
Always tighten the band from the underside of the NOTE:
gear box. Pay attention to difference between right and left
tie-rod ends.
A L
r-
S4M0152A
G4M0126
27) Fix the boot end with clip (small).
CAUTION: 29) Install the tie-rod end plate.
After installing, check boot end is positioned Tightening torque:
into groove on tie-rod. 13 N.m (1.3 kgf-m, 9.4 ft-lb)
30) Inspect the gearbox as follows:
“ A Holding tie-rod end, repeat lock to lock two or
three times as quickly as possible.
“ B Holding tie-rod end, turn it slowly at a radius one
or two times as large as possible.
After all, make sure that the boot is installed in the
specified position without deflation.
S4M0144B
(1) Clip
G4M0127
31) Remove gearbox from ST.

ST 926200000 STAND
32) Install the four pipes on gearbox.
(1) Connect the pipe A and B to the four pipe
joints of gearbox.
Tightening torque:
13 N-m (1.3 kgf-m, 9.4 ft-lb)
(2) Connect the pipe E and F to the gearbox.
Tightening torque:
Pipe E: 15 N.m (1.5 kgf-m, 10.8 ft-lb)
Pipe F: 25 N.m (2.5 kgf-m, 18.1 ft-lb)
PS-37
I
STEERING GEARBOX
2. CONTROL VALVE ASSEMBLY 4) Using ST and press, install the special bearing in
valve housing.
Specified steering grease: ST 34099FA120 INSTALLER & REMOVER
VALIANT GREASE M2 (Part No. 003608001) SEAL
1) Clean all parts and tools before reassembling.
2) Apply a coat of specified power steering fluid to NOTE:
the inner wall of valve housing. To facilitate installation, attach the ball bearing to
the remover and position in valve housing before
pressing it into place.
I Fluid I S4M0162A
3) Attach ST2 to STI , and press the oil seal into the S4M0161B
place using a press.
STI 34099FA120 INSTALLER & REMOVER (1) Special bearing
SEAL (2) Oil seal
ST2 34099FA130 INSTALLER SEAL
(1) Face oil seal in the direction shown in figure 5 ) Put vinyl tape around pinion shaft splines to pro-
when installing. tect oil seal from damage.
(2) To avoid scratching oil seal, apply a coat of 6) Fit pinion and valve assembly into valve housing.
grease to the contact surface of installer and oil 7) Secure valve assembly to ST1 and ST2.
seal.
(3) To facilitate installation, attach oil seal to the
installer and position in valve housing before
pressing into place.
I S4M0160A
PS-38
II
STEERING GEARBOX
8 ) Put ST3 over pinion, and insert oil seal, then 10) Force-fit ball bearing using ST3.
force-fit oil seal into housing using ST4. ST1 926370000 INSTALLER A
ST1 926370000 INSTALLER A ST2 34099FA100 STAND BASE
ST2 34099FA100 STAND BASE ST3 927640000 INSTALLER B
ST3 926360000 INSTALLER A
ST4 927620000 INSTALLER B
I .
S4M04051
(1) Ball bearing

(2) Backing washer
NOTE:
Be careful not to tilt ball bearing during installation.
11) Install the snap ring using snap ring pliers.
NOTE:
Rotate the snap ring to check for proper installa-
tion.
12) Apply the specified grease to the dust cover.
S4M0404A
(1) Oil seal
NOTE:
Apply the specified power steering fluid to the oil
seal and ST3, being careful not to damage oil seal
lip.
Push the oil seal until ST3 contacts housing end
face. I S4M01566
9) Remove ST3, and fit backing washer.
(1) Dust cover
13) Install the dust cover on the valve assembly.

14) Apply genuine grease to the pinion gear and
bearing of valve assembly.
G4M0150
PS-39
STEERING GEARBOX
15) Install the gasket on the valve assembly. Insert 20) Rack and pinion backlash adjustment
the valve assembly into the place while facing rack (1) Loosen the adjusting screw.
teeth toward pinion. (2) Rotate the input shaft so that the rack is in
CAUTION: the straight ahead direction.
Be sure to use a new gasket. (3) Apply grease to the sleeve.
NOTE:
Do not allow packing to be caught when installing
valve assembly.
_I
r I
B4M1130E
(1) Adjusting screw

(2) Locknut
(3) Spring
16) Tighten the bolts alternately to secure the valve (4) Sleeve
assembly.
(4) Tighten the adjusting screw by two threads.
Tightening torque:
25 N-m (2.5 kgf-m, 18.1 ff-lb)
CAUTION:
m I
Be sure to alternately tighten bolts.
17) Apply grease to the sleeve insertion hole.
18) Apply grease to the dust seal insertion hole.
CAUTION:
Apply clean grease with clean hands. If material
having a sharp edge is used for applying
grease, oil seal at the inside might be damaged. G4M0121
19) Apply grease to the sliding surface of sleeve
and spring seat, then insert the sleeve into the pin- perimeter of adjusting screw thread.
ion housing. Fit the spring into the sleeve the
screw, pack grease inside of screw, then install the Liquid packing:
screw. THREE BOND 1141
(1) Adjusting screw

(2) Spring
(3) Sleeve
1 B4M1129B
'(1)
S4M03851

perimeter.
(6) Tighten the adjusting screw to 7.4 N-m(0.75

kgf-m, 5.4 ft-lb) and back off 25".
PS-40
1
STEERING GEARBOX
POWER ASSISTED SYSTEM [POWER STEERING)
(7) Install the lock nut. While holding adjusting

screw with a wrench, tighten the lock nut using
ST.
39 N-m (4.0 kgf-m, 29 ff-lb)
NOTE:
Hold the adjusting screw with a wrench to pre-
vent it from turning while tightening lock nut.
Make adjustment so that the steering wheel can
be rotated fully from lock to lock without binding.
21) Check for service limit as per article of “Service
limit”.<Ref. to PS-42, INSPECTION, Steering
Gearbox.> Make replacement and adjustment if
necessary.
22) Take off the gearbox from ST.
23) Install the four pipes on the gearbox.
(1) Connect the pipe A and 6 to the gearbox.
Tightening torque:
13 N-m (1.3 kgf-m, 9.4 ft-lb)
(2) Connect the pipe E and F to the gearbox.
Tightening torque:
Pipe E: 15 Nom(1.5 kgf-m, 10.8 ft-lb)
Pipe F: 25 N.m (2.5 kgf-m, 18.1 ft-lb)
PS-41
STEERING GEARBOX
E: INSPECTION
1. BASIC INSPECTION
1) Clean all disassembled parts, and check for wear, damage, or any other faults, then repair or replace as
necessary.
2) When disassembling, check inside of gearbox for water. If any water is found, carefully check boot for
damage, input shaft dust seal, adjusting screw and boot clips for poor sealing. If faulty, replace with new
parts.
No. Parts Inspection Corrective action

(1) Bend of input shaft If the bend or damage is excessive, replace the entire
1 Input shaft
(2) Damage on serration gearbox.
(1) Crack or damage If the outer wall slips, the lip is worn out or damage is
2 Dust seal
(2) Wear found. redace it with new one.
~~
(1) Adjust the backlash properly.

By measuring turning torque of gearbox and sliding resis-
tance of rack, check if rack and pinion engage uniformly
and smoothly with each other. (Refer to “Service limit”.)
3 Rack and pinion Poor mating of rack with pinion
(2) Keeping rack pulled out all the way so that all teeth
emerge, check teeth for damage.
Even if abnormality is found in either (1) or (2), replace
the entire aearbox.
(1) Bend of rack shaft
(2) Bend of cylinder portion
Replace the gearbox with new one.
(3) Crack or damage on cast iron
portion
If the free play of rack shaft in radial direction is out of the
4 Gearbox unit
(4) Wear or damage on rack bush specified range, replace the gearbox with new one. (Refer
to “Service limit”.)
If the free plays of input shaft in radial and axial directions
( 5 ) Wear on input shaft bearing are out of the specified ranges, replace the gearbox with
new one. (Refer to “Service limit”.)
5 Boot Crack, damaae or deterioration Replace.
(1) Looseness of ball joint
6 Tie-rod Replace.
(2) Bend of tie-rod
Damage or deterioration on dust
7 Tie-rod end Replace.
seal
Adjusting screw
8 Deterioration Replace.
swing
9 Boot clip Deterioration Replace.
10 Sleeve Damage Replace.
(1) Damage to flared surface
11 Pipes (2) Damage to flare nut Replace.
(3) Damage to pipe
PS-42
a
STEERING GEARBOX
2. SERVICE LIMIT 3. RACK SHAFT PLAY IN RADIAL DIREC-

TION
Make a measurement as follows. If it exceeds
the specified service limit, adjust or replace. Right-turn steering:
NOTE: Service limit
When making a measurement, vise gearbox by us- 0.19 mm (0.0075 in) or less
ing ST. Never vise gearbox by inserting aluminum
plates, etc. between vise and gearbox. On condition
L: 5 mm (0.20 in)
ST 926200000 STAND
P: 122.6 N (12.5 kgf, 27.6 lb)
Sliding resistance of rack shaft:
Service limit
340 N (35 kgf, 76 lb) or less
Left-turn steering:
Service limit
Direction
Direction +I)
0.15 mm (0.0059 in) or less
G4M0110
G4M0112
PS-43
STEERING GEARBOX
4. INPUT SHAFT PLAY 5. TURNING RESISTANCE OF GEARBOX

In radial direction: Using ST, measure gearbox turning resistance.
Service limit ST 34099PA100 SPANNER
0.18 mm (0.0071 in) or less Service limit
On condition Maximum allowable resistance
P: 98 N (10 kg< 22 lb) Less than 12 N (1.2 kgf, 2.7 lb)
In axial direction:
Service limit
On condition
P:20-49N(2-5kgf,4- 11 lb)
PS-44
STEERING GEARBOX
1
6. OIL LEAKING
S4M0153A
(1) Power cylinder (3) Rack piston (5) Input shaft

(2) Cylinder (4) Rackaxle (6) Valve housing
NOTE: 2) Inspect leakage from “a”
If the gearbox is dismounted without confirming The oil seal is damaged. Replace the valve assem-
where the leak is, it must be mounted again to lo- bly with a new one.
cate the leak point. 3) Inspect leakage from “ b
1) Even if the location of the leak can be easily The torsion bar O-ring is damaged. Replace the
found by observing the leaking condition, it is nec- valve assembly with a new one.
essary to thoroughly remove the oil from the sus- 4) Inspect leakage from “c”
pected portion and turn the steering wheel from The oil seal is damaged. Replace the valve assem-
lock to lock about 30 to 40 times with engine run- bly or oil seal with a new one.
ning, then make comparison of the suspected por- 5 ) Inspect leakage from “d”
tion between immediately after and several hours The pipe is damaged. Replace the faulty pipe or 0-
after this operation. ring.
PS-45
I
STEERING GEARBOX
6) If leak is other than a, b, c, or d, and if oil is leak- 2) Adjust the steering angle of wheels.
ing from the gearbox, move the right and left boots
Standard of steering angle:
toward tie-rod end side, respectively,with the gear-
box mounted to the vehicle, and remove oil from TURBO, Sedan,
Model Others
the surrounding portions. Then, turn the steering OUTBACK
wheel from lock to lock 30 to 40 times with the en-
gine running, then make comparison of the leaked
Inner wheel I 34'05' f 1.5" I 36'55' k 1.5"
Outer wheel I 29'35' f 1.5" I 31"35' f 1.5"
portion immediately after and several hours after
this operation. 3) If the steering wheel spokes are not horizontal
(1) Leakage from "e" when wheels are set in the straight ahead position,
The cylinder seal is damaged. Replace the rack and error is more than 5" on the periphery of steer-
bush with a new one. ing wheel, correctly re-install the steering wheel.
(2) Leakage from "f"
There are two possible causes. Take the follow- I -0 - 17 mm I
in)
ing step first. Remove the pipe assembly B from
the valve housing, and close the circuit with ST.
ST 926420000 PLUG
Turn the steering wheel from lock to lock 30 to
40 times with the engine running, then make
comparison of the leaked portion between im-
mediately after and several hours after this op-
eration.
SAhlni R 8 A
CAUTION:
If leakage from "f" is noted again: 4) If the steering wheel spokes are not horizontal
The oil seal of pinion and valve assembly is with vehicle set in the straight ahead position after
damaged. Replace pinion and valve assembly this adjustment, correct it by turning the right and
with a new one. Or replace the oil seal and the left tie-rods in the same direction by the same
parts that are damaged during disassembly turns.
with new ones.
If oil stops leaking from "f":
The oil seal of rack housing is damaged. Re-
place the oil seal and the parts that are dam-
aged during disassembly with new ones.
F: ADJUSTMENT
1) Adjust the front toe.
Standard of front toe:
IN 3 - OUT 1 mm (IN 0.12 - OUT 0.039 in)
G4M0135
(1) Locknut
PS-46
PIPE ASSEMBLY 1
6. Pipe Assembly 4) Remove the clamp E from pipes C and D.
A: REMOVAL
2) Lift the vehicle and remove the jack-up plate.
I
(1) Jack-up plate
3) Remove one pipe joint at the center of gearbox,

and connect a vinyl hose to the pipe and joint. Dis-
charge the fluid by turning steering wheel fully
clockwise and counterclockwise. Discharge the flu-
S4M0437F
id similarly from the other pipe.
CAUTION: (1) Return hose
Improper removal and installation of parts often (2) Pressure hose
causes fluid leak trouble. To prevent this, clean (3) Clamp E
the surrounding portions before disassembly (4) Pipe C
and reassembly, and pay special attention to
(5) Pipe D
keep dirt and other foreign matter from mating
surfaces. 5) Disconnect the pipe C.D from the pipe (on the
gearbox side).
CAUTION:
When disconnecting pipe C-D, use two
wrenches to prevent deformities.
Be careful to keep pipe connections free from
foreign matter.
(1) Pipe A
(2) Pipe B
(1) Pipe C
(2) Pipe D
PS-47
PIPE ASSEMBLY
6 ) Non-TURBO model: (3) Remove the coolant filler tank.

(1) Remove the air intake duct. <Ref. to IN(S0-
HC)-7, REMOVAL, Air Intake Duct.>
(2) Remove the bolt A.
(3) Disconnect the pipe C from the oil pump.
(4) Disconnect the pipe D from the return hose.
CAUTION:
Do not allow fluid from the hose end to come
into contact with pulley belt.
To prevent foreign matter from entering the
hose and pipe, cover the open ends of them
with a clean cloth.
(4) Disconnect the pipe C from oil pump.

(1) Bolt A
(5) Disconnect the pipe D from the return hose.
(2) Pipe C
(3) Pipe D CAUTION:
7) TURBO model: into contact with pulley belt.
(1) Remove the air intake duct, air cleaner up- To prevent foreign matter from entering the
per cover and air intake boot. hose and pipe, cover the open ends of them
<Ref. to IN(D0HC TURBO)-8, REMOVAL, Air with a clean cloth.
Intake Duct.> and <Ref. to IN(D0HC TURBO)-
7, REMOVAL, Air Cleaner.>
(2) Remove the two bolts fixing pipe C and D.
(1) Pipe C
(2) Pipe D
PS-48
PIPE ASSEMBLY 3
B: INSTALLATION 2) Install the coolant filler tank. (Turbo model)

1) Temporarily tighten the bolts fixing pipe C and D. Tightening torque:
CAUTION: T7: 79 N.m (7.9 kgf-m, 73.7 ff-lb)
Visually check that hose between tank and pipe T2: 27 N.m (2.7 kgf-m, 75.2 ff-lb)
D is free from bending or twisting.
Non-TURBO model
(1) Bolt A
(2) Pipe C
(3) Pipe D
TURBOmodel
(1) Pipe C
(2) Pipe D
(1) Connect the pipe D to oil tank.

(2) Install the pipe C to oil pump.
CAUTION:
Use a new gasket.
Tightening torque:
39 N.m (4.0 kgf-m, 28.9 ff-lb)
(3) Tighten bolts fixing pipe C and D.
Tightening torque:
73 N.m (7.3 kgf-m, 9.4 ff-lb)
PS-49
PIPE ASSEMBLY
3) Temporarily connect the pipes C and D to the 5) Tighten the clamp E firmly.
pipes (on the gearbox side).
Tightening torque:
7.4 N-m (0.75 kgf-m, 5.4 ft-lb)
6) Tighten the joint nut.
Tightening torque:
15 N.m (1.5 kgf-m, 10.8 ft-lb)
7) Connect the pipes A and B to the four pipe joints
of gearbox. Connect the upper pipe B first, and low-
er pipe A second.
Tightening torque:
13 N-m (1.3 kgf-m, 9.4 ft-lb)
I S4M0430A
(1) Pipe A
(1) Return hose
(2) Pipe B
(2) Pressure hose
(3) Approx. 30 mm (1.18 in) 8) Install the jack-up plate.
(4) Clamp E 9) Install the air intake duct. (Non-TURBO model).
(5) Pipe C <Ref. to IN(S0HC)-7, INSTALLATION, Air Intake
(6) Pipe D Duct.>
(7) Pipe (on gearbox side) 10) Install the air intake duct, air intake boot and air
cleaner upper cover. (TURBO model)
4) Temporarily install the clamp E on the pipes C <Ref. to IN(D0HC TURBO)-7, INSTALLATION, Air
and D. Cleaner.> and <Ref. to IN(D0HC TURBO)-8, IN-
CAUTION: STALLATION, Air Intake Duct.>
Ensure that the letter “8” on each clamp are di- 11) Connect the battery ground terminal.
agonally opposite each other as shown in fig-
ure.
I I
(1) Clamp E
(2) Pipe C
PS-50
PIPE ASSEMBLY 1
12) Feed the specified fluid.

NOTE:
Never start the engine before feeding the fluid; otherwise vane pump might be seized up.
S4M02728
(1) High-pressure hose (3) Clearance between crossmember

(2) No interferenceis allowed and pipe: 3 - 8 mm (0.12 - 0.31
between hoses. in)
13) Finally check clearance between pipes and/or
hoses, as shown above.
If the clearance between cruise control pump and
power steering hose is less than 10 mm (0.39 in),
proceed as follows:
(1) Move the clamped section (A) (refer to fig-
ure above.) down to a point where the pipe is
close to crossmember.
Pipe-to-crossmember clearance:
10 mm (0.39 in), min.
(2) Check that clearance between cruise con-
trol pump and power steering hose is at least 10
mm (0.39 in). If it is not, bend section (B) down
until a clearance of at least 10 mm (0.39 in) is
obtained.
PS-51
I PIPE ASSEMBLY
C: INSPECTION
Check all disassembled parts for wear, damage or other abnormalities. Repair or replace faulty parts as re-
qui red.
I Part name I Inspection I Remedv
O-ring fitting surface for
damage Replace with
Pipe
Nut for damage new one.
Pipe for damaae
Replace with
new one.
Flare nut for damage

Outer surface for cracks
Replace with
Outer surface for wear
new one.
Clip for damage
I End coupling or adapter for

degradation
CAUTION:
Excessive holding time of relief status Instruct customers.

Pressure hose burst Malfunction of relief valve Replace oil pump.
Poor cold characteristic of fluid Replace fluid.
Poor connection Correct.
Forced out return hose Poor holding of clip Retighten.
Poor cold characteristic of fluid Replace fluid.
1 Wronu lavout, tensioned 1 Replace hose. I
Fluid bleeding out of hose Excessive play of engine due to deterioration of
Replace defective parts.
slightly engine mounting rubber
Improper stop position of pitching stopper Replace defective parts.
I Excessive holding time of relief status
1 Excessive tightening torque for return hose clip I Replace. I

Crack on hose Power steering fluid, brake fluid, engine oil, electro- Replace.
lyte adhere on the hose surface Pay attention on service work.
I Too many times use in extremely cold weather

Replace.
Instruct customers.
PS-52
I
PIPE ASSEMBLY
CAUTION:
It is likely that although one judges fluid leakage, there is actually no leakage. This is because the flu-
id spilt during the last maintenance was not completely wiped off. Be sure to wipe off spilt fluid thor-
oughly after maintenance.
STOOl
PS-53
PIPE ASSEMBLY
Fluid leaking area I Possible cause I Corrective action

Insufficient tightening of flare nut, catching
Loosen and retighten, if ineffective,
dirt or the like, damage to flare or flare nut or
replace.
Leakage from connecting portions of eye bolt
pipes and hoses, numbered with (1) Poor insertion of hose, poor clamping Retighten or replace the clamp.
through (10) in figure Replace O-ring or gasket pipe or hose
Damaged O-ring or gasket with new one, if ineffective, replace the
gearbox also.
Leakage from hose (1 l ) , (12) and Crack or damage in hose I Replace with a new one.
(13) in figure Crack or damage in hose hardware I Replace with a new one.
Leakage from surrounding of cast iron Damaged O-ring Replace the oil pump.
portion of oil pump (14) and (15) in
fiaure Damaged gasket Replace the oil pump.
Leakage from oil tank (16) and (17) in
figure
Crack in oil tank I Replace the oil tank.
Damaged cap packing Replace the cap.

Leakage from filler neck (18) Crack in root of filler neck Replace the oil tank.
Hiah fluid level Adiust the fluid level.
Leakage from surrounding of power
cylinder of gearbox (19) in figure
I Damaged oil seal 1 Replace the oil seal.
Leakage from control valve of gear- Damaged packing or oil seal Replace the problem parts.
box (20) and (21) in figure Damage in control valve Replace the control valve.
PS-54
II
OIL PUMP
6) Disconnect the pipe C and suction hose from the

7. Oil Pump oil pump.
A: REMOVAL CAUTION:
1. NON-TURBO MODEL into contact with pulley belt.
1) Remove the ground terminal from battery. To prevent foreign matter from entering the
2) Remove the pulley belt cover. hose, cover the open ends of them with a clean
3) Loosen the oil pump pulley nut, then remove the cloth.
bolts which secure alternator.
(1) Suction hose

4) Loosen the lock bolt and slider bolt and remove
(2) Pipe C
the power steering pump drive V-belt.
7) Remove the bolts, which install power steering
pump bracket.
5) Disconnect the connector from the power steer-

ing pump switch.
8) Place the oil pump bracket in a vise, remove the
two bolts from the front side of oil pump.
CAUTION:
Do not place oil pump bracket directly in the
vise; use soft pads and hold oil pump lightly to
protect the pump.
STOOl6
I I
9) Remove the bolt from the rear side of oil pump.
PS-55
OIL PUMP
10) Disassemble the oil pump and bracket by in- 6) Remove the bolts which install power steering
serting a screwdriver as shown in the figure. pump bracket.
2. TURBO MODEL 7) Place the oil pump bracket in a vise, remove the
two bolts from the front side of oil pump.
1) Remove the ground terminal from battery.
2) Remove the pulley belt cover. CAUTION:
3) Loosen the lock bolt and slider bolt and remove Do not place oil pump bracket directly in the
the power steering pump drive V-belt. vise; use soft pads and hold oil pump lightly to
protect the pump.
w STOOl8
4) Disconnect the connector from the power steer-
ing pressure switch. 8) Remove the bolt from the rear side of oil pump.
5) Disconnect the pipe C and suction hose from the 9) Disassemble the oil pump and bracket by insert-
oil pump. ing a screwdriver as shown in the figure.
CAUTION:
with a clean cloth.
(1) Suction hose

(2) Pipe C
PS-56
OIL PUMP s
B: INSTALLATION Tightening torque:

37.3 N.m (3.8 kgf-m, 27.5 ft-lb)
1. NON-TURBO MODEL
1) Install the oil pump to the bracket.
(1) Place the oil pump bracket in a vise. Tighten
the bushing using a 12.7 mm (1/2”) type 14 and
21-mm box wrench until it is in contact with oil
pump mounting surface.
CAUTION:
protect the pump. L
ST0019
2) Tighten the bolt which installs power steering

pump bracket.
Tightening torque:
22 N.m (2.2 kgf-m, 75.9 ft-lb)
B4M1670B I
(1) Bush
(2) Nut
(3) 21 mm
(4) 14 mm
(5) Bolt
3) Interconnect the pipe C and suction hose.
(2) Tighten the bolt which installs oil pump to Tightening torque:
the bracket. Joint nut
Tightening torque: 39.2 N.m (4 kgf-m, 28.9 ft-lb)
75.7 N.m (7.6 kgf-m, 7 1.6 ft-lb) CAUTION:
If a hose is twisted at this step, the hose may
come into contact with some other parts.
(1) Suction hose

(2) Pipe C
4) Connect the connector to the power steering

pump switch.
5) Install the pulley belt to the oil pump.
PS-57
OIL PUMP
6) Tighten the oil pump pulley nut to the specified (2) Tighten the bolt which installs oil pump to
torque. the bracket.
52 N.m (5.3 kgf-m, 38 ft-lb) 37.3 N-m (3.8 kgf-m, 27.5 ft-lb)
7) Check the pulley belt tension.
<Ref. to ME(S0HC)-44, INSPECTION, V-belt.>
8) Tighten the bolt belt tension.
Tightening torque:
8 N.m (0.8 kgf-m, 5.8 ft-lb)
9)Install the pulley belt cover.
10) Connect the ground terminal of battery.
11) Feed the specified power steering fluid. <Ref.
to PS-72, Power Steering Fluid.>
CAUTION:
Never start the engine before feeding the fluid; Tightening torque:
otherwise vane pump might be seized up. 15.7 Nom(1.6 kgf-m, 11.6 ft-lb)
2. TURBO MODEL
1) Install the oil pump to the bracket.
(1) Place the oil pump bracket in a vise. Tighten
the bushing using a 12.7 mm (1/2”) type 14- and
21-mm box wrench until it is in contact with oil
pump mounting surface.
CAUTION:
protect the pump. mnni FI
2) Tighten the bolt which install power steering

pump bracket.
Tightening torque:
22 N-m (2.2 kgf-m, 15.9 ft-lb)
(1) Bush
(2) Nut
(3) 21 mm
(4) 14 mm
(5) Bolt
PS-58
I
OIL PUMP
3) Interconnect the pipes C and suction hose. C: DISASSEMBLY

Tightening torque: 1. NON-TURBO MODEL
Joint nut
39.2 N-m (4 kgf-m, 28.9 fi-lb) 1) Remove the nut and detach oil pump pulley.
2) Remove the stay from the oil pump.
CAUTION: 3) Remove the four bolts which secure rear cover.
If a hose is twisted at this step, the hose may
come into contact with some other parts.
v STOOBZ
(1) Rear cover
(1) Suction hose 4) Using a screwdriver, pry the retaining ring off.
(2) Pipe C
4) Connect the connector to the power steering oil

pressure switch.
5) Install the pulley belt to the oil pump.
6) Check the pulley belt tension. <Ref. to
7) Tighten the bolt belt tension.
Tightening torque:
8 N m (0.8 kgf-m, 5.8 fi-lb)
8 ) Install the pulley belt cover.
9) Connect the ground terminal of battery. (1) Retaining ring
10) Feed the specified power steering fluid <Ref. to (2) Screwdriver
PS-72, Power Steering Fluid.>
CAUTION: 5) Extract the shaft from the front casing.
Never start the engine before feeding the fluid;
otherwise vane pump might be seized up.
PS-59
I OIL PUMP
6) Remove the following parts from the front cas- 9) Slightly loosen the outlet connector, and remove
ing. the connector.
CAUTION:
Discard old seal washer; replace with a new
one.
ST0092
(1) Flow control spring

(2) Spool valve assembly
(3) O-ring
(1) O-ring (4) Connector
(2) Straight pin (2 ea.)
(3) Cam ring
2. TURBO MODEL
(4) Rotor 1) Using ST, place the oil pump in a vise and re-
(5) Vane (10 ea.) move the four bolts which secure rear cover.
(6) Pressure plate ST 34199AE020 MOUNT
(7) O-ring (2 ea.)
7) Pry the oil seal off using a screwdriver.

CAUTION:
Be careful not to scratch inner surface of cas-
ing.
2) Using a screwdriver, pry the retaining ring off.

CAUTION:
Do not remove cam ring, rotor, etc.
~~ ~
ST0091
(1) Oil seal

(2) Screwdriver
8) Remove the pressure switch.
3) Extract the oil pump pulley from the front casing.
PS-60
a
OIL PUMP
4) Remove the following parts from the front cas- D: ASSEMBLY

ing.
1. NON-TURBO MODEL
1) Reassembly precautions
(1) Whenever the O-rings, oil seals, and snap
rings are removed, they must be replaced with
new ones.
(2) Thoroughly wash the parts and allow to dry.
They must be kept free from cleaning oil and
dust.
(3) Reassembly procedure must be performed
in clean place. Ensure that the parts are kept
away from the waste threads or other dust parti-
cles.
(1) O-ring (4) Cleaning oil tends to stay inside the front
(2) Straight pin (2 ea.) casing. Remove it completely by blowing com-
(3) Cam ring pressed air.
(4) Rotor (5) Ensure that the parts are free from rust.
(5) Vane (10 ea.) (Use specified hydraulic oil for rust prevention
(6) Pressure plate after cleaning and drying.)
(7) O-ring (2 ea.) (6) Reverse the sequence of disassembly pro-
cedures.
5 ) Place the oil pump in a vise. 2) Apply the grease to the oil seal and inner surface
CAUTION: of front casing (at bearing location).
Do not place oil pump directly in the vise, use CAUTION:
soft pads and hold oil pump lightly to protect Make sure that the front body internal surfaces
the pump. are free from damage.
6) Pry the oil seal off using a screwdriver. 3) Attach ST to the front body. Using a press, install
CAUTION: the oil seal.
Be careful not to scratch inner surface of cas- ST 34199AE030
ing.
B4M1667A
4) Press-fit the shaft assembly into the front body.

5 ) Apply the specified hydraulic oil to the O-rings
and fit them into the front casing.
PS-61
I
OIL PUMP
6) Install the side plate to the front casing. 10) Install the cam ring to the front casing, securing
CAUTION: with knock pins.
Use care not to let side plate gall. CAUTION:
Do not use hammer to fit knock pins in position.
11) Mount the O-ring on the front casing.
ST0094
(1) Front casing

(2) O-ring
(3) Side plate (1) Rotor
(2) Vane
7) Install the cam ring to the front casing with align-
(3) Radius facing
ment mark facing forward.
(4) Cam ring
(5) O-ring
r3
(1) Front
(2) Alignment mark
8) Install the rotor to the front casing with groove

facing rearward.
(1) Rear
(2) Groove
9) Install the 10 vanes into the rotor with their nose

radius facing toward cam ring.
PS-62
1
OIL PUMP
12) Using STs, press the retaining ring into the CAUTION:
shaft groove. Make sure the retaining ring is fit in the second
CAUTION: groove of the shaft.
Discard retaining ring and replace with a new
one.
NOTE:
Use ST2, bending its top edge slightly toward the
inside.
ST1 34099AC030 INSTALLER RETAINING
RING CAP
ST2 34099AC040 INSTALLER RETAINING
RING PIPE
I ST009C
Press
0 (1) First groove

(2) Second groove
(3) Shaft
(4) Retaining ring
(5) Rotor
13) Mount on pressure switch on front casing.

14) With knock pin positions aligned, install the rear
cover.
CAUTION:
Loosely the tighten bolts in the sequence (A),
(B), (C), and (D) shown in figure. Then, tighten
in the same sequence.
Tightening torque:
21 N.m (2.14 kgf-m, 15.5 fi-lb)
I
ST009t
(1) Shaft
(2) Front casing
(3) 48 mm (1.89 in)
(4) Retaining ring
(5) Block
STOl OC
(1) Rear cover
15) Install the spring into the front casing. Then,

with spool valve dipped in specified hydraulic oil, in-
stall it into the front casing.
16) Using a 5-mm dia. round bar, ensure that the
valve moves smoothly.
PS-63
OIL PUMP
17) Set the O-ring, with grease applied to it, onto 2. TURBO MODEL
the connector and secure connector to the front 1) Reassembly precautions
casing. (1) Whenever the O-rings, oil seals, and snap
CAUTION: rings are removed, they must be replaced with
Use care to prevent damage to O-ring at in- new ones.
stallation. (2) Thoroughly wash the parts and allow to dry.
When tightening the connector, ensure that They must be kept free from cleaning oil and
the O-ring does not protrude or get caught. dust.
Tightening torque: (3) Reassembly procedure must be performed
49 N-m (5.0 kgf-m, 36.2 ft-lb) in clean place. Ensure that the parts are kept
away from the waste threads or other dust parti-
cles.
(4) Cleaning oil tends to stay inside the front
casing. Remove it completely by blowing com-
pressed air.
(5) Ensure that the parts are free from rust.
(Use specified hydraulic oil for rust prevention
after cleaning and drying.)
(6) Reverse the sequence of disassembly pro-
cedures.
ST0092 2) Apply grease to the oil seal and inner surface of
front casing (at bearing location).
(1) Flow control spring CAUTION:
(2) Spool valve assembly Make sure that the front body internal surfaces
(3) O-ring are free from damage.
(4) Connector 3) Attach ST to front body. Using a press, install the
oil seal.
18) Fix the oil pump pulley temporarily. ST 34199AE030 INSTALLER
19) When the reassembly procedures have been
completed, turn the shaft by hand to ensure it turns
smoothly. If it binds or other unusual conditions are
evident, disassemble again and check for foreign
matter trapped on sliding surfaces and improper in-
stallation. Eliminate the cause of trouble.
20) Check followings by referring to “CHECK arti-
cle.
Excessive play in pulley shaft
Ditch deflection of pulley
Resistance to rotation of pulley
Measurement of generated oil pressure
4) Install the pump pulley to front body.
5) Using ST, place the oil pump in a vise.
ST 34199AE020 MOUNT
6) Remove the rear cover.
PS-64
OIL PUMP
7) Install the following parts to casing. 9) Install the O-ring to the rear cover.
10) Install the rear cover.
Tightening torque:
27.5 N.m (2.8 kgf-m, 20.3 ff-lb)
CAUTION:
Loosely tighten the bolts in the sequence (A),
(B), (C), and (D) shown in figure. Then, tighten
in the same sequence.
ST007E
(1) O-ring
(2) Pressure plate
(3) Rotor
(4) Vane
(5) Cam ring
(6) Straight pin
I \ I ST0046
(7) O-ring
11) When the reassembly procedures have been
NOTE: completed, turn the shaft by hand to ensure it turns
Install the rotor with the mark facing the rear case smoothly. If it binds or other unusual conditions are
side. evident, disassemble again and check for foreign
matter trapped on sliding surfaces and improper in-
stallation. Eliminate the cause of trouble.
12) Check followings by referring to “CHECK arti-
cle.
Excessive play in pulley shaft
Ditch deflection of pulley
Resistance to rotation of pulley
Measurement of generated oil pressure
(1) Mark
(2) Rear
8) Using 8-mm box wrench, tap the retaining ring

into the shaft groove.
ST004L
PS-65
OIL PUMP
E: INSPECTION
1. BASIC INSPECTION
Perform the following inspection procedures and repair or replace defective parts.
Part name Description Remedy

1) Damage on body surfaces
2) Excessive wear on hole, into which spool
valve is inserted.
Replace with a new one together with spool
1. Front casing 3) Wear and damage on cartridge assembly
valve as selective fit is made.
mounting surface
4) Wear and damage on surfaces in contact with
shaft and oil seal
1) Damage on body surfaces
2. Rear cover Replace with a new one.
2) Wear and damage on sliding surfaces
1) Shaft bend
2) Wear and damage on surfaces in contact with
3. Shaft bushing and oil seal Replace with a new one.
3) Wear and damage on rotor mounting surfaces
4) Bearing damage
4. Pressure plate Wear and damage on sliding surfaces Replace with a new one.
5. Cam ring Ridge wear on sliding surfaces
6. Vane
I Excessive wear on nose radius and side sur-
faces
1) Wear and damage on sliding surfaces
If the damage is serious, replace with a new car-
tridge assembly.
2) Ridge wear on vane sliding grooves (If light
7. Rotor leaks with vane in slit aaainst liaht source)
I 3) Damage resulting from snap ring removal

Correct with oil stone. If the damage is serious,
replace with a new cartridge assembly.
8. Connector I Damage on threads Replace with a new one.
9. Spring Damage Replace with a new one.
10. Bolts and nuts Damage on threads Relslace with a new one.
In accordance with the following table, check all removed parts for wear and damage, and make repair or
replacement if necessary.
No. Parts Inspection Corrective action

(1) Crack. damaae or oil leakaae Replace the oil pump with a new one.
Measure the radial play and axial play.
1 Oil pump (Exterior)
(2) Play of pulley shaft If any of these exceeds the service limit, replace the
oil pump with a new one.
(1) Damage Replace it with a new one.
Measure the V ditch deflection.
2 Pulley
(2) Bend If it exceeds the service limit, replace the pulley with a
new one.
Check the resistance to the rotation of pulley.
(1) Defect or burning of vane pump If it is past the service limit, replace the oil pump with a
new one.
3 Oil pump (Interior) Oil pump emits a noise that is markedly different in
(2) Bend in the shaft or damage to tone and loudness from a sound of a new oil pump
bearing when turning with a string put around its pulley,
replace the oil pump with a new one.
4 0-rina Crack or deterioration Replace it with a new one.
5 Bracket Crack Replace it with a new one.
PS-66
OIL PUMP 1
2. SERVICE LIMIT 2) Ditch deflection of pulley

Make a measurement as follows. If it exceeds the Service limit:
specified service limit, replace the parts with new 1.0 mm (0.039 in) or less
ones. NOTE:
CAUTION: Read the value for one surface of V ditch, and then
Fix oil pump on a vise to make a measure- the value for another off the dial.
ment. At this time, hold oil pump with the least
possible force between two wood pieces.
Do not set outside of flow control valve or
pulley on a vise; otherwise outside or pulley
might be deformed. Select properly sized wood
pieces.
1) Play of pulley shaft
On condition:
P: 9.8 N (1.0 kgc 2.2 16)
Service limit: S4M0441
Radial play (Direction c))
0.4 mm (0.016 in) or less (1) Dial indicator
3) Resistance to rotation of pulley

Service limit:
Maximum load; 9.22 N (0.94 kgf, 2.07 16) or
less
NOTE:
A rather higher value may be indicated when pul-
ley starts turning.
Measure the load during rotation and make a
- 5
judgment.
S4M0439A
(1) Dial indicator
Axial play (Direction ) a

Non-TURBO model
TURBO model
G ' , I
S4M0442A
(1) Spring balance
(1) Dial indicator
PS-67
I OIL PUMP
3. HYDRAULIC PRESSURE 2) Measure relief pressure.

(1) Using STs, measure the relief pressure.
CAUTION: (2) Close the valve.
Be sure to complete all items aforementioned
(3) Measure the relief pressure.
in “INSPECTION”, prior to measuring hydraulic
ST1 92571 1000 PRESSURE GAUGE
pressure. Otherwise, pressure can not be mea-
ST2 34099AC020 ADAPTER HOSE B
sured correctly. <Ref. to PS-74, INSPECTION,
General Diagnostic Table.> ST3 34099AC010 ADAPTER HOSE A
Do not leave the valve of pressure gauge
closed or hold the steering wheel at stop end
for 5 seconds or more in any case, as the oil
pump may be damaged due to long keep of
these conditions.
Put cotton cloth waste at a place where fluid
drops before pressure gauge is installed. Wipe
off spilt fluid thoroughly after the measure-
ment.
NOTE: I1676A
Keep engine idling during the measurement.
Service limit:
1) MEASURE REGULAR PRESSURE.
TURBO model
(1) Remove the two bolts securing power steer-
ing pipes to the engine. 7,350- 8,036kPa
(2) Install ST1,2 and 3 between power steering
(75- 82 k @ d , 1,067- 1,165psi)
pump and pipes using gasket (Part No. Non-TURBO model
34621AC021) and bolt (Part No. 34620AC010). 7,164- 7,840kPa
(3) Replenish the power steering fluid up to (73- 80 k & d , 1,040- 1,137psi)
specified level. (4) If it is not within the specified value, replace
(4) Open the valve, and start the engine. the oil pump.
(5) Measure the regular pressure. 3) Measure working pressure.
STI 92571 1000 PRESSURE GAUGE (1) Using STs, measure the working pressure.
ST2 34099AC020 ADAPTER HOSE B (2) Open the valve.
ST3 34099AC010 ADAPTER HOSE A (3) Measure the working pressure of control
valve by turning wheel from stop to stop.
ST1 925711000 PRESSURE GAUGE
ST2 34099AC020 ADAPTER HOSE B
ST3 34099AC010 ADAPTER HOSE A
-
l675A
~
Service limit:
981 kPa (IO kg/cd, 142 psi) or less
(6) If it is not within the specified value, replace 1 675A
the troubled part caused by the following symp-
toms; pipe or hose clogged, leaks from fluid line, Service limit:
and mix of foreign objects in fluid line. TURBO model
7,350- 8,036kPa
(75- 82 k g k d , 1,067- 1,165psi)
Non-TURBO model
7,164- 7,840kPa
(73- 80 kg/Cd, 1,040- 1,137psi)
PS-68
OIL PUMP
(4) If it is within the specified value, measure

the steering effort. <Ref. to PS-78, MEASURE-
MENT OF STEERING EFFORT, INSPECTION,
General Diagnostic Table.> If it is not within
specified value, replace the control valve itself or
control valve and pinion as a single unit with new
ones.
PS-69
RESERVOIR TANK
8. Reservoir Tank 3) Disconnect the return hose and suction hose

from the reservoir tank.
A: REMOVAL CAUTION:
1. NON-TURBO MODEL
1) Remove the air intake duct. <Ref. to IN(S0HC)- To prevent foreign matter from entering the
7, REMOVAL, Air Intake Duct.> hose, cover the open ends of them with a clean
2) Drain the fluid from the reservoir tank. cloth.
3) Disconnect the pipe D from the return hose and
suction hose from the oil pump.
CAUTION:
with a clean cloth.
(1) Suction hose

(2) Pipe D
(3) Return hose
4) Remove the reservoir tank from the bracket by

pulling it upwards.
B: INSTALLATION
(1) Suction hose 1. NON-TURBO MODEL
(2) Pipe D 1) Install the reservoir tank to the bracket.
(3) Return hose 2) Connect the pipes D to the return hose and suc-
tion hose to the oil pump.
4) Remove the reservoir tank from the bracket by
pulling it upwards.
2. TURBO MODEL
1) Remove the air intake duct. <Ref. to IN(D0HC
TURBO)-9, REMOVAL, Intake Duct.>
2) Drain the fluid from the reservoir tank.
(1) Suction hose

(2) Pipe D
(3) Return hose
3) Feed the specified power steering fluid. <Ref. to

PS-70
RESERVOIR TANK
m
2. TURBO MODEL
1) Install the reservoir tank to the bracket.
2) Connect the pressure hose and suction hose to
the oil pump.
(1) Suction hose

(2) Pipe D
(3) Return hose
3) Feed the specified power steering fluid. <Ref. to

C: INSPECTION
Check the reservoir tank for cracks, breakage, or
damage. If any cracks, breakage, or damage is
found, replace the reservoir tank.
PS-71
POWER STEERING FLUID
9. Power Steering Fluid C: INSTALLATION

1) Set ST on the top of reservoir tank and fill it about
n
A: SPECIFICATION half way with the specified fluid.
I Recommended power steering- fluid [ Manufacturer I ST 34199AE040 OIL CHARGE
CALTEX
CASTROL
DEXRON Ill
MOBIL
SHELL
TEXACO
B: INSPECTION
1) Check the power steering fluid for deterioration
or contamination. If the fluid is highly deteriorated
or contaminated, drain it and refill with new fluid.
2) Continue to turn the steering wheel slowly from
2) Check the joints and units for oil leakage. If any lock to lock until the bubbles stop appearing in the
oil leaks are found, repair or replace the applicable tank while keeping the fluid at that level.
part. 3) In case air is absorbed to deliver bubbles into
3) Inspect the fluid level on flat and level surface piping because the fluid level is lower, leave it
with engine “OFF by indicator of reservoir tank. about half an hour and then do the step 2) all over
If the level is at lower point or below, add fluid to again.
keep the level in the specified range of the indica- 4) Start, and idle the engine.
tor. If at upper point or above, drain the fluid by us-
5) Continue to turn the steering wheel slowly from
ing a syringe or the like.
lock to lock again until the bubbles stop appearing
(1) Check at temperature 20°C (68°F) on reser- in the tank while keeping the fluid at that level.
voir surface of oil pump; read the fluid level on
It is normal that bubbles stop appearing after three
the “COLD” side.
times turning of steering wheel.
(2) Check at temperature 80°C (176°F) on res-
6) In case bubbles do not stop appearing in the
ervoir surface of oil pump: read the fluid level on tank, leave it about half an hour and then do the
the “HOT” side.
step 5 ) all over again.
7) Stop the engine, and take out safety stands after
jacking up vehicle again.
Then lower the vehicle, and idle the engine.
8) Continue to turn the steering wheel from lock to
lock until the bubbles stop appearing and change of
the fluid level is within 3 mm (0.12 in).
9) In case the following happens, leave it about half
an hour and then do step 8) again.
(1) The fluid level changes over 3 mm (0.12 in).
(2) Bubbles remain on the upper surface of the
fluid.
(3) Grinding noise is generated from oil pump.
PS-72
I
POWER STEERING FLUID
~~ ~~ ~
IO) Check the fluid leakage at flare nuts after turn-

ing steering wheel from lock to lock with engine
running.
CAUTION:
Before checking, wipe off any fluid on flare
nuts and piping.
In case the fluid leaks from flare nut, it is
caused by dust (or the like) and/or damage be-
tween flare and tapered seat in piping.
So remove the flare nut, tighten again it to the
specified torque after cleaning flare and ta-
pered seat. If flare or tapered seat is damaged,
replace it with a new one.
PS-73
1O.General Diagnostic Table

A: INSPECTION
Trouble Possible cause Corrective action
1. Pulley belt
Unequal length of pulley belts
Adhesion of oil and grease
Loose or damage of pulley belt
Adjust or replace.
Poor uniformity of pulley belt cross section
Pulley belt touches to pulley bottom
Poor revolution of pulleys except oil pump pulley
Poor revolution of oil pump pulley
2. Tire and rim
Improper tires out of specification
Replace or reinflate.
ieavy steering effort in all Improper rims out of specification
Tires not properly inflated*l
ges
ieavy steering effort at 3. Fluid
nd still Low fluid level
steering wheel surges when Aeration Refill, bleed air, replace or
ling. Dust mix instruct customer.
Deteriorationof fluid
Poor warming-up of fluid *2
4. Idling speed
Lower idling speed
Adjust or instruct customer.
Excessive drop of idling speed at start or at turning steering
wheel *3
5. Measure hydraulic pressure.<Ref. to PS-66, INSPECTION,
Replace problem parts.
Oil Pump.>
6. Measure steering effort.<Ref. to PS-74, INSPECTION, Gen-
Adjust or replace.
eral Diagnostic Table.>
1. Fluid line
Folded hose Reform or replace.
Flattened pipe
2. Tire and rim
Flat tire
Mix use of different tires
Mix use of different rims Fix or replace.
/chicle leads to one side or Abnormal wear of tire
other. Unbalance of remained grooves
'oar return of steering wheel Unbalance of tire pressure
:enter 3. Front alignment
Steering wheel surges when Improper or unbalance caster
Adjust or retighten.
ning. Improper or unbalance toe-in
Loose connection of suspension
4. Others
Damaged joint assembly Replace, adjust or instruct cus.
Unbalanced height tomer.
One-sided weight ~~
5. Measure steering effort.<Ref. to PS-74, INSPECTION,Gen-

Adjust or replace.
eral Diaanostic Table.>
*1 If the tires and/or rims are wider, the load to power steering system is the more. Accordingly, in a condition, for example before
fluid warms-up, relief valve may work before maximum turning angle. In this case, steering effort may be heavy. When the mea-
sured hydraulic pressure is normal, there is no abnormal thing.
*2 In cold weather, steering effort may be heavy due to increased flow resistance of cold fluid. After warming-up engine, turn the
steering wheel from stop to stop several times to warm-up fluid. Then if steering effort reduces normally, there is no abnormal
thing.
*3 In cold weather or with insufficient warm-up of engine, steering effort may be heavy due to excessive drop of idling when turn-
ing steering wheel. In this case, it is recommended to start the vehicle with increasing engine speed than usual. Then if steering
effort reduces normally, there is no abnormal thing.
PS-74
1. NOISE AND VIBRATION

CAUTION:
Don’t keep the relief valve operated over 5 sec-
onds at any time or inner parts of the oil pump
may be damaged due to rapid increase of fluid
temperature.
NOTE:
Grinding noise may be heard immediately after
the engine start in extremely cold condition. In this
case, if the noise goes off during warm-up there is
no abnormal function in the system. This is due to
the fluid characteristic in extremely cold condition.
Oil pump makes whine or growl noise slightly
due to its mechanism. Even if the noise can be
heard when steering wheel is turned at stand still
there is no abnormal function in the system provid-
ed that the noise eliminates when the vehicle is
running.
When stopping with service brake and/or parking
brake applied, power steering can be operated
easily due to its light steering effort. If doing so, the
disk rotates slightly and makes creaking noise. The
noise is generated by creaking between the disk
and pads. If the noise goes off when the brake is re-
leased, there is no abnormal function in the system.
There may be a little vibration around the steer-
ing devices when turning steering wheel at stand-
still, even though the component parts are properly
adjusted and have no defects.
Hydraulic systems are likely to generate this kind of
vibration as well as working noise and fluid noise
because of combined conditions, Le., road surface
and tire surface, engine speed and turning speed of
steering wheel, fluid temperature and braking con-
dition.
This phenomena does not indicate there is some
abnormal function in the system.
The vibration can be known when steering wheel is
turned repeatedly at various speeds from slow to
rapid step by step with parking brake applied on
concrete road and in “D” range for automatic trans-
mission vehicle.
PS-75
Trouble Possible cause Corrective action I

Relief valve emits operating sound when steering wheel is
completely turned in either direction. (Don't keep this con- Normal
Hiss noise (continuous) dition over 5 seconds.)
While engine is running.
Relief valve emits operating sound when steering wheel is Defective
not turned. This means that the relief valve is faulty. Replace the oil pump.
Check the clearance.
Correct if necessary.
Interference with adjacent parts
<Ref. to PS-52, INSPECTION,
Pipe Assembly.>
Loosened installation of oil pump, oil tank, pump bracket,
Rattling noise (intermittent) Retighten.
gearbox or crossmember
Loosened installation of oil D u m Dullev or other DulleW
~~~
Retighten. I
Loosened linkage or play of steering or suspension Loos-
Retighten or replace.
ened tightening of joint or steering column
Replace the bad parts of the
Sound generates from the inside of gearbox or oil pump.
aearbox or oil wmu.
Knocking Excessive backlash
Adjust and retighten.
When turning steering wheel in Loosened lock nut for adjusting backlash
both direction with small angle
Loosened tightening or play of tie-rod, tie-rod end Retighten or replace.
repeatedly at engine ON or OFF.
Inspect and retighten the fluid
Vane pump aeration line connection.
Grinding noise (continuous)
While engine is running. Vane pump seizing
Pulley bearing seizing of oil pump
Folded hose. flat DiDe Replace. I
Maladjustmentof pulley belt
Squeal, squeak (intermittent or Adjust or replace.
Damaged or charged pulley belt
continuous) (Replace two belts as a set.)
Unequal length of pulley belts
Run out or soilage of V-groove surface of oil pump pulley Clean or redace.
Fix the wrong part causing aera-
Fluid aeration tion.
Sizzling noise (continuous) Damaged pipe of gearbox Redace the DiDe.

~
While engine is running. Abnormal inside of hose or pipe

Rectify or replace.
Flat hose or DiDe
Abnormal inside of oil tank Replace. I
Removed oil tank cap
Whistle (continuous)
Abnormal pipe of gearbox or abnormal inside of hose
While engine is running. or hose.
Loosened installation of oil Duma oil Dump bracket RetiQhten. I
Whine or growl (continuous or Replace the oil pump, hose, if the
intermittent) Abnormal inside of oil pump, hose noise can be heard when running
While engine is running with/
without steering turned. Remove the power steering pul-
Torque converter growl, air conditioner compression growl
ley belt and confirm.
Replace the bad parts of gear-
Abnormal inside of gearbox
Creaking noise (intermittent)
While engine is running with Abnormal bearing for steering shaft
steering turned. Generates when turning steering wheel with brake (ser-
vice or Darkina) amlied. is released, it is normal.
PS-76
Trouble Possible cause Corrective action

Too low engine speed at start Adjust and instruct customers.
Vibration I Vane pump aeration

Fix the wrong part.
.- . .. -.air. .
Vent
While engine is running with/ Replace the oil pump, bad parts
without steering turned. Damaged valve in oil pump, gearbox
I
of aearbox.
-
Looseness of play of steering, suspension parts I Retighten.
PS-77
2. MEASUREMENT OF STEERING EFFORT

~~
~~
Step Check Yes No

CHECK STEERING EFFORT. Is the steering effort 31.4 N Go to step 2. 4djustment back-
1)Stop the vehicle on a concrete road. (3.2 kgf, 7.1 Ib) or less? ash.
2)Start the engine.
3)ldle the engine.
4)lnstall the spring scale on the steering wheel.
5)Pull the spring scale at an right angle to the
steering wheel, and measure both right and left
steering wheel effort.
NOTE:
When turning steering more quickly than nec-
essary from a direction to the other direction at
an engine speed over 2,000 rpm, steering effort
may be heavy. This is caused by flow charac-
teristic of oil pump and is not a problem.
! CHECK STEERING EFFORT. Is the steering effort 294.2 N Go to step 3. tdjustment.
1)Stop the engine. (30 kgf, 66.2 Ib) or less?
2)Pull the spring scale at an right angle to the
steering wheel, and measure both right and left
steering wheel effort.
I CHECK STEERING WHEEL EFFORT. Is the maximum force steering Go to step 4. Check, adjust and
1)Remove the universal joint. wheel effort 2.26 N (0.23 kgf, replace if neces-
2)Measure the steering wheel effort. 0.51 Ib) or less? sary.
I CHECK STEERING WHEEL EFFORT. Is the fluctuation width 1.08 N Go to step 5. Check, adjust and
Measure the steering wheel effort. (0.11 kgf, 0.24 Ib) or less? replace if neces-
sary.
CHECK UNIVERSAL JOINT. Is the folding torque 7.3 N Go to step 6. Replace with new
Measure the folding torque of the joint (yoke of (0.74 kgf, 1.64 Ib) or less? one.
steering column side). <Ref. to PS-22,
INSPECTION, Universal Joint.>
i CHECK UNIVERSAL JOINT. Is the folding torque 7.3 N Go to step 7. Replace with new
Measure the folding torque of the joint (yoke of (0.74 kgf, 1.64 Ib) or less? one.
gearbox side). <Ref. to PS-22, INSPECTION,
Universal Joint.>
I CHECK FRONT WHEEL. Are the front wheels for Inspect, readjust Go to step 8.
unsteady revolution or rattling and replace if nec.
and brake for dragging? essary.
5 CHECK TIE-ROD ENDS. Are the tie-rod ends of suspen Inspect and Go to step 9.
Remove the tie-rod ends. sion for unsteady revolution or replace if neces-
ratting? sary.
3 CHECK BALL JOINT. Are the ball joints of suspen- Inspect and Go to step 10.
sion for unsteady revolution or replace if neces-
ratting? sary.
IO CHECK GEARBOX. Is rotating resistance 12.7 N Go to step 11. Readjust back-
Measure the rotating of gearbox. (1.3 kgf, 2.9 Ib) or less in all lash, and if ineffec
<Ref. to PS-44, TURNING RESISTANCE OF positions within 20% difference tive, replace bad
GEARBOX, INSPECTION, Steering Gear- between clockwise and coun- parts.
box.> terclockwise?
I1 CHECK GEARBOX. Is sliding resistance 340 N (35 Steering effort is Readjust back-
Measure sliding of gearbox. kgf, 76 Ib) or less with 20% dif. normal. lash, and if ineffec
<Ref. to PS-43, SERVICE LIMIT, INSPEC- ference between left and right tive, replace bad
TION, Steering Gearbox.> direction? Darts.
PS-78
I
BODY SECTION

of SUBARU vehicles.
c- -

approval.
FUJI HEAVY INDUSTRIES LTD. Gl830BE6

HVAC SYSTEM
(HEATER. VENTILATOR AND A/C)
ACa
Page
2. Refrigerant Pressure with Manifold Gauge Set ......................................... 15
3. Refrigerant Recovery Procedure............................................................... 16
4. Refrigerant Charging Procedure ............................................................... 17
5. Refrigerant Leak Check ............................................................................ 20
6. Compressor Oil ......................................................................................... 21
7. Blower Motor Unit Assembly ..................................................................... 22
8. Blower Resistor ......................................................................................... 23
9. Heater Core............................................................................................... 24
.. 10. Control Unit ............................................................................................... 25
11. Compressor............................................................................................... 26
12. Condenser................................................................................................. 27
13. Heater and Cooling Unit ............................................................................ 28
14. Evaporator................................................................................................. 29
15. Hose and Tube .......................................................................................... 30
16. Relay and Fuse ......................................................................................... 31
17. Pressure Switch (Dual Switch) .................................................................. 32
18. Air Vent Grille ............................................................................................ 33
19. Heater Duct ............................................................................................... 34
20. Heater Vent Duct....................................................................................... 35
21 . General Diagnostics.................................................................................. 36
GENERAL DESCRIPTION
HVAC SYSTEM (HEATER, VENTILATOR AND N C )
A: SPECIFICATIONS
1. HEATER SYSTEM
Item SDecifications Condition

Mode selector switch: HEAT
Temperature control switch: FULL HOT
5.0 kW (4,300 kcal/h, 17,062 BTU/ Temperature difference between hot water
Heating capacity
h) or more and inlet air: 65°C (149°F)
Hot water flow rate: 360 Q (95.1 US gal,
79.2 Imp gal)/h
Air flow rate 280 m3 (9,888 cu ft)/h Heat mode (FRESH), FULL HOT at 12.5 V
Temperature control switch: FULL COLD
Max air flow rate 450 m3 (15,892 cu ft)/h Blower fan speed: 4th position
Mode selector lever: RECIRC
Heater core size 163.9 x 200 x 25.0 mm
(height x length x width) (6.45 x 7.87 x 0.984 in)
Type Maanet motor 200 W or less at 12 V
Blower
Fan type and size Sirocco fan type
motor
(diameter x width) 150 x 75 mm (5.91 x 2.95 in)
AC-2
I
Item Specifications
1 Cooling capacity
5.1 kW
(4.385 kcal/h. 17,402 BTU/h)
HFC-134a (CH,FCF,)
Refrigerant
[0.5f0.05 kg (0.99f0.11 Ib)]
Type Vane rotary, fix volume (CR-14)
Compressor Discharge 144 cm3 (8.79 cu in)/rev
Max. permissible speed 7,000 rpm
Tvpe Drv, single-disc type
Power consumption 47 w
Magnet clutch Type of belt V-Ribbed 4 PK
Pulley dia. (effective dia.) 125 mm (4.92 in)
Pulley ratio 1.064
Type Corrugated fin (Sub cool type)
I c e alea 0.21 m2 (2.26 sq ft)
Condenser
I Core thickness I 16 mm (0.63 in)
c-
I Radiation area I
~
5.34 m2 157.5 sa ft)

Receiver drier Effective inner capacity 250 cm3 (15.26 cu in)
Expansion valve Type Internal equalizing
TvDe Sinale tank
I Evaporator
I Dimensions (W x H x T)
I 255 x 200 x 48 mm
(10 x 7.87 x 1.89 in)
Fan type Sirocco fan
Blower fan Outer diameter x width 150 x 75 mm (5.91 x 2.95 in)
Power consumption 200 W at 12 V
Motor t w e Magnet
1 Condenser fan (Sub fan) I Power consumption I 70 W at 12 V
I Fan outer diameter I 320 mm (12.6 in)
Motor type Magnet
Radiator fan (Main fan) Power consumption 70 W at 12 V
Fan outer diameter 320 mm (12.6 in)
ldlina SDeed 1NC ON)
. , I
I MPFI model 850f100 rpm
278f29 kPa
ON -+ OFF
Low-pressure switch (2.83+0.3 kg/cm2,40.3f4.2 psi)
operating pressure 287+39/L25kPa
OFF + ON
Dual switch kg/cm2,42+5.7
(2.9+0.4/-0.25 /-3.6Psi)
(Pressure switch) 2,800f100 kPa
ON -+ OFF
High-pressureswitch (29fl kg/cm2, 406+15 psi)
operating pressure 600f200kPa
DlFF
(6.12f2 kg/cm2, 87229 psi)
~
Diff. 2.5*0.5"C(36.5&0.9"F)
Thermo control amplifier working temperature
(Evaporator outlet air)
OFF ON
1.5zkO.5"C(35+0.9"F)
HV004!
AC-3
GENERAL DESCRIPTION
HVAC SYSTEM (HEATER. VENTILATOR AND A/C)
B: COMPONENT
1. HEATER COOLING UNIT
~~
(1) Unit cover (10) Heater core (19) Expansion valve

(2) Side link (11) Drain hose (20) Evaporator
(3) Mode acutuator lever (12) Mix acutuator lever (21) Evaporator cover
(4) Foot lever (13) Unit assembly (22) Thermistor
(5) Spring (14) Foot duct
(6) Mode acutuator link (15) Clip Tightening torque: N.m (kgf-m, ft-lb)
(7) Defroster lever (16) Packing T: 7.35 (0.750, 5.421)
(8) Foot nozzle (17) Cooling unit block
(9) Unit duct cover (18) O-ring
AC-4
HVAC SYSTEM (HEATER, VENTILATOR AND NC)
2. BLOWER MOTOR UNIT
(1) Upper case (6) Filter cover Tightening toque: N-m (kgf-m, ft-lb)
(2) Blower link (7) Filter T: 7.35 (0.750,5.421)
(3) Blower link lever A (8) Blower motor assembly
(4) Blower link lever B (9) Hose
(5) Clip (10) Blower resistor
AC-5
GENERAL DESCRIPTION
3. CONTROL UNIT
HV0054
(1) Dial (6) Heater control panel (1 1) Mode cable

(2) Fan control plate (7) Air conditioner knob (12) Temperature cable
(3) Temperature control plate (8) Plug knob (13) Bulb
(4) Mode control plate (9) Heater control base (14) Fan switch ASSY
(5) Heater control knob (IO) Intake cable (15) Harness
AC-6
4. AIR CONDITIONING UNIT
(5)
HV0055
(1) Condenser (6) O-ring Tightening torque: N-m (kgf-m, ft-lb)

(2) Hose (High-pressure) (7) ClampA T1: 7.4 (0.75, 5.4)
(3) Hose (Low-pressure) (8) Clamp B T2: lS(1.5, 10.8)
(4) Bracket (9) Tube (To condenser)
(5) Compressor (IO) Tube (To evaporator)
AC-7
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
5. COMPRESSOR
HV0051
(1) Idler pulley bracket (7) V-belt Tightening torque: N.m (Irgf-m, ft-lb)
(2) Idler pulley adjuster (8) Compressor belt cover TI: 7.4 (0.75, 5.4)
(3) Idler pulley T2: 22.6(2.3, 16.6)
(4) Compressor bracket upper T3: 23.0 (2.35, 17.0)
(5) Compressor T4: 28.9 (2.95, 21.3)
(6) Compressor bracket lower T5: 35 (3.6,26)
AC-8
6. HEATER DUCT
HV0056
(1) Front defroster nozzle (4) Side ventilation duct (LH) (7) Rear heater duct (RH)
(2) Side defroster duct (LH) (5) Side ventilation duct (RH)
(3) Side defroster duct (RH) (6) Rear heater duct (LH)
AC-9
HVAC SYSTEM (HEATER. VENTILATOR AND N C )
C: CAUTION 4. HANDLING OF REFRIGERANT

1. HFC-134A A/C SYSTEM The refrigerant boils at approx. -30°C (-22°F).
When handling it, be sure to wear safety goggles
Unlike the old conventional HFC-12 system com- and protective gloves. Direct contact of the refriger-
ponents, the cooling system components for the ant with skin may cause frostbite.
HFC-134a system such as the refrigerant and com- If the refrigerant gets into your eye, avoid rubbing
pressor oil are incompatible. your eyes with your hands. Wash your eye with
Vehicles with the HFC-134a system can be iden- plenty of water, and receive medical treatment from
tified by the label “ A attached to the vehicle. an eye doctor.
Before maintenance, check which A/C system is in- Do not heat a service can. If a service can is di-
stalled in the vehicle. rectly heated, or put into boiling water, the inside
pressure will become extremely high. This may
cause the can to explode. If a service can must be
warmed up, use hot water in 40°C (104°F) max.
Do not drop or impact a service can. (Observe
the precautions and operation procedure described
on the refrigerant can.)
When the engine is running, do not open the
high-pressure valve of the manifold gauge. The
high-pressure gas will back-flow resulting in an ex-
plosion of the can.
The refrigerant is non-toxic and harmless under
2. COMPRESSOR OIL normal operating circumstance, but it may change
to phosgene (a noxious fume) under open flames
HFC-134a compressor oil has no compatibility or high temperatures (caused by a cigarette or
with that for R12 system. heater).
Use only the manufacturer-authorized compres- Provide good ventilation and do not work in a
sor oil for the HFC-134a system; only use DH-PR. closed area.
Do not mix multiple compressor oils. Never perform a gas leak test using a halide
If HFC-12 compressor oil is used in a HFC-134a torch-type leak tester.
A/C system, the compressor may become stuck In order to avoid destroying the ozone layer, pre-
due to poor lubrication, or the refrigerant may leak vent HFC-134a from being released into the atmo-
due to swelling of rubber parts. sphere. Using a refrigerant recovery system,
On the other hand, if HFC-134a compressor oil is discharge and reuse it.
used in a HFC-12 A/C system, the durability of the
A/C system will be lowered.
HFC-134a compressor oil is very hygroscopic. Goggles Gloves
When replacing or installing/removing A/C parts,
immediately isolate the oil from the atmosphere us-
ing a plug or tape. In order to avoid moisture, store
the oil in a container with its cap tightly closed.
3. REFRIGERANT
The HFC-12 refrigerant cannot be used in the
HFC-134a A/C system. The HFC-134a refrigerant,
also, cannot be used in the HFC-12 A/C system. Avoid open No direct heat Do not
If an incorrect or no refrigerant is used, poor lu- flame on container discharge
brication will result and the compressor itself may Loosen

be damaged.
G4M097S
AC-10
5. O-RING CONNECTIONS Use the oil specified in the service manual to Iu-
bricate the O-rings.
Use new O-rings.
Apply the oil to the top and sides of the O-rings be-
In order to keep the O-rings free of lint which will
fore installation.
cause a refrigerant gas leak, perform operations
Apply the oil to the area including the O-rings and
without gloves and shop towels.
tube beads.
Apply the compressor oil to the O-rings to avoid
sticking, then install them.
Use a torque wrench to tighten the O-ring fittings:
Over-tightening will damage the O-ring and tube
end distortion.
If the operation is interrupted before completing a
pipe connection, recap the tubes, components, and
fittings with a plug or tape to prevent contamination
from entering.
HV0062
Kea' After tightening, use a clean shop towel to re-

move excess oil from the connections and any oil
which may have run on the vehicle body or other
parts.
If any leakage is suspected after tightening, do
not retighten the connections, Disconnect the con-
nections, remove the O-rings, and check the 0-
G4M050'i rings, threads, and connections.
Visually check the surfaces and mating surfaces
of O-rings, threads, and connecting points. If a fail-
ure is found, replace the applicable parts.
Install the O-rings at right angle to the tube
beads.
,-O-ring
O.K. Bead
Not O.K.
Not O.K.
HV0046
AC-11
GENERAL DESCRIPTION
D: PREPARATION TOOL
CAUTION:
When working on vehicles with the HFC-134a
system, only use HFC-134a specified tools and
parts. Do not mix with CFC-12 tools and parts. If
HFC-134a and CFC-12 refrigerant or compres-
sor oil is mixed, poor lubrication will result and HFC-134a CFC-12
the compressor itself may be destroyed. Tool & screw type Millimeter size Inch size
Valve type Quick joint type Screw-in type
Tools and Equipment Description

Wench
Various WRENCHES will be required to service any A/Csystem. A 7 to
40 N.m (0.7 to 4.1 kg-m, 5 to 30 ft-lb) torque wrench with various crow-
loot wrenches will be needed. Open end or flare nut wrenches will be
ieeded for back-up on the tube and hose fittings.
G4M0571
Applicator bottle
A small APPLICATOR BOlTLE is recommended to apply refrigerant
3il to the various parts. They can be obtained at a hardware or drug
store.
G4M0572
Manifold gauge set
A MANIFOLD GAUGE SET (with hoses) can be obtained from either a
sommercial refrigerationsupply house or from an auto shop equipment
suppIier.
AC-12
GENERAL DESCRIPTION

Refrigerant recovery system
A REFRIGERANTRECOVERY SYSTEM is used for the recovery and
reuse of A/C system refrigerant after contaminants and moisture have
been removed from the refrigerant.
G4M0574
Syringe
A graduated plastic SYRINGE will be needed to add oil back into the
system. The syringe can be found at a pharmacy or drug store.
G4M0575
Vacuum pump
A VACUUM PUMP (in good working condition) is necessary, and may
be obtained from either a commercial refrigeration supply house or an
automotive equipment supplier.
G4MQ576
Can tap
A CAN TAP for the 397 g (14 02) can is available from an auto supply
store.
A
G4M0577
AC-13
GENERAL DESCRIPTION

Thermometer
Pocket THERMOMETERS are available from either industrial hard-
ware store or commercial refrigeration supply houses.
G4M0570
Electronic leak detector
An ELECTRONIC LEAK DETECTOR can be obtained from either a
G4M0579
Weight scale
A WEIGHT SCALE such as an electronic charging scale or a bath-
room scale with-digitaldisplay will be needed if a 13.6.kg (30 Ib) refrig-
erant container is used.
AC-14
REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET
2. Refrigerant Pressure with Manifold Gauge Set

A: OPERATION
1) Place the vehicle in the shade and draftless condition.
2) Connect the manifold gauge set.
3) Open the front windows and close all doors.
4) Open the hood.
5) Increase the engine to 1,500 rpm.
6) Turn ON the A/C switch.
7) Turn the temperature control switch to MAX COOL.
8) Put in RECIRC position.
9) Turn the blower control switch to HI.
10) Read the gauge.
Standard:
-
Low pressure: 127 196 kPa (1.3 - 2.0 kg/cn?, 18 - 28 psi)
High pressure: 1,471 - 1,667 kPa (15 - 17 kg/cn?, 213 - 242 psi)
Ambient temperature: 30 - 35 OC (86 95 OF) -
B: INSPECTION
-.
r Svmntnm I Probable cause
I I Defective condenser fan motor Replace the fan motor.
Clogged condenser fan Clean the condenser fin.
High-pressureside is unusually high. Too much refrigerant Discharge refrigerant.
Air inside the system Replace the receiver dryer.
Defective receiver dryer
Defective compressor Replace the compressor.
Not enough refrigerant Check for leaks.
High-pressureside is unusually low. Clogged expansion valve Replace the expansion valve.
Expansion valve frozen temporarily by
moisture
Defective compressor Replace the compressor.
Low-pressure side is unusually high. Defective expansion valve Replace the expansion valve.
Too much refrigerant Discharge refigerant.
Not enough refrigerant Check for leaks.
Clogged expansion valve Replace the expansion valve
Low-pressure side is unusually low. Expansion valve frozen temporarily by Replace the receiver dryer.
moisture
Saturated receiver dryer
AC-15
I REFRIGERANT RECOVERY PROCEDURE
3. Refrigerant Recovery Proce-

dure
A: OPERATION
CAUTION:
During operation, be sure to wear safety gog-
gles and protective gloves.
Connect the refrigerant recovery system with
the manifold gauge set to discharge the refrig-
erant from the A/C system and reuse it.
When reusing the discharged refrigerant,
keep service cans on hand. Because the dis-
charge rate with the recovery system is approx.
90%, service cans are necessary to charge the
refrigerant.
Follow the detailed operation procedure de-
scribed in the operation manual attached to the
refrigerant recovery system.
1) Perform the compressor oil return opera-
tion.cRef. to AC-21, OPERATION, Compressor
"Oi I.>
2) Stop the engine.
3) Close the valves on the low-/high-pressuresides
of the manifold gauge set.
Low-pressure gauge
(Compound pressure gauge)
Close Close
I G4M0585
4) Install the low-/high-pressure hoses to the ser-

vice ports on the low-/high-pressure sides of the
vehicle respectively.
Low-pressure gauge
5) Connect the center hose to the refrigerant recov-

ery system.
6) Follow the operation manual to activate the re-
frigerant recovery system.
AC-16
REFRIGERANT CHARGING PROCEDURE
4. Refrigerant Charging Proce- 4) Carefully open the valves on the low-/high-pres-

sure sides to activate the vacuum pump.
dure
A: OPERATION I Low-pressure gauge
(Compound pressure High-pressure gauge
CAUTION: gauge)
During operation, be sure to wear safety gog-
gles and protective gloves. Slowly Slowly
Before charging the refrigerant, evacuate the open G o p e n
system to remove small amounts of moisture
remaining in the system.
The moisture in the system can be completely
evacuated only under the minimum vacuum 4M0597
level. The minimum vacuum level affects the
temperature in the system. 5) After the low-pressure gauge reaches 100.0 kPa
The list below shows the vacuum values nec- (750 mmHg, 29.5 inHg) or higher, evacuate the
essary to boil water in various temperature. In system for approx. 15 minutes.
addition, the vacuum levels indicated on the
gauge are approx. 3.3 kPa (25 mmHg, 0.98 inHg)
lower than those measured at 304.8 m (1,000 ft)
above sea level.
-.
I Vacuum level required to boil water (at sea level) I
I TemDerature I Vacuum I
I 1.7"C (35°F)
I
1I 100.9 kPa (757 "Ha. -. 29.8 inHal I
I I
"I
7.2"C (45°F) I 100.5 kPa (754 mmHa 29.7 inHa)

I 12.8"C (55°F) I 99.8 kPa (749 mmHa 29.5 inHq) I
18.3"C (65°F) I 99.2 kPa (744 mmHg, 29.3 inHg)
I G4M0598
23.9"C (75°F) 1 98.5 kPa (739 mmHg, 29.1 inHg) 6) After 15 minutes of evacuation, if the reading
29.4"C (85°F) 97.2 kPa (729 mmHg, 28.7 inHg) shows 100.0 kPa (750 mmHg, 29.5 inHg) or higher,
35°C (95°F) 95.8 kPa (719 mmHg, 28.3 inHg) close the valves on the both sides to stop the vac-
uum pump.
1) Close the valves on low-/high-pressure sides of
the manifold gauge. Low-pressure gauge
gauge)
Low-pressure gauge
Close Close
Close Close
Vacuu
Turn OFF G4M0599
u l d u
G4M0596
7) Note the low-pressure gauge reading.
2) Install the low-/high-pressure hoses to the corre-

sponding service ports on the vehicle respectively.
3) Connect the center hose of the manifold gauge
set with the vacuum pump.
AC-17
I REFRIGERANT CHARGING PROCEDURE
8) Leave it at least 5 minutes, and then check the 15) Carefully open the high-pressure valve with the
low-pressure gauge reading for any changes. engine stopping.
When a gauge indicator shows near to zero point, CAUTION:
this is a sign of leakage. Check pipe connector Do not open the low-pressure valve.
points, repair them, make sure there is no leakage
by air bleeding.
Low-pressure gauge
9) Following the can tap operation manual instruc-
tions, install it to the refrigerant can.
(Compound pressure 6 High-pressure
I Center
Tap valve
Close
manifold
hose
\
G4M0601
CAUTION:
Never run the engine during charging from the
G4M0980 high-pressure side.
10) Disconnect the center manifold hose from the 16) Close the high-pressure valve when the low-
,.vacuum pump, and connect the hose to the tap pressure gauge reaches 98 kPa (1 kg/cm2, 14 psi).
valve. Using a leak tester, check the system for leaks.
11) When a 13.6 kg (30 Ib) refrigerant container is If any leakage is found after the refrigerant recov-
used, measure the refrigerant amount in use using ery is completed, repair the applicable area.
a weight scale. 17) After confirming that there are no leaks with the
leak test, charge the required amount of refrigerant.
CAUTION:
Refrigerant Never run the engine during charging from the
container high-pressure side.
(HFC-I34a)
18) Close the high-pressure valve when;
the readings of low- / high-pressure gauges be-
come almost equal, after the charging speed is re-
duced,
Weight
scale
the HFC-134a source becomes empty, or
c the system is filled with the gas.
G4M0981
12) Confirm that all the 3 hoses are tightly connect-

ed to the manifold gauge set.
Low-pressure gauge
Close Close
G4M060E
I G4M0603 I
13) Open the valve on the HFC-134a source.
14) Loosen the center hose connection on the
manifold gauge set (if applicable, press a purge
valve on the manifold gauge set) only for a couple
of seconds to allow the air in the center hose to es-
cape by the refrigerant.
AC-18
REFRIGERANT CHARGING PROCEDURE
a
19) If the HFC-134a source is empty, close the 27) Disconnect the hose from the service port, and
high-pressure valve, close the valve on the can tap, install the service port cap.
and replace the HFC-134a source with a new one
to restart the operation.
Low-pressure gauge
I G4M0606
20) Confirm that both the low- / high-pressure

valves can be closed. Start the engine with the A/C
switch OFF.
21) Quickly repeat ON-OFF cycles a few times to
prevent initial compressor damage.
22).Set up the vehicle to the following status:
A/C switch ON
Engine running at 1,500 rpm
Blower speed setting to “HI”
Temperature setting to “MAX COOL”
Air inlet setting to “RECIRC”
Windows open
23) While reading the low-pressure gauge, careful-
ly open the low-pressure valve with the refrigerant
source connected and the service hose purged.
CAUTION:
Never open the high-pressure valve with the en-
gine is running.
G4M0608
24) Adjust the refrigerant flow to maintain the pres-

sure on the low-pressure side at 276 kPa (2.81 kg/
cm2,40 psi) max.
25) After the system is fully charged, close the low-
pressure valve.
26) Close the valve on the refrigerant source.
I Refrigerant amount I
Refrigerant Minimum Maximum
HFC-134a 0.6 kg (1.3 Ib) 0.7 kg (1.5 Ib)
AC-19
I REFRIGERANT LEAK CHECK
5. Refrigerant Leak Check IO) Visually check the rubber area of the flexible
hose for cracks.
A: INSPECTION Check the entire length of the flexible hose, espe-
1) Operate the A/C system for approx. 10 minutes, cially the connection with the metal hose end.
and confirm that the high-side pressure shows at CAUTION:
least 690 kPa (7.03 kg/cm2, 100 psi). Then stop the Carefully check the external surface of hoses
engine to start the leak test. and tubes at approx. 25 mm (0.98 in) per sec-
2) Starting from the connection between the high- ond.
pressure tube and evaporator, check the system
for leaks along the high-pressure side through the
compressor. The following items must be checked Flexible hose
thoroughly.
3) Check the joint and seam between the pressure
switch (dual switch) and receiver dryer.
4) Check the connections between the condenser
and tubes, and welded joints on the condenser.
The leak tester may detect the oil on the condenser
fins as a leak.
5) Check the joint between the compressor and G4M0617
hoses.
6). Check the machined area of compressor and
c
11) Disconnect the drain hose from the evaporator
other joints on the compressor. case, and check the hose end for at least 10 sec-
7) Check the thermal limiter (if equipped) on the onds.
compressor housing. After the test is finished, reconnect the drain hose.
8) Check the compressor shaft seal at the area 12) Turn the ignition key to ON position, and run the
near the center of compressor clutch pulley. blower at high speed for 1 minute. Stop the blower
Some shaft seals show a slight amount of leakage to check the ventilation grille on the instrument pan-
about 28 g (1.O oz) per year. This is not a problem. el. While moving the tester closer to the grille, run
9) Starting from the connection between the low- the blower for 1 or 2 seconds, then stop it. Check
pressure tube and evaporator, check the system the grille at that point for at least 10 seconds.
for leakage along the high-pressure side through
the compressor. The following items must be
checked thoroughly.
Connection between the tube and tube fitting
Connection between 2 parts
Connection between the tube and nut
13) Check the valve in the service port.

14) Visually check the rubber seal in the service
port cap.
AC-20
COMPRESSOR OIL
HVAC SYSTEM (HEATER. VENTILATOR AND A/Cl
6. Compressor Oil B: REPLACEMENT

A: OPERATION NOTE:
If a component is replaced, add an appropriate
NOTE: amount of compressor oil.
Before making repairs, conduct the oil return oper- When replacing the compressor, the new com-
ation to return the compressor oil in circulation with pressor will already have the specified amount of
the refrigerant to the compressor. oil in it. Install the new compressor after removing
1) Increase the engine to 1,500 rpm. the same amount of oil that is remaining in the com-
2) Turn ON the A/C switch. pressor removed.
3) Turn the temperature control switch to MAX
COOL. I Replacement parts I Amount of oil replenishment I
4) Put in RECIRC position. I Evaporator I 114 m 8 (3.9 US fl 02,4.0 Imp fl 02) I
5) Turn the blower control switch to HI. I Condenser I 7 m 8 (0.24 US fl 02, 0.25 Imp fl 02) I
6) Leave in this condition for 10 minutes. I Hose I 1 m 8 (0.03 US fl 02. 0.04 ImD fl 02) I
AC-21
BLOWER MOTOR UNIT ASSEMBLY
7. Blower Motor Unit Assembly B: INSTALLATION

A: REMOVAL
1) Disconnect the ground terminal from battery. C: INSPECTION
2) Remove the glove box. <Ref. to EI-39, REMOV- Connect the motor connector terminal 1 from the
AL, Glove Box.> battery to the positive (+) lead and terminal 2 to the
3) Loosen the nut to remove support beam stay. negative (-) lead. Make sure the motor runs
smoothly.
I
404
4) Disconnect the blower motor connector.
--
5 ) Disconnect the blower resistor connector
6) Loosen the bolt and nut to remove blower motor

unit assembly.
HV0013
AC-22
BLOWER RESISTOR
8. Blower Resistor
A: REMOVAL
1) Remove the glove box. <Ref. to El-39, REMOV-
AL, Glove Box.>
2) Disconnect the blower resistor connector.
3) Loosen two screws to remove the blower resis-
tor.
B: INSTALLATION
IKstall in the reverse order of removal.
C: INSPECTION
HVO0.57
I 3 and 1 I Approx. 0.51 0 I

If NG, replace the blower resistor
AC-23
HEATER CORE
9. Heater Core
A: REMOVAL
1) Remove the heater and cooling unit. <Ref. to
AC-28, REMOVAL, Heater and Cooling Unit.>
2) Loosen the screws to remove heater core cover.
HVOOOl
3) Remove the heater core.
--
HV0002
B: INSTALLATION
AC-24
CONTROL UNIT
1O.Control Unit 2) Remove the glove box. <Ref. to El-39, REMOV-

AL, Glove Box.>
A: REMOVAL 3) Remove the lower panel. <Ref. to El-42, Instru-
1) Disconnect the ground terminal from battery. ment Panel Assembly.>
4) Remove the control wires.
5 ) Remove the center console panel. 7) Pull out the control unit and disconnect connec-
tors.
B: INSTALLATION
x Install in the reverse order of removal.
=J1 r Clip
6) Remove four screws.

-1-
BOO1 1 i
AC-25
COMPRESSOR
11.Compressor 7) Remove the low-pressure hose and high-pres-

sure hose.
A: INSPECTION
1. MAGNETIC CLUTCH CLEARANCE
1) Check the clearance of the entire circumference
around the drive plate and pulley.
Standard:
0.45-M.15 mm (0.0177-M.0059 in)
2. MAGNETIC CLUTCH OPERATION
1) Disconnect the compressor connector.
2) Connect the battery positive terminal to the No.3
terminal of the compressor connector. 8) Disconnect the compressor harness from body
Ground the negative terminal to the body. harness.
9) Loosen the bolts to remove compressor bracket.
84M2407
3) Make sure the magnet clutch engages.

If NG, replace the compressor. 10) Remove the bolts and then separate compres-
sor and bracket.
B: REMOVAL
1) Perform the compressor oil return operation.
<Ref. to AC-21, OPERATION, Compressor Oil.>
2) Turn A/C switch OFF and stop the engine.
3) Using refrigerant recovery system, discharge re-
frigerant. <Ref. to AC-16, OPERATION, Refriger-
ant Recovery Procedure.>
5) Remove the V-belt. <Ref. to ME(S0HC)-43, RE-
MOVAL, V-belt.> or <Ref. to ME(D0HC TURBO)-
44, REMOVAL, V-belt.> HVOOI 1
6) Remove the generator. <Ref. to SC-13, RE-

MOVAL, Generator.> C: INSTALLATION
2) Replace the O-rings on low-/high-pressure hos-
es with new ones, then apply compressor oil.
3) When replacing the compressor, adjust amount
of compressor oil. <Ref. to AC-21, OPERATION,
Compressor Oil.>
4) Charge refrigerant. <Ref. to AC-17, OPERA-
TION, Refrigerant Charging Procedure.>
AC-26
I
CONDENSER
12.Condenser B: INSTALLATION
1) Install in the reverse order of removal
A: REMOVAL
CAUTION:
1) Using the refrigerant recovery system, discharge
Replace the O-rings on hoses or pipes with new
refrigerant. <Ref. to AC-16, OPERATION, Refriger-
ones, and then apply compressor oil. Confirm
that lower guide of condenser (A) has been fit-
ted into holes on radiator panel.
3) Disconnect the pressure hose and pipe from
condenser.
I Y
B4M1822A
I
4rRemove the radiator bracket (A).
1 C: INSPECTION
1) Confirm that no dust or insects are found on the
condenser fins. Air-blow or flush fins with water as
needed.
2) Confirm that no oil leaks from condenser. If a fail-
ure is found, replace the condenser with a new one.
5 ) Remove two bolts. While lifting condenser, pull it

out through space between the radiator and the ra-
diator panel.
CAUTION:
Be careful not t o damage the condenser fins. If
a damaged fin is found, repair it using a thin
screwdriver.
If the condenser is replaced, add appropriate
amount of compressor oil t o the compressor.
<Ref. t o AC-21, REPLACEMENT, Compressor
Oil.>
AC-27
HEATER AND COOLING UNIT
13.Heater and Cooling Unit B: INSTALLATION

A: REMOVAL 2) Charge refrigerant. <Ref. to AC-17, OPERA-
1) Disconnect the ground terminal from battery. TION, Refrigerant Charging Procedure.>
3) Drain LLC from the radiator. <Ref. to CO-25, RE-
PLACEMENT, Engine Coolant.>
4) Remove the bolts securing expansion valve and
pipe in engine compartment. Release the heater
hose clamps in engine compartment to remove the
hoses.
C.
HVOOE
5) Remove the instrument panel. <Ref. to El-42,

REMOVAL, Instrument Panel Assembly.>
6) Remove the support beam.
7) Remove the blower motor unit assembly. <Ref.
to AC-22, REMOVAL, Blower Motor Unit Assem-
bly.>
8) Loosen the bolt and nuts to remove the heater
and cooling unit.
AC-28
I EVAPORATOR
14.Evaporator
A: REMOVAL
1) Remove the heater and cooling unit. <Ref. to
AC-28, REMOVAL, Heater and Cooling Unit.>
2) Loosen the screws and clip to remove the evap-
orator cover.
HV0024
3) Remove the evaporator.
4) Loosen two bolts to remove the expansion valve.
HV0026
CAUTION:
If the evaporator is replaced, add appropriate
amount of compressor oil to evaporator. <Ref.
to AC-21, REPLACEMENT, Compressor Oil.>
B: INSTALLATION
AC-29
HOSE AND TUBE
15.Hose and Tube 13) Remove the high-pressure tube from the vehi-
cle.
A: REMOVAL
CAUTION:
When disconnecting/connecting hoses, do
not apply excessive force to them. Confirm that
no torsion and excessive tension exists after
installing.
Seal the disconnected hose with a plug or vi-
nyl tape to prevent contamination from enter-
ing.
3) Remove the evaporator unit mounting bolt (A).
4) Remove the low-pressure hose attaching bolts
(B).
5) Disconnect the low-pressure hose from evapora-
-. unit.
tor
6) Disconnect the low-pressure hose from com-
pressor.
7) Remove the low-pressure hose from the vehicle.
8) Remove the high-pressure hose attaching bolts
(C). B: iNSTALLATlON
9) Disconnect the high-pressure hose from com-
pressor. CAUTION:
10) Disconnect the high-pressure hose from con- When disconnectingkonnecting hoses, do
denser. not apply an excessive force to them. Confirm
11) Remove the high-pressure hose from the vehi- that no torsion and excessive tension exists af-
cle. ter installing.
12) Remove the high-pressure tube attaching bolt
Seal the disconnected hose with a plug or vi-
nyl tape to prevent contamination from enter-
0 . ing.
C: INSPECTION
NOTE:
If cracking, damage, or swelling is found on a hose,
replace it with a new one.
AC-30
I RELAY AND FUSE
16.Relay and Fuse B: INSPECTION

A: LOCATION
-Joint box
HV006
Main fuse box
HV0022 (3) - (4): Continuity exists.
(1) - (2): No continuity
Main Fan Relay 1 A While applying battery voltage to the cable be-
Main Fan Relay 2 B tween (3) and (4),check continuity between (1) and
Sub Fan Relay 1 C (2).
If no continuity exists, replace the relay with a new
Sub Fan Relay 2
one.
A/C Relay
Main Fan Fuse
Sub Fan Fuse G
N C Fuse H
AC-31
PRESSURE SWITCH (DUAL SWITCH)
17.Pressure Switch (Dual

Switch)
A: INSPECTION
1) Connect the manifold gauge to the service valve
on the high-pressure side.
2) Remove the pressure switch harness connector.
Using a circuit tester, inspect the ON-OFF opera-
tion of the pressure switch.
1
Terminal
No.
1 Operation
Standard
kPa (kg/cm2, psi)
Increasing to
2,800flOO(29fl14O6k15)
Turns OFF.
Decreasingto
278+29 (2.83k0.3,
40.3M.2)
High and low pressure switch 1 and2
Turns ON.
Decreasing to
I
2,20M200(22.4+2,31%29)
AC-32
AIR VENT GRILLE
18.Air Vent Grille

A: REMOVAL
1. CENTER GRILLE
2) Remove the center console panel (A).
3) Loosen two screws to remove the center air vent
grille (B).
2:-SIDE GRILLE
2) Remove the heater vent duct. <Ref. to AC-35,
REMOVAL, Heater Vent Duct.>
3) Loosen the screws to remove the side air vent
grille.
B: INSTALLATION
C: INSPECTION
The direction and amount of air should be adjusted
smoothly.
The adjustment should be kept in each position.
AC-33
I HEATER DUCT
19.Heater Duct
A: REMOVAL
1) Remove the heater unit. <Ref. to AC-28, Remov-
al.>
2) Remove the front seat. <Ref. to SE-6, REMOV-
AL, Front Seat.>
3) Remove the front side sill cover.
4) Pull off the floor mat to remove the heater duct.
IB: INSTALLATION
AC-34
c3
HEATERVENTDUCT
20.Heater Vent Duct

A: REMOVAL
1) Remove the instrument panel. <Ref. to El-42,
REMOVAL, Instrument Panel Assembly.>
2) Remove the screws.
3) Remove the heater vent duct.
I HV0064 I
B: INSTALLATION
AC-35
GENERAL DIAGNOSTICS
21 .General Diagnostics
A: INSPECTION
I Fuse I
Blower motor relay
Blower motor
Doesn't move.
Blower motor Blower motor resistor
Blower switch
I Wire harness I
1 Blower motor
~
Stranqe noise. I
Refrigerant
Fuse
Air conditioning relay
Maanet clutch
Doesn't move. (Comoressor I
I Pressure switch I
I A/C switch I
Blower switch
Wire harness
V-Belt
Strange noise Magnet clutch
Compressor
I Refrigerant I
I V-Belt I
Magnet clutch
Compressor
Pressure switch
m w i t c h I
I Blower switch I
I Wire harness I
I Heater duct
Heater vent duct
~
Enaine coolant
~ ~~~
Warm air not emitted. Blower switch I

Heater core I
Engine coolant I
Temperature of air from vents does not change. Mode actuator
Wire harness
Mode actuator
Unable to switch blow vents. Air flow switch
Wire harness I
Air inlet select switch I
Unable to switch suction vents. FRESH/RECIRC actuator I
Wire harness
AC-36
AIRBAG SYSTEM
A5
1.
Page
General Description .................................................................................... 2
m
2. Airbag Connector ........................................................................................ 8
3. Inspection Locations After a Collision ....................................................... 10
4. Driver's Airbag Module.............................................................................. 12
5. Passenger'sAirbag Module ...................................................................... 13
6. Side Airbag Module................................................................................... 14
7. Airbag Control Module .............................................................................. 15
8. Side Airbag Sensor ................................................................................... 16
9. Roll Connector .......................................................................................... 17
10. Front Sub Sensor ...................................................................................... 18
AI RBAG SYSTEM
A: COMPONENT
RE0031
(1) Combination switch ASSY with roll (7) Side airbag sensor Tightening torque: N.m (kgf-m, ft-lb)
connector (8) Side airbag harness T1: 7.4 (0.75, 5.4)
(2) TORX@bolt T30 (9) Side airbag module T2: l O ( 1 . 0 , 7.2)
(3) Airbag module ASSY (Driver) (10) Airbag main harness T3: 20 (2.0, 14.5)
(4) Airbag module ASSY (Passenger) (1 1) Front sub sensor harness T4: 25 (2.5, 18.1)
(5) Airbag control module (12) Front sub sensor
(6) T O R P bolt T40 (13) TORX@bolt T30
AB-2
GENERAL DESCRIPTION
AIRBAG SYSTEM
B: CAUTION When checking, use a test harness. Do not di-

rectly apply the tester probe to any connector termi-
When servicing a vehicle, be sure to turn the ig-
nal of the airbag.
nition switch OFF, disconnect the ground terminal
from battery, and wait for more than 20 seconds
before starting work. NO GOOD GOOD
The airbag system is fitted with a backup power
source. If the airbag system is serviced within 20
seconds after the ground terminal is disconnected,
it may inflate.
G5M0293
NO GOOD
\ 1 G5M0292
c-If the sensors, airbag module, airbag control

module, pretensioner and harness are deformed or
damaged, replace them with new genuine parts.
I I
I NO GOOD I GOOD
Test harness
G5M0291
Do not use the airbag or pretensioner parts from G5M0294

other vehicles. Always replace the defective parts
with new parts. Do not check continuity of the driver, passenger,
Never re-use a deployed airbag or pretensioner. side airbag modules and pretensioner.
When checking the system, be sure to use a dig- I
ital circuit tester.
Use of an analog circuit tester may cause the air-
bag to activate erroneously.
NO GOOD G5M0302
AB-3
AIRBAG SYSTEM
Do not allow water or oil to come in contact with Install the wire harness securely with the speci-
the connector terminals. Do not touch the connec- fied clips to avoid interference or tangled up with
tor terminals. other parts.
A
\ NO GOOD
G5M0298 G5M0297
The airbag module (driver, passenger and side) When painting or performing sheet metal work
and pretensioner must not be disassembled. on the front part of the vehicle, including the front
wheel apron, front fender, and front side frame, re-
NO GOOD
move the front sub sensors and wire harness of the
airbag system.
When painting or performing sheet metal work
on the side of the vehicle, including the side sill,
center pillar, and front and rear doors, remove the
side airbag sensors and wire harness of the airbag
system.
v
~’ G5M0299
If any damage, opening, or rust is found on the

airbag system wire harness, do not attempt to re-
pair using soldering equipment. Be sure to replace
the faulty harness with a new genuine part.
\\ NO GOOD
G5M0310
NO GOOD
G5M0296
AB-4
GENERAL DESCRIPTION
AIRBAG SYSTEM
Do not drop the airbag modulator parts, subject

them to high temperature over 93°C (199"F), or let
water, oil, or grease get on them; otherwise, the in-
ternal parts may be damaged and reliability greatly
lowered.
NO GOOD
G5M0295
The removed front seat with the airbag module

must be kept at least 200 mm (8 in) away from walls
and other objects.
I I
When storing a removed airbag module, do not

place any objects on it or pile airbag modules on
top of each other. If the airbag inflates for some rea-
son when it is placed with its pad side facing down-
ward or under any object, a serious accident may
result.
AB-5
GENERAL DESCRIPTION
AIRBAG SYSTEM
Driver side GOOD
Passenger side
L
NO GOOD
NO GOOD
G5M0604
AB-6
GENERAL DESCRIPTION
AIRBAG SYSTEM
C: PREPARATION TOOL
1. GENERAL TOOL
TORP
T ~ O Used for removaVinstallation of drivers airbag module
T O R P T40 (Tamper resistant type) Used for removaVinstallation of airbag control module
TOR)(@T30 (TamDer resistant m e ) Used for removal of side airbag sensor.
AB-7
I AIRBAG CONNECTOR
AIRBAG SYSTEM
2. Airbag Connector 2. DRIVER'S AIRBAG, PASSENGER'S AIR-

BAG, SIDE AIRBAG
A: OPERATION 1) How to disconnect:
1. POWER SUPPLY (1) Push the lock arm (A).
(2) With the lock arm (A) pushed in, move the
1) How to disconnect: slide lock (6)in the direction of the arrow.
(1) Move the slide lock (A) in the direction of the
arrow.
(2) Pull the female connector in the direction of
the arrow with slide lock (A) moved.
(3) With the slide lock (6)pulled, remove the

lock arm (A) to its original position, and then pull
RE0012 in the direction of the arrow and separate the
connector.
CAUTION:
When pulling, be sure to hold onto the connec- CAUTION:
tor and not the wire. When pulling, be sure to hold onto the connec-
tor and not the wire.
2) How to connect:
Holding the connector (A), and push it in carefully
until a connecting sound is heard.
lY 1
B5M1154
2) How to connect:
/ RE0013 I Holding the connector, and push it in carefully until
a connecting sound is heard.
CAUTION:
Be sure to insert the connector in until it locks. CAUTION:
Then pull on it gently to make sure that it is Be sure to insert the connector in until it locks.
locked. Then pull on it gently to make sure that it is
locked.
AB-8
I AIRBAG CONNECTOR
AIRBAG SYSTEM
3. FRONT SUB-SENSOR, SIDE AIRBAG 4. PRETENSIONER

SENSOR 1) How to disconnect:
1) How to disconnect: (1) Move the slide lock (A) in the direction of the
(1) Holding the outer part (A), pull it in the direc- arrow.
tion of the arrow. (2) Pull the connector (B)in the direction of the
arrow with slide lock (A) moved.
CAUTION:
When pulling, be sure to hold onto the connec-
CAUTION:
2) How to connect: tor and not the wire.
Holding the connector, and push it in carefully until 2) How to connect:
a connecting sound is heard. Holding the connector (A), and push it in carefully
CA UTI0N:
Outer (A) moves back, and so do not put your
hand on the outer part.
Be sure to insert the connector in until it
locks. Then pull on it gently to make sure that it
is locked.
CAUTION:
locks.
Then pull on it gently to make sure that it is
locked.
AB-9
I INSPECTION LOCATIONS AFTER A COLLISION
AIRBAG SYSTEM
3. Inspection Locations After a 3. AIRBAG MODULE (SIDE)

Collision Check for the following, and replace damaged
parts with new parts.
A: INSPECTION Front seat is damaged or deformed.
If the vehicle is involved in a collision on any side, Harness and/or connector is cracked, deformed
even if it is a slight collision, be sure to check the or open.
following system parts. Lead wire is exposed.
1. AIRBAG MODULE (DRIVER) 4. AIRBAG CONTROL MODULE
1) Check for the following, and replace the dam- Check for the following, and replace the damaged
aged parts with new parts. parts with new parts.
Airbag module is cracked or deformed. Control module is cracked or deformed.
Harness and/or connector is cracked, deformed Mounting bracket is cracked or deformed.
or open. Lead wire is exposed. Connector is scratched or deformed.
The module surface is fouled with grease, oil, Airbag is deployed.
water or cleaning solvent. Side airbag is deployed.
2) When installing a new driver's airbag module,
check the following. If necessary, install a new air- 5. FRONT SUB SENSOR
bag module and steering wheel. If the front section of vehicle as shown in the figure
The steering wheel is in the way, making it diffi- is damaged:
p ~ ltot install the airbag module.
The clearance between the driver's airbag mod-
ule and steering wheel is not constant.
When steering wheel deformation in axial and ra-
dial directions exceed limits.
Specifications:
Axial direction play A
Less than 6 mm (0.24 in)
Radial direction play L
Less than 17 mm (0.67 in)
I I Check for the following, and replace the damaged

Front sub sensor is cracked or deformed.
Mounting bracket is cracked or deformed.
Connector is scratched or cracked.
Airbag is deployed.
6. FRONT SUB SENSOR HARNESS
Check for the following, and replace the damaged
I I
Harness is open, lead wire is exposed, and cor-
2. AIRBAG MODULE (PASSENGER) rugated tube is noticeably cracked.
Check for the following, and replace damaged Connector is scratched or cracked.
Airbag module is cracked or deformed.
Harness and/or connector is cracked, deformed
or open. Lead wire is exposed.
Mounting bracket is cracked or deformed.
AB-I 0
INSPECTION LOCATIONS AFTER A COLLISION
AIRBAG SYSTEM
7. SIDE AIRBAG SENSOR 8. SIDE AIRBAG SENSOR HARNESS

If the side section of vehicle as shown in the figure Check for the following, and replace the damaged
is damaged: parts with new parts.
rugated tube is noticeably cracked.
9. MAIN HARNESS
rugated tube is noticeably cracked.
05M0514
10.ROLL CONNECTOR
parts with new parts. Check for the following, and replace the damaged
Side airbag sensor is cracked or deformed. parts with new parts.
Mounting bracket is cracked or deformed. Combination switch or steering roll connector is
Connector is scratched or cracked. cracked or deformed.
Side airbag is deployed. (operating side)
r.
11.STEERING SHAFT
Check for the following, and replace the damaged parts with new parts.
Overall length of steering column should be within specifications.
Specifications:
Overall length L
825.751.5 mm (32.5H.06 in)
RE0032
If necessary, replace it with new part.
AB-1 1
I DRIVER’S AIRBAG MODULE
AIRBAG SYSTEM
4. Driver’s Airbag Module D: INSPECTION

A: CAUTION parts with new parts.
Refer to the “CAUTION” of General Description be- Airbag module, harness, connector, and mount-
fore handling the airbag module. <Ref. to AB-3, ing bracket are damaged.
CAUTION, General Description.>
B: REMOVAL
1) Position the front wheels straight ahead. (After
moving a vehicle more than 5 m (16 ft) with front
wheels positioned straight ahead, make sure that
the vehicle moves straight ahead).
2) Turn the ignition switch OFF.
3) Disconnect the ground terminal from battery,
and wait for at least 20 seconds before starting
work.
4) Using TORX@BIT T30, remove the two TOFIX@
bolts on the side of steering wheel.
H5M0662A
5) Disconnect the airbag connector on the back of

airbag module, and then remove the airbag mod-
ule.
6) Refer to the “CAUTION” for handling of a re-

moved airbag module. <Ref. to AB-3, CAUTION,
C: INSTALLATION
CAUTION:
Do not allow harness and connectors to inter-
fere or get tangled up with other parts.
AB-I 2
PASSENGER’S AIRBAG MODULE
AIRBAG SYSTEM
5. Passenger’s Airbag Module

A: CAUTION
Refer to the “CAUTION” of General Description be-
fore handling the airbag module. <Ref. to AB-3,
B: REMOVAL
work.
AL, Glove Box.>
4) Detach the airbag connector from the support
beam bracket, and then disconnect the airbag con-
nector.
5) Remove the three bolts, and then carefully re-
move the airbag module.
6) Refer to the “CAUTION” for handling of a re-

moved airbag module. <Ref. to AB-3, CAUTION,
C: INSTALLATION
CAUTION:
Do not allow harness and connectors to inter-
fere or get tangled up with other parts.
D: INSPECTION
Airbag module, harness, connector, and mount-
ing bracket are damaged.
AB-I 3
I SIDE AIRBAG MODULE
AIRBAG SYSTEM
6. Side Airbag Module

A: CAUTION
Refer to the “CAUTION” of General Description be-
fore handling the airbag module. <Ref. to AB-3,
B: REMOVAL
CAUTION:
The side airbag module cannot be detached
from the front seat assembly.
When replacing side airbag module, replace
front seat assembly.
<Ref. to SE-6, REMOVAL, Front Seat.>
C: INSTALLATION
<Ref. to SE-6, INSTALLATION, Front Seat.>
D: INSPECTION
-* Front seat is deformed or damaged.
Harness and/or connector is cracked, deformed
or open.
Lead wire is exposed.
AB-14
AIRBAG CONTROL MODULE
AIRBAG SYSTEM
7. Airbag Control Module

A: REMOVAL
CAUTION:
Do not disassemble the airbag control mod-
ule.
If the airbag control module is deformed or if
water damage is suspected, replace the airbag
control module with a new genuine part.
Do not drop the airbag control module.
After removal, keep the airbag control mod-
ule on a dry, clean surface away from moisture,
heat, and dust.
work.
4) Disconnect the connector from the airbag control
module.
5 ) Using T40@ TORX bit (Tamper resistant type),
remove the four TORX@bolts.
B: INSTALLATION
CAUTION:
Use new TORX@bolts during re-assembly.
C: INSPECTION
Control module, connector, and mounting brack-
et are damaged.
Airbag is deployed.
Side airbag is deployed.
AB-I 5
I SIDE AIRBAG SENSOR
AIRBAG SYSTEM
8. Side Airbag Sensor

A: REMOVAL
work.
3) Remove the outer belt (FRONT). <Ref. to SB-8,
OUTER BELT (FRONT), REMOVAL, Front Seat
Belt.>
4) Using T30 TORX@bit (Tamper resistant type),
remove the two TORX@bolts.
5) Detach the side airbag sensor, and then discon-
nect the airbag connector.
I
c-
REO018
B: INSTALLATION
CAUTION:
Use new TORX@bolts during re-assembly.
C: INSPECTION
Bracket connector for side airbag sensor is dam-
aged.
AB-I 6
ROLL CONNECTOR
AIRBAG SYSTEM
9. Roll Connector D: ADJUSTMENT

1) Check that front wheels are positioned in straight
A: REMOVAL ahead direction.
1) Turn the ignition switch OFF. 2) Turn the roll connector pin (A) clockwise until it
2) Disconnect the ground terminal from battery, stops.
and wait for at least 20 seconds before starting 3) Turn the roll connector pin (A) counterclockwise
\ I ~~
work. approximately 2.65 turns until “A” marks are

3) Remove the driver’s airbag module. <Ref. to AB- aligned.
12, Driver’s Airbag Module.>
4) Remove the steering wheel. <Ref. to PS-19,
REMOVAL, Steering Wheel.>
5) Remove the steering column cover.
6 ) Remove the screws, and then remove the roll
connector.
I J
W H5M0663B
B: INSTALLATION
1) Install the roll connector and steering column
cover in the reverse order of removal.
2) Before installing steering wheel, be sure the di-
rection of roll connector is adjusted with steering.
<Ref. to AB-17, ADJUSTMENT, Roll Connector.>
3) Install the steering wheel and airbag module.
C: INSPECTION
Combination switch and roll connector is cracked
or deformed.
AB-I 7
FRONT SUB SENSOR
1O.Front Sub Sensor

A: REMOVAL
2) Disconnect the ground cable from the battery,
work.
3) Remove the front bumper. <Ref. to El-23, RE-
MOVAL, Front Bumper.>
4) Loosen the two bolts to remove sensor cover.
5) Remove the bolt, and then detach the front sub

sensor.
6) Disconnect the connector from the front sub sen-
sor.
B: INSTALLATION
C: INSPECTION
Front sub sensor, mounting bracket, and con-
nector are damaged.
AB-I 8
AIRBAG SYSTEM (DIAGNOSTICS)
A5
Page
4. Electrical Components Location................................................................ 18
5. A/B Control Module I/O Signal .................................................................. 20
6. Airbag Connector ...................................................................................... 21
7. Airbag Warning Light Illumination Pattern................................................. 23
8. Read Diagnostic Trouble Code ................................................................. 24
9. Inspection Mode ........................................................................................ 25
11. Airbag Warning Light Failure..................................................................... 27
12. List of Diagnostic Trouble Code ................................................................ 32
13. Diagnostic Chart with Trouble Code ......................................................... 36

A: PROCEDURE
Step Check Yes No
Read Diagnostic Trouble Code. s the normal code being -inish the diagno- Go to step 2.
<Ref. to AB-24, Read Diagnostic Trouble
Code.>
letected?
s the trouble code being

;is.
30 to step 3.
IGo to “Airbag
! Read Diagnostic Trouble Code.
<Ref. to AB-24, Read Diagnostic Trouble jetected? Warning Light Fail,
Code.> ure”.<Ref. to AB-
27, Airbag Warn-
ing Light Failure.>
I Perform the diagnosis. s the trouble code being Perform the proce- Finish the diagno-
1)Judge the possible cause from “List of Diag- Jetected? jure 1) to 5)in sis.
nostic Trouble Code” <Ref. to AB-32, List of
Diagnostic Trouble Code.> .
2)lnspect using “Diagnostic Chart with Trouble
Code”. (DTC)
3)Repair the cause of the trouble.
AB-26, Clear Memory Mode.>
5)Perform the inspection mode. <Ref. to AB-
6)Read diagnostic trouble code.
AB-2
2. Check List for Interview

A: CHECK
Customer's Name Inspector's Name
Date Vehicle Brought In I I Registration No.
Odometer Reading Vin No.

Miles
Date
-. - Problem Occurred I I Registration Year I I
Weather D Fine D Cloudy D Rainy D Snowy I2 Other:
"C (OF)
I2 Level road D Uphill CI Downhill D Rough road CI Others:
CI Starting D Idling
0 Driving (El Constant Speed tl Acceleration D Deceleration
I2 Steering wheel turn CI Other: )
I2 Remains ON D Remains OFF
r-
Check DTC Ll Normal Code
AB-3
D Trouble Code: (Code: )
GENERAL DESCRIPTION
3. General Description When checking, use a test harness. Do not di-

rectly apply the tester probe to any connector termi-
A: CAUTION nal of the airbag.
When servicing a vehicle, be sure to turn the ig-
nition switch OFF, disconnect the ground terminal NO GOOD GOOD
from the battery, and wait for more than 20 seconds
before starting work.
The airbag system is fitted with a backup power
source. If the airbag system is serviced within 20
seconds after the ground terminal is disconnected,
it may inflate.
G5M029:
NO GOOD
c-
\ 1 G5M0292
If the sensors, airbag module, airbag control

module pretensioner and harness are deformed or
damaged, replace them with new genuine parts.
r NO GOOD
GOOD
G5M0291 I
Do not use the airbag system and pretensioners G5M0294
on other vehicles. When replacing parts, be sure to Do not check continuity of the driver, passenger,
replace them with new parts. side airbag modules and pretensioner.
Never re-use a deployed airbag and pretension-
er.
When checking the system, be sure to use a dig-
ital circuit tester.
Use of an analog circuit tester may cause the air-
bag to activate erroneously.
NO GOOD
\
G5M0302 I
GENERAL DESCRIPTION
Do not allow water or oil to come in contact with Install the wire harness securely with the speci-
the connector terminals. Do not touch the connec- fied clips to avoid interference or tangled up with
tor terminals. other parts.
NO GOOD
I G6M0298 I G5M0297
The airbag module (driver, passenger, side) and When painting or performing sheet metal work
pretensioner must not be disassembled. on the front part of the vehicle, including the front
wheel apron, front fender, and front side frame, re-
NO GOOD
move the front sub sensors and wire harness of the
airbag system.
When painting or performing sheet metal work
r
on the side of the vehicle, including the side sill,
center pillar, and front and rear doors, remove the
side airbag sensors and wire harness of the airbag
system.
G5M0299
If any damage, opening or rust is found on the

airbag system wire harness, do not attempt to re-
pair using soldering equipment. Be sure to replace
the faulty harness with a new genuine part.
\\ NO GOOD
G5M0310
NO GOOD
G5M0296
AB-5
GENERAL DESCRIPTION
Do not drop the airbag modulator parts, subject

them to high temperature over 93°C (199"F), or let
water, oil, or grease get on them; otherwise, the in-
ternal parts may be damaged and reliability greatly
lowered.
NO GOOD
G5M029C
The removed front seat with the airbag module

must be kept at least 200 mm (8 in) away from walls
and other objects.
When storing a removed airbag module, do not

place any objects on it or pile airbag modules on
top of each other. If the airbag inflates for some rea-
son when it is placed with its pad side facing down-
ward or under any object, a serious accident may
result.
AB-6
GENERAL DESCRIPTION
Driver side GOOD
NO GOOD
NO GOOD
A
G5M0604
AB-7
GENERAL DESCRIPTION
Do not discard undeployed airbag modules.

They could easily cause a serious accident if acci-
dentally deployed.
B: INSPECTION
Before diagnosing, check the following items that
might be related to the engine problem:
1. BATTERY
electrolyte.
Standard voltage: 12V
AB-8
GENERAL DESCRIPTION
C: PREPARATION TOOL
1. SPECIAL TOOLS
TEST HARNESS M
ILLUSTRATION TOOLNUMBER I DESCRlPTlON REMARKS

98299FE020 I TEST HARNESS M Used when measuring voltage, resistance of air-
bag system.
RE0033
6 5 4 3
RE0034
AB-9
GENERAL DESCRIPTION
TEST HARNESS F
ILLUSTRATION I TOOLNUMBER 1 DESCRIPTION REMARKS

98299FC010 I TEST HARNESS F Used when measuring voltage, resistance of air-
bag module harnesses.
RE0035
I RE0036
AB-I 0
GENERAL DESCRIPTION
TEST HARNESS G

98299FC020
side airbag sensor.
RE0037
G3
1'1 l-4
&,
4 5 6 7 8
RE0038
AB-11
GENERAL DESCRIPTION
TEST HARNESS H
DESCRIPTION REMARKS
TESTHARNESSH Used when measuring voltage, resistance of
front sub-sensor.
I RE0039 I
RE0040
AB-I 2
GENERAL DESCRIPTION
TEST HARNESS L
I seat belt pretensionei
RE0041 I
RE0042
AB-I 3
GENERAL DESCRIPTION
TEST HARNESS 12
ILLUSTRATION I TOOLNUMBER I DESCRIPTION 1 REMARKS

98299FC041 I TEST HARNESS 12 I Used when measuring voltage, resistance of air-
REO045
I
r5 II 1i3 I
It I I 1 1
I
RE0046
GENERAL DESCRIPTION
AIRBAG RESISTOR

98299PA040 AIRBAG RESISTOR Used in replacement of airbag module which
resistance value is same as airbag module.
RE0047 I
RE0048
AB-16

A: LOCATION
*@--
*@-
RE0049
r Male connector
AB-1 8
AI RBAG SYSTEM (DIAGNOSTICS)
(1) Driver’s airbag module (7) Seat belt pretensioner (LH) (13) Airbag main harness
(2) Roll connector (8) Seat belt pretensioner (RH) (14) Front sub-sensor harness (LH)
(3) Passenger’s airbag module (9) Front sub-sensor (LH) (15) Front sub-sensor harness (RH)
(4) Airbag control module (IO) Front sub-sensor (RH) (16) Side airbag harness (LH)
(5) Side airbag module (LH) (1 1) Side airbag sensor (LH) (17) Side airbag harness (RH)
(6) Side airbag module (RH) (12) Side airbag sensor (RH)
AB-19
I A/B CONTROL MODULE I/O SIGNAL
5. A/B Control Module I/O Signal

A: SCHEMATIC
<Ref. to WI-31, Airbag System.>
AB-20
AIRBAG CONNECTOR 91
6. Airbag Connector 2. DRIVER'S AIRBAG, PASSENGER'S AIR-

BAG, AND SIDE AIRBAG
A: OPERATION 1) How to disconnect:
1. POWER SUPPLY (1) Push the lock arm (A).
(2) With lock arm (A) pushed in, move the slide
1) How to disconnect:
lock (B) in the direction of the arrow.
arrow.
(2) Pull the female connector in the direction of
the arrow with slide lock (A) moved.
I \ \ B5M1153AI
* RE0012
(3) With slide lock (B) pulled, remove the lock
arm (A) to its original position, and then pull in
the direction of the arrow and separate the con-
nector.
CAUTION:
When pulling, be sure to hold onto the connec- CAUTION:
tor and not the wire. When pulling, be sure t o hold onto the connec-
2) How to connect:
Holding the connector (A), and push it in carefully
B5M1154
2) How to connect:
/ RE0015 Holding the connector, and push it in carefully until
CAUTION:
Be sure to insert the connector in until it locks. CAUTION:
Then pull on it gently t o make sure that it is Be sure to insert the connector in until it locks.
locked. Then pull on it gently to make sure that it is
locked.
AB-21
I AIRBAG CONNECTOR
AIRBAG SYSTEM fDIAGNOSTICS)
3. FRONT SUB-SENSOR, SIDE AIRBAG 4. PRETENSIONER

SENSOR 1) How to disconnect:
1) How to disconnect: (1) Move the slide lock (A) in the direction of the
(1) Holding the outer part (A), pull it in the direc- arrow.
tion of the arrow. (2) Pull the connector (B) in the direction of the
CAUTION: arrow with slide lock (A) moved.
When pulling, be sure to hold onto the connec- / / -1
(A)
CAUTION:
2) How to connect: tor and not the wire.
Holding the connector, and push it in carefully until 2) How to connect:
a connecting sound is heard. Holding the connector (A), and push it in carefully
CAUTION: until a connecting sound is heard.
Outer (A) moves back, and so do not put your
hand on the outer part.
locks. Then pull on it gently to make sure that it
is locked.
CAUTION:
Be sure to insert the connector in until it locks.
locked.
AB-22
AIRBAG WARNING LIGHT ILLUMINATION PATTERN
7. Airbag Warning Light Illumi-

nation Pattern
A: INSPECTION
Keep the ignition switch ON, and confirm that the
airbag warning light remains off approximately 6
seconds after being turned on.
Approx. 6 seconds
Airbag warning ON
light OFF
A-1m
igniiion
switch ON
I READ DIAGNOSTIC TROUBLE CODE
8. Read Diagnostic Trouble 3) Read trouble code by identifying the way the air
bag warning light flashes.
Code The airbag warning light flashes a code corre-
A: OPERATION sponding to the faulty parts.
The long segment (1.2 sec on) indicates a “ten”,
and the short segment (0.3 sec on) indicates a
2) Connect the diagnosis terminal (1) to the diagno- “0ne”.
sis connector (2) terminal No. 1 in the driver’s seat
lower cover area. NOTE:
“List of Diagnostic Trouble Code” <Ref. to AB-32,
List of Diagnostic Trouble Code.>
“Airbag Warning Light Failure” <Ref. to AB-27,
Airbag Warning Light Failure.>
Example:
Flashing
code 12:
Flashing
code21: OFF - 10
1.2
-
,. 0.3 _.
r
10
1.2 1. 0.3 1
.
0.3 1.2
(Set)
1 1’
Flashing
normal
code:
B5M0117A
4) Turn the ignition switch OFF, and disconnect the

diagnosis terminal from the diagnosis connector
terminal No 1.
5 ) Wind the tape around the diagnosis terminal and
return it to its original position.
AB-24
INSPECTION MODE
9. Inspection Mode
A: OPERATION
According to the contents of check list, reproduce
the condition which problem has occurred as much
as possible.
AB-25
I CLEAR MEMORY MODE
1O.Clear Memory Mode

A: OPERATION
2) Connect the diagnosis terminal (1) to the diagno-
sis connector (2) terminal No. 1 in the driver's seat
lower cover area.
3) While the warning light flashes, connect another

diagnosis terminal (3) to the diagnosis connector
Jerminal No.2.
4) Once the memory is erased, the warning light re-
turns to the normal flash rate (0.6 sec on). The fail-
ure to recover the normal flash rate indicates that
trouble parts still remain. Having repaired such
parts, erase the memory again and confirm that the
normal flash rate has returned.
5) When the memory has been cleared, disconnect
the diagnosis terminal from the diagnosis connec-
tor.
6) Wind the tape around the diagnosis terminal and
return it to its original position.
AB-26
AIRBAG WARNING LIGHT FAILURE
11.Airbag Warning Light Failure

A: AIRBAG WARNING LIGHT REMAINS ON.
DIAGNOSIS:
Airbag warning light unit is faulty.
Airbag control module to airbag warning light circuit is shorted or open.
Grounding circuit is faulty.
Airbag control module is faulty.
(AB1) and (831) are not connected properly.
(AB6) is not connected properly to airbag control module.
CAUTION:
Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the
ground terminal from the battery, and wait more than 20 seconds before starting to work.
Before replacing the airbag module, seat belt pretensioner, roll connector, control module, and
sensor, reconnect each part and confirm that the warning light operates properly.
When inspecting the airbag main harness, disconnect the airbag module connector of the driver
and passenger seats for safety reasons.
AB-27
WIRING DIAGRAM:
IG SW
N0.13
I
TJ"====
INDICATOR
CIRCUIT
UI
r
k
m
I @ AIRBAG CONTROL MODULE
RE0052
1
(ABl) AND (831).
Step I
1)Turn the ignition switch OFF, disconnect the

battery ground terminal, and wait more than 20
seconds.
2)Remove the side sill cover. (Driver'sside)
3)Confirmthat firm contact is secured between
connectors (AB1 and (831).
Check
CHECK POOR CONTACT IN CONNECTORS I Is the Door contact in connec-
tors (ABI) and (B31)? harness or replace
the body harness
with airbag main
harness.
r
I No
Go to step 2.
AB-28
I AIRBAG WARNING LIGHT FAILURE
a
Step Check Yes No

2 CHECK AIRBAG WARNING LIGHT. s the airbag warning light Go to step 4. ;o to step 3.
seconds.
2)Connect the connector (11\11)in the test har-
ness M to the body harness connector (831).
3)Connect the battery ground terminal and
turn the ignition switch ON.
4)Connect two connectors, (3M) and (4M) in
the test harness M.
3 CHECK BODY HARNESS. s the anything unusual to body Repair the body 3eplace combina-
Check the body harness. iarness? harness. ion meter printed
NOTE: :ircuit. <Ref. to
After problem has been eliminated, disconnect DI-11, Combina-
connectors (3M) and (4M). ion Meter Assem-
,lY.>
i
CHECK POOR CONTACT. s the poor contact in connec- Replace the body So to step 5.
Confirm that the firm contact is secured or (AB6)? harness with air-
between the airbag control module and the bag main harness
connector (AB6). <Ref. to AB-15, Airbag Con- or replace the air-
trol Module.> bag control mod-
ule. <Ref. to AB-
15, Airbag Control
Module.>
CHECK AIRBAG MAIN HARNESS. s the airbag warning light Go to step 6. 3eplace the body
1)Turn the ignition switch OFF, disconnect the urned off? iarness with air-
battery ground terminal, and wait more than 20 )ag main harness
seconds.
2)Connect the connector (ABI) to (831).
3)Disconnect the connectors (AB3) and (AB8).
4)Remove the glove box and disconnect the
connectors (AB10) and (AB9).
5)Disconnect the connector (AB6) from the air-
bag control module, and connect the connector
(1I) in the test harness I or 12. <Ref. to AB-15,
Airbag Control Module.>
7)Connect the connectors (41) and (51) in the
test harness I or 12.
NOTE:
After problem has been eliminated, disconnecl
connectors (41) and (51).
CHECK GROUNDING CIRCUIT. 3epair body-
1)Turn the ignition switch OFF, disconnect the 2? control module. jrounding circuit.
battery ground terminal, and wait more than 20 <Ref. to AB-15,
seconds. Airbag Control
bag control module.
3)Connect the connector (1I) in the test har-
ness I or 12 to body harness connector (AB6).
(21) in the test harness I or 12 and the chassis
ground.
(211 No. 10 - Chassis wound:
AB-29
I AIRBAG WARNING LIGHT FAILURE
B: AIRBAG WARNING LIGHT REMAINS OFF.

DIAGNOSIS:
Fuse No. 13 (in fuse box) is blown.
Body harness circuit is open.
Airbag warning light is faulty.
Airbag main harness is faulty.
CAUTION:
WIRING DIAGRAM:
1
F
I @ AIRBAG CONTROL MODULE
RE0052
AB-30
Step Check Yes No

1 CHECK COMBINATION METER. Do warning lights not for the Go to step 2. Repair the combi-
Turn the ignition switch ON, and confirm that airbag turn on? nation meter
warning lights equipped in the combination power supply.
meter are turned on. <Ref. to 101-4,
Combination
Meter System.>
2 CHECK FUSE NO. 13 (IN MAIN FUSE BOX). Is the fuse No. 13 (in main fuse Replace the fuse Go to step 3.
Remove the fuse No. 13 and perform visual box) blown? No. 13. If the fuse
inspection. No. 13 blows
again, go to step
3.
3 CHECK AIRBAG WARNING LIGHT CIRCUIT Is the airbag warning light Go to step 4. Replace the airbag
(IN COMBINATION METER). warning light bulb
1)Turn the ignition switch OFF, disconnect the or combination
battery ground terminal, and wait more than 20 meter printed cir-
seconds. cuit. <Ref. to IDI-
2)Disconnect the connector (ABI) from (831). 11, Combination
3)Connect the battery ground terminal and Meter Assembly.>
4 CHECK AIRBAG MAIN HARNESS. Is the airbag warning light Replace the airbag Replace the body
1)Turnthe ignition switch OFF, disconnect the turned on? control module. harness with air-
r- -
battery ground terminal, and wait more than 20 <Ref. to AB-15, bag main harness.
2)Connect the connector (ABI) to (831). Module.>
bag control module. <Ref. to AB-15, Airbag
Control Module.>
AB-31
I LIST OF DIAGNOSTIC TROUBLE CODE
12.List of Diagnostic Trouble Code

A: LIST
Memory Index No.
Contents of diagnosis
function
Airbag main harness circuit is open, shorted or
shorted to ground.
Airbag module harness (driver) circuit is open, <Ref. to AB-36, TROU-
shorted or shorted to ground. BLE CODE 11, Diag-
Provided. Roll connector circuit is open, shorted or shorted nostic Chart with
to ground. Trouble Code.>
Driver's airbag module is faulty.
Airbag main harness circuit is open, shorted or
shorted to ground. <Ref. to AB-38, TROU-
Airbag module harness (passenger) circuit is BLE CODE 12, Diag-
Provided.
open, shorted or shorted to ground. nostic Chart with
Airbag control module is faulty. Trouble Code.>
Passenger's airbag module is faulty.
Airbag main harness circuit (driver) is shorted to
power supply.
<Ref. to AB-40, TROU-
Airbag module harness (driver) is shorted to power
BLE CODE 15, Diag-
Provided. supply. nostic Chart with
Roll connector is shorted to power supply.
Trouble Code.>
Airbag main harness circuit (passenger) is shorted
to power supply. <Ref. to AB-42, TROU-
Airbag module harness (passenger) is shorted to BLE CODE 16, Diag-
Provided.
power supply. nostic Chart with
BLE CODE 21, Diag-
Provided. Airbag control module is faulty.
nostic Chart with
Trouble Code.>
Front airbag module and seat belt pretensioner (LH/ BLE CODE 22, Diag-
Provided.
RH) are inflated. nostic Chart with
Trouble Code.>
(AB6), (AB17) and (AB18) are not connected prop- BLE CODE 23, Diag-
Not provided. nostic Chart with
erly to airbag control module.
Trouble Code.>
Airbag control module is faulty. <Ref. to AB-46, TROU-
Airbag main harness circuit is open. BLE CODE 24, Diag-
Not provided. Fuse No. 11 (in joint box) is blown. nostic Chart with
Body harness circuit is open. Trouble Code.>
Airbag control module is faulty. <Ref. to AB-48, TROU-
Airbag main harness circuit is open. BLE CODE 25, Diag-
Provided. Fuse No. 6 (in joint box) is blown. nostic Chart with
Body harness circuit is open. Trouble Code.>
Front sub-sensor harness (RH) circuit is shorted. <Ref. to AB-50, TROU-
Front sub-sensor harness (RH) circuit is open. BLE CODE 31, Diag-
Provided. Front sub-sensor (RH) is faulty. nostic Chart with
Airbaq control module is faulty. Trouble Code.>
AB-32
LIST OF DIAGNOSTIC TROUBLE CODE
Trouble code/ Memory Contents of diagnosis Index No.

Contents of troubles function
Front sub-sensor harness (LH) circuit is shorted. <Ref. to AB-54, TROU-
Front sub-sensor harness (LH) circuit is open. BLE CODE 32, Diag-
Front sub-sensor (LH) is faulty. nostic Chart with
Side airbag harness (RH) is faulty. <Ref. to AB-58, TROU-
Side airbag module (RH) is faulty. BLE CODE 41, Diag-
Airbag control module is faulty. nostic Chart with
_____
Trouble Code.>
Side airbag harness (LH) is faulty. <Ref. to AB-60, TROU-
Side airbag module (LH) is faulty. BLE CODE 42, Diag-
42 Provided. nostic Chart with
Trouble Code.>
Side airbag harness (RH) is shorted to power sup- <Ref. to AB-62, TROU-
Ply. BLE CODE 45, Diag-
Trouble Code.>
Side airbag harness (LH) is shorted to power sup- <Ref. to AB-64, TROU-
Ply. BLE CODE 46, Diag-
-.. Trouble Code.>
Side airbag sensor (RH) is faulty. <Ref. to AB-66, TROU-
Side airbag harness (RH) is faulty. BLE CODE 51, Diag-
Trouble Code.>
Side airbag sensor (LH) is faulty. <Ref. to AB-68, TROU-
Side airbag harness (LH) is faulty. BLE CODE 52, Diag-
52 Provided.
Airbag control module is faulty. nostic Chart with
Trouble Code.>
BLE CODE 53, Diag-
53 Provided. Side airbag sensor (RH) is faulty. nostic Chart with
Trouble Code.>
BLE CODE 54, Diag-
54 Provided. Side airbag sensor (LH) is faulty.
nostic Chart with
Trouble Code.>
BLE CODE 55, Diag-
55 Provided. Side airbag module is inflated. nostic Chart with
Trouble Code.>
Seat belt pretensioner (RH) circuit is open, shorted
or shorted to ground. BLE CODE 61, Diag-
61 Provided. Airbag control module is faulty.
nostic Chart with
Pretensioner is faulty. Trouble Code.>
Pretensioner harness is faulty.
Seat belt pretensioner (LH) circuit is open, shorted
<Ref. to AB-74, Trouble
or shorted to ground.
Code 62, Diagnostic
Chart with Trouble
Pretensioner is faulty. Code.>
Seat belt pretensioner (RH) circuit is shorted to
power supply. BLE CODE 65, Diag-
Pretensioner is faulty.
nostic Chart with
Trouble Code.>
AB-33
Trouble codel Memory
Contents of diagnosis Index No.
Contents of troubles function
Seat belt pretensioner (LH) circuit is shorted to
power supply. BLE CODE 66, Diag-
66 Provided. Pretensioner is faulty. nostic Chart with
Trouble Code.>
AB-34
LIST OF DIAGNOSTIC TROUBLE CODE
AB-35
DIAGNOSTIC CHART WITH TROUBLE CODE
13.Diagnostic Chart with Trouble Code

A: TROUBLE CODE 11
DIAGNOSIS:
Airbag main harness circuit is open, shorted or shorted to ground.
Airbag module harness (Driver) circuit is open, shorted or shorted to ground.
Roll connector circuit is open, shorted or shorted to ground.
CAUTION:
When inspecting the airbag main harness, disconnect the driver's airbag module and passenger's
airbag module connectors for safety reasons.
WIRING DIAGRAM:
@(YELLOW) @(YELLOW)
B5M109f
AB-36
I DIAGNOSTIC CHART WITH TROUBLE CODE
Step Check Yes No

CHECK DRIVER'S AIRBAG MODULE. )oes the airbag warning light 3eplace the 30 to step 2.
1)Turn the ignition switch OFF, disconnect the iperate properly? iriver's airbag
battery ground terminal, and wait more than 20 nodule. <Ref. to
seconds. 4B-12, Driver's
2)Remove the driver's airbag module. <Ref. to 4irbag Module.>
AB-12, Driver'sAirbag Module.>
3)Connect the connector (1F) in the test har-
ness F to connector (AB7).
4)Connect the airbag resistor to connector (3F)
in the test harness F.
CHECK ROLL CONNECTOR. )oes the airbag warning light 3eplace the roll 30 to step 3.
1)Turn the ignition switch OFF, disconnect the iperate properly? :onnector. <Ref.
battery ground terminal, and wait more than 20 o AB-17, Roll
seconds. :onnector.>
2)Disconnect the test harness F from the con-
nector (AB7).
3)Remove the lower cover panel, disconnect
the connector (AB3) from (AB8) and connect
the connector (1F) in the test harness F to con.
nector (AB8).
CHECK AIRBAG MAIN HARNESS. ;the resistance less than 10 ;o to step 4. 3eplace the body
1)Turn the ignition switch OFF, disconnect the 1? iarness with air-
battery ground terminal, and wait more than 20 lag main harness
seconds.
2)Disconnect the airbag resistor from the con-
nector (3F) in the test harness F.
3)Remove the glove box, <Ref. to AB-13, Pas-
senger's Airbag Module.> and disconnect the
connectors (ABIO) and (AB9).
(21) in the test harness I or 12 and the connec-
tor (3F) in the test harness F.
(2l) NO. 1 - (3F) NO. 4:
(21) NO. 4 - (3F) NO. 3:
CHECK AIRBAG MAIN HARNESS. ;the resistance more than 1 3eplace the airbag 3eplace the body
Measure the resistance of the connector (21) in 1R? :ontrol module. iarness with air-
the test harness I or 12. :Ref. to AB-15, )ag main harness
Connector & terminal \irbag Control
(21) NO. 1 -NO. 4: Aodule.>
AB-37
~
B: TROUBLE CODE 12
DIAGNOSIS:
Airbag main harness circuit is open, shorted or shorted to ground.
Airbag module harness (Passenger) circuit is open, shorted or shorted to ground.
CAUTION:
WIRING DIAGRAM:
@ AIRBAG CONTROL MODULE
INFLATOR
(PASSENGER SIDE)
AB-38
~
Step No
I CHECK PASSENGER'SAIRBAG MODULE. ;o to step 2.
seconds.
2)Remove the glove box.
3)Disconnect the connector (AB10) from
(AB9).
ness F to connector (AB9).
in the test harness F. I
! CHECK AIRBAG MAIN HARNESS. s the resistance less than 10 Go to step 3. leplace the body
1)Turn the ignition switch OFF, disconnect the Z? iarness with air-
battery ground terminal, and wait more than 20 lag main harness.
seconds.
2)Disconnect the airbag resistor from the con-
nector (3F) in test harness F.
3)Remove lower cover and disconnect the con-
nector (AB3) from (AB8).
r- 4)Disconnect the connector (AB6) from the air-
tor (3F) in the test harness F.
(21) NO. 2 - (3F) NO. 3:
(21) NO. 5 - (3F) NO. 4:
I CHECK AIRBAG MAIN HARNESS. s the resistance more than 1 eeplace airbag leplace the body
Measure the resistance of the connector (21) in An? control module. larness with air-
the test harness I or 12. <Ref. to AB-15, lag main harness.
Connector 81terminal Airbag Control
-
(21)NO. 2 NO. 5: Module.>
-
(21)No. 2 Chassis ground:
-
AB-39
I
C: TROUBLE CODE 15
DIAGNOSIS:
Airbag main harness circuit (Driver) is shorted to the power supply.
Airbag module harness (Driver) is shorted to the power supply.
Roll connector is shorted to the power supply.
CAUTION:
WIRING DIAGRAM:
AB6 AIRBAG CONTROL MODULE
r
IO
I
STEERING
ROLL CONNECTOR
U
INFLATOR
@(YELLOW) @(YELLOW)
@(YELLOW)
B5M109t
AB-40
Step Check Yes No

I CHECK DRIVER'SAIRBAG MODULE. Ioes the airbag warning light Replace the 20 to step 2.
1)Turn the ignition switch OFF, disconnect the )perate properly? driver's airbag
battery ground terminal, and wait more than 20 module. <Ref. to
seconds. AB-12, Driver's
2)Remove the driver's airbag module. <Ref. to Airbag Module.>
AB-12, Driver's Airbag Module.>
3)Connect the connector (AB7) to connector
(1F) in the test harness F.
? CHECK ROLL CONNECTOR. Ioes the airbag warning light Replace the roll 20 to step 3.
1)Turn the ignition switch OFF, disconnect the )perate properly? connector. <Ref.
battery ground terminal, and wait more than 20 to AB-17 , Roll
seconds. Connector.>
2)Disconnect the test harness F from the con-
nector (AB7).
3)Remove the lower cover panel and discon-
nect the connector (AB3) from (AB8).
I
r- ness F to the connector (AB8).
i CHECK AIRBAG MAIN HARNESS. 3eplace the body
1)Turnthe ignition switch OFF, disconnect the control module. iarness with air-
battery ground terminal, and wait more than 20 <Ref. to AB-15, )ag main harness.
2)Disconnect the airbag resistor from the con- Module.>
nector (3F) in test harness F.
3)Remove the glove box, and disconnect the
connectors (AB10) and (AB9).
(1I) in the test harness I or 12. <Ref. to AB-1 5,
turn the ignition switch ON. (Engine OFF)
6)Measure the voltage between connector (21)
in the test harness I or 12 and the chassis
ground.
AB-41
D: TROUBLE CODE 16
DIAGNOSIS:
Airbag main harness circuit (Passenger) is shorted to the power supply.
Airbag module harness (Passenger) is shorted to the power supply.
CAUTION:
WIRING DIAGRAM:
r
INFLATOR
(PASSENGER SIDE)
1 RE0053
AB-42
Step Check
CHECK PASSENGER'S AIRBAG MODULE. )es the airbag warning light
1)Turn the ignition switch OFF, disconnect the 'erate properly? ;enger airbag
battery ground terminal, and wait more than 20 nodule. <Ref. to
seconds. 4B-I 3, Passen-
2)Remve the glove box. jerk Airbag Mod-
3)Disconnect the connector (AB10) from (AB9
ness F to the connector (AB9).
! CHECK AIRBAG MAIN HARNESS. the voltage less than 1 V?
seconds. 4irbag Control
2)Disconnect the airbag resistor from the con- vlodu1e.r
nector (3F) in the test harness F.
3)Remove the lower cover and disconnect the
connector (AB3) from (AB8).
r-
4)Disconnect the connector (AB6) from the air
ground.
E: TROUBLE CODE 21
DIAGNOSIS:
CAUTION:
Step Check Yes No

1 CHECK IF TROUBLE CODE 21 IS INDICAT- Is the airbag warning light trou- Replacethe airbag Perform clear
ED. ble code 21 indicated? control module. memory. <Ref. to
Read Diagnostic Trouble Code. <Ref. to AB- <Ref. to AB-15, AB-26, Clear
24, Read Diagnostic Trouble Code.> Airbag Control Memory Mode.>
Module.>
AB-43
F: TROUBLE CODE 22
This code is indicated when the front airbag and the
pretensioner are in operation.
Once this code is indicated, memory is not erasable; therefore replace the following parts.
Airbag control module. <Ref. to AB-15 , Airbag Control Module.>
Driver's airbag module. <Ref. to AB-12, Driver's Airbag Module.>
Passenger's airbag module. <Ref. to AB-13, Passenger's Airbag Module.>
Front sub-sensor of both sides. <Ref. to AB-18, Front Sub Sensor.>
Front seat belt outer with pretensioner of both sides. <Ref. to SB-8, Front Seat Belt.>
G: TROUBLE CODE 23
DIAGNOSIS:
(AB6), (AB17) and (AB18) are not connected properly to airbag control module.
CAUTION:
Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground
terminal from the battery, and wait more than 20 seconds before starting to work.
Step Check Yes No

1 CHECK POOR CONTACT IN CONECTORS Check if the rust or damage Replace the airbag Go to step 2.
(Ass), (AB17) and (AB18). appear on the harness con- control module.
.. 1)Turn the ignition switch OFF, disconnect the nector and the control module <Ref. to AB-15,
battery ground terminal, and wait more than 20 connector. Airbag Control
seconds. Module.> Replace
2)Disconnect the connectors (AB6), (AB17) the body harness
and (AB18) from the airbag control module. with airbag main
<Ref. to AB-15, Airbag Control Module.> harness.
Replace the body
harness with side
airbag harness.
I
2 CHECKPOORCONTACTINCONECTORS Finish the diagno- I Replace the airbag
(Ass), (AB17) and (AB18). operate properly? sis. control module.
1)Ensure that the connectors are firmly recon- <Ref. to AB-15,
nected. Airbag Control
2)Connect the battery ground terminal and Module.>
AB-44
AB-45
H: TROUBLE CODE 24
DIAGNOSIS:
Airbag main harness circuit is open.
Fuse No, 11 (in joint box) is blown.
CAUTION:
WIRING DIAGRAM:
IG SW
N0.11
I W
I AIRBAG CONTROL MODULE I
RE0054
AB-46
m
At RBAG SYSTEM (DIAGNOSTICS)
Step Check Yes No

CHECK AIRBAG CONTROL MODULE. 3 the voltage more than 10 V? 3eplace the airbag ) to step 2.
1)Turn the ignition switch OFF, disconnect the :ontrol module.

battery ground terminal, and wait more than 20 :Ref. to AB-15,
seconds. 4irbag Control
2)Disconnect the connector (AB6) from the air- vlodule.>
bag control module. <Ref. to AB-15, Airbag
Control Module.>
ness I or 12 to connector (AB6).
in the test harness I or 12 and chassis ground.
CHECK AIRBAG MAIN HARNESS. s the resistance less than 10 30 to step 3. ?placethe body
1)While checking control module, turn the igni- 2? .messwith air-
tion switch OFF and disconnect the battery .g main harness.
ground terminal. Wait more than 20 seconds
before operation.
2)Disconnect the airbag connector (AB1) from
the body harness (B31).
3)Connect the connector (2M) in the test har-
ness M to connector (AB1).
(5M) in the test harness M and the connector
(21) in the test harness I or 12.
(5M) NO. 2 - (21) NO. 3:
CHECK AIRBAG MAIN HARNESS. s the resistance more than 1 30 to step 4. ?placethe body
Measure the following resistance with the dfi? irness with air-
above-mentioned condition maintained. ig main harness
(5M) No. 2 - Chassis ground:
CHECK FUSE No. 11 (IN JOINT BOX). s fuse No. 11 blown? 3eplace fuse No. ?pairthe body
1)Confirmthat the ignition switch is turned 11. Iffuse No. 11 irness.
OFF. lows again, repair
2)Remove the fuse No. 11 (in joint box) and :he body harness.
perform visual inspection.
AB-47
I: TROUBLE CODE 25
DIAGNOSIS:
Airbag main harness circuit is open.
Fuse No. 6 (in joint box) is blown.
CAUTION:
WIRING DIAGRAM:
r Y
RE0055
AB-48
m
~~ ~~ ~
Step Check Yes No

CHECK AIRBAG CONTROL MODULE. the voltage more than 10 V? Replace the airbag i o to step 2.
1)Turn the ignition switch OFF, disconnect the control module.
battery ground terminal, and wait more than 20 <Ref. to AB-15,
2)Disconnect the connector (AB6) from airbag Module.>
control module. <Ref. to AB-15, Airbag Control
Module.>
3)Connect the connector (1 I ) in the test har-
ness I or 12 to the connector (AB6).
4)Connect the battery ground cable, and turn
5)Measure the voltage between the connector
ground.
! CHECK AIRBAG MAIN HARNESS. the resistance less than 10 I Go to step 3. 3eplace the body
1) While checking control module, turn the igni iarness with air-
tion switch OFF and disconnect the battery )ag main harness
ground terminal. Wait more than 20 seconds
before operation.
-. . 2)Disconnect the airbag connector (ABI) from
the body harness (B31).
3)Connect the connector (2M) in the test har-
ness M to the airbag connector (AB1).
4)Measure the resistance between the con-
nector (5M) in the test harness M and the con-
01
nector (21) in the test harness I or 12.
(5M) NO. 2 - (20 NO. 6:
1 CHECK AIRBAG MAIN HARNESS. the resistance more than 1 Go to step 4. 3eplace the body
Measure the following resistance with the iarness with air-
above-mentionedcondition maintained. lag main harness
(5M) No. 2 - Chassis ground:
I CHECK FUSE NO. 6 (IN JOINT BOX). 3epair the body
1)Confirm that the ignition switch is turned No. 6. If the fuse iarness.
OFF. No. 6 is blown
2)Remove the fuse No. 6 (in joint box) and per again, repair the
form visual inspection. bodv harness.
AB-49
J: TROUBLE CODE 31
DIAGNOSIS:
Front sub-sensor harness (RH) circuit is shorted.
Front sub-sensor harness (RH) circuit is open.
Front sub-sensor (RH) is faulty.
CAUTION:
WIRING DIAGRAM:
7
E
m
FRONT SUB SENSOR RH
RE0029
AB-50
DIAGNOSTIC CHART WITH TROUBLE CODE iim
AI RBAG SYSTEM (DIAG NOSTICS1
Step Check Yes No

CHECK FRONT SUB-SENSOR (RH) AND Is the resistance between 30 to step 2. I Go to step 3.
FRONT SUB-SENSOR HARNESS (RH). 7500 and 1 KQ?

(31) NO.2 - NO. 4:
CHECK FRONT SUB-SENSOR (RH) AND Is the resistance more than 1 3eplace the airbag Go to step 3.
FRONT SUB-SENSOR HARNESS (RH). MQ? :ontrol module.
Measure the resistance between connector :Ref. to AB-15,
(31) in the test harness I or 12 and the chassis 4irbag Control
ground. vlodule.>
-
CHECK AIRBAG MAIN HARNESS AND Is the resistance less than 20 to step 4. Go to step 5.
FRONT SUB-SENSOR HARNESS (RH). 1on?
1)Disconnectthe connector (AB16) from the
front sub-sensor. <Ref. to AB-18, Front Sub
Sensor.>
2)Connect the connector (IH) in test harness H
to the connector (AB16).
(31) in test harness I or 12 and connector (3H)
in the test harness H.
(31) NO. 2 - (3H) NO. 5:
(31) NO. 4 - (3H) NO. 6:
CHECK AIRBAG MAIN HARNESS AND Is the resistance more than 1 20 to step 10. Go to step 5.
FRONT SUB-SENSOR HARNESS (RH). MQ?
Measure the resistance between connector
ground.
-
(3l) No. 2 Chassis ground:
-
CHECK AIRBAG MAIN HARNESS Is the resistance less than 10 20 to step 6. Replace the body
1)Disconnect the connector (AB15) from R? harness with air-
(AB14), and connect the connector (1F) in test bag main harness
harness F to the connector (AB14).
(31) in the test harness I or 12 and connector
(31) NO. 2 - (3F) NO. 4:
(31) NO. 4 -(3F) NO. 3:
CHECK AIRBAG MAIN HARNESS Is the resistance more than 1 20 to step 7. Replace the body
Measure the resistance between connector MR? harness with air-
(31) in the test harness I or 12 and the chassis bag main harness
ground.
AB-51
Step Check Yes No

CHECK FRONT SUB-SENSOR HARNESS Is the resistance less than 10 30 to step 8. Replace the body
(RH). R? harness with front
1)Connect the connector (2F) in the test har- sub-sensor har-
ness F to the connector (AB1 5). ness (RH).
(3H) in the test harness H and connector (3F)
(3F) NO.5 - (3H) NO. 5:
(3F) NO. 6 - (3H) NO. 6:
I CHECK FRONT SUB-SENSOR HARNESS Is the resistance more than 1M 20 to step 9. Replace the body
(RH). R? harness with front
Measure the resistance between connector sub-sensor har-
(3H) in the test harness H and connector (3F) ness.
(3F) NO. 6 - (3H) NO. 6:
(3F) NO. 5 - (3H) NO. 5:
I CHECK FRONT SUB-SENSOR HARNESS Is the resistance more than 1 20 to step 10. Replace the body
(RH). MR? harness with front
(3F) in the test harness F and the chassis ness (RH).
ground.
(3F) No. 5 - Chassis ground:
0 CHECK FRONT SUB-SENSOR (RH). Is the resistance between i o to step 11. Replace the front
1)Connect the connector (2H) in test harness 750R and 1 KR? sub-sensor (RH).
H to the front sub-sensor (RH). <Ref. to AB-1 8,
2)Measure the resistance of the connector Front Sub Sen-
(3H) in the test harness H. sor.>
(3H) NO. 3 - NO. 4:
1 CHECK FRONT SUB-SENSOR (RH). Is the resistance more than 1 'inish the diagno- Replace the front
Measure the resistance between connector MR? ;is. sub-sensor (RH).
(3H) in the test harness H and the chassis <Ref. to AB-1 8,
ground. Front Sub Sen-
(3H) No. 3 - Chassis ground:
AB-52
AB-53
K: TROUBLE CODE 32
DIAGNOSIS:
Front sub-sensor harness (LH) circuit is shorted.
Front sub-sensor harness (LH) circuit is open.
Front sub-sensor (LH) is faulty.
CAUTION:
WIRING DIAGRAM:
r AB6 AIRBAG CONTROL MODULE
rA
I I
FRONT SUB SENSOR LH
RE0056
AB-54
a
Step Check Yes No

1 CHECK FRONT SUB-SENSOR (LH) AND 5 the resistance between 30 to step 2. Go to step 3.
FRONT SUB-SENSOR HARNESS (RH). ‘50Q and 1 KR?
seconds.
bag control module, and connect connector
(1I) in the test harness I or 12 to the connector
(AB6). <Ref. to AB-1 5, Airbag Control Mod-
ule.>
3)Measure the resistance of the connector (31)
in the test harness I or 12.
(31) NO. 1 -NO. 3:
2 CHECK FRONT SUB-SENSOR (LH) AND s the resistance more than 1 3eplace the airbag Go to step 3.
FRONT SUB-SENSOR HARNESS (RH). AQ? :ontrol module.
Measure the resistance between connector :Ref. to AB-15,
(31) in the test harness I or 12 and the chassis 4irbag Control
ground. vlodu1e.i
(34 No. 1 - Chassis ground:
-- (31) No. 3 - Chassis ground:
3 CHECK AIRBAG MAIN HARNESS AND s the resistance less than 10 30 to step 4. I Go to step 5.
FRONT SUB-SENSOR HARNESS (LH). 2?
front sub-sensor. <Ref. to AB-18, Front Sub
Sensor.>
2)Connect the connector (1H) in the test har-
ness H to the connector (AB13).
(3H)in the test harness H.
4
(31) NO. 3 - (3H) NO. 6:
(31) NO. 1 -(3H) NO. 5:
CHECK AIRBAG MAIN HARNESS AND
FRONT SUB-SENSOR HARNESS (LH).
Measure the resistance between connector
s the resistance more than 1
AR?
3
30 to step 10. Go to step 5.

ground.
r
5 CHECK AIRBAG MAIN HARNESS. s the resistance less than 10 30 to step 6. Replace the body
1)Disconnect the connector (AB11) from 2? harness with air-
(AB12), and connect the connector (IF) in the bag main harness
test harness F to (AB11).
(31) NO. 3 -(3F) NO. 3:
(31) NO. 1 - (3F) NO. 4:
6 CHECK AIRBAG MAIN HARNESS. s the resistance more than 1
Measure the resistance between connector AR? harness with air-
(31) in the test harness I or 12 and the chassis bag main harness
ground.
Step Check Yes No

, CHECK FRONT SUB-SENSOR HARNESS the resistance less than 10 30 to step 8. Replace the body
(LH). ? harness with front
1)Connect the connector (2F) in the test har- sub-sensor har-
ness F to the connector (AB12). ness (LH).
(3H) in the test harness H and connector (3F)
(3F) NO. 5 - (3H) NO. 5:
(3F) NO. 6 - (3H) NO. 6:
1 CHECK FRONT SUB-SENSOR HARNESS the resistance more than 1M 30 to step 9. Replace the body
? harness with front
W).
(3H) in the test harness H and connector (3F) ness (LH).
(3F) NO. 6 - (3H) NO. 6:
(3F) NO. 5 - (3H) NO. 5:
1 CHECK FRONT SUB-SENSOR HARNESS the resistance more than 1 30 to step 10. Replace the body
(LW n? harness with front
(3F) in the test harness F and the chassis ness (LH).
ground.
0 CHECK FRONT SUB-SENSOR (LH). the resistance between 30 to step 11. Replace the front
1)Coonect connector (2H) in the test harness OR and 1 KR? sub-sensor (LH).
H to the front sub-sensor (LH). <Ref. to AB-18,
2)Measure the resistance of the connector Front Sub Sen-
(3H) in the test harness H. sor.>
(3H) NO. 3 -NO. 4:
1 CHECK FRONT SUB-SENSOR (LH). the resistance more than 1 -inish the diagno- Replace the front
Measure the resistance between connector n? ;is. sub-sensor (LH).
(3H) in the test harness H and the chassis <Ref. to AB-18,
ground. Front Sub Sen-
AB-56
--
AB-57
L: TROUBLE CODE 41
DIAGNOSIS:
Side airbag harness (RH) is faulty.
Side airbag module (RH) is faulty.
CAUTION:
When inspecting the side airbag harness, disconnect the side airbag module connector and seat
belt pretensioner connector for the safety reasons.
WIRING DIAGRAM:
T 818 AIRBAG CONTROL MODULE
SIDE AIRBAG
SENSOR RH
Ih
(SIDE RH)
B5M1105
AB-58
Step Check Yes No

1 CHECK SIDE AIRBAG MODULE. )oes the airbag warning light 3eplace the front i o to step 2.
1)Turn the ignition switch OFF, disconnect the lperate properly? ;eat with side air-
battery ground terminal, and wait more than 20 lag module (RH).
seconds. :Ref. to SE-6,
2)Disconnect the connector (AB26) from the ?ant Seat.>
seat belt pretensioner (RH). <Ref. to SB-8,
Front Seat Belt.>
(AB24), and connect the connector (1F) in the
4)Connect the airbag resistor to the connector
5)Connect the battery ground terminal, and
2 CHECK SIDE AIRBAG HARNESS (RH). s the resistance less than 10 30 to step 3. leplace the body
1)Turn the ignition switch OFF, disconnect the 2? iarness with side
battery ground terminal, and wait more than 20 iirbag harness.
seconds.
2)Disconnect the airbag resistor from the test
harness F.
3)Disconnect the connector (AB18) from the
r.
air bag control module. <Ref. to AB-15, Airbag
Control Module.>
4)Connect the connector (1 I) in the test har-
(31) NO. 7 - (3F) NO. 4:
(31) NO. 9 - (3F) NO. 3:
3 CHECK SIDE AIRBAG HARNESS (RH). s the resistance more than 1 30 to step 4. 3eplace the body
Measure the resistance of the connector (31) in dQ? iarness with side
the test harness I or 12. airbag harness.
(31) NO. 7 - NO. 9:
4 CHECK SIDE AIRBAG HARNESS (RH). s the resistance more 1MR? 30 to step 5. 3eplace the body
Measure the resistance of the connector (3F) iarness with side
in the test harness F. airbag harness.
(3F) NO. 3 -NO. 4:
5 CHECK SIDE AIRBAG HARNESS (RH). s the resistance more than 1 Go to step 6. 3eplace the body
Measure the resistance between connector \nQ? iarness with side
(3F) in the test harness F and the chassis iirbag harness.
ground.
6 CHECK SIDE AIRBAG HARNESS (RH). s the resistance more than 1 Replace the airbag 3eplace the body
Measure the resistance between connector VIR? control module. iarness with side
(31) in the test harness I or 12 and the chassis <Ref. to AB-15, 3irbag harness.
ground. Airbag Control
Connector & terminal Module.>
AB-59
M: TROUBLE CODE 42
DIAGNOSIS:
Side airbag harness (LH) is faulty.
Side airbag module (LH) is faulty.
CAUTION:
WIRING DIAGRAM:
AIRBAG CONTROL MODULE

I-
ll
INF
[
(SI1
R
1)
SIDE AIRBAG
SENSOR LH
[G]
B5M1106
AB-60
m
Step Check Yes No

CHECK SIDE AIRBAG MODULE. Ioes the airbag warning light 3eplace the front Go to step 2.
1)Turn the ignition switch OFF, disconnect the iperate properly? ;eat with side air-
battery ground terminal, and wait more than 20 lag module (LH).
seconds. :Ref. to SE-6,
2)Disconnect the connector (AB21) from the 3ont Seat.>
seat belt pretensioner (LH). <Ref. to SB-8,
Front Seat Belt.>
(AB19), and connect the connector (1 F) in the
I
CHECK SIDE AIRBAG HARNESS (LH). s the resistance less than 10 20 to step 3. Replace the body
1)Turn the ignition switch OFF, disconnect the R? harness with side
battery ground terminal, and wait more than 20 airbag harness.
seconds.
harness F.
r. airbag control module. <Ref. to AB-15, Airbag
Control Module.>
(31) NO. 10 - (3F) NO. 3:
(31) NO. 12 - (3F) NO. 4:
I CHECK SIDE AIRBAG HARNESS (LH). IS the resistance more than 1 30 to step 4. Replace the body
Measure the resistance of the connector (31) in MR? harness with side
(31) NO. 10 - NO. 12:
I CHECK SIDE AIRBAG HARNESS (LH). Is the resistance more than 1 20 to step 5. Replace the body
Measure the resistance of the connector (3F) MR? harness with side
in the test harness F. airbag harness.
(3F) NO. 3 - NO. 4:
1 CHECK SIDE AIRBAG HARNESS (LH). Is the resistance more than 1 30 to step 6. Replace the body
Measure the resistance between connector MR? harness with side
(3F) in the test harness F and the chassis airbag harness.
ground.
i CHECK SIDE AIRBAG HARNESS (LH). Is the resistance more than 1 3eplace the airbag Replace the body
Measure the resistance between connector MR? :ontrol module. harness with side
(31) in the test harness I or 12 and the chassis :Ref. to AB-1 5, airbag harness.
ground. 4irbag Control
Connector & terminal Module.>
AB-61
At RBAG SYSTEM f DIAGNOSTlCSl
~
N: TROUBLE CODE 45
DIAGNOSIS:
Side airbag harness (RH) is shorted to power supply.
CAUTION:
WIRING DIAGRAM:
7
e
B18 AIRBAG CONTROL MODULE
L
SIDE AIR1
SENSOR J
INFLATOR
(SIDE RH)
I@
AB-62
Step Check Yes No

I CHECK SIDE AIRBAG MODULE. >oes the airbag warning light Replace the front i o to step 2.
1)Turn the ignition switch OFF, disconnect the )perate properly? seat with side air-
battery ground terminal, and wait more than 20 bag module (RH).
seconds. <Ref. to SE-6,
2)Disconnect the connector (AB26) from the Front Seat.>
Front Seat Belt.>
test harness F to (AB24 ).
! CHECK SIDE AIRBAG HARNESS (RH). 3eplace the body
1)Turn the ignition switch OFF, disconnect the control module. iarness with side
battery ground terminal, and wait more than 20 <Ref. to AB-15, iirbag harness.
2)Disconnect the airbag resistor from the test Module.>
harness F.
r- - airbag control module. <Ref. to AB-15, Airbag
Control Module.>
ground.
AB-63
I
0: TROUBLE CODE 46
DIAGNOSIS:
Side airbag harness (LH) is shorted to power supply.
CAUTION:
WIRING DIAGRAM:
7 AB17 AIRBAG CONTROL MODULE
SIDE AIRBAG
SENSOR LH
R
1)
B5M1106
AB-64
Step Check No
I CHECK SIDE AIRBAG MODULE. 30 to step 2.
1)Turn the ignition switch OFF, disconnect the )perate properly? seat with side air-
battery ground terminal, and wait more than 20 bag module (LH).
seconds. <Ref. to SE-6,
2)Disconnect the connector (AB21) from the Front Seat.>
Front Seat Belt.>
-l
? CHECK SIDE AIRBAG HARNESS (LH). s the voltage less than 1 V? Replace the airbag 3eplace the body
harness F.
r. airbag control module. <Ref. to AB-15, Airbag
Control Module.>
ground.
AB-65
P: TROUBLE CODE 51
DIAGNOSIS:
Side airbag sensor (RH) is faulty.
Side airbag harness (RH) is faulty.
CAUTION:
WIRING DIAGRAM:
r
t
I
SIDE AIRBAG
SENSOR RH
Ih
(SIDE RH)
@ @
B5MllOL
AB-66
Step Check Yes No

30 to step 2. Replace the body
1)Turnthe ignition switch OFF, disconnect the R? harness with side
seconds.
Front Seat Belt.>
(AB24).
airbag control module. <Ref. to AB-15, Airbag
Control Module.>
side airbag sensor (RH), and connect the con-
nector (1G) in the test harness G to the con-
nector (AB28).
(3G) in the test harness G.
(31) NO. 17 - (3G) NO. 2:
(31) NO. 18 - (3G) NO. 1:
(31) NO. 19 - (3G) NO. 5:
(31) NO. 20 - (3G) NO. 4:
CHECK SIDE AIRBAG HARNESS (RH). Is the resistance more than 1 3eplace the side Replace the body
Measure the resistance between connector MR? iirbag sensor harness with side
(31) in the test harness I or 12 and the chassis RH). <Ref. to AB. airbag harness.
ground. 16, Side Airbag
Connector & terminal Sensor.> When
(31) No. 17 - Chassis ground: he sensor
(31) No. 18 - Chassis ground: eplacement is not
(31) No. 19 - Chassis ground: I K , replace the
(31) No. 20 - Chassis ground: iirbag control
nodule. <Ref. to
4B-15, Airbag
2ontrol Module.>
AB-67
Q: TROUBLE CODE 52
DIAGNOSIS:
Side airbag sensor (LH) is faulty.
Side airbag harness (LH) is faulty.
CAUTION:
WIRING DIAGRAM:
r AB17 AIRBAG CONTROL MODULE
INF 'R
-
SIDE AIRBAG
SENSOR LH
(SIDE LH)
B5M1IO€
AB-68
Step Check Yes No

CHECK SIDE AIRBAG HARNESS (LH). 5 the resistance less than 10 30 to step 2. Replace the body
1)Turn the ignition switch OFF, disconnect the 2? harness with side
seconds.
Front Seat Belt.>
(AB19).
airbag control module. <Ref. to AB-15, Airbag
Control Module.>
side airbag sensor (LH), and connect the con-
nector (1G) in the test harness G to the con-
nector (AB23).
(3G) in the test harness G.
(31) NO.5 - (3G) NO. 4:
-
(31) NO. 14 (3G) NO. 5:
(31) NO. 15 - (3G) NO. 1:
.~ NO. 16 - (3G)
(31) . , NO. 2:
! CHECK SIDE AIRBAG HARNESS (RH). s the resistance more than 1 3eplace the side Replace the body
Measure the resistance between connector AR? iirbag sensor harness with side
(31) in the test harness I or 12 and the chassis LH). <Ref. to AB- airbag harness.
ground. 16, Side Airbag
Connector & terminal Sensor.> When
-
(31) No. 5 Chassis ground: he sensor
-
(31) No. 14 Chassis ground: .eplacement is not
-
(31) No. 15 Chassis ground: 3K, replace the
-
(31) No. 16 Chassis ground: airbag control
nodule. <Ref. to
4B-15, Airbag
Zontrol Module.>
R: TROUBLE CODE 53
DIAGNOSIS:
Side airbag sensor (RH) is faulty.
When Code 53 is displayed, the circuit within the side airbag sensor (RH) is faulty. Replace the side airbag
sensor (RH).
<Ref. to AB-16, Side Airbag Sensor.>
S: TROUBLE CODE 54
DIAGNOSIS:
Side airbag sensor (LH) is faulty.
When Code 54 is displayed, the circuit within the side airbag sensor (LH) is faulty. Replace the side airbag
sensor (LH).
<Ref. to AB-16, Side Airbag Sensor.>
AB-69
T: TROUBLE CODE 55
This code is displayed when the side airbag is deployed.
When this code is displayed, the memory cannot be erased. Replace the following parts.
Airbag control module. <Ref. to AB-15, Airbag Control Module.>
Front seat assembly with side airbag module. (Operating side) <Ref. to SE-6, Front Seat.>
Side airbag sensor. (Operating side) <Ref. to AB-16, Side Airbag Sensor.>
AB-70
AB-71
U: TROUBLE CODE 61
DIAGNOSIS:
Seat belt pretensioner (RH) circuit is open, shorted or shorted to ground.
CAUTION:
WIRING DIAGRAM:

1
0
c
r
-
PRETENSIONER RH
B5M11OE
AB-72
31
~~~
Step Check Yes No

CHECK SEAT BELT PRETENSIONER. Ies the airbag warning light Ieplace the seat 20 to step 2.
1)Turn the ignition switch OFF, disconnect the erate properly? )elt pretensioner
battery ground terminal, and wait more than 20 RH). <Ref. to SB-
seconds. i,Front Seat
2)Disconnect the connector (AB26) from the 3elt.r
Front Seat Belt.>
3)Connect the connector (1 L) in the test har-
ness L to (AB26).
(3L) in the test harness L.
CHECK SIDE AIRBAG HARNESS (RH). the resistance less than 10 20 to step 3. 3eplace the body
1)Turn the ignition switch OFF, disconnect the > iarness with side
battery ground terminal, and wait more than 20 3irbag harness.
seconds.
harness L.
(AB24).
4)Disconnect the connectors (AB17) and
(AB18) from the airbag control module. <Ref.
to AB-15, Airbag Control Module.>
(31) NO. 8 - (3L)NO. 6:
.~ NO. 6 - (3L)
(31) . . NO. 5:
CHECK SIDE AIRBAG HARNESS (RH). the resistance more than 1 30 to step 4. 3eplace the body
Measure the resistance of the connector (31) in n? iarness with side
the test harness I or 12. 3irbag harness.
(31) NO. 6 - NO. 8:
CHECK SIDE AIRBAG HARNESS (RH). the resistance more than 1 3eplace the airbag 3eplace the body
Measure the resistance between connector n? :ontrol module. iarness with side
(31) in the test harness I or 12 and the chassis :Ref. to AB-15, 3irbag harness.
ground. Vrbag Control
Connector & terminal vlodule.>
AB-73
V: TROUBLE CODE 62
DIAGNOSIS:
Seat belt pretensioner (LH) circuit is open, shorted or shorted to ground.
CAUTION:
WIRING DIAGRAM:
T
I
I
017 AIRBAG CONTROL MODULE
1
PRETENSIONER LH
B5M1108
AB-74
Step Check Yes No

CHECK SEAT BELT PRETENSIONER. loes the airbag warning light Ieplace the seat 30 to step 2.
1)Turn the ignition switch OFF, disconnect the iperate properly? )elt pretensioner
battery ground terminal, and wait more than 20 LH). <Ref. to SB-
seconds. b, Front Seat
2)Disconnect the connector (AB21) from the 3elt.>
Front Seat Belt.>
3)Connect the connector (1L) in the test har-
ness L to (AB21).
CHECK SIDE AIRBAG HARNESS (LH). s the resistance less than 10 ;o to step 3. 3eplace the body
1)Turn the ignition switch OFF, disconnect the n? iarness with side
battery ground terminal, and wait more than 20 3irbag harness.
seconds.
harness L.
(AB19).
-_ 4)Disconnect the connectors (AB17) and
tor (3L) in the test harness L.
(31)NO. 11 - (3L)NO. 6:
(31)NO. 13 - (3L)NO. 5:
I CHECK SIDE AIRBAG HARNESS (LH). Is the resistance more than 1 30 to step 4. 3eplace the body
Measure the resistance of the connector (31) in MQ? iarness with side
(31)NO. 11 - NO. 13:
I CHECK SIDE AIRBAG HARNESS (LH). Is the resistance more than 1 3eplace the airbag 3eplace the body
Measure the resistance between the connector MQ? :ontrol module. iarness with side
(31) in the test harness I or 12 and the chassis :Ref. to AB-15, airbag harness.
ground. 4irbag Control
Connector & terminal vlodu1e.r
-
(31)No. 13 Chassis around:
AB-75
W: TROUBLE CODE 65
DIAGNOSIS:
Seat belt pretensioner (RH) circuit is shorted to the power supply.
CAUTION:
WIRING DIAGRAM:
7
E
-
r
PRETENSIONER RH
B5M110!
AB-76
m
Step Check
I CHECK SEAT BELT PRETENSIONER.
1)Turn the ignition switch OFF, disconnect the iperate properly? belt pretensioner
battery ground terminal, and wait more than 20 (RH). <Ref. to SB-
seconds. 8, Front Seat
2)Disconnect the connector (AB26) from the Belt.>
Front Seat Belt.>
ness L to (AB26).
! CHECK SIDE AIRBAG HARNESS (RH). 3eplace the body
harness L.
(AB24).
e. - 4)Disconnect the connectors (AB17) and
6)Connect the battery ground cable and turn
ground.
AB-77
X: TROUBLE CODE 66
DIAGNOSIS:
Seat belt pretensioner (LH) circuit is shorted to the power supply.
CAUTION:
Before replacing the airbag module, seat belt pretensioner, roll connector, control module and the
WIRING DIAGRAM:
T
I
I
817 AIRBAG CONTROL MODULE
-
PRETENSIONER LH
B5M11Ot
AB-78
AIRBAG SYSTEM IDIAGNOSTICS)
Step Check Yes No

CHECK SEAT BELT PRETENSIONER. Does the airbag warning light Replace the seat Go to step 2.
1)Turn the ignition switch OFF, disconnect the operate properly? belt pre-tensioner
battery ground terminal, and wait more than 20 (LH). <Ref. to SB-
seconds. 8, Front Seat
2)Disconnect the connector (AB21) from the Belt.>
Front Seat Belt.>
ness L to (AB21).
CHECK SIDE AIRBAG HARNESS (LH). s the voltage less than 1 V? Replacethe airbag Replace the body
1)Turnthe ignition switch OFF, disconnect the control module. harness with side
battery ground terminal, and wait more than 20 <Ref. to AB-15, airbag harness.
harness L.
(AB19).
4)Disconnect the connectors (AB17) and
ground.
(30 No. 11 (+) - Chassis ground (-):
AB979
--
AB-80
SEAT BELT SYSTEM
~~ ~ ~ ~
SB ~ ~~ ~~
Page
1. General Description ................................................................................... .2
2. Pretensioner Connector ............................................................................. .6
3. Inspection Locations After a Collision ......................................................... 7
4. Front Seat Belt ............................................................................................ 8
5. Rear Seat Belt ........................................................................................... 10
GENERAL DESCRIPTION
SEAT BELT SYSTEM
A: COMPONENT
1. FRONT SEAT BELT
000239
(1) Adjuster anchor ASSY Tightening torque: N.m (kgf-m, ff-lb)

(2) Anchor cover T l : 7.5 (0.76, 5.5)
(3) Outer belt ASSY T2: 30 (3.1,22)
(4) Inner belt ASSY T3: 53 (5.4,39)
SB-2
GENERAL DESCRIPTION
SEAT BELT SYSTEM
2. REAR SEAT BELT (SEDAN)
(1) Outer seat belt RH (6) Inner seat belt LH Tightening torque: N.m (kgf-m, ff-lb)
(2) Outer seat belt CENTER (7) Case center ELR T: 30 (3.1,22)
(3) Outer seat belt LH (8) Anchor cover
(4) Inner seat belt RH (9) Adjustable anchor ASSY
(5) Inner seat belt CENTER
SB-3
SEAT BELT SYSTEM
3. REAR SEAT BELT (WAGON)
(1) Outer seat belt RH (5) Inner seat belt LH Tightening torque: N.m (kgf-m, ff-lb)
(2) Outer seat belt CENTER (6) Anchor cover T: 30 (3.1,22)
(3) Outer seat belt LH (7) Adjustable anchor ASSY
(4) Inner seat belt RH
SB-4
GENERAL DESCRIPTION
SEAT BELT SYSTEM
6: CAUTION
Before starting, turn the ignition switch OFF, dis-
connect the battery ground cable and wait for 20
seconds or more.
The pretension system has a backup power
source. The pretensioner might deploy if you do not
wait for 20 seconds or more before starting work.
Do not drop or apply any impact to the preten-
sioner.
If oil, grease, or water gets on the pretensioner,
wipe it off immediately with a dry cloth.
Do not expose the pretensioner to high tempera-
ture or flame.
Do not allow current to flow through or voltage to
reach the pretensioner. Do not use a circuit tester
to check resistance of the pretensioner.
Do not disassemble or attempt to repair the pre-
tensioner. If it is dented, cracked, or deformed, re-
place it with a new one.
Do not use the airbag or pretensioner parts from
other vehicles. Always replace the parts with new
parts.
When handling a seat belt with a deployed pre-
tensioner, wear gloves and goggles. Wash your
hands afterwards.
Do not re-use a seat belt with a deployed preten-
sioner again.
If the material gets in your eyes or on your skin
during deployment, wash it away with clean water,
and then consult a doctor.
SB-5
PRETENSIONER CONNECTOR
SEAT BELT SYSTEM
2. Pretensioner Connector
A: OPERATION
1) How to disconnect:
arrow.
(2) Pull the connector (B) in the direction of the
arrow with slide lock (A) moved.
CA JTION:
tor and riot the wire.
2) How to connect:
Holding connector (A), and push it in carefully until
CAUTION:
locks.
locked.
SB-6
INSPECTION LOCATIONS AFTER A COLLISION
SEAT BELT SYSTEM
3. Inspection Locations After a

Collision
A: INSPECTION
Check for the following, and then replace with new
parts if necessary.
Center pillar lower garnish is discolored or
cracked.
Wire harness and/or connector is damaged.
SB-7
FRONT SEAT BELT
SEAT BELT SYSTEM
4. Front Seat Belt 2. INNER BELT (FRONT)

A: REMOVAL 2) Remove the anchor bolt, and then detach the in-
1. OUTER BELT (FRONT) ner belt.
1) Fold backrest all the way forward, and then
move the front seat all the way forward.
2) Turn the ignition switch OFF, disconnect the
ground cable from battery, and wait for more than
20 seconds before starting work.
3) Remove the center pillar lower trim. <Ref. to El-
46, REMOVAL, Lower Inner Trim.>
4) Remove the anchor cover. Loosen the shoulder
anchor bolt, and then detach the shoulder anchor
from center pillar. S5M0234
L B5M1070
5 ) Turn over the floor mat to remove the bolts.
6) Disconnect the yellow connector of pretensioner

harness, and remove the outer belt (front).
CAUTION:
Do not drop or apply any impact to the pre-
tensioner.
Pretensioner and bracket should be treated
as an assembly. Do not attempt to disassemble
it.
SB-8
I
FRONT SEAT BELT
SEAT BELT SYSTEM
1. OUTER BELT (FRONT) 1. OUTER BELT (FRONT)
Install in the reverse order of removal. Check for the following, and replace with new parts
CAUTION: if necessary.
Pretensioner is cracked or deformed.
The parts on right and left are not identical.
Before installation, make sure that the correct Seat belt is slackened, bent, or frayed. Seat belt
part is used. is abnormally wound or extended.
Be careful not to twist the belts during instal- 2. INNER BELT (FRONT)
lation.
Check for the following, and replace with new parts
I 2. INNER BELT (FRONT) if necessary.
Install in the reverse order of removal. Inner belt is deformed or damaged.
Seat belt buckle is engaged improperly.
SB-9
REAR SEAT BELT
SEAT BELT SYSTEM
5. Rear Seat Belt 7) Remove the two bolts and adjustable anchor AS-
SY.
A: REMOVAL
1. OUTER BELT SIDE (SEDAN)
1) Remove the rear seat. <Ref. to SE-I 1, REMOV-
AL, Rear Seat.>
2) Remove the side sill rear lower cover. <Ref. to
El-46, REMOVAL, Lower Inner Trim.>
3) Remove the seat belt lower anchor bolt.
2. OUTER BELT CENTER (SEDAN)

1) Remove the rear seat. <Ref. to SE-11, REMOV-
AL, Rear Seat.>
4) Remoce the anchor cover. Remove the bolt and

shoulder anchor from pillar.
3) Remove the quarter pillar trim. <Ref. to El-47,

Removal, Rear Quarter Trim.>
4) Remove the rear shelf trim. <Ref. to El-53, RE-
MOVAL, Rear Shelf Trim.>
I RE0059I 5) Remove the bolts, and then detach the seat belt.
5) Remove the quarter pillar trim. <Ref. to El-47,
6) Remove the bolts, and then detach the seat belt.
\ - \ \
RE0005
SB-I 0
REAR SEAT BELT
SEAT BELT SYSTEM
3. INNER BELT (SEDAN) 7) Remove the bolts, and then detach the outer belt
side.
1) Remove the rear cushion. <Ref. to SE-11, RE-
MOVAL, Rear Seat.>
2) Remove the bolts, and then detach the inner
belt.
,.. .
RE0062 I
8) Remove the two bolts and adjustable anchor AS-
SY.
~
4. OUTER BELT SIDE (WAGON)

1) Remove the luggage floor mat. <Ref. to El-56,
REMOVAL, Luggage Floor Mat.>
AL, Rear Seat.>
3) Remove the side sill rear lower cover. <Ref. to
El-46, REMOVAL, Lower Inner Trim.>
5) Remove the anchor cover. Remove the bolt and

shoulder anchor from pillar.
6) Remove the rear quarter trim. <Ref. to El-47,

SB-11
REAR SEAT BELT
SEAT BELT SYSTEM
5. OUTER BELT CENTER (WAGON) 6. INNER BELT (WAGON)

1) Loosen the shoulder anchor bolt, and then de- 1) Remove the rear cushion.
tach the shoulder anchor from quarter pillar. 2) Remove the bolt, and then detach the inner belt.
0008 B5MO919
2) Remove the quarter trim. <Ref. to El-47, RE-

MOVAL, Rear Quarter Trim.>
3) Remove the three bolts, and then detach the out-
er belt center.
/ ' RE0009
SB-I 2
REAR SEAT BELT
SEAT BELT SYSTEM
1. OUTER BELT SIDE (SEDAN) 1. OUTER BELT SIDE (SEDAN)
Install in the reverse order of removal. Check for the following, and replace with new parts
CAUTION: if necessary.
During installation, make sure that the seat Seat belt is slackened, bent, or frayed. Seat belt
belts are not twisted. is abnormally wound or extended.
After installation, make sure that the seat 2. OUTER BELT CENTER (SEDAN)
belts can be smoothly extended and wound.
Check for the following, and replace with new parts
2. OUTER BELT CENTER (SEDAN) if necessary.
Install in the reverse order of removal. Seat belt is slackened, bent, or frayed. Seat belt
is abnormally wound or extended.
CAUTION:
During installation, make sure that the seat 3. INNER BELT (SEDAN)
belts are not twisted. Check for the following, and replace with new parts
After installation, make sure that the seat if necessary.
belts can be smoothly extended and wound. Inner belt is deformed or damaged.
3. INNER BELT (SEDAN) Seat belt buckle is engaged improperly.
Install in the reverse order of removal. 4. OUTER BELT SIDE (WAGON)
CAUTION: Check for the following, and replace with new parts
During installation, make sure that the seat if necessary.
belts are not twisted. Seat belt is slackened, bent, or frayed. Seat belt
is abnormally wound or extended.
4. OUTER BELT SIDE (WAGON)
5. OUTER BELT CENTER (WAGON)
CAUTION: Check for the following, and replace with new parts
During installation, make sure that the seat if necessary.
belts are not twisted. Seat belt is slackened, bent, or frayed. Seat belt
After installation, make sure that the seat is abnormally wound or extended.
belts can be smoothly extended and wound. 6. INNER BELT (WAGON)
5. OUTER BELT CENTER (WAGON) Check for the following, and replace with new parts
Install in the reverse order of removal. if necessary.
Inner belt is deformed or damaged.
CAUTION: Seat belt buckle is engaged improperly.
During installation, make sure that the seat
belts are not twisted.
After installation, make sure that the seat
belts are smoothly extended and wound.
6. INNER BELT (WAGON)
CAUTION:
During installation, make sure that the seat
belts are not twisted.
SB-13
REAR SEAT BELT
SEAT BELT SYSTEM
SB-14
LIGHTING SYSTEM
Page
2. Headlight and Tail Light System ................................................................. 3
3. Front Fog Light System ............................................................................... 4
4. Turn Signal and Hazard Light System ........................................................ 5
5. Back-up Light System ................................................................................. 6
6. Stop Light System ....................................................................................... 7
7. Interior Light System ................................................................................... 8
8. Combination Switch (Light) ......................................................................... 9
9. Headlight Assembly .................................................................................. 10
10. Headlight Bulb ........................................................................................... 12
11. Front Turn Signal Light Bulb ..................................................................... 13
12. Clearance/Parking Light Bulb.................................................................... 14
13. Front Fog Light Assembly ......................................................................... 15
14. Front Fog Light Bulb.................................................................................. 16
15. Front Side Marker Light Assembly ............................................................ 17
16. Rear Combination Light Assembly ............................................................ 18
17. Stopnail Light Bulb ................................................................................... 19
18. Back-up Light Bulb .................................................................................... 20
19. Rear Turn Signal Light Bulb ...................................................................... 21
20. Rear Side Marker Light Bulb ..................................................................... 22
21. License Plate Light .................................................................................... 23
22 . High-mounted Stop Light .......................................................................... 24
23. Spot Light .................................................................................................. 25
24. Room Light ................................................................................................ 26
25. Luggage Room Light ................................................................................. 27
26 . Trunk Room Light...................................................................................... 28
27. Glove Box Light ......................................................................................... 29
F
GENERAL DESCRIPTION
LIGHTING SYSTEM
A: SPECIFICATIONS
Headliaht 12 V - 55 W/65 W (Haloaen)
Front turn signal light 12v-21 w
Side marker light 12V-5W
Parking light 12V-5W
Front fog light 12 V - 55 W (Halogen)
I Tail/Stou liaht 12v-21 w / 5 w
I Tail liqht I 12v-21 wT5w 1
Sedan I Stop light I 12v-21 w I
1 Turn signal light I 12v-21 w I
Rear combination light Back-up light 12v-21 w
Tail/Stop light 12v-21 w / 5 w
Turn signal light 12v-21 w
Wagon
Back-uD liaht 12v-21 w
I Side marker liqht I 12V-5W I
License plate light I 12V-5W I
Sedan 12v-21 w
High-mounted stop light
I
Waaon
d
12V-13W
Room light 12V-8W
. liaht
Suot " 12V-8W
Luggage room light 12V-13W
Trunk room light 12V-5W
Glove box light 12V-1.4W
B: PRECAUTIONS After reassembly, make sure functional parts op-

Before disassembling or reassembling parts, al- erate smoothly.
ways disconnect the battery ground cable. When WARNING:
replacing the radio, control module, and other parts The air bag system wiring harness is routed
provided with memory functions, record the memo- near electrical parts and switches. All air bag
ry contents before disconnecting the battery system wiring harnesses and connectors are
ground cable. Otherwise, the memory will be yellow. Do not use an electric test equipment
erased. on these circuits.
Reassemble in reverse order of disassembly, un- Be careful not to damage the air bag system
less otherwise indicated. wiring harness when servicing electrical parts
Adjust parts to the given specifications. and switches.
Connect the connectors and hoses securely dur-
ing reassembly.
C: PREPARATION TOOL
1. GENERAL TOOLS
TOOL NAME REMARKS
Circuit Tester Used for measuring resistance and voltage.
I
i
LI-2
HEADLIGHT AND TAIL LIGHT SYSTEM
LIGHTING SYSTEM
-
2. Headlight and Tail Light Sys- 2. TAIL AND ILLUMINATION RELAY
tem Measure the tail and illumination relay resistance
between terminals when connectina terminal No. 4
A: SCHEMATIC to battery positive terminal and teyminal No. 3 to
battery ground terminal.
1. HEADLIGHT
<Ref. to WI-98, SCHEMATIC, Headlight System.>
2. CLEARANCE LIGHT AND ILLUMINA-
TION LIGHT
<Ref. to WI-94, SCHEMATIC, Clearance Light and
Illumination Light System.>
6 : INSPECTION
1. HEADLIGHT RELAY B0030f
Measure the headlight relay resistance between
terminals when connecting terminal No. 4 to battery Current I Terminal No. 1 Standard I
positive terminal and terminal No. 3 to battery Flow Less than 1Q
ground terminal. 1 and 2
No flow More than 1MQ
800308
Current Terminal No. Standard

Flow Less than 1R
1 and2
No flow More than 1MR
LI-3
FRONT FOG LIGHT SYSTEM
LIGHTING SYSTEM
3. Front Fog Light System

A: SCHEMATIC
1. FRONT FOG LIGHT
<Ref. to WI-97, SCHEMATIC, Front Fog Light Sys-
tem.>
B: INSPECTION
1. FRONT FOG LIGHT SWITCH
Measure the front fog light switch resistance.
I
I * B6M1482
I Switch position I Terminal No. I Standard I
2. FRONT FOG LIGHT RELAY

Measure the front fog light relay resistance be-
tween terminals when connectinq terminal No. 4 to
battery positive terminal and terminal No. 3 to bat-
tery ground terminal.
B0030e

Flow Less than la
1 and 2
No flow More than 1 MR
I I I I
LI-4
TURN SIGNAL AND HAZARD LIGHT SYSTEM
LIGHTING SYSTEM
4. Turn Signal and Hazard Light

System
A: SCHEMATIC
1. TURN SIGNAL LIGHT AND HAZARD
LIGHT
<Ref. to WI-104, SCHEMATIC, Turn Signal Light
and Hazard Light System.>
B: INSPECTION
1. TURN SIGNAL SWITCH
<Ref. to LI-9, INSPECTION, Combination Switch
(Light).>
2. HAZARD SWITCH
Measure the hazard switch resistance.
0 7 6 5
B6M1 483
OFF 6 and 7 I Less than 1!2

1,3and4 Less than If2
ON
7 and 8 Less than IC2
3. TURN SIGNAL & HAZARD MODULE

Connect the battery and turn signal light bulb to the
module, as shown in the figure. The module is
properly functioning if it blinks when power is sup-
plied to the circuit.
LI-5
BACK-UP LIGHT SYSTEM
LIGHTING SYSTEM
5. Back-up Light System 2. INHIBITOR SWITCH (A/T)

Measure the inhibitor switch resistance.
A: SCHEMATIC
1. BACK-UP LIGHT
<Ref. to WI-93, SCHEMATIC, Back-up Light Sys-
tem.>
B: INSPECTION
F
rmj
1. BACK-UP LIGHT SWITCH (M/T)
Measure the back-up light switch resistance.
I Switch Dosition I Terminal No. I Standard I

I When select lever I I I
I is set in “R” posi-
tion I 1 and2 I Less than 1 0
I
Other positions More than 1MSL
BO0344
(A) Non-turbo model

(B) Turbo model
Switch position Terminal No. Standard

When shift lever is Turbo model:
I set in reverse
position
Other Dositions
I 2 and 4
Non-t,urb;drydel:
Less than In
LI-6
STOP LIGHT SYSTEM
LIGHTING SYSTEM
6. Stop Light System

A: SCHEMATIC
1. STOP LIGHT
<Ref. to WI-103, SCHEMATIC, Stop Light Sys-
tem.>
B: INSPECTION
1. STOP LIGHT SWITCH
Measure the stop light switch resistance.
Without cruise control
With cruise control
B6M1486A
Switch position I Terminal No. I Standard

I I
When brake pedal I and 2: Without 1 Less than ,* I
is deDressed
IWhenbrabpedalI
is released
cruise
-. -. - - control
2and3:With
-- .-
cruise control
7
1 More than 1 M n
L1-7
INTERIOR LIGHT SYSTEM
LIGHTING SYSTEM
7. Interior Light System

A: SCHEMATIC
1. INTERIOR LIGHT
<Ref. to WI-101, SCHEMATIC, In Compartment
Light System.>
B: INSPECTION
1. DOOR SWITCH
Measure the door switch resistance.
000157
[- Switch position I Terminal No. I Standard

When door is
Less than l R
1 and3
More than 1MR
closed
2. REAR GATE LATCH SWITCH

Measure the rear gate latch switch resistance.
I I I I
kl
Switch Dosition Terminal No. Standard
When rear gate is
Less than 1R
When rear gate is land2
More than 1Mn
3. TRUNK ROOM LIGHT SWITCH

Measure the trunk room light switch resistance.
I Switch Dosition I Terminal No. I Standard 1
When trunk lid is
Less than In
opened
1 and2
When trunk lid is
More than 1Mi2
closed
LI-8
COMBINATION SWITCH (LIGHT)
-
LIGHTING SYSTEM
8. Combination Switch (Light) C: INSPECTION

Measure the combination switch resistance.
A: REMOVAL
1) Remove the instrument panel lower cover. <Ref.
to El-42, REMOVAL, Instrument Panel Assembly.>
2) Remove the screws which secure upper column
cover to lower column cover.
1-r 17 16 1514131211 10 9
06M1184 Lighting and turn signal switch connector
3) Disconnect the connector from combination
switch.
4) Remove the screws which secure switch and re-
move the siitch. Parking switch connector
06M1488A
1. LIGHTING SWITCH
I Switch position I Terminal No. I Standard
I OFF I - I More than 1MR I
Tail 14 and 16 I Less than 1R
2. DIMMER AND PASSING SWITCH

B: INSTALLATION m w i t c h position I Terminal No. I Standard I
Install in the reverse order of removal. Passing 7,8and 16 Less than IR
Low beam 16 and 17 Less than 1R
High beam 7 and 16 Less than 1R

1 and 2 Less than 1R
Neutral More than 1MR
Right 2 and 3 Less than 1R
4. PARKING SWITCH
OFF 2 and 4 Less than 1R
ON 1 and 4 Less than I R
LI-9
HEADLIGHT ASSEMBLY
LIGHTING SYSTEM
9. Headlight Assembly B: INSTALLATION

A: REMOVAL
1) Disconnect the ground terminal from battery. C: ADJUSTMENT
2) Remove the duct (A) (when right side headlight 1. HEADLIGHT AIMING
is removed).
NOTE:
As this headlignt is the “VISUAL AIMING TYPE”, it
is possible to adjust aiming only in the vertical di-
rection. It cannot be adjusted in the horizontal di-
rection.
CAUTION:
Turn off the light before adjusting headlight
aiming. If the light is necessary to check aim-
ing, do not turn on for more than two minutes.
NOTE:
Before checking the headlight aiming, be sure of
3) Remove the front grille and headlight side cover. the following:
<Ref. to El-18, REMOVAL, Front Grille.> and <Ref. The area around the headlight has not sustained
to El-23, REMOVAL, Front Bumper.> any accident, damage or other type of deformation.
4) Disconnect the headlight bulb connector. Vehicle is parked on level ground.
The inflation pressure of tires is correct.
Vehicle’s fuel tank is fully filled.
Bounce the vehicle several times to normalize
the suspension.
Make certain that someone is seated in the driv-
er’s seat.
Turn the headlight on and then adjust the low beam
pattern to the following positions on the screen.
NOTE:
Adjust the headlight aiming by turning the adjusting
screw (A).
5) Remove three bolts and disconnect the connec-
tors, and then detach the headlight assembly.
LI-I 0
HEADLIGHT ASSEMBLY
LIGHTING SYSTEM
Bulb center marking

H
t- 3 m (10 ft)
BOO400
H mm (in)
Sedan Wagon h mm (in) at 3 m (10 ft)
RS, WRX TS, WRX Outback
620 (24.41) 620 (24.41) 630 (24.80) 21 (0.83)
LI-I 1
HEADLIGHT BULB
LIGHTING SYSTEM
1O.Headlight Bulb B: INSTALLATION

A: REMOVAL
C: INSPECTION
CAUTION:
1) Visually check the bulb for blow out.
Because the tungsten halogen bulb operates
2) Check the bulb specification. <Ref. to LI-2,
at a high temperature, dirt and oil on the bulb
SPECIFICATIONS, General Description.>
surface reduces the bulb's service life. Hold the
flange portion when replacing the bulb. Never 3) If NG, replace the bulb with a new one.
touch the glass portion.
Do not leave the headlight without a bulb for
a long time. Dust, moisture, etc. entering the
headlight may affect its the performance.
2) Remove the duct (A) (when right side headlight
is removed).
3) Disconnect the harness connector.

4) Remove the cap (A).
5 ) Remove the headlight bulb (A).
LI-I2
FRONT TURN SIGNAL LIGHT BULB
LIGHTING SYSTEM
-
11.Front Turn Signal Light Bulb
A: REMOVAL
1) Remove the headlight assembly. <Ref. to LI-10,
REMOVAL, Headlight Assembly.>
2) Turn the socket (A) and remove the bulb.
u BO0031
B: INSTALLATION
C: INSPECTION
1) Visually’check the bulb for blow out.
3) If NG, replace the bulb with a new one.
LI-I 3
CLEARANCE/PARKlNG LIGHT BULB
LIGHTING SYSTEM
12.Clearance/Parking Light Bulb

A: REMOVAL
1) Remove the headlight assembly. <Ref. to LI-10,
REMOVAL, Headlight Assembly.>
2) Turn the socket (A) and remove the bulb.
I BOO032
B: INSTALLATION
C: INSPECTION
LI-I 4
FRONT FOG LIGHT ASSEMBLY
LIGHTING SYSTEM
13.Front Fog Light Assembly

A: REMOVAL
2) Remove the mounting bolts, and then detach the
fog light assembly.

B: INSTALLATION
LI-15
FRONT FOG LIGHT BULB
LIGHTING SYSTEM
14.Front Fog Light Bulb

A: REMOVAL
1) Remove the front fog light assembly. <Ref. to LI-
15, REMOVAL, Front Fog Light Assembly.>
2) Remove the back cover.
3) Remove the spring retainer then detach the fog

light bulb.
6: INSTALLATION
Install inthe reverse order of removal.
C: INSPECTION
LI-I 6
FRONT SIDE MARKER LIGHT ASSEMBLY
LIGHTING SYSTEM
15.Front Side Marker Light As-

sembly
A: REMOVAL
2) Pull out the light from body while pushing it up.
3) Disconnect the harness connector and remove

the light.
4) Turn the socket and remove the bulb.
I B003X
B: INSTALLATION
C: INSPECTION
3)If NG,replace the bulb with a new one.
LI-I 7
REAR COMBINATION LIGHT ASSEMBLY
-
LIGHTING SYSTEM
16.Rear Combination Light As- 3) Remove two bolts.

sembly
A: REMOVAL
1. SEDAN
2) Remove the clips and then detach the trunk rear
trim.
4) Remove the rear quarter trim.

<Ref. to El-47, WAGON, REMOVAL, Rear Quarter
Trim.>
5) Disconnect the connector and then detach the
rear combination light assembly.
BOO0
3) Remove the trunk side trim of rear portion.

4) Remove four nuts and then detach the rear com-
bination light while disconnecting the connector.
B: INSTALLATION
2. WAGON
2) Remove the clips and then detach the rear com-
bination light covers.
LI-I 8
STOP/TAIL LIGHT BULB
LIGHTING SYSTEM
17.StoplTaiI Light Bulb

A: REMOVAL
1. SEDAN
I H
-
(C) BOO351
(A) Stop light

(B) Tail light
(C) ‘TaiVstop lignt
2. WAGON
1) Remove the rear combination light assembly.
<Ref. to LI-18, WAGON, REMOVAL, Rear Combi-
nation Light Assembly.>
I
B: INSTALLATION
C: INSPECTION
LI-I 9
BACK-UP LIGHT BULB
LIGHTING SYSTEM
18.Back-up Light Bulb

A: REMOVAL
1. SEDAN
2. WAGON
B: INSTALLATION
C: INSPECTION
LI-20
REAR TURN SIGNAL LIGHT BULB
LIGHTING SYSTEM
19.Rear Turn Signal Light Bulb

A: REMOVAL
1. SEDAN
042
2. WAGON
<Ref. to Ll-18, WAGON, REMOVAL, Rear Combi-
9: INSTALLATION
C: INSPECTION
LI-21
REAR SIDE MARKER LIGHT BULB
LIGHTING SYSTEM
20.Rear Side Marker Light Bulb

A: REMOVAL
B: INSTALLATION
C: INSPECTION
LI-22
LICENSE PLATE LIGHT
LIGHTING SYSTEM
21 .License Plate Light

A: REMOVAL
2) Remove the license plate light mounting screw
(A) and then remove the lens (B)
BOO122 I
3) Remove the bulb.
B: INSTALLATION
c: INSPECTION
LI-23
HIGH-MOUNTED STOP LIGHT
LIGHTING SYSTEM
22.High-mounted Stop Light

A: REMOVAL
1. SEDAN
2) Disconnect the connector of high-mounted stop
light from body harness.
3) Remove the bolts, then detach the high-mounted
stop light assembly.
2. WAGON
2) Remove the screws (A) and then detach the cov-
er (B).
3) Remove the screws (C) and then detach the
high-mounted stop light while disconnecting the
connector.
I
I BO0401
B: INSTALLATION
C: INSPECTION
LI-24
i_
SPOT LIGHT
LIGHTING SYSTEM
23.Spot Light
A: REMOVAL
2) Remove the lens (A) and spot light mounting
screw (B).
I BOO046
ON 1 and 2 *
1.5 0.58
LI-25
ROOM LIGHT
LIGHTING SYSTEM
24.Room Light
A: REMOVAL
2) Remove the lens (A) and room light mounting
screws (6).
B)
B6M1479P
3) Disconnect the harness connectors and remove

the light.
B: INSTALLATION
C: INSPECTION
1. ROOM LIGHT BULB
2 ) Check the bulb specification. <Ref. to LI-2,
2. ROOM LIGHT SWITCH
Measure the room light resistance.
(fig)
B6M1489A

OFF - More than 1MR
ON 1 and 3 1.5 f 0.5R
I DOOR I 1 and2 I 1.5f0.5R I
LI-26
LUGGAGE ROOM LIGHT
LIGHTING SYSTEM
25.Luggage Room Light 2. LUGGAGE ROOM LIGHT SWITCH

Measure the luggage room light resistance.
A: REMOVAL
2) Remove the lens (A)and luggage room light
mounting screws (B).

More than 1MQ
1 and3 1.5 f 0.5R
DOOR 1 and2 1.5 k 0.5Q

the luggage room light.
B: INSTALLATION
C: INSPECTION
1. LUGGAGE ROOM LIGHT BULB
LI-27
TRUNK ROOM LIGHT
LIGHTING SYSTEM
26.Trunk Room Light

A: REMOVAL
the trunk room light.
B: INSTALLATION
C: INSPECTION
LI-28
GLOVE BOX LIGHT
LIGHTING SYSTEM
27.Glove Box Light

A: REMOVAL
AL, Glove Box.>
4) Remove the glove box light.
I\ / 800040
B: INSTALLATION
C: INSPECTION
LI-29
GLOVE BOX LIGHT
LIGHTING SYSTEM
LI-30
.
WIPER AND WASHER SYSTEMS
ww Page
2. Wiper and Washer System ......................................................................... 5
3. Combination Switch (Wiper)........................................................................ 7
4. Wiper Blade................................................................................................. 9
5. Washer Tank and Motor............................................................................ 11
6. Front Wiper Arm ........................................................................................ 12
7. Front Wiper Motor and Link....................................................................... 13
8. Front Washer Nozzle ................................................................................ 15
9. Rear Wiper Arm ........................................................................................ 16
10. Rear Wiper Motor...................................................................................... 17
11. Rear Washer Nozzle ................................................................................. 18
12. Wiper Control Relay .................................................................................. 19
GENERAL DESCRIPTION
A: SPECIFICATIONS
Front wiper motor [ Input 12 V-72 W or less
Rear wiDer motor I Input 12 V - 42 W or less
1 Front washer motor

Pump type
lnout
Centrifugal
12 V - 36 W or less
I I PumDtvDe I Centrifuaal I
I Rear washer motor
B: COMPONENT
1. FRONT WIPER
. .
BOO272
(1) Wiper rubber (4) Wiper link Tightening torque: N.m (kgf-m, ft-lb)
(2) Wiper blade ASSY (5) Wiper motor T1: 6.0 (0.61, 4.4)
(3) Wiper arm T2: 20 (2.0, 14.5)
ww-2
GENERAL DESCRIPTION
2. REARWIPER
(1) Wiper rubber (7) SpacerB Tightening toque: N.m (kgf-myft-lb)

(2) Wiper blade ASSY (8) Nut T1: 6.0 (0.61, 4.4)
(3) Wiper arm (9) Cap T2: 7.5 (0.76, 5.5)
(4) Wiper motor (10 ) Wiper arm cover T3: 8.0 (0.82, 5.9)
(5) SpacerA
(6) Cushion
ww-3
GENERAL DESCRIPTION
3. WASHER TANK
BOO295
(1) Washer nozzle (5) Front washer motor Tightening torque: N-m (kgf-m, ft-lb)
(2) Washer hose (6) Rear washer motor T: 6.0 (0.61, 4.4)
(3) Washer tank (7) Grommet
(4) Washer tank cap
C: CAUTION
Reconnect the connectors and hoses securely.
After reconnecting, confirm that each function operates normally.
Be careful that the wire harnesses of airbag system pass near electrical parts and switches.
Care must be taken when installing the piping hose so that no bending, jamming, etc. are caused.
If even a little oil or grease such as silicon oil gets in the tank and washer passages, an oil film easily forms
on the glass, causing the wiper to chatter and judder. Therefore, be careful not to let this happen.
ww-4
WIPER AND WASHER SYSTEM
2. Wiper and Washer System

A: SCHEMATIC
1. WIPER AND WASHER (FRONT)
<Ref. to WI-127, SCHEMATIC, Wiper and Washer
System (Front).>
2. WIPER AND WASHER (REAR)
<Ref. to WI-128, SCHEMATIC, Wiper and Washer
System (Rear).>
ww-5
WIPER AND WASHER SYSTEM
B: INSPECTION
Svmotom Repair order
Wiper and washers do not operate. (1) Wiper fuse (FIB No. 14, 15)
(2) Combination switch
(3) Wiper motor
(4) Wire harness
Wipers do not operate in LO or HI. (1) Combination switch
(2) Wiper motor
(3) Wire harness
Wipers do not operate in INT. (1) Combination switch
(2) Wiper motor
(3) Wire harness
Washer motor does not operate. (1) Washer switch
(2) Washer motor
(3) Wire harness
Wipers do not operate when washer switch is ON. (1) Washer motor
(2) Wire harness
Washer fluid sprav does not operate. (11 Washer hose and nozzle
WW-6
COMBINATION SWITCH (WIPER)
3. Combination Switch (Wiper) C: INSPECTION

Measure the combination switch.
A: REMOVAL
1) Loosen the screw to remove a steering column
I B6M1184
2) Disconnect the connectors from combination

switches.
3) Loosen the screw to remove combination switch.
S6M0137
OFF I 7and16 I less than 1R

I INT I 7and16 I lessthan 1R
FRONT I LO I 7and17 I lessthan 1R
8 and 17 less than 1R
B: INSTALLATION
Install in the reverse order of removal. 2 and 10
Washer ON 2 and 12 less than 1R
10 and 12
I
more than 1MR
2 and 10 less than 1R
2 and 10
Washer ON 2 and 12 less than 1R
REAR 10 and 12
If continuity is not as specified, replace the switch.
ww-7
COMBINATION SWITCH (WIPER)
Intermittent operation inspection

1) Turn the wiper switch to INT.
2) Adjust the intermittent control switch to MAX.
3) Apply battery voltage to switch terminals 16 and 2, and inspect the voltage of terminals 7 and 2. (Measure
the voltage from after the second time the wiper stops.)
Switch position Voltage
I I
ov
12v T11*5 sec.
Non variable type

1o2vv T3 i 1 sec.
B6M1465A I
If operation is not as specified, replace the switch.
WW-8
WIPER BLADE
4. Wiper Blade D: ASSEMBLY

A: REMOVAL 1. METALTYPE
While pushing the locking clip (A) up, pull out the 1) Insert the wiper rubber onto the blade so that the
blade from arm to arrow direction. stopper is in the position shown.
I B6M1497
B: INSTALLATION 2) Make sure the wiper rubber is securely fastened

1) Install in the reverse order of removal. to the pull stopper (A).
2) Confirm that the clip is locked securely.
c: DISASSEMBLY
1. METALTYPE
Pull on side (A) of the wiper rubber stopper and re-
move the rubber from the blade assembly.
I
I I B6M1498A
I -I I
B6M1496A
2. RESINTYPE
Pull the wiper rubber top slightly from the stopper
and pull out fully.
I I
BOO196
ww-9
b
WIPER BLADE
2. RESINTYPE
B C
BOOl97
1) Insert the wiper rubber through the claw (B). 3) Insert the wiper rubber into the claw (A).
A N . \
2) Insert the wiper rubber top until it protrudes E: INSPECTION

about 20" (0.79 in) from the stopper (D). 1) When the wiper does not perform well, inspect
the following:
Make sure the movable part of the blade assem-
20mm ( 0.79in. ) bly moves smoothly.
Make sure the wiper rubber is not deformed or
damaged.
2) Replace with a new part if damage is found.
BOOl 95
ww-10
WASHER TANK AND MOTOR
5. Washer Tank and Motor D: ASSEMBLY

1) Assemble in the reverse order of disassembly.
A: REMOVAL 2) Confirm that water does not leak from installation
1) Open the hood. area of motor.
3) Remove the two bolts, hose and connector and E: INSPECTION
then remove the tank. Apply battery voltage to the connector terminal of
the washer motor and make sure the motor oper-
ates.
I464
-
W
B: INSTALLATION B6M1567
C: DISASSEMBLY
Pull out the washer motor from tank.
ww-11
FRONT WIPER ARM
6. Front Wiper Arm C: ADJUSTMENT

Operate the wiper once. Align the wiper blade to
A: REMOVAL ceramic print point mark (A) of front window pane.
1) Open the hood.
2) Remove the cap.
3) Loosen the nut to remove arm.
B6M 1193L
B: INSTALLATION
2) Operate the wiper once.
3) Align-the wiper blade to ceramic print point mark
(A) of front window pane.
I B6M1193A
ww-12
FRONT WIPER MOTOR AND LINK
7. Front Wiper Motor and Link C: INSPECTION

1) When the battery is connected to the terminal of
A: REMOVAL connectors, confirm that motor operates at low
1) Disconnect the ground terminal from battery. speed.
2) Remove the cowl panel. <Ref. to El-33, RE-
MOVAL, Cowl Panel.>
3) Disconnect the connector of motor.
4) Loosen the bolts and nuts to remove wiper link.
I 60020'
2) When the battery is connected to the terminal of

connectors, confirm that motor operates at high
speed.
5 ) Loosen the bolts and nuts to remove motor.
BO0202
3) Connect the battery to terminals of connector,

I B5M1467 I and remove the terminal connection with motor ro-
B: INSTALLATION tated at low speed, and stop the wiper motor
1) Connect the battery ground terminal to battery. through operation.
2) To confirm that the motor is at auto stop position,
connect the harness to motor and turn the wiper
switch ON/OFF once.
4) Tighten the nut where rod (A) and link plate (B) is
aligned in a straight line.
80020:
5 ) Install in the reverse order of removal.
ww-13
FRONT WIPER MOTOR AND LINK
4) Connect the battery and confirm that the motor

stops at automatic stop position after the motor op-
erates at low speed again.
BOO204
ww-14
FRONT WASHER NOZZLE
8. Front Washer Nozzle B: INSTALLATION

A: REMOVAL 2) Adjust the position of the washer liquid sprayer.
1) Remove the washer hose from the washer noz- <Ref. to WW-15, ADJUSTMENT, Front Washer
zle. Nozzle.>
2) Open the clips on the underside of the hood with
a thin screwdriver or other tool, and remove the C: INSPECTION
washer nozzle. Make sure the nozzle and hose are not clogged.
Make sure the hose is not bent.
D: ADJUSTMENT
-
I I
1) Turn the wiper switch to OFF position.
2) When the vehicle stops, adjust the washer injec-
tion position as shown in the figure.
lnjection position:
A: 257 mm (10.12 in)
B: 512 mm (20.16 in)
B6M1505
BO0362
ww-15
REAR WIPER ARM
9. Rear Wiper Arm

A: REMOVAL
1) Raise the wiper arm cover (A).
2) Loosen the nut to remove wiper arm.
I B6M1201A
B: INSTALLATION
2) Operate the rear wiper once.
3) Align the blade to rear defogger heat wire (A).
‘ \I
\\
F
BOO206
C: ADJUSTMENT
1) Operate the rear wiper once.
2) Align the blade to rear defogger heat wire (A).
WW-16
REAR WIPER MOTOR
10.Rear Wiper Motor C: INSPECTION

1) Connect the battery to wiper motor connector
A: REMOVAL and confirm that wiper motor operates.
2) Remove the rear wiper arm.
3) Remove the cap (A), nut (B), and spacer (C)
from rear wiper shaft.
S6M0072
2) Connect the battery to terminal of connector and

remove the terminal connections with motor rotat-
ed, and stop the wiper motor through operation.
06M12021
4) Remove the rear gate lower trim. <Ref. to El-52,

REMOVAL, Rear Gate Trim.>
5) Unclip we clip of harness and disconnect con-
nector of wiper motor.
6) Loosen the bolts to remove wiper motor assem-
bly (A).
S6M0073
3) Connect the battery and confirm that the motor

stops at automatic stop position after the motor op-
erates at low speed again.
I
B: INSTALLATION
2) Installthe rear wiper cushion with the arrow mark
facing up, as shown in the figure.
I 05M1463
ww-17
REAR WASHER NOZZLE
11.Rear Washer Nozzle B: INSTALLATION

A: REMOVAL 2) Adjust the position of the washer liquid sprayer.
1) Remove the high-mount stop light. <Ref. to LI- <Ref. to WW-18, ADJUSTMENT, Rear Washer
24, REMOVAL, High-mounted Stop Light.> Nozzle.>
2) Remove the washer hose from the washer noz-
zle. C: INSPECTION
3) Open the clips on the underside of the hood with Make sure the nozzle and hose are not clogged.
a thin screwdriver or other tool, and remove the Make sure the hose is not bent.
washer nozzle.
D: ADJUSTMENT
1) Turn the wiper switch to OFF position.
2) When the vehicle stops, adjust the washer injec-
tion position as shown in the figure.
Injection position:
A: 39 mm (1.54 in)
B: 72"
B6M1200(
ww-I a
WIPER CONTROL RELAY
12.Wiper Control Relay

A: REMOVAL
Remove the right quarter lower trim. <Ref. to El-47,
2) Loosen the nut to remove control unit.
B: INSTALLATION
C: INSPECTION
1) Disconnect the connector from the wiper control
relay.
2) Connect the positive (+) lead from the battery to
terminal 8 and the negative (-) lead to terminal 6.
Connect the positive (+) lead from the voltmeter to
terminal 3 and negative lead to ground.
U BO0276
3) Measure the voltage when the wiper relay is op-

erated.
Switch position Voltage
B6M1523,
If operation is not as specified, replace the switch.
ww-19
WIPER CONTROL RELAY
ww-20
.
ENTERTAINMENT
Page
2. Radio System .............................................................................................. 3
3. Cigarette Lighter System............................................................................. 5
4. Radio Body.................................................................................................. 6
5. Front Speaker ............................................................................................. 7
6. Tweeter ....................................................................................................... 8
7. Rear Speaker .............................................................................................. 9
8. Antenna ..................................................................................................... 10
9. Cigarette Lighter........................................................................................ 11
GENERAL DESCRIPTION
ENTERTAINMENT
A: CAUTION
Before disassembling or reassembling parts, al-
ways disconnect the battery ground cable. When
replacing radio, control module, and other parts
provided with memory functions, record memory
contents before disconnecting the battery ground
cable. Otherwise, the memory will be erased.
Reassemble in reverse order of disassembly, un-
less otherwise indicated.
Adjust the parts to the given specifications.
ing reassembly.
After reassembly, make sure functional parts op-
erate smoothly.
B: PREPARATION TOOL
1. GENERAL TOOLS
I TOOL NAME I REMARKS 1
Circuit Tester Used for measuring resis-
tance and voltage.
ET-2
RADIO SYSTEM
ENTERTAINMENT
~~~ ~ ~~~
2. Radio System
A: SCHEMATIC
1. RADIO
<Ref. to WI-52, SCHEMATIC, Audio System.>
ET-3
-
RADIO SYSTEM
ENTERTAINMENT
B: INSPECTION
Symptom Repair order
No power coming in (No display and no sound from speakers) (1) Check fuse and power supply for radio.
(2) Check radio ground.
(3) Remove radio for repair.
A specific speaker does not operate. (1) Check speaker.
(2) Check output circuit between radio and speaker.
Radio generates noise with engine running (1) Check radio ground.
(2) Check generator.
(3) Check ignition coil.
AM and FM modes are weak or noisy (1) Check antenna.
(2) Check radio ground.
ET-4
B
CIGARETTE LIGHTER SYSTEM

ENTERTAl NM ENT
3. Cigarette Lighter System

A: SCHEMATIC
1. CIGARETTE LIGHTER
<Ref. to WI-88, SCHEMATIC, Front Accessory
Power Supply System.>
ET-5
RADIO BODY
ENTERTAINMENT
4. Radio Body
A: REMOVAL
2) Remove the center panel while disconnecting
connector.
\
0 : Hook pawl
3) Remove the fitting screws, and slightly pull radio
out from the center console.
4) Disconnect the electric connectors and antenna

feeder cord.
B: INSTALLATION
ET-6
FRONT SPEAKER
ENTERTAINMENT
5. Front Speaker
A: REMOVAL
2) Remove the front door trim. <Ref. to El-37, RE-
MOVAL, Front Door Trim.>
3) Remove the front speaker mounting screws.
600019

the front speaker.
B: INSTALLATION
ET-7
TWEETER
ENTERTAINMENT
6. Tweeter
A: REMOVAL
2 ) Remove the front door trim. <Ref. to El-37, RE-
3) Remove the tweeter mounting screws.

the tweeter.
B: INSTALLATION
ET-8
REAR SPEAKER
ENTERTAINMENT
7. Rear Speaker
A: REMOVAL
2) Remove the rear door trim. <Ref. to El-38, RE-
MOVAL, Rear Door Trim.>
3) Remove the rear speaker mounting screws.
S6M05

the rear speaker.
B: INSTALLATION
ET-9
ANTENNA
ENTERTAINMENT
8. Antenna
A: REMOVAL
1) Remove the mounting screws and detach anten-
na.
B: INSTALLATION
ET-10
CIGARETTE LIGHTER
ENTERTAINMENT
9. Cigarette Lighter
A: REMOVAL
2) Remove the center panel. <Ref. to ET-6, RE-
MOVAL, Radio Body.>
the cigarette lighter.
BO0023
B: INSTALLATION
ET-11
CIGARETTE LIGHTER
ENTERTAINMENT
ET-I 2
COMMUNICATION SYSTEM
COM
Page
2. Horn System ............................................................................................... 3
3. Horn ............................................................................................................ 4
4. Horn Switch ................................................................................................. 5
GENERAL DESCRIPTION
A: PREPARATION TOOL
1. GENERAL TOOLS
TOOL REMARKS
NAME
Circuit Used for measuring resistance and voltage.
Tester
COM-2
HORN SYSTEM
2. Horn System
A: SCHEMATIC
1. HORN
<Ref. to WI-89, SCHEMATIC, Horn System.>
B: INSPECTION
1. HORN RELAY
Measure the horn relay resistance between termi-
nals (indicated in table below) when connecting ter-
minal No. 4 to battery positive terminal and terminal
No. 3 to battery ground terminal.
I 800308
Flow Less than 1R

1 and2
No Flow More than 1MR
COM-3
HORN
COM MUNCATION SYSTEM
3. Horn
A: REMOVAL
2) Remove the horn bracket mounting bolt (A).
the horn assembly (B).
B: INSTALLATION
C: INSPECTION
With 12 V direct current supply between horn termi-
nal and case ground, check that the horn sounds
properly.
COM-4
HORN SWITCH
4. Horn Switch C: INSPECTION

Measure the horn switch resistance.
A: REMOVAL
WARNING:
Before servicing, be sure to read the notes in
the AB section for proper handling of the driver
airbag module. <Ref. to AB-3, CAUTION, Gen-
eral Description.>
2) Remove the driver's airbag module. <Ref. to
AB-12, Driver's Airbag Module.>
3) Remove the horn switch from the steering wheel B6M1493
as shown.
Switch position I Terminal No. 1 Resistance I
When horn switch
Less than 1R
is pushed.
When horn switch
More than 1 MR
is not Dushed.
B: INSTALLATION
COM-5
HORN SWITCH
COM-6
GLASSNVlNDOWS/MIRRORS
W
Page
2. Power Window System ............................................................................... 9
3. Rear Window Defogger System ................................................................ 11
4. Remote Control Mirror System.................................................................. 13
5. Front Door Glass ....................................................................................... 15
6. Front Regulator and Motor Assembly ....................................................... 19
7. Rear Door Glass ....................................................................................... 20
8. Rear Regulator and Motor Assembly ........................................................ 22
9. Windshield Glass ...................................................................................... 23
10. Rear Gate Glass ....................................................................................... 26
11. Rear Quarter Glass ................................................................................... 27
12. Rear Window Glass .................................................................................. 28
13. Inner Rearview Mirror................................................................................ 29
14. Power Window Control Switch .................................................................. 30
15. Rear Window Defogger ............................................................................. 32
16. Outer Mirror Assembly .............................................................................. 33
17. Outer Mirror............................................................................................... 35
18. Remote Control Mirror Switch ................................................................... 36
GENERAL DESCRIPTION
GLASSNVINDOWS/MIRRORS
A: COMPONENT
1. FIXED GLASS (SEDAN)
BO0391
(1) Windshield glass (4) Rearview mirror mount (7) Spring

(2) Dam rubber (5) Locate pin
(3) Molding (6) Rear window glass
GW-2
GENERAL DESCRIPTION
GLASSMI NDOWS/MIRRORS
2. FIXED GLASS (WAGON)
BOO392
(1) Windshield glass (4) Rearview mirror mount (7) Rear quarter glass
(2) Dam rubber (5) Locate pin (8) Locate pin
(3) Molding (6) Fastener (9) Glass
GW-3
GENERAL DESCRIPTION
GLASSNVINDOWS/MI RRORS
3. FRONT DOOR GLASS
(1) Glass (5) Motor ASSY Tightening torque: N.m (kgf-m, ft-lb)
(2) Door sash (Front) T1: 7.4 (0.75, 5.5)
(3) Door sash (Rear) T2: 13.7(1.4, 10.1)
(4) Regulator ASSY
GW-4
GENERAL DESCRIPTION
G LASSNVlNDOWS/MIR RO RS
4. REAR DOOR GLASS
(1) Glass (5) Motor ASSY Tightening torque: N-m (kgf-m, ft-lb)
(2) Door sash (Front) T1: 7.4 (0.75, 5.5)
(3) Door sash (Rear) T2: 13.7(1.4, 10.1)
(4) Regulator ASSY
GW-5
GENERAL DESCRIPTION
GLASSNVINDOWSIMIRRORS
5. MIRRORS
B O ~ E
(1) Outer mirror (3) Mount (5) Mirror

(2) Inner rearview mirror (4) Spring
GW-6
GENERAL DESCRIPTION
GLASSNVINDOWS/MI R RORS
B: CAUTION
When electrical connectors are disconnected, al-
ways conduct an operational check after connect-
ing them again.
Avoid impact and damage to the glass.
GW-7
GENERAL DESCRIPTION
C: PREPARATION TOOL
TOOL NAME REMARKS
Circuit Tester Used for checking voltage and continuity.
Piano Wire Used for window alass removal.
IWindshield Knife I Used for window glass removal. I
GW-8
POWER WINDOW SYSTEM
2. Power Window System

A: SCHEMATIC
<Ref. to WI-109, Power Window System.>
GW-9
POWER WINDOW SYSTEM
B: INSPECTION
(1) Fuse (SBFS)
(2) Power window circuit breaker
All power windows does not operate.
(3)Power window relay
I41 Wire harness
(1) Power window main switch
(2) Power window sub switch
One window does not operate.
(3) Power window motor
I41 Wire harness
“Window Lock does not operate. (11 Power window main switch
GW-10
REAR WINDOW DEFOGGER SYSTEM
3. Rear Window Defogger System

A: SCHEMATIC
I <Ref. to WI-117, Rear Window Defogger System.>
GW-11
REAR WINDOW DEFOGGER SYSTEM
B: INSPECTION
(1) Fuse (M/B No. 1) (F/B No. 11)
(2) Rear defogger relay
(3) Rear defogger timer
Rear window defogger does not operate. (4) Defogger switch
(5) Rear defogger condenser
(6) Deffogger wire
(7)Wire harness
GW-12
I
REMOTE CONTROL MIRROR SYSTEM
GLASSMIINDOWSIMIRRORS
4. Remote Control Mirror System

A: SCHEMATIC
<Ref. to WI-118, Remote Controlled Rearview Mir-
I
ror System.>
E
i
1
GW-13
I
REMOTE CONTROL MIRROR SYSTEM
B: INSPECTION
Symptom ReDair order
(1)Fuse (F/B No. 1) (F/B No. 4) (F/B No. 19)
All function does not operate. (2) Mirror switch
(3) Wire harness
(1) Mirror switch
One side of the mirror motor does not operate. (2) Mirror motor
(3) Wire harness
(1) Mirror switch
Mirror heater does not operate. (2) Mirror heater
(3) Wire harness
GW-14
FRONT DOOR GLASS
6) Remove the rear end of door weather strip and

5. Front Door Glass weather strip outer
A: REMOVAL
2) Remove the sealing cover. <Ref. to EB-14, RE-
MOVAL, Front Sealing Cover.>
3) Remove the outer mirror assembly. <Ref. to
GW-33, REMOVAL, Outer Mirror Assembly.>
4) Remove the gusset.
7) Operate the power window switch to move glass

to position shown in the figure, and then remove
the two nuts from the service holes.
8) Remove the door glass.
5 ) Remove the stabilizers and trim hooks.
B5M 1
- -7
CAUTION:
Do not turn regulator in the closing direction
after removal of the glass. Otherwise gear may
be disengaged.
BO0086
GW-15
FRONT DOOR GLASS
-
B: INSTALLATION
CAUTION:
Make sure that glass stay is placed securely in
sash.
2) Adjust the front door glass. <Ref. to GW-17, AD-
JUSTMENT, Front Door Glass.>
GW-16
FRONT DOOR GLASS
C: ADJUSTMENT 5) For adjustment of upper and lower ends of cen-

ter pillar, loosen the adjusting nut (A) of B-channel
NOTE:
(B).
Before adjustment, ensure that all adjusting bolts of
stabilizer, upper stopper, and sash are loose and
door glass is raised so that it is in contact with
weatherstrip.
1) Temporarily tighten one adjusting bolt on one
side of rear sash at the midpoint of slotted hole in
the inner panel.
2) Temporarily tighten the regulator 8-channel in a
position at the top of slotted hole.
3)Lower the door glass 10 to 15 mm (0.39to 0.59
in) from fully closed position. While applying out-
ward pressure of 45.0k4.9N (4.6k0.5kg, 1 1 .&l .1
' B5M0729A
Ib) (F) to upper edge of glass above midpoint of two 6)Adjust so that the upper and lower ends of center
outer stabilizers, press the inner stabilizer at pres- pillar are the same size.
sure of 1 Of5 N (1.0k0.5 kg, 0.2k0.1Ib) to the glass,
then secure it.
Full close
10 - 15 mm
(0.39 - 0.59 in)
,
u G5M0421
4) For adjustment of clearance between front glass

and center pillar cover, loosen the nuts (A), and
move the glass sash back and forward until clear-
,,(-TE Lower B channel
Glass tilts too

far forward
Wide
Narrow
ance becomes the value shown.
Raise B channel BOO389
7) For glass stroke adjustment, close door, raise

glass until positional relationship between glass
and weatherstrip becomes as shown. And secure
the glass so that the upper stopper lightly touches
-
the glass holder.
2-3
\ (0.079-0.118)
12 (0.472) 12 (0.472)
-7
A-A
Unit: mm (in)
800388
GW-17
FRONT DOOR GLASS
GLASSNVlNDOWS/M IRRORS
For preventing wind noise, adjust the glass at the 10) Make adjustment of front sash in the same
position where tip of gusset is raised up a little. manner as that of rear sash.
CAUTION:
Although front and rear sashes must, as a rule,
be adjusted in the same manner, in some door
installation, the adjustment in a different man-
ner may be required. However, adjustment of
one sash to the maximum amount and the other
to the minimum amount is not permitted. Such
adjustment may result in application of exces-
sive load to regulator.
11) After adjustments, tighten the nuts.
12) After adjustment of glass, if there is a gap be-
tween outer lip of gusset and glass surface, adjust
(A) 0-1.5 mm (0-0.059in)
the gap with adjusting bolt (A) in lower fitting part of
8) After stabilizer adjustment, carry out glass crimp gusset to prevent generation of wind noise.
adjustment. First, visually ensure positional rela- 13) During adjustments, loosen other three clamp-
tionship between retainer & molding and glass of ing bolts.
the roof side, and then begin with rear sash adjust-
ment. Adjust two adjusting bolts alternately step by
step to obtain dimensions shown below (cross-sec-
tion A).
NOTE:
If two nuts are loosened at the same time, the sash
moves back and forth. Therefore, when one nut is
adjusted, secure the other.
9) Make the same adjustment of two adjusting bolts
of rear sash.
I
2-3
\ (0.079-0.118)
Unit: mm (in)
BO0267
CAUTION:
Do not tilt sash bracket to inner panel during 14) After adjustment, tighten the bolts and nuts.
adjustment. Otherwise smooth regulator opera-
tion cannot be achieved.
GW-18
FRONT REGULATOR AND MOTOR ASSEMBLY
GLASSMI NDOWS/M IRRORS
6. Front Regulator and Motor B: INSTALLATION

Assembly 2) Adjust the front door glass. <Ref. to GW-17, AD-
A: REMOVAL JUSTMENT, Front Door Glass.>
1) Remove the door glass. <Ref. to GW-15, RE- C: INSPECTION
MOVAL, Front Door Glass.> 1) Make sure that the power window motor rotates
2) Loosen the nuts to remove the rear sash. properly when the battery voltage is applied to the
I terminals of motor connector.
2) Change the polarity of battery connectionsto ter-
minals to ensure that the motor rotates in reverse
direction.
00089 I
I
3) Disconnect the motor connector.

4) Loosen four bolts and two nuts to remove the
regulator assembly .
5) Loosen the screw to remove motor assembly.
800091
GW-19
REAR DOOR GLASS
7. Rear Door Glass 5 ) Loosen two screw to remove weather strip outer.
A: REMOVAL
MOVAL, Rear Sealing Cover.>
3) Remove the stabilizer.
I B5M1044
4) Remove the door weather strip.
\ /
BOO093
6) Operate the power window switch to remove

glass as shown in the figure, and remove two nuts.
7) Loosen two rear sash installation nuts, and move

the rear sash backward.
8) Remove the glass.
CAUTION:
\ BO0092
GW-20
B
REAR DOOR GLASS

~~
9: INSTALLATION After adjustment, move glass up and down to

1) Install in the reverse order of removal. check whether it is caught.
CAUTION:
Make sure that glass stay is placed securely in
sash.
2) Adjust rear door glass. <Ref. to GW-21, AD-
JUSTMENT, Rear Door Glass.>
C: ADJUSTMENT
NOTE:
The rear door glass, as a rule, should be adjusted
in the same manner as front glass, although they
are different in dimension. Special notes for rear
glass are given below.
1) Adjust the glass position using the following di-
mensions as a guide line.
12 (0.472) 12 (0.472)
A-A
Unit: mm (in)
BOO394
CAUTION:
If dimensions are smaller than the given di-
mensions, glass may get caught in weather-
strip during liftinghowering operation. In the
worst case, it may cause glass not to be opened
fully.
After adjustment, move glass up and down to
check whether it is caught.
2) Adjust the crimp of glass using the following di-
mensions as a guide line.
g
2-3
2-
(0.079-0.1 18)
1% (41
6 (0.236)
Unit: mm (in)
BO0269
CAUTION:
If crimp of rear glass is higher than neces-
sary, glass may get caught in weatherstrip of
center pillar corner, resulting in early wear of
weatherstrip. Be careful when adjusting.
GW-21
REAR REGULATOR AND MOTOR ASSEMBLY
8. Rear Regulator and Motor As-

sembly
A: REMOVAL
1) Remove the door glass. <Ref. to GW-20, RE-
MOVAL, Rear Door Grass.>
2) Remove the front sash.
3) Disconnect the motor connector.
4) Loosen four bolts and two nuts to remove r
lator assembly.
5 ) Loosen' screws to remove motor assembly.
1
V
B0009E
B: INSTALLATION
2) Adjust the rear door glass. <Ref. to GW-21, AD-
JUSTMENT, Rear Door Glass.>
C: INSPECTION
1) Make sure that the power window motor rotates
properly when the battery voltage is applied to the
terminals of motor connector.
2) Change the polarity of battery connections to the
terminals to ensure that the motor rotates in re-
verse direction.
GW-22
I
WINDSHIELD GLASS
GLASSMINDOW S/M IRRORS
9. Windshield Glass NOTE:

Because the matching pins are bonded to the cor-
A: REMOVAL ners of glass, use piano wire to cut the pin.
1. USING WINDSHIELD KNIFE
1) Remove the cowl panel. <Ref. to El-33, RE-
MOVAL, Cowl Panel.> Matching pin
2) Remove the glass molding.
3) Tape the body side of the circumference of wind-
shield glass for protection.
4) Apply the sufficient amount of soapy water to the
adhesive layer. A-A
5) Insert the windshield knife into the adhesive lay-
er. G5M0412
6) While holding the knife edge and windshield
2. USING PIANO WIRE
glass edge at a right angle, move the windshield
knife in parallel to the windshield glass edge along 1) Remove the cowl panel. <Ref. to El-33, RE-
face and edge of windshield glass to cut the adhe- MOVAL, Cowl Panel.>
sive layer. 2) Remove the roof molding and upper front mold-
CAUTION: ing.
Do not twist windshield knife. 3) Tape the body side of the circumference of wind-
Cutting'of adhesive layer shall be started with shield glass for protection.
wider gap between windshield glass and body. 4) Make a hole in the adhesive layer using drill or
knife.
5) Pass the piano wire through the hole, and attach
securely both the wire ends to pieces of wood.
A-A
/-
\ \ G5M0494
6) Pull the wire ends alternately to cut off the adhe-

sive layer.
CAUTION:
Do not tightly pull the piano wire against the
windshield glass edge.
Be careful not to damage interior and exterior
parts.
G5M041e When removal is made with area close to in-
strument panel, place a protection plate over it.
Pay particular attention to the removal.
Do not cross piano wires. Otherwise they
may be cut.
GW-23
WINDSHIELD GLASS
B: INSTALLATION 8) Fit the molding mark (B) to notch (A).

1) Clean the external circumference of windshield
glass with alcohol or white gasoline.
2) Remove the adhesive layer on the body using
cutter knife to obtain smooth face 2 mm (0.08 in)
thick.
CAUTION:
Be careful not to damage the body and paint
surface.
' 2mm
(0.08 in)
G5M0553
3) Clean l h e body with alcohol or white gasoline to

remove thoroughly chips, dusts, and dirts from the BOO270
body face.
4) Place the glass on body. 9) Apply the primer to the adhesive layer of glass
5) Adjust the glass position to make uniform clear- using sponge.
ance between body and glass in four corners. 10) Apply the primer to the adhesive layer of body.
6) Bond the matching pins and dam rubber. CAUTION:
Primer once attached to the painted surface
of the body and internal trim is hard to wipe off.
Mask the circumference of such areas.
Let primer dry for about ten minutes before
installing the glass.
/I/ Matching pin Fastener

Do not touch surface coated with primer.
Application
Dam rubber of primer
11 (0.433)
7 1
Ill i
1 15 (0.591)
Glass side Body side
G5M0495
Unit: mm (in)
80039:
7) Remove the glass from body.
GW-24
WINDSHIELD GLASS
G LASSNVINDOWS/MIR RORS
11) Cut off the cartridge nozzle tip and set it in seal-
ant gun as shown.
1
(0.39)
12) Apply the adhesive to the glass end surface as

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

15) Make the adhesive surface flush using spatula.
CAUTION:
When door is openedklosed after glass is
bonded, always lower door glass and then
open/close it carefully.
Move vehicle slowly.
16) After completion of all work, allow vehicle to
stand for about 24 hours.
NOTE:
For minimum drying time and time the vehicle must
be left standing before driving after bonding, follow
instructions or instruction manual from the adhe-
sive manufacturer.
17) After curing of adhesive, pour water on external
surface of vehicle to check that there are no water
leaks.
CAUTION:
When a vehicle is returned to the user, tell him
or her that the vehicle should not be subjected
to heavy impact for at least three days.
18) Jnstall the cowl panel. <Ref. to El-33, INSTAL-
LATION, Cowl Panel.>
GW-25
REAR GATE GLASS
GLASSNVINDOWSIMI RRORS
10.Rear Gate Glass 4) After completion of all work, allow vehicle to

A: REMOVAL NOTE:
1) Remove the rear wiper motor. <Ref. to WW-17, For minimum drying time and time the vehicle must
REMOVAL, Rear Wiper Motor.> be left standing before driving after bonding, follow
2) Remove the electrical connector from the rear instructions or instruction manual from the adhe-
defogger terminal. sive manufacturer.
3) Remove the glass in the same procedure as for CAUTION:
windshield glass. <Ref. to GW-23, REMOVAL, When a vehicle is returned to the user, tell him
Windshield Glass.> or her that the vehicle should not be subjected
B: INSTALLATION to heavy impact for at least three days.
1) Apply the adhesive evenly to the glass attach- 5) Connect the rear defogger terminals.
ment area. 6) Install the rear wiper. <Ref. to WW-17, INSTAL-
2) Insert the glass clip pin into the rear gate hole, LATION, Rear Wiper Motor.>
and after pushing on the area around the clip pin to
secure it, push lightly all around the area to seal it.
3) About one hour after installation, conduct a leak
test.
Upper side
Lower side
BOO396
CAUTION:
When door is openedklosed after glass is
open/close it carefully.
GW-26
REAR QUARTER GLASS
11.Rear Quarter Glass

A: REMOVAL
Remove the glass in the same procedure as for windshield glass. <Ref. to GW-23, REMOVAL, Windshield
Glass.>
< \Molding
B-B
-
A-A 4
Dam rubber
7
-
7
Adhesive
Rear quarter glass
BOO21C
B: INSTALLATION 3) After completion of all work, allow vehicle to

1) Cut off the nozzle tip as shown in the figure. stand for about 24 hours.
NOTE:
Unit: mm (in) For minimum drying time and time the vehicle must
10 (0.39) instructions or instruction manual from the adhe-
-Ti- sive manufacturer.
l l I -
LAdhesive
4) After curing of adhesive, pour the water on exter-
D l 5 (0.59) nal surface of vehicle to check that there are no wa-
12 - 15 ter leaks.
(0.47 - 0 .59 CAUTION:
5M0414
When a vehicle is returned to the user, tell him
or her that the vehicle should not be subjected
2) Install the glass in the same procedure as for to heavy impact for at least three days.
windshield the glass. <Ref. to GW-24, INSTALLA-
TION, Windshield Glass.>
CAUTION:
When door is opened/closed after glass is
openklose it carefully.
GW-27
REAR WINDOW GLASS
GLASSMINDOWS/M I RRORS
12.Rear Window Glass 5 ) After curing of adhesive, pour the water on exter-
nal surface of vehicle to check that there are no wa-
A: REMOVAL ter leaks.
1) Disconnect the electrical connectors from the CAUTION:
rear defogger terminals. When a vehicle is returned to the user, tell him
2) Remove the glass in the Same Procedure as for or her that the vehicle should not be subjected
windshield glass. <Ref. to GW-23, REMOVAL, to heavy impact for at least three days.
Windshield Glass.>
B: INSTALLATION
1) Bond the dam rubber and matching pin.
Unit: mm (in)
BO0271
2) Install the glass in the same procedure as for

windshield glass. <Ref. to GW-24, INSTALLA-
TION, Windshield Glass.>
3) Connect the rear defogger terminals.
CAUTION:
When door is openedclosed after glass is
opedclose door carefully.
4) After completion of all work, allow the vehicle to
NOTE:
For minimum drying time and time the vehicle must
instructions or instruction manual from the adhe-
sive manufacturer.
GW-28
INNER REARVIEW MIRROR
GLASSMI NDOWS/MI RRORS
13.lnner Rearview Mirror

A: REMOVAL
NOTE:
The spring cannot be reused. Prepare a new spring
before removal.
1) Turn the mirror base 90 degrees clockwise or
counterclockwise to remove it.
B5M1059
I
2) Remove the spring from the mirror base.
B5M1060
CAUTION:
Be careful not to damage the mirror surface.
B: INSTALLATION
C: INSPECTION
Do not let mirror be damaged.
Do not let spring deteriorate.
GW-29
POWER WINDOW CONTROL SWITCH
14.Power Window Control 2. SUB-SWITCH

Switch 1) Disconnect the ground terminal from battery.
2) Remove the switch panel.
A: REMOVAL 3) Disconnect the connector.
1. MAIN SWITCH
2) Loosen the screw to remove power window main
switch.
B: INSTALLATlON
1. MAIN SWITCH
2. SUB-SWITCH
C: INSPECTION
1. MAIN SWITCH
Measure switch resistance.
Driver's switch:
UP 13 and 2.1 and 5 less than l R
1 and2
OFF 1 and 5 less than 1R
2 and 5
DOWN 13 and 1 , 2 and 5 less than 1R
AUTO DOWN 13 and 1,2 and 5 less than 1R

UP I 13 and 6, 7 and 5 less than la
OFF 6 and 7 and 5 less than 1R
GW-30
POWER WINDOW CONTROL SWITCH

UP 10 and 13,9 and 5 less than 1R
10 and 9
9 and 5
DOWN 13 and 9, 10 and 5 less than I R

UP 13 and 16,15 and 5 less than 1R
16 and 15
5 and 15
DOWN 13 and 15, 16 and 5 less than 1R
2. SUB-SWITCH

UP 8 and 5,6 and 7 less than IC2
OFF 4 and 5,6 and 7 less than 1R
DOWN 8 and 7,4 and 5 less than 1R
GW-31
REAR WINDOW DEFOGGER
15.Rear Window Defogger B: REPAIR

1) Clean the broken portion with alcohol or white
A: INSPECTION gasoline.
CAUTION: 2) Mask both side of wire with thin film.
When wiping stain on glass off with cloth, use a 3) Apply the conductive silver composition (Du-
drv and soft cloth and move it in the direction of PONT No. 4817) to the broken portion.
the heat wire extension to avoid damage to the
heat wire. I Broken portion,
1) Turn the ignition switch to ON.

2) Turn the defogger switch to ON.
3) Wrap the tips of tester pins with aluminum foil to e
avoid damage to heat wire.
Conductive
composition G6M0138
4) After repair, check wire.
I G6M0136 1
4) Measure the voltage at wire center with DC volt-

meter.
Standard voltage:
Approx. 6 volts
Voltage Criteria
I Acmrox. 12 V or 0 V I Broken I
NOTE:
If the measured value is 12 volts, heat wire is
open between wire center and positive (+) end.
If zero volt, heat wire is open between wire cen-
ter and ground.
5) Apply positive lead of voltmeter to positive termi-
nal of voltmeter, and then move negative lead
along the wire up to the negative terminal end. If
voltage changes from zero to several volts during
movement of lead, heat wire is open at the voltage
change point.
GW-32
OUTER MIRROR ASSEMBLY
GLASSWINDOWS/MIRRORS
16.0uter Mirror Assembly B: INSTALLATION

A: REMOVAL
2) Remove the door trim. <Ref. to El-37, REMOV-
AL, Front Door Trim.>
3) Remove the mirror gusset cover.
4) Disconnect the mirror connector.

5) Loosen the screws to remove mirror assembly.
GW-33
OUTER MIRROR ASSEMBLY
C: INSPECTION
Check to ensure that the rearview mirror moves
properly when the battery voltage is applied to ter-
minals.
Switch position Terminal No.

OFF -
UP 4 (+) and 6 (-)
DOWN 6 (+) and 4 (4
I LEFT I 5 I+) and 6 I-) I
I RIGHT I 6 (+) and 5 (-) I
OFF -
UP 6 (+) and 8 (-)
DOWN 8 (+) and 6 (-)
LEFT 7 (+) and 8 (-)
RIGHT 8 (+) and 7 (-)
GW-34
OUTER MIRROR
17.0uter Mirror
A: REPLACEMENT
1) Remove the door mirror assembly. <Ref. to GW-
33, REMOVAL, Outer Mirror Assembly.>
2) Warm the area around the mirror holder with a
hair drier until the edges of the mirror holder be-
come soft (about 2 or 3 minutes with a 1,000 W dri-
er.)
3) Use a flat-bladed screwdriver without sharp edg-
es to lift the mirror out of the mirror holder. (Also re-
move the connector from the back of mirrors with
heaters.)
I Mirror holder
I 85M1144A
4) Warm the area around the mirror holder with a

hair drier until the edges of the mirror holder be-
come soft (about 2 or 3 minutes with a 1,000 W dri-
er.)
5) Remove the backing of the new two-sided tape,
and push the mirror in to install it.
CAUTION:
Unless the mirror holder is warmed sufficiently,
the mirror holder edges may be damaged or the
mirror cracked.
GW-35
I
REMOTE CONTROL MIRROR SWITCH
18.Remote Control Mirror B: INSTALLATION

Switch Install in the reverse order of removal.
A: REMOVAL
GW-36
C: INSPECTION
Move the rearview mirror switch to each position
and measure switch resistance.
I B5M1132

-
OFF All terminal more than IMR
~
UP 4 and 6 , 2 and 1 less than Is2

LEFT 4 and 8 , 2 and 1 less than 1R
RIGHT 8 and 2 , 4 and 1 less than IR
I OFF All terminal more than 1MR I

UP 4 and 7 , 2 and 1 less than 1R
DOWN 7 and 2 , 4 and 1 less than IR
LEFT 4 and 9 , 2 and 1 less than IR
RIGHT 9 and 2 , 4 and 1 less than IR
GW-37
GLASSMINDOWS/M I RRORS
GW-38
BODY STRUCTURE
BS
Page
Refer to G1831 BE SUPPLEMENT for this section.
BODY STRUCTURE
Page
1. General Description .................................................................................. ..2
2. Datum Points............................................................................................... 3
3. Datum Dimensions.................................................................................... 11
GENERAL DESCRIPTION
BODY STRUCTURE
Tram tracking gauge Used for measuring dimen-

sion.
Tape measure Used for measuring dimen-
sion.
BS-2
DATUM POINTS
BODY STRUCTURE
1
I
2. Datum Points
,
I A: LOCATION
NOTE:
Datum points are specified for body repair.
Guide holes, locators, and indents are provided to facilitate panel replacement and to increase alignment
I accuracy.
Both right and left reference points are symmetrical.
1. WAGONEEDAN
BO0404
Radiator attaching hole 12 mm (10) Cowl panel attaching hole 6 mm (24) Roof panel repair locator hollow
(0.47 in) dia. (Symmetrical) (0.24 in) dia. (Vehicle center) (62) Belt anchor attaching hole 11 mm
Fender attaching hole 7 mm (0.28 (12) Front glass attaching hole Right (0.43 in) dia. (Symmetrical)
in) dia. (Symmetrical) 6.5 mm (0.256 in) dia. Left 6.5 x (70) Trim clip attaching hole 8.5 mm
Fender attaching hole 10 mm 10 mm (0.256 x 0.39 in) dia. (0.335 in) dia. (Symmetrical)
(0.39 in) dia. (Symmetrical) (18) Fender attaching hole 12 mm (71) Harness clip attaching hole 7 mm
Hood hinge attaching hole 12 mm (0.47 in) dia. (Symmetrical) (0.28 in) dia. (Symmetrical)
(0.47 in) dia. (Symmetrical) (19) Fender attaching hole 12 mm (73) Harness clip attaching hole 7 mm
Radiator panel side gauge hole 20 (0.47 in) dia. (Symmetrical) (0.28 in) dia. (Symmetrical)
mm (0.79 in) dia. (Symmetrical) (20) Outer panel center pillar gauge (74) Trim clip attaching hole 10 mm
Fender attaching hole 9 mm (0.35 hole 12 mm (0.47 in) dia. (Sym- (0.39 in) dia. (Symmetrical)
in) dia. (Symmetrical) metrical) (75) Insulator attaching hole 8 mm
Gauge hole 12 mm (0.47 in) dia. (21) Outer panel center pillar gauge (0.31 in) dia. (Symmetrical)
(Symmetrical) hole 12 mm (0.47 in) dia. (Sym-
Front suspension cross member metrical)
attaching hole 12.4 mm (0.488 in) (22) Weather strip patch attaching hole
dia. (Symmetrical) 5.2 mm (0.205 in) dia. (Symmetri-
cal)
BS-3
6 DATUM POINTS
1 BODY STRUCTURE
2. WAGON (REAR SECTION)
BO0405
(30) Child anchor attaching hole 11 (33) Two striker attaching hole 15 mm (67) Gusset floor rear side gauge hole
mm (0.43 in) dia. (0.59 in) dia. 11.5 mm (0.453 in) dia. (Symmet-
(31) Washer hose attaching hole Left 7 (58) Rear bumper plate nut attaching rical)
mm (0.28 in) dia. hole 11 mm (0.43 in) dia. (Sym- (72) Trim upper clip attaching hole 8.5
(32) Rear combination light mounting metrical) mm (0.335 in) dia. (Symmetrical)
hole 7 mm (0.28 in) dia. (Symmet- (65) Floor mat clip attaching hole 8 mm (77) Harness clip attaching hole 7 mm
rical) (0.31 in) dia. (0.28 in) dia. (Symmetrical)
BS-4
DATUM POINTS
BODY STRUCTURE
3. SEDAN (REAR SECTION)
(50) Repair locator hollow (Vehicle (58) Rear bumper attaching hole 11 (67) Gusset floor rear side gauge hole
center) mm (0.43 in) dia. (Symmetrical) 11.5 mm (0.453 in) dia. (Symmet-
(51) Glass attaching hole Right 6.5 mm (60) Choke coil harness attaching hole rical)
(0.256 in) dia. Left 6.5 x 10 mm 5.4 mm (0.213 in) dia. (68) Rear skirt inner side gauge hole
(0.256 x 0.39 in) dia. (63) Feeder line fixing hole 7 mm (0.28 10 mm (0.39 in) dia. (Symmetri-
(55) Rear combination light mounting in). (Symmetrical) cal)
hole 8 mm (0.31 in) dia. (Symmet- (65) Floor mat clip attaching hole 8 mm (69) Rear panel (reinforcement) repair
rical) (0.31 in) dia. locator hollow (Vehicle center)
(56) Bumper attaching hole 7 mm (66) Bulkhead rear gauge hole 10 mm (76) Press location hole 15 mm (0.59
(0.28 in) dia. (Symmetrical) (0.39 in) dia. (Symmetrical) in) dia. (Symmetrical)
BS-5
DATUM POINTS
BODY STRUCTURE
4. UNDERBODY SECTION
BOO407 I
Radiator lower frame gauge hole (85) Transmission mount attaching (90) Strut mount attaching hole 9.5 mm
12 mm (0.47 in) dia. (Symmetri- hole 14 mm (0.55 in) dia. (0.374 in) dia. (Symmetrical)
cal) (86) Side frame gauge hole 18 mm (91) Strut mount attaching hole 10 mm
Side frame gauge hole 20 mm (0.71 in) dia. (Symmetrical) (0.39 in) dia. (Symmetrical)
(0.79 in) dia. (Symmetrical) (87) Rear differential attaching hole 16 (92) Sub frame attaching hole 16 mm
Front crossmember (Ft) attaching mm (0.63 in) dia. (Symmetrical) (0.63 in) dia. (Symmetrical)
hole 12.4 mm (0.488 in) dia. (88) Rear suspension attaching hole (93) Bumper beam attaching hole
(Symmetrical) 16 mm (0.63 in) dia. (Symmetri-
. _ Right 15 mm (0.59 in) dia. Left 19
Suspension attaching hole 17 mm cal) x 15 mm (0.75 x 0.59 in) dia.
(0.67 in) dia. (Symmetrical) (89) Rear side frame gauge hole 15 (94) Side frame gauge hole 15 mm
Side frame gauge hole 20 mm mm (0.59 in) dia. (Symmetrical) (0.59 in) dia. (Symmetrical)
(0.79 in) dia. (Symmetrical)
BS-6
DATUM POINTS
BODY STRUCTURE
BOO408
600409
/
. .
BO0410
WAGON
BO0411
\ BOO417
BS-7
DATUM POINTS
BODY STRUCTURE
WAGON SEDAN
(72)
WAGON SEDAN
.I 9
WAGON
SEDAN
BO0426
BS-8
DATUM POINTS
BODY STRUCTURE
(67)
BOO427
SEDAN
1)
BOO433
BOO430
BS-9
DATUM POINTS
BODY STRUCTURE
BS-10
DATUM DIMENSIONS
BODY STRUCTURE
3. Datum Dimensions
A: MEASUREMENT
Refer to LOCATION for details on measurement
points. <Ref. to BS-3, LOCATION, Datum Points.>
NOTE:
Using a tram tracking gauge, measure all the di-
mensions.
When using a tape measure, carefully measure
dimensions without letting the tape measure sag or
twist.
Measure the linear dimensions between cores of
holes.
Suffixes “RH” and “LH” indicate right-hand and
left-hand.
Tram tracking gauge

A
G5M0122
Measure at the center of the circle around the
outside of the body panel.
...
Datum point
\
Body panel
B5M1133A
BS-I 1
DATUM DIMENSIONS
BODY STRUCTURE
1. CENTER STRUCTURE
'1 : Side sill

*2:Upper surface
BO0438
BS-12
DATUM DIMENSIONS
BODY STRUCTURE
2. WAGONEEDAN (FRONT STRUCTURE)
(5)’ BOO439
(10)to (1)RH 912 (35.91) (2)RH to (2)LH 1,341 (52.80)

(10)to (1) LH 912 (35.91) (5)RH to (5)LH 720 (28.35)
(10)to (90)RH 566 (22.28) (7)RH to (18)RH 1,138(44.80)
(10)to (90)LH 566 (22.28) (7)LH to (18)LH 1,138(44.80)
(10)to (8)RH 581 (22.87) (7)RH to (19)RH 1,116(43.94)
(10)to (8)LH 581 (22.87) (7)LH to (19)LH 1,116(43.94)
. . to (2)
(10) . . RH 947 (37.28) (4)RH to (2)LH 1,583(62.32)
(10)to (2)LH 947 (37.28) (4)LH to (2)RH 1,583(62.32)
(4)RH to (2)RH 778 (30.63) (3)RH to (3)LH 1,396(54.96)
(4)LH to (2)LH 778 (30.63) (3)RH to (4)LH 1,470(57.87)
~~~
(4)RH to (3)RH 430 (16.93) (3)LH to (4)RH 1,470(57.87)
(4)LH to (3)LH 430 (1 6.93) (2)RH to (3)LH 1,412(55.59)
(90)RH to (90)LH 1,065(41.93) (2)LH to (3)RH 1,412(55.59)
(8)RH to (8)LH 894 (35.20) (9)RH to (9)LH 860 (33.86)
(8)RH to (4)LH 1,210(47.64) (9)RH to (8)LH 931 (36.65)
(8)LH to (4)RH 1,210(47.64) (9)LH to (8)RH 931 (36.65)
(3)RH to (2)RH 349 (1 3.74) (9)RH to (4)LH 1,280(50.39)
(3)LH to (2)LH 349 (1 3.74) (9)LH to (4)RH 1,280(50.39)
74)RH to (4)LH 1,417(55.79) - -
BS-13
DATUM DIMENSIONS
BODY STRUCTURE
BO0440
Unit: mm (in)
I Point to point Dimension Point to Doint Dimension
BS-14
DATUM DIMENSIONS
BODY STRUCTURE
3. WAGONEEDAN (REAR STRUCTURE)
> \
(58)
(58) RH to (58) LH 1,128 (44.41) (67) RH to (67) LH 1,110 (43.70)

(62) RH to (62) LH 1,332 (52.44) (67) RH to (91) LH 1,381 (54.37)
(62) RH to (65) 915 (36.02) (67) LH to (91) RH 1,381 (54.37)
(62) LH to (65) 915 (36.02) (70) RH to (70) LH 1,060 (41.73)
(62) RH to (73) RH 762 (30.00) (70) RH to (73) RH 948 (37.32)
(62) LH to (73) LH 762 (30.00) (70) LH to (73) LH 948 (37.32)
. , RH to (73)
(62) . . LH 1,561 (61.46) (70) RH to (73) LH 1,542 (60.71)
(62) LH to (73) RH 1,561 (61.46) (70) LH to (73) RH 1,542 (60.71)
(62) RH to (74) RH 592 (23.31) Wagon (70) RH to (75) RH 1,443 (56.81)
(62) LH to (74) LH 603 (23.74) Sedan (70) LH to (75) LH 1,443 (56.81)
~
(65) to (67) RH 1,501 (59.09) (70) RH to (91) LH 1,532 (60.32)
(65) to (67) LH 1,501 (59.09) (70) LH to (91) RH 1,532 (60.32)
(65) to (71) RH 823 (32.40) (71) RH to (71) LH 1,361 (53.58)
(65) to (71) LH 823 (32.40) (71) RH to (74) RH 954 (37.56) Wagon
(65) to (74) RH 1,275 (50.20) Wagon (71) LH to (74) LH 949 (37.36) Sedan
(65) to (74) LH 1,282 (50.47) Sedan (74) RH to (74) LH 1,135 (44.69) Wagon
(65) to (75) RH 1,450 (57.09) (74) RH to (74) LH 1,147 (45.16) Sedan
(65) to (75) LH 1,450 (57.09) (75) RH to (75) LH 1,399 (55.08)
1
~ (65) to (91) RH 1,064 (41.89) (91) RH to (91) LH 1,205 (47.44)
(65) to (91) LH 1,064 (41.89) - -
BS-15
DATUM DIMENSIONS
BODY STRUCTURE
4. WAGON (FRONT STRUCTURE)
BO0442
Unit:
- . . ... . (in\
.. mm .. .
BS-I 6
DATUM DIMENSIONS
BODY STRUCTURE
5. WAGON (REAR STRUCTURE)
BOO443
Unit: mm (in)
BS-17
DATUM DIMENSIONS
BODY STRUCTURE
6. SEDAN (FRONT STRUCTURE)
Point to point Dimension Point to point Dimension

(50) to (71) RH 1,562 (615 0 ) (63) RH to (65) 1,118 (44.02)
(50) to (71) LH 1,562 (61.50) (63) LH to (65) 1,118 (44.02)
(60) to (62) RH 1,338 (52.68) (63) RH to (71) RH 1,283 (50.51)
(60) to (62) LH 1,338 (52.68) (63) LH to (71) LH 1,283 (50.51)
(62) RH to (63) RH 773 (30.43) (65) to (66) RH 956 (37.64)
(62) LH to (63) LH 773 (30.43) (65) to (66) LH 956 (37.64)
(62) RH to (66) LH 1,449 (57.05) (66) RH to (66) LH 840 (33.07)
(62) LH to (66) RH 1.449 (57.051 - -
BS-I 8
DATUM DIMENSIONS
BODY STRUCTURE
7. SEDAN (REAR STRUCTURE)
(56)
BO0445
Unit: mm (in\
Point to point Dimension Point to point Dimension
(50) to (60) 501 (19.72) (65) to (76) LH 1,544 (60.79)
\
(50) to (65)
I .
1.082 (42.601 1,581 (62.24)
1511
(51) RH to I~ , LH ~~ T
I
1.025 (40.35) I
I
(65)
. . to (68)
. . LH I
I
1,581 (62.24) II
(51) RH to (60) 734 (28.90) (67) RH to (69) 784 (30.87)
(55) RH to (55) LH 1,406 (55.35) (67) LH to (69) 784 (30.87)
(55) RH to (58) LH 1,297 (51.06) (68) RH to (68) LH 1,020 (40.16)
(55) LH to (58) RH 1,297 (51.06) (68) RH to (69) 681 (26.81)
(56) RH to (56) LH 1,426 (56.14) (68) LH to (69) 681 (26.81)
(60) to (63) RH 764 (30.08) (69) to (76) RH 537 (21.14)
(60) to (63) LH 764 (30.08) (69) to (76) LH 537 (21.14)
(63) RH to (63) LH 1,183 (46.57) (76) RH to (76) LH 600 (23.62)
(65) to (76) RH 1,544 (60.79) - -
BS-19
DATUM DIMENSIONS
BS-20
-
BODY STRUCTURE
BS-2
.
INSTRUMENTATION/DRIVER INFO
Page
2. Combination Meter System ......................................................................... 4
3. Combination Meter Assembly ................................................................... 11
4. Speedometer............................................................................................. 13
5. Tachometer ............................................................................................... 14
6. Fuel Gauge ............................................................................................... 15
7. Water Temperature Gauge ....................................................................... 16
8. Ambient Sensor......................................................................................... 17
GENERAL DESCRIPTION
A: SPECIFICATIONS
Speedometer Electric pulse type
Temperature qauqe I Thermistor cross coil type
Fuel gauge I Resistance cross coil type
Tachometer Electric impulse type
Turn signal indicator light 14 V - 1.4 W
Charge indicator light LED
Oil Dressure indicator liaht LED
ABS warninq liqht I LED
CHECK ENGINE warning light
LED
(Malfunction indicator light)
HI-beam indicator light 14 V - 1.4 W
Combination meter Door oDen warnina liaht LED
I
~~ ~
Seat belt warnina liaht LED

Brake fluid and parking brake warning
LED
liaht
-.a-.-
FWD indicator light LED

AIRBAG warning light LED
Meter illumination liaht 14V-3Ww,14V-2W
AT OIL TEMP. warnina liaht I LED
Security indicator light I LED
Low fuel warning light LED
AT select lever position indicator light 14 V - 100 mA
LCD back light 14V-1.4W
IDI-2
GENERAL DESCRIPTION
INSTRUMENTATION/DR IVER INFO
TOOL NAME REMARKS

IDI-3
COMBINATION METER SYSTEM
2. Combination Meter System

A: SCHEMATIC
1. COMBINATION METER
<Ref. to WI-56, SCHEMATIC, Combination
Meter.>
2. OUTSIDE TEMPERATURE INDICATOR
<Ref. to WI-107, SCHEMATIC, Outside Tempera-
ture Display System.>
B: INSPECTION
CAUTION:
When measuring the voltage and resistance of the ECM, TCM, or each sensor, use a tapered pin with
a diameter of less the an 0.64 mm (0.025 in) in order to avoid poor contact. Do not insert the pin more
than 2 mm (0.08 in).
1. SYMPTOM CHART
symptom ~~
ReDair order Reference
>ombination meter assembly does not operate. (1) Power supply <Ref. to IDI-5, CHECK
(2) Ground circuit POWER SUPPLY AND
GROUND CIRCUIT,
INSPECTION, Combi-
nation Meter System.>
Speedometer does not operate. (1) (MT) Vehicle speed sensor MT: <Ref. to IDI-6,
(AT) Transmission control module CHECK VEHICLE
(2) Harness SPEED SENSOR,
(3) Speedometer INSPECTION, Combi-
AT: <Ref. to IDI-7,
CHECK TRANSMIS-
SION CONTROL MOD-
ULE, INSPECTION,
Combination Meter
System.>
rachometer does not operate. (1) Engine control module <Ref. to 101-7, CHECK
(2) Harness ENGINE CONTROL
(3) Tachometer MODULE, INSPEC-
TION, Combination
Meter System.>
%el gauge does not operate. (1) Fuel level sensor <Ref. to IDI-8, CHECK
(2) Harness FUEL LEVEL SEN-
(3) Fuel gauge SOR, INSPECTION,
Combination Meter
System.>
Nater temperature gauge does not operate. (1) Engine coolant temperature sensor <Ref. to IDI-9, CHECK
(2) Harness ENGINE COOLANT
(3) Water temperature gauge TEMPERATURE SEN-
SOR, INSPECTION,
Combination Meter
System.>
3utside temperature indicator does not operate. (1) Ambient sensor <Ref. to IDI-10, CHECK
(2) Harness OUTSIDE TEMPERA-
(3) Combination meter TURE INDICATOR,
INSPECTION, Combi-
IDI-4
2. CHECK POWER SUPPLY AND GROUND CIRCUIT
!
Step Check
30 to step 2. Check the harness
TlON METER. for open or short
1)Remove the combination meter. <Ref. to IDI- between the igni-
11, REMOVAL, Combination Meter Assem- tion switch and
bly.> combination
2)Disconnect the combination meter harness meter.
connector.
4)Measure the voltage between the combina-
tion meter connector (i10) and chassis ground.
-
CHECK POWER SUPPLY FOR COMBINA- Is the voltage more than 10 V? 30 to step 3. Check the harness
TION METER. for open or short
Measure the voltage between the combination between the fuse
meter connector (i10) and chassis ground. and combination
Connector & terminal meter.
-
(i10) No. 10 (+) Chassis ground (-):
I CHECK GROUND CIRCUIT OF COMBINA- Is the resistance less than 10 3eplace the com- Repair the wiring
UON METER. n? )ination meter harness.
1)Turn the ignition switch to OFF. Irinted circuit.
the combination meter connector (i10) and
chassis ground.
tilo) No. 6 - Chassis around:
IDI-5
3. CHECK VEHICLE SPEED SENSOR
Step Check Yes No

I CHECK VEHICLE SPEED SENSOR. s the voltage less than 1V ;heck the speed- 30 to step 2.
1)Set the vehicle on a free roller, or lift-up the -+ more than 4 V? )meter. <Ref. to
vehicle and support it with safety stands. DI-13,
2)Remove the combination meter with harness 3EMOVAL,
connector. Speedometer.>
Warning:
Be careful not to get caught in the running
wheels.
3)Drive the vehicle at a speed greater than 20
km/h (12 MPH).
tion meter connector (il0) and chassis ground.
(i10) No. 2 (+) - Chassis groundI)-(
? CHECK VEHICLE SPEED SENSOR POWER s the voltage more than 10 V? o
; to step 3. ;heck the harnesz
SUPPLY. or open or short
1)Turn the ignition switch to OFF. letween the igni-
2)Disconnect the vehicle speed sensor har- ion switch and
ness connector. iehicle speed sen
3)Turn the ignition switch to ON. ;or.
4)Measure the voltage between the vehicle
speed sensor connector (817) and engine
ground.
(B 17) No. 3 (+) - Engine ground (-):
i CHECK HARNESS BETWEEN VEHICLE s the resistance less than 10 20 to step 4. 3epair the wiring
SPEED SENSOR AND ENGINE GROUND. 2? iarness.
2)Measure the resistance between the vehicle
speed sensor connector (817) and engine
ground.
i
(B17) No. 2 - Engine ground:
I CHECK HARNESS BETWEEN VEHICLE s the resistance less than 10 3eplace the vehi- 3epair the wiring
SPEED SENSOR AND COMBINATION L? :le speed sensor. iarness.
METER.
1)Disconnectthe connector from the combina-
tion meter.
2)Measure the resistance between the vehicle
speed sensor harness connector and combi-
nation meter harness connector.
(B17) NO. 1 - (i10) NO. 2:
IDI-6
B

4. CHECK TRANSMISSION CONTROL MODULE
t
~~
Step Check
CHECK TRANSMISSION CONTROL MOD- s the voltage less than 1 V 50 to step 2. Check the trans-
ULE SIGNAL. -+ more than 4 V? mission control
1)Set the vehicle on a free roller, or lift-up the module. <Ref. to
vehicle and support it with safety stands. AT-2, Basic Diag-
Warning: nostic Procedure.>
Be careful not to get caught in the running
wheels.
2)Drive the vehicle faster than 10 km/h (6
MPH).
3)Measure the voltage between the transmis-
sion control module connector (856: turbo
model) or (855: non-turbo model) and chassis
ground.
Turbo model:
Non-turbo model:
! CHECK HARNESS BETWEEN TRANSMIS- s the resistance less than 10 :heck the speedo 3epair the wiring
SlON CONTROL MODULE AND COMBINA- R? neter. <Ref. to IDI- iarness.
llON METER. 3, REMOVAL,
1)Turn the ignition switch to OFF. ;peedometer.>
2)Disconnect the connector from the transmis-
sion control module and combination meter.
3)Measure the resistance between the trans-
mission control module harness connector
(856: turbo model) or (855: non-turbo model)
and combination meter harness connector
(il0).
Turbo model:
(B56) NO. 17- (i10) NO. 2:
Non-turbo model:
(B55) NO. 13 - (i10) NO. 2:
5. CHECK ENGINE CONTROL MODULE
Step Check Yes No

I CHECK ENGINE CONTROL MODULE SIG- Is the voltage 0 +-+13 V or I Go to step 2. Check the engine
NAL. more? control module.
1)Start the engine. <Ref. to
2)Measure the voltage between the engine EN(S0HC)-2,
control module connector (B136: turbo model) Basic Diagnostic
or (8134: non-turbo model) and engine Procedure.> or
ground. <Ref. to EN(D0HC
Connector & terminal TURBO)-2, Basic
Turbo model: Diagnostic Proce-
(6136) No. 9 (+) - Engine ground (-): dure.>
Non-turbo model:
(8134) No. 30 (+) - Engine ground (-):
IDI-7
Step Check Yes No

2 CHECK HARNESS BETWEEN COMBINA- Is the resistance less than 10 Check the tachom- Repair the wiring
TlON METER AND ENGINE CONTROL MOD- R? eter. <Ref. to IDI- harness.
~ ~~~ ~~ ~~ ~
Step Check Yes No

CHECK FUEL LEVEL SENSOR. Is the resistance 0.5 to 2.5 R IGo to step 2. Replace the fuel
1)Remove the fuel level sensor. <Ref. to (FULL) and 50 to 52 R level sensor.
fU(SOHC)-62, REMOVAL, Fuel Level Sen- (EMPTY)?
sor.> or <Ref. to FU(D0HC TURBO)-62,
REMOVAL, Fuel Level Sensor.>
2)Measure the resistance between the fuel
level sensor terminals when setting the float to
FULL and EMPTY position.
Terminals
NO. 2 - NO. 3:
! CHECK FUEL SUB LEVEL SENSOR. Is the resistance 0.5 to 2.5 R 30 to step 3. Replace the fuel
1)Remove the fuel sub level sensor. <Ref. to (FULL) and 42 to 44 R sub level sensor.
FU(SOHC)B3, REMOVAL, Fuel Sub Level (EMPTY)?
Sensor.> or <Ref. to FU(D0HC TURBO)-63,
REMOVAL, Fuel Sub Level Sensor.>
2)Measure the resistance between the fuel sub
level sensor terminals when setting the float to
FULL and EMPTY position.
Terminals
-
NO. 1 NO. 2:
I CHECK HARNESS BETWEEN FUEL SUB Is the resistance less than 10 30 to step 4. I Repair the wiring
LEVEL SENSOR AND COMBINATION n? harness.
METER.
1)Disconnect the connector from the combina-
tion meter.
2)Measure the resistance between the fuel sub
level sensor harness connector terminal and
combination meter harness connector termi-
nal.
-
(R59) No. 1 (i12) No. 2: I
I CHECK HARNESS BETWEEN FUEL LEVEL Is the resistance less than 10 30 to step 5. I Repair the wiring
SENSOR AND FUEL SUB LEVEL SENSOR. n? harness.
. Measure the resistance between the fuel level
sensor harness connector terminal and fuel
sub level sensor harness connector terminal.
-
(R58) NO. 3 (R59) N0.2:
IDI-8
Step Check Yes No

5 CHECK FUEL LEVEL SENSOR GROUND Is the resistance less than 10 Check the fuel Repair the wiring
CIRCUIT. a? gauge. <Ref. to harness.
Measure the resistance between the fuel level IDI-15,
sensor harness connector terminal and chas- REMOVAL, Fuel
sis ground. Gauge.>
(R58)No. 2 - Chassis ground: 1 I
7. CHECK ENGINE COOLANT TEMPERATURE SENSOR

~ ~~ ~
Step Check Yes No

I CHECK ENGINE COOLANT TEMPERATURE Is the engine coolant tempera- I Go to step 2. Replace the
I
SENSOR. ture sensor OK? engine coolant
Check the engine coolant temperature sen- temperature sen-
sor. <Ref. to EN(S0HC)-120, DTC PO117 - sor.
ENGINE COOLANT TEMPERATURE SEN-
SOR CIRCUIT LOW INPUT -, Diagnostic
Procedure with Diagnostic Trouble Code
(DTC).> or <Ref. to EN(D0HC TURBO)-126,
DTC PO117 - ENGINE COOLANT TEMPER-
ATURE SENSOR CIRCUIT LOW INPUT -,
Code (DTC).>
! CHECK HARNESS BETWEEN ENGJNE Is the resistance less than 10 Check the water 3epair the wiring
COOLANT TEMPERATURE SENSOR AND a? temperature iarness.
COMBINATION METER. gauge. <Ref. to
1)Turn the ignition switch to OFF. IDI-16,
2)Disconnect the connector from the engine REMOVAL, Water
coolant temperature sensor and combination Temperature
meter. Gauge.>
3)Measure the resistance between the engine
coolant temperature sensor harness connector
(E8) and combination meter harness connec-
tor (i12).
(E8) No. 3 - (i12) No. 9:
IDI-9
8. CHECK OUTSIDE TEMPERATURE INDICATOR
Step Check Yes No

I CHECK POWER SUPPLY FOR AMBIENT s the voltage more than 4V? $0to step 2. Replace the com-
SENSOR. bination meter
1)Turn the ignition switch OFF. printed circuit.
2)Disconnect the connector from the combina-
tion meter.
tion meter terminal and chassis ground.
( i l l ) No. 11 (+) - Chassis ground (-):
! CHECK HARNESS BETWEEN AMBIENT s the resistance less than 10 $0to step 3. Repair the wiring
SENSOR AND COMBINATION METER. 2? harness.
2)Disconnect the connector from the ambient
sensor.
3)Measure the resistance between the ambi-
ent sensor harness connector terminal and
combination meter harness connector termi-
nal.
(F78) No. 1 - ( i l l ) No. 11:
(F78) NO. 2 - ( i l l ) NO. 8:
I CHECK AMBIENT SENSOR. s the ambient sensor OK? 20 to step 4. Replace the ambi-
1)Remove the ambient sensor. ent sensor.
2)Check the ambient sensor. <Ref. to IDI-17,
INSPECTION, Ambient Sensor.>
I CHECK OUTSIDE TEMPERATURE INDICA- s the outside temperature indi, Iepair the poor Replace the com-
TOR. :ator indicating 25°C (77"F)? :ontact of ambient bination meter
1)Connect the combination meter harness ;ensor harness printed circuit.
2)Connect a resistor (2.2 kCl) between the ter-
minals of ambient sensor harness connector.
3)Turn the ignition switch ON and check the
outside temperature indicator display.
IDI-IO
COMBINATION METER ASSEMBLY
~~
3. Combination Meter Assem- B: INSTALLATION

bly
CAUTION:
A: REMOVAL Make sure the electrical connector is con-
1) Disconnect the battery ground cable. nected securely.
2) Set the tilt steering at the lowest position. Make sure that each meter operates normally.
3) Remove the screws and detach the meter visor.
4) Remove the screws of combination meter and

pull out the meter toward you.
5 ) Disconnect the connector in the upper area of

combination meter to remove the meter.
CAUTION:
Be careful not to damage the meter or instru-
ment panel.
Pay particular attention to avoid damaging
the meter glass.
IDI-I 1
COMBINATION METER ASSEMBLY
C: DISASSEMBLY
CAUTION:
Use gloves to avoid damage and getting fingerprints on the glass surface and meter surfaces.
1) Disengage claw (F) to remove case (B) from back cover (A).
2) Disengage claw (G) to remove meter glass (E), reflector (D) and window plate (C) from inner case.
I BOO014
3) Pull up claw (A) in portion (B) of combination 1. BULB REPLACEMENT
meter printed circuit (C) with combination pliers.
Push out speedometer and tachometer assembly
(D) and fuel gauge and water temperature gauge
assembly (E) using hole (F).
4) Pull up the claw in the center of combination
meter printed circuit (C), and remove the combina-
tion meter printed circuit from case (G).
(1 )Tachometer
(2) Speedometer and tachometer
(3) Turn RH
(4) HI-beam
(5) Speedometer
(6) Turn LH
(7) Fuel gauge
(8) Temperature gauge
(9) LCD (Outside temperature indicator)
(IO) LCD (Odometer and tripmeter)
D: ASSEMBLY
IDI-12
SPEEDOMETER
~~
4. Speedometer
A: REMOVAL
Disassemble the combination meter, and then re-
move the speedometer and tachometer assembly.
<Ref. to IDI-12, DISASSEMBLY, Combination
Meter Assembly.>
B: INSTALLATION
C: INSPECTION
Measure the speedometer resistance.
I Terminal 1 Resistance 1
SIN+ and SIN- 2oM8 R
IDI-I 3
TACHOMETER
INSTR UMENTATION/DRIVER INFO
5. Tachometer
A: REMOVAL
move the speedometer and tachometer assembly.
<Ref. to IDI-12, DISASSEMBLY, Combination
Meter Assembly.>
B: INSTALLATION
C: INSPECTION
Measure the tachometer resistance.
06M1232A
Terminal Resistance
If NG, replace the speedometer and tachometer

assembly.
If OK, replacethe combination meter printed circuit.
IDI-I 4
FUEL GAUGE
6. FuelGauge
A: REMOVAL
move the water temperature gauge and fuel gauge
assembly. <Ref. to IDI-12, DISASSEMBLY, Com-
bination Meter Assembly.>
B: INSTALLATION
C: INSPECTION
Measure the fuel gauge resistance.
Terminal Resistance
IGN and GND 170+10 R
IGN and UNIT 35+10 R
UNIT and GND 136flO R
If NG, replace the water temperature gauge and

fuel gauge assembly.
If OK, replace the combination meter printed circuit.
IDI-I 5
WATER TEMPERATURE GAUGE
7. Water Temperature Gauge

A: REMOVAL
move the water temperature gauge and fuel gauge
assembly. <Ref. to IDI-12, DISASSEMBLY, Com-
bination Meter Assembly.>
B: INSTALLATION
C: INSPECTION
Measure the water temperature gauge resistance.
B6M1233A
Terminal Resistance
IGN and GND 208H 0 R
IGN and UNIT 56k10 R
I UNIT and GND I 264+10 R I
If NG, replace the water temperature gauge and
fuel gauge assembly.
If OK, replace the combination meter printed circuit.
IDI-I 6
AMBIENT SENSOR
8. Ambient Sensor
A: REMOVAL
2) Disconnect the ambient sensor connector.
3) Remove ambient sensor (A) from the radiator
lower panel.
________c BOO277
B: INSTALLATION
C: INSPECTION
Measure the ambient sensor resistance.
1 and2 2.2 W25"C (77°F)
If NG, replace the ambient sensor.
IDI-I 7
AMBIENT SENSOR
INSTRUMENTATION/D R IVER INFO
IDI-I 8
.
SEATS
SE
Page
2. Front Seat ................................................................................................... 6
3. Rear Seat .................................................................................................. 11
GENERAL DESCRIPTION
SEATS
A: COMPONENT
1. FRONT SEAT
BOO354
(1) Front seat ASSY (6) Seat hinge Tightening toque: N.m (kgf-myft-/&)
(2) Rail cover IN (7) Seat hinge cover T1: 24.5(2.5, 18)
(3) Rail cover OUT (8) Seat lifter lever T2: 30 (3.1 22)
(4) Slide rail OUT (9) Reclining lever T3: 53 (5.4,39)
(5) Slide rail IN
SE-2
GENERAL DESCRIPTION
SEATS
2. REAR SEAT (SEDAN)
(1) Backrest (4) Arm rest Tightening toque: N-m (kgf-m, ft-lb)
(2) Head restraint (5) Center through frame T: 24.5(2.5, 18.1)
(3) Cushion (6) Hook
SE-3
GENERAL DESCRIPTION
SEATS
3. REAR SEAT (WAGON)
El
BOO247
(1) Cushion (4) Head restraint Tightening torque: N.m (kgf-m, ft-lb)
(2) Backrest RH (5) Striker T: 24.5 (2.5, 18.1)
(3) Backrest LH
SE-4
GENERAL DESCRIPTION
SEATS
TOOL NAME REMARKS

Long Nose Pliers Used for removing and installing the hog ring
SE-5
FRONT SEAT
2. Front Seat 8) Remove the two bolts at front side of seat rail.
A: REMOVAL \

2) While pressing the headrest lock button, remove
the headrest.
9) Disconnect the side airbag connector under the

seat. (Side airbag equipped vehicle)
10) Disconnect the connector of seat belt warning.
H5M0704
3) Tilt forward the backrest.

4) Move the seat to full front end.
5) Remove the bolt cover at rear end of slide rail.
11) Remove the front seat from vehicle.

CAUTION:
When removing the seat from vehicle, take care
BOO159 not to damage body, seat or trim.
6) Remove the two bolts at rear side of seat rail. B: INSTALLATION

CAUTION:
Confirm that the seat can move smoothly and
be locked securely at any position.
A BOO16C
7) Move the seat to full rear end.
S E-6
FRONT SEAT
SEATS
C: DISASSEMBLY 6) Turn the cover, and remove the two bolts from
hinge.
1. DRIVER’S SEAT / \
1) Remove the seat from the vehicle. <Ref. to SE-

6, REMOVAL, Front Seat.>
2) Remove the reclining hinge cover.
BOOl 66
7) Loosen the bolt and nuts to remove slide rail.
3) Remove the hook at bottom of seat backrest.
BOOl 63
4) Remove the hinge cover and screw.
BOOl 6;
8) Remove the hog rings, and then remove seat

back rest cover.
Without side airbag model:
”’
BOO164
5) Remove the two bolts.
3 : Hog ring
BOO161
S E-7
FRONT SEAT
With side airbag model: 3) Turn the cover, and remove the two bolts from
hinge.
3 : Hog ring
e 0 0 3 5 7
9) Remove the hog rings, and then remove the seat

cushion cover. 4) Remove the hinge screw cover and screw, and
Standard type model: remove seat back rest from hinge.
3 : Hog ring
B0035€
Sporty type model: 5) Remove the reclining lever cover and hinge cov-
er.
3 : Hog ring
2. PASSENGER'S SEAT
BO0359 1 B5M0970
1) Remove the seat from the vehicle. <Ref. to SE-

6, REMOVAL, Front Seat.>
2) Remove the hook at bottom of seat back rest.
SE-8
FRONT SEAT
SEATS
6) Loosen four bolts to remove the seat cushion. 9) Remove the hog rings, and then remove the seat
back rest cover.
Without side airbag model:
3 : Hog ring
BOO160
With side airbag model:
B5M096E
7) Loosen four screws to remove the hinge.

3 : Hog ring
10) Remove the hog rings, and then remove the
seat cushion cover.
Standard type model:
8) Loosen two bolts to remove the slide rail.
The lower side of seat rail 3 : Hog ring

B0035E
Sporty type model:

1
3 : Hog ring
BOO359 I
SE-9
FRONT SEAT
SEATS
D: ASSEMBLY
1. DRIVER’S SEAT
NOTE:
Do not contaminate or damage the cover.
While installing the hog rings, prevent the seat
from getting wrinkled.
2. PASSENGER’S SEAT
NOTE:
SEI0
REAR SEAT
SEATS
3. Rear Seat 2. SEDAN

1) Remove the bolts, and then detach rear seat
A: REMOVAL cushion.
1. WAGON
1) Remove the bolts, and then detach rear seat
cushion.
2) Remove the bolts securing lower portion of back-

rest and then open the center trunk through lid.
2) Remove the headrest.

3) Remove the luggage floor mat. <Ref. to El-56,
REMOVAL, Luggage Floor Mat.>
4) Turn over the mat to remove bolts.
3) Lift the rear seat backrest and then remove it.
5 ) Remove the rear seat backrest.
SE-11
REAR SEAT
SEATS
B: INSTALLATION 2) Remove the hog rings from around the seat

backrest.
1. WAGON
2. SEDAN
1) Hook and fasten the upper-back side of the rear
seat backrest to the body hook.
i I
BOO172
3) Remove the hog rings on front side of cushion

pad, and then remove the cover.
2) Tighten the bolts.
4) Remove the hog rings from around the seat

cushion.
3) Hook and fasten the seat cushion to the hook on

the lower part of the rear seat backrest.
I I
5 ) Remove the hog rings, and then remove the cov-

er.
C: DISASSEMBLY
1. WAGON
1) Remove the rear seat. <Ref. to SE-11, WAG-
ON, REMOVAL, Rear Seat.>
SE-12
REAR SEAT
SEATS
2. SEDAN D: ASSEMBLY
1) Remove the rear seat. <Ref. to SE-11, SEDAN, 1. WAGON
REMOVAL, Rear Seat.>
2) Remove the hog rings from around the seat Assemble in the reverse order Of disassembly.
backrest. NOTE:
2. SEDAN
NOTE:
-log ring
BOO180 I

cover.
ring
BOO182
4) Remove the hog rings around the seat cushion.

cover.
I BO0362
SE-13
REAR SEAT
SEATS
SE-14
SECURITY AND LOCKS
Sf
2. Door Lock Control System .......................................................................... 8
3. Keyless Entry System ............................................................................... 12
4. Security System ........................................................................................ 21
5. Front Inner Remote ................................................................................... 28
6. Front Outer Handle ................................................................................... 29
7. Front Door Latch Assembly ....................................................................... 30
8. Front Door Lock Actuator .......................................................................... 31
9. Rear Inner Remote.................................................................................... 32
10. Rear Outer Handle .................................................................................... 33
11. Rear Door Latch Assembly ....................................................................... 34
12. Rear Door Lock Actuator ........................................................................... 35
13. Rear Gate Outer Handle ........................................................................... 36
14. Rear Gate Latch Assembly ....................................................................... 37
15. Rear Gate Latch Lock Actuator ................................................................. 38
16. Trunk Lid Lock Assembly .......................................................................... 39
17. Trunk Lid Release Handle......................................................................... 40
18. Front Hood Lock Assembly ....................................................................... 41
19. Remote Openers ....................................................................................... 42
20 . Ignition Key Lock ....................................................................................... 43
21 . Key Lock Cylinders ................................................................................... 44
22 . Security Control Module ............................................................................ 45
23. Security Horn ............................................................................................ 46
24. Security Horn Relay .................................................................................. 47
25 . Interrupt Relay........................................................................................... 48
26 . Keyless Entry Control Module ................................................................... 49
27. Integrated Module ..................................................................................... 50
28. Keyless Transmitter .................................................................................. 51
I
GENERAL DESCRIPTION
SECURITY AND LOCKS
A: COMPONENT
1. DOOR LOCK ASSEMBLY
FRONT
(4)
BOO397
(1) Inner remote ASSY (6) Striker Tightening torque: N.m (kgf-m, ft-lb)
(2) Inner remote cover (7) Door outer handle T l : 6.4 (0.65, 4.7)
(3) Bell crank (8) Key cylinder T2: 7.4 (0.75, 5.4)
(4) Auto-door lock actuator T3: 14 (1.4, 10.1)
(5) Door latch
SL-2
GENERAL DESCRIPTION
SECURITY AND LOCKS
2. TRUNK LID AND REAR GATE LOCK
TRUNK REAR GATE
5
’ ‘(8)
B0032E
(1) Key cylinder (5) Rear gate outer handle Tightening torque: N.m (kgf-m, ff-lb)
(2) Cable (6) Rear gate actuator T1: 4.5 (0.46, 3.3)
(3) Striker (7) Trunk lid release handle T2: 18 (1.84, 13.3)
(4) Trunk lid lock ASSY (8) Rear gate latch T3: 25 (2.5, 18.1)
sL-3
GENERAL DESCRIPTION
SECURITY AND LOCKS
3. HOOD LOCK AND REMOTE OPENERS
-b-T(5) WAGON
BO0244
(1) Hood lock ASSY (5) Pull handle ASSY Tightening torque: N.m (kgf-m, ft-lb)
(2) Lever ASSY T1: 6.4 (0.65, 4.7)
(3) Cable T2: 32 (3.3, 23.9)
(4) Cover
SL-4
GENERAL DESCRIPTION
SECURITY AND LOCKS
4. KEYLESS ENTRY SYSTEM
(1) Keyless entry control module (3) Door switch

(2) Rear gate latch switch (Wagon) (4) Integrated module
SL-5
GENERAL DESCRIPTION
SECURITY AND LOCKS
5. SECURITY SYSTEM
BO0310
(1) Horn (5) Trunk room light switch (Sedan), (8) Passive arm connector
(2) Security horn rear gate latch switch (Wagon) (9) Security horn relay
(3) Security control module (6) Door switch (10) Interrupt relay
(4) Security indicator light (in combi- (7) Keyless entry control module (1 1) Horn relay (in main fuse box)
nation meter)
.
6: CAUTION
Before disassembling or reassembling the
parts, always disconnect the battery ground
All airbag system wiring harness and
COnneCtOrS are colored yellow. DO not Use the
electrical test equipment on these circuits.
cable. When repairing the radio, control Be careful not to damage the Airbag system
module, etc. which are provided with memory Wiring harness when Servicing the ignition key
functions, record the memory contents before cylinder-
disconnecting battery ground cable.
Otherwise, these contents are cancelled upon
disconnection.
Reassemble the parts in the reverse order of
disassembly procedure unless otherwise
indicated.
Adjust the parts to the specifications
contained in this manual if so designated.
Connect the connectors and hoses securely
during reassembly.
After reassembly, ensure the functional parts
operate smoothly.
The airbag system wiring harness is routed
near the electrical parts and switch.
SL-6
GENERAL DESCRIPTION
SECURITY AND LOCKS
C: PREPARATION TOOL
1. SPECIAL TOOLS
925580000 PULLER Used for removing trim clip
B5M1120
2. GENERAL TOOLS
TOOL NAME REMARKS

Drill Used for replacing ignition key lock.
SL-7
DOOR LOCK CONTROL SYSTEM
SECURITY AND LOCKS
2. Door Lock Control System

A: SCHEMATIC
1. DOOR LOCK CONTROL
<Ref. to WI-64, SCHEMATIC, Door Lock System.>
SL-8
SECURITY AND LOCKS
B: INSPECTION
1. SYMPTOM CHART
~
Symptom Reoair order Reference

The door lock control system does 1. Check the fuse. <Ref. to SL-9, CHECK FUSE,
lot operate. INSPECTION, Door Lock Control
Svstem.>
2. Check the power supply and ground circuit for <Ref. to SL-IO, CHECK POWER
the integrated module. SUPPLY AND GROUND CIRCUIT,
INSPECTION, Door Lock Control
System.>
3. Check the door lock switch and the circuit. <Ref. to SL-10, CHECK DOOR
LOCK SWITCH AND CIRCUIT,
System.>
4. Check the door lock actuator and the circuit. <Ref. to SL-11, CHECK DOOR
LOCK ACTUATOR AND CIRCUIT,
System.>
The driver side or passenger side Check the door lock switch and the circuit. <Ref. to SL-IO, CHECK DOOR
door lock switch does not operate. LOCK SWITCH AND CIRCUIT,
System.>
A specific door lock actuator does not Check the door lock actuator and the circuit. <Ref. to SL-11, CHECK DOOR
operate. LOCK ACTUATOR AND CIRCUIT,
System.>
2. CHECKFUSE
Step Check Yes No

1 CHECK FUSE. Is the fuse blown (15A)? Replace the fuse Check the power
Remove and visually check the fuse No. 2 (in with a new one. supply and ground
the main fuse box) and No. 3 (in the fuse and circuit. <Ref. to
relay box). SL-IO, CHECK
POWER SUPPLY
AND GROUND
CIRCUIT,
INSPECTION,
Door Lock Control
System.>
SL-9
SECURITY AND LOCKS
Step Check
1 CHECK POWER SUPPLY. s the voltage more than 10 V?
1)Disconnect the integrated module harness for open circuits or
connector. shorts between
2)Measure the voltage between the harness the integrated
connector terminal and chassis ground. module and the
Connector & terminal fuse.
2 CHECK GROUND CIRCUIT. s the resistance less than 10
Measure the resistance between the harness 2?
connector terminal and chassis ground. is OK.
-
(6281) No. 4, 13 Chassis ground:
4. CHECK DOOR LOCK SWITCH AND CIRCUIT
Step Check Yes No

I CHECK DOOR LOCK SWITCH CIRCUIT. the resistance less than 10 30 to step 2. Go to step 3.
1)Disconnect the integrated module harness ?
connector.
2)Measure the resistance between the har-
ness connector terminal and chassis ground
when moving the door lock switch to LOCK.
Driver side:
Passenger side:
! CHECK DOOR LOCK SWITCH CIRCUIT. the resistance less than 10
Measure the resistance between the harness ? switch is OK.
connector terminal and chassis ground when
the door lock switch is moved to UNLOCK.
Driver side:
Passenger side:
I CHECK DOOR LOCK SWITCH. the resistance less than 1 30 to step 4. Replace the door
1)Disconnectthe door lock switch harness ? lock switch.
connector.
2)Measure the resistance between the door
lock switch terminals when moving the door
lock switch to LOCK.
Terminal
-
Driver side: No. 5 No. 9:
Passenger side: No. 5 - No. 4:
I CHECK DOOR LOCK SWITCH. the resistance less than 1 ;heck the harness Replace the door
Measure the resistance between the door lock > or open circuits or lock switch.
switch terminals when moving the door lock shorts between
switch to UNLOCK. he integrated
Terminal nodule and the
Driver side: No. 5 - No. 8: loor lock switch.
Passenger side: No. 5 - No. 2:
SL-10
SECURITY AND LOCKS
5. CHECK DOOR LOCK ACTUATOR AND CIRCUIT

~
Step Check Yes No

1 CHECK OUTPUT SIGNAL. Is the voltage more than 10 V? Go to step 2. Replace the inte-
Measure the voltage between the harness con- grated module.
nector terminal and chassis ground when mov-
ing the door lock switch to LOCK.
connector & terminal
2 CHECK OUTPUT SIGNAL. Is the voltage more than 10 V? Go to step 3. Replace the inte-
Measure the voltage between the harness con- grated module.
nector terminal and chassis ground when mov-
ing the door lock switch to UNLOCK.
(8291) No. 7, 8 (+) - Chassis ground (-):
3 CHECK DOOR LOCK ACTUATOR. Is the door lock actuator OK? Check the harness Replace the door
Check the door lock actuator. for open circuits 01 lock actuator.
Front door lock actuator: <Ref. to SL-31, Front shorts between
Door Lock Actuator.> the integrated
Rear door lock actuator: <Ref. to SL-35, Rear module and the
Door Lock Actuator.> door lock actuator.
Rear gate latch lock actuator: <Ref. to SL-38,
Rear Gate Latch Lock Actuator.>
SL-11
KEYLESSENTRYSYSTEM
SECURITY AND LOCKS
3. Keyless Entry System

A: SCHEMATIC
1. KEYLESS ENTRY
<Ref. to WI-90, SCHEMATIC, Keyless Entry Sys-
tem.>
B: ELECTRICAL SPECIFICATION
1. KEYLESS ENTRY CONTROL MODULE
Inl Inl
176 5 4 '
I I I I I I 1
' I
3 2 1'1
I I
I I
Content Terminal No. Measuring condition

Battery voltage is present when pressing the transmitter LOCWARM
Integrated module
(OUTPUT) button one time.
Power supply (Back-up) 3 Battery voltage is constantly present.
Door lock switch 5 (INPUT) 0 V is present when operating the door lock switch.
Trunk room light switch (Sedan),
6 (INPUT) 0 V is present when opening the trunk lid or rear gate.
rear gate latch switch (Wagon)
Ground 8 0 V is constantlv Dresent.
I ,
Battery voltage is present when pressing the transmitter UNLOCWDIS-

Integrated module (OUTPUT) ARM button one time.
Security control module 110 I - I
Securitv control module I11 I - I
0 V is present when pressing the transmitter UNLOCWDISARM or
Horn relay l 2 (OUTPUT) LOCWARM button.
p-ppI
Ignition switch (ON) I 14 (INPUT) I Battery voltaqe is present when ianition switch is turned ON.
Door unlock switch I 15 (INPUT) I 0 V is present when operating the door lock switch. I
Key warning switch I 16 (INPUT) I Battery voltage is present when inserting the key into the ignition switch. I
SL-12
KEYLESSENTRYSYSTEM
SECURITY AND LOCKS
2. INTEGRATED MODULE
1 0 9 8 7 6 5 4 3 2 1
20 19 18 17 1 6 15 14 13 12 11
BOO311
Content Terminal No. Measuring condition

Door switch (Except driver's door) A7 (INPUT) 0V is present when any door is open (Except driver's door).
Door switch (Driver's door) A8 (INPUT) 0V is present when driver's door is open.
Door unlock switch A1 1 (INPUT) 0V is present when operating the door lock switch.
Door lock switch I A12 (INPUT) I0 V is present when operating the door lock switch.
Keyless entry control module I A13 I -
Keyless entry control module A14 -
Ignition switch (ON) A19 (INPUT) Battery voltage is present when iginition switch is turned ON.
Key warning switch A20 (INPUT) Battery voltage is present when inserting the key into ignition switch.
Power SUPP~V B1 Battery voltage is constantly present.
Power supply I 82 I Battery voltage is constantly present.
Ground B4 0 V is constantly present.
0 V is present when pressing the transmitter UNLOCWDISARM button
Room light 85 (OUTPUT) one time*
Battery voltage is present when pressing the transmitter LOCWARM
Door and rear gate lock actuator
B6 (OUTPUT) button one time.
Door and rear gate lock actuator Battery voltage is present when pressing the transmitter UNLOCWDIS-
(Except driver side) B7 (OUTPUT) ARM button two times.
Battery voltage is present when pressing the transmitter UNLOCWDIS-
Door lock actuator (Driver side) B8 (OUTPUT) ARM button one time.
Ground 1813 I o v is constantly present.
SL-13
KEYLESSENTRYSYSTEM
SECURITY AND LOCKS
C: INSPECTION
1. SYMPTOM CHART
Symptom Repair order Reference

None of the functions of the keyless 1. Check the transmitter battery and function. <Ref. to SL-16, CHECK TRANSMIT-
entry system operate. TER BATTERY AND FUNCTION,
INSPECTION, Keyless Entry Sys-
tem.>
2. Check the fuse. <Ref. to SL-17, CHECK FUSE,
tem.>
3. Check the keyless entry control module power <Ref. to SL-17, CHECK POWER
supply and ground circuit. SUPPLY AND GROUND CIRCUIT,
tem.>
4. Replace the keyless entry control module. <Ref. to SL-49, Keyless Entry Control
Module.>
The transmitter cannot be pro- 1. Check the transmitter battery and function. <Ref. to SL-16, CHECK TRANSMIT-
grammed. TER BATTERY AND FUNCTION,
tem.>
2. Check the ignition switch circuit. <Ref. to SL-17, CHECK IGNITION
SWITCH CIRCUIT, INSPECTION,
Keyless Entry System.>
3. Check the door switch. <Ref. to SL-18, CHECK DOOR
SWITCH, INSPECTION, Keyless
Entry System.>
Module.>
The door lock or unlock does not 1. Check the transmitter battery and function. <Ref. to SL-16, CHECK TRANSMIT-
operate. TER BATTERY AND FUNCTION,
NOTE: INSPECTION, Keyless Entry Sys-
If the door lock control system does tem.>
not operate when using the door lock 2. Check the key warning switch. <Ref. to SL-19, CHECK KEY WARN-
switch, check the door lock control ING SWITCH, INSPECTION, Keyless
system. <Ref. to SL-9, INSPECTION, Entry System.>
Door Lock Control System.>
Entry System.>
4. Check the output signal to integrated module. <Ref. to SL-20, CHECK OUTPUT
SIGNAL TO INTEGRATED MOD-
ULE, INSPECTION, Keyless Entry
System.>
Module.>
The panic alarm does not operate. 1. Check the transmitter battery and function. <Ref. to SL-16, CHECK TRANSMIT-
TER BATTERY AND FUNCTION,
tem.>
2. Check the horn operation. <Ref. to SL-19, CHECK HORN
OPERATION, INSPECTION, Key-
less Entrv Svstem.>
Module.>
SL-14
KEYLESSENTRYSYSTEM
SECURITY AND LOCKS
Symptom Repair order Reference

The horn chirp does not operate. 1. Check the horn chirp function. <Ref. to SL-16, CHECK HORN
CHIRP SETTING, INSPECTION,
2. Check the transmitter battery and function. <Ref. to SL-16, CHECK TRANSMIT-
tem.>
3. Check the key warning switch. <Ref. to SL-19, CHECK KEY WARN-
ING SWITCH, INSPECTION, Keyless
Entrv Svstem.>
Entry System.>
less Entry System.>
Module.>
The room light operation does not 1. Check the transmitter battery and function. <Ref. to SL-16, CHECK TRANSMIT-
activate. TER BATTERY AND FUNCTION,
tem.>
2. Check the room light operation. <Ref. to SL-20, CHECK ROOM
LIGHT OPERATION, INSPECTION,
3. Check the key warning switch. <Ref. to SL-19, CHECK KEY WARN-
ING SWITCH, INSPECTION, Keyless
Entrv Svstem.>
Entry System.>
5. Check the output signal to integrated module. <Ref. to SL-20, CHECK OUTPUT
SIGNAL TO INTEGRATED MOD-
ULE, INSPECTION, Keyless Entry
System.>
Module.>
The door warning does not operate. 1. Check the transmitter battery and function. <Ref. to SL-16, CHECK TRANSMIT-
tem.>
Entry System.>
less Entry System.>
Module.>
SL-15
I KEYLESSENTRYSYSTEM
SECURITY AND LOCKS
2. CHECK TRANSMllTER BATTERY AND FUNCTION
Step Check Yes No

1 CHECK TRANSMITTER BATTERY. Is the voltage more than 2 V? Go to step 2. Replace the trans-
1)Remove the battery from the transmitter. mitter battery.
<Ref. to SL-51, REMOVAL, Keyless Transmit-
ter.>
2)Check the battery voltage. <Ref. to SL-51,
INSPECTION, Keyless Transmitter.> I I
2 CHECK LED OF TRANSMITTER. Does the LED blink one time? Go to step 3. Replace the trans-
1)Press the LOCWARM or UNLOCWDISARM mitter. <Ref. to SL-
button six times to synchronize with the key- 51, REPLACE-
less entry control module. MENT, Keyless
2)Press the LOCWARM button. Transmitter.>
3 CHECK LED OF TRANSMITTER. Does the LED blink one time Go to step 4. Replace the trans-
Keep the LOCWARM button pressed. and then turn on? mitter. <Ref. to SL-
51, REPLACE-
MENT, Keyless
Transmitter.>
4 CHECK LED OF TRANSMITTER. Does the LED blink one time? Go to step 5. Replace the trans-
Press the UNLOCWDISARM button. mitter. <Ref. to SL-
51, REPLACE-
MENT, Keyless
Transmitter.>
5 CHECK LED OF TRANSMITTER. Does the LED blink two times? The transmitter is Replace the trans-
Keep the UNLOCWDISARM button pressed. OK. mitter. <Ref. to SL-
51, REPLACE-
MENT, Keyless
Transmitter.>
3. CHECK HORN CHIRP SETTING
Step Check I Yes I No I

I
I
I I
1 CHECK HORN CHIRP SETTING. Does the horn signal chirp? lThe
The horn chirp IGo to step 2.
Check the current setting of the horn chirp. function is OK.
1)Remove the key from the ignition switch.
2)Close all doors and the rear gate or trunk lid.
3)Press the LOCWARM or UNLOCWDISARM
button.
2 CHECK HORN CHIRP SETTING. Does the horn signal chirp? The horn chirp Check the trans-
1)Press the UNLOCWDISARM button once. function is OK. mitter function.
2)Press both the LOCWARM and UNLOCK/ <Ref. to SL-16,
DISARM button for more than 2 seconds. CHECK TRANS-
3)Press the LOCWARM or UNLOCWDISARM MITTER BAT-
button. TERY AND
FUNCTION,
INSPECTION,
Keyless Entry Sys-
tem.>
SL-16
KEYLESSENTRYSYSTEM
SECURITY AND LOCKS
4. CHECKFUSE
Step Check Yes No

1 CHECK FUSE. Is the fuse blown? (15 A) Replace the fuse Check the power
Remove and visually check the fuse No. 2 (in with a new one. supply and ground
the main fuse box) circuit. <Ref. to
SL-17, CHECK
POWER SUPPLY
AND GROUND
CIRCUIT, Keyless
Entry System.>
Step Check Yes No

1 CHECK POWER SUPPLY. Is the voltage more than 10 V? Go to step 2. Check the harness
1)Disconnect the keyless entry control module for open circuits
harness connector. and shorts
2)Measure the voltage between the harness between the key-
connector terminal and chassis ground. less entry control
Connector & terminal module and fuse.
(B176) No. 3 (+) - chassis ground (-):
2 CHECK GROUND CIRCUIT. Repair the har-
Measure the resistance between the harness and ground circuit ness.
connector terminal and chassis ground. are OK.
(8176) No. 8 - chassis ground:
6. CHECK IGNITION SWITCH CIRCUIT
Step Check Yes No

1 CHECK IGNITION SWITCH SIGNAL. Is the voltage more than 10 V? The ignition switch Check the harness
1)Disconnectthe keyless entry control module circuit is OK. for open circuits
harness connector. and shorts
2)Turn the ignition switch ON. between the key-
3)Measure the voltage between the harness less entry control
connector terminal and chassis ground. module and igni-
Connector & terminal tion relay.
(6176) No. 14 (+) - chassis ground (-):
SL-17
KEYLESS ENTRY SYSTEM
SECURITY AND LOCKS
7. CHECK DOOR SWITCH
Step Check Yes No

CHECK DOOR SWITCH CIRCUIT. s the voltage 0 V when each o
Measure the voltage between the keyless entry joor, rear gate and trunk lid is
control module harness connector terminal Ipened?
and chassis ground.
Front and rear door:
(6176)No. 7 (+) - chassis ground (-):
Rear gate or trunk lid:
CHECK DOOR SWITCH CIRCUIT. s the voltage approx. 10 V The door switch is 30 to step 3.
Measure the voltage between the keyless entry Nhen each door, rear gate and IK.
control module harness connector terminal runk lid is closed?
and chassis ground.
I CHECK DOOR SWITCH. s the resistance more than 1 20 to step 4. 3eplace the door
1)Disconnect the door switch harness connec- vlR when the door switch is ;witch.
tor. iushed?
switch terminals.
Terminal
Front LH No. 1 - No. 3:
Front RH No. 1 - No. 3:
Rear RH No. I - No. 3:
Rear gate No. 1 - No. 2:
Trunk lid No. 1 -No. 2:
1 CHECK DOOR SWITCH. s the resistance less than 1 C2 :heck the harness 3eplace the door
Measure the resistance between the door Nhen the door switch is or open circuits ;witch.
switch terminals. .eleased? md shorts
Terminal )etween the key-
Front LH No. 1 -No. 3: ess entry control
Front RH No. 1 - No. 3: nodule and door
Rear LH No. 1 - No. 3: ;witch.
Trunk lid No. 1 - No. 2:
SL-18
KEYLESSENTRYSYSTEM
SECURITY AND LOCKS
8. CHECK KEY WARNING SWITCH
Step Check Yes No

1 CHECK FUSE. s the fuse blown? (15A) Replace the fuse So to step 2.
Remove and visually check the fuse No. 6 (in with a new one.
the main fuse box).
2 CHECK KEY WARNING SWITCH CIRCUIT. s the voltage more than 10 V? Go to step 3. So to step 4.
1)Disconnect the keyless entry control module
harness connector.
2)lnsert the key into the ignition switch. (LOCK
position)
3)Measure the voltage between the harness
connector terminal and chassis ground.
(8176) No. 16 (+) -chassis ground (-):
3 CHECK KEY WARNING SWITCH CIRCUIT. s the voltage 0 V? The key warning Go to step 4.
1)Remove the key from the ignition switch. switch is OK.
2)Measure the voltage between the harness
connector terminal and chassis ground.
(B176) No. 16 (+) - chassis ground (-):
4 CHECK KEY WARNING SWITCH. s the resistance less than 1 Go to step 5. Replace the key
1)Disconnect the key warning switch harness 2? warning switch.
connector.
2)lnsert the key into the ignition switch. (LOCK
position)
3)Measure the resistance between the key
warning switch terminals.
Terminal
NO. 1 - NO. 2:
5 CHECK KEY WARNING SWITCH. Cthe resistance more than 1 Check the Replace the key
1)Removethe key from the ignition switch. m? following: warning switch.
2)Measure the resistance between the key Harnessfor
warning switch terminals. open circuits and
Terminal shorts between
NO. 1 - NO.2: the key warning
switch and fuse
Harness for
open circuits and
shorts between
the keyless entry
control module
and key warning
switch
9. CHECK HORN OPERATION
Step Check Yes No

1 CHECK HORN OPERATION. Does the horn sound? Go to step 2. Check the horn cir.
Make sure the horn sounds when the horn cuit.
switch is pushed.
2 CHECK HORN OPERATION. Does the horn sound? Replace the key- Check the harness
1)Disconnect the keyless entry control module less entry control for open circuits
harness connector. module. and/or shorts
2)Ground the harness connector terminal with between the key-
a suitable wire. less entry control
Connector & terminal module and horn
(B176) No. 12 - chassis ground: relay.
SL-19
KEYLESSENTRYSYSTEM
SECURITY AND LOCKS
10.CHECK ROOM LIGHT OPERATION
Step Check Yes No

1 CHECK ROOM LIGHT OPERATION. Does the room light illuminate? Go to step 2. Check the room
Make sure the room light illuminates when the Iight circuit.
room light switch is turned ON.
2 CHECK HARNESS BETWEEN ROOM LIGHT Is resistance less than 10 Q? The room light Check the harness
AND INTEGRATED MODULE. operation circuit is for open circuits
1)Disconnect the integrated module harness OK. and/or shorts
connector and room light harness connector. between the inte-
2)Measure the resistance between the integrated module and
grated module harness connector terminal and room light.
the room light harness connector terminal.
(6281) NO. 5 - (R52) NO. 2:
Step Check Yes No

1 CHECK OUTPUT SIGNAL. Is the voltage more than 10 V? Go to step 2. Replace the key-
Measure the voltage between the keyless entry less entry control
control module harness connector terminal module.
and chassis ground when UNLOCWDISARM
button of transmitter is pressed.
(61 76) No. 9 (+) - Chassis ground (-):
2 CHECK OUTPUT SIGNAL. Is the voltage more than 10 V? Go to step 3. Replace the key-
Measure the voltage between the keyless entry less entry control
control module harness connector terminal module.
and chassis ground when LOCWARM button
of transmitter is pressed.
(61 76) No. 2 (+) - Chassis ground (-):
3 CHECK HARNESS BETWEEN KEYLESS EN- Is the resistance less than 10
TRY CONTROL MODULE AND INTEGRAT- n?
ED MODULE. shorts between
1)Disconnectthe keyless entry control module the keyless entry
harness connector and integrated module har- control module
ness connector. and integrated
2)Measure the resistance between the keyless module.
entry control module harness connector termi-
nal and integrated module harness conector
terminal.
(61 76) NO. 9 - (6280) NO. 14:
(61 76) NO. 2 - (6280) NO. 13:
sL-20
SECURITY SYSTEM
SECURITY AND LOCKS
4. Security System
A: SCHEMATIC
SCHEMATIC, Security System.>
<Ref. to WI-121,
B: ELECTRICAL SPECIFICATION
06M0972
Content I Terminal No. I Measuring condition

Empty 1 -
Ignition switch (ON) 2 (INPUT) Battery voltage is present when ignition switch is turned ON.
Passive arm 3 -
Trunk room light switch (Sedan), 0 V is present when trunk room light switch or rear gate latch switch is
(INPUT)
rear gate latch switch (Wagon) turned ON.
Door switch 5 (INPUT) 0 V is present when any door is open.
Empty 6 -
Keyless entry control module 7 -
Keyless entry control module 8 -
Securitv indicator liaht 9 (OUTPUT) 0 V is Dresent when activating the alarm operation.
Kevless entry control module I 10 I -
Power supply for clearance light
(Back-uo\
I - - r,
I Battery voltage is constantly present.
Clearance light 12 (OUTPUT) Battery voltage is present when activating the alarm operation.
Power SUDDIV (Back-ud 13 Batterv voltaae is constantlv Dresent.
Ground-- 114 I o v is constantly present.
Interrupt relay 15 (OUTPUT) Battery voltage is present when activating the alarm operation.
Security horn relay 16 (INPUT) Battery voltage is present when activating the alarm operation.
Security horn 17 (OUTPUT) Battery voltage is present when activating the alarm operation.
Securitv horn relav 18 (INPUT) Batterv voltaae is Dresent when activatina the alarm operation.
SL-21
I
SECURITY SYSTEM
SECURITY AND LOCKS
C: INSPECTION
1. BASIC DIAGNOSTIC PROCEDURE
Step Check Yes No

CHECK SECURITY SYSTEM SET OPERA- Can the security system be Go to step 2. Go to symptom 1.
TION. set? <Ref. to SL-23,
1)Before starting this diagnosis, open all win- SYMPTOM
dows. CHART, INSPEC-
2)Remove the key from ignition key cylinder, TION, Security
and then close all doors and rear gate or trunk System.>
lid.
3)Press the LOCWARM button of transmitter.
CHECK SECURITY INDICATOR LIGHT AND Do the security indicator light Go to step 3. Go to symptom 2.
CLEARANCE LIGHT BLINKING. and clearance light blink? <Ref. to SL-23,
Check the security indicator light and clear- SYMPTOM
ance light blinking. CHART, INSPEC-
TION, Security
System.>
CHECK SECURITY ALARM OPERATION. Does the security system not Go to symptom 3. Go to step 4.
1)Unlock all doors using the door lock switch alarm when one of the doors is <Ref. to SL-23,
on front door. opened? SYMPTOM
2)Open any door, rear gate or trunk lid. CHART, INSPEC-
I TION, Security
System.>
CHECK SECURITY ALARM OPERATION. Does the security alarm (horn, Go to step 5. Go to symptom 4.
Check the security alarm operation. clearance light and security <Ref. to SL-23,
indicator light) operate? And is SYMPTOM
the starter motor deactivated? CHART, INSPEC-
TION, Security
System.>
CHECK SECURITY ALARM CANCEL OPER- Does the security alarm (horn Go to step 6. Go to symptom 5.
ATION. and clearance light) stop? And <Ref. to SL-23,
Press the UNLOCWDISARM button of trans- is the starter motor activated? SYMPTOM
mitter. CHART, INSPEC-
TION, Security
System.>
CHECK BATTERY DISCONNECT PROTEC- Is the battery disconnect pro- Go to step 7. Replace the secu-
TION. tection OK? rity control mod-
Check the battery disconnect protection. <Ref. ule.
to SL-22, CHECK BATTERY DISCONNECT
PROTECTION, INSPECTION, Security Sys-
tem.>
PERFORM IMPACT SENSITIVITY TEST. Is the impact sensitivity OK? Press the Replace the secu-
Perform the impact sensitivity test. <Ref. to SL-
45, IMPACT SENSITIVITY TEST, INSPEC-
TION, Security Control Module.> transmitter, and
finish the diagno-
sis.
2. CHECK BATTERY DISCONNECT PROTECTION

1) Remove the key from the ignition switch. If NG, replace the security control module.
2) Close all the doors and rear gate or trunk lid.
3) Open the front hood.
4) Press the LOCWARM button of the transmitter.
5) Disconnect the ground cable from the battery.
6) Reconnect the cable to the battery.
7) Check that the security indicator light blinks after
reconnecting the battery cable.
sL-22
SECURITY SYSTEM
SECURITY AND LOCKS
3. SYMPTOM CHART
SvmDtom Repair order Reference
The security system cannot be set. 1. Check the transmitter func- <Ref. to SL-16, CHECK TRANS-
tion MITTER BATTERY AND FUNC-
TION, INSPECTION, Keyless Entry
System.>
2. Check the fuse. <Ref. to SL-24, CHECK FUSE,
INSPECTION, Securitv Svstem.>
3. Check the security control <Ref. to SL-24, CHECK POWER
module power supply and SUPPLY AND GROUND CIRCUIT,
ground circuit. INSPECTION, Security System.>
SWITCH, INSPECTION, Security
System.>
5. Replace the security control <Ref. to SL-45, Security Control
module. Module.>
The security system can be set, Security indica- Check the security indicator light <Ref.cSL-25, CHECK SECURITY
but the security indicator light or tor light circuit. INDICATOR LIGHT CIRCUIT,
clearance light does not blink. INSPECTION, Security System.>
Clearance light Check the clearance light opera- <Ref. to SL-27, CHECK CLEAR-
tion. ANCE LIGHT OPERATION,
INSPECTION, Security System.>
The security system does not alarm when one of Check the door switch. <Ref. to SL-24, CHECK DOOR
the door is opened. SWITCH, INSPECTION, Security
Svstem.>
The security alarm does not All functions Check the door switch. <Ref. to SL-24, CHECK DOOR
activate. SWITCH, INSPECTION, Security
System.>
Security indica- Check the security indicator light <Ref. to SL-25, CHECK SECURtTY
tor light circuit. INDICATOR LIGHT CIRCUIT,
Security horn Check the security horn. <Ref. to SL-26, CHECK SECURITY
HORN, INSPECTION, Security Sys.
tem.>
Clearance light Check the clearance light opera- <Ref. to SL-27, CHECK CLEAR-
tion. ANCE LIGHT OPERATION,
Starter motor Check the interrupt relay circuit. <Ref. to SL-27, CHECK INTER-
deactivation RUPT RELAY CIRCUIT, INSPEC-
TION, Security System.>
The security system cannot be Transmitter Check the transmitter function. <Ref. to SL-16, CHECK TRANS-
canceled. MITTER BATTERY AND FUNC-
TION, INSPECTION, Keyless Entry
System.>
Ignition switch Check the ignition switch circuit. <Ref. to SL-27, CHECK IGNITION
SWITCH CIRCUIT, INSPECTION,
Security System.>
S L-23
SECURITY SYSTEM
SECURITY AND LOCKS
4. CHECKFUSE
~~
Step Check Yes No

1 CHECK FUSE. Is the fuse blown? (15 A and Replace the fuse Check the power
Remove and visually check the fuse No. 2 and 20 A) with a new one. supply and ground
7 (in main fuse box). circuit. <Ref. to
SL-24, CHECK
POWER SUPPLY
AND GROUND
CIRCUIT,
INSPECTION,
Securitv %stem.>
Step Check Yes No

CHECK POWER SUPPLY. Is the voltage more than 10 V? So to step 2. Check the harness
1)Disconnectthe security control module har- for open circuits
ness connector. and shorts
2)Measure the voltage between the harness between the secu-
connector terminal and chassis ground. rity control module
Connector & terminal and fuse.
CHECK POWER SUPPLY. Is the voltage more than 10 V? Go to step 3. Check the harness
1)Disconnect the security control module har- for open circuits
2)Measure the voltage between the harness between the secu-
connector terminal and chassis ground. rity control module
Connector & terminal and fuse.
CHECK GROUND CIRCUIT. Is the resistance less than 10 The power supply Repair the har-
Measure the resistance between the harness a? and ground circuit ness.
connector terminal and chassis ground. are OK.
(B93)No. 14 - chassis ground:
6. CHECK DOOR SWITCH
Step Check Yes No

1 CHECK DOOR SWITCH CIRCUIT. Is the voltage 0 V when each Go to step 2. Go to step 3.
Measure the voltage between the security con- door, rear gate or trunk lid is
trol module harness connector terminal and opened?
chassis ground.
CHECK DOOR SWITCH CIRCUIT. Is the voltage approx. 10 V The door switch is Go to step 3.
Measure the voltage between the security con- when each door, rear gate or OK.
trol module harness connector terminal and trunk lid is closed?
chassis ground.
SECURITY SYSTEM
SECURITY AND LOCKS
Step Check Yes No

CHECK DOOR SWITCH. Is the resistance more than 1 IGo to step 4. Replace the door
I
1)Disconnectthe door switch harness connec- MR when the door switch is
tor. pushed?
1 switch.

switch terminals.
Terminal
Front LH No. 1 - No. 3:
Front RH No. 1 - No. 3:
Rear RH No. 1 - No. 3:
Trunk lid No. 1 - No. 2: I
I CHECK DOOR SWITCH. I Is the resistance less than 1Q I Check the harness Replace the door
Measure the resistance between the door when the door switch is for open circuits switch.
switch terminals. released? and shorts
Terminal between the secu-
Front LH No. 1 - No. 3: rity control module
Front RH No. 1 -No. 3: and door switch.
Trunk lid No. 1 - No. 2:
7. CHECK SECURITY INDICATOR LIGHT CIRCUIT
Step Check Yes No

I CHECK SECURITY INDICATOR LIGHT. Does the security indicator Replace the secu- Go to step 2.
1)Disconnectthe security control module har- light illuminate? rity control mod-
ness connector. ule.
2)Ground the harness connector terminal with
a suitable wire.
(B93) No. 9 - chassis ground:
2 CHECK POWER SUPPLY FOR SECURITY Is the voltage more than 10 V? Go to step 3. Check the harness
INDICATOR LIGHT. for open circuits
1)Disconnectthe connector from the combina- and shorts
tion meter. between the com-
2)Measure the voltage between the combina- bination meter and
tion meter harness connector terminal and the fuse.
chassis ground.
(i10) No. 10 (+) - chassis ground (-):
3 CHECK SECURITY INDICATOR LIGHT CIR- Is the resistance less than 10 Replace the com- Check the harness
CUIT. R? Dination meter for open circuits
Measure the resistance between the combina- Drinted circuit. and shorts
tion meter harness connector terminal and between the com-
security control module harness connector ter- bination meter and
minal. security control
Connector & terminal module.
( i l l ) No. 6 - (B93) No. 9:
SL-25
SECURITY SYSTEM
SECURITY AND LOCKS
8. CHECK SECURITY HORN

~ ~~
Step Check Yes No

CHECK SECURITY HORN RELAY. the security horn relay OK? Go to step 2. Replace the secu-
Remove and check the security horn relay. rity horn relay.
<Ref. to SL-47, Security Horn Relay.>
, CHECK POWER SUPPLY FOR SECURITY the voltage more than 10 V? Go to step 3. Check the harness
HORN RELAY. for open circuits
Measure the voltage between the security horn and shorts
relay harness connector terminal and chassis between the secu-
ground. rity horn relay and
Connector & terminal horn relay.
I CHECK POWER SUPPLY FOR SECURITY the voltage more than 10 V? Go to step 4. Check the harness
HORN RELAY. for open circuits
Measure the voltage between the security horn and shorts
relay harness connector terminal and chassis between the secu-
ground. rity horn relay and
Connector & terminal the fuse.
(6243) No. 2 (+) - chassis groundI)-(
I CHECK HARNESS BETWEEN SECURITY the resistance less than 10 Go to step 5. Check the harness
HORN RELAY AND SECURITY CONTROL )
for open circuits
MODULE. and shorts
1)Disconnect the security control module har- between the secu-
ness connector. rity horn relay and
2)Measure the resistance between the security security control
horn relay harness connector terminal and module.
security control module harness connector ter-
minal.
(8243) NO. 3 - (693) NO. 18:
HORN RELAY AND SECURITY CONTROL )
for open circuits
MODULE. and shorts
Measure the resistance between the security between the secu-
horn relay harness connector terminal and rity horn relay and
security control module harness connector ter- security control
minal. module.
(6243) NO. 4 - (893) NO. 16:
CONTROL MODULE AND SECURITY HORN )
for open circuits
1)Disconnectthe security horn harness con- and shorts
nector. between the secu-
2)Measure the resistance between the security rity control module
control module harness connector terminal and security horn.
and security horn harness connector terminal.
(693) NO. 17 - (6204) NO. 1:
I
CHECK SECURITY HORN. the security horn OK? Replace the secu- Replace the secu-
Remove and check the security horn. <Ref. to rity control mod- rity horn.
SL-46, Security Horn.> ule.
SL-26
SECURITY SYSTEM
SECURITY AND LOCKS
9. CHECK CLEARANCE LIGHT OPERATION
Step Check Yes No

I CHECK CLEARANCE LIGHT OPERATION. loes the clearance light illumi- Go to step 2. Check the clear-
Turn the parking switch ON and check if the late? ance light circuit.
clearance light illuminates.
2 CHECK POWER SUPPLY FOR SECURITY s the voltage more than 10 V? Go to step 3. Check the harness
CONTROL MODULE. for open circuits
1)Turnthe parking switch OFF. and shorts
2)Disconnect the security control module har- between the secu-
ness connector. rity control module
3)Measure the voltage between the security and the fuse.
control module harness connector terminal
and chassis ground.
3 CHECK HARNESS BETWEEN SECURITY s the resistance less than 10 Replace the secu- Check the harness
CONTROL MODULE AND FUSE BOX. n? rity control mod- for open circuits
1)Disconnect the fuse box harness connector ule. and shorts
(B152). between the secu-
2)Measure the resistance between the security rity control module
control module harness connector terminal and the fuse.
and fuse box harness connector terminal.
(693) NO. 12 - (6152) NO. 11:
10.CHECK INTERRUPT RELAY CIRCUIT
Step Check Yes No

1 CHECK INTERRUPT RELAY. Is the interrupt relay OK? Go to step 2. Replace the inter-
Remove and check the interrupt relay. <Ref. to rupt relay.
SL-48, Interrupt Relay.>
2 CHECK POWER SUPPLY FOR INTERRUPT Is the voltage more than 10 V Go to step 3. Check the harness
RELAY. when the ignition switch is for open circuits
Measure the voltage between the interrupt turned to START? and shorts
relay harness connector terminal and chassis between the inter-
ground. rupt relay and igni-
Connector & terminal tion switch.
3 CHECK HARNESS BETWEEN INTERRUPT Is the resistance less than 10 Replace the secu- Check the harness
RELAY AND SECURITY CONTROL MOD- !2? rity control mod- for open circuits
ULE. ule. and shorts
Measure the resistance between the interrupt between the inter-
relay harness connector terminal and security rupt relay and
control module harness connector terminal. security control
Connector & terminal module.
(659) NO. 4 - (693) NO. 15:
11.CHECK IGNITION SWITCH CIRCUIT
Step Check Yes No

1 CHECK IGNITION SWITCH SIGNAL. Is the voltage more than 10 V? The ignition switch Check the harness
1)Disconnect the security control module har- circuit is OK. for open circuits
2)Turn the ignition switch ON. between the secu-
3)Measure the voltage between the harness rity control module
connector terminal and chassis ground. and ignition switch
SL-27
FRONT INNER REMOTE
SECURITY AND LOCKS
5. Front Inner Remote

A: REMOVAL
3) Remove the screw and the two rod joints.
4) Remove the front inner remote.
B: INSTALLATION
CAUTION:
Make sure the lock works properly after ins,al-
lation.
C: INSPECTION
1) Make sure the rod is not deformed.
2) Make sure the lever and rod work smoothly.
S L-28
FRONT OUTER HANDLE
SECURITY AND LOCKS
6. Front Outer Handle

A: REMOVAL
3) Remove bolt (A).
4) Move the front door glass downward. Remove
the bolt and rod clamp.
5 ) Remove the front outer handle.
CAUTION:
Do not use excessive force to remove the door
panel. This will deform it.
B: INSTALLATION
C: INSPECTION
SL-29
FRONT DOOR LATCH ASSEMBLY
SECURITY AND LOCKS
7. Front Door Latch Assembly

A: REMOVAL
4) Remove the front inner remote. <Ref. to SL-28,
REMOVAL, Front Inner Remote.>
5) Remove the three screws and bolt.
6) Disconnect the connector. Remove the front

door latch assembly.
B: INSTALLATION
CAUTION:
Make sure the lock works properly after instal-
lation.
C: INSPECTION
SL-30
FRONT DOOR LOCK ACTUATOR
SECURITY AND LOCKS
8. Front Door Lock Actuator

A: REMOVAL
1) Remove the front door latch assembly. <Ref. to
SL-28, REMOVAL, Front Inner Remote.>
2) Loosen two screws to remove the front door lock
acutuator.
B: INSTALLATION
C: INSPECTION
1) Disconnect the door lock actuator harness con-
nector.
2) Connect the battery to the door lock actuator ter-
minals.
No. 3 (+) and No. 1 (-) Unlocked + Locked

No. 1 (+) and No. 3 (-) Locked -+ Unlocked
SL-31
REAR INNER REMOTE
SECURITY AND LOCKS
9. Rear Inner Remote

A: REMOVAL
3) Remove the screw and the two rod joints.
4) Remove the inner remote.
B: INSTALLATION
CAUTION:
lation.
C: INSPECTION
3) Make sure the child safety lock on rear doors
work properly, when applicable.
SL-32
REAR OUTER HANDLE
SECURITY AND LOCKS
1O.Rear Outer Handle

A: REMOVAL
3) Remove the rear inner remote. <Ref. to SL-32,
REMOVAL, Rear Inner Remote.>
4) Remove the rear door latch assembly. <Ref. to
SL-34, REMOVAL, Rear Door Latch Assembly.>
5) Loosen two bolts and nut to remove the rear out-
er handle.
CAUTION:
\,\\\ -/r" .. BOO1I11
Do not use excessive force to remove the door

panel. This will deform it.
B: INSTALLATION
C: INSPECTION
SL-33
REAR DOOR LATCH ASSEMBLY
SECURITY AND LOCKS
11.Rear Door Latch Assembly

A: REMOVAL
4) Remove the rear inner remote. <Ref. to SL-32,
REMOVAL, Rear Inner Remote.>
5 ) Remove the three screws and bolt.
6) Disconnect the connector, and then remove the

rear door latch assembly.
B: INSTALLATION
CAUTION:
lation.
C: INSPECTION
SL-34
REAR DOOR LOCK ACTUATOR
SECURITY AND LOCKS
12.Rear Door Lock Actuator

A: REMOVAL
1) Remove the rear door latch assembly. <Ref. to
SL-34, REMOVAL, Rear Door Latch Assembly.>
2) Loosen two screws to remove the rear door lock
acutuator
BOO110
6 : INSTALLATION
CAUTION:
lation.
C: INSPECTION
nector.
minals.
Terminal No. Actuator operation

No. 3 (+) and No. 1 (-) Unlocked + Locked
No. 1 (+) and No. 3 (4 ~~
Locked + Unlocked
If NG, replace the door lock actuator.
sL-35
REAR GATE OUTER HANDLE
SECURITY AND LOCKS
13.Rear Gate Outer Handle

A: REMOVAL
1) Remove the rear gate trim. <Ref. to El-52, RE-
MOVAL, Rear Gate Trim.>
2) Remove the rear gate latch assembly. <Ref. to
SL-37, REMOVAL, Rear Gate Latch Assembly.>
3) Loosen two nuts to remove the rear gate outer
handle.
I
I BOO114
B: INSTALLATION
C: INSPECTION
1) Inspect the rod for deformation.
2) Make sure the lever and rod move smoothly.
SL-36
REAR GATE LATCH ASSEMBLY
SECURITY AND LOCKS
14.Rear Gate Latch Assembly

A: REMOVAL
MOVAL, Rear Gate Trim.>
3) Remove the rear gate key cylinder rod clamp.
4) Remove the three bolts.
4-- 4 BOO112
5) Disconnect the connectors, and then remove the

rear gate latch assembly.
B: INSTALLATION
CAUTION:
lation.
C: INSPECTION
SL-37
REAR GATE LATCH LOCK ACTUATOR
SECURITY AND LOCKS
15.Rear Gate Latch Lock Actua-

tor
A: REMOVAL
2) Loosen two screws to remove the rear gate lock
actuator.
800113 I
B: INSTALLATION
C: INSPECTION
nector.
minals.
BOO191
I No. 1 (+) and No. 2 (-1 I Unlocked + Locked I

I No. 2 (+) and No. 1 (-) I Locked -+ Unlocked I
If NG, replace the rear gate latch lock actuator.
SL-38
TRUNK LID LOCK ASSEMBLY
SECURITY AND LOCKS
16.Trunk Lid Lock Assembly

A: REMOVAL
1) Remove the trunk lid key cylinder rod clamp.
2) Loosen two bolts to remove the trunk lid lock as-
sembly.
BOO115
9: INSTALLATION
CAUTION:
Apply grease to the parts that rub.
Make sure the lock works properly after in-
stallation.
C: INSPECTION
1) Check the striker for bending or abnormal wear.
2) Check the safety lever for improper movement.
3) Check other levers and the spring for rust forma-
tion and unsmooth movement.
sL-39
SECURITY AND LOCKS
17.Trunk Lid Release Handle

A: REMOVAL
1) Remove the five clips.
I
2) Remove the cable from trunk lid release handle.
BOO331
B: INSTALLATION
C: INSPECTION
1) Make sure the cable is not deformed.
2) Make sure the lever works smoothly.
SL-40
FRONT HOOD LOCK ASSEMBLY
SECURITY AND LOCKS
~~
18.Front Hood Lock Assembly

A: REMOVAL
1) Open the hood.
2) Remove the bolt. Remove the hood lock assem-
bly.
3) Remove the release cable from the lock assem-
bly.
I I
I BOO187
B: INSTALLATION
CAUTION:
Apply grease to the parts that rub.
Make sure the release cable works properly
after installation.
C: ADJUSTMENT
Loosen the bolt. Adjust the lock assembly while
moving it up and down.
r
I BOO188
D: INSPECTION
1) Check the striker for bending or abnormal wear.
2) Check the safety lever for improper movement.
3) Check other levers and the spring for rust forma-
tion and unsmooth movement.
SL-41
REMOTE OPENERS
SECURITY AND LOCKS
19.Remote Openers 3. FUEL FLAP OPENER

A: REMOVAL AL, Rear Seat.>
1. HOOD OPENER 2) Remove the center pillar lower trim and side sill
cover on the passenger side. Remove the rear pil-
1) Remove the release cable from the hood lock. lar lower trim. Pull back the floor mat. Remove the
2) Remove the bolt. Remove the opener lever. clip holding the cable.
3) Remove the bolt. Remove the opener pull han-
4
dle.
Wagon
8 I 9
75 1
2. TRUNK LID OPENER

AL, Rear Seat.> 4) Remove the cable from the opener pull handle.
2) Remove the center pillar lower trim and side sill 5) Remove the right rear quarter trim. <Ref. to El-
cover on the passenger side. Remove the rear pil- 47, REMOVAL, Rear Quarter Trim.>
lar lower trim. Pull back the floor mat. Remove the 6) Rotate the fuel lock inside the quarter panel to
clip holding the cable. the left and remove.
3) Remove the bolt. Remove the opener pull han-
dle.
Waaon
?We -
Cover
Pull handle
ASSY
G5M0151
B: INSTALLATION
4) Remove the cable from the opener pull handle. 1. HOOD OPENER
5) Remove the striker from the trunk lid. Install in the reverse order of removal.
6) Remove the cable from the striker.
2. TRUNK LID OPENER
3. FUEL FLAP OPENER
C: INSPECTION
Make sure the fuel flap opens and closes smoothly.
G5M0147
SL-42
IGNITION KEY LOCK
SECURITY AND LOCKS
20.Ignition Key Lock

A: REPLACEMENT
2) Remove the steering column. <Ref. to PS-23,
REMOVAL, Tilt Steering Column.>
3) Secure the steering column in a vise. Remove
the bolt with a drill.
4) Remove the ignition key lock.

5 ) Use a new torn bolt. Tighten the torn bolt to the
end of the thread.

LOCK - -
ACC No. 1 and No. 2 less than 1 R
ON No. 1 and No. 2 less than 1 R
No. 1 and No. 4
No. 2 and No. 4
ST No. 1 and No. 3 less than 1 R
No. 1 and No. 4
No. 3 and No. 4
If NG, replace the ignition switch.
SL-43
KEY LOCK CYLINDERS
SECURITY AND LOCKS
21 .Key Lock Cylinders 3. REARGATE

A: REPLACEMENT MOVAL, Rear Gate Trim.>
1. FRONT DOOR 2) Remove the rod clamp. Remove the lock plate.
Replace the key cylinder.
2) Pull back the sealing cover.
3) Move the front door glass downward.
4) Remove the rod clamp. Remove the bolt. Re-
place the key cylinder.
-
BOO190
2. TRUNKLID
1) Remove the trunk lid release handle. <Ref. to
SL-40, Trunk Lid Release Handle.>
2) Remove the rod clamp. Remove the lock plate.
Replace the key cylinder.
B5M1085
sL-44
SECURITY CONTROL MODULE
SECURITY AND LOCKS
22.Security Control Module 7) Hit the center of the windshield with your palm
and make sure the alarm operates.
A: REMOVAL
1) Disconnect the ground terminal from battery. r- Center of windshield
06M1424A
If NG, adjust the impact sensitivity. <Ref. to SL-45,

1
.
0.
-I : Hook pawl
I+
1,
:: Clip \
\ 000072
ADJUSTMENT, Security Control Module.>
D: ADJUSTMENT
3) Disconnect the connector from the security con-
trol module. 1. IMPACT SENSITIVITY
4) Remove bolt (A) and loosen bolt (B).
NOTE:
NOTE: Before adjustment, make sure the security control
Loosen bolt (B) without completely removing it. module has been securely installed on the bracket.
1) Remove the security control module. <Ref. to
SL-45, REMOVAL, Security Control Module.>
2) Adjust the sensitivity adjust screw in the security
control module.
NOTE:
After adjusting, be sure to plug the adjust screw
hole.
5) Remove the security control module.

B: INSTALLATION
NOTE:
To install the security control module, tighten the
bolts securely so that the bolts do not come loose. B6M1309A
C: INSPECTION 3) Install the security control module.

4) Perform the impact sensitivity test.
1. IMPACT SENSITIVITY TEST
1) Remove the key from the ignition switch.
2) Close all windows.
3) Close all doors and the rear gate or trunk lid.
4) Cover the hood with a blanket.
5) Press the LOCWARM button of the transmitter.
6) Confirm that the security indicator light blinks ev-
ery 2 seconds.
SL-45
SECURITY HORN
SECURITY AND LOCKS
23.Security Horn
A: REMOVAL
2) Remove the nuts and then detach the security
horn while disconnecting the connector.
B0038t
B: INSTALLATION
C: INSPECTION
Connect the battery to the security horn terminal
and case ground and make sure the horn sounds
properly.
B6M1397
If NG, replace the security horn.
SL-46
SECURITY HORN RELAY
SECURITY AND LOCKS
24.Security Horn Relay

A: REMOVAL
2) Remove the mounting bolt and detach the secu-
rity horn relay (near thefuse box).
B: INSTALLATION
C: INSPECTION
Measure the security horn relay resistance be-
tween terminals (indicated in the table below) when
connecting terminal No. 4 to battery positive termi-
nal and terminal No. 1 to battery ground terminal.
I Current I Terminal No. I Standard I
T L lNo flow 2and3
Less than 1 C2
B6M1391
If NG, replace the security horn relay.
SL-47
INTERRUPT RELAY
SECURITY AND LOCKS
25lnterrupt Relay
A: REMOVAL
2) Remove the mounting nuts and detach the inter-
rupt relay (near the fuse box).
B: INSTALLATION
C: INSPECTION
Measure the interrupt relay resistance between ter-
minals (indicated in the table below) when connect-
ing terminal No.4 to battery positive terminal and
terminal No.1 to battery ground terminal.
Flow Less than 1 R
2 and 6
No flow More than 1 M R
86M0994
If NG, replace the interrupt relay.
SL-48
KEYLESS ENTRY CONTROL MODULE
SECURITY AND LOCKS
26.Keyless Entry Control Mod-

ule
A: REMOVAL
3) Remove the nut, then remove the keyless entry
control module while disconnecting the connector.
/------
B: INSTALLATION
SL-49
INTEGRATED MODULE
SECURITY AND LOCKS
27. Integrated Module

A: REMOVAL
3) Remove the nut, then remove the integrated
module while disconnecting the connector.
6: INSTALLATION
SL-50
KEYLESS TRANSMITTER
SECURITY AND LOCKS
28. Keyless Transmitter

A: REMOVAL (+\
\ , .,
(--)
Battery (+) termi- Battery (-) termi-
More than 2 V
1. TRANSMITTER BATTERY nal nal
Remove the battery from the transmitter. If NG, replace the battery. (Use CR2032 or equiva-
NOTE: lent.)
To prevent static electricity damage to the transmit- D: REPLACEMENT
ter printed circuit board, touch the steel area of
building with hand to discharge static electricity car- 1. TRANSMITTER PROGRAMMING
ried on body or clothes before disassembling the
transmitter. NOTE:
Perform the programming when the transmitter is
replaced and when an additional transmitter is re-
quired.
NOTE:
Finish the operation from step 1) through 4) within
45 seconds.
1) Sit on the driver's seat and close all doors, rear
gate and trunk lid.
2) Open the driver's door.
3) Close the driver's door.
B6M0950 4) Turn the ignition switch from ON to LOCK ten
times within 15 seconds.
B: INSTALLATlON
NOTE:
1. TRANSMITTER BATTERY Do not start the engine at this time.
Install in the reverse order of removal. 5) The horn chirps one time to indicate that the sys-
tem has entered in the programming mode.
C: INSPECTION 6) Open the driver's door.
1. TRANSMITTER BATTERY 7) Close the driver's door.
8) Press any button on the transmitter that you wish
Measure the voltage between the battery (+) termi- to program into the system.
nal and (-) terminal. 9) Horn will chirp two times to indicate that the
NOTE: transmitter has been programmed.
Battery discharge occurs during the measure- NOTE:
ment. Complete the measurement within 5 sec- Any additional transmitter can also be programmed
onds. at this time. Repeat steps 6) through 9) for an addi-
During the battery voltage measurement, the tional transmitter.
voltage falls more than 1.8 volts in 3 seconds peri-
10) Remove the ignition key from the ignition
od.
switch.
11) The horn will chirp three times to indicate that
the system has exited the programming mode.
12) Check the keyless entry system properly oper-
ates by operating each transmitter.
iA
SL-51
KEYLESS TRANSMITTER
SECURITY AND LOCKS
SL-52
EXTERIOR/INTERIOR TRIM
Page
2. Front Grille ................................................................................................ 18
3. Hood Grille ................................................................................................ 19
4. Front Under Cover .................................................................................... 22
5. Front Bumper ............................................................................................ 23
6. Rear Bumper ............................................................................................. 30
7. Mud Guard ................................................................................................ 32
8. Cowl Panel ................................................................................................ 33
9. Roof Spoiler .............................................................................................. 34
10. Rear Spoiler .............................................................................................. 35
11. Side Sill Spoiler ......................................................................................... 36
12. Front Door Trim ......................................................................................... 37
13. Rear Door Trim ......................................................................................... 38
14. Glove Box.................................................................................................. 39
15. Roof Rail ................................................................................................... 40
16. Console Box .............................................................................................. 41
17. Instrument Panel Assembly ...................................................................... 42
18. Upper Inner Trim ....................................................................................... 45
19. Lower Inner Trim ....................................................................................... 46
20. Rear Quarter Trim ..................................................................................... 47
21 . Sun Visor ................................................................................................... 49
22. Roof Trim .................................................................................................. 50
23. Rear Gate Trim ......................................................................................... 52
24. Rear Shelf Trim ......................................................................................... 53
25 . Trunk Trim ................................................................................................. 54
26 . Floor Mat ................................................................................................... 55
27 . Luggage Floor Mat .................................................................................... 56
28 . Trunk Room Mat ....................................................................................... 57
GENERAL DESCRIPTION
EXTERIOR/INTERlOR TRIM
A: COMPONENT
1. FRONT GRILLE
BOO293
(1) Front grille (2) Front grille emblem (3) Clip
2. UNDER COVER
BOO294
(1) Under cover (3) Clip Tightening torque: N.m (kgf-m, ft-lb)
(2) Clip (side) T: 14 (1.42, 10.3)
El-2
GENERAL DESCRIPTION
EXTERIOFUINTERIORTRIM
3. HOOD GRILLE
BOO403
(1) Hood grille (7) Clip Tightening torque: N-m (kgf-myft-lb)

(2) Bolt (8) Black clip T: 4.4 (0.45, 3.25)
(3) Metal washer (9) White clip
(4) Foam rubber washer (IO) Packing
(5) Grille duct (11) Packing
(6) Grille lower duct
El-3
GENERAL DESCRIPTION
EXTERIOWINTERIOR TRIM
4. FRONT BUMPER
I BO0281
(1) Bumper face (5) License plate bracket Tightening torque: N.m (kgf-m, ft-lb)
(2) Head light side cover (6) Bumper energy absorber T1: 32 (3.3,24)
(3) Bumper side bracket (7) Bumper back beam T2: 69 (7.0,51)
(4) Bumper corner bracket
El-4
GENERAL DESCRIPTION
5. REAR BUMPER
BO0282
(1) Bumper face (5) Bumper side cover Tightening torque: N.m (kgf-m, ft-lb)
(2) Bumper upper beam (6) License plate base T1: 33 (3.4,24)
(3) Bumper corner bracket (7) Bumper energy absorber T2: 34 (3.5,25)
(4) Bumper side bracket (8) Bumper back beam T3: 95 (9.7, 70)
El-5
GENERAL DESCRIPTION
6. MUDGUARD
Q
BOO
(1) Mud guard (3) Sub frame cover (5) Mud guard plate
(2) Clip (4) Brake duct plate
7. COWLPANEL
%
BO0297
(1) Cowl panel (3) Protector

(2) Cowl side panel (4) Seal
El-6
GENERAL DESCRIPTION
8. ROOF SPOILER
(1) Roof spoiler (3) Clip Tightening torque: N.m (kgf-m, ft-lb)
(2) Cap T: 7.35 (0.749, 5.42)
9. REAR SPOILER
BOO299
(1) Rear spoiler (4) Grommet Tightening torque: N.m (kgf-m, ft-lb)
(2) Protector (5) Seal (only RH side) E 7.4 (0.75, 5.46)
(3) Clip (6) High mount stop lamp
El-7
GENERAL DESCRIPTION
10.SIDE SILL SPOILER
BOO300
(1) Side sill spoiler (3) Protector (5) Clip

(2) End cover (4) Rivet clip (6) Spoiler clip
El-8
GENERAL DESCRIPTION
11.DOOR TRIM
BOO253
(1) Gusset cover (4) Clip (7) Lower trim

(2) Bracket (5) Trim panel
(3) Weatherstrip upper (6) Power window switch cover
El-9
GENERAL DESCRIPTION
EXTERIOR/INTERIORTRIM
12.ROOF RAIL
I
@--m
BOO301
(1) Roof rail Tightening torque: N.m (kgf-m, ft-lb)

T: 7.4 (0.75, 5.46)
El-1 0
m
GENERAL DESCRIPTION
13.CONSOLE BOX
BOO302
(1) Console cover (7) Rear lid (13) Lock

(2) Cup holder (8) Console box (14) Front cover (MT)
(3) Bracket (9) Console pocket (15) Boot
(4) Strip (10) Upper bracket (16) Front cover (AT)
(5) Upper lid (11) Pad
(6) Lid hinge (12) Lower bracket
El-I 1
GENERAL DESCRIPTION
14.1NSTRUMENT PANEL
80030:
(1) Pad &frame (9) Air vent grille (Side) (17) Glove box panel
(2) Center upper panel (10) Lower cover (18) Console rein forcement
(3) Air vent grille (Defroster) (1 1)Console cover (19) Coin box
(4) Grille cover (12) Center panel
(5) Meter visor (13) Center pocket Tightening torque: N.m (kgf-m, ft-lb)
(6) Defroster grille (14) Ash tray T: 7 (0.71, 5.2)
(7) Cup holder (15) Audio bracket
(8) Air vent grille (Center) (16) Glove box lid
El-12
GENERAL DESCRIPTION
15.1NNER TRIM (SEDAN)
BOO38C
(1) Front pillar upper trim (6) Trunk rear trim (1 1) Side sill front cover
(2) Center pillar upper trim (7) Trunk side trim (12) Front garnish
(3) Rear pillar upper trim (8) Rear pillar lower trim (13) Rear garnish
(4) Rear shelf trim (9) Side sill rear cover
(5) Rear bulk trim (10) Center pillar lower trim
El-13
GENERAL DESCRIPTION
16.INNER TRIM (WAGON)
BO0381
(1) Front pillar upper trim (6) Rear quarter lower trim (1 1) Side sill front cover
(2) Center pillar upper trim (7) Hook (10) Front garnish
(3) Rear pillar upper trim (8) Rear skirt trim (11) Rear garnish
(4) Rear rail trim (9) Side sill rear cover (12) Front garnish
(5) Rear pillar lower trim (10) Center pillar lower trim (13) Rear garnish
El-14
GENERAL DESCRIPTION
17.ROOF TRIM (SEDAN)
BO0304
(1) Roof trim
18.ROOF TRIM (WAGON)
BOO305
(1) Roof trim (2) Roof trim (sun roof model) (3) Sun roof garnish
El-I 5
GENERAL DESCRIPTION
19.LUGGAGE FLOOR MAT
BO0306
(1) Front floor mat (3) Side floor mat (RH) (5) Side floor mat (LH)
(2) Floor box (4) Center floor mat
El-I 6
GENERAL DESCRIPTION
EXTERIOWINTERIORTRIM
20.1NNER ACCESSORIES
TOOL NAME REMARKS

I Clip remover I Used for removal of trim. I
El-17
FRONT GRILLE
2. Front Grille
A: REMOVAL
1) Open the hood.
2) Remove the four clips.
I 0L-
1: clip
.-----J
BOO055
3) Remove the two hooks.
B: INSTALLATION
El-I 8
HOOD GRILLE
3. Hood Grille
A: REMOVAL
1) Remove the four clips of hood insulator.
80037'
2) Remove seven bolts and clip (A) to remove the

hood duct.
/(A) I
3) Remove three nuts.

0
4) Remove three white clips and two black clips to

remove the hood grille.
v
I
El-I 9
HOOD GRILLE
B: INSTALLATION
(A) White clip (6) Black clip (C) Bolt

1) Replace the black clip ( I ) , (2) with a new one. In- 3) Attach the metal washer (A) only to bolt (6). At-
stall the clip with arrow mark facing the front side of tach the foam rubber washer (B) to bolt (6), (7),
(8).
grille (A).
BOO376
2) Replace the white clip (3), (4),(5) with a new

one. Install the white clip (3),(4) by aligning the rib
of clip parallel with the grille fronthear direction (A).
CAUTION:
Do not use foam rubber washer with new white
clips.
I I
B0037E
El-20
HOOD GRILLE
EXTERIOR/INTERlORTRIM
4) Insert the hood grille clip and engage the five 7) Install the hood duct with clip (A) and seven
clips. bolts.
CAUTION:
Make sure that the anchor portion of each clip
is firmly engaged.
0
8) Install the hood insulator with four new clips.
5 ) Install the three nuts.

Tightening torque:
4.4 N-m (0.45 kgf-m, 3.25 fWb)
0
C: INSPECTION
Make sure that the clip is firmly engaged.
Make sure that there is no abnormal gap at whole
periphery of hood grille.
Make sure that there is no damage on hood grille.
6) Catch the two hooks of hood duct to the hood
holes.
El-21
FRONT UNDER COVER
EXTERlORllNTERlOR TRIM
4. Front Under Cover

A: REMOVAL
2) Loosen the bolts and clips to remove the under
cover.
Q BO0382
B: INSTALLATION
El-22
FRONT BUMPER
5. Front Bumper 6) Disconnect the fog light connector to remove the

bumper.
A: REMOVAL
CAUTION:
Handle the bumper carefully to avoid damage
to the bumper face.
Do not damage the body during removal or
installation of bumper.
To avoid damage to the bumper, lay the re-
moved bumper on sheet spread on the floor. Do
not lay it directly on the floor.
1) Disconnect the ground terminal from battery. ‘\I B0005E
2) Remove the front grille. <Ref. to El-18, REMOV-
AL, Front Grille.> 7) Remove the E/A FORM from bumper beam.
3) Loosen the three clips to remove the head light CAUTION:
side cover. E/A FORM may easily break. Do not apply ex-
I cessive force to it during removal.
B0006C
4) Pull off the front side of front mud guard to re-
move the clip. 8) Remove the bumper beam.
d BO0391
5) Remove clips, and pull out bumper slightly.
El-23
FRONT BUMPER
B: INSTALLATION
CAUTION:
to the bumper face.
1) install in the reverse order of removal.
2) Fit the slider (A) to guide plate (B) securely.
Tightening torque:
Refer to COMPONENT of General Description
for tightening torque. <Ref. to El-4, FRONT
BUMPER, COMPONENT, General Descrip-
tion.>
El-24
FRONT BUMPER
C: REPAIR
1. COATING METHOD FOR PP BUMPER
~~
Pro-
cess Process name Job contents
No.
Set the bumper on paint worktable if required.

1 Bumper mounting Use paint worktable conforming to inner shape
of bumper when possible.
Set bumper section G5M0164
Mask specified part (black base) with masking tape. Use masking tape for PP (example, Nichiban
2 Masking
No. 533, etc.).
Degreasing, clean-
3 Clean all parts to be painted with white gasoline, normal alcohol, etc. to remove dirt, oil, fat, etc.
ing
4 Primer paint Apply primer one to all parts to be painted, using air gun. Use primer (clear).
Dry at normal temperature [IO to 15 min. at 20°C (68"F)I.
5 Drying In half-dried condition, PP primer paint is dissolved by solvent, e.g. thinner, etc.
Therefore, if dust or dirt must be removed, use ordinary alcohol, etc.
Solid color Metallic color
Use section (block) paint for top coat. Use section (block) paint for top coat.
Paint in use (for each color): Paint in use (for each color):
Solid paint Metallic paint
Hardener PB Hardener PB
Thinner T-301 Thinner T-306
Top coat paint (I)
Mixing ratio: Mixing ratio:
Main agent vs. hardener = 4:l Main agent vs. hardener = 1O:l
Viscosity: 10 - 13 sec/20"C (68°F) Viscosity: 10 - 13 sec/20"C (68°F)
Film thickness: 35 - 45p Film thickness: 15 - 20p
Spraying pressure: 245 - 343 kPa Spraying pressure: 245 - 343 kPa
(2.5 - 3.5 kg/cm2,36 - 50 psi) (2.5 - 3.5 kg/cm2,36 - 50 psi)
Dry at normal temperature [ l o min. or more at
Drying Not required. 20°C (68"F)I.
In half-driedcondition, avoid dust, dirt.
Apply a clear coat to parts with top coat paint
(I), three times, at 5 - 7 minutes intervals.
Paint in use:
Metallic paint
Hardener PB
8 Top coat paint (11) Not required. Thinner T-301
Mixing ratio: Clear vs. hardener = 6:l
Viscosity: 14 - 16 sec/2O0C(68°F)
Film thickness: 25 - 30p
Spraying pressure: 245 - 343 kPa
(2.5 - 3.5 kQ/Cm2,36 - 50 Psi)
60°C (140"F), 60 min. or 80°C (176"F), 30 min.
9 Drying
If higher than 80°C (176"F), PP may be deformed. Keep maximum temperature of 80°C (176°F).
10 Inspection Faint check.
11 Masking removal Remove masking in process No. 2.
El-25
FRONT BUMPER
2. REPAIR INSTRUCTIONS FOR COLORED PP BUMPER

NOTE:
All PP bumpers are provided with a grained surface, and if the surface is damaged, it cannot normally be re-
stored to its former condition. Damage limited to shallow scratches that cause only a change in the lustre of
the base material or coating, can be almost fully restored. Before repairing a damaged area, explain this point
to the customer and get an understanding about the matter. Repair methods are outlined below, based on a
classification of the extent of damage.
Minor damage causing only a change in the lustre of the bumper due to a light touch
Almost restorable.
Process name Job contents
Cleaning Clean the area to be repaired using water.

Sanding Grind the repairing area with #500 sand paper in a “feathering” motion.
Resin section Coated section
Repeatedly apply wax to the affected area
using a soft cloth (such as flannel). Recom- Perform either the same operation as for the
Finish mended wax: NITTO KASEI Soft 99 TIRE WAX resin section or process No. 18 and subse-
BLACK, or eauivalent. quent operations in the “(3)” section, depending
Polish the waxed area with a clean cloth after 5 on the degree and nature of damage.
to 10 minutes.
Deep damage caused by scratching fences, etc.
A dent cannot be repaired but a whitened or swelled part can be removed.
Pro-
No.
1 I cleaning I Clean damaged area with water. I
Removal of dam-
aaed area
1
I
Cut off protruding area, if any, due to collision, using a putty knife.
3 I Sandina I Grind the affected area with #lo0 to #500 sand DaDer.
I L
Resin section I
Coated section I
4 Finish Perform Process No. 12 and subsequent oper-
Same as Process No. 3 in the “(1)” section.
ations in the “(3)” section.
El-26
FRONT BUMPER
Deep damage such as a break or hole that requires filling

Much of the peripheral grained surface must be sacrificed for repair, and the degree of restoration is not really
worth the expense. (The surface, however, will become almost flush with adjacent areas.)
Recommended repair kit: PP Part Repair Kit (NRM)
Pro-
No.
1 BumDer removal Remove the bumper as required.
2 Part removaI Remove the parts built into bumper as required.
I
Place the bumper on a paint worktable as

required.
Bumper placement
It is recommended that contour of worktable
accommodate internal shape of bumper.
I Set bumper section G5M0164
Surface prepara-
tion
Unit: mm (in)
20 - 30 (0.79- 1.18)
If nature of damage are cracks or holes, cut a

guide slit of 20 to 30 mm (0.79 to 1.18 in) in
1
Cutting length along the crack or hole up to the
bumper's base surface. Then, bevel or "vee-
out" the affected area using a knife or grinder.
f
3 (0,~~)
surface
G5M0165
Sandina (I) Grind beveled surface with sand paper (#40 to #60) to smooth finish.
7 Cleaning Clean the sanded surface with the same solvent as used in Process No. 4.
Grind the side just opposite the beveled area with sand paper (#40 to #60) and clean using a sol,
vent.
TemDorarilv sDot-weld the side, usinq a PP welding rod and heater gun.
Welded spot (Use heater gun

and PP welding rod)
8 Temporary welding
Beveled section
G5M016E
NOTE:
.Do not melt welding rod until it flows out. This results in reduced strength.
Leave the welded mot unattended until it cools completely.
El-27
FRONT BUMPER
Pro-
No.
Using a heater gun and PP welding rod, weld the beveled spot while melting the rod and dam-
aged area.
9 Welding Melt hatched Section

area
G5M0167
NOTE:
Melt the sections indicated by hatched area.
Do not melt the welding rod until it flows out, in order to provide strength.
Always keep the heater gun 1 to 2 cm (0.4 to 0.8 in) away from the welding spot.
Leave the welded sDot unattended until it cools completely.
Remove excess part of weld with a putty knife. If a drill or disc wheel is used instead of the knife,
operate it at a rate lower than 1,500 rpm and grind the excess part little by little. A higher rpm will
cause the PP substrate to melt from the heat.
10 Sanding (11)
G5M0168
Sand the welded spot smooth with #240 sand paper.

Mask the black substrate section using masking tape.
11 Masking
Recommended maskina taDe: Nichiban No. 533 or eauivalent
~~
Cleaning/
12 Completely clean the entire coated area, using solvent similar to that used in Process No. 4.
degreasing
Apply a coat of primer to the repaired surface and its surrounding areas. Mask these areas, if nec-
essary.
Recommended primer: Mpl364 PP Primer
13 Primer coating
NOTE:
Be sure to apply one coat of primer at a spraying pressure of 245 to 343 kPa
(2.5 to 3.5 kg/cm2, 36 to 50 psi) with a spray gun.
Leave the repaired area unattended at 20°C (68°F) for 10 to 15 minutes until primer is half-dry.
14 Leaveunattended. NOTE:
If dirt or dust comes in contact with the coated area, wipe it off with a cloth dampended with alcohol.
(Donot use thinner since the coated area tends to melt.)
Apply a COG ofprimer surfacer to the repaired area two or three times at an interval of 3 to 5 min-
utes.
Recommended surfacer:
UPS 300 Flex Primer
Primer surfacer No. 303 UPS 300 Exclusive hardener
15
coating
NPS 725 Exclusive Reducer (thinner)
Mixing ratio: 2 : 1 (UPS 300: No. 303)
Viscosity: 12 - 14 sec/20"C (68°F)
Coated film thickness: 40 - 50u
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 (Ill) Sand the coated surface and its surrounding areas using #400 sand paper and water.
CIeaning/
18 Same as Process No. 12.
degreasing
El-28
FRONT BUMPER II
~
Pro-
No.
Solid color Metallic color
Use a "block" coating method. Use a "block" coating method.
Recommended paint: Recommended paint:
Suncryl (SC) Suncryl (SC)
No. 307 Flex Hardener No. 307 Flex Hardener
SC Reducer (thinner) SC Reducer (thinner)
19 Top coat (I) Mixing ratio: 3 : 1 Mixing ratio: 3 : 1
Suncryl (SC) vs. No. 307 Flex Hardener Suncryl (SC) vs. No. 307 Flex Hardener
Viscosity: 11 - 13 sec/2O0C (68°F) Viscosity: 11 - 13 secI20"C (68°F)
Coated film thickness: 40 - 50p Coated film thickness: 20 - 30p
Spraying thickness: 245 - 343 kPa Spraying thickness: 245 - 343 kPa
(2.5 - 3.5 kg/cm2,36 - 50 psi) (2.5 - 3.5 ka/cm2, 36 - 50 psi)
Leave unattended at 20°C (68°F) for at least 10
minutes until the topcoated area is half-dry.
20 Leave unattended. Not required. NOTE:
Be careful to keep dust or dirt from coming ir
contact with the affected area.
Apply a clear coat three times at an interval of 3
to 5 minutes.
Recommended paint:
SC710 Overlay Clear
No. 307 Flex Hardener
SC Reducer (thinner)
21 Top coat (11) Not required. Mixing ratio: 3 : 1
Suncryl (SC) vs. No. 307 Flex Hardener
Viscosity: 10 - 13 sec/20"C (68°F)
Coated film thickness: 20 - 30p
Spraying pressure: 245 - 343 kPa
(2.5 - 3.5 ka/cm2.36 - 50 ,Dsi),
" I
22 Drying NOTE:
Do not allow the temperature to exceed 80°C (176°F) since this will deform the PP substrate.
23 Inspection Carefully check the condition of the repaired area.
24 Maskina removal Remove the masking tape applied in Process No. 11 and 13.
25 Parts installation Install parts on the bumper in reverse order of removal.
26 Bumper installation Install the bumper.
El-29
REAR BUMPER
6. Rear Bumper 7 ) Pull off the rear end of rear quarter lower trim,
and then loosen the two nuts from each side to re-
A: REMOVAL move the rear bumper.
1. WAGON
CAUTION:
to the bumper face.
To avoid damage to the bumper, lay the re-
moved bumper on sheet spread on the floor. Do
not lay it directly on the floor.
2) Remove the bolts and clips. 8) Loosen the clips to remove the bumper beam.
BOO283
9) Remove the E/A FORM from bumper beam.

CAUTION:
E/A FORM may easily break. Do not apply ex-
cessive force to it during removal.
I I
\ -
BOO063

<Ref. to LI-18, REMOVAL, Rear Combination Light
Assembly.>
4) Remove the screw and two clips from each side.
10) Remove the bolt.
BOO064
5) Remove the floor box. U BOO285
6) Remove the rear skirt trim.
El-30
REAR BUMPER
~
~~
11) Remove the canister. <Ref. to EC(S0HC)-5,

REMOVAL, Canister.>
12) Remove the three bolts, then remove the
bumper beam.
2. SEDAN
Refer to rear bumper removal WAGON. <Ref. to
El-30, WAGON, REMOVAL, Rear Bumper.>
B: INSTALLATION
1. WAGON
CAUTION:
to the bumper face.
Tightening torque:
for tightening torque. <Ref. to €1-5, REAR
tion.,
2. SEDAN
CAUTION:
to the bumper face.
Tightening torque:
for tightening torque. <Ref. to €1-5, REAR
tion.>
C: REPAIR
Refer to front bumper repair. <Ref. to El-23, RE-
MOVAL, Front Bumper.>
El-31
MUD GUARD
7. MudGuard
A: REMOVAL
1) Jack-up the vehicle.
2) Loosen the screws and clips to remove the mud
guard.
BO0399
B: INSTALLATION
Insert the hook into body, and tighten it with screw
and clip.
El-32
COWL PANEL
8. Cowl Panel
A: REMOVAL
1) Open the hood.
2) Remove the wiper arm. <Ref. to WW-12, RE-
MOVAL, Front Wiper Arm.>
3) Remove the front panel seal.
4) Loosen the clips to remove the cowl panel.

, / 0
\
B: INSTALLATION
El-33
ROOF SPOILER
9. Roof Spoiler
A: REMOVAL
1) Remove the bolt cap, then remove the two bolts.
2) Detach the roof spoiler.
I\\ \ BO030
B: INSTALLATION
El-34
REAR SPOILER
10.Rear Spoiler
A: REMOVAL
2) Open the trunk lid.
3) Remove the electrical connector (A) of high-
mounted stop light.
4) Loosen the mounting nut of rear spoiler to re-
move the rear spoiler.
CAUTION:
When removing the nut, do not drop it into
trunk lid.
Pay attention to avoid damage during remov-
al or installation.
B: INSTALLATION
1) install in the reverse order of removal.
2) Clean the mounting surfaces of trunk lid and
spoiler before installation.
El-35
SIDE SILL SPOILER
11.Side Sill Spoiler

A: REMOVAL
Remove the clips (1 on front, 6 on lower), then re-
move the side sill spoiler.
BO0004
6: INSTALLATION
El-36
FRONT DOOR TRIM
12.Front Door Trim B: INSTALLATION

A: REMOVAL
CAUTION:
Do not apply excessive force to the clip. Other-
wise the clip may be broken.
2) Pull up the inner remote cover toward you to re-
move the upper hook. Pull down it to remove the
lower hook. Remove the inner remote cover.
3) Remove the screw.

4) Remove the power window switch assembly and
disconnect the harness connector.
5 ) Remove the screw.

6) Remove the clips of trim panel using clip remov-
er to remove the trim panel.
El-37
REAR DOOR TRIM
13.Rear Door Trim 5) Disconnect the power window harness connec-

tor.
A: REMOVAL
CAUTION:
Do not apply excessive force to the clip. Other-
wise the clip may be broken.
2) Pull up the inner remote cover toward you to re-
move the upper hook. Pull down it to remove the
lower hook. Remove the inner remote cover.
B: INSTALLATION
3) Remove the screw and clip.
4) Remove the clips of trim panel using clip remov-

er to remove the trim panel.
El-38
GLOVE BOX
EXTERIORANTERIOR TRIM
14.Glove Box
A: REMOVAL
1) Open the glove box.
2) Loosen the screws to remove glove box.
B: INSTALLATION
Install in the reverse order of removal
El-39
I
ROOF RAIL
15.Roof Rail
A: REMOVAL
1) Remove the roof trim. <Ref. to El-50, REMOVAL, Roof Trim.>
2) Remove the four mounting nuts and then detach the roof rail carefully.
B: INSTALLATION
CAUTION:
Be careful not to scratch the body panels with
roof rail stud bolts when removing and install-
ing them.
El-40
CONSOLE BOX
EXTERIOFUINTERIORTRIM
16.Console Box B: INSTALLATION

A: REMOVAL
I c
.
'.,I: Hook pawl
E
Clip
i~,: \ ' BOO072
3) Remove the shift knob (MT model) and front cov-

er.
4) Loosen the screws to remove the console box.
I I--
I BOO074
El-41
INSTRUMENT PANEL ASSEMBLY
EXTER IORA NTERIOR TR I M
17.lnstrument Panel Assembly 8) Remove the two nuts and disconnect the two
connectors.
A: REMOVAL
WARNING:
All airbag system wiring harness and con-
Be careful not to damage the airbag system
harness when servicing the instrument panel.
2) Loosen the screws and clips to remove the lower
cover.
I I
W
' S5M0044A 1
AL, Glove Box.>
4) Remove the center console panel. <Ref. to AC-
25, REMOVAL, Control Unit.>
5) Remove the passenger airbag module. <Ref. to
AB-13, Passenger's Airbag Module.>
6) Loosen the four screws and two nuts to remove
the lower console panel.
BOO
7) Loosen the hooks to remove the defroster panel.
El-42
9) Remove the instrument panel mounting bolts.
10) Remove the instrument panel. CAUTION:

CAUTION: Take care not to scratch the instrument panel
Do not pull the harness when disconnecting the and related Parts.
connector.
NOTE:
If necessary, make matching marks for easy reas-
sembly.
El-43
When storing the removed instrument panel, B: INSTALLATION

place it standing up on the floor. Install in the reverse order of removal.
CAUTION:
Be careful not to snag the harness.
Make sure to connect the harness connector.
Take care not to scratch the instrument panel
and related parts.
NOTE:
When setting the instrument panel into position,
push the hook into grommet (A) on the body panel.
G5M060;
I “‘2 L BOO152
El-44
UPPER INNER TRIM
18.Upper Inner Trim

A: REMOVAL
1) Remove the lower inner trim. <Ref. to El-46, RE-
MOVAL, Lower Inner Trim.>
2) Remove the front mole (A).
3) Remove the front pillar upper trim (B).
4) Detach the front seat belt shoulder anchor, then
remove the center pillar upper trim (C).
I
I B5M1021A
B: INSTALLATION
CAUTION:
Be sure to securely hook pawls of inner trim
panel to body flange.
NOTE:
When installing the center pillar upper trim and
front pillar upper trim, be sure to set the front mole
as shown in figure.
b-1
Outside Inside
Weatherstrip
Trim
B5M0673A
El-45
LOWER INNER TRIM
19.Lower Inner Trim

A: REMOVAL
1) Remove the side sill front cover (A).
2) Remove the rear seat cushion <Ref. to SE-11,
REMOVAL, Rear Seat.>, then remove side sill rear
cover (B).
3) Remove the center pillar lower trim (C).
..
‘,-I Hook pawl
BO0075
B: INSTALLATION
CAUTION:
El-46
REAR QUARTER TRIM
m
20.Rear Quarter Trim 2. WAGON

A: REMOVAL AL, Rear Seat.>
1. SEDAN 2) Remove the side sill rear cover.
3) Remove the rear rail trim (A).
1) Remove the rear seat. <Ref. to SE-11, REMOV- 4) Loosen the screws and clips to remove the rear
AL, Rear Seat.> quarter upper trim (B).
2) Remove the side sill rear cover. <Ref. to El-46, 5) Remove the rear skirt trim (C).
REMOVAL, Lower Inner Trim.> 6) Loosen the bolts and clips to remove the rear
3) Remove the rear pillar lower cover (A). quarter lower trim (D).
4) Remove the seatbelt lower anchor bolt, and then
remove the rear pillar upper trim (B).
c
.
8.c ,Clip
80038:
El-47
I REAR QUARTER TRIM
B: INSTALLATION
CAUTION:
NOTE:
When installing the rear quarter upper trim, be sure
to set the rearmole as shown in the figure.
b-1
Outside Inside
Weatherstrip
Trim
El-48
SUN VISOR
21.Sun Visor
A: REMOVAL
Remove the mounting screws then detach the sun
visor (A), hook (B) and center visor (C).
I
I- BVVVlt
B: INSTALLATION
--
El-49
I ROOF TRIM
EXTERIORANTERIOR TRIM
22.Roof Trim 2. WAGON

A: REMOVAL 2) Remove the room light. <Ref. to LI-26, REMOV-
CAUTION: AL, Room Light.>
When removing the clip, use great care not to 3) Remove the sun visor and hook on both sides.
damage the roof trim. <Ref. to El-49, REMOVAL, Sun Visor.>
4) Remove the assist-grips (A).
1. SEDAN
2) Remove the spots light. <Ref. to LI-25, REMOV-
AL, Spot Light.>
3) Remove the room light. <Ref. to LI-26, REMOV-
AL, Room Light.>
4) Remove the sun visor and hook on both sides.
<Ref. to El-49, REMOVAL, Sun Visor.>
5) Remove the assist-grips (A).
r I
5) Remove the upper inner trim. <Ref. to El-45, RE-

MOVAL, Upper Inner Trim.>
6) Remove the rear quarter upper trim shown in the
figure.
7) Remove the rear rail trim (A).
8) Remove the rear quarter upper trim (B) of both
sides.
6) Remove the upper inner trim. <Ref. to El-45, RE-

MOVAL, Upper Inner Trim.>
7) Remove the quarter upper trim. <Ref. to El-47,
SEDAN, REMOVAL, Rear Quarter Trim.>
8) Remove the clips, and then remove the roof trim.
BOO126
..
#..I Clip
BO0382
El-50
ROOF TRIM
9) Remove the clips, and then remove the roof trim.
6: INSTALLATION
El-51
I REAR GATE TRIM
23.Rear Gate Trim

A: REMOVAL
CAUTION:
Be careful not to damage the clips or their
holes.
1) Remove the clips and detach the rear gate trim.
B: INSTALLATION
Lnstall in the reverse order of removal.
El-52
REAR SHELF TRIM
24.Rear Shelf Trim

A: REMOVAL
2) Remove the high-mounted stop light.
d
0 0
3) Remove the rear quarter upper trim. <Ref. to El-

47, REMOVAL, Rear Quarter Trim.>
4) Remove the seat belt center lower anchor bolt.
5) Remove the rear shelf trim.
BOO127
B: INSTALLATION
El-53
I TRUNK TRIM
25.Trunk Trim
A: REMOVAL
1) Remove the rear seat backrest. <Ref. to SE-11,
SEDAN, REMOVAL, Rear Seat.>
2) Remove the clip (A).
3) Loosen the clips, and then detach the trunk rear
trim (B).
4) Loosen the clips to remove the trunk side trim
(C).
C.
B: INSTALLATION
El-54
FLOOR MAT
26.Floor Mat
A: REMOVAL
1) Remove the front seats. <Ref. to SE-6, REMOV-
AL, Front Seat.>
2) Remove the rear seat cushion. <Ref. to SE-11,
REMOVAL, Rear Seat.>
3) Remove the console box. <Ref. to El-41, Con-
sole Box.>
4) Remove the side sill front cover, side sill rear
cover and center Dillar lower trim. <Ref. to El-46,
REMOVAL, Lowe; Inner Trim.>
5) Remove the clips from floor mat.
6) Remove the mat hook.
7) Remove the mat from toe board area.
8) Remove the mat from rear heater duct.
9) Roll the mat, and then take it out of opened rear
door.
BO0123
B: INSTALLATION
NOTE:
Secure the mat firmly with hook and Velcro tape.
Insert the mat edge firmly into the groove of side
sill cover.
El-55
I LUGGAGE FLOOR MAT
27. Luggage Floor Mat

A: REMOVAL
Remove the clips, then detach the rear floor mats
and boxes.
BO0081
I
B: INSTALLATION
__. .
El-56
TRUNK ROOM MAT
28,Trunk Room Mat

A: REMOVAL
Draw out the trunk room mat.
B: INSTALLATION
El-57
I TRUNK ROOM MAT
El-58
EXTERIOR BODY PANELS
E6
Page
2. Front Hood ................................................................................................ 10
3. Fender Panel............................................................................................. 11
4. Front Door Panel ....................................................................................... 12
5. Front Sealing Cover .................................................................................. 14
6. Rear Door Panel ....................................................................................... 15
7. Rear Sealing Cover ................................................................................... 17
8. Trunk Lid Panel ......................................................................................... 18
9. Rear Gate Panel ....................................................................................... 19
.
GENERAL DESCRIPTION
A: SPECIFICATIONS
Front hood --f/---
??'k SECTION A
Front fender
Front fender
SECTION B
\
Front door
Front door & Rear door
SECTION C
Rear door
Rear quarter
SECTION D SECTION E,F
I A
I Front hood to Front fender
NA: 4.0 mm f 1.O (0.16 f 0.04 in)
TURBO: 3.7 mm f 1.O (0.15 f 0.04 in)
B Front fender to Front door 4.6 mm f 1.0 (0.18 f 0.04 in)
C Front door to Rear door 5.0mm (0.20 in)
D Rear door to Rear auarter 4.6 mm (0.18 in)
I E, F I Door panel to Side sill I 5.9 mm (0.23 in) I
EB-2
GENERAL DESCRIPTION
Ia
B: COMPONENT
1. FRONT HOOD
BOO364
(1) Front hood (6) Clip Tightening torque: N.m (kgf-m, ft-lb)
(2) Seal (Front panel) (7) Locking piece F 7.35 (0.75, 5.4)
(3) Hinge (8) Seal (Intake duct) T1: 24.5 (2.5, 18.1)
(4) Hood grille (Only turbo model)
(5) Packing (9) Seal (Hood)
EB-3
GENERAL DESCRIPTION
2. FRONT FENDER PANEL
BOO321
(1) Front fender panel Tightening torque: N-m (kgf-m, ft-lb)

T: 7.35 (0.75, 5.4)
EB-4
GENERAL DESCRIPTION
3. FRONT DOOR PANEL
(1) Gusset (6) Sealing cover Tightening torque: N.m (kgf-m, ft-lb)
(2) Weatherstrip (Outer) (7) Checker T I : 7.4 (0.75, 5.5)
(3) Clip (Weatherstrip, outer) (8) Lower hinge T2: 24.5(2.49, 18)
(4) Stabilizer (Outer) (9) Upper hinge T3: 29.4 (3.0, 21.7)
(5) Stabilizer (Inner) (10) Door panel T4: 32.3 (3.29,23.8)
E8-5
4. REAR DOOR PANEL
B0036t
(1) Weatherstrip (Outer) (7) Sealing cover Tightening torque: N-m (kgf-m, ft-lb)
(2) Clip (Weatherstrip, outer) (8) Checker T1: 7.4 (0.75, 5.5)
(3) Stabilizer (Outer) (9) Lower hinge T2: 24.5(2.49, 18)
(4) Stabilizer (Inner) (IO) Upper hinge T3: 29.4 (3.0, 21.7)
(5) Door panel T4: 32.3 (3.29,23.8)
(6) Bracket
EB-6
I
GENERAL DESCRIPTION
5. TRUNK LID PANEL
(1) Torsion bar (4) Hinge ASSY Tightening torque: N-m (kgf-mJft-lb)
(2) Trunk lid T1: 7.5 (0.7S, 5.5)
(3) Weatherstrip T2: 14 11.8, 13)
EB-7
GENERAL DESCRIPTION
6. REAR GATE PANEL
BOO367
~~
(1) Gas stay Tightening torque: N-m (kgf-m, ft-lb)

(2) Hinge T: 14(1.43, 10.3)
(3) Rear gate T1: 25 (2.5, 18.1)
C: CAUTION
Exterior body panels are heavy. Do not drop and
damage the panels. During removal and installa-
tion, do not damage the panel painting surface.
While removing mounting bolts, using assistance
devices such as a support jack will help support the
panel.
Be careful not to lose small parts.
E8-8
GENERAL DESCRIPTION
D: PREPARATION TOOL
1. SPECIAL TOOLS

925610000 WRENCH Used for removing and installing door hinge.
B5M1117
927780000 REMOVER Used for removing and installing trunk torsion
bar.
B5M1118
2. GENERAL TOOL
TOOL NAME REMARKS
EB-9
I FRONT HOOD
2. Front Hood 2) Adjust the height at front end of hood. <Ref. to

SL-41 ADJUSTMENT, Front Hood Lock Assem-
. .
zles.
2) Release the clips to remove the hood insulator.
3) Remove the bolts to disconnect the hood from

hinges.
'47
4) Remove the hood grille. (Turbo model) <Ref. to

El-19, REMOVAL, Hood Grille.>
B: INSTALLATION
2) Adjust the clearance between hood and fender.
Clearance must be equal at both sides.
Tightening torque:
24.5 N-m (2.49 kgf-m, 18 ft-lb)
C: ADJUSTMENT
1) Use the hinge mounting holes to align the front
hood longitudinally and laterally.
EB-10
a
FENDER PANEL
3. Fender Panel
A: REMOVAL
2) Remove the side sill spoilers. <Ref. to El-36,
Side Sill Spoiler.> (If fitted)
3) Remove the front bumper face. <Ref. to El-23,
REMOVAL, Front Bumper.>
4) Remove the mud guard. <Ref. to El-32, RE-
MOVAL, Mud Guard.>
5) Loosen the bolts to remove front fender.
6 : INSTALLATION
2) When the fender panel is installed, the clearance
between fender panel and hood or front fender
must be equal.
Tightening torque:
7.35 N.m (0.75 kgf-m, 5.4 &/6)
EB-11
FRONT DOOR PANEL
4. Front Door Panel 10) Remove the checker bolts.
A: REMOVAL
3) Remove the outer mirror assembly. <Ref. to
GW-33, REMOVAL, Outer Mirror Assembly.>
4) Remove the front door glass. <Ref. to GW-15,
REMOVAL, Front Door Glass.>
5) Remove the front door regulator and motor.
<Ref. to GW-19, REMOVAL, Front Regulator and
Motor Assembly.> 11) Remove the door-side bolts for upper and lower
6) Remove the front door latch assembly. <Ref. to hinges to remove the door.
SL-30, REMOVAL, Front Door Latch Assembly.>
7) Remove the front outer handle. <Ref. to SL-29,
REMOVAL, Front Outer Handle.>
8) Remove the front pillar lower trim to disconnect
connector from the body harness.
r. -
CAUTION:
During removal and installation of doors, do
not damage body.
Doors are heavy. Be careful not to drop and
damage them.
9) Put a wooden block on jack and place jack under
the door. Support the door with a support jack to B: INSTALLATION
protect it from damage. 1) Install in the reverse order of removal.
2) Apply grease to sliding area of the door hinges.
Refer to COMPONENT of General Description for
tightening torque. <Ref. to EB-5, FRONT DOOR
PANEL, General Description.>
EB-12
FRONT DOOR PANEL
C: ADJUSTMENT
1) Using special tool, loosen the body-side bolts of
upper and lower hinges to align the position of front
door panel longitudinally and vertically.
ST 925610000 DOOR HINGE WRENCH
2) Loosen the screw (A) and tap striker (B) using

plastic hammer to adjust striker to align the position
of front door panel vertically and laterally at the rear
end.
CAUTION:
Do not use impact wrench. Welding area on
striker nut plate is easily broken.
EB-13
FRONT SEALING COVER
5. Front Sealing Cover

A: REMOVAL
3) Remove the front speaker. <Ref. to ET-7, RE-
MOVAL, Front Speaker.>
4) Using a spatula, remove the sealer.
CAUTION:
Carefully remove sealer. Excessive force will
easily break the cover.
If cover gets broken, replace it with a new
one.
B: INSTALLATION
2) When replacing sealing cover, use the CEME-
DINE 5430L sealer.
3) Press the sealer-applied area firmly to prevent
any floating on surface.
Sealer:
CEMEDINE 54301. or equivalent
CAUTION:
Apply a uniform bead of sealer.
Attach sealing cover, keeping it from becom-
ing wrinkled.
Breaks in the bead will allow water leakage
and contamination.
C: INSPECTION
If the sealing cover is damaged, replace it with a
new one.
EB-14
im
REAR DOOR PANEL
6. Rear Door Panel 10) Remove the checker bolts.
A: REMOVAL
CAUTION:
During removal and installation of doors, do
not damage body.
Doors are heavy. Be careful not to drop and
damage them.
3) Remove the rear door glass. <Ref. to GW-20,
REMOVAL, Rear Door Glass.> 11) Remove the door-side bolts for upper and lower
4) Remove the rear door regulator and motor as- hinges to remove door.
sembly. <Ref. to GW-22, REMOVAL, Rear Regula-
tor and Motor Assembly.>
5) Remove the rear door latch. <Ref. to SL-34, RE-
MOVAL, Rear Door Latch Assembly.>
6) Remove the rear outer handle. <Ref. to SL-33,
REMOVAL, Rear Outer Handle.>
Remove the center pillar lower trim. <Ref. to El-
46, REMOVAL, Lower Inner Trim.>
8) Disconnect the connector of door harness.
- B: INSTALLATION
2) Apply grease to sliding area of the door hinges.
tightening torque. <Ref. to EB-6, REAR DOOR
BOO154
9) Put a wooden block on the jack and place the

jack under the door. Support the door with the jack
to protect it.
S5M051
EB-15
REAR DOOR PANEL
C: ADJUSTMENT
1) Open the front door, loosen the door-side bolts
of upper and lower hinges to align the position of
rear door panel longitudinally and vertically.
2) Loosen the screw (A) and tap striker (B) using

plastic hammer to adjust striker to align the position
of front door panel vertically and laterally at the rear
end.
JXUTION:
Do not use an impact wrench. The welding area
on the striker nut plate is easily broken.
EB-16
REAR SEALING COVER
7. Rear Sealing Cover

A: REMOVAL
3) Remove the rear speaker. <Ref. to ET-9, RE-
MOVAL, Rear Speaker.>
4) Using a spatula, remove the sealer.
CAUTION:
Carefully remove sealer. Excessive force will
easily break the cover.
If cover gets broken, replace it with a new
one.
B: INSTALLATION
2) When replacing sealing cover, use the CEME-
DINE 5430L sealer.
3) Press the sealer-applied area firmly to prevent
any floating on surface.
Sealer:
CEMEDINE 5430L or equivalent
CAUTION:
Apply an uniform bead of sealer.
Attach sealing cover, keeping it from becom-
ing wrinkled.
Breaks in the bead will allow water leakage
and contamination.
C: INSPECTION
If the sealing cover gets damaged, replace it with a
new one.
EB-17
I TRUNK LID PANEL
8. Trunk Lid Panel B: INSTALLATION

A: REMOVAL 1. TRUNK LID
1. TRUNK LID 2) Install the trunk lid with uniform clearance.
2) Remove the trunk lid release handle. <Ref.to>
Tightening torque:
14 N-m (1.8 kgf-m, 13 ft-lb)
3) Loosen the trunk lid mounting- bolts to remove
tbnk lid from the hinges. 2. TORSION BAR
2) Apply the grease to rotating area of hinges and
mating surface of torsion bar.
2; TORSION BAR
2) Using special tool, remove the torsion bar from
the hinge link.
CAUTION:
During removal and installation, carefully han-
dle torsion bar. It will generate reactive force.
3) Remove the rightheft torsion bars.

CAUTION:
After the torsion bar is removed, the trunk lid
will slam shut. Be careful not to get hit by the
trunk lid.
EB-18
REAR GATE PANEL
9. Rear Gate Panel 10) Using a support, support the rear gate while re-
moving gas stay mounting bolts.
A: REMOVAL
1. REAR GATE PANEL
2) Open the rear gate.
3) Remove the rear gate outer handle. <R f. to SL-
36, REMOVAL, Rear Gate Outer Handle.>
5 ) Remove the rear gate key lock cylinders. <Ref.
to SL-44, REAR GATE, REPLACEMENT, Key
Lock Cy1inders.>
6) Remove the rear wiper. <Ref. to WW-17, RE-
MOVAL, Rear Wiper Motor.>
7) Disconnect the connectors of rear wiper, rear de-
fogger, and other lighting devices.
8) Disconnect the washer hose.
9) Remove the rubber duct (A) connection, and pull
Qut the harness and washer hose from the rear
gate.
BOO155
CAUTION:
When the rear gate is released, it may hit and
damage the body. To prevent this, place a shop
cloth between body and gate.
11) Loosen the rear gate bolts to remove the rear
gate.
EB-19
I REAR GATE PANEL
2. GASSTAY B: INSTALLATION
1) Open the rear gate. Using a support jack to sup- 1. REAR GATE PANEL
port the rear gate.
2) Install the rear gate panel with uniform clearance
to the body.
tightening torque. <Ref. to EB-8, REAR GATE
CAUTION:
Do not damage painted surfaces of body and
rear gate.
2. GASSTAY
1) Install mounting bolt (A) to the rear gate panel
CAUTION:
and body.
After gas stay is removed, rear gate cannot
stay open. Supporting the rear gate with a jack, Tightening torques
remove the bolts. 14 N-m (1.8 kgf-m, 13 ft-16)
Do not damage piston rods and oil seals. 2) Firmly install the gas stay (B) to mounting bolt
-. - Never
. disassemble cylinders: They contain (A).
gas.
2) Loosen the bolts to remove gas stay from rear
gate.
/ BO0368
CAUTION:
After supporting rear gate with a jack, start op-
eration.
BOO15E
EB-20
REAR GATE PANEL
m
C: DISPOSAL
1. GAS STAY
CAUTION:
Gas is colorless, odorless, and harmless. How-
ever, gas pressure may spray cutting powder or
oil. Be sure to wear dust-resistant goggles.
1) Cover with a vinyl sack as shown in the figure.
Gas stay
@Lh!$j
Vinyl sack
800261
WLJTION:
Prevent the vinyl sack from being caught by
drill cutting edge
2) Lift the body side slightly with piston rods fully ex-
tended, and secure the body side on vise stand.
Drill a hole in 2 to 3 mm (0.08 to 0.12 in) diameter at
a point 10 to 200 mm (0.39 to 7.87 in) from door
side, and bleed gas stay completely.
Bodv side Door side
190" 10"
(7.48 in) (0.39 in)
I / \ Portion to be drilled
Piston rod Cylinder
BO0262
EB-21
REAR GATE PANEL
EB-22
~~
cc Page
2. Actuator ....................................................................................................... 4
3. Cruise Control Module ................................................................................ 5
4. Cruise Control Main Switch ......................................................................... 6
5. Cruise Control Command Switch ................................................................ 7
6. Stop and Brake Switch ................................................................................ 8
7. Clutch Switch .............................................................................................. 9
8. Inhibitor Switch .......................................................................................... 10
.
A: COMPONENT
BO0322
(1) Actuator (4) Cruise control main switch (7) Cruise control module
(2) Inhibitor switch (AT) (5) Clutch switch (MT)
(3) Cruise control command switch (6) Stop and brake switch .
cc-2
GENERAL DESCRIPTION
B: CAUTION
Before disassembling or reassembling parts, al-
ways disconnect the battery ground cable. When
repairing the radio, control module and other parts
with memory functions, make note of the memory
before disconnecting the battery ground cable. All
memory will be erased.
Reassemble the parts in the reverse order of dis-
assembly unless otherwise indicated.
Adjust the parts to specifications specified in this
manual.
ing reassembly.
After reassembly, ensure functional parts oper-
ate properly.
C: PREPARATION TOOL
TOOL NAME REMARKS
Circuit Tester Used for measuring resis-
tance and voltage.
cc-3
I ACTUATOR
2. Actuator B: INSTALLATION
A: REMOVAL
Tightening torque:
CAUTION: 7.4 N.m (0.75 kgf-m, 5.4 ff-lb)
Be careful not to apply excessive load to the
wire cable when adjusting and/or installing; NOTE:
otherwise, the actuator may be deformed or (A): Must be adjusted when cable end outer is fixed
damaged. in place, so that the gap between throttle cam and
Do not bend cable sharply with a radius less lever is 0 - 1 mm (0 - 0.04 in).
than 100 mm (3.94 in); otherwise, cable may (Must be attached while throttle cam is being pulled
bend permanently, resulting in poor perfor- by wire cable.)
mance. (B): Must be coated evenly on cam end inner con-
When installing cable, be careful not to nection.
sharply bend or pinch the inner cable; other- (C): Cover must be inserted securely, until tip of ca-
wise, the cable may break. ble touches cover stopper.
2) Remove the clip bands from cruise control cable.
3) Loosen the nut which secures cruise control ca-
ble end to throttle cam and then remove the cable
from throttle cam.
r- ,
B6M1213A
C: INSPECTION
Measure the cruise control actuator resistance
4) Remove the actuator attaching bolts.

5 ) Remove the actuator while disconnecting con-
nector.
I Terminal No. I Standard -1

I 4 and 1 I Approx. 5R I
4 and 2 Approx. 5R
4 and 5 Approx. 552
3 and 6 Approx. 3952
cc-4
I CRUISE CONTROL MODULE
3. Cruise Control Module

A: REMOVAL
2) Remove the side sill front cover.
,
BOO321
3) Disconnect the connector from the cruise control

module.
4) Remove the cruise control module (A).
B0032E
B: INSTALLATION
Install is in the reverse order of removal.
cc-5
CRUISE CONTROL MAIN SWITCH
4. Cruise Control Main Switch C: INSPECTION

Measure the cruise control main switch resistance.
A: REMOVAL
2) Remove the screws and clip from the instrument
panel lower cover.
3) Remove the instrument panel lower cover.
Main switch side
Efzl
I G6M0244

OFF 3 and 5 More than 1Mi2
ON 3 and 5 Less than In
If NG, replace the cruise control main switch.

4) Disconnect the connector from the cruise control
main switch(A).
r-
5) Remove the main switch by pushing it outward.
B0032E
B: INSTALLATION
Install is in the reverse order of removal.
CC-6
CRUISE CONTROL COMMAND SWITCH m
5. Cruise Control Command 7) Disconnect the horn and cruise control com-
mand switch connector, then remove the cruise
Switch control command switch.
A: REMOVAL
WARNING:
Before servicing, be sure to read the notes in
the AB section for proper handling of the driv-
er's airbag module. <Ref. to AB-3, CAUTION,
1) Set the front wheels in straight ahead position.
2) Turn ignition switch OFF.
3) Disconnect the ground terminal from battery and
wait for at least 20 seconds before starting work.
4) Using TORX@BIT T30 (Tamper resistant type), B: INSTALLATION
loosen two TORX@bolts which secure driver's air- Install is in the reverse order of removal.
bag module.
C: INSPECTION
Measure the cruise control command switch resis-
tance.
5) Disconnect the airbag module connector on

back of the airbag module.
6) Remove the horn switch from the steering wheel
as shown. Terminal No. Standard
1
Switch Position
ON 1 (+) and 2 (-) Less than 1R
CANCEL
ON 1 (+) and 3 (4 Less than 1R
1 and 3 More than 1MQ
SET/COAST
1 and 3 Less than 1R
RESUME/ OFF 1 and 2 More than 1MR
ACCEL 1 and 2 Less than 1R
If NG, replace the cruise control command switch.
cc-7
I STOP AND BRAKE SWITCH
6. Stop and Brake Switch

A: REMOVAL
2) Disconnect the connector from the switch, and
then remove the switch. <Ref. to BR-55, REMOV-
AL, Stop Light Switch.>
B: INSTALLATION
C: INSPECTION
Measure the brake switch (1) and stop light switch
(2) resistance.
I
B6M1564A
Switch Pedal
Brake
Stop light
If NG, replace the stop and brake switch.
CC-8
I CLUTCH SWITCH im
7. Clutch Switch
A: REMOVAL
2) Disconnect the connector from the clutch switch,
and then remove the switch. <Ref. to CL-26, DIS-
ASSEMBLY, Clutch Pedal.>
B: INSTALLATION
C: INSPECTION
Measure the clutch switch resistance.
I Switch I Pedal I Terminal No. I Standard 1

I Clutch I Released
Depressed
I
I
1 and 2
1 and 2
I
1
Less than 1 Q
More than 1MQ
If NG, replace the clutch switch.
cc-9
INHIBITOR SWITCH
8. Inhibitor Switch
A: REMOVAL
1) Disconnect the ground terminal from the battery.
2) Disconnect the connector from the switch, and
then remove the switch. <Ref. to AT-29, REMOV-
AL, Inhibitor Switch.>
B: INSTALLATION
Installation is in the reverse order of removal.
C: INSPECTION
Measure the inhibitor switch resistance.
B6M1530
Selector lever
Terminal No, Standard
position
P Less than In
N 7 and 12 Less than la
Except P and N More than 1MQ
cc-10
(DIAG NOSTICS)
cc Page
4. Cruise Control Module I/O Signal ................................................................ 6
5. Subaru Select Monitor................................................................................. 9
6. Diagnostics Chart with Symptom .............................................................. 11
8. Diagnostics Chart with Diagnostic Trouble Code ...................................... 28
.
CRUISE CONTROL SYSTEM (DIAGNOSTICS)

A: PROCEDURE
~ ~~~
Step Check Yes No

1 START DIAGNOSIS. Is cruise control main switch So to step 2. Go to symptom 1.
1)Perform pre-inspection. <Ref. to CC-4, turned ON? <Ref. to CC-I 1,
INSPECTION, General Description.> SYMPTOM
2)Check cruise control main switch operation. CHART, Diagnos-
tics Chart with
Symptom.>
2 PREPARE SUBARU SELECT MONITOR. Is the select monitor available? So to step 3. Go to step 4.
3 PERFORM CRUISE CANCEL CONDITIONS Is trouble code indicated? So to “Diagnos- Go to step 4.
DIAGNOSIS. tics Chart with
Perform cruise cancel conditions diagnosis. Trouble Code”.
<Ref. to CC-9, Subaru Select Monitor.>
4 CHECK CRUISE CONTROL SET OPERA- Can cruise control be set while So to step 5. Go to symptom 2.
TION. driving at 40 km/h (25 MPH)? <Ref. to CC-11,
Check cruise control set operation. SYMPTOM
CHART, Diagnos-
tics Chart with
._ Symptom.>
5 CHECK VEHICLE SPEED IS HELD WITHIN Is vehicle speed held within set So to step 6. Go to symptom 3.
SET SPEED. speed +3 km/h (f2MPH) ? <Ref. to CC-11,
Make sure vehicle speed is held within set SYMPTOM
speed. CHART, Diagnos-
tics Chart with
Symptom.>
6 CHECK RESUMWACCEL OPERATION. Does vehicle speed increase So to step 7. Go to symptom 4.
Check RESUME/ACCEL operation. or return to set speed after <Ref. to CC-11,
RESUME/ACCEL switch has SYMPTOM
been pressed? CHART, Diagnos-
tics Chart with
Symptom.>
7 CHECK SETKOAST OPERATION. Does vehicle speed decrease Go to step 8. Go to symptom 5.
Check SET/COAST operation. after SET/COAST switch has <Ref. to CC-11,
been pressed? SYMPTOM
CHART, Diagnos-
tics Chart with
Symptom.>
8 CHECK CANCEL OPERATION. Is cruise control released after Go to step 9. Go to symptom 6.
Check CANCEL operation. CANCEL switch has been <Ref. to CC-11,
pressed? SYMPTOM
CHART, Diagnos-
tics Chart with
Symptom.>
9 CHECK CRUISE CONTROL RELEASE OP- Is cruise control released after Go to step 10. Go to symptom 7.
ERATION. brake pedal has been <Ref. to CC-11,
Check cruise control release operation. depressed? SYMPTOM
CHART, Diagnos-
tics Chart with
Symptom.>
10 CHECK CRUISE CONTROL RELEASE OP- Is cruise control released after Finish the diag- Go to symptom 8.
ERATION. clutch pedal has been nostics. <Ref. to CC-11,
Check cruise control release operation. depressed? (MT) SYMPTOM
CHART, Diagnos-
tics Chart with
Symptom.>
cc-2
GENERAL DESCRIPTION
2. General Description CAUTION:

A: CAUTION nectors are colored yellow. Do not use electri-
1. SUPPLEMENTAL RESTRAINT SYSTEM Be careful not to damage Airbag system wir-
"AIRBAG" ing harness when servicing the cruise control
Airbag system wiring harness is routed near the module and cruise control command switch.
cruise control module and cruise control command
switch.
B: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION REMARKS
B2M3876
22771AA030
I SELECT MONITOR
KIT
b English:
German:
French:
Spanish:
2. GENERAL TOOLS
TOOL NAME REMARKS
cc-3
a
C: INSPECTION 5. CABLE FREE PLAY

1. BATTERY
electrolyte.
Standard voltage:
12 V, or more
Specific gravity:
Above 1.260
2. CRUISE CONTROL CABLE I1 0, mm (0.04PO,, in) ]
B6M0241A
Check that the throttle cam-to-lever clearance is

Throttle cam-to-lever clearance:
0 - 1 mm (0 - 0.04 in)
If NG, adjust the clearance with the adjust nut.
NOTE:
Check that the cap is positioned in the groove.
Check the cruise control cable installation.

If NG, install the cable securely.
3. ACCELERATOR CABLE
Check movement of the accelerator cable when the

cruise control throttle is moved by hand.
If NG, check the throttle cam.
4. THROTTLE CAM
Check that the throttle cam moves smoothly.
If NG, repair the throttle cam.
cc-4
I ELECTRICAL COMPONENTS LOCATION

A: LOCATION
(1) Actuator (4) Cruise control main switch (7) Cruise control module
(2) Inhibitor switch (AT) (5) Clutch switch (MT)
(3) Cruise control command switch (6) Stop and brake switch
cc-5
CRUISE CONTROL MODULE I/O SIGNAL
4. Cruise Control Module I/O Signal

11111-1..11
109 8 7 6 5 4 3 2 1
1111111111
20 19 18 17 16 15 14 13 12 11
G6M001!
Main light 1 Battery voltage is present when main switch is turned OFF.
~~ ~
I I “ 0 volt is present when main switch is turned ON.
Inhibitor switch (AT) Battery voltage is present when selector lever is other than “ P or “N” position.
Motor B
cruise control is operating.
“ 0 volt is present when main switch is turned OFF.
Ground 6 -
Motor A 7 I ON-and-OFF (“0”-and-battery voltage) operation is alternately repeated while
---I---
RESUME/ACCEL switch Battery voltage is present when command switch is turned to RESUMUACCEL
position.
“ 0 volt is present when command switch is released.
SET/COAST switch 10 Battery voltage is present when command switch is turned to SET/COAST
position.
I I * “0” volt is present when command switch is released.
Main power supply Battery voltage is present when main power is turned ON
“0” volt is present when main power is turned OFF.
Ignition switch Battery voltage is present when ignition switch is turned ON.
“ 0 volt is present when ignition switch is turned OFF.
Motor C 13 ON-and-OFF (‘‘0”-and-battery voltage) operation is alternately repeated while
11
Motor clutch ON-and-OFF (“0-and-battery voltage) operation is alternately repeated while
“ 0 volt is present when vehicle is stopped.
15
Cruise control main switch Battery voltage is present during pressing the cruise control main switch, and
then battery voltage is present while main switch is turned ON.
“0” volt is present when main switch is turned OFF.
CC-6
Content Terminal No. Measuring conditions and I/O signals (ignition switch ON and engine idling)
Brake switch 16 Leave clutch pedal released (MT), while cruise control main switch is turned ON.
Then check that;
Battery voltage is present when brake pedal is released.
“0” volt is present when brake pedal is depressed.
Additionally only in MT vehicle, keep the cruise control main switch to ON and
leave brake pedal released.
Then check that;
Battery voltage is present when clutch pedal is released.
“ 0 volt is present when clutch pedal is depressed.
Data link connector 17 -
Data link connector 18
Vehicle speed sensor (MT) 19 Lift-up the vehicle until all four wheels are raised off ground, and then rotate any
TCM (AT) wheel manually.
Approx. “ 5 and “ 0 volt pulse signals are alternately input to cruise control mod-
ule.
Stop light switch 20 Turn ignition switch to OFF.
Then check that:
Battery voltage is present when brake pedal is depressed.
“0” volt is Dresent when brake Dedal is released.
NOTE:
Voltage at terminals 5, 7, 13 and 14 cannot be checked unless vehicle is driving by cruise control operation.
cc-7
B: SCHEMATIC
1. CRUISE CONTROL
<Ref. to WI-61, SCHEMATIC, Cruise Control Sys-
tem.>
c- .
CC-8
m
5. Subaru Select Monitor 2. CRUISE CANCEL CONDITIONS DIAG-

NOSIS
A: OPERATION 1) Prepare Subaru Select Monitor kit.
1. GENERAL
The on-board diagnosis function of the cruise con-
trol system uses an external Subaru Select Moni-
tor.
The on-board diagnosis function operates in two
categories, which are used depending on the type
of problems;
1) Cruise cancel conditions diagnosis
(1) This category of diagnosis requires actual
vehicle driving in order to determine the cause, S2M0285
(as when cruise speed is cancelled during driv-
ing although cruise cancel condition is not en- 2) Connect the diagnosis cable to the Subaru Se-
tered). lect Monitor.
(2) Cruise control module memory stores the 3) Insert the cartridge into the Subaru Select Moni-
cancel condition (Code No.) which occurred dur- tor.
ing driving. When there are plural cancel condi- <Ref. to CC-3, SPECIAL TOOLS, PREPARATION
-. tions (Code No.), they are shown on the Subaru TOOL, General Description.>
Select Monitor.
CAUTION:
The cruise control memory stores not only
the cruise “cancel” which occurred (although
“cancel” operation is not entered by the driver),
but also the “cancel” condition input by the
driver.
The content of memory is cleared when igni-
tion switch or cruise main switch is turned OFF.
2) Real-time diagnosis S2M0286A
The real-time diagnosis function is used to deter-
mine whether or not the input signal system is in 4) Connect the Subaru Select Monitor to the data
good order, according to signal emitted from link connector.
switches, sensors, etc. (1) Data link connector located in the lower por-
(1) Vehicle cannot be driven at cruise speed be- tion of the instrument panel (on the driver’s
cause problem occurs in the cruise control sys- side).
tem or its associated circuits.
(2) Monitor the signal conditions from switches
and sensors.
(2) Connect the diagnosis cable to the data link

connector.
cc-9
5) Start the engine and turn the cruise control main 3. REAL-TIME DIAGNOSIS
switch to ON. 1) Connect the select monitor.
6) Turn the Subaru Select Monitor switch to ON. 2) Turn the ignition switch and cruise control main
switch to ON.
Power switch 3) Turn the Subaru Select Monitor switch to ON.
4) On the Main Menu display screen, select the
5) On the System Selection Menu display screen,
select the {Cruise Control} and press the [YES]
key.
7) On the Cruise Control Diagnosis display screen,
” S2M0288A
select the {Current Data Display & Save} and press
7) On the Main Menu display screen, select the {All the [YES] key.
System Diagnosis} and press the [YES] key. 8) Make sure that normal indication is displayed
NOTE: when controls are operated as indicated below:
The diagnostic trouble code is also shown in the Depresshelease the brake pedal. (Stop light
{Each System Check} mode. This mode is called switch and brake switch turn ON.)
upon the Cruise Control Diagnosis screen by se-
r.
Turn ON the “SETKOAST” switch.
lecting the item {Cancel Code(s) Display}. Turn ON the “RESUME/ACCEL” switch.
Depresshelease the clutch pedal. (MT)
8) Drive vehicle at least 30 km/h (19 MPH) with
cruise speed set. Set the selector lever to P or N. (AT)
9) If the cruise speed is canceled itself (without do- NOTE:
ing any cancel operations), a diagnostic trouble For detailed operation procedure, refer to the
code will appear on select monitor display. SUBARU SELECT MONITOR OPERATION MAN-
CAUTION: UAL.
A diagnostic trouble code will also appear For detailed concerning diagnostic trouble
when cruise cancel is effected by driver. Do not codes, refer to the LIST OF DIAGNOSTIC TROU-
confuse. BLE CODE.
Have a co-worker ride in vehicle to assist in <Ref. to CC-26, LIST OF DIAGNOSTIC TROUBLE
diagnosis during driving. CODE (DTC), .>
NOTE:
Diagnostic trouble code will be cleared by turning
ignition switch or cruise control main switch to OFF.
cc-10
DIAGNOSTICS CHART WITH SYMPTOM
a
6. Diagnostics Chart with Symptom

A: SYMPTOM CHART
Svmptom Repair area Reference
Cruise control main switch is (1) Check power supply. <Ref. to CC-14, CHECK POWER SUPPLY, Diagnostics
not turned ON. Chart with SvmDtom.>
(2) Check cruise control main I <Ref. to CC-16, CHECK CRUISE CONTROL MAIN
switch. SWITCH, Diagnostics Chart with Symptom.>
Cruise control cannot be set. (1) Check SET/COAST <Ref. to CC-18, CHECK CRUISE CONTROL COM-
switch. I MAND SWITCH. Diaanostics Chart with SvmDtom.>
(2) Check stop light switch <Ref. to CC-20, CHECK STOP LIGHT SWITCH AND-
and brake switch. BRAKE SWITCH, Diagnostics Chart with Symptom.>
(3) Check clutch switch (MT). <Ref. to CC-22, CHECK CLUTCH SWITCH (MT), Diag-
nostics Chart with Symptom.>
(4) Check inhibitor switch <Ref. to CC-24, CHECK INHIBITOR SWITCH (AT),
(AT). Diagnostics Chart with Symptom.>
(5) Check vehicle speed sen- <Ref. to CC-30, DTC 22 VEHICLE SPEED SENSOR,
sor. Diagnostics Chart with Diagnostic Trouble Code.>
(6) Check motor drive sys- <Ref. to CC-34, DTC 35 AND 36 ACTUATOR MOTOR,
tem. Diaanostics Chart with Diaanostic Trouble Code.>
(7) Check motor clutch drive <Ref. to CC-36, DTC 37 ACTUATOR MOTOR CLUTCH,
system. Diagnostics Chart with Diagnostic Trouble Code.>
Vehicle speed is not held (1) Check vehicle speed sen- <Ref. to CC-30, DTC 22 VEHICLE SPEED SENSOR,
within set speed k3 km/h (+2 sor. Diagnostics Chart with Diagnostic Trouble Code.>
MPH). (2) Check motor drive sys- <Ref. to CC-34, DTC 35 AND 36 ACTUATOR MOTOR,
tem. Diagnostics Chart with Diagnostic Trouble Code.>
Vehicle speed does not (1) Check RESUME/ACCEL <Ref. to CC-18, CHECK CRUISE CONTROL COM-
increase or does not return to switch. MAND SWITCH, Diaqnostics Chart with SvmDtom.>
set speed after RESUME/ (2) Check motor drive sys- <Ref. to CC-34, DTC 35 AND 36 ACTUATOR MOTOR,
4 ACCEL switch has been tem. Diagnostics Chart with Diagnostic Trouble Code.>
Dressed. (3) Check motor clutch drive <Ref. to CC-36, DTC 37 ACTUATOR MOTOR CLUTCH,
Vehicle speed does not (1) Check SET/COAST <Ref. to CC-18, CHECK CRUISE CONTROL COM-
jecrease after SET/COAST switch. MAND SWITCH, Diagnostics Chart with Symptom.>
;witch has been pressed. (2) Check motor drive sys- <Ref. to CC-34, DTC 35 AND 36 ACTUATOR MOTOR,
5
2ruise control is not released (1) Check CANCEL switch. <Ref. to CC-18, CHECK CRUISE CONTROL COM-
3fter CANCEL switch has MAND SWITCH, Diagnostics Chart with Symptom.>
Deen pressed. (2) Check motor drive sys- <Ref. to CC-34, DTC 35 AND 36 ACTUATOR MOTOR,
6
-
2ruise control is not released (1) Check stop light switch <Ref. to CC-20, CHECK STOP LIGHT SWITCH AND
3fter brake pedal has been and brake switch. BRAKE SWITCH, Diagnostics Chart with Symptom.>
jepressed. (2) Check motor drive sys- <Ref. to CC-34, DTC 35 AND 36 ACTUATOR MOTOR,
7
tem. Diagnostics Chart with Diaqnostic Trouble Code.>
-
cc-11
Symptom Repair area Reference

Cruise control is not released (1) Check clutch switch. <Ref. to CC-22, CHECK CLUTCH SWITCH (MT), Diag-
after clutch pedal has been nostics Chart with Symptom.>
depressed (MT). (2) Check motor drive sys- <Ref. to CC-34, DTC 35 AND 36 ACTUATOR MOTOR,
8
svstem. Diaunostics Chart with Diaunostic Trouble Code.>
cc-12
CC-13
B: CHECK POWER SUPPLY

TROUBLE SYMPTOM:
Cruise control can be set normally, but indicator does not come on. (When main switch is pressed.)
WIRING DIAGRAM:
SBF-4 FIB No.18

-e 0
r
CRUISE CONTROL
MAIN SWITCH
@ CRUISE CONTROL MODULE
BO0287
CC-14
Step Check No
1 CHECK POWER SUPPLY. Check fuse No.
1)Disconnectcruise control module harness 18 (in fuse & relay
connector. box).
2)Turn ignition switch ON. Check harness
3)Measure voltage between harness connec- for open or short
tor terminal and chassis ground. between cruise
Connector & terminal control module
(894) No. 12 - Chassis ground: and fuse & relay
I
box.
2 CHECK GROUND CIRCUIT. Is the resistance less than 10 I Power supply and Repair harness.
Measure resistance between harness connec- n? ground circuit are
tor terminal and chassis ground. IOK.
CC-15
I
C: CHECK CRUISE CONTROL MAIN SWITCH

TROUBLE SYMPTOM:
Cruise control main switch is not turned ON and cruise control cannot be set.
NOTE:
When the main relay (built-in cruise control module) operates, the main switch circuit is in normal condition.
The main relay operation can be checked by hearing the operation sounds.
This operation sounds will be heard when ignition switch and cruise control main switch is turned to ON.
WIRING DIAGRAM:
SBF-4 FIB No.18

-0 -e
-
I
@ CRUISE CONTROL MODULE
i
BOO287
CC-16
m
Step Check Yes No

CHECK CRUISE CONTROL MAIN SWITCH s the voltage more than 10 V? $0 to step 2. Check fuse No.
CIRCUIT. I 8 (in fuse & relay
1)Disconnect cruise control main switch har- lox).
ness connector. ' Check harness
2)Turn ignition switch ON. or open or short
3)Measure voltage between harness connec- letween cruise
tor terminal and chassis ground. :ontrol main
Connector & terminal ;witch and fuse &
(8161) No. 3 (+) - Chassis ground (-): .eIay box.
CHECK CRUISE CONTROL MAIN SWITCH s the resistance less than 10 o
; to step 3. 3epair harness.
CIRCUIT. 2?
1)Turn ignition switch OFF.
2)Disconnect cruise control module harness
connector.
3)Measure resistance between cruise control
module harness connector terminal and cruise
control main switch harness connector termi-
nal.
(894) NO. 15 - (8161) NO. 5:
(894) NO. 1 - (8161) NO. 6:
-. (894) NO. 11 - (8161) NO. 1:
I CHECK CRUISE CONTROL MAIN SWITCH. s cruise control main switch 3eplace cruise 3eplace cruise
Remove and check cruise control main switch. 3K? :ontrol module. :ontrol main
<Ref. to CC-6, Cruise Control Main Switch.> ;witch.
CC-17
D: CHECK CRUISE CONTROL COMMAND SWITCH

TROUBLE SYMPTOM:
Cruise control cannot be set. (Cancelled immediately.)
WIRING DIAGRAM:
1-
-
- HORNS W C H
Yo
-
1 1' RESUME/
ACCEL
0 SWITCH
ob
0 CANCEL
* :G I I CRUISE CONTROL
COMMAND SWITCH
1
B HORN RELAY
Io
I
894 CRUISE CONTROL MODULE
n
1 12 13141 516171819110 1121314151 16171819110111
11~12~13[14115~16~17~18~19~20 12~13~14[15[16~17~18~19~20~21~22~23~24
BO0288
CC-18
Step Check Yes No

CHECK SETKOAST SWITCH CIRCUIT. ;the voltage 0 V when SET1 Go to step 2. Go to step 4.
1)Disconnect cruise control module harness :OAST switch is not pressed?
connector. ;the voltage more than 10 V
2)Turn ignition switch ON. ,hen SET/COAST switch is
3)Measure voltage between harness connec- ressed?
tor terminal and chassis ground when SET/
COAST switch is pressed and not pressed.
Connector i? terminal
CHECK RESUMWACCEL SWITCH CIRCUIT s the voltage 0 V when Go to step 3. Go to step 4.
Measure voltage between harness connector IESUME/ACCEL switch is not
terminal and chassis ground when RESUME/ ressed? Is the voltage more
ACCEL switch is pressed and not pressed. han 10 V when RESUME/
Connector i? terminal CCEL switch is pressed?
CHECK CANCEL SWITCH CIRCUIT. s the voltage 0 V when CAN- Cruise control Go to step 4.
Measure voltage between harness connector :EL switch is not pressed? IS command switch
terminal and chassis ground when CANCEL he voltage more than 10 V circuit is OK.
switch is pressed and not pressed. vhen CANCEL switch is
Connector i? terminal )ressed?
CHECK POWER SUPPLY FOR COMMAND >oes horn sound? Go to step 5. Check fuse No.
SWITCH. 6 (in fuse & relay
Check horn operation. box).
Check horn
relay. <Ref. to
COM-3, HORN
RELAY, INSPEC-
TION, Horn Sys-
tem.>
Check harness
for open or short
between cruise
control command
switch and fuse &
relay box.
CHECK CRUISE CONTROL COMMAND s cruise control command Check harness Replace cruise
SWITCH. ;witch OK? between cruise control command
Remove and check cruise control command control command switch.
switch. <Ref. to CC-7, Cruise Control Com- switch and cruise
mand Switch.> control module.
cc-19
E: CHECK STOP LIGHT SWITCH AND BRAKE SWITCH

TROUBLE SYMPTOM:
Cruise control cannot be set.
WIRING DIAGRAM:
BATTERY
SBF-1 SBF-2 F/B N0.16
0 0
STOP LIGHT SWITCH

AND BRAKE SWITCH
CLUTCH
SWITCH (Mn
@ : AT MODEL
@ . MT MODEL
I CRUISE I
m Q3 4
BO0289
cc-20
I H
Step Check Yes No

CHECK STOP LIGHT SWITCH AND BRAKE Is the voltage more than 10 V? ;o to step 2. Check fuse No.
SWITCH CIRCUIT. I6 (in fuse & relay
1)Disconnectstop light switch and brake switch )OX).
harness connector. Check harness
2)Turn ignition switch ON. or open or short
3)Turn cruise control main switch ON. )etween stop light,
4)Measure voltage between harness connec- )rake switch and
tor terminal and chassis ground. use & relay box.
CHECK STOP LIGHT SWITCH AND BRAKE Is the voltage more than 10 V? i o to step 3. Check harness
SWITCH CIRCUIT. or open or short
Measure voltage between harness connector letween stop light,
terminal and chassis ground. )rake switch and
Connector & terminal mise control
(665) No. 4 (+) - Chassis ground (-): nodule (AT).
I Check clutch
;witch and the cir-
:uit (MT).
I CHECK STOP LIGHT SWITCH AND BRAKE Is the resistance less than 10 20 to step 4. 3epair harness.
SWITCH CIRCUIT. a?
1)Turn cruise control main switch and ignition
switch OFF.
2)Disconnect cruise control module harness
connector.
module harness connector terminal and stop
light switch and brake switch harness connec-
tor terminal.
(694) NO. 20 - (665) NO. 3:
(694) NO. 16 - (665) NO. 1:
1 CHECK STOP LIGHT SWITCH AND BRAKE Are stop light switch and brake ;top light switch 3eplace stop light
SWITCH. switch OK? ind brake switch switch and brake
Remove and check stop light switch and brake ;ircuit are OK. switch.
switch. <Ref. to CC-8, Stop and Brake
Switch.>
cc-21
F: CHECK CLUTCH SWITCH (MT)

TROUBLE SYMPTOM:
WIRING DIAGRAM:
BAlTERY
SBF-1 SBF-2 F/B No.16
0 0
I-
r.
STOP LIGHT SWITCH

AND BRAKE SWITCH
CLUTCH
SWITCH (NIT)
;PI BRAKE
SWITCH
@ : AT MODEL
@ MT MODEL
I I
.
CRUISE
CONTROL
MODULE
BOO289
cc-22
iil
Step Check Yes No

CHECK CLUTCH SWITCH CIRCUIT. Is the voltage more than 10 V? $0 to step 2. Check harness for
1)Disconnect clutch switch harness connector. open or short
2)Turn ignition switch ON. between clutch
3)Turn cruise control main switch ON. switch and cruise
4)Measure voltage between harness connec- control module.
tor terminal and chassis ground.
CHECK CLUTCH SWITCH CIRCUIT. Is the resistance less than 10 o
; to step 3. Repair harness.
1)Turn cruise control main switch and ignition 2?
switch OFF.
2)Disconnect stop light switch and brake switch
harness connector.
3)Measure resistance between clutch switch
harness connector terminal and stop light
switch and brake switch harness connector ter,
minal.
(6107) NO. 1 - (B65) NO. 4:
CHECK CLUTCH SWITCH. IS clutch switch OK? 2lutch switch cir- deplace clutch
Remove and check clutch switch. <Ref. to CC :uit is OK. switch.
9, Clutch Switch.>
CC-23
G: CHECK INHIBITOR SWITCH (AT)

TROUBLE SYMPTOM:
WIRING DIAGRAM:
CRUISE
CONTROL
MODULE
r.
TO SECURITY SYSTEM 41-
WS :WITH SECURITY SYSTEM
:WITHOUT SECURITY SYSTEM

I
INHIBITOR
SWITCH(AT)
-
_.
-
@
dq$fI
9 10 11 12
1['2[314[5[6[7[8[9110
111121131 14[15[16[17[18[19120
BOO290
CC-24
m
Step Check Yes No

CHECK INHIBITOR SWITCH CIRCUIT. s the voltage more than 10 V? So to step 2. Check the follow-
1)Disconnect inhibitor switch harness connec- ing.
tor. Interrupt relay
2)Turn ignition switch ON. (with security sys-
3)Turn cruise control main switch ON. tem) <Ref. to SL-
4)Measure voltage between harness connec- 48, Interrupt
tor terminal and chassis ground. Relay.>
Connector & terminal Harness for
(T7) No. 12 (+) - Chassis ground (-): open or short
between inhibitor
switch and cruise
control module.
CHECK INHIBITOR SWITCH CIRCUIT. 3 the resistance less than 10 Go to step 3. Repair harness.
1)Turn cruise control main switch and ignition I?
switch OFF.
2)Disconnect starter motor harness connector.
3)Measure resistance between inhibitor switch
harness connector terminal and chassis
ground.
(V) NO. 7 - (614) NO. 1:
.. CHECK INHIBITOR SWITCH. 3 inhibitor switch OK? Inhibitor switch cir- Replace inhibitor
Remove and check inhibitor switch. <Ref. to cuit is OK. switch .
CC-IO, Inhibitor Switch.>
CC-25
I LIST OF DIAGNOSTIC TROUBLE CODE (DTC)
7. List of Diagnostic Trouble Code (DTC)

A: LIST
DTC Item Contents of diaanosis Reference
21 Inner relay is seized. Cruise control module inner relay is seized when main <Ref. to CC-28, DTC 21,
switch is OFF. 24,25 AND 2A CRUISE
CONTROL MODULE
BUILT-IN RELAY, CPU
RAM, Diagnostics Chart
with Diagnostic Trouble
Code.>
22 Vehicle speed sensor Vehicle speed signal changes more than 10 km/h (6 <Ref. to CC-30, DTC 22
MPH) within 350 ms. VEHICLE SPEED SEN-
SOR, Diagnostics Chart
Code.>
24 Cruise control module is Two vehicle speed values stored in cruise control module <Ref. to CC-28, DTC 21,
abnormal. memory are not the same. 24,25 AND 2A CRUISE
CONTROL MODULE
BUILT-IN RELAY, CPU
Code.>
25 Cruise control module is Two output values stored in cruise control module mem- <Ref. to CC-28, DTC 21,
abnormal. ory are not the same. 24,25 AND 2A CRUISE
CONTROL MODULE
BUILT-IN RELAY, CPU
Code.>
28 Wiring harness opened. Open wiring harness circuit is detected via control mod- <Ref. to CC-33, DTC 28
ule relay when main switch is ON. WIRING HARNESS
OPENED., Diagnostics
Chart with Diagnostic
Trouble Code.>
35 Motor drive system is Motor output circuit is open or shorted. <Ref. to CC-34, DTC 35
abnormal. Motor drive circuit is open or shorted. AND 36 ACTUATOR
MOTOR, Diagnostics
Trouble Code.>
36 Trouble of motor Motor turning speed is low. <Ref. to CC-34, DTC 35
AND 36 ACTUATOR
MOTOR, Diagnostics
Trouble Code.>
37 Motor clutch drive system Motor clutch output circuit is open or shorted. <Ref. to CC-36, DTC 37
is abnormal. Motor clutch drive circuit is open or shorted. ACTUATOR MOTOR
CLUTCH, Diagnostics
Trouble Code.>
38 Motor drive shaft does not Motor drive gear engagement is not properly adjusted. <Ref. to CC-38, DTC 38
engage properly. MOTOR DRIVE SHAFT
DOES NOT ENGAGE
PROPERLY., Diagnostics
Trouble Code.>
CC-26
DTC Item Contents of diagnosis Reference

39 Motor is overloaded.
normal conditions. MOTOR IS OVER-
LOADED., Diagnostics
Trouble Code.>
2A Cruise control module is Cruise control module self-diagnosis function senses <Ref. to CC-28, DTC 21,
abnormal. abnormality. 24,25 AND 2A CRUISE
CONTROL MODULE
BUILT-IN RELAY, CPU
Code.>
CC-27
I DIAGNOSTICS CHART WITH DIAGNOSTIC TROUBLE CODE
8. Diagnostics Chart with Diagnostic Trouble Code

A: DTC 21,24,25 AND 2A CRUISE CONTROL MODULE BUILT-IN RELAY, CPU
RAM
DIAGNOSIS:
Poor welding of built-in relay of cruise control module.
Failure of built-in CPU RAM of cruise control module.
TROUBLE SYMPTOM:
Cruise control is canceled and memorized cruise speed is also canceled.
Once the cruise control is canceled, the cruise control cannot be set until the ignition switch and cruise con-
trol main switch turns OFF, and then turns ON again.
NOTE:
Check the input/output signal and vehicle speed signal with select monitor. When the signals are in good
condition, failure is in cruise control module. (Check power supply and ground conditions of cruise control
module.)
CC-28
CC-29
B: DTC 22 VEHICLE SPEED SENSOR

DIAGNOSIS:
Disconnection or short circuit of vehicle speed sensor system.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
IGNITION
BAlTERY
--
@ : TURBO MODEL
@ : NON-TURBO MODEL
@ AT MODEL
'
@ : MT MODEL
@:NA @:TB A: .:a
BOO291
CC-30
DIAGNOSTICS CHART WITH DIAGNOSTIC TROUBLE CODE a
Step Check No
I CHECK TRANSMISSION TYPE. $0 to step 6.
! CHECK HARNESS BETWEEN BATTERY :heck harness for
AND VEHICLE SPEED SENSOR. )pen or short
1)Disconnect harness connector from vehicle letween ignition
speed sensor. ;witch and vehicle
2)Turn ignition switch to ON. I ;peed sensor.
3)Measure voltage between vehicle speed
sensor harness connector terminal and chas-
sis ground.
I CHECK HARNESS BETWEEN CRUISE CON- s the resistance less than 10 Go to step 4. 3epair harness.
TROL MODULE AND VEHICLE SPEED SEN- 2?
SOR.
1)Turn ignition switch to OFF.
2)Disconnect harness connector from cruise
control module. I
3)Measure resistance between vehicle speed

sensor harness connector terminal and cruise
I
control module harness connector terminal.
-. (81 7) NO. 1 - (894) NO. 19: 1
I CHECK HARNESS BETWEEN VEHICLE s the resistance less than 10 1 Go to step 5. 3epair harness.
SPEED SENSOR AND ENGINE GROUND. 2?
Measure resistance between vehicle speed
sensor harness connector terminal and engine
ground.
) CHECK VEHICLE SPEED SENSOR. 3eplace vehicle
1)Connect harness connector to vehicle speed -+ more than 4 V? control module. ;peed sensor.
sensor. <Ref. to CC-5,
2)Set the vehicle on free roller, or lift-up the Cruise Control
vehicle and support with safety stands. Module.>
Warning:
Be careful not to be caught up by the run-
ning wheels.
3)Drive the vehicle at speed greater than 20
km/h (12 MPH).
4)Measure voltage between cruise control
module harness connector terminal and chas-
sis ground.
CC-31
Step Check Yes No

i CHECK HARNESS BETWEEN CRUISE CON- s the resistance less than 10 ;o to step 7 . 3epair harness
TROL MODULE AND TRANSMISSION CON- 2? :onnector
TROL MODULE. letween cruise
1)Disconnect harness connector from trans- :ontrol module
mission control module and cruise control ind transmission
module. :ontrol module.
module harness connector terminal and trans-
mission control module harness connector ter-
minal.
CAUTION:
To measure the voltage andlor resistance,
use a tapered pin with a diameter of less
than 0.64 mm (0.025 in). Do not insert the pin
more than 5 mm (0.20 in).
Turbo model:
(B94) NO. 19 - (B56) NO. 17:
Non-turbo model:
(B94) NO. 19 - (B55) NO. 13:
r CHECK TRANSMISSION CONTROL MOD- s the voltage less than 1 V leplace cruise 3eplace transmis-
_._ .. ULE. -+ more than 4 V? :ontrol module. ;ion control mod-
1)Connect harness connector to transmission :Ref. to CC-5, de. <Ref. to AT
control module. ;ruise Control 15, Transmission
2)Set the vehicle on free roller, or lift-up the nodule.> :ontrol Module
vehicle and support with safety stands. TCM).>
Warning:
Be careful not to be caught by the running
wheels.
3)Drive the vehicle faster than 10 km/h (6
MPH).
4)Measure voltage between transmission con-
trol module harness connector terminal and
chassis ground.
CAUTION:
To measure the voltage andlor resistance,
use a tapered pin with a diameter of less
than 0.64 mm (0.025 in). Do not insert the pin
more than 5 mm (0.20 in).
Turbo model:
Non-turbo model:
CC-32
DIAGNOSTICS CHART WITH DIAGNOSTIC TROUBLE CODE
C: DTC 28 WIRING HARNESS OPENED.

Step Check Yes No
1 CHECK BATTERY. Is battery specific gravity more Go to step 2. Charge or replace
Measure battery specific gravity of electrolyte. than 1.250? battery. Go to step
2.
2 CHECK FUSES, CONNECTORS AND HAR- Is there anything unusual Repair or replace End of inspection.
NESSES. about the appearance of main faulty parts.
Check the condition of the main and other fuse, fuse, harness, connector
fuses, and harnesses and connectors. Also and grounding?
check for proper grounding.
cc-33
D: DTC 35 AND 36 ACTUATOR MOTOR

DIAGNOSIS:
Open or poor contact of cruise control actuator motor.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
IGNITION
8-
SWITCH
FIB No.18
CRUISE
ACTUATOR I
CRUSE
MODULE
BO0292
cc-34
m
Step Check Yes No

1 CHECK POWER SUPPLY. Is the voltage more than 10 V? Go to step 2. Sheck harness for
1)Turn ignition switch OFF. 3pen or short
2)Disconnect harness connector from cruise between cruise
control actuator. sontrol main
3)Turn ignition switch ON. switch and cruise
4)Turn cruise control main switch ON. sontrol actuator.
actuator harness connector terminal and chas-
sis ground.
Terminals
(67) No. 4 (+) - Chassis ground (-): I
I
2 CHECK GROUND CIRCUIT OF ACTUATOR. Is resistance less than 10 R? Go to step 3. Repair harness.
Measure resistance between cruise control
sis ground.
Terminals
3 MEASURE RESISTANCE OF ACTUATOR. Is resistance approximately 5 IGo to step 4. Replace cruise
Measure resistance of cruise control actuator Q? control actuator.
motor. <Ref. to CC-4,
Terminals Actuator.>
e. NO. 4 -NO. 1:
NO. 4 - NO. 2:
NO. 4 - NO. 5:
4 CHECK HARNESS BETWEEN ACTUATOR Is resistance less than 10 Q? io to step 5. Repair harness.
AND CRUISE CONTROL MODULE.
control module.
control actuator harness connector terminal.
(67) NO. 1 - (694) NO. 7:
5 CHECK HARNESS BETWEEN ACTUATOR Is resistance less than 10 R? Replace cruise Repair harness.
AND CRUISE CONTROL MODULE. control module.
Measure resistance between cruise control <Ref. to CC-5,
module harness connector terminal and cruise Cruise Control
control actuator harness connector terminal . Module.>
(67) NO. 5 - (694) NO. 5:
cc-35
E: DTC 37 ACTUATOR MOTOR CLUTCH

DIAGNOSIS:
Open or poor contact of cruise control actuator motor clutch.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
IGNITION
BATERY SWITCH
SBF-4 FIB No.18
0 0
CRUISE
CONTROL
ACTUATOR
L m
CRUISE CONTROL
CRUISE
:oNTRot
MODULE
11213141516171819110
11~12~13~14~15~16~17~18~19~20
BOO292
CC-36
Step Check Yes No

I CHECK POWER SUPPLY. Is the voltage more than 10 V? Go to step 2. Check harness for
1)Turn ignition switch OFF. open or short
2)Disconnect harness connector from cruise between cruise
control actuator. control main
3)Turn ignition switch ON. switch and cruise
4)Turn cruise control main switch ON. Eontrol actuator.
sis ground.
Terminals
(B7)No. 4 (+) - Chassis groundI)-(
! CHECK GROUND CIRCUIT OF ACTUATOR. Is resistance less than 10 a? Go to step 3. I Repair harness.
Measure resistance between cruise control
sis ground.
Terminals
I MEASURE RESISTANCE OF ACTUATOR Is resistance approximately 39 I Go to step 4. Replace cruise
CLUTCH. n? :ontrol actuator.
Measure resistance of cruise control actuator <Ref. to CC-4,
clutch. Actuator.>
.. . Terminals
NO. 3 - NO. 6:
--
I CHECK HARNESS BETWEEN ACTUATOR Is resistance less than 10 a? Go to step 5. Repair harness.
AND CRUISE CONTROL MODULE.
control module.
control actuator harness connector terminal.
(B7)NO. 2 - (B94)NO. 13:
> CHECK HARNESS BETWEEN ACTUATOR Is resistance less than 10 R? ' Replace cruise Repair harness.
AND CRUISE CONTROL MODULE. control module.
Measure resistance between cruise control <Ref. to CC-5,
module harness connector terminal and cruise Cruise Control
control actuator harness connector terminal. l Module.>
(87)NO. 3 - (894)NO. 14:
cc-37
F: DTC 38 MOTOR DRIVE SHAFT DOES NOT ENGAGE PROPERLY.

Step Check Yes No
1 CHECK ACTUATOR MOTOR. Are foreign particles caught in Replace cruise Check the cruise
1)Disconnect harness connector from cruise inner gear or does inner gear control actuator. control cable
control actuator. engage and disengage <Ref. to CC-4, adjustment.<Ref.
2)Remove cruise control actuator from mount- improperly? Actuator.> to CC-4, CABLE
ing bracket. FREE PLAY, Gen-
3)Pull cable by hand to check for looseness or eral Description.>
status of inner gear engagement.
CC-38
m
G: DTC 39 MOTOR IS OVERLOADED.

Step Check Yes No
1 CHECK THE OPERATING CURRENT TO AC- Is current more than 1OA? Replace cruise Check the power
TUATOR MOTOR. control module. supply circuit.
1)Connect Subaru Select Monitor to data link <Ref. to CC-5, <Ref. to CC-14,
connector. Cruise Control CHECK POWER
2)Try to drive the vehicle while operating the Module.> SUPPLY, Diagnos
cruise control system. tics Chart with
3)Check the operation current to the cruise Symptom.>
control actuator motor.
cc-39
c- .
CC-40
OPTION PARTS
OP
Page
Refer to GI831 BE SUPPLEMENT for this section.
OPTION PARTS
OP
Page
-
1. General Description ................................................................................... .2
2. Rear Spoiler ................................................................................................ 5
3. Crossbar .................................................................................................... ..6
4. Trailer Hitch ............................................................................................... ..7
5. Rear Differential Protector......................................................................... ..8
GENERAL DESCRIPTION
OPTION PARTS
A: COMPONENT
1. REAR SPOILER
BO0454
(1) Rear spoiler (3) Retention cable Tightening torque: N-m (kgf-m, ft-lb)
(2) High mount stop lamp T: 7.4 (0.75, 5.46)
2. CROSSBAR
BOO455
(1) Front crossbar (2) Caution label (Front crossbar) (3) Rear crossbar
OP-2
GENERAL DESCRIPTION
OPTION PARTS
3. TRAILER HITCH
BO0456
(1) Receiver hitch (4) Ball mount clip Tightening torque: N.m (kgf-m, ft-/&)
(2) Ball mount (5) Receiver cover T: 95 (9.7, 70)
(3) Ball mount pin
OP-3
GENERAL DESCRIPTION
OPTION PARTS
4. REAR DIFFERENTIAL PROTECTOR
I
i
i
i
i
P
.\,
9 i
(1) Differential front member (4) Spacer (Long) Tightening toque: N-m (kgf-m, ft-lb)
(2) Differential rear member (5) Rear differential protector T: 70 (7.1, 51.6)
(3) Spacer (Short) (6) Washer
OP-4
REAR SPOILER
OPTION PARTS
2. Rear %oiler . B: INSTALLATION

A: REMOVAL
Tightening torque:
Rear spoiler to trunk lid
3) Disconnect the connector of high mounted stop- 7.5 N.m (0.76 kgf-m, 5.5 ft-lb)
light. Retention cable to trunk hinge
13.7 N.m (1.4 kgf-m, 10.1 fi-lb)
(1) Connector
(2) Trunk hinge
4) Rembve the retention cable with the trunk hinge

lower side bolt.
5 ) Remove the mounting nuts of rear spoiler.
(1) Retention cable

(2) Mounting nut
6) Remove the rear spoiler with retention cable.

CAUTION:
Pay attention to avoid damage during removal
or installation.
OP-5
c
CROSSBAR
OPTION PARTS
3. Crossbar B: INSTALLATION
1) Rotate the lower clamp of each end support
A: REMOVAL about 90 degrees downward.
1) Remove the TORX@bolt T30 from each end sup- 2) Set the front crossbar so that front direction mark
port. on the right side top face of crossbar point in the di-
2) Rotate the lower clamp of each end support rection of vehicle front.
about 90 degress downward to remove the cross- 3) Place the crossbar end support at position 76.2
bar. mm (3 in) behind the joint of front roof rail support
and roof rail.
Length A:
76.2 mm (3in)
(1) TORX@bolt T30

(2) End support
80044s
(3) Roof rail
(4) Lower clamp
(1) Front of vehicle
CAUTION: (2) Front direction mark
Pay attention to avoid damage to the roof panel (3) Caution label (Front crossbar)
during removal or installation.
4) Set the rear crossbar so that front direction mark
on the right side top face of crossbar point in the di-
rection of vehicle front.
5 ) Place the crossbar end support on a joint of rear
roof rail support and roof rail.
0-f-
BOO450
(1) Front of vehicle

(2) Front direction mark
6) Tighten the end support and clamp using TORX@

bolt T30.
OP-6
TRAILER HITCH
OPTION PARTS
4. Trailer Hitch 5) Remove the trailer hitch while lowering tail pipe.
A: REMOVAL B: INSTALLATION
CAUTION: CAUTION:
Because the trailer hitch is heavy, two people Because the trailer hitch is heavy, two people
are required to remove it. are required to install it.
1) Lift-up the vehicle. Install in the reverse order of removal.
2) Remove the rubber cushion from tail pipe. Tightening torque:
Trailer hitch to body:
95 N-m (9.7 kgf-m, 70 W b )
Canister:
23 N-m (2.3 kgf-m, 17 ft-lb)
3) Remove the three nuts and canister.
4) Remove the trailer hitch installation bolts.
w BO0453
OP-7
REAR DIFFERENTIAL PROTECTOR
OPTION PARTS
5. Rear Differential Protector B: INSTALLATION

A: REMOVAL
1) Remove the rear exhaust pipe and muffer. Tightening torque:
2) Remove the differential front member installation 70 N-m (7.1 kgf-m, 51.6 ft-16)
bolts.
DR002:
DR0022
NOTE:
3) Loosen the nuts until the rear differential protec- Install the protector between the nuts and differen-
tor can be removed. tial rear member.
Tightening torque:
70 N-m (7.7 kgf-m, 51.6 ft-16)
4) Remove the rear differential protector.
OP-8
OPTION PARTS
r.
OP-2

2002 Subaru Impreza WRX Service

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I 3

2002 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX

This service manual has been prepared

All information, illustration and specifi-

FUJI HEAVY INDUSTRIES LTD. G1830BE1

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

The additional manuals below are also available:

The manuals contain the latest information at the

1. How to Use This Manuals

Tread I Front mm (in) I

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

I valve arranqement I Overhead camshaft tvDe 1

4th 1.088 0.694 1.088 1.694

Final reduction Type of gear Hypoid Hypoid Hypoid Hypoid

Type Rack and Pinion

Front Macpherson strut type, Independent, Coil spring

Model SEDAN WAGON

Rim size 15 x 6JJ 16 x 6’/2JJ

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

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

*1: Excludes weight of air conditioner

1. Precaution 7. AIRBAG MODULE

5. LIFTS AND JACKS

Rear Rear differential

Hook for tie-down

Hook for towing

Hook for tie-down Hook for towing

Vacuum hose piping label

' Model number plate

Transmission serial number

Engine sdrial number G l0007A I o. G10008A I

Model number plate /

Digits Code Meaning Details

3. MODEL NUMBER PLATE

Digits Code Meaning Details

Digits Code Meaning Details

3 and 4 25 Displacement 20: 2.0 L

< 5W-30 Recommend I

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

Fluid Recommended Alternative Remarks

Coolant Recommended Item number Alternative

Air conditioner Recommended Item number Alternative

Grease Application point Recommended Item number Alternative

Step Check point

Step Check point

Pynamic Test with the Vehicle Running

I Step I Check point I

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

1. APPEARANCE CHECK 4. CHECK THE DOOR OPERATIONS,

5. POWER WINDOW OPERATION CHECK

7. CHECK THE REAR GATE OPERATIONS,

2) Move the release handle from outside the vehi-

Operate the power door locking switch to check

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

12.CONNECTION OF AIR CONDITIONER 16.TRANSMISSION FLUID

17.AT FRONT DIFFERENTIAL OIL

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

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

Check selecting audible signal operation.

Press the “UNLOCWDISARM” button on the

Press the “UNLOCWDISARM” button on the

26.WHEEL ALIGNMENT 35. LIGHTING SYSTEM

28.KEY WARNING SYSTEM

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