Service Manual PDF

2001 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
GENERAL INFORMATION
SECTION
This service manual has been prepared

to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair of
SUBARU vehicles.
This manual includes the procedures for
maintenance, disassembling, reassem-
bling, inspection and adjustment of com-
ponents and diagnostics for guidance 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 genu-
ine parts.
All information, illustration and specifica-

tions contained in this manual are based
on the latest product information avail-
able at the time of publication approval.
FUJI HEAVY INDUSTRIES LTD.
G8050GE1
ENGINE1 SECTION

SUBARU vehicles.
ine parts.

G8050GE2
ENGINE2 SECTION

SUBARU vehicles.
ine parts.

G8050GE3
TRANSMISSION SECTION

SUBARU vehicles.
ine parts.

G8050GE4
CHASSIS SECTION

SUBARU vehicles.
ine parts.

G8050GE5
BODY SECTION

SUBARU vehicles.
ine parts.

G8050GE6
BODY SECTION
G8050GE6
WIRING SYSTEM SECTION

SUBARU vehicles.
ine parts.

G8050GE7
FOREWORD
FW
Page
1. Foreword .....................................................................................................2
FOREWORD
Foreword
1. Foreword SA01674
A: FOREWORD SA01674G21
These manuals are used when performing

maintenance, repair, or diagnosis of the Subaru
Forester.
Applied model: SF***** from 2001MY.
The additional manuals below are also available:

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

time of publication. Changes in specifications,
methods, etc. may be made without notice.
FW-2
HOW TO USE THIS MANUALS
HU
Page
1. How to Use This Manuals...........................................................................2
HOW TO USE THIS MANUALS
How to Use This Manuals
1. How to Use This Manuals SA02675
A: HOW TO USE THIS MANUALS

SA02675F69
1. STRUCTURE SA02675F6901
Each section consists of SCT that are broken down

into SC that are divided into sections for each com-
ponent. The specification, maintenance and other
information for the components are included, and
diagnosis information has also been added where
necessary.
2. INDEX SA02675F6902
The first page has an index with tabs. And at the

end of each section is an alphabetical index.
3. COMPONENTS SA02675F6903
For each component, a composition drawing is

included.
4. SPECIFICATIONS SA02675F6904
If necessary, specifications are also included

5. INSPECTION SA02675F6905
Inspections are included to be carried out before

and after maintenance.
6. MAINTENANCE SA02675F6906
Maintenance instructions are provided for each

component. When multiple components comprise
one process, refer to the instructions for that pro-
cess for each component.
7. DIAGNOSIS SA02675F6907
Tables showing a step-by-step process make it

easy to conduct diagnosis.
8. SI UNITS SA02675F6909
Measurements in these manuals are according to

the SI units. Metric and yard/pound measurements
are also included.
HU-2
SPECIFICATIONS
SPC
Page
1. Forester .......................................................................................................2
FORESTER
Specifications
1. Forester SA08758
A: DIMENSIONS SA08758G28
Model 2.0 L Non-TURBO 2.0 L TURBO

Overall length mm (in) 4,460 (175.6), 4,530 (178.3)*1
Overall width mm (in) 1,735 (68.3), 1,765 (69.5)*2
Overall height (at CW) mm (in) 1,595 (62.8) 1,585 (62.4)
Compartment Length mm (in) 1,745 (68.7)
Width mm (in) 1,435 (56.5)
Height mm (in) 1,245 (49.0), 1,220 (48.0)*3
Wheelbase mm (in) 2,525 (99.4)
Tread Front mm (in) 1,475 (58.1)
Rear mm (in) 1,465 (57.7)
Minimum road clearance mm (in) 190 (7.5), 200 (7.9)*4
*1: With bushing bar
*2: With fender flare
*3: With sunroof
*4: Australia spec. vehicles
B: ENGINE SA08758G29

Engine type Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine
Valve arrangement Overhead camshaft type
Bore × Stroke mm (in) 92 × 75 (3.62 × 2.95)
3
Displacement cm (cu in) 1,994 (121.67)
Compression ratio 10.0 8.0
Firing order 1—3—2—4
Idle speed at Park/ rpm 700±100
Neutral position
Maximum output kW (HP)/rpm 101 (137)/5,600 130 (174)/5,600
Maximum torque N·m (kgf-m, ft-lb)/rpm 186 (19.0, 137.0)/3,600 245 (25, 181)/3,200
C: ELECTRICAL SA08758G30

Ignition timing at idling speed BTDC/rpm 12°±10°/700
Spark plug Type and manufacturer NGK: BK5E-11 (without catalyst) NGK: PFR6B
CHAMPION: RC10YC4 (with catalyst)
Generator 12 V — 75 A
Battery Type and capacity For Europe 5MT: 12 V — 48AH
(5HR) 4AT: 12 V — 52AH
For Australia 12 V — 40AH
Others 12 V — 40AH
SPC-2
FORESTER
Specifications
D: TRANSMISSION SA08758G31

AWD
Transmission type 5MT*1 4AT*2 5MT*1 4AT*2
Clutch type DSPD TCC DSPD TCC
Gear ratio 1st 3.454 2.785 3.454 2.785
2nd 2.062 1.545 1.947 1.545
3rd 1.448 1.000 1.366 1.000
4th 1.088 0.694 0.972 0.694
5th 0.871 — 0.738 —
Reverse 3.333 2.272 3.333 2.272
Auxiliary transmission gear ratio High 1.000 — — —
Low 1.447 — — —
Reduction gear 1st reduction Type of gear — Helical — Helical
(Front drive) Gear ratio — 1.000 — 1.000
Final reduction Type of gear Hypoid Hypoid Hypoid Hypoid
Gear ratio 4.111 4.444 4.444 4.111
Reduction gear Transfer reduc- Type of gear Hypoid — Hypoid —
(Rear drive) tion Gear ratio 1.000 — 1.081*4, 1.000*5 —
Final reduction Type of gear Hypoid Hypoid Hypoid Hypoid
Gear ratio 4.111 4.444 4.111*4, 4.444*5 4.111
5MT*1: 5 × 2 forward speeds with synchromesh and 1-reverse — with center differential and viscous coupling
4AT*2: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse — with hydraulically controlled transfer clutch
5MT*3: 5-forward speeds with synchromesh and 1-reverse — with center differential and viscous coupling
DSPD: Dry Single Plate Diaphragm
TCC: Torque Converter Clutch
*4: For Europe
*5: Others
E: STEERING SA08758G32
Model LHD RHD

Type Rack and Pinion
Turns, lock to lock 3.4 3.0
Minimum turning circle m (ft) Curb to curb: 10.8 (35.4)
F: SUSPENSION SA08758G33
Front MacPherson strut type, Independent, Coil spring

Rear Dual link strut type, Independent, Coil spring
SPC-3
FORESTER
Specifications
G: BRAKE SA08758G34
Model Australia spec. vehicles and 2000 Others

TURBO
Service brake system Dual circuit hydraulic with vacuum suspended power unit
Front Ventilated disc brake
Rear Disc brake Drum brake
Parking brake Mechanical on rear brakes
H: TIRE SA08758G35
Rim size 15 × 6J 16 × 61/2JJ

Tire size 205/70R15 215/60R16
Type Steel belted radial, Tubeless
I: CAPACITY SA08758G36

AWD AWD
5MT 4AT 5MT 4AT
Fuel tank (US gal, Imp gal) 60 (15.9, 13.2) 60 (15.9, 13.2)
Engine oil Upper level (US qt, Imp qt) 4.5 (4.8, 4.0) 5.0 (5.3, 4.4)
Lower level (US qt, Imp qt) 3.5 (3.7, 3.1) 4.0 (4.2, 3.5)
Transmission gear oil (US qt, Imp qt) 4.0 (4.2, 3.5) — 3.5 (3.7, 3.1) —
Automatic transmission fluid (US qt, Imp qt) — 8.4 (8.9, 7.4) — 9.3 (9.8, 8.2)
AT differential gear oil (US qt, Imp qt) — 1.2 (1.3, 1.1) — 1.2 (1.3, 1.1)
AWD rear differential gear oil (US qt, Imp qt) 0.8 (0.8, 0.6) 0.8 (0.8, 0.6)
Power steering fluid (US qt, Imp qt) 0.7 (0.7, 0.6) 0.7 (0.7, 0.6)
Engine coolant (US qt, Imp qt) 6.4 (6.8, 5.6) 6.3 (6.7, 5.5) 6.4 (6.8, 5.6) 6.3 (6.7, 5.5)
SPC-4
FORESTER
Specifications
J: WEIGHT SA08758G37
1. EXCEPT AUSTRALIA SPEC. VEHICLE SA08758G3706
Model 2.0 L Non-TURBO

AWD
LHD RHD
5MT 4AT 5MT 4AT
Curb weight (CW) Front kg (lb) 730 (1,610) 745 (1,643) 745 (1,643) 760 (1,676)
Rear kg (lb) 615 (1,356) 615 (1,356) 620 (1,367) 620 (1,367)
Total kg (lb) 1,345 (2,966) 1,360 (2,999) 1,365 (3,010) 1,380 (3,043)
Maximum permissible Front kg (lb) 920 (2,029) 930 (2,051) 920 (2,029) 930 (2,051)
axle weight (MPAW) Rear kg (lb) 990 (2,183) 990 (2,183) 990 (2,183) 990 (2,183)
Maximum permissible Total kg (lb) 1,875 (4,134) 1,890 (4,163) 1,875 (4,134) 1,890 (4,167)
weight (MPW)
Model 2.0 L TURBO

AWD
LHD RHD
5MT 4AT 5MT 4AT
Curb weight (CW) Front kg (lb) 795 (1,753) 815 (1,797) 790 (1,742) 810 (1,786)
Rear kg (lb) 635 (1,400) 630 (1,389) 630 (1,389) 630 (1,389)
Total kg (lb) 1,430 (3,153) 1,445 (3,186) 1,420 (3,131) 1,440 (3,185)
Maximum permissible Front kg (lb) 975 (2,150) 995 (2,195) 975 (2,150) 975 (2,150)
axle weight (MPAW) Rear kg (lb) 1,010 (2,225) 1,010 (2,225) 1,010 (2,225) 1,010 (2,225)
Maximum permissible Total kg (lb) 1,950 (4,300) 1,970 (4,344) 1,950 (4,300) 1,970 (4,344)
weight (MPW)
NOTE:
When any of the following optional parts are installed, add the weight to the curb weight.
Weight of ABS ABS Cruise Self- Fog Air con- Sunroof SRS SRS Cold Cold
optional (Turbo (Non- control levelizer lamp ditioner airbag airbag weather weather
parts model) Turbo (Driver & (Side) pack pack
model) Passen- (Leather
ger) seat)
Front kg (lb) 10 (22) 11 (24) 2 (4) −1 (−2) 3.6 (7.9) 17 (38) 9 (20) 3 (7) 2 (4.4) 2 (4) 2.6 (5.7)
Rear kg (lb) −1 (−2) −1 (−2) 0 (0) 2 (4) −1 (−2) −3 (−7) 14 (31) 2 (4) 2 (4.4) −1 (−2) 4.4 (9.7)
Total kg (lb) 9 (20) 10 (22) 2 (4) 1 (2) 2.6 (5.7) 14 (31) 23 (51) 5 (11) 4 (8.8) 1 (2) 7.0
(15.4)
SPC-5
FORESTER
Specifications
2. AUSTRALIA SPEC. VEHICLE SA08758G3704

AWD AWD
RHD RHD
5MT 4AT 5MT 4AT
Unladen mass (UM) Front kg (lb) 740 (1,632) 755 (1,665) 810 (1,786) 835 (1,841)
Rear kg (lb) 625 (1,378) 625 (1,378) 630 (1,389) 625 (1,378)
Total kg (lb) 1,365 (3,010) 1,380 (3,043) 1,440 (3,175) 1,460 (3,219)
Gross vehicle mass Front kg (lb) 885 (1,951) 910 (2,007) 960 (2,117) 980 (2,161)
(GVM ) Rear kg (lb) 990 (2,183) 980 (2,161) 990 (2,183) 990 (2,183)
Total kg (lb) 1,875 (4,134) 1,890 (4,167) 1,950 (4,300) 1,970 (4,344)
NOTE:
When any of the following optional parts are installed, add the weight to the unladen mass.
Weight of ABS Cruise Self- Fog lamp Air condi- Sunroof SRS airbag SRS airbag Cold
optional parts control levelizer tioner (Driver & (Side) weather
Passenger) pack
Front kg (lb) 10 (22) 2 (4) −1 (−2) 3.6 (7.9) 17 (38) 9 (20) 3 (7) 2 (4.4) 2.6 (5.7)
Rear kg (lb) −1 (−2) 0 (0) 2 (4) −1 (−2) −3 (−7) 14 (31) 2 (4) 2 (4.4) 4.4 (9.7)
Total kg (lb) 9 (20) 2 (4) 1 (2) 2.6 (5.7) 14 (31) 23 (51) 5 (11) 4 (8.8) 7.0 ( 15.4)
SPC-6
PRECAUTION
PC
Page
1. Precaution ...................................................................................................2
PRECAUTION
Precaution
1. Precaution SA04677
7. AIRBAG MODULE SA04677F5907
Adhere to the following when handing and storing

A: PRECAUTION SA04677F59
the airbag module to prevent bodily injury from
Please clearly understand and adhere to the fol- unexpected deployment:
lowing general precautions. They must be strictly 쐌 Do not hold harnesses or connectors to carry
followed to avoid minor or serious injury to the per- the module.
son doing the work or people in the area. 쐌 Do not face the bag in the direction that it opens
towards yourself or other people.
1. ABS SA04677F5901
쐌 Do not face the bag in the direction that it opens
Handle the ABS as a total system. Do not disas- towards the floor or walls.
semble or attempt to repair individual parts. Doing
so could prevent the ABS system from operating 8. AIRBAG SPECIAL TOOLS SA04677F5908
when needed or cause it to operate incorrectly and To prevent unexpected deployment, only use spe-
result in injury. cial tools.
2. BRAKE FLUID SA04677F5902 9. WINDOW SA04677F5909
If brake fluid gets in your eyes or on your skin, do Always wear safety glasses when working around
the following: any glass to prevent glass fragments from damag-
쐌 Wash out your eyes and seek immediate medi- ing your eyes.
cal attention.
쐌 Wash your skin with soap and then rinse thor- 10. WINDOW ADHESIVE SA04677F5910
oughly with water. Always use the specified urethane adhesive when
attaching glass to prevent it from coming loose and
3. ELECTRIC FAN SA04677F5903
falling, resulting in accidents and injury.
The electric fan may rotate without warning, even
when the engine is not on. Do not place your hand,
cloth, tools, or other items near the fan at any time.
4. ROAD TESTS SA04677F5904
Always conduct road tests in accordance with traf-

fic rules and regulations to avoid bodily injury and
interrupting traffic.
5. AIRBAG SA04677F5905
To prevent bodily injury from unexpected deploy-

ment of airbags and unnecessary maintenance,
follow the instructions in this manual when per-
forming maintenance on airbag components or
nearby, and airbag wiring harnesses or nearby.
To prevent unexpected deployment, perform one
of the steps below and then wait at least 20 sec-
onds to discharge electricity before beginning
work.
쐌 Step 1: Turn the ignition switch OFF.
쐌 Step 2: Remove the negative battery terminal.
6. AIRBAG DISPOSAL SA04677F5906
To prevent bodily injury from unexpected airbag

deployment, do not dispose airbag modules in the
same way as other refuse. Follow the special
instructions for disposal in this manual. Follow all
government regulations concerning disposal of
refuse.
PC-2
NOTE
NT
Page
1. Note .............................................................................................................2
NOTE
Note
1. Note SA03676
A: NOTE SA03676A15
This is information that can improve efficiency of

maintenance and assure sound work.
1. FASTENER NOTICE SA03676A1501
Fasteners are used to prevent parts from damage

and dislocation due to looseness. Fasteners must
be tightened to the specified torque.
Do not apply paint, lubricant, rust retardant, or
other substances to the surface around bolts,
fasteners, etc. Doing so will make it difficult to
obtain the correct torque and result in looseness
and other problems.
2. STATIC ELECTRICITY DAMAGE SA03676A1502
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 SA03676A1503
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 SA03676A1504
Use authentic service parts for maximum perfor-

mance and maintenance, when conducting
repairs. Subaru/FHI will not be responsible for poor
performance resulting from the use of parts not
specified by a genuine dealer.
NT-2
NOTE
Note
5. LIFTS AND JACKS SA03676A1505
When using a lift or jack-ridged rack to raise a vehicle, always follow instructions concerning jack-up points
and weight limits to prevent the vehicle from falling, which could result in injury. Be especially careful to make
sure the vehicle is balanced before raising it.
S1M0137A
NT-3
NOTE
Note
S1M0138A
S1M0139A
NT-4
NOTE
Note
6. TIE DOWNS SA03676A1506
Tie downs are used when transporting vehicles

and when using the chassis dynamo. Attach tie
downs only to the specified points on the vehicle.
S1M0142A
7. TOWING SA03676A1507
Avoid towing vehicles except when the vehicle

S1M0140A
cannot be driven. For vehicles with AWD, AT, or
VTD, use a loader instead of towing. When towing
other vehicles, to prevent excessive weight from
damaging the hook or vehicle:
쐌 Do not tow other vehicles with a front towing
hook.
쐌 Make sure the vehicle towing is heavier that the
vehicle being towed.
8. TRAINING SA03676A1508
For information about training, contact a dealer or

agent.
S1M0141A
9. GENERAL SCAN TOOL SA03676A1509
Using general scan tools will greatly improve effi-

ciency of repairing engine electronic controls. The
Subaru Select Monitor can be used to diagnose
the engine and also the ABS, and other parts.
GI0103
NT-5
NOTE
Note
MEMO:
NT-6
IDENTIFICATION
ID
Page
1. Identification ................................................................................................2
IDENTIFICATION
Identification
1. Identification SA06679
A: IDENTIFICATION SA06679F70
1. IDENTIFICATION NUMBER AND LABEL LOCATIONS SA06679F7001
The VIN (Vehicle Identification Numbers) is used to classify the vehicle.

Positioning of the plate label for identification
S1M0148A
GI0007A GI0009A
ID-2
IDENTIFICATION
Identification
GI0008A S1M0149A
GI0011A
ID-3
IDENTIFICATION
Identification
2. MEANING OF V.I.N. SA06679F7002
The meaning of the VIN is as follows:

쐌 Europe, Australia and General (Except GCC)
]JF1SF5LJ31G002001[
The starting and ending brackets ( ][ ) are stop marks.
Digits Code Meaning Details
1 to 3 JF1 Manufacturer body area JF1: Passenger car, FHI made
JF2: MPV, FHI made
4 S Car line Forester
5 F Body type F: Wagon
6 5 Displacement 5: 2.0 L AWD
7 L Steering position K: RHD (Right-hand drive)
L: LHD (Left-hand drive)
8 J Engine & transmission J: SOHC MPI Full-time AWD 5-speed MT
R: SOHC MPI 4-speed AT
D: DOHC Turbo Full-time AWD 5-speed MT
P: DOHC Turbo 4-speed AT
9 3 Drive type 3: Full-time AWD 5-speed MT single range
4: Full-time AWD 5-speed MT dual range
5: Full-time AWD 4-speed AT
10 1 Model year 1: 2001MY
2: 2002MY
11 G Factory location G: FHI (Gunma)
12 to 17 002001 Serial number
쐌 GCC countries (Saudi Arabia, etc.)

]JF1SF53MX1J002001[
The starting and ending brackets ( ][ ) are stop marks.
1 to 3 JF1 Manufacturer body area JF1: Passenger car, FHI made
4 S Car line Forester
5 F Body type E: Wagon
6 5 Displacement 5: 2.0 L AWD
7 3 Grade 3: BASE
5: NA SPRT
8 M Restraint M: Manual belts, dual airbag
9 X Check digit
10 1 Model year 1: 2001MY
2: 2002MY
11 J Transmission type H: Full-time AWD 4-speed AT
J: Full-time AWD 5-speed MT dual range
12 to 17 002001 Serial number
ID-4
IDENTIFICATION
Identification
3. MODEL NUMBER PLATE SA06679F7003
The model number plate indicates: the applied model, the option code, the trim code, the engine type, the
transmission type, and the exterior color code. This information is helpful when placing orders for parts.
SF9CL7R
1 S Series Forester
2 F Body style F: Wagon
3 9 Engine displacement 5: 2.0 L AWD
Drive system 9: 2.5 L AWD
Suspension system
4 C Minor change 2001MY
5 L Destination K: Right-hand drive for general market
L: Left-hand drive for general market
Y: For United States, Canada
6 7 Grade 2: BASE
3: HUNTER Ver.
4: NA SPORT
5: TYPES
7 R Transmission, fuel feed E: DOHC MPI 4-speed AT
system P: DOHC MPI Turbo 4-speed AT
D: DOHC MPI Turbo center differential AWD
J: SOHC MPI center differential AWD
R: SOHC MPI 4-speed AT
The engine and transmission type are as follows:

쐌 Engine
EJ20DAXBBB

1 and 2 EJ Engine type EJ: 4 cylinders
3 and 4 20 Displacement 20: 2.0 L
25: 2.5 L
5 D Fuel feed system 1: D-MPI SOHC-A
2: D-MPI SOHC-B
4: MPI DOHC
5: MPI Turbo
6 A Detailed specifications Used when ordering parts. See the parts catalog for details.
7 X Transmission W: AWD MT
X: AWD AT
8 to 10 BBB Detailed specifications Used when ordering parts. See the parts catalog for details.
ID-5
IDENTIFICATION
Identification
쐌 Transmission
TZ1A3ZS3AA
1 T Transmission T: Transmission
2 Z Transmission type Y: Full-time AWD MT center differential
Z: Full-time AWD AT MPT
3 and 4 1A Classification 75: MT
1A: New AT
5 3 Series 3: AT
5: MT
6 Z Transmission specifica- V: Full-time AWD 5-speed MT with viscous coupling center
tions differential single range
X: Full-time AWD 5-speed MT with viscous coupling center
differential dual range
Z: Full-time AWD 4-speed AT with MPT
7 to 10 AAA Detailed specifications Used when ordering parts. See the parts catalog for details.
쐌 Rear differential 1
VA1RFF

1 V For AWD V: AWD
2 A Type A: A type
3 1 Hypoid gear diameter 1: 152 dia.
2: 160 dia.
4 R Installation position R: Rear
5 F Reduction gear ratio F: 4.444
6 F Specification differences F: Case A
쐌 Rear differential 2
T1
Code Reduction LSD
gear ratio
T1 3.900 No
T2 4.111 No
TP 4.444 No
BK 4.111 No
BP 4.111 Strengthened type
BL 4.444 Strengthened type
VB 3.700 No
ID-6
RECOMMENDED MATERIALS
RM
Page
1. Recommended Materials ............................................................................2
Recommended Materials
1. Recommended Materials SA05678
A: RECOMMENDED MATERIALS
SA05678G22
1. GENERAL SA05678G2201
To insure the best performance, always use the

specified oil, gasoline, adhesive, sealant, etc. or
that of equivalent quality.
2. FUEL SA05678G2202
Always use a gasoline of the same or higher

octane value than specified in the owner’s manual.
Ignoring the specifications below will result in dam-
age or poor operation of the engine and fuel injec-
tion system. Use the specified gasoline to correct
performance.
쐌 Unleaded gasoline
Use unleaded gasoline and not leaded gasoline on
vehicles with catalytic converter installed to reduce
air pollution. Using leaded gasoline will damage
the catalytic converter.
쐌 Leaded gasoline
On vehicles without catalytic converter, use gaso-
line with an octane value of 90 RON or higher.
RM-2
3. LUBRICANTS SA05678G2203
Use either the lubricants in the table below or equivalent lubricants. See the table below to choose the cor-
rect SAE viscosity.
Lubricant Recommended Alternative
API Spec. CCMC Spec. ACEA Spec.
Engine oil SJ Grade “Energy conserving” G4 or G5 A1, A2 or A3 API: SH or SG
GI0001
GI0002
Manual transmission oil GL-5 — — —
Front differential GL-5 — — —
Rear differential GL-5 — — —
SAE viscosity SAE viscosity No. and applicable temperature SAE J300
Engine oil
GI0003A
RM-3
SAE viscosity SAE viscosity No. and applicable temperature SAE J300
Manual transmission oil
Rear differential
GI0004A
Front differential
GI0005A
4. FLUID SA05678G2204
Use the fluids specified in the table below. Do not mix two different kinds or makes of fluid.
Fluid Recommended Alternative Remarks
Automatic transmission fluid DEXRON III —
Power steering fluid DEXRON III —
Brake fluid FMVSS No. 116 DOT3 FMVSS No. 116 DOT4
Clutch fluid FMVSS No. 116 DOT3 FMVSS No. 116 DOT4
5. COOLANT SA05678G2205
Use genuine coolant to protect the engine.

Coolant Recommended Item number Alternative
Coolant SUBARU coolant 000016218 None
Water for dilution Distilled water — Tap water
RM-4
The table below shows the ratio of coolant to distilled water.

Coolant Specifications
Lowest antici- SUBARU Specification gravity
pated atmo- coolant-to-
at 10°C at 20°C at 30°C at 40°C at 50°C Freezing point
spheric tem- *water ratio
perature (Volume) % (50°F) (68°F) (86°F) (104°F) (122°F)
Above −30°C −36°C
50 — 50 1.084 1.079 1.074 1.068 1.062
(−22°F) (−33°F)
Above −15°C −16°C
30 — 70 1.050 1.049 1.042 1.037 1.032
(5°F) (3°F)
*: It is recommended that distilled water be used.
6. REFRIGERANT SA05678G2206
Standard air conditioners on Subaru vehicles use HFC134a refrigerant. Do not mix it with other refriger-
ants. Also, do not use any air compressor oil except for ZXL200PG and DENSO OIL 9.
Air conditioner Recommended Item number Alternative
Refrigerant HFC134a — None
Compressor oil ZXL200PG — None
7. GREASE SA05678G2207
Use the grease and supplementary lubricants shown in the table below.
Grease Application point Recommended Item number Alternative
Supplementary lubricants 쐌 O2 sensor SUBARU CRC 004301003 —
쐌 Bolts, etc.
Grease MT main shaft FX clutch grease 000040901 —
Clutch master cylinder Slicolube G-40M 004404003 —
push rod
쐌 Steering shaft bear- SUNLIGHT2 003602010 —
ing
쐌 Gear shift bush
Steering gear box Valiant grease M-2 003608001 —
Disc brake Niglube RX-2 003606000 or —
725191040
Drum brake Molykote No. 7439 72519460 —
쐌 Brake pad Molykote AS-880N 26298AC000 —
쐌 Brake shoe
Front axle SFJ SSG-6003 28093TA000 —
Front BJ NTG 2218 28093AA000 —
Rear axle BJ Molykote No. 2 723223010 —
Rear axle EBJ (Turbo- NTG 2218 28093AA000 —
model)
Rear axle DOJ VU-3A702 23223GA050 —
쐌 Control cable Slicolube G-30M 004404002 —
쐌 Throttle linkage
쐌 Water pump
쐌 Door latch
쐌 Door striker
RM-5
8. ADHESIVES SA05678G2210
Use the adhesives shown in the table below, or equivalent.

Adhesive Application point Recommended Item number Alternative
Adhesive Windshield and body Essex Chemical Crop’s Ure- — Sunstar 580
thane E
Weatherstrip, rubber Cemedine 5430L — 3M’s EC-1770 EC-1368
parts
Soft vinyl Cemedine 540 — 3M’s EC-776 EC-847 or EC-1022
(Spray type)
Momentary sealant Cemedine 3000 RS-300 — Armstrong’s Eastman 910
9. SEAL MATERIAL SA05678G2209
Use seal material shown in the table below, or equivalent.

Seal material Application point Recommended Item number Alternative
Engine case Three Bond 1215B 004403007 Dow Corning’s No. 7038
Transmission Three Bond 1217B K0877YA020 —
Rear differential Three Bond 1324 004403042 —
Rear differential Three Bond 1105 004403010 Dow Corning’s No. 7038
Weatherstrip Starcalking B-33A 000018901 Butyl Rubber sealant
Steering adjusting Three Bond 1102 004403006 —
screw
SOHC cam cap Three Bond 1280B K0877YA018 —
RM-6
PRE-DELIVERY INSPECTION
PI
Page
1. Pre-delivery Inspection................................................................................2
Pre-delivery Inspection
1. Pre-delivery Inspection SA09719
A: GENERAL SA09719G23
The purposes of the pre-delivery inspection (PDI)

are as follows.
쐌 Remove the additional parts used for ensuring
the vehicle quality during transportation and
restore the vehicle to its normal state.
쐌 Check if the vehicle before delivery is in a nor-
mal state.
쐌 Check for any damage or missing parts that may
have taken place during transportation or storage.
쐌 Make sure to provide a complete vehicle to the
customer.
Because of the above reasons, all dealerships
must always carry out the PDIs before delivering a
vehicle.
In addition, all franchised shops and PDI centers
must check the status of every vehicle received to
identify who is responsible for any possible
defects.
PI-2
B: PDI PROCEDURE SA09719G50
Follow the procedures shown in the table below.

Static Checks Just After Vehicle Receipt
Step Check point
1. Appearance check (1) If the vehicle is covered with protective coating, visually check the
vehicle body for damage and dents. If the protective coating has been
removed, visually check the body paints for small areas of damage or
stains.
(2) Visually check the glass and light lenses for any damage and cracks
or excessive gaps to the body sheet metal.
(3) Visually check the plated parts for any damage.
2. Tire check (1) Check the tires for damage, abnormal conditions, and dents on the
wheels.
(2) Check the tire air pressure.
3. Fuse installation (1) If the vehicle is about to be delivered to the customer, attach a room
lamp fuse.
4. Check the doors for lock/unlock and open/ (1) Using the key, check if the door can be locked and unlocked normally.
close operations. (2) Open and close the all doors to see that there are no abnormal condi-
tions.
5. Operation check of trunk lock release lever (1) Operate the trunk lock release lever to check that the trunk opens nor-
mally.
6. Check the rear gate for lock/unlock and open/ (1) Using the key, check if the door can be locked and unlocked normally.
close operations. (2) Open and close the doors to see that there are no abnormal condi-
tions.
7. Operation check of fuel lid opener lock release (1) Operate the fuel lid opener to check that the fuel lid is unlocked nor-
lever mally.
8. Operation check of child lock system. (1) Check that the child lock operates normally.
9. Accessory check Check the following accessories are provided:
쐌 Owner’s manual
쐌 Warranty booklet
쐌 Service booklet
쐌 Spare key
쐌 Jack
쐌 Tool set
쐌 Spare tire
10. Operation check of hood lock release system (1) Operate the hood lock release lever to check that the hood opens nor-
mally.
11. Connection of air conditioner harness (1) If the vehicle is about to be delivered to the customer, connect the air
conditioner harness.
12. Battery (1) Check the battery for any abnormal conditions such as rust and trace
of battery fluid leaks.
13. Brake fluid (1) Check the fluid amount.
14. Engine oil (1) Check the oil amount.
15. Transmission fluid (1) Check the fluid amount.
(2) For AT, check the front differential oil.
16. AT front differential oil (1) Check the AT front differential oil amount.
17. Coolant (1) Check the coolant amount.
18. Clutch fluid (1) Check the clutch fluid amount.
19. Window washer fluid (1) Check the window washer fluid amount.
20. Hood latch check (1) Check that the hood is closed and latched securely.
21. Keyless entry system (1) Check that the keyless entry system operates normally.
22. Seat (1) Check the seat surfaces for smears or dirt.
(2) Check the seat installation conditions and functionality.
23. Seat belt (1) Check the seat belt installation conditions and functionality.
24. Wheel alignment (1) Check that the wheel alignments are properly adjusted.
PI-3
Checks with the Engine Running
Step Check point

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

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

1. ATF level (1) Check that the ATF level is normal.
2. Power steering fluid level (1) Check that the power steering fluid level is normal.
3. Fluid leak check (1) Check for fluid/oil leaks.
4. Water leak check (1) Spray the vehicle with water and check for water leaks.
5. Appearance check 2 (1) Remove the protective coating (if any).
(2) Check the body paints for damage and smears.
(3) Check the plated parts for damage and rust.
PI-4
1. APPEARANCE CHECK SA09719G5001 4. CHECK THE DOOR OPERATIONS,

쐌 If the vehicle is covered with protective coating, LOCK/UNLOCK AND OPEN/CLOSE, AS
visually check the vehicle body for damage and FOLLOWS. SA09719G5003
dents. Using the key, lock and unlock the door several
쐌 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 close the door several times for smooth move-
repair as necessary. ment.
쐌 Check the window glass, door glass, and lights
for any cracks or damage and repair or replace the
parts as necessary.
쐌 Check the plated parts, such as the grilles and
door knobs, for damage or loss of gloss and repair
or replace the parts as necessary.
2. TIRE CHECK SA09719G5002
쐌 Check the tire outer faces for any damage.

쐌 Check the tire air pressure by referring to the
following table. GI0078A
Tire inflation pressure

Tire size kPa (kg/cm2 , psi)
쐌 Vehicles with manual door locks:
Front Rear Sit in the driver seat, close the door completely,
P205/70R15 95S* Light 200 190 and move the lock lever to the lock position. Then,
Non- 205/70R15 95H load (2.0, 29) (1.9, 28) pull the inside door handle to ensure the door will
TURBO 205/70R15 95Q Full 200 250 not open.
(SNOW) load (2.0, 29) (2.5, 36)
P215/60R16 94H* Light 200 190
쐌 Vehicles with power door locks:
215/60R16 95V load (2.0, 29) (1.9, 28) Sit in the driver seat, close the driver’s door
TURBO
215/60R16 95Q Full 200 250 completely, and place the door lock knob (A) to the
(SNOW) load (2.0, 29) (2.5, 36) lock position. Then pull the all inside door handles
*: Australia model (B) to ensure that the all doors will not open.
NOTE: For other doors, place the lock levers to the lock
쐌 After inspecting and adjusting the tire pressure, positions and then pull the inside door handles to
be sure to put the valve cap back. ensure that the doors will not open.
쐌 When towing, adjust the tire inflation pressures
as follows:
Front: 200 kPa (2.0 kg/cm2, 29 psi)
Rear: 280 kPa (2.8 kg/cm2, 41 psi)
3. FUSE INSTALLATION SA09719G5010
A vehicle just delivered has no fuses for the room

lamp circuit to prevent battery discharge. Attach a
15 A fuse as shown in the figure.
S1M0145A
5. OPERATION CHECK OF TRUNK LOCK

RELEASE LEVER SA09719G5005
Operate the trunk lock release lever and verify that
the trunk lid opens.
GI0084A
PI-5
6. OPERATION CHECK OF REAR GATE 9. ACCESSORY CHECK SA09719G5008
LOCK RELEASE LEVER SA09719G5006 Check that the following accessories are provided
쐌 Operate the rear gate lock release lever and in the luggage compartment or cargo area.
verify that the rear gate is unlocked and opened 쐌 Owner’s manual
smoothly. 쐌 Warranty booklet
쐌 Using the key, lock and unlock the door several 쐌 Service booklet
times to check for normal operation. Open and 쐌 Spare key
close the door several times for smooth move- 쐌 Jack
ment. 쐌 Tool set
쐌 Spare tire
7. OPERATION CHECK OF FUEL LID
OPENER LOCK RELEASE LEVER SA09719G5007
Operate the fuel lid opener and verify that the fuel
lid opens normally. Check that the filler cap is
securely closed.
8. CHECK THE OPERATION OF CHILD
SAFETY LOCKS SA09719G5052
1) Set the child safety lock on both rear doors to
the lock positions.
S1M0143A
2) Close the rear doors completely.
3) Check that the lock levers of the rear doors are
in the unlock positions. Then, pull the inside door 10. OPERATION CHECK OF HOOD LOCK
handles of the rear doors to ensure that the doors RELEASE SYSTEM SA09719G5009
will not open. Unlatch and open the hood while checking that no
4) Next, pull the outside door handles of the rear abnormal conditions are found. Then, support the
doors to ensure that the doors will open. hood with the hood stay.
5) Repeat the above steps two or three times.
GI0082A
S1M0157A
S1M0144A
PI-6
11. CONNECTION OF AIR CONDITIONER 14. ENGINE OIL SA09719G5014
HARNESS SA09719G5011 Check the engine oil amount. If the amount is

A vehicle just delivered has its air conditioner har- insufficient, check that no leaks are found. Then,
ness disconnected to protect the air conditioner add the necessary amount of the specified engine
compressor. Connect the harness as shown in the oil.
figure.
GI0087A
GI0085
15. TRANSMISSION FLUID SA09719G5015
12. BATTERY SA09719G5012

Check the transmission fluid amount. If the amount
Check the battery terminals to make sure that no is insufficient, check that no leaks are found. Then,
rust or corrosions due to fluid leaks are found. add the necessary amount of the specified fluid.
Check that the battery tent is securely tightened.
GI0088A
GI0086A
16. AT FRONT DIFFERENTIAL OIL SA09719G5016
13. BRAKE FLUID SA09719G5013

Check the AT front differential oil amount. If the
Check the brake fluid amount. If the amount is amount is insufficient, check that no leaks are
insufficient, carry out a brake line test to identify found. Then, add the necessary amount of the
brake fluid leaks and check the brake operation. specified AT front differential oil.
After that, refill the brake fluid tank with the speci-
fied type of fluid.
GI0089A
PI-7
17. COOLANT SA09719G5017 21. KEYLESS ENTRY SYSTEM SA09719G5021
Check the coolant amount on the reservoir. If the Check the keyless entry system operations as fol-
amount is insufficient, check that no leaks are lows.
found. Then, add the necessary amount of coolant 쐌 Remove the key from the ignition switch and
with the specified concentration. close all the doors including rear gate (wagon).
쐌 Press the “LOCK” button on the transmitter
18. CLUTCH FLUID SA09719G5018
momentarily once and check if all the doors are
Check the clutch fluid amount. If the amount is locked and the hazard light flashes ones.
insufficient, check that no leaks are found. Then,
add the necessary amount of the specified fluid.
B5M1182
GI0090A 쐌 Press the “OPEN” button on the transmitter

momentarily once and check if the driver’s door is
19. WINDOW WASHER FLUID SA09719G5019
unlocked, the hazard light flashes twice and the
dome light illuminates.
Check the window washer fluid amount. If the 쐌 Close all doors and rear gate, press the “LOCK”
amount is insufficient, check that no leaks are button of the transmitter. Press the “OPEN” button
found. Then, add the necessary amount of washer of the transmitter and wait for 30 seconds. Check
fluid commercially available.
that all doors and the rear gate are automatically
20. HOOD LATCH CHECK SA09719G5020
locked again.
Retract the hood stay and close the hood. Check 22. SEAT SA09719G5023
that the hood is securely latched.

Check that each seat provides full functionality in
sliding and reclining. Check all available functions
of the rear seat such as a trunk-through center arm
rest.
23. SEAT BELT SA09719G5024
Pull out the seat belt and then release it. Check
that the belt webbing retracts smoothly.
24. WHEEL ALIGNMENT SA09719G5026
Check the wheel alignments. <Ref. to FS-6 Wheel

Alignment.> and <Ref. to RS-7 Wheel Alignment.>
PI-8
25. READ MEMORY AND TEST MODE 30. RADIO SA09719G5033
CONNECTORS SA09719G5050 Check the radio for full functionality and normal
Turn the ignition switch to ON and check that the noise level. Also check the CD unit operations.
check-engine light starts blinking. If the light blinks,
31. CIGARETTE LIGHTER SA09719G5034
return the ignition key to LOCK and disconnect the
test mode connector. Then, turn the ignition key to Check that the cigarette lighter operations.
ON again. If the check-engine light blinks at that
time in spite of the disconnected test mode
32. LIGHTING SYSTEM SA09719G5035
connector, carry out an engine diagnosis. 쐌 Check the headlight operations.

With OBD model 쐌 Check the brake light operations.
쐌 Check the other lights for normal operations.
33. WINDOW WASHER SA09719G5036
Check that the window washer system injects

washer fluid to the specified area of the windshield
shown in the figure.
GI0095A
Without OBD model
S1M0146A
GI0119A
26. STARTING CONDITION SA09719G5029
Start the engine and check that the engine starts

smoothly. If any battery voltage problems are S1M0147A
found, recharge or replace the battery. If any

abnormal noises are observed, immediately stop 34. WIPER SA09719G5037
the engine and check and repair the necessary Check the front and rear wipers for normal opera-
components. tions.
27. EXHAUST SYSTEM SA09719G5030
35. POWER WINDOW OPERATION
Listen to the exhaust noise to see if no abnormal CHECK SA09719G5004
noises are observed. Manipulate the power window switches one by one
28. INDICATOR LIGHT SA09719G5031
to check that each of the power windows goes up
and down with no abnormal noises.
Check that all the indicator lights are off.
36. BRAKE TEST SA09719G5038
29. CLOCK SA09719G5032

Check the foot brake for normal operations.
Check the clock for normal operations and enough
accuracy. 37. PARKING BRAKE SA09719G5039
Check the parking brake for normal operations.
PI-9
38. AT SHIFT CONTROL SA09719G5041 43. POWER STEERING FLUID LEVEL

SA09719G5046
Set the AT select lever to each gear position while
checking that the demanded gear position is cor- 1) Check power steering fluid for deterioration or
rectly attained. contamination. If the fluid is highly deteriorated or
contaminated, drain it and refill with new fluid.
2) Check joints and units for oil leakage. If any oil
leaks are found, repair or replace the applicable
part.
3) Inspect fluid level on flat and level surface with
engine “OFF” by indicator of reservoir tank.
If the level is at lower point or below, add fluid to
keep the level in the specified range of the indica-
tor. If at upper point or above, drain fluid by using
a syringe or the like.
GI0113A (1) Check at temperature 20°C (68°F) on res-
ervoir surface of oil pump; read the fluid level on
Selector Gear Position
the “COLD” side.
Position
(2) Check at temperature 80°C (176°F) on res-
1st 2nd 3rd 4th
D Yes Yes Yes Yes
the “HOT” side.
3 Yes Yes Yes
Non-turbo model
2 Yes Yes
1 Yes
39. HEATER & VENTILATION SA09719G5042
Operate the heater and ventilation system to check

for normal airflow and heating capacity.
40. AIR CONDITIONER SA09719G5043
Operate the air conditioner. Check that the A/C

compressor operates normally and enough cooling
is provided. H4M1007
41. CRUISE CONTROL SA09719G5044 Turbo model

Operate the cruise control system. Check that the
system is activated and deactivated correctly.
42. ATF LEVEL SA09719G5045
Check that the ATF level is normal. If insufficient,

check that no leaks are found. Then add the nec-
essary amount of the specified ATF.
B4M1674A
44. FLUID LEAK CHECK SA09719G5047
Check the entire areas of the vehicle for any trace

of coolant/oil/fluid leaks.
GI0098A
PI-10
45. WATER LEAK TEST SA09719G5048
Spray the vehicle with water and check that no

water enters the passenger compartment.
쐌 Before performing the water leakage test,
remove anything that may obstruct the operation or
which must be kept dry.
쐌 Close all of the windows completely, and then
close all of the doors tightly. Close the hood and
trunk lid before starting the test.
쐌 Connect a hose to a tap, and spray water on the
vehicle. The rate of water discharge must be
approx. 20 to 25 liters (5.3 to 6.6 US gal, 4.4 to 5.5
Imp gal) per minute.
When spraying water on areas adjacent to the floor
and wheel house, increase the pressure. When
directing water on areas other than the floor portion
and wheel house, decrease the pressure. But the
force of water must be made strong occasionally
by pressing the end of the hose.
NOTE:
Be sure to keep the hose at least 10 cm (3.9 in)
from the vehicle.
쐌 Check the following areas:
쐌 Front window and body framework mating
portion
쐌 Door mating portions
쐌 Glass mating portions
쐌 Rear quarter window mating portions
쐌 Rear window and body framework mating
portion
쐌 Around roof drips
쐌 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.
46. APPEARANCE CHECK 2 SA09719G5049
Check the vehicle body paints, plated faces, glass,

and lenses for any dirt or damage.
PI-11
MEMO:
PI-12
PERIODIC MAINTENANCE SERVICES
PM
Page
1. General Description.....................................................................................2
2. Schedule......................................................................................................3
3. Engine Oil....................................................................................................6
4. Engine Oil Filter...........................................................................................8
5. Spark Plugs .................................................................................................9
6. Drive Belt(s)...............................................................................................10
7. Camshaft Drive Belt ..................................................................................12
8. Valve Clearance ........................................................................................14
9. Fuel Line....................................................................................................15
10. Fuel Filter ..................................................................................................16
11. Air Cleaner Element ..................................................................................17
12. Cooling System .........................................................................................18
13. Coolant ......................................................................................................19
14. Idle Mixture................................................................................................21
15. Clutch System ...........................................................................................22
16. Hill-holder System .....................................................................................24
17. Transmission Oil........................................................................................25
18. ATF ............................................................................................................26
19. Front & Rear Differential Oil......................................................................27
20. Brake Line .................................................................................................29
21. Brake Fluid ................................................................................................31
22. Disc Brake Pads and Discs ......................................................................32
23. Brake Linings and Drums..........................................................................33
24. Suspension................................................................................................35
25. Wheel Bearing...........................................................................................37
26. Axle Boots & Joints ...................................................................................38
27. Steering System (Power Steering)............................................................39
28. Supplemental Restraint System................................................................42
GENERAL DESCRIPTION
Periodic Maintenance Services
1. General Description SA07001
A: GENERAL SA07001G23
Be sure to perform periodic maintenance in order

to maintain vehicle performance and find problems
before they become serious.
PM-2
SCHEDULE
2. Schedule SA07682
A: MAINTENANCE SCHEDULE 1 SA07682G24
1. MAINTENANCE SCHEDULE 1 – (1) SA07682G2401
For periodic maintenance of over 50,000 km (30,000 miles) or 48 months, carry out inspections by refer-
ring to the following tables. For a maintenance period gone beyond these tables, apply them repeatedly as
a set of 50,000 km (30,000 miles) or 48 months.
Maintenance Interval
[Number of months or km (miles), whichever occurs first]
Months 12 24 36 48 Remarks
× 1,000 km 5 12.5 25 37.5 50
× 1,000 miles 3 7.5 15 22.5 30
1 Engine oil R R R R
2 Engine oil filter R R R R
2. MAINTENANCE SCHEDULE 1 – (2) SA07682G2402
For periodic maintenance of over 100,000 km (60,000 miles) or 48 months, carry out inspections by refer-
ring to the following tables. For a maintenance period gone beyond these tables, apply them repeatedly as
a set of 100,000 km (60,000 miles) or 48 months.
× 1,000 km 1.6 25 50 75 100
× 1,000 miles 1 15 30 45 60
3 Spark plugs R R
4 Drive belt(s) I I I I
5 Camshaft drive belt R
6 Valve clearance Use in Europe coun- Inspect every 100,000 km (60,000
tries miles)
Use in others Inspect every 160,000 km (100,000
miles)
7 Fuel line I I
8 Fuel filter R
9 Air cleaner element I R I R
10 Cooling system I I
11 Coolant R R
12 Idle mixture I I I I I For models without catalyst con-
verter
13 Clutch system I I I I
14 Hill-holder system I I I I I
15 Transmission oil R R
16 ATF R R
17 Front & rear differ- R R
ential oil
18 Brake line I I
19 Brake fluid R R
20 Disc brake pads & I I I I
discs
21 Brake linings and I I
drums
22 Parking brake I I I I
23 Suspension I I I I
PM-3
SCHEDULE
× 1,000 km 1.6 25 50 75 100
× 1,000 miles 1 15 30 45 60
24 Wheel bearing I I
25 Axle boots & joints I I I I
26 Steering system I I I I
(Power steering)
Symbols used:
R: Replace
I: Inspection
(R) or (I): Recommended service for safe vehicle operation.
NOTE:
(1) When the vehicle is used in extremely dusty conditions, the air cleaner element should be replaced more often.
(2) ATF filter is maintenance free part. ATF filter needs replacement, when it has physically damaged or ATF leaked.
PM-4
SCHEDULE
B: MAINTENANCE SCHEDULE 2 SA07682G25
Item Every Repeat short Repeat Extremely Salt or other High humidity Repeat tow-
distance drive rough/muddy cold weather corrosive or mountain ing trailer
road drive area used or area
coastal area
Engine oil Replace more Replace more Replace more
frequently frequently frequently
Engine oil filter Replace more Replace more Replace more
frequently frequently frequently
Fuel line 6 months I
12,500 km
7,500 miles
Transmission oil Replace more
frequently
ATF Replace more
frequently
Front & rear dif- Replace more
ferential oil frequently
Brake line 6 months I I I I
12,500 km
7,500 miles
Brake fluid 12 months R
25,000 km
15,000 miles
Brake pads 6 months I I I I
12,500 km
7,500 miles
Brake linings 6 months I I I I
and drums 12,500 km
7,500 miles
Parking brake 6 months I I I I
12,500 km
7,500 miles
Suspension 6 months I I I I
12,500 km
7,500 miles
Axle boots & 6 months I I I I I
joints 12,500 km
7,500 miles
Steering system 6 months I I I I I
(Power steering) 12,500 km
7,500 miles
PM-5
ENGINE OIL
3. Engine Oil SA07077

NOTE:
쐌 When replenishing oil, it does not matter if the oil
A: REPLACEMENT SA07077A20 to be added is a different brand from that in the
engine; however, use oil having the API classifica-
1) Drain engine oil by loosening engine oil drain tion and SAE viscosity No. designated by
plug. SUBARU.
쐌 If vehicle is used in desert areas with very high
temperatures or for other heavy duty applications,
the following viscosity oils may be used:
API classification: SJ or SH
SAE Viscosity No.: 30, 40, 10W-50, 20W-40,
20W-50
6) Close engine oil filler cap.
7) Start engine and warm it up for a time.
8) After engine stops, recheck the oil level.
If necessary, add engine oil up to upper level on
GI0012A
level gauge.
2) Open engine oil filler cap for quick draining of
the engine oil.
3) Replace drain plug gasket.
4) Tighten engine oil drain plug after draining
engine oil.
Tightening torque:
44 N·m (4.5 kgf-m, 33 ft-lb)
5) Fill engine oil through filler pipe up to upper
point on level gauge. Make sure that vehicle is
placed level when checking oil level. Use engine oil GI0016A
of proper quality and viscosity, selected in accor-

dance with the table in figure.
Engine oil capacity (Non-TURBO model):
Upper level
4.5 (4.8 US qt, 4.0 Imp qt)
Lower level
3.5 (3.7 US qt, 3.1 Imp qt)
Engine oil capacity (TURBO model):
Upper level
5.0 (5.3 US qt, 4.4 Imp qt)
Lower level
4.0 (4.2 US qt, 3.5 Imp qt)
GI0015A
The proper viscosity helps vehicle get good cold

and hot starting by reducing viscous friction and
thus increasing cranking speed.
PM-6
ENGINE OIL
B: INSPECTION SA07077A10
1) Park vehicle on a level surface.

2) Remove oil level gauge and wipe it clean.
3) Reinsert the level gauge all the way. Be sure
that the level gauge is correctly inserted and in the
proper orientation.
4) Remove it again and note the reading. If the
engine oil level is below the “L” line, add oil to bring
the level up to the “F” line.
GI0013A
5) After turning off the engine, wait a few minutes

for the oil to drain back into the oil pan before
checking the level.
6) Just after driving or while the engine is warm,
engine oil level may show in the range between the
“F” line and the notch mark. This is caused by
thermal expansion of the engine oil.
7) To prevent overfilling the engine oil, do not add
oil above the “F” line when the engine is cold.
PM-7
ENGINE OIL FILTER
4. Engine Oil Filter SA07585
A: REPLACEMENT SA07585A20
1) Remove oil filter with ST.

ST 498547000 OIL FILTER WRENCH
GI0012A
2) Get a new oil filter and apply a thin coat of

engine oil to the seal rubber.
3) Install oil filter by turning it by hand, being care-
ful not to damage seal rubber.
4) Tighten more (approximately 2/3 to 3/4 turn)
after the seal rubber contacts the oil pump case.
Do not tighten excessively, or oil may leak.
5) After installing oil filter, run engine and make
sure that no oil is leaking around seal rubber.
NOTE:
The filter element and filter case are permanently
joined; therefore, interior cleaning is not necessary.
6) Check the engine oil level. <Ref. to PI-7,
ENGINE OIL, PDI PROCEDURE, Pre-delivery
Inspection.>
PM-8
SPARK PLUGS
5. Spark Plugs SA07683

tighten further 1/4 to 1/2 turns.
2. TURBO MODEL SA07683A2004
NOTE:
1. NON-TURBO MODEL SA07683A2003
For spark plug replacement procedure details,
NOTE: refer to IG section. <Ref. to IG(DOHC TURBO)-4,
For spark plug replacement procedure details, Spark Plug.>
refer to IG section. <Ref. to IG(SOHC)-4, Spark 1) Disconnect battery ground cable, and then
Plug.> and <Ref. to IG(SOHCw/oOBD)-5, Spark remove battery and battery carrier.
Plug.> 2) Remove air cleaner lower case. <Ref. to
1) Disconnect battery ground cable. IN(DOHC TURBO)-7, Air Cleaner.>
2) Remove air intake duct as a unit. 3) Remove washer tank and put it aside.
3) Remove resonator chamber. 4) Disconnect connector from ignition coil.
4) Remove washer tank and put it aside. 5) Remove ignition coil.
5) Disconnect spark plug cord. 6) Remove spark plug with a plug-wrench.
6) Remove spark plug with a plug-wrench.
EN0859
GI0018
7) Set new spark plug.
7) Set new spark plug. Recommended spark plug:
Recommended spark plug: NGK: PFR6B
With OBD 8) Tighten spark plug lightly with hand, and then
CHAMPION RC10YC4 secure with a plug-wrench to the specified torque.
CHAMPION RC8YC4
NGK BKR6E-11 Tightening torque:
NIPPONDENSO K20PR-U11 Spark plug
Spark plug gap 21 N·m (2.1 kgf-m, 15 ft-lb)
1.0 — 1.1 mm (0.039 — 0.043 in) Ignition coil
Without OBD 16 N·m (1.63 kgf-m, 11.8 ft-lb)
NGK BKR6E (Without catalytic converter) NOTE:
CHAMPION RC10YC4 (With catalytic con- 쐌 Be sure to place the gasket between the cylin-
verter) der head and spark plug.
NGK BKR5E-11 (With catalytic converter) 쐌 If torque wrench is not available, tighten spark
Spark plug gap plug until gasket contacts cylinder head; then
0.7— 0.8 mm (0.028 — 0.031 in) (Without tighten further 1/4 to 1/2 turns.
catalytic converter)
1.0 — 1.1 mm (0.039 — 0.043 in) (With
catalytic converter)
8) Tighten spark plug lightly with hand, and then
secure with a plug-wrench to the specified torque.
Tightening torque:
20.6 N·m (2.10 kgf-m, 15.19 ft-lb)
NOTE:
쐌 Be sure to place the gasket between the cylin-
der head and spark plug.
쐌 If torque wrench is not available, tighten spark
plug until gasket contacts cylinder head; then
PM-9
DRIVE BELT(S)
6. Drive Belt(s) SA07684 B: REPLACEMENT SA07684A20
A: INSPECTION SA07684A10
NOTE:
Wipe off any oil or water on the belt and pulley.
1) Replace belts, if cracks, fraying or wear is
found. 1) Loosen the lock bolt (A).
2) Check drive belt tension and adjust it if neces- 2) Loosen the slider bolt (B).
sary by changing generator installing position 3) Remove the front side belt (C).
and/or idler pulley installing position.
Belt tension
(A)
replaced: 7 — 9 mm (0.276 — 0.354 in)
reused: 9.0 — 10.0 mm (0.354 — 0.394 in)
(B)*
replaced: 7.5 — 8.5 mm (0.295 — 0.335
in)
reused: 9.0 — 10.0 mm (0.354 — 0.394 in)
*: There is no belt (B) on models without an air
GI0021A
conditioner.
4) Loosen the lock nut (A).
5) Loosen the slider bolt (B).
6) Remove the rear side belt.
GI0019A
C/P Crankshaft pulley

GEN Generator
P/S Power steering oil pump pulley GI0022A
A/C Air conditioning compressor pulley

7) Install a new belt, and tighten the slider bolt so
I/P Idler pulley
as to obtain the specified belt tension.
8) Tighten the slider bolt (B).
9) Tighten the lock nut (A).
Tightening torque:
22.6 N·m (2.3 kgf-m, 16.6 ft-lb)
GI0022A
10) Install a new belt, and tighten the slider bolt so

as to obtain the specified belt tension.
11) Tighten the slider bolt (B).
12) Tighten the lock bolt (A).
PM-10
DRIVE BELT(S)
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, 5.8 ft-lb)
GI0021A
PM-11
CAMSHAFT DRIVE BELT
7. Camshaft Drive Belt SA07685

2. DOHC MODEL SA07685A2002
NOTE:
For camshaft drive belt replacement procedure
1. SOHC MODEL SA07685A2001 details, refer to ME(DOHC) section. <Ref. to
ME(SOHC)-46, Timing Belt Assembly.>
NOTE:
For camshaft drive belt replacement procedure 1) Remove radiator fan and air conditioning fan.
details, refer to ME(SOHC) section. <Ref. to <Ref. to CO-32, Radiator Main Fan and Fan
ME(SOHC)-46, Timing Belt Assembly.> Motor.> and <Ref. to CO-34, Radiator Sub Fan and
Fan Motor.>
1) Remove radiator fan <Ref. to CO-32, Radiator 2) Remove V-belts. <Ref. to ME(DOHC TURBO)-
Main Fan and Fan Motor.> and air conditioner fan 44, V-belt.>
<Ref. to CO-34, Radiator Sub Fan and Fan 3) Remove air conditioning compressor drive belt
Motor.>. tensioner.
2) Remove V-belt cover. 4) Remove pulley bolt.
3) Remove V-belts. <Ref. to ME(SOHC)-42, ST 499977300 CRANKSHAFT PULLEY
V-belt.> WRENCH
4) Remove air conditioning compressor drive belt 5) Remove crankshaft pulley.
tensioner. 6) Remove air conditioning compressor drive belt
5) Remove pulley bolt. tensioner.
ST 499977100 CRANKSHAFT PULLEY 7) Remove left side belt cover.
WRENCH 8) Remove right side belt cover.
6) Remove crankshaft pulley. 9) Remove front belt cover.
7) Remove left side belt cover. 10) Remove timing belt guide. (MT vehicle only)
8) Remove front belt cover. 11) Turn crankshaft and align alignment marks on
9) Remove timing belt guide. (MT vehicle only) crankshaft, and left and right camshaft sprockets
10) Turn crankshaft and align alignment marks on with notches of belt cover and cylinder block. To
crankshaft, and left and right camshaft sprockets turn crankshaft, Use ST:
with notches of belt cover and cylinder block: ST 499987500 CRANKSHAFT SOCKET
ST 499987500 CRANKSHAFT SOCKET
S1M0150A
GI0025A
12) Remove belt idler.
11) Remove belt idler. 13) Remove timing belt.
12) Remove belt idler (No. 2). 14) Remove automatic belt tension adjuster
13) Remove timing belt. assembly.
14) Remove automatic belt tension adjuster
assembly.
PM-12
CAMSHAFT DRIVE BELT
B: INSTALLATION SA07685A11 C: INSPECTION SA07685A10
1. SOHC MODEL SA07685A1101 1. SOHC MODEL SA07685A1001
Install in the reverse order of removal. <Ref. to 1) Remove left and right timing belt covers.
ME(SOHC)-46, Timing Belt Assembly.> 2) While cranking engine at least four rotations,
check timing belt back surface for cracks or dam-
age. Replace faulty timing belt as needed.
Install in the reverse order of removal. <Ref. to 3) Measure timing belt width W. If it is less than 27
ME(DOHC TURBO)-48, Timing Belt Assembly.> mm (1.06 in), check idlers, tensioner, water pump
pulley and cam sprocket to determine idler align-
NOTE: ment (squareness). Replace worn timing belt.
When installing the timing belt, be sure to align all
alignment marks on the belt with corresponding
marks on the sprockets. If incorrectly installed,
interference between pistons and valves may
occur.
GI0028A
4) Install left and right timing belt covers.

1) Remove left and right timing belt covers.

2) While cranking engine at least four rotations,
check timing belt back surface for cracks or dam-
age. Replace faulty timing belt as needed.
3) Measure timing belt width W. If it is less than 30
mm (1.18 in), check idlers, tensioner, water pump
pulley and cam sprocket to determine idler align-
ment (squareness). Replace worn timing belt.
4) Install left and right timing belt covers.
S1M0151A
PM-13
VALVE CLEARANCE
8. Valve Clearance SA07083
For the inspection procedures of the valve clear-

ance: <Ref. to ME(SOHC)-29, Valve Clearance.>
or <Ref. to ME(DOHC TURBO)-28, Valve Clear-
ance.>
PM-14
FUEL LINE
9. Fuel Line SA07686
The fuel line is located mostly internally, so check

pipes, areas near pipes, and engine compartment
piping for rust, hose damage, loose bands, etc. If
faulty parts are found, repair or replace them. <Ref.
to FU(SOHC)-69, Fuel Delivery, Return and
Evaporation Lines.> or <Ref. to FU(SOHCw/
oOBD)-56, Fuel Delivery, Return and Evaporation
Lines.> or <Ref. to FU(DOHC TURBO)-67, Fuel
Delivery, Return and Evaporation Lines.>
PM-15
FUEL FILTER
10. Fuel Filter SA07027
For fuel filter replacement procedures, refer to “FU”

section.
<Ref. to FU(SOHC)-66, Fuel Filter.> or <Ref. to
FU(SOHCw/oOBD)-54 Fuel Filter.> or <Ref. to
FU(DOHC TURBO)-64, Fuel Filter.>
PM-16
AIR CLEANER ELEMENT
11. Air Cleaner Element SA07687

2. TURBO MODEL SA07687A2002
NOTE:
Do not attempt to clean the air cleaner element.
The filter paper of the element is wetted with a
special 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-
GI0126
tion into the filter paper. If this filter paper is
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 SA07687A2001
GI0127
2) Remove air cleaner.

GI0032 3) Install in the reverse order of removal.
1) Remove bolt (A) which install air cleaner case CAUTION:
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
lower case, then secure upper cover to lower
case.
H2M2947A
3) Remove air cleaner. EN0906
4) Install in the reverse order of removal.

CAUTION:
Fasten with a clip after inserting the lower tab
of the case.
PM-17
COOLING SYSTEM
12. Cooling System SA07688

Raise the pressure until the needle of gauge stops
and see if the pressure can be retained for five to
A: INSPECTION SA07688A10 six seconds. The radiator cap is normal if a pres-
sure above the service limit value has been main-
1) Check radiator for leakage, filling it with coolant tained for this period.
and attach radiator cap tester (A) to the filler neck.
Then apply a pressure of 157 kPa (1.6 kg/cm2 , 23 Radiator cap valve open pressure
psi) and check the following points: Standard value:
쐌 Each portion of radiator for leakage 93 — 123 kPa (0.95 — 1.25 kg/cm2, 14 —
쐌 Hose joints and other connections for leakage 18 psi)
Service limit:
CAUTION: 83 kPa (0.85 kg/cm2 , 12 psi)
쐌 When attaching or detaching tester and
when operating tester, use special care not to
deform radiator filler neck.
Non-TURBO model
GI0034
S1M0152A
TURBO model
GI0035A
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
S1M0153A
one.
쐌 When performing this check, be sure to keep 4) If electric fan does not operate when coolant
temperature exceeds 90 to 94°C (194 to 201°F),
the engine stationary and fill radiator with cool-
check thermoswitch or fan motor.
ant.
쐌 Wipe off check points before applying pres-
sure.
쐌 Use care not to spill coolant when detaching
tester from radiator.
2) Check the radiator cap valve open pressure
using radiator cap tester.
NOTE:
Rust or dirt on cap may prevent valve from func-
tioning normally: be sure to clean cap before test-
ing.
PM-18
COOLANT
13. Coolant SA07689

(4) Stop engine and wait until coolant tempera-
ture lowers. Then open radiator cap to check
A: REPLACEMENT SA07689A20 coolant level and add coolant up to radiator filler
neck. Next, add coolant into reservoir tank up to
1. REPLACEMENT OF COOLANT SA07689A2001
“FULL” level.
WARNING: (5) After adding coolant, securely install radia-
The radiator is of the pressurized type. Do not tor and reservoir tank caps.
attempt to open the radiator cap immediately 11) TURBO model.
after the engine has been stopped. (1) Slowly pour prepared coolant from coolant
flow tank filler port up to the brim of port, and
1) Lift up the vehicle. install cap, then pour coolant into reserve tank
2) Remove under cover. up to “FULL” level.
3) Fit vinyl tube to drain pipe. (2) Run engine for about 15 minutes, not
4) Place a container under drain tube. exceeding 2,000 rpm. (Run engine until radiator
5) Loosen drain cock to drain engine coolant into becomes hot in order to purge air trapped in
container. cooling system.)
(3) Stop engine and wait until coolant tempera-
ture lowers. [below 50°C (122°F) or 60°C
(140°F)] Open coolant flow tank cap and add
coolant up to the brim of the port.
(4) Wait until coolant temperature lowers fur-
ther [below 30°C (86°F)], then pour into reserve
tank up to the “FULL” level.
(5) Run the vehicle until the coolant tempera-
ture rises to 80°C (176°F) and check the level
in the coolant flow tank, add coolant up to the
S1M0156A
“FULL” level.
Coolant capacity (fill up to “FULL” level)
6) For quick draining, open radiator cap. MT model
CAUTION: Approx. 6.4 (6.8 US qt, 5.6 Imp qt)
Be careful not to spill coolant on the floor. AT model
Approx. 6.3 (6.7 US qt, 5.5 Imp qt)
7) Drain coolant from reservoir tank.
8) Tighten radiator drain screw securely after
draining coolant.
9) Install reservoir tank to original position.
10) Non-TURBO model.
(1) Slowly pour prepared coolant from radiator
filler port to neck of filler, then pour into reser-
voir tank up to “FULL” level.
Coolant capacity (fill up to “FULL” level)
MT model:
AT 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.
(2) Securely install radiator cap.
(3) 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-19
COOLANT
2. RELATIONSHIP OF SUBARU COOLANT 3. PROCEDURE TO ADJUST THE

CONCENTRATION AND FREEZING CONCENTRATION OF THE COOLANT
TEMPERATURE SA07689A2002 SA07689A2003
The concentration and safe operating temperature To adjust the concentration of the coolant accord-
of the SUBARU coolant is shown in the diagram. ing to temperature, find the proper fluid concentra-
Measuring the temperature and specific gravity of tion in the above diagram and replace the neces-
the coolant will provide this information. sary amount of coolant with an undiluted solution
[Example] of SUBARU genuine coolant (concentration 50).
If the coolant temperature is 25°C (77°F) and its The amount of coolant that should be replaced can
specific gravity is 1.054, the concentration is 35% be determined using the diagram.
(point A), the safe operating temperature is –14°C [Example]
(7°F) (point B), and the freezing temperature is Assume that the coolant concentration must be
–20°C (–4°F) (point C). increased from 25% to 40%. Find point A, where
the 25% line of coolant concentration intersects
with the 40% curve of the necessary coolant
concentration, and read the scale on the vertical
axis of the graph at height A. The quantity of cool-
ant to be drained is 2.1 liters (2.2 US qt, 1.8 Imp
qt). Drain 2.1 liters (2.2 US qt, 1.8 Imp qt) of cool-
ant from the cooling system and add 2.1 liters (2.2
US qt, 1.8 Imp qt) of the undiluted solution of
SUBARU coolant.
If a coolant concentration of 50% is needed, drain
all the coolant and refill with the undiluted solution
only.
GI0037A
GI0038A
PM-20
IDLE MIXTURE
14. Idle Mixture SA07734
A: INSPECTION AND ADJUSTMENT

SA07734G26
1. IDLE MIXTURE SA07734G2601
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 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%
4) If out of specification, adjust the idle mixture

using CO adjusting screw of mass air flow sensor.
5) After adjusting the CO value, check and adjust
increment coefficient of CO resistor by using Select
Monitor.
(1) Select “Current data display & Save” on the
select monitor.
(2) If out of specified data, adjust the increment
coefficient of CO resistor while rotating CO
adjusting screw.
Specified data:
0.28 — 4.22 V
GI0114A
NOTE:
If driving the vehicle on out of specified data, the
“trouble code 49” is indicated in many case.
PM-21
CLUTCH SYSTEM
15. Clutch System SA07690

Standard:
80 mm (3.15 in) or more
A: INSPECTION AND ADJUSTMENT 3) Pedal height
SA07690G26
Check that the clutch pedal pad surface is level
1. MECHANICAL CLUTCH TYPE SA07690G2601 with or higher than brake pedal pad surface.
1) Inspect free play of clutch pedal by operating 2. HYDRAULIC CLUTCH TYPE SA07690G2602
pedal by hand.
If it is out of the specified value, adjust it by turn- 1) Push the release lever to retract the push rod
ing wing nut on engine side of clutch cable at of the operating cylinder and check if the fluid level
release fork. in the clutch reservoir tank rises or not.
Tightening torque
(Adjusting nut on release fork):
4.4 — 7.4 N·m (0.45 — 0.75 kgf-m, 3.3 —
5.4 ft-lb)
Standard free play:
AT clutch pedal
10 — 20 mm (0.39 — 0.79 in)
GI0128
GI0144
Fork lever free play allowance:

2 — 4 mm (0.08 — 0.16 in)
S1M0159A
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-37 Clutch Pedal.>
4) Inspect the underside of master cylinder, clutch
damper and operating cylinder for clutch system,
hoses, piping and their couplings for fluid leaks.
If fluid leaks are found, correct them by retighten-
ing their fitting bolt and/or replacing their parts.
GI0145 5) Check the fluid level using the scale on the
2) Pedal-to-floor plate gap in disengaged position. outside of the clutch master cylinder tank (A). If the
(1) With the engine idling, pull parking brake level is below “MIN” (B), add clutch fluid to bring it
lever completely. up to “MAX” (C).
(2) Slowly depress clutch pedal while moving Recommended clutch fluid:
shift lever into reverse. FMVSS No. 116, fresh DOT3 or DOT4
(3) Stop depressing clutch pedal when gear- brake fluid
shifting is complete. With clutch pedal in this
position, measure the distance between the
upper side of pedal pad and the lower end of
front panel (intersection of front panel with
floor). Check that the measured value is within
the specified standard.
PM-22
CLUTCH SYSTEM
NOTE:
쐌 Avoid mixing different brakes of brake fluid to
prevent degradation of the fluid.
쐌 Be careful not to allow dirt or dust to get into the
reservoir tank.
GI0040A
PM-23
HILL-HOLDER SYSTEM
16. Hill-holder System SA07735
A: INSPECTION AND ADJUSTMENT

SA07735G26
1) Confirm stopping and starting performance by

activating hill-holder on an uphill road of 3° or
higher inclination.
(1) When vehicle does not stop;
Tighten adjusting nut of PHV cable.
(2) When vehicle does not start properly;
A; When hill-holder is released later than
engagement of clutch (engine tends to stall):
Loosen adjusting nut gradually until smooth
starting is enabled.
B; When hill-holder is released earlier than
engagement to clutch (vehicle slips down
slightly): Tighten adjusting nut so that hill-holder
is released later than engagement of clutch
(status in A). Then make adjustment the same
as in A.
NOTE:
쐌 Whenever turning adjusting nut, hold inner cable
with pliers to prevent it from turning.
쐌 Replace pressure hold valve (PHV), return
spring of PHV or PHV cable with new one, if they
are defective and/or damaged.
GI0115A
PM-24
TRANSMISSION OIL
17. Transmission Oil SA07691
1. MANUAL TRANSMISSION SA07691A2001
1) Drain gear oil by removing drain plug after

allowing the engine to cool for 3 to 4 hours.
NOTE:
Before starting work, cool off the engine well.
GI0041
2) Reinstall drain plug after draining gear oil and

tighten it to the specified torque.
Tightening torque:
44 N·m (4.5 kgf-m, 32.5 ft-lb)
NOTE:
쐌 Be sure to place a gasket between the transmis-
sion case and drain plug.
쐌 Replace the gasket with a new one.
쐌 Each oil manufacturer has its base oil and addi-
tives. Thus, do not mix two or more brands.
3) Fill transmission gear oil through the oil level
gauge hole up to the upper point of level gauge.
Gear oil capacity:
Single range model
3.5 (3.7 US qt, 3.1 Imp qt)
Dual range model
4.0 (4.2 US qt, 3.5 Imp qt)
GI0042A
PM-25
ATF
18. ATF SA07692

2. ATF FILTER SA07692A2002
NOTE:
ATF filter is maintenance free part. ATF filter needs
1. AUTOMATIC TRANSMISSION FLUID replacement, when it has physically damaged or
SA07692A2001 ATF leaked.
1) Drain ATF (Automatic Transmission Fluid) by For the replacement procedures of the ATF filter:
removing drain plug after allowing the engine to <Ref. to AT-46, ATF Filter.>
cool for 3 to 4 hours.
NOTE:
GI0043A
2) Reinstall drain plug after draining ATF, and

tighten it to the specified torque.
Tightening torque:
25.0 N·m (2.55 kgf-m, 18.4 ft-lb)
3) Fill ATF up to the middle of the “COLD” side on
level gauge by using the gauge hole.
Recommended fluid:
Dexron III type automatic transmission
fluid
Fluid capacity:
Fill the same amount drained from ATF
drain plug hole.
4) Run the vehicle until the ATF temperature rises
to 60 to 80°C (140 to 176°F) and check the ATF
level.
GI0044A
PM-26
FRONT & REAR DIFFERENTIAL OIL
19. Front & Rear Differential Oil 3) Fill differential gear oil through the oil level
SA07693
gauge hole up to the upper point of level gauge.
Differential gear oil capacity:
1.1 — 1.3 (1.2 — 1.4 US qt, 1.0 — 1.1
1. FRONT DIFFERENTIAL (MANUAL lmp qt)
TRANSMISSION) SA07693A2001
For M/T vehicle, manual transmission oil works as
differential oil to lubricate differential. Refer to
“Transmission Oil”. <Ref. to PM-25 MANUAL
TRANSMISSION, REPLACEMENT, Transmission
Oil.>
2. FRONT DIFFERENTIAL (AUTOMATIC
TRANSMISSION) SA07693A2002
1) Drain differential gear oil by removing drain plug GI0046A
after allowing the engine to cool for 3 to 4 hours.
NOTE: 3. REAR DIFFERENTIAL SA07693A2003
1) Drain oil by removing drain plug.
2) Remove filler plug for quick draining oil.
3) Reinstall drain plug after draining oil.
NOTE:
쐌 Apply fluid packing to drain plug threads before
installation in T-type.
쐌 VA-type uses a new aluminum gasket.
Fluid packing:
Three Bond 1105
GI0045 Tightening torque:
T-type:
2) Reinstall drain plug after draining differential 49.0 N·m (5.0 kgf-m, 36.2 ft-lb)
gear oil and tighten it to the specified torque. VA-type:
Tightening torque: 34 N·m (3.5 kgf-m, 25.3 ft-lb)
44 N·m (4.5 kgf-m, 32.5 ft-lb) 4) After installing drain plug onto rear differential
NOTE: gear case firmly, fill oil up fully to the mouth of filler
쐌 Be sure to place a gasket between the transmis- plug.
sion case and drain plug.
쐌 Replace the gasket with a new one.
쐌 Each oil manufacturer has its base oil and addi-
GI0047A
Oil capacity:
0.8 (0.8 US qt, 0.7 lmp qt)
NOTE:
Each oil manufacturer has its base oil and addi-
PM-27
FRONT & REAR DIFFERENTIAL OIL
5) Install filler plug onto rear differential gear case

firmly.
NOTE:
쐌 Apply fluid packing to filler plug before installa-
tion in T-type.
Fluid packing:
Three Bond 1105
Tightening torque:
T-type:
49.0 N·m (5.0 kgf-m, 36.2 ft-lb)
VA-type:
34 N·m (3.5 kgf-m, 25.3 ft-lb)
PM-28
BRAKE LINE
20. Brake Line SA07694 B: CHECKING SA07694G27
1. SERVICE BRAKE SA07694G2701
1. BRAKE LINE SA07694A1001

1) Check the free play of brake pedal with a force
of less than 10 N (1 kgf, 2 lb).
1) Check scratches, swelling, corrosion and/or
traces of fluid leakage on brake hoses or pipe Brake pedal free play:
joints. 1 — 3 mm (0.04 — 0.12 in)
2) Check the possibility of adjacent parts interfer-
ing with brake pipes/hoses during driving, and
loose connections/clamps.
3) Check any trace of fluid leakage, scratches,
etc. on master cylinder, wheel cylinder and pres-
sure control valve.
NOTE:
쐌 When the brake fluid level in the reservoir tank
is lower than the specified limit, the brake fluid
warning light on the combination meter will come
GI0050A
on.
쐌 Visually check brake hose (using a mirror where 2) If the free play is out of specifications above,
it is difficult to see) for any damage. adjust the brake pedal as follows:
(1) Be sure engine is off. (No vacuum is applied
to brake booster.)
(2) There should be play between brake
booster clevis and pin at brake pedal installing
portion.
[Depress brake pedal pad with a force of less
than 10 N (1 kgf, 2 lb) to a stroke of 1 to 3 mm
(0.04 to 0.12 in).]
(3) Depress the surface of brake pad by hand.
(4) If there is no free play between clevis pin
GI0048A and clevis, turn brake switch adjusting nut until
the clearance between stopper and screw of
brake switch becomes 0.3 mm (0.012 in).
S1M0154A
GI0051A
PM-29
BRAKE LINE
3) Check the pedal stroke. 4) Check valve is built into vacuum hose. Discon-
While the engine is idling, depress the brake pedal nect vacuum hose to inspect function of check
with a 490 N (50 kgf, 110 lb) load and measure the 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 Replace both check valve and vacuum hose if
distance is more than specified, there is a possibil- check valve is faulty. Engine side of vacuum hose
ity air is in the inside of the hydraulic unit. is indicated by marking “ENGINE” as shown.
Brake pedal reserve distance: A
more than 95 mm (3.74 in)/ 490 N (50 kgf,
110 lb)
GI0053A
5) Check vacuum hose for cracks or other dam-

age.
GI0052A NOTE:
When installing the vacuum hose on the engine
4) Check to see if air is in the hydraulic brake line and brake booster, do not use soapy water or lubri-
by the feel of pedal operation. If air appears to exist cating oil on their connections.
in the line, bleed it from the system.
5) Check for even operation of all brakes, using a 6) Check vacuum hose to make sure it is tight and
secure.
brake tester or by driving the vehicle for a short
distance on a straight road.
2. BRAKE SERVO SYSTEM SA07694G2702
1) With the engine off, depress the brake pedal

several times applying the same pedal force: Make
sure the travel distance should not change.
2) With the brake pedal depressed, start the
engine: Make sure the pedal should move slightly
toward the floor.
3) With the brake pedal depressed, stop the
engine and keep the pedal depressed for 30 sec-
onds: Make sure the pedal height should not
change.
PM-30
BRAKE FLUID
21. Brake Fluid SA07162

NOTE:
쐌 Cover bleeder with waste cloth, when loosening
A: REPLACEMENT SA07162A20 it, to prevent brake fluid from being splashed over
surrounding parts.
1) Either jack up vehicle and place a safety stand 쐌 During bleeding operation, keep the brake
under it, or lift up vehicle. reserve tank filled with brake fluid to eliminate entry
2) Remove both front and rear wheels. of air.
3) Draw out the brake fluid from master cylinder 쐌 Brake pedal operation must be very slow.
with syringe. 쐌 For convenience and safety, it is advisable to
4) Refill reservoir tank with recommended brake have two men working.
fluid. 쐌 The amount of brake fluid required is approxi-
Recommended brake fluid: mately 500 m (16.9 US fl oz, 17.6 Imp fl oz) for
FMVSS No. 116, fresh DOT3 or 4 brake total brake system.
fluid 6) Instruct your co-worker to depress the brake
NOTE: pedal slowly two or three times and then hold it
depressed.
쐌 Avoid mixing different brands of brake fluid to
7) Loosen bleeder screw approximately 1/4 turn
prevent degrading the quality of the fluid.
until a small amount of brake fluid drains into
쐌 Be careful not to allow dirt or dust to get into the container, and then quickly tighten screw.
reservoir tank. 8) Repeat steps 6) and 7) above until there are no
Bleeding sequence (1) → (2) → (3) → (4) air bubbles in drained brake fluid and new fluid
flows through vinyl tube.
NOTE:
Add brake fluid as necessary while performing the
air bleed operation, in order to prevent the tank
from running short of brake fluid.
9) After completing the bleeding operation, hold
brake pedal depressed and tighten screw and
install bleeder cap.
Tightening torque:
GI0054A
8 N·m (0.8 kgf-m, 5.8 ft-lb)
10) Bleed air from each wheel cylinder by follow-
(1) Front right
ing the previous 5 steps.
(2) Rear left
11) Depress brake pedal with a force of approxi-
(3) Front left
mately 294 N (30 kgf, 66 lb) and hold it there for
(4) Rear right
approximately 20 seconds. At this time check
(5) Secondary
pedal to see if it makes any unusual movement.
(6) Primary
Visually inspect bleeder screws and brake pipe
5) Install one end of a vinyl tube onto the air joints to make sure that there is no fluid leakage.
bleeder and insert the other end of the tube into a 12) Install wheels, and drive vehicle for a short
container to collect the brake fluid. distance between 2 to 3 km (1 to 2 miles) to make
sure that brakes are operating properly.
GI0055
PM-31
DISC BRAKE PADS AND DISCS
22. Disc Brake Pads and Discs NOTE:

SA07695
When replacing a pad, always replace the pads for
both the left and right wheels at the same time.
A: INSPECTION SA07695A10 Also replace pad clips if they are twisted or worn.
1. DISC BRAKE PAD AND DISC SA07695A1001
1) Jack up vehicle and support with rigid racks.

Then remove wheels.
2) Visually check pad thickness through inspec-
tion hole of disc brake assembly. Replace pad if
necessary.
GI0058
GI0056A
Pad thickness including back metal mm (in)

Front Rear
Standard 17 (0.67) 14 (0.55)
Service limit 7.5 (0.295) 6.5 (0.256)
Service limit 1.5 (0.059) 1.5 (0.059)
(exclusive back metal)
GI0057A
3) Check the disc rotor, and correct or replace if it

is damaged or worn.
Brake disc thickness mm (in)
Front Rear
Standard 24 (0.94) 10 (0.39)
Wear limit 22 (0.87) 8.5 (0.335)
4) Measure the disc rotor runout at a point less

than 5 mm (0.20 in) from the outer periphery of the
rotor.
Disc rotor runout limit:
Front: 0.075 mm (0.0030 in)
Rear: 0.075 mm (0.0030 in)
PM-32
BRAKE LININGS AND DRUMS
23. Brake Linings and Drums If deformation or wear of back plate, shoe, etc. is
SA07696
noticeable, replace the affected parts.
1. REAR DRUM BRAKE SA07696A1001
1) Remove brake drum, and check that there is no

fluid leakage from wheel cylinder.
If there is fluid leakage from wheel cylinder, replace
it. <Ref. to BR-34, Rear Drum Brake Drum.>
2) Inspect brake shoes for damage or deformities
and check brake linings for wear.
GI0060A
NOTE:
쐌 Always replace both leading and trailing brake
shoes for the left and right wheels at the same 2. PARKING BRAKE (REAR DISC BRAKE)
time. SA07696A1002
쐌 When either the left or the right brake assembly

Inspect brake linings and drums of both sides of
is replaced, always replace the leading shoe and
the rear brake at the same time by removing brake
trailing shoe of the other.
drums.
쐌 The cotter pin, once removed, cannot be
1) Inspect brake shoes for damage or deformation
reused.
and check brake linings for wear.
Thickness of lining (except back metal)
NOTE:
Standard value: 4.1 mm (0.161 in)
Always replace both primary and secondary brake
Service limit: 1.5 mm (0.059 in)
shoes for the left and right wheels at the same
time.
Brake lining thickness excluding back metal
Wear limit: 1.5 mm (0.059 in)
GI0059A
(1) Rotational direction of drum (Forward)

(2) Wheel cylinder
(3) Upper shoe return spring
(4) Adjusting lever
S1M0158A
(5) Trailing shoe
(6) Lower shoe return spring
(7) Leading shoe
To replace trailing shoe, remove cotter pin. Clevis

pin should also be replaced if worn.
3) Check brake drum for wear, dents or other
damage.
If the inside surface of brake drum is streaked,
correct the surface with emery cloth (#200 or
more). If it is unevenly worn, tapered, or the out-
side surface of brake drum is damaged, correct or
replace it.
Brake drum inner diameter
Service limit: 230.6 mm (9.079 in)
PM-33
BRAKE LININGS AND DRUMS
2) Check brake drum for wear, dents or other B: ADJUSTMENT SA07696A01

damage. If the inside surface of brake drum is
streaked, correct the surface with emery cloth 1. REAR DRUM BRAKE SA07696A0101
(#200 or more). If it is unevenly worn, tapered, or The main brake is adjusted automatically, and so
the outside surface of brake drum is damaged, there is no need to adjust it.
correct or replace it.
2. PARKING BRAKE (REAR DISC BRAKE)
Brake drum inside diameter
SA07696A0102
Standard value: 170 mm (6.69 in)
Wear limit: 171 mm (6.73 in) For rear disc brake, adjust parking brake after
bleeding the air.
1) Remove rear cover (rubber) installed at back
plate.
2) Turn adjuster toward arrow mark (upward) until
it is locked slightly, by using slot-type screwdriver
as shown in illustration.
GI0062A
3) If the deformation or wear of back plate, shoe,

etc. is noticeable, replace them.
4) When the shoe return spring tension is exces-
sively weakened, replace it, taking care to identify
upper and lower springs. GI0063A
3) Turn back (downward) adjuster 3 to 4 notches.

4) Install cover (rubber) at original position cor-
rectly.
PM-34
SUSPENSION
24. Suspension SA07697

NOTE:
When transverse link ball joint has been removed
A: INSPECTION SA07697A10 or replaced, check toe-in of front wheel. If front
wheel toe-in is not at specified value, adjust toe-in.
1. SUSPENSION BALL JOINT SA07697A1001
<Ref. to FS-6, Wheel Alignment.>
1) Jack up vehicle until front wheels are off
ground.
2) Next, grasp bottom of tire and move it in and
out. If relative movement is observed between
brake disc cover and end of transverse link, ball
joint may be excessively worn.
3) Next, grasp end of transverse link and move it
up and down. Relative movement between hous-
ing and transverse link boss indicates ball joint
may be excessively worn.
4) If relative movement is observed in the imme- GI0066A
diately preceding two steps, remove and inspect

ball joint. If free play exceeds standard, replace 2. TRANSVERSE LINK’S REAR BUSHING
ball joint. <Ref. to FS-17, Front Ball Joint.> SA07697A1002
Check oil leaks at around liquid-filled bushing. If oil

leaks, replace bushing.
GI0064A
GI0067A
3. WHEEL ARCH HEIGHT SA07697A1003
1) Unload cargoes and set vehicle in curb weight

condition.
2) Then, check wheel arch height of front and rear
suspensions to ensure that they are within speci-
fied values.
3) When wheel arch height is out of standard,
GI0065A visually inspect following components and replace
deformed parts.
5) Damage of dust seal 쐌 Suspension components [Front strut assembly
Visually inspect ball joint dust seal. If it is damaged, and rear strut assembly]
remove transverse link. <Ref. to FS-14, Front 쐌 Body parts to which suspensions are installed.
Transverse Link.> And measure free play of ball 4) When no components are deformed, adjust
joint. <Ref. to FS-17, Front Ball Joint.> wheel arch height by replacing coil spring in the
(1) When looseness exceeds standard value, suspension whose wheel arch height is out of stan-
replace ball joint. dard. <Ref. to FS-6, Wheel Alignment.> and <Ref.
(2) If the dust seal is damaged, replace with the to RS-7, Wheel Alignment.>
new ball joint.
PM-35
SUSPENSION
4. WHEEL ALIGNMENT OF FRONT 8. DAMAGE TO SUSPENSION PARTS

SUSPENSION SA07697A1004 SA07697A1008
1) Check alignment of front suspension to ensure 1) Check the following parts and the fastening por-
that following items conform to standard values. tion of the vehicle body for deformation or exces-
쐌 Toe-in sive rusting which impairs the suspension. If
쐌 Camber angle necessary, replace damaged parts with new ones.
쐌 Caster angle If minor rust formation, pitting, etc. are noted,
쐌 Steering angle remove rust and apply remedial anti-corrosion
<Ref. to FS-6, Wheel Alignment.> measures.
2) When caster angle does not conform to stan- 쐌 Front suspension
dard value, visually inspect following components 쐌 Transverse link
and replace deformed parts. 쐌 Crossmember
쐌 Suspension components [Strut assembly, 쐌 Strut
crossmember, transverse link, etc.] 쐌 Rear suspension
쐌 Body parts to which suspensions are installed. 쐌 Lateral link
3) When toe-in and camber are out of standard 쐌 Crossmember
value, adjust them so that they conform to respec- 쐌 Strut
tive service standard. 쐌 In the district where salt is sprayed to melt snow
4) When right-and-left turning angles of tire are on a road in winter, check suspension parts for
out of standard, adjust to standard value. damage caused by rust every 12 months after
lapse of 60 months. Take rust prevention measure
5. WHEEL ALIGNMENT OF REAR as required.
SUSPENSION SA07697A1005
1) Check alignment of rear suspension to ensure
that following items are within standard values.
쐌 Toe-in
쐌 Camber angle
쐌 Thrust angle
<Ref. to RS-7, Wheel Alignment.>
2) When camber angle does not conform to stan-
dard value, visually inspect parts listed below. If
deformation is observed, replace damaged parts.
쐌 Suspension components [Strut assembly,
crossmember, lateral link, etc.]
쐌 Body parts to which suspensions are installed.
3) When toe-in and thrust angle are out of stan-
dard value, adjust them so that they conform to
respective service standard.
6. OIL LEAKAGE OF STRUT SA07697A1009
Visually inspect front strut and rear strut for oil

leakage as instructed. Replace front strut and rear
strut if oil leaks excessively.
7. TIGHTNESS OF BOLTS AND NUTS
SA07697A1007
Check bolts and nuts shown in the figure for loose-

ness. Retighten bolts and nuts to specified torque.
If self-lock nuts and bolts are removed, replace
them with new ones.
Front suspension: <Ref. to FS-2, General Descrip-
tion.>
Rear suspension: <Ref. to RS-2, General Descrip-
tion.>
PM-36
WHEEL BEARING
25. Wheel Bearing SA07698

6) While supporting rear drive shaft horizontally
with one hand, turn hub COMPL with the other to
A: INSPECTION SA07698A10 check for noise or binding.
If hub COMPL is noisy or binds, disassemble rear
1. FRONT WHEEL BEARING SA07698A1001
axle and check condition of oil seals, bearings, etc.
NOTE:
Inspect the condition of front wheel bearing
grease.
1) Jack up the front of vehicle.
2) While holding front wheel by hand, swing it in
and out to check bearing free play.
3) Loosen wheel nuts and remove front wheel.
4) If bearing free play exists in step 2) above,
attach a dial gauge to hub and measure axial dis-
placement in axial direction.
GI0134
Service limit:
Straight-ahead position within 0.05 mm
(0.0020 in)
5) Remove bolts and self-locking nuts, and extract
transverse link from front crossmember.
6) While lightly hammering spring pin which
secures S.F.J. to transmission spindle, remove it.
7) Extract S.F.J. from transmission spindle. <Ref.
to DS-17, Front Axle.>
8) While supporting front drive shaft horizontally
with one hand, turn hub with the other to check for
noise or binding.
If hub is noisy or binds, disassemble front axle and
check condition of oil seals, bearing, etc.
GI0133
2. REAR WHEEL BEARING SA07698A1002
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 wheel nuts and remove rear wheel.
4) If bearing free play exists in step 2) above,
attach a dial gauge to hub COMPL and measure
axial displacement in axial direction.
Service limit:
Straight-ahead position within 0.05 mm
(0.0020 in)
5) Remove the DOJ of rear drive shaft from rear
differential. <Ref. to DS-38, Rear Drive Shaft.>
PM-37
AXLE BOOTS & JOINTS
26. Axle Boots & Joints SA07699
1. FRONT AND REAR AXLE BOOTS SA07699A1001
Inspect front axle boots (A) and rear axle boots (B)
for deformation, damage or failure. If faulty, replace
them with new ones. <Ref. to DS-32, Front Drive
Shaft.> and <Ref. to DS-38, Rear Drive Shaft.>
GI0070A
GI0135
2. PROPELLER SHAFT SA07699A1002
Inspect propeller shaft for damage or failure. If

faulty, replace with new one. <Ref. to DS-14, Pro-
peller Shaft.>
PM-38
STEERING SYSTEM (POWER STEERING)
27. Steering System (Power 2. STEERING SHAFT JOINT SA07701A1002
Steering) SA07701 1) When steering wheel free play is excessive,

disconnect universal joint of steering shaft and
A: INSPECTION SA07701A10 check it for any play and yawing torque (at the
1. STEERING WHEEL SA07701A1001
point of the crossing direction). Also inspect for any
damage to sealing or worn serrations. If the joint is
1) Set steering wheel in a straight-ahead position, loose, retighten the mounting bolts to the specified
and check wheel spokes to make sure they are torque.
correctly set in their specified positions.
2) Lightly turn steering wheel to the left and right Tightening torque:
to determine the point where front wheels start to 24 N·m (2.4 kgf-m, 17.4 ft-lb)
move.
Measure the distance of the movement of steering
wheel at the outer periphery of wheel.
Steering wheel free play:
0 — 17 mm (0 — 0.67 in)
GI0075A
3. GEARBOX SA07701A1003
1) With wheels placed on a level surface, turn

steering wheel 90° in both the left and right direc-
GI0074A
tions.
Move steering wheel vertically toward the shaft to While wheel is being rotated, reach under vehicle
ascertain if there is play in the direction. and check for looseness in gearbox.
Maximum permissible play: Tightening torque:
0.5 mm (0.020 in) 59 N·m (6.0 kgf-m, 43.4 ft-lb)
3) Drive vehicle and check the following items dur-
ing operation.
(1) Steering force ..............
The effort required for steering should be
smooth and even at all points, and should not
vary.
(2) Pull to one side ............
Steering wheel should not be pulled to either
side while driving on a level surface.
(3) Wheel runout ................
Steering wheel should not show any sign of GI0076A
runout.
(4) Return factor ............... 2) Check boot for damage, cracks or deterioration.
Steering wheel should return to its original posi-
tion after it has been turned and then released.
PM-39
3) With vehicle on a level surface, quickly turn 3) Check lock nut on the tie-rod end for tightness.
steering wheel to the left and right. If it is loose, retighten it to the specified torque.
While steering wheel is being rotated, check the Tightening torque:
gear backlash. If any unusual noise is noticed, 83 N·m (8.5 kgf-m, 61.5 ft-lb)
adjust the gear backlash in the following manner.
(1) Loosen the adjusting screw three to four 5. POWER STEERING FLUID LEVEL
rotations. SA07701A1005
(2) Apply liquid packing to at least 1/3 of entire 1) Check power steering fluid for deterioration or
perimeter of adjusting screw thread. contamination. If the fluid is highly deteriorated or
(3) Tighten adjusting screw to 7.4 N·m (0.75 contaminated, drain it and refill with new fluid.
kgf-m, 5.4 ft-lb) and then loosen. Repeat this 2) Check joints and units for oil leakage. If any oil
operation twice. leaks are found, repair or replace the applicable
(4) Retighten adjusting screw to 7.4 N·m (0.75 part.
kgf-m, 5.4 ft-lb) and back off 25°. 3) Inspect fluid level on flat and level surface with
engine “OFF” by indicator of reservoir tank.
keep the level in the specified range of the indica-
tor. If at upper point or above, drain fluid by using
a syringe or the like.
the “COLD” side.
GI0077A the “HOT” side.
(5) Install lock nut. While holding adjusting Non-turbo model
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.
4. TIE-ROD SA07701A1004
1) Check tie-rod and tie-rod ends for bends,

scratches or other damage. H4M1007
Turbo model
GI0105A
2) Check connections of knuckle ball joints for B4M1674A

play, inspect for damage on dust seals, and check
free play of ball studs. If castle nut is loose,
NOTE:
retighten it to the specified torque, then tighten fur-
ther up to 60° until cotter pin hole is aligned. If fluid level is at MAX level or above, drain fluid to
keep the level in the specified range of indicator by
Tightening torque: using a syringe or the like.
27 N·m (2.75 kgf-m, 19.9 ft-lb)
PM-40
Recommended fluid: 9. GEARBOX BOOTS SA07701A1009
Dexron IIE or III

Inspect both sides of gearbox boots as follows, and
Fluid capacity: correct the defects if necessary.
0.7 (0.7 US qt, 0.6 Imp qt) 1) (A) and (B) positions of gearbox boot are fitted
6. POWER STEERING FLUID FOR LEAKS correspondingly in (A) and (B) grooves of gearbox
SA07701A1006
and the rod.
2) Clips are fitted outside of (A) and (B) positions
Inspect the underside of oil pump and gearbox for of boot.
power steering system, hoses, piping and their 3) Boot does not have crack and hole.
couplings for fluid leaks.
If fluid leaks are found, correct them by retighten- NOTE:
ing their fitting bolts (or nuts) and/or replacing their Rotate (B) position of gearbox boot against twist of
parts. it produced by adjustment of toe-in, etc.
NOTE:
쐌 Wipe the leakage fluid off after correcting fluid
leaks, or a wrong diagnosis is taken later.
쐌 Also pay attention to clearances between hoses
(or pipings) and other parts when inspecting fluid
leaks.
7. HOSES OF OIL PUMP FOR DAMAGES
SA07701A1007
Check pressure hose and return hose of oil pump

GI0023A
for crack, swell or damage. Replace hose with new
one if necessary.
NOTE: 10. FITTING BOLTS AND NUTS SA07701A1010
Prevent hoses from revolving and/or turning when Inspect fitting bolts and nuts of oil pump and
installing hoses. bracket for looseness, and retighten them if neces-
sary.
Inspect and/or retighten them when engine is cold.
GI0017
8. POWER STEERING PIPES FOR

DAMAGE SA07701A1008
Check power steering pipes for corrosion and
damage.
Replace pipes with new one if necessary.
PM-41
SUPPLEMENTAL RESTRAINT SYSTEM
28. Supplemental Restraint System SA07702
Check the airbag system in accordance with the result of the self-diagnosis. <Ref. to AB-2, Basic Diagnos-
tic Procedure.>
1) Ensure that airbag connectors are connected. If not, properly connect (also double lock the connector).
When the ignition switch is turned ON with the connector(s) disconnected, the airbag warning light turns on
to identify the fault.
S1M0160A
2) Turn the ignition switch ON, and connect the airbag diagnosis terminal of the service connector (located
below lower cover) to the ground terminal.
3) The warning light blinks to indicate a trouble code (a fault is identified). When the airbag system is in
good order (no trouble codes are stored in the memory), the warning light blinks on and off at 0.6 second
intervals (as long as the diagnosis terminal is connected to the ground terminal).
4) When the warning light indicates a trouble code, check the airbag system in accordance with the
troubleshooting procedure. <Ref. to AB-2, Basic Diagnostic Procedure.>
PM-42
BODY SECTION

SUBARU vehicles.
ine parts.

G8050GE6
HVAC SYSTEM (HEATER, VENTILATOR
AND A/C)
AC
Page
2. Refrigerant Pressure with Manifold Gauge Set ........................................18
3. Refrigerant Recovery Procedure...............................................................19
4. Refrigerant Charging Procedure ...............................................................20
5. Refrigerant Leak Check ............................................................................23
6. Compressor Oil .........................................................................................25
7. Heater Unit ................................................................................................26
8. Blower Motor Assembly.............................................................................27
9. Power Transistor (Heater Blower Resistor) ..............................................28
10. Heater Core...............................................................................................29
11. Control Unit ...............................................................................................30
12. Compressor ...............................................................................................32
13. Condenser .................................................................................................34
14. Receiver Drier ...........................................................................................35
15. Intake Unit .................................................................................................36
16. Flexible Hose.............................................................................................38
17. Relay and Fuse .........................................................................................39
18. Pressure Switch (Dual Switch)..................................................................40
19. Air Vent Grille ............................................................................................41
20. Heater Duct ...............................................................................................42
21. Heater Vent Duct.......................................................................................43
22. General Diagnostics ..................................................................................44
GENERAL DESCRIPTION
HVAC System (Heater, Ventilator and A/C)
1. General Description S701001
A: SPECIFICATIONS S701001E49
1. HEATER SYSTEM S701001E4901
Item Specifications Condition

쐌 Mode selector switch: HEAT
5.1 kW (4,386 kcal/h, 17,404 BTU/h)
LHD model 쐌 Temperature control switch: FULL HOT
or more
쐌 Temperature difference between hot
Heating capacity
water and inlet air: 65°C (149°F)
4.93 kW (4,240 kcal/h, 16,824 BTU/h)
RHD model 쐌 Hot water flow rate: 360 (95.1 US gal,
or more
79.2 Imp gal)/h
LHD model 280 m3 (9,887 cu ft)/h
Air flow rate Heat mode (FRESH), FULL HOT at 12.5 V
RHD model 300 m3 (10,593 cu ft)/h
LHD model 480 m3 (16,949 cu ft)/h 쐌 Temperature control switch: FULL COLD
Max air flow rate 쐌 Blower fan speed: 4th position
RHD model 460 m3 (16,243 cu ft)/h 쐌 Mode selector lever: RECIRC
193.5 × 152 × 35.0 mm
LHD model
Heater core size (7.62 × 5.98 × 1.378 in)
—
(height × length × width) 161.4 × 176.4 × 32 mm
RHD model
(6.35 × 6.94 × 1.26 in)
LHD model Magnet motor 260 W or less
Type at 12 V
RHD model Magnet motor 250 W or less
Blower Sirocco fan type
LHD model
motor Fan type and size 150 × 75 mm (5.91 × 2.95 in)
—
(diameter × width) Sirocco fan type
RHD model
150 × 75 mm (5.91 × 2.95 in)
AC-2
GENERAL DESCRIPTION
2. A/C SYSTEM S701001E4902
쐌 LHD Model:
Item Specifications
Type of air conditioner Reheat air-mix type
5.117 kW
Cooling capacity
(4,400 kcal/h, 17,459 BTU/h)
HFC-134a (CH2FCF3)
Refrigerant
[0.65±0.05 kg (1.43±0.11 lb)]
Type 5-vane rotary, fix volume (KC50G)
Compressor Discharge 140 cm3 (8.54 cu in)/rev
Max. permissible speed 7,000 rpm
Type Dry, single-disc type
Power consumption 38 W
Magnet clutch Type of belt V-Ribbed 4 PK
Pulley dia. (effective dia.) 125 mm (4.92 in)
Pulley ratio 1.064
Type Corrugated fin (Multi-flow)
Core face area 0.255 m2 (2.74 sq ft)
Condenser 22 × 374 × 683 mm
Dimensions (W × H × T)
(0.87 × 14.72 × 26.89 in)
Radiation area 6.52 m2 (70 sq ft)
Receiver drier Effective inner capacity 250 cm3 (15.26 cu in)
Expansion valve Type Internal equalizing
Type Single tank
Evaporator 60 × 224 × 235 mm
(2.36 × 8.82 × 9.25 in)
Fan type Sirocco fan
Blower fan Outer diameter × width 150 × 75 mm (5.91 × 2.95 in)
Power consumption 260 W at 12 V
Motor type Magnet
Condenser fan (Sub fan) Power consumption 70 W at 12 V
Fan outer diameter 320 mm (12.60 in)
Motor type Magnet
Radiator fan (Main fan) Power consumption 70 W at 12 V
177±25 kPa
ON → OFF
Low-pressure switch (1.80±0.25 kg/cm2, 25.6±3.6 psi)
operating pressure Less than 216 kPa
OFF → ON
Dual switch (2.2 kg/cm2, 31 psi)
(Pressure switch) 2,940±200 kPa
ON → OFF
High-pressure switch (29.98±2.04 kg/cm2, 426.3±29.0 psi)
operating pressure 590±200 kPa
DIFF
(6.02±2.04 kg/cm2, 85.6±29.0 psi)
3,600±300 kPa
Compressor relief valve blow-out pressure
(36.71±3.06 kg/cm2, 522.0±43.5 psi)
Thermo control amplifier working temperature

(Evaporator outlet air)
S4M0511A
AC-3
GENERAL DESCRIPTION
쐌 RHD Model:
Item Specifications
Type of air conditioner Reheat air-mix type
Cooling capacity 5.059 kW (4,350 kcal/h, 17,261 BTU/h)
HFC-134a (CH2FCF3)
Refrigerant
[0.65±0.05 kg (1.43±0.11 lb)]
Type 5-vane rotary, fix volume (KC50G)
Compressor Discharge 140 cm3 (8.54 cu in)/rev
Max. permissible speed 7,000 rpm
Type Dry, single-disc type
Power consumption 38 W
Magnet clutch Type of belt V-Ribbed 4 PK
Pulley dia. (effective dia.) 125 mm (4.92 in)
Pulley ratio 1.064
Type Corrugated fin (Multi-flow)
Core face area 0.231 m2 (2.48 sq ft)
Condenser 20 × 331 × 698 × mm
(0.79 × 13.03 × 27.48 in)
Radiation area 7.2 m2 (77 sq ft)
Receiver drier Effective inner capacity 250 cm3 (15.26 cu in)
Expansion valve Type Internal equalizing
Type Single tank
Evaporator 60 × 224 × 235 mm
(2.36 × 8.82 × 9.25 in)
Fan type Sirocco fan
Blower fan Outer diameter × width 150 × 75 mm (5.91 × 2.95 in)
Power consumption 250 W at 12 V
Motor type Magnet
Condenser fan (Sub fan) Power consumption 70 W at 12 V
Motor type Magnet
Radiator fan (Main fan) Power consumption 70 W at 12 V
177±25 kPa
ON → OFF
Low-pressure switch (1.8±0.25 kg/cm2, 26±3.6 psi)
operating pressure Less than 216 kPa
OFF → ON
Dual switch (2.2 kg/cm2, 31 psi)
(Pressure switch) 2,650±200 kPa
ON → OFF
High-pressure switch (27.02±2.04 kg/cm2, 384±29 psi)
operating pressure 1,471±200 kPa
OFF → ON
(15±2.04 kg/cm2, 213±29 psi)
3,600±300 kPa
Compressor relief valve blow-out pressure
(36.71±3.06 kg/cm2, 522.0±43.5 psi)
Thermo control amplifier working temperature

(Evaporator outlet air)
S4M0275A
AC-4
GENERAL DESCRIPTION
B: COMPONENT S701001A05
1. HEATER UNIT S701001A0501
쐌 LHD Model:
H4M1045B
(1) Vent door (7) Mix lever (13) Vent lever

(2) DEF door (8) Foot door (14) Side link
(3) DEF lever (9) Foot duct
(4) Heater core (10) Heater case REAR Tightening torque: N·m (kgf-m, ft-lb)
(5) Heater case FRONT (11) Foot lever lower T: 7.35 (0.750, 5.421)
(6) Mix door (12) Foot lever upper
AC-5
GENERAL DESCRIPTION
쐌 RHD Model:
S4M0309A
(1) Heater case upper A (8) Vent door lever (15) Mix door lever
(2) Heater case upper B (9) Side link (16) Foot duct
(3) Vent door (10) Foot door
(4) DEF door (11) Mix door Tightening torque: N·m (kg-m, ft-lb)
(5) Sealing sponge (12) Heater core T: 7.35 (0.750, 5.421)
(6) DEF door lever (13) Heater case lower
(7) DEF door link (14) Foot door lever
AC-6
GENERAL DESCRIPTION
2. INTAKE UNIT WITH EVAPORATOR S701001A0505
쐌 LHD Model:
S4M0501A
(1) Evaporator (With A/C model) (8) Door (B) (16) Aspirator pipe
(2) Boot (9) Intake unit case inlet (17) Cover
(3) Block expansion valve (With A/C (10) Thermistor (With A/C model) (18) Separator
model) (11) Intake unit case upper (19) Rod
(4) Link (12) Intake unit case lower
(5) Lever (A) (13) Drain hose Tightening torque: N·m (kgf-m, ft-lb)
(6) Lever (B) (14) Resistor T: 7.35 (0.750, 5.421)
(7) Door (A) (15) Blower motor ASSY
AC-7
GENERAL DESCRIPTION
쐌 RHD Model:
S4M0545A
(1) Door (A) (9) Door (B) (16) Expansion valve (With A/C
(2) Sealing sponge (10) Link model)
(3) Door (B) lever (11) Door (A) lever (17) Drain hose
(4) Intake unit case upper (12) Evaporator (With A/C model)
(5) Separator (13) Thermo control amplifier (With Tightening torque: N·m (kgf-m, ft-lb)
(6) Cover A/C model) T: 7.35 (0.750, 5.421)
(7) Intake unit case lower (14) Clamp
(8) Blower motor ASSY (15) Pipe (With A/C model)
AC-8
GENERAL DESCRIPTION
3. CONTROL UNIT S701001A0503
S4M0083A
(1) Temperature control cable (6) Bulb (11) Control lever knob
(2) Recirc control cable (7) A/C switch ASSY (12) Plate
(3) Clip (8) Mode control cable (13) Base unit
(4) Blower switch ASSY (9) Control dial knob
(5) Harness ASSY (10) A/C switch knob
AC-9
GENERAL DESCRIPTION
4. AIR CONDITIONING UNIT S701001A0504
쐌 LHD Model:
S4M0486A
(1) Condenser (5) Hose (Low-pressure) Tightening torque: N·m (kgf-m, ft-lb)
(2) Pipe (From condenser to (6) Compressor
T1: 7.4 (0.75, 5.4)
receiver drier) (7) Hose (High-pressure)
T2: 15 (1.5, 10.8)
(3) Receiver drier
(4) Pipe (From receiver drier to
intake unit)
AC-10
GENERAL DESCRIPTION
쐌 RHD Model:
S4M0487A
(1) Compressor (5) Receiver drier Tightening torque: N·m (kgf-m, ft-lb)
(2) Hose (Low-pressure) (6) Pipe (From condenser to
T1: 7.4 (0.75, 5.4)
(3) Condenser receiver drier)
T2: 15 (1.5, 10.8)
(4) Pipe (From receiver drier to (7) Hose (High-pressure)
intake unit)
AC-11
GENERAL DESCRIPTION
5. COMPRESSOR S701001A0506
S4M0488A
(1) Idler pulley adjuster (7) V-belt Tightening torque: N·m (kgf-m, ft-lb)
(2) Idler pulley bracket (8) Compressor belt cover
T1: 7.4 (0.75, 5.4)
(3) Idler pulley
T2: 23 (2.3, 17)
(4) Compressor bracket upper
T3: 23.0 (2.35, 17.0)
(5) Compressor
(6) Compressor bracket lower T4: 28.9 (2.95, 21.3)
T5: 35 (3.6, 26)
AC-12
GENERAL DESCRIPTION
C: CAUTION S701001A03 4. HANDLING OF REFRIGERANT S701001A0304
1. HFC-134a A/C SYSTEM S701001A0301

쐌 The refrigerant boils at approx. −30°C (−22°F).
When handling it, be sure to wear safety goggles
쐌 Unlike the old conventional HFC-12 system and protective gloves. Direct contact of the refrig-
components, the cooling system components for erant with skin may cause frostbite.
the HFC-134a system such as the refrigerant and If the refrigerant gets into your eye, avoid rubbing
compressor oil are incompatible. your eyes with your hands. Wash your eye with
쐌 Vehicles with the HFC-134a system can be plenty of water, and receive medical treatment
identified by the label “A” attached to the vehicle. from an eye doctor.
Before maintenance, check which A/C system is 쐌 Do not heat a service can. If a service can is
installed in the vehicle. directly heated, or put into boiling water, the inside
pressure will become extremely high. This may
cause the can to explode. If a service can must be
warmed up, use hot water in 40°C (104°F) max.
쐌 Do not drop or impact a service can. (Observe
the precautions and operation procedure
described on the refrigerant can.)
쐌 When the engine is running, do not open the
high-pressure valve of the manifold gauge. The
high-pressure gas will back-flow resulting in an
explosion of the can.
S4M0547A 쐌 The refrigerant is non-toxic and harmless under
normal operating circumstance, but it may change
2. COMPRESSOR OIL S701001A0302
to phosgene (a noxious fume) under open flames
or high temperatures (caused by a cigarette or
쐌 HFC-134a compressor oil has no compatibility heater).
with that for R12 system. 쐌 Provide good ventilation and do not work in a
쐌 Use only the manufacturer-authorized compres- closed area.
sor oil for the HFC-134a system; only use 쐌 Never perform a gas leak test using a halide
ZXL200PG. torch-type leak tester.
쐌 Do not mix multiple compressor oils. 쐌 In order to avoid destroying the ozone layer, pre-
If HFC-12 compressor oil is used in a HFC-134a vent HFC-134a from being released into the atmo-
A/C system, the compressor may become stuck sphere. Using a refrigerant recovery system, dis-
due to poor lubrication, or the refrigerant may leak charge and reuse it.
due to swelling of rubber parts.
On the other hand, if HFC-134a compressor oil is
used in a HFC-12 A/C system, the durability of the
A/C system will be lowered.
쐌 HFC-134a compressor oil is very hygroscopic.
When replacing or installing/removing A/C parts,
immediately isolate the oil from the atmosphere
using a plug or tape. In order to avoid moisture,
store the oil in a container with its cap tightly
closed.
3. REFRIGERANT S701001A0303
쐌 The HFC-12 refrigerant cannot be used in the

HFC-134a A/C system. The HFC-134a refrigerant,
also, cannot be used in the HFC-12 A/C system.
쐌 If an incorrect or no refrigerant is used, poor
lubrication will result and the compressor itself may
be damaged.
G4M0979
AC-13
GENERAL DESCRIPTION
5. O-RING CONNECTIONS S701001A0305 쐌 Use the oil specified in the service manual to
lubricate the O-rings.
쐌 Use new O-rings.
Apply the oil to the top and sides of the O-rings
쐌 In order to keep the O-rings free of lint which will
before installation.
cause a refrigerant gas leak, perform operations
Apply the oil to the area including the O-rings and
without gloves and shop towels.
tube beads.
쐌 Apply the compressor oil to the O-rings to avoid
sticking, then install them.
쐌 Use a torque wrench to tighten the O-ring fit-
tings: Over-tightening will damage the O-ring and
tube end distortion.
쐌 If the operation is interrupted before completing
a pipe connection, recap the tubes, components,
and fittings with a plug or tape to prevent contami-
nation from entering.
G4M0581
쐌 Visually check the surfaces and mating surfaces

of O-rings, threads, and connecting points. If a fail- G4M0583
ure is found, replace the applicable parts.
쐌 Install the O-rings at right angle to the tube 쐌 When connecting hoses or pipes, use 2
beards. wrenches (a torque wrench for tightening). While
securing one side with a wrench, tighten the other
side to the specified torque with a torque wrench.
If only one wrench is used to tighten, the tighten-
ing torque will be excessive or insufficient. This
may cause a pipe distortion or gas leak, resulting
in damage to hoses and pipes.
쐌 After tightening, using a clean shop towel to
remove excess oil from the connections and any oil
which may have run on the vehicle body or other
parts.
쐌 If any leakage is suspected after tightening, do
G4M0582 not retighten the connections, Disconnect the
connections, remove the O-rings, and check the
O-rings, threads, and connections.
G4M0584
AC-14
GENERAL DESCRIPTION
D: PREPARATION TOOL S701001A17
CAUTION:
When working on vehicles with the HFC-134a
system, only use HFC-134a specified tools and
parts. Do not mix with CFC-12 tools and parts.
If HFC-134a and CFC-12 refrigerant or com-
pressor oil is mixed, poor lubrication will result
and the compressor itself may be destroyed.
In order to help prevent mixing HFC-134a and
CFC-12 parts and liquid, the tool and screw
type and the type of service valves used are
different. The gas leak detectors for the HFC-
134a and CFC-12 systems must also not be
interchanged.
HFC-134a CFC-12
Tool & screw type Millimeter size Inch size
Valve type Quick joint type Screw-in type
Tools and Equipment Description

Wrench
Various WRENCHES will be required to service any A/C system. A 7

to 40 N·m (0.7 to 4.1 kg-m, 5 to 30 ft-lb) torque wrench with various
crowfoot wrenches will be needed. Open end or flare nut wrenches
will be needed for back-up on the tube and hose fittings.
G4M0571
Applicator bottle
A small APPLICATOR BOTTLE is recommended to apply refrigerant

oil to the various parts. They can be obtained at a hardware or drug
store.
G4M0572
Manifold gauge set
A MANIFOLD GAUGE SET (with hoses) can be obtained from either

a commercial refrigeration supply house or from an auto shop equip-
ment supplier.
G4M0573
AC-15
GENERAL DESCRIPTION

Refrigerant recovery system
A REFRIGERANT RECOVERY SYSTEM is used for the recovery

and reuse of A/C system refrigerant after contaminants and moisture
have been removed from the refrigerant.
G4M0574
Syringe
A graduated plastic SYRINGE will be needed to add oil back into the
system. The syringe can be found at a pharmacy or drug store.
G4M0575
Vacuum pump
A VACUUM PUMP (in good working condition) is necessary, and may

be obtained from either a commercial refrigeration supply house or an
automotive equipment supplier.
G4M0576
Can tap
A CAN TAP for the 397 g (14 oz) can is available from an auto sup-
ply store.
G4M0577
AC-16
GENERAL DESCRIPTION

Thermometer
Pocket THERMOMETERS are available from either industrial hard-

ware store or commercial refrigeration supply houses.
G4M0578
Electronic leak detector
An ELECTRONIC LEAK DETECTOR can be obtained from either a

specialty tool supply or an A/C equipment supplier.
G4M0579
Weight scale
A WEIGHT SCALE such as an electronic charging scale or a bath-

room scale with digital display will be needed if a 13.6 kg (30 lb)
refrigerant container is used.
G4M0580
AC-17
REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET
2. Refrigerant Pressure with Manifold Gauge Set S701631
A: OPERATION S701631A16
1) Place the vehicle in the shade and draftless condition.

2) Connect the manifold gauge set.
3) Open the front windows and close all doors.
4) Open the hood.
5) Increase engine rpm to 1,500.
6) Turn ON the A/C switch.
7) Turn the temperature control switch to MAX COOL.
8) Put in RECIRC position.
9) Turn the blower control switch to HI.
10) Read the gauge.
Standard:
Low pressure: 127 - 196 kPa (1.3 - 2.0 kg/cm2, 18 - 28 psi)
High pressure: 1,471 - 1,667 kPa (15 - 17 kg/cm2, 213 - 242 psi)
Ambient temperature: 30 - 35 °C (86 - 95 °F)
B: INSPECTION S701631A10
Symptom Probable cause Repair order

쐌 Defective condenser fan motor 쐌 Replace the fan motor.
쐌 Clogged condenser fan 쐌 Clean the condenser fin.
High-pressure side is unusually high. 쐌 Too much refrigerant 쐌 Discharge refrigerant.
쐌 Air inside the system 쐌 Replace the receiver dryer.
쐌 Defective receiver dryer
쐌 Defective compressor 쐌 Replace the compressor.
쐌 Not enough refrigerant 쐌 Check for leaks.
High-pressure side is unusually low. 쐌 Clogged expansion valve 쐌 Replace the expansion valve.
쐌 Expansion valve frozen temporarily by
moisture
쐌 Defective compressor 쐌 Replace the compressor.
Low-pressure side is unusually high. 쐌 Defective expansion valve 쐌 Replace the expansion valve.
쐌 Too much refrigerant 쐌 Discharge refigerant.
쐌 Not enough refrigerant 쐌 Check for leaks.
쐌 Clogged expansion valve 쐌 Replace the expansion valve
Low-pressure side is unusually low. 쐌 Expansion valve frozen temporarily by 쐌 Replace the receiver dryer.
moisture
쐌 Saturated receiver dryer
AC-18
REFRIGERANT RECOVERY PROCEDURE
3. Refrigerant Recovery 6) Follow the operation manual to activate the

refrigerant recovery system.
Procedure S701291
CAUTION:
쐌 During operation, be sure to wear safety
goggles and protective gloves.
쐌 Connect the refrigerant recovery system
with the manifold gauge set to discharge the
refrigerant from the A/C system and reuse it.
쐌 When reusing the discharged refrigerant,
keep service cans on hand. Because the dis-
charge rate with the recovery system is approx.
90%, service cans are necessary to charge the
refrigerant.
쐌 Follow the detailed operation procedure
described in the operation manual attached to
the refrigerant recovery system.
1) Turn the A/C switch ON.
Leave the engine running for approx. 5 minutes to
activate the compressor. Perform the refrigerating
cycle with the refrigerant to discharge the com-
pressor oil remaining on the functional parts into
the compressor as much as possible.
2) Stop the engine.
3) Close the valves on the low-/high-pressure
sides of the manifold gauge set.
G4M0585
4) Install the low-/high-pressure hoses to the ser-

vice ports on the low-/high-pressure sides of the
vehicle respectively.
G4M0586
5) Connect the center hose to the refrigerant

recovery system.
AC-19
REFRIGERANT CHARGING PROCEDURE
4. Refrigerant Charging 4) Carefully open the valves on the low-/high-

pressure sides to activate the vacuum pump.
Procedure S701292
CAUTION:
쐌 During operation, be sure to wear safety
goggles and protective gloves.
쐌 Before charging the refrigerant, evacuate the
system to remove small amounts of moisture
remaining in the system.
The moisture in the system can be completely
evacuated only under the minimum vacuum G4M0597
level. The minimum vacuum level affects the
temperature in the system. 5) After the low-pressure gauge reaches 100.0
쐌 The list below shows the vacuum values kPa (750 mmHg, 29.5 inHg) or higher, evacuate
necessary to boil water in various temperature. the system for approx. 15 minutes.
In addition, the vacuum levels indicated on the
gauge are approx. 3.3 kPa (25 mmHg, 0.98
inHg) lower than those measured at 304.8 m
(1,000 ft) above sea level.
Vacuum level required to boil water (at sea level)
Temperature Vacuum
1.7°C (35°F) 100.9 kPa (757 mmHg, 29.8 inHg)
7.2°C (45°F) 100.5 kPa (754 mmHg, 29.7 inHg)
12.8°C (55°F) 99.8 kPa (749 mmHg, 29.5 inHg)
G4M0598
18.3°C (65°F) 99.2 kPa (744 mmHg, 29.3 inHg)
23.9°C (75°F) 98.5 kPa (739 mmHg, 29.1 inHg) 6) After 15 minutes of evacuation, if the reading
29.4°C (85°F) 97.2 kPa (729 mmHg, 28.7 inHg) shows 100.0 kPa (750 mmHg, 29.5 inHg) or
35°C (95°F) 95.8 kPa (719 mmHg, 28.3 inHg) higher, close the valves on the both sides to stop
the vacuum pump.
1) Close the valves on low-/high-pressure sides of
the manifold gauge.
G4M0599
G4M0596 7) Note the low-pressure gauge reading.
2) Install the low-/high-pressure hoses to the cor-

responding service ports on the vehicle respec-
tively.
3) Connect the center hose of the manifold gauge
set with the vacuum pump.
G4M0600
AC-20
8) Leave it at least 5 minutes, and then check the 15) Carefully open the high-pressure valve with
low-pressure gauge reading for any changes. the engine 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.
9) Following the can tap operation manual
instructions, install it to the refrigerant can.
G4M0604
CAUTION:
G4M0980 Never run the engine during charging from the
high-pressure side.
10) Disconnect the center manifold hose from the
vacuum pump, and connect the hose to the tap 16) Close the high-pressure valve when the low-
valve. pressure gauge reaches 98 kPa (1 kg/cm2, 14 psi).
11) When a 13.6 kg (30 lb) refrigerant container is Using a leak tester, check the system for leaks.
used, measure the refrigerant amount in use using If any leakage is found after the refrigerant recov-
a weighting scale. ery is completed, repair the applicable area.
17) After confirming that there are no leaks with
the leak test, charge the required amount of refrig-
erant.
CAUTION:
Never run the engine during charging from the
high-pressure side.
18) Close the high-pressure valve when;
쐌 the readings of low- and high-pressure gauges
become almost equal, after the charging speed is
G4M0981
reduced,
쐌 the HFC-134a source becomes empty, or
12) Confirm that all the 3 hoses are tightly con- 쐌 the system is filled with the gas.
nected to the manifold gauge set.
G4M0605
G4M0603
13) Open the valve on the HFC-134a source.

14) Loosen the center hose connection on the
manifold gauge set (if applicable, press a purge
valve on the manifold gauge set) only for a couple
of seconds to allow the air in the center hose to
escape by the refrigerant.
AC-21
19) If the HFC-134a source is empty, close the 26) Close the valve on the refrigerant source.
high-pressure valve, close the valve on the can
tap, and replace the HFC-134a source with a new Refrigerant amount
one to restart the operation. Refrigerant Minimum Maximum
HFC-134a 0.6 kg (1.3 lb) 0.7 kg (1.5 lb)
27) Disconnect the hose from the service port,

and install the service port cap.
G4M0606
20) Confirm that both the low- and high-pressure

valves can be closed. Start the engine with the A/C
switch OFF.
21) Quickly repeat ON-OFF cycles a few times to
prevent initial compressor damage.
22) Set up the vehicle to the following status:
쐌 A/C switch ON
쐌 Engine running at 1,500 rpm
쐌 Blower speed setting to “HI”
쐌 Temperature setting to “MAX COOL”
쐌 Air inlet setting to “RECIRC”
쐌 Windows open
23) While reading the low-pressure gauge, care-
fully open the low-pressure valve with the refriger-
ant source connected and the service hose
purged.
CAUTION:
Never open the high-pressure valve with the
engine running.
G4M0608
24) Adjust the refrigerant flow to maintain the

pressure on the low-pressure side at 276 kPa (2.81
kg/cm2, 40 psi) max.
25) After the system is fully charged, close the
low-pressure valve.
AC-22
REFRIGERANT LEAK CHECK
5. Refrigerant Leak Check S701293

5) Check the joint between the compressor and
hoses.
A: INSPECTION S701293A10 6) Check the machined area of compressor and
1) Operate the A/C system for approx. 10 minutes, other joints on the compressor.
and confirm that the high-side pressure shows at 7) Check the thermal limiter (if equipped) on the
least 690 kPa (7.03 kg/cm2, 100 psi). Then stop compressor housing.
the engine to start the leak test. 8) Check the compressor shaft seal at the area
2) Starting from the connection between the high- near the center of compressor clutch pulley.
pressure tube and evaporator, check the system Some shaft seals show a slight amount of leakage
for leaks along the high-pressure side through the about 28 g (1.0 oz) per year. This is not a problem.
compressor. The following items must be checked 9) Starting from the connection between the low-
thoroughly. pressure tube and evaporator, check the system
쐌 Connection between the tube and tube fitting for leakage along the high-pressure side through
the compressor. The following items must be
checked thoroughly.
쐌 Connection between the tube and tube fitting
쐌 Connection between 2 parts
쐌 Connection between the tube and nut
G4M0612
쐌 Connection between 2 parts
S4M0038
10) Visually check the rubber area of the flexible

hose for cracks.
Check the entire length of the flexible hose, espe-
cially the connection with the metal hose end.
CAUTION:
Carefully check the external surface of hoses
G4M0613 and tubes at approx. 25 mm (0.98 in) per sec-
ond.
쐌 Connection between the tube and nut
G4M0617
G4M0614
3) Check the joint and seam between the pressure 11) Disconnect the drain hose from the evaporator
switch (dual switch) and receiver dryer. case, and check the hose end for at least 10 sec-
4) Check the connections between the condenser onds.
and tubes, and welded joints on the condenser. After the test is finished, reconnect the drain hose.
The leak tester may detect the oil on the condenser
fins as a leak.
AC-23
REFRIGERANT LEAK CHECK
12) Turn the ignition key to ON position, and run

the blower at high speed for 1 minute. Stop the
blower to check the ventilation grill on the instru-
ment panel. While moving the tester closer to the
grill, run the blower for 1 or 2 seconds, then stop
it. Check the grill at that point for at least 10 sec-
onds.
G4M0618
13) Check the valve in the service port.

14) Visually check the rubber seal in the service
port cap.
G4M0619
AC-24
COMPRESSOR OIL
6. Compressor Oil S701294 B: REPLACEMENT S701294A20
NOTE:
쐌 If a component is replaced, add an appropriate
NOTE: amount of compressor oil.
Before making repairs, conduct the oil return 쐌 When replacing the compressor, the new com-
operation to return the compressor oil in circulation pressor will already have the specified amount of
with the refrigerant to the compressor. oil in it. Install the new compressor after removing
1) Increase engine rpm to 1,500. the same amount of oil that is remaining in the
2) Turn ON the A/C switch. compressor removed.
3) Turn the temperature control switch to MAX
Replacement parts Amount of oil replenishment
COOL.
Evaporator 70 m (2.4 US fl oz, 2.5 Imp fl oz)
4) Put in RECIRC position.
5) Turn the blower control switch to HI. Receiver drier 5 m (0.2 US fl oz, 0.2 Imp fl oz)
6) Leave in this condition for 10 minutes. Condenser 50 m (1.7 US fl oz, 1.8 Imp fl oz)
Hose 50 m (1.7 US fl oz, 1.8 Imp fl oz)
AC-25
HEATER UNIT
7. Heater Unit S701290
A: REMOVAL S701290A18
1) Disconnect ground cable from battery.

2) Drain engine coolant. <Ref. to CO-14, DRAIN-
ING OF ENGINE, REPLACEMENT, Engine Cool-
ant.>
3) Remove air cleaner case. (Non-turbo model)
<Ref. to IN(SOHC)-7, REMOVAL, Air Cleaner.>
4) Remove intercooler. (Turbo model) <Ref. to
IN(DOHC TURBO)-10, REMOVAL, Intercooler.>
5) Release heater hose clamps in engine com-
partment to remove the hoses.
B4M2299
6) Remove instrument panel. <Ref. to EI-31

REMOVAL, Instrument Panel Assembly.>
7) Loosen nuts and bolts of support beam to
remove support beam.
8) Remove A/C unit. <Ref. to AC-36 REMOVAL,
Intake Unit.>
9) Loosen nuts and bolts of heater unit to remove
heater unit.
G4M0554
B: INSTALLATION S701290A11

2) Refill engine coolant. <Ref. to CO-14, FILLING
OF ENGINE COOLANT, REPLACEMENT, Engine
Coolant.>
AC-26
BLOWER MOTOR ASSEMBLY
8. Blower Motor Assembly S701295 B: INSTALLATION S701295A11
Install in the reverse order of removal.
1) Disconnect ground cable from battery. C: INSPECTION S701295A10

2) Remove glove box.
Connect motor connector terminal 1 from the bat-
tery to the positive (+) lead and terminal 2 to the
negative (−) lead. Make sure the motor runs
smoothly.
S5M0047A
3) Disconnect motor connector.
B4M2404
B4M2304
4) Remove 3 screws.
5) Disconnect aspirator pipe (A) and remove
blower motor.
S4M0033A
AC-27
POWER TRANSISTOR (HEATER BLOWER RESISTOR)
9. Power Transistor (Heater

Blower Resistor) S701553
1) Remove glove box. <Ref. to EI-28 REMOVAL,

Glove Box.>
2) Disconnect power transistor connector.
3) Loosen 2 screws to remove power transistor.
B4M2305
C: INSPECTION S701553A10
B4M2463A
Check continuity between connector terminals.

Tester connection Condition Specified condition
4—3 Constant Approx. 0.4 Ω
If NG, replace the blower resistor.
AC-28
HEATER CORE
10. Heater Core S701554
1) Remove heater unit. <Ref. to AC-26

REMOVAL, Heater Unit.>
2) Remove screws to separate heater unit case.
3) Remove heater core.
B4M2306
AC-29
CONTROL UNIT
11. Control Unit S701285

7) Remove control unit assembly from center con-
sole.
1) Disconnect GND cable from battery.

2) Set temperature control switch to “FULL HOT”
and mode selector switch to “DEF” position and
recirc switch to “FRESH” position.
3) Disconnect temperature control cable and
mode door control cable from heater unit then dis-
connect recirc control cable from intake unit.
NOTE:
Do not attempt to move links during installation. S4M0034

NOTE:
Before installing control unit, set temperature con-
trol switch to “FULL HOT” and mode selector
switch to “DEF” position and recirc switch to
“FRESH” position.
1. FAN SWITCH S701285A1003
Check continuity between terminals at each switch

position.
S5M0049A
4) Remove console box. <Ref. to EI-30

REMOVAL, Console Box.>
5) Remove center panel and then disconnect con- H5M1280A
nector.
6) Remove audio.
H4M1051
S5M0048A
AC-30
CONTROL UNIT
2. A/C SWITCH S701285A1004
Check A/C switch continuity between each termi-

nal.
H5M1281A
H4M1052
D: ADJUSTMENT S701285A01
1) Operate temperature control switch to “FULL

COLD” and mode selector switch to “VENT” posi-
tion and recirc switch to “RECIRC” position.
2) Install control cable to lever. While pushing
outer cable, secure control cable with clip.
H4M1053A
AC-31
COMPRESSOR
12. Compressor S701281

5) Disconnect low-pressure hose (A) and high-
pressure hose (B).
A: INSPECTION S701281A10
CAUTION:
1. MAGNETIC CLUTCH CLEARANCE Be careful not to lose O-rings on hose. Imme-
S701281A1001 diately seal hose with a plug or vinyl tape to
prevent the entry of contamination.
1) Check the clearance of the entire circumfer-
ence around the drive plate and pulley.
Standard:
0.45±0.15 mm (0.0177±0.0059 in)
H4M1159C
6) Remove V-belt. (SOHC) <Ref. to ME(SOHC)-

42, REMOVAL, V-belt.> or (DOHC TURBO) <Ref.
B4M0091 to ME(DOHC TURBO)-44, REMOVAL, V-belt.>
7) Remove generator. <Ref. to SC-12 REMOVAL,
Generator.>
2. MAGNETIC CLUTCH OPERATION 8) Disconnect compressor harness from body har-
S701281A1002
ness.
1) Disconnect the compressor connector. 9) Remove bolts from compressor bracket.
2) Connect the No. 3 terminal of the compressor
connector from the battery to the positive (+) lead.
Ground the negative (−) lead to the body.
B4M2311
10) Loosen bolts to remove compressor from

B4M2407
bracket.
3) Make sure the magnet clutch engages.

If NG, replace the compressor.
B: REMOVAL S701281A18
1) Perform oil return operation. <Ref. to AC-25

OPERATION, Compressor Oil.>
2) Turn A/C switch OFF and stop the engine.
3) Using refrigerant recovery system, discharge
refrigerant. <Ref. to AC-19 OPERATION, Refriger-
B4M2312
ant Recovery Procedure.>
AC-32
COMPRESSOR
C: INSTALLATION S701281A11

2) Replace O-rings on low-/high-pressure hoses
with new ones, then apply compressor oil.
3) When replacing compressor, adjust amount of
compressor oil. <Ref. to AC-25 Compressor Oil.>
4) Charge refrigerant. <Ref. to AC-20
OPERATION, Refrigerant Charging Procedure.>
AC-33
CONDENSER
13. Condenser S701282

5) Remove 2 bolts. While lifting condenser, pull it
out through the space between the radiator and the
A: REMOVAL S701282A18 radiator panel.
3) Disconnect high-pressure hose (A) and high-
pressure pipe (B) from condenser.
B4M1821
CAUTION:
Be careful not to damage condenser fins. If a
damaged fin is found, repair it using a thin
screwdriver.
If condenser is replaced, add appropriate
S4M0489A amount of compressor oil to the compressor.
<Ref. to AC-25 REPLACEMENT, Compressor
Oil.>

CAUTION:
Replace O-rings on hoses or pipes with new
ones, and then apply compressor oil. Confirm
that lower guide of condenser has been fitted
into holes on radiator panel.
H4M1161B
4) Remove radiator bracket (A).
S4M0490A

B4M1820A
1) Confirm that no dust or insects are found on the

condenser fins. Air-blow or flush fins with water as
needed.
2) Confirm that no oil leaks from condenser. If a
failure is found, replace condenser with a new one.
AC-34
RECEIVER DRIER
14. Receiver Drier S701283

3) Disconnect pressure switch harness (A).
4) Disconnect pipe (B).
5) Loosen mounting bolts (C) to remove receiver
dryer.
H4M1263A
CAUTION:
The receiver drier contains a desiccant. After
disconnecting receiver drier, plug it to avoid
moisture.
If receiver drier is replaced, add appropriate
amount of compressor oil to the compressor.
<Ref. to AC-25 REPLACEMENT, Compressor
Oil.>

CAUTION:
Replace O-rings with new ones, and apply
compressor oil.
AC-35
INTAKE UNIT
15. Intake Unit S701632

7) Remove intake unit mounting bolt and nut.

3) LHD: Remove bolt then disconnect discharge
pipe and suction pipe.
RHD: Disconnect discharge pipe, suction pipe and
grommets.
S4M0502A
S4M0211A
S4M0213A

CAUTION:
Replace O-rings with new ones, and apply
compressor oil.
S4M0212A
S5M0047A
5) Disconnect the harness connector from intake

unit.
6) Disconnect drain hose.
AC-36
INTAKE UNIT
C: DISASSEMBLY S701632A06 2. RHD MODEL S701632A0602
1. LHD MODEL S701632A0601

1) Remove some screws, then separate intake
unit case.
1) Remove thermistor (A) from intake unit case.
2) Remove some screws then separate intake unit
case.
3) Remove thermistor from clip with the evapora-
tor.
S4M0214
2) Remove thermostat (A) from lower case and

then detach evaporator (B).
S4M0215A
3) Disconnect the connection between the expan-

S4M0503A sion valve and pipe from receiver drier.
4) Remove the expansion valve (A) from pipes.
4) Remove the block expansion valve (A) from
pipes.
S4M0216A
S4M0504A CAUTION:
If evaporator is replaced, add appropriate
amount of compressor oil to evaporator. <Ref.
to AC-25 REPLACEMENT, Compressor Oil.>
D: ASSEMBLY S701632A02
Assemble in the reverse order of disassembly.

CAUTION:
Replace O-rings with new ones, and then apply
compressor oil.
AC-37
FLEXIBLE HOSE
16. Flexible Hose S701286
CAUTION:
쐌 When disconnecting/connecting hoses, do
not apply excessive force them. Confirm that
no torsion and excessive tension exist after
installing.
쐌 Seal the disconnected hose with a plug or
vinyl tape to prevent contamination from enter- S4M0217A
ing.
1) Disconnect ground cable from battery. B: INSTALLATION S701286A11
refrigerant. <Ref. to AC-19 OPERATION, Refriger- CAUTION:
ant Recovery Procedure.> When disconnecting/connecting hoses, do not
3) Remove hose attaching bolts (C). apply an excessive force them. Confirm that no
4) Disconnect hose from evaporator unit. torsion and excessive tension exist after
installing. Seal the disconnected hose with a
5) Disconnect hose from compressor.
plug or vinyl tape to prevent contamination
6) Remove low-pressure hose (A) from the
from entering.
vehicle.
7) Remove hose attaching bolts (D). 1) Install in the reverse order of removal.
8) Disconnect hose from compressor. 2) Charge refrigerant. <Ref. to AC-20
9) Disconnect hose from condenser. OPERATION, Refrigerant Charging Procedure.>
10) Disconnect high-pressure hose (B) from the
vehicle. C: INSPECTION S701286A10
NOTE:
If cracking, damage, or swelling is found on a hose,
replace it with a new one.
S4M0494A
AC-38
RELAY AND FUSE
17. Relay and Fuse S701287 B: INSPECTION S701287A10
A: LOCATION S701287A13
B4M2308A
S4M0546A (3) — (4): Continuity exists.

(1) — (2): No continuity
(A) A/C fuse While applying battery voltage to the cable
(B) Main fan relay between (3) and (4), check continuity between (1)
(C) Sub fan relay and (2).
(D) A/C relay If no continuity exists, replace the relay with a new
(E) Main fan fuse one.
(F) Sub fan fuse
AC-39
PRESSURE SWITCH (DUAL SWITCH)
18. Pressure Switch (Dual

Switch) S701555
1) Connect the manifold gauge to the service

valve on the high-pressure side.
2) Remove the pressure switch harness connec-
tor. Using a circuit tester, inspect the ON-OFF
operation of the pressure switch.
G4M0654
Terminal Operation High-pressure side line pressure

Increasing to
2,940±200 kPa (29.98±2.04 kg/cm2, 426.3±29.0 psi): LHD model
Turns OFF. 2,650±200 kPa (27.02±2.04 kg/cm2, 384±29 psi): RHD model
Decreasing to
High and low 177±25 kPa (1.80±0.25 kg/cm2, 25.6±3.6 psi):
1—2
pressure switch Increasing to
Less than 216 kPa (2.2 kg/cm2, 31 psi):
Turns ON. Decreasing to
2,350±200 kPa (23.97±2.04 kg/cm2, 341±29 psi): LHD model
1,471±200 kPa (15±2.04 kg/cm2, 213 ±29 psi): RHD model
AC-40
AIR VENT GRILLE
19. Air Vent Grille S701284 B: INSTALLATION S701284A11
1. CENTER AIR VENT GRILLE S701284A1803 C: INSPECTION S701284A10
1) Remove center panel. The direction and amount of air should be adjusted
2) Loosen screw to remove grille. smoothly.
The adjustment should be kept in each position.
S4M0517
2. SIDE AIR VENT GRILLE S701284A1804
1) Remove grille using sharp-edged screwdriver.
B4M2314
CAUTION:
Wrap screwdriver with vinyl tape to prevent
damage to interior parts.
AC-41
HEATER DUCT
20. Heater Duct S701556
1) Remove front seat. <Ref. to SE-5 REMOVAL,

Front Seat.>
2) Remove heater unit. <Ref. to AC-26
REMOVAL, Heater Unit.>
3) Remove front side sill cover.
4) Pull off floor mat to remove heater duct.
S4M0518
AC-42
HEATER VENT DUCT
21. Heater Vent Duct S701557

2) Remove screws.
3) Remove heater vent duct.

REMOVAL, Instrument Panel.>
S4M0519
AC-43
GENERAL DIAGNOSTICS
22. General Diagnostics S701278
Symptom Repair order

Fuse
Blower motor relay
Blower motor
Doesn’t move.
Blower motor Blower motor resister
Blower switch
Wire harness
Strange noise. Blower motor
Refrigerant
Fuse
Air conditioning relay
Magnet clutch
Doesn’t move. Compressor
Pressure switch
Compressor
A/C switch
Blower switch
Wire harness
V-Belt
Strange noise Magnet clutch
Compressor
Refrigerant
V-Belt
Magnet clutch
Compressor
Pressure switch
Cold air not emitted.
A/C switch
Blower switch
Wire harness
Heater duct
Heater vent duct
Engine coolant
Warm air not emitted. Blower switch
Heater core
Engine coolant
Temperature of air from vents does not change. Mode actuator
Wire harness
Mode actuator
Unable to switch blow vents. Air flow switch
Wire harness
Air inlet select switch
Unable to switch suction vents. FRESH/RECIRC actuator
Wire harness
AC-44
BODY SECTION

SUBARU vehicles.
ine parts.

G8050GE6
AIRBAG SYSTEM
AB
Page
2. Airbag Connector ........................................................................................8
3. Inspection Locations After a Collision .......................................................10
4. Driver’s Airbag Module ..............................................................................12
5. Passenger’s Airbag Module ......................................................................14
6. Side Airbag Module ...................................................................................15
7. Main Harness ............................................................................................16
8. Side Airbag Harness .................................................................................17
9. Airbag Control Module ..............................................................................18
10. Side Airbag Sensor ...................................................................................19
11. Roll Connector...........................................................................................20
12. Front Sub Sensor ......................................................................................21
13. Front Sub Sensor Harness .......................................................................22
14. Disposal of Airbag Module (Deploying While Installed in Vehicle) ...........23
15. Disposal of Airbag Module (Deploying After Removal from Vehicle) .......27
GENERAL DESCRIPTION
Airbag System
A: COMPONENT S802001A05
1. SRS AIRBAG S802001A0501
S5M0418A
(1) Combination switch ASSY with (8) Side airbag module Tightening torque: N·m (kgf-m, ft-lb)
roll connector (9) Side airbag harness (RH)
T1: 4.4 (0.45, 3.3)
(2) TORX姞 bolt T30 (10) Side airbag harness (LH)
T2: 7.4 (0.75, 5.4)
(3) Airbag module ASSY (Driver) (11) Airbag main harness
T3: 10 (1.0, 7.2)
(4) Airbag module ASSY (Passen- (12) Front sub sensor (RH)
ger) (13) Front sub sensor harness (RH) T4: 20 (2.0, 14.5)
(5) Airbag control module (14) Front sub sensor harness (LH) T5: 25 (2.5, 18.1)
(6) TORX姞 bolt T40 (15) Front sub sensor (LH)
(7) Side airbag sensor
AB-2
GENERAL DESCRIPTION
Airbag System
B: CAUTION S802001A03 쐌 When checking, use a test harness. Do not

directly apply the tester probe to any connector
쐌 When servicing a vehicle, be sure to turn the terminal of the airbag.
ignition switch OFF, disconnect the ground cable
from the battery, and wait for more than 20 sec-
onds before starting work.
쐌 The airbag system is fitted with a backup power
source. If the airbag system is serviced within 20
seconds after the ground cable is disconnected, it
may inflate.
G5M0293
G5M0292
쐌 If sensors, airbag module, airbag control module

and harness are deformed or damaged, replace
them with new genuine parts.
G5M0291
쐌 Do not use the airbag parts from other vehicles. G5M0294
Always replace defective parts with new parts.

쐌 Do not check continuity of the driver, passenger
쐌 Never re-use a deployed airbag.
and side airbag modules.
쐌 When checking the system, be sure to use a
digital circuit tester.
Use of an analog circuit tester may cause the air-
bag to activate erroneously.
G5M0302
AB-3
GENERAL DESCRIPTION
Airbag System
쐌 Do not allow water or oil to come in contact with 쐌 Install the wire harness securely with the speci-
the connector terminals. Do not touch the connec- fied clips to avoid interference or tongled up with
tor terminals. other parts.
G5M0298 G5M0297
쐌 Either of the airbag modules for driver, passen- 쐌 When painting or performing sheet metal work
ger or side, must not be disassembled. on the front part of the vehicle, including the front
wheel apron, front fender, and front side frame,
remove the front sub sensors and wire harness of
the airbag system.
쐌 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.
G5M0299
쐌 If any damage, opening, or rust is found on the

airbag system wire harness, do not attempt to
repair using soldering equipment. Be sure to
replace the faulty harness with a new genuine part.
G5M0310
G5M0296
AB-4
GENERAL DESCRIPTION
Airbag System
쐌 Do not drop the airbag modulator parts, subject 쐌 The removed front seat with the airbag module
them to high temperature over 93°C (199°F), or let must be kept at least 200 mm (8 in) away from
water, oil, or grease get on them; otherwise, the walls and other objects.
internal parts may be damaged and reliability
greatly lowered.
B5M1072A
쐌 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
reason when it is placed with its pad side facing
downward or under any object, a serious accident
may result.
G5M0295
AB-5
GENERAL DESCRIPTION
Airbag System
G5M0604
AB-6
GENERAL DESCRIPTION
Airbag System
C: PREPARATION TOOL S802001A17
1. SPECIAL TOOLS S801001A1703
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

98299FC030 DEPLOYMENT 쐌 Used for deploying the airbag module.
ADAPTER A 쐌 Used with DEPLOYMENT TOOL
(98299PA030).
B5M1114
98299PA030 DEPLOYMENT 쐌 Used for deploying the airbag module.
TOOL 쐌 Used with DEPLOYMENT ADAPTER A
(98299FC030).
B5M1115
2. GENERAL TOOL S802001A1701
TOOL NAME REMARKS

TORX姞 T30 Used for removal/installation of drivers airbag module
TORX姞 T40 (Tamper resistant type) Used for removal/installation of airbag control module
AB-7
AIRBAG CONNECTOR
Airbag System
2. Airbag Connector S802659

쐌 How to connect:
Holding the connector, and push it in carefully until
a connecting sound is heard.
1. DRIVER’S AIRBAG, PASSENGER’S CAUTION:
AIRBAG, SIDE AIRBAG S802659A1605 Be sure to insert the connector in until it locks.
쐌 How to disconnect: Then pull on it gently to make sure that it is
locked.
1) Push lock arm (A).
2) With lock arm (A) pushed in, move slide lock (B)
in the direction of the arrow.
B5M1155
B5M1153A
2. FRONT SUB-SENSOR, SIDE AIRBAG
SENSOR S802659A1603
3) With slide lock (B) pulled, remove lock arm (A)
to its original position, and then pull in the direction 쐌 How to disconnect:
of the arrow and separate the connector. 1) Holding outer part (A), pull it in the direction of
CAUTION: the arrow.
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.
B5M1154
RE0014
AB-8
AIRBAG CONNECTOR
Airbag System
쐌 How to connect:
CAUTION:
쐌 Outer (A) moves back, and so do not put
your hand on the outer part.
쐌 Be sure to insert the connector in until it
locks. Then pull on it gently to make sure that
it is locked.
RE0015
AB-9
INSPECTION LOCATIONS AFTER A COLLISION
Airbag System
3. Inspection Locations After a 4. AIRBAG CONTROL MODULE S802306A1004
Collision S802306
Check for the following, and replace damaged
parts with new parts.
A: INSPECTION S802306A10 쐌 Control module is cracked or deformed.
If the vehicle is involved in a collision on any side, 쐌 Mounting bracket is cracked or deformed.
even if it is a slight collision, be sure to check the 쐌 Connector is scratched or deformed.
following system parts. 쐌 Airbag is deployed.
쐌 Side airbag is deployed.
1. AIRBAG MODULE (DRIVER) S802306A1001
5. FRONT SUB SENSOR S802306A1005
1) Check for the following, and replace damaged
parts with new parts. If the front section of vehicle as shown in the fig-
쐌 Airbag module is cracked or deformed. ure is damaged:
쐌 Harness and/or connector is cracked, deformed
or open. Lead wire is exposed.
2) When installing a new driver’s airbag module,
check the following. If necessary, install a new air-
bag module and steering wheel.
쐌 The steering wheel is in the way, making it diffi-
cult to install the airbag module.
쐌 The clearance between the driver’s airbag mod-
ule and steering wheel is not constant.
쐌 When steering wheel deformation in axial and
radial directions exceed limits. G5M0311
Deformation limit:
Axial direction play A
Less than 6 mm (0.24 in) parts with new parts.
Radial direction play L 쐌 Front sub sensor is cracked or deformed.
Less than 7 mm (0.28 in) 쐌 Mounting bracket is cracked or deformed.
쐌 Connector is scratched or cracked.
쐌 Airbag is deployed.
6. FRONT SUB SENSOR HARNESS S802306A1006

쐌 Harness is open, lead wire is exposed, and cor-
rugated tube is noticeably cracked.
B5M0096A
2. AIRBAG MODULE (PASSENGER) S802306A1002

쐌 Airbag module is cracked or deformed.
or open. Lead wire is exposed.
쐌 Mounting bracket is cracked or deformed.
3. AIRBAG MODULE (SIDE) S802306A1003

쐌 Front seat is damaged or deformed.
or open.
쐌 Lead wire is exposed.
AB-10
Airbag System
7. SIDE AIRBAG SENSOR S802306A1007 11. STEERING SHAFT S802306A1011
If the side section of vehicle as shown in the figure Check for the following, and replace damaged
is damaged: parts with new parts.
The clearance between capsule (A) and tip of col-
umn bracket (B) on steering column upper side
should be within specifications.
Specifications:
Clearance of expand plate: L
More than 15 mm (0.59 in)
B5M0514

쐌 Side airbag sensor is cracked or deformed.
쐌 Mounting bracket is cracked or deformed.
쐌 Side airbag is deployed. (operating side)
8. SIDE AIRBAG SENSOR HARNESS
S802306A1008

9. MAIN HARNESS S802306A1009
S5M0213B
parts with new parts. If necessary, replace them with new parts.
10. ROLL CONNECTOR S802306A1010

쐌 Combination switch or steering roll connector is
cracked or deformed.
AB-11
DRIVER’S AIRBAG MODULE
Airbag System
4. Driver’s Airbag Module S802307

Do not check continuity of the airbag module
(driver, passenger, and side).
A: CAUTION S802307A03
When disconnecting and connecting the airbag

connector, be sure to turn the ignition switch OFF,
disconnect the ground cable from the battery, and
wait for more than 20 seconds before starting
work.
G5M0302
Do not use the airbag system and pretensioners on

other vehicles. When replacing parts, be sure to
replace them with new parts.
G5M0292
1) Position front wheels straight ahead. (After
The airbag module (driver, passenger, and side) moving a vehicle more than 5 m (16 ft) with front
must not be disassembled. wheels positioned straight ahead, make sure that
The airbag module cannot be used again once the vehicle moves straight ahead).
inflated. 2) Turn ignition switch OFF.
3) Disconnect the ground cable from the battery,
and wait for at least 20 seconds before starting
work.
4) Using TORX姞 BIT T30, remove two TORX姞
bolts on side of steering wheel.
G5M0299
After removal, keep the airbag module with the pad

facing upward on a dry, clean, and flat surface
away from heat and light sources, and moisture
and dust. H5M0662A
5) Disconnect airbag connector on back of airbag

module, and then remove airbag module.
G5M0301
H5M0664
AB-12
DRIVER’S AIRBAG MODULE
Airbag System
6) Refer to “CAUTION” for handling of a removed

airbag module. <Ref. to AB-3 CAUTION, General
Description.>

CAUTION:
Do not allow harness and connectors to inter-
fere or get tangled up with other parts.
D: INSPECTION S802307A10

쐌 Airbag module, harness, connector, and mount-
ing bracket are damaged.
AB-13
PASSENGER’S AIRBAG MODULE
Airbag System
5. Passenger’s Airbag Module Do not check continuity of the airbag module

(driver, passenger, and side) with airbag removed
S802308
from the vehicle.
When disconnecting and connecting the airbag

work.
G5M0302
1) Turn ignition switch OFF.

G5M0292 work.
The airbag module (driver, passenger, and side)
Glove Box.>
must not be disassembled. 4) Detach airbag connector from support beam
The airbag module cannot be used again once bracket, and then disconnect airbag connector.
inflated. 5) Remove seven bolts, and then carefully remove
airbag module.
G5M0299
S5M0215
After removal, keep the airbag module with the pad
facing upward on a dry, clean, and flat surface 6) Refer to “CAUTION” for handling of a removed
away from heat and light sources, and moisture airbag module. <Ref. to AB-3 CAUTION, General
and dust. Description.>

CAUTION:
Do not allow harness and connectors to inter-
fere or get tangled up with other parts.

G5M0301
쐌 Airbag module, harness, connector, and mount-
ing bracket are damaged.
AB-14
SIDE AIRBAG MODULE
Airbag System
6. Side Airbag Module S802311

The removed front seat with the airbag module
must be kept at least 200 mm (8 in) away from
A: CAUTION S802311A03 walls and other objects.
When disconnecting and connecting airbag
work.
B5M1072A
CAUTION:
쐌 The side airbag module cannot be detached
G5M0292 from the front seat assembly.
쐌 When replacing side airbag module, replace
The airbag module (driver, passenger, and side)
front seat assembly.
must not be disassembled.
<Ref. to SE-5 REMOVAL, Front Seat.>
The airbag module cannot be used again once
inflated. C: INSTALLATION S802311A11
<Ref. to SE-5 INSTALLATION, Front Seat.>

쐌 Front seat is deformed or damaged.
or open.
쐌 Lead wire is exposed.
G5M0299
Do not check continuity of the airbag module

(driver, passenger, and side) with airbag removed
from the vehicle.
G5M0302
AB-15
MAIN HARNESS
Airbag System
7. Main Harness S802310 B: INSTALLATION S802310A11
1) Turn ignition switch OFF. C: INSPECTION S802310A10
2) Disconnect the ground cable from the battery

work. 쐌 Harness and/or connector is damaged.
REMOVAL, Instrument Panel Assembly.>
4) Disconnect connector from airbag control mod-
ule.
S5M0216
5) Disconnect body harness connector (B31) from

airbag connector (ABI) located at front pillar lower
(driver side).
S5M0217A
6) Disconnect front sub sensor connector (yellow)

from airbag main harness located at front pillar
(both sides).
7) Detach clips (A) from steering support beam,
and remove main harness.
H5M0933B
AB-16
SIDE AIRBAG HARNESS
Airbag System
8. Side Airbag Harness S802309

work.
3) Remove front seat. <Ref. to SE-5 REMOVAL,
Front Seat.>
5) Roll up floor mat, and then disconnect two
12-pin yellow connectors from airbag control mod-
ule.
6) Disconnect connector from side airbag sensor.
<Ref. to AB-19 REMOVAL, Side Air Bag Sensor.>
7) Detach clips, and then remove side airbag har-
ness.
S5M0307

쐌 Harness and/or connector is damaged.
AB-17
AIRBAG CONTROL MODULE
Airbag System
9. Airbag Control Module S802302
CAUTION:
쐌 Do not disassemble the airbag control mod-
ule.
쐌 If the airbag control module is deformed or if
water damage is suspected, replace the airbag
control module with a new genuine part.
쐌 Do not drop the airbag control module.
쐌 After removal, keep the airbag control mod-
ule on a dry, clean surface away from moisture,
heat, and dust.
work.
3) Remove console box. <Ref. to EI-30 Removal,
CONSOLE BOX.>
4) Disconnect connector from airbag control mod-
ule.
5) Using T40姞 TORX bit (Tamper resistant type),
remove four TORX姞 bolts in the order shown in the
figure.
S5M0219A
CAUTION:
Use new TORX姞 bolts during installation.

쐌 Control module, connector, and mounting
bracket are damaged.
쐌 Airbag is deployed.
쐌 Side airbag is deployed.
AB-18
SIDE AIRBAG SENSOR
Airbag System
10. Side Airbag Sensor S802298 C: INSPECTION S802298A10
1) Turn ignition switch OFF. 쐌 Bracket connector for side airbag sensor is dam-
2) Disconnect the ground cable from the battery, aged.
work.
3) Remove center pillar lower trim. <Ref. to EI-38,
REMOVAL, Lower Inner Trim.>
4) Remove Outer Belt (FRONT). <Ref. to SB-6,
OUTER BELT (FRONT), REMOVAL, Front Seat
Belt.>
5) Remove two TORX姞 bolts, and then detach
side airbag sensor.
S5M0308
CAUTION:
Use new TORX姞 nuts during installation.
AB-19
ROLL CONNECTOR
Airbag System
11. Roll Connector S802299 B: INSTALLATION S802299A11
1) Install combination switch assembly and steer-
ing column cover in the reverse order of removal.
1) Turn ignition switch OFF. 2) Adjust centering roll connector. <Ref. to AB-20
2) Disconnect the ground cable from the battery, ADJUSTMENT, Roll Connector.>
and wait for at least 20 seconds before starting 3) Install steering wheel and airbag module.
work.
3) Remove instrument panel lower cover. C: INSPECTION S802299A10
4) Disconnect airbag connector (AB3) and (AB8) Check for the following, and replace damaged
below steering column. parts with new parts.
쐌 Combination switch and roll connector is
cracked or deformed.
1) Check that front wheels are positioned in

straight ahead direction.
2) Turn roll connector pin (A) clockwise until it
stops.
3) Turn roll connector pin (A) counterclockwise
approximately 2.65 turns until “왖” marks are
G5M0312
aligned.
5) Remove driver’s airbag module. <Ref. to
AB-12, Driver’s Airbag Module.>
6) Remove steering wheel. <Ref. to PS-27,
REMOVAL, Steering Wheel.>
7) Remove steering column cover.
8) Remove screws, and then remove combination
switch assembly.
H5M0663B
S5M0220
9) Remove lighting switch and wiper switch from

roll connector.
B5M0940
AB-20
FRONT SUB SENSOR
Airbag System
12. Front Sub Sensor S802300

work.
3) Remove front wheel and mud guard. <Ref. to
EI-21 REMOVAL, Mud Guard.>
4) Disconnect connector from front sub sensor.
S5M0335
5) Remove front sub sensor.
S5M0336

쐌 Front sub sensor, mounting bracket, and con-
nector are damaged.
AB-21
FRONT SUB SENSOR HARNESS
Airbag System
13. Front Sub Sensor Harness B: INSTALLATION S802572A11
S802572
2) Disconnect the ground cable from the battery, Check for the following, and replace damaged
and wait for at least 20 seconds before starting parts.
work. 쐌 Harness and/or connector is damaged.
3) Remove front side sill cover, and then discon-
nect front sub sensor connector.
B5M0517
4) Disconnect connector from front sub sensor.

<Ref. to AB-21 REMOVAL, Front Sub Sensor.>
5) Remove wiring harness clips.
G5M0315
6) Remove grommet, and then detach front sub

sensor harness.
G5M0316
AB-22
DISPOSAL OF AIRBAG MODULE (DEPLOYING WHILE INSTALLED IN
VEHICLE)
Airbag System
14. Disposal of Airbag Module 5) Short terminal to alligator clip furnished as

deployment tool (ST1).
(Deploying While Installed in 6) Connect the deployment tool (ST1) and deploy-
Vehicle) S802573 ment adapter (ST2).
ST1 98299PA030 DEPLOYMENT TOOL
ST2 98299FC030 DEPLOYMENT ADAPTER
CAUTION: A
쐌 Do not discard undeployed airbag module CAUTION:
because it may cause serious personal injury The deployment tool should be kept shorted
when accidentally deployed. until just before deployment of the airbag mod-
쐌 As a rule, the airbag module should be ule.
deployed while still installed in the vehicle. Do
not remove it unless necessary.
쐌 Deployment of the airbag module should be
done on a flat place free from any possible dan-
ger. Avoid deploying outdoors during rainy or
windy weather.
쐌 Because deploying the airbag module
causes a high explosive noise, be sure to warn
people in the area, and do not allow anyone
within a 5 m (16 ft) radius of the disposal site.
쐌 Some smoke will be emitted from deploy- S5M0309C
ment of the airbag module. Therefore, it must
be deployed in a well-ventilated place with no 7) Connect deployment adapter (ST2) connector
fire alarms nearby. (2D) to airbag connector (AB3).
쐌 Wear gloves, goggles, and earplugs during
this operation. Wash your hands afterwards.
쐌 After deployment, the airbag module will be
especially hot. Leave it unattended for 40
minutes, and then discard it.
쐌 Do not let water get on the deployed airbag
module.
쐌 Wrap the deployed airbag module in an air-
tight vinyl bag, and discard it.
쐌 If circumstances do not permit airbag mod-
ule deployment, contact a Subaru dealer. S5M0310A
8) Extend the deployment tool to the limit, and
1) Turn ignition switch OFF. make sure that the vehicle is empty. Close all
2) Disconnect the ground cable from the battery, windows, sunroof, and rear gate completely.
work.
3) Remove lower cover.
4) Disconnect airbag connector (AB3) and (AB8)
below steering column.
B5M1068
9) Move the battery at least 5 m (16 ft) from

vehicle, and secure the nearby area. Connect the
deployment tool alligator clip to the battery minus
G5M0312 terminal.
AB-23
VEHICLE)
Airbag System
10) Connect the other terminal of the deployment CAUTION:

tool to the battery plus terminal. Then, deploy the The deployment tool should be kept shorted
airbag module. until just before deployment of the airbag mod-
ule.
G5M0531
S5M0309C
CAUTION:
쐌 After deployment, the airbag module will be 7) Connect deployment adapter (ST2) connector
especially hot. Leave it unattended for 40 (2D) to airbag connector (AB10).
module.
11) Remove airbag module. <Ref. to AB-12 Driv-
er’s Airbag Module.>
12) Wrap the deployed airbag module in an air-
S5M0311A

make sure that the vehicle is empty. Close all
windows, sunroof, and rear gate completely.
G5M0532

work. B5M1068
3) Remove the glove box. <Ref. to EI-28,
REMOVAL, Glove Box.> 9) Move the battery at least 5 m (16 ft) from
4) Disconnect airbag connectors (AB9) and vehicle, and secure the nearby area. Connect the
(AB10). deployment tool alligator clip to the battery minus
5) Short terminal to alligator clip furnished as terminal.
6) Connect the deployment tool (ST1) and deploy-
ment adapter (ST2).
A
AB-24
VEHICLE)
Airbag System
10) Connect the other terminal of the deployment CAUTION:

tool to the battery plus terminal. Then, deploy the The deployment tool should be kept shorted
airbag module. until just before deployment of the airbag mod-
ule.
G5M0531
S5M0309C
CAUTION:
쐌 After deployment, the airbag module will be 7) Connect deployment adapter (ST2) connector
especially hot. Leave it unattended for 40 (2D) to side airbag module connector (yellow).
minutes, and then discard it. CAUTION:
쐌 Do not let water get on the deployed airbag Do not put any objects on the front seat.
module.
11) Remove airbag module. <Ref. to AB-14 Pas-
senger’s Airbag Module.>
S5M0313A

make sure that the vehicle is empty. Close all
windows, sunroof, and rear gate completely.
G5M0532

work.
3) Disconnect the side airbag module connector
(yellow) under the front seat cushion.
B5M1068
4) Adjust both the front seat and front seat back-
rest to center positions. 9) Move the battery at least 5 m (16 ft) from
5) Short terminal to alligator clip furnished as vehicle, and secure the nearby area. Connect the
deployment tool (ST1). deployment tool alligator clip to the battery minus
6) Connect the deployment tool (ST1) and deploy- terminal.
ment adapter (ST2).
A
AB-25
VEHICLE)
Airbag System
10) Connect the other terminal of the deployment

tool to the battery plus terminal. Then, deploy the
airbag module.
G5M0531
CAUTION:
module.
11) Remove side airbag module.
G5M0532
AB-26
DISPOSAL OF AIRBAG MODULE (DEPLOYING AFTER REMOVAL FROM
VEHICLE)
Airbag System
15. Disposal of Airbag Module 5) Bundle three wire automotive harnesses [each
with a sectional area of 1.25 mm2 (0.00194 sq in)
(Deploying After Removal from or more], and bind them twofold around the airbag
Vehicle) S802574 module stay.
CAUTION:
쐌 Do not discard undeployed airbag module
because it may cause serious personal injury
when accidentally deployed.
쐌 As a rule, the airbag module should be
deployed while still installed in the vehicle. Do
not remove it unless necessary.
쐌 Deployment of the airbag module should be
done on a flat place free from any possible dan- H5M0736
ger. Avoid deploying outdoors during rainy or
windy weather. 6) Short terminal to alligator clip furnished as
쐌 Do not damage the airbag module or drop it. deployment tool (ST1).
쐌 Because deploying the airbag module 7) Connect the deployment tool (ST1) and deploy-
causes a high explosive noise, be sure to warn ment adapter (ST2).
people in the area, and do not allow anyone ST1 98299PA030 DEPLOYMENT TOOL
within a 5 m (16 ft) radius of the disposal site. ST2 98299FC030 DEPLOYMENT ADAPTER
쐌 Some smoke will be emitted from deploy- A
ment of the airbag module. Therefore, it must
be deployed in a well-ventilated place with no CAUTION:
fire alarms nearby. The deployment tool should be kept shorted
쐌 Wear gloves, goggles, and earplugs during until just before deployment of the airbag mod-
this operation. Wash your hands afterwards. ule.
module.
쐌 Wrap the deployed airbag module in an air-
쐌 If circumstances do not permit airbag mod-
ule deployment, contact a Subaru dealer.
S5M0309C
2) Disconnect the ground cable from the battery, 8) Connect deployment adapter (ST2) connector
and wait for at least 20 seconds before starting (2D) to airbag module.
work. 9) Install airbag module with pad side facing
3) Remove airbag module. <Ref. to AB-12 Driver’s upward on the wheel with the tire.
Airbag Module.>
4) Install the removed bolts to airbag module.
G5M0535
H5M0735
AB-27
VEHICLE)
Airbag System
10) Put three tires without the wheel on the tire 13) Wrap the deployed airbag module in an air-
installed with the airbag module. Put on an addi- tight vinyl bag, and discard it.
tional tire with the wheel, and then fasten them
tight with rope.
G5M0532
G5M0536
11) Move the battery at least 5 m (16 ft) from 1) Turn ignition switch OFF.
vehicle, and secure the nearby area. Connect the 2) Disconnect the ground cable from the battery,
deployment tool alligator clip to the battery minus and wait for at least 20 seconds before starting
terminal. work.
3) Remove airbag module. <Ref. to AB-14 Pas-
senger’s Airbag Module.>
4) Bundle three wire automotive harnesses [each
or more], and route them through the airbag mod-
ule bracket (A). Then, twist them for added
strength.
G5M0537

airbag module.
S5M0312A
5) Short terminal to alligator clip furnished as

ment adapter (ST2).
G5M0531 A
CAUTION:
module.
AB-28
VEHICLE)
Airbag System
CAUTION: 10) Move the battery at least 5 m (16 ft) from

The deployment tool should be kept shorted vehicle, and secure the nearby area. Connect the
until just before deployment of the airbag mod- deployment tool alligator clip to the battery minus
ule. terminal.
S5M0309C G5M0537
7) Connect deployment adapter (ST2) connector 11) Connect the other terminal of the deployment
(2D) to airbag module. tool to the battery plus terminal. Then, deploy the
8) Install airbag module with pad side facing airbag module.
upward on 14 inch or greater size wheel with the
tire.
G5M0531
CAUTION:
G5M0613
9) Put three tires without the wheel on the tire especially hot. Leave it unattended for 40
installed with the airbag module. Put on an addi- minutes, and then discard it.
tional tire with the wheel on top, and then fasten 쐌 Do not let water get on the deployed airbag
them tight with rope. module.
G5M0536
G5M0532

work.
AB-29
VEHICLE)
Airbag System
3) Remove front seat. <Ref. to SE-5 REMOVAL, 10) Install side airbag module on 14 inch or
Front Seat.> greater size tire without disk wheel.
4) Remove side airbag module.
5) Install nuts to side airbag module.
6) Bundle three wire automotive harnesses [each
or more], and bind them twofold around the airbag
module stay.
S5M0317
Put two tires without the wheel (A) under the tire
installed with the side airbag module (B). Put on an
additional tire without disk wheel (C), and then put
a tire with the wheel (D) on top. Fasten them tight
S5M0316
with rope.
7) Short terminal to alligator clip furnished as

ment adapter (ST2).
A
CAUTION:
The deployment tool should be kept shorted
B5M0768A
until just before deployment of the airbag mod-
ule. 11) Move the battery at least 5 m (16 ft) from the
vehicle, and secure the nearby area. Connect the
deployment tool alligator clip to the battery minus
terminal.
S5M0309C
9) Connect deployment adapter (ST2) connector

(2D) to airbag module.
G5M0537
AB-30
VEHICLE)
Airbag System

airbag module.
G5M0531
CAUTION:
module.
G5M0532
AB-31
VEHICLE)
Airbag System
MEMO:
AB-32
BODY SECTION

SUBARU vehicles.
ine parts.

G8050GE6
SEAT BELT SYSTEM
SB
Page
2. Inspection Locations After a Collision ........................................................5
3. Front Seat Belt ............................................................................................6
4. Rear Seat Belt.............................................................................................8
5. Disposal of Pretensioner ...........................................................................10
GENERAL DESCRIPTION
Seat Belt System
1. FRONT SEAT BELT S801001A0501
S5M0301A
(1) Adjuster anchor ASSY (5) Outer belt ASSY Tightening torque: N·m (kgf-m, ft-lb)
(2) Anchor cover
T1: 7.5 (0.76, 5.5)
(3) Webbing guide
T2: 30 (3.1, 22)
(4) Inner belt ASSY
SB-2
GENERAL DESCRIPTION
Seat Belt System
2. REAR SEAT BELT S801001A0504
S5M0505A
(1) Outer seat belt RH (5) Outer seat belt CENTER Tightening torque: N·m (kgf-m, ft-lb)
(2) Outer seat belt LH (6) Anchor cover
T1: 7.5 (0.76, 5.5)
(3) Inner seat belt LH (7) Adjustable anchor ASSY
T2: 30 (3.1, 22)
(4) Inner seat belt RH
SB-3
GENERAL DESCRIPTION
Seat Belt System
B: CAUTION S801001A03
쐌 Before removing pretensioner, be sure to rotate

while pulling the safety lever to the right until it
stops to set the lock position.
S5M0304A
쐌 Do not drop or apply any impact to the preten-

sioner.
쐌 If oil, grease, or water gets on the pretensioner,
wipe it off immediately with a dry cloth.
쐌 Do not expose the pretensioner to high tempera-
ture or flame.
쐌 Do not disassemble or attempt to repair the pre-
tensioner. If it is dented, cracked, or deformed,
replace it with a new one.
쐌 Do not use the pretensioner parts from other
vehicles. Always replace parts with new parts
쐌 When handling a seat belt with a deployed
pretensioner, wear gloves and goggles. Wash your
hands afterwards.
쐌 Do not re-use a seat belt with a deployed pre-
tensioner again.
쐌 Be sure to deploy pretensioner before disposal.
<Ref. to SB-10 OPERATION Disposal of Preten-
sioner.>
쐌 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-4
Seat Belt System
2. Inspection Locations After a

Collision S801306
Check for the following, and then replace with new

parts if necessary.
쐌 Center pillar lower garnish is discolored or
cracked.
쐌 Wire harness and/or connector is damaged.
SB-5
FRONT SEAT BELT
Seat Belt System
3. Front Seat Belt S801303

5) Remove webbing guide.
1. OUTER BELT (FRONT) S801303A1807
1) Fold backrest all the way forward, and then

move front seat all the way forward.
2) Remove anchor cover and shoulder anchor bolt
(A).
3) Remove center pillar cover (B) and center pillar
lower trim. <Ref. to EI-38 REMOVAL, Lower Inner
Trim.> S5M0233
S5M0231B
G5M0653
4) Rotate while pulling the safety lever to the right
until it stops, then set the lock position. 6) Remove lap anchor bolt.
7) Remove belt retractor and outer belt.
CAUTION:
Once undeployed pretensioner has been
removed from the vehicle body, do not move
the safety lever until re-installation.
S5M0232
CAUTION:
쐌 Do not drop or apply any impact to preten-
sioner.
쐌 Pretensioner and bracket should be treated
as an assembly. Do not attempt to disassemble
it.
S5M0304A
SB-6
FRONT SEAT BELT
Seat Belt System
2. INNER BELT (FRONT) S801303A1802
1) Disconnect connector.
2) Remove anchor bolt, and then detach inner
belt.
S5M0234

CAUTION:
쐌 The parts on left and right are not identical.
Before installation, make sure that the correct
part is used.
쐌 Be careful not to twist belts during installa-
tion.
Check for the following, and replace with new parts

if necessary.
쐌 Pretensioner is cracked or deformed.
쐌 Seat belt is slackened, bent, or frayed. Seat belt
is abnormally wound or extended.

if necessary.
쐌 Inner belt is deformed or damaged.
쐌 Seat belt buckle is engaged improperly.
SB-7
REAR SEAT BELT
Seat Belt System
4. Rear Seat Belt S801304

3. OUTER BELT CENTER S801304A1811
CAUTION:
When removing clip, use great care not to dam-
1. OUTER BELT SIDE S801304A1809 age the roof trim.
1) Remove rear seat. <Ref. to SE-6 REMOVAL, 1) Remove rear rail trim (I).
Rear Seat.> 2) Remove strut cover (J).
2) Remove side sill rear upper cover. <Ref. to 3) Remove rear outer belt side anchor bolt.
EI-38 REMOVAL, Lower Inner Trim.> 4) Remove caps and screws then remove rear
3) Remove quarter trim. <Ref. to EI-39 quarter upper trim (H).
REMOVAL, Rear Quarter Trim.>
4) Remove bolts, then detach outer belt side.
S5M0236
2. INNER BELT S801304A1810
1) Remove the rear cushion. <Ref. to SE-6

REMOVAL, Rear Seat.>
2) Remove bolts, and then detach inner belt.
B5M1037A
5) Remove cover (B) while detaching snap lock

carefully. Put the outer belt center tongue (A) out
to the other side of the trim through the hole.
S5M0408
B5M0675A
6) Remove clips and hang down rear end of roof

trim.
SB-8
REAR SEAT BELT
Seat Belt System
7) Disconnect harness and connector, and then C: INSPECTION S801304A10
remove outer belt center assembly.

1. OUTER BELT SIDE S801304A1009

if necessary.
is abnormally wound or extended.

if necessary.
S5M0411 is abnormally wound or extended.
B: INSTALLATION S801304A11 Check for the following, and replace with new parts
1. OUTER BELT SIDE S801304A1109
if necessary.
쐌 Inner belt is deformed or damaged.
Install in the reverse order of removal. 쐌 Seat belt buckle is engaged improperly.
CAUTION:
쐌 During installation, make sure that seat belts
are not twisted.
쐌 After installation, make sure that seat belts
can be smoothly extended and wound.

CAUTION:
쐌 During installation, make sure that seat belts
are not twisted.
쐌 After installation, make sure that seat belts
can be smoothly extended and wound.

CAUTION:
During installation, make sure that seat belts
are not twisted.
SB-9
DISPOSAL OF PRETENSIONER
Seat Belt System
5. Disposal of Pretensioner S801305 B: OPERATION S801305A16
1) Rotate while pulling the safety lever to the right
until it stops, then set the lock position.
쐌 Do not discard undeployed pretensioners,
because they may cause serious personal injury
when accidentally deployed.
쐌 Deployment of the pretensioners should be
done on a flat place free from any possible danger.
Avoid deploying outdoors during rainy or windy
weather.
쐌 Do not drop or damage pretensioner.
쐌 Because deploying the pretensioners causes a
high-explosive noise, be sure to warn people in the
area, and do not allow anyone within a 5-meter (16
ft) radius of the disposal site.
쐌 Some smoke will be emitted after deployment of
the pretensioners. Therefore, it must be deployed
in a well-ventilated area with no smoke alarms
nearby.
쐌 Wear gloves, goggles, and earplugs during this
operation. Wash your hands afterwards.
쐌 After deployment, the pretensioner is especially
hot. Leave it unattended for 40 minutes, and then
discard it.
쐌 Do not let water get on the deployed preten-
sioner. S5M0304A
쐌 Wrap the deployed the pretensioner in an air-
tight vinyl bag, and then discard it. 2) Remove outer belt (FRONT). <Ref. to SB-6
OUTER BELT (FRONT), REMOVAL, Front Seat
Belt.>
3) Mark an arrow on pretensioner which indicates
vehicle front.
WARNING:
Never move the safety lever of pretensioner
until instructed to do so.
B5M0493
SB-10
Seat Belt System
4) Cut the webbing of the pretensioner. 7) Rotate while pulling the safety lever to the left
until it stops, then set the unlock position.
CAUTION:
Pay careful attention not to apply impact to the
pretensioner with its safety system unlocked. It
may deploy even with a slight impact.
B5M0494
5) Tie the pretensioner with a rope of a minimum

6 m (20 ft) so that the arrow on the pretensioner
faces downward.
B5M0495
6) Pile three tires without disc wheels on a flat and S5M0304A

rigid floor. Softly place the pretensioner in the tires
with the arrow facing downward. 8) Put a tire with disk wheel on the three tires so
that the rope comes out of the wheel center as
shown in the figure. Then, fix the four tires with
another rope.
WARNING:
Pay careful attention not to apply impact to the
pretensioner with its safety system unlocked. It
may deploy even with a slight impact.
B5M0496
B5M0498
SB-11
Seat Belt System
9) Pull the rope on the pretensioner from a mini-

mum 5 m (16 ft) away from the tires so that the
pretensioner is lifted a minimum 400 mm (15.75 in)
from the floor.
CAUTION:
Before pulling the rope, confirm the safety in
the working area, and inform the people around
you of the deployment.
B5M0499A
10) Release the rope to drop the pretensioner so

that the pretensioner is deployed by impact.
CAUTION:
쐌 The pretensioner may not deploy if the
safety system is locked completely or it falls in
a direction different from the one shown by the
arrow. In this case, repeat the procedure from
the beginning paying attention not to apply
impact to the pretensioner.
쐌 After deployment, the pretensioner is
extremely hot. Leave it unattended for 40 min-
utes.
쐌 Do not let water get on the deployed preten-
sioner.
11) Wrap the deployed pretensioner in an airtight
vinyl bag and discard it.
B5M0500
SB-12
BODY SECTION

SUBARU vehicles.
ine parts.

G8050GE6
LIGHTING SYSTEM
LI
Page
2. Headlight and Tail Light System .................................................................4
3. Front Fog Light System.............................................................................14
4. Rear Fog Light System .............................................................................18
5. Turn Signal and Hazard Light System ......................................................22
6. Back-up Light System ...............................................................................28
7. Stop Light System .....................................................................................30
8. Interior Light System .................................................................................32
9. Headlight Beam Leveler System...............................................................38
10. Combination Switch (Light) .......................................................................40
11. Headlight Assembly...................................................................................42
12. Headlight Bulb ...........................................................................................44
13. Front Turn Signal Light Assembly .............................................................45
14. Front Turn Signal Light Bulb .....................................................................46
15. Parking Light Bulb .....................................................................................47
16. Front Fog Light Assembly .........................................................................48
17. Front Fog Light Bulb .................................................................................49
18. Rear Combination Light Assembly............................................................50
19. Rear Finisher Light Assembly ...................................................................51
20. Brake/Tail Light Bulb .................................................................................52
21. Back-up Light Bulb ....................................................................................53
22. Rear Turn Signal Light Bulb......................................................................54
23. Rear Fog Light Assembly..........................................................................55
24. Rear Fog Light Bulb ..................................................................................56
25. License Plate Light....................................................................................57
26. High-mounted Stop Light ..........................................................................58
27. Side Turn Signal Light...............................................................................59
28. Spot Light ..................................................................................................60
29. Room Light ................................................................................................61
30. Luggage Room Light.................................................................................62
31. Glove Box Light.........................................................................................63
GENERAL DESCRIPTION
Lighting System
1. General Description S914001 A: SPECIFICATIONS S914001E49
Headlight 12 V — 60 W/55 W (Halogen)

Front turn signal light 12 V — 21 W
Side turn signal light 12 V — 5 W
Parking light 12 V — 5 W
Front fog light 12 V — 51 W
Rear fog light 12 V — 21 W
Tail/Stop light 12 V — 5/21 W
Rear combination light Turn signal light 12 V — 21 W
Back-up light 12 V — 16 W
License plate light 12 V — 5 W
High-mounted stop light 12 V — 10 W
Room light 12 V — 8 W
Spot light 12 V — 8 W
Luggage room light 12 V — 5 W
B: PRECAUTIONS S914001E59 쐌 After reassembly, make sure functional parts

operate smoothly.
쐌 Before disassembling or reassembling parts,
always disconnect battery ground cable. When WARNING:
replacing radio, control module, and other parts 쐌 Air bag system wiring harness is routed near
provided with memory functions, record memory electrical parts and switches. All air bag sys-
contents before disconnecting the battery ground tem wiring harnesses and connectors are yel-
cable. Otherwise, the memory will be erased. low. Do not use electric test equipment on
쐌 Reassemble in reverse order of disassembly, these circuits.
unless otherwise indicated. 쐌 Be careful not to damage the air bag system
쐌 Adjust parts to the given specifications. wiring harness when servicing electrical parts
쐌 Connect connectors and hoses securely during and switches.
reassembly.
1. GENERAL TOOLS S914001A1701
TOOL NAME REMARKS

Circuit Tester Used for measuring resistance and voltage.
LI-2
GENERAL DESCRIPTION
Lighting System
MEMO:
LI-3
HEADLIGHT AND TAIL LIGHT SYSTEM
Lighting System
2. Headlight and Tail Light System S914415
A: SCHEMATIC S914415A21
1. HEADLIGHT LHD MODEL S914415A2104
SL19-20
LI-4
Lighting System
2. HEADLIGHT RHD MODEL S914415A2105
SR19-20
LI-5
Lighting System
3. CLEARANCE LIGHT AND ILLUMINATION LIGHT LHD MODEL S914415A2106
SL21-20A
LI-6
Lighting System
SL21-20B
LI-7
Lighting System
SL21-20C
LI-8
Lighting System
4. CLEARANCE LIGHT AND ILLUMINATION LIGHT RHD MODEL S914415A2107
SR21-20A
LI-9
Lighting System
SR21-20B
LI-10
Lighting System
SR21-20C
LI-11
Lighting System
1. HEADLIGHT RELAY S914415A1001
Check continuity between terminals when terminal

No. 4 is connected to battery and terminal No. 3 is
grounded.
When current Between terminals
Continuity exists.
flows. No. 1 and No. 2
Between terminals Continuity does not
When current No. 1 and No. 2 exist.
does not flow. Between terminals
Continuity exists.
No. 3 and No. 4
S6M0048A
2. TAIL AND ILLUMINATION RELAY S914415A1002
Check continuity between terminals (indicated in

table below) when terminal No. 4 is connected to
battery and terminal No. 3 is grounded.
Continuity exists.
Continuity exists.
No. 3 and No. 4
S6M0048A
LI-12
Lighting System
MEMO:
LI-13
FRONT FOG LIGHT SYSTEM
Lighting System
3. Front Fog Light System S914473
1. FRONT FOG LIGHT LHD MODEL S914473A2105
SL22-20
LI-14
Lighting System
2. FRONT FOG LIGHT RHD MODEL S914473A2106
SR22-20
LI-15
Lighting System
1. FRONT FOG LIGHT SWITCH S914473A1001
B6M1583
Check continuity between terminals when operat-

ing the switch.
Specified condi-
Switch position Tester connection
tion
OFF — No continuity
ON 3-5-6 Continuity
2. FRONT FOG LIGHT RELAY S914473A1002

Continuity exists.
Continuity exists.
No. 3 and No. 4
S6M0048A
LI-16
Lighting System
MEMO:
LI-17
REAR FOG LIGHT SYSTEM
Lighting System
4. Rear Fog Light System S914476
1. REAR FOG LIGHT LHD MODEL S914476A2102
SL30-20
LI-18
Lighting System
2. REAR FOG LIGHT RHD MODEL S914476A2103
SR30-20
LI-19
Lighting System
1. REAR FOG LIGHT SWITCH S914476A1001
1) Turn ignition switch ON.

2) Turn on the headlight or front fog light.
3) Push the rear fog light switch and check if the
rear fog light turns on.
2. REAR FOG LIGHT RELAY S914476A1002

Continuity exists.
Continuity exists.
No. 3 and No. 4
S6M0048A
LI-20
Lighting System
MEMO:
LI-21
TURN SIGNAL AND HAZARD LIGHT SYSTEM
Lighting System
5. Turn Signal and Hazard Light System S914481
LI-22
Lighting System
1. TURN SIGNAL LIGHT AND HAZARD LIGHT LHD MODEL S914481A2102
SL26-20A
LI-23
Lighting System
SL26-20B
LI-24
Lighting System
2. TURN SIGNAL LIGHT AND HAZARD LIGHT RHD MODEL S914481A2103
SR26-20A
LI-25
Lighting System
SR26-20B
LI-26
Lighting System
1. TURN SIGNAL SWITCH S914481A1001
<Ref. to LI-40 REMOVAL, Combination Switch

(Light).>
2. HAZARD SWITCH S914481A1002
B6M1483

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

S914481A1003
B6M1584
Connect battery and turn signal light bulb to the

module, as shown in the figure. The module is
properly functioning if it blinks when power is sup-
plied to the circuit.
LI-27
BACK-UP LIGHT SYSTEM
Lighting System
6. Back-up Light System S914414
1. BACK-UP LIGHT S914414A2101
SG29-20
LI-28
BACK-UP LIGHT SYSTEM
Lighting System
1. BACK-UP LIGHT SWITCH (M/T) S914414A1001
Check continuity between terminals.

Specified condi-
tion
When shift lever Turbo engine
is set in reverse model: 2 - 4 Continuity
position Non-turbo engine
Other positions model: 1 - 2 No continuity
2. INHIBITOR SWITCH (A/T) S914414A1002
B6M1485

Specified condi-
tion
When select lever
is set in “R” posi- Continuity
tion 1-2
Other positions No continuity
LI-29
STOP LIGHT SYSTEM
Lighting System
7. Stop Light System S914417
1. STOP LIGHT S914417A2103
SG25-20
LI-30
STOP LIGHT SYSTEM
Lighting System
1. STOP LIGHT SWITCH S914417A1001
S6M0570A

Specified condi-
tion
When brake pedal 1 - 2: Without Continuity
is depressed cruise control
When brake pedal 2 - 3: With cruise
No continuity
is released control
LI-31
INTERIOR LIGHT SYSTEM
Lighting System
8. Interior Light System S914418
1. INTERIOR LIGHT LHD MODEL S914418A2102
SL24-20A
LI-32
Lighting System
SL24-20B
LI-33
Lighting System
2. INTERIOR LIGHT RHD MODEL S914418A2103
SR24-20A
LI-34
Lighting System
SR24-20B
LI-35
Lighting System
1. DOOR SWITCH S914418A1001

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

Specified condi-
tion
When rear gate is
Continuity
open.
1-2
When rear gate is
No continuity
closed.
LI-36
Lighting System
MEMO:
LI-37
HEADLIGHT BEAM LEVELER SYSTEM
Lighting System
9. Headlight Beam Leveler System S914493
1. HEADLIGHT BEAM LEVELER S914493A2101
SG83-20
LI-38
HEADLIGHT BEAM LEVELER SYSTEM
Lighting System
1. HEADLIGHT BEAM LEVELER

ACTUATOR S914493A1001
1) Turn on the headlights.
2) Confirm the headlight beam level is lowered by
changing the switch position to 0 - 1 - 2 - 3 - 4 - 5.
2. HEADLIGHT BEAM LEVELER SWITCH
S914493A1002
Measure the resistance between headlight beam

leveler switch terminals at each switch position.
S6M0558A
Switch position Resistance

0 2.7 kΩ
1 1.2 kΩ
2 750 Ω
3 350 Ω
4 120 Ω
5 1 - 10 Ω
LI-39
COMBINATION SWITCH (LIGHT)
Lighting System
10. Combination Switch (Light) C: INSPECTION S914411A10
S914411
1) Remove instrument panel lower cover. <Ref. to

EI-31 REMOVAL, Instrument Panel Assembly.>
2) Remove screws which secure upper column
cover to lower column cover.
S6M0042
3) Disconnect connector from combination switch.

4) Remove screws which secure switch and
remove switch.
B6M1560B
Move combination switch to respective positions

and check continuity between terminals.
1. LIGHTING SWITCH S914411A1001
LHD model:
Specified condi-
tion
S6M0046 Tail 14 - 16 Continuity
Head 13 - 14 - 16 Continuity
RHD model:
Specified condi-
tion
Tail 9 - 15 Continuity
Head 9 - 14 - 15 Continuity
2. DIMMER AND PASSING SWITCH S914411A1002
LHD model:
Specified condi-
tion
Passing 7 - 8 - 16 Continuity
Low beam 16 - 17 Continuity
High beam 7 - 16 Continuity
LI-40
COMBINATION SWITCH (LIGHT)
Lighting System
RHD model:
Specified condi-
tion
Passing 1-2-9 Continuity
Low beam 9 - 10 Continuity
High beam 2-9 Continuity
3. TURN SIGNAL SWITCH S914411A1003
LHD model:
Specified condi-
tion
Left 1-2 Continuity
Neutral — No continuity
Right 2-3 Continuity
RHD model:
Specified condi-
tion
Left 6-7 Continuity
Neutral — No continuity
Right 7-8 Continuity
4. PARKING SWITCH S914411A1004
Specified condi-
tion
OFF 2-4 Continuity
ON 1-4 Continuity
LI-41
HEADLIGHT ASSEMBLY
Lighting System
11. Headlight Assembly S914409 B: INSTALLATION S914409A11
1) Remove duct (A) (when right side headlight is C: ADJUSTMENT S914409A01
removed).
1. HEADLIGHT AIMING S914409A0101
CAUTION:
Turn off the light before adjusting headlight
aiming. If the light is necessary to check
aiming, do not turn on for more than two min-
utes.
NOTE:
Before checking the headlight aiming, be sure of
the following:
S6M0532A
쐌 The area around the headlight has not sustained
any accident, damage or other type of deformation.
2) Disconnect headlight bulb connector. 쐌 Vehicle is parked on level ground.
쐌 The inflation pressure of tires is correct.
쐌 Vehicle’s gas tank is fully charged.
쐌 Bounce the vehicle several times to normalize
the suspension.
쐌 Make certain that someone is seated in the driv-
er’s seat.
Turn the headlights on and then adjust the low
beam pattern to the following positions on the
screen.
S6M0533 NOTE:
쐌 Set the headlight leveler switch to “0” position.
3) Remove front grille. <Ref. to EI-10 REMOVAL, 쐌 Adjust vertical aim (A) first, then horizontal aim
Front Grille.>
(B).
4) Remove screw (A) then remove front turn sig-
nal light while disconnecting connector.
5) Remove extension (B). <Ref. to EI-12,
REMOVAL, Front Bumper.>
6) Remove bolts (C) which secure headlight and
remove headlight.
S6M0426A
S6M0534A
LI-42
HEADLIGHT ASSEMBLY
Lighting System
S6M0535A
This illustration is for LHD model.
The pattern for RHD model is symmetrically opposite.
H mm (in)
W mm (in) h mm (in) at 3 m (10 ft)
Non-turbo model Turbo model
1,090 (42.91) 710 (27.95) 697 (27.44) 30 (1.18)
LI-43
HEADLIGHT BULB
Lighting System
12. Headlight Bulb S914410 B: INSTALLATION S914410A11
CAUTION:
쐌 Because the tungsten halogen bulb operates
at a high temperature, dirt and oil on the bulb
surface reduces the bulb’s service life. Hold the
flange portion when replacing the bulb. Never
touch the glass portion.
쐌 Do not leave the headlight without a bulb for
a long time. Dust, moisture, etc. entering the
headlight may affect its the performance.
1) Remove duct (A) (when right side headlight is
removed).
S6M0532A
2) Disconnect headlight bulb connector.

3) Remove back cover (A).
S6M0536A
4) Push to remove spring retainer (A) and then

detach headlight bulb (B).
S6M0537A
LI-44
FRONT TURN SIGNAL LIGHT ASSEMBLY
Lighting System
13. Front Turn Signal Light

Assembly S914408
1) Remove screw and disconnect connector, and

then detach front turn signal light assembly.
S6M0538
LI-45
FRONT TURN SIGNAL LIGHT BULB
Lighting System
14. Front Turn Signal Light

Bulb S914412
1) Remove front turn signal light assembly. <Ref.

to LI-45, REMOVAL, Front Turn Signal Light
Assembly.>
2) Turn the socket and remove the bulb.
S6M0539
LI-46
PARKING LIGHT BULB
Lighting System
15. Parking Light Bulb S914419
1) Remove headlight assembly. <Ref. to LI-42

REMOVAL, Headlight Assembly.>
S6M0540
LI-47
FRONT FOG LIGHT ASSEMBLY
Lighting System
16. Front Fog Light Assembly

S914427
1) Remove the two screws, then draw out the front

fog light from front bumper.
S6M0085
2) Disconnect the connector.
LI-48
FRONT FOG LIGHT BULB
Lighting System
17. Front Fog Light Bulb S914428
1) Remove front fog light assembly. <Ref. to LI-48

REMOVAL, Front Fog Light Assembly.>
2) Remove front fog light bulb (A).
S6M0541A
LI-49
REAR COMBINATION LIGHT ASSEMBLY
Lighting System
18. Rear Combination Light

Assembly S914426
1) Remove rear quarter upper and lower trim.

<Ref. to EI-39 REMOVAL, Rear Quarter Trim.>
2) Remove nuts and disconnect connector.
S6M0045
3) Attach adhesive cloth tape to body area around

rear combination light.
4) Using a standard screwdriver, carefully pry rear
combination light off.
CAUTION:
쐌 Do not pry on the rear combination light
forcefully as this may scratch the vehicle body.

CAUTION:
쐌 Remove all traces of adhesive tape from
body before installation.
쐌 Attach butyl rubber tape to back of rear com-
bination light before installing rear combina-
tion light on body for sealing purposes.
LI-50
REAR FINISHER LIGHT ASSEMBLY
Lighting System
19. Rear Finisher Light

Assembly S914429
1) Remove rear gate trim access hole cover.

2) Remove the four nuts.
S6M0427
3) Detach rear finisher light while disconnecting

connector.
LI-51
BRAKE/TAIL LIGHT BULB
Lighting System
20. Brake/Tail Light Bulb S914430
1) Remove rear combination light cover.

S6M0542
LI-52
BACK-UP LIGHT BULB
Lighting System
21. Back-up Light Bulb S914424
1) Remove rear gate trim access hole cover.

S6M0543
LI-53
REAR TURN SIGNAL LIGHT BULB
Lighting System
22. Rear Turn Signal Light Bulb

S914421
1) Remove rear combination light cover.

S6M0544
LI-54
REAR FOG LIGHT ASSEMBLY
Lighting System
23. Rear Fog Light Assembly

S914422
1) Disconnect connector from rear fog light.

2) Remove nuts and then detach rear fog light.
NOTE:
Take out rear fog light by pulling out it from behind
the bumper.
S6M0429
LI-55
REAR FOG LIGHT BULB
Lighting System
24. Rear Fog Light Bulb S914423
1) Remove screw (A) and rear fog light lens (B).
S6M0545A
2) Remove the bulb.
LI-56
LICENSE PLATE LIGHT
Lighting System
25. License Plate Light S914420
1) Remove license plate light mounting screw (A)

and then remove the lens (B)
S6M0546A
2) Remove the bulb.
LI-57
HIGH-MOUNTED STOP LIGHT
Lighting System
26. High-mounted Stop Light

S914425
1) Remove cap (a) by prying on the edge with a

screwdriver.
2) Remove screws (b) and then detach cover (c).
3) Remove screws (d) and then detach high-
mounted stop light while disconnecting connector.
B6M1343A
LI-58
SIDE TURN SIGNAL LIGHT
Lighting System
27. Side Turn Signal Light S914407
1) Pull out the light from body while pushing it in

direction of vehicle front.
2) Disconnect harness connector and remove the
light.
B6M1543
LI-59
SPOT LIGHT
Lighting System
28. Spot Light S914398
1) Remove spot light lens (A).
S6M0547A
2) Remove sunroof switch. <Ref. to SR-12,

REMOVAL, Sunroof Switch.>
3) Remove spot light mounting screw (B).
S6M0548A
4) Disconnect harness connectors and remove

spot light.

Specified condi-
tion
ON 1-2 Continuity
LI-60
ROOM LIGHT
Lighting System
29. Room Light S914397
1) Remove lens (A) and room light mounting

screws (B).
B6M1479A

the light.
B6M1489A

Specified condi-
tion
ON 1-3 Continuity
DOOR 1-2 Continuity
LI-61
LUGGAGE ROOM LIGHT
Lighting System
30. Luggage Room Light S914399
1) Remove lens (A) and luggage room light

mounting screws (B).
B6M1480A

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

between terminals.
Specified condi-
tion
ON (A) - (C) Continuity
DOOR (A) - (B) Continuity
LI-62
GLOVE BOX LIGHT
Lighting System
31. Glove Box Light S914396

Glove Box.>
2) Disconnect harness connector.
3) Remove glove box light.
S6M0549
LI-63
GLOVE BOX LIGHT
Lighting System
MEMO:
LI-64
BODY SECTION

SUBARU vehicles.
ine parts.

G8050GE6
WIPER AND WASHER SYSTEMS
WW
Page
2. Wiper and Washer System .........................................................................6
3. Combination Switch (Wiper)......................................................................10
4. Wiper Blade...............................................................................................12
5. Washer Tank and Motor ............................................................................13
6. Front Wiper Arm ........................................................................................14
7. Front Wiper Motor and Link ......................................................................15
8. Front Washer.............................................................................................17
9. Rear Wiper Arm.........................................................................................19
10. Rear Wiper Motor......................................................................................20
11. Rear Washer .............................................................................................21
12. Wiper Control Relay ..................................................................................23
13. Headlight Washer ......................................................................................24
GENERAL DESCRIPTION
Wiper and Washer Systems
Front wiper motor Input 12 V — 54 W or less

Rear wiper motor Input 12 V — 42 W or less
Pump type Centrifugal
Front washer motor
Input 12 V — 36 W or less
Pump type Centrifugal
Rear washer motor
Input 12 V — 36 W or less
1. FRONT WIPER S902001A0501
S6M0485A
(1) Wiper rubber (5) Wiper motor Tightening torque: N·m (kgf-m, ft-lb)
(2) Wiper blade ASSY
T1: 6.0 (0.61, 4.4)
(3) Wiper arm
T2: 20 (2.0, 14.5)
(4) Wiper link
WW-2
GENERAL DESCRIPTION
2. REAR WIPER S902001A0502
S6M0486A
(1) Wiper blade ASSY (5) Wiper arm cover Tightening torque: N·m (kgf-m, ft-lb)
(2) Wiper arm
T1: 5.9 (0.6, 4.3)
(3) Wiper motor
T2: 7.8 (0.8, 5.6)
(4) Pivot cap
WW-3
GENERAL DESCRIPTION
3. WASHER TANK S902001A0503
S6M0564A
(1) Washer nozzle (7) Grommet (13) Clip

(2) Washer hose (8) Headlight washer motor (14) Joint valve
(3) Washer tank (9) Motor bracket
(4) Washer tank cap (10) Headlight washer case Tightening torque: N·m (kgf-m, ft-lb)
(5) Front washer motor (11) Headlight washer upper nozzle T: 6.0 (0.61, 4.4)
(6) Rear washer motor (12) Headlight washer lower nozzle
C: CAUTION S902001A03
쐌 Reconnect connectors and hoses securely.

After reconnecting, confirm that each function operates normally.
쐌 Be careful that wire harnesses of airbag system pass near electrical parts and switches.
쐌 Wire harnesses and connectors of all airbag system are yellow color. Do not use a tester on these cir-
cuits.
쐌 Care must be taken when installing the piping hose so that no bending, jamming, etc. are caused.
쐌 If even a little oil or grease such as silicon oil gets in the tank and washer passages, an oil film easily
forms on the glass, causing the wiper to chatter and judder. Therefore, be careful not to let this happen.
WW-4
GENERAL DESCRIPTION
MEMO:
WW-5
WIPER AND WASHER SYSTEM
2. Wiper and Washer System S902394
1. WIPER AND WASHER (FRONT) S902394A2101
SG50-20
WW-6
2. WIPER AND WASHER (REAR) S902394A2102
SG51-20
WW-7
3. HEADLIGHT WASHER S902394A2107
SG53-20
WW-8

Wiper and washers do not operate. (1) Wiper fuse (F/B No. 14, 15)
(2) Combination switch
(3) Wiper motor
(4) Wire harness
Wipers do not operate in LO or HI. (1) Combination switch
(2) Wiper motor
(3) Wire harness
Wipers do not operate in INT. (1) Combination switch
(2) Wiper motor
(3) Wire harness
Washer motor does not operate. (1) Washer switch
(2) Washer motor
(3) Wire harness
Wipers do not operate when washer switch is ON. (1) Washer motor
(2) Wire harness
Washer fluid spray does not operate. (1) Washer hose and nozzle
WW-9
COMBINATION SWITCH (WIPER)
3. Combination Switch (Wiper) C: INSPECTION S902395A10
S902395
쐌 Inspect the continuity between each connector
terminal.
1) Loosen screw to remove a steering column

cover.
S6M0042
2) Disconnect connectors from combination

switches.
3) Loosen screw to remove combination switch.
S6M0137
LHD model:
Test Specified
Switch position
connection condition
OFF 7 — 16 Continuity
B6M1499 INT 7 — 16 Continuity
FRONT LO 7 — 17 Continuity
HI 8 — 17 Continuity
Washer ON 2 — 11 Continuity
Install in the reverse order of removal. Washer ON 2 — 10 — 12 Continuity
REAR
ON 2 — 10 Continuity
Washer ON 2 — 10 — 12 Continuity
If continuity is not as specified, replace the switch.

RHD model:
Test Specified
Switch position
connection condition
OFF 3 — 12 Continuity
INT 3 — 12 Continuity
FRONT LO 3 — 11 Continuity
HI 2 — 11 Continuity
Washer ON 8 — 17 Continuity
REAR
ON 8 — 18 Continuity
If continuity is not as specified, replace the switch.
WW-10
COMBINATION SWITCH (WIPER)
쐌 Intermittent operation inspection

1) Turn the wiper switch to INT.
2) Adjust the intermittent control switch to MAX.
3) Apply battery voltage to switch terminals 16 and 2, and inspect the voltage of terminals 7 and 2. (Mea-
sure the voltage from after the second time the wiper stops.)
B6M1465A
If operation is not as specified, replace the switch.
WW-11
WIPER BLADE
4. Wiper Blade S902392 D: ASSEMBLY S902392A02
1) Insert the wiper rubber onto the blade so that
the stopper is in the position shown (at the bottom
While pushing locking clip (A) up, pull out blade of the wiper arm).
from arm to arrow direction.
B6M1497
B6M1570A
2) Make sure the wiper rubber is securely fas-
tened to the pull stopper (A).

2) Confirm that clip was locked securely.
C: DISASSEMBLY S902392A06
Pull on side (A) of the wiper rubber stopper and

remove the rubber from the blade assembly.
B6M1498A
E: INSPECTION S902392A10
1) When the wiper does not perform well, inspect

the following:
쐌 Make sure the movable part of the blade assem-
bly moves smoothly.
B6M1496A 쐌 Make sure the wiper rubber is not deformed or
damaged.
2) Replace with a new part if damage is found.
WW-12
WASHER TANK AND MOTOR
5. Washer Tank and Motor S902405 C: DISASSEMBLY S902405A06
Remove bolt, and then pull out washer motor from
tank.
1) Disconnect the ground cable from the battery.
2) Remove the two bolts, and then disconnect the
connectors from washer motors.
S6M0563
B5M1464
1) Assemble in the reverse order of disassembly.

3) Lift the washer tank, and then disconnect the 2) Confirm that water does not leak from installa-
connector from headlight washer motor. Discon- tion area of motor.
nect washer hoses.
Apply battery voltage to the connector terminal of

the washer motor and make sure the motor oper-
ates.
S6M0561
4) Disconnect the washer hose from the motor,

and then detach the washer tank.
B6M1567
S6M0562
WW-13
FRONT WIPER ARM
6. Front Wiper Arm S902404 C: ADJUSTMENT S902404A01
NOTE:
The positions for RHD model are symmetrically
NOTE: opposite.
The positions for RHD model are symmetrically Operate wiper once. Align wiper blade to ceramic
opposite. print point mark (A) of front window pane.
1) Open hood.
2) Remove cap.
3) Loosen nut to remove wiper arm.
S6M0049B
S6M0050
NOTE:
opposite.
2) Operate wiper once.
3) Align wiper blade to ceramic print point mark
(A) of front window pane.
S6M0049B
WW-14
FRONT WIPER MOTOR AND LINK
7. Front Wiper Motor and Link 5) Remove wiper link from service hole in front
S902406
panel.
NOTE:
opposite.
1) Remove cowl panel. <Ref. to EI-25 REMOVAL,
Cowl Panel.>
2) Disconnect connector of motor, and remove
motor attaching bolts.
G6M0121
1) When battery is connected to terminal of

connectors, confirm that motor operates at low
S6M0051
speed.
3) Remove cowl cover, and remove the motor link

nut on the back side of the motor.
S6M0055
2) When battery is connected to terminal of

S6M0052
connectors, confirm that motor operates at high
speed.
4) Remove bolts which secure sleeve unit.
S6M0056
S6M0053
WW-15
FRONT WIPER MOTOR AND LINK
3) Connect battery to terminals of connector, and

remove terminal connection with motor rotated at
low speed, and stop wiper motor through opera-
tion.
S6M0057
4) Connect battery and confirm that motor stops at

automatic stop position after motor operates at low
speed again.
S6M0058
WW-16
FRONT WASHER
8. Front Washer S902401
S6M0559
B: REMOVAL S902401A18 C: INSTALLATION S902401A11
1. NOZZLE S902401A1801 1. NOZZLE S902401A1101
1) Remove the washer hose from the washer 1) Install in the reverse order of removal.
nozzle. 2) Adjust the position of the washer liquid sprayer.
2) Open the clips on the underside of the hood <Ref. to WW-18 ADJUSTMENT, Front Washer.>
with a thin screwdriver or other tool, and remove
the washer nozzle. D: INSPECTION S902401A10
쐌 Make sure the nozzle and hose are not clogged.

쐌 Make sure the hose is not bent.
B6M1505
WW-17
FRONT WASHER
E: ADJUSTMENT S902401A01
NOTE:
Adjustment positions for left-handed vehicle. Carry
out left-right symmetry for adjustment positions for
right-handed vehicle.
1) Turn wiper switch to OFF position.
2) When vehicle stops, adjust washer injection
position as shown in the figure.
Injection position:
A: 410 mm (16.14 in)
B: 150 mm (5.91 in)
C: 370 mm (14.57 in)
D: 530 mm (20.87 in)
S6M0165A
WW-18
REAR WIPER ARM
9. Rear Wiper Arm S902402
1) Raise wiper arm cover.

2) Loosen nut to remove wiper arm.
S6M0061

2) Adjust the position of the wiper blade. <Ref. to
WW-19, ADJUSTMENT, Rear Wiper Arm.>
C: ADJUSTMENT S902402A01
1) Operate rear wiper once.

2) Adjust wiper blade to original position as shown
in figure.
Original position:
A: 30±5 mm (1.18±0.20 in)
S6M0059A
WW-19
REAR WIPER MOTOR
10. Rear Wiper Motor S902532 C: INSPECTION S902532A10
1) Connect battery to wiper motor connector and
confirm that wiper motor operates.
1) Remove rear wiper arm.
<Ref. to WW-19, REMOVAL, Rear Wiper Arm.>
2) Remove rear gate lower trim. <Ref. to EI-42
REMOVAL, Rear Gate Trim.>
3) Unclip clip of harness and disconnect connec-
tor of wiper motor.
4) Loosen bolts to remove wiper motor assembly.
CAUTION:
Be careful not to damage O-ring when remov-
ing wiper motor assembly.
S6M0072
2) Connect battery to terminal of connector and

remove terminal connections with motor rotated,
and stop wiper motor through operation.
S6M0062

S6M0073
3) Connect battery and confirm that motor stops at

automatic stop position after motor operates at low
speed again.
S6M0074
WW-20
REAR WASHER
11. Rear Washer S902400
S6M0560
B: REMOVAL S902400A18 C: INSTALLATION S902400A11
1. NOZZLE S902400A1801 1. NOZZLE S902400A1101
1) Remove the high-mount stop light. <Ref. to 1) Install in the reverse order of removal.
LI-58 REMOVAL, High Mount Stop Light.> 2) Adjust the position of the washer liquid sprayer.
2) Remove the washer hose from the washer <Ref. to WW-22 ADJUSTMENT, Rear Washer.>
nozzle.
3) Open the clips on the underside of the hood D: INSPECTION S902400A10
with a thin screwdriver or other tool, and remove

쐌 Make sure the nozzle and hose are not clogged.
the washer nozzle.
쐌 Make sure the hose is not bent.
B6M1505
WW-21
REAR WASHER
1) Turn wiper switch to OFF position.

2) When vehicle stops, adjust washer injection
position as shown in the figure.
Injection position:
A: 60 mm (2.36 in)
B: 60 mm (2.36 in)
S6M0320A
WW-22
WIPER CONTROL RELAY
12. Wiper Control Relay S902403

3) Measure the voltage when the wiper relay is
operated.
1. WAGON S902403A1801
1) Remove right quarter lower trim.<Ref. to EI-39

2) Remove quarter pocket.
3) Loosen nut to remove control unit.
B6M1523A
If operation is not as specified, replace the switch.
S6M0488
1. WAGON S902403A1101
1. WAGON S902403A1001
1) Disconnect the connector from the wiper con-

trol 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.
BO0276
WW-23
HEADLIGHT WASHER
13. Headlight Washer S902736 B: INSTALLATION S902736A11

2) Remove the front grille. <Ref. to EI-10,
REMOVAL, Front Grille.>
3) Draw out headlight washer hose.
4) Disconnect hose (A) from valve (B).
NOTE:
Washer fluid may drain from valve. Put a pan under
the valve, then disconnect valve from hose while
pinching the hose edge.
S5M0394A
5) Remove nozzle cover (A).
S5M0395A
6) Push the three pawls to remove outer nozzle

(A). Then, pull out inner nozzle (B).
NOTE:
Before pushing the outer nozzle pawls, cover the
bumper to avoid scratches.
S5M0396A
WW-24
BODY SECTION

SUBARU vehicles.
ine parts.

G8050GE6
ENTERTAINMENT
ET
Page
2. Radio System ..............................................................................................4
3. Cigarette Lighter System.............................................................................9
4. Accessory Power Socket System .............................................................10
5. Radio Body ................................................................................................11
6. Front Speaker............................................................................................12
7. Rear Speaker ............................................................................................13
8. Antenna .....................................................................................................14
9. Antenna Amplifier ......................................................................................15
10. Cigarette Lighter........................................................................................16
11. Accessory Power Socket ..........................................................................17
GENERAL DESCRIPTION
Entertainment

always disconnect battery ground cable. When
replacing radio, control module, and other parts
provided with memory functions, record memory
contents before disconnecting the battery ground
cable. Otherwise, the memory will be erased.
쐌 Reassemble in reverse order of disassembly,
unless otherwise indicated.
쐌 Adjust parts to the given specifications.
쐌 Connect connectors and hoses securely during
reassembly.
쐌 After reassembly, make sure functional parts
operate smoothly.
B: PREPARATION TOOL S901001A17
TOOL NAME REMARKS

Circuit Tester Used for measuring resis-
tance and voltage.
Conductive Silver Composi- Used for repairing antenna
tion wire.
(DUPONT NO. 4817 or
equivalent)
ET-2
GENERAL DESCRIPTION
Entertainment
MEMO:
ET-3
RADIO SYSTEM
Entertainment
2. Radio System S901467
1. RADIO LHD MODEL S901467A2103
SL76-20A
ET-4
RADIO SYSTEM
Entertainment
SL76-20B
ET-5
RADIO SYSTEM
Entertainment
2. RADIO RHD MODEL S901467A2104
SR76-20A
ET-6
RADIO SYSTEM
Entertainment
SR76-20B
ET-7
RADIO SYSTEM
Entertainment

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 antenna amplifier.
(3) Check radio ground.
ET-8
CIGARETTE LIGHTER SYSTEM
Entertainment
3. Cigarette Lighter System S901494
1. CIGARETTE LIGHTER S901494A2101
SG97-20
ET-9
ACCESSORY POWER SOCKET SYSTEM
Entertainment
4. Accessory Power Socket System S901785
1. ACCESSORY POWER SOCKET S901785A2101
SG90-20
ET-10
RADIO BODY
Entertainment
5. Radio Body S901469

2) Remove AT cover (AT model).
3) Remove center panel.
4) Remove fitting screws, and slightly pull radio
out from center console.
S5M0048A
5) Disconnect electric connectors and antenna

feeder cord.
ET-11
FRONT SPEAKER
Entertainment
6. Front Speaker S901466
1) Remove front door trim. <Ref. to EI-26

REMOVAL, Front Door Trim.>
2) Remove front speaker mounting screws.
S6M0568
3) Disconnect harness connector and remove

front speaker.
ET-12
REAR SPEAKER
Entertainment
7. Rear Speaker S901470
1) Remove rear door trim. <Ref. to EI-27>

REMOVAL, Rear Door Trim.
2) Remove rear speaker mounting screws.
S6M0569
3) Disconnect harness connector and remove rear

speaker.
ET-13
ANTENNA
Entertainment
8. Antenna S901463 B: REPAIR S901463A19
1) Clean antenna wire and the surrounding area
with a cloth dampened by alcohol.
Check continuity between antenna terminal and 2) Paste a thin masking film on glass along the
each antenna wire. broken wire.
If an antenna wire is OK, continuity should exist. If 3) Deposit conductive silver composition
an antenna wire is broken, no continuity should (DUPONT NO. 4817) on the broken portion with a
exist. drawing pen.
NOTE:
When checking continuity, wind a piece of tin foil
around the tip of the tester probe and press the foil
against the wire with your finger.
G6M0138
4) Dry out the deposited portion.

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

the antenna wire.
B6M1495
ET-14
ANTENNA AMPLIFIER
Entertainment
9. Antenna Amplifier S901460
1) Remove rear quarter lower trim. <Ref. to EI-39

2) Disconnect harness connector and terminal.
3) Remove mounting screw and detach antenna
amplifier.
S6M0507
S6M0508A
Measure resistance between terminal and ampli-

fier body.
Tester connection Resistance
A — Amplifier More than 100 kΩ
B — Amplifier More than 100 kΩ
a — Amplifier More than 100 kΩ
ET-15
CIGARETTE LIGHTER
Entertainment
10. Cigarette Lighter S901461
1) Remove center panel. <Ref. to ET-11

REMOVAL, Radio Body.>
cigarette lighter.
S6M0509
ET-16
ACCESSORY POWER SOCKET
Entertainment
11. Accessory Power Socket S901786
1) Remove rear quarter lower trim. <Ref. to EI-39,

accessory power socket.
S6M0566
ET-17
ACCESSORY POWER SOCKET
Entertainment
MEMO:
ET-18
BODY SECTION

SUBARU vehicles.
ine parts.

G8050GE6
COMMUNICATION SYSTEM
COM
Page
2. Horn System................................................................................................3
3. Horn.............................................................................................................5
4. Horn Switch .................................................................................................6
GENERAL DESCRIPTION
Communication System
A: PREPARATION TOOL S904001A17
TOOL NAME REMARKS

COM-2
HORN SYSTEM
2. Horn System S904436
1. HORN S904436A2101
SG74-20
COM-3
HORN SYSTEM
1. HORN RELAY S904436A1001

Continuity exists.
Continuity exists.
No. 3 and No. 4
S6M0048A
COM-4
HORN
3. Horn S904437
1) Remove horn bracket mounting bolt (A).

2) Disconnect harness connector and remove
horn assembly (B).
S6M0506A
With 12 V direct current supply between horn ter-

minal and case ground, check that the horn sounds
properly.
B6M1492
COM-5
HORN SWITCH
4. Horn Switch S904434
WARNING:
Before servicing, be sure to read the notes in
the AB section for proper handling of the driver
airbag module. <Ref. to AB-3 CAUTION, Gen-
eral Description.>
1) Remove the driver’s airbag module. <Ref. to
AB-12 Driver’s Airbag Module.>
2) Remove horn switch from steering wheel as
shown.
S6M0095
B6M1493
Switch position Tester connection Specified condition

When horn
Continuity
switch is pushed.
When horn 1—Body ground
switch is not No continuity
pushed.
COM-6
BODY SECTION

SUBARU vehicles.
ine parts.

G8050GE6
GLASS/WINDOWS/MIRRORS
GW
Page
2. Power Window System ...............................................................................9
3. Rear Window Defogger System................................................................19
4. Windshield Wiper Deicer System..............................................................23
5. Remote Control Mirror System .................................................................25
6. Front Door Glass.......................................................................................28
7. Front Regulator and Motor Assembly .......................................................31
8. Rear Door Glass .......................................................................................32
9. Rear Regulator and Motor Assembly........................................................34
10. Windshield Glass.......................................................................................35
11. Rear Gate Glass .......................................................................................38
12. Rear Quarter Glass ...................................................................................39
13. Roof Window Glass...................................................................................41
14. Inner Rearview Mirror................................................................................42
15. Power Window Control Switch..................................................................43
16. Rear Window Defogger Switch .................................................................46
17. Rear Window Defogger.............................................................................48
18. Outer Mirror Assembly ..............................................................................49
19. Outer Mirror ...............................................................................................51
20. Remote Control Mirror Switch...................................................................52
21. Wiper Deicer..............................................................................................54
22. Wiper Deicer Switch..................................................................................55
GENERAL DESCRIPTION
Glass/Windows/Mirrors
GW-2
GENERAL DESCRIPTION
1. FIXED GLASS S905001A0506
S5M0497A
(1) Windshield glass (5) Side molding (9) Rear gate glass
(2) Dam rubber (6) Rear quarter glass (10) Spring
(3) Molding (7) Locate pin
(4) Rearview mirror mount (8) Rear quarter garnish
GW-3
GENERAL DESCRIPTION
2. FRONT DOOR GLASS S905001A0503
S5M0509A
(1) Door sash (Front) (5) Motor ASSY Tightening torque: N·m (kgf-m, ft-lb)
(2) Glass
T1: 7.35 (0.75, 5.4)
(3) Door sash (Rear)
T2: 14 (1.4, 10.1)
(4) Regulator ASSY
GW-4
GENERAL DESCRIPTION
3. REAR DOOR GLASS S905001A0504
S5M0510A
(1) Door sash (Front) (5) Motor ASSY Tightening torque: N·m (kgf-m, ft-lb)
(2) Glass
T1: 7.35 (0.75, 5.4)
(3) Door sash (Rear)
T2: 14 (1.4, 10.1)
(4) Regulator ASSY
GW-5
GENERAL DESCRIPTION
4. MIRRORS S905001A0505
S5M0457A
(1) Outer mirror (3) Mount (5) Mirror

(2) Inner rearview mirror (4) Spring
GW-6
GENERAL DESCRIPTION
쐌 When electrical connectors are disconnected,

always conduct an operational check after con-
necting them again.
쐌 Avoid impact and damage to the glass.
GW-7
GENERAL DESCRIPTION
TOOL NAME REMARKS

Circuit Tester Used for checking voltage and continuity.
Piano Wire Used for window glass removal.
Windshield Knife Used for window glass removal.
GW-8
POWER WINDOW SYSTEM
2. Power Window System S905456
GW-9
POWER WINDOW SYSTEM
1. POWER WINDOW LHD MODEL S905456A2101
SL70-20A
GW-10
POWER WINDOW SYSTEM
SL70-20B
GW-11
POWER WINDOW SYSTEM
SL70-20C
GW-12
POWER WINDOW SYSTEM
SL70-20D
GW-13
POWER WINDOW SYSTEM
2. POWER WINDOW RHD MODEL S905456A2102
SR70-20A
GW-14
POWER WINDOW SYSTEM
SR70-20B
GW-15
POWER WINDOW SYSTEM
SR70-20C
GW-16
POWER WINDOW SYSTEM
SR70-20D
GW-17
POWER WINDOW SYSTEM

(1) Fuse (SBF-6) (F/B No. 18)
(2) Power window circuit breaker
All power windows does not operate.
(3) Power window relay
(4) Wire harness
(1) Power window main switch
(2) Power window sub switch
One window does not operate.
(3) Power window motor
(4) Wire harness
“Window Lock” does not operate. (1) Power window main switch
GW-18
REAR WINDOW DEFOGGER SYSTEM
3. Rear Window Defogger System S905455
GW-19
1. REAR WINDOW DEFOGGER LHD MODEL S905455A2102
SL52-20
GW-20
2. REAR WINDOW DEFOGGER RHD MODEL S905455A2103
SR52-20
GW-21

(1) Fuse (M/B No. 1)
(2) Rear defogger relay
(3) Defogger switch
Rear window defogger does not operate.
(4) Rear defogger condenser
(5) Deffogger wire
(6) Wire harness
GW-22
WINDSHIELD WIPER DEICER SYSTEM
4. Windshield Wiper Deicer System S905457
1. WINDSHIELD WIPER DEICER S905457A2101
SG78-20
GW-23
WINDSHIELD WIPER DEICER SYSTEM

(1) Fuse (F/B No. 18, 19)
(2) Wiper deicer relay
Wiper deicer does not operate.
(3) Wiper deicer switch
(4) Wire harness
GW-24
REMOTE CONTROL MIRROR SYSTEM
5. Remote Control Mirror System S905458
1. REMOTE CONTROL MIRROR LHD MODEL S905458A2102
SL79-20
GW-25
2. REMOTE CONTROL MIRROR RHD MODEL S905458A2103
SR79-20
GW-26

(1) Fuse (F/B No. 4)
All function does not operate. (2) Mirror switch
(3) Wire harness
(1) Mirror switch
One side of the mirror motor does not operate. (2) Mirror motor
(3) Wire harness
(1) Mirror switch
Mirror heater does not operate. (2) Mirror heater
(3) Wire harness
GW-27
FRONT DOOR GLASS
6. Front Door Glass S905452

7) Operate the power window switch to move
glass to the position shown in the figure, and then
A: REMOVAL S905452A18 remove the two nuts from service holes.
1) Remove door trim. <Ref. to EI-26, REMOVAL,
Front Door Trim.>
2) Remove sealing cover. <Ref. to EB-13,
REMOVAL, Front Sealing Cover.>
3) Remove inner remote. <Ref. to SL-27,
REMOVAL, Front Inner Remote.>
4) Remove inner stabilizer.
B5M1046
8) Take out glass door panel upward.
B5M1044
5) Remove outer mirror. <Ref. to GW-49,

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

CAUTION:
Make sure that glass stay is placed securely in
sash.
2) Adjust front door glass. <Ref. to GW-29,
ADJUSTMENT, Front Door Glass.>
B5M1045
GW-28
FRONT DOOR GLASS
C: ADJUSTMENT S905452A01 5) For adjustment of upper and lower ends of cen-

ter pillar, loosen adjusting nut (A).
NOTE:
Before adjustment, ensure that all adjusting bolts
of stabilizer, upper stopper, and sash are loose and
door glass is raised so that it is in contact with
weatherstrip.
1) Temporarily tighten one adjusting bolt on one
side of rear sash at the midpoint of slotted hole in
the inner panel.
2) Temporarily tighten regulator B-channel in a
position slightly lower than midpoint of slotted hole.
3) Lower door glass 10 to 15 mm (0.39 to 0.59 in)
S5M0197B
from fully closed position. While applying outward
pressure of 45.0±4.9 N (4.59±0.50 kgf, 10.12±1.10 6) Adjust so that upper and lower ends of center
lb) (F) to upper edge of glass above midpoint of pillar are the same size.
two outer stabilizers, press inner stabilizer until it
just touches the glass, then secure it.
G5M0421
4) For adjustment of clearance between front and

rear glasses, loosen nuts (A), and move glass sash
back and forward until clearance becomes the
value shown.
G5M0639
7) For glass stroke adjustment, close door, raise

glass until positional relationship between glass
and weatherstrip becomes as shown. And secure
the glass so that upper stopper lightly touches the
S5M0199B glass holder.
S5M0200A
S5M0198A
GW-29
FRONT DOOR GLASS
8) After stabilizer adjustment, carry out glass 11) After adjustments, tighten nuts.
crimp adjustment. First, visually ensure positional 12) After adjustment of glass, if there is a gap
relationship between retainer & molding and glass between outer lip of gusset and glass surface,
of the roof side, and then begin with rear sash adjust the gap with adjusting bolt (A) in lower fitting
adjustment. Adjust two adjusting bolts alternately part of gusset to prevent generation of wind noise.
step by step to obtain dimensions shown below 13) During adjustments, loosen other three clamp-
(cross-section A). ing bolts.
NOTE:
If two nuts are loosened at the same time, sash
moves back and forth. Therefore, when one nut is
adjusted, secure the other.
9) Make the same adjustment of two adjusting
bolts of rear sash.
S5M0513A
14) After adjustment, tighten bolts and nuts.
S5M0200A
CAUTION:
Do not tilt sash bracket to inner panel during
adjustment. Otherwise smooth regulator
operation cannot be achieved.
S5M0201A
10) Make adjustment of front sash in the same

manner as that of rear sash.
CAUTION:
Although front and rear sashes must, as a rule,
be adjusted in the same manner, in some door
installation, the adjustment in a different man-
ner may be required. However, adjustment of
one sash to the maximum amount and the
other to the minimum amount is not permitted.
Such adjustment may result in application of
excessive load to regulator.
GW-30
FRONT REGULATOR AND MOTOR ASSEMBLY
7. Front Regulator and Motor

Assembly S905449

Front Door Trim.>
2) Remove sealing cover. <Ref. to EB-13,
3) Remove inner remote. <Ref. to SL-27,
4) Remove door glass. <Ref. to GW-28,
REMOVAL, Front Door Glass.>
5) Disconnect electrical connector.
6) Loosen four bolts and two nuts to pull out regu-
lator assembly.
B5M1049
7) Loosen screws to remove motor assembly.
B5M1050

2) Adjust front door glass. <Ref. to GW-29,
ADJUSTMENT, Front Door Glass.>
1) Make sure that power window motor rotates

properly when battery voltage is applied to termi-
nals of motor connector.
2) Change polarity of battery connections to termi-
nals to ensure that motor rotates in reverse direc-
tion.
GW-31
REAR DOOR GLASS
8. Rear Door Glass S905450 B: INSTALLATION S905450A11
1) Remove door trim. <Ref. to EI-27, REMOVAL, CAUTION:
Rear Door Trim.> Make sure that glass stay is placed securely in
2) Remove sealing cover. <Ref. to EB-16, sash.
REMOVAL, Rear Sealing Cover.> 2) Adjust rear door glass. <Ref. to GW-32,
3) Remove stabilizer. ADJUSTMENT, Rear Door Glass.>
NOTE:
Rear door glass, as a rule, should be adjusted in
the same manner as front glass, although they are
different in dimension. Special notes for rear glass
are given below.
1) Adjust glass position using the following dimen-
sions as a guide line.
B5M1044
4) Operate power window switch to move glass as

shown in the figure, and remove two nuts.
S5M0384A
CAUTION:
쐌 If dimensions are smaller than the given
B5M1046
dimensions, glass may get caught in weather-
5) Loosen two screws to remove weatherstrip. strip during lifting/lowering operation. In the
worst case, it may cause glass not to be
opened fully.
쐌 After adjustment, move glass up and down
to check whether it is caught.
2) Adjust crimp of glass using the following dimen-
sions as a guide line.
B5M1051
6) Pull out glass.

CAUTION:
Avoid impact and damage to the glass.
S5M0385A
CAUTION:
쐌 If crimp of rear glass is higher than
necessary, glass may get caught in weather-
strip of center pillar corner, resulting in early
GW-32
REAR DOOR GLASS
wear of weatherstrip. Be careful when adjust-

ing.
쐌 After adjustment, move glass up and down
to check whether it is caught.
GW-33
REAR REGULATOR AND MOTOR ASSEMBLY
9. Rear Regulator and Motor B: INSTALLATION S905451A11
Assembly S905451 1) Install in the reverse order of removal.

2) Adjust rear door glass. <Ref. to GW-32,
ADJUSTMENT, Rear Door Glass.>
Rear Door Trim.> C: INSPECTION S905451A10
2) Remove sealing cover. <Ref. to EB-16, 1) Make sure that power window motor rotates
REMOVAL, Rear Sealing Cover.> properly when battery voltage is applied to termi-
3) Remove door glass. <Ref. to GW-32, nals of motor connector.
REMOVAL, Rear Door Glass.> 2) Change polarity of battery connections to termi-
4) Secure bolts using screwdriver to remove front nals to ensure that motor rotates in reverse direc-
sash adjusting nut. tion.
B5M1052
5) Remove front sash.

6) Disconnect electrical connector.
7) Loosen four bolts and two nuts to remove regu-
lator assembly.
B5M1049
8) Loosen screws to remove motor assembly.
B5M1050
GW-34
WINDSHIELD GLASS
10. Windshield Glass S905448
1. USING WINDSHIELD KNIFE S905448A1801
1) Remove cowl panel. <Ref. to EI-25, REMOVAL,

Cowl Panel.>
2) Remove front side molding and upper front
molding.
3) Tape body side of the circumference of wind-
G5M0412
shield glass for protection.
4) Apply sufficient amount of soapy water to adhe-
sive layer. 2. USING PIANO WIRE S905448A1802
5) Insert windshield knife into the adhesive layer. 1) Remove cowl panel. <Ref. to EI-25, REMOVAL,
6) While holding the knife edge and windshield Cowl Panel.>
glass edge at a right angle, move windshield knife 2) Remove roof molding and upper front molding.
in parallel to windshield glass edge along face and 3) Tape the body side of the circumference of
edge of windshield glass to cut the adhesive layer. windshield glass for protection.
CAUTION: 4) Make a hole in adhesive layer using drill or
쐌 Do not twist windshield knife. knife.
쐌 Cutting of adhesive layer shall be started 5) Pass piano wire through the hole, and attach
with wider gap between windshield glass and securely both the wire ends to pieces of wood.
body.
G5M0494
6) Pull the wire ends alternately to cut off the

adhesive layer.
CAUTION:
쐌 Do not tightly pull the piano wire against the
windshield glass edge.
쐌 Be careful not to damage interior and exte-
rior parts.
쐌 When removal is made with area close to
instrument panel, place a protection plate over
it. Pay particular attention to the removal.
쐌 Do not cross piano wires. Otherwise they
G5M0418 may be cut.
NOTE:
Because matching pins are bonded to the corners
of glass, use piano wire to cut the pin.
GW-35
WINDSHIELD GLASS
B: INSTALLATION S905448A11 9) Apply primer to adhesive layer of body.

1) Clean external circumference of windshield CAUTION:
glass with alcohol or white gasoline. 쐌 Primer once attached to the painted surface
2) Remove adhesive layer on the body using cut- of the body and internal trim is hard to wipe off.
ter knife to obtain smooth face 2 mm (0.08 in) thick. Mask the circumference of such areas.
쐌 Let primer dry for about ten minutes before
CAUTION: installing the glass.
Be careful not to damage the body and paint 쐌 Do not touch surface coated with primer.
surface.
G5M0495
G5M0553
10) Cut off cartridge nozzle tip and set it in seal-
3) Clean body with alcohol or white gasoline to ant gun as shown.
remove thoroughly chips, dusts, and dirts from
body face.
4) Place glass on body.
5) Adjust glass position to make uniform clear-
ance between body and glass in four corners.
6) Place matching pins and body on glass.
G5M0408
11) Apply adhesive to glass end surface as

shown.
12) Fit matching pins using suction rubber cup to
install windshield glass.
G5M0407
7) Remove glass from body.

8) Apply primer to adhesive layer of glass using
sponge.
G5M0409
13) Lightly press windshield glass for tight fit.
GW-36
WINDSHIELD GLASS
14) Remove adhesive overflowing from outside of

glass until it becomes level with outer height of
glass. Then, add adhesive to portions that need it,
and clean with alcohol or white gasoline.
G5M0496
15) First, press-fit upper front window molding and

last, roof molding.
G5M0417
CAUTION:
쐌 When door is opened/closed after glass is
bonded, always lower door glass and then
open/close it carefully.
쐌 Move vehicle slowly.
16) After completion of all work, allow vehicle to
stand for about 24 hours.
NOTE:
For minimum drying time and time the vehicle must
be left standing before driving after bonding, follow
instructions or instruction manual from the adhe-
sive manufacturer.
17) After curing of adhesive, pour water on exter-
nal surface of vehicle to check that there are no
water leaks.
CAUTION:
When a vehicle is returned to the user, tell him
or her that the vehicle should not be subjected
to heavy impact for at least three days.
18) Install cowl panel. <Ref. to EI-25,
INSTALLATION, Cowl Panel.>
GW-37
REAR GATE GLASS
11. Rear Gate Glass S905376

2) Install glass in the same procedure as for wind-
shield glass. <Ref. to GW-36, INSTALLATION,
A: REMOVAL S905376A18 Windshield Glass.>
1) Remove real wiper motor. <Ref. to WW-20,
REMOVAL, Rear Wiper Motor.>
2) Remove electrical connector from rear defog-
ger terminal.
3) Remove glass in the same procedure as for
windshield glass. <Ref. to GW-35, REMOVAL,
Windshield Glass.>
NOTE:
A matching pin is cemented to corners of the glass
on the compartment side. Use a piano wire when
cutting each pin.
S5M0209A
S5M0511A
3) About one hour after installation, conduct a leak
(1) Body panel test.
(2) Glass
CAUTION:
(3) Matching pin
1) Install a new rubber strip (A) by aligning it with 쐌 Move vehicle slowly.
the end of the rear gate glass (B). 4) After completion of all work, allow vehicle to
NOTE:
sive manufacturer.
CAUTION:
S5M0208B to heavy impact for at least three days.
5) Connect rear defogger terminals.
6) Install rear wiper. <Ref. to WW-20,
INSTALLATION, Rear Wiper Motor.>
GW-38
REAR QUARTER GLASS
12. Rear Quarter Glass S905453
1) Remove rear quarter molding on corner.

2) Remove glass in the same procedure as for windshield glass. <Ref. to GW-35, REMOVAL, Windshield.>
S5M0388A
B: INSTALLATION S905453A11 7) Apply primer to surface of body to be adhered.

1) Using a putty knife, etc., cut layer of adhesive CAUTION:
stick firmly to body and finish it into a smooth sur- 쐌 If primer has dropped on body finish, it is
face of about 2 mm (0.08 in) in thickness. hard to wipe it off. So protect with masking.
쐌 Primer must not project from black frame of
CAUTION: glass.
Be careful not to damage body finish. 쐌 After applying primer, let it dry naturally for
about 10 minutes.
G5M0497
G5M0495
2) Remove chips, dirt and dust from body surface.
3) Clean body wall surface and upper surface of 8) Cut nozzle tip as shown in the figure.
adhesive layer with a solvent such as alcohol or
white gasoline.
4) Remove dirt and dust from surface of glass to
be adhered.
5) Clean surface of glass to be adhered with alco-
hol or white gasoline.
6) Using a sponge, apply primer to surface of
glass to be adhered.
G5M0414
9) Open cartridge and put it into a gun with nozzle

attached.
10) Apply adhesive uniformly to all sides of adhe-
sion surface while operating gun along glass end
face.
11) Hold glass with rubber suction cups.
GW-39
REAR QUARTER GLASS
12) Mount glass on body with matching pins (A)

aligned.
S5M0211B
13) Attach quickly and press all sides lightly.

CAUTION:
쐌 Move vehicle slowly.
14) After completion of all work, allow vehicle to
NOTE:
sive manufacturer.
15) After curing of adhesive, pour water on exter-
nal surface of vehicle to check that there are no
water leaks.
CAUTION:
to heavy impact for at least three days.
GW-40
ROOF WINDOW GLASS
13. Roof Window Glass S905339
<Ref. to SR-7, REMOVAL, Sunroof Lid.>
<Ref. to SR-7, INSTALLATION, Sunroof Lid.>
<Ref. to SR-7, ADJUSTMENT, Sunroof Lid.>
GW-41
INNER REARVIEW MIRROR
14. Inner Rearview Mirror S905340
NOTE:
The spring cannot be reused. Prepare a new
spring before removal.
1) Turn mirror base 90 degrees clockwise or coun-
terclockwise to remove it.
B5M1059
2) Remove spring from mirror base.
B5M1060
CAUTION:
Be careful not to damage the mirror surface.
Do not let mirror be damaged.
GW-42
POWER WINDOW CONTROL SWITCH
15. Power Window Control 2. SUB-SWITCH S903621A1802
Switch S905621 1) Remove door trim. <Ref. to EI-27, REMOVAL,

Rear Door Trim.>
A: REMOVAL S903621A18 2) Remove screws and sub-switch.
1. MAIN SWITCH S903621A1801
1) Release two hooks (A) of switch panel to

remove power window main switch.
2) Disconnect electrical connector from power
window main switch.
S5M0494
1. MAIN SWITCH S903621A1101

2. SUB-SWITCH S903621A1102
S5M0512A
1. MAIN SWITCH (LHD MODEL) S903621A1003

Driver’s switch:

AUTO UP 12 — 1, 2 — 7 Continuity
UP 12 — 1, 2 — 7 Continuity
OFF 1—2—7 Continuity
DOWN 12 — 2, 1 —7 Continuity
AUTO DOWN 12 — 2, 1 —7 Continuity
Front passenger’s switch:

DOWN 12 — 6, 5 — 7 Continuity
GW-43
Rear left switch:

OFF 9 — 10 — 7 Continuity
Rear right switch:

If NG, replace the main switch.

2. MAIN SWITCH (RHD MODEL) S903621A1004

Driver’s switch:

AUTO UP 7 — 16, 15 — 2 Continuity
DOWN 7 — 15, 16 —2 Continuity
AUTO DOWN 7 — 15, 16 —2 Continuity
Front passenger’s switch:

Rear left switch:

Rear right switch:

If NG, replace the main switch.

3. SUB-SWITCH (FRONT) S903621A1005

Front passenger’s door switch:

UP 8 — 3 — 5, 4 — 7 Continuity
OFF 4 — 7, 6 — 5 Continuity
DOWN 8 — 3 — 7, 6 — 5 Continuity
If NG, replace the sub-switch.
GW-44
4. SUB-SWITCH (REAR) S903621A1006

Rear door switch:

UP 6— 5, 1 — 4 Continuity
OFF 1— 4, 2 — 5 Continuity
DOWN 6— 4, 2 — 5 Continuity
If NG, replace the sub-switch.
GW-45
REAR WINDOW DEFOGGER SWITCH
16. Rear Window Defogger

Switch S905559
1) Remove center air vent grille. <Ref. to AC-41,

REMOVAL, Air Vent Grille.>
2) Pull out switch and disconnect the connector.
S5M0495
GW-46
REAR WINDOW DEFOGGER SWITCH

2) Check continuity between terminals on the wire
harness side with connectors connected.
Connector & terminal
(i18) No. 6 (+) — No. 8 (−):
S5M0514A
IGN SW Switch position Tester connection Specified condition

ON OFF (i18)6 — (i18)8 10V — 14V
ON ON 6—8 0V
GW-47
REAR WINDOW DEFOGGER
17. Rear Window Defogger S905341 B: REPAIR S905341A11
1) Clean broken portion with alcohol or white
gasoline.
CAUTION: 2) Mask both side of wire with thin film.
When wiping stain on glass off with cloth, use 3) Apply conductive silver composition (DUPONT
a dry and soft cloth and move it in the direction No. 4817) to broken portion.
of the heat wire extension to avoid damage to
the heat wire.
1) Turn ignition switch to ON.
2) Turn defogger switch to ON.
3) Wrap tips of tester pins with aluminum foil to
avoid damage to heat wire.
G6M0138
4) After repair, check wire.
G6M0136
4) Measure voltage at wire center with DC voltme-

ter.
Standard voltage:
Approx. 6 volts
B5M1053A
Voltage Criteria
Approx. 6 V OK
Approx. 12 V or 0 V Broken
NOTE:
쐌 If the measured value is 12 volts, heat wire is
open between wire center and positive (+) end.
쐌 If zero volt, heat wire is open between wire cen-
ter and ground.
5) Apply positive lead of voltmeter to positive ter-
minal of voltmeter, and then move negative lead
along the wire up to the negative terminal end. If
voltage changes from zero to several volts during
movement of lead, heat wire is open at the voltage
change point.
GW-48
OUTER MIRROR ASSEMBLY
18. Outer Mirror Assembly S905338

Front Door Trim.>
2) Pull off sealing cover to disconnect mirror elec-
trical connector.
B5M1054
3) Loosen screws to remove mirror assembly.
B5M1055
GW-49
OUTER MIRROR ASSEMBLY
Check to ensure that rearview mirror moves prop-

erly when battery voltage is applied to terminals.
Mirror heater not-equipped model:
Switch position Terminal connection

OFF —
UP 1 (+) — 3 (−)
DOWN 3 (+) — 1 (−)
LEFT 2 (+) — 3 (−)
RIGHT 3 (+) — 2 (−)
If NG, replace the mirror.

Mirror heater equipped model:
Switch position Terminal connection

OFF —
UP 2 (+) — 4 (−)
DOWN 4 (+) — 2 (−)
LEFT 3 (+) — 4 (−)
RIGHT 4 (+) — 3 (−)
If NG, replace the mirror.
GW-50
OUTER MIRROR
19. Outer Mirror S905658
A: REPLACEMENT S905658A20
1) Remove the door mirror assembly. <Ref. to

GW-49, REMOVAL, Outer Mirror Assembly.>
2) Warm the area around the mirror holder with a
hair drier until the edges of the mirror holder
become soft (about 2 or 3 minutes with a 1,000 W
drier.)
3) Use a flat-bladed screwdriver without sharp
edges to lift the mirror out of the mirror holder.
(Also remove the connector from the back of mir-
rors with heaters.)
B5M1144A
4) Warm the area around the mirror holder with a

hair drier until the edges of the mirror holder
become soft (about 2 or 3 minutes with a 1,000 W
drier.)
5) Remove the backing of the new two-sided tape,
and push the mirror in to install it.
CAUTION:
Unless the mirror holder is warmed sufficiently,
the mirror holder edges may be damaged or the
mirror cracked.
GW-51
REMOTE CONTROL MIRROR SWITCH
20. Remote Control Mirror

Switch S905342
Using a thin flat-bladed screwdriver, remove the

switch and disconnect the connector.
S5M0496
GW-52
REMOTE CONTROL MIRROR SWITCH
Move rearview mirror switch to each position and

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

NEUTRAL All terminals No continuity
LEFT 9 — 4, 2 — 1 Continuity
RIGHT 9 — 2, 4 — 1 Continuity
Change over switch right position:

NEUTRAL All terminals No continuity
LEFT 8 — 4, 2 — 1 Continuity
RIGHT 8 — 2, 4 — 1 Continuity
If NG, replace the switch.
GW-53
WIPER DEICER
21. Wiper Deicer S905622
Refer to INSPECTION under Rear Window Defog-

ger. <Ref. to GW-48, INSPECTION, Rear Window
Defogger.>
B: REPAIR S905622A11
Refer to REPAIR under Rear Window Defogger.

<Ref. to GW-48, REPAIR, Rear Window Defogger.
GW-54
WIPER DEICER SWITCH
22. Wiper Deicer Switch S905623
1) Remove lower cover.

2) Disconnect the connector and remove the
switch.
S5M0044A
Move wiper deicer switch to each position and

check continuity between terminals.
Specified condi-
tion
ON 3—5 Continuity
If NG, replace the switch.
GW-55
WIPER DEICER SWITCH
MEMO:
GW-56
BODY SECTION

SUBARU vehicles.
ine parts.

G8050GE6
BODY STRUCTURE
BS
Page
2. Datum Points...............................................................................................3
3. Datum Dimensions ....................................................................................15
GENERAL DESCRIPTION
Body Structure
A: PREPARATION TOOL S906001A17
TOOL NAME REMARKS

Tram tracking gauge Used for measuring dimen-
sion.
Tape measure Used for measuring dimen-
sion
BS-2
DATUM POINTS
Body Structure
2. Datum Points S906540
NOTE:
쐌 Datum points are specified for body repair.
쐌 Guide holes, locators, and indents are provided to facilitate panel replacement and to increase alignment
accuracy.
쐌 Both right and left reference points are symmetrical.
BS-3
DATUM POINTS
Body Structure
1. ROOM SECTION S906540A1301
S5M0073B
(1) Radiator panel (UPR) repair bolt (10) Hood hinge attaching bolt hole (20) Center pillar gauge hole 12 mm
hole M8 (Right) M8 (Symmetrical) (0.47 in) dia. (Symmetrical)
(2) Radiator panel (UPR) repair bolt (11) Cowl panel mounting hole 6 mm (21) Belt anchor attaching bolt hole
hole M8 (Left) (0.24 in) dia. (Symmetrical) 11.1 mm (7/16 in) dia. (Sym-
(3) Fender attaching bolt hole M6 (12) Roof inner trim attaching bolt metrical)
(Symmetrical) hole 8 mm (0.31 in) dia. (22) Wax coat hole, 20 mm (0.79 in)
(4) Repair locator 8 mm (0.31 in) (13) Fender attaching bolt hole M6 dia. (Symmetrical)
dia. (Symmetrical) (Symmetrical) (23) Rear door switch attaching hole
(5) Radiator panel side gauge hole (14) Front pillar gauge hole 20 mm 20 mm (0.79 in) dia. (Symmetri-
24 mm (0.94 in) dia. (Symmetri- (0.79 in) dia. (Symmetrical) cal)
cal) (15) Wax coat hole 20 mm (0.79 in) (24) Retainer attaching square hole 7
(6) Front bumper mounting hole 14 dia. (Symmetrical) mm (0.28 in) (Symmetrical)
× 16 mm (0.55 × 0.63 in) dia. (16) Retainer attaching square hole 7 (25) Spare tire attaching bolt hole M8
(Symmetrical) mm (0.28 in) (Symmetrical) (26) Air draw hole 7 mm (0.28 in) dia.
(7) Front crossmember attaching (17) Sun visor attaching hole 17 mm (Symmetrical)
bolt hole 12.4 mm (0.488 in) dia. (0.67 in) dia. (Symmetrical) (60) Fender attaching bolt hole M6
(Symmetrical) (18) Retainer attaching square hole 7 (Symmetrical)
(8) Fender attaching bolt hole M6 mm (0.28 in) (Symmetrical) (64) Door switch attaching hole 13.5
(Symmetrical) (19) Retainer attaching square hole 7 mm (0.531 in) dia. (Symmetrical)
(9) Front strut mounting hole 9.5 mm (0.28 in) (Symmetrical) (67) Front glass attaching hole Right
mm (0.374 in) dia. (Symmetrical) 6.5 mm (0.256 in) dia. Left 6.5 ×
10 mm (0.256 × 0.39 in) dia.
BS-4
DATUM POINTS
Body Structure
2. REAR SECTION S906540A1302
S5M0074A
(27) Rear pillar (Inner) harness and (43) Pad attaching square hole 9 mm (70) Buffer attaching hole M6 (Sym-
hose clip attaching hole 7 mm (0.35 in) dia. (Symmetrical) metrical)
(0.28 in) dia. (Symmetrical) (44) Rear quarter glass attaching (71) Bumper face attaching square
(34) Rear skirt gauge hole 20 mm hole 8 mm (0.31 in) dia. (Sym- hole 8 × 9 mm (0.31 × 0.35 in)
(0.79 in) dia. (Symmetrical) metrical) (72) Bumper face attaching square
(36) Rear quarter bumper side gauge (45) Rear locator hollow 4 mm (0.16 hole 8 × 9 mm (0.31 × 0.35 in)
hole 20 mm (0.79 in) dia. (Left) in) dia. (Symmetrical)
(37) Rear quarter bumper side gauge (46) Rear strut mounting hole 10 mm (73) Head console bracket gauge
hole 20 mm (0.79 in) dia. (Right) (0.39 in) dia. (Symmetrical) hole 8 mm (0.31 in) dia.
(38) Instrument panel attaching (47) Rear gate stay attaching bolt (74) Inner system carrier attaching
square hole 22 × 34.5 mm (0.87 hole M8 (Symmetrical) bolt hole 8 mm (0.31 in) (Sym-
× 1.358 in) (Right) (48) Inner trim clip attaching hole 8 × metrical)
(39) Steering support beam attaching 20 mm (0.31 × 0.79 in) dia. (75) Inner system carrier attaching
bolt hole M8 (Symmetrical) (Symmetrical) bolt hole 8 mm (0.31 in) (Sym-
(40) Front pillar (Inner) gauge hole 10 (49) Rear combination light mounting metrical)
mm (0.39 in) dia. (Symmetrical) hole 8 mm (0.31 in) dia. (Sym- (76) Head console bracket gauge
(41) Floor mat attaching clip hole 8 metrical) hole 8 mm (0.31 in) dia.
mm (0.31 in) dia. (Symmetrical) (61) Side rail (Inner) gauge hole 10
(42) Rear quarter glass attaching mm (0.39 in) dia. (Symmetrical)
hole 8 × 15 mm (0.31 × 0.59 in) (65) Repair location hole 12 mm
dia. (Symmetrical) (0.47 in) dia. (Symmetrical)
BS-5
DATUM POINTS
Body Structure
3. UNDERBODY SECTION S906540A1303
S5M0075A
(50) Radiator panel (LWR) frame (53) Front suspension attaching bolt (57) Rear differential attaching bolt
gauge hole 15 mm (0.59 in) dia. hole M14 hole M12 (Symmetrical)
(Symmetrical) (54) Side frame gauge hole 20 mm (58) Rear suspension attaching bolt
(51) Front side frame gauge hole 20 (0.79 in) dia. (Symmetrical) hole M12 (Symmetrical)
mm (0.79 in) dia. (Symmetrical) (55) Repair location hole 12 mm (59) Rear side frame gauge hole 15
(52) Front crossmember attaching (0.47 in) dia. (Symmetrical) mm (0.59 in) dia. (Symmetrical)
hole 12.4 mm (0.488 in) dia. (56) Side frame gauge hole 15 mm
(Symmetrical) (0.59 in) dia. (Symmetrical)
BS-6
DATUM POINTS
Body Structure
S5M0076A S5M0077A
S5M0079A
S5M0078A
S5M0080A S5M0081A
S5M0083B
S5M0082A
BS-7
DATUM POINTS
Body Structure
S5M0085A
S5M0084A
S5M0087A
S5M0086A
S5M0088A S5M0089A
S5M0091A
S5M0090A
BS-8
DATUM POINTS
Body Structure
S5M0092A S5M0093A
S5M0095A
S5M0094A
S5M0097A
S5M0096A
S5M0098A S5M0099A
BS-9
DATUM POINTS
Body Structure
S5M0100A S5M0101A
S5M0102A S5M0103A
S5M0104A
S5M0105B
S5M0106A
S5M0107A
BS-10
DATUM POINTS
Body Structure
S5M0108A S5M0109A
S5M0110A
S5M0111A
S5M0113A
S5M0112A
S5M0114A
S5M0115A
BS-11
DATUM POINTS
Body Structure
S5M0116A S5M0117A
S5M0516A
S5M0118A
S5M0120A S5M0121A
S5M0122A S5M0123B
BS-12
DATUM POINTS
Body Structure
S5M0124A S5M0125A
S5M0126B S5M0127A
S5M0129A
S5M0128A
S5M0130A
S5M0131A
BS-13
DATUM POINTS
Body Structure
S5M0132A S5M0133A
S5M0134A
S5M0135A
S5M0136A
BS-14
DATUM DIMENSIONS
Body Structure
3. Datum Dimensions S906337
A: MEASUREMENT S906337A14
Refer to LOCATION for details on measurement

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

outside of the body panel.
B5M1133A
BS-15
DATUM DIMENSIONS
Body Structure
1. FRONT STRUCTURE S906337A1401
S5M0137A
Unit: mm (in)
Point to point Dimension Point to point Dimension
(11) R to (1) 852 (33.54) (10) R to (8) R 390 (15.35)
(11) L to (1) 913 (35.94) (10) L to (8) L 390 (15.35)
(11) R to (2) 960 (37.80) (11) L to (9) R 659 (25.94)
(11) L to (2) 865 (34.06) (11) R to (9) L 659 (25.94)
(11) R to (9) R 392 (15.43) (9) R to (9) L 966 (38.03)
(11) L to (9) L 392 (15.43) (11) L to (6) R 1,059 (41.69)
(11) R to (6) R 926 (36.46) (11) R to (6) L 1,059 (41.69)
(11) L to (6) L 926 (36.46) (6) R to (6) L 914 (35.98)
(11) R to (3) R 891 (35.08) (6) R to (10) L 1,549 (60.98)
(11) L to (3) L 891 (35.08) (6) L to (10) R 1,549 (60.98)
(10) R to (3) R 917 (36.10) (8) R to (3) R 528 (20.79)
(10) L to (3) L 917 (36.10) (8) L to (3) L 528 (20.79)
(10) R to (10) L 1,374 (54.09) (10) L to (3) R 1,637 (64.45)
(3) R to (3) L 1,338 (52.68) (8) R to (8) L 1,396 (54.96)
(5) R to (5) L 924 (36.38) (8) R to (10) L 1,438 (56.61)
(4) R to (4) L 1,296 (51.02) (8) L to (10) R 1,438 (56.61)
(5) R to (4) L 1,176 (46.30) (3) R to (8) L 1,465 (57.68)
(5) L to (4) R 1,176 (46.30) (3) L to (8) R 1,465 (57.68)
(60) R to (13) R 1,174 (46.22) (7) R to (7) L 860 (33.86)
(60) L to (13) L 1,174 (46.22) (7) R to (6) L 982 (38.66)
(60) R to (14) R 1,076 (42.36) (7) L to (6) R 982 (38.66)
(60) L to (14) L 1,076 (42.36) (7) R to (10) L 1,302 (51.26)
(10) R to (3) L 1,637 (64.45) (7) L to (10) R 1,302 (51.26)
BS-16
DATUM DIMENSIONS
Body Structure
S5M0141A
Unit: mm (in)
(11) to (A) 909.9 (35.82) (11) to (C) 1,097.7 (43.22)
(11) to (B) 915 (36.02) (11) to (D) 1,022 (40.24)
BS-17
DATUM DIMENSIONS
Body Structure
2. CENTER STRUCTURE S906337A1402
S5M0138B
BS-18
DATUM DIMENSIONS
Body Structure
3. WINDSHIELD AND DOORS S906337A1403
S5M0139A
BS-19
DATUM DIMENSIONS
Body Structure
Unit: mm (in)
(14) L to (18) L 1,453 (57.20) (16) L to (64) L 859 (33.82)
(14) R to (18) R 1,453 (57.20) (16) R to (64) R 859 (33.82)
(13) L to (64) L 944 (37.17) (20) L to (23) L 845 (33.27)
(13) R to (64) R 944 (37.17) (20) R to (23) R 845 (33.27)
(20) L to (24) L 947 (37.28) (19) L to (23) L 885 (34.84)
(20) R to (24) R 947 (37.28) (19) R to (23) R 885 (34.84)
(20) L to (36) 1,484 (58.43) (11) L to (67) R 1,147 (45.16)
(20) R to (37) 1,488 (58.58) (11) R to (67) L 1,147 (45.16)
(42) L to (44) L 769 (30.28) (41) to (38) 1,157 (45.55)
(42) R to (44) R 769 (30.28) (41) to (39) R 1,530 (60.24)
(11) R to (12) 918 (36.14) (41) to (39) L 1,530 (60.24)
(11) L to (12) 918 (36.14) (41) to (40) R 1,447 (56.97)
(67) R to (67) L 1,045 (41.14) (41) to (40) L 1,447 (56.97)
(11) R to (67) R 1,006 (39.61) (41) to (15) R 1,140 (44.88)
(11) L to (67) L 1,006 (39.61) (41) to (15) L 1,140 (44.88)
(12) to (67) L 525 (20.67) (41) to (22) R 733 (28.86)
(12) to (67) R 525 (20.67) (41) to (22) L 733 (28.86)
(12) to (10) L 1,027 (40.43) (41) to (26) R 1,568 (61.73)
(12) to (10) R 1,027 (40.43) (41) to (26) L 1,568 (61.73)
(21) R to (21) L 1,322 (52.05) (41) to (25) 1,212 (47.72)
(15) R to (15) L 1,453 (57.20) (41) to (12) 1,298 (51.10)
(22) R to (22) L 1,453 (57.20) (41) to (21) R 944 (37.17)
(39) R to (39) L 1,392 (54.80) (41) to (21) L 944 (37.17)
(40) R to (40) L 1,402 (55.20) (41) to (17) R 1,332 (52.44)
(11) L to (17) R 1,168 (45.98) (41) to (17) L 1,332 (52.44)
(11) R to (17) L 1,168 (45.98)
BS-20
DATUM DIMENSIONS
Body Structure
4. COMPARTMENT S906337A1404
S5M0140A
Unit: mm (in)
(45) to (48) L 862 (33.94) (41) to (65) R 1,131 (44.53)
(45) to (48) R 862 (33.94) (41) to (65)L 1,131 (44.53)
(45) to (47) L 876 (34.49) (41) to (45) 1,569 (61.77)
(45) to (47) R 876 (34.49) (41) to (43) R 1,435 (56.50)
(47) R to (47) L 1,426 (56.14) (41) to (43) L 1,435 (56.50)
(49)R to (49) L 1,479 (58.23) (41) to (48) L 1,576 (62.05)
(34) R to (34) L 945 (37.20) (41) to (48) R 1,576 (62.05)
(48) R to (46) R 992 (39.06) (65) R to (65) L 1,267 (49.88)
(48) L to (46) L 992 (39.06) (17) R to (76) 627 (24.68)
(70) R to (70) L 1,218 (47.95) (17) L to (76) 680 (26.77)
(61) R to (75) R 447 (17.60) (72) R to (72) L 1,111 (43.74)
(61) L to (75) L 447 (17.60) (74) R to (75) R 480 (18.90)
(17) R to (75) R 1,137 (44.76) (74) L to (75) L 480 (18.90)
(17) L to (75) L 1,137 (44.76) (17) R to (73) 518 (20.39)
(45) to (71) 913 (35.94) (17) L to (73) 476 (18.74)
BS-21
DATUM DIMENSIONS
Body Structure
MEMO:
BS-22
BODY SECTION

SUBARU vehicles.
ine parts.

G8050GE6
INSTRUMENTATION/DRIVER INFO
IDI
Page
2. Combination Meter System.........................................................................4
3. Combination Meter Assembly ...................................................................15
4. Speedometer .............................................................................................17
5. Tachometer................................................................................................18
6. Fuel Gauge................................................................................................19
7. Water Temperature Gauge........................................................................20
8. Ambient Sensor.........................................................................................21
GENERAL DESCRIPTION
Instrumentation/Driver Info
Speedometer Electric pulse type

Temperature gauge Thermistor cross coil type
Fuel gauge Resistance cross coil type
Tachometer Electric impulse type
Turn signal indicator light 14 V — 1.4 W
Charge indicator light 14 V — 1.4 W
Oil pressure indicator light 14 V — 1.4 W
ABS warning light 14 V — 1.4 W
CHECK ENGINE warning light 14 V — 1.4 W
(Malfunction indicator light)
HI-beam indicator light 14 V — 1.4 W
Door open warning light LED
Combination meter Seat belt warning light 14 V — 1.4 W
Brake fluid and parking brake warning light 14 V — 1.4 W
FWD indicator light 14 V — 1.4 W
AIRBAG warning light 14 V — 1.4 W
Meter illumination light 14 V — 3 W, 1.4 W
AT OIL TEMP. warning light 14 V — 1.4 W
LO indicator light 14 V — 1.4 W
HOLD indicator light 14 V — 1.4 W
POWER indicator light 14 V — 1.4 W
Rear differential oil temperature warning light 14 V — 1.4 W
Immobilizer indicator light LED
Low fuel warning light 14 V — 1.4 W
LCD back light 14 V — 1.4 W
IDI-2
GENERAL DESCRIPTION
쐌 Be careful not to damage meters and instrument panel.

쐌 Be careful not to damage meter glasses.
쐌 Make sure that electrical connector is connected securely.
쐌 After installation, make sure that each meter operates normally.
쐌 Use gloves to avoid damage and getting fingerprints on the glass surface and meter surfaces.
쐌 Do not apply excessive force to circuit plate.
쐌 Do not drop or otherwise apply impact.
TOOL NAME REMARKS

IDI-3
COMBINATION METER SYSTEM
2. Combination Meter System S907607
1. COMBINATION METER S907607A2101
SG6420A
IDI-4
2. OUTSIDE TEMPERATURE INDICATOR LHD MODEL S907607A2103
SL96-20
IDI-5
3. OUTSIDE TEMPERATURE INDICATOR RHD MODEL S907607A2104
SR96-20
IDI-6
CAUTION:
When measuring voltage and resistance of the ECM, TCM, or each sensor, use a tapered pin with
a diameter of less than 0.64 mm (0.025 in) in order to avoid poor contact. Do not insert the pin more
than 2 mm (0.08 in).
1. SYMPTOM CHART S907607A1007
Symptom Repair order Reference

Combination meter assembly does not operate. (1) Power supply <Ref. to IDI-8 CHECK
(2) Ground circuit POWER SUPPLY AND
GROUND CIRCUIT,
INSPECTION, Combina-
tion Meter System.>
Speedometer does not operate. (1) (MT) Vehicle speed sensor MT: <Ref. to IDI-9
(AT) Transmission control module CHECK VEHICLE
(2) Harness SPEED SENSOR,
(3) Speedometer INSPECTION, Combina-
tion Meter System.>
AT: <Ref. to IDI-10
CHECK TRANSMIS-
SION CONTROL
MODULE,
tion Meter System.>
Tachometer does not operate. (1) Engine control module <Ref. to IDI-11 CHECK
(2) Harness ENGINE CONTROL
(3) Tachometer MODULE,
tion Meter System.>
Fuel gauge does not operate. (1) Fuel level sensor <Ref. to IDI-12 CHECK
(2) Harness FUEL LEVEL SENSOR,
(3) Fuel gauge INSPECTION, Combina-
tion Meter System.>
Water temperature gauge does not operate. (1) Engine coolant temperature sensor <Ref. to IDI-13 CHECK
(2) Harness ENGINE COOLANT
(3) Water temperature gauge TEMPERATURE
SENSOR,
tion Meter System.>
Outside temperature indicator does not operate. (1) Ambient sensor <Ref. to IDI-14 CHECK
(2) Harness OUTSIDE TEMPERA-
(3) Combination meter TURE INDICATOR,
tion Meter System.>
IDI-7
2. CHECK POWER SUPPLY AND

GROUND CIRCUIT S907607A1001
No. Step Check Yes No
1 CHECK POWER SUPPLY FOR COMBINA- Is the voltage more than 10 Go to step 2. Check harness for
TION METER. V? open or short
1) Remove combination meter. <Ref. to IDI-15 between fuse and
REMOVAL, Combination Meter Assembly.> combination
2) Disconnect combination meter harness meter.
connector.
4) Measure voltage between combination
meter connector (i10) and chassis ground.
(i10) No. 1 (+) — Chassis ground (−):
2 CHECK POWER SUPPLY FOR COMBINA- Is the voltage more than 10 Go to step 3. Check harness for
TION METER. V? open or short
Measure voltage between combination meter between ignition
connector (i10) and chassis ground. relay and combi-
Connector & terminal nation meter.
3 CHECK GROUND CIRCUIT OF COMBINA- Is the resistance less than Replace combina- Repair wiring har-
TION METER. 10 Ω? tion meter printed ness.
1) Turn ignition switch to OFF. circuit.
2) Measure resistance of harness between
combination meter connector (i10) and chas-
sis ground.
IDI-8
3. CHECK VEHICLE SPEED SENSOR

S907607A1002

1 CHECK VEHICLE SPEED SENSOR. Is the voltage less than 1 V Check speedom- Go to step 2.
1) Set the vehicle on a free roller, or lift-up the ←→ more than 4? eter. <Ref. to
vehicle and support it with safety stands. IDI-17 REMOVAL,
2) Remove the combination meter with har- Speedometer.>
ness connector.
WARNING:
Be careful not to get caught in the running
wheels.
3) Drive the vehicle at a speed greater than
20 km/h (12 MPH).
4) Measure voltage between combination
meter connector (i10) and chassis ground.
2 CHECK VEHICLE SPEED SENSOR POWER Is the voltage more than 10 Go to step 3. Check harness for
SUPPLY. V? open or short
1) Turn ignition switch to OFF. between ignition
2) Disconnect vehicle speed sensor harness relay and vehicle
connector. speed sensor.
4) Measure voltage between vehicle speed
sensor connector (B17) and engine ground.
(B17) No. 3 (+) — Engine ground (−):
3 CHECK HARNESS BETWEEN VEHICLE Is the resistance less than Go to step 4. Repair wiring har-
SPEED SENSOR AND ENGINE GROUND. 10 Ω? ness.
1) Turn ignition switch to OFF.
2) Measure resistance between vehicle speed
sensor connector (B17) and engine ground.
4 CHECK HARNESS BETWEEN VEHICLE Is the resistance less than Replace vehicle Repair wiring har-
SPEED SENSOR AND COMBINATION 10 Ω? speed sensor. ness.
METER.
1) Disconnect connector from combination
meter.
sensor harness connector and combination
meter harness connector.
(B17) No. 1 — (i10) No. 7:
IDI-9
4. CHECK TRANSMISSION CONTROL

MODULE S907607A1008
1 CHECK TRANSMISSION CONTROL MOD- Is the voltage less than 1 V Go to step 2. Check transmis-
ULE SIGNAL. ←→ more than 4 V? sion control mod-
1) Set the vehicle on a free roller, or lift-up the ule. <Ref. to AT-2
vehicle and support it with safety stands. Basic Diagnostic
WARNING: Procedure.>
Be careful not to get caught in the running
wheels.
2) Drive the vehicle faster than 10 km/h (6
MPH).
3) Measure voltage between transmission
control module connector (B55) and chassis
ground.
(B56) No. 17 (+) — Chassis ground (−):
2 CHECK HARNESS BETWEEN TRANSMIS- Is the resistance less than Check speed Repair wiring har-
SION CONTROL MODULE AND COMBINA- 10 Ω? meter. <Ref. to ness.
TION METER. IDI-17 REMOVAL,
1) Turn ignition switch to OFF. Speedometer.>
2) Disconnect connector from transmission
control module and combination meter.
3) Measure resistance between transmission
control module harness connector (B55) and
combination meter harness connector (i10).
(B56) No. 17 — (i10) No. 7:
IDI-10
5. CHECK ENGINE CONTROL MODULE

S907607A1004

1 CHECK ENGINE CONTROL MODULE SIG- Is the voltage 0 ←→ 13 V Go to step 2. Check engine
NAL. or more? control module.
1) Start the engine. <Ref. to
2) Measure voltage between engine control EN(SOHC)-2,
module connector (B84, B134 or B136) and Basic Diagnostic
engine ground. Procedure.>,
Connector & terminal <Ref. to
SOHC model: EN(SOHCw/
(B134) No. 30 (+) — Engine ground (−): oOBD)-2, Basic
SOHC without OBD model: Diagnostic Proce-
(B84) No. 6 (+) — Engine ground (−): dure.> or <Ref. to
DOHC turbo model: EN(DOHC
(B136) No. 9 (+) — Engine ground (−): TURBO)-2, Basic
Diagnostic Proce-
dure.>
2 CHECK HARNESS BETWEEN COMBINA- Is the resistance less than Check tachom- Repair wiring har-
TION METER AND ENGINE CONTROL 10 Ω? eter. <Ref. to ness.
MODULE. IDI-18 REMOVAL,
1) Turn ignition switch to OFF. Tachometer.>
2) Disconnect connector from engine control
module and combination meter.
3) Measure resistance between engine control
module harness connector (B84, B134 or
B136) and combination meter harness con-
nector (i11).
SOHC model:
(B134) No. 30 — (i10) No. 8:
SOHC without OBD model:
(B84) No. 6 (+) — (i10) No. 8:
DOHC turbo model:
(B136) No. 9 (+) — (i10) No. 8:
IDI-11
6. CHECK FUEL LEVEL SENSOR S907607A1005

1 CHECK FUEL LEVEL SENSOR. Is the resistance 0.5 to 2.5 Go to step 2. Replace the fuel
1) Remove fuel level sensor. <Ref. to Ω (FULL) and 50 to 52 Ω level sensor.
FU(SOHC)-64, REMOVAL, Fuel Level (EMPTY)?
Sensor.>, <Ref. to FU(SOHCw/oOBD)-52,
REMOVAL, Fuel Level Sensor.> or <Ref. to
FU(DOHC TURBO)-62, REMOVAL, Fuel
Level Sensor.>
2) Measure resistance between fuel level sen-
sor terminals when setting the float to FULL
and EMPTY position.
Terminals
No. 3 — No. 5:
2 CHECK FUEL SUB LEVEL SENSOR. Is the resistance 0.5 to 2.5 Go to step 3. Replace the fuel
1) Remove fuel sub level sensor. <Ref. to Ω (FULL) and 42 to 44 Ω sub level sensor.
FU(SOHC)-65, REMOVAL, Fuel Sub Level (EMPTY)?
Sensor.>, <Ref. to FU(SOHCw/oOBD)-53,
REMOVAL, Fuel Sub Level Sensor.> or <Ref.
to FU(DOHC TURBO)-63, REMOVAL, Sub
Fuel Level Sensor.>
2) Measure resistance between fuel sub level
sensor terminals when setting the float to
FULL and EMPTY position.
Terminals
No. 1 — No. 2:
3 CHECK HARNESS BETWEEN FUEL SUB Is the resistance less than Go to step 4. Repair wiring har-
LEVEL SENSOR AND COMBINATION 10 Ω? ness.
METER.
meter.
sensor harness connector terminal and com-
bination meter harness connector terminal.
(R59) No. 1 — (i11) No. 10:
4 CHECK HARNESS BETWEEN FUEL LEVEL Is the resistance less than Go to step 5. Repair wiring har-
SENSOR AND FUEL SUB LEVEL SENSOR. 10 Ω? ness.
Measure resistance between fuel level sensor
harness connector terminal and fuel sub level
sensor harness connector terminal.
(R58) No. 3 — (R59) No. 2:
5 CHECK FUEL LEVEL SENSOR GROUND Is the resistance less than Check fuel gauge. Repair wiring har-
CIRCUIT. 10 Ω? <Ref. to IDI-19, ness.
Measure resistance between fuel level sensor REMOVAL, Fuel
harness connector terminal and chassis Gauge.>
ground.
(R58) No. 5 — Chassis ground:
IDI-12
7. CHECK ENGINE COOLANT

TEMPERATURE SENSOR S907607A1006
1 CHECK ENGINE COOLANT TEMPERA- Is engine coolant tempera- Go to step 2. Replace engine
TURE SENSOR. ture sensor OK? coolant tempera-
Check engine coolant temperature sensor. ture sensor.
<Ref. to EN(SOHC)-122, DTC
P0117—ENGINE COOLANT TEMPERATURE
SENSOR CIRCUIT LOW INPUT—, Diagnos-
tic Procedure with Diagnostic Trouble Code
(DTC).>, <Ref. to EN(SOHCw/oOBD)-70,
DTC21 ENGINE COOLANT TEMPERATURE
SENSOR, Diagnostic Procedure with Diag-
nostic Trouble Code (DTC).> or <Ref. to
EN(DOHC TURBO)-130, DTC
P0117—ENGINE COOLANT TEMPERATURE
SENSOR CIRCUIT LOW INPUT—, Diagnos-
tic Procedure with Diagnostic Trouble Code
(DTC).>
2 CHECK HARNESS BETWEEN ENGINE Is the resistance less than Check water tem- Repair wiring har-
COOLANT TEMPERATURE SENSOR AND 10 Ω? perature gauge. ness.
COMBINATION METER. <Ref. to IDI-20
1) Turn ignition switch to OFF. REMOVAL, Water
2) Disconnect connector from engine coolant Temperature
temperature sensor and combination meter. Gauge.>
3) Measure resistance between engine cool-
ant temperature sensor harness connector
(E8) and combination meter harness connec-
tor (i12).
(E8) No. 3 — (i12) No. 13:
IDI-13
8. CHECK OUTSIDE TEMPERATURE

INDICATOR S907607A1009
1 CHECK POWER SUPPLY FOR AMBIENT Is the voltage more than 4 Go to step 2. Check harness for
SENSOR. V? open or short
1) Turn ignition switch OFF. between ambient
2) Disconnect connector from ambient sensor. sensor and com-
3) Turn ignition switch ON. bination meter.
4) Measure voltage between ambient sensor
harness connector terminal and chassis
ground.
(F78) No. 2 (+) — Chassis ground (−):
2 CHECK AMBIENT SENSOR. Is the ambient sensor OK? Go to step 3. Replace the ambi-
1) Turn ignition switch OFF. ent sensor.
2) Remove ambient sensor.
3) Check ambient sensor. <Ref. to IDI-21
INSPECTION, Ambient Sensor.>
3 CHECK HARNESS BETWEEN AMBIENT Is the resistance less than Go to step 4. Repair wiring har-
SENSOR AND COMBINATION METER. 10 Ω? ness.
meter.
2) Measure resistance between ambient sen-
sor harness connector terminal and combina-
tion meter harness connector terminal.
(F78) No. 1 — (i10) No. 4:
(F78) No. 2 — (i10) No. 5:
4 CHECK OUTSIDE TEMPERATURE INDICA- Is the outside temperature Check poor con- Replace combina-
TOR. indicator indicating 25°C tact in ambient tion meter printed
1) Connect combination meter harness con- (77°F)? sensor harness circuit.
nector. connector.
2) Connect a resistor (3.0 kΩ) between termi-
nals of ambient sensor harness connector.
3) Turn ignition switch ON and check the out-
side temperature indicator display.
IDI-14
COMBINATION METER ASSEMBLY
3. Combination Meter B: INSTALLATION S907335A11
Assembly S907335 Install in the reverse order of removal.

CAUTION:
쐌 Make sure that electrical connector is con-
1) Disconnect ground cable from battery. nected securely.
2) Set tilt steering at the lowest position. 쐌 Make sure that each meter operates nor-
3) Remove screws and detach meter visor. mally.
CAUTION:
Use gloves to avoid damage and getting finger-
prints on the glass surface and meter surfaces.
1) Disengage claw (F) to remove case (B) from
back cover (A).
2) Disengage claw (G) to remove meter glass (E),
reflector (D), and window plate (C) from inner case.
S6M0076A
4) Remove screws of combination meter and pull

out the meter toward you.
S6M0511A
3) Pull up claw (A) of combination meter printed

circuit with combination pliers. Push out speedom-
S6M0077 eter assembly (B) and tachometer assembly (C)
5) Disconnect connector in the upper area of com- using hole (D).
bination meter to remove meter. 4) Pull up claw in the center of combination meter
printed circuit and remove combination meter
CAUTION: printed circuit from case (F).
쐌 Be careful not to damage meter or instru-
ment panel.
쐌 Pay particular attention to avoid damaging
the meter glass.
S6M0512A
IDI-15
COMBINATION METER ASSEMBLY
1. BULB REPLACEMENT S907335A0601
S6M0565A
(1) Check engine

(2) Oil pressure
(3) Charge
(4) Seat belt (RHD)
(5) AT oil temp.
(6) Brake
(7) Tachometer
(8) Turn RH
(9) Airbag warning light
(10) HI-beam
(11) Turn LH
(12) Speedometer
(13) FWD
(14) Seat belt (LHD)
(15) ABS
(16) AWD LO
(17) R. DIFF TEMP
(18) Low fuel
(19) Speedometer and fuel gauge
(20) Odometer and trip meter
(21) HOLD
(22) Outside air temperature display
(23) POWER
(24) Tachometer and temperature gauge
IDI-16
SPEEDOMETER
4. Speedometer S907608
Disassemble combination meter, and then remove

speedometer and fuel gauge assembly. <Ref. to
IDI-15 DISASSEMBLY, Combination Meter
Assembly.>
Measure resistance between speedometer termi-

nals.
B6M1232A

Terminals SIN+ —SIN— 200±8 Ω
Terminals COS+ —COS— 200±8 Ω
If NG, replace speedometer and fuel gauge

assembly.
If OK, replace combination meter printed circuit.
IDI-17
TACHOMETER
5. Tachometer S907609

tachometer and water temperature gauge assem-
bly. <Ref. to IDI-15 DISASSEMBLY, Combination
Meter Assembly.>
Measure resistance between tachometer termi-

nals.
B6M1232A

Terminals SIN+ —SIN— 200±8 Ω
Terminals COS+ —COS— 200±8 Ω
If NG, replace tachometer and water temperature

gauge assembly.
IDI-18
FUEL GAUGE
6. Fuel Gauge S907610

speedometer and fuel gauge assembly. <Ref. to
IDI-15 DISASSEMBLY, Combination Meter
Assembly.>
Measure resistance between fuel gauge terminals.
B6M1233A

Terminals IGN — GND 170±10 Ω
Terminals IGN — UNIT 35±10 Ω
Terminals UNIT — GND 136±10 Ω
If NG, replace speedometer and fuel gauge

assembly.
IDI-19
WATER TEMPERATURE GAUGE
7. Water Temperature Gauge S907611

tachometer and water temperature gauge assem-
bly. <Ref. to IDI-15 DISASSEMBLY, Combination
Meter Assembly.>
Measure resistance between fuel gauge terminals.
B6M1233A

Terminals IGN — GND 208±10 Ω
Terminals IGN — UNIT 56±10 Ω
Terminals UNIT — GND 264±10 Ω
If NG, replace tachometer and water temperature

gauge assembly.
IDI-20
AMBIENT SENSOR
8. Ambient Sensor S907644

2) Disconnect ambient sensor connector.
3) Remove ambient sensor (A) from radiator lower
panel.
S6M0510A
Measure resistance between ambient sensor ter-

minals.
B6M1537

1—2 3.0 kΩ/25°C (77°F)
If NG, replace the ambient sensor.
IDI-21
AMBIENT SENSOR
MEMO:
IDI-22
BODY SECTION

SUBARU vehicles.
ine parts.

G8050GE6
SEATS
SE
Page
2. Front Seat....................................................................................................5
3. Rear Seat ....................................................................................................6
GENERAL DESCRIPTION
Seats
1. FRONT SEAT S908001A0501
S5M0440A
(1) Lumbar lever (8) Lifter dial (15) Slide rail ASSY OUT
(2) Lumbar cover (9) Hinge cover OUT (16) Bracket
(3) Lumbar unit (10) Reclining lever
(4) Headrest (11) Hinge ASSY Tightening torque: N·m (kgf-m, ft-lb)
(5) Backrest (12) Hinge spring cover T1: 18 (1.8, 13)
(6) Cushion (13) Slide rail ASSY IN T2: 52 (5.3, 38)
(7) Cushion frame (14) Connecting wire
SE-2
GENERAL DESCRIPTION
Seats
2. REAR SEAT S908001A0505
S5M0508A
(1) Backrest RH (7) Hinge LH Tightening torque: N·m (kgf-m, ft-lb)

(2) Backrest LH (8) Cushion
T1: 10 (1.0, 7.2)
(3) Headrest OUTSIDE (9) Striker
T2: 25 (2.5, 18.1)
(4) Headrest CENTER (10) Cap
(5) Hinge RH (11) Webbing guide
(6) Hinge CENTER
SE-3
GENERAL DESCRIPTION
Seats
쐌 Take care not to contaminate or damage seat

surface.
쐌 While loading to or unloading to vehicle, take
care not to contact body.
쐌 When removing front seat from a side airbag
loaded vehicle, follow cautions given in the airbag
section.
SE-4
FRONT SEAT
Seats
2. Front Seat S908343

CAUTION:
쐌 When removing seat from vehicle, take care
A: REMOVAL S908343A18 not to damage body, seat, or trim.
쐌 After the front seat has been removed from
1) While operating button (located on top of side airbag equipped vehicle, store it as
backrest), lift headrest out with hand placed instructed in AIRBAG REPAIR SECTION. <Ref.
between backrest and headrest. to AB-15, CAUTION, Side Airbag Module.>
1) While operating button (located on top of

backrest), lift headrest out by placing your hand
between backrest and headrest.
S5M0303
2) Pull reclining lever back to fold backrest all the

way forward. While pulling slide adjuster lever,
move seat all the way forward.
3) Remove bolt cover at rear end of slide rail.
S5M0303
4) Remove bolts securing seat rear.
2) Pull reclining lever back to fold backrest all the
way forward. Pull slide adjuster lever and move
lower slide rail all the way backward.
3) Position seat in compartment and align the
holes on the seat with the holes on the vehicle
body side.
4) Secure the front of seat using inward and out-
ward bolts (A) and (B) in that order.
5) While pulling slide adjuster lever, move seat all
the way forward.
6) Secure the rear of seat using inward and out-
S5M0366
ward bolts (C) and (D).
5) While pulling slide adjuster lever, slide seat all
the way back.
6) Remove bolts securing front of seat.
S5M0227A
7) Connect inner belt connector.

8) Connect side airbag connector. (Side airbag
G5M0344 equipped model)
9) Install bolt cover on rear end of slide rail.
7) While disconnecting side airbag connector,
10) Install headrest on backrest.
detach front seat. (Side airbag equipped vehicle)
and inner belt connector. CAUTION:
Confirm that seat can move smoothly and be
locked securely at any position.
SE-5
REAR SEAT
Seats
3. Rear Seat S908350
1) Remove bolts securing hinges (located at front

of cushion) to body.
2) Slightly raise front of cushion while pushing
down on cushion in the direction of “A”. With cush-
ion held in that position, move it forward until it is
unhooked.
S5M0228A
3) Remove rear quarter lower trim. <Ref. to EI-39,

4) Remove bolts and nuts.
S5M0407
5) Detach backrest.
SE-6
BODY SECTION

SUBARU vehicles.
ine parts.

G8050GE6
SECURITY AND LOCKS
SL
Page
2. Door Lock Control System ..........................................................................8
3. Keyless Entry System ...............................................................................14
4. Front Inner Remote ...................................................................................27
5. Front Outer Handle ...................................................................................28
6. Front Door Latch Assembly.......................................................................29
7. Front Door Lock Actuator ..........................................................................30
8. Rear Inner Remote....................................................................................31
9. Rear Outer Handle ....................................................................................32
10. Rear Door Latch Assembly .......................................................................33
11. Rear Door Lock Actuator...........................................................................34
12. Rear Gate Outer Handle ...........................................................................35
13. Rear Gate Latch Assembly .......................................................................36
14. Rear Gate Latch Lock Actuator.................................................................37
15. Front Hood Lock Assembly .......................................................................38
16. Remote Openers .......................................................................................39
17. Ignition Key Lock.......................................................................................40
18. Key Lock Cylinders ...................................................................................41
19. Immobilizer Control Module ......................................................................42
20. Immobilizer Antenna..................................................................................43
21. Keyless Entry Control Module...................................................................44
22. Keyless Transmitter...................................................................................45
GENERAL DESCRIPTION
Security and Locks
1. DOOR LOCK ASSEMBLY S909001A0501
S5M0444A
(1) Inner remote ASSY (6) Door outer handle Tightening torque: N·m (kgf-m, ft-lb)
(2) Bell crank (7) Key cylinder
T1: 6.4 (0.65, 4.7)
(3) Auto-door lock actuator
T2: 7.4 (0.75, 5.4)
(4) Door latch
T3: 14 (1.4, 10.1)
(5) Striker
SL-2
GENERAL DESCRIPTION
Security and Locks
2. REAR GATE LOCK S909001A0502
S5M0445A
(1) Key cylinder (5) Rear gate actuator Tightening torque: N·m (kgf-m, ft-lb)
(2) Rear gate latch
T1: 7.4 (0.75, 5.4)
(3) Striker
T2: 25 (2.5, 18.1)
(4) Rear gate outer handle
SL-3
GENERAL DESCRIPTION
Security and Locks
3. HOOD LOCK AND REMOTE OPENERS S909001A0503
S5M0446A
(1) Hood lock ASSY (4) 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)
SL-4
GENERAL DESCRIPTION
Security and Locks
4. IMMOBILIZER SYSTEM S909001A0509
S6M0413A
(1) Antenna (3) Immobilizer control module (IMM

(2) Immobilizer indicator light (LED ECM): LHD model
bulb) (4) Transponder
NOTE:
IMM ECM location for RHD model is symmetrically
opposite.
SL-5
GENERAL DESCRIPTION
Security and Locks
5. KEYLESS ENTRY SYSTEM S909001A0505
S5M0447A
(1) Keyless entry control module (2) Rear gate latch switch (3) Door switch

repairing radio, control module, etc. which are
provided with memory functions, record
memory contents before disconnecting battery
ground cable. Otherwise, these contents are
cancelled upon disconnection.
쐌 Reassemble parts in reverse order of disas-
sembly procedure unless otherwise indicated.
쐌 Adjust parts to specifications contained in
this manual if so designated.
쐌 Connect connectors and hoses securely dur-
ing reassembly.
쐌 After reassembly, ensure functional parts
operate smoothly.
쐌 Airbag system wiring harness is routed near
the electrical parts and switch.
쐌 All airbag system wiring harness and con-
nectors are colored yellow. Do not use electri-
cal test equipment on these circuits.
쐌 Be careful not to damage Airbag system wir-
ing harness when servicing the ignition key
cylinder.
SL-6
GENERAL DESCRIPTION
Security and Locks

925580000 PULLER Used for removing trim clip
B5M1120
TOOL NAME REMARKS

Drill Used for replacing ignition key lock.
SL-7
DOOR LOCK CONTROL SYSTEM
Security and Locks
2. Door Lock Control System S909348
1. DOOR LOCK CONTROL LHD MODEL S909348A2106
SL73-20
SL-8
Security and Locks
2. DOOR LOCK CONTROL RHD MODEL S909348A2107
SR73-20
SL-9
Security and Locks

The door lock control system does 1. Check the fuse. <Ref. to SL-10 CHECK FUSE,
not operate. INSPECTION, Door Lock Control
System.>
2. Check the power supply and ground circuit for <Ref. to SL-11 CHECK POWER
the keyless entry control module. SUPPLY AND GROUND CIRCUIT,
INSPECTION, Door Lock Control
System.>
3. Check the door lock switch and the circuit. <Ref. to SL-11 CHECK DOOR
LOCK SWITCH AND CIRCUIT,
System.>
4. Check the door lock actuator and the circuit. <Ref. to SL-12 CHECK DOOR
LOCK ACTUATOR AND CIRCUIT,
System.>
The door lock switch (knob) does not Check the door lock switch and the circuit. <Ref. to SL-11 CHECK DOOR
operate. LOCK SWITCH AND CIRCUIT,
System.>
A specific door lock actuator does not Check the door lock actuator and the circuit. <Ref. to SL-12 CHECK DOOR
operate. LOCK ACTUATOR AND CIRCUIT,
System.>
2. CHECK FUSE S909348A1002

1 CHECK FUSE. Is the fuse blown (15A)? Replace the fuse Check power sup-
Remove and visually check fuse No. 2 (in the with a new one. ply and ground
main fuse box) and No. 3 (in the fuse and circuit. <Ref. to
relay box). SL-11 CHECK
POWER SUPPLY
AND GROUND
CIRCUIT,
INSPECTION,
Door Lock Control
System.>
SL-10
Security and Locks
3. CHECK POWER SUPPLY AND

GROUND CIRCUIT S909348A1003
1 CHECK POWER SUPPLY. Is the voltage more than 10 Go to step 2. Check the har-
1) Disconnect the door lock timer or keyless V? ness for open cir-
entry control module harness connector. cuits or shorts
2) Measure the voltage between the harness between the key-
connector terminal and chassis ground. less entry control
Connector & terminal module and the
(B176) No. 5 (+) — Chassis ground (–): fuse.
(B176) No. 16 (+) — Chassis ground
(–):
2 CHECK GROUND CIRCUIT. Is the resistance less than Power supply and Repair harness.
Measure the resistance between the harness 10 Ω? ground circuit is
connector terminal and chassis ground. OK.
(–):
4. CHECK DOOR LOCK SWITCH AND

CIRCUIT S909348A1004
1 CHECK DOOR LOCK SWITCH CIRCUIT. Is the resistance less than Go to step 2. Go to step 3.
1) Disconnect the keyless entry control mod- 10 Ω?
ule harness connector.
2) Measure the resistance between the har-
ness connector terminal and chassis ground
when moving the driver’s door lock knob to
UNLOCK.
(B176) No. 7 (+) — Chassis ground (–):
2 CHECK DOOR LOCK SWITCH CIRCUIT. Is the resistance less than Go to step 3. The door lock
Measure the resistance between the harness 10 Ω? switch is OK.
connector terminal and chassis ground when
the driver’s door lock knob is moved to LOCK.
3 CHECK DOOR LOCK SWITCH. Does continuity exist? Go to step 4. Replace the door
1) Disconnect the driver’s door lock switch lock switch
(actuator) harness connector. (actuator).
2) Check the continuity between the door lock
switch terminals when moving the door lock
knob to UNLOCK.
Terminal
No. 1 — No. 3:
4 CHECK DOOR LOCK SWITCH. Does continuity exist? Replace the door Check the har-
Check the continuity between the door lock lock switch ness for open cir-
switch terminals when moving the door lock (actuator). cuits or shorts
knob to LOCK. between the key-
Terminal less entry control
No. 1 — No. 3: module and the
door lock switch.
SL-11
Security and Locks
5. CHECK DOOR LOCK ACTUATOR AND

CIRCUIT S909348A1005
1 CHECK OUTPUT SIGNAL. Is the voltage more than 10 Go to step 2. Replace the key-
Measure the voltage between the harness V? less entry control
connector terminal and chassis ground when module.
moving the door lock knob to LOCK.
(–):
2 CHECK OUTPUT SIGNAL. Is the voltage more than 10 Go to step 3. Replace the key-
Measure the voltage between the harness V? less entry control
connector terminal and chassis ground when module.
moving the door lock knob to UNLOCK.
(–):
3 CHECK DOOR LOCK ACTUATOR. Is the door lock actuator Check the har- Replace the door
Check the door lock actuator. OK? ness for open cir- lock actuator.
Front door lock actuator: <Ref. to SL-30 Front cuits or shorts
Door Lock Actuator.> between the key-
Rear door lock actuator: <Ref. to SL-34 Rear less entry control
Door Lock Actuator.> module and the
Rear gate latch lock actuator: <Ref. to SL-37 door lock actuator.
Rear Gate Latch Lock Actuator.>
SL-12
Security and Locks
MEMO:
SL-13
KEYLESS ENTRY SYSTEM
Security and Locks
3. Keyless Entry System S909345
1. KEYLESS ENTRY LHD MODEL S909345A2101
SL77-20A
SL-14
Security and Locks
SL77-20B
SL-15
Security and Locks
SL77-20C
SL-16
Security and Locks
2. KEYLESS ENTRY RHD MODEL S909345A2102
SR77-20A
SL-17
Security and Locks
SR77-20B
SL-18
Security and Locks
SR77-20C
SL-19
Security and Locks
B: ELECTRICAL SPECIFICATION S909345A08
B5M1141
Content Terminal No. Measuring condition

Battery voltage is present when inserting the key into the ignition
Key warning switch 1 (INPUT)
switch.
Registration connector 2 (INPUT) 0 V is present when connecting the registration connector.
Door switch 3 (INPUT) 0 V is present when any door is open.
Empty 4 —
Power supply 5 Battery voltage is constantly present.
Empty 6 —
Door lock switch 7 (INPUT) 0 V is present when driver’s door is unlocked.
Empty 8 —
Empty 9 —
Empty 10 —
Room light/Ignition switch illumina- 쐌 0 V is present when pressing the transmitter OPEN button.
11 (OUTPUT)
tion 쐌 0 V is present when any door is open.
Battery voltage is present when pressing the transmitter OPEN or
Turn signal light (Right) 12 (OUTPUT)
LOCK button.
Battery voltage is present when pressing the transmitter OPEN or
Turn signal light (Left) 13 (OUTPUT)
LOCK button.
Ground 14 0 V is constantly present.
Power supply (Hazard light) 15 Battery voltage is constantly present.
Power supply 16 Battery voltage is constantly present.
Door and rear gate lock actuator Battery voltage is present when pressing the transmitter OPEN but-
17 (OUTPUT)
(Unlock) ton.
Door and rear gate lock actuator Battery voltage is present when pressing the transmitter LOCK but-
18 (OUTPUT)
(Lock) ton.
SL-20
Security and Locks

None of the functions of the keyless 1. Check the transmitter battery. <Ref. to SL-22 CHECK TRANSMIT-
entry system operate. TER BATTERY, INSPECTION, Key-
less Entry System.>
2. Check the fuse. <Ref. to SL-22 CHECK FUSE,
INSPECTION, Keyless Entry Sys-
tem.>
3. Check the keyless entry control module <Ref. to SL-23 CHECK POWER
power supply and ground circuit. SUPPLY AND GROUND CIRCUIT,
INSPECTION, Keyless Entry sys-
tem.>
4. Replace the keyless entry control module. <Ref. to SL-44 Keyless Entry Control
Module.>
The transmitter cannot be registered. 1. Check the transmitter battery. <Ref. to SL-22 CHECK TRANSMIT-
TER BATTERY, INSPECTION, Key-
less Entry System.>
2. Check the registration connector circuit. <Ref. to SL-23 CHECK REGISTRA-
TION CONNECTOR CIRCUIT,
tem.>
Module.>
The door lock or unlock does not 1. Check the transmitter battery. <Ref. to SL-22 CHECK TRANSMIT-
operate. TER BATTERY, INSPECTION, Key-
NOTE: less Entry System.>
If the door lock control system does 2. Check the key warning switch. <Ref. to SL-24 CHECK KEY WARN-
not operate when using the door lock ING SWITCH, INSPECTION, Keyless
switch, check the door lock control Entry System.>
system. <Ref. to SL-10 3. Check the door switch. <Ref. to SL-24 CHECK DOOR
INSPECTION, Door Lock Control SWITCH, INSPECTION, Keyless
System.> Entry System.>
4. Replace the keyless entry control module. <Ref. to SL- 44 Keyless Entry Control
Module.>
The hazard light does not operate. 1. Check the transmitter battery <Ref. to SL-22 CHECK TRANSMIT-
TER BATTERY, INSPECTION, Key-
less Entry System.>
2. Check the key warning switch. <Ref. to SL-24 CHECK KEY WARN-
ING SWITCH, INSPECTION, Keyless
Entry System.>
3. Check the door switch. <Ref. to SL-24 CHECK DOOR
SWITCH, INSPECTION, Keyless
Entry System.>
4. Check the hazard light operation. <Ref. to SL-25 CHECK HAZARD
LIGHT OPERATION, INSPECTION,
Keyless Entry System.>
Module.>
SL-21
Security and Locks

The room light and ignition switch 1. Check the transmitter battery. <Ref. to SL-22 CHECK TRANSMIT-
illumination operation does not acti- TER BATTERY, INSPECTION, Key-
vate. less Entry System.>
2. Check the room light operation. <Ref. to SL-26 CHECK ROOM
LIGHT OPERATION, INSPECTION,
Keyless Entry System.>
3. Check the ignition switch illumination circuit. <Ref. to SL-26 CHECK IGNITION
SWITCH ILLUMINATION CIRCUIT,
tem.>
4. Check the key warning switch. <Ref. to SL-24 CHECK KEY WARN-
ING SWITCH, INSPECTION, Keyless
Entry System.>
5. Check the door switch. <Ref. to SL-24 CHECK DOOR
SWITCH, INSPECTION, Keyless
Entry System.>
Module.>
2. CHECK TRANSMITTER BATTERY S909345A1011

1 CHECK TRANSMITTER BATTERY. Is the battery voltage OK? Further inspection Replace the trans-
1) Remove the battery from the transmitter. is necessary, refer mitter battery.
<Ref. to SL-45 REMOVAL, Keyless Transmit- to “SYMPTOM
ter.> CHART”. <Ref. to
2) Check the battery voltage. <Ref. to SL-45 SL-21 SYMPTOM
INSPECTION, Keyless Transmitter.> CHART,
INSPECTION,
Keyless Entry
System.>
3. CHECK FUSE S909345A1004

1 CHECK FUSE. Is the fuse blown? (15 A Replace the fuse Check power sup-
Remove and visually check fuse No. 2 (in the and 30 A) with a new one. ply and ground
main fuse box), No. 3 (in the fuse and relay circuit. <Ref. to
box) and SBF-6 (in the main fuse box) SL-23 CHECK
POWER SUPPLY
AND GROUND
CIRCUIT,
INSPECTION,
Keyless Entry
system.>
SL-22
Security and Locks
4. CHECK POWER SUPPLY AND GROUND CIRCUIT S909345A1005

1 CHECK POWER SUPPLY. Is the voltage more than 10 Go to step 2. Check the har-
1) Disconnect the keyless entry control mod- V? ness for open cir-
ule harness connector. cuits or 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. 5, No. 15, No. 16 (+) —
Chassis ground (–):
2 CHECK GROUND CIRCUIT. Is the resistance less than The power supply Repair the har-
Measure the resistance between the harness 10 Ω? and ground circuit ness.
connector terminal and chassis ground. are OK.
(–):
5. CHECK REGISTRATION CONNECTOR CIRCUIT S909345A1012

1 REGISTRATION CONNECTOR INPUT VOLT- Is the voltage more than 10 Go to step 2. Repair harness,
AGE INSPECTION V? and (or) connec-
1) Disconnect registration connector. tor.
2) Measure voltage between keyless entry
control module harness connector and chas-
sis ground.
2 REGISTRATION CONNECTOR INPUT VOLT- Is the voltage 0 V? Registration con- Repair harness,
AGE INSPECTION nector circuit is and (or) connec-
1) Connect registration connector. OK. tor.
2) Measure voltage between keyless entry
control module harness connector and chas-
sis ground.
SL-23
Security and Locks
6. CHECK DOOR SWITCH S909345A1007

1 CHECK DOOR SWITCH CIRCUIT. Is the voltage 0 V when Go to step 2. Go to step 3.
Measure the voltage between the keyless each door and rear gate is
entry control module harness connector termi- opened?
nal and chassis ground.
2 CHECK DOOR SWITCH CIRCUIT. Is the voltage more than 10 The door switch is Go to step 3.
Measure the voltage between the keyless V when each door and rear OK.
entry control module harness connector termi- gate is closed?
nal and chassis ground.
(B176) No. 3 (+) — chassis ground (–):
3 CHECK DOOR SWITCH. Does continuity exist when Replace the door Go to step 4.
1) Disconnect the door switch harness con- the door switch is pushed? switch.
nector.
2) Check the continuity between the door
switch terminal and chassis ground.
Terminal
Front LH No. 1 — Chassis ground:
Front RH No. 1 — Chassis ground:
Rear LH No. 1 — Chassis ground:
Rear RH No. 1 — Chassis ground:
Rear gate No. 1 — No. 2:
4 CHECK DOOR SWITCH. Does continuity exist when Check the har- Replace the door
Check continuity between the door switch ter- the door switch is ness for open cir- switch.
minal and chassis ground. released? cuits and shorts
Terminal between the key-
Front LH No. 1 — Chassis ground: less entry control
Front RH No. 1 — Chassis ground: module and door
Rear LH No. 1 — Chassis ground: switch.
Rear gate No. 1 — No. 2:
7. CHECK KEY WARNING SWITCH S909345A1008

1 CHECK FUSE. Is the fuse blown? (15A) Replace the fuse Go to step 2.
Remove and visually check fuse No. 6 (in the with a new one.
main fuse box).
2 CHECK KEY WARNING SWITCH CIRCUIT. Is the voltage more than 10 Go to step 3. Go to step 4.
1) Disconnect the keyless entry control mod- V?
ule harness connector.
2) Insert the key into the ignition switch.
(LOCK position)
3) Measure the voltage between the harness
connector terminal and chassis ground.
3 CHECK KEY WARNING SWITCH CIRCUIT. Is the voltage 0 V? The key warning Go to step 4.
1) Remove the key from the ignition switch. switch is OK.
2) Measure the voltage between the harness
connector terminal and chassis ground.
SL-24
Security and Locks

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

S909345A1013

1 CHECK HAZARD LIGHT OPERATION. Does hazard light brink? Go to step 2. Check hazard
Make sure the hazard light blinks when haz- light circuit.
ard switch is turned ON.
2 CHECK OUTPUT SIGNAL. Is the voltage more than 10 Check harness for Replace the key-
1) Remove the key from ignition switch. V? open or short less entry control
2) Close all doors and rear gate. between keyless module.
3) Measure voltage between keyless entry entry control mod-
control module harness connector terminal ule and turn sig-
and chassis ground when LOCK or OPEN nal lights.
button of transmitter is pressed.
(B176) No. 12, No. 13 (+) — Chassis
ground (−):
SL-25
Security and Locks
9. CHECK ROOM LIGHT OPERATION

S909345A1010

1 CHECK ROOM LIGHT OPERATION. Does the room light illumi- Go to step 2. Check the room
Make sure the room light illuminates when the nate? light circuit.
room light switch is turned ON.
2 CHECK HARNESS BETWEEN ROOM Is the resistance less than The room light Check the har-
LIGHT AND KEYLESS ENTRY CONTROL 10 Ω? operation circuit is ness for open cir-
MODULE. OK. cuits or shorts
1) Disconnect the keyless entry control mod- between the key-
ule harness connector and room light harness less entry control
connector. module and room
2) Measure the resistance between the key- light.
less entry control module harness connector
terminal and the room light harness connector
terminal.
(B176) No. 11 — (R52) No. 2:
10. CHECK IGNITION SWITCH ILLUMINATION CIRCUIT S909345A1014

1 CHECK IGNITION SWITCH ILLUMINATION Is the voltage more than 10 Go to step 2. Check harness for
POWER SUPPLY. V? open circuit or
1) Disconnect the ignition switch illumination shorts between
harness connector. the ignition switch
2) Measure voltage between the ignition illumination and
switch illumination harness connector terminal fuse.
and chassis ground.
2 CHECK HARNESS BETWEEN IGNITION Is the resistance less than Check the ignition Repair the har-
SWITCH ILLUMINATION AND KEYLESS 10 Ω? switch illumina- ness.
ENTRY CONTROL MODULE. tion. If NG,
1) Disconnect the keyless entry control mod- replace the igni-
ule harness connector. tion switch illumi-
2) Measure the resistance between the key- nation.
less entry harness connector terminal and the
ignition switch illumination harness connector.
(B176) No. 11 — (B224) No. 2:
SL-26
FRONT INNER REMOTE
Security and Locks
4. Front Inner Remote S909344
1) Remove the door trim. <Ref. to EI-26

2) Remove the sealing cover. <Ref. to EB-13
3) Remove the two rod joints.
4) Unlatch rod holder
5) Remove the front inner remote.
S5M0186

NOTE:
Make sure the inner remote works properly after
installation.
1) Make sure the rod is not deformed.

2) Make sure the lever and rod work smoothly.
SL-27
FRONT OUTER HANDLE
Security and Locks
5. Front Outer Handle S909349

3) Remove the front inner remote. <Ref. to SL-27
4) Remove the two bolts. Remove the front outer
handle (B).
S5M0189A
CAUTION:
Do not use excessive force to remove the door
panel. This will deform it.

NOTE:
Make sure outer handle works properly after instal-
lation.

SL-28
FRONT DOOR LATCH ASSEMBLY
Security and Locks
6. Front Door Latch Assembly

S909334
1) Remove the front door trim. <Ref. to EI-26

3) Remove the front inner remote. <Ref. to SL-27
4) Turn rod holder to disconnect joint between key
lock and rod.
5) Turn rod holder to disconnect joint between
outer handle and rod.
6) Turn rod holder to disconnect joint between
crank and rod.
7) Remove the three screws and bolt.
S5M0189A
8) Disconnect the connector. Remove the front

door latch assembly (A).

NOTE:
Make sure parts work properly after installation.

SL-29
FRONT DOOR LOCK ACTUATOR
Security and Locks
7. Front Door Lock Actuator S909319
1) Remove the front door latch assembly. <Ref. to

SL-27 REMOVAL, Front Door Latch Assembly.>
2) Remove the bolt. Remove the front door lock
actuator.
B5M0998
1) Disconnect the door lock actuator harness con-

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

No. 2 (+) — No. 4 (–) Unlocked → Locked
No. 4 (+) — No. 2 (–) Locked → Unlocked
If NG, replace the door lock actuator.
SL-30
REAR INNER REMOTE
Security and Locks
8. Rear Inner Remote S909321
1) Remove the rear door trim. <Ref. to EI-27

REMOVAL, Rear Door Trim.>
REMOVAL, Rear Sealing Cover.>
3) Remove the two rod joints.
4) Remove the inner remote.
S5M0186

NOTE:
Make sure the inner remote works properly after
installation.

3) Make sure the child safety lock on rear doors
work properly, when applicable.
SL-31
REAR OUTER HANDLE
Security and Locks
9. Rear Outer Handle S909322

3) Remove the rear inner remote. <Ref. to SL-31
REMOVAL, Rear Inner Remote.>
4) Remove the rear door latch assembly. <Ref. to
SL-33 REMOVAL, Rear Door Latch Assembly.>
5) Remove the two bolts and nut. Remove the rear
outer handle.
B5M1000
CAUTION:
Do not use excessive force to remove the door
panel. This will deform it.

NOTE:
Make sure the outer handle works properly after
installation.

SL-32
REAR DOOR LATCH ASSEMBLY
Security and Locks
10. Rear Door Latch Assembly

S909320

3) Remove the rear inner remote. <Ref. to SL-31
REMOVAL, Rear Inner Remote.>
4) Remove the three screws and bolt.
B5M1001
5) Disconnect the connector. Remove the rear

door latch assembly.

NOTE:

SL-33
REAR DOOR LOCK ACTUATOR
Security and Locks
11. Rear Door Lock Actuator S909323
1) Remove the rear door latch assembly. <Ref. to

SL-33 REMOVAL, Rear Door Latch Assembly.>
2) Remove the bolt. Remove the rear door lock
actuator.
B5M1002

NOTE:
Make sure the lock works properly after installa-
tion.

nector.
terminals.
B6M0135

If NG, replace the door lock actuator.
SL-34
REAR GATE OUTER HANDLE
Security and Locks
12. Rear Gate Outer Handle S909626
1) Remove the rear gate lower trim. <Ref. to 42

2) Disconnect rod (latch to outer handle) from
outer handle (B).
3) Remove the four nuts used to hold outer handle
(B) to the inside of rear gate and detach outer
handle.
S5M0387A

NOTE:
Make sure the outer handle works properly after
installation.
1) Inspect the rod for deformation.

2) Make sure the lever and rod move smoothly.
SL-35
REAR GATE LATCH ASSEMBLY
Security and Locks
13. Rear Gate Latch Assembly

S909316
1) Remove the rear gate lower trim. <Ref. to EI-42

2) Disconnect rod (latch to link) from latch (A).
3) Disconnect rod (latch to outer handle) from
outer handle (B).
4) Remove bolts from latch (A).
S5M0387A
5) Disconnect rear gate switch connector from

latch (A) and then detach the latch.

NOTE:

SL-36
REAR GATE LATCH LOCK ACTUATOR
Security and Locks
14. Rear Gate Latch Lock

Actuator S909313
1) Remove rear gate trim. <Ref. to EI-42

2) Disconnect rod from key cylinder.
3) Loosen two bolts to remove rear gate actuator
(E).
S5M0387A

NOTE:
Make sure the lock works properly after installa-
tion.

nector.
terminals.
B6M0135

If NG, replace the rear gate latch lock actuator.
SL-37
FRONT HOOD LOCK ASSEMBLY
Security and Locks
15. Front Hood Lock Assembly

S909595
1) Open the hood.

2) Remove the bolt. Remove the hood lock
assembly.
3) Remove the release cable from the lock assem-
bly.
S5M0148

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

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

2) Check the safety lever for improper movement.
3) Check other levers and the spring for rust for-
mation and unsmooth movement.
SL-38
REMOTE OPENERS
Security and Locks
16. Remote Openers S909317

2. FUEL FLAP OPENER S909317A1803
1) Remove the rear seat. <Ref. to SE-6

1. HOOD OPENER S909317A1801 2) Remove the center pillar lower trim and side sill
cover on the passenger side. Remove the rear pil-
1) Remove the release cable from the hood lock.
lar lower trim. Pull back the floor mat. Remove the
2) Remove the bolt. Remove the opener lever.
clip holding the cable.
3) Remove the bolt. Remove the opener pull
handle.
S5M0149
S5M0291B
4) Remove the cable from the opener pull handle.

5) Remove the right rear quarter trim. <Ref. to
EI-39 REMOVAL, Rear Quarter Trim.>
6) Rotate the fuel lock inside the quarter panel to
left and remove.
B5M1067
1. HOOD OPENER S909317A1101

2. FUEL FLAP OPENER S909317A1103
Make sure the fuel flap opens and closes smoothly.
SL-39
IGNITION KEY LOCK
Security and Locks
17. Ignition Key Lock S909318
1) Remove the battery ground cable.

2) Remove the steering column. <Ref. to DS-30
REMOVAL, Steering Column.>
3) Secure the steering column in a vise. Remove
the bolt with a drill.
B5M1061
4) Remove the ignition key lock.

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

2) Remove the lower column cover.
3) Unfasten the holddown clip which secures the
harness and disconnect the connector of the igni-
tion switch from the body harness.
4) Turn the ignition key plate to each position and
check the continuity between the terminals of the
ignition connector.
Switch position Tester connection Specified condi-
tion
LOCK
ACC No. 1 — No. 2 Continuity
ON No. 1 — No. 2 — Continuity
No. 4
ST No. 1 — No. 3 — Continuity
No. 4
If NG, replace the ignition switch.
SL-40
KEY LOCK CYLINDERS
Security and Locks
18. Key Lock Cylinders S909326
1. FRONT DOOR S909326A2001

2) Pull back the sealing cover.
3) Remove the rod clamp. Remove the lock plate.
Replace the key cylinder.
S5M0515
2. REAR GATE S909326A2003
1) Remove the rear gate lower trim. <Ref. to EI-42

2) Remove the rod clamp. Remove the lock plate.
Replace the key cylinder (C).
S5M0387A
SL-41
IMMOBILIZER CONTROL MODULE
Security and Locks
19. Immobilizer Control Module

S909315
NOTE:
The following positions for removal and installation
are for LHD models. The positions for RHD mod-
els are symmetrically opposite.
3) Disconnect connector from immobilizer control
module.
4) Remove immobilizer control module.
DOHC Turbo and SOHC with OBD model:
H6M0712
S6M0163
SL-42
IMMOBILIZER ANTENNA
Security and Locks
20. Immobilizer Antenna S909331

3) Remove screws, separate upper column cover
and lower column cover.
S6M0042
4) Disconnect immobilizer antenna connector (A)

from immobilizer control module.
5) Remove immobilizer antenna (B).
DOHC Turbo and SOHC with OBD model:
H6M0710A
B6M0585B
SL-43
KEYLESS ENTRY CONTROL MODULE
Security and Locks
21. Keyless Entry Control

Module S909324
1) Disconnect battery ground cable.

3) Remove nut, then remove keyless entry control
module (A) while disconnecting connector.
S6M0481A
4) Disconnect keyless entry control module.
SL-44
KEYLESS TRANSMITTER
Security and Locks
22. Keyless Transmitter S909325

If NG, replace the battery. (Use CR1620 or equiva-
lent.)
D: REPLACEMENT S909325A20
1. TRANSMITTER BATTERY S909325A1801
1. TRANSMITTER REGISTRATION S909325A2001

Remove battery from transmitter.
NOTE:
NOTE: A maximum of 3 transmitters can be registered for
To prevent static electricity damage to transmitter each individual vehicle.
printed circuit board, touch steel area of building
with hand to discharge static electricity carried on 1) Remove the side sill cover at the driver’s side,
body or clothes before disassembling transmitter. then connect the registration connectors at the
front pillar lower section.
2) Unlock the door lock.
3) Press any button of the transmitter twice to be
registered.
4) The door lock will automatically lock and unlock
in sequence. This indicates the completion of
transmitter registration for the first transmitter.
5) If registration of a second transmitter is now to
be carried out, press any button of that transmitter
twice.
6) The door lock will automatically lock and unlock
B5M1182 in sequence. This indicates the completion of
transmitter registration for the second transmitter.
7) If registration of third transmitter is now to be
carried out, repeat procedure of step 5) and 6).
1. TRANSMITTER BATTERY S909325A1101 8) Disconnect the registration connectors after the
completion of all registration operations. After con-
Install in the reverse order of removal. firming the operation of the door lock using the
newly registered transmitter(s), reinstall the side
sill cover at the driver’s side.
1. TRANSMITTER BATTERY S909325A1001
1) Measure voltage between battery (+) terminal

and (–) terminal.
NOTE:
쐌 Battery discharge occurs during measurement.
Complete measurement within 5 seconds.
쐌 During battery voltage measurement, voltage
falls more than 1.8 volts in 3 seconds period.
S6M0291A
Tester connection
Voltage (V)
(+) (–)
Battery (+) termi- Battery (–) termi-
More than 2
nal nal
SL-45
KEYLESS TRANSMITTER
Security and Locks
MEMO:
SL-46
BODY SECTION

SUBARU vehicles.
ine parts.

G8050GE6
SUNROOF/T-TOP/CONVERTIBLE TOP
(SUNROOF)
SR
Page
2. Sunroof Control System ..............................................................................5
3. Sunroof Lid ..................................................................................................7
4. Sunroof Assembly .......................................................................................8
5. Sunroof Motor............................................................................................10
6. Sunroof Switch ..........................................................................................12
GENERAL DESCRIPTION
Sunroof/T-top/Convertible Top (Sunroof)
S5M0290A
SR-2
GENERAL DESCRIPTION
(1) Glass lid

(2) Rear drain ASSY
(3) Frame ASSY
(4) Motor ASSY
(5) Drive unit
(6) Drain tube
(7) Harness
(8) Sunshade
(9) Garnish
(10) Frame bracket
(11) Cover
(12) Deflector
(13) Shim
Tightening torque: N·m (kgf-m, ft-lb)

T: 7.4 (0.75, 5.4)
SR-3
GENERAL DESCRIPTION

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

tance and voltage.
SR-4
SUNROOF CONTROL SYSTEM
2. Sunroof Control System S910328
1. SUNROOF S910328A2101
SG75-20
SR-5
SUNROOF CONTROL SYSTEM
Symptom Checking order

Water leaks. (1) Check roof panel and sunroof lid for improper or poor sealing.
(2) Check drain tube for clogging.
(3) Check sunroof frame seal and body for improper fit.
Booming noise (1) Check sunroof lid and roof panel for improper clearance.
(2) Check sunshade and roof trim for improper clearance.
Abnormal motor noise (1) Check motor for looseness.
(2) Check gears and bearings for wear.
(3) Check cables for wear.
(4) Check cable pipe for deformities.
Failure of sunroof (1) Check guide rail for foreign particles.
(Motor operates properly.) (2) Check guide rail for improper installation.
(3) Check parts for mutual interference.
(4) Check cable slider for improper clinching.
(5) Check cable for improper installation.
(6) Check clutch adjustment nut for improper tightness.
Motor does not rotate or rotates improperly. (1) Check fuse for blow-out.
(2) Check switch for improper function.
(3) Check motor for incorrect terminal voltage.
(4) Check relay for improper operation.
(5) Check poor grounding system.
(6) Check harness for open or short and terminals for poor connections.
(7) Check limit switch for improper operation.
SR-6
SUNROOF LID
3. Sunroof Lid S910536 C: ADJUSTMENT S910536A01
1. ALIGNMENT OF HEIGHT BETWEEN
SUNROOF LID AND ROOF PANEL S910536A0101
1) Completely close glass lid and open sunshade.
2) Detach the four covers (A) and then remove Loosen sunroof lid nuts and then adjust height by
eight nuts. adding (max: four pieces) or extracting (max: two
pieces) shims (A) (standard: two pieces) between
sunroof lid (B) and roof panel (C).
Difference in height between sunroof lid and
roof panel
2.0±1.0 mm (0.079±0.039 in)
S5M0292A
3) Carefully remove glass lid.
S5M0294C
SR-7
SUNROOF ASSEMBLY
4. Sunroof Assembly S910329 C: DISASSEMBLY S910329A06
1) Remove sunroof frame.
2) Remove rail stoppers (A).
1) Remove roof trim. <Ref. to EI-41, REMOVAL,
Roof Trim.>
2) Remove sunroof lid. <Ref. to SR-7, REMOVAL,
Sunroof Lid.>
3) Disconnect the four drain tubes (A) from sun-
roof frame.
4) Disconnect sunroof harness connector.
5) Remove bolts and nuts and then detach sun-
roof frame.
S5M0470A
3) Pull out the sunshade (B) from sunroof frame.
S5M0293A
Install in the reverse order of removal. S5M0471A
CAUTION:
Be careful not to snag harness. D: ASSEMBLY S910329A02
NOTE: Assemble in the reverse order of disassembly.

쐌 Make sure to connect harness connector.
쐌 When installing drain tube, insert it securely into
drain pipe.
Length A:
G5M0205
SR-8
SUNROOF ASSEMBLY
1. CHECK FOR MOVEMENT OF

SUNSHADE S910329A1001
1) Place a cloth on sunshade, and attach a spring
scale to sunshade edge using a cloth.
S5M0295
2) Pull spring scale to measure force required to

move the sunshade.
Force required to move sunshade:
Less than 24.5±9.8 N (2.5±1.0 kgf, 5.5±2.2
lb)
NOTE:
Considerable effort is required to start sunshade
moving, so take scale reading while sunroof panel
is moving smoothly.
3) If force required exceeds specifications, check
the sunroof glass lid, sunshade and deflector, and
guide rail assembly for improper installation.
SR-9
SUNROOF MOTOR
5. Sunroof Motor S910537
CAUTION:
쐌 Fully open sunroof when removing sunroof
motor.
쐌 When removing clip, use great care to not
damage the roof trim.
1) Completely open the sunroof.
2) Remove roof trim. <Ref. to EI-41, REMOVAL,
Roof Trim.>
3) Disconnect harness connector (A) and remove
sunroof motor mounting screw (B) and nut (C).
S5M0472A
CAUTION:
쐌 Never rotate the sunroof motor while
removed.
쐌 Be careful not to move the sunroof cable
when installing sunroof motor.
1) Install sunroof motor.
2) Connect sunroof motor harness connector and
then connect battery ground cable.
3) Operate the sunroof switch, and check the sun-
roof stop position.
4) Move sunroof to completely closed position.
SR-10
SUNROOF MOTOR
5) Check sunroof operation with the following procedure.

Checking order Switch position
(1) Completely close sunroof. Closed
(2) Open sunroof until it is almost completely open. Open
(3) Completely open sunroof. Open
(4) Close sunroof 500 mm (19.69 in) from completely open position. Closed
(5) Completely close sunroof. Closed
6) Install trim in the reverse order of removal.
SR-11
SUNROOF SWITCH
6. Sunroof Switch S910538

2) Remove sunroof switch panel (A).
S5M0458A

sunroof switch.
B5M1058

ing the switch.
Open 3—4 Continuity
Close 1—3 Continuity
SR-12
BODY SECTION

SUBARU vehicles.
ine parts.

G8050GE6
EXTERIOR/INTERIOR TRIM
EI
Page
2. Front Grille.................................................................................................10
3. Front Under Cover.....................................................................................11
4. Front Bumper ............................................................................................12
5. Rear Bumper .............................................................................................19
6. Mud Guard ................................................................................................21
7. Protector ....................................................................................................22
8. Cowl Panel ................................................................................................25
9. Front Door Trim .........................................................................................26
10. Rear Door Trim..........................................................................................27
11. Glove Box..................................................................................................28
12. Roof Rail....................................................................................................29
13. Console Box ..............................................................................................30
14. Instrument Panel Assembly.......................................................................31
15. Upper Inner Trim .......................................................................................37
16. Lower Inner Trim .......................................................................................38
17. Rear Quarter Trim .....................................................................................39
18. Sun Visor...................................................................................................40
19. Roof Trim...................................................................................................41
20. Rear Gate Trim..........................................................................................42
21. Floor Mat ...................................................................................................43
22. Luggage Floor Mat ....................................................................................44
GENERAL DESCRIPTION
Exterior/Interior Trim
1. FRONT BUMPER S911001A0501
S5M0500A
(1) Bumper face (5) Beam upper Tightening torque: N·m (kgf-m, ft-lb)
(2) Spacer (6) Plate
T1: 33 (3.4, 25)
(3) E/A foam (7) Bracket
T2: 70 (7.1, 51)
(4) Back beam
EI-2
GENERAL DESCRIPTION
2. REAR BUMPER S911001A0511
S5M0392A
(1) Bumper beam (5) Lower bracket Tightening torque: N·m (kgf-m, ft-lb)
(2) Cushion (6) Side upper bracket
T: 93 (9.5, 69)
(3) Lower center bracket (7) Bumper face
(4) Rear bumper plate (8) Bumper side plate
EI-3
GENERAL DESCRIPTION
3. SIDE PROTECTOR S911001A0504
S5M0393A
(1) Side protector (Front fender) (3) Side protector (Rear door) (5) Side protector (Side sill)
(2) Side protector (Front door) (4) Side protector (Rear quarter)
EI-4
GENERAL DESCRIPTION
4. DOOR TRIM S911001A0505
S5M0448A
(1) Gusset cover (5) Handle (9) Side trim

(2) Weatherstrip (6) Pocket (10) Lower trim
(3) Trim panel (7) Speaker grille
(4) Pull handle (8) Upper trim
EI-5
GENERAL DESCRIPTION
5. INNER TRIM S911001A0512
S5M0406A
(1) Front pillar upper trim (6) Rear quarter lower trim (11) Center pillar lower trim
(2) Center pillar upper trim (7) Rear skirt trim (12) Side sill rear lower cover
(3) Rear pillar upper trim (8) Front pillar lower trim (13) Side sill front upper cover
(4) Cover (9) Center pillar cover (14) Side sill front lower cover
(5) Pocket (10) Side sill rear upper cover
EI-6
GENERAL DESCRIPTION
6. INSTRUMENT PANEL S911001A0508
S5M0377A
(1) Pad & frame (12) Pocket (23) Rear cup holder
(2) Grille side (D) (13) Panel center (24) Console box
(3) Front def. grille (14) Center pocket lid (25) Console pocket
(4) Grille side (P) (15) Grille center (26) Rear console BRKT
(5) Grille vent (P) (16) Cup holder (27) Front cover
(6) Glove box panel (17) Side pocket
(7) Glove box lid (18) Lower cover ASSY Tightening torque: N·m (kgf-m, ft-lb)
(8) Knob (19) Meter visor T: 7 (0.7, 5.1)
(9) Instrument panel center console (20) Grille vent (D)
(10) BRKT (Radio) (21) Console cover
(11) Center console cover (22) Console lid
EI-7
GENERAL DESCRIPTION
7. INNER ACCESSORIES S911001A0510
S5M0449A
(1) Hook (3) Assist rail bracket (5) Assist grip (fixed)
(2) Sun visor (4) Assist grip (retractable)
EI-8
GENERAL DESCRIPTION
TOOL NAME REMARKS

Clip remover Used for removal of trim.
Adhesive remover Used for removal of side protector.
Primer Used for installation of side protector.
Infrared lamp Used for disassembly/assembly of side protector.
Tow-sided tape Used for installation of side protector.
EI-9
FRONT GRILLE
2. Front Grille S911379
1) Open hood.
2) Remove the four upper clips from the body
panel. Push the part shown in the figure by using
a screwdriver while lightly pulling the front grille.
S5M0401A
1) Attach all clips to front grille.

2) Align them with clip holes in body and push
them into place.
EI-10
FRONT UNDER COVER
3. Front Under Cover S911372
1) Lift-up the vehicle.

2) Loosen bolts and clips to remove under cover.
S5M0402
EI-11
FRONT BUMPER
4. Front Bumper S911371

7) Remove under cover. <Ref. to EI-11,
REMOVAL, Front Under Cover.>
A: REMOVAL S911371A18 8) Remove the seven clips from under side of
CAUTION: bumper.
쐌 Handle bumper carefully to avoid damage to
bumper face.
쐌 Do not damage body during removal or
installation of bumper.
쐌 To avoid damage to bumper, lay removed
bumper on sheet spread on the floor. Do not lay
it directly on the floor.
2) Remove front fog light. <Ref. to LI-48,
REMOVAL, Front Fog Light Assembly.> S5M0153
3) Remove the front grille. <Ref. to EI-10,
REMOVAL, Front Grille.> 9) Turn over the front mud guard of the front por-
4) Remove headlight washer nozzle. (Headlight tion and then remove bolt.
washer equipped vehicle) <Ref. to WW-24,
REMOVAL, Headlight Washer.>
5) Remove the extension of both sides.
S5M0154
10) Remove bumper face and E/A foam.

11) Remove the four bolts and then detach the
S5M0152A
back beam.
6) Remove the seven clips and then detach plate
(A).
S5M0398
S5M0397A
EI-12
FRONT BUMPER
12) Remove the four bolts and then detach the

beam upper.
S5M0156

CAUTION:
bumper face.
EI-13
FRONT BUMPER
C: REPAIR S911371A19
1. COATING METHOD FOR PP BUMPER S911371A1901
Process
Process name Job contents
No.
Set bumper on paint worktable if required. Use

1 Bumper mounting paint worktable conforming to inner shape of
bumper when possible.
G5M0164
Mask specified part (black base) with masking tape. Use masking tape for PP (example,
2 Masking
Nichiban No. 533, etc.).
Degreasing, Clean all parts to be painted with white gasoline, normal alcohol, etc. to remove dirt, oil, fat,
3
cleaning etc.
4 Primer paint Apply primer one to all parts to be painted, using air gun. Use primer (clear).
Dry at normal temperature [10 to 15 min. at 20°C (68°F)].
5 Drying In half-dried condition, PP primer paint is dissolved by solvent, e.g. thinner, etc.
Therefore, if dust or dirt must be removed, use ordinary alcohol, etc.
Solid color Metallic color
Use section (block) paint for top coat. Use section (block) paint for top coat.
쐌 Paint in use (for each color): 쐌 Paint in use (for each color):
Solid paint Metallic paint
Hardener PB Hardener PB
Thinner T-301 Thinner T-306
6 Top coat paint (I)
쐌 Mixing ratio: 쐌 Mixing ratio:
Main agent vs. hardener = 4:1 Main agent vs. hardener = 10:1
쐌 Viscosity: 10 — 13 sec/20°C (68°F) 쐌 Viscosity: 10 — 13 sec/20°C (68°F)
쐌 Film thickness: 35 — 45µ 쐌 Film thickness: 15 — 20µ
쐌 Spraying pressure: 245 — 343 kPa 쐌 Spraying pressure: 245 — 343 kPa
(2.5 — 3.5 kg/cm2, 36 — 50 psi) (2.5 — 3.5 kg/cm2, 36 — 50 psi)
Dry at normal temperature [10 min. or more at
7 Drying Not required. 20°C (68°F)].
In half-dried condition, avoid dust, dirt.
Apply a clear coat to parts with top coat paint
(I), three times, at 5 — 7 minutes intervals.
쐌 Paint in use:
Metallic paint
Hardener PB
8 Top coat paint (II) Not required. Thinner T-301
쐌 Mixing ratio: Clear vs. hardener = 6:1
쐌 Viscosity: 14 — 16 sec/20°C (68°F)
쐌 Film thickness: 25 — 30µ
쐌 Spraying pressure: 245 — 343 kPa
(2.5 — 3.5 kg/cm2, 36 — 50 psi)
60°C (140°F), 60 min. or 80°C (176°F), 30 min.
9 Drying If higher than 80°C (176°F), PP may be deformed. Keep maximum temperature of 80°C
(176°F).
10 Inspection Paint check.
11 Masking removal Remove masking in process No. 2.
EI-14
FRONT BUMPER
2. REPAIR INSTRUCTIONS FOR COLORED PP BUMPER S911371A1902
NOTE:
All PP bumpers are provided with a grained surface, and if the surface is damaged, it cannot normally be
restored to its former condition. Damage limited to shallow scratches that cause only a change in the lus-
tre of the base material or coating, can be almost fully restored. Before repairing a damaged area, explain
this point to the customer and get an understanding about the matter. Repair methods are outlined below,
based on a classification of the extent of damage.
쐌 Minor damage causing only a change in the lustre of the bumper due to a light touch
Almost restorable.
Process
No.
1 Cleaning Clean the area to be repaired using water.
2 Sanding Grind the repairing area with #500 sand paper in a “feathering” motion.
Resin section Coated section
Repeatedly apply wax to the affected area
using a soft cloth (such as flannel). Recom- Perform either the same operation as for the
3 Finish mended wax: NITTO KASEI Soft 99 TIRE resin section or process No. 18 and subse-
WAX BLACK, or equivalent. quent operations in the “(3)” section, depend-
Polish the waxed area with a clean cloth after ing on the degree and nature of damage.
5 to 10 minutes.
쐌 Deep damage caused by scratching fences, etc.

A dent cannot be repaired but a whitened or swelled part can be removed.
Process
No.
1 Cleaning Clean damaged area with water.
Removal of dam-
2 Cut off protruding area, if any, due to collision, using a putty knife.
aged area
3 Sanding Grind the affected area with #100 to #500 sand paper.
Resin section Coated section
4 Finish Perform Process No. 12 and subsequent
Same as Process No. 3 in the “(1)” section.
operations in the “(3)” section.
EI-15
FRONT BUMPER
쐌 Deep damage such as a break or hole that requires filling

Much of the peripheral grained surface must be sacrificed for repair, and the degree of restoration is not
really worth the expense. (The surface, however, will become almost flush with adjacent areas.)
Recommended repair kit: PP Part Repair Kit (NRM)
Process
No.
1 Bumper removal Remove bumper as required.
2 Part removal Remove parts built into bumper as required.
Place bumper on a paint worktable as

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

guide slit of 20 to 30 mm (0.79 to 1.18 in) in
5 Cutting length along the crack or hole up to the
bumper’s base surface. Then, bevel or “vee-
out” the affected area using a knife or grinder.
G5M0165
6 Sanding (I) Grind beveled surface with sand paper (#40 to #60) to smooth finish.
7 Cleaning Clean the sanded surface with the same solvent as used in Process No. 4.
Grind the side just opposite the beveled area with sand paper (#40 to #60) and clean using a
solvent.
Temporarily spot-weld the side, using a PP welding rod and heater gun.
8 Temporary welding
G5M0166
NOTE:
쐌 Do not melt welding rod until it flows out. This results in reduced strength.
쐌 Leave the welded spot unattended until it cools completely.
EI-16
FRONT BUMPER
Process
No.
Using a heater gun and PP welding rod, weld the beveled spot while melting the rod and dam-
aged area.
9 Welding
G5M0167
NOTE:
쐌 Melt the sections indicated by hatched area.
쐌 Do not melt welding rod until it flows out, in order to provide strength.
쐌 Always keep the heater gun 1 to 2 cm (0.4 to 0.8 in) away from the welding spot.
쐌 Leave the welded spot unattended until it cools completely.
Remove excess part of weld with a putty knife. If a drill or disc wheel is used instead of the
knife, operate it at a rate lower than 1,500 rpm and grind the excess part little by little. A
higher rpm will cause the PP substrate to melt from the heat.
10 Sanding (II)
G5M0168
Sand the welded spot smooth with #240 sand paper.
Mask the black substrate section using masking tape.
11 Masking
Recommended masking tape: Nichiban No. 533 or equivalent
Cleaning/
12 Completely clean the entire coated area, using solvent similar to that used in Process No. 4.
degreasing
Apply a coat of primer to the repaired surface and its surrounding areas. Mask these areas, if
necessary.
Recommended primer: Mp/ 364 PP Primer
13 Primer coating
NOTE:
Be sure to apply one coat of primer at a spraying pressure of 245 to 343 kPa
(2.5 to 3.5 kg/cm2, 36 to 50 psi) with a spray gun.
Leave the repaired area unattended at 20°C (68°F) for 10 to 15 minutes until primer is half-
dry.
14 Leave unattended. NOTE:
If dirt or dust comes in contact with the coated area, wipe it off with a cloth dampended with
alcohol. (Do not use thinner since the coated area tends to melt.)
Apply a coat of primer surfacer to the repaired area two or three times at an interval of 3 to 5
minutes.
Recommended surfacer:
쐌 UPS 300 Flex Primer
Primer surfacer
15 쐌 No. 303 UPS 300 Exclusive hardener
coating
쐌 NPS 725 Exclusive Reducer (thinner)
쐌 Mixing ratio: 2 : 1 (UPS 300: No. 303)
쐌 Coated film thickness: 40 — 50µ
16 Drying Allow the coated surface to dry for 60 minutes at 20°C (68°F) [or 30 minutes at 60°C (140°F)].
17 Sanding (III) Sand the coated surface and its surrounding areas using #400 sand paper and water.
Cleaning/
18 Same as Process No. 12.
degreasing
EI-17
FRONT BUMPER
Process
No.
Solid color Metallic color
Use a “block” coating method. Use a “block” coating method.
쐌 Recommended paint: 쐌 Recommended paint:
Suncryl (SC) Suncryl (SC)
No. 307 Flex Hardener No. 307 Flex Hardener
SC Reducer (thinner) SC Reducer (thinner)
19 Top coat (I)
쐌 Mixing ratio: 3 : 1 쐌 Mixing ratio: 3 : 1
Suncryl (SC) vs. No. 307 Flex Hardener Suncryl (SC) vs. No. 307 Flex Hardener
쐌 Viscosity: 11 — 13 sec/20°C (68°F) 쐌 Viscosity: 11 — 13 sec/20°C (68°F)
쐌 Coated film thickness: 40 — 50µ 쐌 Coated film thickness: 20 — 30µ
쐌 Spraying thickness: 245 — 343 kPa 쐌 Spraying thickness: 245 — 343 kPa
(2.5 — 3.5 kg/cm2, 36 — 50 psi) (2.5 — 3.5 kg/cm2, 36 — 50 psi)
Leave unattended at 20°C (68°F) for at least
10 minutes until the topcoated area is half-dry.
20 Leave unattended. Not required. NOTE:
Be careful to keep dust or dirt from coming in
contact with the affected area.
Apply a clear coat three times at an interval of
3 to 5 minutes.
쐌 Recommended paint:
SC710 Overlay Clear
No. 307 Flex Hardener
SC Reducer (thinner)
21 Top coat (II) Not required.
쐌 Mixing ratio: 3 : 1
Suncryl (SC) vs. No. 307 Flex Hardener
쐌 Coated film thickness: 20 — 30µ
쐌 Spraying pressure: 245 — 343 kPa
(2.5 — 3.5 kg/cm2, 36 — 50 psi)
Allow the coated surface to dry at 20°C (68°F) for two hours or 60°C (140°F) for 30 minutes.
22 Drying NOTE:
Do not allow the temperature to exceed 80°C (176°F) since this will deform the PP substrate.
23 Inspection Carefully check the condition of the repaired area.
24 Masking removal Remove masking tape applied in Process No. 11 and 13.
25 Parts installation Install parts on bumper in reverse order of removal.
26 Bumper installation Install bumper.
EI-18
REAR BUMPER
5. Rear Bumper S911370

8) Remove rear bumper beam.
CAUTION:
bumper face.
쐌 To avoid damage to bumper, lay removed
bumper on sheet spread on the floor. Do not lay
it directly on the floor.
2) Open rear gate.
3) Remove the five screws and the clip from the
rear bumper.
S5M0399
4) Disconnect license plate light and rear fog light

(if equipped) connectors.
5) Remove bolts and clips from under side of
bumper.
S5M0157
6) Remove bumper face.

7) Remove bolts from bumper stay.
G5M0161
EI-19
REAR BUMPER
CAUTION:
bumper face.
C: REPAIR S911370A19
Refer to front bumper repair. <Ref. to EI-12

EI-20
MUD GUARD
6. Mud Guard S911374
1) Jack-up the vehicle.

2) Remove screws and clips. Move mud guard
toward the center of the body and remove mud
guard.
S5M0166
Insert hook into body, and tighten it with screw and

clip.
EI-21
PROTECTOR
7. Protector S911380
S5M0400A
(1) Side protector (Door) (4) Side protector (Rear quarter) (7) Clip
(2) Side protector (Side sill) (5) Screw
(3) Side protector (Front fender) (6) Clip
EI-22
PROTECTOR
1) Attach masking tape (A) on the upper painted 4) Attach plastic wrap (A) to adhesive remover
area of the protector. coated areas and heat to 40 to 60°C (104 to 140°F)
for 5 to 10 minutes using an infrared lamp (B).
CAUTION:
Do not overheat until plastic wrap is somewhat
white.
S5M0501A
2) Release clip engagement using clip remover,

and remove the protector while peeling off two-
sided tape.
S5M0503A
5) Using a plastic spatula, remove traces of two-

sided tape from body panel.
6) Remove masking tape and clean traces of two-
sided tape using a cloth dampened with white
gasoline.
7) Similarly, clean traces of adhesive from two-
sided tape on side protector.
CAUTION:
S5M0502 Make sure side protector is clean and free of
adhesive remover. Clean if necessary.
NOTE: B: INSTALLATION S911380A11
쐌 To increase adhesive remover strength, leave
two-sided tape on body and side protector. 1) Apply primer to original side protector (if used),
쐌 If two-sided tape is too thick, use a putty knife to and attach two-sided tape (A) to upper of side pro-
cut it thin so that adhesive remover is ready for tectors as shown.
use. Two-sided tape:
쐌 If two-sided tape is hard to remove, heat to Thickness; 1.2 mm (0.047 in)
approximately 40°C (104°F). Width; 5 mm (0.20 in)
3) Apply an even coat of adhesive remover to the Recommended primer:
two-sided tape. SUMITOMO 3MK-500 or equivalent
Recommended adhesive remover: Recommended two-sided tape:
SUMITOMO 3M4000 or equivalent SUMITOMO 3M5305 or equivalent
CAUTION:
Do not apply adhesive remover to lacquer base
coated body panels.
S5M0504A
2) Using an infrared lamp, heat body panel to 40

to 60°C (104 to 140°F) and rear surface of side
protector to 20 to 30°C (68 to 86°F).
EI-23
PROTECTOR
3) Remove tack paper from two-sided paper.

While aligning clips with holes in body panel,
attach two-sided tape to side protector and body
panel with a force of more than 49 N (5 kg, 11 lb)
with roller. Do not allow air to enter mating surface
of the two.
CAUTION:
쐌 To maintain adhesive power, do not wash the
vehicle for 24 hours after tape application.
쐌 Push clip in securely using hands.
(To prevent deformation, do not use excessive
force.)
EI-24
COWL PANEL
8. Cowl Panel S911387
1) Remove cowl panel side.
S5M0167
2) Open hood.
3) Remove wiper arm. <Ref. to WW-14
REMOVAL, Wiper Arm.>
4) Lift cowl panel (RH), and then lift cowl panel
(LH).
S5M0168A
EI-25
FRONT DOOR TRIM
9. Front Door Trim S911356
CAUTION:
Do not apply excessive force to clip. Otherwise
the clip may be broken.
1) Remove gusset cover (A), power window
switch assembly (B) and pocket (C).
2) Remove screws, and then detach trim panel.
S5M0450A
EI-26
REAR DOOR TRIM
10. Rear Door Trim S911354
CAUTION:
Do not apply excessive force to clip. Otherwise
the clip may be broken.
1) Remove handle (A), pocket (B) and clips (C).
2) Remove screws, and then detach trim panel.
S5M0451A
EI-27
GLOVE BOX
11. Glove Box S911558
Loosen screws to remove glove box.
S5M0047A
EI-28
ROOF RAIL
12. Roof Rail S911383
1) Remove roof trim. <Ref. to EI-41 REMOVAL, Roof Trim.>

2) Remove seven mounting nuts and then detach roof rail carefully.
S5M0171A

CAUTION:
Be careful not to scratch body panels with roof
rail stud bolts when removing and installing
them.
EI-29
CONSOLE BOX
13. Console Box S911382 B: INSTALLATION S911382A11
1) Remove shift knob and drive select lever (MT

model).
2) Remove console cover (A) and front cover (B).
S5M0297A
3) Remove console box.
S5M0043
EI-30
INSTRUMENT PANEL ASSEMBLY
14. Instrument Panel Assembly 5) Remove lower cover and then disconnect con-
S911381
nector.
Airbag system wiring harness is routed near com-

bination meter.
CAUTION:
쐌 All airbag system wiring harness and con-
쐌 Be careful not to damage airbag system wir-
ing harness when servicing the instrument S5M0044A
panel.
6) Disconnect data link connector (A) from lower
NOTE:
cover.
The following positions for removal and installation
are for LHD models. The positions for RHD mod-
els are symmetrically opposite.
2) Remove shift knob and drive select lever. (MT
model)
3) Remove console cover (A) and front cover (B).
S5M0045A
7) Remove knee panel.
S5M0297A
4) Remove console box.
S5M0046
S5M0043
S5M0047A
EI-31
9) Remove center panel and disconnect connec- 13) Disconnect temperature control cable and
tor. mode control cable from heater unit then discon-
10) Remove audio. nect recirc control cable from intake unit.
NOTE:
Do not move switch and link when installing.
S5M0048A
11) Remove two bolts and lower steering column.
G5M0278
S5M0049A
12) Set temperature control switch to “FULL

HOT”, mode selector switch to “DEF” position and
recirc switch to “FRESH” position.
EI-32
14) Disconnect harness connectors and then remove the installing bolts and nuts.
CAUTION:
Be sure to hold socket section and not harness when disconnecting.
NOTE:
Put matching mark, if necessary, for easy reassembly.
S5M0378A
EI-33
S5M0379A
EI-34
15) Remove front defroster grille and two bolts.
S5M0051
16) Remove instrument panel carefully from the

body.
CAUTION:
쐌 Do not pull the harness when disconnecting
the connector.
쐌 Take care not to scratch the instrument panel
and related parts.
쐌 When storing removed instrument panel with
passenger airbag module, place it standing up
on the floor.
G5M0602
EI-35

CAUTION:
쐌 Be careful not to snag the harness.
쐌 Make sure to connect harness connector.
쐌 Take care not to scratch the instrument panel
and related parts.
NOTE:
When setting the instrument panel into position,
push the two pins into grommet on the body panel.
S5M0052A
EI-36
UPPER INNER TRIM
15. Upper Inner Trim S911384
1) Remove front mole (A).

2) Remove front pillar upper trim (B).
3) Remove center pillar cover (C).
4) Detach front seat belt shoulder anchor.
5) Loosen screws to remove center pillar upper
trim (D).
S5M0452A

CAUTION:
Be sure to securely hook pawls of inner trim
panel to body flange.
NOTE:
When installing center pillar upper trim and front
pillar upper trim, be sure to set front mole as shown
in figure.
B5M0673A
EI-37
LOWER INNER TRIM
16. Lower Inner Trim S911369
1) Remove front pillar lower trim (A).

2) Remove side sill front upper cover (B).
3) Remove rear seat cushion <Ref. to SE-6
REMOVAL, Rear Seat.>, then remove side sill rear
upper cover (C).
4) Remove center pillar cover (D).
5) Remove front seat belt shoulder anchor.
6) Loosen screws to remove center pillar upper
trim (E).
7) Remove center pillar lower trim (F).
S5M0453A

CAUTION:
Be sure to securely hook pawls of inner trim
panel to body flange.
EI-38
REAR QUARTER TRIM
17. Rear Quarter Trim S911358 B: INSTALLATION S911358A11
1) Remove rear rail trim (A). CAUTION:

2) Remove strut cover (B). Be sure to securely hook pawls of inner trim
3) Remove rear seat belt anchor. panel to body flange.
4) Remove caps and screws, and then remove NOTE:
rear quarter upper trim (C). When installing rear quarter upper trim, be sure to
5) Remove rear skirt trim (D). set rear mole as shown in the figure.
6) Remove luggage floor mat. <Ref. to EI-44,
REMOVAL, Luggage Floor Mat.>
7) Remove rear quarter lower trim (E).
B5M0673A
S5M0412B
EI-39
SUN VISOR
18. Sun Visor S911359
Remove mounting screws then detach sun visor

(A) and hook (B).
S5M0454A
EI-40
ROOF TRIM
19. Roof Trim S911360

8) Remove cover (B) while detaching snap lock
carefully. Put the rear seat belt tongue (A) out to
A: REMOVAL S911360A18 the other side of the trim through the hole.
CAUTION:
When removing clip, use great care not to dam-
age the roof trim.
2) Remove head console.
B5M0675A
9) Remove clips and then remove roof trim.
S5M0243
3) Remove sun visor and hook of both sides.

<Ref. to EI-40, REMOVAL, Sun Visor.>
4) Remove assist grips (A).
S5M0413
B5M1025A
5) Remove upper inner trim. <Ref. to EI-37,

REMOVAL, Upper Inner Trim.>
6) Remove rear quarter trim. <Ref. to EI-39,
REMOVAL, Rear quarter Trim.>
7) Detach sunroof garnish (A). (Sunroof equipped
model)
S5M0305B
EI-41
REAR GATE TRIM
20. Rear Gate Trim S911357
CAUTION:
Be careful not to damage clips or their holes.
Remove rear gate inner handle (A) from rear gate
and then detach trim panel.
S5M0386A
EI-42
FLOOR MAT
21. Floor Mat S911362
1) Remove front seats. <Ref. to SE-5 REMOVAL,

Front Seat.>
2) Remove rear seat cushion. <Ref. to SE-6
3) Remove console box. <Ref. to EI-30 Console
Box.>
4) Remove front pillar lower trim, side sill rear
upper cover and center pillar lower trim. <Ref. to
EI-38 REMOVAL, Lower Inner Trim.>
5) Remove clips from floor mat.
NOTE:
When pulling out edge, do not pull mat alone; pull
mat together with edge. Ply off two steel clips on
side sill front cover and one on side sill rear cover
using screwdriver.
6) Remove mat hook.
7) Remove mat from toe board area.
8) Remove mat from rear heater duct.
9) Roll mat, and then take it out of opened rear
door.
S5M0240

NOTE:
쐌 Secure mat firmly with hook and Velcro tape.
쐌 Insert mat edge firmly into the groove of side sill
cover.
EI-43
LUGGAGE FLOOR MAT
22. Luggage Floor Mat S911353
Remove clips, then detach rear floor mats and

boxes.
S5M0241
EI-44
BODY SECTION

SUBARU vehicles.
ine parts.

G8050GE6
EXTERIOR BODY PANELS
EB
Page
2. Front Hood ..................................................................................................9
3. Fender Panel.............................................................................................10
4. Front Door Panel .......................................................................................11
5. Front Sealing Cover ..................................................................................13
6. Rear Door Panel .......................................................................................14
7. Rear Sealing Cover...................................................................................16
8. Rear Gate Panel .......................................................................................17
GENERAL DESCRIPTION
Exterior Body Panels
S5M0380A
EB-2
GENERAL DESCRIPTION
1. FRONT HOOD S913001A0501
S5M0442A
(1) Front hood (5) Front hood stay Tightening torque: N·m (kg-m, ft-lb)
(2) Striker
T1: 24.5 (2.5, 18.1)
(3) Hinge
T2: 33 (3.4, 25)
(4) Seal
EB-3
GENERAL DESCRIPTION
2. FRONT DOOR PANEL S913001A0502
S5M0506A
(1) Gusset (7) Sealing cover Tightening torque: N·m (kgf-m, ft-lb)
(2) Weatherstrip (8) Lower hinge
T1: 7.35 (0.75, 5.4)
(3) Stabilizer (Outer) (9) Upper hinge
T2: 13 (1.3, 9.4)
(4) Stabilizer (Inner)
T3: 25 (2.5, 18)
(5) Door panel
(6) Checker T4: 30 (3.1, 22)
T5: 32 (3.3, 24)
EB-4
GENERAL DESCRIPTION
3. REAR DOOR PANEL S913001A0503
S5M0507A
(1) Weatherstrip (7) Checker Tightening torque: N·m (kgf-m, ft-lb)

(2) Stabilizer (Outer) (8) Lower hinge
T1: 7.35 (0.75, 5.4)
(3) Stabilizer (Inner) (9) Upper hinge
T2: 25 (2.5, 18)
(4) Door panel
T3: 30 (3.1, 18)
(5) Plate
(6) Sealing cover T4: 32 (3.3, 24)
EB-5
GENERAL DESCRIPTION
4. REAR GATE PANEL S913001A0505
S5M0443B
(1) Gas stay (5) Buffer cover Tightening torque: N·m (kg-m, ft-lb)
(2) Hinge (6) Buffer (Back door)
T1: 7.5 (0.76, 5.5)
(3) Rear gate
T2: 14 (1.4, 10.1)
(4) Stopper
T3: 25 (2.5, 18.1)
EB-6
GENERAL DESCRIPTION
쐌 Exterior body panels are heavy. Do not drop and

damage the panels. During removal and
installation, do not damage the panel painting sur-
face.
쐌 While removing mounting bolts, using assis-
tance devices such as a support jack will help sup-
port the panel.
쐌 Be careful not to lose small parts.
EB-7
GENERAL DESCRIPTION

925610000 WRENCH Used for removing and installing door hing.
B5M1117
TOOL NAME REMARKS

Support Jack Used for supporting door panel.
EB-8
FRONT HOOD
2. Front Hood S913367
1) Open front hood to remove washer nozzles.

2) Remove bolts to detach hood from hinges.
G5M0137

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

longitudinally and laterally.
G5M0137
2) Adjust height at front end of hood. <Ref. to

SL-38 ADJUSTMENT, Front Hood Lock Assem-
bly.>
3) Rotate hood buffer to adjust lateral height.
G5M0141
EB-9
FENDER PANEL
3. Fender Panel S913368
1) Disconnect ground (−) cable from battery.

2) Remove side protectors and fender protectors.
<Ref. to EI-22, REMOVAL, Protector.>
3) Remove mud guard. <Ref. to EI-21 REMOVAL,
Mud Guard.>
4) Remove front bumper face. <Ref. to EI-12
5) Remove headlights. <Ref. to LI-42 REMOVAL,
Headlight Assembly.>
6) Remove bolts to remove front fender.
S5M0165

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

10) Remove checker bolts.
1) Disconnect (−) cable from battery.

3) Remove outer mirror assembly. <Ref. to GW-49
REMOVAL, Outer Mirror Assembly.>
4) Remove front door glass. <Ref. to GW-28,
REMOVAL, Front Door Glass.>
5) Remove front door regulator and motor. <Ref.
S5M0183
to GW-31 REMOVAL, Front Regulator and Motor.>
6) Remove front door latch assembly. <Ref. to 11) Remove door-side bolts for upper and lower
SL-29 REMOVAL, Front Door Latch Assembly.> hinges to remove door.
7) Remove front outer handle. <Ref. to SL-28
REMOVAL, Front Outer Handle.>
8) Remove front pillar lower trim to disconnect
connector from body harness.
G5M0385
12) Using special tool, remove body-side bolts for

upper and lower hinges, and remove door hinges.
ST 925610000 DOOR HINGE WRENCH
B5M0726
9) Put wooden block on jack and place jack under

door. Support door with a jack to protect it from
damage.
B5M0933A
CAUTION:
쐌 During removal and installation of doors, do
not damage body.
S5M0518
쐌 Doors are heavy. Be careful not to drop and
damage them.

2) Apply grease to sliding area of door hinges.
EB-11
FRONT DOOR PANEL
1) Using special tool, loosen body-side bolts of

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

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

using plastic hammer to adjust striker to align the
position of front door panel vertically and laterally
at the rear end.
B5M0934A
CAUTION:
Do not use impact wrench. Welding area on
striker nut plate is easily broken.
EB-12
FRONT SEALING COVER
5. Front Sealing Cover S913564

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

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

one.
EB-13
REAR DOOR PANEL
6. Rear Door Panel S913364

9) Remove checker bolts.
1) Disconnect (−) cable from battery.

2) Remove rear door trim. <Ref. to EI-27
3) Remove rear door glass. <Ref. to GW-32,
REMOVAL, Rear Door Glass.>
4) Remove rear door regulator and motor assem-
bly. <Ref. to GW-34 REMOVAL, Rear Regulator
and Motor Assembly.>
S5M0183
5) Remove rear outer handle. <Ref. to SL-32
REMOVAL, Rear Outer Handle.> 10) Remove door-side bolts for upper and lower
6) Remove center pillar lower trim. <Ref. to EI-38 hinges to remove door.
REMOVAL, Lower Inner Trim.>
7) Remove seatbelt bracket and blind plug.
Disconnect connector of door harness and remove
door hinge nut.
G5M0385
11) Using special tool, remove body-side bolts for

upper and lower hinges, and remove door hinges.
B5M1062 CAUTION:
쐌 During removal and installation of doors, do
8) Put a wooden block on the jack and place the not damage body.
jack under the door. Support the door with the jack 쐌 Doors are heavy. Be careful not to drop and
to protect it. damage them.

2) Apply grease to sliding area of door hinges.
S5M0518
EB-14
REAR DOOR PANEL
1) Using special tool, loosen body-side bolts of

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

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

using plastic hammer to adjust striker to align the
position of front door panel vertically and laterally
at the rear end.
B5M0934A
CAUTION:
Do not use an impact wrench. The welding area
on the striker nut plate is easily broken.
EB-15
REAR SEALING COVER
7. Rear Sealing Cover S913565
1) Remove rear door trim. <Ref. to EI-27

2) Remove rear speaker. <Ref. to ET-13
REMOVAL, Rear Speaker.>
3) Using a spatula, remove sealer.
CAUTION:
쐌 Carefully remove sealer. Excessive force will
easily break the cover.
쐌 If cover gets broken, replace it with a new
one.
G5M0391

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

new one.
EB-16
REAR GATE PANEL
8. Rear Gate Panel S913363

CAUTION:
When the rear gate is released, it may hit and
A: REMOVAL S913363A18 damage the body. To prevent this, place a shop
cloth between body and gate.
1. REAR GATE PANEL S913363A1801
2. GAS STAY S913363A1802
1) Open rear gate.
2) Remove rear gate outer handle. <Ref. to SL-35 1) Open rear gate. Using a jack to support the rear
REMOVAL, Rear Gate Outer Handle.> gate.
3) Remove rear gate latch assembly. <Ref. to
SL-36 REMOVAL, Rear Gate Latch Assembly.>
4) Remove rear gate key lock cylinders. <Ref. to
SL-41 REMOVAL, Key Lock Cylinders.>
5) Remove rear wiper. <Ref. to WW-20
REMOVAL, Rear Wiper Motor.>
6) Disconnect connectors of rear wiper, rear
defogger, and other lighting devices.
7) Disconnect washer hose.
8) Remove rubber duct (A) connection, and pull
out harness and washer hose from rear gate. BO0262
CAUTION:
쐌 After gas stay is removed, rear gate cannot
stay open. Supporting the rear gate with a jack,
remove the bolts.
쐌 Do not damage piston rods and oil seals.
쐌 Never disassemble cylinders: They contain
gas.
2) Loosen bolts to remove gas stay from rear gate.
B5M0733A
9) Using a support, support the rear gate while 1. REAR GATE PANEL S913363A1101
removing gas stay mounting bolts.
10) Loosen rear gate bolts to remove rear gate. 1) Install in the reverse order of removal.
2) Install rear gate panel with uniform clearance to
body.
CAUTION:
Do not damage painted surfaces of body and
rear gate.
2. GAS STAY S913363A1102

CAUTION:
쐌 Do not confuse right and left sides of gas
BO0262 stay.
쐌 After supporting rear gate with a jack, start
operation.
S5M0206
EB-17
REAR GATE PANEL
C: DISPOSAL S913363A07
1. GAS STAY S913363A0701
CAUTION:
Gas is colorless, odorless, and harmless.
However, gas pressure may spray cutting pow-
der or oil. Be sure to wear dust-resistant
goggles.
1) Cover with a vinyl case as shown in the figure.
BO0264
CAUTION:
Prevent the vinyl case from being caught by
drill cutting edge
2) Lift body side slightly with piston rods fully
extended, and secure body side on vise stand.
Drill a hole in 2 to 3 mm (0.08 to 0.12 in) diameter
at a point 10 to 200 mm (0.39 to 7.87 in) from door
side, and bleed gas stay completely.
BO0263
EB-18
BODY SECTION

SUBARU vehicles.
ine parts.

G8050GE6
CRUISE CONTROL SYSTEM
CC
Page
2. Actuator (Turbo Model) ...............................................................................5
3. Actuator (Non-turbo Model).........................................................................7
4. Cruise Control Module ................................................................................8
5. Cruise Control Main Switch.........................................................................9
6. Cruise Control Command Switch..............................................................10
7. Stop and Brake Switch..............................................................................11
8. Clutch Switch.............................................................................................12
9. Inhibitor Switch ..........................................................................................13
GENERAL DESCRIPTION
Cruise Control System
1. TURBO MODEL S912001A0501
S6M0487A
(1) Actuator (4) Cruise control command switch (7) Clutch switch (MT)
(2) Inhibitor switch (AT) (5) Cruise control module
(3) Cruise control main switch (6) Stop and brake switch
CC-2
GENERAL DESCRIPTION
2. NON-TURBO MODEL S912001A0502
S6M0106A
(1) Actuator (with valves) (4) Cruise control command switch (7) Clutch switch (MT)
NOTE:
Electrical component location are for LHD
vehicles. Cruise control actuator and cruise control
module location for RHD vehicles are symmetri-
cally opposite.
CC-3
GENERAL DESCRIPTION

always 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.
쐌 Reassemble parts in the reverse order of disas-
sembly unless otherwise indicated.
쐌 Adjust parts to specifications specified in this
manual.
reassembly.
쐌 After reassembly, ensure functional parts oper-
ate properly.
TOOL NAME REMARKS

tance and voltage.
CC-4
ACTUATOR (TURBO MODEL)
2. Actuator (Turbo Model) S912753 B: INSTALLATION S912753A11
Tightening torque:
CAUTION:
7.4 N·m (0.75 kgf-m, 5.4 ft-lb)
쐌 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 gap between throttle cam and
쐌 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
bend permanently, resulting in poor perfor- pulled by wire cable.)
mance. (B): Must be coated evenly on cam end inner con-
nection.
쐌 When installing cable, be careful not to
(C): Cover must be inserted securely, until tip of
sharply bend or pinch the inner cable;
cable touches cover stopper.
otherwise, the cable may break.
1) Remove clip bands from cruise control cable.
2) Loosen nut which secures cruise control cable
end to throttle cam and then remove cable from
throttle cam.
B6M1213A
S6M0088
3) Remove actuator attaching bolts.

4) Remove actuator while disconnecting connec-
tor.
CC-5
ACTUATOR (TURBO MODEL)
B6M1568
Measure resistance between cruise control actua-

tor terminals.
Tester connection Resistance (Ω)
4—1 Approx. 5
4—2 Approx. 5
4—5 Approx. 5
3—6 Approx. 39
If NG, replace cruise control actuator.
CC-6
ACTUATOR (NON-TURBO MODEL)
3. Actuator (Non-turbo Model) 5) Disconnect cruise control vacuum hose from

intake manifold.
S912754
1) Remove air intake chamber.
S6M0089
6) Remove actuator attaching bolts.

7) Disconnect connector from actuator, then
S6M0007 remove the actuator.
2) Remove air intake chamber stay.

3) Remove clip bands from cruise control cable.
S6M0090
S6M0087

4) Remove cruise control cable end from throttle
cam. Tightening torque:
7.4 N·m (0.75 kgf-m, 5.4 ft-lb)
CAUTION:
When inserting vacuum hose to intake
manifold, apply sealant to the fitting hose.
Fluid packing:
THREE BOND 1105 or equivalent
CAUTION:
쐌 Be careful not to apply excessive load to the
wire cable when adjusting and/or installing;
S6M0088
otherwise, the actuator may be deformed or
damaged.
쐌 Do not bend cable sharply with a radius less
than 100 mm (3.94 in); otherwise, cable may
bend permanently, resulting in poor perfor-
mance.
쐌 When installing cable, be careful not to
sharply bend or pinch the inner cable;
otherwise, the cable may break.
CC-7
CRUISE CONTROL MODULE
4. Cruise Control Module S912500
1) Remove front pillar lower trim.
S6M0097
2) Disconnect connector from cruise control mod-

ule.
3) Remove bolt, then remove cruise control mod-
ule.
S6M0098
CC-8
CRUISE CONTROL MAIN SWITCH
5. Cruise Control Main Switch C: INSPECTION S912498A10
S912498
1) Remove screws and clip from instrument panel

lower cover.
2) Remove panel lower cover.
S6M0091
3) Disconnect connector from cruise control main

switch.
S6M0520A
Check continuity between cruise control main

switch terminals.
Specified condi-
tion
OFF 3—5 No continuity
ON 3—5 Continuity
S6M0092A
If NG, replace cruise control main switch.
4) Remove main switch by pushing it outward.
S6M0093
CC-9
CRUISE CONTROL COMMAND SWITCH
6. Cruise Control Command 7) Disconnect horn and cruise control command

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

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

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

S6M0095
CC-10
STOP AND BRAKE SWITCH
7. Stop and Brake Switch S912496
Disconnect connector from switch, and then

remove the switch. <Ref. to BR-60 REMOVAL,
Stop Light Switch.>
S6M0567A
Check continuity brake switch (1) and stop light

switch (2) between terminals.
Switch Pedal
nection condition
Released 1—4 Continuity
Brake
Depressed 1—4 No continuity
Released 2—3 No continuity
Stop light
Depressed 2—3 Continuity
If NG, replace stop and brake switch.
CC-11
CLUTCH SWITCH
8. Clutch Switch S912258
Disconnect the connector from the switch, and

then remove the switch. <Ref. to CL-38
DISASSEMBLY, Clutch Pedal.>
G6M0184
Check continuity between clutch switch terminals.

Switch Pedal
nection condition
Released 1—2 Continuity
Clutch
Depressed 1—2 No continuity
If NG, replace the clutch switch.
CC-12
INHIBITOR SWITCH
9. Inhibitor Switch S912243
Disconnect connector from switch, and then

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

nals.
Selector lever Specified condi-
Tester connection
position tion
P Continuity
N 7 — 12 Continuity
Except P and N No continuity
If NG, replace inhibitor switch.
CC-13
INHIBITOR SWITCH
MEMO:
CC-14
BODY SECTION

SUBARU vehicles.
ine parts.

G8050GE6
AIRBAG SYSTEM (DIAGNOSTICS)
AB
Page
1. Basic Diagnostic Procedure ........................................................................2
2. Check List for Interview...............................................................................3
4. Electrical Components Location................................................................16
5. A/B Control Module I/O Signal..................................................................18
6. Airbag Connector ......................................................................................24
7. Airbag Warning Light Illumination Pattern.................................................26
8. Read Diagnostic Trouble Code .................................................................27
9. Inspection Mode ........................................................................................28
10. Clear Memory Mode..................................................................................29
11. Airbag Warning Light Failure ....................................................................30
12. List of Diagnostic Trouble Code................................................................36
13. Diagnostic Chart with Trouble Code .........................................................39
BASIC DIAGNOSTIC PROCEDURE
Airbag System (Diagnostics)
1. Basic Diagnostic Procedure

S002627
A: PROCEDURE S002501E45

1 Read Diagnostic Trouble Code. Is the normal code being Finish the diagno- Go to step 2.
<Ref. to AB-27 Read Diagnostics Trouble detected? sis.
Code.>
2 Read Diagnostic Trouble Code. Is the trouble code being Go to step 3. Go to “Airbag
<Ref. to AB-27 Read Diagnostics Trouble detected? Warning Light
Code.> Failure”. <Ref. to
AB-30 Airbag
Warning Light
Failure.>
3 Perform the diagnosis. Is the trouble code being Perform the pro- Finish the diagno-
1) Judge the possible cause from “List of detected? cedure 1) to 5) in sis.
Diagnostic Trouble Code” <Ref. to AB-36 List step 3.
of Diagnostic Trouble Code.>.
2) Inspect using “Diagnostic Chart with
Trouble Code”. (DTC)
3) Repair the cause of the trouble.
4) Perform the clear memory mode. <Ref. to
AB-29 Clear Memory Mode.>
5) Perform the inspection mode. <Ref. to
AB-28 Inspection Mode.>
6) Read diagnostic trouble code.
AB-2
CHECK LIST FOR INTERVIEW
2. Check List for Interview S002502
A: CHECK S002502A04
Customer’s Name Inspector’s Name
Date Vehicle Brought In / / Registration No.
Km
Odometer Reading Vin No.
Miles
Date Problem Occurred / / Registration Year / /
Weather 쏔 Fine 쏔 Cloudy 쏔 Rainy 쏔 Snowy 쏔 Other:
Temperature °C (°F)
Road Condition 쏔 Level road 쏔 Uphill 쏔 Downhill 쏔 Rough road 쏔 Other:
쏔 Starting 쏔 Idling
Vehicle Operation 쏔 Driving (쏔 Constant Speed 쏔 Acceleration 쏔 Deceleration
쏔 Steering wheel turn 쏔 Other: )
Details of Problem
Check Airbag Warning Light 쏔 Remains ON 쏔 Remains OFF
Check DTC 쏔 Normal Code 쏔 Trouble Code: (Code: )
AB-3
GENERAL DESCRIPTION

쐌 When checking, use a test harness. Do not
directly apply the tester probe to any connector
A: CAUTION S002001A03 terminal of the airbag.
쐌 When servicing a vehicle, be sure to turn the
ignition switch OFF, disconnect the ground cable
from the battery, and wait for more than 20 sec-
onds before starting work.
쐌 The airbag system is fitted with a backup power
source. If the airbag system is serviced within 20
seconds after the ground cable is disconnected, it
may inflate.
G5M0293
G5M0292
쐌 If sensors, airbag module, airbag control module

and harness are deformed or damaged, replace
them with new genuine parts.
쐌 Do not use the airbag system on other vehicles.
When replacing parts, be sure to replace them with
new parts.
G5M0294
쐌 Do not check continuity of the airbag module

(driver, passenger, and side).
G5M0291
쐌 When checking the system, be sure to use a

digital circuit tester.
Use of an analog circuit tester may cause the air-
bag to activate erroneously.
G5M0302
AB-4
GENERAL DESCRIPTION
쐌 Do not allow water or oil to come in contact with

the connector terminals. Do not touch the connec-
tor terminals.
G5M0298
쐌 The airbag module (driver, passenger, and side)

must not be disassembled.
쐌 The airbag module cannot be used again once
inflated.
G5M0295
쐌 If any damage, opening or rust is found on the

airbag system wire harness, do not attempt to
repair using soldering equipment. Be sure to
replace the faulty harness with a new genuine part.
G5M0299
쐌 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
internal parts may be damaged and reliability
greatly lowered.
G5M0296
쐌 Install the wire harness securely with the speci-

fied clips to avoid interference or tangled up with
other parts.
G5M0297
AB-5
GENERAL DESCRIPTION

on the front part of the vehicle, including the front
wheel apron, front fender, and front side frame,
remove the front sub sensors and wire harness of
the airbag system.
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.
G5M0310
쐌 The removed front seat with the airbag module

must be kept at least 200 mm (8 in) away from
walls and other objects.
B5M1072A
쐌 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
reason when it is placed with its pad side facing
downward or under any object, a serious accident
may result.
AB-6
GENERAL DESCRIPTION
G5M0604
AB-7
GENERAL DESCRIPTION
쐌 Do not discard undeployed airbag modules.

They could easily cause a serious accident if acci-
dentally deployed.
Before diagnosing, check the following items that

might be related to the engine problem:
1. BATTERY S002001A1001
Measure battery voltage and specific gravity of

electrolyte.
Standard voltage: 12V
Specific gravity: Above 1.260
AB-8
GENERAL DESCRIPTION
CAUTION:
Be sure to use specified test harness A, F, G, H and I or I2 when measuring voltage, resistance, etc.
of AIRBAG system component parts.
1. TEST HARNESS A S002001A1701
B5M0112A
AB-9
GENERAL DESCRIPTION
2. TEST HARNESS F S002001A1702
S5M0247A
AB-10
GENERAL DESCRIPTION
3. TEST HARNESS G S002001A1703
S5M0248A
AB-11
GENERAL DESCRIPTION
4. TEST HARNESS H S002001A1704
B5M0553B
AB-12
GENERAL DESCRIPTION
5. TEST HARNESS I S002001A1705
S5M0340A
AB-13
GENERAL DESCRIPTION
6. TEST HARNESS I2 S002001A1706
B5M0927A
AB-14
GENERAL DESCRIPTION
7. AIRBAG RESISTOR S002001A1707
The airbag resistor is used during diagnostics. The airbag resistor has the same resistance as the airbag
module and thus provides safety when used instead of the airbag module. It also makes it possible to finish,
diagnostics in less time.
B5M0114A
AB-15
ELECTRICAL COMPONENTS LOCATION
4. Electrical Components Location S002507
S5M0460A
Connec-
(AB1) (AB2) (AB3) (AB6) (AB7) (AB8) (AB9) (AB10) (AB11) (AB12) (AB13)
tor No.
Pole 7 2 2 28 2 2 2 2 2 2 2
Color Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Blue Blue Yellow
Male/
Male Male Male Female Female Female Female Male Female Male Female
Female
Connec-
tor No.
Pole 2 2 2 12 12 2 2 4 2 2 4
Color Blue Blue Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow
Male/
Female Male Female Female Female Female Male Female Female Male Female
Female
AB-16
2. RHD MODEL S002507A1302
S5M0461A
Connec-
tor No.
Pole 7 2 2 28 2 2 2 2 2 2 2
Color Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Blue Blue Yellow
Male/
Male Male Male Female Female Female Female Male Female Male Female
Female
Connec-
tor No.
Pole 2 2 12 12 2 2 4 2 2 4 2
Color Blue Blue Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow
Male/
Female Male Female Female Female Female Male Female Female Male Female
Female
AB-17
A/B CONTROL MODULE I/O SIGNAL
5. A/B Control Module I/O Signal S002745
1. AIRBAG LHD MODEL S002745A2101
SL86-20A
AB-18
SL86-20B
AB-19
SL86-20C
AB-20
2. AIRBAG RHD MODEL S002745A2102
SR86-20A
AB-21
SR86-20B
AB-22
SR86-20C
AB-23
AIRBAG CONNECTOR
6. Airbag Connector S002659

쐌 How to connect:
1. DRIVER’S AIRBAG, PASSENGER’S CAUTION:
AIRBAG, SIDE AIRBAG S002659A1607 Be sure to insert the connector in until it locks.
쐌 How to disconnect: Then pull on it gently to make sure that it is
locked.
1) Push lock arm (A).
2) With lock arm (A) pushed in, move slide lock (B)
in the direction of the arrow.
B5M1155
B5M1153A
2. FRONT SUB-SENSOR, SIDE AIRBAG
SENSOR S002659A1603
3) With slide lock (B) pulled, remove lock arm (A)
to its original position, and then pull in the direction 쐌 How to disconnect:
of the arrow and separate the connector. 1) Holding outer part (A), pull it in the direction of
CAUTION: the arrow.
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.
B5M1154
RE0014
AB-24
AIRBAG CONNECTOR
쐌 How to connect:
CAUTION:
쐌 Outer (A) moves back, and so do not put
your hand on the outer part.
쐌 Be sure to insert the connector in until it
locks. Then pull on it gently to make sure that
it is locked.
RE0015
AB-25
AIRBAG WARNING LIGHT ILLUMINATION PATTERN
7. Airbag Warning Light

Illumination Pattern S002629
Keep the ignition switch ON, and confirm that the

airbag warning light remains off approximately 6
seconds after being turned on.
B5M1096A
AB-26
READ DIAGNOSTIC TROUBLE CODE
8. Read Diagnostic Trouble 3) Read trouble code by identifying the way the air
bag warning light flashes.
Code S002508
The airbag warning light flashes a code corre-
sponding to the faulty parts.
The long segment (1.2 sec on) indicates a “ten”,
1) Turn the ignition switch ON. and the short segment (0.3 sec on) indicates a
2) Connect the diagnosis terminal to diagnosis “one”.
connector terminal No. 1 in the driver’s seat lower
cover area. NOTE:
쐌 “List of Diagnostic Trouble Code” <Ref. to AB-36
List of Diagnostic Trouble Code.>
쐌 “Airbag Warning Light Failure” <Ref. to AB-30
Airbag Warning Light Failure.>
B5M0115D
B5M0117A
4) Turn the ignition switch OFF, and disconnect

the diagnosis terminal from the diagnosis connec-
tor terminal No 1.
5) Wind tape around the diagnosis terminal and
return it to its original position.
AB-27
INSPECTION MODE
9. Inspection Mode S002510
Recreate the circumstance by referring to the con-

ditions described in the checklist.
AB-28
CLEAR MEMORY MODE
10. Clear Memory Mode S002513
1) Turn the ignition switch ON.

2) Connect the diagnosis terminal “A” to diagnosis
connector terminal No. 1 in the driver’s seat lower
cover area.
B5M0116D
3) While the warning light flashes, connect

another diagnosis terminal “B” to diagnosis con-
nector terminal No.2.
4) Once the memory is erased, the warning light
returns to the normal flash rate (0.6 sec on). The
failure 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, discon-
nect the diagnosis terminal from the diagnosis con-
nector.
6) Wind tape around the diagnosis terminal and
return it to its original position.
AB-29
AIRBAG WARNING LIGHT FAILURE
11. Airbag Warning Light Failure S002681
A: AIRBAG WARNING LIGHT REMAINS ON. S002681E28
DIAGNOSIS:
쐌 Airbag warning light unit is faulty.
쐌 Airbag control module to airbag warning light circuit is shorted or open.
쐌 Grounding circuit is faulty.
쐌 Airbag control module is faulty.
쐌 (AB1) and (B31) are not connected properly.
쐌 (AB6) is not connected properly to airbag control module.
CAUTION:
쐌 Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the
ground cable from the battery, and wait more than 20 seconds before starting to work.
쐌 Before replacing the airbag module, roll connector, control module, and sensor, reconnect each
part and confirm that the warning light operates properly.
쐌 When inspecting the airbag main harness, disconnect the airbag module connector of the driver
and passenger seats for safety reasons.
AB-30
WIRING DIAGRAM:
S5M0462

1 CHECK POOR CONTACT IN CONNECTORS Is the poor contact in Repair the body Go to step 2.
(AB1) AND (B31). double lock of connectors harness or
1) Turn the ignition switch OFF, disconnect (AB1) and (B31)? replace airbag
the battery ground cable, and wait more than main
20 seconds. harness.<Ref. to
2) Remove front pillar lower trim. (Driver’s AB-16 Main Har-
side) ness.>
3) Confirm that firm contact is secured
between connectors (AB1) and (B31).
AB-31

2 CHECK AIRBAG WARNING LIGHT. Is the airbag warning light Go to step 4. Go to step 3.
1) Turn the ignition switch OFF, disconnect turned off?
the battery ground cable, and wait more than
20 seconds.
2) Connect the connector (1A) in test harness
A to the body harness connector (B31).
3) Connect the battery ground cable and turn
the ignition switch ON.
4) Connect two connectors, (3A) and (4A) in
test harness A.
3 CHECK BODY HARNESS. Is the anything unusual to Repair the body Replace combina-
Check the body harness. body harness? harness. tion meter printed
NOTE: circuit. <Ref. to
After problem has been eliminated, discon- IDI-15 Combina-
nect connectors (3A) and (4A). tion Meter Assem-
bly.>
4 CHECK POOR CONTACT. Is the poor contact in con- Replace airbag Go to step 5.
Confirm that firm contact is secured between nector (AB6)? main harness.
the airbag control module and the connector <Ref. to AB-16
(AB6). <Ref. to AB-18 Airbag Control Mod- Main Harness.> or
ule.> Replace the air-
bag control mod-
ule. <Ref. to
AB-18 Airbag
Control Module.>
5 CHECK AIRBAG MAIN HARNESS. Is the airbag warning light Go to step 6. Replace airbag
1) Turn the ignition switch OFF, disconnect turned off? main harness.
the battery ground cable, and wait more than <Ref. to AB-16
20 seconds. Main Harness.>
2) Connect the connector (AB1) to (B31).
3) Disconnect connectors (AB3) and (AB8).
4) Remove glove box and disconnect connec-
tors (AB10) and (AB9).
5) Disconnect the connector (AB6) from the
airbag control module, and connect the con-
nector (1I) in test harness I or I2. <Ref. to
AB-18 Airbag Control Module.>
7) Connect connectors (4I) and (5I) in test
harness I or I2.
NOTE:
After problem has been eliminated, discon-
nect connectors (4I) and (5I).
6 CHECK GROUNDING CIRCUIT. Is the resistance less than Go to step 7. Repair body-
1) Turn the ignition switch OFF, disconnect 10 Ω? grounding circuit.
20 seconds.
body harness connector (B31).
A to body harness connector (B31).
4) Measure the resistance between connector
(5A) in test harness A and the chassis
ground.
(5A) No. 17 — Chassis ground:
AB-32

7 CHECK AIRBAG MAIN HARNESS. Is the resistance less than Replace the air- Replace airbag
1) Connect the connector (AB1) to (B31). 10 Ω? bag control mod- main harness.
2) Disconnect the connector (AB6) from the ule. <Ref. to <Ref. to AB-16
airbag control module, and connect the con- AB-18 Airbag Main Harness.>
nector (1I) in test harness I or I2. <Ref. to Control Module.>
(2I) in test harness I or I2 and the chassis
ground.
(2I) No. 9 — Chassis ground:
AB-33
B: AIRBAG WARNING LIGHT REMAINS OFF. S002681E27
DIAGNOSIS:
쐌 Fuse No. 5 (in fuse box) is blown.
쐌 Body harness circuit is open.
쐌 Airbag warning light is faulty.
쐌 Airbag main harness is faulty.
CAUTION:
WIRING DIAGRAM:
S5M0462
AB-34

1 CHECK COMBINATION METER. Do warning lights not for Go to step 2. Repair combina-
Turn the ignition switch ON, and confirm that the airbag turn on? tion meter power
warning lights equipped in the combination supply. <Ref. to
meter are turned on. IDI-4 Combination
Meter System.>
2 CHECK FUSE NO. 5 (IN MAIN FUSE BOX). Is fuse No. 5 (in main fuse Replace fuse No. Go to step 3.
Remove fuse No. 5 and perform visual box) blown? 5. If fuse No. 5
inspection. blows again, go to
step 3.
3 CHECK AIRBAG WARNING LIGHT CIRCUIT Is the airbag warning light Go to step 4. Replace airbag
(IN COMBINATION METER). turned on? warning light bulb
1) Turn the ignition switch OFF, disconnect or combination
the battery ground cable, and wait more than meter printed cir-
20 seconds. cuit. <Ref. to
2) Disconnect the connector (AB1) from IDI-15 Combina-
(B31). tion Meter Assem-
3) Connect the battery ground cable and turn bly.>
4 CHECK AIRBAG MAIN HARNESS. Is the airbag warning light Replace the air- Replace airbag
1) Turn the ignition switch OFF, disconnect turned on? bag control mod- main harness.
the battery ground cable, and wait more than ule. <Ref. to <Ref. to AB-16
20 seconds. AB-18 Airbag Main Harness.>
2) Connect the connector (AB1) to (B31). Control Module.>
airbag control module. <Ref. to AB-18 Airbag
Control Module.>
AB-35
LIST OF DIAGNOSTIC TROUBLE CODE
12. List of Diagnostic Trouble Code S002511
A: LIST S002511A12
Trouble code/
Memory function Contents of diagnosis Index No.
Contents of troubles
쐌 Airbag main harness circuit is open, shorted or
shorted to ground.
쐌 Airbag module harness (driver) circuit is open, <Ref. to AB-39
shorted or shorted to ground. TROUBLE CODE 11,
11 Provided.
쐌 Roll connector circuit is open, shorted or shorted Diagnostic Chart with
to ground. Trouble Code.>
쐌 Driver’s airbag module is faulty.
쐌 Airbag main harness circuit is open, shorted or
shorted to ground. <Ref. to AB-43
쐌 Airbag module harness (passenger) circuit is TROUBLE CODE 12,
12 Provided.
open, shorted or shorted to ground. Diagnostic Chart with
쐌 Airbag control module is faulty. Trouble Code.>
쐌 Passenger’s airbag module is faulty.
쐌 Airbag main harness circuit (driver) is shorted to
power supply.
<Ref. to AB-45
쐌 Airbag module harness (driver) is shorted to
TROUBLE CODE 15,
15 Provided. power supply.
Diagnostic Chart with
쐌 Roll connector is shorted to power supply.
Trouble Code.>
쐌 Airbag main harness circuit (passenger) is
shorted to power supply. <Ref. to AB-47
쐌 Airbag module harness (passenger) is shorted TROUBLE CODE 16,
16 Provided.
to power supply. Diagnostic Chart with
<Ref. to AB-48
TROUBLE CODE 21,
21 Provided. Airbag control module is faulty.
Trouble Code.>
<Ref. to AB-49
TROUBLE CODE 22,
22 Provided. Front airbag module is inflated.
Trouble Code.>
<Ref. to AB-50
(AB6), (AB17) and (AB18) are not connected prop- TROUBLE CODE 23,
23 Not provided.
erly to airbag control module. Diagnostic Chart with
Trouble Code.>
쐌 Airbag control module is faulty. <Ref. to AB-51
쐌 Airbag main harness circuit is open. TROUBLE CODE 24,
24 Not provided.
쐌 Fuse No. 11 (in joint box) is blown. Diagnostic Chart with
쐌 Body harness circuit is open. Trouble Code.>
쐌 Airbag control module is faulty. <Ref. to AB-53
쐌 Airbag main harness circuit is open. TROUBLE CODE 25,
25 Provided.
쐌 Fuse No. 6 (in joint box) is blown. Diagnostic Chart with
쐌 Body harness circuit is open. Trouble Code.>
쐌 Front sub-sensor harness (RH) circuit is shorted. <Ref. to AB-55
쐌 Front sub-sensor harness (RH) circuit is open. TROUBLE CODE 31,
31 Provided.
쐌 Front sub-sensor (RH) is faulty. Diagnostic Chart with
AB-36
Trouble code/
Memory function Contents of diagnosis Index No.
Contents of troubles
쐌 Front sub-sensor harness (LH) circuit is shorted. <Ref. to AB-59
쐌 Front sub-sensor harness (LH) circuit is open. TROUBLE CODE 32,
32 Provided.
쐌 Front sub-sensor (LH) is faulty. Diagnostic Chart with
<Ref. to AB-63
쐌 Side airbag harness (RH) is faulty.
TROUBLE CODE 41,
41 Provided. 쐌 Side airbag module (RH) is faulty.
Trouble Code.>
<Ref. to AB-65
쐌 Side airbag harness (LH) is faulty.
TROUBLE CODE 42,
42 Provided. 쐌 Side airbag module (LH) is faulty.
Trouble Code.>
<Ref. to AB-67
쐌 Side airbag harness (RH) is shorted to power
TROUBLE CODE 45,
45 Provided. supply.
Trouble Code.>
<Ref. to AB-69
쐌 Side airbag harness (LH) is shorted to power
TROUBLE CODE 46,
46 Provided. supply.
Trouble Code.>
<Ref. to AB-71
쐌 Side airbag sensor (RH) is faulty.
TROUBLE CODE 51,
51 Provided. 쐌 Side airbag harness (RH) is faulty.
Trouble Code.>
<Ref. to AB-73
쐌 Side airbag sensor (LH) is faulty.
TROUBLE CODE 52,
52 Provided. 쐌 Side airbag harness (LH) is faulty.
Trouble Code.>
<Ref. to AB-74
TROUBLE CODE 53,
53 Provided. Side airbag sensor (RH) is faulty.
Trouble Code.>
<Ref. to AB-74
TROUBLE CODE 54,
54 Provided. Side airbag sensor (LH) is faulty.
Trouble Code.>
<Ref. to AB-74
TROUBLE CODE 55,
55 Provided. Side airbag module is inflated.
Trouble Code.>
AB-37
MEMO:
AB-38
DIAGNOSTIC CHART WITH TROUBLE CODE
13. Diagnostic Chart with Trouble Code S002630
A: TROUBLE CODE 11 S002630C38
DIAGNOSIS:
쐌 Airbag main harness circuit is open, shorted or shorted to ground.
쐌 Airbag module harness (Driver) circuit is open, shorted or shorted to ground.
쐌 Roll connector circuit is open, shorted or shorted to ground.
CAUTION:
쐌 Before replacing the airbag module, roll controller, control module, and sensor, reconnect each
쐌 When inspecting the airbag main harness, disconnect the driver’s airbag module and passenger’s
airbag module connectors for safety reasons.
AB-39
WIRING DIAGRAM:
S5M0463

1 CHECK DRIVER’S AIRBAG MODULE. Does the airbag warning Replace the driv- Go to step 2.
1) Turn the ignition switch OFF, disconnect light operate properly? er’s airbag mod-
battery ground cable, and wait more than 20 ule. <Ref. to
seconds. AB-12 Driver’s
2) Remove the driver’s airbag module. <Ref. Airbag Module.>
to AB-12 Driver’s Airbag Module.>
3) Connect the connector (1F) in test harness
F to connector (AB7).
4) Connect airbag resistor to connector (3F)
in test harness F.
AB-40

2 CHECK ROLL CONNECTOR. Does the airbag warning Replace the roll Go to step 3.
1) Turn the ignition switch OFF, disconnect light operate properly? connector. <Ref.
the battery ground cable, and wait more than to AB-20 Roll
20 second. Connector.>
2) Disconnect the test harness from the con-
nector (AB7).
3) Remove the lower cover panel, disconnect
the connector (AB3) from (AB8) and connect
the connector (1F) in test harness F to con-
nector (AB8).
4) Connect the airbag resistor to connector
(3F) in test harness F.
3 CHECK AIRBAG MAIN HARNESS. Is the resistance less than Go to step 4. Replace airbag
1) Turn the ignition switch OFF, disconnect 10 Ω? main harness.
the ground cable, and wait more than 20 sec- <Ref. to AB-16
onds. Main Harness.>
2) Disconnect the airbag resistor from the
connector (3F) in test harness F.
3) Remove the glove box, <Ref. to AB-14
Passenger’s Airbag Module.> and disconnect
connectors (AB10) and (AB9).
(2I) in test harness I or I2 and the connector
(2I) No. 1 — (3F) No. 3:
(2I) No. 4 — (3F) No. 4:
4 CHECK AIRBAG MAIN HARNESS. Is the resistance more than Replace the air- Replace airbag
Measure the resistance of the connector (2I) 1 MΩ? bag control mod- main harness.
in test harness I or I2. ule. <Ref. to <Ref. to AB-16
Connector & terminal AB-18 Airbag Main Harness.>
(2I) No. 1 — No. 4: Control Module.>
AB-41
MEMO:
AB-42
B: TROUBLE CODE 12 S002630C40
DIAGNOSIS:
쐌 Airbag main harness circuit is open, shorted or shorted to ground.
쐌 Airbag module harness (Passenger) circuit is open, shorted or shorted to ground.
CAUTION:
WIRING DIAGRAM:
S5M0464
AB-43

1 CHECK PASSENGER’S AIRBAG MODULE. Does the airbag warning Replace the pas- Go to step 2.
1) Turn the ignition switch OFF, disconnect light operate properly? senger airbag
the battery ground cable, and wait more than module. <Ref. to
20 seconds. AB-14 Passen-
2) Remove the glove box. ger’s Airbag Mod-
3) Disconnect the connector (AB10) from ule.>
(AB9).
1) Turn the ignition switch OFF, disconnect 10 Ω? main harness.
20 seconds. Main Harness.>
2) Disconnect the airbag resistor from the
3) Remove lower cover and disconnect the
connector (AB3) from (AB8).
(2I) in test harness I or I2 and the connector
(2I) No. 2 — (3F) No. 3:
(2I) No. 5 — (3F) No. 4:
3 CHECK AIRBAG MAIN HARNESS. Is the resistance more than Replace airbag Replace airbag
Measure the resistance of the connector (2I) 1 MΩ? control module. main harness.
in test harness I or I2. <Ref. to AB-18 <Ref. to AB-16
Connector & terminal Airbag Control Main Harness.>
(2I) No. 2 — No. 5: Module.>
AB-44
C: TROUBLE CODE 15 S002630C41
DIAGNOSIS:
쐌 Airbag main harness circuit (Driver) is shorted to the power supply.
쐌 Airbag module harness (Driver) is shorted to the power supply.
쐌 Roll connector is shorted to the power supply.
CAUTION:
WIRING DIAGRAM:
S5M0463
AB-45

1 CHECK DRIVER’S AIRBAG MODULE. Does the airbag warning Replace the driv- Go to step 2.
1) Turn the ignition switch OFF, disconnect light operate properly? er’s airbag mod-
the battery ground cable, and wait more than ule. <Ref. to
20 seconds. AB-12 Driver’s
2) Remove the driver’s airbag module. <Ref. Airbag Module.>
to AB-12 Driver’s Airbag Module.>
3) Connect the connector (AB7) to connector
2 CHECK ROLL CONNECTOR. Does the airbag warning Replace the roll Go to step 3.
1) Turn the ignition switch OFF, disconnect light operate properly? connector. <Ref.
the battery ground cable, and wait more than to AB-20 Roll
20 seconds. Connector.>
2) Disconnect the test harness from the con-
nector (AB7).
3) Remove the lower cover panel and discon-
nect the connector (AB3) from (AB8).
3 CHECK AIRBAG MAIN HARNESS. Is the voltage less than 1 Replace the air- Replace airbag
1) Turn the ignition switch OFF, disconnect V? bag control mod- main harness.
2) Disconnect the airbag resistor from the Control Module.>
3) Remove the glove box, and disconnect
connectors (AB10) and (AB9).
the ignition switch ON. (Engine OFF)
6) Measure the voltage between connector
ground.
(2I) No. 4 (+) — Chassis ground (−):
AB-46
D: TROUBLE CODE 16 S002630C42
DIAGNOSIS:
쐌 Airbag main harness circuit (Passenger) is shorted to the power supply.
쐌 Airbag module harness (Passenger) is shorted to the power supply.
CAUTION:
WIRING DIAGRAM:
S5M0464
AB-47

1 CHECK PASSENGER’S AIRBAG MODULE. Does the airbag warning Replace the pas- Go to step 2.
1) Turn the ignition switch OFF, disconnect light operate properly? senger airbag
the battery ground cable, and wait more than module. <Ref. to
20 seconds. AB-14 Passen-
2) Remove the glove box. ger’s Airbag Mod-
3) Disconnect the connector (AB10) from ule.>
(AB9)
2 CHECK AIRBAG MAIN HARNESS. Is the voltage less than 1 Replace the air- Replace airbag
1) Turn the ignition switch OFF, disconnect V? bag control mod- main harness.
2) Disconnect the airbag resistor from the Control Module.>
3) Remove the lower cover and disconnect
the connector (AB3) from (AB8).
ground.
E: TROUBLE CODE 21 S002630C45
DIAGNOSIS:
CAUTION:
1 CHECK IF TROUBLE CODE 21 IS INDI- Is airbag warning light Replace the air- Perform clear
CATED. trouble code 21 indicated? bag control mod- memory. <Ref. to
Read Diagnostic Trouble Code. <Ref. to ule. <Ref. to AB-29 Clear
AB-27 Read Diagnostics Trouble Code.> AB-18 Airbag Memory Mode.>
Control Module.>
AB-48
F: TROUBLE CODE 22 S002630C51
This code is indicated when the front airbag is in operation.

Once this code is indicated, memory is not erasable; therefore replace the following parts.
쐌 Airbag control module. <Ref. to AB-18 Airbag Control Module.>
쐌 Driver’s airbag module. <Ref. to AB-12 Driver’s Airbag Module.>
쐌 Passenger’s airbag module. <Ref. to AB-14 Passenger’s Airbag Module.>
쐌 Front sub-sensor of both sides. <Ref. to AB-21 Front Sub Sensor.>
AB-49
G: TROUBLE CODE 23 S002630C56
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
cable from the battery, and wait more than 20 seconds before starting to work.
1 CHECK POOR CONTACT IN CONNECTORS Check if rust or damage Replace the air- Go to step 2.
(AB6), (AB17) and (AB18). appear on the harness con- bag control mod-
1) Turn the ignition switch OFF, disconnect nector and the control module. <Ref. to
the battery ground cable, and wait more than ule connector. AB-18 Airbag
20 seconds. Control Module.>
2) Disconnect the connectors (AB6), (AB17) Replace airbag
and (AB18) from the airbag control module. main harness.
<Ref. to AB-18 Airbag Control Module.> <Ref. to AB-16
Main Harness.>
Replace side air-
bag harness.
<Ref. to AB-17
Side Airbag Har-
ness.>
2 CHECK POOR CONTACT IN CONNECTORS Does the airbag warning Finish the diagno- Replace the air-
(AB6), (AB17) and (AB18). light operate properly? sis. bag control mod-
1) Ensure that connectors are firmly recon- ule. <Ref. to
nected. AB-18 Airbag
2) Connect the battery ground cable and turn Control Module.>
AB-50
H: TROUBLE CODE 24 S002630C61
DIAGNOSIS:
쐌 Airbag main harness circuit is open.
쐌 Fuse No, 11 (in joint box) is blown.
CAUTION:
WIRING DIAGRAM:
B5M1101
AB-51

1 CHECK AIRBAG CONTROL MODULE. Is the voltage more than 10 Replace the air- Go to step 2.
1) Turn the ignition switch OFF, disconnect V? bag control mod-
20 seconds. AB-18 Airbag
2) Disconnect the connector (AB6) from the Control Module.>
Control Module.>
3) Connect the connector (1I) in test harness I
or I2 to connector (AB6).
(2I) in test harness I or I2 and chassis
ground.
1) While checking control module, turn the 10 Ω? main harness.
ignition switch OFF and disconnect the bat- <Ref. to AB-16
tery ground cable. Wait more than 20 seconds Main Harness.>
before operation.
2) Disconnect the airbag connector (AB1)
from the body harness (B31).
A to connector (AB1).
(5A) in test harness A and the connector (2I)
in test harness I or I2.
(5A) No. 9 — (2I) No. 3:
3 CHECK AIRBAG MAIN HARNESS. Is the resistance more than Go to step 4. Replace airbag
Measure the following resistance with the 1 MΩ? main harness.
above-mentioned condition maintained. <Ref. to AB-16
Connector & terminal Main Harness.>
4 CHECK FUSE No. 11 (IN JOINT BOX). Is fuse No. 11 blown? Replace fuse No. Repair the body
1) Confirm that the ignition switch is turned 11. If fuse No. 11 harness.
OFF. blows again,
2) Remove fuse No. 11 (in joint box) and per- repair the body
form visual inspection. harness.
AB-52
I: TROUBLE CODE 25 S002630C66
DIAGNOSIS:
쐌 Airbag main harness circuit is open.
쐌 Fuse No. 6 (in joint box) is blown.
CAUTION:
WIRING DIAGRAM:
B5M1102
AB-53

1 CHECK AIRBAG CONTROL MODULE. Is the voltage more than 10 Replace the air- Go to step 2.
1) Turn the ignition switch OFF, disconnect V? bag control mod-
20 seconds. AB-18 Airbag
2) Disconnect the connector (AB6) from air- Control Module.>
bag control module. <Ref. to AB-18 Airbag
Control Module.>
3) Connect the connector (1I) in test harness I
or I2 to connector (AB6).
4) Connect the battery ground cable, and turn
5) Measure the voltage between the connec-
tor (2I) in test harness I or I2 and the chassis
ground.
2 CHECK AIRBAG MAIN HARNESS. Is the resistance less than Go to step 3. Replace the air-
1) While checking control module, turn the 10 Ω? bag main har-
ignition switch OFF and disconnect the bat- ness. <Ref. to
tery ground cable. Wait more than 20 seconds AB-16 Main Har-
before operation. ness.>
2) Disconnect the airbag connector (AB1)
from the body harness (B31).
A to the airbag connector (AB1).
4) Measure the resistance between the con-
nector (5A) in test harness A and the connec-
tor (2I) in test harness I or I2.
(5A) No. 1 — (2I) No. 6:
3 CHECK AIRBAG MAIN HARNESS. Is the resistance more than Go to step 4. Replace the air-
Measure the following resistance with the 1 MΩ? bag main har-
above-mentioned condition maintained. ness. <Ref. to
Connector & terminal AB-16 Main Har-
(5A) No. 1 — Chassis ground: ness.>
4 CHECK FUSE NO. 6 (IN JOINT BOX). Is fuse No. 6 blown? Replace fuse No. Repair the body
1) Confirm that the ignition switch is turned 6. If fuse No. 6 is harness.
OFF. blown again,
2) Remove No. 6 fuse (in joint box) and per- repair the body
form visual inspection. harness.
AB-54
J: TROUBLE CODE 31 S002630C89
DIAGNOSIS:
쐌 Front sub-sensor harness (RH) circuit is shorted.
쐌 Front sub-sensor harness (RH) circuit is open.
쐌 Front sub-sensor (RH) is faulty.
CAUTION:
WIRING DIAGRAM:
S5M0465
AB-55

1 CHECK FRONT SUB-SENSOR (RH) AND Is the resistance between Go to step 2. Go to step 3.
FRONT SUB-SENSOR HARNESS (RH). 750Ω and 1 KΩ?
1) Turn the ignition switch OFF, disconnect
20 seconds.
airbag control module , and connect the con-
3) Measure the resistance of the connector
(3I) in test harness I or I2.
(3I) No. 2 — No. 4:
2 CHECK FRONT SUB-SENSOR (RH) AND Is the resistance more than Replace the air- Go to step 3.
FRONT SUB-SENSOR HARNESS (RH). 1 MΩ? bag control mod-
Measure the resistance between connector ule. <Ref. to
(3I) in test harness I or I2 and the chassis AB-18 Airbag
ground. Control Module.>
3 CHECK AIRBAG MAIN HARNESS AND Is the resistance less than Go to step 4. Go to step 5.
FRONT SUB-SENSOR HARNESS (RH). 10Ω?
1) Disconnect connector (AB16) from the front
sub-sensor. <Ref. to AB-21 Front Sub Sen-
sor.>
2) Connect connector (1H) in test harness H
to connector (AB16).
(3I) in test harness I or I2 and connector (3H)
in test harness H.
(3I) No. 2 — (3H) No. 5:
(3I) No. 4 — (3H) No. 6:
4 CHECK AIRBAG MAIN HARNESS AND Is the resistance more than Go to step 9. Go to step 5.
FRONT SUB-SENSOR HARNESS (RH). 1 MΩ?
Measure the resistance between connector
ground.
5 CHECK AIRBAG MAIN HARNESS Is the resistance less than Go to step 6. Replace airbag
1) Remove the instrument panel. <Ref. to 10 Ω? main harness.
EI-31 Instrument Panel Assembly.> <Ref. to AB-16
2) Disconnect connector (AB15) from (AB14), Main Harness.>
and connect connector (1F) in test harness F
(3I) in test harness I or I2 and connector (3F)
in test harness F.
(3I) No. 2 — (3F) No. 3:
(3I) No. 4 — (3F) No. 4:
AB-56

6 CHECK AIRBAG MAIN HARNESS Is the resistance more than Go to step 7. Replace airbag
Measure the resistance between connector 1 MΩ? main harness.
(3I) in test harness I or I2 and the chassis <Ref. to AB-16
ground. Main Harness.>
7 CHECK FRONT SUB-SENSOR HARNESS Is the resistance less than Go to step 8. Replace the front
(RH). 10 Ω? sub-sensor har-
1) Connect connector (2F) in test harness F ness (RH) <Ref.
to the connector (AB15). to AB-22 Front
2) Measure the resistance between connector Sub Sensor Har-
(3H) in test harness H and connector (3F) in ness.>
the test harness F.
(3F) No. 6 — (3H) No. 5:
(3F) No. 5 — (3H) No. 6:
8 CHECK FRONT SUB-SENSOR HARNESS Is the resistance more than Go to step 9. Replace the front
(RH). 1 MΩ? sub-sensor har-
Measure the resistance between connector ness (RH). <Ref.
(3H) in test harness H and connector (3F) in to AB-22, Front
test harness F. Sub Sensor Har-
Connector & terminal ness.>
(3F) No. 6 — (3H) No. 6:
(3F) No. 5 — (3H) No. 5:
(RH). 1 MΩ? sub-sensor har-
Measure the resistance between connector ness (RH) <Ref.
(3F) in test harness F and the chassis to AB-22 Front
ground. Sub Sensor Har-
(3F) No. 6 — Chassis ground:
10 CHECK FRONT SUB-SENSOR (RH). Is the resistance between Go to step 11. Replace the front
1) Connect connector (2H) in test harness H 750Ω and 1 KΩ? sub-sensor (RH)
to front sub-sensor (RH). <Ref. to AB-21
2) Measure the resistance of the connector Front Sub Sen-
(3H) in test harness H. sor.>
(3H) No. 3 — No. 4:
11 CHECK FRONT SUB-SENSOR (RH). Is the resistance more than Finish the diagno- Replace the front
Measure the resistance between connector 1 MΩ? sis. sub-sensor (RH)
(3H) in test harness H and the chassis <Ref. to AB-21
ground. Front Sub Sen-
Connector & terminal sor.>
(3H) No. 3 — Chassis ground:
AB-57
MEMO:
AB-58
K: TROUBLE CODE 32 S002630C95
DIAGNOSIS:
쐌 Front sub-sensor harness (LH) circuit is shorted.
쐌 Front sub-sensor harness (LH) circuit is open.
쐌 Front sub-sensor (LH) is faulty.
CAUTION:
WIRING DIAGRAM:
S5M0466
AB-59

1 CHECK FRONT SUB-SENSOR (LH) AND Is the resistance between Go to step 2. Go to step 3.
FRONT SUB-SENSOR HARNESS (RH). 750Ω and 1 KΩ?
1) Turn the ignition switch OFF, disconnect
20 seconds.
2) Disconnect connector (AB6) from the air-
bag control module, and connect connector
(1I) in the test harness I or I2 to connector
(AB6). <Ref. to AB-18 Airbag Control Mod-
ule.>
3) Measure the resistance of the connector
(3I) in the test harness I or I2.
(3I) No. 1 — No. 3:
2 CHECK FRONT SUB-SENSOR (LH) AND Is the resistance more than Replace the air- Go to step 3.
FRONT SUB-SENSOR HARNESS (RH). 1 MΩ? bag control mod-
Measure the resistance between connector ule. <Ref. to
(3I) in test harness I or I2 and the chassis AB-18 Airbag
ground. Control Module.>
3 CHECK AIRBAG MAIN HARNESS AND Is the resistance less than Go to step 4. Go to step 5.
FRONT SUB-SENSOR HARNESS (LH). 10 Ω?
front sub-sensor. <Ref. to AB-21 Front Sub
Sensor.>
2) Connect connector (1H) in test harness H
(3I) in test harness I or I2 and connector (3H)
in test harness H.
(3I) No. 3 — (3H) No. 5:
(3I) No. 1 — (3H) No. 6:
4 CHECK AIRBAG MAIN HARNESS AND Is the resistance more than Go to step 9. Go to step 5.
FRONT SUB-SENSOR HARNESS (LH). 1 MΩ?
Measure the resistance between connector
ground.
5 CHECK AIRBAG MAIN HARNESS. Is the resistance less than Go to step 6. Replace the air-
1) Remove the instrument panel. <Ref. to 10 Ω? bag main har-
EI-31 Instrument Panel Assembly.> ness. <Ref. to
2) Disconnect connector (AB11) from (AB12), AB-16 Main Har-
and connect connector (1F) in test harness F ness.>
to (AB11).
in test harness F.
(3I) No. 3 — (3F) No. 3:
(3I) No. 1 — (3F) No. 4:
AB-60

6 CHECK AIRBAG MAIN HARNESS. Is the resistance more than Go to step 7. Replace the air-
Measure the resistance between connector 1 MΩ? bag main har-
(3I) in the test harness I or I2 and the chassis ness. <Ref. to
ground. AB-16 Main Har-
7 CHECK FRONT SUB-SENSOR HARNESS Is the resistance less than Go to step 8. Replace the front
(LH). 10 Ω? sub-sensor har-
1) Connect connector (2F) in test harness F ness (LH). <Ref.
to connector (AB12). to AB-22 Front
2) Measure the resistance between connector Sub Sensor Har-
(3H) in test harness H and connector (3F) in ness.>
test harness F.
(3F) No. 6 — (3H) No. 5:
(3F) No. 5 — (3H) No. 6:
(LH). 1 MΩ? sub-sensor har-
Measure the resistance between connector ness (LH). <Ref.
(3H) in test harness H and connector (3F) in to AB-22, Front
test harness F. Sub Sensor Har-
(3F) No. 6 — (3H) No. 6:
(3F) No. 5 — (3H) No. 5:
(LH). 1 MΩ? sub-sensor har-
Measure the resistance between connector ness (LH). <Ref.
(3F) in test harness F and the chassis to AB-22 Front
ground. Sub Sensor Har-
10 CHECK FRONT SUB-SENSOR (LH). Is the resistance between Go to step 11. Replace the front
1) Connect connector (2H) in test harness H 750Ω and 1 KΩ? sub-sensor (LH).
to front sub-sensor (LH). <Ref. to AB-21
2) Measure the resistance of the connector Front Sub Sen-
(3H) in test harness H. sor.>
(3H) No. 3 — No. 4:
11 CHECK FRONT SUB-SENSOR (LH). Is the resistance more than Finish the diagno- Replace the front
Measure the resistance between connector 1 MΩ? sis. sub-sensor (LH).
(3H) in test harness H and the chassis <Ref. to AB-21
ground. Front Sub Sen-
Connector & terminal sor.>
AB-61
MEMO:
AB-62
L: TROUBLE CODE 41 S002630D28
DIAGNOSIS:
쐌 Side airbag module (RH) is faulty.
CAUTION:
쐌 When inspecting the side airbag harness, disconnect the side airbag module connector for the
safety reasons.
WIRING DIAGRAM:
S5M0517
AB-63

1 CHECK SIDE AIRBAG MODULE. Does the airbag warning Replace front seat Go to step 2.
1) Turn the ignition switch OFF, disconnect light operate properly? with side airbag
the battery ground cable, and wait more than module (RH).
20 seconds. <Ref. to SE-5
2) Disconnect connector (AB25) from (AB24), Front Seat.>
to (AB24).
in test harness F.
2 CHECK SIDE AIRBAG HARNESS (RH). Is the resistance less than Go to step 3. Replace side air-
1) Turn the ignition switch OFF, disconnect 10 Ω? bag harness.
20 seconds. Side Airbag Har-
2) Disconnect airbag resistor from test harness.>
ness.
3) Disconnect the connector (AB18) from air
Control Module.>
4) Connect connector (1I) in test harness I or
I2 to connector (AB18).
in test harness F.
(3I) No. 7 — (3F) No. 3:
(3I) No. 9 — (3F) No. 4:
3 CHECK SIDE AIRBAG HARNESS (RH). Is the resistance more than Go to step 4. Replace side air-
Measure the resistance of the connector (3I) 1 MΩ? bag harness.
in test harness I or I2. <Ref. to AB-17
Connector & terminal Side Airbag Har-
(3I) No. 7 — No. 9: ness.>
4 CHECK SIDE AIRBAG HARNESS (RH). Is the resistance more Go to step 5. Replace side air-
Measure the resistance of the connector (3F) 1MΩ? bag harness.
in test harness F. <Ref. to AB-17
(3F) No. 3 — No. 4: ness.>
5 CHECK SIDE AIRBAG HARNESS (RH). Is the resistance more than Go to step 6. Replace side air-
Measure the resistance between connector 1 MΩ? bag harness.
(3F) in test harness F and the chassis <Ref. to AB-17
ground. Side Airbag Har-
6 CHECK SIDE AIRBAG HARNESS (RH). Is the resistance more than Replace the air- Replace side air-
Measure the resistance between connector 1 MΩ? bag control mod- bag harness.
(3I) in test harness I or I2 and the chassis ule. <Ref. to <Ref. to AB-17
ground. AB-18 Airbag Side Airbag Har-
Connector & terminal Control Module.> ness.>
AB-64
M: TROUBLE CODE 42 S002630D33
DIAGNOSIS:
쐌 Side airbag module (LH) is faulty.
CAUTION:
safety reasons.
WIRING DIAGRAM:
S5M0468
AB-65

1 CHECK SIDE AIRBAG MODULE. Does the airbag warning Replace front seat Go to step 2.
1) Turn the ignition switch OFF, disconnect light operate properly? with side airbag
the battery ground cable, and wait more than module (LH).
to (AB19).
in test harness F.
2 CHECK SIDE AIRBAG HARNESS (LH). Is the resistance less than Go to step 3. Replace side air-
1) Turn ignition switch OFF, disconnect the 10 Ω? bag harness.
battery ground cable, and wait more than 20 <Ref. to AB-17
seconds. Side Airbag Har-
2) Disconnect airbag resistor from the test ness.>
harness.
Control Module.>
in test harness F.
(3I) No. 10 — (3F) No. 4:
(3I) No. 12 — (3F) No. 3:
3 CHECK SIDE AIRBAG HARNESS (LH). Is the resistance more than Go to step 4. Replace side air-
Measure the resistance of the connector (3I) 1 MΩ? bag harness.
in test harness I or I2. <Ref. to AB-17
(3I) No. 10 — No. 12: ness.>
Measure the resistance of the connector (3F) 1 MΩ? bag harness.
in test harness F. <Ref. to AB-17
(3F) No. 3 — No. 4: ness.>
Measure the resistance between connector 1 MΩ? bag harness.
(3F) in test harness F and the chassis <Ref. to AB-17
ground. Side Airbag Har-
6 CHECK SIDE AIRBAG HARNESS (LH). Is the resistance more than Replace airbag Replace side air-
Measure the resistance between connector 1 MΩ? control module. bag harness.
(3I) in test harness I or I2 and the chassis <Ref. to AB-18 <Ref. to AB-17
ground. Airbag Control Side Airbag Har-
Connector & terminal Module.> ness.>
AB-66
N: TROUBLE CODE 45 S002630D45
DIAGNOSIS:
쐌 Side airbag harness (RH) is shorted to power supply.
CAUTION:
safety reasons.
WIRING DIAGRAM:
S5M0517
AB-67

1 CHECK SIDE AIRBAG MODULE. Does airbag warning light Replace front seat Go to step 2.
1) Turn the ignition switch OFF, disconnect operate properly? with side airbag
the battery ground cable, and wait more than module (RH).
2) Disconnect the connector (AB25) from Front Seat.>
(AB24), and connect connector (1F) in test
harness F to (AB24 ).
in test harness F.
2 CHECK SIDE AIRBAG HARNESS (RH). Is the voltage less than 1 Replace the air- Replace side air-
1) Turn the ignition switch OFF, disconnect V? bag control mod- bag harness.
20 seconds. AB-18 Airbag Side Airbag Har-
2) Disconnect airbag resistor from the test Control Module.> ness.>
harness.
Control Module.>
ground.
AB-68
O: TROUBLE CODE 46 S002630D50
DIAGNOSIS:
쐌 Side airbag harness (LH) is shorted to power supply.
CAUTION:
safety reasons.
WIRING DIAGRAM:
S5M0468
AB-69

1 CHECK SIDE AIRBAG MODULE. Does airbag warning light Replace front seat Go to step 2.
1) Turn the ignition switch OFF, disconnect operate properly? with side airbag
the battery ground cable, and wait more than module (LH).
to (AB19).
in test harness F.
2 CHECK SIDE AIRBAG HARNESS (LH). Is the voltage less than 1 Replace the air- Replace side air-
1) Turn the ignition switch OFF, disconnect V? bag control mod- bag harness.
20 seconds. AB-18 Airbag Side Airbag Har-
2) Disconnect airbag resistor from the test Control Module.> ness.>
harness.
Control Module.>
ground.
AB-70
P: TROUBLE CODE 51 S002630D60
DIAGNOSIS:
CAUTION:
safety reasons.
WIRING DIAGRAM:
S5M0517
AB-71

1 CHECK SIDE AIRBAG HARNESS (RH). Is the resistance less than Go to step 2. Replace side air-
2) Disconnect connector (AB25) from (AB24). ness.>
Control Module.>
I2 to the connector (AB18).
5) Disconnect connector (AB28) from the side
airbag sensor (RH), and connect connector
(1G) in test harness G to connector (AB28).
(3I) in test harness I or I2 and connector (3G)
in test harness G.
(3I) No. 17 — (3G) No. 2:
(3I) No. 18 — (3G) No. 1:
(3I) No. 19 — (3G) No. 5:
(3I) No. 20 — (3G) No. 4:
2 CHECK SIDE AIRBAG HARNESS (RH). Is the resistance more than Replace side air- Replace side air-
Measure the resistance between connector 1 MΩ? bag sensor (RH). bag harness.
ground. Side Airbag Sen- Side Airbag Har-
Connector & terminal sor.> When sen- ness.>
(3I) No. 17 — Chassis ground: sor replacement is
(3I) No. 18 — Chassis ground: not OK, replace
(3I) No. 19 — Chassis ground: the airbag control
(3I) No. 20 — Chassis ground: module. <Ref. to
AB-18 Airbag
Control Module.>
AB-72
Q: TROUBLE CODE 52 S002630D64
DIAGNOSIS:
CAUTION:
safety reasons.
WIRING DIAGRAM:
S5M0468
AB-73

1 CHECK SIDE AIRBAG HARNESS (LH). Is the resistance less than Go to step 2. Replace side air-
2) Disconnect connector (AB20) from (AB19). ness.>
Control Module.>
5) Disconnect connector (AB23) from the side
airbag sensor (LH), and connect connector
(1G) in test harness G to connector (AB23).
(3I) in test harness I or I2 and connector (3G)
in test harness G.
(3I) No. 5 — (3G) No. 4:
(3I) No. 14 — (3G) No. 5:
(3I) No. 15 — (3G) No. 1:
(3I) No. 16 — (3G) No. 2:
2 CHECK SIDE AIRBAG HARNESS (RH). Is the resistance more than Replace side air- Replace side air-
Measure the resistance between connector 1 MΩ? bag sensor (LH). bag harness.
ground. Side Airbag Sen- Side Airbag Har-
Connector & terminal sor.> When sen- ness.>
(3I) No. 5 — Chassis ground: sor replacement is
(3I) No. 14 — Chassis ground: not OK, replace
(3I) No. 15 — Chassis ground: the airbag control
(3I) No. 16 — Chassis ground: module. <Ref. to
AB-18 Airbag
Control Module.>
R: TROUBLE CODE 53 S002630D69
DIAGNOSIS:
When Code 53 is displayed, the circuit within the side airbag sensor (RH) is faulty. Replace the side airbag
sensor (RH).
<Ref. to AB-19 Side Airbag Sensor.>
S: TROUBLE CODE 54 S002630D70
DIAGNOSIS:
When Code 54 is displayed, the circuit within the side airbag sensor (LH) is faulty. Replace the side airbag
sensor (LH).
<Ref. to AB-19 Side Airbag Sensor.>
T: TROUBLE CODE 55 S002630D73
This code is displayed when the side airbag is deployed.

When this code is displayed, the memory cannot be erased. Replace the following parts.
쐌 Airbag control module. <Ref. to AB-18 Airbag Control Module.>
쐌 Front seat with side airbag module. (Operating side) <Ref. to SE-5 Front Seat.>
쐌 Side airbag sensor. (Operating side) <Ref. to AB-19 Side Airbag Sensor.>
AB-74
BODY SECTION

SUBARU vehicles.
ine parts.

G8050GE6
CRUISE CONTROL SYSTEM
(DIAGNOSTICS)
CC
Page
3. Electrical Components Location..................................................................8
4. Cruise Control Module I/O Signal .............................................................10
5. Subaru Select Monitor...............................................................................19
6. Diagnostics Chart with Symptom (Turbo Model) ......................................21
7. Diagnostics Chart with Trouble Code (Turbo Model)................................37
8. Diagnostics Chart with Symptom (Non-turbo Model) ...............................49
9. Diagnostics Chart with Trouble Code (Non-turbo Model).........................57
Cruise Control System (Diagnostics)
1. Basic Diagnostic Procedure S003501

1 START DIAGNOSIS. Is cruise control main Go to step 2. Go to symptom 1.
1) Perform pre-inspection. <Ref. to CC-6 switch turned ON? Turbo model:
INSPECTION, General Description.> <Ref. to CC-21
2) Check cruise control main switch operation. SYMPTOM
CHART, Diagnos-
tics Chart with
Symptom (Turbo
Model).>
Non-turbo
model: <Ref. to
CC-49, SYMP-
TOM CHART,
Diagnostics Chart
with Symptom
(Non-turbo
Model).>
2 PREPARE SUBARU SELECT MONITOR. Is the select monitor avail- Go to step 3. Go to step 4.
able?
3 PERFORM CRUISE CANCEL CONDITIONS Is trouble code indicated? Go to “Diagnos- Go to step 4.
DIAGNOSIS. tics Chart with
Perform cruise cancel conditions diagnosis. Trouble Code”.
<Ref. to CC-19 Subaru Select Monitor.>
4 CHECK CRUISE CONTROL SET OPERA- Can cruise control be set Go to step 5. Go to symptom 2.
TION. while driving at 40 km/h (25 Turbo model:
Check cruise control set operation. MPH)? <Ref. to CC-21
SYMPTOM
CHART, Diagnos-
tics Chart with
Symptom (Turbo
Model).>
Non-turbo
model: <Ref. to
CC-49, SYMP-
TOM CHART,
Diagnostics Chart
with Symptom
(Non-turbo
Model).>
5 CHECK VEHICLE SPEED IS HELD WITHIN Is vehicle speed held within Go to step 6. Go to symptom 3.
SET SPEED. set speed ±3 km/h (±2 Turbo model:
Make sure vehicle speed is held within set MPH) ? <Ref. to CC-21
speed. SYMPTOM
CHART, Diagnos-
tics Chart with
Symptom (Turbo
Model).>
Non-turbo
model: <Ref. to
CC-49, SYMP-
TOM CHART,
Diagnostics Chart
with Symptom
(Non-turbo
Model).>
CC-2

6 CHECK RESUME/ACCEL OPERATION. Does vehicle speed Go to step 7. Go to symptom 4.
Check RESUME/ACCEL operation. increase or return to set Turbo model:
speed after RESUME/ <Ref. to CC-21
ACCEL switch has been SYMPTOM
pressed? CHART, Diagnos-
tics Chart with
Symptom (Turbo
Model).>
Non-turbo
model: <Ref. to
CC-49, SYMP-
TOM CHART,
Diagnostics Chart
with Symptom
(Non-turbo
Model).>
7 CHECK SET/COAST OPERATION. Does vehicle speed Go to step 8. Go to symptom 5.
Check SET/COAST operation. decrease after SET/COAST Turbo
switch has been pressed? model:<Ref. to
CC-21 SYMPTOM
CHART, Diagnos-
tics Chart with
Symptom (Turbo
Model).>
Non-turbo
model: <Ref. to
CC-49, SYMP-
TOM CHART,
Diagnostics Chart
with Symptom
(Non-turbo
Model).>
8 CHECK CANCEL OPERATION. Is cruise control released Go to step 9. Go to symptom 6.
Check CANCEL operation. after CANCEL switch has Turbo model:
been pressed? <Ref. to CC-21
SYMPTOM
CHART, Diagnos-
tics Chart with
Symptom (Turbo
Model).>
Non-turbo
model: <Ref. to
CC-49, SYMP-
TOM CHART,
Diagnostics Chart
with Symptom
(Non-turbo
Model).>
CC-3

9 CHECK CRUISE CONTROL RELEASE Is cruise control released Go to step 10. Go to symptom 7.
OPERATION. after brake pedal has been Turbo model:
Check cruise control release operation. depressed? <Ref. to CC-21
SYMPTOM
CHART, Diagnos-
tics Chart with
Symptom (Turbo
Model).>
Non-turbo
model: <Ref. to
CC-49, SYMP-
TOM CHART,
Diagnostics Chart
with Symptom
(Non-turbo
Model).>
10 CHECK CRUISE CONTROL RELEASE Is cruise control released Finish the diag- Go to symptom 8.
OPERATION. after clutch pedal has been nostics. Turbo model:
Check cruise control release operation. depressed? (MT) <Ref. to CC-21
SYMPTOM
CHART, Diagnos-
tics Chart with
Symptom (Turbo
Model).>
Non-turbo
model: <Ref. to
CC-49, SYMP-
TOM CHART,
Diagnostics Chart
with Symptom
(Non-turbo
Model).>
CC-4
GENERAL DESCRIPTION

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

24082AA150 CARTRIDGE Troubleshooting for electrical systems.
(Newly adopted tool)
B2M3876
22771AA030 SELECT MONITOR Troubleshooting for electrical systems.
KIT 쐌 English:
22771AA030 (Without printer)
쐌 German:
쐌 French:
쐌 Spanish:
B2M3877
TOOL NAME REMARKS

Circuit Tester Used for measuring resistance, voltage and ampere.
CC-5
GENERAL DESCRIPTION
C: INSPECTION S003001A10 5. CABLE FREE PLAY S003001A1006
1. BATTERY S003001A1002
Measure battery voltage and specific gravity of

electrolyte.
Standard voltage:
12 V, or more
Specific gravity:
Above 1.260
2. CRUISE CONTROL CABLE S003001A1003
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.
S6M0099A
6. VACUUM HOSE (NON-TURBO MODEL)
S003001A1009
Check the cruise control cable installation.

If NG, install the cable securely.
3. ACCELERATOR CABLE S003001A1004
S6M0101A
Check vacuum hose (which connects actuator and

intake manifold).
If NG, replace vacuum hose.
S6M0099A
Check movement of the accelerator cable when

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

If NG, repair throttle cam.
CC-6
GENERAL DESCRIPTION
7. ACTUATOR (NON-TURBO MODEL) S003001A1010

1 MEASURE RESISTANCE OF VALVE. Is resistance less than 22 Go to step 2. Replace actuator.
1) Disconnect connector from actuator. Ω? <Ref. to CC-7,
2) Measure resistance between terminals of REMOVAL, Actua-
actuator. tor (Non-turbo
Terminals Model).>
No. 2 — No. 3:
Measure resistance between terminals of Ω? <Ref. to CC-7,
actuator. REMOVAL, Actua-
Terminals tor (Non-turbo
No. 2 — No. 1: Model).>
Measure resistance between terminals of Ω? <Ref. to CC-7,
actuator. REMOVAL, Actua-
Terminals tor (Non-turbo
No. 2 — No. 4: Model).>
4 CHECK FOR LEAKAGE AND STICKING OF Does cruise control cable Go to step 5. Replace actuator.
VALVES. have a stroke of 35 mm <Ref. to CC-7,
1) Disconnect connector from actuator. (1.38 in) within 3 seconds? REMOVAL, Actua-
2) Disconnect vacuum hose from actuator. tor (Non-turbo
3) Connect vacuum pump. Model).>
4) Apply a vacuum pressure of 40.0 kPa (300
mmHg, 11.81 inHg) to actuator.
5) Make sure that cruise control cable moves
smoothly when connecting + (positive) battery
cable to terminal No. 2 and − (negative) bat-
tery cable to terminals No. 1, 3 and 4 of
actuator connector.
5 CHECK FOR LEAKAGE AND STICKING OF Does cruise control cable Go to step 6. Replace actuator.
VALVES. get back to its original posi- <Ref. to CC-7,
When the battery cable is disconnected from tion within 1.5 seconds? REMOVAL, Actua-
former condition, make sure the cable returns tor (Non-turbo
to its original position smoothly. Model).>
6 CHECK CABLE MOVEMENT. Does cruise control perform Go to step 7. Replace actuator.
1) Connect + (positive) battery cable to termi- pull operation? <Ref. to CC-7,
nal No. 2 and − (negative) battery cable to REMOVAL, Actua-
terminals No. 1, 3 and 4 of actuator connector (Non-turbo
tor. Model).>
2) Apply a vacuum pressure of 40 kPa (300
mmHg, 11.81 inHg) to actuator.
7 CHECK CABLE MOVEMENT. Does cruise control perform Go to step 8. Replace actuator.
After step 6, disconnect − (negative) battery hold operation? <Ref. to CC-7,
cable from terminal 3 of actuator connector REMOVAL, Actua-
and remove vacuum pump. tor (Non-turbo
Model).>
8 CHECK CABLE MOVEMENT. Does cruise control perform End of actuator Replace actuator.
After step 7, disconnect − (negative) battery release operation? inspection. <Ref. to CC-7,
cable from terminal 1 of actuator connector. REMOVAL, Actua-
tor (Non-turbo
Model).>
CC-7
NOTE:
Electrical component locations are for LHD vehicles.
Cruise control actuator and cruise control module locations for RHD vehicles are symmetrically opposite.
S6M0487A
(1) Actuator (4) Cruise control command switch (7) Clutch switch (MT)
CC-8
S6M0106A
(1) Actuator (with valves)

(2) Inhibitor switch (AT)
(3) Cruise control main switch
(4) Cruise control command switch
(5) Cruise control module
(6) Stop and brake switch
(7) Clutch switch (MT)
CC-9
CRUISE CONTROL MODULE I/O SIGNAL
4. Cruise Control Module I/O Signal S003515
A: ELECTRICAL SPECIFICATION S003515A08
G6M0015
Content Terminal No. Measuring conditions and I/O signals (ignition switch ON and engine idling)
Main light 1 쐌 Battery voltage is present when main switch is turned OFF.
쐌 “0” volt is present when main switch is turned ON.
Inhibitor switch (AT) 4 쐌 Battery voltage is present when selector lever is other than “P” or “N” posi-
tion.
쐌 “0” volt is present when selector lever is set to “P” or “N” position.
Motor B 5 쐌 ON-and-OFF (“0”-and-battery voltage) operation is alternately repeated
while cruise control is operating.
쐌 “0” volt is present when main switch is turned OFF.
Ground 6 —
Motor A 7 쐌 ON-and-OFF (“0”-and-battery voltage) operation is alternately repeated
RESUME/ACCEL switch 9 쐌 Battery voltage is present when command switch is turned to RESUME/
ACCEL position.
쐌 “0” volt is present when command switch is released.
SET/COAST switch 10 쐌 Battery voltage is present when command switch is turned to SET/COAST
position.
Main power supply 11 쐌 Battery voltage is present when main power is turned ON.
쐌 “0” volt is present when main power is turned OFF.
Ignition switch 12 쐌 Battery voltage is present when ignition switch is turned ON.
쐌 “0” volt is present when ignition switch is turned OFF.
Motor C 13 쐌 ON-and-OFF (“0”-and-battery voltage) operation is alternately repeated
Motor clutch 14 쐌 ON-and-OFF (“0”-and-battery voltage) operation is alternately repeated
쐌 “0” volt is present when vehicle is stopped.
Cruise control main switch 15 쐌 Battery voltage is present during pressing the cruise control main switch,
and then battery voltage is present while main switch is turned ON.
Brake switch 16 Leave clutch pedal released (MT), while cruise control main switch is turned
ON.
Then check that;
쐌 Battery voltage is present when brake pedal is released.
쐌 “0” volt is present when brake pedal is depressed.
Additionally only in MT vehicle, keep the cruise control main switch to ON and
leave brake pedal released.
Then check that;
쐌 Battery voltage is present when clutch pedal is released.
쐌 “0” volt is present when clutch pedal is depressed.
CC-10
Content Terminal No. Measuring conditions and I/O signals (ignition switch ON and engine idling)
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
TCM (AT) any wheel manually.
Approx. “5” and “0” volt pulse signals are alternately input to cruise control
module.
Stop light switch 20 Turn ignition switch to OFF.
Then check that;
쐌 Battery voltage is present when brake pedal is depressed.
쐌 “0” volt is present when brake pedal is released.
NOTE:
Voltage at terminals 5, 7, 13 and 14 cannot be checked unless vehicle is driving by cruise control operation.
G6M0015
Terminal
Content Measuring conditions and I/O signals (ignition switch ON and engine idling)
No.
Vent valve 1 쐌 Power supply is ON when vehicle is stopped.
쐌 ON-and-OFF (“0”-and-battery voltage) operation is alternately repeated while
cruise control is operating.
Safety valve 2 쐌 Power supply is ON when vehicle is stopped.
Ignition switch 3 쐌 Battery voltage is present when ignition switch is turned ON.
쐌 “0” volt is present when ignition switch is turned OFF.
Cruise control main switch 4 쐌 Battery voltage is present when main power is turned ON.
쐌 “0” volt is present when main power is turned OFF.
Power supply to vacuum 5 쐌 Battery voltage is present when main power is turned ON.
valve, vent valve, safety valve 쐌 “0” volt is present when main power is turned OFF.
and indicator light
SET/COAST switch 6 쐌 Battery voltage is present when command switch is turned to SET/COAST
position.
RESUME/ACCEL switch 7 쐌 Battery voltage is present when command switch is turned to RESUME/
ACCEL position.
CC-11
Terminal
Content Measuring conditions and I/O signals (ignition switch ON and engine idling)
No.
Brake switch 8 Set selector lever to any position other than “P” or “N” position (AT) / leave
clutch pedal released (MT), while cruise control main switch is turned ON.
Then check that;
쐌 Battery voltage is present when brake pedal is released.
쐌 “0” volt is present when brake pedal is depressed, or
쐌 Battery voltage is present when clutch pedal is released (MT).
쐌 “0” volt is present when clutch pedal is depressed (MT).
쐌 Battery voltage is present when selector lever is in any position other than “P”
or “N” position (AT).
쐌 “0” volt is present when selector lever is set to “P” or “N” position (AT).
Clutch switch (MT)/ 9 쐌 Battery voltage is present when clutch pedal is released (MT).
Inhibitor switch (AT) 쐌 “0” volt is present when clutch pedal is depressed (MT).
쐌 Battery voltage is present when selector lever is in any position other than “P”
or “N” position (AT).
쐌 “0” volt is present when selector lever is set to “P” or “N” position (AT).
Vacuum valve 11 쐌 Power supply is ON when vehicle is stopped.
Set signal to transmission 12 쐌 TCM emits a ground-level signal while driving vehicle at least 40 km/h (25
control module (AT) MPH) with SET switch ON.
Ground 13 —
Check connector/ 14 —
OBD-II service connector
Check connector/ 15 —
OBD-II service connector
Vehicle speed sensor 2 (MT) 18 Lift-up the vehicle until all four wheels are raised off ground, and then rotate any
Automatic transmission con- wheel manually. Approx. 5 and 0 volt pulse signals are alternately input to cruise
trol module (AT) control module.
Stop light switch 19 Turn ignition switch to OFF. Then check that;
쐌 Battery voltage is present when brake pedal is depressed.
쐌 “0” volt is present when brake pedal is released.
Ground 20 —
NOTE:
Voltage at terminals 1, 2, 11 and 12 cannot be checked unless vehicle is driving by cruise control operation.
CC-12
B: SCHEMATIC S003515A21
1. CRUISE CONTROL TURBO MODEL S003515A2107
SG71-20A
CC-13
SG71-20B
CC-14
SG71-20C
CC-15
2. CRUISE CONTROL NON-TURBO

MODEL S003515A2108
SG71-21A
CC-16
SG71-21B
CC-17
SG71-21C
CC-18
SUBARU SELECT MONITOR
5. Subaru Select Monitor S003503

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

trol system uses an external Subaru Select Moni-
tor.
The on-board diagnosis function operates in two
categories, which are used depending on the type
of problems;
1) Cruise cancel conditions diagnosis
(1) This category of diagnosis requires actual
vehicle driving in order to determine the cause,
(as when cruise speed is cancelled during driv- S2M0285
ing although cruise cancel condition is not
entered). 2) Connect diagnosis cable to Subaru Select
(2) Cruise control module memory stores the Monitor.
cancel condition (Code No.) which occurred 3) Insert cartridge into Subaru Select Monitor.
during driving. When there are plural cancel
conditions (Code No.), they are shown on the
Subaru Select Monitor.
CAUTION:
쐌 The cruise control memory stores not only
the cruise “cancel” which occurred (although
“cancel” operation is not entered by the
driver), but also the “cancel” condition input by
the driver.
쐌 The content of memory is cleared when igni-
tion switch or cruise main switch is turned OFF. S2M0286A
2) Real-time diagnosis 4) Connect Subaru Select Monitor to data link

The real-time diagnosis function is used to deter- connector.
mine whether or not the input signal system is in
(1) Data link connector located in the lower por-
good order, according to signal emitted from
tion of the instrument panel (on the driver’s
switches, sensors, etc.
(1) Vehicle cannot be driven at cruise speed side).
because problem occurs in the cruise control
system or its associated circuits.
(2) Monitor the signal conditions from switches
and sensors.
S2M2157
(2) Connect diagnosis cable to data link con-

nector.
CC-19
5) Start engine and turn cruise control main switch 3. REAL-TIME DIAGNOSIS S003503A1606
to ON.
1) Connect select monitor.
6) Turn Subaru Select Monitor switch to ON.
2) Turn ignition switch and cruise control main
switch to ON.
3) Turn Subaru Select Monitor switch to ON.
4) On the ⰆMain MenuⰇ display screen, select
the {Each System Check} and press the [YES] key.
5) On the ⰆSystem Selection MenuⰇ display
screen, select the {Cruise Control} and press the
[YES] key.
6) Press the [YES] key after displayed the infor-
mation of engine type.
7) On the ⰆCruise Control DiagnosisⰇ display
S2M0288A screen, select the {Current Data Display & Save}
and press the [YES] key.
8) Make sure that normal indication is displayed
the {All System Diagnosis} and press the [YES]
when controls are operated as indicated below:
key.
쐌 Depress/release the brake pedal. (Stop light
NOTE: switch and brake switch turn ON.)
The diagnostic trouble code is also shown in the 쐌 Turn ON the “SET/COAST” switch.
{Each System Check} mode. This mode is called 쐌 Turn ON the “RESUME/ACCEL” switch.
up on the ⰆCruise Control DiagnosisⰇ screen by 쐌 Depress/release the clutch pedal. (MT)
selecting the item {Cancel Code(s) Display}. 쐌 Set the selector lever to P or N. (AT)
8) Drive vehicle at least 30 km/h (19 MPH) with NOTE:
cruise speed set. 쐌 For detailed operation procedure, refer to the
9) If cruise speed is canceled itself (without doing SUBARU SELECT MONITOR OPERATION
any cancel operations), a diagnostic trouble code MANUAL.
will appear on select monitor display. 쐌 For detailed concerning diagnostic trouble
CAUTION: codes, refer to the LIST OF DIAGNOSTIC
쐌 A diagnostic trouble code will also appear TROUBLE CODE.
when cruise cancel is effected by driver. Do not <Ref. to CC-37 LIST OF DIAGNOSTIC TROUBLE
confuse. CODE, Diagnostics Chart with Trouble Code
쐌 Have a co-worker ride in vehicle to assist in (Turbo Model).> or <Ref. to CC-57, LIST OF DIAG-
diagnosis during driving. NOSTIC TROUBLE CODE, Diagnostics Chart with
Trouble Code (Non-turbo Model).>
NOTE:
Diagnostic trouble code will be cleared by turning
ignition switch or cruise control main switch to OFF.
CC-20
DIAGNOSTICS CHART WITH SYMPTOM (TURBO MODEL)
6. Diagnostics Chart with Symptom (Turbo Model) S003749
A: SYMPTOM CHART S003749F22
Symptom Repair area Reference

Cruise control main switch is (1) Check power supply. <Ref. to CC-23 CHECK POWER SUPPRY, Diagnostics
not turned ON. Chart with Symptom (Turbo Model).>
1 (2) Check cruise control main <Ref. to CC-25 CHECK CRUISE CONTROL MAIN
switch. SWITCH, Diagnostics Chart with Symptom (Turbo
Model).>
Cruise control cannot be set. (1) Check SET/COAST <Ref. to CC-29 CHECK CRUISE CONTROL COM-
switch. MAND SWITCH, Diagnostics Chart with Symptom
(Turbo Model).>
(2) Check stop light switch <Ref. to CC-31 CHECK STOP LIGHT SWITCH AND
and brake switch. BRAKE SWITCH, Diagnostics Chart with Symptom
(Turbo Model).>
(3) Check clutch switch (MT). <Ref. to CC-33 CHECK CLUTCH SWITCH (MT), Diag-
nostics Chart with Symptom (Turbo Model).>
(4) Check inhibitor switch <Ref. to CC-35 CHECK INHIBITOR SWITCH (AT),
2 (AT). Diagnostics Chart with Symptom (Turbo Model).>
(5) Check vehicle speed sen- <Ref. to CC-39 DIAGNOSTIC TROUBLE CODE 22 —
sor. VEHICLE SPEED SENSOR —, Diagnostics Chart with
Trouble Code (Turbo Model).>
(6) Check motor drive sys- <Ref. to CC-43 DIAGNOSTIC TROUBLE CODE 35
tem. AND 36 — ACTUATOR MOTOR — , Diagnostics Chart
with Trouble Code (Turbo Model).>
(7) Check motor clutch drive <Ref. to CC-45 DIAGNOSTIC TROUBLE CODE 37 —
system. ACTUATOR MOTOR CLUTCH — , Diagnostics Chart
Vehicle speed is not held (1) Check vehicle speed sen- <Ref. to CC-39 DIAGNOSTIC TROUBLE CODE 22 —
within set speed ±3 km/h (±2 sor. VEHICLE SPEED SENSOR —, Diagnostics Chart with
MPH). Trouble Code (Turbo Model).>
3 tem. AND 36 — ACTUATOR MOTOR — , Diagnostics Chart
Vehicle speed does not (1) Check RESUME/ACCEL <Ref. to CC-29 CHECK CRUISE CONTROL COM-
increase or does not return switch. MAND SWITCH, Diagnostics Chart with Symptom
to set speed after RESUME/ (Turbo Model).>
ACCEL switch has been (2) Check motor drive sys- <Ref. to CC-43 DIAGNOSTIC TROUBLE CODE 35
4 pressed. tem. AND 36 — ACTUATOR MOTOR — , Diagnostics Chart
Vehicle speed does not (1) Check SET/COAST <Ref. to CC-29 CHECK CRUISE CONTROL COM-
decrease after SET/COAST switch. MAND SWITCH, Diagnostics Chart with Symptom
switch has been pressed. (Turbo Model).>
CC-21

Cruise control is not released (1) Check CANCEL switch. <Ref. to CC-29 CHECK CRUISE CONTROL COM-
after CANCEL switch has MAND SWITCH, Diagnostics Chart with Symptom
been pressed. (Turbo Model).>
Cruise control is not released (1) Check stop light switch <Ref. to CC-31 CHECK STOP LIGHT SWITCH AND
after brake pedal has been and brake switch. BRAKE SWITCH, Diagnostics Chart Symptom (Turbo
depressed. Model).>
Cruise control is not released (1) Check clutch switch. <Ref. to CC-33 CHECK CLUTCH SWITCH (MT), Diag-
after clutch pedal has been nostics Chart with Symptom (Turbo Model).>
depressed (MT). (2) Check motor drive sys- <Ref. to CC-43 DIAGNOSTIC TROUBLE CODE 35
tem. AND 36 — ACTUATOR MOTOR — , Diagnostics Chart
8
CC-22
B: CHECK POWER SUPPLY S003749F23
TROUBLE SYMPTOM:
Cruise control can be set normally, but indicator does not come on. (When main switch is pressed.)
WIRING DIAGRAM:
S6M0521
CC-23

1 CHECK POWER SUPPLY. Is the voltage more than 10 Go to step 2. 쐌 Check fuse No.
1) Disconnect cruise control module harness V? 18 (in fuse & relay
connector. box).
2) Turn ignition switch ON. 쐌 Check harness
3) Measure voltage between harness connec- for open or short
tor terminal and chassis ground. between cruise
Connector & terminal control module
(B94) No. 12 (+) — Chassis ground (−): and fuse & relay
box.
Measure resistance between harness connec- 10 Ω? ground circuit are
tor terminal and chassis ground. OK.
CC-24
C: CHECK CRUISE CONTROL MAIN SWITCH S003749F24
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 condi-
tion.
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.
CC-25
WIRING DIAGRAM:
S6M0521
CC-26

1 CHECK CRUISE CONTROL MAIN SWITCH Is the voltage more than 10 Go to step 2. 쐌 Check fuse No.
CIRCUIT. V? 18 (in fuse & relay
1) Disconnect cruise control main switch har- box).
ness connector. 쐌 Check harness
2) Turn ignition switch ON. for open or short
3) Measure voltage between harness connec- between cruise
tor terminal and chassis ground. control main
Connector & terminal switch and fuse &
(B161) No. 3 (+) — Chassis ground (−): relay box.
2 CHECK CRUISE CONTROL MAIN SWITCH Is the resistance less than Go to step 3. Repair harness.
CIRCUIT. 10 Ω?
2) Disconnect cruise control module harness
connector.
3) Measure resistance between cruise control
module harness connector terminal and cruise
control main switch harness connector termi-
nal.
(B94) No. 15 (+) — (B161) No. 5 (−):
(B94) No. 1 (+) — (B161) No. 6 (−):
(B94) No. 11(+) — (B161) No. 1 (−):
3 CHECK CRUISE CONTROL MAIN SWITCH. Is cruise control main Replace cruise Replace cruise
Remove and check cruise control main switch OK? control module. control main
switch. <Ref. to CC-9 Cruise Control Main switch.
Switch.>
CC-27
MEMO:
CC-28
D: CHECK CRUISE CONTROL COMMAND SWITCH S003749F25
TROUBLE SYMPTOM:
Cruise control cannot be set. (Cancelled immediately.)
WIRING DIAGRAM:
S6M0522
CC-29

1 CHECK SET/COAST SWITCH CIRCUIT. Is the voltage 0 V when Go to step 2. Go to step 4.
1) Disconnect cruise control module harness SET/COAST switch is not
connector. pressed? Is the voltage
2) Turn ignition switch ON. more than 10 V when SET/
3) Measure voltage between harness connec- COAST switch is pressed?
tor terminal and chassis ground when SET/
COAST switch is pressed and not pressed.
2 CHECK RESUME/ACCEL SWITCH CIRCUIT. Is the voltage 0 V when Go to step 3. Go to step 4.
Measure voltage between harness connector RESUME/ACCEL switch is
terminal and chassis ground when RESUME/ not pressed? Is the voltage
ACCEL switch is pressed and not pressed. more than 10 V when
Connector & terminal RESUME/ACCEL switch is
(B94) No. 9 (+) — Chassis ground (−): pressed?
3 CHECK CANCEL SWITCH CIRCUIT. Is the voltage 0 V when Cruise control Go to step 4.
Measure voltage between harness connector CANCEL switch is not command switch
terminal and chassis ground when CANCEL pressed? Is the voltage circuit is OK.
switch is pressed and not pressed. more than 10 V when
Connector & terminal CANCEL switch is
4 CHECK POWER SUPPLY FOR COMMAND Does horn sound? Go to step 5. 쐌 Check fuse No.
SWITCH. 6 (in main fuse
Check horn operation. box).
쐌 Check horn
relay. <Ref. to
COM-4 HORN
RELAY,
INSPECTION,
Horn System.>
쐌 Check harness
for open or short
between cruise
control command
switch and fuse &
relay box.
5 CHECK CRUISE CONTROL COMMAND Is cruise control command Check harness Replace cruise
SWITCH. switch OK? between cruise control command
Remove and check cruise control command control command switch.
switch. <Ref. to CC-10 Cruise Control Com- switch and cruise
mand Switch.> control module.
CC-30
E: CHECK STOP LIGHT SWITCH AND BRAKE SWITCH S003749F26
TROUBLE SYMPTOM:
Cruise control cannot be set.
WIRING DIAGRAM:
S6M0523
CC-31

1 CHECK STOP LIGHT SWITCH AND BRAKE Is the voltage more than 10 Go to step 2. 쐌 Check fuse No.
SWITCH CIRCUIT. V? 16 (in fuse & relay
1) Disconnect stop light switch and brake box).
switch harness connector. 쐌 Check harness
3) Turn cruise control main switch ON. between stop
4) Measure voltage between harness connec- light/brake switch
tor terminal and chassis ground. and fuse & relay
Connector & terminal box.
2 CHECK STOP LIGHT SWITCH AND BRAKE Is the voltage more than 10 Go to step 3. 쐌 Check harness
SWITCH CIRCUIT. V? for open or short
Measure voltage between harness connector between stop
terminal and chassis ground. light/brake switch
Connector & terminal and cruise control
(B65) No. 1 (+) — Chassis ground (−): module (AT).
쐌 Check clutch
switch and the
circuit (MT).
3 CHECK STOP LIGHT SWITCH AND BRAKE Is the resistance less than Go to step 4. Repair harness.
SWITCH CIRCUIT. 10 Ω?
1) Turn cruise control main switch and ignition
switch OFF.
connector.
module harness connector terminal and stop
light switch and brake switch harness connec-
tor terminal.
(B94) No. 20 (+) — (B65) No. 3 (−):
(B94) No. 16 (+) — (B65) No. 4 (−):
4 CHECK STOP LIGHT SWITCH AND BRAKE Are stop light switch and Stop light switch Replace stop light
SWITCH. brake switch OK? and brake switch switch and brake
Remove and check stop light switch and circuit are OK. switch.
brake switch. <Ref. to CC-11 Stop and Brake
Switch.>
CC-32
F: CHECK CLUTCH SWITCH (MT) S003749F27
TROUBLE SYMPTOM:
WIRING DIAGRAM:
S6M0523
CC-33

1 CHECK CLUTCH SWITCH CIRCUIT. Is the voltage more than 10 Go to step 2. Check harness for
1) Disconnect clutch switch harness connec- V? open or short
tor. between clutch
2) Turn ignition switch ON. switch and cruise
3) Turn cruise control main switch ON. control module.
4) Measure voltage between harness connec-
tor terminal and chassis ground.
2 CHECK CLUTCH SWITCH CIRCUIT. Is the resistance less than Go to step 3. Repair harness.
1) Turn cruise control main switch and ignition 10 Ω?
switch OFF.
2) Disconnect stop light switch and brake
switch harness connector.
3) Measure resistance between clutch switch
harness connector terminal and stop light
switch and brake switch harness connector
terminal.
(B107) No. 1 (+) — (B65) No. 1 (−):
3 CHECK CLUTCH SWITCH. Is clutch switch OK? Clutch switch cir- Replace clutch
Remove and check clutch switch. <Ref. to cuit is OK. switch.
CC-12 Clutch Switch.>
CC-34
G: CHECK INHIBITOR SWITCH (AT) S003749F28
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B6M1527
CC-35

1 CHECK INHIBITOR SWITCH CIRCUIT. Is the voltage more than 10 Go to step 2. Check harness for
1) Disconnect inhibitor switch harness con- V? open or short
nector. between inhibitor
(T7) No. 12 (+) — Chassis ground (−):
2 CHECK INHIBITOR SWITCH CIRCUIT. Is the resistance less than Go to step 3. Repair harness.
switch OFF.
2) Disconnect starter motor harness connec-
tor.
3) Measure resistance between inhibitor
switch harness connector terminal and chas-
sis ground.
(T7) No. 7 (+) — (B14) No. 1 (−):
3 CHECK INHIBITOR SWITCH. Is inhibitor switch OK? Inhibitor switch Replace inhibitor
Remove and check inhibitor switch. <Ref. to circuit is OK. switch.
CC-13 Inhibitor Switch.>
CC-36
DIAGNOSTICS CHART WITH TROUBLE CODE (TURBO MODEL)
7. Diagnostics Chart with Trouble Code (Turbo Model) S003750
A: LIST OF DIAGNOSTIC TROUBLE CODE S003750E40
Diagnostic
trouble Item Contents of diagnosis Reference
code
21 Inner relay is seized. Cruise control module inner relay is seized when main <Ref. to CC-38 DIAG-
switch is OFF. NOSTIC TROUBE CODE
21, 24, 25, AND 2A —
CRUISE CONTROL MOD-
ULE BUILT-IN RELAY,
CPU RAM —, Diagnostics
Chart with Trouble Code
(Turbo Model).>
22 Vehicle speed sensor Vehicle speed signal changes more than 10 km/h (6 <Ref. to CC-39 DIAG-
MPH) within 350 ms. NOSTIC TROUBLE CODE
22 — VEHICLE SPEED
SENSOR —, Diagnostics
(Turbo Model).>
24 Cruise control module is Two vehicle speed values stored in cruise control mod- <Ref. to CC-38 DIAG-
abnormal. ule memory are not the same. NOSTIC TROUBE CODE
21, 24, 25, AND 2A —
CRUISE CONTROL MOD-
ULE BUILT-IN RELAY,
(Turbo Model).>
25 Cruise control module is Two output values stored in cruise control module <Ref. to CC-38 DIAG-
abnormal. memory are not the same. NOSTIC TROUBE CODE
21, 24, 25, AND 2A —
CRUISE CONTROL MOD-
ULE BUILT-IN RELAY,
(Turbo Model).>
28 Wiring harness opened. Open wiring harness circuit is detected via control mod- <Ref. to CC-42 DIAG-
ule relay when main switch is ON. NOSTIC TROUBLE CODE
28 — WIRING HARNESS
OPENED —, Diagnostics
(Turbo Model).>
35 Motor drive system is 쐌 Motor output circuit is open or shorted. <Ref. to CC-43 DIAG-
abnormal. 쐌 Motor drive circuit is open or shorted. NOSTIC TROUBLE CODE
35 AND 36 — ACTUATOR
MOTOR — , Diagnostics
(Turbo Model).>
36 Trouble of motor Motor turning speed is slow. <Ref. to CC-43, DIAG-
NOSTIC TROUBLE CODE
35 AND 36 — ACTUATOR
MOTOR —, Diagnostics
(Turbo Model).>
CC-37
Diagnostic
trouble Item Contents of diagnosis Reference
code
37 Motor clutch drive system 쐌 Motor clutch output circuit is open or shorted. <Ref. to CC-45 DIAG-
is abnormal. 쐌 Motor clutch drive circuit is open or shorted. NOSTIC TROUBLE CODE
37 — ACTUATOR
MOTOR CLUTCH — ,
Diagnostics Chart with
Trouble Code (Turbo
Model).>
38 Motor drive shaft does not Motor drive gear engagement is not properly adjusted. <Ref. to CC-47 DIAG-
engage properly. NOSTIC TROUBLE CODE
38 — MOTOR DRIVE
SHAFT DOES NOT
ENGAGE PROPERLY.— ,
Trouble Code (Turbo
Model).>
39 Motor is overloaded. Current flows through motor more frequently than under <Ref. to CC-48 DIAG-
normal conditions. NOSTIC TROUBLE CODE
39 — MOTOR IS
OVERLOADED.—, Diag-
nostics Chart with Trouble
Code (Turbo Model).>
2A Cruise control module is Cruise control module self-diagnosis function senses <Ref. to CC-38 DIAG-
abnormal. abnormality. NOSTIC TROUBE CODE
21, 24, 25, AND 2A —
CRUISE CONTROL MOD-
ULE BUILT-IN RELAY,
(Turbo Model).>
B: DIAGNOSTIC TROUBLE CODE 21, 24, 25 AND 2A

— CRUISE CONTROL MODULE BUILT-IN RELAY, CPU RAM — S003750F29
DIAGNOSIS:
쐌 Poor welding of built-in relay of cruise control module.
쐌 Failure of built-in CPU RAM of cruise control module.
TROUBLE SYMPTOM:
쐌 Cruise control is canceled and memorized cruise speed is also canceled.
쐌 Once cruise control is canceled, cruise control cannot be set until the ignition switch and cruise control
main switch turns OFF, and then turns ON again.
NOTE:
Check input/output signal and vehicle speed signal with select monitor. When signals are in good condition,
failure is in cruise control module. (Check power supply and ground conditions of cruise control module.)
CC-38
C: DIAGNOSTIC TROUBLE CODE 22

— VEHICLE SPEED SENSOR — S003750F30
DIAGNOSIS:
Disconnection or short circuit of vehicle speed sensor system.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
S6M0524
CC-39

1 CHECK TRANSMISSION TYPE. Is the transmission type Go to step 2. Go to step 6.
MT?
2 CHECK HARNESS BETWEEN BATTERY Is the voltage more than 10 Go to step 3. Check harness for
AND VEHICLE SPEED SENSOR. V? open or short
1) Disconnect harness connector from vehicle between ignition
speed sensor. relay and vehicle
2) Turn ignition switch to ON. speed sensor.
sensor harness connector terminal and chas-
sis ground.
3 CHECK HARNESS BETWEEN CRUISE Is the resistance less than Go to step 4. Repair harness.
CONTROL MODULE AND VEHICLE SPEED 10 Ω?
SENSOR.
1) Disconnect harness connector from cruise
control module.
sensor harness connector terminal and cruise
control module harness connector terminal.
(B17) No. 1 — (B94) No. 19:
4 CHECK HARNESS BETWEEN VEHICLE Is the resistance less than Go to step 5. Repair harness.
SPEED SENSOR AND ENGINE GROUND. 10 Ω?
sensor harness connector terminal and
engine ground.
5 CHECK VEHICLE SPEED SENSOR. Is the voltage less than 1 V Replace cruise Replace vehicle
1) Connect harness connector to vehicle ←→ more than 4 V? control module. speed sensor.
speed sensor. <Ref. to CC-8
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-40

6 CHECK HARNESS BETWEEN CRUISE Is the resistance less than Go to step 7. Repair harness
CONTROL MODULE AND TRANSMISSION 10 Ω? connector
CONTROL MODULE. between cruise
1) Disconnect harness connector from trans- control module
mission control module and cruise control and transmission
module. control module.
module harness connector terminal and trans-
mission control module harness connector
terminal.
CAUTION:
To measure the voltage and/or resistance,
use a tapered pin with a diameter of less
than 0.64 mm (0.025 in). Do not insert the
pin more than 5 mm (0.20 in).
(B94) No. 19 — (B56) No. 17:
7 CHECK TRANSMISSION CONTROL MOD- Is the voltage less than 1 V Replace cruise Replace transmis-
ULE. ←→ more than 4 V? control module. sion control mod-
1) Connect harness connector to transmission <Ref. to CC-8 ule. <Ref. to
control module. Cruise Control AT-48 Transmis-
2) Set the vehicle on free roller, or lift-up the Module.> sion Control Mod-
vehicle and support with safety stands. ule (TCM).>
WARNING:
Be careful not to be caught by the running
wheels.
MPH).
control module harness connector terminal
and chassis ground.
CAUTION:
CC-41
D: DIAGNOSTIC TROUBLE CODE 28

— WIRING HARNESS OPENED. — S003750F31

1 CHECK BATTERY. Is battery specific gravity Go to step 2. Charge or replace
Measure battery specific gravity of electrolyte. more than 1.250? battery. Go to step
2.
2 CHECK FUSES, CONNECTORS AND HAR- Is there anything unusual Repair or replace End of inspection.
NESSES. about the appearance of faulty parts.
Check the condition of the main and other main fuse, fuse, harness,
fuses, and harnesses and connectors. Also connector and grounding?
check for proper grounding.
CC-42
E: DIAGNOSTIC TROUBLE CODE 35 AND 36

— ACTUATOR MOTOR — S003750F32
DIAGNOSIS:
Open or poor contact of cruise control actuator motor.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
S6M0525
CC-43

1 CHECK POWER SUPPLY. Is the voltage more than 10 Go to step 2. Check harness for
1) Turn ignition switch OFF. V? open or short
2) Disconnect harness connector from cruise between cruise
control actuator. control main
4) Turn cruise control main switch ON. control actuator.
actuator harness connector terminal and
chassis ground.
Terminals
2 CHECK GROUND CIRCUIT OF ACTUATOR. Is resistance less than 10 Go to step 3. Repair harness.
Measure resistance between cruise control Ω?
chassis ground.
Terminals
3 MEASURE RESISTANCE OF ACTUATOR. Is resistance approximately Go to step 4. Replace cruise
Measure resistance of cruise control actuator 5 Ω? control actuator.
motor. <Ref. to CC-5,
Terminals Actuator (Turbo
No. 4 — No. 1: Model).>
No. 4 — No. 2:
No. 4 — No. 5:
4 CHECK HARNESS BETWEEN ACTUATOR Is resistance less than 10 Go to step 5. Repair harness.
AND CRUISE CONTROL MODULE. Ω?
control module.
control actuator harness connector terminal.
(B7) No. 1 — (B94) No. 7:
5 CHECK HARNESS BETWEEN ACTUATOR Is resistance less than 10 Replace cruise Repair harness.
AND CRUISE CONTROL MODULE. Ω? control module.
Measure resistance between cruise control <Ref. to CC-8
module harness connector terminal and cruise Cruise Control
control actuator harness connector terminal . Module.>
(B7) No. 5 — (B94) No. 5:
CC-44
F: DIAGNOSTIC TROUBLE CODE 37

— ACTUATOR MOTOR CLUTCH — S003750F33
DIAGNOSIS:
Open or poor contact of cruise control actuator motor clutch.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
S6M0525
CC-45

1 CHECK POWER SUPPLY. Is the voltage more than 10 Go to step 2. Check harness for
1) Turn ignition switch OFF. V? open or short
2) Disconnect harness connector from cruise between cruise
control actuator. control main
4) Turn cruise control main switch ON. control actuator.
chassis ground.
Terminals
2 CHECK GROUND CIRCUIT OF ACTUATOR. Is resistance less than 10 Go to step 3. Repair harness.
Measure resistance between cruise control Ω?
chassis ground.
Terminals
(B7) No. 6 — Chassis ground:
3 MEASURE RESISTANCE OF ACTUATOR Is resistance approximately Go to step 4. Replace cruise
CLUTCH. 39 Ω? control actuator.
Measure resistance of cruise control actuator <Ref. to CC-5,
clutch. Actuator (Turbo
Terminals Model).>
No. 3 — No. 6:
4 CHECK HARNESS BETWEEN ACTUATOR Is resistance less than 10 Go to step 5. Repair harness.
AND CRUISE CONTROL MODULE. Ω?
control module.
control actuator harness connector terminal.
(B7) No. 2 — (B94) No. 13:
5 CHECK HARNESS BETWEEN ACTUATOR Is resistance less than 10 Replace cruise Repair harness.
AND CRUISE CONTROL MODULE. Ω? control module.
Measure resistance between cruise control <Ref. to CC-8
module harness connector terminal and cruise Cruise Control
control actuator harness connector terminal. Module.>
(B7) No. 3 — (B94) No. 14:
CC-46
G: DIAGNOSTIC TROUBLE CODE 38

— MOTOR DRIVE SHAFT DOES NOT ENGAGE PROPERLY. — S003750F34

1 CHECK ACTUATOR MOTOR. Are foreign particles caught Replace cruise Check the cruise
1) Disconnect harness connector from cruise in inner gear or does inner control actuator. control cable
control actuator. gear engage and disen- <Ref. to CC-5, adjustment. <Ref.
2) Remove cruise control actuator from gage improperly? Actuator (Turbo to CC-6 CABLE
mounting bracket. Model).> FREE PLAY,
3) Pull cable by hand to check for looseness INSPECTION,
or status of inner gear engagement. General Descrip-
tion.>
CC-47
H: DIAGNOSTIC TROUBLE CODE 39

— MOTOR IS OVERLOADED. — S003750F35

1 CHECK THE OPERATING CURRENT TO Is current more than 10A? Replace cruise Check the power
ACTUATOR MOTOR. control module. supply circuit.
1) Connect Subaru Select Monitor to data link <Ref. to CC-8 <Ref. to CC-23,
connector. Cruise Control CHECK POWER
2) Try to drive the vehicle while operating the Module.> SUPPLY, Diag-
cruise control system. nostics Chart with
3) Check the operation current to the cruise Symptom (Turbo
control actuator motor. Model).>
CC-48
DIAGNOSTICS CHART WITH SYMPTOM (NON-TURBO MODEL)
8. Diagnostics Chart with Symptom (Non-turbo Model) S003751
A: SYMPTOM CHART S003751F22

Cruise control main switch is (1) Check power supply. <Ref. to CC-51 CHECK POWER SUPPLY, Diagnostics
not turned ON. Chart with Symptom (Non-turbo Model).>
1 (2) Check cruise control main <Ref. to CC-53 CHECK CRUISE CONTROL MAIN
switch. SWITCH, Diagnostics Chart with Symptom (Non-turbo
Model).>
Cruise control cannot be set. (1) Check SET/COAST <Ref. to CC-66 DIAGNOSTIC TROUBLE CODE 14 —
switch. SET/COAST SWITCH, RESUME/ACCEL SWITCH AND
CANCEL SWITCH —, Diagnostics Chart with Trouble
Code (Non-turbo Model).>
(2) Check stop light switch <Ref. to CC-59 DIAGNOSTIC TROUBLE CODE 11 —
and brake switch. BRAKE SWITCH AND STOP LIGHT SWITCH —, Diag-
nostics Chart with Trouble Code (Non-turbo Model).>
(3) Check clutch switch (MT). <Ref. to CC-61 DIAGNOSTIC TROUBLE CODE 12 —
CLUTCH SWITCH AND INHIBITOR SWITCH —, Diag-
2
(4) Check inhibitor switch <Ref. to CC-61 DIAGNOSTIC TROUBLE CODE 12 —
(AT). CLUTCH SWITCH AND INHIBITOR SWITCH —, Diag-
(5) Check vehicle speed sen- <Ref. to CC-63, DIAGNOSTIC TROUBLE CODE 13
sor. AND 24 — SPEED SENSOR SYSTEM —, Diagnostics
Chart with Trouble Code (Non-turbo Model).>
(6) Check actuator. <Ref. to CC-68 DIAGNOSTIC TROUBLE CODE 21, 22
AND 23 — VACUUM VALVE, VENT 2 VALVE AND
VENT 1 VALVE —, Diagnostics Chart with Trouble
Vehicle speed is not held (1) Check vehicle speed sen- <Ref. to CC-63, DIAGNOSTIC TROUBLE CODE 13
within set speed ±3 km/h (±2 sor. AND 24 — SPEED SENSOR SYSTEM —, Diagnostics
MPH). Chart with Trouble Code (Non-turbo Model).>
3 (2) Check actuator. <Ref. to CC-68 DIAGNOSTIC TROUBLE CODE 21, 22
Vehicle speed does not (1) Check RESUME/ACCEL <Ref. to CC-66 DIAGNOSTIC TROUBLE CODE 14 —
increase or does not return switch. SET/COAST SWITCH, RESUME/ACCEL SWITCH AND
to set speed after RESUME/ CANCEL SWITCH —,Diagnostics Chart with Trouble
ACCEL switch has been Code (Non-turbo Model).>
4 pressed. (2) Check actuator. <Ref. to CC-68 DIAGNOSTIC TROUBLE CODE 21, 22
Vehicle speed does not (1) Check SET/COAST <Ref. to CC-66 DIAGNOSTIC TROUBLE CODE 14 —
decrease after SET/COAST switch. SET/COAST SWITCH, RESUME/ACCEL SWITCH AND
switch has been pressed. CANCEL SWITCH —,Diagnostics Chart with Trouble
5
CC-49

Cruise control is not released (1) Check CANCEL switch. <Ref. to CC-66 DIAGNOSTIC TROUBLE CODE 14 —
after CANCEL switch has SET/COAST SWITCH, RESUME/ACCEL SWITCH AND
been pressed. CANCEL SWITCH —,Diagnostics Chart with Trouble
6
Cruise control is not released (1) Check stop light switch <Ref. to CC-59 DIAGNOSTIC TROUBLE CODE 11 —
after brake pedal has been and brake switch. BRAKE SWITCH AND STOP LIGHT SWITCH —, Diag-
depressed. nostics Chart with Trouble Code (Non-turbo Model).>
Cruise control is not released (1) Check clutch switch. <Ref. to CC-61 DIAGNOSTIC TROUBLE CODE 12 —
after clutch pedal has been CLUTCH SWITCH AND INHIBITOR SWITCH —, Diag-
depressed (MT). nostics Chart with Trouble Code (Non-turbo Model).>
CC-50
B: CHECK POWER SUPPLY S003751F23
TROUBLE SYMPTOM:
Cruise control can be set normally, but indicator does not come on. (When main switch is pressed.)
WIRING DIAGRAM:
S6M0526
CC-51

1 CHECK POWER SUPPLY. Is the voltage more than 10 Go to step 2. 쐌 Check fuse No.
1) Disconnect cruise control module harness V? 18 (in fuse & relay
connector. box).
2) Turn ignition switch ON. 쐌 Check harness
3) Measure voltage between harness connec- for open or short
tor terminal and chassis ground. between cruise
Connector & terminal control module
(B94) No. 3 (+) — Chassis ground (−): and fuse & relay
box.
Measure resistance between harness connec- 10 Ω? ground circuit are
tor terminal and chassis ground. OK.
(B94) No. 13, No. 20 (+) — Chassis
ground (−):
CC-52
C: CHECK CRUISE CONTROL MAIN SWITCH S003751F24
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 condi-
tion.
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.
CC-53
WIRING DIAGRAM:
S6M0526
CC-54

1 CHECK CRUISE CONTROL MAIN SWITCH Is the voltage more than 10 Go to step 2. 쐌 Check fuse No.
CIRCUIT. V? 18 (in fuse & relay
1) Disconnect cruise control main switch har- box).
ness connector. 쐌 Check harness
3) Measure voltage between harness connec- between cruise
tor terminal and chassis ground. control main
Connector & terminal switch and fuse &
(B161) No. 3 (+) — Chassis ground (−): relay box.
2 CHECK CRUISE CONTROL MAIN SWITCH Is the resistance less than Go to step 3. Repair harness.
CIRCUIT. 10 Ω?
connector.
control main switch harness connector termi-
nal.
(B94) No. 4 (+) — (B161) No. 5 (−):
(B94) No. 5 (+) — (B161) No. 1 (−):
(B161) No. 6 (+) — Chassis ground:
3 CHECK CRUISE CONTROL MAIN SWITCH. Is cruise control main Replace cruise Replace cruise
Remove and check cruise control main switch OK? control module. control main
switch. <Ref. to CC-9 Cruise Control Main switch.
Switch.>
CC-55
MEMO:
CC-56
DIAGNOSTICS CHART WITH TROUBLE CODE (NON-TURBO MODEL)
9. Diagnostics Chart with Trouble Code (Non-turbo Model) S003752
A: LIST OF DIAGNOSTIC TROUBLE CODE S003752E40
Diagnostic
Item Contents of diagnosis Index No.
code
11 BRAKE SW/STOP SW Input signals from brake switch “OFF”, stop light<Ref. to CC-59 DIAGNOS-
switch “ON” TIC TROUBLE CODE 11
(Brake pedal is depressed.) — BRAKE SWITCH AND
STOP LIGHT SWITCH —,
Trouble Code (Non-turbo
Model).>
12 CLUTCH SW/INHIBITOR SW Input signals from clutch switch “OFF” (MT), or <Ref. to CC-61 DIAGNOS-
inhibitor switch “P or N” (AT) TIC TROUBLE CODE 12
[Clutch pedal is depressed (MT), or selector lever is — CLUTCH SWITCH AND
set to P or N position (AT).] INHIBITOR SWITCH —,
Model).>
13 LOW SPEED LIMIT Low-speed control limiter <Ref. to CC-63 DIAGNOS-
TIC TROUBLE CODE 13
AND 24 — VEHICLE
SPEED SENSOR SYS-
TEM —, Diagnostics Chart
with Trouble Code (Non-
turbo Model).>
14 CANCEL SW Input signal from cancel switch <Ref. to CC-66 DIAGNOS-
(faulty SET/COAST switch or RESUME/ACCEL TIC TROUBLE CODE 14
switch) — SET/COAST SWITCH,
RESUME/ACCEL SWITCH
AND CANCEL SWITCH
—, Diagnostics Chart with
Model).>
21 VACUUM VALVE Faulty vacuum valve or valve drive system <Ref. to CC-68 DIAGNOS-
TIC TROUBLE CODE 21,
22 AND 23 — VACUUM
VALVE, VENT 2 VALVE
AND VENT 1 VALVE —,
Model).>
22 VENT 2 VALVE Faulty vent 2 valve or valve drive system <Ref. to CC-68 DIAGNOS-
VALVE, VENT 2 VALVE
Model).>
23 VENT 1 VALVE Faulty vent 1 valve or valve drive system <Ref. to CC-68 DIAGNOS-
VALVE, VENT 2 VALVE
Model).>
CC-57
Diagnostic
Item Contents of diagnosis Index No.
code
24 SPEED SENSOR Faulty vehicle speed sensor 2 (MT) or transmission <Ref. to CC-63 DIAGNOS-
control module (AT) TIC TROUBLE CODE 13
AND 24 — VEHICLE
SPEED SENSOR SYS-
TEM —, Diagnostics Chart
with Trouble Code (Non-
turbo Model).>
25 CONTROL MODULE Faulty CPU RAM included in cruise control module <Ref. to CC-70 DIAGNOS-
TIC TROUBLE CODE 25
— CRUISE CONTROL
MODULE BUILT-IN RELAY
AND CPU RAM —, Diag-
nostics Chart with Trouble
CC-58
B: DIAGNOSTIC TROUBLE CODE 11 — BRAKE SWITCH AND STOP LIGHT

SWITCH — S003752H52
DIAGNOSIS:
쐌 Failure or disconnection of the stop light switch and brake switch.
WIRING DIAGRAM:
S6M0527
CC-59

1 CHECK STOP LIGHT SWITCH AND BRAKE Is the voltage more than 10 Go to step 2. 쐌 Check fuse No.
SWITCH CIRCUIT. V? 16 (in fuse & relay
1) Disconnect stop light switch and brake box).
switch harness connector. 쐌 Check harness
3) Turn cruise control main switch ON. between stop
4) Measure voltage between harness connec- light/brake switch
tor terminal and chassis ground. and fuse & relay
Connector & terminal box.
2 CHECK STOP LIGHT SWITCH AND BRAKE Is the voltage more than 10 Go to step 3. 쐌 Check harness
SWITCH CIRCUIT. V? for open or short
Measure voltage between harness connector between stop
terminal and chassis ground. light/brake switch
Connector & terminal and cruise control
(B65) No. 1 (+) — Chassis ground (−): module.
3 CHECK STOP LIGHT SWITCH AND BRAKE Is the resistance less than Go to step 4. Repair harness.
SWITCH CIRCUIT. 10 Ω?
1) Turn cruise control main switch and ignition
switch OFF.
connector.
module harness connector terminal and stop
light switch and brake switch harness connec-
tor terminal.
(B94) No. 5 (+) — (B65) No. 4 (−):
(B94) No. 19 (+) — (B65) No. 3 (−):
4 CHECK STOP LIGHT SWITCH AND BRAKE Are stop light switch and Stop light switch Replace stop light
SWITCH. brake switch OK? and brake switch switch and brake
Remove and check stop light switch and circuit are OK. switch.
brake switch. <Ref. to CC-11 Stop and Brake
Switch.>
CC-60
C: DIAGNOSTIC TROUBLE CODE 12 — CLUTCH SWITCH AND INHIBITOR

SWITCH — S003752H53
DIAGNOSIS:
쐌 Failure or disconnection of the clutch switch. (MT)
쐌 Failure or disconnection of the inhibitor switch. (AT)
WIRING DIAGRAM:
S6M0528
CC-61

1 CHECK INHIBITOR SWITCH CIRCUIT (AT). Is the voltage more than 10 Go to step 2. Check harness for
1) Disconnect inhibitor switch harness con- V? open or short
nector. between inhibitor
(T7) No. 12 (+) — Chassis ground (−):
2 CHECK INHIBITOR SWITCH CIRCUIT (AT). Is the resistance less than Go to step 3. Repair harness.
switch OFF.
2) Disconnect starter motor harness connec-
tor.
3) Measure resistance between inhibitor
sis ground.
(T7) No. 7 (+) — (B14) No. 1 (−):
3 CHECK INHIBITOR SWITCH (AT). Is inhibitor switch OK? Inhibitor switch Replace inhibitor
Remove and check inhibitor switch. <Ref. to circuit is OK. switch.
CC-13 Inhibitor Switch.>
4 CHECK CLUTCH SWITCH CIRCUIT (MT). Is the voltage more than 10 Go to step 5. Check harness for
1) Disconnect clutch switch harness connec- V? open or short
tor. between clutch
5 CHECK CLUTCH SWITCH CIRCUIT (MT). Is the resistance less than Go to step 6. Repair harness.
switch OFF.
2) Disconnect stop light switch and brake
switch harness connector.
3) Measure resistance between clutch switch
harness connector terminal and stop light
switch and brake switch harness connector
terminal.
6 CHECK CLUTCH SWITCH (MT). Is clutch switch OK? Clutch switch cir- Replace clutch
Remove and check clutch switch. <Ref. to cuit is OK. switch.
CC-12 Clutch Switch.>
CC-62
D: DIAGNOSTIC TROUBLE CODE 13 AND 24 — VEHICLE SPEED SENSOR

SYSTEM — S003752F52
DIAGNOSIS:
쐌 Disconnection or short circuit of vehicle speed sensor (MT model) or transmission control module (AT
model).
WIRING DIAGRAM:
S6M0529
CC-63

MT?
2 CHECK HARNESS BETWEEN BATTERY Is the voltage more than 10 Go to step 3. Check harness for
AND VEHICLE SPEED SENSOR. V? open or short
1) Disconnect harness connector from vehicle between ignition
speed sensor. relay and vehicle
2) Turn ignition switch to ON. speed sensor.
sensor harness connector terminal and chas-
sis ground.
3 CHECK HARNESS BETWEEN CRUISE Is the resistance less than Go to step 4. Repair harness.
CONTROL MODULE AND VEHICLE SPEED 10 Ω?
SENSOR.
control module.
sensor harness connector terminal and cruise
control module harness connector terminal.
(B17) No. 1 — (B94) No. 18:
4 CHECK HARNESS BETWEEN VEHICLE Is the resistance less than Go to step 5. Repair harness.
SPEED SENSOR AND ENGINE GROUND. 10 Ω?
sensor harness connector terminal and
engine ground.
5 CHECK VEHICLE SPEED SENSOR. Is the voltage less than 1 Replace cruise Replace vehicle
1) Connect harness connector to vehicle ←→ more than 4 V? control module. speed sensor.
speed sensor. <Ref. to CC-8
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).
module harness connector terminal and chas-
sis ground.
CC-64

6 CHECK HARNESS BETWEEN CRUISE Is the resistance less than Go to step 7. Repair harness
CONTROL MODULE AND TRANSMISSION 10 Ω? connector
CONTROL MODULE. between cruise
1) Disconnect harness connector from trans- control module
mission control module and cruise control and transmission
module. control module.
module harness connector terminal and trans-
mission control module harness connector
terminal.
CAUTION:
(B94) No. 18 — (B56) No. 17:
7 CHECK TRANSMISSION CONTROL MOD- Is the voltage less than 1 V Replace cruise Replace transmis-
ULE. ←→ more than 4 V? control module. sion control mod-
1) Connect harness connector to transmission <Ref. to CC-8 ule. <Ref. to
control module. Cruise Control AT-48 Transmis-
2) Set the vehicle on free roller, or lift-up the Module.> sion Control Mod-
vehicle and support with safety stands. ule (TCM).>
WARNING:
Be careful not to be caught by the running
wheels.
MPH).
control module harness connector terminal
and chassis ground.
CAUTION:
CC-65
E: DIAGNOSTIC TROUBLE CODE 14 — SET/COAST SWITCH,

RESUME/ACCEL SWITCH AND CANCEL SWITCH — S003752H54
DIAGNOSIS:
쐌 Short circuit inside the SET SW and RESUME SW.
WIRING DIAGRAM:
S6M0530
CC-66

1 CHECK SET/COAST SWITCH CIRCUIT. Is the voltage 0 V when Go to step 2. Go to step 4.
1) Disconnect cruise control module harness SET/COAST switch is not
connector. pressed? Is the voltage
2) Turn ignition switch ON. more than 10 V when SET/
3) Measure voltage between harness connec- COAST switch is pressed?
tor terminal and chassis ground when SET/
COAST switch is pressed and not pressed.
2 CHECK RESUME/ACCEL SWITCH CIRCUIT. Is the voltage 0 V when Go to step 3. Go to step 4.
Measure voltage between harness connector RESUME/ACCEL switch is
terminal and chassis ground when RESUME/ not pressed? Is the voltage
ACCEL switch is pressed and not pressed. more than 10 V when
Connector & terminal RESUME/ACCEL switch is
3 CHECK CANCEL SWITCH CIRCUIT. Is the voltage 0 V when Cruise control Go to step 4.
Measure voltage between harness connector CANCEL switch is not command switch
terminal and chassis ground when CANCEL pressed? Is the voltage circuit is OK.
switch is pressed and not pressed. more than 10 V when
Connector & terminal CANCEL switch is
4 CHECK POWER SUPPLY FOR COMMAND Does horn sound? Go to step 5. 쐌 Check fuse No.
SWITCH. 6 (in main fuse
Check horn operation. box).
쐌 Check horn
relay. <Ref. to
COM-4 HORN
RELAY,
INSPECTION,
Horn System.>
쐌 Check harness
for open or short
between cruise
control command
switch and main
fuse box.
5 CHECK CRUISE CONTROL COMMAND Is cruise control command Check harness Replace cruise
SWITCH. switch OK? between cruise control command
Remove and check cruise control command control command switch.
switch. <Ref. to CC-10 Cruise Control Com- switch and cruise
mand Switch.> control module.
CC-67
F: DIAGNOSTIC TROUBLE CODE 21, 22 AND 23 — VACUUM VALVE, VENT 2

VALVE AND VENT 1 VALVE — S003752H55
DIAGNOSIS:
쐌 Open or poor contact of vacuum valve, vent 2 valve and vent 1 valve.
WIRING DIAGRAM:
S6M0531
CC-68

1 MEASURE RESISTANCE OF VACUUM Is resistance less than 22 Go to step 2. Replace actuator.
VALVE, VENT 2 VALVE AND VENT 1 Ω? <Ref. to CC-7,
VALVE. REMOVAL, Actua-
1) Disconnect connector from actuator. tor (Non-turbo
2) Measure resistance of vacuum valve, vent Model).>
2 valve and vent 1 valve.
Terminals
No. 2 — No. 3:
Measure resistance of vacuum valve, vent 2 tor (Non-turbo
valve and vent 1 valve. Model).>
Terminals
No. 2 — No. 1:
Measure resistance of vacuum valve, vent 2 tor (Non-turbo
valve and vent 1 valve. Model).>
Terminals
No. 2 — No. 4:
4 PERFORM A CIRCUIT TEST IN HARNESS Is resistance less than 10 Go to step 5. Repair or replace
BETWEEN ACTUATOR AND CRUISE CON- Ω? wiring harness
TROL MODULE. between actuator
1) Disconnect connector from cruise control and cruise control
module. module.
2) Measure resistance of harness connector
between cruise control module and actuator.
(B7) No. 1 — (B94) No. 1:
Measure resistance of harness connector and cruise control
between cruise control module and actuator. module.
(B7) No. 2 — (B94) No. 8:
Measure resistance of harness connector and cruise control
between cruise control module and actuator. module.
(B7) No. 3 — (B94) No. 11:
7 PERFORM A CIRCUIT TEST IN HARNESS Is resistance less than 10 Replace cruise Repair or replace
BETWEEN ACTUATOR AND CRUISE CON- Ω? control module. wiring harness
TROL MODULE. <Ref. to CC-8 between actuator
Measure resistance of harness connector REMOVAL, Cruise and cruise control
between cruise control module and actuator. Control Module.> module.
(B7) No. 4 — (B94) No. 2:
CC-69
G: DIAGNOSTIC TROUBLE CODE 25 — CRUISE CONTROL MODULE BUILT-

IN RELAY AND CPU RAM — S003752H56
DIAGNOSIS:
쐌 Poor welding of built-in relay of cruise control module.
쐌 Failure of built-in CPU RAM of cruise control module.
TROUBLE SYMPTOM:
쐌 Cruise control is canceled and memorized cruise speed is also canceled.
쐌 Once cruise control is canceled, cruise control cannot be set until the ignition switch and cruise control
main switch turns OFF, and then turns ON again.
NOTE:
Check input/output signal and vehicle speed signal with select monitor. When signals are in good condition,
failure is in cruise control module. (Check power supply and ground conditions of cruise control module.)
CC-70
BODY SECTION

SUBARU vehicles.
ine parts.

G8050GE6
IMMOBILIZER (DIAGNOSTICS)
IM
Page
3. Electrical Components Location..................................................................5
4. Immobilizer Control Module I/O Signal .......................................................6
8. Diagnostics Chart for Immobilizer Indicator Light .....................................19
9. List of Diagnostic Trouble Code................................................................25
10. Diagnostics Chart with Trouble Code .......................................................26
Immobilizer (Diagnostics)

S009501

1 CHECK ILLUMINATION OF IMMOBILIZER Does immobilizer indicator Go to step 2. Go to step 3.
INDICATOR LIGHT. light illuminate?
Turn ignition switch ON.
2 CHECK ENGINE START. Is the engine hard to start? Go to step 5. Go to step 3.
Turn ignition switch to START position.
3 CHECK ILLUMINATION OF IMMOBILIZER Does immobilizer indicator Go to step 4. Check immobilizer
INDICATOR LIGHT. light blink? indicator light cir-
1) Turn ignition switch to OFF or ACC posi- cuit. <Ref. to
tion. IM-19, CHECK
2) Wait at least 60 seconds. IMMOBILIZER
INDICATOR
CIRCUIT,
INSPECTION,
Diagnostics Chart
for Immobilizer
Indicator Light.>
4 CHECK ILLUMINATION OF IMMOBILIZER Does immobilizer indicator The immobilizer Check key switch
INDICATOR LIGHT. light begin to blink 5 sec- system is OK. circuit. <Ref. to
Remove key from ignition switch. onds after the key is IM-22, CHECK
removed? KEY SWITCH
CIRCUIT,
INSPECTION,
Diagnostics Chart
for Immobilizer
Indicator Light.>
5 CHECK INDICATION OF DTC ON DISPLAY. Is trouble code indicated on Go to step 6. Repair the related
1) Turn ignition switch OFF. display? parts.
2) Connect the Subaru Select Monitor to data
link connector. <Ref. to IM-14, OPERATION,
Subaru Select Monitor.>
3) Turn ignition switch and Subaru Select
Monitor switch ON.
4) Read DTC on the display.
6 PERFORM THE DIAGNOSIS. Is trouble code indicated on Inspect using Finish the diag-
1) Inspect using “Diagnostics Chart with display? “Diagnostic Chart nostics.
Trouble Code”. <Ref. to IM-26, Diagnostics with Trouble
Chart with Trouble Code.> Code”. <Ref. to
2) Repair the trouble cause. IM-26, Diagnos-
3) Perform clear memory mode. tics Chart with
4) Read DTC again. Trouble Code.>
IM-2
GENERAL DESCRIPTION

쐌 When repeatedly turning ignition ON or OFF
while diagnostic items are being checked, it
A: CAUTION S009001A03 should be switched in cycles of “ON” for at
least 5 seconds → “OFF” for at least 8 sec-
CAUTION: onds.
쐌 Airbag system wiring harness is routed near
the immobilizer control module. All airbag sys-
tem wiring harness and connectors are colored
yellow. Do not use electrical test equipment on
these circuits.
쐌 Be careful not to damage airbag system wir-
ing harness when servicing the immobilizer
control module.
쐌 While diagnostic items are being checked,
do not operate radios, portable telephones, etc.
which emit electromagnetic waves near or B6M0618A
inside the vehicle.
쐌 If engine fails to start with a registered igni-
tion key, detach ignition key from ignition
switch and wait for approximately 1 second
until immobilizer indicator light begins to flash.
Start engine again.
쐌 Before checking diagnostic items, obtain all
keys for vehicle to be checked possessed by
owner.
B6M0616
쐌 When ignition switch is being turned ON or

OFF while diagnostic items are being checked,
do not allow keys with different ID codes close
to the ignition switch. If ignition key is in a key
holder, remove it from holder before carrying
out diagnoses.
B6M0617
IM-3
GENERAL DESCRIPTION

B2M3876
KIT 쐌 English:
쐌 German:
쐌 French:
쐌 Spanish:
B2M3877
TOOL NAME REMARKS

IM-4
3. Electrical Components
Location S009507
S6M0413A
(1) Antenna (3) Immobilizer control module (IMM

(2) Immobilizer indicator light (LED ECM)
bulb) (4) Transponder
NOTE:
IMM ECM location for RHD model is symmetrically
opposite.
IM-5
IMMOBILIZER CONTROL MODULE I/O SIGNAL
4. Immobilizer Control Module I/O Signal S009517
1. IMMOBILIZER LHD WITH OBD MODEL S009517A2103
SL91-20A
IM-6
SL91-20B
IM-7
2. IMMOBILIZER LHD WITHOUT OBD

MODEL S009517A2104
SL91-21A
IM-8
SL91-21B
IM-9
3. IMMOBILIZER RHD WITH OBD MODEL

S009517A2105
SR91-20A
IM-10
SR91-20B
IM-11
4. IMMOBILIZER RHD WITHOUT OBD

MODEL S009517A2106
SR91-21A
IM-12
SR91-21B
IM-13

CAUTION:
Do not connect scan tools except for Subaru
A: OPERATION S009503A16 Select Monitor.
1. HOW TO USE SUBARU SELECT 5) Turn ignition switch to ON (engine OFF) and
MONITOR S009503A1605 Subaru Select Monitor switch to ON.
S2M0288A
S2M0285 6) Using Subaru Select Monitor, call up diagnostic

trouble code(s) and various data, then record
2) Connect diagnosis cable to Subaru Select them.
Monitor.
3) Insert cartridge into Subaru Select Monitor. 2. READ DIAGNOSTIC TROUBLE CODE
<Ref. to IM-4, SPECIAL TOOLS, PREPARATION (DTC) FOR ENGINE. S009503A1606
TOOL, General Description.>
Refer to Read Diagnostic Trouble Code for infor-
mation about how to indicate DTC. <Ref. to IM-16,
Read Diagnostic Trouble Code.>
3. INTERFACE CHECK S009503A1604
NOTE:
Communication line between ECM and IMM ECM
can be checked in ⰆSystem Operation Check
ModeⰇ. This is referred to as “interface check”.
1) Connect select monitor.
S2M0286A 2) Set the ⰆSystem Operation Check ModeⰇ
menu display screen then select ⰆImmobilizer
4) Connect Subaru Select Monitor to data link SystemⰇ.
connector. 3) Screen indicates as shown.
side).
S6M0210
S2M2157

nector.
IM-14
4) Start interface check.

5) Does “Communication Line not Shorted”
appear on screen?
If “YES”. Go to step 6).
If “NO”. Go to step 7).
S6M0211
6) After diagnostic results, it is determined that

short circuit is not a diagnostic item. This com-
pletes interface check.
7) If a problem is detected, repair. <Ref. to IM-27,
DTC P1572 — IMM CIRCUIT FAILURE (EXCEPT
ANTENNA CIRCUIT) —, Diagnostics Chart with
Trouble Code.>
IM-15
6. Read Diagnostic Trouble Code S009508
1. WITH SUBARU SELECT MONITOR S009508A1601
1) On the ⰆMain MenuⰇ display screen, select the {Each System Check} and press the [YES] key.
2) On the ⰆSystem Selection MenuⰇ display screen, select the {Engine Control System} and press the
[YES] key.
3) Press the [YES] key after displayed the information of engine type.
4) On the ⰆEngine DiagnosisⰇ display screen, select the {Diagnostic Code(s) Display} and press the [YES]
key.
5) On the ⰆDiagnostic Code(s) DisplayⰇ display screen, select the {Current Diagnostic Code(s)} or {His-
tory Diagnostic Code(s)} and press the [YES] key.
NOTE:
쐌 For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
쐌 For detailed concerning diagnostic trouble codes, refer to the List of Diagnostic Trouble Code (DTC).
<Ref. to IM-25, LIST, List of Diagnostic Trouble Code.>
2. WITHOUT SUBARU SELECT MONITOR S009508A1602

1 CHECK STATUS OF CHECK ENGINE MAL- Does the MIL come on? Go to step 2. Check the follow-
FUNCTION INDICATOR LAMP (MIL). ing and repair if
1) Turn ignition switch to OFF. necessary.
2) Connect read memory connector. <Ref. to NOTE:
EN(SOHCw/oOBD)-10, LOCATION, Electrical 쐌 Open or short
Components Location.> circuit in engine
3) Turn ignition switch to ON. control module
power supply or
ground line
쐌 Open or short
circuit in CHECK
ENGINE malfunc-
tion indicator lamp
2 CHECK DIAGNOSTIC TROUBLE CODE Does the MIL indicate diag- Record diagnostic Complete read
(DTC). nostic trouble code (DTC)? trouble code diagnostic trouble
(DTC). Then turn code. Turn ignition
ignition switch to switch to OFF and
OFF, disconnect disconnect read
read memory con- memory connec-
nector. tor.
IM-16
The CHECK ENGINE malfunction indicator lamp (MIL) flashes the code corresponding to the faulty parts.
The long segment (1.3 seconds ON) indicates a “ten”, and the short segment (0.2 seconds ON) signifies
“one”. And middle segment (0.5 seconds ON) means OK code.
NOTE:
<Ref. to IM-25, LIST, List of Diagnostic Trouble Code.>
S2M1768A
IM-17
CLEAR MEMORY MODE

5) When the ‘Done’ and ‘Turn Ignition Switch OFF’
are shown on the display screen, turn the Subaru
A: OPERATION S009513A16 Select Monitor and ignition switch to OFF.
1. WITH SUBARU SELECT MONITOR NOTE:
S009513A1601 쐌 After the memory has been cleared, the ISC
1) On the ⰆMain MenuⰇ display screen, select must be initialized. To do this, turn the ignition
the {2. Each System Check} and press the [YES] switch to the ON position. Wait 3 seconds before
key. starting the engine.
2) On the ⰆSystem Selection MenuⰇ display 쐌 For detailed operation procedure, refer to the
screen, select the {Engine Control System} and SUBARU SELECT MONITOR OPERATION
press the [YES] key. MANUAL.
4) On the ⰆEngine DiagnosisⰇ display screen,
select the {Clear Memory} and press the [YES]
key.

2) Set shift lever to neutral position (MT NOTE:
vehicles), or set selector lever to “P” position 쐌 Open or short
(AT vehicles). circuit in engine
3) Connect test mode connector and read control module
memory connector. power supply or
4) Turn ignition switch to ON. ground line
쐌 Open or short
circuit in CHECK
ENGINE malfunc-
tion indicator lamp
2 CHECK DIAGNOSTIC TROUBLE CODE Does the MIL indicate diag- Record diagnostic Turn ignition
(DTC). nostic trouble code (DTC)? trouble code. switch to OFF,
1) Set selector lever “N” position, and then set <Ref. to IM-25, LIST, List of Repair the trouble Disconnect read
selector lever to “P” position again (AT Diagnostic Trouble Code.> cause. memory connec-
vehicles only). tor and test mode
2) Start the engine. connector. Com-
3) Drive vehicle at speed greater than 11 plete clear
km/h (7 MPH) for at least one minute. memory mode.
4) Warm-up engine above 2,000 rpm.
IM-18
DIAGNOSTICS CHART FOR IMMOBILIZER INDICATOR LIGHT
8. Diagnostics Chart for Immobilizer Indicator Light S009641
1. CHECK IMMOBILIZER INDICATOR CIRCUIT S009641A1001
WIRING DIAGRAM (WITH OBD MODEL):
S6M0513
IM-19
WIRING DIAGRAM (WITHOUT OBD MODEL):
S6M0514
IM-20

1 CHECK IMMOBILIZER INDICATOR LIGHT Does indicator light comes Go to step 2. Go to step 5.
COMES ON. on?
2) Disconnect harness connector from IMM
ECM.
3) Connect a resistor (750 Ω) between IMM
ECM harness connector terminal No. 9 and
chassis ground.
2 CHECK IMM ECM GROUND CIRCUIT. Is the resistance less than Go to step 3. Repair open cir-
Measure resistance between IMM ECM har- 10 Ω? cuit of IMM ECM
ness connector terminal and chassis ground. ground circuit.
With OBD:
(B141) No. 2, No. 3 (+) — Chassis
ground (−):
Without OBD:
(B141) No. 14, No. 15 (+) — Chassis
ground (−):
3 CHECK IMM ECM IGNITION CIRCUIT. Is the voltage more than 10 Go to step 4.. Check harness for
1) Turn ignition switch ON. (Engine OFF.) V? open or short
2) Measure voltage between IMM ECM har- between IMM
ness connector terminal and chassis ground. ECM and ignition
Connector & terminal switch.
With OBD:
(−):
Without OBD:
4 CHECK IMM ECM POWER SUPPLY CIR- Is the voltage more than 10 Replace IMM Check harness for
CUIT. V? ECM <Ref. to open or short
1) Turn ignition switch OFF. SL-42, Immobi- between IMM
2) Measure voltage between IMM ECM har- lizer Control Mod- ECM and fuse.
ness connector terminal and chassis ground. ule.> and then
Connector & terminal replace all ignition
With OBD: keys (including
(B141) No. 10, No. 11 (+) — Chassis the transponder).
ground (−): Then perform
Without OBD: teaching opera-
(B141) No. 5, No. 6 (+) — Chassis tion. Refer to
ground (−): teaching operation
manual (Pub. No.
S0820GZ).
5 CHECK COMBINATION METER CIRCUIT. Is the voltage more than 10 Go to step 6. Check harness for
1) Remove combination meter. <Ref. to IDI- V? open or short
15, Combination Meter Assembly.> between combina-
2) Measure voltage between combination tion meter and
meter harness connector terminal and chassis fuse.
ground.
6 CHECK COMBINATION METER CIRCUIT. Is the resistance less than Faulty LED bulb. Repair harness or
Measure resistance between IMM ECM har- 10 Ω? Replace combina- connector.
ness connector terminal and combination tion meter printed
meter harness connector terminal. circuit. <Ref. to
Connector & terminal IDI-15,
With OBD: DISASSEMBLY,
(B141) No. 9 — (i10) No. 18: Combination
Without OBD: Meter Assembly.>
(B141) No. 13 (+) — (i10) No. 18:
IM-21
2. CHECK KEY SWITCH CIRCUIT S009641A1002
S6M0515
IM-22
S6M0516
IM-23

1 CHECK POWER SUPPLY CIRCUIT. Is the voltage more than 10 Go to step 2. Check harness for
1) Disconnect harness connector from key V? open or short
warning switch. between key
2) Turn ignition switch ACC or LOCK position warning switch
(The key inserted). and fuse.
3) Measure voltage between key warning
sis ground.
2 CHECK KEY SWITCH. Dose continuity exist? Go to step 3. Replace key
1) Insert the ignition key to the ignition switch. warning switch.
(OFF or ACC position)
2) Check continuity between key warning
switch connector terminals.
No. 1 — No. 2:
3 CHECK KEY SWITCH. Does continuity exsit? Replace key Go to step 4.
1) Remove the ignition key from the ignition warning switch.
switch.
2) Check continuity between key warning
switch connector terminals.
No. 1 — No. 2:
4 CHECK HARNESS BETWEEN KEY SWITCH Is the resistance less than Replace IMM Repair harness
AND IMM ECM. 10 Ω? ECM <Ref. to between key
1) Disconnect harness connector from key SL-42, Immobi- warning switch
warning switch. lizer Control Mod- and IMM ECM.
2) Disconnect harness connector from IMM ule.> and then
ECM. replace all ignition
3) Measure resistance between key warning keys (including
switch harness connector terminal and IMM the transponder).
ECM harness connector terminal. Then perform
Connector & terminal teaching opera-
With OBD: tion. Refer to
(B74) No. 1 — (B141) No. 4: teaching operation
Without OBD: manual (Pub. No.
(B74) No. 1 — (B141) No. 9: S0820GZ).
IM-24
9. List of Diagnostic Trouble Code S009511
A: LIST S009511A12
DTC
Without With Item Contents of diagnosis Index No.
OBD OBD
<Ref. to IM-26, DTC P1571 —
Reference code incompatibility REFERENCE CODE INCOM-
P1571 Reference Code Incompatibility
between IMM ECM and ECM PATIBILITY —, Diagnostics
Chart with Trouble Code.>
IMM CIRCUIT FAILURE
IMM Circuit Failure Communication failure between IMM
P1572 (EXCEPT ANTENNA CIRCUIT)
(Except Antenna Circuit) ECM and ECM
—, Diagnostics Chart with
Trouble Code.>
Failure of IMM ECM to verify key KEY COMMUNICATION FAIL-
P1574 Key Communication Failure
(transponder) ID code URE —, Diagnostics Chart with
Trouble Code.>
53 INNCORRECT IMMOBILIZER
Incorrect immobilizer key (Use of
P0153 Use of Unregistered Key KEY (USE OF UNREGIS-
unregistered key in IMM ECM)
TERED KEY) —, Diagnostics
EGI CONTROL MODULE
P1576 EGI Control Module EEPROM ECM malfunctioning
EEPROM —, Diagnostics Chart
with Trouble Code.>
IMM CONTROL MODULE
P1577 IMM Control Module EEPROM IMM ECM malfunctioning
EEPROM —, Diagnostics Chart
with Trouble Code.>
P1570 ANTENNA Faulty antenna ANTENNA —, Diagnostics
NOTE:
쐌 When reading diagnostic trouble code except with SUBARU SELECT MONITOR, the item cannot be
specified. Therefore diagnose for all items.
쐌 When a diagnostic trouble code except for the above immobilizer trouble code has been output, carry
out diagnosis for the engine trouble code. <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).>
or <Ref. to EN(SOHCw/oOBD)-65, List of Diagnostic Trouble Code (DTC).> or <Ref. to EN(DOHC TURBO)-
82, List of Diagnostic Trouble Code (DTC).>
IM-25
DIAGNOSTICS CHART WITH TROUBLE CODE
10. Diagnostics Chart with Trouble Code S009620
A: DTC P1571 — REFERENCE CODE INCOMPATIBILITY — S009620H45
DIAGNOSIS:
쐌 Reference code incompatibility between IMM ECM and ECM
1 PERFORM TEACHING OPERATION ON Is teaching operation for all END Replace ECM.
IGNITION KEY. keys completed? <Ref. to
Perform teaching operation on all keys of the FU(SOHC)-49,
vehicle. Refer to teaching operation manual. Engine Control
Module.>, <Ref.
to FU(SOHCw/
oOBD)-38, Engine
Control Module.>,
or <Ref. to
FU(DOHC
TURBO)-47,
Engine Control
Module.>, IMM
ECM <Ref. to
SL-42, Immobi-
lizer Control Mod-
ule.> and then
replace all ignition
keys (including
the transponder).
Then perform
teaching opera-
tion. Refer to
teaching operation
manual (Pub. No.
S0820GZ).
IM-26
B: DTC P1572 — IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT) — S009620H46
DIAGNOSIS:
쐌 Communication failure between IMM ECM and ECM
S6M0517
IM-27
S6M0518
IM-28

1 CHECK POWER SUPPLY CIRCUIT OF IMM Is the voltage more than 10 Go to step 2. Check harness for
ECM. V? open or short
1) Turn ignition switch OFF. between IMM
2) Disconnect harness connector from IMM ECM and fuse.
ECM.
3) Measure voltage between IMM ECM har-
ness connector terminal and chassis ground.
With OBD:
(B141) No. 10, No. 11 (+) — Chassis
ground (−):
Without OBD:
(B141) No. 5, No. 6 (+) — Chassis
ground (−):
2 CHECK POWER SUPPLY CIRCUIT OF IMM Is the voltage more than 10 Go to step 3. Check harness for
ECM. V? open or short
1) Turn ignition switch ON. (Engine OFF.) between IMM
2) Measure voltage between IMM ECM har- ECM and ignition
ness connector terminal and chassis ground. switch.
With OBD:
(−):
Without OBD:
3 CHECK GROUND CIRCUIT OF IMM ECM. Is the resistance less than Go to step 4. Repair open cir-
1) Turn ignition switch OFF. 10 Ω? cuit of IMM ECM
2) Measure resistance between IMM ECM ground circuit.
harness connector terminal and chassis
ground.
With OBD:
(B141) No. 2, No .3 (+) — Chassis
ground (−):
Without OBD:
(B141) No. 14, No. 15 (+) — Chassis
ground (−):
4 CHECK HARNESS BETWEEN IMM ECM Is the resistance less than Go to step 5. Repair open cir-
AND ECM. 10 Ω? cuit of harness
1) Disconnect harness connector from ECM between IMM
and IMM ECM. ECM and ECM.
2) Measure resistance between IMM ECM
harness connector terminal and ECM harness
connector terminal.
With OBD (turbo):
(B141) No. 1 — (B135) No. 5:
With OBD (LHD non-turbo):
(B141) No. 1 — (B135) No. 22:
With OBD (RHD non-turbo):
(B141) No. 1 — (B135) No. 23:
Without OBD:
(B141) No. 10 — (B84) No. 23:
IM-29

5 CHECK HARNESS BETWEEN IMM ECM Is the resistance less than Go to step 6. Repair open cir-
AND ECM. 10 Ω? cuit of harness
Measure resistance between IMM ECM har- between IMM
ness connector terminal and ECM harness ECM and ECM.
connector terminal.
With OBD (turbo):
(B141) No. 6 (+) — (B135) No. 14 (−):
With OBD (LHD non-turbo):
(B141) No. 6 (+) — (B135) No. 23 (−):
With OBD (RHD non-turbo):
(B141) No. 6 — (B135) No. 22:
Without OBD:
(B141) No. 11 — (B84) No. 31:
6 CHECK HARNESS OF COMMUNICATION Is the voltage 0 V? Go to step 7. Repair harness
LINE. between IMM
1) Turn ignition switch ON. (Engine OFF.) ECM and ECM,
2) Measure voltage between IMM ECM har- because there is
ness connector terminal and chassis ground. short circuit in
Connector & terminal battery voltage
With OBD: line or ignition
(B141) No. 1, No. 6 (+) — Chassis switch “ON” line.
ground (−):
Without OBD:
(B141) No. 10, No. 11 (+) — Chassis
ground (−):
7 CHECK HARNESS OF COMMUNICATION Is the voltage 0 V? Go to step 8. Repair harness
LINE. between IMM
Measure voltage between ECM harness con- ECM and ECM,
nector terminal and engine ground. because there is
Connector & terminal short circuit in
With OBD (turbo): battery voltage
(B135) No. 5, No. 14 (+) — Chassis line or ignition
ground (−): switch “ON” line.
With OBD (non-turbo):
(B135) No. 22, No. 23 (+) — Chassis
ground (−):
Without OBD:
(B84) No. 23, No. 31 (+) — Chassis
ground (−):
8 CHECK ECM BY INTERFACE CHECK. Does “Commun. Line Replace ECM. Go to step 9.
1) Connect harness connector to ECM. Shorted to Ground” appear <Ref. to
2) Disconnect harness connector from IMM on screen? FU(SOHC)-49,
ECM. Engine Control
3) Perform interface check. <Ref. to IM-14, Module.>, <Ref.
INTERFACE CHECK, OPERATION, Subaru to FU(SOHCw/
Select Monitor.> oOBD)-38, Engine
Control Module.>,
or <Ref. to
FU(DOHC
TURBO)-47,
Engine Control
Module.> Then
perform teaching
operation. Refer
to teaching opera-
tion manual (Pub.
No. S0820GZ).
IM-30

9 CHECK ECM BY INTERFACE CHECK. Does “Commun. Line Replace ECM. Go to step 10.
Perform interface check. <Ref. to
Shorted to Battery” appear
on screen? FU(SOHC)-49,
Engine Control
Module.>, <Ref.
to FU(SOHCw/
oOBD)-38, Engine
Control Module.>
or <Ref. to
FU(DOHC
TURBO)-47,
Engine Control
Module.> Then
perform teaching
operation. Refer
to teaching opera-
tion manual (Pub.
No. S0820GZ).
10 CHECK ECM BY INTERFACE CHECK. Does “Communication Line Replace IMM When “Check
Perform interface check. not Shorted” appear on ECM <Ref. to (Time Out)”
screen? SL-42, Immobi- appears on
lizer Control Mod- screen, perform
ule.> and then interface check
replace all ignition again.
keys (including
the transponder).
Then perform
teaching opera-
tion. Refer to
teaching operation
manual (Pub. No.
S0820GZ).
IM-31
MEMO:
IM-32
C: DTC P1574 — KEY COMMUNICATION FAILURE — S009620H47
DIAGNOSIS:
쐌 Failure of IMM ECM to verify key (transponder) ID code
1 CHECK IMM ECM FUNCTION. Is the voltage −30 to 30 V? Go to step 2. Replace IMM
Insert the key to ignition switch (LOCK (Approximately 0.1 second ECM <Ref. to
position), measure changes in voltage after inserting the key.) Is SL-42, Immobi-
between Antenna connector. the voltage 0 V? (Approxi- lizer Control Mod-
Connector & terminal mately 1 second after ule.> and then
(B142) No. 1 — No. 2: inserting the key.) replace all ignition
keys (including
the transponder).
Then perform
teaching opera-
tion. Refer to
teaching operation
manual (Pub. No.
S0820GZ).
2 CHECK IGNITION KEY (TRANSPONDER). Does engine start? Replace ignition Replace IMM
1) Remove the key from ignition switch. key (including the ECM <Ref. to
2) Start engine using other keys that have transponder). SL-42, Immobi-
undergone the teaching operation, furnished Then perform lizer Control Mod-
with vehicle. teaching opera- ule.> and then
tion. Refer to replace all ignition
teaching operation keys (including
manual (Pub. No. the transponder).
S0820GZ). Then perform
teaching opera-
tion. Refer to
teaching operation
manual (Pub. No.
S0820GZ).
IM-33
D: DTC P0153 — INCORRECT IMMOBILIZER KEY (USE OF UNREGISTERED

KEY) — S009620H48
DIAGNOSIS:
쐌 Use of unregistered key in IMM ECM
1 PERFORM TEACHING OPERATION ON Is teaching operation for all END Replace all igni-
IGNITION KEY. keys completed? tion keys (includ-
Perform teaching operation on all keys of the ing the transpon-
vehicle. Refer to teaching operation manual der). Go to step 2.
(Pub. No. S0820GZ).
2 PERFORM TEACHING OPERATION ON Is teaching operation for all END Replace IMM
IGNITION KEY. keys completed? ECM <Ref. to
Perform teaching operation on all keys with SL-42, Immobi-
vehicle. Refer to teaching operation manual lizer Control Mod-
(Pub. No. S0820GZ). ule.> and then
replace all ignition
keys (including
the transponder).
Then perform
teaching opera-
tion. Refer to
teaching operation
manual (Pub. No.
S0820GZ).
E: DTC P1576 — EGI CONTROL MODULE EEPROM — S009620H49
DIAGNOSIS:
쐌 ECM malfunctioning
1. REPLACE ECM. S009620H4901
Replace ECM.
<Ref. to FU(SOCH)-49, Engine Control Module.>,
<Ref. to FU(SOHCw/oOBD)-38, Engine Control Module.> or <Ref. to FU(DOHC TURBO)-47, Engine Con-
trol Module.>
Then perform teaching operation. Refer to teaching operation manual (Pub. No. S0820GZ).
F: DTC P1577 — IMM CONTROL MODULE EEPROM — S009620H50
DIAGNOSIS:
쐌 IMM ECM malfunctioning
1. REPLACE IMM ECM. S009620H5001
Replace IMM ECM <Ref. to SL-42, Immobilizer Control Module.> and then replace all ignition keys (includ-
ing the transponder). Then perform teaching operation. Refer to teaching operation manual (Pub. No.
S0820GZ).
IM-34
G: DTC P1570 — ANTENNA — S009620H51
DIAGNOSIS:
쐌 Faulty antenna
B6M1534
IM-35
S6M0519
IM-36

1 CHECK ENGINE TYPE. Is the vehicle with OBD? Go to step 2. Go to step 8.
2 CHECK ANTENNA CIRCUIT. Is the resistance less than Go to step 3. Replace antenna.
1) Turn ignition switch OFF. 10 Ω? <Ref. to SL-43,
Disconnect harness antenna connector from Immobilizer
IMM ECM. <Ref. to SL-43, Immobilizer Antenna.>
Antenna.>
2) Measure resistance of antenna circuit.
(B142) No. 1 — No. 2:
3 CHECK ANTENNA CIRCUIT. Is the resistance less than Replace antenna. Go to step 4.
Measure resistance between antenna harness 10 Ω? <Ref. to SL-43,
connector and chassis ground. Immobilizer
Connector & terminal Antenna.>
4 CHECK ANTENNA CIRCUIT. Is the resistance less than Replace antenna. Go to step 5.
Measure resistance between antenna harness 10 Ω? <Ref. to SL-43,
5 CHECK ANTENNA CIRCUIT. Is the voltage 0 V? Go to step 6. Replace antenna.
1) Turn ignition switch ON. (Engine OFF.) <Ref. to SL-43,
2) Measure voltage between antenna harness Immobilizer
connector and chassis ground. Antenna.>
6 CHECK ANTENNA CIRCUIT. Is the voltage 0 V? Go to step 7. Replace antenna.
Measure voltage between antenna harness <Ref. to SL-43,
1) Turn ignition switch OFF. (Approximately 0.1 second ECM <Ref. to
2) Connect antenna harness connector to after inserting the key.) Is SL-42, Immobi-
IMM ECM. the voltage 0 V? (Approxi- lizer Control Mod-
3) Insert the key to ignition switch, measure mately 1 second after ule.> and then
changes in voltage between antenna harness inserting the key.) replace all ignition
connector. keys (including
Connector & terminal the transponder).
(B142) No. 1 — No. 2: Then perform
teaching opera-
tion. Refer to
teaching operation
manual (Pub. No.
S0820GZ).
8 CHECK ANTENNA CIRCUIT. Is the resistance less than Go to step 9. Replace antenna.
1) Turn ignition switch OFF. 10 Ω? <Ref. to SL-43,
2) Disconnect harness antenna connector. Immobilizer
<Ref. to SL-43, Immobilizer Antenna.> Antenna.>
3) Measure resistance of antenna circuit.
(B142) No. 1 — No. 2:
IM-37

9 CHECK ANTENNA CIRCUIT. Is the resistance less than Go to step 10. Repair harness
1) Disconnect IMM ECM harness connector. 10 Ω? between IMM
2) Measure resistance between IMM ECM ECM and antenna
harness connector terminal and antenna har- harness connec-
ness connector terminal. tor.
(B141) No. 1 — (B142) No. 2:
(B141) No. 2 — (B142) No. 1:
10 CHECK ANTENNA CIRCUIT. Is the resistance less than Repair harness Go to step 11.
Measure resistance between IMM ECM har- 10 Ω? between IMM
ness connector and chassis ground. ECM and antenna
Connector & terminal harness connec-
(B141) No. 1 (+) — Chassis ground (−): tor.
11 CHECK ANTENNA CIRCUIT. Is the resistance less than Repair harness Go to step 12.
Measure resistance between IMM ECM har- 10 Ω? between IMM
ness connector and chassis ground. ECM and antenna
12 CHECK ANTENNA CIRCUIT. Is the voltage 0 V? Go to step 13. Repair harness
1) Turn ignition switch ON. (Engine OFF.) between IMM
2) Measure voltage between IMM ECM har- ECM and antenna
ness connector and chassis ground. harness connec-
Connector & terminal tor.
13 CHECK ANTENNA CIRCUIT. Is the voltage 0 V? Go to step 14. Repair harness
Measure voltage between IMM ECM harness between IMM
connector and chassis ground. ECM and antenna
1) Turn ignition switch OFF. (Approximately 0.1 second ECM <Ref. to
2) Connect antenna harness connector and after inserting the key.) Is SL-42, Immobi-
IMM ECM harness connector. the voltage 0 V? (Approxi- lizer Control Mod-
3) Insert the key to ignition switch, measure mately 1 second after ule.> and then
changes in voltage between IMM ECM har- inserting the key.) replace all ignition
ness connector. keys (including
Connector & terminal the transponder).
(B141) No. 1 — No. 2: Then perform
teaching opera-
tion. Refer to
teaching operation
manual (Pub. No.
S0820GZ).
15 CHECK IGNITION KEY (TRANSPONDER). Does engine start? Replace ignition Replace IMM
1) Remove key from ignition switch. key (including the ECM <Ref. to
2) Start engine using other keys that have transponder). SL-42, Immobi-
undergone the teaching operation, furnished Then perform lizer Control Mod-
with vehicle. teaching opera- ule.> and then
tion. Refer to replace all ignition
teaching operation keys (including
manual (Pub. No. the transponder).
S0820GZ). Then perform
teaching opera-
tion. Refer to
teaching operation
manual (Pub. No.
S0820GZ).
IM-38
CHASSIS SECTION

SUBARU vehicles.
ine parts.

G8050GE5
FRONT SUSPENSION
FS
Page
2. Wheel Alignment .........................................................................................6
3. Front Transverse Link ...............................................................................14
4. Front Ball Joint ..........................................................................................17
5. Front Strut .................................................................................................18
6. Front Stabilizer ..........................................................................................22
7. Front Crossmember ..................................................................................23
8. General Diagnostic Table ..........................................................................24
GENERAL DESCRIPTION
Front Suspension
1. STABILIZER S202001E4901
Bar dia.
Model
Front Rear
NON-TURBO 19 mm (0.75 in) 13 mm (0.51 in)
TURBO 20 mm (0.79 in) 15 mm (0.59 in)
2. WHEEL ALIGNMENT S202001E4902
Model NON-TURBO TURBO

Camber (tolerance: ±0°30′) −0°15′ −0°20′
Caster (common difference: ±0°45′) −0°37′ −0°57′
0±3 mm (0±0.12 in)*
Toe-in
Each toe angle: ±0°09′
Kingpin angle 13°25′ 13°40′
Wheel arch height
432 mm (17.01 in) 422 mm (16.61 in)
[tolerance: +12/−24 mm (+0.47/−0.94 in)
*: When performing toe-in adjustment, align as close to 0 mm (0 in) as possible.
NOTE:
쐌 Front and rear toe-ins and front camber can be
adjusted. If toe-in or camber tolerance exceeds
specifications, adjust toe-in and camber to the
middle value of specification.
쐌 The other items indicated in the specification
table cannot be adjusted. If the other items
exceeds specifications, check suspension parts
and connections for deformities; replace with new
ones as required.
B4M2250B
(1) Front
A − B = Positive: Toe-in, Negative: Toe-out
α = Each toe angle
FS-2
GENERAL DESCRIPTION
Front Suspension
S4M0317B
(1) Front crossmember (17) Dust seal Tightening torque: N·m (kgf-m, ft-lb)
(2) Bolt ASSY (18) Strut mount
T1: 20 (2.0, 14.5)
(3) Housing (19) Spacer
T2: 25 (2.5, 18.1)
(4) Washer (20) Upper spring seat
T3: 30 (3.1, 22)
(5) Stopper rubber (Rear) (21) Rubber seat
(6) Rear bushing (22) Dust cover T4: 40 (4.1, 30)
(7) Stopper rubber (Front) (23) Helper T5: 45 (4.6, 33)
(8) Ball joint (24) Coil spring T6: 50 (5.1, 37)
(9) Transverse link (25) Damper strut T7: 55 (5.6, 41)
(10) Cotter pin (26) Adjusting bolt T8: 100 (10.2, 74)
(11) Front bushing (27) Castle nut T9: 175 (17.8, 129)
(12) Stabilizer link (28) Self-locking nut T10: 190 (19.4, 140)
(13) Clamp (Non-Turbo model) (29) Adapter front crossmember T11: 245 (25.0, 181)
(14) Bushing (Non-Turbo model) (30) Clip
(15) Stabilizer (31) Clamp (Turbo model)
(16) Jack-up plate (32) Bushing (Turbo model)
FS-3
GENERAL DESCRIPTION
Front Suspension
쐌 Wear working clothing, including a cap, protec-

tive goggles, and protective shoes during opera-
tion.
쐌 Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
쐌 Keep the disassembled parts in order and pro-
tect them from dust or dirt.
쐌 Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary
removal, installation, disassembly, and replace-
ment.
쐌 Use SUBARU genuine grease etc. or the
equivalent. Do not mix grease etc. with that of
another grade or from other manufacturers.
쐌 Be sure to tighten fasteners including bolts and
nuts to the specified torque.
쐌 Place shop jacks or safety stands at the speci-
fied points.
쐌 Apply grease onto sliding or revolution surfaces
쐌 Before installing O-rings or snap rings, apply
sufficient amount of grease to avoid damage and
deformation.
쐌 Before securing a part on a vise, place cushion-
ing material such as wood blocks, aluminum plate,
or shop cloth between the part and the vise.
FS-4
GENERAL DESCRIPTION
Front Suspension

927380002 ADAPTER Used as an adapter for camber & caster gauge
when measuring camber and caster.
(1) 28199AC000 PLATE
(2) 28199AC010 BOLT
B4M2378A
927680000 INSTALLER & Used for replacing transverse link bushing.
REMOVER SET
B4M2385
927760000 STRUT MOUNT Used for disassembling and assembling strut
SOCKET and shock mount.
B4M2384
2. GENERAL PURPOSE TOOLS S202001A1702
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-5
WHEEL ALIGNMENT
Front Suspension
2. Wheel Alignment S202116
Check, adjust and/or measure wheel alignment in accordance with procedures indicated in figure:
B4M1088A
FS-6
WHEEL ALIGNMENT
Front Suspension
1. WHEEL ARCH HEIGHT S202116A1006
1) Adjust tire pressure to specifications.

2) Set vehicle under “curb weight” conditions. (Empty luggage compartment, install spare tire, jack, ser-
vice tools, and top up fuel tank.)
3) Set steering wheel in a wheel-forward position.
4) Suspend thread from wheel arch (point “A” in figure below) to determine a point directly above center
of spindle.
5) Measure distance between measuring point “A” and center of spindle.
S4M0086B
(1) Wheel arch height (4) Front wheel arch height (7) Measuring point
(2) Front fender (5) Rear wheel arch height (8) End of spindle
(3) Outer rear quarter (6) Cross-section of arch
Specified wheel arch height

Model
Front Rear
Non-Turbo 432+12/−24 mm (17.01+0.47/−0.94 in) 435+12/−24 mm (17.13+0.47/−0.94 in)
Turbo 422+12/−24 mm (16.61+0.47/−0.94 in) 425+12/−24 mm (16.73+0.47/−0.94 in)
FS-7
WHEEL ALIGNMENT
Front Suspension
2. CAMBER S202116A1002 쐌 Front Camber Adjustment

쐌 Inspection 1) Loosen two self-locking nuts located at lower
front portion of strut.
1) Place front wheel on turning radius gauge.
Make sure ground contacting surfaces of front and CAUTION:
쐌 When adjusting bolt needs to be loosened or
rear wheels are set at the same height.
tightened, hold its head with a wrench and turn
2) Set ST into the center of the wheel, and then self-locking nut.
install the wheel alignment gauge. 쐌 Discard loosened self-locking nut and
ST 927380002 ADAPTER replace with a new one.
쐌 When performing toe-in adjustment, align as
close to 0 mm (0 in) as possible.
2) Turn camber adjusting bolt so that camber is
set at the specification.
NOTE:
Moving the adjusting bolt by one scale graduation
changes camber by approximately 0°10′.
S4M0087C
(1) Alignment gauge

(2) Turning radius gauge
NOTE:
Refer to the “SPECIFICATIONS” for the camber
values.
Front
<Ref. to FS-2, SPECIFICATIONS, General
Description.>
Rear
<Ref. to RS-2, SPECIFICATIONS, General
Description.>
S4M0300B
(1) Strut
(2) Adjusting bolt
(3) Housing
(4) Outer
(5) Inner
(6) Camber is increased.
(7) Camber is decreased.
FS-8
WHEEL ALIGNMENT
Front Suspension
Left side Right side
Rotate counterclock-
Camber is increased. Rotate clockwise.
wise.
B4M0190 B4M0350
Rotate counterclock-
Camber is decreased. Rotate clockwise.
wise.
B4M0350 B4M0190
3) Tighten the two self-locking nuts. 4. FRONT WHEEL TOE-IN S202116A1004
Tightening torque: 쐌 Inspection

175 N·m (17.8 kgf-m, 129 ft-lb)
1) Using a toe gauge, measure front wheel toe-in.
3. CASTER S202116A1003
Toe-in:
쐌 Inspection 0±3 mm (0±0.12 in)
1) Place front wheel on turning radius gauge. 2) Mark rear sides of left and right tires at height
Make sure ground contacting surfaces of front and corresponding to center of spindles and measure
rear wheels are set at the same height. distance “A” between marks.
2) Set ST into the center of the wheel, and then 3) Move vehicle forward so that marks line up with
install the wheel alignment gauge. front sides at height corresponding to center of
ST 927380002 ADAPTER spindles.
4) Measure distance “B” between left and right
marks. Toe-in can then be obtained by the follow-
ing equation:
A − B = Toe-in
S4M0087C
(1) Alignment gauge

(2) Turning radius gauge
NOTE: H4M1279B
Refer to the “SPECIFICATIONS” for the caster val-
ues. <Ref. to FS-2 SPECIFICATIONS, General
Description.>
FS-9
WHEEL ALIGNMENT
Front Suspension
쐌 Adjustment B − A = Toe-in
1) Loosen the left and right side steering tie-rods
lock nuts.
2) Turn the left and right tie rods equal amounts
until the toe-in is at the specification.
Both the left and right tie-rods are right-hand
threaded. To increase toe-in, turn both tie-rods
clockwise equal amounts (as viewed from the
inside of the vehicle).
M4A0059
쐌 Adjustment
1) Loosen self-locking nut on inner side of rear
lateral link.
CAUTION:
쐌 When loosening or tightening adjusting bolt,
S4M0348A
hold bolt head and turn self-locking nut.
쐌 Discard loosened self-locking nut and
(1) Lock nut replace with a new one.
쐌 When performing toe-in adjustment, align as
3) Tighten tie-rod lock nut.
close to 0 mm (0 in) as possible.
Tightening torque:
83 N·m (8.5 kgf-m, 61.5 ft-lb)
CAUTION:
Correct tie-rod boot, if it is twisted.
NOTE:
Check the left and right wheel steering angle is
5. REAR WHEEL TOE-IN S202116A1007
쐌 Inspection
S4M0349A
1) Using a toe-in gauge, measure rear wheel toe-
in. (1) Adjusting scale
(2) Rear lateral link
Toe-in: 2±3 mm (0.08±0.12 in)
2) Mark rear sides of left and right tires at height 2) Turn adjusting bolt head until toe-in is at the
corresponding to center of spindles and measure specification.
distance “B” between marks. NOTE:
3) Move vehicle forward so that marks line up with When left and right wheels are adjusted for toe-in
front sides at height corresponding to center of at the same time, the movement of one scale
spindles. graduation changes toe-in by approximately 3 mm
4) Measure distance “A” between left and right (0.12 in).
marks. Toe-in can then be obtained by the follow-
ing equation:
FS-10
WHEEL ALIGNMENT
Front Suspension
Left side Right side
Toe-in is Rotate counter-

Rotate clockwise.
increased. clockwise.
B4M0192 B4M0352
Toe-in is Rotate counter-

Rotate clockwise.
decreased. clockwise.
B4M0352 B4M0192
3) Tighten self-locking nut. 6. THRUST ANGLE S202116A1008
Tightening torque: 쐌 Inspection

100 N·m (10.2 kgf-m, 74 ft-lb)
1) Position vehicle on a level surface.
2) Move vehicle 3 to 4 meters directly forward.
3) Determine locus of both front and rear axles.
4) Measure distance “L” between center line of
loci of the axles.
Thrust angle:
Less than 20 ′ when “L” is equal to or
less than 15 mm (0.59 in).
S4M0350B
(1) Center line of loci (front axle)

(2) Center line of loci (rear axle)
FS-11
WHEEL ALIGNMENT
Front Suspension
쐌 Adjustment NOTE:
Thrust angle refers to a mean value of left and right
1) Make thrust angle adjustments by turning toe-in rear wheel toe angles in relation to vehicle body
adjusting bolts of rear suspension equally in the center line. Vehicle is driven straight in the thrust
same direction. angle direction while swinging in the oblique direc-
2) When one rear wheel is adjusted in a toe-in tion depending on the degree of the mean thrust
direction, adjust the other rear wheel equally in angle.
toe-out direction, in order to make thrust angle
adjustment.
3) When left and right adjusting bolts are turned
incrementally by one graduation in the same
direction, the thrust angle will change approxi-
mately 10′ [“L” is almost equal to 7.5 mm (0.295
in)].
Thrust angle:
0°±20 ′
B4M0193B
(1) Front
(2) Thrust angle
(3) Body center line
Thrust angle: r = (α − β)/2
α: Right rear wheel toe-in angle
β: Left rear wheel toe-in angle
NOTE:
Here, use only positive toe-in values from each
wheel to substitute for α and β in the equation.
S4M0350B
B4M0194B
(1) Center line of loci (front axle)
(2) Center line of loci (rear axle) (1) Front
(2) Body center line
FS-12
WHEEL ALIGNMENT
Front Suspension
7. STEERING ANGLE S202116A1005
쐌 Inspection
1) Place vehicle on a turning radius gauge.
2) While depressing brake pedal, turn steering
wheel fully to the left and right. With steering wheel
held at each fully turned position, measure both the
inner and outer wheel steering angle.
Steering angle:
Inner wheel
34.4°±1.5°
Outer wheel
30.2°±1.5°
쐌 Adjustment
Turn tie-rod to adjust steering angle of both inner
and outer wheels.
CAUTION:
쐌 Check toe-in.
쐌 Correct boot if it is twisted.
S4M0348A
(1) Lock nut
FS-13
FRONT TRANSVERSE LINK
Front Suspension
3. Front Transverse Link S202113 B: INSTALLATION S202113A11
1) Temporarily tighten the two bolts used to secure
rear bushing of the transverse link to body.
1) Set the vehicle on the lift.
2) Disconnect ground terminal from the battery. NOTE:
3) Lift-up the vehicle and remove the wheel. These bolts should be tightened to such an extent
4) Disconnect stabilizer link from transverse link. that they can still move back and forth in the oblong
5) Remove bolt securing ball joint of transverse shaped hole in the bracket (which holds the bush-
link to housing. ing).
2) Install bolts used to connect transverse link to
crossmember and temporarily tighten with nut.
CAUTION:
Discard loosened self-locking nut and replace
with a new one.
3) Insert ball joint into housing.
4) Connect stabilizer link to transverse link, and
temporarily tighten bolts.
CAUTION:
S4M0090
Discard loosened self-locking nut and replace
6) Remove nut (do not remove bolt.) securing with a new one.
transverse link to crossmember.
7) Remove two bolts securing bushing bracket of
transverse link to vehicle body at rear bushing
location.
S4M0090
5) Tighten the following points in the order shown

below when wheels are in full contact with the
S4M0091 ground and vehicle is curb weight.
(1) Transverse link and stabilizer
8) Extract ball joint from housing.
9) Remove bolt securing transverse link to cross- Tightening torque:
member and extract transverse link from cross- 30 N·m (3.1 kgf-m, 22 ft-lb)
member. (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:
245 N·m (25 kgf-m, 181 ft-lb)
S4M0092
FS-14
Front Suspension
NOTE: C: DISASSEMBLY S202113A06

쐌 Move rear bushing back and forth until trans-
verse link-to-rear bushing clearance is established 1. FRONT BUSHING S202113A0601
(as indicated in figure.) before tightening. Using ST, press front bushing out of place.
쐌 Check wheel alignment and adjust if necessary. ST 927680000 INSTALLER & REMOVER SET
S4M0352A G4M0494
(1) Rear bushing

2. REAR BUSHING S202113A0602
1) Scribe an aligning mark on transverse link and

rear bushing.
2) Loosen nut and remove rear bushing.
G4M0495
FS-15
Front Suspension
D: ASSEMBLY S202113A02 E: INSPECTION S202113A10
1. FRONT BUSHING S202113A0201 1) Check transverse link for wear, damage and
cracks, and correct or replace if defective.
To reassemble, reverse disassembly procedures.
2) Check bushings for cracks, fatigue or damage.
CAUTION: 3) Check rear bushing for oil leaks.
Install front bushing in correct direction, as
shown in figure.
S4M0351A
(1) Face bushing toward center of ball joint

(2) Ball joint
2. REAR BUSHING S202113A0202
1) Install rear bushing to transverse link and align

aligning marks scribed on the two.
2) Tighten self-locking nut.
CAUTION:
쐌 Discard loosened self-locking nut and
replace with a new one.
쐌 While holding rear bushing so as not to
change position of aligning marks, tighten self-
locking nut.
Tightening torque:
190 N·m (19.4 kgf-m, 140 ft-lb)
FS-16
FRONT BALL JOINT
Front Suspension
4. Front Ball Joint S202114 C: INSPECTION S202114A10
1) Measure play of ball joint by the following pro-
cedures. Replace with a new one when the play
1) Set the vehicle on the lift. exceeds the specified value.
2) Disconnect ground terminal from the battery. (1) With 690 N (70.4 kgf, 155 lb) loaded in the
3) Lift-up the vehicle and remove the wheel. direction shown in the figure, measure dimen-
4) Pull out the cotter pin from the ball stud, remove sion 1.
the castle nut, and extract the ball stud from the
transverse link.
5) Remove the bolt securing the ball joint to the
housing.
G4M0500
(2) With 690 N (70.4 kgf, 155 lb) loaded in the

opposite direction shown in the figure, measure
G4M0499 dimension 2.
6) Extract the ball joint from the housing.
1) Install ball joint onto housing.

Torque (Bolt):
50 N·m (5.1 kgf-m, 37 ft-lb)
CAUTION:
Do not apply grease to tapered portion of ball
stud. G4M0501
2) Connect ball joint to transverse link. (3) Calculate plays from the following formula.
Torque (Castle nut): S = 2 − 1
40 N·m (4.1 kgf-m, 30 ft-lb) (4) When plays are larger than the following
3) Retighten castle nut further within 60° until a value, replace with a new one.
slot in castle nut is aligned with the hole in ball stud FRONT BALL JOINT
end, then insert new cotter pin and bend it around Specified play for replacement: S
castle nut. Less than 0.3 mm (0.012 in)
4) Install front wheel. 2) When play is smaller than the specified value,
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 the
new ball joint.
FS-17
FRONT STRUT
Front Suspension
5. Front Strut S202115

7) Scribe an alignment mark on the camber
adjusting bolt which secures strut to housing.
A: REMOVAL S202115A18 8) Remove bolt securing the ABS sensor harness
on models equipped with ABS.
2) Disconnect ground terminal from the battery.
3) Lift-up the vehicle and remove the wheel.
4) Depress brake pedal and hold it down using a
wooden block etc.
5) Remove union bolts from caliper.
CAUTION:
Use brake hose cap to prevent brake fluid from
escaping.
B4M1442C
(1) Sensor harness
9) Remove two bolts securing housing to strut.

CAUTION:
While holding head of adjusting bolt, loosen
self-locking nut.
10) Remove the three nuts securing strut mount to
S4M0093
body.
6) Remove brake hose clamp and disconnect

brake hose from strut. Attach brake hose to body
using gum tape.
S4M0094C
(1) Clamp
G4M0505
FS-18
FRONT STRUT
Front Suspension
B: INSTALLATION S202115A11 C: DISASSEMBLY S202115A06
1) Install strut mount at upper side of strut to body 1) Using a coil spring compressor, compress coil
and tighten with nuts. spring.
Tightening torque:
20 N·m (2.0 kgf-m, 14.5 ft-lb)
2) Install ABS sensor harness to strut. (ABS
equipped models)
Tightening torque:
32 N·m (3.3 kgf-m, 24 ft-lb)
3) Position aligning mark on camber adjustment
bolt with aligning mark on lower side of strut.
CAUTION: S4M0095
쐌 While holding head of adjusting bolt, tighten
self-locking nut. 2) Using ST, remove self-locking nut.
쐌 Be sure to use new self-locking nut. ST 927760000 STRUT MOUNT SOCKET
Tightening torque:
175 N·m (17.8 kgf-m, 129 ft-lb)
4) Install brake hose at lower side of strut with
clamp.
5) Install union bolts which secure brake caliper to
brake hose.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
S4M0096A
3) Remove strut mount, upper spring seat and

rubber seat from strut.
4) Gradually decreasing compression force, and
remove coil spring.
5) Remove dust cover and helper spring.
S4M0093
CAUTION:
Be sure to bleed air from brake system.
6) Install wheels.
NOTE:
Check wheel alignment and adjust if necessary.
FS-19
FRONT STRUT
Front Suspension
D: ASSEMBLY S202115A02 5) Set the coil spring correctly so that its end face
fits well into the spring seat as shown.
1) Before installing coil spring, strut mount, etc.,
on the strut, check for the presence of air in the
dampening force generating mechanism of the
strut since air prevents proper dampening force
from being produced.
2) Checking for the presence of air
(1) Place the strut vertically with the piston rod
facing up.
(2) Move the piston rod to the center of its
entire stroke.
(3) While holding the piston rod end with S4M0353A
fingertips, move the rod up and down.
(4) If the piston rod moves at least 10 mm (0.39 6) Install helper and dust cover to the piston rod.
in) in the former step, purge air from the strut. 7) Pull the piston rod fully upward, and install rub-
3) Air purging procedure ber seat and spring seat.
(1) Place the strut vertically with the piston rod NOTE:
facing up. Ensure that upper spring seat is positioned as
(2) Fully extend the piston rod. shown in figure.
(3) With the piston rod fully extended, place the
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”.
S4M0097B
4) Using a coil spring compressor, compress the
coil spring. (1) Outside of body
NOTE: 8) Install strut mount to the piston rod, and tighten

Make sure that the vertical installing direction of the self-locking nut temporarily.
coil spring is as shown in figure. CAUTION:
Be sure to use a new self-locking nut.
9) Using 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)
B4M0568B
(1) Flat (top side)

(2) Identification paint
(3) Inclined (bottom side)
S4M0096A
10) Loosen the coil spring carefully.
FS-20
FRONT STRUT
Front Suspension
E: INSPECTION S202115A10 5. HELPER S202115A1005
Check the disassembled parts for cracks, damage Replace it with new one if cracked or damaged.
and wear, and replace with new parts if defective.
1. DAMPER STRUT S202115A1001
1) Check for oil leakage.

2) Move the piston rod up and down to check it
operates smoothly without any binding.
3) Play of piston rod
쐌 Measure the play as follows:
Fix outer shell and fully extend the rod. Set a dial
gauge at the end of the rod: L [10 mm (0.39 in)],
then apply a force of W [20 N (2 kgf, 4 lb)] to
threaded portion. With the force of 20 N (2 kgf, 4
lb) applied, read dial gauge indication: P1. Apply a
force of 20 N (2 kgf, 4 lb) in the opposite direction
of “W”, then read dial gauge indication: P2.
G4M0508
The free play is determined by the following equa-

tion:
Play = P1, P2
Limit of play:
Less than 0.8 mm (0.031 in)
If the play is greater, replace the strut.
2. STRUT MOUNT S202115A1002
Check rubber part for creep, cracks and

deterioration, and replace it with new one if defec-
tive.
3. DUST COVER S202115A1003
If any cracks or damage are found, replace it with

a new one.
4. COIL SPRING S202115A1004
One having permanent strain should be replaced

with a new one. When vehicle posture is uneven,
although there are no considerable reasons like
tire puncture, uneven loading, etc., check coil
spring for its free length referring to specifications,
cracks, etc., and replace it with a new one if defec-
tive.
FS-21
FRONT STABILIZER
Front Suspension
6. Front Stabilizer S202119 B: INSTALLATION S202119A11
1) Set the vehicle on the lift. NOTE:

2) Disconnect ground terminal from the battery. 쐌 Install bushing (on front crossmember side)
3) Jack-up the front part of the vehicle and support while aligning it with paint mark on stabilizer.
it with safety stand (rigid racks). 쐌 Ensure that bushing and stabilizer have the
4) Remove jack-up plate from lower part of cross- same identification colors when installing.
member.
5) Remove bolts which secure stabilizer to cross-
member.
S4M0356A
(1) Mark stamped on stabilizer

(2) Bushing identification color
B4M1846A
2) Always tighten rubber bushing location when
(1) Nut (Turbo model) wheels are in full contact with the ground and
(2) Bolt vehicle is curb weight.
6) Remove bolts which secure stabilizer link to Tightening torque:
front transverse link. Jack-up plate to crossmember:
20 N·m (2.0 kgf-m, 14 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)
1) Check bushing for cracks, fatigue or damage.

2) Check stabilizer link for deformities, cracks, or
damage, and bushing for protrusions from the hole
S4M0355
of stabilizer link.
7) Remove front stabilizer.
FS-22
FRONT CROSSMEMBER
Front Suspension
7. Front Crossmember S202108

12) Support crossmember with a jack, remove
nuts securing crossmember to body and lower
A: REMOVAL S202108A18 crossmember gradually along with steering gear-
box.
2) Disconnect ground cable from the battery. CAUTION:
3) Lift-up vehicle and remove front tires and When removing crossmember downward, be
wheels. careful that tie-rod end does not interfere with
4) Remove both stabilizer and jack-up plate. SFJ boot.

CAUTION:
Always tighten rubber bushing when wheels
are in full contact with the ground and vehicle
is curb weight.
Tightening torque:
Transverse link bushing to crossmember:
100 N·m (10.2 kgf-m, 74 ft-lb)
S4M0354B Stabilizer to bushing:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
(1) Front stabilizer
Tie-rod end to housing:
(2) Front crossmember
27.0 N·m (2.75 kgf-m, 19.9 ft-lb)
(3) Jack-up plate
Front cushion rubber to crossmember:
5) Disconnect tie-rod end from housing. 85 N·m (8.7 kgf-m, 63 ft-lb)
6) Remove front exhaust pipe. (Non-turbo model) Universal joint to pinion shaft:
With OBD 24 N·m (2.4 kgf-m, 17.4 ft-lb)
<Ref. to EX(SOHC)-5, REMOVAL, Front Exhaust Crossmember to body:
100 N·m (10.2 kgf-m, 74 ft-lb)
Pipe.>
Without OBD 2) Purge air from power steering system. <Ref. to
<Ref. to EX(SOHCw/oOBD)-6, REMOVAL, Front PS-102, INSTALLATION, Power Steering Fluid.>
Exhaust Pipe.> NOTE:
7) Remove front transverse link from front cross- Check wheel alignment and adjust if necessary.
member and body.
Check crossmember for wear, damage and cracks,

and correct or replace if defective.
S4M0092
8) Remove nuts attaching engine mount cushion

rubber to crossmember.
9) Remove steering universal joint. <Ref. to
PS-28, REMOVAL, Universal Joint.>
10) Disconnect power steering pipe from steering
gear box.
11) Lift engine by approx. 10 mm (0.39 in) by
using chain block.
FS-23
GENERAL DIAGNOSTIC TABLE
Front Suspension
8. General Diagnostic Table S202121
1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT S202121A1001
Possible causes Countermeasures

(1) Permanent distortion or breakage of coil spring Replace.
(2) Unsmooth operation of damper strut and/or shock absorber Replace.
(3) Installation of wrong strut and/or shock absorber Replace with proper parts.
(4) Installation of wrong coil spring Replace with proper parts.
2. POOR RIDE COMFORT S202121A1002
1) Large rebound shock

2) Rocking of vehicle continues too long after running over bump and/or hump.
3) Large shock in bumping
(1) Breakage of coil spring Replace.
(2) Overinflation pressure of tire Adjust.
(3) Improper wheel arch height Adjust or replace coil springs with new ones.
(4) Fault in operation of damper strut and/or shock absorber Replace.
(5) Damage or deformation of strut mount and/or shock absorber mount Replace.
(6) Unsuitability of maximum and/or minimum length of damper strut and/or Replace with proper parts.
shock absorber
(7) Deformation or loss of bushing Replace.
(8) Deformation or damage of helper in strut assembly and/or shock Replace.
absorber
(9) Oil leakage of damper strut and/or shock absorber Replace.
3. NOISE S202121A1003

(1) Wear or damage of damper strut and/or shock absorber component Replace.
parts
(2) Loosening of suspension link installing bolt Retighten to the specified torque.
(4) Unsuitability of maximum and/or minimum length of damper strut Replace with proper parts.
and/or shock absorber
(6) Wear or damage of ball joint Replace.
(7) Deformation of stabilizer clamp Replace.
FS-24
CHASSIS SECTION

SUBARU vehicles.
ine parts.

G8050GE5
REAR SUSPENSION
RS
Page
2. Wheel Alignment .........................................................................................7
3. Rear Stabilizer.............................................................................................8
4. Rear Trailing Link ........................................................................................9
5. Lateral link .................................................................................................12
6. Rear Strut ..................................................................................................16
7. Rear Crossmember ...................................................................................20
GENERAL DESCRIPTION
Rear Suspension
Item Non-turbo Turbo

Camber (tolerance: ±0°45′) −0°35′ −0°45′
2±3 mm (0.08±0.12 in)*
Toe-in
Each toe-in angle: 0°06′±0°09′
Wheel arch height
435 mm (17.13 in) 425 mm (16.73 in)
[tolerance: +12/−24 mm (+0.47/−0.94 in)]
Thrust angle 0°±20′
Diameter of stabilizer 13 mm (0.51 in) 15 mm (0.59 in)
*: When performing toe-in adjustment, align as close to 2 mm (0.08 in) as possible.
NOTE:
쐌 Front and rear toe-ins and front camber can be
adjusted. If toe-in or camber tolerance exceeds
specifications, adjust toe-in and camber to the
middle value of specification.
쐌 The other items indicated in the specification
table cannot be adjusted. If the other items
exceeds specifications, check suspension parts
and connections for deformities; replace with new
ones as required.
B4M2250C
(1) Front
A − B = Positive: Toe-in, Negative: Toe-out
α1, α2: Each toe-in angle
RS-2
GENERAL DESCRIPTION
Rear Suspension
S4M0085B
(1) Stabilizer (15) Trailing link front bushing Tightening torque: N·m (kgf-m, ft-lb)
(2) Stabilizer bracket (16) Trailing link bracket
T1: 20 (2.0, 14.5)
(3) Stabilizer bushing (17) Cap (Protection)
T2: 25 (2.5, 18.1)
(4) Clamp (18) Washer
T3: 45 (4.6, 33)
(5) Floating bushing (19) Rear crossmember
(6) Stopper (20) Strut mount cap T4: 60 (6.1, 44)
(7) Stabilizer link (21) Strut mount T5: 100 (10.2, 74)
(8) Rear lateral link (22) Rubber seat upper T6: 115 (11.7, 85)
(9) Bushing (C) (23) Dust cover T7: 130 (13.3, 96)
(10) Bushing (A) (24) Coil spring T8: 140 (14.3, 103)
(11) Front lateral link (25) Helper T9: 200 (20.4, 148)
(12) Bushing (B) (26) Rubber seat lower
(13) Trailing link rear bushing (27) Damper strut
(14) Trailing link (28) Self-locking nut
RS-3
GENERAL DESCRIPTION
Rear Suspension

tion.
ment.
fied points.
deformation.
쐌 Before disposing shock absorbers, be sure to
bleed gas completely. Also, do not throw away in
fire.
RS-4
GENERAL DESCRIPTION
Rear Suspension
1. SPECIAL TOOL S201001A1701

927380002 ADAPTER Used as an adapter for camber & caster gauge
when measuring camber and caster.
(1) 28199AC000 PLATE
(2) 28199AC010 BOLT
B4M2378A
927690000 INSTALLER & Used for replacing lateral link bushing (12 dia.).
REMOVER SET
H5M0979
927700000 INSTALLER & Used for replacing lateral link bushing (14 dia.).
REMOVER SET
H5M0979
927720000 INSTALLER & Used for replacing trailing link bushing.
REMOVER SET
H5M0980
RS-5
GENERAL DESCRIPTION
Rear Suspension

927730000 INSTALLER & Used for replacing rear housing bushing.
REMOVER SET
H5M0979
927760000 STRUT MOUNT Used for disassembling and assembling strut
SOCKET mount.
B4M2384
TOOL NAME REMARKS

Alignment Gauge Used for wheel alignment measurement.
Turning Radius Gauge Used for wheel alignment measurement.
Toe-in Gauge Used for toe-in measurement.
Transmission Jack Used for suspension assembly/disassembly.
Bearing Puller Used for removing bushings.
RS-6
WHEEL ALIGNMENT
Rear Suspension
2. Wheel Alignment S201116
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
together with the front. Follow the procedure in
“FS” section “Wheel Alignment” for measurement
and/or adjustment of wheel alignment. <Ref. FS-6,
INSPECTION, Wheel Alignment.>
RS-7
REAR STABILIZER
Rear Suspension
3. Rear Stabilizer S201118 B: INSTALLATION S201118A11
1) Set vehicle on a lift. NOTE:

2) Disconnect ground terminal from battery. 쐌 Install bushing while aligning it with paint mark
3) Jack-up the rear part of the vehicle, support it on stabilizer.
with safety stands (rigid racks). 쐌 Ensure that bushing and stabilizer have the
4) Remove bolts which secure stabilizer link to same identification colors when installing.
rear lateral link.
S4M0356A
S4M0525 (1) Mark stamped on stabilizer

(2) Bushing identification color
5) Remove bolts which secure stabilizer to stabi-
lizer bracket. 2) Always tighten rubber bushing location when
wheels are in full contact with the ground and
vehicle is curb weight.
3) Tightening torque:
Stabilizer to stabilizer link:
45 N·m (4.6 kgf-m, 33 ft-lb)
Stabilizer link to rear lateral link:
45 N·m (4.6 kgf-m, 33 ft-lb)
Stabilizer to stabilizer bracket:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
S4M0526
6) Separate rear stabilizer and stabilizer link.

1) Check bushing for cracks, fatigue or damage.
2) Check stabilizer links for deformities, cracks, or
damage, and bushing for protrusions from the hole
of stabilizer link.
RS-8
REAR TRAILING LINK
Rear Suspension
4. Rear Trailing Link S201107 B: INSTALLATION S201107A11
1) Set vehicle on a lift. CAUTION:
2) Disconnect ground terminal from battery. Always tighten rubber bushing location when
3) Loosen rear wheel nuts. wheels are in full contact with the ground and
4) Jack-up vehicle, and remove rear wheels. vehicle is at curb weight condition.
5) Remove both rear parking brake clamp and NOTE:
ABS sensor harness. (Models equipped with ABS) Check wheel alignment and adjust if necessary.
1. FRONT BUSHING S201107A0601
Using ST, press front bushing out of place.

ST 927720000 INSTALLER & REMOVER SET
S4M0527A
(1) Parking brake cable

(2) ABS sensor harness
6) Remove bolt which secure trailing link to trailing

link bracket.
S4M0103B
S4M0358A
(1) Trailing link
(1) Press
7) Remove bolt which secure trailing link to rear (2) Trailing link
housing.
RS-9
REAR TRAILING LINK
Rear Suspension
2. REAR BUSHING S201107A0602 D: ASSEMBLY S201107A02
1) Remove housing. <Ref. to DS-23, REMOVAL, Assemble in the reverse order of disassembly.
Rear Axle.> for removal procedures.
2) Using ST, press rear bushing out of place. 1. FRONT BUSHING S201107A0201
ST 927730000 INSTALLER & REMOVER SET Using ST, press bushing into trailing link.
ST 927720000 INSTALLER & REMOVER SET
CAUTION:
When installing bushing, turn ST plunger
upside down and press it until plunger end sur-
face contacts trailing link end surface.
S4M0359A
(1) Press
(2) Housing
S4M0360A
(1) Press
(2) Front bushing
(3) Trailing link
CAUTION:
Install front bushing in the proper direction, as
shown in figure.
S4M0361A
(1) Front
RS-10
REAR TRAILING LINK
Rear Suspension
2. REAR BUSHING S201107A0202 E: INSPECTION S201107A10
1) Using ST, press bushing into trailing link. Check trailing links for bends, corrosion or dam-
ST 927730000 INSTALLER & REMOVER SET age.
NOTE:
If it is difficult to press bushing into trailing link,
apply water-diluted TIRE LUBE to the inner surface
of ST as a lubricant.
Specified lubricant:
TIRE LUBE : water = 1 : 3
B4M0224B
(1) Press
2) Install housing. <Ref. to DS-26,

INSTALLATION, Rear Axle.>
RS-11
LATERAL LINK
Rear Suspension
5. Lateral link S201576

8) Remove DOJ from rear differential using ST.
(Except Non-TURBO AT model)
A: REMOVAL S201576A18 ST 28099PA100 DRIVE SHAFT REMOVER
2) Disconnect battery ground terminal from bat- The side spline shaft circlip comes out together
tery. with the shaft.
3) Loosen wheel nuts. Jack-up vehicle and
remove wheel.
4) Remove stabilizers. <Ref. to RS-8, REMOVAL,
Rear Stabilizer.>
5) Remove ABS sensor harness from trailing link.
(Models equipped with ABS)
S4M0362A
(1) Bolt
(2) DOJ
CAUTION:
Be careful not to damage side bearing retainer.
S4M0527A Always use bolt as shown in figure, as support-
ing point for ST during removal.
6) Remove bolt securing trailing link to housing.
9) Remove DOJ from rear differential using tire
lever. (Non-TURBO AT model)
NOTE:
The side spline shaft circlip comes out together
with the shaft.
B4M0573B
(1) Rear housing

(2) Trailing link
7) Remove bolts which secure lateral link assem-

bly to rear housing. S4M0363A
(1) Tire lever
RS-12
LATERAL LINK
Rear Suspension
CAUTION:
When removing the DOJ from the rear
differential, fit tire lever to the bolt as shown in
figure so as not to damage the axle shaft
holder.
S4M0364A
(1) Axle shaft holder
10) Scribe an alignment mark on rear lateral link

adjusting bolt and crossmember.
11) Remove bolts securing front and rear lateral S4M0100B
links to crossmember, detach lateral links.
CAUTION: (1) Bushing A
(2) Bushing B
To loosen adjusting bolt, always loosen nut
(3) Bushing C
while holding the head of adjusting bolt.
(4) Front
B: INSTALLATION S201576A11 (5) Outside of body
Install in the reverse order of removal, observing

the following instructions.
NOTE:
Installation of DOJ to differential; <Ref. to DS-39,
INSTALLATION, Rear Drive Shaft.>
CAUTION:
쐌 Always tighten rubber bushing when wheels
are in full contact with the ground and vehicle
is curb weight.
쐌 Tighten nut when installing adjusting bolt.
쐌 Replace self-locking nut.
NOTE:
Using ST, press bushing out of place.

NOTE:
쐌 Using the following table as a guide, verify the
type of bushings.
쐌 Select ST according to the type of bushings S4M0365A
used.
(1) Press
Bushing ST: INSTALLER & REMOVER SET
(2) Lateral link
Bushing A 927700000
Bushing B 927690000
Bushing C 927700000
RS-13
LATERAL LINK
Rear Suspension
D: ASSEMBLY S201576A02 2) Press ST plunger until bushing flange protrudes

beyond lateral link.
1) Using ST, press bushing into place.
NOTE:
CAUTION: Use the same ST as that used during disassembly.
Select ST according to the type of bushings
used.
NOTE:
쐌 Use the same ST as that used during disassem-
bly.
쐌 If it is difficult to press bushing into trailing link,
apply water-diluted TIRE LUBE to the inner surface
of ST as a lubricant.
Specified lubricant:
TIRE LUBE : water = 1 : 3
B4M0197B
(1) Press
(2) Plunger
(3) Lateral link
(4) Flange
S4M0366A
(1) Press
(2) Bushing
(3) Lateral link
RS-14
LATERAL LINK
Rear Suspension
3) Turn lateral link upside down. Press ST plunger E: INSPECTION S201576A10

in the direction opposite that outlined in the former
procedure until bushing is correctly positioned in Visually check lateral links for damage or bends.
trailing link.
NOTE:
Use the same ST as that used during disassembly.
B4M0198B
(1) Press
(2) Plunger
(3) Lateral link
RS-15
REAR STRUT
Rear Suspension
6. Rear Strut S201132

10) Use a garage jack to support the rear housing.
1) Set vehicle on a lift.

2) Disconnect ground terminal from battery.
3) Depress brake pedal and secure it in that posi-
tion using a wooden block, etc.
4) Remove strut cap of rear quarter trim.
S4M0104
11) Remove nuts securing strut mount to body.
S4M0105B
(1) Strut cap
5) Loosen rear wheel nuts.

6) Jack-up vehicle, and remove rear wheels.
S4M0102
7) Remove brake hose clip.
12) Remove bolts which secure rear strut to hous-
ing.
S4M0528A
(1) Clip
G4M0539
8) Models equipped with rear disc brakes: 13) Remove strut mount.
Remove union bolt from brake caliper.
S4M0106
9) Models equipped with rear drum brakes:

Disconnect brake hose and brake pipe from strut,
and disconnect brake pipe from drum brake.
RS-16
REAR STRUT
Rear Suspension
1) Install strut mount cap. For disassembly of rear strut, refer to procedures
2) Tighten self-locking nut used to secure strut outlined under front strut as a guide. <Ref. to
mount to vehicle body. FS-19, DISASSEMBLY, Front Strut.>
CAUTION:
Use a new self-locking nut. D: ASSEMBLY S201132A02
NOTE: Refer to Front Strut as a guide for assembly pro-

Tighten strut mount and cap as a unit. cedures. <Ref. to FS-20, ASSEMBLY, Front Strut.>
Tightening torque: CAUTION:
20 N·m (2.0 kgf-m, 14.5 ft-lb) 쐌 Install rear strut with “4WD” mark on strut
mount facing outside of vehicle body.
3) Tighten bolts securing rear strut to housing. 쐌 Insert the protrusion of lower rubber seat
Tightening torque: into the strut spring seat hole.
200 N·m (20.4 kgf-m, 148 ft-lb)
CAUTION:
Use a new self-locking nut.
4) Models with rear disc brakes:
Tighten brake hose union bolt on brake caliper.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
Models with rear drum brakes:
Connect brake hose to brake pipe.
S4M0184B
Tightening torque:
15 N·m (1.5 kgf-m, 10.8 ft-lb) (1) Front of vehicle
(2) “4WD” mark
5) Insert brake hose clip between brake hose and
lower side of strut.
CAUTION:
쐌 Check that hose clip is positioned properly.
쐌 Check brake hose for twisting, or excessive
tension.
쐌 Models equipped with ABS:
Do not subject ABS sensor harness to exces-
sive tension.
6) Be sure to bleed air from brake system.
7) Lower vehicle and tighten wheel nut.
Tightening torque:
88 N·m (9 kgf-m, 65 ft-lb)
8) Install strut cap of rear quarter trim.
NOTE:
RS-17
REAR STRUT
Rear Suspension
1) Refer to Front Strut as a guide for inspection procedures. <Ref. to FS-21, INSPECTION, Front Strut.>
2) For models equipped with self leveling struts: Inspect the following.
1 CHECK WHEEL ARCH HEIGHT. Is C less than 30 mm (1.18 Go to step 2. Replace damper
1) Remove all cargo from the vehicle. in)? strut.
2) Fill gasoline tank completely.
3) Drive vehicle (only the driver aboard) for at
least 1 km (0.6 mile).
4) Measure the rear wheel arch height. This is
value “A” in the equation. <Ref. to FS-6,
Wheel Alignment.>
5) Put 4 people in the vehicle.
NOTE:
The total weight of the 4 people should be
approximately 300 kg (662 lb).
6) Drive the vehicle for at least 5 km (3
miles).
7) Stop the vehicle. With the 4 people in the
vehicle, measure the rear wheel arch height.
This value is “B” in the equation.
8) A − B = C
2 CHECK WHEEL ARCH HEIGHT. Is E less than ±10 mm Go to step 3. Replace damper
1) Let the 4 people get off of the vehicle. (0.39 in)? strut.
2) Drive the vehicle (only the driver aboard)
for at least 1 km (0.6 mile).
3) Measure the rear wheel arch height. This is
value “D” in the equation.
4) A − D = E
3 CHECK VEHICLE. Is it a non-turbo vehicle? Go to step 4. Go to step 5.
4 CHECK WHEEL ARCH HEIGHT. Is E less than 435+12/−24 Correct. Replace coil
mm (17.13+0.47/−0.94 in)? spring.
5 CHECK WHEEL ARCH HEIGHT. Is E less than 425+12/−24 Correct. Replace coil
mm (16.73+0.47/−0.94 in)? spring.
RS-18
REAR STRUT
Rear Suspension
F: DISPOSAL S201132A07
CAUTION:
쐌 Completely discharge the gas from the
green-painted struts on outer housings, before
disposal. Follow the disposal procedure out-
lined below.
쐌 Do not disassemble strut damper or place
into a fire.
쐌 Drill holes before disposing of self leveling
struts.
쐌 Before handling self leveling struts, be sure
to wear goggles to protect eyes from gas, oil
and/or filings.
1) Place self leveling strut upside-down (the oppo-
site of its installation position on the vehicle) on a
flat surface.
2) Using a 2 to 3 mm (0.08 to 0.12 in) dia. drill, drill
30 mm (1.18 in) deep holes in areas shown in the
figure.
S4M0229B
(1) Self leveling strut
RS-19
REAR CROSSMEMBER
Rear Suspension
7. Rear Crossmember S201133 B: INSTALLATION S201133A11
2) For installation and tightening torque of rear
CAUTION: differential, always tighten rubber bushing when
Do not subject ABS sensor harness to exces- wheels are in full contact with the ground and
sive tension. (Models equipped with ABS) vehicle is curb weight.
2) Disconnect ground terminal from battery. Check wheel alignment and adjust if necessary.
3) Loosen wheel nuts. Jack-up vehicle and
remove wheels.
4) Separate front exhaust pipe and rear exhaust Check removed parts for wear, damage and
pipe. (Non-turbo model) cracks, and correct or replace if defective.
5) Separate center exhaust pipe (rear) and rear
exhaust pipe. (Turbo model)
6) Remove rear exhaust pipe and muffler.
7) Remove rear differential.
T-Type: <Ref. to DI-25, Rear Differential for
T-type.>
VA-Type: <Ref. to DI-42, Rear Differential for VA-
type.>
8) Place transmission jack under rear crossmem-
ber.
G4M0544
9) Remove bolts securing crossmember to vehicle

body, and remove crossmember.
G4M0545
10) Scribe an alignment mark on rear lateral link

cam bolt and crossmember.
11) Remove front and rear lateral links by loosen-
ing nuts.
RS-20
Rear Suspension
1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT S201257A1001

(1) Permanent distortion or breakage of coil spring Replace.
(2) Unsmooth operation of damper strut Replace.
(3) Installation of wrong strut Replace with proper parts.
(4) Installation of wrong coil spring Replace with proper parts.
2. POOR RIDE COMFORT S201257A1002
1) Large rebound shock

2) Rocking of vehicle continues too long after running over bump and/or hump.
3) Large shock in bumping
(2) Overinflation pressure of tire Adjust.
(3) Improper wheel arch height Adjust or replace coil springs with new ones.
(4) Fault in operation of damper strut Replace.
(5) Damage or deformation of strut mount Replace.
(6) Unsuitability of maximum and/or minimum length of Replace with proper parts.
damper strut
(8) Deformation or damage of helper in strut assembly Replace.
(9) Oil leakage of damper strut Replace.
3. NOISE S201257A1003

(1) Wear or damage of damper strut component parts Replace.
(2) Loosening of suspension link installing bolt Retighten to the specified torque.
(4) Unsuitability of maximum and/or minimum length of Replace with proper parts.
damper strut
(6) Wear or damage of ball joint Replace.
(7) Deformation of stabilizer clamp Replace.
RS-21
Rear Suspension
MEMO:
RS-22
CHASSIS SECTION

SUBARU vehicles.
ine parts.

G8050GE5
WHEEL AND TIRE SYSTEM
WT
Page
2. Tire ..............................................................................................................4
3. Steel Wheel .................................................................................................5
4. Aluminum Wheel .........................................................................................6
5. Wheel Balancing .........................................................................................7
6. General Diagnostics Table ..........................................................................8
GENERAL DESCRIPTION
Wheel and Tire System
S4M0367A
(1) Offset
(2) P.C.D.
Model Tire size Rim size Rim offset P.C.D.

P205/70R15 95S 15 × 6J
Australia model 48 mm (1.89 in)
P215/60R16 94H 16 × 6 1/2JJ
Front and Rear 100 mm (3.94 in) dia.
205/70R15 95H 15 × 6J
Except Australia model 48 mm (1.89 in)
215/60R16 95V 16 × 6 1/2JJ
Tire inflation pressure

Model Tire size
Light load Full load
P205/70R15 95S
Australia model
P215/60R16 94H Ft: 200 kPa (2.0 kg/cm2, 29 psi) Ft: 200 kPa (2.0 kg/cm2, 29 psi)
205/70R15 95H Rr: 190 kPa (1.9 kg/cm2, 28 psi) Rr: 250 kPa (2.5 kg/cm2, 36 psi)
Except Australia model
215/60R16 95V
NOTE:
쐌 Spare tires are the same for both front and rear.
쐌 At trailer towing, rear inflation pressure is 280 kPa (2.8 kg/cm2, 41 psi).
WT-2
GENERAL DESCRIPTION
1. SERVICE DATA S204001E4901 B: PREPARATION TOOL S204001A17
Item Axial runout Radial runout 1. GENERAL PURPOSE TOOLS S204001A1701
Steel wheel 1.5 mm (0.059 in)

TOOL NAME REMARKS
Aluminum wheel 1.0 mm (0.039 in)
Air Pressure Gauge Used for measuring tire air pressure.
2. ADJUSTING PARTS S204001E4902 Dial Gauge Used for measuring wheel runout.
Wheel balancing Standard Service limit

Dynamic unbalance Less than 5 g (0.18 oz)
Balance weight part number

Weight
(For steel wheel)
28101FC000 5 g (0.18 oz)
28101FC010 10 g (0.35 oz)
28101FC020 15 g (0.53 oz)
723141320 20 g (0.71 oz)
723141330 25 g (0.88 oz)
723141340 30 g (1.06 oz)
723141350 35 g (1.23 oz)
723141360 40 g (1.41 oz)
723141370 45 g (1.59 oz)
723241380 50 g (1.76 oz)
723241580 55 g (1.94 oz)
723241590 60 g (2.12 oz)

Weight
(For aluminum wheel)
23141GA462 5 g (0.18 oz)
23141GA472 10 g (0.35 oz)
23141GA482 15 g (0.53 oz)
23141GA492 20 g (0.71 oz)
23141GA502 25 g (0.88 oz)
23141GA512 30 g (1.06 oz)
23141GA522 35 g (1.23 oz)
23141GA532 40 g (1.41 oz)
23141GA542 45 g (1.59 oz)
23141GA552 50 g (1.76 oz)
— 55 g (1.94 oz)
23141GA572 60 g (2.12 oz)
WT-3
TIRE
2. Tire S204125
1) Take stone, glass, nail etc. off the tread groove.

2) Replace tire:
CAUTION:
쐌 When replacing a tire, make sure to use only
the same size, construction and load range as
originally installed.
쐌 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.
S4M0377A
(1) Tread wear indicator

(2) Tire tread
1. TIRE ROTATION S204125A1001
If tires are maintained at the same positions for a

long period of time, uneven wear results.
Therefore, they should be periodically rotated.
This lengthens service life of tires.
CAUTION:
When rotating tires, replace unevenly worn or
damaged tires with new ones.
B4M1765
WT-4
STEEL WHEEL
3. Steel Wheel S204131 C: INSPECTION S204131A10
1) Deformation or damage on the rim can cause
air leakage. Check the rim flange for deformation,
1) Apply parking brake, and position select lever crack, or damage, and repair or replace as neces-
to “P” or “LOW”. sary.
2) Set shop jacks or a lift to the specified point, 2) Jack-up vehicle until wheels clear the floor.
and support the vehicle with its wheels slightly con- 3) Slowly rotate wheel to check rim “runout” using
tacting the floor. a dial gauge.
3) Loosen wheel nuts.
4) Raise the vehicle until its wheels take off the
ground using a jack or a lift.
5) Remove wheel nuts and wheels.
NOTE:
쐌 While removing wheels, prevent hub bolts from
damage.
쐌 Place wheels with their outer sides facing
upward to prevent wheels from damage.
G4M0298
1) Attach the wheel to the hub by aligning the
wheel bolt hole with the hub bolt.
Axial runout limit Radial runout limit
2) Temporarily attach the wheel nuts to the hub
1.5 mm (0.059 in)
bolts. (In the case of aluminum wheel, use
SUBARU 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 the specified torque. Use a wheel nut wrench.
Wheel nut tightening torque:
88 N·m (9 kgf-m, 65 ft-lb)
CAUTION:
쐌 Tighten the wheel nuts in two or three steps G4M0299
by gradually increasing the torque and working
diagonally, until the specified torque is 4) If rim runout exceeds specifications, remove
reached. For drum brake models, excess tight- tire from rim and check runout while attaching dial
ening of wheel nuts may cause wheels to “jud- gauge to positions shown in figure.
der”. 5) If measured runout still exceeds specifications,
쐌 Do not depress the wrench with a foot; replace the wheel.
Always use both hands when tightening.
쐌 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
repair of a puncture, retighten the wheel nuts to the
specified torque after running 1,000 km (600
miles).
WT-5
ALUMINUM WHEEL
4. Aluminum Wheel S204130
Refer to Steel Wheel for removal procedure of alu-

minum wheels. <Ref. to WT-5 REMOVAL Steel
Wheel.>
B: INSTALLATION A204130A11
Refer to Steel Wheel for installation procedure of

aluminum wheels. <Ref. to WT-5 INSTALLATION,
Steel Wheel.>
Refer to Steel Wheel for inspection procedure of

aluminum wheels. <Ref. to WT-5 INSPECTION,
Steel Wheel.>
Rim runout:
Axial runout limit Radial runout limit
1.0 mm (0.039 in)
D: CAUTION S204130A03
Aluminum wheels are easily scratched. To main-

tain their appearance and safety, do the following:
1) Do not damage aluminum wheels during
removal, disassembly, installation, wheel
balancing, etc. After removing aluminum wheels,
place them on a rubber mat, etc.
2) While vehicle is being driven, be careful not to
ride over sharp obstacles or allow aluminum
wheels to contact the shoulder of the road.
3) When installing tire chain, be sure to install it
properly not to have a slack; otherwise it may hit
wheel while driving.
4) When washing aluminum wheel, use neutral
synthetic detergent and water. Avoid using the
cleanser including abrasive, hard brushes or an
automatic car washer.
WT-6
WHEEL BALANCING
5. Wheel Balancing S204127 B: INSPECTION S204127A10
1) Proper wheel balance may be lost if the tire is
repaired or if it wears. Check the tire for dynamic
1) Remove balance weights. balance, and repair as necessary.
2) Using dynamic balancing, measure wheel bal- 2) To check for dynamic balance, use a dynamic
ance. 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
Weight adjusting the wheel balance.
(For steel wheel)
4) Use genuine balance weights.
28101FC000 5 g (0.18 oz)
28101FC010 10 g (0.35 oz) CAUTION:
28101FC020 15 g (0.53 oz)
쐌 55 g (1.94 oz) weight used with aluminum
wheel is not available.
723141320 20 g (0.71 oz)
쐌 Balance weights are available for use with
723141330 25 g (0.88 oz)
any of 14- to 16-inch wheels.
723141340 30 g (1.06 oz)
723141350 35 g (1.23 oz)
723141360 40 g (1.41 oz)
723141370 45 g (1.59 oz)
723241380 50 g (1.76 oz)
723241580 55 g (1.94 oz)
723241590 60 g (2.12 oz)

Weight
(For aluminum wheel)
23141GA462 5 g (0.18 oz)
23141GA472 10 g (0.35 oz)
23141GA482 15 g (0.53 oz)
23141GA492 20 g (0.71 oz)
23141GA502 25 g (0.88 oz)
23141GA512 30 g (1.06 oz)
23141GA522 35 g (1.23 oz)
23141GA532 40 g (1.41 oz)
23141GA542 45 g (1.59 oz)
23141GA552 50 g (1.76 oz)
— 55 g (1.94 oz)
23141GA572 60 g (2.12 oz) B4M0053B
4) Install the selected weight to the point desig- (1) Weight for aluminum wheel
nated by dynamic balancing. (2) Weight for steel wheel
5) Using dynamic balancing, measure wheel bal- Service limit: A
ance again. Check that wheel balance is correctly Weight for steel wheel;
adjusted. 1.8 — 2.0 mm (0.071 — 0.079 in)
Weight for aluminum wheel;
4.6 — 5.4 mm (0.181 — 0.213 in)
WT-7
GENERAL DIAGNOSTICS TABLE
6. General Diagnostics Table S204121
Symptom Possible cause Remedy

Front wheel shimmy 쐌 Worn or improperly inflated of tire. Replace
쐌 Wheel is out of balance. Adjustment
Abnormal tire wear 쐌 Improperly inflated of tire. Replace
Sways/pitches 쐌 Worn or improperly inflated of tire. Replace
Wander/pulls 쐌 Worn or improperly inflated of tire. Replace
WT-8
CHASSIS SECTION

SUBARU vehicles.
ine parts.

G8050GE5
DIFFERENTIALS
DI
Page
2. Differential Gear Oil...................................................................................22
3. Front Differential........................................................................................24
4. Rear Differential for T-type ........................................................................25
5. Rear Differential for VA-type .....................................................................42
6. Rear Differential Front Oil Seal.................................................................59
7. Rear Differential Side Oil Seal ..................................................................61
8. Rear Differential Member ..........................................................................66
GENERAL DESCRIPTION
Differentials
Non-Turbo Turbo
Except Europe
Model MT AT Europe
MT AT
T type VA type T type (with LSD)
HP (with oil tem-
Rear differential type T2 XH CF JP
perature sensor)
Gear Hypoid gear
Gear ratio 4.111 (37/9) 4.444 (40/9)
Oil capacity 0.8 L (0.8 US qt, 0.7 Imp qt)
Rear differential gear oil GL-5
쐌 Identification
When replacing a rear differential assembly, select
the correct one according to the following table.
CAUTION:
Using the different rear differential assembly
causes the drive line and tires to “drag” or emit
abnormal noise when AWD is selected.
S3M0613
DI-2
GENERAL DESCRIPTION
Differentials
쐌 Rear differential gear oil

Recommended oil
CAUTION:
Each oil manufacturer has its base oil and addi-
H3M1272A
1. SERVICE DATA S303001E4901
T-type 19.6 — 28.4 (2.0 — 2.9, 4.4 — 6.4)

Front and rear bearing preload at companion New bearing
VA-type 12.7 — 32.4 (1.3 — 3.3, 2.9 — 7.3)
flange bolt hole N (kgf, lb)
Used bearing T-type 8.34 — 16.67 (0.85 — 1.7, 1.87 — 3.75)
T-type 0.10 — 0.20 (0.0039 — 0.0079)
Side gear backlash mm (in)
VA-type 0.05 — 0.15 (0.0020 — 0.0059)
Side bearing standard width mm (in) 20.00 (0.7874)
T-type 0.10 — 0.20 (0.0039 — 0.0079)
Crown gear to drive pinion backlash mm (in)
VA-type 0.10 — 0.15 (0.0039 — 0.0059)
Crown gear runout on its back surface mm (in) Less than 0.05 (0.0020)
DI-3
GENERAL DESCRIPTION
Differentials
2. ADJUSTING PARTS S303001E4902
쐌 VA-type
Item Part No. Length or thickness
32288AA040 52.3 mm (2.059 in)
32288AA050 52.5 mm (2.067 in)
31454AA100 52.6 mm (2.071 in)
32288AA060 52.7 mm (2.075 in)
Preload adjusting spacer 31454AA110 52.8 mm (2.079 in)
32288AA070 52.9 mm (2.083 in)
31454AA120 53.0 mm (2.087 in)
32288AA080 53.1 mm (2.091 in)
32288AA090 53.3 mm (2.098 in)
38336AA000 1.500 mm (0.0591 in)
38336AA120 1.513 mm (0.0596 in)
38336AA010 1.525 mm (0.0600 in)
38336AA130 1.538 mm (0.0606 in)
38336AA020 1.550 mm (0.0610 in)
38336AA140 1.563 mm (0.0615 in)
38336AA030 1.575 mm (0.0620 in)
38336AA150 1.588 mm (0.0625 in)
38336AA040 1.600 mm (0.0630 in)
38336AA160 1.613 mm (0.0635 in)
38336AA050 1.625 mm (0.0640 in)
Preload adjusting washer 38336AA170 1.638 mm (0.0645 in)
38336AA060 1.650 mm (0.0650 in)
38336AA180 1.663 mm (0.0655 in)
38336AA070 1.675 mm (0.0659 in)
38336AA190 1.688 mm (0.0665 in)
38336AA080 1.700 mm (0.0669 in)
38336AA200 1.713 mm (0.0674 in)
38336AA090 1.725 mm (0.0679 in)
38336AA210 1.738 mm (0.0684 in)
38336AA100 1.750 mm (0.0689 in)
38336AA220 1.763 mm (0.0694 in)
38336AA110 1.775 mm (0.0699 in)
32295AA200 0.150 mm (0.0059 in)
32295AA210 0.175 mm (0.0069 in)
32295AA220 0.200 mm (0.0079 in)
Pinion height adjusting shim
32295AA230 0.225 mm (0.0089 in)
32295AA240 0.250 mm (0.0098 in)
32295AA250 0.275 mm (0.0108 in)
0.925 — 0.950 mm
803135011
(0.0364 — 0.0374 in)
0.950 — 0.975 mm
803135012
(0.0374 — 0.0384 in)
0.975 — 1.000 mm
Side gear thrust washer 803135013
(0.0384 — 0.0394 in)
1.000 — 1.025 mm
803135014
(0.0394 — 0.0404 in)
1.025 — 1.050 mm
803135015
(0.0404 — 0.0413 in)
DI-4
GENERAL DESCRIPTION
Differentials
쐌 T-type

383695201 56.2 mm (2.213 in)
383695202 56.4 mm (2.220 in)
383695203 56.6 mm (2.228 in)
Preload adjusting spacer
383695204 56.8 mm (2.236 in)
383695205 57.0 mm (2.244 in)
383695206 57.2 mm (2.252 in)
383705200 2.59 mm (0.1020 in)
383715200 2.57 mm (0.1012 in)
383725200 2.55 mm (0.1004 in)
383735200 2.53 mm (0.0996 in)
383745200 2.51 mm (0.0988 in)
383755200 2.49 mm (0.0980 in)
383765200 2.47 mm (0.0972 in)
Preload adjusting washer 383775200 2.45 mm (0.0965 in)
383785200 2.43 mm (0.0957 in)
383795200 2.41 mm (0.0949 in)
383805200 2.39 mm (0.0941 in)
383815200 2.37 mm (0.0933 in)
383825200 2.35 mm (0.0925 in)
383835200 2.33 mm (0.0917 in)
383845200 2.31 mm (0.0909 in)
383495200 3.09 mm (0.1217 in)
383505200 3.12 mm (0.1228 in)
383515200 3.15 mm (0.1240 in)
383525200 3.18 mm (0.1252 in)
383535200 3.21 mm (0.1264 in)
383545200 3.24 mm (0.1276 in)
383555200 3.27 mm (0.1287 in)
383565200 3.30 mm (0.1299 in)
383575200 3.33 mm (0.1311 in)
383585200 3.36 mm (0.1323 in)
383595200 3.39 mm (0.1335 in)
383605200 3.42 mm (0.1346 in)
383615200 3.45 mm (0.1358 in)
383625200 3.48 mm (0.1370 in)
383635200 3.51 mm (0.1382 in)
383645200 3.54 mm (0.1394 in)
383655200 3.57 mm (0.1406 in)
383665200 3.60 mm (0.1417 in)
383675200 3.63 mm (0.1429 in)
383685200 3.66 mm (0.1441 in)
383445201 0.75 — 0.80 mm (0.0295 — 0.0315 in)
383445202 0.80 — 0.85 mm (0.0315 — 0.0335 in)
Side gear thrust washer 383445203 0.85 — 0.90 mm (0.0335 — 0.0354 in)
383445204 0.90 — 0.95 mm (0.0354 — 0.0374 in)
383445205 0.95 — 1.0 mm (0.0374 — 0.0394 in)
DI-5
GENERAL DESCRIPTION
Differentials

383475201 0.20 mm (0.0079 in)
383475202 0.25 mm (0.0098 in)
Side bearing retainer shim 383475203 0.30 mm (0.0118 in)
383475204 0.40 mm (0.0157 in)
383475205 0.50 mm (0.0197 in)
DI-6
GENERAL DESCRIPTION
Differentials
1. REAR DIFFERENTIAL FOR T-TYPE WITHOUT LSD S303001A0501
B3M0130C
(1) Pinion crown gear set (13) Side bearing (26) Stud bolt
(2) Pinion height adjusting washer (14) O-ring (27) Oil filler plug
(3) Rear bearing (15) Side bearing retainer shim (28) Oil drain plug
(4) Bearing preload adjusting spacer (16) Side bearing retainer (29) Rear cover
(5) Bearing preload adjusting (17) Side oil seal (30) Differential case
washer (18) Side gear thrust washer
(6) Differential carrier (19) Side gear Tightening torque: N·m (kgf-m, ft-lb)
(7) Front bearing (20) Pinion mate gear T1: 10.3 (1.05, 7.6)
(8) Spacer (21) Pinion mate gear washer T2: 29.4 (3.00, 21.7)
(9) Pilot bearing (22) Pinion shaft lock pin T3: 49.0 (5.0, 36.2)
(10) Front oil seal (23) Circlip T4: 103.0 (10.50, 75.9)
(11) Companion flange (24) Pinion mate shaft T5: 181.4 (18.50, 133.8)
(12) Self-locking nut (25) Air breather cap
DI-7
GENERAL DESCRIPTION
Differentials
2. REAR DIFFERENTIAL FOR T-TYPE

WITH LSD S303001A0502
S3M0643A
(1) Pinion crown gear set (12) Self-locking nut (23) Oil filler plug (With oil tempera-
(2) Pinion height adjusting shim (13) Side bearing ture sensor)
(3) Rear bearing (14) O-ring (24) Oil filler plug (Without oil tem-
(4) Bearing preload adjusting spacer (15) Side bearing retainer shim perature sensor)
(5) Bearing preload adjusting (16) Side bearing retainer (25) Oil drain plug
washer (17) Side oil seal
(6) Differential carrier (18) Gasket Tightening torque: N·m (kgf-m, ft-lb)
(7) Front bearing (19) Differential case T1: 10.3 (1.05, 7.6)
(8) Collar (20) Rear cover T2: 29 (3.0, 21.7)
(9) Pilot bearing (21) Air breather cap T3: 49.0 (5.0, 36.2)
(10) Front oil seal (22) Stud bolt T4: 103 (10.5, 76)
(11) Companion flange T5: 181 (18.5, 134)
DI-8
GENERAL DESCRIPTION
Differentials
3. REAR DIFFERENTIAL FOR VA-TYPE

S303001A0503
H3M1663A
(1) Pinion crown gear set (13) Lock plate (26) Gasket
(2) Pinion height adjusting shim (14) Side bearing (27) Oil filler plug
(3) Rear bearing (15) O-ring (28) Oil drain plug
(4) Bearing preload adjusting spacer (16) Axle shaft holder (29) Rear cover
(5) Bearing preload adjusting (17) Side oil seal
washer (18) Side gear thrust washer Tightening torque: N·m (kgf-m, ft-lb)
(6) Differential carrier (19) Side gear T1: 25 (2.5, 18.1)
(7) Front bearing (20) Pinion mate gear T2: 25 (2.5, 18.1)
(8) Collar (21) Pinion shaft lock pin T3: 34 (3.5, 25.3)
(9) Pilot bearing (22) Differential case T4: 62 (6.3, 45.6)
(10) Front oil seal (23) Pinion mate shaft T5: 188 (19.2, 139)
(11) Companion flange (24) Air breather cap
(12) Self-locking nut (25) Stud bolt
DI-9
GENERAL DESCRIPTION
Differentials
4. REAR DIFFERENTIAL MOUNTING

SYSTEM S303001A0504
S3M0231A
(1) Differential front member (8) Differential mount bracket Tightening torque: N·m (kgf-m, ft-lb)
(2) Plate (9) Dynamic damper A
T1: 20 (2.0, 14.5)
(3) Crossmember (10) Mass damper (Turbo model)
T2: 32 (3.3, 23.9)
(4) Rear bushing (11) Dynamic damper B (Non-Turbo
T3: 40 (4.1, 30)
(5) Differential mount lower bracket model)
(Non-Turbo model) (12) Differential mount front cover T4: 64 (6.5, 47.0)
(6) Differential mount lower bracket T5: 69 (7.0, 50.6)
(Turbo model) T6: 69 (7.0, 50.6)
(7) Stopper T7: 88 (9.0, 65)
T8: 98 (10.0, 72)
DI-10
GENERAL DESCRIPTION
Differentials

tion.
ment.
쐌 Be careful not to burn your hands, because each
part on the vehicle is hot after running.
쐌 Use SUBARU genuine gear oil, grease etc. or
the equivalent. Do not mix gear oil, grease etc. with
that of another grade or from other manufacturers.
fied points.
쐌 Apply gear oil onto sliding or revolution surfaces
sufficient amount of gear oil to avoid damage and
deformation.
쐌 Avoid damaging the mating face of the case.
DI-11
GENERAL DESCRIPTION
Differentials

398477701 HANDLE Used for installing front and rear bearing cone.
B3M1893
398477702 DRIFT Used press-fitting the bearing cone of differen-
tial carrier (rear).
B3M1894
398217700 ATTACHEMENT Stand for rear differential carrier disassembly
SET and assembly.
B3M1895
498447120 OIL SEAL Used for installing front oil seal.
INSTALLER
B3M1896
DI-12
GENERAL DESCRIPTION
Differentials

498427200 FLANGE WRENCH Used for stopping rotaiotn of companion flange
when loosening and tightening self-lock nut.
B3M1897
398467700 DRIFT Used for removing pinion, pilot bearing and
front bearing cone.
B3M1898
399780104 WEIGHT Used for installing front bearing cone, pilot
bearing companion flange.
B3M1899
899580100 INSTALLER Used for press-fitting the front bearing cone,
pilot bearing.
B3M1900
899904100 STRAIGHT PIN Used for driving out differential pinion shaft lock
REMOVER pin.
B3M1901
DI-13
GENERAL DESCRIPTION
Differentials

399703600 PULLEY ASSY 쐌 Used for removing companion flange.
B3M1930
498247001 MAGENT BASE 쐌 Used for measuring backlash between side
gear and pinion, and hypoid gear..
쐌 Used with DIAL GAUGE (498247100).
B3M1902
498247100 DAIL GAUGE 쐌 Used measurng backlash between side gear
and pinion, hypoid gear.
쐌 Used with MAGNET BASE (498247001).
B3M1903
398507704 BLOCK Used for adjusting pinion height and preload.
B3M1904
DI-14
GENERAL DESCRIPTION
Differentials

398177700 INSTALLER 쐌 Used for installing rear bearing cone.
쐌 For T-type.
B3M1905
398457700 ATTACHMENT 쐌 Used for removing side bearing retainer.
쐌 For T-type.
B3M1906
398477703 DRIFT2 쐌 Used forpress-fitting the bearing race (rear)
of differential carrier.
쐌 For T-type.
B3M1907
398437700 DRIFT 쐌 Used for installing said oil seal.
쐌 For T-type.
B3M1908
DI-15
GENERAL DESCRIPTION
Differentials

398507702 DUMMY SHAFT 쐌 Used for adjusting pinion height and preload.
쐌 For T-type.
B3M1909
398507703 DUMMY COLLAR 쐌 Used for adjusting pinion height and preload.
쐌 For T-type.
B3M1910
398517700 REPLACER 쐌 Used for removing rear bearing cone.
쐌 For T-type.
B3M1911
398487700 DRIFT 쐌 Used for press-fitting the side bearing cone.
쐌 For T-type.
B3M1912
398507701 GAUGE 쐌 Used for adjusting pinion height.
쐌 For T-type.
B3M1913
DI-16
GENERAL DESCRIPTION
Differentials

398527700 PULLER ASSY 쐌 Used for removing oil seal and side bearing
cup.
쐌 For T-type.
B3M1914
399527700 PULLER SET 쐌 Used for extracking side bearing cone.
(1) BOLT (899521412)
(2) PULLER (399527702)
(3) HOLDER (399527703)
(4) ADAPTER (398497701)
(5) BOLT (899520107)
(6) NUT (021008000)
쐌 For T-type.
B3M1915A
28099PA090 OIL SEAL PROTEC- 쐌 Used for installing rear drive shaft into rear
TOR differential.
쐌 For protecting oil seal.
쐌 For T-type.
B3M1917
28099PA100 DRIVE SHAFT 쐌 Used for removing rear drive shaft from rear
REMOVER differential.
쐌 For T-type.
B3M1919
DI-17
GENERAL DESCRIPTION
Differentials

498175500 INSTALLER 쐌 Used for installing rear bearing cone.
쐌 For VA-type.
B3M1920
399780111 WRENCH ASSY 쐌 Used for removing and installing side oil seal
holder.
쐌 For VA-type.
B3M1921
498447100 INSTALLER 쐌 Used for installing oil seal.
쐌 For VA-type.
B3M1922
399520105 SEAT 쐌 Used for removing side bearing cone.
쐌 Used with PULLER SET (899524100).
쐌 For VA-type.
B3M1923
DI-18
GENERAL DESCRIPTION
Differentials

498485400 DRIFT 쐌 UUsed for installing side bearing cone.
쐌 For VA-type.
B3M1924
498505501 GAUGE 쐌 Used for adjusting pinion height.
쐌 For VA-type.
B3M1925
498447110 BEARING OUTER 쐌 Used for press-fitting the bearing race (front)
RACE DRIFT of differential carrier.
쐌 For VA-type.
B3M1926
498447150 DUMMY SHAFT 쐌 Used for adjusting pinion height and Pre-
load.
쐌 For VA-type.
B3M1927
DI-19
GENERAL DESCRIPTION
Differentials

32285AA000 DUMMY COLLAR 쐌 Used for adjusting pinion height and Pre-
load.
쐌 For VA-type.
B3M1928
499705404 SEAT 쐌 Used for removing side bearing race.
쐌 Used with PULLEY ASSY (499705401).
쐌 For VA-type.
B3M1929
499705401 PULLEY ASSY 쐌 Used for removing side bearing race.
쐌 Used with SEAT (499705404).
쐌 For VA-type.
B3M1930
899874100 INSTALLER 쐌 Used for installing companion flange.
쐌 For VA-type.
B3M1931
899524100 DIFFERENTIAL 쐌 Used for removing side bearing cone of dif-
BEARING PULLER ferential.
SET 쐌 For VA-type.
(1) Puller
(2) Cap
쐌 Used with SEAT (399520105)
B3M1932A
DI-20
GENERAL DESCRIPTION
Differentials
TOOL NAME REMERKS

Transmission Jack Used for assembly/disassembly of rear differential.
Puller Used for removal of side bearing retainer. (T-type)
Thickness Gauge Used for measuring clearance.
Tire Lever Used for removal of rear drive shaft. (VA-type)
DI-21
DIFFERENTIAL GEAR OIL
Differentials
2. Differential Gear Oil S303150 B: REPLACEMENT S303150A20
2) Jack-up vehicle and support it with sturdy
1) Set vehicle on a lift. racks.
2) Disconnect ground terminal from battery. 3) Disconnect oil temperature sensor connector
3) Lift vehicle. (Turbo model for Europe).
4) Disconnect oil temperature sensor connector
(Turbo model for Europe).
S3M0615A
S3M0615A (A) Connector
(A) Connector 4) Remove the oil drain plug and filler plug, and
drain the gear oil.
5) Take out filler plug, and replace gear oil if it is
contaminated or deteriorated. <Ref. to DI-22 CAUTION:
REPLACEMENT, Differential Gear Oil.> Be careful not to burn your hands, because
6) Check gear oil level is up to the bottom part of gear oil becomes extremely hot after running.
filler bolt. If the level is low, refill up to the bottom
of filler bolt.
B3M0136B
(A) Filler plug

S3M0527A (B) Drain plug
(A) Filler plug 5) Tighten oil drain plug.

(B) Drain plug
CAUTION:
쐌 Apply fluid packing to drain plug in T-type.
Fluid packing:
Tightening torque:
T-type;
49.0 N·m (5.0 kgf-m, 36.2 ft-lb)
VA-type;
34 N·m (3.5 kgf-m, 25.3 ft-lb)
DI-22
Differentials
6) Fill differential carrier with gear oil to the upper

plug level.
CAUTION:
Carefully refill oil while watching the level.
Excess or insufficient oil must be avoided.
Oil capacity:
0.8 (0.8 US qt, 0.7 Imp qt)
S3M0527A
(A) Filler plug

(B) Drain plug
7) Install filler plug.

CAUTION:
Fluid packing:
Tightening torque:
T-type;
49.0 N·m (5.0 kgf-m, 36.2 ft-lb)
VA-type;
34 N·m (3.5 kgf-m, 25.3 ft-lb)
8) Connect oil temperature sensor connector.
DI-23
FRONT DIFFERENTIAL
Differentials
3. Front Differential S303152
A: NOTE S303152A15
1. AT MODEL S303152A1501
Refer to AUTOMATIC TRANSMISSION in sepa-

rate publication “AUTOMATIC TRANSMISSION for
Front Differential. (Pub No. G0853ZE)
2. MT MODEL S303152A1502
For front differential of manual transmission, refer

to “MT” section. <Ref. to MT-92, Front Differential
Assembly.>
DI-24
REAR DIFFERENTIAL FOR T-TYPE
Differentials
4. Rear Differential for T-type 12) Remove heat sealed cover.

S303145

3) Move select lever or gear shift lever to “N”.
4) Release the parking brake.
racks.
S2M0166
7) Remove wheels.
8) Remove rear exhaust pipe and muffler. 13) Remove clamps and bracket of parking brake
Non-turbo model with OBD: cable.
<Ref. to EX(SOHC)-9, REMOVAL, Rear Exhaust
Pipe.> and <Ref. to EX(SOHC)-11, REMOVAL,
Muffler.>
Non-turbo model without OBD:
<Ref. to EX(SOHCw/oOBD)-10, REMOVAL, Rear
Exhaust Pipe.> and <Ref. to EX(SOHCw/oOBD)-
12, REMOVAL, Muffler.>
Turbo model:
<Ref. to EX(DOHC TURBO)-14, REMOVAL, Rear
Exhaust Pipe.> and <Ref. to EX(DOHC TURBO)-
15, REMOVAL, Muffler.> S2M0191
9) Remove front exhaust cover. (Non-Turbo
model) 14) Disconnect connector from oil temperature
sensor. (Turbo model for Europe)
S3M0502
S3M0615A
10) Remove front cover of rear differential mount.
(A) Connector
S3M0503
11) Remove propeller shaft.

<Ref. to DS-14, REMOVAL, Propeller Shaft.>
DI-25
Differentials
15) Remove DOJ of rear drive shaft from rear dif- 18) Support rear differential with transmission
ferential using ST. <Ref. to DS-38, REMOVAL, jack.
Rear Drive Shaft.>
ST 28099PA100 DRIVE SHAFT REMOVER
S3M0505
H3M1179B
19) Remove self-locking nuts connecting rear dif-
ferential to rear crossmember.
(A) Bolt
(B) DOJ
16) Secure rear drive shaft to rear crossmember

using wire.
G3M1028
20) Remove bolts which secure rear differential

front member to body.
(1) Loosen bolt A first, then remove bolts B.
S3M0500
NOTE:
17) Remove lower differential bracket. Support front member with a help of an assistant
to prevent it from dropping.
S3M0529
B3M0657C
(A) Bolt A
(B) Bolt B
(2) Remove bolt A.
DI-26
Differentials
21) While slowly lowering transmission jack, move B: INSTALLATION S303145A11

rear differential forward and remove bolts from rear
crossmember. To install, reverse the removal sequence.
22) Remove front member from body. 1) Install the air breather cap tapping with a plas-
tic hammer.
CAUTION:
Be sure to install new air breather cap.
2) Position front member on body by passing it
under parking brake cable and securing to rear
differential.
NOTE:
When installing rear differential front member, do
not confuse the installation sequence of the upper
and lower stoppers.
G3M1029
3) Install DOJ of rear drive shaft into rear differen-
23) Remove rear differential from body. tial.
ST 28099PA090 SIDE OIL SEAL PROTEC-
TOR
G3M1030
G3M1026

5) After installing rear differential carrier on
vehicle, remove filler plug and replenish gear oil
up. <Ref. to DI-22, Differential Gear Oil.>
6) Connect connector to rear differential tempera-
ture sensor. (Turbo model for Europe)
7) If the results of the following inspections are not
satisfactory, check rear differential temperature
sensor and circuit. Then repair or replace if neces-
sary.
(1) Check that rear differential temperature
sensor warning light lights up when ignition
switch is turned to on (engine stopped).
(2) Start engine, then check that the warning
light goes off after a few seconds.
DI-27
Differentials
C: DISASSEMBLY S303145A06 4) Remove rear cover by loosening retaining

bolts.
To detect real cause of trouble, inspect the follow-
ing items before disassembling.
쐌 Tooth contact of crown gear and pinion, and
backlash
쐌 Runout of crown gear at its back surface
쐌 Turning resistance of drive pinion
1) Set ST on vise and install the differential
assembly to ST.
ST 398217700 ATTACHMENT SET
S3M0531A
(A) Rear cover

(B) Differential carrier
5) Make right and left side bearing retainers in

order to identify them at reassembly. Remove side
bearing retainer attaching bolts, set ST to differen-
tial case, and extract right and left side bearing
G3M1031
retainers with a puller.
CAUTION:
2) Drain gear oil by removing plug. Each shim, which is installed to adjust the side
3) Remove the air breather cap. bearing preload, should be kept together with
NOTE: its mating retainer.
Do not attempt to replace the air breather cap ST 398457700 ATTACHMENT
unless necessary.
S3M0532A
S3M0530A
6) Pull out differential case assembly from differ-
(A) Air breather cap
ential carrier.
(B) Rear cover
CAUTION:
Be careful not to hit the teeth against the case.
S3M0533
DI-28
Differentials
7) When replacing side bearing, pull bearing cup 10) Drive out pinion shaft lock pin from crown gear
from side bearing retainer using ST. side.
ST 398527700 PULLER ASSY NOTE:
The lock pin is staked at the pin hole end on the
differential carrier; do not drive it out forcibly before
unstaking it.
ST 899904100 STRAIGHT PIN REMOVER
S3M0534A
8) Extract bearing cone with ST.

CAUTION:
Do not attempt to disassemble the parts unless
necessary. B3M0133
NOTE: 11) Draw out pinion mate shaft and remove pinion
쐌 Set puller so that its claws catch the edge of the mate gears, side gears and thrust washers.
bearing cone. NOTE:
쐌 Never mix up the right and left hand bearing The gears as well as thrust washers should be
races and cones. marked or kept separated left and right, and front
ST 399527700 PULLER SET and rear.
G3M0068
S3M0510A
9) Remove crown gear by loosening crown gear (A) Side gear

bolts. (B) Pinion mate gear
CAUTION: (C) Thrust washer
Further disassembling is not allowed. (D) Differential case
(E) Pinion mate shaft
S3M0509
DI-29
Differentials
12) Hold companion flange with ST and remove 15) Remove rear bearing cone from drive pinion
drive pinion nut. by supporting cone with ST.
ST 498427200 FLANGE WRENCH NOTE:
Place the replacer so that its center-recessed side
faces the pinion gear.
ST 398517700 REPLACER
G3M1052
13) Extract the companion flange with a puller.
S3M0512A
16) Remove front oil seal from differential carrier

using ST.
ST 398527700 PULLER ASSY
S3M0511
14) Press the end of drive pinion shaft and extract

it together with rear bearing cone, preload adjust-
ing spacer and washer.
NOTE:
Hold the drive pinion so as not to drop it. S3M0513
ST 398467700 DRIFT 17) Remove pilot bearing together with front bear-
ing cone using ST.
ST 398467700 DRIFT
G3M0074
S3M0514A
(A) Pinion bearing

(B) Front bearing
(C) Rear bearing cup
DI-30
Differentials
18) When replacing bearings, tap front bearing 2) Adjusting preload for front and rear bearings
cup and rear bearing cup in this order out of case Adjust the bearing preload with spacer and washer
by using a brass bar. between front and rear bearings. Pinion height
adjusting washer are not affected by this adjust-
ment. The adjustment must be carried out without
oil seal inserted.
(1) Press rear bearing race into differential car-
rier with ST1 and ST2.
ST1 398477701 HANDLE
ST2 398477703 DRIFT 2
S3M0515A
(A) 2 cutouts along diagonal lines

(B) Tap alternately with brass bar.
1) Precautions for assembling

쐌 Assemble in the reverse order of disassembling.
G3M1037
쐌 Check and adjust each part during assembly.
쐌 For correct installation, keep the shims and (2) Insert ST1 into carrier with pinion height
washers in order. adjusting washer and rear bearing cone fitted
쐌 Thoroughly clean the surfaces on which the onto it.
shims, washers and bearings are to be installed.
쐌 Apply gear oil when installing the bearings and CAUTION:
thrust washers. 쐌 Re-use the used washer if not deformed.
쐌 Be careful not to mix up the right and left hand 쐌 Use a new rear bearing cone.
races of the bearings. (3) Then install preload adjusting spacer and
쐌 Replace the oil seal with new one at every dis- washer, front bearing cone, ST2, companion
assembly. Apply chassis grease between the lips flange, and washer and drive pinion nut.
when installing the oil seal.
ST1 398507702 DUMMY SHAFT
ST2 398507703 DUMMY COLLAR
G3M0079
S3M0516A
(A) Pinion height adjusting shim

(B) Preload adjusting spacer
(C) Preload adjusting washer
DI-31
Differentials
(4) Turn ST1 with hand to make it seated, and Part No. Thickness mm (in)
tighten drive pinion nut while measuring the pre- 383705200 2.59 (0.1020)
load with spring balance. Select preload adjust- 383715200 2.57 (0.1012)
ing washer and spacer so that the specified pre-
383725200 2.55 (0.1004)
load is obtained when nut is tightened to the
383735200 2.53 (0.0996)
specified torque.
383745200 2.51 (0.0988)
CAUTION: 383755200 2.49 (0.0980)
Use a new lock nut. Preload adjusting 383765200 2.47 (0.0972)
NOTE: washer 383775200 2.45 (0.0965)
쐌 Be careful not to give excessive preload. 383785200 2.43 (0.0957)
쐌 When tightening the drive pinion nut, lock ST1 383795200 2.41 (0.0949)
with ST2 as shown in the figure. 383805200 2.39 (0.0941)
383815200 2.37 (0.0933)
ST1 398507704 BLOCK
ST2 398507702 DUMMY SHAFT 383825200 2.35 (0.0925)
383835200 2.33 (0.0917)
Tightening torque: 383845200 2.31 (0.0909)
181 N·m (18.5 kgf-m, 134 ft-lb) Part No. Length mm (in)
383695201 56.2 (2.213)
383695202 56.4 (2.220)
Preload adjusting
383695203 56.6 (2.228)
spacer
383695204 56.8 (2.236)
383695205 57.0 (2.244)
383695206 57.2 (2.252)
3) Adjusting drive pinion height

Adjust drive pinion height with shim installed
between rear bearing cone and the back of pinion
G3M1038 gear.
(1) Install ST1, ST2 and ST3, as shown in the
Front and rear bearing preload figure, and apply the specified preload on the
For new bearing: bearings.
19.6 — 28.4 N (2.0 — 2.9 kgf, 4.4 — 6.4 lb)
at companion flange bolt hole Front and rear bearing preload
For used bearing: For new bearing:
8.34 — 16.67 N (0.85 — 1.7 kgf, 1.87 — 3.75 lb) 19.6 — 28.4 N (2.0 — 2.9 kgf, 4.4 — 6.4 lb)
at companion flange bolt hole at companion flange bolt hole
For used bearing:
8.34 — 16.67 N (0.85 — 1.7 kgf, 1.87 — 3.75 lb)
at companion flange bolt hole
Adjusting preload for front and rear bearings

NOTE:
At this time, install a pinion height adjusting shim
which is temporarily selected or the same as that
used before. Measure and record the thickness.
ST2 398507701 GAUGE
S3M0518A
ST3 398507703 DUMMY COLLAR
DI-32
Differentials
(Example of calculation)
To = 2.20 + 1.20 = 3.40 mm
N = 0.23 mm H = + 1,
T = 3.40 + 0.23 − 0.01 − 0.20 = 3.42
Result: Thickness = 3.42 mm
Therefore use the shim 383605200.
Part No. Thickness mm (in)
383495200 3.09 (0.1217)
S3M0518B 383505200 3.12 (0.1228)
(A) Pinion height adjusting shim 383515200 3.15 (0.1240)
383525200 3.18 (0.1252)
(2) Measure the clearance N between the end 383535200 3.21 (0.1264)
of ST2 and the end surface of ST1 by using a 383545200 3.24 (0.1276)
thickness gauge. 383555200 3.27 (0.1287)
NOTE: 383565200 3.30 (0.1299)
Make sure there is no clearance between the case 383575200 3.33 (0.1311)
and ST2. 383585200 3.36 (0.1323)
383595200 3.39 (0.1335)
383605200 3.42 (0.1346)
ST2 398507701 GAUGE
383615200 3.45 (0.1358)
383625200 3.48 (0.1370)
383635200 3.51 (0.1382)
383645200 3.54 (0.1394)
383655200 3.57 (0.1406)
383665200 3.60 (0.1417)
383675200 3.63 (0.1429)
383685200 3.66 (0.1441)
4) Install the selected pinion height adjusting shim

on drive pinion, and press the rear bearing cone
H3M1309B
into position with ST.
(3) Obtain the thickness of pinion height adjust- ST 398177700 INSTALLER
ing shim to be inserted from the following
formula, and replace the temporarily installed
shim with this one.
T = To + N − (H x 0.01) − 0.20 mm (0.0079
in)
NOTE:
Use copies of this page.
T Thickness of shim temporarily
inserted mm (in)
To Thickness of pinion height adjusting S3M0519A
shim mm (in)
N Reading of thickness gauge mm (in)
H Figure marked on drive pinion head
Memo:
DI-33
Differentials
5) Insert drive pinion into differential carrier, install 8) Fit a new oil seal with ST.
the previously selected bearing preload adjusting NOTE:
spacer and washer. 쐌 Press-fit until end of oil seal is 1 mm (0.04 in)
inward from end of carrier.
쐌 Apply grease between the oil seal lips.
ST 498447120 INSTALLER
B3M0560B
(A) Drive pinion

(B) Bearing adjusting spacer
(C) Washer G3M0087
(D) Differential carrier
9) Press-fit companion flange with ST1 and ST2.
6) Press-fit front bearing cone into case with ST1,
ST2 and ST3. CAUTION:
ST1 398507703 DUMMY COLLAR Be careful not to damage bearing.
ST2 399780104 WEIGHT ST1 899874100 INSTALLER
ST3 899580100 INSTALLER ST2 399780104 WEIGHT
G3M0085 S3M0521A
7) Insert spacer, then press-fit pilot bearing with 10) Install self-locking nut. Then tighten it with ST.
ST1 and ST2. ST 498427200 FLANGE WRENCH
ST1 399780104 WEIGHT
Tightening torque:
ST2 899580100 INSTALLER
181 N·m (18.5 kgf-m, 134 ft-lb)
S3M0520A
G3M1052
DI-34
Differentials
11) Assembling differential case (1) Measure the side gear backlash.
Install side gears and pinion mate gears, with their Side gear back clearance:
thrust washers and pinion mate shaft, into differen- 0.10 — 0.20 mm (0.0039 — 0.0079 in)
tial case.
CAUTION:
쐌 Apply gear oil on both sides of the washer
and on the side gear shaft before installing.
쐌 Insert the pinion mate shaft into the differen-
tial case by aligning the lock pin holes.
B3M1933
(2) Adjust the backlash as specified by select-

ing side gear thrust washer.
Side gear thrust washer
383445201 0.75 — 0.80 (0.0295 — 0.0315)
383445202 0.80 — 0.85 (0.0315 — 0.0335)
383445203 0.85 — 0.90 (0.0335 — 0.0354)
383445204 0.90 — 0.95 (0.0354 — 0.0374)
383445205 0.95 — 1.00 (0.0374 — 0.0394)
(3) Check the condition of rotation after apply-

ing oil to the gear tooth surfaces and thrust sur-
faces.
(4) After inserting pinion shaft lock pin into dif-
ferential case, stake the both sides of the hole
G3M0089 to prevent pin from falling off.
12) Install crown gear on differential case.
CAUTION:
Before installing bolts, apply Lock Tite to bolt
threads.
Lock Tite:
NOTE:
Tighten diagonally while tapping the bolt heads.
Tightening torque:
103 N·m (10.5 kgf-m, 76 ft-lb)
S3M0509
DI-35
Differentials
13) Press side bearing cone onto differential case (4) Align arrow marked on differential carrier
with ST. with that marked on side retainer during instal-
ST 398487700 DRIFT lation.
CAUTION:
Be careful that side bearing outer race is not
damaged by bearing roller.
G3M0091
14) Adjusting side bearing retainer shims

(1) The driven gear backlash and side bearing
preload can be determined by the side bearing S3M0172B
retainer shim thickness. (A) Arrow mark

(2) Install the differential case assembly into
differential carrier in the reverse order of disas- (5) Tighten side bearing retainer bolts.
sembly. CAUTION:
Before tightening the two side bearing retainer
bolts, apply Lock Tite to bolt threads.
Lock Tite:
Tightening torque:
10.3 N·m (1.05 kgf-m, 7.6 ft-lb)
S3M0533
(3) Install side retainer shims and O-rings to the

left and right retainers from which they were
removed.
NOTE:
쐌 Replace broken or cracked O-ring with new one.
쐌 Replace broken or corroded side retainer shim S3M0173
with new one of same thickness.
Side bearing retainer shim
383475201 0.20 (0.0079)
383475202 0.25 (0.0098)
383475203 0.30 (0.0118)
383475204 0.40 (0.0157)
383475205 0.50 (0.0197)
DI-36
Differentials
(6) Measure the crown gear-to-drive pinion 16) Check the crown gear runout on its back
backlash. Set magnet base on differential car- surface, and make sure pinion and crown gear
rier. Align contact point of dial gauge with tooth rotate smoothly.
face of crown gear, and move crown gear while Limit of runout:
holding drive pinion still. Read value indicated Less than 0.05 mm (0.0020 in)
on dial gauge.
Backlash:
0.10 — 0.20 mm (0.0039 — 0.0079 in)
S3M0525
17) Checking and adjusting tooth contact of crown

gear
G3M1047 (1) Apply an even coat of red lead on both
sides of three or four teeth on the crown gear.
(7) At the same time, measure the turning
Check the contact pattern after rotating crown
resistance of drive pinion. Compared with the gear several revolutions back and forth until a
resistance when differential case is not definite contact pattern appears on the crown
installed, if the increase of the resistance is not gear.
within the specified range, readjust side bearing (2) When the contact pattern is incorrect, read-
retainer shims. just according to the instructions given in
Turning resistance increase: “TOOTH CONTACT PATTERN”.
2.9 — 10.8 N (0.3 — 1.1 kgf, 0.7 — 2.4 lb) NOTE:
15) Re-check crown gear-to-pinion backlash. Be sure to wipe off red lead completely after
adjustment is completed.
Backlash:
0.10 — 0.20 mm (0.0039 — 0.0079 in) 18) If proper tooth contact is not obtained, once
again adjust the drive pinion height changing RH
and LH side bearing retainer shims and the hypoid
gear backlash.
G3M1047
DI-37
Differentials
(1) Drive pinion height (2) Hypoid gear backlash

Backlash:
ST2 398507701 GAUGE
0.10 — 0.20 mm (0.0039 — 0.0079 in)
H3M1309B
G3M1047
T = To + N − (H x 0.01) − 0.20 (mm)
Where:
T = Thickness of pinion height adjusting shim
(mm)
To = Thickness of shim temporarily inserted
(mm)
N = Reading of thickness gauge (mm)
H = Figure marked on drive pinion head
DI-38
Differentials
TOOTH CONTACT PATTERN

Condition Contact pattern Adjustment
Correct tooth contact
Tooth contact pattern slightly shifted
towards toe under no load rotation.
(When loaded, contact pattern moves
—
toward heel.)
G3M0098A
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.
G3M0098B
G3M0098F
Flank contact This may cause noise and stepped wear Reduce thickness of drive pinion height
Backlash is too small. on surfaces. adjusting shim in order to move drive
pinion away from crown gear.
G3M0098C
G3M0098G
Toe contact This may cause chipping at toe ends. Adjust as for flank contact.
Contact area is small.
G3M0098D G3M0098G
Heel contact This may cause chipping at heel ends. Adjust as for face contact.
Contact area is small.
G3M0098E G3M0098F
: Adjusting direction of drive pinion

: Adjusting direction of crown gear
DI-39
Differentials
19) Install rear cover and tighten bolts to specified 9) Rear differential oil temperature sensor (Turbo
torque. model for Europe)
CAUTION: If the results of the following inspections are not
Securely connect ground terminal of rear dif- satisfactory, replace rear differential temperature
ferential temperature sensor. sensor.
(1) At room temperature, check for continuity
Tightening torque: between the sensor terminal and body.
29 N·m (3.0 kgf-m, 21.7 ft-lb) (2) Soak the sensor in oil, then raise the oil
temperature. Check that the continuity is cut off
when the oil temperature is between 144°C
(291°F) and 156°C (313°F). Then, check that
the continuity resumes by the time the oil tem-
perature drops to 135°C (275°F).
CAUTION:
The oil is hot, so be careful not to burn yourself
when inspecting.
1. SIDE GEAR BACKLASH S303145A1001
G3M1050
Using a dial gauge, check the backlash of the side
gear.
E: INSPECTION S303145A10 Side gear backlash:
Wash all the disassembled parts clean, and exam- 0.1 — 0.2 mm (0.004 — 0.008 in)
ine them for wear, damage, or other defects. If side gear backlash is not within the specification,
Repair or replace defective parts as necessary. adjust clearance as specified by selecting side
1) Crown gear and drive pinion gear thrust washer.
쐌 If abnormal tooth contact is evident, find out the
cause and adjust to give correct tooth contact at
assembly. Replace the gear if excessively worn or
incapable of adjustment.
쐌 If crack, score, or seizure is evident, replace as
a set. Slight damage of tooth can be corrected by
oil stone or the like.
2) Side gear and pinion mate gear
쐌 Replace if crack, score, or other defects are evi-
dent on tooth surface.
쐌 Replace if thrust washer contacting surface is
B3M1934
worn or seized. Slight damage of the surface can
be corrected by oil stone or the like.
3) Bearing
Replace if seizure, peeling, wear, rust, dragging
during rotation, abnormal noise or other defect is
evident.
4) Thrust washers of side gear and pinion mate
gear
Replace if seizure, flaw, abnormal wear or other
defect is evident.
5) Oil seal
Replace if deformed or damaged, and at every
disassembling.
6) Differential carrier
Replace if the bearing bores are worn or damaged.
7) Differential case
Replace if its sliding surfaces are worn or cracked.
8) Companion flange
Replace if the oil seal lip contacting surfaces have
flaws.
DI-40
Differentials
2. CROWN GEAR BACKLASH S303145A1002 5. TOTAL PRELOAD S303145A1005
Using a dial gauge, check the backlash of the Using a gauge, check the turning resistance
crown gear. increase.
Crown gear backlash: Total preload:
0.1 — 0.2 mm (0.004 — 0.008 in) 2.9 — 10.8 N (0.3 — 1.1 kgf, 0.7 — 2.4 lb)
If crown gear backlash is not within the If the increase of the resistance is not within the
specification, adjust the side bearing preload or specification, adjust the side bearing retainer
repair if necessary. shims.
B3M1935
G3M1047
3. CROWN GEAR RUNOUT S303145A1003

F: ADJUSTMENT S303145A01
Using a dial gauge, check the crown gear runout. 1. SIDE GEAR BACKLASH A303145A0101
Crown gear runout: Adjust side gear backlash.

Less than 0.05 mm (0.0020 in) <Ref. to DI-31 ASSEMBLY, Differential for T-type.>
If the crown gear runout exceeds 0.05 mm (0.0020 2. CROWN GEAR BACKLASH A303145A0102
in), replace the crown gear. Adjust crown gear backlash.

<Ref. to DI-31 ASSEMBLY, Differential for T-type.>
3. TOOTH CONTACT BETWEEN CROWN
GEAR AND DRIVE PINION A303145A0103
Adjust the tooth contact between crown gear and
drive pinion gear.
4. TOTAL PRELOAD A303145A0104
Adjust side bearing shim.

S3M0525

GEAR AND DRIVE PINION S303145A1004
Inspect tooth contact between crown gear and
driven pinion. <Ref. to DI-31 ASSEMBLY, Differen-
tial for T-type.>
DI-41
REAR DIFFERENTIAL FOR VA-TYPE
Differentials
5. Rear Differential for VA-type 12) Remove heat sealed cover.

S303151

racks.
S2M0166
7) Remove wheels.
8) Remove rear exhaust pipe and muffler. 13) Remove clamps and bracket of parking brake
With OBD: cable.
Muffler.>
Without OBD:
9) Remove front exhaust cover.
S2M0191
14) Remove DOJ of rear drive shaft from rear dif-

ferential. <Ref. to DS-38, REMOVAL, Rear Drive
Shaft.>
S3M0502
10) Remove front cover of rear differential mount.
S3M0504A
(A) DOJ
(B) Tire lever
S3M0503
11) Remove propeller shaft. <Ref. to DS-14,

REMOVAL, Propeller Shaft.>
DI-42
Differentials
15) Secure rear drive shaft to rear crossmember 19) Remove bolts which secure rear differential
using wire. front member to body.
(1) Loosen bolt A first, then remove bolts B.
NOTE:
Support front member with a help of an assistant
to prevent it from dropping.
S3M0500
16) Remove lower differential bracket.
B3M0657C
(A) Bolt A
(B) Bolt B
(2) Remove bolt A.

20) While slowly lowering transmission jack, move
rear differential forward and remove bolts from rear
crossmember.
H3M1273B 21) Remove front member from body.
(A) Lower differential bracket
(B) Rear differential
17) Support rear differential with transmission

jack.
G3M0058
22) Remove rear differential from body.
S3M0505
18) Remove self-locking nuts connecting rear dif-

ferential to rear crossmember.
G3M0059
To install, reverse the removal sequence.

1) Position front member on body by passing it
B3M0131
differential.
DI-43
Differentials
NOTE: 3) Remove rear cover by loosening retaining

When installing rear differential front member, do bolts.
not confuse the installation sequence of the upper
and lower stoppers.
2) Install DOJ of rear drive shaft into rear differen-
tial.
TOR
S3M0506
4) Replace air breather cap.

NOTE:
Do not attempt to replace the air breather cap
unless necessary.
G3M0049

4) After installation, fill differential carrier with gear
oil. <Ref. to DI-22, Differential Gear Oil.>
To detect real cause of trouble, inspect the follow-

ing items before disassembling.
쐌 Tooth contact of crown gear and pinion, and
S3M0507A
backlash
쐌 Runout of crown gear at its back surface (A) Air breather cap
쐌 Turning resistance of drive pinion (B) Rear cover
1) Set ST on vise and install the differential
assembly to ST. 5) Remove right and left lock plates.
ST 398217700 ATTACHMENT
G3M0063
G3M0060
2) Drain gear oil by removing plug.
DI-44
Differentials
6) Remove right and left holders with ST. 9) Remove oil seal from right and left holders with
ST 399780111 WRENCH screwdriver.
CAUTION:
Perform this operation only when changing oil
seal.
G3M0064
7) Pull out differential assembly from differential

case.
B3M0132
CAUTION:
Be careful not to hit the teeth against the case. 10) Extract bearing cone with ST1 and ST2.
CAUTION:
Do not attempt to disassemble the parts unless
necessary.
NOTE:
쐌 Set Puller so that its claws catch the edge of the
bearing cone.
쐌 Never mix up the right and left hand bearing
races and cones.
ST1 899524100 PULLER SET
G3M0065 ST2 399520105 SEAT
8) Remove bearing race from right and left holders
with ST1 and ST2.
ST1 499705401 PULLER ASSY
ST2 499705404 OUTER RACE PULLER
SEAT
H3M1970A
11) Remove crown gear by loosening crown gear

bolts.
S3M0508A
(A) Bearing race

(B) Holder
S3M0509
DI-45
Differentials
12) Drive out pinion shaft lock pin from crown gear 14) Hold companion flange with ST and remove
side. self-locking nut.
NOTE: ST 498427200 FLANGE WRENCH
The lock pin is staked at the pin hole end on the
differential case; do not drive it out forcibly before
unstaking it.
ST 899904100 STRAIGHT PIN REMOVER
G3M0072
15) Extract the companion flange with a puller.
B3M0133
13) Draw out pinion mate shaft and remove pinion

mate gears, side gears and thrust washers.
NOTE:
The gears as well as thrust washers should be
marked or kept separated left and right, and front
and rear.
S3M0511A
(A) Companion
(B) Puller
16) Press the end of drive pinion shaft and extract

it together with rear bearing cone, preload adjust-
ing spacer and washer.
NOTE:
Hold the drive pinion so as not to drop it.
S3M0510A ST 398467700 DRIFT
(A) Side gear

(B) Pinion mate gear
(C) Thrust washer
(D) Differential case
(E) Pinion mate shaft
G3M0074
DI-46
Differentials
17) Remove rear bearing cone from drive pinion 20) When replacing bearings, tap front bearing
by supporting cone with ST. cup and rear bearing cup in this order out of case
NOTE: by using a brass bar.
Place the replacer so that its center-recessed side
faces the pinion gear.
ST 498515500 REPLACER
S3M0515A
(A) 2 cutouts along diagonal lines

(B) Tap alternately with brass bar.
S3M0512A
18) Remove front oil seal from differential carrier 1) Precautions for assembling
using ST. 쐌 Assemble in the reverse order of disassembling.
ST 398527700 PULLER ASSY 쐌 Check and adjust each part during assembly.
쐌 Keep the shims and washers in order, so that
they are not misinstalled.
쐌 Thoroughly clean the surfaces on which the
shims, washers and bearings are to be installed.
쐌 Apply gear oil when installing the bearings and
thrust washers.
쐌 Be careful not to mix up the right and left hand
races of the bearings.
쐌 Replace the oil seal with new one at every dis-
assembly. Apply chassis grease between the lips
S3M0513A
when installing the oil seal.
(A) Differential carrier
(B) Front oil seal
19) Remove pilot bearing together with front bear-

ing cone using ST.
ST 398467700 DRIFT
G3M0079
2) Adjust preload for front and rear bearings.

Adjust the bearing preload with spacer and washer
between front and rear bearings. Pinion height
adjusting washer are not affected by this adjust-
S3M0514A ment. The adjustment must be carried out without
oil seal inserted.
(A) Pilot bearing
(B) Front bearing
(C) Rear bearing cup
DI-47
Differentials
(1) Press rear bearing race into differential car- CAUTION:

rier with ST1 and ST2. Use a new self-locking nut.
ST1 398477701 HANDLE NOTE:
ST2 398477702 DRIFT 쐌 Be careful not to give excessive preload.
(2) Press front bearing race into differential car- 쐌 When tightening the drive pinion nut, lock ST1
rier with ST1 and ST2. with ST2 as shown in the figure.
ST1 398477701 HANDLE
ST2 498447110 DRIFT ST1 398507704 BLOCK
Tightening torque:
188 N·m (19.2 kgf-m, 139 ft-lb)
G3M0080
(3) Insert front bearing cone.

CAUTION: G3M1038
Use a new front bearing cone.
(4) Insert ST1 into case with pinion height Front and rear bearing preload
adjusting shim and rear bearing cone fitted onto For new bearing:
it. 12.7 — 32.4 N (1.3 — 3.3 kgf, 2.9 — 7.3 lb)
CAUTION:
쐌 Re-use the used washer if not deformed.
쐌 Use a new rear bearing cone.
(5) Then install preload adjusting spacer and
washer, front bearing cone, ST2, companion
flange, and washer and self-locking nut.
ST2 32285AA000 DUMMY COLLAR
S3M0517
S3M0516A
(A) Pinion height adjujusting shim

(B) Preload adjusting spacer
(C) Preload adjusting washer
(6) Turn ST1 with hand to make it seated, and

tighten drive pinion nut while measuring the pre-
load with spring balance. Select preload adjust-
ing washer and spacer so that the specified pre-
load is obtained when nut is tightened to the
specified torque.
DI-48
Differentials
Part No. Thickness mm (in) ST3 498505501 DIFFERENTIAL CARRIER

38336AA000 1.500 (0.0591)
GAUGE
38336AA120 1.513 (0.0596)
38336AA010 1.525 (0.0600)
38336AA130 1.538 (0.0606)
38336AA020 1.550 (0.0610)
38336AA140 1.563 (0.0615)
38336AA030 1.575 (0.0620)
38336AA150 1.588 (0.0625)
38336AA040 1.600 (0.0630)
38336AA160 1.613 (0.0635)
Preload adjusting 38336AA050 1.625 (0.0640) S3M0518A
washer 38336AA170 1.638 (0.0645)
(A) Pinion height adjusting shim
38336AA060 1.650 (0.0650)
38336AA180 1.663 (0.0655) (2) Measure the clearance N between the end
38336AA070 1.675 (0.0659) of ST3 and the end surface of ST1 by using a
38336AA190 1.688 (0.0665) thickness gauge.
38336AA080 1.700 (0.0669) NOTE:
38336AA200 1.713 (0.0674) Make sure there is no clearance between the case
38336AA090 1.725 (0.0679) and ST3.
38336AA210 1.738 (0.0684)
38336AA100 1.750 (0.0689)
ST2 498505501 DIFFERENTIAL CARRIER
38336AA220 1.763 (0.0694) GAUGE
38336AA110 1.775 (0.0699)
Part No. Length mm (in)
32288AA040 52.3 (2.059)
32288AA050 52.5 (2.067)
31454AA100 52.6 (2.071)
Preload adjusting 32288AA060 52.7 (2.075)
spacer 31454AA110 52.8 (2.079)
32288AA070 52.9 (2.083)
31454AA120 53.0 (2.087)
32288AA080 53.1 (2.091)
32288AA090 53.3 (2.098) H3M1309B
3) Adjusting drive pinion height

Adjust drive pinion height with shim installed
between rear bearing cone and the back of pinion
gear.
(1) Install ST1, ST2 and ST3, as shown in the
figure, and apply the specified preload on the
bearings
Front and rear bearing preload
For new bearing:
12.7 — 32.4 N (1.3 — 3.3 kgf, 2.9 — 7.3 lb)
Adjusting preload for front and rear bearings

NOTE:
At this time, install an original pinion height adjust-
ing shim.
ST2 32285AA000 DUMMY COLLAR
DI-49
Differentials
(3) Obtain the thickness of pinion height adjust- 5) Insert drive pinion into differential carrier, install
ing washer to be inserted from the following the previously selected bearing preload adjusting
formula, and replace the temporarily installed spacer and washer.
shim with this one.
NOTE:
Use 1 to 3 shims as required for adjustment.
T = To + N − 0.05 (mm)
where
(mm)
To = Thickness of shim originally installed
(mm)
N = Reading of thickness gauge (mm) H3M1666A
H = Figure marked on drive pinion head
(Example of calculation) (A) Drive pinion
To = 0.15 mm (B) Bearing preload adjusting spacer
N = 0.1 mm (C) Bearing preload adjusting washer
T = 0.15 + 0.1 − 0.05 = 0.2 mm (D) Differential carrier
Result: Thickness = 0.2 mm 6) Press-fit front bearing cone into carrier with
Therefore use the 32295AA220. ST1, ST2 and ST3.
Pinion height adjusting shim ST1 32285AA000 DUMMY COLLAR
32295AA200 0.150 (0.0059)
32295AA210 0.175 (0.0069)
32295AA220 0.200 (0.0079)
32295AA230 0.225 (0.0089)
32295AA240 0.250 (0.0098)
32295AA250 0.275 (0.0108)
4) Install the selected pinion height adjusting shim

on drive pinion, and press the rear bearing cone
into position with ST.
G3M0085
7) Insert spacer, then press-fit pilot bearing with

ST1 and ST2.
S3M0519A
S3M0520A
DI-50
Differentials
8) Fit a new oil seal with ST. 11) Assembling differential case
NOTE: Install side gears and pinion mate gears, with their
쐌 Press-fit until end of oil seal is 1 mm (0.04 in) thrust washers and pinion mate shaft, into differen-
inward from end of carrier. tial case.
쐌 Apply grease between the oil seal lips. NOTE:
ST 498447120 OIL SEAL INSTALLER 쐌 Apply gear oil on both sides of the washer and
on the side gear shaft before installing.
쐌 Insert the pinion mate shaft into the differential
case by aligning the lock pin holes.
G3M0087
9) Press-fit companion flange with ST1 and ST2.

CAUTION:
Be careful not to damage bearing.
G3M0089
S3M0521A
10) Install self-locking nut. Then tighten it with ST.

ST 398427200 FLANGE WRENCH
Tightening torque:
188 N·m (19.2 kgf-m, 139 ft-lb)
G3M0721
DI-51
Differentials
(1) Measure the side gear backlash. 12) Press side bearing cone onto differential case
Side gear back clearance: with ST.
0.05 — 0.15 mm (0.0020 — 0.0059 in) ST 498485400 DRIFT
G3M0091
B3M1933
(2) Adjust the side gear backlash as specified 13) Assemble holders.
by selecting side gear thrust washer. (1) Install oil seal into right and left holders.
Side gear thrust washer
803135011 0.925 — 0.950 (0.0364 — 0.0374)
803135012 0.950 — 0.975 (0.0374 — 0.0384)
803135013 0.975 — 1.000 (0.0384 — 0.0394)
803135014 1.000 — 1.025 (0.0394 — 0.0404)
803135015 1.025 — 1.050 (0.0404 — 0.0413)
(3) Check the condition of rotation after apply-

ing oil to the gear tooth surfaces and thrust sur-
faces. S3M0522A
(4) After driving in pinion shaft lock pin, stake
the both sides of the hole to prevent pin from (2) Install bearing race into right and left hold-
falling off. ers.
(5) Install crown gear on differential case. ST 398477702 DRIFT
CAUTION:
Before installing bolts, apply Lock Tite to bolt
threads.
Lock Tite
NOTE:
Tighten diagonally while tapping the bolt heads.
Tightening torque:
62 N·m (6.3 kgf-m, 45.6 ft-lb) G3M0093
S3M0509
DI-52
Differentials
(3) Install the differential case assembly into (4) Temporarily tighten lock plate.
differential carrier in the reverse order of disas- NOTE:
sembly. Turn over lock plate to displace holder 1/2 tooth.
G3M0065
G3M0063
14) Perform adjustment of backlash of pinion (5) Measure the crown gear-to-drive pinion
crown gear set and adjustment of preload of differ- backlash. Set magnet base on differential car-
ential side bearing. rier. Align contact point of dial gauge with tooth
(1) Turn drive pinion with ST for better fitting of face of crown gear, and move crown gear while
differential side bearing. holding drive pinion still. Read value indicated
ST 498427200 FLANGE WRENCH on dial gauge.
NOTE:
If measured backlash is not within specified range,
repeat procedures for pinion crown gear set back-
lash adjustment and differential side bearing pre-
load adjustment.
Backlash:
0.10 — 0.15 mm (0.0039 — 0.0059 in)
G3M0094
(2) Screw in side (left-side) holder until light

contact is made with ST.
ST 399780111 WRENCH
S3M0523
G3M0064
(3) Back off side (left-side) holder approxi-

mately 1 1/2 teeth of holder, and tighten left-side
holder by approximately 2 teeth (approximately
1 1/2 + 1/2 teeth).
[Back off amount of side (left-side) holder + 1/2
tooth.]
This + 1/2 tooth gives preload.
DI-53
Differentials
15) Draw a matching mark on both differential car- 18) Check the crown gear runout on its back
rier and holder. Remove holder one side at a time. surface, and make sure pinion and crown gear
Replace in the original position after inserting an rotate smoothly.
O-ring and applying grease to threaded portion. Limit of runout:
0.05 mm (0.0020 in)
S3M0524A
(A) Matching mark S3M0525
(B) Holder
19) Checking and adjusting tooth contact of crown
16) Tighten bolt of lock plate to specified torque. gear.
(1) Apply an even coat of red lead on both
Tightening torque:
sides of three or four teeth on the crown gear.
25 N·m (2.5 kgf-m, 18.1 ft-lb)
Check the contact pattern after rotating crown
gear several revolutions back and forth until a
definite contact pattern appears on the crown
gear.
(2) When the contact pattern is incorrect, read-
just according to the instructions given in
“TOOTH CONTACT PATTERN”.
NOTE:
Be sure to wipe off red lead completely after
adjustment is completed.
G3M0063 20) If proper tooth contact is not obtained, once
again adjust the drive pinion height and the differ-
17) Re-check crown gear-to-pinion backlash. ential side bearing preload (already mentioned)
Backlash: and the hypoid gear backlash.
0.10 — 0.15 mm (0.0039 — 0.0059 in) (1) Drive pinion height
ST2 498505501 DIFFERENTIAL GAUGE
S3M0523
H3M1309B
T = To + N − 0.05 (mm)
where
(mm)
To = Thickness of shim originally installed
(mm)
DI-54
Differentials
N = Reading of thickness gauge (mm) (3) Hypoid gear backlash

(2) Differential side bearing preload Backlash:
Screw in side (left-side) holder until light contact
0.10 — 0.15 mm (0.0039 — 0.0059 in)
is made with ST.
Back off side (left-side) holder approximately 1
1/2 teeth of holder, and tighten left-side holder
by approximately 2 teeth (approximately 1 1/2 +
1/2 teeth).
[Back off amount of side (left-side) holder + 1/2
tooth.]
This + 1/2 tooth gives preload.
ST 399780111 WRENCH
S3M0523
G3M0064
DI-55
Differentials
TOOTH CONTACT PATTERN

Condition Contact pattern Adjustment
Correct tooth contact
Tooth contact pattern slightly shifted
towards toe under no load rotation.
(When loaded, contact pattern moves
—
toward heel.)
G3M0098A
Face contact This may cause noise and chipping at Increase thickness of drive pinion height
Backlash is too large. tooth ends. adjusting washer in order to bring drive
pinion closer to crown gear center.
G3M0098B
G3M0098F
Flank contact This may cause noise and stepped wear Reduce thickness of drive pinion height
Backlash is too small. on surfaces. adjusting washer in order to move drive
pinion away from crown gear.
G3M0098C
G3M0098G
Toe contact Contact area is small. Adjust as for flank contact.
This may cause chipping at toe ends.
G3M0098G
G3M0098D
Heel contact Contact area is small. Adjust as for face contact.
This may cause chipping at heel ends.
G3M0098F
G3M0098E
: Adjusting direction of drive pinion

: Adjusting direction of crown gear
DI-56
Differentials
21) Install rear cover and tighten bolts to specified 1. SIDE GEAR BACKLASH S303151A1001
torque. Using a dial gauge, check the backlash of the side

Tightening torque: gear.
25 N·m (2.5 kgf-m, 18.1 ft-lb) Side gear backlash:
0.05 — 0.15 mm (0.0020 — 0.0059 in)
If side gear backlash is not within the specification,
adjust clearance as specified by selecting side
gear trust washer.
S3M0526A
(A) Rear cover
B3M1934
Wash all the disassembled parts clean, and exam-
ine them for wear, damage, or other defects.
Repair or replace defective parts as necessary. 2. CROWN GEAR BACKLASH S303151A1002
1) Crown gear and drive pinion Using a dial gauge, check the backlash of the
쐌 If abnormal tooth contact is evident, find out the crown gear.
cause and adjust to give correct tooth contact at
Crown gear backlash:
assembly. Replace the gear if excessively worn or
0.10 — 0.15 mm (0.0039 — 0.0059 in)
incapable of adjustment.
쐌 If crack, score, or seizure is evident, replace as If crown gear backlash is not within the
a set. Slight damage of tooth can be corrected by specification, adjust the side bearing preload or
oil stone or the like. repair if necessary.
2) Side gear and pinion mate gear
쐌 Replace if crack, score, or other defects are evi-
dent on tooth surface.
쐌 Replace if thrust washer contacting surface is
worn or seized. Slight damage of the surface can
be corrected by oil stone or the like.
3) Bearing
Replace if seizure, peeling, wear, rust, dragging
during rotation, abnormal noise or other defect is
evident.
4) Thrust washers of side gear and pinion mate G3M1047
gear
Replace if seizure, flaw, abnormal wear or other
defect is evident.
5) Oil seal
Replace if deformed or damaged, and at every
disassembling.
6) Differential carrier
Replace if the bearing bores are worn or damaged.
7) Differential case
Replace if its sliding surfaces are worn or cracked.
8) Companion flange
Replace if the oil seal lip contacting surfaces have
flaws.
DI-57
Differentials
3. CROWN GEAR RUNOUT S303151A1003
Using a dial gauge, check the crown gear runout.

Crown gear runout:
If the crown gear runout exceeds 0.05 mm (0.0020
in), replace the crown gear.
S3M0525

GEAR AND DRIVE PINION S303151A1004
Inspect tooth contact between crown gear and
drive pinion.
<Ref. to DI-47 ASSEMBLY Rear Differential for VA-
type.>
1. SIDE GEAR BACKLASH A303151A0101
Adjust side gear backlash.

type.>
2. CROWN GEAR BACKLASH A303151A0102
Adjust crown gear backlash.

type.>
GEAR AND DRIVE PINION A303151A0103
Adjust the tooth contact between crown gear and
drive pinion gear.
type.>
DI-58
REAR DIFFERENTIAL FRONT OIL SEAL
Differentials
6. Rear Differential Front Oil 10) Remove self-locking nut while holding com-
panion flange with ST.
Seal S303139
Check front oil seal portion for oil leakage, if any

leak is found, replace the oil seal and inspect pro-
peller shaft.
B: REPLACEMENT S303139A20

S3M0031A
5) Lift the vehicle. 11) Extract companion flange using ST.
6) Remove oil drain plug, and drain gear oil. ST 399703600 PULLEY ASSY
B3M0136B B3M1644B
(A) Drain plug 12) Remove oil seal using ST.

(B) Filler plug ST 499705401 PULLER ASSY
7) Install oil drain plug.
CAUTION:
Tightening torque:
T-type;
49 N·m (5.0 kgf-m, 36.2 ft-lb)
VA-type;
34 N·m (3.5 kgf-m, 25.3 ft-lb)
B3M1609B
9) Remove propeller shaft from body. <Ref. to 13) Fit a new oil seal using ST.
DS-17 REMOVAL, Propeller Shaft.> ST 498447120 OIL SEAL INSTALLER
G3M0037
14) Install companion flange.
DI-59
REAR DIFFERENTIAL FRONT OIL SEAL
Differentials
NOTE:
Use a plastic hammer to install companion flange.
15) Tighten self-locking nut within the specified
torque range so that the turning resistance of com-
panion flange becomes the same as that before
replacing oil seal.
CAUTION:
Tightening torque:
181.4 N·m (18.50 kgf-m, 133.8 ft-lb)
S3M0031A

17) Fill differential carrier with gear oil. <Ref. to
DI-22 Differential Gear Oil.>
DI-60
REAR DIFFERENTIAL SIDE OIL SEAL
Differentials
7. Rear Differential Side Oil (2) Remove the ABS sensor cable clamp from
the trailing link.
Seal S303137
Check side oil seal portion for oil leakage, if any

leak is found, replace the side oil seal and inspect
propeller shaft.
1. VA-TYPE S303137A2002
1) Set vehicle on a lift. H3M1398

3) Move select lever or gear shift lever to “N”. (3) Remove the ABS sensor cable clamp and
4) Release the parking brake. parking brake cable guide from the trailing link.
5) Loosen both wheel nuts.
6) Jack-up the vehicle and support it with rigid
racks.
7) Remove wheels.
With OBD:
Muffler.>
Without OBD:
<Ref. to EX(SOHCw/oOBD)-10, REMOVAL, Rear H3M1399B
(A) Parking brake cable guide
(B) ABS sensor cable clamp
9) Remove the DOJ of rear drive shaft from rear
differential. (4) Remove the rear stabilizer link.
(1) Remove the ABS sensor cable clamp and
parking brake cable guide from bracket.
H3M1396
(5) Remove the bolts which secure the trailing

H3M1397B
link to the rear housing.
(A) ABS sensor cable clamp
(B) Parking brake cable guide
G3M0042
DI-61
Differentials
(6) Remove the bolts which secure the front 10) Secure rear drive shaft to rear crossmember
and rear lateral link to the rear housing. using wire.
G3M0043 S3M0500
(7) Remove the DOJ from the rear differential 11) Remove oil seal with screwdriver.
with tire lever.
CAUTION:
holder.
NOTE:
The side spline shaft circlip comes out together
with the shaft.
S3M0501A
(A) Side oil seal

(B) Screwdriver
12) Drive in a new side oil seal with ST.

CAUTION:
Apply chassis grease between the oil seal lips.
ST 498447100 OIL SEAL INSTALLER
G3M0048
13) Insert the DOJ into rear differential.

H3M1664B
CAUTION:
(A) Tire lever Before inserting, replace the circlip at the end
(B) Axle shaft holder of the spline shaft with a new one.
DI-62
Differentials
(1) Install ST to rear differential. 6) Jack-up the vehicle and support it with rigid
ST 28099PA090 SIDE OIL SEAL PROTEC- racks.
TOR 7) Remove wheels.
Non-turbo model with OBD:
Muffler.>
Turbo model:
G3M0256 <Ref. to EX(DOHC TURBO)-14, REMOVAL, Rear
Exhaust Pipe.> and <Ref. to EX(DOHC TURBO)-
(2) Insert the spline shaft until the spline portion 15, REMOVAL, Muffler.>
is inside the side oil seal. 9) Remove the DOJ of rear drive shaft from rear
differential.
(1) Remove the ABS sensor cable clamp and
parking brake cable guide from bracket.
G3M0049
(3) Remove ST.

H3M1397B
TOR
(4) Completely insert DOJ into rear differential (A) ABS sensor cable clamp
by pressing rear housing. (B) Parking brake cable guide
NOTE:
(2) Remove the ABS sensor cable clamp from
Make sure that oil seal lip is not folded over inward.
the trailing link.
H4M1095
H3M1398

2. T-TYPE S303137A2001

5) Loosen both wheel nuts.
DI-63
Differentials
(3) Remove the ABS sensor cable clamp and (7) Remove the DOJ from the rear differential
parking brake cable guide from the trailing link. by using ST.
CAUTION:
differential, fit ST to the bolt as shown in figure
so as not to damage the side bearing retainer.
H3M1399B
(A) ABS sensor cable clamp

(B) Parking brake cable guide
(4) Remove the rear stabilizer link.
S3M0528
(5) Remove the bolts which secure the trailing H3M1667C

link to the rear housing.
(A) Bolt
(B) DOJ
10) Secure rear drive shaft to rear crossmember

using wire.
G3M0042
(6) Remove the bolts which secure the front

and rear lateral link to the rear housing.
S3M0500
G3M0043
DI-64
Differentials
11) Remove side oil seal with ST. (2) Insert the spline shaft until the spline portion
ST 398527700 PULLER ASSY is inside the side oil seal.
(3) Remove ST.
TOR
G3M1023
12) Drive in a new side oil seal with ST.

G3M1026
CAUTION:
Apply chassis grease between the oil seal lips. (4) Completely insert DOJ into rear differential
ST 398437700 DRIFT by pressing rear housing.
NOTE:
Make sure that oil seal lip is not folded over inward.
G3M1024
13) Insert the DOJ into rear differential.

(1) Install ST to rear differential. G3M0050
ST 28099PA090 SIDE OIL SEAL PROTEC- 14) Install in the reverse order of removal.
TOR
G3M1025
DI-65
REAR DIFFERENTIAL MEMBER
Differentials
8. Rear Differential Member S303135

NOTE:
When installing rear differential front member, do
A: REMOVAL S303135A18 not confuse the installation sequence of the stop-
per.
racks.
7) Remove wheels.
<Ref. to EX(SOHC)-9, REMOVAL, Rear Exhaust H3M1402B
Pipe.> and <Ref. to EX(SOHC)-11 REMOVAL,
Muffler.> (A) Stopper
Non-turbo model without OBD: (B) Differential mount bracket
2) Insert DOJ of rear drive shaft into rear differen-
tial.
12, REMOVAL, Muffler.> ST 28099PA090 SIDE OIL SEAL PROTEC-
Turbo model: TOR
Exhaust Pipe.> and <Ref. to EX(DOHC TURBO)- CAUTION:
15, REMOVAL, Muffler.> Before inserting, replace the differential side
9) Remove rear differential front member. oil seal and the circlip at the end of the spline
VA-type: shaft with a new one.
<Ref. to DI-42, REMOVAL, Rear Differential for
VA-type.>
T-type:
<Ref. to DI-25, REMOVAL, Rear Differential for
T-type.>
NOTE:
When removing rear differential front member,
work the removal procedure as rear differential.
G3M0049
To install, reverse the removal sequence.
1) Position front member on body by passing it 3) Install in the reverse order of removal.
differential. C: INSPECTION S303135A10
1) Check rear differential member for damage,

bend, or corrosion.
If damage, bend, or corrosion is excessive, replace
rear differential member.
2) Check bushings of rear differential member for
cracking, hardening, or damage.
If cracking, hardening, or damage is excessive,
replace rear differential member.
G3M0058
DI-66
Differentials
Symptom or trouble Possible cause Remedy

1. Oil leakage Worn, scratched, or incorrectly seated Repair or replace.
front or side oil seal. Scored, battered, or
excessively worn sliding surface of com-
panion flange.
Clogged or damaged air breather. Clean, repair or replace.
Loose bolts on differential spindle or side Tighten bolts to specified torque.
retainer, or incorrectly fitted O-ring. Replace O-ring.
Loose rear cover attaching bolts or dam- Tighten bolts to specified torque.
aged gasket. Replace gasket and apply liquid packing.
Loose oil filler or drain plug. Retighten and apply liquid packing.
Wear, damage or incorrectly fitting for Repair or replace.
spindle, side retainer and oil seal.
2. Seizure Insufficient backlash for hypoid gear. Readjust or replace.
NOTE:
Seized or damaged parts should be Excessive preload for side, rear, or front Readjust or replace.
replaced, and also other parts should be bearing.
thoroughly checked for any defect and
should be repaired or replaced as Insufficient or improper oil used. Replace seized part and fill with speci-
required. fied oil to specified level.
3. Damage Improper backlash for hypoid gear. Replace.
NOTE: Insufficient or excessive preload for side, Readjust or replace.
Damaged parts should be replaced, and rear, or front bearing.
also other parts should be thoroughly
checked for any defect and should be Excessive backlash for differential gear. Replace gear or thrust washer.
repaired or replaced as required. Loose bolts and nuts such as crown Retighten.
gear bolt.
Damage due to overloading. Replace.
4. Noises when starting or shifting Excessive backlash for hypoid gear. Readjust.
gears Excessive backlash for differential gear. Replace gear or thrust washer.
NOTE:
Noises may be caused by differential Insufficient preload for front or rear bear- Readjust.
assembly, universal joint, wheel bearing, ing.
etc. Find out what is actually making Loose drive pinion nut. Tighten to specified torque.
noise before disassembly. Loose bolts and nuts such as side bear- Tighten to specified torque.
ing retainer attaching bolt.
5. Noises when cornering Damaged differential gear. Replace.
Excessive wear or damage of thrust Replace.
washer.
Broken pinion mate shaft. Replace.
Seized or damaged side bearing. Replace.
6. Gear noises Improper tooth contact of hypoid gear. Readjust or replace hypoid gear set.
NOTE:
Since noises from engine, muffler, Improper backlash for hypoid gear. Readjust.
transmission, propeller shaft, wheel Scored or chipped teeth of hypoid gear. Replace hypoid gear set.
bearings, tires, and body are sometimes
mistaken for noises from differential Seized hypoid gear. Replace hypoid gear set.
assembly, be careful in checking them.
Inspection methods to locate noises Improper preload for front or rear bear- Readjust.
include coasting, accelerating, cruising, ings.
and jacking-up all four wheels. Perform Seized, scored, or chipped front or rear Replace.
these inspections according to condition bearing.
of trouble. When listening to noises, shift
gears into four wheel drive and fourth Seized, scored, or chipped side bearing. Replace.
speed position, trying to pick up only dif-
ferential noise. Vibrating differential carrier. Replace.
DI-67
Differentials
MEMO:
DI-68
CHASSIS SECTION

SUBARU vehicles.
ine parts.

G8050GE5
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 Driven Gear without VTD...........................................................9
9. Center Differential .....................................................................................10
10. Oil Pump....................................................................................................11
11. Transfer Clutch Pressure Test...................................................................12
12. Transfer Duty Solenoid and Valve Body ...................................................13
GENERAL DESCRIPTION
Transfer Case
A: NOTE S302001A15
For removal, installation and inspection work, refer

to “AT” section or “MT” section.
AT model:
<Ref. to AT-2, General Description.>
MT model:
<Ref. to MT-2, General Description.>
TC-2
TRANSFER CASE AND EXTENSION FOR MT
Transfer Case
2. Transfer Case and Extension

for MT S302138
A: NOTE S302138A15

to “MT” section. <Ref. to MT-46, Transfer Case and
Extension Case Assembly.>
TC-3
TRANSFER CLUTCH AND EXTENSION FOR AT
Transfer Case
3. Transfer Clutch and

Extension for AT S302142
A: NOTE S302142A15

to “AUTOMATIC TRANSMISSION” (a separate
publication: Pub. No. G0853ZE).
TC-4
OIL SEAL
Transfer Case
4. Oil Seal S302143
A: NOTE S302143A15

to “AT” section or “MT” section.
AT model:
<Ref. to AT-27, Extension Case Oil Seal.>
MT model:
<Ref. to MT-41, Oil Seal.>
TC-5
TRANSFER DRIVE GEAR (MT)
Transfer Case
5. Transfer Drive Gear (MT) S302146
A: NOTE S302146A15

to “MT” section. <Ref. to MT-52, Transfer Drive
Gear.>
TC-6
TRANSFER DRIVEN GEAR (MT)
Transfer Case
6. Transfer Driven Gear (MT) S302141
A: NOTE S302141A15

to “MT” section. <Ref. to MT-54, Transfer Driven
Gear .>
TC-7
REDUCTION DRIVE GEAR WITHOUT VTD
Transfer Case
7. Reduction Drive Gear

without VTD S302144
A: NOTE S302144A15

TC-8
REDUCTION DRIVEN GEAR WITHOUT VTD
Transfer Case
8. Reduction Driven Gear

without VTD S302147
A: NOTE S302147A15

TC-9
CENTER DIFFERENTIAL
Transfer Case
9. Center Differential S302158
A: NOTE S302158A15

publication: Pub. No. G0853ZE) or “MT” section.
<Ref. to MT-56, Center Differential.>
TC-10
OIL PUMP
Transfer Case
10. Oil Pump S302070
A: NOTE S302070A15

to “MT”section. <Ref. to MT-50, Oil Pump.>
TC-11
TRANSFER CLUTCH PRESSURE TEST
Transfer Case
11. Transfer Clutch Pressure

Test S302159
A: NOTE S302159A15

to “AT” section <Ref. to AT-18, Transfer Clutch
Pressure Test.>
TC-12
TRANSFER DUTY SOLENOID AND VALVE BODY
Transfer Case
12. Transfer Duty Solenoid and

Valve Body S302161
A: NOTE S302161A15

to “AT” section. <Ref. to AT-41, TRANSFER DUTY
SOLENOID AND TRANSFER VALVE BODY,
REMOVAL, Shift Solenoids, Duty Solenoids and
ATF Temperature Sensor.>
TC-13
TRANSFER DUTY SOLENOID AND VALVE BODY
Transfer Case
MEMO:
TC-14
CHASSIS SECTION

SUBARU vehicles.
ine parts.

G8050GE5
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 Boot ..............................................................................37
7. Rear Drive Shaft........................................................................................38
8. Rear Drive Shaft Boot ...............................................................................44
GENERAL DESCRIPTION
Drive Shaft System
1. PROPELLER SHAFT S301001E4901
Non-Turbo model Turbo model

Propeller shaft type UJ type DOJ type
Front propeller shaft AT 585 (23.03) 580 (22.83)
Joint-to-joint length: L1
mm (in) MT 644 (25.35) 639 (25.16)
Rear propeller shaft
Joint-to-joint length: L2 707 (27.83) 712 (28.03)
mm (in)
Outside dia. of tube D1 63.5 (2.500)
mm (in) D2 57.0 (2.244)
S3M0021E
DS-2
GENERAL DESCRIPTION
Drive Shaft System
2. FRONT DRIVE SHAFT ASSEMBLY S301001E4902
Type of drive shaft SHAFT Boot band identifica-

Model Tone wheel
assembly Shaft diameter tion color
Non-TURBO MT (With ABS) 쎻 BJ87L+SFJ82 28 mm (1.10 in) Pink
Non-TURBO MT (Without ABS) — BJ87L+SFJ82 28 mm (1.10 in) Purple
Non-TURBO AT (With ABS)
쎻 BJ87L+SFJ82 26 mm (1.02 in) —
TURBO
Non-TURBO AT (Without ABS) — BJ87L+SFJ82 26 mm (1.02 in) Brown
B4M2218C
(1) Measuring point (2) Boot band identification color (3) Tone wheel
DS-3
GENERAL DESCRIPTION
Drive Shaft System
3. REAR DRIVE SHAFT ASSEMBLY S301001E4903
SHAFT
Model Type of axle shaft assembly No. of identification grooves Boot band identification color
on shaft
TURBO 82AC-RH, 82AC-LH 2 (Two) Auburn
NON-TURBO MT 79AC-RH, 79AC-LH 1 (One) White
NON-TURBO AT 79AC None Orange
S4M0521A
(1) Indication mark of RH (2) Identification padding (3) Boot band Identification
DS-4
GENERAL DESCRIPTION
Drive Shaft System
1. PROPELLER SHAFT S301001A0501
S4M0522A
(1) Propeller shaft (Turbo model) (4) Rear differential (T-type) Tightening torque: N·m (kgf-m, ft-lb)
(2) Propeller shaft (Non-Turbo
T1: 31 (3.2, 23.1)
model)
T2: 52 (5.3, 38.3)
(3) Rear differential (VA-type)
DS-5
GENERAL DESCRIPTION
Drive Shaft System
2. FRONT AXEL S301001A0502
B4M2213B
(1) Baffle plate (SFJ) (10) Boot (BJ) (19) Hub bolt
(2) Spring pin (11) BJ ASSY (20) Hub
(3) Outer race (SFJ) (12) Tone wheel (21) Axle nut
(4) Snap ring (13) Baffle plate
(5) Trunnion (14) Oil seal (IN) Tightening torque: N·m (kgf-m, ft-lb)
(6) Free ring (15) Snap ring T: 186 (19, 137)
(7) Circlip (16) Bearing
(8) Boot band (17) Housing
(9) Boot (SFJ) (18) Oil seal (OUT)
DS-6
GENERAL DESCRIPTION
Drive Shaft System
3. REAR AXLE S301001A0503
S4M0523A
(1) Circlip (Non-turbo AT vehicle) (11) Boot (BJ or EBJ) (21) Hub bolt
(2) Baffle plate (DOJ) (12) BJ or EBJ ASSY (22) Hub
(3) Outer race (DOJ) (13) Oil seal (IN. No. 2) (23) Axle nut
(4) Snap ring (14) Baffle plate
(5) Inner race (15) Oil seal (IN) Tightening torque: N·m (kgf-m, ft-lb)
(6) Ball (16) Housing T1: 13 (1.3, 9.4)
(7) Cage (17) Bearing T2: 186 (19, 137)
(8) Circlip (18) Snap ring
(9) Boot band (19) Oil seal (OUT)
(10) Boot (DOJ) (20) Tone wheel
DS-7
GENERAL DESCRIPTION
Drive Shaft System

tion.
ment.
fied points.
deformation.
DS-8
GENERAL DESCRIPTION
Drive Shaft System

922431000 AXLE SHAFT 쐌 Used for installing axle shaft into housing.
INSTALLER 쐌 Used with ADAPTER (927390000).
B4M2386
925091000 BAND TIGHTENING 쐌 Used for tightening boot band. Except front
TOOL axle housing side)
(A) Jig for band
(B) Ratchet wrench
B4M2387A
926470000 AXLE SHAFT Used for removing axle shaft.
PULLER
B4M2388
927060000 HUB REMOVER 쐌 Used for removing front hub.
쐌 Used with HUB STAND (927080000).
B4M2389
DS-9
GENERAL DESCRIPTION
Drive Shaft System

927080000 HUB STAND Used for disassembling and assembling hub
bolt in hub.
B4M2390
927100000 BEARING 쐌 Used for disassembling and assembling front
REMOVER housing bearing.
쐌 Used with HOUSING STAND (927400000).
B4M2391
927140000 PLATE Same as plate 2 included in AXLE SHAFT
PULLER (926470000).
B4M2392
927390000 ADAPTER Used as an adapter for AXLE SHAFT
INSTALLER (922431000).
B4M2393
927400000 HOUSING STAND 쐌 Used for disassembling and assembling front
housing bearing.
쐌 Used with BEARING PULLER (927100000).
B4M2394
DS-10
GENERAL DESCRIPTION
Drive Shaft System

927410000 OIL SEAL 쐌 Used for installing oil seal into front housing.
INSTALLER 쐌 Used with HOUSING STAND (927400000).
B4M2395
927120000 HUB INSTALLER Used for installing hub.
B4M2399
927420000 HUB REMOVER 쐌 Used for removing rear hub.
H5M0981
927430000 HOUSING STAND 쐌 Used for disassembling and assembling rear
housing bearing.
쐌 Used with BEARING PULLER (927440000).
H5M0982
DS-11
GENERAL DESCRIPTION
Drive Shaft System

927440000 BEARING 쐌 Used for disassembling and assembling rear
REMOVER housing bearing.
H5M0983
927460000 OIL SEAL 쐌 Used for installing outer bearing and sub
INSTALLER bearing into housing.
H5M0984
927450000 HUB INSTALLER 쐌 Used for installing rear hub into hub ASSY.
B4M2400
28099PA090 OIL SEAL PROTEC- 쐌 Used for installing rear drive shaft into rear
TOR differential.
쐌 For protecting oil seal.
B4M2401
DS-12
GENERAL DESCRIPTION
Drive Shaft System

28099PA100 DRIVE SHAFT Used for removing rear drive shaft from rear
REMOVER differential.
B4M2402
28099AC000 BOOT BAND PLI- Used for tightening front BJ boot band. (Front
ERS axle housing side)
B4M2403
TOOL NAME REMARKS

Puller Used for removing ball joint from knuckle arm.
Dial Gauge Used for inspecting propeller shaft run-out.
Snap Ring Pliers Used for installing and removing snap ring.
DS-13
PROPELLER SHAFT
Drive Shaft System
2. Propeller Shaft S301160

8) Remove the four bolts which hold propeller
shaft to rear differential.
NOTE:
NOTE: 쐌 Put matching mark on affected parts before
쐌 Before removing propeller shaft, wrap metal removal.
parts with a cloth or rubber material. 쐌 Remove all but one bolt.
쐌 In case of DOJ type, before removing propeller
shaft, wrap metal parts (installed at the rubber boot
of center DOJ) with a cloth or rubber material, as
shown in the figure. Rubber boot may be damaged
due to interference with adjacent metal parts while
bending the DOJ during removal.
S3M0027
9) Remove the two bolts which hold center bear-

ing to car body.
S3M0030

racks.
6) Remove front exhaust cover. (Non-Turbo S3M0028
model)
S3M0025
7) Remove differential mount front cover.
S3M0026
DS-14
PROPELLER SHAFT
Drive Shaft System
10) Remove propeller shaft from transmission. B: INSTALLATION S301160A11
CAUTION: 1) Insert sleeve yoke into transmission and attach

쐌 Be sure not to damage oil seals and the fric- center bearing to body.
tional surface of sleeve yoke.
쐌 Cover the center exhaust pipe with a cloth to Tightening torque:
keep off any ATF or oil spilled from transmis- 52 N·m (5.3 kgf-m, 38.3 ft-lb)
sion when removing propeller shaft.
NOTE:
쐌 Be sure to use an empty oil can to catch oil
flowing out when removing propeller shaft.
쐌 Be sure to plug the opening in transmission after
removal of propeller shaft.
B3M1606
2) Align matching marks and connect flange yoke

and rear differential.
Tightening torque:
31 N·m (3.2 kgf-m, 23.1 ft-lb)
S3M0029B
(A) Propeller shaft

(B) Cloth
11) 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.
B3M1587C
(A) Matching mark
3) Install front exhaust cover. (Non-turbo model)

4) Install differential mount front cover.
Tightening torque:
88 N·m (9.0 kgf-m, 65 ft-lb)
S3M0498A
(A) Extension cap
S3M0026
DS-15
PROPELLER SHAFT
Drive Shaft System
C: INSPECTION S301160A10 3. RUNOUT OF PROPELLER SHAFT

S301160A1003
NOTE:
Do not disassemble propeller shaft. Check the fol- 1) Remove front exhaust cover. (Non-turbo model)
lowing and replace if necessary. 2) Turn rear wheels by hand to check for “runout”
of propeller shaft.
1) Tube surfaces for dents or cracks
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
front and rear propeller shaft tubes.
noise
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
installed in vehicle.
1. JOINTS AND CONNECTIONS S301160A1001
1) Remove center exhaust pipes.

2) Remove heat shield cover.
3) Check for any looseness of yoke flange con-
necting bolts and center bearing retaining bolts.
B3M1603A
2. SPLINES AND BEARING LOCATIONS
(A) Propeller shaft
S301160A1002
(B) Dial gauge
1) Remove front exhaust cover. (Non-turbo model)
2) Turn propeller shaft by hand to see if abnormal 4. CENTER BEARING FREE PLAY S301160A1004
free play exists at splines. Also move yokes to see 1) Remove front exhaust cover. (Non-turbo model)
if abnormal free play exists at spiders and bear- 2) While holding propeller shaft near center bear-
ings. ing with your hand, move it up and down, and left
and right to check for any abnormal bearing free
play.
B3M1602
B3M1604
DS-16
FRONT AXLE
Drive Shaft System
3. Front Axle S301148

8) Remove cotter pin and castle nut which secure
tie-rod end to housing knuckle arm.

2) Jack-up vehicle, support it with safety stands,
and remove front wheels.
3) Unlock axle nut.
B4M2214A
(A) Cotter pin

(B) Castle nut
(C) Tie-rod
G4M0214 9) Using a puller, remove tie-rod ball joint from

knuckle arm.
4) Remove axle nut using a socket wrench.
CAUTION:
Be sure to loose and retighten axle nut after
removing wheel from vehicle. Failure to follow
this rule may damage wheel bearings.
5) Remove stabilizer link.
B4M2215
10) Remove ABS sensor assembly and harness in

advance. (ABS equipped model)
G4M0215
6) Remove disc brake caliper from housing, and

suspend it from strut using a wire.
7) Remove disc rotor from hub.
If disc rotor seizes up within hub, drive disc rotor
out by installing an 8-mm bolt in screw hole on the
rotor. B4M2209
B4M1678
DS-17
FRONT AXLE
Drive Shaft System
11) Remove bolt which secures sensor harness to 15) After scribing an alignment mark on camber
strut. (ABS equipped model) adjusting bolt head, remove bolts which connect
housing and strut, and disconnect housing from
strut.
B4M1442
12) Remove transverse link ball joint from hous- B4M1970

ing.
1) Install transverse link ball joint to housing.

Tightening torque:
49 N·m (5.0 kgf-m, 36 ft-lb)
2) While aligning alignment mark on camber
adjusting bolt head, connect housing and strut.
CAUTION:
B4M2216
Tightening torque:
13) Remove SFJ from transmission spindle. 155 N·m (15.8 kgf-m, 114 ft-lb)
14) Remove front drive shaft assembly from hub.
If it is hard to remove, use STs. 3) Install ABS sensor on housing.
ST1 926470000 AXLE SHAFT PULLER Tightening torque:
ST2 927140000 PLATE 32 N·m (3.3 kgf-m, 23.9 ft-lb)
CAUTION: 4) Install ABS sensor harness on strut.
쐌 Be careful not to damage oil seal lip and tone 5) Install disc rotor on hub.
wheel when removing front drive shaft. 6) Install disc brake caliper on housing.
쐌 When replacing front drive shaft, also
Tightening torque:
replace inner oil seal.
78 N·m (8 kgf-m, 57.9 ft-lb)
7) Install front drive shaft. <Ref. to DS-32
INSTALLATION, Front Drive Shaft.>
8) Connect stabilizer link.
S4M0108A
DS-18
FRONT AXLE
Drive Shaft System
9) Connect tie-rod end ball joint and knuckle arm Tightening torque:
with a castle nut, and insert cotter pin into tie-rod 88 N·m (9 kgf-m, 65 ft-lb)
end.
Castle nut tightening torque:

Tighten to 27.0 N·m (2.75 kgf-m, 19.9 1) Using ST1, support housing and hub securely.
ft-lb), and tighten further within 60° until 2) Attach ST2 to housing and drive hub out.
cotter pin hole is aligned with a slot in ST1 927060000 HUB REMOVER
the nut. ST2 927080000 HUB STAND
CAUTION:
When connecting, do not hit cap at the bottom
of tie-rod end with hammer.
B4M2214A
(A) Cotter pin

(B) Castle nut
(C) Tie-rod
10) While depressing brake pedal, tighten axle nut

and lock it securely.
G4M0223
Tightening torque:
186 N·m (19 kgf-m, 137 ft-lb)
If inner bearing race remains in the hub, remove it
CAUTION: with a suitable tool (commercially available).
쐌 Use a new axle nut.
CAUTION:
쐌 Always tighten axle nut before installing
쐌 Be careful not to scratch polished area of
wheel on vehicle. If wheel is installed and
hub.
comes in contact with ground when axle nut is
쐌 Be sure to install inner race on the side of
loose, wheel bearings may be damaged.
outer race from which it was removed.
쐌 Be sure to tighten axle nut to specified
torque. Do not overtighten it as this may dam-
age wheel bearing.
11) After tightening axle nut, lock it securely.
G4M0224
G4M0238
12) Install wheel and tighten wheel nuts to speci-

fied torque.
DS-19
FRONT AXLE
Drive Shaft System
3) Remove disc cover from housing. 8) Using ST and a hydraulic press, drive hub bolts
out.
ST 927080000 HUB STAND
CAUTION:
Be careful not to hammer hub bolts. This may
deform hub.
G4M0225
4) Using a standard screwdriver, remove outer

and inner oil seals.
CAUTION:
Do not use old oil seals. G4M0228
5) Using flat bladed screwdriver, remove snap
ring.
CAUTION:
Remove without scratching axle housing. 1) Attach hub to ST securely.
H4M1001
G4M0230
6) Using ST1, support housing securely.
7) Using ST2, press inner race to drive out outer 2) Using a hydraulic press, press new hub bolts
bearing. into place.
ST1 927400000 HOUSING STAND CAUTION:
ST2 927100000 BEARING REMOVER Be sure to press hub bolts until their seating
CAUTION: surfaces contact the hub.
쐌 Do not remove outer race unless it is faulty. NOTE:
쐌 Discard outer race after removal. Use 12 mm (0.47 in) dia. holes in HUB STAND to
쐌 Do not replace inner or outer race sepa- prevent bolts from tilting.
rately; always replace as a unit. 3) Clean dust or foreign particles from inside the
housing.
4) Using ST1 and ST2, press a new bearing into
place.
ST1 927400000 HOUSING STAND
ST2 927100000 BEARING REMOVER
G4M0227
DS-20
FRONT AXLE
Drive Shaft System
CAUTION: 8) Using ST1 and ST2, press outer oil seal until it
쐌 Always press outer race when installing contacts the bottom of housing.
bearing. ST1 927410000 OIL SEAL INSTALLER
쐌 Be careful not to remove plastic lock from ST2 927400000 HOUSING STAND
inner race when installing bearing.
쐌 Charge bearing with new grease when outer
race is not removed.
Specified grease:
SHELL 6459N
G4M0233
9) Apply sufficient grease to oil seal lip.

Specified grease
SHELL 6459N
G4M0232 CAUTION:
쐌 If specified grease is not available, remove
5) Using pliers, install snap ring in its groove. bearing grease and apply Auto Rex A instead.
CAUTION: 쐌 Do not mix different types of grease.
쐌 Make sure to install it firmly to groove. 10) Install disc cover to housing the three bolts.
쐌 Install without scratching axle housing.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
11) Attach hub to ST1 securely.
12) Clean dust or foreign particles from the pol-
ished surface of hub.
13) Using ST2, press bearing into hub by driving
inner race.
ST1 927080000 HUB STAND
ST2 927120000 HUB INSTALLER
B4M2253
6) Using ST1 and ST2, press inner oil seal until it

contacts circlip.
ST1 927410000 OIL SEAL INSTALLER
G4M0235
G4M0234
7) Invert ST and housing.

ST 927400000 HOUSING STAND
DS-21
FRONT AXLE
Drive Shaft System
1) Moving front tire up and down by hand, check

that there is no backlash in the bearing. And check
that wheel rotates smoothly.
S4M0572
2) Inspect the removed parts for wear and dam-

age. If defective, replace with new ones.
CAUTION:
쐌 If bearing is faulty, replace it as the bearing
set.
쐌 Be sure to replace oil seal at every overhaul.
H4M1002C
(A) Replace as a set.
DS-22
REAR AXLE
Drive Shaft System
4. Rear Axle S301154

8) Disconnect parking brake cable end.
1. DISC BRAKE S301154A1802

2) Jack-up vehicle, and remove rear wheel cap
and wheels.
CAUTION:
Be sure to loosen and retighten axle nut after
S4M0368A
3) Unlock axle nut. (1) Cable end
5) Return parking brake lever and loosen adjust- 9) Disconnect rear stabilizer from rear lateral link.
ing nut. 10) Remove bolts which secure trailing link
assembly to rear housing.
CAUTION:
Discard old self-locking nut. Replace with a
new one.
S4M0520A
(1) Parking brake lever

(2) Lock nut
(3) Adjusting nut
S4M0109
6) Remove disc brake caliper from back plate, and

suspend it from strut using a piece of wire.
bly to rear housing.
CAUTION:
new one.
G4M0240
7) Remove disc rotor from hub.

NOTE:
If disc rotor seizes up within hub, drive it out by S4M0110
installing an 8-mm bolt into bolt hole in disc rotor.
DS-23
REAR AXLE
Drive Shaft System
12) Disengage BJ from housing splines, and 2. DRUM BRAKE S301154A1803
remove rear drive shaft assembly. If it is hard to

remove, use STs.
2) Jack-up vehicle, and remove rear wheel cap
ST1 926470000 AXLE SHAFT PULLER
and wheels.
ST2 927140000 PLATE
CAUTION:
CAUTION:
쐌 Be careful not to damage oil seal lip when
removing rear drive shaft.
쐌 When rear drive shaft is to be replaced, also
replace inner oil seal with a new one. 3) Unlock axle nut.
5) Return parking brake lever and loosen adjust-
ing nut.
G4M0247
13) Remove rear ABS sensor from back plate

(only vehicle equipped with ABS). S4M0520A

(2) Lock nut
(3) Adjusting nut
6) Remove brake drum from hub.

7) If it is difficult to remove brake drum, remove
adjusting hole cover from back plate, and then turn
adjusting screw using a slot-type screwdriver until
brake shoe separates from the drum.
H4M1139B
(1) ABS sensor
14) Remove bolts which secure rear housing to

strut, and separate the two.
S4M0369A
(1) Back plate

(2) Wheel cylinder
(3) Adjuster ASSY pawls
(4) Adjusting lever
(5) Tightening direction
G4M0249
(6) Push
DS-24
REAR AXLE
Drive Shaft System
NOTE: 11) Remove bolts which secure trailing link

If brake drum is difficult to remove, drive it out by assembly to rear housing.
installing an 8-mm bolt into bolt hole in brake drum. CAUTION:
new one.
G4M0243
8) Using a flare-nut wrench, disconnect brake pipe

from wheel cylinder. S4M0109
CAUTION: 12) Remove bolts which secure lateral link assem-

Cover open end of wheel cylinder to prevent bly to rear housing.
entry of foreign particles. CAUTION:
new one.
G4M0244
9) Disconnect parking brake cable end.

S4M0110
13) Disengage BJ from housing splines, and

remove rear drive shaft assembly. If it is hard to
remove, use STs.
ST2 927140000 PLATE
CAUTION:
S4M0368A
replace inner oil seal with a new one.
(1) Cable end
10) Disconnect rear stabilizer from rear lateral link.
G4M0247
DS-25
REAR AXLE
Drive Shaft System
14) Remove rear ABS sensor from back plate 3) Connect rear housing assembly to lateral link
(only vehicle equipped with ABS). assembly.
CAUTION:
Tightening torque:
137 N·m (14 kgf-m, 101 ft-lb)
H4M1139B
(1) ABS sensor
15) Remove bolts which secure rear housing to

strut, and separate the two.
S4M0110
4) Connect rear housing assembly to trailing link

assembly.
CAUTION:
Tightening torque:
113 N·m (11.5 kgf-m, 83 ft-lb)
G4M0249
1. DISC BRAKE S301154A1102
1) Connect rear housing assembly and strut

assembly.
CAUTION: S4M0109
5) Connect rear stabilizer to rear lateral link.
Tightening torque:
196 N·m (20 kgf-m, 145 ft-lb) CAUTION:
2) Fit BJ (bell joint) to rear housing splines.
Tightening torque:
CAUTION: 44 N·m (4.5 kgf-m, 32.5 ft-lb)
Be careful not to damage inner oil seal lip.
6) Connect parking brake cable to parking brake.
7) Install disc rotor on rear housing assembly.
DS-26
REAR AXLE
Drive Shaft System
8) Install disc brake caliper on back plate. 2. DRUM BRAKE S301154A1103
Tightening torque: 1) Connect rear housing assembly and strut

52 N·m (5.3 kgf-m, 38.3 ft-lb) assembly.
CAUTION:
Tightening torque:
196 N·m (20 kgf-m, 145 ft-lb)
2) Fit BJ (bell joint) to rear housing splines.
CAUTION:
3) Connect rear housing assembly to lateral link
G4M0240 assembly.
9) Install rear ABS sensor to back plate (only CAUTION:
vehicle equipped with ABS). Use a new self-locking nut.
Tightening torque:
137 N·m (14 kgf-m, 101 ft-lb)
H4M1139B
(1) ABS sensor

S4M0110
10) Bleed air from brake system. <Ref. to BR-47, 4) Connect rear housing assembly to trailing link
Air Bleeding.> assembly.
11) Adjust parking brake lever stroke by turning
adjuster. CAUTION:
12) Move brake lever back to apply brakes. While Use a new self-locking nut.
depressing brake pedal, tighten axle nut using a Tightening torque:
socket wrench. Lock axle nut after tightening. 113 N·m (11.5 kgf-m, 83 ft-lb)
Tightening torque:
186 N·m (19 kgf-m, 137 ft-lb)
CAUTION:
torque. Do not overtighten it as this may dam- S4M0109
age wheel bearing.
5) Connect rear stabilizer to rear lateral link.
fied torque. CAUTION:
Tightening torque:
Tightening torque:
88 N·m (9 kgf-m, 65 ft-lb)
44 N·m (4.5 kgf-m, 32.5 ft-lb)
6) Connect parking brake cable to parking brake.
DS-27
REAR AXLE
Drive Shaft System
7) Clean brake pipe connection. Using a flare-nut C: DISASSEMBLY S301154A06
wrench, connect brake pipe to wheel cylinder.

8) Connect rear ABS sensor to back plate (only 1) Using ST1 and ST2, remove hub from rear
vehicle equipped with ABS). housing.
ST2 927420000 HUB REMOVER
H4M1139B
(1) ABS sensor G4M0250
9) Connect parking brake cable to lever. 2) Remove back plate from rear housing.
10) Install brake drum on rear housing assembly. 3) Using a standard screwdriver, remove outer
11) Bleed air from brake system. <Ref. to BR-47, and inner oil seals.
Air Bleeding.> CAUTION:
12) Adjust parking brake lever stroke by turning Use new oil seals.
adjuster.
13) Move brake lever back to apply brakes. While 4) Using flat bladed screwdriver, remove snap
depressing brake pedal, tighten axle nut using a ring.
socket wrench. Lock axle nut after tightening. CAUTION:
Tightening torque: Remove without scratching axle housing.
186 N·m (19 kgf-m, 137 ft-lb)
CAUTION:
age wheel bearing.
H4M1003
fied torque.
Tightening torque:
88 N·m (9 kgf-m, 65 ft-lb)
DS-28
REAR AXLE
Drive Shaft System
5) Using ST1 and ST2, remove bearing by press- D: ASSEMBLY S301154A02
ing inner race.

ST1 927430000 HOUSING STAND 1) Using ST, press new hub bolt into place.
ST2 927440000 BEARING REMOVER CAUTION:
CAUTION: 쐌 Ensure hub bolt closely contacts hub.
쐌 Do not remove bearing unless damaged. 쐌 Use a 12 mm (0.47 in) hole in the ST to pre-
쐌 Do not re-use bearing after removal. vent hub bolt from tilting during installation.
G4M0252
G4M0230
6) Remove tone wheel bolts and remove tone
wheel from hub (only vehicle equipped with ABS). 2) Remove foreign particles (dust, rust, etc.) from
7) Using ST, press hub bolt out. mating surfaces of hub and tone wheel, and install
ST 927080000 HUB STAND tone wheel to hub (only vehicle equipped with
CAUTION: ABS).
Be careful not to hammer hub bolts. This may CAUTION:
deform hub. 쐌 Ensure tone wheel closely contacts hub.
쐌 Be careful not to damage tone wheel teeth.
G4M0228
S4M0370A
(1) Tone wheel
DS-29
REAR AXLE
Drive Shaft System
3) Clean housing interior completely. Using ST1 5) Using ST1 and ST2, press outer oil seal until it
and ST2, press bearing into housing. comes in contact with snap ring.
ST1 927430000 HOUSING STAND ST1 927430000 HOUSING STAND
ST2 927440000 BEARING REMOVER ST2 927460000 OIL SEAL INSTALLER
CAUTION:
쐌 Always press outer race when installing
bearing.
쐌 Be careful not to remove plastic lock from
inner race when installing bearing.
쐌 Charge bearing with new grease when outer
race is not removed.
S4M0267B
(1) Snap ring
6) Invert both ST1 and housing.

7) Using ST2, press inner oil seal into housing
until it touches bottom.
S4M0266A ST2 927460000 OIL SEAL INSTALLER
4) Using plier, install snap ring.

CAUTION:
쐌 Ensure snap ring fits in groove properly.
쐌 Install without scratching axle housing.
S4M0268A
8) Using ST1 and ST2, press sub seal into place.

S4M0371A
(1) Plier
S4M0269A
9) Apply sufficient grease to oil seal lip.

Specified grease:
SHELL 6459N
CAUTION:
쐌 If specified grease is not available, remove
bearing grease and apply Auto Rex A instead.
쐌 Do not mix different types of grease.
DS-30
REAR AXLE
Drive Shaft System
10) Install back plate to rear housing.

Tightening torque:
52 N·m (5.3 kgf-m, 38 ft-lb)
11) Using ST1 and ST2, press bearing into hub.
ST2 927450000 HUB INSTALLER
S4M0270B
(1) Back plate
1) Check that there is no backlash in the rear

bearing as well as front. And check that wheel
rotates smoothly. <Ref. to DS-22, INSPECTION,
Front Axle.>
2) Inspect the removed parts for wear and dam-
age. If defective, replace with a new one.
CAUTION:
쐌 If a bearing is faulty, replace it as the bearing
set.
쐌 Be sure to replace oil seal at every overhaul.
H4M1002B
(A) Replace as a set.
DS-31
FRONT DRIVE SHAFT
Drive Shaft System
5. Front Drive Shaft S301153 B: INSTALLATION S301153A11
1) Insert BJ into hub splines.
1) Disconnect ground terminal from battery. CAUTION:
2) Jack-up vehicle, support it with safety stands Be careful not to damage inner oil seal lip and
(rigid rocks), and remove front wheel cap and tone wheel.
wheels. 2) Using ST1 and ST2, pull drive shaft into place.
3) Unlock axle nut. ST1 922431000 AXLE SHAFT INSTALLER
4) Depress brake pedal and remove axle nut ST2 927390000 ADAPTER
using a socket wrench.
CAUTION:
CAUTION: Do not hammer drive shaft when installing it.
5) Remove stabilizer link from transverse link.
6) Disconnect transverse link from housing.
7) Remove spring pin which secures transmission
spindle to SFJ.
CAUTION:
Use a new spring pin.
G4M0291
3) Tighten axle nut temporarily.

4) Install SFJ on transmission spindle and drive
spring pin into place.
CAUTION:
Always use a new spring pin.
G4M0279
8) Remove front drive shaft assembly. If it is hard

to remove, use ST1 and ST2.
ST2 927140000 PLATE
CAUTION:
쐌 Be careful not to damage oil seal lip and tone
wheel when removing front drive shaft. G4M0279
쐌 When front drive shaft is to be replaced, also
replace inner oil seal. 5) Connect transverse link to housing.
Tightening torque (self-locking nut):
49 N·m (5.0 kgf-m, 36 ft-lb)
CAUTION:
6) Install stabilizer bracket.
7) While depressing brake pedal, tighten axle nut
to the specified torque.
Tightening torque:
S4M0108A 186 N·m (19 kgf-m, 137 ft-lb)
DS-32
FRONT DRIVE SHAFT
Drive Shaft System
CAUTION: CAUTION:
쐌 Use a new axle nut. The grease is a special grease. Do not confuse
쐌 Always tighten axle nut before installing with other greases.
wheel on vehicle. If wheel is installed and 6) Place alignment mark on free ring and trunnion.
age wheel bearing.
1) Place alignment marks on shaft and outer race.
B4M0774
2) Remove SFJ boot band and boot. B4M0777
CAUTION: 7) Remove free ring from trunnion.

Be careful not to damage boot.
CAUTION:
Be careful with the free ring position.
8) Place alignment mark on trunnion and shaft.
B4M0775
3) Remove circlip from SFJ outer race using

screwdriver. B4M0778
9) Remove snap ring and trunnion.
B4M0776
4) Remove SFJ outer race from shaft assembly. B4M0779

5) Wipe off grease.
DS-33
FRONT DRIVE SHAFT
Drive Shaft System
CAUTION: D: ASSEMBLY S301153A02
Be sure to wrap shaft splines with vinyl tape to

prevent boot from scratches. CAUTION:
Use specified grease.
10) Remove SFJ boot.
11) Place drive shaft in a vise between wooden BJ side:
blocks. NTG2218 (Part No. 28093AA000)
CAUTION: SFJ side:

Do not place drive shaft directly in the vise; use SSG6003 (Part No. 28093TA000)
wooden block. 1) Place BJ boot and small boot band on BJ side
12) Raise boot band claws by means of screw- of shaft.
driver and hammer. CAUTION:
prevent boot from scratches.
2) Place drive shaft in a vise.
CAUTION:
Do not place drive shaft directly in the vise; use
wooden blocks.
3) Apply a coat of specified grease [60 to 70 g
(2.12 to 2.47 oz)] to BJ.
4) Apply an even coat of specified grease [20 to
30 g (0.71 to 1.06 oz)] to the entire inner surface
of boot. Also apply grease to shaft.
NOTE:
The inside of the larger end of BJ boot and the boot
groove shall be cleaned so as to be free from
grease and other substances.
5) Install boot projecting portion to BJ groove.
B4M2220B
(A) Boot band claws
13) Cut and remove the boot.

CAUTION:
The boot must be replaced with a new one
whenever it is removed. B4M2217B
(A) BJ
(B) Lorge boot band
(C) Boot
6) Set large boot band in place.
B4M0690
14) Thus, disassembly of axle is completed, but

BJ cannot be disassembled.
DS-34
FRONT DRIVE SHAFT
Drive Shaft System
7) Install boot projecting portion to shaft groove. 11) Install snap ring to shaft.
CAUTION:
Confirm that the snap ring is completely fitted
in the shaft groove.
12) Fill 100 to 110 g (3.53 to 3.88 oz) of specified
grease into the interior of SFJ outer race.
13) Apply a coat of specified grease to free ring
and trunnion.
14) Align alignment marks on free ring and trun-
nion and install free ring.
B4M1297C CAUTION:
Be careful with the free ring position.
(A) Boot
(B) Small boot band
(C) Shaft
8) Tighten boot bands using ST, torque wrench

and socket flex handle.
ST 28099AC000 BOOT BAND PLIER
B4M0693C
(A) Large boot band

(B) Boot
(C) Torque wrench
(D) Socket flex handle
B4M0777
(E) BJ
Tightening torque: 15) Align alignment marks on shaft and outer
Large boot band race, and install outer race.
157 N·m (16.0 kgf-m, 116 ft-lb) or more
Small boot band
133 N·m (13.6 kgf-m, 98 ft-lb) or more
9) Place SFJ boot at the center of shaft.
10) Align alignment marks and install trunnion on
shaft.
B4M0774
16) Install circlip in the groove on SFJ outer race.

CAUTION:
Pull the shaft lightly and assure that the circlip
is completely fitted in the groove.
B4M0778
DS-35
FRONT DRIVE SHAFT
Drive Shaft System
17) Apply an even coat of the specified grease 30 23) Cut off band with an allowance of about 10
to 40 g (1.06 to 1.41 oz) to the entire inner surface mm (0.39 in) left from the clip and bend this allow-
of boot. ance over the clip.
18) Install SFJ boot taking care not to twist it. CAUTION:
CAUTION: Be careful so that the end of the band is in
쐌 The inside of the larger end of SFJ boot and close contact with clip.
the boot groove shall be cleaned so as to be 24) Fix up boot on BJ in the same manner.
free from grease and other substances.
NOTE:
쐌 When installing SFJ boot, position outer
Extend and retract SFJ to provide equal grease
race of SFJ at center of its travel. coating.
19) Put a band through the clip and wind twice in
alignment with band groove of boot. E: INSPECTION S301153A10
CAUTION: Check the removed parts for damage, wear, corro-

sion etc. If faulty, repair or replace.
Use a new band.
1) DOJ (Double Offset Joint)
20) Pinch the end of band with pliers. Hold the clip Check seizure, corrosion, damage, wear and
and tighten securely. excessive play.
NOTE: 2) SFJ (Shudder-less Freering tripod Joint)
Check seizure, corrosion, damage and excessive
When tightening boot, exercise care so that the air
play.
within the boot is appropriate.
3) Shaft
21) Tighten band by using ST. Check excessive bending, twisting, damage and
ST 925091000 BAND TIGHTENING TOOL wear.
4) BJ (Bell Joint)
NOTE:
Tighten band until it cannot be moved by hand.
play.
5) Boot
Check for wear, warping, breakage or scratches.
6) Grease
Check for discoloration or fluidity.
G4M0289
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.
G4M0290
DS-36
FRONT DRIVE SHAFT BOOT
Drive Shaft System
6. Front Drive Shaft Boot S301755
Check boot for deterioration, deform and damage.

If any fault is found, replace the boot.

3) Jack-up vehicle, support it with safety stands
(rigid rocks), and remove front wheel cap and
wheels.
NOTE:
Do not remove axle nut.
4) Remove stabilizer link.
5) Disconnect transverse link from housing.
6) Remove spring pin which secures transmission
spindle to SFJ.
CAUTION:
Use a new spring pin.
G4M0279
7) Remove BJ and SFJ boots from drive shaft.

<Ref. to DS-33, DISASSEMBLY, Front Drive
Shaft.>
8) Install BJ and SFJ boots to drive shaft.
<Ref. to DS-34, ASSEMBLY, Front Drive Shaft.>
9) Install SFJ on transmission spindle and drive
spring pin into place.
CAUTION:
Always use a new spring pin.
G4M0279
10) Connect transverse link to housing.

11) Install stabilizer link.
DS-37
REAR DRIVE SHAFT
Drive Shaft System
7. Rear Drive Shaft S301156

CAUTION:
A: REMOVAL S301156A18 Always use bolt as shown in figure, as support-
1) Set vehicle on a lift. ing point for ST during removal.
2) Disconnect ground cable from battery. ST 28099PA100 DRIVE SHAFT REMOVER
3) Lift vehicle. Remove rear wheel cap and
wheels.
CAUTION:
4) Unlock axle nut.
5) Loosen axle nut using a socket wrench.
CAUTION:
Do not remove axle nut. S4M0373A
6) Remove ABS sensor clamps and parking brake (1) Side bearing retainer
cable bracket.
7) Remove bolts which secure lateral link assem- 10) Remove DOJ from rear differential using tire
bly to rear housing. lever. (Non-TURBO AT vehicles)
CAUTION: NOTE:
Discard old self-locking nut. Replace with a The side spline shaft circlip comes out together
new one. with the shaft.
8) Remove bolts which secure trailing link assem-
bly to rear housing.
CAUTION:
new one.
9) Remove DOJ from rear differential using ST.
(Except Non-TURBO AT vehicle)
CAUTION: S4M0374A
Do not remove circlip attached to inside of dif-
ferential. (1) Tire lever
CAUTION:
holder.
S4M0372A
(1) Bolt
(2) DOJ
S4M0375A
(1) Axle shaft holder
DS-38
REAR DRIVE SHAFT
Drive Shaft System
11) Remove axle nut and drive shaft. If it is hard 5) Using ST, install DOJ into differential.
to remove, use ST1 and ST2. ST 28099PA090 SIDE OIL SEAL PROTEC-
ST1 926470000 AXLE SHAFT PULLER TOR
ST2 927140000 PLATE
CAUTION:
replace inner oil seal with a new one.
B4M0549A
6) Insert DOJ spline end into bore of side oil seal,

and remove ST.
CAUTION:
Do not allow DOJ splines to damage side oil
seal.
G4M0247
TOR
1) Insert BJ into rear housing splines.

CAUTION:
2) Using ST1 and ST2, pull drive shaft into place.
ST1 922431000 AXLE SHAFT INSTALLER
ST2 927390000 ADAPTER
CAUTION:
Do not hammer drive shaft when installing it. B4M0550A
7) Align DOJ and differential splines.

8) Push housing to insert DOJ into differential.
NOTE:
Make sure DOJ is inserted properly.
G4M0293
3) Tighten axle nut temporarily.

4) Replace circlips from DOJ spline with new one.
G3M0050

assembly, and tighten self-locking nut.
Tightening torque:
113 N·m (11.5 kgf-m, 83 ft-lb)
DS-39
REAR DRIVE SHAFT
Drive Shaft System
Tightening torque: 6) Take out DOJ outer race from shaft assembly.
137 N·m (14 kgf-m, 101 ft-lb) 7) Wipe off grease and take out balls.
11) Install stabilizer bracket. CAUTION:
12) While depressing brake pedal, tighten axle nut The grease is a special grease (grease for con-
using a socket wrench. stant velocity joint). Do not confuse with other
Tightening torque: greases.
186 N·m (19 kgf-m, 137 ft-lb) NOTE:
CAUTION: Disassemble exercising care not to lose balls (6
쐌 Use a new axle nut. pcs).
age wheel bearing.
B4M0227E
1) Straighten bent claw of larger end of DOJ boot. (A) Outer race
2) Loosen band by means of screwdriver or pliers (B) Grease
with care of not damaging boot.
8) To remove the cage from the inner race, turn
the cage by a half pitch to the track groove of the
inner race and shift the cage.
9) Remove snap ring, which fixes inner race to
shaft, by using pliers.
10) Take out DOJ inner race.
11) Take off DOJ cage from shaft and remove DOJ
boot.
CAUTION:
G4M0281
prevent boot from scratches.
3) Remove boot band on the small end of DOJ 12) Remove BJ boot in the same procedure as
boot in the same manner. DOJ boot.
4) Remove the larger end of DOJ boot from DOJ 13) Thus, disassembly of axle is completed, but
outer race. BJ is unable to be disassembled.
5) Pry and remove round circlip located at the
neck of DOJ outer race with a screwdriver. D: ASSEMBLY S301156A02
CAUTION:
Use specified grease.
BJ side (Non-turbo model):
Molylex No. 2 (Part No. 723223010)
EBJ side (Turbo model):
NTG 2218 (Part No. 28093AA000)
DOJ side:
VU-3A702 (Yellow) (Part No. 23223GA050)
G4M0282 1) Install BJ or EBJ boot in specified position, and
fill it with 60 to 70 g (2.12 to 2.47 oz) of specified
grease.
2) Place DOJ boot at the center of shaft.
DS-40
REAR DRIVE SHAFT
Drive Shaft System
CAUTION: 5) Install cage, which was previously fitted, to

Be sure to wrap shaft splines with vinyl tape to inner race fixed upon shaft.
prevent boot from scratches. NOTE:
3) Insert DOJ cage onto shaft. Fit the cage with the protruded part aligned with the
NOTE: track on the inner race and then turn by a half
Insert the cage with the cut-out portion facing the pitch.
shaft end, since the cage has an orientation.
B4M0228E
S4M0376B (A) Inner race

(B) Cage
(A) Cage
(B) Cut-out portion 6) Fill 80 to 90 g (2.82 to 3.17 oz) of specified
4) Install DOJ inner race on shaft and fit snap ring grease into the interior of DOJ outer race.
with pliers. 7) Apply a coat of specified grease to the cage
pocket and six balls.
NOTE: 8) Insert six balls into the cage pocket.
Confirm that the snap ring is completely fitted in the 9) Align the outer race track and ball positions and
shaft groove. place in the part where shaft, inner race, cage and
balls are previously installed, and then fit outer
race.
G4M0285
B4M0227E
(A) Outer race

(B) Grease
DS-41
REAR DRIVE SHAFT
Drive Shaft System
10) Install circlip in the groove on DOJ outer race. 15) Tighten band by using ST.
NOTE: ST 925091000 BAND TIGHTENING TOOL
쐌 Assure that the balls, cage and inner race are NOTE:
completely fitted in the outer race of DOJ. Tighten band until it cannot be moved by hand.
쐌 Exercise care not to place the matched position
of circlip in the ball groove of outer race.
쐌 Pull the shaft lightly and assure that the circlip is
completely fitted in the groove.
G4M0289
16) Tap on the clip with the punch provided at the

end of ST.
ST 925091000 BAND TIGHTENING TOOL
G4M0282
CAUTION:
11) Apply an even coat of the specified grease [20 Tap to an extent that the boot underneath is not
to 30 g (0.71 to 1.06 oz)] to the entire inner surface damaged.
of boot. Also apply grease to shaft.
12) Install DOJ boot taking care not to twist it.
NOTE:
쐌 The inside of the larger end of DOJ boot and the
boot groove shall be cleaned so as to be free from
grease and other substances.
쐌 When installing DOJ boot, position outer race of
DOJ at center of its travel.
13) Put a band through the clip and wind twice in
alignment with band groove of boot. G4M0290
CAUTION: 17) Cut off band with an allowance of about 10

Use a new band. mm (0.39 in) left from the clip and bend this allow-
14) Pinch the end of band with pliers. Hold the clip ance over the clip.
and tighten securely. CAUTION:
NOTE: Be careful so that the end of the band is in
When tightening boot, exercise care so that the air close contact with clip.
within the boot is appropriate. 18) Fix up boot on BJ or EBJ in the same manner.
NOTE:
Extend and retract DOJ to provide equal grease
coating.
DS-42
REAR DRIVE SHAFT
Drive Shaft System
Check the removed parts for damage, wear, corro-

sion etc. If faulty, repair or replace.
1) DOJ (Double Offset Joint)
Check seizure, corrosion, damage, wear and
excessive play.
2) SFJ (Shudder-less Freering tripod Joint)
play.
3) Shaft
Check excessive bending, twisting, damage and
wear.
4) BJ (Bell Joint) or EBJ (High efficiency compact
ball fixed joint)
play.
5) Boot
Check for wear, warping, breakage or scratches.
6) Grease
Check for discoloration or fluidity.
DS-43
REAR DRIVE SHAFT BOOT
Drive Shaft System
8. Rear Drive Shaft Boot S301756

CAUTION:
A: INSPECTION S301756A10 Always use bolt as shown in figure, as support-
Check boot for deterioration, deform and damage. ing point for ST during removal.
If any fault is found, replace the boot. ST 28099PA100 DRIVE SHAFT REMOVER

3) Lift vehicle. Remove rear wheel cap and
wheels.
NOTE:
Axle nut need not be removed.
4) Remove ABS sensor clamps and parking brake
cable bracket. S4M0373A
5) Disconnect stabilizer link from lateral link. (1) Side bearing retainer
bly to rear housing. 9) Remove DOJ and BJ or EBJ boots from drive
7) Remove bolts which secure trailing link assem- shaft. <Ref. to DS-40, DISASSEMBLY, Front Drive
bly to rear housing. Shaft.>
8) Remove DOJ from rear differential using ST. 10) Install DOJ and BJ or EBJ boots to drive shaft.
ST 28099PA100 DRIVE SHAFT REMOVER <Ref. to DS-40, ASSEMBLY, Rear Drive Shaft.>
NOTE: 11) Using ST, install DOJ into differential.
The side spline shaft circlip comes out together ST 28099PA090 SIDE OIL SEAL PROTEC-
with the shaft. TOR
B4M0549A
S4M0372A
(1) Bolt
(2) DOJ
DS-44
REAR DRIVE SHAFT BOOT
Drive Shaft System
12) Insert DOJ spline end into bore of side oil seal,
and remove ST.
CAUTION:
Do not allow DOJ splines to damage side oil
seal.
TOR
B4M0550A
13) Align DOJ and differential splines.

14) Push housing to insert DOJ into differential.
NOTE:
Make sure DOJ is inserted properly.
G3M0050
CAUTION:
new one.
17) Connect stabilizer link to lateral link.
18) Install ABS sensor clamps and parking brake
cable bracket.
DS-45
Drive Shaft System
NOTE:
Vibration while cruising may be caused by an unbalanced tire, improper tire inflation pressure, improper
wheel alignment, etc.
1. Vibration of propeller shaft (1) Worn or damaged universal joint. Replace.
NOTE: (2) Unbalanced propeller shaft due to Replace.
Vibration is caused by propeller shaft bend or dent.
during operation and is transferred to (3) Loose installation of propeller shaft. Retighten.
vehicle body. Generally vibration
(4) Worn or damaged center bearing and Replace.
increase in proportion to vehicle speed.
damaged center mounting rubber.
2. Tapping when starting and noise (1) Worn or damaged universal joint. Replace.
while cruising, caused by propeller (2) Worn spline of sleeve yoke. Replace.
shaft. (3) Loose installation of propeller shaft. Retighten.
(4) Loose installation of joint. Replace.
(5) Worn or damaged center bearing and Replace.
damaged center mounting rubber.
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
CHASSIS SECTION

SUBARU vehicles.
ine parts.

G8050GE5
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
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)
Front 1.25±0.25 kΩ
ABS sensor resistance
Rear 1.0±0.2 kΩ
ABS sensor
Front LH Brown
Front RH Blue
Marks of the harness
Rear LH Yellow
Rear RH White
G sensor G sensor voltage 2.3±0.2 V
ABS control module and AT C7
hydraulic control unit
(ABSCM&H/U) marks MT C8
ABS-2
GENERAL DESCRIPTION
ABS
1. SENSOR S401001A0501
H4M1386A
(1) G sensor (5) Front ABS sensor LH Tightening torque: N·m (kgf-m, ft-lb)
(2) Rear ABS sensor RH (6) Front ABS sensor RH
T1: 18 (1.8, 13.0)
(3) ABS spacer
T2: 32 (3.3, 24)
(4) Rear ABS sensor LH
ABS-3
GENERAL DESCRIPTION
ABS
2. ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U) S401001A0502
B4M2462A
(1) Stud bolt (6) Front-RH outlet Tightening torque: N·m (kgf-m, ft-lb)
(2) Damper (7) Primary inlet
T1: 18 (1.8, 13.06)
(3) ABS control module and hydrau- (8) Rear-LH outlet
T2: 32 (3.3, 24)
lic control unit (9) Rear-RH outlet
T3: 38 (3.8, 28)
(4) Front-LH outlet (10) Bracket
(5) Secondary inlet
ABS-4
GENERAL DESCRIPTION
ABS

tion.
ment.
part in the vehicle is hot after running.
fied points.
쐌 Before disconnecting electrical connectors of
sensors or units, be sure to disconnect negative
terminal from battery.
ABS-5
GENERAL DESCRIPTION
ABS

(Newly adapted tool)
B2M3876
KIT 쐌 English: 22771AA030 (Without printer)
쐌 German: 22771AA070 (Without printer)
쐌 French: 22771AA080 (Without printer)
쐌 Spanish: 22771AA090 (Without printer)
B2M3877
TOOL NAME REMARKS

Pressure Gauge Used for measuring oil pressure.
Oscilloscope Used for measuring sensor.
ABS-6
ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
ABS
2. ABS Control Module and

Hydraulic Control Unit
(ABSCM&H/U) S401543

2) Remove air intake duct from engine compart-
ment to facilitate removal of ABSCM&H/U.
3) Use an air gun to get rid of water around the B4M1222
ABSCM&H/U.
CAUTION:
The contact will be insufficient if the terminal
gets wet.
4) Pull off the lock of the ABSCM&H/U connector
to remove it.
B4M1224
5) Disconnect 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 cable clip.
7) Disconnect brake pipes from ABSCM&H/U.
CAUTION:
Wrap brake pipes with vinyl bag to avoid spill-
ing brake fluid on vehicle body.
8) Remove ABSCM&H/U ground terminal from
bracket.
9) Remove ABSCM&H/U from engine compart-
ment.
CAUTION:
쐌 ABSCM&H/U cannot be disassembled. Do
not attempt to loosen bolts and nuts.
쐌 Do not drop or bump ABSCM&H/U.
쐌 Do not turn the ABSCM&H/U upside down or
place it on its side.
쐌 Be careful to prevent foreign particles from
getting into ABSCM&H/U.
쐌 Apply a coat of rust-preventive wax (Nippeco
LT or GB) to bracket attaching bolt after tight-
ening.
쐌 Do not pull harness when disconnecting
connector.
ABS-7
ABS
B: INSTALLATION S401543A11 C: INSPECTION S401543A10
1) Install ABSCM&H/U. 1) Check connected and fixed condition of con-

CAUTION: nector.
Confirm that the specifications of the 2) Check specifications of the mark with
ABSCM&H/U conforms to the vehicle specifica- ABSCM&H/U.
tions. Mark Model
Tightening torque: C7 AT
18 N·m (1.8 kgf-m, 13.0 ft-lb) C8 MT
2) Install ABSCM&H/U ground terminal to bracket.
Tightening torque:
32 N·m (3.3 kgf-m, 24 ft-lb)
3) Connect brake pipes to their correct
ABSCM&H/U connections.
Tightening torque:
15 N·m (1.5 kgf-m, 10.8 ft-lb)
S4M0289C
(1) Mark
1. CHECKING THE HYDRAULIC UNIT ABS

OPERATION BY PRESSURE GAUGE
S401543A1001
1) Lift-up vehicle and remove wheels.

2) Disconnect the air bleeder screws from the FL
B4M1222
and FR caliper bodies.
4) Using cable clip, secure ABSCM&H/U harness 3) Connect two pressure gauges to the FL and FR
to bracket. caliper bodies.
5) Connect connector to ABSCM&H/U. CAUTION:
CAUTION: 쐌 Pressure gauges used exclusively for brake
쐌 Be sure to remove all foreign matter from fluid must be used.
inside the connector before connecting. 쐌 Do not employ pressure gauge previously
쐌 Ensure that the ABSCM&H/U connector is used for transmission since the piston seal is
securely locked. expanded which may lead to malfunction of the
brake.
6) Install air intake duct.
7) Connect ground terminal to battery. NOTE:
8) Bleed air from the brake system. Wrap sealing tape around the pressure gauge.
B4M1732
ABS-8
ABS
4) Bleed air from the pressure gauges. 2. CHECKING THE HYDRAULIC UNIT ABS
5) Perform ABS sequence control. OPERATION WITH BRAKE TESTER S401543A1002
<Ref. to ABS-11 ABS Sequence Control.>
6) When the hydraulic unit begins to work, and 1) In the case of AWD AT vehicles, install a spare
first the FL side performs decompression, holding, fuse with the FWD connector in the main fuse box
and compression, and then the FR side performs to simulate FWD vehicles.
decompression, holding, and compression.
7) Read values indicated on the pressure gauge
and check if the fluctuation of the values between
decompression and compression meets the stan-
dard values. Also check if any irregular brake pedal
tightness is felt.
Front wheel Rear wheel
3,432 kPa 3,432 kPa
Initial value (35 kg/cm2, 498 (35 kg/cm2, 498
psi) psi)
S4M0127B
490 kPa 490 kPa
When
(5 kg/cm2, 71 psi) (5 kg/cm2, 71 psi) (1) Main fuse box
decompressed
or less or less (2) FWD connector
3,432 kPa 3,432 kPa
When (35 kg/cm2, 498 (35 kg/cm2, 498 2) Prepare for operating ABS sequence control.
compressed psi) psi) <Ref. to ABS-11 ABS Sequence Control.>
or more or more 3) Set the front wheels or rear wheels on the brake
8) Remove pressure gauges from FL and FR cali- tester and set the select lever’s position at “neu-
per bodies. tral”.
9) Remove air bleeder screws from the RL and RR
caliper bodies.
10) Connect the air bleeder screws to the FL and
FR caliper bodies.
11) Connect two pressure gauges to the RL and
RR caliper bodies.
12) Bleed air from the pressure gauges and the FL
and FR caliper bodies.
13) Perform ABS sequence control.
14) When the hydraulic unit begins to work, at first B4M1733B
the RR side performs decompression, holding, and
compression, and then the RL side performs
decompression, holding, and compression.
15) Read values indicated on the pressure
gauges and check if they meet the standard value.
16) After checking, remove the pressure gauges
from caliper bodies.
17) Connect the air bleeder screws to RL and RR
caliper bodies.
18) Bleed air from brake line.
B4M1730B
(1) Brake tester
4) Operate the brake tester.

5) Perform ABS sequence control.
ABS-9
ABS
6) Hydraulic unit begins to work; and check the

following working sequence.
(1) The FL wheel performs decompression,
holding, and compression in sequence, and
subsequently the FR wheel repeats the cycle.
(2) The RR wheel performs decompression,
holding, and compression in sequence, and
subsequently the RL wheel repeats the cycle.
7) Read values indicated on the brake tester and
check if the fluctuation of values, when decom-
pressed and compressed, meet the standard val-
ues.
Front wheel Rear wheel
981 N 981 N
Initial value
(100 kgf, 221 lb) (100 kgf, 221 lb)
490 N 490 N
When
(50 kgf, 110 lb) (50 kgf, 110 lb)
decompressed
or less or less
981 N 981 N
When
(100 kgf, 221 lb) (100 kgf, 221 lb)
compressed
or more or more
8) After checking, also check if any irregular brake

pedal tightness is felt.
ABS-10
ABS SEQUENCE CONTROL
ABS
3. ABS Sequence Control S401187

2. ABS SEQUENCE CONTROL WITH
SELECT MONITOR S401187A1602
NOTE:
1) Under the ABS sequence control, after the 쐌 In the event of any trouble, the sequence con-
hydraulic unit solenoid valve is driven, the opera- trol may not be operative. In such a case, activate
tion of the hydraulic unit can be checked by means the sequence control, referring to “ABS
of the brake tester or pressure gauge. SEQUENCE CONTROL WITH DIAGNOSIS CON-
2) ABS sequence control can be started by diag- NECTOR”.
nosis connector or select monitor. <Ref. to ABS-11 ABS SEQUENCE CONTROL
WITH DIAGNOSIS CONNECTOR, OPERATION,
1. ABS SEQUENCE CONTROL WITH ABS Sequence Control.>
DIAGNOSIS CONNECTOR S401187A1601 쐌 When the diagnosis terminal is connected to the
1) Connect diagnosis terminals to terminals No. 5 diagnosis connector, the sequence control will not
and No. 8 of the diagnosis connector beside driv- operate.
er’s seat heater unit. 1) Connect select monitor to data link connector
under driver’s seat instrument panel lower cover.
3) Turn select monitor switch ON.
4) Put select monitor to “BRAKE CONTROL”
mode.
5) When “Function check sequence” is selected,
“ABS sequence control” will start.
6) The message ‘Press Brake Pedal Firmly’ is dis-
played as follows:
(1) When using the brake tester, depress brake
B4M0082E pedal with braking force of 981 N (100 kg, 221
lb).
(1) Diagnosis connector (2) When using the pressure gauge, depress
(2) Diagnosis terminals brake pedal so as to make the pressure gauge
(3) 3 terminal indicate 3,432 kPa (35 kg/cm2, 498 psi).
(4) 6 terminal
CAUTION:
2) Set the speed of all wheels at 2.75 km/h (2 Do not depress the clutch pedal.
MPH) or less. 7) When the message “Press YES” is displayed,
3) Turn ignition switch OFF. press ⰆYESⰇ key.
4) Within 0.5 seconds after the ABS warning light 8) Operation points will be displayed on select
goes out, depress the brake pedal and hold it monitor.
immediately after ignition switch is turned to ON.
CAUTION:
Do not depress the clutch pedal.
NOTE:
쐌 When the ignition switch is set to on, the brake
pedal must not be depressed.
쐌 Engine must not operate.
5) After completion of ABS sequence control, turn
ignition switch OFF.
ABS-11
ABS
3. CONDITIONS FOR ABS SEQUENCE CONTROL S401187A1603
B4M1001C
NOTE:
쐌 When select monitor is used, control operation starts at point A. The patterns from IGN key ON to the
point A show that operation is started by diagnosis connector.
쐌 HIGH means high voltage.
쐌 LOW means low voltage.
ABS-12
ABS
4. CONDITIONS FOR COMPLETION OF

ABS SEQUENCE CONTROL S401187A1604
When the following conditions develop, the ABS
sequence control stops and ABS operation is
returned to the normal control mode.
1) When the speed of at least one wheel reaches
10 km/h (6 MPH).
2) When terminal No. 5 or No. 8 are separated
from diagnosis terminals. (When select monitor is
not used.)
3) When the brake pedal is released during
sequence control and the braking lamp switch is
set to off.
4) When brake pedal is depressed after ignition
key is turned to ON, and before ABS warning light
goes out. (When select monitor is not used.)
5) When brake pedal is not depressed after igni-
tion key is turned to ON, and within 0.5 seconds
after ABS warning light goes out. (When select
monitor is not used.)
6) After completion of the sequence control.
7) When malfunction is detected. (When select
monitor is used.)
ABS-13
FRONT ABS SENSOR
ABS
4. Front ABS Sensor S401190

8) Remove bolts which secure front ABS sensor to
housing, and remove front ABS sensor.
CAUTION:
1) Set vehicle on a lift. 쐌 Be careful not to damage pole piece located
2) Disconnect battery ground terminal. at tip of the sensor and teeth faces during
3) Loosen the wheel nuts. removal.
4) Lift vehicle and remove wheels. 쐌 Do not pull sensor harness during removal.
5) Disconnect front ABS sensor connector located
next to front strut mounting house in engine com-
partment.
6) Remove bolts which secure sensor harness to
strut.
B4M2209
B4M1442
7) Remove bolts which secure sensor harness to

body.
B4M1181B
(1) To front ABS sensor connector

(2) Bracket
ABS-14
FRONT ABS SENSOR
ABS
B: INSTALLATION S401190A11 3) Place a thickness gauge between ABS sensor’s

pole piece and tone wheel’s tooth face. After stan-
1) Temporarily install front ABS sensor on hous- dard clearance is obtained over the entire
ing. perimeter, tighten ABS sensor on housing to speci-
CAUTION: fied torque.
Be careful not to strike ABS sensor’s pole ABS sensor standard clearance:
piece and tone wheel’s teeth against adjacent 0.3 — 0.8 mm (0.012 — 0.031 in)
metal parts during installation.
Tightening torque:
32 N·m (3.3 kgf-m, 24 ft-lb)
B4M2209
B4M2209
2) Install front ABS sensor on strut and wheel
apron bracket.
CAUTION:
Tightening torque: Check the marks on the harness to make sure
32 N·m (3.3 kgf-m, 24 ft-lb) that no distortion exists.
LH RH
Mark Brown Light blue
NOTE:
If the clearance is outside specifications, readjust.
4) After confirmation of the ABS sensor clearance,
connect connector to ABS sensor.
5) Install the wheels.
6) Connect connector to battery ground terminal.
B4M1181B
(1) To front ABS sensor connector

(2) Bracket
ABS-15
FRONT ABS SENSOR
ABS
C: INSPECTION S401190A10 2) Measure the distance “B” between surface

where the front axle housing meets the ABS
1. ABS SENSOR S401190A1001
sensor, and the tone wheel.
1) Check pole piece of ABS sensor for foreign par- NOTE:
ticles or damage. If necessary, clean pole piece or Measure so that the gauge touches the tone wheel
replace ABS sensor. teeth top.
2) Measure ABS sensor resistance.
S4M0510A
B4M0248
(1) Axle housing
(2) Tone wheel
Terminal No. Standard
1 and 2 1.25±0.25 kΩ 3) Find the gap between the ABS sensor pole face
and the surface of the tone wheel teeth by putting
CAUTION:
the measured valves in the formula below and cal-
If resistance is outside the standard value,
culating.
replace ABS sensor with new one.
ABS sensor clearance = B − A
NOTE:
Check ABS sensor cable for discontinuity. If ABS sensor standard clearance:
necessary, replace with a new one. 0.3 — 0.8 mm (0.012 — 0.031 in)
2. SENSOR GAP S401190A1002 NOTE:
1) Measure the distance “A” between ABS sensor
surface and sensor pole face.
B4M2482A
ABS-16
FRONT ABS SENSOR
ABS
3. OUTPUT VOLTAGE S401190A1003 D: ADJUSTMENT S401190A01
Output voltage can be checked by the following Adjust the gap using spacer (Part No. 26755A000).
method. Install resistor and condenser, then rotate
wheel about 2.75 km/h (2 MPH) or equivalent.
NOTE:
Regarding terminal No., please refer to item 1.
ABS SENSOR.
B4M0118B
ABS-17
REAR ABS SENSOR
ABS
5. Rear ABS Sensor S401185 B: INSTALLATION S401185A11
1) Temporarily install rear ABS sensor on back
plate.
2) Disconnect battery ground terminal. CAUTION:
3) Loosen wheel nuts. Be careful not to strike ABS sensor’s pole
4) Lift vehicle, and remove wheels. piece and tone wheel’s teeth against adjacent
5) Remove rear seat and disconnect rear ABS metal parts during installation.
sensor connector.
6) Remove rear sensor harness bracket from rear
trailing link and bracket.
7) Remove rear ABS sensor from rear back plate.
B4M1182B
(1) Rear ABS sensor
2) Install rear sensor harness on rear trailing link.

B4M1182B
Tightening torque:
(1) Rear ABS sensor 32 N·m (3.3 kgf-m, 24 ft-lb)
S4M0299B
(1) Rear sensor harness

(2) Trailing link
3) Place a thickness gauge between ABS sensor’s

pole piece and tone wheel’s tooth face. After stan-
dard clearance is obtained over the entire
perimeter, tighten ABS sensor on back plate to
specified torque.
ABS sensor standard clearance:
0.7 — 1.2 mm (0.028 — 0.047 in)
Tightening torque:
32 N·m (3.3 kgf-m, 24 ft-lb)
CAUTION:
Check the marks on the harness to make sure
that no distortion exists.
LH RH
Mark Blue Pink
ABS-18
REAR ABS SENSOR
ABS
NOTE: C: INSPECTION S401185A10

1. ABS SENSOR S401185A1001
4) Connect rear ABS sensor connector.
5) Install rear seat. 1) Check pole piece of ABS sensor for foreign par-
6) Install wheels. ticles or damage. If necessary, clean pole piece or
7) Connect battery ground terminal. replace ABS sensor.
2) Measure ABS sensor resistance.
B4M0248
Terminal No. Standard

1 and 2 1.0±0.2 kΩ
CAUTION:
If resistance is outside the standard value,
replace ABS sensor with new one.
NOTE:
Check ABS sensor cable for discontinuity. If
necessary, replace with a new one.
2. SENSOR GAP S401185A1002
Clearances (sensor gaps) should be measured

one by one to ensure tone wheel and speed sen-
sor are installed correctly.
S4M0515A
(1) Rear ABS sensor

(2) Rear tone wheel
(3) Sensor gap
ABS sensor clearance:
0.7 — 1.2 mm (0.028 — 0.047 in)
NOTE:
쐌 If clearance is narrow, adjust by using a spacer
(Part No. 26755AA000).
쐌 If clearance is wide, check the outputted voltage
then replace ABS sensor or tone wheel if the out-
putted voltage is outside the specification.
ABS-19
REAR ABS SENSOR
ABS
3. OUTPUT VOLTAGE S401185A1003 D: ADJUSTMENT S401185A01
Output voltage can be checked by the following Adjust the gap using spacer (Part No.
method. Install resistor and condenser, then rotate 26755AA000).
wheel about 2.75 km/h (2 MPH) or equivalent.
NOTE:
Regarding terminal No., refer to item 1. ABS SEN-
SOR.
B4M0118B
ABS-20
FRONT TONE WHEEL
ABS
6. Front Tone Wheel S401184
Refer to Front Drive Shaft, because front tone

wheel is integrated with front drive shaft.
<Ref. to DS-32 REMOVAL, Front Drive Shaft.>
Refer to Front Drive Shaft, because front tone

wheel is integrated with front drive shaft.
<Ref. to DS-32 INSTALLATION, Front Drive
Shaft.>
Visually check tone wheels teeth (44 pieces) for

cracks or dents. If necessary, replace tone wheel
with a new one.
NOTE:
Replace BJ assembly with new one as a single unit
if there are any defects found on tone wheel is
unitized with BJ assembly of drive shaft.
ABS-21
REAR TONE WHEEL
ABS
7. Rear Tone Wheel S401182
For removal procedures of rear tone wheel, refer to

“Rear Axle”. <Ref. to DS-23, Rear Axle.>
For installation procedures of rear tone wheel,

refer to “Rear Axle”. <Ref. to DS-23, Rear Axle.>
Visually check tone wheels teeth (44 pieces) for

cracks or dents. If necessary, replace tone wheel
with a new one.
ABS-22
G SENSOR
ABS
8. G Sensor S401183 B: INSTALLATION S401183A11
1) Disconnect battery ground terminal. Tightening torque (G sensor):

18 N·m (1.8 kgf-m, 13.0 ft-lb)
G6M0095
2) Remove console cover.

<Ref. to EI-30 Console Box.>
3) Disconnect connector from G sensor.
4) Remove G sensor from body.
CAUTION:
Do not drop or bump G sensor.
H4M1324
ABS-23
G SENSOR
ABS

1 CHECK SUBARU SELECT MONITOR. Do you have SUBARU Go to step 5. Go to step 2.
SELECT MONITOR?
2 CHECK G SENSOR. Is the voltage 2.3±0.2 V Go to step 3. Replace G sen-
1) Turn ignition switch to OFF. when G sensor is horizon- sor.
2) Remove G sensor from vehicle. tal?
3) Connect connector to G sensor.
5) Measure voltage between G sensor con-
nector terminals.
Connector & terminal:
(R70) No. 2 (+) — No. 3 (−)
3 CHECK G SENSOR. Is the voltage 3.9±0.2 V Go to step 4. Replace G sen-
Measure voltage between G sensor connector when G sensor is inclined sor.
terminals. forwards to 90°?
(R70) No. 2 (+) — No. 3 (−)
4 CHECK G SENSOR. Is the voltage 0.7±0.2 V G sensor is nor- Replace G sen-
Measure voltage between G sensor connector when G sensor is inclined mal. sor.
terminals. backwards to 90°?
(R70) No. 2 (+) — No. 3 (−)
5 CHECK G SENSOR. Is the indicated reading Go to step 6. Replace G sen-
1) Turn ignition switch to OFF. 2.3±0.2 V when the vehicle sor.
2) Connect select monitor connector to data is in horizontal position?
link connector.
3) Turn select monitor into {BRAKE CON-
TROL} mode.
4) Set the display in the {Current Data Display
& Save} mode.
5) Read the G sensor output voltage.
6 CHECK G SENSOR. Is the indicated reading Go to step 7. Replace G sen-
1) Remove console box. 3.9±0.2 V when G sensor sor.
2) Remove G sensor from vehicle. (Do not is inclined forwards to 90°?
disconnect connector.)
3) Read the select monitor display.
7 CHECK G SENSOR. Is the indicated reading G sensor is nor- Replace G sen-
Read the select monitor display. 0.7±0.2 V when G sensor mal. sor.
is inclined backwards to
90°?
ABS-24
CHASSIS SECTION

SUBARU vehicles.
ine parts.

G8050GE5
BRAKE
BR
Page
2. Front Brake Pad ........................................................................................20
3. Front Disc Rotor ........................................................................................22
4. Front Disc Brake Assembly.......................................................................23
5. Rear Brake Pad.........................................................................................26
6. Rear Disc Rotor.........................................................................................27
7. Rear Disc Brake Assembly .......................................................................29
8. Rear Drum Brake Shoe.............................................................................32
9. Rear Drum Brake Drum ............................................................................34
10. Rear Drum Brake Assembly......................................................................35
11. Master Cylinder .........................................................................................38
12. Brake Booster............................................................................................40
13. Proportioning Valve ...................................................................................44
14. Brake Fluid ................................................................................................45
15. Air Bleeding ...............................................................................................47
16. Brake Hose................................................................................................49
17. Brake Pipe.................................................................................................50
18. Hill Holder..................................................................................................51
19. Brake Pedal...............................................................................................54
20. Stop Light Switch ......................................................................................60
21. General Diagnostics ..................................................................................62
GENERAL DESCRIPTION
Brake
Engine (cc) 2000

Driving system AWD
Non-TURBO
Model Others TURBO
Australia
Type Disc (Floating type, ventilated)
Effective disc diameter mm (in) 228 (8.98)
Front Disc thickness × Outer diameter mm (in) 24 × 277 (0.94 × 10.91)
disc Effective cylinder diameter mm (in) 42.8 (1.685) × 2
brake Pad dimensions
mm (in) 112.3 × 50.0 × 17.0 (4.42 × 1.969 × 0.669)
(length × width × thickness*)
Clearance adjustment Automatic adjustment
Type — Disc (Floating type)
Effective disc diameter mm (in) — 230 (9.06)
Rear Disc thickness × Outer diameter mm (in) — 10 × 266 (0.39 × 10.47)
disc Effective cylinder diameter mm (in) — 38.1 (1.500)
brake Pad dimensions 82.4 × 33.7 × 14.0
mm (in) —
(length × width × thickness*) (3.244 × 1.327 × 0.551)
Clearance adjustment — Automatic adjustment
Drum
Type —
(Leading-Trailing type)
Rear Effective drum diameter mm (in) 228.6 (9) —
drum Effective cylinder diameter mm (in) 19.0 (0.748) —
brake Lining dimensions 218.8 × 35.0 × 4.1
mm (in) —
(length × width × thickness) (8.61 × 1.378 × 0.161)
Clearance adjustment Automatic adjustment —
Type Tandem
Master Effective diameter mm (in) 26.99 (1-1/16)
cylinder Reservoir type Sealed type
Brake fluid reservoir capacity cm3 (cu in) 205 (12.51)
Brake Type Vacuum suspended
booster Effective diameter mm (in) 205 + 230 (8.07 + 9.06)
Propor- Split point kPa (kg/cm2, psi) 3,678 (37.5, 533)
tioning
valve Reducing ratio 0.3
Brake line Dual circuit system
ABS OP STD
Brake fluid FMVSS No. 116, DOT3 or DOT4
*: Including back metal
NOTE:
Refer to “PB section” for parking brake SPECIFICATIONS. <Ref. to PB-2, General Description.>
BR-2
GENERAL DESCRIPTION
Brake
ITEM STANDARD SERVICE LIMIT

Pad thickness
17 mm (0.67 in) 7.5 mm (0.295 in)
(including back metal)
Front brake
Disc thickness 24 mm (0.94 in) 22 mm (0.87 in)
Disc runout — 0.075 mm (0.0030 in)
Pad thickness
14 mm (0.55 in) 6.5 mm (0.256 in)
(including back metal)
Rear brake (Disc type)
Disc thickness 10 mm (0.39 in) 8.5 mm (0.335 in)
Disc runout — 0.070 mm (0.0028 in)
Inside diameter 228.6 mm (9 in) 230.6 mm (9.08 in)
Rear brake (Drum type)
Lining thickness 4.1 mm (0.161 in) 1.5 mm (0.059 in)
Inside diameter 170 mm (6.69 in) 171 mm (6.73 in)
Rear brake (Disc type parking)
Lining thickness 3.2 mm (0.126 in) 1.5 mm (0.059 in)
Parking brake Lever stroke 7 to 8 notches/196 N (20 kgf, 44 lb)
Brake pedal force Fluid pressure

Brake fluid pressure without 147 N (15 kgf, 33 lb) 588 kPa (6 kg/cm2, 85 psi)
engine running 294 N (30 kgf, 66 lb) 1,667 kPa (17 kg/cm2, 242 psi)
Brake booster
Brake fluid pressure with engine 147 N (15 kgf, 33 lb) 5,394 kPa (55 kg/cm2, 782 psi)
running and vacuum at 66.7 kPa
(500 mmHg, 19.69 inHg) 294 N (30 kgf, 66 lb) 10,003 kPa (102 kg/cm2, 1,450 psi)
1 — 3 mm (0.04 — 0.12 in)

Brake pedal Free play
[Depress brake pedal pad with a force of less than 10 N (1 kgf, 2 lb).]
BR-3
GENERAL DESCRIPTION
Brake
1. FRONT DISC BRAKE S405001A0511
B4M1151C
(1) Caliper body (9) Lock pin (Yellow) (17) Disc cover
(2) Air bleeder screw (10) Support
(3) Guide pin (Green) (11) Pad clip Tightening torque: N·m (kgf-m, ft-lb)
(4) Pin boot (12) Outer shim (For Australia) T1: 8 (0.8, 5.8)
(5) Piston seal (13) Inner shim (For Australia) T2: 18 (1.8, 13.0)
(6) Piston (14) Pad (Outside) T3: 39 (4.0, 28.9)
(7) Piston boot (15) Pad (Inside) T4: 78 (8.0, 58)
(8) Boot ring (16) Disc rotor
BR-4
GENERAL DESCRIPTION
Brake
2. REAR DISC BRAKE S405001A0503
H4M1355A
(1) Caliper body (14) Shim (27) Primary shoe return spring
(2) Air bleeder screw (15) Shoe hold-down pin (28) Adjusting spring
(3) Guide pin (Green) (16) Cover (29) Adjuster
(4) Pin boot (17) Back plate (30) Shoe hold-down cup
(5) Piston seal (18) Retainer (31) Shoe hold-down spring
(6) Piston (19) Spring washer (32) Disc rotor
(7) Piston boot (20) Parking brake lever
(8) Boot ring (21) Parking brake shoe (Secondary) Tightening torque: N·m (kgf-m, ft-lb)
(9) Lock pin (Yellow) (22) Parking brake shoe (Primary) T1: 8 (0.8, 5.8)
(10) Support (23) Strut T2: 39 (4.0, 28.9)
(11) Pad clip (24) Strut shoe spring T3: 52 (5.3, 38.3)
(12) Inner pad (25) Shoe guide plate
(13) Outer pad (26) Secondary shoe return spring
BR-5
GENERAL DESCRIPTION
Brake
3. REAR DRUM BRAKE S405001A0504
B4M1120A
(1) Air bleeder cap (11) Upper shoe return spring (21) Lower shoe return spring
(2) Air bleeder screw (12) Retainer (22) Adjusting spring
(3) Boot (13) Washer (23) Drum
(4) Piston (14) Parking brake lever (24) Plug
(5) Cup (15) Brake shoe (Trailing)
(6) Spring (16) Brake shoe (Leading) Tightening torque: N·m (kgf-m, ft-lb)
(7) Wheel cylinder body (17) Shoe hold-down spring T1: 8 (0.8, 5.8)
(8) Pin (18) Cup T2: 10 (1.0, 7.2)
(9) Plug (19) Adjusting lever T3: 52 (5.3, 38.3)
(10) Back plate (20) Adjuster
BR-6
GENERAL DESCRIPTION
Brake
4. MASTER CYLINDER S405001A0505
쐌 LHD model
S4M0325B
(1) Cap (6) Secondary piston Tightening torque: N·m (kgf-m, ft-lb)
(2) Filter (7) Cylinder body
T: 14 (1.4, 10.1)
(3) Reservoir tank (8) Cylinder pin (With ABS)
(4) Piston retainer (9) Seal
(5) Primary piston (10) Pin
BR-7
GENERAL DESCRIPTION
Brake
쐌 RHD model
B4M1155D
(1) Cap (6) Primary piston (11) Pin

(2) Filter (7) Secondary piston
(3) Reservoir tank (8) Cylinder body Tightening torque: N·m (kgf-m, ft-lb)
(4) Bracket (9) Cylinder pin (With ABS) T: 14 (1.4, 10.1)
(5) Piston retainer (10) Seal
BR-8
GENERAL DESCRIPTION
Brake
5. HILL HOLDER S405001A0510
S4M0240A
(1) Clamp (5) Lock nut Tightening torque: N·m (kgf-m, ft-lb)
(2) PHV cable
T1: 3.5 (0.35, 2.5)
(3) PHV (Pressure hold valve)
T2: 18 (1.8, 13.0)
(4) Adjusting nut
BR-9
GENERAL DESCRIPTION
Brake
6. BRAKE PIPES AND HOSE S405001A0506
쐌 Front brake pipe for model with ABS (LHD)
S4M0533A
(1) Front brake pipe assembly (7) ABS control module and hydrau- Tightening torque: N·m (kgf-m, ft-lb)
(2) Proportioning valve lic control unit
T1: 15 (1.5, 10.8)
(3) Front brake hose RH (8) Bracket
T2: 18 (1.8, 13.0)
(4) Front brake hose LH (9) Master cylinder
(5) Clamp (10) Hill holder
(6) Gasket (11) Adapter pipe
쐌 Front brake pipe for model with ABS (RHD)
S4M0534A
(1) Front brake pipe assembly (7) ABS control module and hydrau- Tightening torque: N·m (kgf-m, ft-lb)
(2) Proportioning valve lic control unit
T1: 15 (1.5, 10.8)
(3) Front brake hose RH (8) Bracket
T2: 18 (1.8, 13.0)
(4) Front brake hose LH (9) Master cylinder
(5) Clamp (10) Hill holder
(6) Gasket (11) Adapter pipe
BR-10
GENERAL DESCRIPTION
Brake
쐌 Front brake pipe for model without ABS (LHD)
S4M0535A
(1) Front brake pipe assembly (6) Gasket Tightening torque: N·m (kgf-m, ft-lb)
(2) Proportioning valve (7) Bracket
T1: 15 (1.5, 10.8)
(3) Front brake hose RH (8) Master cylinder
T2: 18 (1.8, 13.0)
(4) Front brake hose LH (9) Hill holder
(5) Clamp (10) Adapter pipe
쐌 Front brake pipe for model without ABS (RHD)
S4M0536A
(1) Front brake pipe assembly (6) Gasket Tightening torque: N·m (kgf-m, ft-lb)
(2) Proportioning valve (7) Bracket
T1: 15 (1.5, 10.8)
(3) Front brake hose RH (8) Master cylinder
T2: 18 (1.8, 13.0)
(4) Front brake hose LH (9) Hill holder
(5) Clamp (10) Adapter pipe
BR-11
GENERAL DESCRIPTION
Brake
쐌 Center and rear brake pipe
S4M0537A
(1) Center brake pipe assembly (7) Rear brake pipe assembly Tightening torque: N·m (kgf-m, ft-lb)
(2) Clamp (8) Two-way connector
T1: 15 (1.5, 10.8)
(3) Rear brake hose RH (With ABS) (9) Rear brake hose LH (With ABS)
T2: 18 (1.8, 13.0)
(4) Gasket (10) Rear brake hose LH (Without
T3: 32 (3.3, 23.6)
(5) Rear brake pipe RH (Without ABS)
ABS) (11) Rear brake pipe LH (Without
(6) Rear brake hose RH (Without ABS)
ABS)
BR-12
GENERAL DESCRIPTION
Brake
7. BRAKE BOOSTER S405001A0507
쐌 LHD model
S4M0538A
쐌 RHD model
S4M0539A
(1) Brake master cylinder (7) Snap pin Tightening torque: N·m (kgf-m, ft-lb)
(2) Vacuum hose (8) Brake pedal
T1: 14 (1.4, 10.1)
(3) Clip (9) Bracket
T2: 18 (1.8, 13.0)
(4) Brake booster assembly (10) Vacuum hose (Non-turbo model)
(5) Seal (11) Vacuum hose (Turbo model)
(6) Clevis pin (12) Vacuum pipe (Turbo model)
BR-13
GENERAL DESCRIPTION
Brake
8. BRAKE PEDAL FOR MT MODEL S405001A0508
쐌 LHD model
B4M2467A
(1) Stopper (12) Clutch clevis pin (23) Clutch switch (With cruise con-
(2) Bushing (13) Assist rod A trol)
(3) Spring pin (14) Clip (24) Stop light switch
(4) Snap pin (15) Assist spring (25) Pedal bracket
(5) Brake pedal pad (16) Assist bushing (26) Clutch master cylinder bracket
(6) Brake pedal (17) Assist rod B (27) Lever
(7) Clevis pin (18) Spring S
(8) Brake pedal spring (19) Rod S Tightening torque: N·m (kgf-m, ft-lb)
(9) Clutch pedal pad (20) Bushing S T1: 8 (0.8, 5.8)
(10) Clutch pedal (21) O-ring T2: 18 (1.8, 13.0)
(11) Bushing C (22) Clip
BR-14
GENERAL DESCRIPTION
Brake
쐌 RHD model
S4M0544A
(1) Bushing (9) Brake pedal pad (17) Accelerator spring

(2) Accelerator pedal (10) Brake pedal
(3) Accelerator pedal spring (11) Snap pin Tightening torque: N·m (kgf-m, ft-lb)
(4) Spring pin (12) Brake pedal spring T1: 8 (0.8, 5.8)
(5) Accelerator pedal pad (13) Brake spacer T2: 18 (1.8, 13.0)
(6) Stopper (14) Clip T3: 29 (3.0, 21.7)
(7) Spacer (15) Pedal bracket
(8) Clevis pin (16) Stop light switch
BR-15
GENERAL DESCRIPTION
Brake
9. BRAKE PEDAL FOR AT MODEL S405001A0509
쐌 LHD model
B4M2346A
(1) Stopper (7) Snap pin Tightening torque: N·m (kgf-m, ft-lb)
(2) Bushing (8) Brake pedal pad
T1: 8 (0.8, 5.8)
(3) Plug (9) Brake pedal
T2: 18 (1.8, 13.0)
(4) Pedal bracket (10) Clevis pin
T3: 30 (3.1, 22.4)
(5) Stop light switch (11) Brake spacer
(6) Spacer (12) Brake pedal spring
BR-16
GENERAL DESCRIPTION
Brake
쐌 RHD model
S4M0321A
(1) Accelerator pedal (9) Clip (17) Brake pedal pad

(2) Accelerator pedal spring (10) Stop light switch (18) Snap pin
(3) Spring pin (11) Accelerator spring
(4) Accelerator pedal pad (12) Brake pedal spring Tightening torque: N·m (kgf-m, ft-lb)
(5) Stopper (13) Brake spacer T1: 8 (0.8, 5.8)
(6) Bushing (14) Brake pedal T2: 18 (1.8, 13.0)
(7) Kick-down switch (15) Spacer T3: 29 (3.0, 21.7)
BR-17
GENERAL DESCRIPTION
Brake

tion.
ment.
fied points.
deformation.
쐌 Do not put fluid on body. If the body is tainted,
wash away with water.
BR-18
GENERAL DESCRIPTION
Brake

926460000 WHEEL CYLINDER Used for installing cup onto wheel cylinder pis-
3/4″ ADAPTER ton (Size 3/4 in).
B4M2406
TOOL NAME REMARKS

Snap Ring Pliers Used for removing and installing snap ring.
BR-19
FRONT BRAKE PAD
Brake
2. Front Brake Pad S405178

(4) Attach a rod of less than 12 mm (0.47 in)
dia. to the shaded area of brake pad, and strike
A: REMOVAL S405178A18 the rod with a hammer to drive brake pad out of
place.
1) Loosen wheel nuts, jack-up vehicle, support it
with safety stands, and remove wheel.
2) Remove lock pin.
3) Raise caliper body.
4) Remove pad.
B4M2231
1) Apply thin coat of Molykote AS880N (Part No.

B4M1167 26298AC000) to the frictional portion between pad
and pad clip.
NOTE: 2) Apply thin coat of Molykote AS880N (Part No.
If brake pad is difficult to remove, proceed as fol- 26298AC000) to the frictional portion between pad
lows: and pad inner shim. (Australia model)
(1) Remove caliper body and fasten it provi-
sionally to coil spring.
(2) Remove support.
(3) Place a support in a vise between wooden
blocks.
B4M1169A
3) Install pads on support.

4) Install caliper body on support.
Tightening torque:
39 N·m (4.0 kgf-m, 28.9 ft-lb)
B4M2230B
NOTE:
(1) Support If it is difficult to push piston during pad
(2) Wooden blocks replacement, loosen air bleeder to facilitate work.
BR-20
FRONT BRAKE PAD
Brake
Check pad thickness A.
B4M1168A
Pad thickness Standard value 17 mm (0.67 in)

(including back
metal) Wear limit 7.5 mm (0.295 in)
CAUTION:
쐌 Always replace the pads for both the left and
right wheels at the same time. Also replace pad
clips if they are twisted or worn.
쐌 A wear indicator is provided on the inner
disc brake pad. If the pad wears down to such
an extent that the end of the wear indicator
contacts the disc rotor, a squeaking sound is
produced as the wheel rotates. If this sound is
heard, replace the pad.
쐌 Replace pad if there is oil or grease on it.
BR-21
FRONT DISC ROTOR
Brake
3. Front Disc Rotor S405173 C: INSPECTION S405173A10
1) Install disc rotor by tightening the five wheel
nuts.
1) Loosen wheel nuts, jack-up vehicle, support it 2) Set a dial gauge on the disc rotor. Turn disc
with safety stands, and remove wheel. rotor to check runout.
2) Remove caliper body from housing, and sus-
pend it from strut using a wire.
B4M2353
BR0076 NOTE:
3) Remove the disc rotor. 쐌 Make sure that dial gauge is set 5 mm (0.20 in)
inward of rotor outer perimeter.
NOTE: 쐌 If disc rotor runout is above standard value,
If disc rotor seizes up within the hub, drive disc inspect play of hub bearing axial direction and
rotor out by installing an 8-mm bolt in holes B on runout of axle hub. <Ref. to DS-22, INSPECTION,
the rotor. Front Axle.>
If bearing and hub are normal, replace disc rotor.
0.075 mm (0.0030 in)
3) Measure disc rotor thickness.
If thickness of disc rotor is outside the standard
value, replace disc rotor.
G4M0365
4) Clean mud and foreign particles from caliper

body assembly and support.
1) Install the disc rotor.

2) Install the caliper body to housing. G4M0365
Tightening torque:
NOTE:
78 N·m (8 kgf-m, 58 ft-lb)
Make sure that micrometer is set 5 mm (0.20 in)
Standard Service limit Disc outer
value dia.
Disc rotor 24.0 mm 22.0 mm 277 mm
thickness A (0.945 in) (0.866 in) (10.91 in)
BR-22
FRONT DISC BRAKE ASSEMBLY
Brake
4. Front Disc Brake Assembly 6) Remove disc rotor from hub.

S405176 NOTE:
If disc rotor seizes up within hub, drive disc rotor
out by installing an 8-mm bolt in holes B on the
1) Loosen wheel nuts, jack-up vehicle, support it rotor.
2) Remove union bolt and disconnect brake hose
from caliper body assembly.
G4M0365
7) Clean mud and foreign particles from caliper

B4M1844
3) Remove bolt securing lock pin to caliper body.
B4M1845
4) Raise caliper body and move it toward vehicle

center to separate it from support.
5) Remove support from housing.
NOTE:
Remove support only when replacing it or the rotor.
It need not be removed when servicing caliper
body assembly.
B4M1192
BR-23
Brake
1) Install disc rotor on hub. 1) Clean mud and foreign particles from caliper
2) Install support on housing. body assembly and support.
78 N·m (8 kgf-m, 58 ft-lb) Be careful not to allow foreign particles to enter
CAUTION: inlet (at brake hose connector).
쐌 Always replace the pads for both the left and 2) Using a standard screwdriver, remove boot ring
right wheels at the same time. Also replace pad from piston.
clips if they are twisted or worn.
쐌 A wear indicator is provided on the inner
쐌 When replacing the pads, replace pads of the
right and left wheels at the same time.
26298AC000) to the frictional portion between pad B4M1164C
and pad clip.
4) Apply thin coat of Molykote AS880N (Part No. (1) Boot ring
26298AC000) to the frictional portion between pad
and inner shim. (Australia model) 3) Remove boot from piston end.
4) Gradually supply compressed air via caliper
body brake hose to force piston out.
CAUTION:
Place a wooden block as shown in Figure to
prevent damage to piston.
B4M1169A

Tightening torque:
39 N·m (4.0 kgf-m, 28.9 ft-lb) B4M1165C
7) Connect brake hose. (1) Place a 30 mm (1.18 in) wide wooden block here.
Tightening torque:
5) Remove piston seal from caliper body cylinder.
18 N·m (1.8 kgf-m, 13.0 ft-lb)
CAUTION:
Replace brake hose gaskets with new ones.
8) Bleed air from brake system.
<Ref. to BR-47, Air Bleeding.>
B4M1172B
(1) Piston pin
BR-24
Brake
6) Remove lock pin boot and guide pin boot. 8) Apply a coat of specified grease to lock pin and
guide pin, outer surface, cylinder inner surface,
D: ASSEMBLY S405176A02 and boot grooves.
1) Clean caliper body interior using brake fluid. Grease:
2) Apply a coat of brake fluid to piston seal and fit NIGLUBE RX-2 (Part No. 003606000)
piston seal in groove on caliper body.
3) Apply a coat of brake fluid to the entire inner
surface of cylinder and outer surface of piston.
4) Insert piston into cylinder.
CAUTION:
Do not force piston into cylinder.
B4M1176B
(1) Pin boot

(2) Lock pin or guide pin
(3) Apply grease.
9) Install lock pin boot and guide pin boot on sup-

port.
B4M0771
5) Apply a coat of specified grease to boot and fit E: INSPECTION S405176A10
in groove on ends of cylinder and piston. NOTE:

Grease: Repair or replace faulty parts.
NIGLUBE RX-2 (Part No. 003606000) 1) Check caliper body and piston for uneven wear,
damage or rust.
To facilitate installation, fit boot starting with piston
2) Check rubber parts for damage or deterioration.
end.
S4M0448A
(1) Piston boot

(2) Boot ring
(3) Piston seal
(4) Caliper body
6) Position boot in grooves on cylinder and piston.

7) Install boot ring. Be careful not scratch boot.
BR-25
REAR BRAKE PAD
Brake
5. Rear Brake Pad S405175 C: INSPECTION S405175A10
Check pad thickness (including back metal).
Pad thickness: A
Standard value
with safety stands, and remove wheel. 14.0 mm (0.551 in)
2) Remove lock pin. Wear limit
6.5 mm (0.256 in)
S4M0115
S4M0187A
3) Raise caliper body.
4) Remove pad from support.
CAUTION:
NOTE: 쐌 Always replace the pads for both the left and
If brake pad is difficult to remove, use the same right wheels at the same time. Also replace pad
procedure as for front disc brake pad. clips if they are twisted or worn.
<Ref. to BR-20 REMOVAL, Front Brake Pad.> 쐌 A wear indicator is provided on the inner
쐌 Replace pad if there is oil or grease on it.
S4M0116

and pad clip.
2) Install pad on support.
Tightening torque:
39 N·m (4.0 kgf-m, 28.9 ft-lb)
NOTE:
If it is difficult to push piston during pad
replacement, loosen air bleeder to facilitate work.
BR-26
REAR DISC ROTOR
Brake
6. Rear Disc Rotor S405177

(2) If disc rotor seizes up within hub, drive disc
rotor out by installing an 8-mm bolt in holes B on
A: REMOVAL S405177A18 the rotor.
1) Disconnect battery ground terminal from bat-
tery.
3) Remove the two mounting bolts and remove
the disc brake assembly.
G4M0383

2) Adjust parking brake. <Ref. to PB-11
ADJUSTMENT, Parking Brake Assembly (Rear
S4M0459A Disc Brake).>
(1) Disc brake
4) Suspend the disc brake assembly so that the

hose is not stretched.
5) Pull down and release parking brake.
6) Remove the disc rotor.
NOTE:
If the disc rotor is difficult to remove try the follow-
ing two methods in order.
(1) Turn adjusting screw using a slot-type
screwdriver until brake shoe gets away enough
from the disc rotor.
S4M0569A
(1) Adjusting screw

(2) Cover
(3) Slot-type screwdriver
(4) Back plate
BR-27
REAR DISC ROTOR
Brake
1) Secure disc rotor by tightening the five wheel

nuts.
2) Set a dial gauge on the disc rotor. Turn disc
rotor to check runout.
CAUTION:
Securely adjust disc rotor to hub.
B4M1771
NOTE:
쐌 Make sure that dial gauge is set 5 mm (0.20 in)
쐌 If disc rotor runout is above standard value,
inspect play of hub bearing axial direction and
runout of axle hub. <Ref. to DS-31, INSPECTION,
Rear Axle.>
0.070 mm (0.0028 in)
3) Measure disc rotor thickness.
If thickness of disc rotor is outside the standard
value, replace disc rotor.
G4M0383
NOTE:
Make sure that micrometer is set 5 mm (0.20 in)
Disc rotor thickness: A
Standard value
10 mm (0.39 in)
Service limit
8.5 mm (0.335 in)
BR-28
REAR DISC BRAKE ASSEMBLY
Brake
7. Rear Disc Brake Assembly B: INSTALLATION S405172A11
S405172
1) Install disc rotor on hub.
2) Install support on back plate.
1) Loosen wheel nuts, jack-up vehicle, support it Tightening torque:

with safety stands, and remove wheel. 78 N·m (8.0 kgf-m, 58 ft-lb)
2) Disconnect brake hose from caliper body CAUTION:
assembly. 쐌 Always replace the pads for both the left and
CAUTION: right wheels at the same time. Also replace pad
Do not allow brake fluid to come in contact with clips if they are twisted or worn.
vehicle body; wipe off completely if spilled. 쐌 A wear indicator is provided on the inner
3) Remove lock pin. an extent that the end of the wear indicator
쐌 Replace pads if there is oil or grease on
them.
and pad clip.
S4M0119
Tightening torque:
4) Raise caliper body and move it toward vehicle 39 N·m (4.0 kgf-m, 28.9 ft-lb)
center to separate it from support. 6) Connect brake hose.
5) Remove support from back plate.
Tightening torque:
NOTE: 18 N·m (1.8 kgf-m, 13.0 ft-lb)
Remove support only when replacing it or the rotor.
It need not be removed when servicing caliper CAUTION:
body assembly. 쐌 The brake hose must be connected without
any twist.
6) Clean mud and foreign particles from caliper 쐌 Replace brake hose gaskets with new ones.
CAUTION: <Ref. to BR-47, Air Bleeding.>
Be careful not to allow foreign particles to enter
inlet (at brake hose connector).
BR-29
Brake
C: DISASSEMBLY S405172A06 4) Remove piston seal from caliper body cylinder.

1) Remove the boot ring.
S4M0122
S4M0120B 5) Remove lock pin sleeve and boot from caliper

body.
(1) Boot ring 6) Remove guide pin boot.
2) Remove the piston boot.
S4M0121
3) Gradually supply compressed air via inlet of

caliper body to force piston out.
CAUTION:
쐌 Place a wooden block as shown in Figure to
prevent damage to piston.
쐌 Do not apply excessively high-pressure.
B4M1174C
(1) Place a 30 mm (1.18 in) wide wooden block here.
BR-30
Brake
1) Clean caliper body interior using brake fluid. NOTE:

2) Apply a coat of brake fluid to piston seal and fit Repair or replace faulty parts.
piston seal in groove on caliper body. 1) Check caliper body and piston for uneven wear,
3) Apply a coat of brake fluid to the entire inner damage or rust.
surface of cylinder and outer surface of piston. 2) Check rubber parts for damage or deterioration.
4) Insert piston into cylinder.
CAUTION:
Do not force piston into cylinder.
5) Apply a coat of specified grease to boot and fit
in groove on ends of cylinder and piston.
Grease:
NIGLUBE RX-2 (Part No. 003606000)
6) Install the piston boot to the caliper body, and
attach boot ring.
S4M0448A
(1) Piston boot

(2) Boot ring
(3) Piston seal
(4) Caliper body
7) Apply a coat of specified grease to guide pin,

outer surface, sleeve outer surface, cylinder inner
surface, and boot grooves.
Grease:
B4M1176B
(1) Pin boot

(2) Lock pin or guide pin
(3) Apply grease.
8) Install guide pin boot on caliper body.

9) Install lock pin boot on caliper body and insert
lock pin sleeve into place.
BR-31
REAR DRUM BRAKE SHOE
Brake
8. Rear Drum Brake Shoe S405174

4) Hold hold-down pin by securing rear of back
plate with your hand.

2) Release parking brake.
3) Remove brake drum from brake assembly.
NOTE:
쐌 If it is difficult to remove brake drum, remove
adjusting hole cover from drum, and then turn
adjuster assembly pawls using a slot-type screw-
driver until brake shoe separates from the drum. S4M0451A
(1) Hold-down cup

(2) Hold-down pin
5) Disconnect hold-down cup from hold-down pin

by rotating hold-down cup.
6) Disconnect lower shoe return spring from
shoes.
S4M0369A
(1) Back plate

(2) Wheel cylinder
(3) Adjuster ASSY pawls
(4) Adjusting lever
(6) Push.
S4M0452
쐌 If brake drum is difficult to remove, drive it out by
installing an 8-mm bolt into bolt hole in brake drum. 7) Remove shoes one by one from back plate with
adjuster.
CAUTION:
Be careful not to bend parking brake cable
excessively when removing brake shoes.
B4M0243
S4M0453A
(1) Wheel cylinder

(2) Adjuster
(3) Back plate
(4) Lower shoe return spring
(5) Parking lever
(6) Trailing shoe
BR-32
REAR DRUM BRAKE SHOE
Brake
8) Disconnect parking brake cable from parking 6) While positioning shoes (one at a time) in
lever. groove on wheel cylinder, secure shoes.
1) Clean back plate and wheel cylinder.

2) Apply grease to portions indicated by arrows in
Figure.
Brake grease:
Dow Corning Molykote No. 7439 (Part No.
725191460)
S4M0458A
(1) Wheel cylinder

(2) Shoe (Trailing)
7) Fix shoes by connecting hold-down cup to hold-

down pin.
8) Connect lower shoe return spring.
9) Set the outside diameter of brake shoes less
than 0.5 to 0.8 mm (0.020 to 0.031 in) in compari-
G4M0407 son with the inside diameter of brake drum.
10) Install drum.
3) Apply grease to adjusting screw and both ends
of adjuster. C: INSPECTION S405174A10
Brake grease: 1) Measure the lining thickness.

Lining thickness:
725191460)
Standard 4.1 mm (0.161 in)
Service limit 1.5 mm (0.059 in)
2) If the deformation or wear of back plate, shoe,
etc. are notable, replace them.
3) When the shoe return spring tension is exces-
sively weakened, replace it, taking care to identify
upper and lower springs.
S4M0457B
4) Connect upper shoe return spring to shoes.

5) Connect parking brake cable to parking lever.
BR-33
REAR DRUM BRAKE DRUM
Brake
9. Rear Drum Brake Drum S405180 B: INSTALLATION S405180A11
1) Set the outside diameter of brake shoes less
than 0.5 to 0.8 mm (0.020 to 0.031 in) in compari-
1) Loosen wheel nuts, jack-up vehicle, support it son with the inside diameter of brake drum.
with safety stands, and remove wheel. 2) Install drum.
3) Remove brake drum from brake assembly. C: INSPECTION S405180A10
NOTE: 1) If the inside surface of brake drum is streaked,

쐌 If it is difficult to remove brake drum, remove correct the surface. And, if it is unevenly worn,
adjusting hole cover from drum, and then turn taperingly streaked, or the outside surface of brake
adjuster assembly pawls using a slot-type screw- drum is damaged, correct or replace it.
driver until brake shoe separates from the drum. 2) Measure the drum inner diameter.
Drum inner diameter: “L”
Standard 228.6 mm (9 in)
Service limit 230.6 mm (9.08 in)
S4M0369A
(1) Back plate

(2) Wheel cylinder
(3) Adjuster ASSY pawls G4M0403
(4) Adjusting lever
(6) Push.
쐌 If brake drum is difficult to remove, drive it out by

installing an 8-mm bolt into bolt hole in brake drum.
B4M0243
BR-34
REAR DRUM BRAKE ASSEMBLY
Brake
10. Rear Drum Brake Assembly 10) Remove the bolts installing wheel cylinder on
S405179
back plate, and remove it.

tery.
4) Remove brake drum from brake assembly.
<Ref. to BR-34, REMOVAL, Rear Drum Brake
Drum.>
S4M0454A
5) Remove brake shoe. <Ref. to BR-32,
REMOVAL, Rear Drum Brake Shoe.> (1) Air bleeder
6) Unscrew the brake pipe flare nut and discon-
nect brake pipe. B: INSTALLATION S405179A11
1) Clean back plate and wheel cylinder.

2) Install wheel cylinder on back plate, and tighten
bolts.
Tightening torque:
10 N·m (1.0 kgf-m, 7.2 ft-lb)
G4M0399
7) Disconnect ABS sensor from back plate. (only

vehicle equipped with ABS)
8) Remove hub. <Ref. to DS-23, Rear Axle.>
9) Remove the bolts installing back plate, and
then, remove brake assembly. S4M0454
3) Apply grease to portions indicated by arrows in

Figure.
Brake grease:
725191460)
G4M0400
G4M0407
BR-35
Brake
4) Install brake assembly on housing, and tighten C: DISASSEMBLY S405179A06
bolts to install back plate.

1) Remove right and left dust boots from wheel
Tightening torque: cylinder.
52 N·m (5.3 kgf-m, 38.3 ft-lb)
B4M1126B
G4M0400
(1) Bleeder cap
5) Install hub. <Ref. to DS-23, Rear Axle.> (2) Bleeder screw
6) Connect brake pipe, and tighten brake pipe (3) Spring
flange nut. (4) Cylinder
(5) Cup
Tightening torque:
(6) Piston
15 N·m (1.5 kgf-m, 10.8 ft-lb)
(7) Boot
7) Connect ABS sensor to back plate. (only
vehicle equipped with ABS) 2) Remove piston, cup, spring and air bleeder
screw and cap.
Tightening torque:
32 N·m (3.3 kgf-m, 24 ft-lb) D: ASSEMBLY S405179A02
8) Apply grease to adjusting screw and both ends 1) Clean all parts in brake fluid. Check and replace
of adjuster. faulty parts.
Brake grease: 쐌 Cup and boot for damage or fatigue
Dow Corning Molykote No. 7439 (Part No. 쐌 Cylinder, piston and spring or damage or rust
725191460) formation
2) Assembly is the reverse order of disassembly.
(1) When installing the cup, use ST, apply
brake fluid to the frictional surface for smooth
installation and pay attention to cup direction.
(2) STs are available in different sizes.
CAUTION:
쐌 When replacing the repair kit, make sure that
the sizes of cylinder and cup are the same as
those which were replaced.
쐌 Use only the tool of the correct size.
S4M0457B
ST: ADAPTER
9) Install brake shoe. <Ref. to BR-33,
Applicable size Part No.
INSTALLATION, Rear Drum Brake Shoe.>
19.0 mm (3/4 in) 926460000
10) Install drum. <Ref. to BR-34, INSTALLATION,
Rear Drum Brake Drum.>
11) Bleed air from brake system. <Ref. to BR-47,
Air Bleeding.>
BR-36
Brake
CAUTION: E: INSPECTION S405179A10
While assembling, be careful to prevent any

metal chip, dust or dirt from entering the wheel 1) Check wheel cylinder for leakage.
2) Inspect the disassembled parts for wear, rust or
cylinder.
damage.
3) Inspect lining thickness. <Ref. to BR-33,
INSPECTION, Rear Drum Brake Shoe.>
4) Inspect brake drum. <Ref. to BR-34,
INSPECTION, Rear Drum Brake Drum.>
S4M0455A
(1) Cup
(2) Piston
3) Apply rubber grease to the boot inside as

shown in Figure.
CAUTION:
Never use brake grease.
Grease:
S4M0456B
BR-37
MASTER CYLINDER
Brake
11. Master Cylinder S405168

2. DISASSEMBLING PROCEDURE S405168A0603
1) Remove pin with drift pin which secures reserve

tank to master cylinder.
1) Pull up parking brake lever, and block the tires. 2) Remove cylinder pin with magnetic pick-up tool
2) Disconnect battery ground terminal from bat- while pushing in primary piston. (Only vehicle
tery. equipped with ABS)
3) Thoroughly drain brake fluid from reservoir
tank.
4) Disconnect fluid level indicator harness connec-
tor.
5) Remove brake pipes from master cylinder.
6) Remove master cylinder mounting nuts, and
take out master cylinder from brake booster.
CAUTION:
Be extremely careful not to spill brake fluid.
Brake fluid spilt on the vehicle body will harm
the painted surface; wipe it off quickly if spilt. S4M0123B
B: INSTALLATION S405168A11 (1) Cylinder pin

1) Install in the reverse order of removal. 3) Pry up the pawl and remove the piston retainer.
Tightening torque: NOTE:
Master cylinder mounting nut Piston may jump out from master cylinder.
14 N·m (1.4 kgf-m, 10.1 ft-lb)
Piping flare nut
15 N·m (1.5 kgf-m, 10.8 ft-lb)
CAUTION:
Be sure to use recommended brake fluid.
Air Bleeding.>
1. PRECAUTIONS FOR DISASSEMBLING S4M0124

S405168A0602
4) Extract primary piston assembly and secondary
1) Remove mud and dirt from the surface of brake piston assembly.
master cylinder.
2) Prepare tools necessary for disassembly CAUTION:
operation, and arrange them neatly on work bench. 쐌 Do not disassemble the piston assembly;
3) Clean work bench. otherwise, the spring set value may be
changed.
쐌 Use brake fluid or methanol to wash inside
wall of cylinder, pistons and piston cups. Be
careful not to damage parts when washing. If
methanol is used for washing, do not dip rub-
ber parts, such as piston cups, in it for more
than 30 seconds; otherwise, they may become
swelled.
BR-38
MASTER CYLINDER
Brake
1. PRECAUTIONS FOR ASSEMBLING If any damage, deformation, wear, swelling, rust,

S405168A0201 and other faults are found on the primary piston
assembly, secondary piston assembly, supply
1) When assembling, be sure to use recom-
valve stopper, or gasket, replace the faulty part.
mended brake fluid.
2) Ensure that the inside wall of cylinder, pistons, CAUTION:
and piston cups are free from dirt when assem- 쐌 The primary and secondary pistons must be
bling. replaced as complete assemblies.
3) Be extremely careful not to damage, scratch, or 쐌 The service limit of the clearance between
dent cylinder inside wall, pistons, and piston cups. each piston and the master cylinder inner dia.
4) Do not drop parts. Never attempt to use any is 0.11 mm (0.0043 in).
part that has been dropped accidentally. 쐌 When handling parts, be extremely careful
not to damage or scratch the parts, or let any
2. ASSEMBLING PROCEDURE S405168A0202 foreign matter get on them.
1) Assembling piston assembly:
Apply recommended brake fluid to inside wall of
cylinder, and to outer surface of piston assembly,
and install piston assemblies carefully into cylinder.
2) Press the pawl (only vehicle equipped with
ABS) and install the piston retainer into the master
cylinder.
S4M0124
3) Install seal to reservoir tank.
B4M1450C
(1) Seal
4) Install pin with drift pins which secures reservoir

tank to master cylinder.
BR-39
BRAKE BOOSTER
Brake
12. Brake Booster S405166

쐌 Do not change the push rod length. If it has been
changed, reset the projected length “L” to the stan-
A: REMOVAL S405166A18 dard length.
CAUTION: Standard:
If external force “F” is applied from above L = 10 mm (0.39 in)
when brake booster is placed in this position,
the resin portion as indicated by “P”, may be
damaged.
G4M0424
S4M0464B
1) Pull up parking brake lever, and block the tires.

tery.
3) Remove or disconnect the following parts at
engine compartment.
(1) Disconnect connector for brake fluid level
indicator.
(2) Remove brake pipes from master cylinder.
(3) Remove master cylinder installing nuts.
(4) Disconnect vacuum hose from brake
booster.
4) Remove the following parts from the pedal
bracket.
(1) Snap pin and clevis pin
(2) Four brake booster installing nuts
5) Remove brake booster while shunning brake
pipes.
NOTE:
쐌 Be careful not to drop brake booster. Brake
booster should be discarded if it has been
dropped.
쐌 Use special care when handling operating rod.
If excessive force is applied to operating rod, suf-
ficient to cause a change in the angle in excess of
±3°, it may result in damage to the power piston
cylinder.
쐌 Use care when placing brake booster on the
floor.
BR-40
BRAKE BOOSTER
Brake
B: INSTALLATION S405166A11 7) Adjust operating rod of brake booster.

1) Mount brake booster in position. Standard: L
2) Connect operating rod to brake pedal with cle- LHD:
vis pin and snap pin. 144.6 mm (5.69 in)
RHD:
173.2 mm (6.82 in)
If it is not in specified value, adjust it by adjusting
brake booster operating rod.
B4M0616A
8) Measure the clearance between threaded end

of stop light switch and stopper.
position of stop light switch.
CAUTION:
Be careful not to rotate stop light switch.
B4M0117C
Stop light switch clearance: A
(1) Nuts 0.3 mm (0.012 in)
(2) Clevis pin
(3) Snap pin
(4) Operating rod
3) Connect vacuum hose to brake booster.
B4M0617H
9) Apply grease to operating rod connecting pin to

prevent it from wearing.
S4M0125
Tightening torque (Air bleeder screw):
4) Mount master cylinder onto brake booster. 8 N·m (0.8 kgf-m, 5.8 ft-lb)
5) Connect brake pipes to master cylinder. 11) Conduct road tests to ensure brakes do not
6) Connect electric connector for brake fluid level drag.
indicator.
BR-41
BRAKE BOOSTER
Brake
C: INSPECTION S405166A10 쐌 Operation check

1. OPERATION CHECK (WITHOUT 1) With engine off, depress brake pedal several
GAUGES) S405166A1001 times applying the same pedal force and make
sure that the pedal height does not vary with each
CAUTION: depression of the pedal.
When checking operation, be sure to securely
apply the hand brake.
쐌 Checking without gauges
This method cannot determine the exact portion
which has failed, but it can provide a rough under-
standing of the nature of the failure if checking is
conducted in accordance with the following proce-
dures.
쐌 Air tightness check
S4M0466A
Start engine, and run it for 1 to 2 minutes, then turn
it off. Depress brake pedal several times applying (1) When engine is stopped
the same pedal force as that used in ordinary brak- (2) When engine is started
ing operations. The pedal stroke should be great- 2) With brake pedal depressed, start engine.
est on the 1st depression, and it should become 3) As engine starts, brake pedal should move
smaller with each successive depression. If no slightly toward the floor. If no change occurs in the
change occurs in the pedal height while in a pedal height, brake booster is faulty.
depressed state, brake booster is faulty.
NOTE:
If faulty, check precisely with gauges.
쐌 Loaded air tightness check
Depress brake pedal while engine is running, and
turn off engine while the pedal is still depressed.
Keep the pedal depressed for 30 seconds; if no
change occurs in the pedal height, brake booster
is functioning normally; if the pedal height
increases, it is faulty.
NOTE:
S4M0465A
If faulty, check precisely with gauges.
(1) OK 2. OPERATION CHECK (WITH GAUGES)
(2) NOT OK S405166A1002
(3) 1st
(4) 2nd CAUTION:
(5) 3rd When checking operation, be sure to securely
apply the hand brake.
NOTE:
쐌 In the event of defective operation, inspect the
condition of the check valve and vacuum hose.
쐌 Replace them if faulty and conduct the test
again.
쐌 If no improvement is observed, check precisely
with gauges.
BR-42
BRAKE BOOSTER
Brake
쐌 Checking with gauges 쐌 Loaded air tightness check

Connect gauges as shown in Figure. After bleed- 1) Start engine and depress brake pedal with
ing air from pressure gauges, proceed to each pedal force of 196 N (20 kg, 44 lb). Keep engine
check. running until a vacuum of 66.7 kPa (500 mmHg,
19.69 inHg) = point B is indicated on vacuum
gauge while the pedal is still depressed.
S4M0467A
(1) Pressure gauge S4M0469A

(2) Vacuum gauge
(3) Adapter hose (1) Pressure gauge
(4) Vacuum hose (2) Vacuum gauge
(5) Pedal force gauge (3) Pedal force gauge
(4) Depress
쐌 Air tightness check
2) Stop engine and watch vacuum gauge.
1) Start engine and keep it running until a vacuum If the vacuum drop range is less than 3.3 kPa (25
of 66.7 kPa (500 mmHg, 19.69 inHg) = point A is mmHg, 0.98 inHg) within 15 seconds after stop-
indicated on vacuum gauge. Do not depress brake ping engine, brake booster is functioning properly.
pedal. If defective, refer to “AIR TIGHTNESS CHECK”.
<Ref. to BR-42 INSPECTION, Brake Booster.>
쐌 Lack of boosting action check
Turn off engine, and set the vacuum gauge read-
ing at “0”. Then, check the fluid pressure when
brake pedal is depressed. The pressure must be
greater than the standard value listed.
Brake pedal 147 N 294 N
force (15 kgf, 33 lb) (30 kgf, 66 lb)
Fluid 588 kPa 1,667 kPa
S4M0468A pressure (6 kg/cm2, 85 psi) (17 kg/cm2, 242 psi)
(1) Pressure gauge 쐌 Boosting action check
(2) Vacuum gauge
Set the vacuum gauge reading at 66.7 kPa (500
2) Stop engine and watch the gauge. If the mmHg, 19.69 inHg) by running engine. Then,
vacuum drop range is less than 3.3 kPa (25 check the fluid pressure when brake pedal is
mmHg, 0.98 inHg) within 15 seconds after stop- depressed. The pressure must be greater than the
ping engine, brake booster is functioning properly. standard value listed.
If defective, the cause may be one of those listed
Brake pedal 147 N 294 N
below.
force (15 kgf, 33 lb) (30 kgf, 66 lb)
쐌 Check valve malfunction
10,003 kPa
쐌 Leak from vacuum hose Fluid 5,394 kPa
(102 kg/cm2, 1,450
쐌 Leak from the shell jointed portion or stud bolt pressure (55 kg/cm2, 782 psi)
psi)
welded portion
쐌 Damaged diaphragm
쐌 Leak from valve body seal and bearing portion
쐌 Leak from plate and seal assembly portion
쐌 Leak from poppet valve assembly portion
BR-43
PROPORTIONING VALVE
Brake
13. Proportioning Valve S405167 B: INSTALLATION S405167A11
1) Install proportioning valve to bracket.
2) Connect brake pipes correctly to proportioning
With ABS model valve.
3) Bleed air, then check each joint of brake pipe
for oil leaks.
Tightening torque:
Proportioning valve to brake pipe flare nut:
15 N·m (1.5 kgf-m, 10.8 ft-lb)
Proportioning valve to bracket:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
1) Install the oil pressure gauges to measure the

B4M1177C master cylinder fluid pressure (front wheel brake
(1) Proportioning valve fluid pressure) and rear wheel cylinder fluid pres-
sure.
Without ABS model 2) Bleed air from the oil pressure gauges.
3) Check the master cylinder fluid pressure and
rear wheel cylinder fluid pressure.
The standard values are shown in Figure.
B4M1197B
(1) Proportioning valve

B4M1198A
1) Pull up parking brake lever, and block the tires.
2) Remove brake pipe from proportioning valve at 4) For the oil pressure in case of split point, refer
four places. to “SPECIFICATIONS”.
3) Remove proportioning valve from its bracket. <Ref. to BR-2 SPECIFICATIONS, General
CAUTION: Description.>
Do not disassemble or adjust the proportioning
valve. (The proportioning valve must be
replaced as an assembly.)
BR-44
BRAKE FLUID
Brake
14. Brake Fluid S405162

5) Install one end of a vinyl tube onto the air
bleeder of and insert the other end of the tube into
A: INSPECTION S405162A10 a container to collect the brake fluid.
1) Check that 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 fluid for discoloration. If fluid color has
excessively changed, drain the fluid and refill with
new fluid.
CAUTION: S4M0246
쐌 To always maintain the brake fluid
characteristics, replace the brake fluid accord-
ing to maintenance schedule or earlier than
that when used in severe condition.
쐌 The FMVSS No. 116, fresh DOT3 or 4 brake
fluid must be used.
쐌 Cover bleeder with waste cloth, when loos-
ening it, to prevent brake fluid from being
splashed over surrounding parts.
쐌 Avoid mixing different brands of brake fluid
to prevent degrading the quality of the fluid.
쐌 Be careful not to allow dirt or dust to get into S4M0477A
the reservoir tank.

CAUTION:
NOTE:
Brake fluid replacement sequence; (A) Front
쐌 During bleeding operation, keep the brake res-
right → (B) Rear left → (C) Front left → (D) Rear
ervoir tank filled with brake fluid to eliminate entry
right
of air.
쐌 Brake pedal operating must be very slow.
쐌 For convenience and safety, two people should
do the work.
쐌 The amount of brake fluid required is approxi-
mately 500 m (16.9 US fl oz, 17.6 Imp fl oz) for
total brake system.
1) Either jack-up vehicle and place a safety stand
under it, or lift-up vehicle.
2) Remove both front and rear wheels.
3) Draw out the brake fluid from master cylinder S4M0475A
with syringe.
4) Refill reservoir tank with recommended brake (1) Master cylinder
fluid. (2) Hydraulic unit
(3) Proportioning valve
Recommended brake fluid:
FMVSS No. 116, fresh DOT3 or 4 brake 6) Instruct your co-worker to depress the brake
fluid pedal slowly two or three times and then hold it
depressed.
7) Loosen bleeder screw approximately 1/4 turn
until a small amount of brake fluid drains into
container, and then quickly tighten screw.
8) Repeat steps 6) and 7) above until there are no
air bubbles in drained brake fluid and new fluid
flows through vinyl tube.
BR-45
BRAKE FLUID
Brake
NOTE:
Add brake fluid as necessary while performing the
air bleed operation, in order to prevent the tank
from running short of brake fluid.
9) After completing the bleeding operation, hold
brake pedal depressed and tighten screw and
install bleeder cap.
Tightening torque (Bleeder screw):
8 N·m (0.8 kgf-m, 5.8 ft-lb)
10) Bleed air from each wheel cylinder using the
same procedures as described in steps 6) through
7) above.
11) Depress brake pedal with a force of approxi-
mately 294 N (30 kgf, 66 lb) and hold it there for
approximately 20 seconds. At this time check
pedal to see if it shows any unusual movement.
Visually inspect bleeder screws and brake pipe
joints to make sure that there is no fluid leakage.
12) Install wheels, and drive vehicle for a short
distance between 2 to 3 km (1 to 2 miles) to make
sure that brakes are operating properly.
BR-46
AIR BLEEDING
Brake
15. Air Bleeding S405163

5) Close outlet plug with your finger, and release
brake pedal.
CAUTION:
쐌 The FMVSS No. 116, fresh DOT3 or 4 brake
fluid must be used.
쐌 Cover bleeder with waste cloth when loosen-
ing it to prevent brake fluid from being
splashed over surrounding parts.
쐌 Avoid mixing different brands of brake fluid
to prevent degrading the quality of the fluid.
쐌 Be careful not to allow dirt or dust to get into
S4M0541
the reservoir tank.
NOTE: 6) Repeat items 3) and 4), until brake fluid come
쐌 Start with the brakes (wheels) connected to the out of all outlet port.
secondary chamber of the master cylinder. 7) Remove the plastic bag cover.
쐌 The time interval between two brake pedal 8) Install brake pipes to master cylinder.
operations (from the time when the pedal is Tightening torque:
released to the time when it is depressed another 8 N·m (0.8 kgf-m, 5.8 ft-lb)
time) shall be approximately 3 seconds.
쐌 The air bleeder on each brake shall be released 9) Cleanly wash away brake fluid spill on master
for 1 to 2 seconds. cylinder etc.
1. MASTER CYLINDER S405163E4501
BRAKE LINE, PROCEDURE, Air Bleeding.>
NOTE:
2. BRAKE LINE
쐌 If master cylinder is disassembled or reservoir
S405163E4502
tank is empty, bleed master cylinder. NOTE:

쐌 During bleeding operation, keep the brake res- 쐌 During bleeding operation, keep the brake res-
ervoir tank filled with brake fluid to eliminate entry ervoir tank filled with brake fluid to eliminate entry
of air. of air.
쐌 Brake pedal operating must be very slow. 쐌 Brake pedal operating must be very slow.
쐌 For convenience and safety, two people should 쐌 For convenience and safety, two people should
do the work. do the work.
1) Loosen wheel nuts, jack-up vehicle, support it 1) Make sure that there is no leak from joints and
with safety stands, and remove wheel. connections of the brake system.
2) Disconnect brake line at primary and secondary 2) Fit one end of vinyl tube into the air bleeder and
sides. put the other end into a brake fluid container.
3) Put plastic bag cover on the master cylinder.
4) Carefully depress and hold brake pedal.
S4M0246
S4M0540
BR-47
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 → (B) Rear left → (C) Front left → (D) Rear with a 490 N (50 kgf, 110 lb) 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.
S4M0475A
(1) Master cylinder

(2) Hydraulic unit
(3) Proportioning valve S4M0467A
3) Slowly depress the brake pedal and keep it (1) Steering wheel
depressed. Then, open the air bleeder to discharge (2) Toe board
air together with the fluid. Specified pedal stroke:
Release air bleeder for 1 to 2 seconds. Without ABS
Next, with the bleeder closed, slowly release the 90 mm (3.54 in)
brake pedal. With ABS
Repeat these steps until there are no more air 95 mm (3.74 in)
bubbles in the vinyl tube. When depressing brake pedal with a 490
Allow 3 to 4 seconds between two brake pedal N (50 kgf, 110 lb) load.
operations. 7) If the distance is more than specifications, there
CAUTION: is a possibility that air is in the brake line. Bleed
Cover bleeder with waste cloth, when loosen- brake line until pedal stroke meets the specifica-
ing it, to prevent brake fluid from being tion.
splashed over surrounding parts. 8) Operate hydraulic control unit in the sequence
control mode. (Only vehicle equipped with ABS)
NOTE: <Ref. to ABS-11 ABS Sequence Control.>
Brake pedal operating must be very slow. 9) Recheck the brake stroke.
4) Tighten air bleeder securely when no air 10) If the distance is more than specifications,
bubbles are visible. there is a possibility air is in the inside of the
hydraulic unit. Repeat above steps 2) to 9) above
Air bleeder tightening torque: until pedal stroke meets the specification.
8 N·m (0.8 kgf-m, 5.8 ft-lb) 11) Add brake fluid to the required level (MAX.
5) Perform these steps for the brakes connecting level) of reservoir tank.
to the secondary chamber of master cylinder, first, 12) As a final step, test run the vehicle at low
and then for the ones connecting to primary cham- speed and apply brakes relatively hard 2 to 3 times
ber. With all procedures completed, fully depress to ensure that brakes provide normal braking
the brake pedal and keep it in that position for action on all four wheels without dragging and
approximately 20 seconds to make sure that there uneven braking.
is no leak evident in the entire system.
BR-48
BRAKE HOSE
Brake
16. Brake Hose S405164

5) Temporarily tighten flare nut to connect brake
pipe and hose.
A: REMOVAL S405164A18 6) Fix brake hose with clamp at wheel apron
bracket.
1) Loosen wheel nuts, jack-up vehicle, support it 7) While holding hexagonal part of brake hose fit-
with safety stands, and remove wheel. ting with a wrench, tighten flare nut to the specified
2) Separate brake pipe from brake hose. torque.
(Always use flare nut wrench and be careful not to
deform flare nut.) Tightening torque (Brake pipe flare nut):
15 N·m (1.5 kgf-m, 10.8 ft-lb)
8) Bleed air from the brake system. <Ref. to
BR-47, Air Bleeding.>
2. REAR BRAKE HOSE S405164A1102
1) Pass brake hose through the hole of bracket,

and lightly tighten flare nut to connect brake pipe.
2) Insert clamp upward to fix brake hose.
3) While holding hexagonal part of brake hose fit-
ting with a wrench, tighten flare nut to the specified
S4M0470A torque.
Tightening torque (Brake pipe flare nut):
(1) Clamp
15 N·m (1.5 kgf-m, 10.8 ft-lb)
(2) Brake pipe
(3) Brake hose 4) Bleed air from the brake system. <Ref. to
BR-47, Air Bleeding.>
3) Pull out clamp to remove brake hose.
4) Remove clamp at strut and union bolt. C: INSPECTION S405164A10
Ensure there are no cracks, breakage, or damage
on hoses. Check joints for fluid leakage. If any
1. FRONT BRAKE HOSE S405164A1101 cracks, breakage, damage or leakage is found,
repair or replace hose.
1) Route end of brake hose (on caliper side)
through hole in brake hose bracket at strut loca-
tion.
2) Tighten end of brake hose at caliper using a
union bolt.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
S4M0113
3) Secure middle fitting of brake hose to bracket at

strut location using a clamp.
4) Position disc in straight-forward direction and
route brake hose through hole in bracket on wheel
apron side.
CAUTION:
Be sure brake hose is not twisted.
BR-49
BRAKE PIPE
Brake
17. Brake Pipe S405165 C: INSPECTION S405165A10
Ensure there are no cracks, breakage, or damage
on pipes. Check joints for fluid leakage. If any
NOTE: cracks, breakage, damage or leakage is found,
Airbag system wiring harness is routed near the repair or replace pipe.
center brake pipe.
NOTE:
CAUTION: Use a mirror when inspecting low-visible part or
쐌 All Airbag system wiring harness and con- back side.
ing harness when servicing the center brake
pipe.
쐌 When removing the brake pipe, make sure
that it is not bent.
NOTE:
Airbag system wiring harness is routed near the
center brake pipe.
CAUTION:
ing harness when servicing the center brake
pipe.
쐌 When installing the brake pipe, make sure
that it is not bent.
쐌 After installing the brake pipe and hose,
bleed the air.
쐌 After installing the brake hose, make sure
that it does not touch the tire or suspension
assembly, etc.
Brake pipe tightening torque:
15 N·m (1.5 kgf-m, 10.8 ft-lb)
BR-50
HILL HOLDER
Brake
18. Hill Holder S405661

7) Detach PHV along with support from side
frame.
CAUTION:
1. PHV (PRESSURE HOLD VALVE) S405661A1801 Exercise utmost care to prevent foreign matter
from entering into PHV when removing it.
<Ref. to IN(SOHC)-7, REMOVAL, Air Cleaner
Case.>
3) Drain brake fluid from reservoir of master cylin-
der.
4) Remove adjusting nut and lock nut.
S4M0243
2. PHV CABLE S405661A1802

Case.>
S4M0241C IN(DOHC TURBO)-10, REMOVAL, Intercooler.>
(1) Adjusting nut 3) Remove adjusting nut and lock nut.
(2) Lock nut
(3) PHV
5) Remove cable clamp, and disconnect PHV

cable from PHV.
CAUTION:
Carefully protect boots and inner cable from
damage when disconnecting PHV cable.
S4M0241C
(1) Adjusting nut

(2) Lock nut
(3) PHV
S4M0242C
(1) PHV cable

(2) Clamp
6) Disconnect brake pipes from PHV.

CAUTION:
쐌 Pay attention not to drop brake fluid onto
body painting since it may dissolve paint.
쐌 Pay attention not to damage hexagonal head
of flare nut by using pipe wrench without fail.
BR-51
HILL HOLDER
Brake
4) Remove cable clamp, and disconnect PHV B: INSTALLATION S405661A11

cable from PHV.
1. PHV (PRESSURE HOLD VALVE) S405661A1101
CAUTION:
Carefully protect boot and inner cable from 1) Install PHV onto side frame.
damage when disconnecting PHV cable. Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
2) Connect brake pipes to PHV.
Tightening torque:
15 N·m (1.5 kgf-m, 10.8 ft-lb)
CAUTION:
Confirm that brake pipes are not deformed
and/or damaged. Replace them with new ones
if necessary.
S4M0242C 3) Install PHV cable to PHV.
(1) PHV cable CAUTION:
(2) Clamp If cable clamp (and clips) is damaged, replace
it with a new one.
5) Remove cable clamp from clutch pedal bracket.
4) Connect PHV cable with clips.
LHD model
NOTE:
Avoid sharp bending of PHV cable as it may cause
breakage.
5) Apply grease to the following points.
쐌 Hook portion of return spring
쐌 Cable end portion of lever
Grease:
SUNLIGHT 2 (Part No. 003602010)
6) Be sure to bleed air from the brake system.
S4M0244B 7) Adjust PHV cable. <Ref. to BR-53
ADJUSTMENT, Hill Holder.>
(1) Clamp
(2) PHV cable
CAUTION:
(3) Clutch pedal
After replacing PHV cable with new one, oper-
ate clutch pedal about 30 times as a running-in
RHD model operation prior to adjustment.
8) Install air cleaner case. (Non-turbo model)
Case.>
9) Install intercooler. (Turbo model) <Ref. to
IN(DOHC TURBO)-10, INSTALLATION, Inter-
cooler.>
2. PHV CABLE S405661A1102
1) Install PHV cable in the reverse order of

removal.
S4M0245B
CAUTION:
(1) Clamp 쐌 If cable clamp is damaged, replace it with a
(2) PHV cable new one.
(3) Clutch pedal 쐌 Avoid sharp bending of PHV cable as it may
cause breakage.
6) Remove PHV cable.
2) Apply grease to the following points.
쐌 Hook portion of return spring
쐌 Cable end portion of lever
BR-52
HILL HOLDER
Brake
Grease: D: ADJUSTMENT S405661A01

SUNLIGHT 2 (Part No. 003602010)
Confirm stopping and starting performances by
3) Adjust PHV cable. <Ref. to BR-53 activating hill holder on an uphill road of 3° or
ADJUSTMENT, Hill Holder.> higher inclination.
CAUTION: 1) If vehicle does not stop;
After replacing PHV cable with new one, oper- Tighten adjusting nut of PHV cable.
ate clutch pedal about 30 times as a running-in 2) If vehicle does not start properly;
operation prior to adjustment. 쐌 Case A — When hill holder is released later than
engagement of clutch pedal (Engine tends to
4) Install air cleaner case. (Non-turbo model) stall.):
<Ref. to IN (SOHC)-7, INSTALLATION, Air Cleaner Loosen adjusting nut gradually until smooth start-
Case.> ing is enabled.
5) Install intercooler. (Turbo model) <Ref. to IN 쐌 Case B — When hill holder is released earlier
(DOHC TURBO)-10, INSTALLATION, Intercooler.> than engagement of clutch pedal (Vehicle slips
down slightly.):
Tighten adjusting nut so that hill holder is released
Check up removed parts as follows, and replace later than engagement of clutch pedal (status in
defective ones. Case A). Then make adjustment the same as in
1) Check if boots of PHV cable are damaged or Case A.
degraded, and if inner cable is damaged or cor- CAUTION:
roded. Whenever turning adjusting nut, prevent PHV
2) Check if return spring is worn out, damaged or cable from revolving.
corroded.
3) Confirm that rolling sound of ball is heard with
PHV inclined and lever rotates smoothly.
CAUTION:
Never disassemble PHV. Replace entire PHV
assembly if necessary.
S4M0241B
(1) Adjusting nut

(2) Lock nut
(3) PHV
3) Tighten lock nut.

Tightening torque:
3.4 N·m (0.35 kgf-m, 2.5 ft-lb)
BR-53
BRAKE PEDAL
Brake
19. Brake Pedal S405541

8) Remove cable clamp, and disconnect PHV
cable from PHV.
CAUTION:
1. MT MODEL S405541A1801
Carefully protect boot and inner cable from
damage when disconnecting PHV cable.
쐌 LHD model
1) Pull up parking brake lever and block tires.
tery.
3) Remove steering column.
<Ref. to PS-30 REMOVAL, Tilt Steering Column.>
4) Disconnect connectors from stop light and
clutch switches.
5) Remove snap pins which secure lever to push
rod and operating rod.
S4M0242B
6) Remove clevis pins which secure lever to push
rod and operating rod. (A) PHV cable
(B) Clamp
9) Remove nut which secures clutch master cylin-

der.
B4M1743A
(A) Operating rod

(B) Push rod
(C) Snap pin B4M1744
(D) Clevis pin
10) Remove bolts and nuts which secure brake
7) Remove PHV adjusting nut and lock nut. and clutch pedals, and remove pedal assembly.
S4M0241B
(A) Adjusting nut

(B) Lock nut
(C) PHV
BR-54
BRAKE PEDAL
Brake
쐌 RHD model 10) Remove nuts and bolts which secure pedal
bracket.
1) Pull up parking brake lever.
tery.
3) Disconnect accelerator cable from throttle body.
CAUTION:
Be careful not to kink accelerator cable.
4) Remove instrument panel lower cover from
instrument panel.
5) Remove clevis pin which secures brake pedal
to brake booster operating rod. Also disconnect
electrical connectors (for stop light switch, etc.).
6) Disconnect accelerator cable from accelerator
pedal lever.
B4M0157B
(1) Accelerator pedal

S4M0482A (2) Brake pedal
(1) Slot type screwdriver
7) Remove the casing cap out of the toe board by

turning it clockwise.
B4M0156B
(1) Accelerator cable

(2) Toe board hole
(3) Casing cap
8) Pull out the cable from the toe board hole.

9) Disconnect stop light switch connector.
BR-55
BRAKE PEDAL
Brake
2. AT MODEL S405541A1802 B: INSTALLATION S405541A11
쐌 LHD model 1) Install in the reverse order of removal.

1) Pull up parking brake lever. CAUTION:
2) Disconnect battery ground terminal from bat- 쐌 Be careful not to bend clutch cable too
tery. much.
3) Remove instrument panel lower cover from 쐌 Never fail to cover outer cable end with boot.
instrument panel. 쐌 Be careful not to kink accelerator cable.
4) Remove clevis pin which secures brake pedal 쐌 Make sure that holder and casing cap are
to brake booster operating rod. Also disconnect securely connected. (LHD model only)
stop light switch connector.
5) Remove two bolts and four nuts which secure
brake pedal to pedal.
B4M0159B
(1) Casing cap

G4M0324
(3) Toe board
(4) Accelerator pedal bracket
쐌 RHD model (5) Holder
NOTE:
For removal procedures, refer to “MT MODEL”. 2) Adjustment of clutch pedal <Ref. to BR-58
<Ref. to BR-54 MT MODEL, REMOVAL, Brake ASSEMBLY, Brake Pedal.>
Pedal.> 3) Inspect after pedal installation <Ref. to BR-59
INSPECTION, Brake Pedal.>
BR-56
BRAKE PEDAL
Brake
C: DISASSEMBLY S405541A06 쐌 RHD model

1. MT MODEL S405541A0601
1) Remove the stop light switch and kick-down
switch.
쐌 LHD model 2) Remove clip, bushing, accelerator spring and
1) Remove the stop light switch. accelerator pedal.
<Ref. to BR-60 REMOVAL, Stop Light Switch.>
2) Remove the clutch pedal.
<Ref. to CL-38 DISASSEMBLY, Clutch Pedal.>
3) Remove the clutch master cylinder bracket.
S4M0542A
(1) Clip
(2) Bushing
(3) Accelerator spring
B4M2349
4) Remove bushing, spring and stopper. 3) Unbolt, and then remove the brake pedal.
B4M2350A
S4M0543
(1) Stopper
4) Remove spacer, bushing, brake pedal spring
(2) Bushing
and brake pedal.
(3) Brake pedal
(4) Brake pedal spring
5) Remove the brake pedal pad.
B4M2350A
(1) Stopper
(2) Bushing
(3) Brake pedal
5) Remove the brake pedal pad.
BR-57
BRAKE PEDAL
Brake
2. AT MODEL S405541A0602 D: ASSEMBLY S405541A02
1) Remove the brake switch. 1) Attach stop light switch, etc. to pedal bracket
2) Unbolt, and then remove the brake pedal. temporarily.
2) Clean inside of bores of clutch pedal and brake
pedal, apply grease, and set bushings into bores.
3) Align bores of pedal bracket, clutch pedal and
brake pedal, attach brake pedal return spring and
clutch pedal effort reducing spring (vehicle with hill
holder), and then install pedal bolt.
NOTE:
Clean up inside of bushings and apply grease
before installing spacer.
B4M2347
Tightening torque:
T: 29 N·m (3.0 kgf-m, 21.7 ft-lb)
3) Remove bushing, spacer and spring.
B4M1753C
B4M2348A
4) Set brake pedal position by adjusting position of
(1) Spacer stop light switch.
(2) Bushing
Pedal position: L
(3) Stopper
LHD model
(4) Brake pedal
125.9 mm (4.96 in)
(5) Brake spacer
RHD model
154.9 mm (6.10 in)
4) Remove the brake pedal pad. Tightening torque:
T: 8 N·m (0.8 kgf-m, 5.8 ft-lb)
B4M1754B
BR-58
BRAKE PEDAL
Brake
E: INSPECTION S405541A10 2) Check position of pedal pad.

1) Move brake and clutch pedal pads in the lateral Pedal height: L
direction with a force of approximately 10 N (1 kgf, 148 mm (5.83 in)
2 lb) to ensure pedal deflection is in specified Brake pedal free play: A
range. 1 — 3 mm (0.04 — 0.12 in) [Depress
brake pedal pad with a force of less than
CAUTION:
10 N (1 kgf, 2 lb).]
If excessive deflection is noted, replace bush-
ings with new ones.
Deflection of brake and clutch pedal:
Service limit
5.0 mm (0.197 in) or less
B4M0366B
(1) Stop light switch

(2) Mat
(3) Toe board
(4) Brake booster operating rod
S4M0135B
3) If it is not in specified value, adjust it by adjust-
(1) Clutch pedal
ing brake booster operating rod length.
(2) Brake pedal
G4M0326
BR-59
STOP LIGHT SWITCH
Brake
20. Stop Light Switch S405542 C: INSPECTION S405542A10
1) If stop light switch does not operate properly (or
if it does not stop at the specified position), replace
1) Disconnect ground terminal from battery. with a new one.
2) Disconnect stop light switch connector.
3) Loosen nuts, and unscrew stop light switch to Specified position: L
remove. 2+1.5/0 mm (0.079+0.059/0 in)
G4M0327
B4M1753D
(1) Stop light switch 2) Measure the clearance between threaded end
of stop light switch and stopper.
CAUTION:
1) Screw the stop light switch onto a bracket and Be careful not to rotate stop light switch.
secure it temporarily with a nut. Stop light switch clearance: A
2) Adjust stop light switch position, and then 0.3 mm (0.012 in)
tighten the nut.
<Ref. to BR-61 ADJUSTMENT, Stop Light
Switch.>
Tightening torque:
8 N·m (0.8 kgf-m, 5.8 ft-lb)
B4M0617E
(1) Stop light switch

(2) Stopper
(3) Brake pedal
B4M1753E 3) If it is not in specified value, adjust it by adjust-

ing position of stop light switch.
CAUTION:
Be careful not to rotate stop light switch.
BR-60
STOP LIGHT SWITCH
Brake
Loosen the lock nut, and adjust 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.
B4M0617E
BR-61
GENERAL DIAGNOSTICS
Brake
21. General Diagnostics S405278
1. BRAKE SYSTEM S405278A1001
Trouble and possible cause Corrective action

1. Insufficient braking (1) Fluid leakage from the hydraulic mechanism Repair or replace (cup, piston seal, piston boot,
master cylinder piston kit, pipe or hose).
(2) Entry of air into the hydraulic mechanism Bleed the air.
(3) Excessively wide shoe clearance Adjust the clearance.
(4) Wear, deteriorated surface material, adhering Replace, grind or clean.
water or fluid on the lining
(5) Improper operation of master cylinder, disc Correct or replace.
caliper, brake booster or check valve
2. Unstable or uneven (1) Fluid on the lining, drum or rotor Eliminate cause of fluid leakage, clean, or
braking replace.
(2) Drum or rotor eccentricity Correct or replace the drum or rotor.
(3) Worn brake drum, or damage to the drum Correct by grinding, or replace.
caused by sand
(4) Improper lining contact, deteriorated surface Correct by grinding, or replace.
material, improper inferior material, or wear
(5) Deformed back plate Correct or replace.
(6) Improper tire inflation Inflate to correct pressure.
(7) Disordered wheel alignment Adjust alignment.
(8) Loosened back plate or the support installing Retighten.
bolts
(9) Loosened wheel bearing Retighten to normal tightening torque or replace.
(10) Trouble in the hydraulic system Replace the cylinder, brake pipe or hose.
(11) Uneven effect of the parking brake Check, adjust, or replace the rear brake and
cable system.
3. Excessive pedal (1) Entry of air into the hydraulic mechanism Bleed the air.
stroke (2) Excessive play in the master cylinder push Adjust.
rod
(3) Fluid leakage from the hydraulic mechanism Repair or replace (cup, piston seal, piston boot,
master cylinder piston kit, pipe or hose).
(4) Improperly adjusted shoe clearance Adjust.
(5) Improper lining contact or worn lining Correct or replace.
4. Brake dragging or (1) Insufficient pedal play Adjust play.
improper brake return (2) Improper master cylinder return Clean or replace the cylinder.
(3) Clogged hydraulic system Replace.
(4) Improper return or adjustment of parking Correct or adjust.
brake
(5) Weakened spring tension or breakage of shoe Replace the spring.
return spring
(6) Excessively narrow shoe clearance Adjust the clearance.
(7) Improper disc caliper operation Correct or replace.
(8) Improper adjusted wheel bearing Adjust or replace.
5. Brake noise (1) (1) Hardened or deteriorated lining Replace the shoe assembly or pad.
(creak sound) (2) Worn lining Replace the shoe assembly or pad.
(3) Loosened back plate or the support installing Retighten.
bolts
(4) Loose wheel bearing Retighten to normal tightening torque.
(5) Dirty drum or rotor Clean the drum or rotor, or clean and replace the
brake assembly.
BR-62
GENERAL DIAGNOSTICS
Brake

6. Brake noise (2) (1) Worn lining Replace the shoe assembly or pad.
(hissing sound) (2) Improper installed shoe or pad Correct or replace the shoe assembly or pad.
(3) Loose or bent drum or rotor Retighten or replace.
7. Brake noise (3) In the case of the disc brake:
(click sound) (1) Excessively worn pad or the support Replace the pad or the support.
In the case of the drum brake:
(1) Excessively worn shoe ridge Replace the back plate.
(2) Lack of oil on the shoe ridge surface and Add more grease.
anchor
2. HILL HOLDER S405278A1002 쐌 When vehicle cannot travel (brake cannot be

released) because return spring is broken,
CAUTION:
쐌 Description in parentheses is a characteris- remove adjust nut, disconnect clutch and PHV,
tic of hill holder and does not indicate abnor- and then return PHV lever to release the brake.
mality. (Be sure to apply the parking brake before
Depressing force required for clutch pedal starting this operation.)
equipped to hill holder specifications is 20 to 쐌 The hill holder may not be activated on a
29 N (2 to 3 kg, 4 to 7 lb) larger than the con- slope of an extremely small inclination.
ventional specifications, which does not con-
stitute abnormality.

1. Counterforce of (1) PHV cable is damaged or does not operate Repair or replace.
clutch pedal is too properly.
strong. (2) Lever of PHV is defective. Replace entire PHV assembly.
(3) Clutch system is anomalous. Replace clutch system.
2. Vehicle does not (1) Front side of vehicle is lowered. Replace suspension.
stop on uphill road of (2) PHV cable is broken. Replace.
3° or higher inclina- (3) Play of clutch is excessive. Adjust.
tion.
(4) PHV cable is elongated. Adjust.
(5) Sealing of PHV is poor. Replace entire PHV assembly.
3. Shock is felt when (1) Poor adjustment of starting performance. Adjust.
starting. (2) When depressing the brake pedal strongly: (The stronger brake pedal depressing force, the
later hill holder releases.)
(3) When starting on flat road after stopping (Because hill holder is activated.)
reverse movement:
4. Vehicle slips down (1) PHV cable is elongated. Adjust.
when starting. (2) Clutch facing is worn out. Adjust or replace.
(3) Bracket (cable) or stay (PHV) is deformed. Repair or replace.
5. Vehicle cannot start (1) Return spring is fatigued or broken. Replace.
after stoppage. (2) PHV lever won’t return. Replace entire PHV assembly.
(3) When intentionally depressing brake pedal [When the brake pedal is depressed by a force of
strongly: 1,177 N (120 kgf, 265 lb) or more.]
6. Abnormal sound is (1) Rotor and pad matched with each other due (Abnormal sound is not generated when depress-
generated upon to inadequate depressing force to brake pedal. ing brake pedal a little stronger.)
releasing brake pedal
when stopping.
7. Abnormal sound is (1) Grease is inadequate for the hook of return Apply grease.
generated when oper- spring and sliding portion of PHV cable end.
ating clutch pedal. (2) When releasing after maintaining high fluid (Flowing sound of fluid when releasing high fluid
pressure: pressure.)
(3) Clutch system is anomalous. Replace clutch system.
BR-63
GENERAL DIAGNOSTICS
Brake
MEMO:
BR-64
CHASSIS SECTION

SUBARU vehicles.
ine parts.

G8050GE5
PARKING BRAKE
PB
Page
2. Parking Brake Lever....................................................................................6
3. Parking Brake Cable ...................................................................................7
4. Parking Brake Assembly (Rear Disc Brake) ...............................................9
GENERAL DESCRIPTION
Parking Brake
Model Rear drum brake Rear disc brake

Type Mechanical on rear brakes, drum in disc
Effective drum diameter mm (in) 228.6 (9) 170 (6.69)
Lining dimensions 218.8 × 35.0 × 4.1 162.6 × 30.0 × 3.2
mm (in)
(length × width × thickness) (8.61 × 1.378 × 0.161) (6.40 × 1.181 × 0.126)
Clearance adjustment Automatic adjustment Manual adjustment
Lever stroke noches/N (kgf, lb) 7 to 8/196 (20, 44)
PB-2
GENERAL DESCRIPTION
Parking Brake
1. PARKING BRAKE (REAR DISC BRAKE) S404001A0501
B4M1127A
(1) Back plate (8) Strut (15) Shoe hold down spring
(2) Retainer (9) Shoe guide plate (16) Shoe hold down pin
(3) Spring washer (10) Primary return spring (17) Adjusting hole cover
(4) Lever (11) Secondary return spring
(5) Parking brake shoe (Primary) (12) Adjusting spring Tightening torque: N·m (kgf-m, ft-lb)
(6) Parking brake show (Secondary) (13) Adjuster T: 52 (5.3, 38.3)
(7) Strut spring (14) Shoe hold-down cup
PB-3
GENERAL DESCRIPTION
Parking Brake
2. PARKING BRAKE CABLE S404001A0502
B4M0070B
(1) Parking brake lever (7) Clamp Tightening torque: N·m (kgf-m, ft-lb)
(2) Parking brake switch (8) Parking brake cable RH
T1: 5.9 (0.60, 4.3)
(3) Lock nut (9) Cable guide
T2: 18 (1.8, 13.0)
(4) Adjusting nut (10) Clamp (Rear disc brake model
T3: 32 (3.3, 24)
(5) Equalizer only)
(6) Bracket (11) Parking brake cable LH
PB-4
GENERAL DESCRIPTION
Parking Brake

tion.
ment.
fied points.
deformation.
쐌 Keep grease etc. away from parking brake
shoes.
PB-5
PARKING BRAKE LEVER
Parking Brake
2. Parking Brake Lever S404171

쐌 Be sure to adjust the lever stroke. <Ref. to PB-6
ADJUSTMENT, Parking Brake Lever.>
1) To immobilize vehicle, put the select lever in

While pulling parking brake lever upward, count
“1st ” or “P” position, and lock the tires. the notches.
2) Disconnect ground terminal connector from bat-
tery. Lever stroke:
3) Remove console cover. <Ref. to EI-30, Console 7 to 8 notches when pulled with a force
Box.> of 196 N (20 kgf, 44 lb)
4) Disconnect connector parking brake switch. Incorrect, adjust the parking brake. <Ref. to PB-11
5) Loosen parking cable adjusting nut and remove ADJUSTMENT, Parking Brake Assembly (Rear
inner cable end from equalizer. Disc Brake).>
6) Remove parking brake lever.
1) Remove console cover.

2) Forcibly pull parking brake lever 3 to 5 times.
3) Adjust parking brake lever by turning adjuster
until parking brake lever stroke is set at 7 to 8
notches with operating force of 196 N (20 kgf, 44
lb).
Lever stroke:
7 to 8 notches when pulled with a force
S4M0126B
of 196 N (20 kgf, 44 lb)
(1) Console bracket Tightening torque (Lock nut):
(2) Parking brake lever 5.9 N·m (0.60 kgf-m, 4.3 ft-lb)
7) Unbend parking brake lever pawls and remove
cable.
S4M0520A

S4M0471A (2) Lock nut
(3) Adjusting nut
(2) Cable 5) Install console cover.

Tightening torque:
Parking brake lever;
18 N·m (1.8 kgf-m, 13.0 ft-lb)
Adjusting nut;
5.9 N·m (0.6 kgf-m, 4.3 ft-lb)
NOTE:
쐌 Be sure to pass cable through guide inside the
tunnel.
PB-6
PARKING BRAKE CABLE
Parking Brake
3. Parking Brake Cable S404170

11) Remove inner cable end from equalizer.

tery.
3) Lift-up vehicle.
4) Remove rear tires and wheels.
5) Remove rear cushion.
6) Remove console box. <Ref. to EI-30, Console
Box.>
S4M0473A
7) Loosen parking cable adjusting nut and console
bracket. (1) Equalizer
8) Remove parking brake lever. (2) Inner cable end
12) Pull out parking brake cable from rear brake.

Disc brake: <Ref. to PB-9 REMOVAL, Parking
Brake Assembly (Rear Disc Brake).>
Dram brake: <Ref. to BR-35, Rear Drum Brake
Assembly.>
13) Pull out clamp from rear brake.
14) Remove bolt and bracket from trailing link
bracket.
15) Remove bolt and clamp from rear floor.
S4M0126B
(1) Console bracket

9) Roll up floor mat and remove clamps.
S4M0474
16) Detach grommet from rear floor.

17) Remove cable assembly from cabin by forc-
ibly pulling it backward.
18) Detach parking brake cable from cable guide
at rear trailing link.
S4M0472
10) Remove equalizer cover.
PB-7
PARKING BRAKE CABLE
Parking Brake
B: INSTALLATION S404170A11 C: INSPECTION S404170A10
Install (new) parking brake assembly in the reverse Check the removed cable and replace if damaged,
order of removal. rusty, or malfunctioning.
NOTE: 1) Check for smooth operation of the cable.
쐌 Be sure to pass cable through cable guide inside 2) Check the inner cable for damage and rust.
the tunnel. 3) Check the outer cable for damage, bends, and
쐌 Be sure to adjust the lever stroke. <Ref. to PB-6 cracks.
ADJUSTMENT, Parking Brake Lever.> 4) Check the boot for damage, cracks, and dete-
rioration.
PB-8
PARKING BRAKE ASSEMBLY (REAR DISC BRAKE)
Parking Brake
4. Parking Brake Assembly (2) If disc rotor seizes up within hub, drive disc
rotor out by installing an 8-mm bolt in holes B on
(Rear Disc Brake) S404552
the rotor.

tery.
4) Lift-up vehicle, and remove wheels.
5) Remove the two mounting bolts and remove
the disc brake assembly.
G4M0383
9) Remove shoe return spring from parking brake

assembly.
10) Remove front shoe hold down spring and pin
with pliers.
S4M0459A
6) Suspend the disc brake assembly so that the

hose is not stretched.
7) Pull down and release parking brake.
8) Remove the disc rotor.
NOTE: S4M0524
If the disc rotor is difficult to remove try the follow-
ing two methods in order. 11) Remove strut and strut spring.
12) Remove adjuster assembly from parking
(1) Turn adjusting screw using a slot-type brake assembly.
screwdriver until brake shoe gets away enough 13) Remove brake shoe.
from the disc rotor. 14) Remove rear shoe hold-down spring and pin
with pliers.
15) Remove parking cable from parking lever.
S4M0569A
(1) Adjusting screw

B4M1774B
(2) Adjusting hole cover (rubber)
(3) Slot-type screwdriver (1) Parking brake cable
(4) Back plate (2) Parking brake lever
16) Using a standard screwdriver, raise retainer.

Remove parking lever and washer from brake
shoe.
PB-9
Parking Brake
B: INSTALLATION S404552A11 NOTE:

Ensure that shoe return spring is installed as
CAUTION: shown in Figure.
Be sure lining surface is free from oil contami-
nation.
Brake grease:
725191460)
1) Apply brake grease to the following places.
쐌 Six contact surfaces of shoe rim and back plate
packing
쐌 Contact surface of shoe wave and anchor pin
쐌 Contact surface of lever and strut S4M0462A
쐌 Contact surface of shoe wave and adjuster
assembly (1) Back plate
쐌 Contact surface of shoe wave and strut (2) Shoe guide plate
쐌 Contact surface of lever and shoe wave (3) Retainer
2) Install in reverse order of removal. (4) Spring washer
(5) Lever
CAUTION: (6) Primary shoe return spring (Blue)
쐌 Use new retainers and clinch them when (7) Secondary shoe return spring (Yellow)
installing brake shoes to levers. (8) Parking brake shoe (Primary)
쐌 Ensure that parking lever moves smoothly. (9) Parking brake shoe (Secondary)
쐌 Do not confuse left parking lever with right
one. 3) Adjust parking brakes. <Ref. to PB-11
쐌 Do not confuse left strut with right one. ADJUSTMENT, Parking Brake Assembly (Rear
Disc Brake).>
NOTE:
Ensure that adjuster assembly is securely installed CAUTION:
with screw in the left side, facing vehicle front. After replacing parking brake lining, be sure to
drive vehicle for “break-in” purposes.
(1) Drive the vehicle about 35 km/h (22 MPH).
(2) With the parking brake release button
pushed in, pull the parking brake lever gently.
(3) Drive the vehicle for about 200 meter (0.12
mile) in this condition.
(4) Wait 5 to 10 minutes for the parking brake
to cool down. Repeat this procedure once
more.
(5) After breaking-in, re-adjust parking brakes.
S4M0461A
(1) LEFT
PB-10
Parking Brake
C: INSPECTION S404552A10 D: ADJUSTMENT S404552A01
1) Measure brake disc inside diameter. If the disc 1. SHOE CLEARANCE S404552A0101
is scored or worn, replace the brake disc.

1) Remove adjusting hole cover from back plate.
Disc inside diameter: 2) Turn adjusting screw using a slot-type screw-
Standard driver until brake shoe is in close contact with disc
170 mm (6.69 in) rotor.
Service limit
171 mm (6.73 in)
2) Measure the lining thickness. If it exceeds the
limit, replace shoe assembly.
Lining thickness:
Standard
3.2 mm (0.126 in)
Service limit
1.5 mm (0.059 in)
CAUTION: S4M0463A
Replace the brake shoes on the right and left
brake assembly at the same time. (1) Adjusting screw
(2) Adjusting hole cover (rubber)
(3) Slot-type screwdriver
(4) Back plate
3) Turn back (downward) adjusting screw 3 or 4

notches.
4) Install adjusting hole cover to back plate.
2. LEVER STROKE S404552A0102
1) Remove console box lid.

2) Forcibly pull parking brake lever 3 to 5 times.
3) Adjust parking brake lever by turning adjuster
until parking brake lever stroke is set at 6 notches
with operating force of 196 N (20 kgf, 44 lb).
S4M0520A

(2) Lock nut
(3) Adjusting nut

5) Install console box lid.
Lever stroke:
7 to 8 notches when pulled with a force
of 196 N (20 kgf, 44 lb)
Tightening torque (Adjuster lock nut):
5.9 N·m (0.60 kgf-m, 4.3 ft-lb)
PB-11
Parking Brake

쐌 Parking brake lever is maladjusted. 쐌 Adjustment.
쐌 Parking brake cable does not move. 쐌 Repair or replace.
Brake drag
쐌 Parking brake shoe clearance is maladjusted. 쐌 Adjustment.
쐌 Return spring is faulty. 쐌 Replace.
쐌 Return spring is faulty. 쐌 Replace.
Noise from brake
쐌 Shoe hold down spring is faulty. 쐌 Replace.
PB-12
CHASSIS SECTION

SUBARU vehicles.
ine parts.

G8050GE5
POWER ASSISTED SYSTEM (POWER
STEERING)
PS
Page
2. Steering Wheel..........................................................................................27
3. Universal Joint...........................................................................................28
4. Tilt Steering Column..................................................................................30
5. Steering Gearbox [LHD Model].................................................................33
6. Steering Gearbox [RHD Model] ................................................................53
7. Pipe Assembly...........................................................................................78
8. Oil Pump....................................................................................................93
9. Reservoir Tank ........................................................................................100
10. Power Steering Fluid...............................................................................101
11. General Diagnostic Table ........................................................................103
GENERAL DESCRIPTION
Power Assisted System (Power Steering)
Model LHD RHD

Steering wheel Free play mm (in) 17 (0.67)
Inner tire & wheel 34.4°±1.5°
Turning angle
Outer tire & wheel 30.2°±1.5°
Clearance between steering
Steering shaft mm (in) 3.0 (0.118)
wheel and column cover
Sliding resistance N (kgf, lb) 304.0 (31.0, 68.4) or less
Horizontal movement:
Right-turn 0.6 (0.024) or less
mm (in) 0.15 (0.0059) or less
Rack steering Vertical movement:
shaft play 0.4 (0.016) or less
in radial Horizontal movement:
direction Left-turn 0.3 (0.012) or less
Steering gearbox mm (in) 0.4 (0.016) or less
steering Vertical movement:
(Power steering 0.15 (0.0059) or less
system)
In radial
mm (in) 0.18 (0.0071) or less
Input direction
shaft play In axial
mm (in) 0.1 (0.004) or less
direction
Within 30 mm (1.18 in) from rack center in straight
Turning resistance N (kgf, lb) ahead position: Less than 11.18 (1.14, 2.51)
Maximum allowable value: 12.7 (1.3, 2.9)
Pulley Radial play mm (in) 0.4 (0.016) or less
shaft Axial play mm (in) 0.9 (0.035) or less
Oil pump Ditch deflection mm (in) 1.0 (0.039) or less
[Non-turbo model
Pulley Resistance to
(Power steering N (kgf, lb) 9.22 (0.94, 2.07) or less
system)] rotation
Regular pressure kPa (kg/cm2, psi) 981 (10, 142) or less
Relief pressure kPa (kg/cm2, psi) 7,355 (75, 1,067)
Pulley Radial play mm (in) 0.4 (0.016) or less
shaft Axial play mm (in) 0.6 (0.024) or less
Oil pump
Ditch deflection mm (in) 1.0 (0.039) or less
[Turbo model
Pulley Resistance to
(Power steering N (kgf, lb) 9.22 (0.94, 2.07) or less
rotation
system)]
2
Regular pressure kPa (kg/cm , psi) 981 (10, 142) or less
Relief pressure kPa (kg/cm2, psi) 9,807 (100, 1,422)
Steering wheel At standstill with engine
N (kgf, lb) 29.4 (3.0, 6.6) or less
effort idling on a concrete road
(Power steering At standstill with engine
system) N (kgf, lb) 294.2 (30, 66.2) or less
stalled on a concrete road
Recommended power steering fluid Manufacturer

B.P.
CALTEX
CASTROL
ATF DEXRON IIE or III
MOBIL
SHELL
TEXACO
PS-2
GENERAL DESCRIPTION
Model Non-turbo Turbo

Minimum turning radius m (ft) 5.4 (17.7)
Steering angle (Inside-Outside) 34.4°±1.5° — 30.2°±1.5°
Whole system With AIRBAG: 385 (15.16)
Steering wheel diameter mm (in)
Without AIRBAG: 385 (15.16)
LHD: 19.0 (3.4)
Overall gear ratio (Turns, lock to lock)
RHD: 16.7 (3.0)
Type Rack and pinion, Integral
Gearbox Backlash 0 (Automatically adjustable)
Valve (Power steering system) Rotary valve
Type Vane pump
Oil tank Installed on pump
cm3 (cu in)/
Output 7.2 — 0.6 (0.439 — 0.037) 9.6 — 0.65 (0.586— 0.040)
rev.
Pump kPa (kg/cm2,
Relief pressure 7,355 (75, 1,067) 7,846 (80, 1,138)
(Power steering psi)
system) Hydraulic fluid control Drooping in response to increased engine revolutions
(US qt, Imp 1,000 rpm: 7 (7.4, 6.2)
Hydraulic fluid
qt) 3,000 rpm: 5 (5.3, 4.4)
Range of revolution rpm 500 — 7,500 500 — 8,000
Revolving direction Clockwise
Name ATF DEXRON IIE or III
Working fluid Oil tank (US qt, Imp
0.3 (0.3, 0.3)
(Power steering qt)
system) Capacity
Total (US qt, Imp
0.7 (0.7, 0.6)
qt)
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 15 mm (0.59 in)
(7) Exhaust pipe — Gearbox bolt 15 mm (0.59 in)
(8) Side frame — Hose A and B 15 mm (0.59 in)
(9) Cruise control pump — Hose A and B 15 mm (0.59 in)
(10) Pipe portion of hose A — Pipe portion of hose B 1.5 mm (0.059 in)
(11) AT cooling hose — Joint (LHD model) 20 mm (0.79 in)
PS-3
GENERAL DESCRIPTION
쐌 Non-turbo model
S4M0172A
쐌 Turbo model
S4M0565A
PS-4
GENERAL DESCRIPTION
1. STEERING WHEEL AND COLUMN S601001A0501
쐌 With Airbag Model
S4M0304B
(1) Bushing (6) Steering wheel Tightening torque: N·m (kgf-m, ft-lb)
(2) Steering shaft (7) Airbag module
T1: 1.2 (0.12, 0.9)
(3) Knee protector
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
쐌 Without Airbag Model
S4M0311A
(1) Bushing (6) Steering wheel Tightening torque: N·m (kgf-m, ft-lb)
(2) Steering shaft (7) Pad ASSY
T1: 1.2 (0.12, 0.9)
(3) Knee protector
T2: 3.4 (0.35, 2.5)
(4) Combination switch
T3: 25 (2.5, 18.1)
(5) Column cover
T4: 44 (4.5, 32.5)
PS-6
GENERAL DESCRIPTION
MEMO:
PS-7
GENERAL DESCRIPTION
2. POWER ASSISTED SYSTEM FOR NON-TURBO MODEL S601001A0504
쐌 LHD Model
S4M0175E
PS-8
GENERAL DESCRIPTION
(1) Eye bolt (27) Oil seal (53) Steering body

(2) Pipe C (28) Special bearing (54) Oil seal
(3) Gasket (29) Seal ring (55) Piston ring
(4) Clip (30) Pinion and valve ASSY (56) Rack
(5) Pipe D (31) Oil seal (57) Rack bushing
(6) Clamp E (32) Back-up washer (58) Rack stopper
(7) O-ring (33) Ball bearing (59) Circlip
(8) Cap (34) Snap ring
(9) Strainer (35) Lock nut Tightening torque: N·m (kgf-m, ft-lb)
(10) Upper shell (36) Adjusting screw T1: 6 (0.6, 4.3)
(11) Buffle (37) Spring T2: 7.4 (0.75, 5.4)
(12) Seal washer (38) Sleeve T3: 8 (0.8, 5.8)
(13) Lower shell (39) Adapter T4: 13 (1.3, 9.4)
(14) Pulley (40) Clamp T5: 15 (1.5, 10.8)
(15) Oil pump (41) Cotter pin
T6: 18 (1.8, 13.0)
(16) Bracket (42) Castle nut
T7: 22 (2.2, 15.9)
(17) Belt tension nut (43) Dust seal
T8: 24 (2.4, 17.4)
(18) Bushing (44) Clip
(19) Belt cover (45) Tie-rod end T9: 25 (2.5, 18.1)
(20) Pipe E (46) Clip T10: 27.0 (2.75, 19.9)
(21) Pipe F (47) Boot T11: 39 (4.0, 28.9)
(22) Clamp plate (48) Band T12: 52 (5.3, 38)
(23) Universal joint (49) Tie-rod T13: 59 (6.0, 43)
(24) Dust cover (50) Lock washer T14: 78 (8.0, 58)
(25) Valve housing (51) Pipe B T15: 83 (8.5, 61.5)
(26) Gasket (52) Pipe A
PS-9
GENERAL DESCRIPTION
쐌 RHD Model
S4M0232C
PS-10
GENERAL DESCRIPTION
(1) Eye bolt (29) O-ring (57) Lock nut

(2) Pipe C (30) Oil seal (58) Adjusting screw
(3) Gasket (31) Spacer (59) Spring
(4) Clip (32) Pinion (60) Sleeve
(5) Pipe D (33) Shim (61) Seat pad
(6) Clamp E (34) Adapter
(7) O-ring (35) Clamp Tightening torque: N·m (kgf-m, ft-lb)
(8) Cap (36) Castle nut T1: 7.4 (0.75, 5.4)
(9) Strainer (37) Cotter pin T2: 8 (0.8, 5.8)
(10) Upper shell (38) Dust seal T3: 13 (1.3, 9.4)
(11) Buffle (39) Clip T4: 15 (1.5, 10.8)
(12) Seal washer (40) Tie-rod end T5: 18 (1.8, 13.0)
(13) Lower shell (41) Clip
T6: 20 (2.0, 14.5)
(14) Pulley (42) Boot
T7: 22 (2.2, 15.9)
(15) Oil pump (43) Wire
T8: 24 (2.4, 17.4)
(16) Bracket (44) Tie-rod
(17) Belt tension nut (45) Lock washer T9: 24.5 (2.50, 18.1)
(18) Bushing (46) Holder T10: 25 (2.5, 18.1)
(19) Belt cover (47) Bushing T11: 27.0 (2.75, 19.9)
(20) Universal joint (48) Oil seal T12: 39 (4.0, 28.9)
(21) Dust cover (49) Oil seal T13: 59 (6.0, 43)
(22) Valve housing (50) O-ring T14: 52 (5.3, 38)
(23) Oil seal (51) Rack T15: 64 (6.5, 47)
(24) Ball bearing (52) Oil seal T16: 78 (8.0, 58)
(25) Retaining ring (53) Back-up washer T17: 83 (8.5, 61.5)
(26) Seal ring (54) Steering body
(27) Valve sleeve (55) Pipe A
(28) Seal ring (56) Pipe B
PS-11
GENERAL DESCRIPTION
3. POWER ASSISTED SYSTEM FOR TURBO MODEL S601001A0505
쐌 LHD Model
S4M0566A
PS-12
GENERAL DESCRIPTION
(1) Eye bolt (28) Oil seal (55) Rack stopper

(2) Pipe C (29) Back-up washer (56) Circlip
(3) Gasket (30) Ball bearing (57) Suction hose
(4) Clip (31) Snap ring (58) Tank hose
(5) Pipe D (32) Lock nut
(6) Clamp E (33) Adjusting screw Tightening torque: N·m (kgf-m, ft-lb)
(7) O-ring (34) Spring T1: 6 (0.6, 4.3)
(8) Cap (35) Sleeve T2: 7.4 (0.75, 5.4)
(9) Reservoir tank (36) Adapter T3: 8 (0.8, 5.8)
(10) Reservoir tank bracket (37) Clamp T4: 13 (1.3, 9.4)
(11) Pulley (38) Cotter pin T5: 15 (1.5, 10.8)
(12) Oil pump (39) Castle nut
T6: 15 (1.5, 10.8)
(13) Bracket (40) Dust seal
T7: 15.7 (1.6, 11.6)
(14) Belt tension nut (41) Clip
T8: 22 (2.2, 15.9)
(15) Bushing (42) Tie-rod end
(16) Belt cover (43) Clip T9: 24 (2.4, 17.4)
(17) Pipe E (44) Boot T10: 25 (2.5, 18.1)
(18) Pipe F (45) Band T11: 25 (2.5, 18.1)
(19) Clamp plate (46) Tie-rod T12: 27 (2.75, 19.9)
(20) Universal joint (47) Lock washer T13: 37.3 (3.8, 27.5)
(21) Dust cover (48) Pipe B T14: 39 (4.0, 28.9)
(22) Valve housing (49) Pipe A T15: 59 (6.0, 43)
(23) Gasket (50) Steering body T16: 78 (8.0, 58)
(24) Oil seal (51) Oil seal T17: 83 (8.5, 61.5)
(25) Special bearing (52) Piston ring
T18: 25 (2.5, 18.1)
(26) Seal ring (53) Rack
(27) Pinion and valve ASSY (54) Rack bushing
PS-13
GENERAL DESCRIPTION
쐌 RHD Model
S4M0567A
PS-14
GENERAL DESCRIPTION
(1) Eye bolt (28) Pinion (55) Spring

(2) Pipe C (29) Shim (56) Sleeve
(3) Gasket (30) Adapter (57) Seat pad
(4) Clip (31) Clamp (58) Suction hose
(5) Pipe D (32) Castle nut (59) Tank hose
(6) Clamp E (33) Cotter pin
(7) Cap (34) Dust seal Tightening torque: N·m (kgf-m, ft-lb)
(8) Reservoir tank (35) Clip T1: 7.4 (0.75, 5.4)
(9) Reservoir tank bracket (36) Tie-rod end T2: 8 (0.8, 5.8)
(10) Pulley (37) Clip T3: 13 (1.3, 9.4)
(11) Oil pump (38) Boot T4: 15 (1.5, 10.8)
(12) Bracket (39) Wire T5: 15.7 (1.6, 11.6)
(13) Belt tension nut (40) Tie-rod
T6: 20 (2.0, 14.5)
(14) Bushing (41) Lock washer
T7: 22 (2.2, 15.9)
(15) Belt cover (42) Holder
T8: 24 (2.4, 17.4)
(16) Universal joint (43) Bushing
(17) Dust cover (44) Oil seal T9: 24 (2.4, 17.4)
(18) Valve housing (45) Seal ring T10: 24.5 (2.50, 18.1)
(19) Oil seal (46) O-ring T11: 25 (2.5, 18.1)
(20) Ball bearing (47) Rack T12: 27.0 (2.75, 19.9)
(21) Retaining ring (48) Oil seal T13: 37.3 (3.8, 27.5)
(22) Seal ring (49) Back-up ring T14: 39 (4.0, 28.9)
(23) Valve sleeve (50) Steering body T15: 59 (6.0, 43)
(24) Seal ring (51) Pipe A T16: 64 (6.5, 47)
(25) O-ring (52) Pipe B T17: 78 (8.0, 58)
(26) Oil seal (53) Lock nut
T18: 83 (8.5, 61.5)
(27) Spacer (54) Adjusting screw
PS-15
GENERAL DESCRIPTION
쐌 This section includes Airbag related repair

works. For those corresponding to the repair
procedures, read carefully CAUTION items in AB
section before working and be sure to follow the
instructions.
tion.
removal, installation, disassembly and replace-
ment.
쐌 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
manufacturers.
fied points.
쐌 Apply steering fluid onto sliding or revolution
surfaces before installation.
sufficient amount of steering fluid to avoid damage
and deformation.
PS-16
GENERAL DESCRIPTION

925700000 WRENCH 쐌 Used for removing and installing tie-rod.
쐌 Apply this tool to rack.
B4M2411
925711000 PRESSURE GAUGE Used for measuring oil pump pressure.
B4M2412
926200000 STAND Used when inspecting characteristic of gearbox
assembly and disassembling it.
B4M2413
34099AC010 ADAPTER HOSE A Used with PRESSURE GAUGE (925711000).
B4M2414
PS-17
GENERAL DESCRIPTION

34099AC020 ADAPTER HOSE B Used with PRESSURE GAUGE (925711000).
B4M2415
926230000 SPANNER 쐌 For the lock nut when adjusting backlash of
gearbox.
쐌 Measurement of rotating resistance of gear-
box assembly.
B4M2416
34199AE040 OIL CHARGE 쐌 Used for charging power steering oil.
GUIDE 쐌 For TURBO model
B4M2419
927640000 INSTALLER B 쐌 Used for installing ball bearing into housing.
쐌 For LHD model
B4M2420
926370000 INSTALLER A 쐌 Used for installing valve assembly into valve
housing assembly.
쐌 Used with STAND BASE (927630000).
쐌 For LHD model
B4M2421
PS-18
GENERAL DESCRIPTION

926390001 COVER & 쐌 Used for assembling rack assembly.
REMOVER ASSY 쐌 For LHD model
B4M2422
926420000 PLUG 쐌 When oil leaks from pinion side of gearbox
assembly, remove pipe B from valve housing,
attach this tool and check oil leaking points.
쐌 For LHD model
B4M2423
926400000 GUIDE 쐌 Right side of rack when installing rack bush.
쐌 Used with GUIDE (927660000).
쐌 For LHD model
B4M2424
927660000 GUIDE 쐌 Right side of rack when installing rack bush.
쐌 Used with GUIDE (926400000).
쐌 For LHD model
B4M2425
927620000 INSTALLER B 쐌 Used for installing oil seal of valve housing.
쐌 Used with INSTALLER A (926360000).
쐌 For LHD model
B4M2426
PS-19
GENERAL DESCRIPTION

34099FA100 STAND BASE 쐌 Used for assembling power steering gearbox.
쐌 For LHD model
B4M2427
926360000 INSTALLER A 쐌 Used as a guide to install oil seal.
쐌 Used with INSTALLER B (927620000).
쐌 For LHD model
B4M2428
34199AE050 INSTALLER 쐌 Used for installing oil seal.
쐌 For LHD model
B4M2429
34099FA120 INSTALLER 쐌 Used for installing valve housing oil seal.
쐌 For LHD model
B4M2430
34199AE050 REMOVER OIL 쐌 Used for removing back-up ring and oil seal.
SEAL 쐌 For LHD model
B4M2432
PS-20
GENERAL DESCRIPTION

34099FA130 INSTALLER SEAL 쐌 Used for installing valve housing oil seal.
쐌 Used with INSTALLER AND REMOVER
SEAL (34099FA120).
쐌 For LHD model
B4M2431
926250000 GUIDE 쐌 Used for installing holder ASSY into rack
hous-ing.
쐌 For RHD model
B4M2488
926270000 COVER 쐌 Used for installing oil seal to pinion.
쐌 For RHD model
B4M2489
926280000 FORMER 쐌 Used for installing seal ring to pinion.
쐌 For RHD model
B4M2490
PS-21
GENERAL DESCRIPTION

926450000 COVER 쐌 Used for installing oil seal to pinion.
쐌 For RHD model
B4M2491
927490000 INSTALLER A, B, C 쐌 Used for installing oil seal into rack ASSY.
쐌 For RHD model
B4M2492A
927580000 REMOVER 쐌 Used for removing back-up ring and oil seal.
쐌 For RHD model
B4M2493
927590000 WRENCH 쐌 Used for removing wire from boot.
쐌 For RHD model
B4M2494
PS-22
GENERAL DESCRIPTION

927600000 FORMER 쐌 Used for installing seal ring to rack pinion.
쐌 For RHD model
B4M2495
927520000 INSTALLER D 쐌 Used for installing pinion bearing.
쐌 For RHD model
B4M2496
927530000 INSTALLER E 쐌 Used for installing pinion bearing.
쐌 For RHD model
B4M2497
34099FA000 INSTALLER & 쐌 Used for removing and installing Y-packing.
REMOVER 쐌 For RHD model
B4M2499
PS-23
GENERAL DESCRIPTION

34099FA010 GUIDE 쐌 Used for installing rack and seal into housing
assembly.
쐌 For RHD model
B4M2500
34099FA020 GUIDE 쐌 Used for installing valve assembly into valve
housing assembly.
쐌 For RHD model
B4M2501
34099FA030 INSTALLER & 쐌 Used for removing and installing rack oil seal
REMOVER (outer & inner).
쐌 For RHD model
B4M2502
34099FA040 INSTALLER 쐌 Used for installing rack oil seal (outer).
쐌 For RHD model
B4M2503
PS-24
GENERAL DESCRIPTION

34099FA050 SPACER 쐌 Used for installing bearing into valve housing.
쐌 For RHD model
B4M2504
34099FA060 PUNCH 쐌 Used for caulking.
쐌 For RHD model
B4M2505
34099FA070 BASE 쐌 Used for supporting housing assembly.
쐌 For RHD model
B4M2506
34099FA080 PUNCH 쐌 Used for removing caulking.
쐌 For RHD model
B4M2507
PS-25
GENERAL DESCRIPTION

926050000 FORMER 쐌 Used for installing seal ring to rack pinion.
쐌 For RHD model
B4M2508
TOOL NAME REMARKS

Spring scale Used for measuring tightening torque.
Snap ring pliers Used for removing and installing snap ring.
Dial gauge Used for measuring steering gearbox.
PS-26
STEERING WHEEL
2. Steering Wheel S601274

NOTE:
Align matching marks on steering wheel and steer-
A: REMOVAL S601274A18 ing column.
1) Disconnect ground terminal from battery. Tightening torque:
2) Set tires to straight-ahead position. 44 N·m (4.5 kgf-m, 32.5 ft-lb)
3) Remove airbag module. (with airbag model) Column cover-to-steering wheel clearance:
<Ref. to AB-12 REMOVAL, Driver’s Airbag Mod- 2 — 4 mm (0.08 — 0.16 in)
ule.>
WARNING:
WARNING: Always refer to “Airbag System” before per-
Always refer to “Airbag System” before performing airbag module service (if so equipped).
forming airbag module service (if so equipped). (with airbag model) <Ref. to AB-12 CAUTION,
<Ref. to AB-12 CAUTION, Driver’s Airbag Mod- Driver’s Airbag Module.>
ule.> CAUTION:
4) Remove lower screw and slide horn pad Insert roll connector guide pin into guide hole
assembly forward, then disconnect connector. on lower end of surface of steering wheel to
(without airbag model) prevent damage. Draw out airbag system
5) Remove horn pad by pulling on it. (without air- connector, horn connector and cruise control
bag model) connectors from guide hole of steering wheel
lower end. (with airbag model)
1) Check steering wheel for deformation. If the

deformation is excessive, replace steering wheel.
2) Check splines on steering wheel for damage. If
the damage is excessive, replace steering wheel.
B4M0125B
(1) Front
(2) Screw
6) Remove steering wheel nut, and then draw out

steering wheel from shaft using steering puller.
NOTE:
Make matching marks on steering wheel and
steering column in advance.
B4M2433A
(1) Matching mark
1) Align center of roll connector. <Ref. to AB-20

ADJUSTMENT, Roll Connector.>
PS-27
UNIVERSAL JOINT
3. Universal Joint S601273 B: INSTALLATION S601273A11
1) Install universal joint.
(1) Align bolts hole on the long yoke side of
1) Set the vehicle on the lift. universal joint with the cutout at the serrated
2) Remove the steering wheel. <Ref. to PS-27 section of shaft end, and insert universal joint.
REMOVAL, Steering Wheel.> (2) Align bolt hole on the short yoke side of
3) Lift-up the vehicle. universal joint with the cutout at the serrated
4) Remove universal joint bolts and then remove section of gearbox assembly. Lower universal
universal joint. joint completely.
CAUTION: (3) Temporarily tighten bolt on the short yoke
Scribe alignment marks on universal joint so side. Raise universal joint to make sure the bolt
that it can be reassembled at the original ser- is properly passing through the cutout at the
ration. serrated section.
(4) Tighten bolt on the long yoke, then that on
the short yoke side.
Tightening torque:
24 N·m (2.4 kgf-m, 17.4 ft-lb)
CAUTION:
쐌 Make sure that universal joint bolt is tight-
ened through notch in shaft serration.
쐌 Excessively large tightening torque of uni-
versal joint bolts may lead to heavy steering
wheel operation.
B4M1653
Standard clearance between gearbox to DOJ:
Over 15 mm (0.59 in)
2) Lower the vehicle.
3) Align center of roll connector. (with airbag
model) <Ref. to AB-20 ADJUSTMENT, Roll Con-
nector.>
CAUTION:
Ensure that front wheel are set straight forward
direction.
4) Install steering wheel and airbag module. (with
airbag model) <Ref. to PS-27 INSPECTION,
Steering Wheel.>
WARNING:
Always refer to “Airbag System” before per-
forming airbag module service (if so equipped).
<Ref. to AB-12 CAUTION, Driver’s Airbag Mod-
ule.> and <Ref. to AB-13 INSTALLATION, Driv-
er’s Airbag Module.>
5) Install horn pad to steering wheel. (without air-
bag model)
PS-28
UNIVERSAL JOINT
Clean the disassembled parts with a cloth, and check for wear, damage, or any other faults. If necessary,
repair or replace faulty parts.
Corrective action
Inspection
쐌 Free play
쐌 Swinging torque
Yawing torque
Looseness
Replace if faulty.
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; 8.43 N (0.86 kgf, 1.90 lb)
or less
Service limit:
Maximum load; 5.49 N (0.56 kgf, 1.23 lb)
or less
S4M0445A
(1) Short yoke

S4M0443A
Service limit:
(1) Long yoke Maximum load; 8.43 N (0.86 kgf, 1.90 lb)
or less
Service limit:
Maximum load; 5.49 N (0.56 kgf, 1.23 lb)
or less
S4M0446A
(1) Short yoke

S4M0444A
(1) Long yoke
PS-29
TILT STEERING COLUMN
4. Tilt Steering Column S601544
S4M0136B
(1) Tilt steering column Tightening torque: N·m (kgf-m, ft-lb)

(2) Universal joint
T1: 24 (2.4, 17.4)
T2: 25 (2.5, 18.1)
PS-30
1) Set the vehicle on the lift. B: INSTALLATION S601544A11
2) Disconnect battery minus terminal.

3) Remove airbag module. <Ref. to AB-12 1) Insert end of steering shaft into toe board grom-
REMOVAL, Driver’s Airbag Module.> met.
2) Tighten steering shaft mounting bolts under
WARNING: instrument panel.
Always refer to “Airbag System” before per-
Tightening torque:
forming airbag module service (if so equipped). 25 N·m (2.5 kgf-m, 18.1 ft-lb)
<Ref. to AB-12 CAUTION, Driver’s Airbag Mod-
ule.> 3) Connect all connectors under instrument panel.
4) Connect airbag system connector at harness
4) Remove steering wheel. <Ref. to PS-27 spool.
REMOVAL, Steering Wheel.>
5) Lift-up the vehicle. NOTE:
6) Remove universal joint. <Ref. to PS-28 Make sure to apply double lock.
REMOVAL, Universal Joint.> 5) Install lower column cover with tilt lever held in
7) Lower the vehicle. the lowered position.
8) Remove trim panel under instrument panel. 6) Install universal joint. <Ref. to PS-28
9) Remove knee bolster. INSTALLATION, Universal Joint.>
7) Install knee bolster.
S4M0138B
S4M0138B
(1) Knee bolster
(1) Knee bolster
10) Disconnect connectors for ignition switch and
combination switch wiring harness under instru- 8) Align center of roll connector. <Ref. to AB-20
ment panel. ADJUSTMENT, Roll Connector.>
11) Remove the two bolts under instrument panel
CAUTION:
securing steering column.
Ensure that front wheels are set in straight for-
ward direction.
9) Install steering wheel. <Ref. to PS-27
INSTALLATION, Steering Wheel>
Set steering wheel to neutral and install it onto
steering shaft.
CAUTION:
Insert roll connector guide pin into guide hole
on lower end of surface of steering wheel to
prevent damage. Draw out airbag system
S4M0139B connector, horn connector and cruise control
connectors from guide hole of steering wheel
(1) Steering column lower end.
12) Pull out steering shaft assembly from hole on 10) Install airbag module to steering wheel. (with
toe board. airbag model) <Ref. to AB-13, INSTALLATION,
CAUTION: Driver’s Airbag Module.>
Be sure to remove universal joint before WARNING:
removing steering shaft assembly installing Always refer to “Airbag System” before per-
bolts when removing steering shaft assembly forming the service operation. <Ref. to AB-12
or when lowering it for servicing of other parts. CAUTION, Driver’s Airbag Module.>
PS-31
11) Install horn pad to steering wheel. (without air-

bag model)
Remove the two screws securing upper steering

column covers, and the two screws securing com-
bination switch, then remove related parts.
1) Insert combination switch to upper column

shaft, and install upper column cover. Then route
ignition key harness and combination switch har-
ness between column cover mounting bosses.
Tightening torque:
1.2 N·m (0.12 kgf-m, 0.9 ft-lb)
CAUTION:
Don’t overtorque screw.
1. BASIC INSPECTION S601544A1001
Clean the disassembled parts with a cloth, and check for wear, damage, or any other faults. If necessary,
repair or replace faulty parts.
Inspection Corrective action
쐌 Overall length of steering column
Measure overall length of steering column.
Standard overall length of steering column:
Replace steering column

assembly.
S4M0141B
2. AIRBAG MODEL INSPECTION S601544A1002
WARNING:
For airbag model inspection procedures, refer
to “Airbag System”. <Ref. to AB-12 CAUTION,
Airbag Module.> and <Ref. to AB-13
INSPECTION, Driver’s Airbag Module.>
PS-32
STEERING GEARBOX [LHD MODEL]
5. Steering Gearbox [LHD 7) Remove one pipe joint at the center of gearbox,
and connect vinyl hose to pipe and joint. Discharge
Model] S601272
fluid by turning steering wheel fully clockwise and
counterclockwise. Discharge fluid similarly from
the other pipe.
1) Disconnect battery ground terminal.
2) Loosen front wheel nut.
3) Lift vehicle and remove front wheels.
4) Remove front exhaust pipe assembly. (Non-
turbo model)
With OBD:
<Ref. to EX(SOHC)-5, REMOVAL, Front Exhaust
Pipe.>
Without OBD:
<Ref. to EX(SOHCw/oOBD)-6, REMOVAL, Front
Exhaust Pipe.> S4M0381A
WARNING: (1) Pipe A

Be careful, exhaust pipe is hot. (2) Pipe B
5) Using a puller, remove tie-rod end from knuckle
arm after pulling off cotter pin and removing castle 8) Remove universal joint. <Ref. to PS-28,
nut. REMOVAL, Universal Joint.>
9) Disconnect pipes C and D from pipe of gear-
box.
CAUTION:
Be careful not to damage these pipes.
NOTE:
Disconnect upper pipe D first, and lower pipe C
second.
S4M0379A
(1) Castle nut

(2) Tie-rod end
(3) Knuckle arm
6) Remove jack-up plate and front stabilizer.
S4M0382A
(1) Pipe C
(2) Pipe D
10) Remove clamp bolts securing gearbox to

crossmember, and remove gearbox.
S4M0380A
(1) Jack-up plate
PS-33
4) Connect tie-rod end and knuckle arm, and

tighten with castle nut. Fit 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:
S4M0383A When connecting, do not hit cap at the bottom
(1) Clamp
1) Insert gearbox into crossmember, being careful

not to damage gearbox boot.
2) Tighten gearbox to crossmember bracket via
clamp with bolt to the specified torque.
Tightening torque:
59 N·m (6.0 kgf-m, 43 ft-lb)
S4M0379A
(1) Castle nut

(2) Tie-rod end
(3) Knuckle arm
5) Install front stabilizer to vehicle. <Ref. to FS-22,

INSTALLATION, Front Stabilizer.>
6) Install front exhaust pipe assembly. (Non-turbo
model)
S4M0383A With OBD: <Ref. to EX(SOHC)-6, INSTALLATION,
Front Exhaust Pipe.>
(1) Clamp
Without OBD: <Ref. to EX(SOHCw/oOBD)-7,
3) Install universal joint. <Ref. to PS-28, INSTALLATION, Front Exhaust Pipe.>
INSTALLATION, Universal Joint.> 7) Install tires.
8) Tighten wheel nuts to the specified torque.
Tightening torque:
88 N·m (9.0 kgf-m, 65 ft-lb)
9) Connect ground terminal to battery.
10) Pour fluid into oil tank, and bleed air.
<Ref. to PS-101, Power Steering Fluid.>
11) Check for fluid leaks. <Ref. to PS-51, OIL
LEAKING, INSPECTION, Steering Gearbox [LHD
Model].>
12) Install jack-up plate.
WARNING:
Be careful, exhaust manifold is hot.
13) Lower vehicle.
14) Check fluid level in oil tank.
PS-34
15) After adjusting toe-in and steering angle, 4) Remove small clip from boot using pliers, and
tighten lock nut on tie-rod end. move boot to tie-rod end side.
Tightening torque:
83 N·m (8.5 kgf-m, 61.5 ft-lb)
CAUTION:
When adjusting toe-in, hold boot as shown to
prevent it from being rotated or twisted. If
twisted, straighten it.
S4M0144B
(1) Clip
5) Using standard screwdriver, remove band from

boot.
G4M0132
1. RACK HOUSING ASSEMBLY S601272A0601
1) Disconnect four pipes from gearbox.

2) Secure gearbox removed from vehicle in vise
using ST.
ST 926200000 STAND S4M0145B
CAUTION:
(1) Band
Secure the gearbox in a vise using the ST as
(2) Standard screwdriver
shown. Do not attempt to secure it without this
ST. 6) Extend rack approximately 40 mm (1.57 in) out.
Unlock lock wire at lock washer on each side of
tie-rod end using a standard screwdriver.
CAUTION:
Be careful not to scratch rack surface as oil
leaks may result.
S4M0143A
3) Remove tie-rod end and lock nut from gearbox.
S4M0146B
(1) Standard screwdriver

(2) Lock washer
PS-35
7) Using ST, loosen lock nut. 11) Remove two bolts securing valve assembly.
S4M0154
S4M0147B
12) Carefully draw out input shaft and remove
(1) Lock nut valve assembly.
8) Tighten adjusting screw until it no longer tight-
ens.
S4M0155B
(1) Valve ASSY

S4M0148B
13) Using a sharp pointed pliers, rotate the rack
(1) Adjusting screw stopper in the direction of the arrow until the end
9) Using a wrench [32 mm (1.26 in) width across of the circlip comes out of the stopper. Rotate the
flats] or adjustable wrench, remove tie-rod. circlip in the opposite direction and pull it out.
CAUTION:
쐌 Check ball joint for free play, and tie-rod for
bends. Replace if necessary.
쐌 Check dust seals used with tie-rod end ball
joint for damage or deterioration. Replace if
necessary.
S4M0158B
(1) Rack stopper
S4M0149B
(1) Tie-rod
10) Loosen adjusting screw and remove spring

and sleeve.
CAUTION:
Replace spring and/or sleeve if damaged.
PS-36
14) Pull rack assembly from cylinder side, and NOTE:

draw out rack bushing and rack stopper together Discard removed oil seal.
with rack assembly.
2. CONTROL VALVE ASSEMBLY S601272A0602
CAUTION:
NOTE:
Be careful not to contact rack to inner wall of
Parts requiring replacement are described in the
cylinder when drawing out. Any scratch on cyl-
smallest unit of spare parts including damaged
inder inner wall will cause oil leakage.
parts and spare parts damaged. In actual disas-
sembly work, accidental damage as well as inevi-
table 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.
1) Using ST, loosen lock nut.
S4M0402A
(1) Rack bushing

(2) Rack ASSY
(3) Rack stopper
15) Remove rack bushing and rack stopper from

rack assembly.
CAUTION:
Do not reuse removed rack bushing and circlip. S4M0147B
16) Insert ST from pinion housing side and
(1) Lock nut
remove oil seal using a press.
ST 34199AE050 OIL SEAL REMOVER 2) Tighten adjusting screw until it no longer tight-
ens.
S4M0148B
(1) Adjusting screw
S4M0163B
(1) Press
(2) Oil seal
PS-37
3) Remove two bolts securing valve assembly. 6) Using a press remove pinion and valve assem-
bly from valve housing.
S4M0154
S4M0157B
4) Carefully draw out input shaft and remove valve
assembly. (1) Valve ASSY
(2) Valve housing
(3) Cloth
7) Using ST and press, remove dust seal, oil seal

and special bearing from valve housing.
ST 34099FA120 SEAL INSTALLER &
REMOVER
CAUTION:
쐌 Do not apply a force to end surface of valve
housing.
S4M0155B 쐌 Do not reuse oil seal after removal.
(1) Valve ASSY
5) Slide dust cover out.
S4M0159B
(1) Oil seal

(2) Special bearing
S4M0156B
(1) Dust cover
PS-38
8) Remove snap ring using snap ring pliers. D: ASSEMBLY S601272A02
CAUTION: 1. RACK HOUSING ASSEMBLY S601272A0201

쐌 Do not reuse removed snap ring.
쐌 Be careful not to scratch pinion and valve CAUTION:
assembly. Use only SUBARU genuine grease for gearbox.
Grease:
VALIANT GREASE M2
[Part No. 003608001, net 0.5 kg (1.1 lb)]
1) Clean all parts and tools before reassembling.
2) Apply grease to teeth of rack so that grease
applied is about as high as teeth, and also apply a
thin film of grease to sliding portion of rack shaft.
CAUTION:
쐌 When moving rack to stroke end without tie-
rod attached, prevent shocks from being
G4M0147
applied at the end.
쐌 Do not apply grease to threaded portion at
9) Press out bearing together with backing washer end of rack shaft.
using pipe of I.D. 38.5 to 39.5 mm (1.516 to 1.555 쐌 Move rack shaft to stroke end two (2) or three
in) and press. (3) times to squeeze grease which accumulates
CAUTION: on both ends. Remove grease to prevent it
Do not reuse removed bearing. from choking air passage hole.
3) Apply grease to sleeve insertion hole.
4) Apply grease to dust seal insertion hole.
CAUTION:
Apply clean grease with clean hands. If mate-
rial having a sharp edge is used for applying
grease, oil seal at the inside might be damaged.
5) Apply grease to sliding surface of sleeve and
spring seat, then insert sleeve into pinion housing.
Fit spring into sleeve screw, pack grease inside of
screw, then install the screw.
B4M1129B
S4M0403A
(1) Adjusting screw
(1) Bearing (2) Spring
(2) Backing washer (3) Sleeve
(3) Oil seal
(4) Pipe 6) Force-fit oil seal using ST.
ST 34099FA110 INSTALLER
10) Remove oil seal.
CAUTION:
CAUTION: Be careful not to damage or scratch cylinder
Do not reuse removed oil seal. inner wall.
NOTE:
쐌 Apply specified power steering fluid to oil seal.
PS-39
쐌 Pay special attention not to install oil seal in 8) Fit ST over toothed portion of rack assembly,
wrong direction. and check for binding or unsmooth insertion. If any
쐌 Push oil seal until the stepped portion of A con- deformation is noted on flats at the end of rack,
tacts end face of B. shape by using file, and wash with cleaning fluid.
ST 926390001 COVER & REMOVER
S4M0406A
(1) Rack ASSY
9) Apply genuine grease to teeth of thoroughly

washed rack assembly, and fit ST over the toothed
portion.
CAUTION:
쐌 Be careful not to block air passage with
grease. Remove excessive grease.
S4M0164B
쐌 After fitting cover, check air passage hole for
clogging. If clogged, open by removing grease
(1) Press from the hole.
(2) Oil seal 쐌 Check rack shaft for damage.
쐌 Apply specified power steering fluid to this
7) Fixing rack housing ST and surface of piston ring to prevent seal
Fix rack housing in vise using ST. from being damaged.
ST 926200000 STAND
10) Insert rack assembly into rack housing from
CAUTION: cylinder side, and remove ST after it has passed
쐌 When fixing rack housing in vise, be sure to completely through oil seal.
use this special tool. Do not fix rack housing in
vise using pad such as aluminum plates, etc. NOTE:
쐌 When using old rack housing, be sure to Before inserting rack assembly, apply a coat of
clean and remove rust before assembling. specified power steering fluid to surfaces of ST and
Check pinion housing bushing carefully. rack piston.
ST 926390001 COVER & REMOVER
PS-40
11) Fit ST1 and ST2 over the end of rack, and 15) Apply genuine grease to pinion gear and bear-
install rack bushing. ing of valve assembly.
ST1 926400000 GUIDE
ST2 927660000 GUIDE
CAUTION:
쐌 If burrs, or nicks are found on this guide and
rack shaft portion, remove by filing.
쐌 Dip rack bushing in specified power steering
fluid before installing, and pay attention not to
damage O-ring and oil seal.
G4M0158
16) Install gasket on valve assembly. Insert valve

assembly into place while facing rack teeth toward
pinion.
CAUTION:
Be sure to use a new gasket.
NOTE:
S4M0407A Do not allow packing to be caught when installing
valve assembly.
(1) Rack bushing ASSY
12) Insert rack stopper into cylinder tube until

internal groove (on cylinder side) is aligned with
external groove (on rack stopper). Turn rack stop-
per with ST so that rack stopper hole is seen
through cylinder slits.
13) Insert rack stopper into rack housing, and
wrap circlip using a sharp pointed pliers to secure
rack stopper in position.
CAUTION: S4M0155B
Be careful not to scratch rack while winding
circlip. (1) Valve ASSY
NOTE: 17) Tighten bolts alternately to secure valve
Rotate wrench another 90 to 180° after the end of assembly.
circlip has been wrapped in.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
CAUTION:
Be sure to alternately tighten bolts.
18) Install lock washers and tighten left and right
tie-rods into rack ends.
On condition
L: Approximately 40 mm (1.57 in)
S4M0167
14) Fit mounting rubber onto rack housing.
PS-41
Tightening torque: (4) Tighten adjusting screw by two threads.

78 N·m (8.0 kgf-m, 58 ft-lb)
G4M0121
S4M0150B
(5) Apply liquid packing to at least 1/3 of entire
(1) Tie-rod perimeter of adjusting screw thread.
19) Bend lock washer using a chisel. Liquid packing:
THREE BOND 1141
CAUTION:
Be careful not to scratch rack when bending
lock washer.
S4M0385A
(1) Apply liquid packing to at least 1/3 of entire perim-

S4M0384A eter.
(1) Lock washer (6) Tighten adjusting screw to 7.4 N·m (0.75
kgf-m, 5.4 ft-lb) and back off 25°.
20) Rack and pinion backlash adjustment (7) Install lock nut. While holding adjusting
(1) Loosen adjusting screw. screw with a wrench, tighten lock nut using ST.
(2) Rotate input shaft so that rack is in the ST 926230000 SPANNER
straight ahead direction.
(3) Apply grease to sleeve. Tightening torque (Lock nut):
39 N·m (4.0 kgf-m, 29 ft-lb)
NOTE:
쐌 Hold adjusting screw with a wrench to prevent it
from turning while tightening lock nut.
쐌 Make adjustment so that steering wheel can be
rotated fully from lock to lock without binding.
21) Inspect for service limit as per article of “Ser-
vice limit”. <Ref. to PS-49, SERVICE LIMIT,
INSPECTION, Steering Gearbox [LHD Model].>
Make replacement and adjustment if necessary.
B4M1130B
(1) Adjusting screw

(2) Lock nut
(3) Spring
(4) Sleeve
PS-42
22) Install boot to housing. 24) Fix boot end with clip (small).
NOTE: CAUTION:
쐌 Before installing boot, be sure to apply grease to After installing, check boot end is positioned
the groove of tie-rod. into groove on tie-rod.
쐌 Install fitting portions of boots to the following
portions in both sides of assembled steering gear-
box.
The groove on gearbox
The groove on the rod
쐌 Make sure that boot is installed without unusual
inflation or deflation.
S4M0144B
(1) Clip
25) If tie-rod end was removed, screw in lock nut

and tie-rod end to screwed portion of tie-rod, and
tighten lock nut temporarily in a position as shown
in figure.
S4M0151A
Installed tie-rod length: L
23) Using a screwdriver, tighten the screw until the 15 mm (0.59 in)
ends “A” and “B” of the band come into contact with NOTE:
each other. Pay attention to difference between right and left
NOTE: tie-rod ends.
Always tighten the band from the underside of the
gearbox.
G4M0126
S4M0152A
PS-43
26) Inspect gearbox as follows: ST1 34099FA120 SEAL INSTALLER &

“A” Holding tie-rod end, repeat lock to lock two or REMOVER
three times as quickly as possible. ST2 34099FA130 SEAL INSTALLER
“B” Holding tie-rod end, turn it slowly at a radius (1) Face oil seal in the direction shown in figure
one or two times as large as possible. when installing.
After all, make sure that boot is installed in the (2) To avoid scratching oil seal, apply a coat of
specified position without deflation. grease to contact surface of installer and oil
seal.
(3) To facilitate installation, attach oil seal to
installer and position in valve housing before
pressing into place.
G4M0127
27) Remove gearbox from ST.

ST 926200000 STAND
28) Install four pipes on gearbox.
(1) Connect pipes A and B to four pipe joints of
gearbox. Connect upper pipe B first, and lower
pipe A.
Tightening torque:
13 N·m (1.3 kgf-m, 9.4 ft-lb)
(2) Connect pipes C and D to gearbox.
Connect lower pipe C first, and upper pipe D
second.
Tightening torque:
15 N·m (1.5 kgf-m, 10.8 ft-lb) S4M0160A

4) Using ST and press, install special bearing in
Specified steering grease: valve housing.
VALIANT GREASE M2 (Part No. ST 34099FA120 SEAL INSTALLER &
003608001) REMOVER
1) Clean all parts and tools before reassembling. NOTE:
2) Apply a coat of specified power steering fluid to To facilitate installation, attach ball bearing to
inner wall of valve housing. remover and position in valve housing before
pressing it into place.
S4M0162B
S4M0161B
(1) Fluid
(1) Special bearing
3) Attach ST2 to ST1, and press oil seal into place
(2) Oil seal
using a press.
PS-44
5) Put vinyl tape around pinion shaft splines to 10) Force-fit ball bearing using ST3.
protect oil seal from damage. ST1 926370000 INSTALLER A
6) Fit pinion and valve assembly into valve hous- ST2 34099FA100 STAND BASE
ing. ST3 927640000 INSTALLER B
NOTE:
Apply specified power steering fluid to outer diam-
eter surface of input shaft and outer surface of
valve body seal ring, and pay special attention not
to damage seal when inserting pinion and valve
assembly.
7) Secure valve assembly to ST1 and ST2.
8) Put ST3 over pinion, and insert oil seal, then
force-fit oil seal into housing using ST4.
ST1 926370000 INSTALLER A S4M0405A
ST2 34099FA100 STAND BASE
ST3 926360000 INSTALLER A (1) Ball bearing
ST4 927620000 INSTALLER B (2) Backing washer
NOTE:
Be careful not to tilt ball bearing during installation.
11) Install snap ring using snap ring pliers.
NOTE:
Rotate snap ring to check for proper installation.
12) Apply specified grease to dust cover.
S4M0166B
(1) Dust cover
S4M0404A
13) Install dust cover on valve assembly.
14) Apply genuine grease to pinion gear and bear-
(1) Oil seal ing of valve assembly.
NOTE:
쐌 Apply specified power steering fluid to oil seal
and ST3, being careful not to damage oil seal lip.
쐌 Push oil seal until ST3 contacts housing end
face.
9) Remove ST3, and fit backing washer.
G4M0158
PS-45
15) Install gasket on valve assembly. Insert valve 20) Rack and pinion backlash adjustment
assembly into place while facing rack teeth toward (1) Loosen adjusting screw.
pinion. (2) Rotate input shaft so that rack is in the
CAUTION: straight ahead direction.
Be sure to use a new gasket. (3) Apply grease to sleeve.
NOTE:
Do not allow packing to be caught when installing
valve assembly.
B4M1130B
(1) Adjusting screw

(2) Lock nut
S4M0155B (3) Spring
(4) Sleeve
(1) Valve ASSY
(4) Tighten adjusting screw by two threads.
16) Tighten bolts alternately to secure valve
assembly.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
CAUTION:
Be sure to alternately tighten bolts.
17) Apply grease to sleeve insertion hole.
18) Apply grease to dust seal insertion hole.
CAUTION:
G4M0121
Apply clean grease with clean hands. If mate-
rial having a sharp edge is used for applying (5) Apply liquid packing to at least 1/3 of entire
grease, oil seal at the inside might be damaged. perimeter of adjusting screw thread.
19) Apply grease to sliding surface of sleeve and Liquid packing:
spring seat, then insert sleeve into pinion housing. THREE BOND 1141
Fit spring into sleeve screw, pack grease inside of
screw, then install the screw.
S4M0385A
B4M1129B (1) Apply liquid packing to at least 1/3 of entire perim-

eter.
(1) Adjusting screw
(2) Spring (6) Tighten adjusting screw to 7.4 N·m (0.75
(3) Sleeve kgf-m, 5.4 ft-lb) and back off 25°.
PS-46
(7) Install lock nut. While holding adjusting

screw with a wrench, tighten lock nut using ST.
Tightening torque (Lock nut):
39 N·m (4.0 kgf-m, 29 ft-lb)
NOTE:
쐌 Hold adjusting screw with a wrench to prevent it
from turning while tightening lock nut.
쐌 Make adjustment so that steering wheel can be
rotated fully from lock to lock without binding.
21) Check for service limit as per article of “Ser-
vice limit”. <Ref. to PS-49, SERVICE LIMIT,
INSPECTION, Steering Gearbox [LHD Model].>
Make replacement and adjustment if necessary.
PS-47
1) Clean all disassembled parts, and check for wear, damage, or any other faults, then repair or replace
as necessary.
2) When disassembling, check inside of gearbox for water. If any water is found, carefully check boot for
damage, input shaft dust seal, adjusting screw and boot clips for poor sealing. If faulty, replace with new
parts.
No. Parts Inspection Corrective action
(1) Bend of input shaft
1 Input shaft If bend or damage is excessive, replace entire gearbox.
(2) Damage on serration
(1) Crack or damage If outer wall slips, lip is worn out or damage is found,
2 Dust seal
(2) Wear replace it with new one.
(1) Adjust backlash properly.
By measuring turning torque of gearbox and sliding
resistance of rack, check if rack and pinion engage uni-
formly and smoothly with each other. (Refer to “Service
3 Rack and pinion Poor mating of rack with pinion limit”.)
(2) Keeping rack pulled out all the way so that all teeth
emerge, check teeth for damage.
Even if abnormality is found in either (1) or (2), replace
entire gearbox.
(1) Bend of rack shaft
(2) Bend of cylinder portion
Replace gearbox with new one.
(3) Crack or damage on cast iron
portion
If 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 gearbox with new one. (Refer
to “Service limit”.)
If free plays of input shaft in radial and axial directions
(5) Wear on input shaft bearing are out of the specified ranges, replace gearbox with
new one. (Refer to “Service limit”.)
5 Boot Crack, damage 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.
spring
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-48
2. SERVICE LIMIT S601272A1002 3. RACK SHAFT PLAY IN RADIAL

Make a measurement as follows. If it exceeds the DIRECTION S601272A1003
specified service limit, adjust or replace. Right-turn steering:
NOTE: Service limit
When making a measurement, vise gearbox by 0.19 mm (0.0075 in) or less
using ST. Never vise gearbox by inserting alumi-
On condition
num plates, etc. between vise and gearbox.
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
304 N (31 kgf, 68 lb) or less
G4M0111
Left-turn steering:
G4M0109 Service limit
Direction
Direction
0.15 mm (0.0059 in) or less
G4M0110
G4M0112
PS-49
4. INPUT SHAFT PLAY S601272A1004 5. TURNING RESISTANCE OF GEARBOX

S601272A1005
In radial direction:
Using ST, measure gearbox turning resistance.
Service limit
0.18 mm (0.0071 in) or less ST 926230000 SPANNER
On condition Service limit:
P: 98 N (10 kgf, 22 lb) Straight-ahead position within 30 mm (1.18
in) from rack center
Less than 11.18 N (1.14 kgf, 2.51 lb)
Maximum allowable resistance
12.7 N (1.3 kgf, 2.9 lb)
G4M0113
In axial direction:
Service limit G4M0115
On condition
P: 20 — 49 N (2 — 5 kgf, 4 — 11 lb)
G4M0114
PS-50
6. OIL LEAKING S601272A1006
S4M0153A
(1) Power cylinder (3) Rack piston (5) Input shaft

(2) Cylinder (4) Rack axle (6) Valve housing
NOTE: (1) Inspect leakage from “e”.

If gearbox is dismounted without confirming where The cylinder seal is damaged. Replace rack
the leak is, it must be mounted again to locate the bushing with a new one.
leak point. (2) Inspect leakage from “f”.
1) Even if the location of the leak can be easily There are two possible causes. Take following
found by observing the leaking condition, it is nec- step first. Remove the pipe assembly B from the
essary to thoroughly remove the oil from the sus- valve housing, and close the circuit with ST.
pected portion and turn the steering wheel from ST 926420000 PLUG
lock to lock about 30 to 40 times with engine CAUTION:
running, then make comparison of the suspected 쐌 If leakage from “f” is noted again:
portion between immediately after and several The oil seal of pinion and valve assembly is
hours after this operation. damaged. Replace pinion and valve assembly
2) Inspect leakage from “a”. with a new one. Or replace the oil seal and the
The oil seal is damaged. Replace valve assembly parts that are damaged during disassembly
with a new one. with new ones.
3) Inspect leakage from “b”. 쐌 If oil stops leaking from “f”:
The torsion bar O-ring is damaged. Replace valve The oil seal of rack housing is damaged.
assembly with a new one.
Replace the oil seal and the parts that are dam-
4) Inspect leakage from “c”.
aged during disassembly with new ones.
The oil seal is damaged. Replace valve assembly
or oil seal with a new one.
5) Inspect leakage from “d”.
The pipe is damaged. Replace the faulty pipe or
O-ring.
6) If leak is other than a, b, c, or d, and if oil is
leaking from the gearbox, move the right and left
boots toward tie-rod end side, respectively, with the
gearbox mounted to the vehicle, and remove oil
from the surrounding portions. Then, turn the steer-
ing wheel from lock to lock 30 to 40 times with the
engine running, then make comparison of the
leaked portion immediately after and several hours
after this operation.
PS-51
1) Adjust front toe.

Standard of front toe:
IN 3 — OUT 3 mm (IN 0.12 — OUT 0.12
in)
G4M0133
2) Adjust steering angle of wheels.

Standard of steering angle:
Inner wheel: 37.4°±1.5°
Outer wheel: 32.5°±1.5°
PS-52
STEERING GEARBOX [RHD MODEL]
6. Steering Gearbox [RHD 7) Disconnect one pipe joint A from center of gear-
box assembly, and connect a vinyl hose to it. While
Model] S601276
turning steering wheel to the left and right, drain
fluid through the hose. Similarly, drain fluid from
the other pipe joint B.
2) Lift vehicle with a jack and remove front wheel.
3) Disconnect front exhaust pipe assembly. (Non-
turbo model)
With OBD:
Pipe.>
Without OBD:
<Ref. to EX(SOHCw/oOBD)-6, REMOVAL, Front
Exhaust Pipe.>
4) Remove universal joint. <Ref. to PS-28, S4M0387A
REMOVAL, Universal Joint.>
(1) Pipe A
5) Remove cotter pin and castle nut. Using a
(2) Pipe B
puller, remove tie-rod end from knuckle arm.
8) Remove lower and upper bolts from universal
joint, and remove universal joint in the upward
direction.
NOTE:
Scribe alignment marks on universal joint so that it
can be reassembled at the original serration.
9) Using ST, remove flare nuts from control valve
of gearbox assembly, and disconnect upper and
lower hoses.
ST 34099AC050 GEARBOX SPANNER
S4M0379A
CAUTION:
(1) Castle nut 쐌 Always disconnect hoses B and A in that
(2) Tie-rod end order.
(3) Knuckle arm 쐌 Be careful not to damage the hoses during
removal.
6) Remove jack-up plate and stabilizer.
S4M0235B
S4M0380A
(1) Steering gearbox
(1) Jack-up plate
10) Remove bolts securing gearbox to
crossmember, and detach gearbox.
PS-53
B: INSTALLATION S601276A11 11) Check for fluid leaks. <Ref. to PS-76, OIL
LEAKING, INSPECTION, Steering Gearbox [RHD
1) Insert gearbox into crossmember, being careful Model].>
not to damage gearbox boot. 12) Install jack-up plate.
2) Tighten gearbox to crossmember bracket via
clamp with bolt to the specified torque. WARNING:
Be careful, exhaust manifold is hot.
Tightening torque:
59 N·m (6.0 kgf-m, 43 ft-lb) 13) Lower vehicle.
14) Check fluid level in oil tank.
3) Install the universal joint. <Ref. to PS-28, 15) After adjusting toe-in and steering angle,
INSTALLATION, Universal Joint.> tighten lock nut on tie-rod end.
4) Connect tie-rod end and knuckle arm, and
tighten with castle nut. Fit cotter pin into the nut Tightening torque:
and bend the pin to lock. 83 N·m (8.5 kgf-m, 61.5 ft-lb)
Castle nut tightening torque: CAUTION:
Tighten to 27.0 N·m (2.75 kgf-m, 19.9 When adjusting toe-in, hold boot as shown to
ft-lb), and tighten further within 60° until prevent it from being rotated or twisted. If
cotter pin hole is aligned with a slot in twisted, straighten it.
the nut.
CAUTION:
When connecting, do not hit cap at the bottom
G4M0132
S4M0379A
NOTE:
(1) Castle nut Parts requiring replacement are described in the
(2) Tie-rod end smallest unit of spare parts including damaged
(3) Knuckle arm parts and spare parts damaged. In actual disas-
5) Install front stabilizer to vehicle. <Ref. to FS-22, table damage to some related parts must be taken
INSTALLATION, Front Stabilizer.> into account, and spare parts for them must also
6) Install front exhaust pipe assembly. (Non-turbo be prepared. However, it is essential to pinpoint the
model) cause of trouble, and limit the number of replace-
With OBD: ment parts as much as possible.
<Ref. to EX(SOHC)-6, INSTALLATION, Front
Exhaust Pipe.> 1) Disconnect four pipes from gearbox.
Without OBD:
<Ref. to EX(SOHCw/oOBD)-7, INSTALLATION,
Front Exhaust Pipe.>
7) Install tires.
8) Tighten wheel nuts to the specified torque.
Tightening torque:
88 N·m (9.0 kgf-m, 65 ft-lb)
9) Connect ground terminal to battery.
10) Pour fluid into oil tank, and bleed air.
<Ref. to PS-101, Power Steering Fluid.>
PS-54
2) Secure gearbox removed from vehicle in vise 5) Extend rack approximately 40 mm (1.57 in) out.
using ST. Unlock lock wire at lock washer on each side of
ST 926200000 STAND tie-rod end using a standard screwdriver.
CAUTION: CAUTION:
Secure the gearbox assembly in a vise using Be careful not to scratch rack surface as oil
the ST as shown. Do not attempt to secure it leaks may result.
without this ST.
G4M0791
S4M0388A
NOTE:
(1) Clamp
Parts requiring replacement are described in the
3) Pry off clip from outer end of boot, and slide smallest unit of spare parts including damaged
boot toward tie-rod end. parts and spare parts damaged. In actual disas-
table 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.
6) Using ST, loosen lock nut.
S4M0389A
(1) Clip
4) Using ST, remove lock wire from inner end of

boot, and remove boot.
ST 927590000 WRENCH
S4M0391A
(1) Lock nut
S4M0390A
(1) Wire
PS-55
7) Tighten adjusting screw until it no longer tight- 10) Disconnect pipes A and B from steering body
ens. and control valve housing.
CAUTION:
Replace pipes and/or flare nuts if damaged.
S4M0392A
(1) Adjusting screw

S4M0394A
8) Using a wrench (32 mm width across flats) or
adjustable wrench, remove tie-rod. (1) Pipe A
(2) Pipe B
CAUTION:
쐌 Check ball joint for free play, and tie-rod for 11) Slide dust cover out.
bends. Replace if necessary. CAUTION:
쐌 Check dust seals used with tie-rod end ball 쐌 Be careful not to scratch housing or input
joint for damage or deterioration. Replace if shaft during dust cover removal. Also do not
necessary. allow foreign matter to enter housing interior.
쐌 Replace dust cover with a new one if its
inside bore or lips are worn or damaged.
S4M0393A
(1) Tie-rod
S4M0409A
9) Loosen adjusting screw and remove spring and
sleeve. (1) Dust cover
CAUTION: 12) Remove the two bolts securing valve housing.

Replace spring and/or sleeve if damaged.
S4M0410A
(1) Socket bolt
PS-56
13) Remove valve housing, pinion and valve as a 15) Install ST on valve side of rack and press
unit. outer side oil seal out.
ST 34099FA030 INSTALLER & REMOVER
CAUTION:
쐌 Block pipe connection of steering body to
prevent fluid from flowing out.
쐌 Do not allow rack to come in contact with
inner wall of cylinder. Otherwise, cylinder wall
may be scratched, resulting in oil leaks.
쐌 Remove holder and rack as a unit.
쐌 Check rack and steering body for bends or
cracks; replace as required.
G4M0819
쐌 Discard oil seal after removal and replace
14) Remove holder using a 32 mm wrench or with new ones.
adjustable wrench.
CAUTION:
Discard old holder and replace with new one.
G4M0820
S4M0411A
(1) Rack piston

(2) Outer side oil seal
PS-57
16) Insert ST from valve side and press back-up 17) Using ST1 and ST2, repair cylinder’s clinched
ring and oil seal out. sections.
CAUTION: ST1 34099FA080 PUNCH
Discard back-up ring and oil seal after removal ST2 34099FA070 BASE
and replace with new ones.
ST 927580000 REMOVER
S4M0412A
(1) Cylinder
G4M0822
18) If cylinder edge is deformed in a convex
shape, repair using an oil stone.
G4M0889
19) Using a sharp-edged, long rod, remove seal

ring and O-ring from rack piston.
CAUTION:
Be careful not to scratch outer surface of rack
piston and seal ring groove. A scratch may
reduce the sealing effect, resulting in faulty
piston operation.
PS-58
4) Using ST, remove lock wire from inner end of

boot, and remove boot.
ST 927590000 WRENCH
S4M0423A
(1) Sharp-edged, long rod

(2) Seal ring
(3) O-ring S4M0390A

(1) Wire
1) Disconnect four pipes from gearbox. 5) Using ST, loosen lock nut.
2) Secure gearbox removed from vehicle in vice ST 926230000 SPANNER
using ST.
ST 926200000 STAND
CAUTION:
Secure the gearbox assembly in a vice using
the ST as shown. Do not attempt to secure it
without this ST.
S4M0391A
(1) Lock nut
6) Tighten adjusting screw until it no longer tight-

ens.
S4M0388A
(1) Clamp
3) Pry off clip from outer end of boot, and slide

boot toward tie-rod end.
S4M0392A
(1) Adjusting screw
7) Loosen adjusting screw and remove spring and

sleeve.
CAUTION:
S4M0389A Replace spring and/or sleeve if damaged.
(1) Clip
PS-59
8) Slide dust cover out. 11) After removing dust cover, extract pinion and
CAUTION: valve from valve housing.
쐌 Be careful not to scratch housing or input CAUTION:
shaft during dust cover removal. Also do not 쐌 If pinion and valve is difficult to remove, use
allow foreign matter to enter housing interior. a press.
쐌 Replace dust cover with a new one if its 쐌 Discard oil seal after removal and replace
inside bore or lips are worn or damaged. with a new one.
쐌 Check rotor for bends and serrations for
damage and replace as required.
S4M0409A
(1) Dust cover

G4M0824
9) Remove the two bolts securing valve housing. 12) Using ST and press, remove dust seal,
back-up washer, oil seal and ball bearing from
valve housing.
CAUTION:
쐌 Use the “A” end of remover.
쐌 Do not apply a force to end surface of valve
housing.
쐌 Do not reuse oil seal after removal.
S4M0410A
(1) Socket bolt
10) Remove valve housing, pinion and valve as a

unit.
H4M1250B
(1) Oil seal

(2) Ball bearing
(3) A side
(4) B side
G4M0819
PS-60
13) Remove snap ring securing valve sleeve to D: ASSEMBLY S601276A02

pinion and valve, and remove valve sleeve.
CAUTION:
CAUTION: Use only SUBARU genuine grease for gearbox.
Be careful not to scratch pinion and valve when
removing snap ring. Specified grease for gearbox:
VALIANT GREASE M2 (Part No.
003608001)

2) Move rack shaft fully to the left and right two or
three times to lubricate shaft ends with grease.
Remove excess grease, being careful not to block
air vent hole.
CAUTION:
S4M0417A 쐌 When rack is fully moved to its stroke ends
(1) Valve sleeve
with tie-rod removed, be careful not to bump
(2) Retaining ring
rack ends.
쐌 Ensure that screw located at end of rack
14) Remove oil seal and spacer. shaft is free from grease.
15) Using a long rod, remove seal ring and O-ring
3) Apply grease to bore wall which accommodates
from pinion.
sleeve.
CAUTION:
Be careful not to scratch outer surface and seal CAUTION:
ring groove of input shaft. If scratched, sealing Ensure that hands are clean when applying
effect will be lost, resulting in a malfunctioning grease.
valve. 4) Install O-ring and seal ring in groove on rack
piston.
CAUTION:
쐌 Do not expand O-ring and seal ring more
than necessary.
쐌 To facilitate installation of seal ring, first
position one half of entire seal ring in groove.
Then slowly position the second half using a
spatula, as shown.
S4M0418A
(1) Ball bearing

(2) Spacer
(3) Oil seal
(4) Seal ring
(5) O-ring
S4M0424A
(1) O-ring
(2) Seal ring
(3) Spatula
PS-61
5) Apply a coat of grease to inner surface of ST 7) Using ST·B and ST·C, attach oil seal to ST·A.
and insert rack piston into it. Leave ST at least 10 Insert ST·A into rack from gear side. Remove oil
minutes until seal ring settles down in place. seal from ST·A when it approaches piston and
CAUTION: remove STs from rack.
Be careful not to scratch rack, piston and seal ST 927490000 INSTALLER; A·B·C
ring during installation. NOTE:
ST 927600000 FORMER Face oil seal in the direction shown in figure.
S4M0427A
S4M0425A
(1) Oil-seal
(1) Seal ring
(2) Rack
(2) O-ring
6) Attach steering body to ST as shown. Apply a 8) Install back-up ring from gear side of rack.
coat of grease to needle bearing.
ST 926200000 STAND
CAUTION:
쐌 Use a ST to support steering body.
쐌 Ensure that needle bearing is free from
defects. If it is faulty, replace steering body
with a new one.
NOTE:
If steering body is removed from vehicle, be sure
to remove rust and clean. S4M0428A
(1) Oil seal

(2) Back-up ring
(3) Rack
S4M0426A
(1) Steering body
PS-62
9) Install ST on rack and equally apply a thin coat 11) Slowly press inner side oil seal until distance
of grease to rack and ST, then install oil seal. between ST and end of rack is 65 mm (2.56 in).
ST 926250000 GUIDE ST 34099FA010 GUIDE (Oil seal)
CAUTION: CAUTION:
Be careful not to scratch oil seal lips with pis- Ensure ST’s inner wall is free of scratches.
ton’s knurl section. Otherwise, it may damage oil seal during instal-
lation.
S4M0429A
S4M0431A
(1) Rack piston inner ring
(2) Outer side oil seal (1) Rack piston
(3) Rack (2) Inner side oil seal
(3) Back-up ring
10) Apply a coat of grease to grooves in rack,
sliding surface of sleeve and sealing surface of 12) Pass ST2 and pipe through rack and press
piston. Install ST on the end of steering body cyl- outer side oil seal until ST1 is in contact with ST2.
inder. Then insert rack into steering body from cyl- ST1 34099FA010 GUIDE (Oil seal)
inder side. ST2 34099FA040 INSTALLER (Oil seal)
ST 34099FA010 GUIDE (Oil seal)
CAUTION:
쐌 Be sure to apply grease so that it covers the
entire surface of rack gear teeth.
쐌 Do not allow grease to block air vent hole on
rack.
S4M0432A
(1) Pipe
(2) Outer side oil seal
S4M0430A
(1) Cylinder side of steering body

(2) Air vent hole
(3) Oil seal
(4) Rack
PS-63
13) Install holder from cylinder side of steering 15) Using ST, clinch steering body cylinder at a
body. point less than 3 mm (0.12 in) from holder.
64 N·m (6.5 kgf-m, 47.0 ft-lb) Be careful not to deform holder.
ST 34099FA060 PUNCH
G4M0820
14) Attach ST to rack cylinder. Using a press,

install back-up ring and oil seal.
NOTE:
Press ST until its groove is aligned with end of
holder.
S4M0434A
(1) Holder
16) Remove traces of sealer, oil, rust, etc., from

mating surfaces of valve housing and steering
body.
17) Position a shim in graded portion of steering
body pinion housing, and apply an even coat of
sealer (Fuji Bond C: 004403004) to end of pinion
housing.
S4M0433A
(1) Installer guide

(2) Holder S4M0435A
(3) Rack piston
(4) Oil seal (1) Shim
(5) Back-up ring (2) Fuji Bond C (004403004)
18) Use the same number of shims as that used

when steering body was removed.
19) If steering body, valve housing or pinion and
valve is replaced with a new one, add two or three
shims, install valve on pinion housing and tighten
PS-64
with two bolts to 25 N·m (2.5 kgf-m, 18.1 ft-lb). 23) Apply a coat of grease to sliding surface of
Then, measure clearance between steering body seat pad, sleeve and seating surface of spring, and
and valve housing using a thickness gauge. insert sleeve into steering body. Charge adjusting
Remove shims so that the clearance is zero. screw with grease, insert spring into adjusting
20) Extend rack 72.4 mm (2.850 in) beyond pinion screw and install on steering body.
side of steering body.
S4M0274A
S4M0436A
(1) Seat pad
(1) Rack (2) Sleeve
(3) Spring
21) Apply grease to pinion gear teeth and ball (4) Adjusting screw
bearing. Insert valve into place. (5) Lock nut
24) Installation of tie-rod

(1) Tighten adjusting screw until it will no longer
tighten.
(2) Install lock washers and tighten left and
right tie-rods into rack ends.
On condition
L: Approximately 40 mm (1.57 in)
Tightening torque:
G4M0853
78 N·m (8.0 kgf-m, 58 ft-lb)
22) Alternately and slowly tighten socket bolts.

NOTE:
Replace faulty parts before installing valve.
Otherwise, valve may not be installed properly.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
G4M0804
PS-65
25) Using a chisel and hammer, bend lock wash- (5) Tighten adjusting plug to 5 N·m (0.5 kgf-m,
ers (at two places). 3.6 ft-lb) and loosen, then tighten to 5 N·m (0.5
CAUTION: kgf-m, 3.6 ft-lb) and loosen, and finally tighten to
Be careful not to scratch rack. 5 N·m (0.5 kgf-m, 3.6 ft-lb) and loosen 30°.
(6) While holding adjusting plug using a closed
wrench, tighten lock nut using ST.
Tightening torque:
39 N·m (4 kgf-m, 29 ft-lb)
CAUTION:
쐌 Do not allow liquid packing to come in con-
tact with sleeve.
쐌 While rotating input shaft to fully move rack
shaft to the left and right, ensure that rack
S4M0399A
moves smoothly without binding, and that
(1) Lock washer rotating torque is constant.
26) Rack and pinion backlash adjustment

(1) Loosen adjusting plug.
(2) Rotate input shaft so that rack is in the
straight ahead direction. [Ensure that distance
between rack end and stopper is 70.8 mm
(2.787 in).]
(3) Tighten adjusting plug by two threads.
G4M0808
27) Installation of boot

(1) Apply a coat of grease to inner wall of boot
small end.
(2) Position boot large end in rubber mount
groove and gearbox, and small end in groove of
tie-rod.
G4M0807 CAUTION:
쐌 Ensure that both ends of boot are properly
(4) Turn adjusting screw so that the entire
situated in grooves.
thread area is coated with liquid packing.
쐌 Ensure that boot is free from abnormal swell-
Liquid packing: ing or dents.
NOTE:
쐌 Apply liquid packing of approximately 1.5 g
(0.053 oz) to adjusting screw thread area.
쐌 Also turn plug to ensure that its entire contact
area is coated with liquid packing.
PS-66
28) Attach lock wire to boot large end, and twist it 31) Install pipes A and B.
while pulling it upward (with a force of approxi- Tightening torque:
mately 39 N (4 kgf, 9 lb). Valve housing side
ST 927590000 WRENCH 20 N·m (2.0 kgf-m, 14.5 ft-lb)
CAUTION: Steering body side
Ensure that lock wire is not loose. 24 N·m (2.4 kgf-m, 17.4 ft-lb)

2) Attach ST to pinion, and apply grease to outer
perimeter of the cover and mating surface of oil
seal.
ST 926270000 COVER
S4M0390A
(1) Wire
29) Then bend wire end along boot as shown.
G4M0828
3) Apply a coat of grease to spacer and sealing

lips of oil seal, and install spacer and oil seal.
CAUTION:
쐌 Face chamfered side of spacer toward oil
seal.
S4M0400A
쐌 Face oil seal in correct direction.
(1) Twist wire up to this point.
30) Install clip using pliers.

CAUTION:
After installing clip, ensure that boot’s small
end is properly positioned in groove on tie-rod.
S4M0419A
(1) Spacer
(2) Oil seal
S4M0401A
(1) Clip
PS-67
4) Install ST to input shaft, and apply a coat of 9) Apply a coat of grease to the inner wall of the
grease to the cover surface. Install O-ring and seal ST. Secure the four seal rings (installed in the
ring. former procedure) using the ST as shown in the
CAUTION: figure. Leave the seal rings for approximately 10
Do not expand O-ring and seal ring more than minutes until they have properly set.
necessary. ST 926050000 FORMER
ST 926450000 COVER
S4M0271B
S4M0420A (1) Seal ring

(2) Valve sleeve
(1) O-ring
(2) Seal ring 10) While aligning valve sleeve pin with groove on
pinion, secure with snap ring.
5) Apply a coat of grease to inner wall of ST, and
secure seal ring assembled in the former proce- CAUTION:
dure as shown. Leave seal ring unattended for 쐌 Be careful not to damage inner wall of valve
approximately 10 minutes until it settles down. sleeve and contact surface of pinion.
ST 926280000 FORMER 쐌 Before assembling valve sleeve and pinion,
clean in kerosene and dry with compressed air.
S4M0421A
S4M0422A
(1) Seal ring
(2) O-ring (1) Pin
(2) Groove on pinion
6) Remove the four seal rings from the valve
sleeve using a sharp-pointed tool.
CAUTION:
Be careful not to scratch seal ring grooves on
the valve sleeve. A scratch may reduce the
sealing effect, resulting in faulty valve opera-
tion.
7) Clean the valve sleeve.
8) Attach the four seal rings to the valve sleeve
grooves.
CAUTION:
Do not expand the seal rings more than neces-
sary.
PS-68
11) Apply a coat of grease to inner wall of valve 13) Attach ST2 to ST1, and press ball bearing into
housing, oil seal and outer perimeter of dust seal. place using a press.
NOTE:
쐌 To facilitate installation, attach ball bearing to
remover and position in valve housing before
pressing it into place.
쐌 Use the “B” end of remover.
ST1 34099FA000 INSTALLER & REMOVER
ST2 34099FA050 SPACER
S4M0413A
(1) Valve housing
12) Using ST and press, install oil seal in valve

housing.
(1) Face oil seal in the direction shown in figure
when installing.
(2) To avoid scratching oil seal, apply a coat of
S4M0414A
grease to contact surface of installer and oil
seal. (1) B side
(3) To facilitate installation, attach oil seal to
installer and position in valve housing before 14) Charge oil seal with specified steering grease.
pressing into place.
G4M0840
15) Apply a coat of specified steering grease to ST

H4M1251B
surface, and install ST onto end of input shaft.
(1) Oil seal Insert pinion and valve until “A” of oil seal contacts
“B” of valve housing. The ST is used to prevent
scratching oil seal.
ST 34099FA020 GUIDE
G4M0841
PS-69
16) While supporting pinion and valve, push end 20) Position a shim in graded portion of steering
of pinion until bearing contacts brazed end of valve body pinion housing, and apply an even coat of
housing. sealer (Fuji Bond C: 004403004) to end of pinion
CAUTION: housing.
Do not allow spacer to extend beyond brazed
end. Otherwise, pinion cannot be inserted
properly.
S4M0435A
(1) Shim
(2) Fuji Bond C (004403004)
S4M0415A
21) Use the same number of shims as that used
(1) Spacer when steering body was removed.
17) Apply a coat of grease to sealing lips of dust 22) If steering body, valve housing or pinion and
cover, and insert dust cover until it contacts staged valve is replaced with a new one, add two or three
portion of input shaft. shims, install valve on pinion housing and tighten
with two bolts to 25 N·m (2.5 kgf-m, 18.1 ft-lb).
Then, measure clearance between steering body
and valve housing using a thickness gauge.
Remove shims so that the clearance is zero.
23) Extend rack 72.4 mm (2.850 in) beyond pinion
side of steering body.
S4M0416A
(1) Dust cover
18) Adjust sealing lip-to-housing end clearance to

0 to 0.5 mm (0 to 0.020 in). If sealing lip is too close
to housing end, steering wheel will not return S4M0436A
smoothly; if it is too far from housing end, dust or
dirt will enter the clearance. (1) Rack
NOTE: 24) Apply grease to pinion gear teeth and ball

Ensure that pinion and valve is properly positioned bearing. Insert valve into place.
in valve housing before adjustment.
19) Remove traces of sealer, oil, rust, etc., from
mating surfaces of valve housing and steering
body.
G4M0853
PS-70
25) Alternately and slowly tighten socket bolts. 쐌 Also turn plug to ensure that its entire contact
NOTE: area is coated with liquid packing.
Replace faulty parts before installing valve. (5) Tighten adjusting plug to 5 N·m (0.5 kgf-m,
Otherwise, valve may not be installed properly. 3.6 ft-lb) and loosen, then tighten to 5 N·m (0.5
Tightening torque: kgf-m, 3.6 ft-lb) and loosen, and finally tighten to
25 N·m (2.5 kgf-m, 18.1 ft-lb) 5 N·m (0.5 kgf-m, 3.6 ft-lb) and loosen 30°.
(6) While holding adjusting plug using a closed
26) Apply a coat of grease to sliding surface of wrench, tighten lock nut using ST.
seat pad, sleeve and seating surface of spring, and ST 926300000 SPANNER
insert sleeve into steering body. Charge adjusting
screw with grease, insert spring into adjusting Tightening torque:
screw and install on steering body. 39 N·m (4 kgf-m, 29 ft-lb)
CAUTION:
쐌 Do not allow liquid packing to come in con-
tact with sleeve.
쐌 While rotating input shaft to fully move rack
shaft to the left and right, ensure that rack
moves smoothly without binding, and that
rotating torque is constant.
S4M0274A
(1) Seat pad

(2) Sleeve
(3) Spring
(4) Adjusting screw
(5) Lock nut
27) Rack and pinion backlash adjustment G4M0808

(1) Loosen adjusting plug.
28) Installation of boot
(2) Rotate input shaft so that rack is in the
(1) Apply a coat of grease to inner wall of boot
straight ahead direction. [Ensure that distance
small end.
between rack end and stopper is 70.8 mm
(2) Position boot large end in rubber mount
(2.787 in).]
groove and gearbox, and small end in groove of
(3) Tighten adjusting plug by two threads.
tie-rod.
CAUTION:
쐌 Ensure that both ends of boot are properly
situated in grooves.
쐌 Ensure that boot is free from abnormal swell-
ing or dents.
G4M0807
(4) Turn adjusting screw so that the entire

thread area is coated with liquid packing.
Liquid packing:
NOTE:
쐌 Apply liquid packing of approximately 1.5 grams
(0.053 oz) to adjusting screw thread area.
PS-71
29) Attach lock wire to boot large end, and twist it

while pulling it upward (with a force of approxi-
mately 39 N (4 kgf, 9 lb).
ST 927590000 WRENCH
CAUTION:
Ensure that lock wire is not loose.
S4M0390A
(1) Wire
30) Then bend wire end along boot as shown.
S4M0400A
(1) Twist wire up to this point.
31) Install clip using pliers.

CAUTION:
After installing clip, ensure that boot’s small
end is properly positioned in groove on tie-rod.
S4M0401A
(1) Clip
PS-72
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.
(1) Bend of input shaft If bend or damage is excessive, replace entire
1 Input shaft
(2) Damage on serration gearbox.
(1) Crack or damage If outer wall slips, lip is worn out or damage is
2 Dust seal
(2) Wear found, replace it with new one.
(1) Adjust backlash properly.
By measuring turning torque of gearbox and sliding
resistance of rack, check if rack and pinion engage
uniformly and smoothly with each other.
3 Rack and pinion Poor mating of rack with pinion (Refer to “Service limit”.)
(2) Keeping rack pulled out all the way so that all
teeth emerge, check teeth for damage.
Even if abnormality is found in either (1) or (2),
replace entire gearbox.
(1) Bend of rack shaft
(2) Bend of cylinder portion
Replace gearbox with new one.
(3) Crack or damage on cast
iron portion
If free play of rack shaft in radial direction is out of
(4) Wear or damage on rack
4 Gearbox unit the specified range, replace gearbox with new one.
bush
(Refer to “Service limit”.)
If free plays of input shaft in radial and axial direc-
tions are out of the specified ranges, replace gear-
(5) Wear on input shaft bearing
box with new one.
(Refer to “Service limit”.)
5 Boot Crack, damage 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
8 Adjusting screw spring Deterioration Replace.
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-73
2. SERVICE LIMIT S601276A1002 3. RACK SHAFT PLAY IN RADIAL

Make a measurement as follows. If it exceeds the DIRECTION S601276A1003
specified service limit, adjust or replace. Right-turn steering:
NOTE: Service limit
When making a measurement, vise gearbox by Less than 0.4 mm (0.016 in)
using ST. Never vise gearbox by inserting alumi- (direction )
num plates, etc. between vise and gearbox. Less than 0.6 mm (0.024 in)
ST 926200000 STAND (direction )
Sliding resistance of rack shaft: On condition
Service limit L: 5 mm (0.20 in)
304 N (31 kgf, 68 lb) or less P: 98 N (10 kgf, 22 lb)
Difference between left and right sliding resis-
tance
Less than 20%
G4M0798
Left-turn steering:
G4M0796 Service limit
(direction and )
On condition
L: 5 mm (0.20 in)
P: 98 N (10 kgf, 22 lb)
G4M0797
G4M0799
PS-74
4. INPUT SHAFT PLAY S601276A1004 5. TURNING RESISTANCE OF GEARBOX

S601276A1005
In radial direction:
Using ST, measure gearbox turning resistance.
Service limit
0.18 mm (0.0071 in) or less
Service limit:
On condition Straight-ahead position within 30 mm (1.18
P: 98 N (10 kgf, 22 lb) in) from rack center
Less than 11.18 N (1.14 kgf, 2.51 lb)
Maximum allowable resistance
15.79 N (1.61 kgf, 3.55 lb) or less
Difference between left and right sliding resis-
tance:
Less than 20%
G4M0800
In axial direction:
Service limit
0.27 mm (0.0106 in) or less
On condition
G4M0802
P: 20 — 49 N (2 — 5 kgf, 4 — 11 lb)
G4M0801
PS-75
6. OIL LEAKING S601276A1006
S4M0408A
(1) Power cylinder (4) Rack shaft (7) From pump

(2) Cylinder (5) Gearbox (8) To tank
(3) Rack piston (6) Pinion shaft
NOTE: 6) If leak is other than a, b, c, or d, and if oil is

If gearbox is dismounted without confirming where leaking from the gearbox, move the right and left
the leak is, it must be mounted again to locate the boots toward tie-rod end side, respectively, with the
leak point. gearbox mounted to the vehicle, and remove oil
1) Even if the location of the leak can be easily from the surrounding portions. Then, turn the steer-
found by observing the leaking condition, it is nec- ing wheel from lock to lock 30 to 40 times with the
essary to thoroughly remove the oil from the sus- engine running, then make comparison of the
pected portion and turn the steering wheel from leaked portion immediately after and several hours
lock to lock about 30 to 40 times with engine after this operation.
running, then make comparison of the suspected (1) Inspect leakage from “e”.
portion between immediately after and several The cylinder seal is damaged. Replace rack
hours after this operation. bushing with a new one.
2) Inspect leakage from “a”. (2) Inspect leakage from “f”.
The oil seal is damaged. Replace valve assembly There are two possible causes. Take following
with a new one. step first. Remove the pipe assembly B from the
3) Inspect leakage from “b”. valve housing, and close the circuit with ST.
The torsion bar O-ring is damaged. Replace valve ST 926420000 PLUG
assembly with a new one.
4) Inspect leakage from “c”.
The oil seal is damaged. Replace valve assembly
with a new one.
5) Inspect leakage from “d”.
The pipe is damaged. Replace the faulty pipe or
O-ring.
PS-76
CAUTION: 4) If steering wheel spokes are not horizontal with

쐌 If leakage from “f” is noted again: vehicle set in the straight ahead position after this
The oil seal of pinion and valve assembly is adjustment, correct it by turning the right and left
damaged. Replace pinion and valve assembly tie-rods in the same direction by the same amount.
with a new one. Or replace the oil seal and the
parts that are damaged during disassembly
with new ones.
쐌 If oil stops leaking from “f”:
The oil seal of rack housing is damaged.
Replace the oil seal and the parts that are dam-
aged during disassembly with new ones.
1) Adjust front toe.

G4M0135
Standard of front toe:
IN 3 — OUT 3 mm (IN 0.12 — OUT 0.12
in)
G4M0133
2) Adjust steering angle of wheels.

Standard of steering angle:
Inner wheel: 37.4°±1.5°
Outer wheel: 32.5°±1.5°
3) If steering wheel spokes are not horizontal
when wheels are set in the straight ahead position,
and error is more than 5° on the periphery of steer-
ing wheel, correctly re-install the steering wheel.
S4M0188A
PS-77
PIPE ASSEMBLY
7. Pipe Assembly S601277

RHD model

3) Lift vehicle and remove jack-up plate.
B4M0671F
(1) Pipe A
(2) Pipe B
5) Remove clamp E from pipes.

LHD model
S4M0380A
(1) Jack-up plate
4) Remove one pipe joint at the center of gearbox,

and connect vinyl hose to pipe and joint. Discharge
fluid by turning steering wheel fully clockwise and
the other pipe.
CAUTION:
Improper removal and installation of parts
often causes fluid leak trouble. To prevent this,
clean the surrounding portions before disas-
sembly and reassembly, and pay special atten-
tion to keep dirt and other foreign matter from
mating surfaces.
LHD model
S4M0437A
(1) Return hose

(2) Pressure hose
(3) Clamp E
(4) Pipe C
(5) Pipe D
S4M0381A
(1) Pipe A
(2) Pipe B
PS-78
PIPE ASSEMBLY
RHD model
S4M0235B

8) Remove intake duct and cleaner case. <Ref.
IN(SOHC)-8, INSTALLATION, Air Intake Duct.>
and <Ref. IN(SOHC)-7, Air Cleaner Case.>
9) Remove bolt A.
10) Disconnect pipe C from oil pump. Disconnect
pipe D from return hose.
CAUTION:
쐌 Do not allow fluid from the hose end to come
B4M2509A
into contact with pulley belt.
6) Disconnect pipe C·D. 쐌 To prevent foreign matter from entering the
(1) LHD model hose and pipe, cover the open ends of them
Disconnect pipe C·D from pipe (on the gearbox with a clean cloth.
side).
CAUTION:
쐌 When disconnecting pipe C·D, use two
wrenches to prevent deformities.
쐌 Be careful to keep pipe connections free
from foreign matter.
S4M0310B
(1) Bolt A
(2) Pipe C
(3) Pipe D
S4M0382A
(1) Pipe C 2) Disconnect battery minus terminal.
(2) Pipe D
(2) RHD model

Using ST, remove flare nuts from control valve of
gearbox assembly, and then disconnect pipe.
CAUTION:
쐌 When disconnecting pipes, use two
PS-79
PIPE ASSEMBLY
3) Lift vehicle and remove jack-up plate. RHD model
S4M0380A B4M0671F
(1) Jack-up plate (1) Pipe A

(2) Pipe B
4) Remove one pipe joint at the center of gearbox,
and connect vinyl hose to pipe and joint. Discharge 5) Remove clamp E from pipes.
fluid by turning steering wheel fully clockwise and LHD model
the other pipe.
CAUTION:
Improper removal and installation of parts
often causes fluid leak trouble. To prevent this,
clean the surrounding portions before disas-
sembly and reassembly, and pay special atten-
tion to keep dirt and other foreign matter from
mating surfaces.
LHD model
S4M0381A S4M0437A
(1) Pipe A (1) Return hose

(2) Pipe B (2) Pressure hose
(3) Clamp E
(4) Pipe C
(5) Pipe D
PS-80
PIPE ASSEMBLY
RHD model (2) RHD model

Using ST, remove flare nuts from control valve of
gearbox assembly, and then disconnect pipe.
CAUTION:
쐌 When disconnecting pipes, use two
S4M0235B

B4M2509A
6) Disconnect pipe C·D. 8) Remove intake duct.
(1) LHD model 9) Remove bolt A.
Disconnect pipe C·D from pipe (on the gearbox (1) Remove air intake duct, air cleaner upper
side). cover and air intake boot.
<Ref. to IN(DOHC TURBO)-8, REMOVAL, Air
CAUTION:
Intake Duct.> and <Ref. to IN(DOHC
쐌 When disconnecting pipe C·D, use two
TURBO)-9, REMOVAL, Intake Duct.>
(2) Remove two bolts fixing pipe C and D.
(3) Remove coolant filler tank.
B4M1696B
(1) Pipe C
(2) Pipe D
EN0126
PS-81
PIPE ASSEMBLY
(4) Disconnect pipe C from oil pump. Discon- B: INSTALLATION S601277A11
nect pipe D from return hose.

CAUTION:
쐌 Do not allow fluid from the hose end to come 1) Tighten bolt A.
into contact with pulley belt. CAUTION:
쐌 To prevent foreign matter from entering the Visually check that hose between tank and pipe
hose and pipe, cover the open ends of them D is free from bending or twisting.
with a clean cloth.
(1) Connect pipe D to oil tank.
(2) Connect pipe C or pressure hose to oil
pump.
CAUTION:
Use a new gasket.
Tightening torque:
39 N·m (4.0 kgf-m, 28.9 ft-lb)
(3) Tighten bolt A.
Tightening torque:
ST0012 13 N·m (1.3 kgf-m, 9.4 ft-lb)
(1) Pipe C
(2) Pipe D
S4M0310B
(1) Bolt A
(2) Pipe C
(3) Pipe D
PS-82
PIPE ASSEMBLY
2) Temporarily connect pipes C and D. (LHD 4) Temporarily install clamp E on pipes C and D,
model) and tighten clamp E firmly.
CAUTION:
Ensure that the letter “8” on each clamp are
diagonally opposite each other as shown in fig-
ure.
Tightening torque:
7.4 N·m (0.75 kgf-m, 5.4 ft-lb)
B4M0667C
(1) Clamp E
(2) Pipe C
S4M0438A 5) Tighten joint nut.

(1) Return hose Tightening torque:
(2) Pressure hose 15 N·m (1.5 kgf-m, 10.8 ft-lb)
(3) Approx. 30 mm (1.18 in) 6) Connect pipe A and B.
(4) Clamp E (1) LHD model
(5) Pipe C Connect pipes A and B to four pipe joints of gear-
(6) Pipe box. Connect upper pipe B first, and lower pipe A
(7) Pipe (on gearbox side) second.
3) Using ST, remove flare nuts from control valve Tightening torque:
of gearbox assembly, and disconnect upper and 13 N·m (1.3 kgf-m, 9.4 ft-lb)
lower hoses.
CAUTION:
쐌 Always disconnect hoses B and A in that
order.
쐌 Be careful not to damage the hoses during
removal.
S4M0381A
(1) Pipe A
(2) Pipe B
S4M0235B
PS-83
PIPE ASSEMBLY
(2) RHD model 7) Install jack-up plate.

Connect pipes A and B to four pipe joints of gear- 8) Connect battery ground terminal.
box. Connect upper pipe A first, and lower pipe B 9) Feed the specified fluid.
second.
NOTE:
Tightening torque: Never start the engine before feeding the fluid; oth-
T1: 20 N·m (2.0 kgf-m, 14.5 ft-lb) erwise vane pump might be seized up.
T2: 24 N·m (2.4 kgf-m, 17.4 ft-lb)
B4M0671G
(1) Pipe A
(2) Pipe B
LHD model
S4M0272B
(1) High-pressure hose
(2) No interference is allowed between hoses.
(3) Clearance between crossmember and pipe: 3 — 8 mm (0.12 — 0.31 in)
PS-84
PIPE ASSEMBLY
RHD model
B4M1205B
(1) Clearance between blow-by hose and pipe: 3 — 5 mm (0.12 — 0.20 in)
(2) No interference is allowed between hoses
(3) Clearance between side frame and hose: 15 mm (0.59 in) or more
10) Finally check clearance between pipes and/or

hoses, as shown above.
If clearance between cruise control pump and
power steering hose is less than 10 mm (0.39 in),
proceed as follows:
(1) Move clamped section (A) (refer to figure
above.) down to a point where 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-85
PIPE ASSEMBLY
2. TURBO MODEL S601277A1104 2) Install coolant filler tank. (Turbo model)

1) Tighten bolt A. Tightening torque:
T1: 19 N·m (1.9 kgf-m, 13.7 ft-lb)
CAUTION:
T2: 21 N·m (2.1 kgf-m, 15.2 ft-lb)
Visually check that hose between tank and pipe
D is free from bending or twisting.
(1) Connect pipe D to oil tank.
(2) Connect pipe C or pressure hose to oil
pump.
CAUTION:
Use a new gasket.
Tightening torque:
39 N·m (4.0 kgf-m, 28.9 ft-lb)
(3) Tighten bolt A.
Tightening torque:
13 N·m (1.3 kgf-m, 9.4 ft-lb)
EN0127
B4M1658B
(1) Bolt A
(2) Pipe C
(3) Pipe D
PS-86
PIPE ASSEMBLY
3) Temporarily connect pipes C and D. (LHD 5) Temporarily install clamp E on pipes C and D,
model) and tighten clamp E firmly.
CAUTION:
Ensure that the letter “8” on each clamp are
diagonally opposite each other as shown in fig-
ure.
Tightening torque:
7.4 N·m (0.75 kgf-m, 5.4 ft-lb)
B4M0667C
(1) Clamp E
(2) Pipe C
S4M0438A 6) Tighten joint nut.

(1) Return hose Tightening torque:
(2) Pressure hose 15 N·m (1.5 kgf-m, 10.8 ft-lb)
(3) Approx. 30 mm (1.18 in) 7) Connect pipe A and B.
(4) Clamp E (1) LHD model
(5) Pipe C Connect pipes A and B to four pipe joints of gear-
(6) Pipe box. Connect upper pipe B first, and lower pipe A
(7) Pipe (on gearbox side) second.
4) Using ST, temporarily connect pipes to control Tightening torque:
valve of gearbox. (RHD model) 13 N·m (1.3 kgf-m, 9.4 ft-lb)
S4M0381A
S4M0235B
(1) Pipe A
(1) Steering gearbox (2) Pipe B
PS-87
PIPE ASSEMBLY
(2) RHD model 8) Install jack-up plate.

Connect pipes A and B to four pipe joints of gear- 9) Connect battery ground terminal.
box. Connect upper pipe A first, and lower pipe B 10) Feed the specified fluid.
second.
NOTE:
Tightening torque: Never start the engine before feeding the fluid; oth-
T1: 20 N·m (2.0 kgf-m, 14.5 ft-lb) erwise vane pump might be seized up.
T2: 24 N·m (2.4 kgf-m, 17.4 ft-lb)
B4M0671G
(1) Pipe A
(2) Pipe B
LHD model
S4M0272B
(1) High-pressure hose
(2) No interference is allowed between hoses.
PS-88
PIPE ASSEMBLY
RHD model
B4M1205B
(1) Clearance between blow-by hose and pipe: 3 — 5 mm (0.12 — 0.20 in)
(2) No interference is allowed between hoses
(3) Clearance between side frame and hose: 15 mm (0.59 in) or more
11) Finally check clearance between pipes and/or

hoses, as shown above.
If clearance between cruise control pump and
power steering hose is less than 10 mm (0.39 in),
proceed as follows:
(1) Move clamped section (A) (refer to figure
above.) down to a point where 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-89
PIPE ASSEMBLY
Check all disassembled parts for wear, damage or

other abnormalities. Repair or replace faulty parts
as required.
Part name Inspection Remedy
쐌 O-ring fitting surface for
damage Replace with
Pipe
쐌 Nut for damage new one.
쐌 Pipe for damage
Clamp B
쐌 Clamps for weak clamping Replace with
Clamp C
force new one.
Clamp E
쐌 Flared surface for damage
쐌 Flare nut for damage
쐌 Outer surface for cracks
Replace with
Hose 쐌 Outer surface for wear
new one.
쐌 Clip for damage
쐌 End coupling or adapter for
degradation
CAUTION:
Although surface layer materials of rubber hoses have excellent weathering resistance, heat resis-
tance and resistance for low temperature brittleness, they are likely to be damaged chemically by
brake fluid, battery electrolyte, engine oil and automatic transmission fluid and their service lives
are to be very shortened. It is very important to keep the hoses free from before mentioned fluids
and to wipe out immediately when the hoses are adhered with the fluids.
Since resistances for heat or low temperature brittleness are gradually declining according to time
accumulation of hot or cold conditions for the hoses and their service lives are shortening
accordingly, it is necessary to perform careful inspection frequently when the vehicle is used in hot
weather areas, cold weather area and/or a driving condition in which many steering operations are
required in short time.
Particularly continuous work of relief valve over 5 seconds causes to reduce service lives of the
hoses, the oil pump, the fluid, etc. due to over heat.
So, avoid to keep this kind of condition when servicing as well as driving.
Trouble Possible cause Corrective action
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.
Wrong layout, tensioned Replace hose.
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.
Replace.
Excessive holding time of relief status
Instruct customer.
Excessive tightening torque for return hose clip Replace.
Crack on hose Power steering fluid, brake fluid, engine oil, elec- Replace.
trolyte adhere on the hose surface Pay attention on service work.
Replace.
Too many times use in extremely cold weather
Instruct customers.
PS-90
PIPE ASSEMBLY
CAUTION:
It is likely that although one judges fluid leakage, there is actually no leakage. This is because the
fluid spilt during the last maintenance was not completely wiped off. Be sure to wipe off spilt fluid
thoroughly after maintenance.
Non-turbo model
S4M0171A
Fluid leaking area Possible cause Corrective action

Insufficient tightening of flare nut, catching
Loosen and retighten, if ineffective,
dirt or the like, damage to flare or flare nut
replace.
Leakage from connecting portions of or eye bolt
pipes and hoses, numbered with (1) Poor insertion of hose, poor clamping Retighten or replace clamp.
through (9) in figure Replace O-ring or gasket pipe or hose
Damaged O-ring or gasket with new one, if ineffective, replace gear-
box also.
Leakage from hose (10) and (11) in Crack or damage in hose Replace with a new one.
figure Crack or damage in hose hardware Replace with a new one.
Leakage from surrounding of cast Damaged O-ring Replace oil pump.
iron portion of oil pump (12) and (13)
in figure Damaged gasket Replace oil pump.
Leakage from oil tank (14) and (15) Crack in oil tank, (14) Replace oil tank.
in figure Damaged O-ring, (15) Replace O-ring.
Damaged cap packing Replace cap.
Leakage from filler neck (16) Crack in root of filler neck Replace oil tank.
High fluid level *1 Adjust fluid level.
Leakage from surrounding of power
Damaged oil seal Replace oil seal.
cylinder of gearbox (17) in figure
Leakage from control valve of gear- Damaged packing or oil seal Replace problem parts.
box (18) and (19) in figure Damage in control valve Replace control valve.
PS-91
PIPE ASSEMBLY
Turbo model
S4M0565B
Fluid leaking area Possible cause Corrective action

Insufficient tightening of flare nut, catching
Loosen and retighten, if ineffective,
dirt or the like, damage to flare or flare nut
replace.
Leakage from connecting portions of or eye bolt
pipes and hoses, numbered with (1) Poor insertion of hose, poor clamping Retighten or replace clamp.
through (11) in figure Replace O-ring or gasket pipe or hose
Damaged O-ring or gasket with new one, if ineffective, replace gear-
box also.
Leakage from hose (12), (13) and Crack or damage in hose Replace with a new one.
(14) in figure Crack or damage in hose hardware Replace with a new one.
Leakage from surrounding of cast Damaged O-ring Replace oil pump.
iron portion of oil pump (15) and (16)
in figure Damaged gasket Replace oil pump.
Leakage from oil tank (17) and (18)
Crack in oil tank Replace oil tank.
in figure
Damaged cap packing Replace cap.
Leakage from filler neck (19) Crack in root of filler neck Replace oil tank.
High fluid level *1 Adjust fluid level.
Leakage from surrounding of power
Damaged oil seal Replace oil seal.
cylinder of gearbox (20) in figure
Leakage from control valve of gear- Damaged packing or oil seal Replace problem parts.
box (21) and (22) in figure Damage in control valve Replace control valve.
NOTE:
Fluid level is specified at optimum position (range) for ordinary use. Accordingly, if the vehicle is used often
under hard conditions such as on very rough roads or in mountainous areas, fluid may bleed out from cap
air vent hole. This is not a problem. If a customer complains strongly and is not likely to be satisfied with
the leakage, lower the fluid level to the extent that fluid will not bleed out under the conditions described,
and have the customer check the fluid level and its quality more frequency than usual.
PS-92
OIL PUMP
8. Oil Pump S601070

8) Remove three bolts from the front side of oil
pump and detach the pump.
1) Remove ground cable from battery.

2) Drain the working fluid about 0.3 (0.3 US qt,
0.3 Imp qt) from oil tank.
3) Remove pulley belt cover bracket.
4) Loosen oil pump pulley nut, then remove bolts
which secure alternator.
H4M1077B
(1) Oil pump
9) Remove three bolts from the lower side of

bracket and detach the bracket.
CAUTION:
The bracket does not need to be removed
unless it is damaged.
H4M1076B 10) Place oil pump in a vise, and remove upper
shell and baffle from lower shell.
(1) Oil pump pulley nut
CAUTION:
5) Loosen pulley belt(s). Do not clamp oil pump too hard; otherwise oil
6) Remove the nut and detach oil pump pulley. pump may be dented.
7) Disconnect pipe C from oil pump. Disconnect
pipe D from oil tank.
CAUTION:
쐌 Do not allow fluid from the hose end to come
into contact with pulley belt.
쐌 To prevent foreign matter from entering the
hose and pipe, cover the open ends of them
with a clean cloth.
쐌 Except when only oil tank needs to be
inspected, detach oil tank and oil pump as a
unit. Then separate one from the other on a H4M1078B
work bench to prevent oil from spilling on any
(1) Upper shell
part of the engine.
(2) Lower shell
11) Remove lower shell from oil pump.
S4M0310B
(1) Bolt A
H4M1075B
(2) Pipe C
(3) Pipe D (1) Lower shell
PS-93
OIL PUMP
1) Remove ground terminal from battery.

2) Remove intake duct. <Ref. to IN(DOHC
TURBO)-8, REMOVAL, Air Intake Duct.>
3) Remove pulley belt cover.
4) Loosen lock bolt and slider bolt and remove
power steering pump drive V-belt.
B2M3151
9) Place oil pump bracket in a vise, remove 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.
G2M0286
5) Disconnect connector from power steering

pressure switch.
6) Remove intake boot and air cleaner upper.
<Ref. to IN(DOHC TURBO)-7, REMOVAL, Air
Cleaner.>
7) Disconnect pipe C and suction hose from oil
pump.
CAUTION:
쐌 Do not allow fluid from the hose end to come B4M1660
into contact with pulley belt. 10) Remove bolt from the rear side of oil pump.
쐌 To prevent foreign matter from entering the 11) Disassemble oil pump and bracket by inserting
hose and pipe, cover the open ends of them a screwdriver as shown in the figure.
with a clean cloth.
B4M1661
ST0017
(1) Suction hose

(2) Pipe C
8) Remove bolts which install power steering

pump bracket.
PS-94
OIL PUMP
1) Install bracket on engine.

Tightening torque:
22 N·m (2.2 kgf-m, 15.9 ft-lb)
2) Install oil pump on oil tank as follows outside
the vehicle:
NOTE: H4M1078B
Prior to installation, make sure that all oil is
removed from oil pump, oil tank and pipe. (1) Upper shell
(2) Lower shell
3) Place oil pump in a vise and install stay to oil
pump. 6) Install oil pump, previously assembled to oil
CAUTION: tank, on bracket.
Do not place oil pump directly in vise; use soft Tightening torque:
pads and hold oil pump lightly to protect it. 18 N·m (1.8kgf-m, 13.0 ft-lb)
Tightening torque:
15.7 N·m (1.60 kgf-m, 11.6 ft-lb)
4) Install lower shell to oil pump.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
CAUTION:
Be sure to use a new seal washer.
H4M1077B
(1) Oil pump

8) Inspect pulley belt tension. <Ref. to
ME(SOHC)-43, INSPECTION, V-belt.>
9) Feed the specified power steering fluid. <Ref. to
PS-101, Power Steering Fluid.>
H4M1075B
(1) Lower shell 1) Install oil pump to bracket.

5) Install upper shell and baffle to lower shell. (1) Place oil pump bracket in a vise. Tighten
bushing using a 12.7 mm (1/2″) type 14- and
Tightening torque: 21-mm box wrench until it is in contact with oil
13 N·m (1.3 kgf-m, 9.4 ft-lb) pump mounting surface.
CAUTION:
Do not place oil pump bracket directly in the
vise; use soft pads and hold oil pump lightly to
protect the pump.
PS-95
OIL PUMP
2) Tighten bolt which install power steering pump

bracket.
Tightening torque:
22 N·m (2.2 kgf-m, 15.9 ft-lb)
B4M1670B
(1) Bush
(2) Nut
(3) 21 mm
(4) 14 mm B2M3151
(5) Bolt
3) Interconnect pipes C and suction hose.
(2) Tighten bolt which installs oil pump to Tightening torque:
bracket. Joint nut
Tightening torque: 39.2 N·m (4 kgf-m, 28.9 ft-lb)
37.3 N·m (3.8 kgf-m, 27.5 ft-lb) CAUTION:
If a hose is twisted at this step, the hose may
come into contact with some other parts.
B4M2532
Tightening torque: ST0017

15.7 N·m (1.6 kgf-m, 11.6 ft-lb)
(1) Suction hose
(2) Pipe C
4) Connect connector to power steering oil pres-

sure switch.
5) Install pulley belt to oil pump.
6) Check pulley belt tension. <Ref. to ME(DOHC
TURBO)-45, INSPECTION, V-belt.>
7) Tighten bolt belt tension.
Tightening torque:
8 N·m (0.8 kgf-m, 5.8 ft-lb)
B4M1660
8) Install pulley belt cover.
9) Install air intake boot.
10) Connect ground terminal of battery.
11) Feed the specified power steering fluid. <Ref.
to PS-101, Power Steering Fluid.>
CAUTION:
Never start the engine before feeding the fluid;
otherwise vane pump might be seized up.
PS-96
OIL PUMP
쐌 In accordance with the following table, check all removed parts for wear and damage, and make repair
or replacement if necessary.
(1) Crack, damage or oil leakage Replace oil pump with a new one.
1 Oil pump (Exterior) Measure radial play and axial play.
(2) Play of pulley shaft If any of these exceeds the service limit, replace oil
pump with a new one.
(1) Damage Replace it with a new one.
2 Pulley Measure V ditch deflection.
(2) Bend If it exceeds the service limit, replace pulley with a
new one.
3 Cap Crack or damage Replace it with a new one.
(1) Clogging with dirt Wash it.
4 Strainer
(2) Breakage Replace it with a new one.
Check resistance to rotation of pulley.
(1) Defect or burning of vane pump If it is past the service limit, replace oil pump with a
new one.
5 Oil pump (Interior) Oil pump emits a noise that is markedly different in
(2) Bend in the shaft or damage to tone and loudness from a sound of a new oil pump
bearing when turning with a string put around its pulley,
replace oil pump with a new one.
6 O-ring Crack or deterioration Replace it with a new one.
7 Oil tank Crack, damage or oil leakage Replace it with a new one.
8 Bracket Crack Replace it with a new one.
PS-97
OIL PUMP
2. SERVICE LIMIT S601070A1001 NOTE:

Read the value for one surface of V ditch, and then
Make a measurement as follows. If it exceeds the
the value for another off the dial.
specified service limit, replace the parts with new
ones.
CAUTION:
쐌 Fix oil pump on a vise to make a measure-
ment. At this time, hold oil pump with the least
possible force between two wood pieces.
쐌 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 S4M0441A
On condition: (1) Dial indicator

P: 9.8 N (1.0 kgf, 2.2 lb)
3) Resistance to rotation of pulley
Service limit:
Radial play (Direction ) Service limit:
0.4 mm (0.016 in) or less Maximum load; 9.22 N (0.94 kgf, 2.07 lb)
or less
NOTE:
쐌 A rather higher value may be indicated when
pulley starts turning.
쐌 Measure the load during rotation and make a
judgment.
S4M0439A
(1) Dial indicator

Axial play (Direction )
Non-turbo model:
Turbo model: S4M0442A
(1) Spring balance
3. HYDRAULIC PRESSURE S601070A1003
CAUTION:
쐌 Be sure to complete all items aforemen-
tioned in “INSPECTION”, prior to measuring
hydraulic pressure. Otherwise, pressure can
not be measured correctly. <Ref. to PS-103
INSPECTION, General Diagnostic Table.>
쐌 Do not leave the valve of pressure gauge
S4M0440A
closed or hold the steering wheel at stop end
for 5 seconds or more in any case, as the oil
(1) Dial indicator pump may be damaged due to long keep of
these conditions.
2) Ditch deflection of pulley
쐌 Put cotton cloth waste at a place where fluid
Service limit: drops before pressure gauge is installed. Wipe
1.0 mm (0.039 in) or less off split fluid thoroughly after the measure-
ment.
PS-98
OIL PUMP
NOTE: Service limit:

Keep engine idling during the measurement. Non-turbo model:
7,159 — 7,748 kPa (73 — 79 kg/cm2, 1,038
1) MEASURE REGULAR PRESSURE.
— 1,123 psi)
(1) Remove two bolts securing power steering Turbo model:
pipes to engine. 9,611 — 10,199 kPa (98 — 104 kg/cm2,
(2) Install ST1, 2 and 3 between power steer- 1,394 — 1,479 psi)
ing pump and pipes using gasket (Part No.
34621AC021) and bolt (Part No. 34620AC010). (4) If it is not within the specified value, replace
(3) Replenish power steering fluid up to speci- the oil pump.
fied level. 3) Measure working pressure.
(4) Open valve, and start the engine. (1) Using STs, measure working pressure.
(2) Open valve.
(5) Measure regular pressure.
(3) Measure working pressure of control valve
ST1 925711000 PRESSURE GAUGE
by turning wheel from stop to stop.
ST2 34099AC020 ADAPTER HOSE B ST1 925711000 PRESSURE GAUGE
ST3 34099AC010 ADAPTER HOSE A ST2 34099AC020 ADAPTER HOSE B
ST3 34099AC010 ADAPTER HOSE A
B4M1675A
B4M1675A
Service limit:
981 kPa (10 kg/cm2, 142 psi) or less Service limit:
(6) If it is not within the specified value, replace Non-turbo model:
the troubled part caused by the following symp- 7,159 — 7,748 kPa (73 — 79 kg/cm2, 1,038
toms; pipe or hose clogged, leaks from fluid line, — 1,123 psi)
and mix of foreign objects in fluid line. Turbo model:
9,611 — 10,199 kPa (98 — 104 kg/cm2,
2) Measure relief pressure.
1,394 — 1,479 psi)
(1) Using STs, measure relief pressure.
(2) Close valve. (4) If it is within the specified value, measure
(3) Measure relief pressure. steering effort. <Ref. to PS-106 MEASURE-
ST1 925711000 PRESSURE GAUGE MENT OF STEERING EFFORT, INSPECTION,
ST2 34099AC020 ADAPTER HOSE B General Diagnostic Table.> If it is not within
ST3 34099AC010 ADAPTER HOSE A specified value, replace control valve itself or
control valve and pinion as a single unit with
new ones.
B4M1676A
PS-99
RESERVOIR TANK
9. Reservoir Tank S601075

1) Install reservoir tank to bracket.

2) Connect return hose and suction hose to reser-
1. NON-TURBO MODEL S601075A1804 voir tank.
Refer to “Oil Pump” section for details of reservoir
tank removal order. <Ref. to PS-93, NON-TURBO
MODEL, REMOVAL, Oil Pump.>
1) Remove air intake duct. <Ref. to IN(DOHC

TURBO)-8, REMOVAL, Air Intake Duct.>
2) Drain fluid from the reservoir tank.
3) Disconnect return hose and suction hose from
reservoir tank. ST0022
CAUTION: (1) Suction hose

쐌 Do not allow fluid from the hose end to come (2) Pipe D
into contact with pulley belt. (3) Return hose
쐌 To prevent foreign matter from entering the
hose, cover the open ends of them with a clean 3) Feed the specified power steering fluid. <Ref. to
cloth. PS-101, Power Steering Fluid.>
Check reservoir tank for cracks, breakage, or dam-

age. If any cracks, breakage, or damage is found,
replace reservoir tank.
ST0022
(1) Suction hose

(2) Pipe D
(3) Return hose
4) Remove reservoir tank from bracket by pulling

it upwards.
Refer to “Oil Pump” section for details of reservoir

tank installation order. <Ref. to PS-95, NON-
TURBO MODEL, INSTALLATION, Oil Pump.>
PS-100
POWER STEERING FLUID
10. Power Steering Fluid S601275 C: REMOVAL S601275A18
A: SPECIFICATION S601275A22
Recommended power steering fluid Manufacturer 3) Remove air intake duct.
B.P. 4) Drain fluid from the reservoir tank.
CALTEX 5) Lift-up the vehicle.
CASTROL 6) Remove under cover.
DEXRON IIE or III 7) Remove jack-up plate.
MOBIL
SHELL
TEXACO
1) Check power steering fluid for deterioration or

contamination. If the fluid is highly deteriorated or
contaminated, drain it and refill with new fluid.
2) Check joints and units for oil leakage. If any oil
leaks are found, repair or replace the applicable
part.
S4M0380A
3) Inspect fluid level on flat and level surface with
engine “OFF” by indicator of reservoir tank. (1) Jack-up plate
keep the level in the specified range of the indica- 8) Disconnect one pipe joint A from center of gear-
tor. If at upper point or above, drain fluid by using box assembly, and connect a vinyl hose to it. While
a syringe or the like. turning steering wheel to the left and right, drain
(1) Check at temperature 20°C (68°F) on res- fluid through the hose. Similarly, drain fluid from
ervoir surface of oil pump; read the fluid level on the other pipe joint B.
the “COLD” side. LHD model
the “HOT” side.
Non-turbo model
S4M0381A
(1) Pipe A
(2) Pipe B
H4M1007
Turbo model
B4M1674A
PS-101
POWER STEERING FLUID
RHD model 8) Stop the engine, and take out safety stands
after jacking up vehicle again.
Then lower the vehicle, and idle the engine.
9) Continue to turn steering wheel from lock to
lock until bubbles stop appearing and change of
the fluid level is within 3 mm (0.12 in).
10) 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.
B4M0671F
11) Check the fluid leakage at flare nuts after turn-
(1) Pipe A ing steering wheel from lock to lock with engine
(2) Pipe B running.
CAUTION:
9) Connect pipe joint A and B.
쐌 Before checking, wipe off any fluid on flare
10) When pouring power steering fluid, refer to
nuts and piping.
“Installation” under “Power Steering Fluid”. <Ref. to 쐌 In case the fluid leaks from flare nut, it is
PS-102 INSTALLATION, Power Steering Fluid.> caused by dust (or the like) and/or damage
11) Install in the reverse order of removal. between flare and tapered seat in piping.
쐌 So remove the flare nut, tighten again it to
D: INSTALLATION S601275A11
the specified torque after cleaning flare and
1) Feed the specified fluid with its level being tapered seat. If flare or tapered seat is
about 4 cm (1.6 in) lower than the mouth of tank. damaged, replace it with a new one.
2) Set ST on top of reservoir tank and fill it about
half way with the specified fluid. (Turbo model)
ST 34199AE040 OIL CHARGE
B4M1673A
3) Continue to turn steering wheel slowly from lock

to lock until bubbles stop appearing in the tank
while keeping the fluid at that level.
4) In case air is absorbed to deliver bubbles into
piping because the fluid level is lower, leave it
about half an hour and then do the step 2) all over
again.
5) Start, and idle the engine.
6) Continue to turn steering wheel slowly from lock
to lock again until bubbles stop appearing in the
tank while keeping the fluid at that level.
It is normal that bubbles stop appearing after three
times turning of steering wheel.
7) In case bubbles do not stop appearing in the
tank, leave it about half an hour and then do the
step 5) all over again.
PS-102
11. General Diagnostic Table

S601257

1. Pulley belt
쐌 Unequal length of pulley belts
쐌 Adhesion of oil and grease
쐌 Loose or damage of pulley belt
Adjust or replace.
쐌 Poor uniformity of pulley belt cross section
쐌 Pulley belt touches to pulley bottom
쐌 Poor revolution of pulleys except oil pump pulley
쐌 Poor revolution of oil pump pulley
2. Tire and rim
쐌 Improper tires out of specification
Replace or reinflate.
쐌 Heavy steering effort in all 쐌 Improper rims out of specification
ranges 쐌 Tires not properly inflated*1
쐌 Heavy steering effort at 3. Fluid
stand still 쐌 Low fluid level
쐌 Steering wheel surges when 쐌 Aeration Refill, bleed air, replace or
turning. 쐌 Dust mix instruct customer.
쐌 Deterioration of fluid
쐌 Poor warming-up of fluid *2
4. Idling speed
쐌 Lower idling speed
Adjust or instruct customer.
쐌 Excessive drop of idling speed at start or at turning steer-
ing wheel *3
5. Measure hydraulic pressure. <Ref. to PS-97
Replace problem parts.
INSPECTION, Oil Pump.>
6. Measure steering effort. <Ref. PS-103 INSPECTION,
Adjust or replace.
General Diagnostic Table.>
1. Fluid line
쐌 Folded hose Reform or replace.
쐌 Flattened pipe
2. Tire and rim
쐌 Flat tire
쐌 Mix use of different tires
쐌 Mix use of different rims Fix or replace.
쐌 Vehicle leads to one side or 쐌 Abnormal wear of tire
the other. 쐌 Unbalance of remained grooves
쐌 Poor return of steering 쐌 Unbalance of tire pressure
wheel to center 3. Front alignment
쐌 Steering wheel surges when 쐌 Improper or unbalance caster
Adjust or retighten.
turning. 쐌 Improper or unbalance toe-in
쐌 Loose connection of suspension
4. Others
쐌 Damaged joint assembly Replace, adjust or instruct cus-
쐌 Unbalanced height tomer.
쐌 One-sided weight
5. Measure steering effort. <Ref. to PS-103 INSPECTION,
Adjust or replace.
General Diagnostic Table.>
*1 If tires and/or rims are wider, the load to power steering system is the more. Accordingly, in a condition, for example before fluid
warms-up, relief valve may work before maximum turning angle. In this case, steering effort may be heavy. When measured
hydraulic pressure is normal, there is no abnormal thing.
*2 In cold weather, steering effort may be heavy due to increased flow resistance of cold fluid. After warming-up engine, turn steer-
ing wheel from stop to stop several times to warm-up fluid. Then if steering effort reduces normally, there is no abnormal thing.
*3 In cold weather or with insufficient warm-up of engine, steering effort may be heavy due to excessive drop of idling when turn-
ing steering wheel. In this case, it is recommended to start the vehicle with increasing engine speed than usual. Then if steering
effort reduces normally, there is no abnormal thing.
PS-103
1. NOISE AND VIBRATION S601257A1001
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:
쐌 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.
쐌 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 pro-
vided that the noise eliminates when the vehicle is
running.
쐌 When stopping with service brake and/or park-
ing 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
released, there is no abnormal function in the sys-
tem.
쐌 There may be a little vibration around the steer-
ing devices when turning steering wheel at
standstill, 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, i.e., road surface
and tire surface, engine speed and turning speed
of steering wheel, fluid temperature and braking
condition.
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-104

Relief valve emits operating sound when steering wheel
is completely turned in either direction. (Don’t keep this Normal
Hiss noise (continuous) condition over 5 seconds.)
While engine is running.
Relief valve emits operating sound when steering wheel Defective
is not turned. This means that the relief valve is faulty. Replace oil pump.
Check clearance.
Correct if necessary.
Interference with adjacent parts
<Ref. to PS-90 INSPECTION,
Pipe Assembly.>
Loosened installation of oil pump, oil tank, pump bracket,
Rattling noise (intermittent) Retighten.
gearbox or crossmember
Loosened installation of oil pump pulley or other pulley(s) Retighten.
Loosened linkage or play of steering or suspension Loos-
Retighten or replace.
ened tightening of joint or steering column
Replace bad parts of the gear-
Sound generates from the inside of gearbox or oil pump.
box or oil pump.
Knocking Excessive backlash
When turning steering wheel in Adjust and retighten.
Loosened lock nut for adjusting backlash
both direction with small angle
repeatedly at engine ON or OFF. Loosened tightening or play of tie-rod, tie-rod end Retighten or replace.
Inspect and retighten fluid line
Vane pump aeration connection.
Grinding noise (continuous) Refill fluid and vent air.
While engine is running. Vane pump seizing Replace oil pump.
Pulley bearing seizing of oil pump Replace oil pump.
Folded hose, flat pipe Replace.
Maladjustment of 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 replace.
Fix wrong part causing aeration.
Fluid aeration
Replace fluid and vent air.
Damaged pipe of gearbox Replace pipe.
Sizzling noise (continuous)
Abnormal inside of hose or pipe
While engine is running. Rectify or replace.
Flat hose or pipe
Abnormal inside of oil tank Replace.
Removed oil tank cap Install cap.
Whistle (continuous) Replace bad parts of gearbox or
Abnormal pipe of gearbox or abnormal inside of hose
While engine is running. hose.
Loosened installation of oil pump, oil pump bracket Retighten.
Whine or growl (continuous or Replace oil pump, hose, if the
intermittent) Abnormal inside of oil pump, hose noise can be heard when run-
While engine is running with/ ning as well as stand still.
without steering turned. Torque converter growl, air conditioner compression Remove power steering pulley
growl belt and confirm.
Abnormal inside of gearbox Replace bad parts of gearbox.
Creaking noise (intermittent)
Abnormal bearing for steering shaft Apply grease or replace.
While engine is running with
steering turned. Generates when turning steering wheel with brake (ser- If the noise goes off when brake
vice or parking) applied. is released, it is normal.
Too low engine speed at start Adjust and instruct customers.
Fix wrong part.
Vibration Vane pump aeration
Vent air.
While engine is running with/
without steering turned. Replace oil pump, bad parts of
Damaged valve in oil pump, gearbox
gearbox.
Looseness of play of steering, suspension parts Retighten.
PS-105
2. MEASUREMENT OF STEERING EFFORT S601257A1002

1 CHECK STEERING EFFORT. Is the steering effort 29.4 N Go to step 2. Adjustment back-
1) Stop the vehicle on a concrete road. (3.0 kgf, 6.6 lb) or less? lash.
2) Start the engine.
3) Idle the engine.
4) Install spring scale on the steering wheel.
5) Pull 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
characteristic of oil pump and is not a prob-
lem.
2 CHECK STEERING EFFORT. Is the steering effort 29.4 N Go to step 3. Adjustment.
1) Stop the engine. (3.0 kgf, 6.6 lb) or less?
2) Pull spring scale at an right angle to the
steering wheel, and measure both right and
left steering wheel effort.
3 CHECK STEERING WHEEL EFFORT. Is the maximum force Go to step 4. Check, adjust and
1) Remove universal joint. steering wheel effort 2.26 N replace if neces-
2) Measure steering wheel effort. (0.23 kgf, 0.51 lb) or less? sary.
4 CHECK STEERING WHEEL EFFORT. Is the fluctuation width 1.08 Go to step 5. Check, adjust and
Measure steering wheel effort. N (0.11 kgf, 0.24 lb) or replace if neces-
less? sary.
5 CHECK UNIVERSAL JOINT. Is the folding torque 8.43 N Go to step 6. Replace with new
Measure folding torque of the joint (short (0.86 kgf, 1.90 lb) or less? one.
yoke). <Ref. to PS-29 INSPECTION, Univer-
sal Joint.>
6 CHECK UNIVERSAL JOINT. Is the folding torque 5.49 N Go to step 7. Replace with new
Measure folding torque of the joint (long (0.56 kgf, 1.23 lb) or less? one.
yoke). <Ref. to PS-29 INSPECTION, Univer-
sal Joint.>
7 CHECK FRONT WHEEL. Are front wheels for Inspect, readjust Go to step 8.
unsteady revolution or rat- and replace if
tling and brake for drag- necessary.
ging?
8 CHECK TIE-ROD ENDS. Are tie-rod ends of suspen- Inspect and Go to step 9.
Remove the tie-rod ends. sion for unsteady revolution replace if neces-
or ratting? sary.
9 CHECK BALL JOINT. Are ball joints of suspen- Inspect and Go to step 10.
sion for unsteady revolution replace if neces-
or ratting? sary.
10 CHECK GEARBOX. Is rotating resistance is Go to step 11. Readjust
Measure rotating of gearbox. <Ref. to PS-50 11.18 N (1.14 kgf, 2.51 lb) backlash, and if
TURNING RESISTANCE OF GEAR BOX, or less around center posi- ineffective,
INSPECTION, Steering Gearbox.> tion and 15.79 N (1.61 kgf, replace bad parts.
3.55 lb) or less in all posi-
tions within 20% difference
between clockwise and
counterclockwise?
11 CHECK GEARBOX. Is rotating resistance is 304 Steering effort is Readjust
Measure sliding of gearbox. <Ref. to PS-49 N (31 kgf, 68 lb) or less normal. backlash, and if
SERVICE LIMIT, INSPECTION, Steering with 20% difference ineffective,
Gearbox.> between left and right replace bad parts.
direction?
PS-106
CHASSIS SECTION

SUBARU vehicles.
ine parts.

G8050GE5
ABS (DIAGNOSTICS)
ABS
Page
5. Control Module I/O Signal.........................................................................14
8. Inspection Mode ........................................................................................21
10. ABS Warning Light Illumination Pattern....................................................23
11. List of Diagnostics Trouble Code ..............................................................24
12. Diagnostics Chart with Diagnosis Connector............................................28
13. Diagnostics Chart with Subaru Select Monitor .........................................90
14. General Diagnostics Table ......................................................................174
ABS (DIAGNOSTICS)
1. Basic Diagnostic Procedure S006501
1. WITHOUT SUBARU SELECT MONITOR S006501E4501
CAUTION:
Remove foreign matter (dust, water, etc.) from the ABSCM&H/U connector during removal and
installation.
NOTE:
쐌 To check harness for broken wires or short circuits, shake it while holding it or the connector.
쐌 When ABS warning light illuminates, read and record trouble code indicated by ABS warning light.
1 CHECK PRE-INSPECTION. Is unit that might influence Go to step 2. Repair or replace
1) Ask the customer when and how the the ABS problem normal? each unit.
trouble occurred using interview checklist.
<Ref. to ABS-6, Check List for Interview.>
2) Before performing diagnosis, inspect unit
which might influence the ABS problem. <Ref.
to ABS-9, INSPECTION, General Descrip-
tion.>
2 CHECK INDICATION OF TROUBLE CODE. Is trouble code readable? Go to step 3. Inspect using
Calling up trouble code. <Ref. to ABS-20, diagnostic chart
Read Diagnostic Trouble Code.> for ABS warning
light failure.<Ref.
to ABS-28, Diag-
nostics Chart with
Diagnosis Con-
nector.>
NOTE:
Call up trouble
code again after
inspecting ABS
warning light.
<Ref. to ABS-20,
Read Diagnostic
Trouble Code.>
3 CHECK TROUBLE CODE. Is only the start code Go to step 4. Go to step 5.
NOTE: issued?
Record all trouble codes.
4 PERFORM THE GENERAL DIAGNOSTICS. Is only the start code Complete the Go to step 5.
1) Inspect using “General Diagnostics Table”. issued? diagnosis.
<Ref. to ABS-174, General Diagnostics
Table.>
ABS-22, WITHOUT SUBARU SELECT
MONITOR, OPERATION, Clear Memory
Mode.>
ABS-21, Inspection Mode.>
Calling up the trouble code. <Ref. to ABS-20,
Read Diagnostic Trouble Code.>
ABS-2
ABS (DIAGNOSTICS)

5 PERFORM THE DIAGNOSIS. Is only the start code Complete the Inspect using
1) Inspect using “Diagnostics Chart with Diag- issued? diagnosis. “Diagnostics Chart
nostic Connector”.<Ref. to ABS-28, Diagnos- with Diagnostic
tics Chart with Diagnosis Connector.> Connector”. <Ref.
NOTE: to ABS-28, Diag-
For trouble code list, refer to “List of Diagnos- nostics Chart with
tics Trouble Code”.<Ref. to ABS-24, WITH- Diagnosis Con-
OUT SUBARU SELECT MONITOR, LIST, List nector.>
of Diagnostics Trouble Code.>
2) Repair trouble cause.
ABS-22, WITHOUT SUBARU SELECT
MONITOR, OPERATION, Clear Memory
Mode.>
5) Calling up the trouble code. <Ref. to ABS-
20, Read Diagnostic Trouble Code.>
ABS-3
ABS (DIAGNOSTICS)
2. WITH SUBARU SELECT MONITOR S006501E4502
CAUTION:
Remove foreign matter (dust, water, etc.) from the ABSCM&H/U connector during removal and
installation.
NOTE:
쐌 To check harness for broken wires or short circuits, shake it while holding it or the connector.
쐌 Check list for interview. <Ref. to ABS-26, WITH SUBARU SELECT MONITOR, LIST, List of Diagnostics
Trouble Code.>
1 CHECK PRE-INSPECTION. Is unit that might influence Go to step 2. Repair or replace
1) Ask the customer when and how the the ABS problem normal? each unit.
trouble occurred using interview checklist.
<Ref. to ABS-6, Check List for Interview.>
2) Before performing diagnosis, inspect unit
which might influence the ABS problem. <Ref.
to ABS-9, INSPECTION, General Descrip-
tion.>
2 CHECK INDICATION OF TROUBLE CODE Is the corresponding Go to step 3. Go to step 4.
DISPLAY. trouble encoding?
2) Connect the SUBARU SELECT MONITOR
to data link connector.
3) Turn ignition switch to ON and SUBARU
SELECT MONITOR to ON.
NOTE:
If the communication function of the select
monitor cannot be executed normally, check
the communication circuit. <Ref. to ABS-90,
COMMUNICATION FOR INITIALIZING
IMPOSSIBLE , Diagnostics Chart with Subaru
Select Monitor.>
4) Read diagnostic trouble code. <Ref. to
ABS-18, OPERATION, Subaru Select Moni-
tor.>
5) Record all trouble codes and frame data.
3 PERFORM THE GENERAL DIAGNOSTICS. Is no trouble code desig- Complete the Go to step 4.
1) Inspect using “General Diagnostics Table”. nated and ABS warning diagnosis.
<Ref. to ABS-174, General Diagnostics light goes out after turning
Table.> on?
ABS-19, CLEAR MEMORY MODE,
OPERATION, Subaru Select Monitor.>
18, READ DIAGNOSTIC TROUBLE CODE,
ABS-4
ABS (DIAGNOSTICS)

4 PERFORM THE DIAGNOSIS. Is no trouble code desig- Complete the Inspect using
1) Inspect using “Diagnostics Chart with nated and does ABS warn- diagnosis. “Diagnostics Chart
Subaru Select Monitor”.<Ref. to ABS-90, ing light go out after turning with Subaru
Diagnostics Chart with Subaru Select Moni- on? Select Monitor”.
tor.> <Ref. to ABS-90,
NOTE: Diagnostics Chart
For trouble code list, refer to “List of Diagnos- with Subaru
tics Trouble Code”.<Ref. to ABS-24, WITH- Select Monitor.>
OUT SUBARU SELECT MONITOR, LIST, List
of Diagnostics Trouble Code.>
2) Repair trouble cause.
ABS-19, CLEAR MEMORY MODE,
18, READ DIAGNOSTIC TROUBLE CODE,
ABS-5
ABS (DIAGNOSTICS)
A: CHECK S006502A04
Check the following items about the vehicle’s state.

1. STATE OF ABS WARNING LIGHT S006502A0401
ABS warning light 쏔 Always

comes on. 쏔 Sometimes
쏔 Only once
쏔 Does not come on
쐌 When / how long does it come on?:
Ignition key position 쏔 LOCK
쏔 ACC
쏔 ON (before starting engine)
쏔 START
쏔 On after starting (Engine is running)
쏔 On after starting (Engine is stop)
Timing 쏔 Immediately after ignition is ON.
쏔 Immediately after ignition starts.
쏔 When advancing km/h to km/h
MPH to MPH
쏔 While traveling at a constant speed km/h MPH
쏔 When decelerating km/h to km/h
MPH to MPH
쏔When turning to right Steering angle : deg
Steering time : sec
쏔 When turning to left Steering angle : deg
Steering time : sec
쏔 When moving other electrical parts
쐌 Parts name :
쐌 Operating condition :
ABS-6
ABS (DIAGNOSTICS)
2. SYMPTOMS S006502A0402
ABS operating con- 쏔 Performs no work.

dition 쏔 Operates only when abruptly applying brakes. Vehicle speed : km/h
MPH
쐌 How to step on brake pedal :
a) Operating time : sec
b) Operating noise : 쏔 Produce / 쏔 Does not produce
쐌 What kind of noise? 쏔 Knock
쏔 Gong gong
쏔 Bong
쏔 Buzz
쏔 Gong gong buzz
쏔 Others :
c) Reaction force of brake pedal
쏔 Stick
쏔 Press down once with a clunk
쏔 Press and released
쏔 Others :
Behavior of vehicle a) Directional stability cannot be obtained or steering arm refuses to work when applying brakes :
쏔 Yes / 쏔 No
쐌 When : 쏔 Vehicle turns to right
쏔 Vehicle turns to left
쏔 Spins
쏔 Others :
b) Directional stability cannot be obtained or steering arm refuses to work when accelerating :
쏔 Yes / 쏔 No
쐌 When : 쏔 Vehicle turns to right
쏔 Vehicle turns to left
쏔 Spins
쏔 Others :
c) Brakes are out of order : 쏔 Yes / 쏔 No
쐌 What : 쏔 Braking distance is long
쏔 Brakes lock or drag
쏔 Pedal stroke is long
쏔 Pedal sticks
쏔 Others :
d) Poor acceleration : 쏔 Yes / 쏔 No
쐌 What : 쏔 Fails to accelerate
쏔 Engine stalls
쏔 Others :
e) Occurrence of vibration : 쏔 Yes / 쏔 No
쐌 Where
쐌 What kind :
f) Occurrence of abnormal noise : 쏔 Yes / 쏔 No
쐌 Where
쐌 What kind :
g) Occurrence of other phenomena : 쏔 Yes / 쏔 No
쐌 What kind :
ABS-7
ABS (DIAGNOSTICS)
3. CONDITIONS UNDER WHICH TROUBLE OCCURS S006502A0403
Environment a) Weather 쏔 Fine

쏔 Cloudy
쏔 Rainy
쏔 Snowy
쏔 Various/Others :
b) Ambient temperature °F (°C)
c) Road 쏔 Urban area
쏔 Suburbs
쏔 Highway
쏔 General road
쏔 Ascending slope
쏔 Descending slope
쏔 Paved road
쏔 Gravel road
쏔 Muddy road
쏔 Sandy place
쏔 Others :
d) Road surface 쏔 Dry
쏔 Wet
쏔 New-fallen snow
쏔 Compressed snow
쏔 Frozen slope
쏔 Others :
Condition a) Brakes Deceleration : g
쏔 Continuous / 쏔 Intermittent
b) Accelerator Acceleration : g
쏔 Continuous / 쏔 Intermittent
c) Vehicle speed km/h MPH
쏔 Advancing
쏔 Accelerating
쏔 Reducing speed
쏔 Low speed
쏔 Turning
쏔 Others :
d) Tire inflation pressure Front RH tire : kPa
Front LH tire : kPa
Rear RH tire : kPa
Rear LH tire : kPa
e) Degree of wear Front RH tire :
Front LH tire :
Rear RH tire :
Rear LH tire :
f) Genuine parts are used. : 쏔 Yes / 쏔 No
g) Chain is passed around tires. : 쏔 Yes / 쏔 No
h) T tire is used. : 쏔 Yes / 쏔 No
i) Condition of suspension alignment :
j) Loading state :
k) Repair parts are used. : 쏔 Yes / 쏔 No
쐌 What :
l) Others :
ABS-8
GENERAL DESCRIPTION
ABS (DIAGNOSTICS)
3. General Description S006001 B: INSPECTION S006001A10
Before performing diagnostics, check the following
items which might affect ABS problems:
1. SUPPLEMENTAL RESTRAINT SYSTEM
“AIRBAG” S006001A0301 1. BATTERY S006001A1001
Airbag system wiring harness is routed near the Measure battery voltage and specific gravity of
ABS sensor, ABS control module and hydraulic electrolyte.
control unit. Standard voltage: 12 V, or more
CAUTION: Specific gravity: Above 1.260
nectors are colored yellow. Do not use electri- 2. BRAKE FLUID S006001A1002
cal test equipment on these circuit. 1) Check brake fluid level.

쐌 Be careful not to damage Airbag system wir- 2) Check brake fluid leakage.
ing harness when servicing the ABS sensor,
ABS control module and hydraulic control unit. 3. HYDRAULIC UNIT S006001A1006
Check the hydraulic unit.

쐌 With brake tester <Ref. to ABS-9, CHECKING
THE HYDRAULIC UNIT ABS OPERATION WITH
BRAKE TESTER, INSPECTION, ABS Control
Module and Hydraulic Control Unit (ABSCM&H/
U).>
쐌 Without brake tester <Ref. to ABS-8, CHECK-
ING THE HYDRAULIC UNIT ABS OPERATION
BY PRESSURE GAUGE, INSPECTION, ABS
Control Module and Hydraulic Control Unit
(ABSCM&H/U).>
4. BRAKE DRAG S006001A1003
Check brake drag.

5. BRAKE PAD AND ROTOR S006001A1004
Check brake pad and rotor.

쐌 Front <Ref. to BR-21, INSPECTION, Front
Brake Pad.> and <Ref. to BR-22, INSPECTION,
Front Disc Rotor.>
쐌 Rear <Ref. to BR-26, INSPECTION, Rear Brake
Pad.> and <Ref. to BR-28, INSPECTION, Rear
Disc Rotor.> or <Ref. to BR-33, INSPECTION,
Rear Drum Brake Shoe.> and <Ref. to BR-34,
INSPECTION, Rear Drum Brake Drum.>
6. TIRE S006001A1005
Check tire specifications, tire wear and air pres-

sure. <Ref. to WT-2, SPECIFICATIONS, General
Description.>
ABS-9
GENERAL DESCRIPTION
ABS (DIAGNOSTICS)

B2M3876
B2M3877
TOOL NAME REMARKS

Circuit tester Used for measuring resistance, voltage and ampere.
Oscilloscope Used for measuring sensor.
ABS-10
GENERAL DESCRIPTION
ABS (DIAGNOSTICS)
MEMO:
ABS-11
ABS (DIAGNOSTICS)
S4M0478A
(1) ABS control module and hydrau- (6) Automatic transmission control (12) G sensor
lic control unit (ABSCM&H/U) module (13) Stop light switch
(2) Proportioning valve (7) Front tone wheel (14) Master cylinder
(3) Diagnosis connector (8) Front ABS sensor
(4) ABS warning light (9) Rear tone wheel
(5) Data link connector (for (10) Rear ABS sensor
SUBARU select monitor) (11) Wheel cylinder
ABS-12
ABS (DIAGNOSTICS)
S2M2018B
B4M1226B
B4M2285A
H4M1328B
B4M0646H B4M0231E
S4M0056A
ABS-13
CONTROL MODULE I/O SIGNAL
ABS (DIAGNOSTICS)
5. Control Module I/O Signal S006524
B4M1228A
NOTE:
쐌 The terminal numbers in the ABS control module and hydraulic control unit connector are as shown in
the figure.
쐌 When the connector is removed from the ABSCM&H/U, the connector switch closes the circuit between
terminal No. 21 and No. 23. The ABS warning light illuminates.
ABS-14
ABS (DIAGNOSTICS)
Terminal No. Input/Output signal

Contents
(+)—(−) Measured value and measuring conditions
Front left wheel 9—10
ABS sensor*2 Front right wheel 11—12 0.12 — 1 V
(Wheel speed sensor) Rear left wheel 7—8 (When it is 20 Hz.)
Rear right wheel 13—15
Valve relay power supply 24—23 10 — 15 V
Motor relay power supply 25—23 10 — 15 V
Power supply 30—28 4.75 — 5.25 V
G sensor*2 Ground 28 —
Output 6—28 2.3±0.2 V when vehicle is in horizontal position.
Less than 1.5 V when the stop light is OFF and, 10 — 15 V
Stop light switch*1 2—23
when the stop light is ON.
Less than 1.5 V during 1.5 seconds when ignition switch is
ABS warning light*2 21—23
ON, and 10 — 15 V after 1.5 seconds.
AT ABS signal*2 Less than 1.5 V when the ABS control still operates and
31—23
(AT model only) more than 5.5 V when ABS does not operate.
Less than 1.5 V when the ABS control still operates and
ABS operation signal monitor*2 3—23
more than 5.5 V when ABS does not operate.
Data is received. 20—23 Less than 1.5 V when no data is received.
Select monitor*2
Data is sent. 5—23 4.75 — 5.25 V when no data is sent.
ABS diagnosis connec- Terminal No. 3 29—23 10 — 15 V when ignition switch is ON.
tor*2 Terminal No. 6 4—23 10 — 15 V when ignition switch is ON.
Power supply*1 1—23 10 — 15 V when ignition switch is ON.
Grounding line 23 —
Grounding line 26 —
*1: Measure the I/O signal voltage after removing the connector from the ABSCM&H/U terminal.
*2: Measure the I/O signal voltage at connector (B62) and (R48) of LHD model or (B100) of RHD model.
ABS-15
ABS (DIAGNOSTICS)
B: SCHEMATIC S006524A21
B4M2226
(1) ABS control module and hydrau- (9) Front right outlet solenoid valve (17) ABS warning light
lic control unit (ABSCM&H/U) (10) Rear left inlet solenoid valve (18) Stop light switch
(2) ABS control module area (11) Rear left outlet solenoid valve (19) Stop light
(3) Valve relay (12) Rear right inlet solenoid valve (20) G sensor
(4) Motor relay (13) Rear right outlet solenoid valve (21) Front left ABS sensor
(5) Motor (14) Transmission control module (22) Front right ABS sensor
(6) Front left inlet solenoid valve (only AT model) (23) Rear left ABS sensor
(7) Front left outlet solenoid valve (15) Diagnosis connector (24) Rear right ABS sensor
(8) Front right inlet solenoid valve (16) Data link connector
ABS-16
ABS (DIAGNOSTICS)
C: WAVEFORM S006524G79
B4M2526A
ABS-17
ABS (DIAGNOSTICS)

5) Turn ignition switch to ON (engine OFF) and
Subaru Select Monitor switch to ON.
1. READ DIAGNOSTIC TROUBLE CODE

S006503A1601
S2M0288D
(1) Power switch

the {Each System Check} and press the [YES] key.
S2M0285 7) On the ⰆSystem Selection MenuⰇ display
screen, select the {Brake Control System} and
2) Connect diagnosis cable to Subaru Select press the [YES] key.
Monitor. 8) Press the [YES] key after displayed the infor-
3) Insert cartridge into Subaru Select Monitor. mation of engine type.
<Ref. to ABS-10, SPECIAL TOOLS, PREPARA- 9) On the ⰆABS DiagnosisⰇ display screen,
TION TOOL, General Description.> select the {Diagnostic Code(s) Display} and press
the [YES] key.
10) On the ⰆDiagnostic Code(s) DisplayⰇ display
screen, select the {Current Diagnostic Code(s)} or
{History Diagnostic Code(s)} and press the [YES]
key.
NOTE:
쐌 For detailed operation procedure, refer to the
SUBARU SELECT MONITOR OPERATION
MANUAL.
쐌 For detailed concerning diagnostic trouble
S2M0286 codes, refer to the LIST OF DIAGNOSTICS
TROUBLE CODE. <Ref. to ABS-24, List of Diag-
4) Connect Subaru Select Monitor to data link nostics Trouble Code.>
connector.
side).
S2M2157

nector.
ABS-18
ABS (DIAGNOSTICS)
2. READ CURRENT DATA S006503A1602
1) On the ⰆMain MenuⰇ display screen, select the {Each System Check} and press the ⰆYESⰇ key.
2) On the ⰆSystem Selection MenuⰇ display screen, select the {Brake Control System} and press the
ⰆYESⰇ key.
3) Press the ⰆYESⰇ key after displayed the information of ABS type.
4) On the ⰆBrake Control DiagnosisⰇ display screen, select the {Current Data Display & Save} and press
the ⰆYESⰇ key.
5) On the ⰆData Display MenuⰇ display screen, select the {Data Display} and press the ⰆYESⰇ key.
6) Using the scroll key, move the display screen up or down until the desired data is shown.
쐌 A list of the support data is shown in the following table.
Display screen Contents to be monitored Unit of measure
Wheel speed detected by the Front Right ABS sensor is dis-
FR Wheel Speed km/h or MPH
played
Wheel speed detected by the Front Left ABS sensor is dis-
FL Wheel Speed km/h or MPH
played
Wheel speed detected by the Rear Right ABS sensor is dis-
RR Wheel Speed km/h or MPH
played
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.
G sensor output Signal V
It appears on the select monitor display in volts.
Valve Relay Signal Valve Relay Signal ON or OFF
Motor Relay Signal Motor Relay Signal ON or OFF
ABS Signal to TCM ABS operation signal from ABS control module to TCM ON or OFF
ABS Warning Lamp ON operation of the ABS warning light is displayed. ON or OFF
Motor Relay Monitor Operating condition of the motor relay is displayed. High or Low
Valve Relay Monitor Operating condition of the valve relay is displayed. ON or OFF
CCM Signal ABS operation signal from ABS control module to TCM ON or OFF
NOTE:
For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
3. CLEAR MEMORY MODE S006503A1603
1) On the ⰆMain MenuⰇ display screen, select the {2. Each System Check} and press the ⰆYESⰇ key.
2) On the ⰆSystem Select MenuⰇ display screen, select {Brake System} and press the ⰆYESⰇ key.
3) Press the ⰆYESⰇ key after displayed the information of engine type.
4) On the ⰆBrake Control DiagnosisⰇ display screen, select the {Clear Memory} and press the ⰆYESⰇ
key.
5) When the “Done” and “turn ignition switch OFF” are shown on the display screen, turn the Subaru Select
Monitor and ignition switch to OFF.
NOTE:
ABS-19
ABS (DIAGNOSTICS)
A: OPERATION S006508A16 2) Turn ignition switch OFF.

3) Connect diagnosis connector terminal 6 to
1. WITHOUT SUBARU SELECT MONITOR diagnosis terminal.
S006508A1602
1) Take out diagnosis connector from side of driv- 5) ABS warning light is set in the diagnostic mode
er’s seat heater unit. and blinks to identify trouble code.
B4M0231E
6) After the start code (11) is shown, the trouble codes will be shown in order of the last information first.
These repeat for a maximum of 3 minutes.
NOTE:
쐌 When there are no trouble codes in memory, only the start code (11) is shown.
쐌 When on-board diagnosis of the ABS control module detects a problem, the information (up to a maxi-
mum of three) will be stored in the EEPROM as a trouble code. When there are more than three, the most
recent three will be stored. (Stored codes will stay in memory until they are cleared.)
B4M0232A
Refer to SUBARU SELECT MONITOR for information about how to obtain and understand trouble codes.
<Ref. to ABS-18, Subaru Select Monitor.>
ABS-20
INSPECTION MODE
ABS (DIAGNOSTICS)
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)
1. WITHOUT SUBARU SELECT MONITOR

S006513A1602
1) After calling up a trouble code, disconnect diag-

nosis connector terminal 6 from diagnosis terminal.
B4M0231E
2) Repeat 3 times within approx. 12 seconds; connecting and disconnecting terminal 6 and diagnosis ter-
minal for at least 0.2 seconds each time.
B4M0233G
NOTE:
After diagnostics is completed, make sure to clear memory. Make sure only start code (11) is shown after
memory is cleared.
Refer to SUBARU SELECT MONITOR for information about how to clear trouble codes. <Ref. to ABS-18,
ABS-22
ABS WARNING LIGHT ILLUMINATION PATTERN
ABS (DIAGNOSTICS)
10. ABS Warning Light Illumination Pattern S006581
B4M0781A
1) When the ABS warning light does not illuminate in accordance with this illumination pattern, there must
be an electrical malfunction.
2) When the ABS warning light remains constantly OFF, repair the ABS warning light circuit or diagnosis
circuit. <Ref. to ABS-28, Diagnostics Chart with Diagnosis Connector.>
NOTE:
Even though the ABS warning light does not go out 1.5 seconds after it illuminates, the ABS system oper-
ates normally when the warning light goes out while driving at approximately 12 km/h (7 MPH). However,
the Anti-lock brakes do not work while the ABS warning light is illuminated.
ABS-23
LIST OF DIAGNOSTICS TROUBLE CODE
ABS (DIAGNOSTICS)
11. List of Diagnostics Trouble Code S006511
A: LIST S006511A12
Trouble
Contents of diagnosis Index No.
code
Start code
11 쐌 Trouble code is shown after start code. —
쐌 Only start code is shown in normal condition.
<Ref. to ABS-42, TROUBLE CODE 21— ABNORMAL ABS SEN-
21 Front right ABS sensor SOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH) (FRONT
RH) —, Diagnostics Chart with Diagnosis Connector.>
<Ref. to ABS-42, TROUBLE CODE 23 — ABNORMAL ABS SEN-
23 Front left ABS sensor SOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH) (FRONT
Abnormal ABS sensor LH) —, Diagnostics Chart with Diagnosis Connector.>
(Open circuit or input
voltage too high) <Ref. to ABS-42, TROUBLE CODE 25 — ABNORMAL ABS SEN-
25 Rear right ABS sensor SOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH) (REAR
RH) —, Diagnostics Chart with Diagnosis Connector.>
27 Rear left ABS sensor SOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH) (REAR
LH) —, Diagnostics Chart with Diagnosis Connector.>
22 Front right ABS sensor SOR (FRONT RH) —, Diagnostics Chart with Diagnosis Connec-
tor.>
24 Front left ABS sensor SOR (FRONT LH) —, Diagnostics Chart with Diagnosis Connec-
tor.>
Abnormal ABS sensor <Ref. to ABS-48, TROUBLE CODE 26 — ABNORMAL ABS SEN-
26 (Abnormal ABS sensor Rear right ABS sensor SOR (REAR RH) —, Diagnostics Chart with Diagnosis Connec-
signal) tor.>
28 Rear left ABS sensor SOR (REAR LH) —, Diagnostics Chart with Diagnosis Connec-
tor.>
29 Any one of four SOR SIGNAL (ANY ONE OF FOUR) —, Diagnostics Chart with
Diagnosis Connector.>
ABS-24
ABS (DIAGNOSTICS)
Trouble
Contents of diagnosis Index No.
code
<Ref. to ABS-62, TROUBLE CODE 31 — ABNORMAL INLET
31 Front right inlet valve SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (FRONT RH) —,
Diagnostics Chart with Diagnosis Connector.>
<Ref. to ABS-66, TROUBLE CODE 32 — ABNORMAL OUTLET
32 Front right outlet valve SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (FRONT RH) —,
33 Front left inlet valve SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (FRONT LH) —,
34 Abnormal solenoid Front left outlet valve SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (FRONT LH) —,
valve circuit(s) in ABS Diagnostics Chart with Diagnosis Connector.>
control module and <Ref. to ABS-62, TROUBLE CODE 35 — ABNORMAL INLET
35 hydraulic unit Rear right inlet valve SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (REAR RH) —,
36 Rear right outlet valve SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (REAR RH) —,
37 Rear left inlet valve SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (REAR LH) —,
38 Rear left outlet valve SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (REAR LH) —,
<Ref. to ABS-70, TROUBLE CODE 41 — ABNORMAL ABS CON-
41 Abnormal ABS control module
TROL MODULE —, Diagnostics Chart with Diagnosis Connector.>
<Ref. to ABS-72, TROUBLE CODE 42 — SOURCE VOLTAGE IS
42 Source voltage is abnormal.
ABNORMAL. —, Diagnostics Chart with Diagnosis Connector.>
<Ref. to ABS-74, TROUBLE CODE 44 — A COMBINATION OF AT
44 A combination of AT control abnormal CONTROL ABNORMAL —, Diagnostics Chart with Diagnosis Con-
nector.>
<Ref. to ABS-76, TROUBLE CODE 51 — ABNORMAL VALVE
51 Abnormal valve relay
RELAY —, Diagnostics Chart with Diagnosis Connector.>
<Ref. to ABS-78, TROUBLE CODE 52 — ABNORMAL MOTOR
52 Abnormal motor and/or motor relay AND/OR MOTOR RELAY —, Diagnostics Chart with Diagnosis
Connector.>
<Ref. to ABS-82, TROUBLE CODE 54 — ABNORMAL STOP
54 Abnormal stop light switch
LIGHT SWITCH —, Diagnostics Chart with Diagnosis Connector.>
<Ref. to ABS-84, TROUBLE CODE 56 — ABNORMAL G SEN-
56 Abnormal G sensor output voltage SOR OUTPUT VOLTAGE —, Diagnostics Chart with Diagnosis
Connector.>
ABS-25
ABS (DIAGNOSTICS)
Code Display screen Contents of diagnosis Index No.

Communication for ini- Select monitor commu- <Ref. to ABS-90, COMMUNICATION FOR INITIALIZING IMPOS-
—
tializing impossible nication failure SIBLE , Diagnostics Chart with Subaru Select Monitor.>
Although no trouble
code appears on the
<Ref. to ABS-94, NO TROUBLE CODE, Diagnostics Chart with
— No trouble code select monitor display,
the ABS warning light
remains on.
Open or short circuit in Open or short circuit in <Ref. to ABS-98, TROUBLE CODE 21 — OPEN OR SHORT CIR-
21 front right ABS sensor front right ABS sensor CUIT IN FRONT RIGHT ABS SENSOR CIRCUIT —, Diagnostics
circuit circuit Chart with Subaru Select Monitor.>
<Ref. to ABS-106, TROUBLE CODE 22 — FRONT RIGHT
Front right ABS sensor Front right ABS sensor
22 ABNORMAL ABS SENSOR SIGNAL —, Diagnostics Chart with
abnormal signal abnormal signal
23 front left ABS sensor front left ABS sensor CUIT IN FRONT LEFT ABS SENSOR CIRCUIT —, Diagnostics
<Ref. to ABS-106, TROUBLE CODE 24 — FRONT LEFT ABNOR-
Front left ABS sensor Front left ABS sensor
24 MAL ABS SENSOR SIGNAL —, Diagnostics Chart with Subaru
Select Monitor.>
25 rear right ABS sensor rear right ABS sensor CUIT IN REAR RIGHT ABS SENSOR CIRCUIT —, Diagnostics
<Ref. to ABS-106, TROUBLE CODE 26 — REAR RIGHT ABNOR-
Rear right ABS sensor Rear right ABS sensor
Select Monitor.>
27 rear left ABS sensor rear left ABS sensor CUIT IN REAR LEFT ABS SENSOR CIRCUIT —, Diagnostics
<Ref. to ABS-106, TROUBLE CODE 28 — REAR LEFT ABNOR-
Rear left ABS sensor Rear left ABS sensor
Select Monitor.>
Abnormal ABS sensor Abnormal ABS sensor <Ref. to ABS-114, TROUBLE CODE 29 — ABNORMAL ABS SEN-
29 signal on any one of signal on any one of SOR SIGNAL ON ANY ONE OF FOUR SENSOR —, Diagnostics
four sensor four Chart with Subaru Select Monitor.>
<Ref. to ABS-120, TROUBLE CODE 31 — FRONT RIGHT INLET
Front right inlet valve Front right inlet valve
31 VALVE MALFUNCTION —, Diagnostics Chart with Subaru Select
malfunction malfunction
Monitor.>
<Ref. to ABS-124, TROUBLE CODE 32 — FRONT RIGHT OUT-
Front right outlet valve Front right outlet valve
32 LET VALVE MALFUNCTION —, Diagnostics Chart with Subaru
Select Monitor.>
<Ref. to ABS-120, TROUBLE CODE 33 — FRONT LEFT INLET
Front left inlet valve Front left inlet valve
Monitor.>
<Ref. to ABS-124, TROUBLE CODE 34 — FRONT LEFT OUTLET
Front left outlet valve Front left outlet valve
Monitor.>
<Ref. to ABS-120, TROUBLE CODE 35 — REAR RIGHT INLET
Rear right inlet valve Rear right inlet valve
Monitor.>
<Ref. to ABS-124, TROUBLE CODE 36 — REAR RIGHT OUTLET
Rear right outlet valve Rear right outlet valve
Monitor.>
<Ref. to ABS-120, TROUBLE CODE 37 — REAR LEFT INLET
Rear left inlet valve Rear left inlet valve
Monitor.>
ABS-26
ABS (DIAGNOSTICS)
Code Display screen Contents of diagnosis Index No.

<Ref. to ABS-124, TROUBLE CODE 38 — REAR LEFT OUTLET
Rear left outlet valve Rear left outlet valve
Monitor.>
ABS control module <Ref. to ABS-128, TROUBLE CODE 41 — ABS CONTROL MOD-
ABS control module
41 and hydraulic control ULE MALFUNCTION —, Diagnostics Chart with Subaru Select
malfunction
unit malfunction Monitor.>
<Ref. to ABS-130, TROUBLE CODE 42 — POWER SUPPLY
Power supply voltage Power supply voltage
42 VOLTAGE TOO LOW —, Diagnostics Chart with Subaru Select
too low too low
Monitor.>
<Ref. to ABS-132, TROUBLE CODE 42 — POWER SUPPLY
Power supply voltage Power supply voltage
42 VOLTAGE TOO HIGH —, Diagnostics Chart with Subaru Select
too high too high
Monitor.>
<Ref. to ABS-134, TROUBLE CODE 44 — ABS-AT CONTROL
ABS-AT control (Non ABS-AT control (Non
44 (NON CONTROLLED) —, Diagnostics Chart with Subaru Select
Controlled) Controlled)
Monitor.>
<Ref. to ABS-136, TROUBLE CODE 44 — ABS-AT CONTROL
ABS-AT control (Con- ABS-AT control (Con-
44 (CONTROLLED) —, Diagnostics Chart with Subaru Select Moni-
trolled) trolled)
tor.>
<Ref. to ABS-138, TROUBLE CODE 51 — VALVE RELAY MAL-
51 Valve relay malfunction Valve relay malfunction
FUNCTION —, Diagnostics Chart with Subaru Select Monitor.>
<Ref. to ABS-140, TROUBLE CODE 51 — VALVE RELAY ON
51 Valve relay ON failure Valve relay ON failure
FAILURE —, Diagnostics Chart with Subaru Select Monitor.>
<Ref. to ABS-142, TROUBLE CODE 52 — OPEN CIRCUIT IN
Open circuit in motor Open circuit in motor
52 MOTOR RELAY CIRCUIT —, Diagnostics Chart with Subaru
relay circuit relay circuit
Select Monitor.>
<Ref. to ABS-146, TROUBLE CODE 52 — MOTOR RELAY ON
52 Motor relay ON failure Motor relay ON failure
FAILURE —, Diagnostics Chart with Subaru Select Monitor.>
<Ref. to ABS-150, TROUBLE CODE 52 — MOTOR MALFUNC-
52 Motor malfunction Motor malfunction
TION —, Diagnostics Chart with Subaru Select Monitor.>
<Ref. to ABS-154, TROUBLE CODE 54 — STOP LIGHT SWITCH
Stop light switch signal Stop light switch signal
54 SIGNAL CIRCUIT MALFUNCTION —, Diagnostics Chart with
circuit malfunction circuit malfunction
<Ref. to ABS-156, TROUBLE CODE 56 — OPEN OR SHORT
Open or short circuit in Open or short circuit in
56 CIRCUIT IN G SENSOR CIRCUIT —, Diagnostics Chart with
G sensor circuit G sensor circuit
<Ref. to ABS-160, TROUBLE CODE 56 — BATTERY SHORT IN
Battery short in G sen- Battery short in G sen-
56 G SENSOR CIRCUIT —, Diagnostics Chart with Subaru Select
sor circuit sor circuit
Monitor.>
<Ref. to ABS-166, TROUBLE CODE 56 — ABNORMAL G SEN-
Abnormal G sensor Abnormal G sensor
56 SOR HIGH µ OUTPUT —, Diagnostics Chart with Subaru Select
high µ output high µ output
Monitor.>
<Ref. to ABS-170, TROUBLE CODE 56 — DETECTION OF G
Detection of G sensor Detection of G sensor
56 SENSOR STICK —, Diagnostics Chart with Subaru Select Moni-
stick stick
tor.>
NOTE:
High µ means high friction coefficient against road surface.
ABS-27
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)
12. Diagnostics Chart with Diagnosis Connector S006522
A: ABS WARNING LIGHT DOES NOT COME ON. S006522E24
DIAGNOSIS:
쐌 ABS warning light circuit is open or shorted.
TROUBLE SYMPTOM:
쐌 When ignition switch is turned ON (engine OFF), ABS warning light does not come on.
ABS-28
ABS (DIAGNOSTICS)
WIRING DIAGRAM: LHD MODEL
S4M0553
ABS-29
ABS (DIAGNOSTICS)
WIRING DIAGRAM: RHD MODEL
S4M0554
ABS-30
ABS (DIAGNOSTICS)

1 CHECK IF OTHER WARNING LIGHTS Do other warning lights turn Go to step 2. Repair combina-
TURN ON. on? tion meter. <Ref.
Turn ignition switch to ON (engine OFF). to IDI-15, Combi-
nation Meter
Assembly.>
2 CHECK ABS WARNING LIGHT BULB. Is ABS warning light bulb Go to step 3. Replace ABS
1) Turn ignition switch to OFF. OK? warning light bulb.
2) Remove combination meter. <Ref. to IDI-15,
3) Remove ABS warning light bulb from com- Combination
bination meter. Meter Assembly.>
3 CHECK BATTERY SHORT OF ABS WARN- Is the voltage less than 3 Go to step 4. Repair warning
ING LIGHT HARNESS. V? light harness.
1) Disconnect connector (B62) or (B100) from
connector (F45) or (F2).
2) Measure voltage between connector
(B200) and chassis ground.
LHD turbo: (B62) No. 10 (+) — Chassis
ground (−):
LHD non-turbo: (B62) No. 8 (+) —
Chassis ground (−):
RHD: (B100) No. 14 (+) — Chassis
ground (−):
4 CHECK BATTERY SHORT OF ABS WARN- Is the voltage less than 3 Go to step 5. Repair warning
ING LIGHT HARNESS. V? light harness.
2) Measure voltage between connector (B62)
or (B100) and chassis ground.
ground (−):
ground (−):
5 CHECK WIRING HARNESS. Is the voltage between 10 Go to step 6. Repair wiring har-
1) Turn ignition switch to OFF. and 15 V? ness.
2) Install ABS warning light bulb to combina-
tion meter.
3) Install combination meter.
5) Measure voltage between connector (B62)
or (B100) and chassis ground.
ground (−):
ground (−):
ABS-31
ABS (DIAGNOSTICS)

6 CHECK BATTERY SHORT OF ABS WARN- Is the voltage less than 3 Go to step 7. Repair wiring har-
ING LIGHT HARNESS. V? ness.
2) Measure voltage between connector (F45)
or (F2) and chassis ground.
LHD turbo: (F45) No. 10 (+) — Chassis
ground (−):
LHD non-turbo: (F45) No. 8 (+) —
RHD: (F2) No. 14 (+) — Chassis ground
(−):
7 CHECK BATTERY SHORT OF ABS WARN- Is the voltage less than 3 Go to step 8. Repair wiring har-
ING LIGHT HARNESS. V? ness.
2) Measure voltage between connector (F45)
ground (−):
(−):
8 CHECK GROUND CIRCUIT OF Is the resistance less than Go to step 9. Repair
ABSCM&H/U. 0.5 Ω? ABSCM&H/U
Measure resistance between ABSCM&H/U ground harness.
and chassis ground.
(F49) No. 23 — GND:
9 CHECK WIRING HARNESS. Is the resistance less than Go to step 10. Repair harness/
Measure resistance between connector (F45) 0.5 Ω? connector.
ground (−):
(−):
10 CHECK POOR CONTACT IN CONNEC- Is there poor contact in Repair connector. Replace
TORS. connectors between combi- ABSCM&H/U.
Turn ignition switch to OFF. nation meter and <Ref. to ABS-7,
ABSCM&H/U? ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
ABS-32
ABS (DIAGNOSTICS)
MEMO:
ABS-33
ABS (DIAGNOSTICS)
B: ABS WARNING LIGHT DOES NOT GO OFF. S006522E25
DIAGNOSIS:
쐌 ABS warning light circuit is open or shorted.
TROUBLE SYMPTOM:
쐌 When starting the engine and while ABS warning light is kept ON.
S4M0553
ABS-34
ABS (DIAGNOSTICS)
S4M0554
ABS-35
ABS (DIAGNOSTICS)

1 CHECK INSTALLATION OF ABSCM&H/U Is ABSCM&H/U connector Go to step 2. Insert
CONNECTOR. inserted into ABSCM until ABSCM&H/U con-
Turn ignition switch to OFF. the clamp locks onto it? nector into
ABSCM&H/U until
the clamp locks
onto it.
2 CHECK DIAGNOSIS TERMINAL. Is the resistance less than Go to step 3. Repair diagnosis
Measure resistance between diagnosis termi- 0.5 Ω? terminal harness.
nals (B81) and chassis ground.
Terminals
Diagnosis terminal (A) — Chassis
ground:
Diagnosis terminal (B) — Chassis
ground:
3 CHECK DIAGNOSIS LINE. Is the resistance less than Go to step 4. Repair harness
1) Turn ignition switch to OFF. 0.5 Ω? connector
2) Connect diagnosis terminal (B81) to diag- between
nosis connector (B82) No. 6. ABSCM&H/U and
3) Disconnect connector from ABSCM&H/U. diagnosis connec-
4) Measure resistance between ABSCM&H/U tor.
connector and chassis ground.
(F49) No. 4 — Chassis ground:
4 CHECK GENERATOR. Is the voltage between 10 Go to step 5. Repair generator.
1) Start the engine. and 15 V? <Ref. to SC-12,
2) Idle the engine. Generator.>
3) Measure voltage between generator and
chassis ground.
Terminal
Generator B terminal (+) — Chassis
ground (−):
5 CHECK BATTERY TERMINAL. Is there poor contact at Repair battery Go to step 6.
Turn ignition switch to OFF. battery terminal? terminal.
6 CHECK POWER SUPPLY OF ABSCM. Is the voltage between 10 Go to step 7. Repair
1) Disconnect connector from ABSCM&H/U. and 15 V? ABSCM&H/U
2) Start engine. power supply cir-
3) Idle the engine. cuit.
4) Measure voltage between ABSCM&H/U
7 CHECK WIRING HARNESS. Does the ABS warning light Go to step 8. Repair front wiring
1) Disconnect connector (F45) or (F2) from remain off? harness.
connector (B62) or (B100).
8 CHECK PROJECTION AT ABSCM&H/U. Are the projection broken? Go to step 9. Replace
1) Turn ignition switch to OFF. ABSCM&H/U.
2) Check for broken projection at the <Ref. to ABS-7,
ABSCM&H/U terminal. ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
9 CHECK ABSCM&H/U. Is the resistance more than Go to step 10. Replace
Measure resistance between ABSCM&H/U 1 MΩ? ABSCM&H/U.
terminals. <Ref. to ABS-7,
Terminal ABS Control Mod-
No. 21 — No. 23: ule and Hydraulic
Control Unit
(ABSCM&H/U).>
ABS-36
ABS (DIAGNOSTICS)

10 CHECK WIRING HARNESS. Is the resistance less than Go to step 11. Repair harness.
Measure resistance between connector (F45) 0.5 Ω?
LHD turbo: (F45) No. 10 — Chassis
ground:
LHD non-turbo: (F45) No. 8 — Chassis
ground:
RHD: (F2) No. 14 — Chassis ground:
11 CHECK WIRING HARNESS. Is the resistance more than Go to step 12. Repair harness.
1) Connect connector to ABSCM&H/U. 1 MΩ?
2) Measure resistance between connector
(F45) or (F2) and chassis ground.
ground:
ground:
12 CHECK POOR CONTACT IN ABSCM&H/U Is there poor contact in Repair connector. Replace
CONNECTOR. ABSCM&H/U connector? ABSCM&H/U.
<Ref. to ABS-7,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
ABS-37
ABS (DIAGNOSTICS)
C: TROUBLE CODE DOES NOT APPEAR. S006522E50
DIAGNOSIS:
쐌 Diagnosis circuit is open.
TROUBLE SYMPTOM:
쐌 The ABS warning light turns on or off normally but the start code cannot be read out in the diagnostic
mode.
ABS-38
ABS (DIAGNOSTICS)
S4M0553
ABS-39
ABS (DIAGNOSTICS)
S4M0554
ABS-40
ABS (DIAGNOSTICS)

1 CHECK DIAGNOSIS TERMINAL. Is the resistance less than Go to step 2. Repair diagnosis
1) Turn ignition switch to OFF. 0.5 Ω? terminal harness.
2) Measure resistance between diagnosis ter-
minals (B81) and chassis ground.
Terminals
Diagnosis terminal (A) — Chassis
ground:
Diagnosis terminal (B) — Chassis
ground:
2 CHECK DIAGNOSIS LINE. Is the resistance less than Go to step 3. Repair harness
1) Turn ignition switch to OFF. 0.5 Ω? connector
2) Connect diagnosis terminal (B81) to diag- between
nosis connector (B82) No. 6. ABSCM&H/U and
3) Disconnect connector from ABSCM&H/U. diagnosis connec-
4) Measure resistance between ABSCM&H/U tor.
<Ref. to ABS-7,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
ABS-41
ABS (DIAGNOSTICS)
D: TROUBLE CODE 21
— ABNORMAL ABS SENSOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO
HIGH) (FRONT RH) — S006522E60
NOTE:
For the diagnostic procedure, refer to TROUBLE CODE 27. <Ref. to ABS-42, TROUBLE CODE 27 —
ABNORMAL ABS SENSOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH) (REAR LH) —, Diagnos-
tics Chart with Diagnosis Connector.>
E: TROUBLE CODE 23
HIGH) (FRONT LH) — S006522E61
NOTE:
F: TROUBLE CODE 25
HIGH) (REAR RH) — S006522E62
NOTE:
G: TROUBLE CODE 27
HIGH) (REAR LH) — S006522E63
DIAGNOSIS:
쐌 Faulty ABS sensor (Broken wire, input voltage too high)
쐌 Faulty harness connector
TROUBLE SYMPTOM:
쐌 ABS does not operate.
ABS-42
ABS (DIAGNOSTICS)
S4M0555
ABS-43
ABS (DIAGNOSTICS)
S4M0556
ABS-44
ABS (DIAGNOSTICS)

1 CHECK ABS SENSOR. Is the resistance between 1 Go to step 2. Replace ABS sen-
1) Turn ignition switch to OFF. and 1.5 kΩ? sor. Front: <Ref.
2) Disconnect connector from ABS sensor. to ABS-14, Front
3) Measure resistance of ABS sensor connec- ABS Sensor.>
tor terminals. Rear: <Ref. to
Terminal ABS-18, Rear
Front RH No. 1 — No. 2: ABS Sensor.>
Front LH No. 1 — No. 2:
Rear RH No. 1 — No. 2:
Rear LH No. 1 — No. 2:
2 CHECK BATTERY SHORT OF ABS SEN- Is the voltage less than 1 Go to step 3. Replace ABS sen-
SOR. V? sor. Front: <Ref.
1) Disconnect connector from ABSCM&H/U. to ABS-14, Front
2) Measure voltage between ABS sensor and ABS Sensor.>
chassis ground. Rear: <Ref. to
Front RH No. 1 (+) — Chassis ground ABS Sensor.>
(−):
Front LH No. 1 (+) — Chassis ground
(−):
Rear RH No. 1 (+) — Chassis ground
(−):
Rear LH No. 1 (+) — Chassis ground
(−):
1) Turn ignition switch to ON. to ABS-14, Front
(−):
(−):
(−):
(−):
4 CHECK HARNESS/CONNECTOR Is the resistance between 1 Go to step 5. Repair harness/
BETWEEN ABSCM&H/U AND ABS SEN- and 1.5 kΩ? connector
SOR. between
1) Turn ignition switch to OFF. ABSCM&H/U and
2) Connect connector to ABS sensor. ABS sensor.
3) Measure resistance between ABSCM&H/U
connector terminals.
Trouble code 21 / (F49) No. 11 — No.
12:
10:
15:
Trouble code 27 / (F49) No. 7 — No. 8:
ABS-45
ABS (DIAGNOSTICS)

5 CHECK BATTERY SHORT OF HARNESS. Is the voltage less than 1 Go to step 6. Repair harness
Measure voltage between ABSCM&H/U con- V? between
nector and chassis ground. ABSCM&H/U and
Connector & terminal ABS sensor.
Trouble code 21 / (F49) No. 11 (+) —
Trouble code 23 / (F49) No. 9 (+) —
Trouble code 25 / (F49) No. 13 (+) —
1) Turn ignition switch to ON. V? between
2) Measure voltage between ABSCM&H/U ABSCM&H/U and
connector and chassis ground. ABS sensor.
Trouble code 21 / (F49) No. 11 (+) —
Trouble code 25 / (F49) No. 13 (+) —
7 CHECK INSTALLATION OF ABS SENSOR. Are the ABS sensor instal- Go to step 8. Tighten ABS sen-
Turn ignition switch to OFF. lation bolts tightened sor installation
Tightening torque: securely? bolts securely.
32±10 N·m (3.3±1.0 kgf-m, 24±7 ft-lb)
8 CHECK ABS SENSOR GAP. Is the gap within the speci- Go to step 9. Adjust the gap.
Measure tone wheel to ABS sensor piece gap fications? NOTE:
over entire perimeter of the wheel. Adjust the gap
Front wheel using spacers
0.3 — 0.8 mm (0.012 — 0.031 in) (Part No.
Rear wheel 26755AA000). If
0.7 — 1.2 mm (0.028 — 0.047 in) spacers cannot
correct the gap,
replace worn sen-
sor or worn tone
wheel.
9 CHECK TONE WHEEL RUNOUT. Is the runout less than 0.05 Go to step 10. Replace tone
Measure tone wheel runout. mm (0.0020 in)? wheel. Front:
<Ref. to ABS-21,
Front Tone
Wheel.> Rear:
<Ref. to ABS-22,
Rear Tone
Wheel.>
ABS-46
ABS (DIAGNOSTICS)

10 CHECK GROUND SHORT OF ABS SEN- Is the resistance more than Go to step 11. Replace ABS sen-
SOR. 1 MΩ? sor and
1) Turn ignition switch to ON. ABSCM&H/U.
2) Measure resistance between ABS sensor Front: <Ref. to
and chassis ground. ABS-14, Front
Terminal ABS Sensor.>
Front RH No. 1 — Chassis ground: Rear: <Ref. to
Front LH No. 1 — Chassis ground: ABS-18, Rear
Rear RH No. 1 — Chassis ground: ABS Sensor.> and
Rear LH No. 1 — Chassis ground: <Ref. to ABS-7,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
11 CHECK GROUND SHORT OF HARNESS. Is the resistance more than Go to step 12. Repair harness
1) Turn ignition switch to OFF. 1 MΩ? between
2) Connect connector to ABS sensor. ABSCM&H/U and
3) Measure resistance between ABSCM&H/U ABS sensor.
connector terminal and chassis ground. Replace
Connector & terminal ABSCM&H/U.
Trouble code 21 / (F49) No. 11 — Chas- <Ref. to ABS-7,
sis ground: ABS Control Mod-
Trouble code 23 / (F49) No. 9 — Chas- ule and Hydraulic
sis ground: Control Unit
Trouble code 25 / (F49) No. 13 — Chas- (ABSCM&H/U).>
sis ground:
Trouble code 27 / (F49) No. 7 — Chas-
sis ground:
12 CHECK POOR CONTACT IN CONNEC- Is there poor contact in Repair connector. Go to step 13.
TORS. connectors between
ABSCM&H/U and ABS
sensor?
13 CHECK ABSCM&H/U. Is the same trouble code Replace Go to step 14.
1) Connect all connectors. as in the current diagnosis ABSCM&H/U.
2) Erase the memory. still being output? <Ref. to ABS-7,
3) Perform inspection mode. ABS Control Mod-
4) Read out the trouble code. ule and Hydraulic
Control Unit
(ABSCM&H/U).>
14 CHECK ANY OTHER TROUBLE CODES Are other trouble codes Proceed with the A temporary poor
APPEARANCE. being output? diagnosis corre- contact.
sponding to the NOTE:
trouble code. Check harness
and connectors
between
ABSCM&H/U and
ABS sensor.
ABS-47
ABS (DIAGNOSTICS)
H: TROUBLE CODE 22
— ABNORMAL ABS SENSOR (FRONT RH) — S006522E64
NOTE:
ABNORMAL ABS SENSOR (REAR LH) —, Diagnostics Chart with Diagnosis Connector.>
I: TROUBLE CODE 24
— ABNORMAL ABS SENSOR (FRONT LH) — S006522E65
NOTE:
J: TROUBLE CODE 26
— ABNORMAL ABS SENSOR (REAR RH) — S006522E66
NOTE:
K: TROUBLE CODE 28
— ABNORMAL ABS SENSOR (REAR LH) — S006522E67
DIAGNOSIS:
쐌 Faulty ABS sensor signal (noise, irregular signal, etc.)
쐌 Faulty harness/connector
TROUBLE SYMPTOM:
ABS-48
ABS (DIAGNOSTICS)
S4M0555
ABS-49
ABS (DIAGNOSTICS)
S4M0556
ABS-50
ABS (DIAGNOSTICS)

Turn ignition switch to OFF. lation bolts tightened sor installation
Tightening torque: securely? bolts securely.
32±10 N·m (3.3±1.0 kgf-m, 24±7 ft-lb)
Front wheel using spacer (Part
0.3 — 0.8 mm (0.012 — 0.031 in) No. 26755AA000).
Rear wheel If spacers cannot
0.7 — 1.2 mm (0.028 — 0.047 in) correct the gap,
replace worn sen-
sor or worn tone
wheel.
3 PREPARE OSCILLOSCOPE. Is an oscilloscope avail- Go to step 4. Go to step 5.
able?
4 CHECK ABS SENSOR SIGNAL. Is oscilloscope pattern Go to step 8. Go to step 7.
1) Raise all four wheels of ground. smooth, as shown in fig-
2) Turn ignition switch OFF. ure?
3) Connect the oscilloscope to the connector.
5) Rotate wheels and measure voltage at
specified frequency. <Ref. to ABS-17,
WAVEFORM, Control Module I/O Signal.>
NOTE:
When this inspection is completed, the ABS
control module sometimes stores the trouble
code 29.
Trouble code 22 /
LHD turbo: (B62) No. 7 (+) — No. 18
(−):
LHD non-turbo: (B62) No. 5 (+) — No.
14 (−):
RHD: (B100) No. 8 (+) — No. 20 (−):
Trouble code 24 /
LHD turbo: (B62) No. 9 (+) — No. 20
(−):
16 (−):
RHD: (B100) No. 10 (+) — No. 22 (−):
Trouble code 26 /
LHD: (F55) No. 12 (+) — No. 11 (−):
RHD: (B98) No. 15 (+) — No. 16 (−):
Trouble code 28 /
LHD: (F55) No. 5 (+) — No. 4 (−):
RHD: (B98) No. 5 (+) — No. 6 (−):
5 CHECK CONTAMINATION OF ABS SEN- Is the ABS sensor piece or Thoroughly Go to step 6.
SOR OR TONE WHEEL. the tone wheel contami- remove dirt or
Remove disc rotor or drum from hub in accor- nated by dirt or other for- other foreign mat-
dance with trouble code. eign matter? ter.
ABS-51
ABS (DIAGNOSTICS)

6 CHECK DAMAGE OF ABS SENSOR OR Are there broken or dam- Replace ABS sen- Go to step 7.
TONE WHEEL. aged in the ABS sensor sor or tone wheel.
piece or the tone wheel? Front: <Ref. to
ABS-14, Front
ABS Sensor.>
Rear: <Ref. to
ABS-18, Rear
ABS Sensor.> and
Front: <Ref. to
ABS-21, Front
Tone Wheel.>
Rear: <Ref. to
ABS-22, Rear
Tone Wheel.>
<Ref. to ABS-21,
Front Tone
Wheel.> Rear:
<Ref. to ABS-22,
Rear Tone
Wheel.>
8 CHECK RESISTANCE OF ABS SENSOR. Is the resistance between 1 Go to step 9. Replace ABS sen-
1) Turn ignition switch OFF. and 1.5 kΩ? sor. Front: <Ref.
3) Measure resistance between ABS sensor ABS Sensor.>
connector terminals. Rear: <Ref. to
SOR. 1 MΩ? sor. Front: <Ref.
Measure resistance between ABS sensor and to ABS-14, Front
chassis ground. ABS Sensor.>
Terminal Rear: <Ref. to
Front RH No. 1 — Chassis ground: ABS-18, Rear
Front LH No. 1 — Chassis ground: ABS Sensor.>
SOR. between
2) Disconnect connector from ABSCM&H/U. ABS sensor.
3) Measure resistance at ABSCM&H/U con-
nector terminals.
12:
10:
15:
ABS-52
ABS (DIAGNOSTICS)

11 CHECK GROUND SHORT OF HARNESS. Is the resistance more than Go to step 12. Repair harness/
Measure resistance between ABSCM&H/U 1 MΩ? connector
connector and chassis ground. between
Connector & terminal ABSCM&H/U and
Trouble code 22 / (F49) No. 11 — Chas- ABS sensor.
sis ground:
sis ground:
sis ground:
sis ground:
and chassis ground.
(F49) No. 23 — GND:
ABSCM&H/U and ABS
sensor?
14 CHECK SOURCES OF SIGNAL NOISE. Is the car telephone or the Go to step 15. Properly install
wireless transmitter prop- the car telephone
erly installed? or the wireless
transmitter.
15 CHECK SOURCES OF SIGNAL NOISE. Are noise sources (such as Install the noise Go to step 16.
an antenna) installed near sources apart
the sensor harness? from the sensor
harness.
16 CHECK SHIELD CIRCUIT. Is the resistance less than Go to step 17. Repair shield har-
1) Connect all connectors. 0.5 Ω? ness.
2) Measure resistance between shield con-
nector and chassis ground.
Trouble code 22 /
LHD turbo: (B62) No. 19 — Chassis
ground:
LHD non-turbo: (B62) No. 15 — Chas-
sis ground:
RHD: (B100) No. 21 — Chassis ground:
Trouble code 24 /
ground:
LHD non-turbo: (B62) No. 6 — Chassis
ground:
Trouble code 26 /
LHD: (F55) No. 10 — Chassis ground:
Trouble code 28 /
Control Unit
(ABSCM&H/U).>
ABS-53
ABS (DIAGNOSTICS)

18 CHECK ANY OTHER TROUBLE CODES Are other trouble codes Proceed with the A temporary noise
APPEARANCE. being output? diagnosis corre- interference.
sponding to the
trouble code.
ABS-54
ABS (DIAGNOSTICS)
MEMO:
ABS-55
ABS (DIAGNOSTICS)
L: TROUBLE CODE 29
— ABNORMAL ABS SENSOR SIGNAL (ANY ONE OF FOUR) — S006522E68
DIAGNOSIS:
쐌 Faulty tone wheel
쐌 Wheels turning freely for a long time
TROUBLE SYMPTOM:
ABS-56
ABS (DIAGNOSTICS)
S4M0555
ABS-57
ABS (DIAGNOSTICS)
S4M0556
ABS-58
ABS (DIAGNOSTICS)

1 CHECK IF THE WHEELS HAVE TURNED Check if the wheels have The ABS is nor- Go to step 2.
FREELY FOR A LONG TIME. been turned freely for more mal. Erase the
than one minute, such as trouble code.
when the vehicle is jacked- NOTE:
up, under full-lock corner- When the wheels
ing or when tire is not in turn freely for a
contact with road surface. long time, such as
when the vehicle
is towed or
jacked-up, or
when steering
wheel is continu-
ously turned all
the way, this
trouble code may
sometimes occur.
2 CHECK TIRE SPECIFICATIONS. Are the tire specifications Go to step 3. Replace tire.
Turn ignition switch to OFF. correct?
3 CHECK WEAR OF TIRE. Is the tire worn exces- Replace tire. Go to step 4.
sively?
4 CHECK TIRE PRESSURE. Is the tire pressure correct? Go to step 5. Adjust tire pres-
sure.
Tightening torque: lation bolts tightened sor installation
32±10 N·m (3.3±1.0 kgf-m, 24±7 ft-lb) securely? bolts securely.
Specifications using spacer (Part
Front wheel No. 26755AA000).
0.3 — 0.8 mm (0.012 — 0.031 in) If spacers cannot
Rear wheel correct the gap,
0.7 — 1.2 mm (0.028 — 0.047 in) replace worn sen-
sor or worn tone
wheel.
able?
ABS-59
ABS (DIAGNOSTICS)

NOTE:
When this inspection is completed, the
ABSCM&H/U sometimes stores the trouble
code 29.
Front RH
LHD turbo: (B62) No. 7 (+) — No. 18
(−):
14 (−):
RHD: (B100) No. 8 (+) — No. 20 (−):
Front LH
LHD turbo: (B62) No. 9 (+) — No. 20
(−):
16 (−):
RHD: (B100) No. 10 (+) — No. 22 (−):
Rear RH
LHD: (F55) No. 12 (+) — No. 11 (−):
RHD: (B98) No. 15 (+) — No. 16 (−):
Rear LH
LHD: (F55) No. 5 (+) — No. 4 (−):
RHD: (B98) No. 5 (+) — No. 6 (−):
Remove disc rotor from hub. nated by dirt or other for- other foreign mat-
eign matter? ter.
TONE WHEEL. aged teeth in the ABS sensor or tone wheel.
sor piece or the tone Front: <Ref. to
wheel? ABS-14, Front
ABS Sensor.>
Rear: <Ref. to
ABS-18, Rear
ABS Sensor.> and
Front: <Ref. to
ABS-21, Front
Tone Wheel.>
Rear: <Ref. to
ABS-22, Rear
Tone Wheel.>
<Ref. to ABS-21,
Front Tone
Wheel.> Rear:
<Ref. to ABS-22,
Rear Tone
Wheel.>
ABS-60
ABS (DIAGNOSTICS)

1) Turn ignition switch to OFF. as in the current diagnosis ABSCM&H/U.
2) Connect all connectors. still being output? <Ref. to ABS-7,
3) Erase the memory. ABS Control Mod-
4) Perform inspection mode. ule and Hydraulic
5) Read out the trouble code. Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-61
ABS (DIAGNOSTICS)
M: TROUBLE CODE 31
— ABNORMAL INLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (FRONT
RH) — S006522E69
NOTE:
ABNORMAL INLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (REAR LH) —, Diagnostics Chart with
N: TROUBLE CODE 33
— ABNORMAL INLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (FRONT
LH) — S006522E70
NOTE:
O: TROUBLE CODE 35
— ABNORMAL INLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (REAR
RH) — S006522E71
NOTE:
P: TROUBLE CODE 37
— ABNORMAL INLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (REAR
LH) — S006522E72
DIAGNOSIS:
쐌 Faulty inlet solenoid valve in ABSCM&H/U
TROUBLE SYMPTOM:
ABS-62
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
S4M0557
ABS-63
ABS (DIAGNOSTICS)

1 CHECK FUSE. Is the fuse blown out? Replace fuse. Go to step 2.
2 CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage between 10 Go to step 3. Repair harness
1) Disconnect connector from ABSCM&H/U. and 15 V? connector
2) Run the engine at idle. between fuse and
3) Measure voltage between ABSCM&H/U ABSCM&H/U.
1) Turn ignition switch to OFF. ground harness.
generator, battery and
ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-64
ABS (DIAGNOSTICS)
MEMO:
ABS-65
ABS (DIAGNOSTICS)
Q: TROUBLE CODE 32
— ABNORMAL OUTLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U
(FRONT RH) — S006522E73
NOTE:
ABNORMAL OUTLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (REAR LH) —, Diagnostics Chart
with Diagnosis Connector.>
R: TROUBLE CODE 34
(FRONT LH) — S006522E74
NOTE:
S: TROUBLE CODE 36
(REAR RH) — S006522E75
NOTE:
T: TROUBLE CODE 38
(REAR LH) — S006522E76
DIAGNOSIS:
쐌 Faulty outlet solenoid valve in ABSCM&H/U
TROUBLE SYMPTOM:
ABS-66
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
S4M0557
ABS-67
ABS (DIAGNOSTICS)

ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-68
ABS (DIAGNOSTICS)
MEMO:
ABS-69
ABS (DIAGNOSTICS)
U: TROUBLE CODE 41
— ABNORMAL ABS CONTROL MODULE — S006522D29
DIAGNOSIS:
쐌 Faulty ABSCM&H/U.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M1457
ABS-70
ABS (DIAGNOSTICS)

and chassis ground.
battery, ignition switch and
ABSCM&H/U?
transmitter.
harness.
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-71
ABS (DIAGNOSTICS)
V: TROUBLE CODE 42
— SOURCE VOLTAGE IS ABNORMAL. — S006522D37
DIAGNOSIS:
쐌 Power source voltage of the ABSCM&H/U is low or high.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
S4M0557
ABS-72
ABS (DIAGNOSTICS)

1) Start engine. and 17 V? <Ref. to SC-12,
2) Idling after warm-up. Generator.>
3) Measure voltage between generator B ter-
minal and chassis ground.
Terminal
Generator B terminal — Chassis
ground:
2 CHECK BATTERY TERMINAL. Are the positive and nega- Go to step 3. Tighten the clamp
Turn ignition switch to OFF. tive battery terminals tightly of terminal.
clamped?
ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-73
ABS (DIAGNOSTICS)
W: TROUBLE CODE 44
— A COMBINATION OF AT CONTROL ABNORMAL — S006522D42
DIAGNOSIS:
쐌 Combination of AT control faults
TROUBLE SYMPTOM:
WIRING DIAGRAM:
S4M0558
ABS-74
ABS (DIAGNOSTICS)

1 CHECK SPECIFICATIONS OF THE Is an ABSCM&H/U for AT Replace Go to step 2.
ABSCM&H/U. model installed on a MT ABSCM&H/U.
Check specifications of the mark to the model? <Ref. to ABS-7,
ABSCM&H/U. ABS Control Mod-
C7: AT ule and Hydraulic
C8: MT Control Unit
(ABSCM&H/U).>
1) Turn ignition switch to OFF. 1 MΩ? between TCM and
2) Disconnect two connectors from TCM. ABSCM&H/U.
Measure voltage between ABSCM&H/U con- V? between TCM and
nector and chassis ground. ABSCM&H/U.
1) Turn ignition switch to ON. V? between TCM and
5 CHECK TCM. Is the voltage between 10 Go to step 7. Go to step 6.
1) Turn ignition switch to OFF. and 15 V?
2) Connect all connectors to TCM.
4) Measure voltage between TCM connector
terminal and chassis ground.
6 CHECK AT. Is the AT functioning nor- Replace TCM. Repair AT.
mally?
7 CHECK OPEN CIRCUIT OF HARNESS. Is the voltage between 10 Go to step 8. Repair harness/
Measure voltage between ABSCM&H/U con- and 15 V? connector
nector and chassis ground. between TCM and
TORS. connectors between TCM
and ABSCM&H/U?
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-75
ABS (DIAGNOSTICS)
X: TROUBLE CODE 51
— ABNORMAL VALVE RELAY — S006522D61
DIAGNOSIS:
쐌 Faulty valve relay
TROUBLE SYMPTOM:
WIRING DIAGRAM:
S4M0559
ABS-76
ABS (DIAGNOSTICS)

1) Turn ignition switch to OFF. and 15 V? connector
2) Disconnect connector from ABSCM&H/U. between fuse and
3) Run the engine at idle. ABSCM&H/U.
4 CHECK VALVE RELAY IN ABSCM&H/U. Is the resistance more than Go to step 5. Replace
and terminals. <Ref. to ABS-7,
Terminals ABS Control Mod-
No. 23 (+) — No. 24 (−): ule and Hydraulic
Control Unit
(ABSCM&H/U).>
ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-77
ABS (DIAGNOSTICS)
Y: TROUBLE CODE 52
— ABNORMAL MOTOR AND/OR MOTOR RELAY — S006522D65
DIAGNOSIS:
쐌 Faulty motor
쐌 Faulty motor relay
TROUBLE SYMPTOM:
ABS-78
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
S4M0560
ABS-79
ABS (DIAGNOSTICS)

1 CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage between 10 Go to step 2. Repair harness/
2) Disconnect connector from ABSCM&H/U. between battery
3) Turn ignition switch to ON. and ABSCM&H/U
4) Measure voltage between ABSCM&H/U and check fuse
connector and chassis ground. SBF-holder.
2 CHECK GROUND CIRCUIT OF MOTOR. Is the resistance less than Go to step 3. Repair
1) Turn ignition switch to OFF. 0.5 Ω? ABSCM&H/U
2) Measure resistance between ABSCM&H/U ground harness.
1) Run the engine at idle. and 15 V? connector
2) Measure voltage between ABSCM&H/U between fuse and
connector and chassis ground. ABSCM&H/U.
6 CHECK MOTOR OPERATION. Can motor revolution noise Go to step 7. Replace
Operate the sequence control. <Ref. to ABS- (buzz) be heard when car- ABSCM&H/U.
11, ABS Sequence Control.> rying out the sequence <Ref. to ABS-7,
NOTE: control? ABS Control Mod-
Use the diagnosis connector to operate the ule and Hydraulic
sequence control. Control Unit
(ABSCM&H/U).>
TORS. connector between
Turn ignition switch to OFF. generator, battery and
ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-80
ABS (DIAGNOSTICS)
MEMO:
ABS-81
ABS (DIAGNOSTICS)
Z: TROUBLE CODE 54
— ABNORMAL STOP LIGHT SWITCH — S006522D72
DIAGNOSIS:
쐌 Faulty stop light switch
TROUBLE SYMPTOM:
WIRING DIAGRAM:
S4M0561
ABS-82
ABS (DIAGNOSTICS)

1 CHECK STOP LIGHTS COME ON. Do stop lights come on? Go to step 2. Repair stop lights
Depress the brake pedal. circuit.
2 CHECK OPEN CIRCUIT IN HARNESS. Is the voltage between 10 Go to step 3. Repair harness
1) Turn ignition switch to OFF. and 15 V? between stop light
2) Disconnect connector from ABSCM&H/U. switch and
3) Depress brake pedal. ABSCM&H/U.
TORS. connector between stop
light switch and
ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-83
ABS (DIAGNOSTICS)
AA: TROUBLE CODE 56

— ABNORMAL G SENSOR OUTPUT VOLTAGE — S006522E77
DIAGNOSIS:
쐌 Faulty G sensor output voltage
TROUBLE SYMPTOM:
S4M0562
ABS-84
ABS (DIAGNOSTICS)
S4M0563
ABS-85
ABS (DIAGNOSTICS)

1 CHECK ALL FOUR WHEELS FOR FREE Have the wheels been The ABS is nor- Go to step 2.
TURNING. turned freely such as when mal. Erase the
the vehicle is lifted up, or trouble code.
operated on a rolling road?
2 CHECK SPECIFICATIONS OF ABSCM&H/U. Does the vehicle specifica- Replace Go to step 3.
Check specifications of the mark to the tion and the ABSCM&H/U ABSCM&H/U.
ABSCM&H/U. specification match? <Ref. to ABS-7,
C7: AT ABS Control Mod-
C8: MT ule and Hydraulic
Control Unit
(ABSCM&H/U).>
CAUTION:
Be sure to turn
ignition switch
to OFF when
removing
ABSCM&H/U.
3 CHECK INPUT VOLTAGE OF G SENSOR. Is the voltage between 4.75 Go to step 4. Repair harness/
1) Turn ignition switch to OFF. and 5.25 V? connector
2) Remove console box. between G sensor
3) Disconnect G sensor from body. (Do not and ABSCM&H/U.
nector terminals.
(R70) No. 1 (+) — No. 3 (−):
4 CHECK OPEN CIRCUIT IN G SENSOR OUT- Is the resistance between Go to step 5. Repair harness/
PUT HARNESS AND GROUND HARNESS. 4.3 and 4.9 kΩ? connector
1) Turn ignition switch to OFF. between G sensor
2) Disconnect connector from ABSCM&H/U. and ABSCM&H/U.
(F49) No. 6 — No. 28:
5 CHECK GROUND SHORT IN G SENSOR Is the resistance more than Go to step 6. Repair harness
OUTPUT HARNESS. 1 MΩ? between G sensor
1) Disconnect connector from G sensor. and ABSCM&H/U.
Measure voltage between ABSCM&H/U con- V? between G sensor
nector and chassis ground. and ABSCM&H/U.
1) Turn ignition switch to ON. V? between G sensor
2) Measure voltage between ABSCM&H/U and ABSCM&H/U.
ABS-86
ABS (DIAGNOSTICS)

Measure resistance between ABSCM&H/U 1 MΩ? between G sensor
connector and chassis ground. and ABSCM&H/U.
Connector & terminal Replace
(F49) No. 28 — Chassis ground: ABSCM&H/U.
<Ref. to ABS-7,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
9 CHECK G SENSOR. Is the voltage between 2.1 Go to step 10. Replace G sen-
1) Turn ignition switch to OFF. and 2.4 V when G sensor sor. <Ref. to ABS-
2) Remove G sensor from vehicle. is horizontal? 23, G Sensor.>
4) Connect connector to ABSCM&H/U.
nector terminals.
(R70) No. 2 (+) — No. 3 (−):
Measure voltage between G sensor connector and 4.1 V when G sensor sor. <Ref. to ABS-
terminals. is inclined forwards to 90°? 23, G Sensor.>
(R70) No. 2 (+) — No. 3 (−):
terminals. is inclined backwards to 23, G Sensor.>
Connector & terminal 90°?
(R70) No. 2 (+) — No. 3 (−):
ABSCM&H/U and G sen-
sor?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-87
ABS (DIAGNOSTICS)
AB: SELECT MONITOR S006522E48 AE: ANALOG DATA ARE

Applicable cartridge of select monitor: <Ref. to DISPLAYED. S006522E29
ABS-10, Special Tools, PREPARATION TOOL,

Display screen Contents to be monitored
Wheel speed detected by the Front
NOTE: FR wheel speed Right ABS sensor is displayed in km/h
For basic handling of the select monitor, refer to its or mile/h.
Operation Manual. Wheel speed detected by the Front Left
FL wheel speed ABS sensor is displayed in km/h or
AC: TROUBLE CODES ARE mile/h.
DISPLAYED. S006522E51
Wheel speed detected by the Rear
A maximum of 3 trouble codes are displayed in RR wheel speed Right ABS sensor is displayed in km/h
or mile/h.
order of occurrence.
쐌 If a particular trouble code is not properly stored Wheel speed detected by the Rear Left
RL wheel speed ABS sensor is displayed in km/h or
in memory (due to a drop in ABSCM&H/U power
mile/h.
supply, etc.) when a problem occurs, the trouble
Stop light switch monitor voltage is dis-
code, followed by a question mark “?”, appears on
Stop light switch played.
the select monitor display. This shows it may be an
unreliable reading.
Refers to vehicle acceleration detecting
G sensor output
by the analog G sensor. It appears on
voltage
the select monitor display in volts.
AF: ON/OFF DATA ARE

DISPLAYED. S006522E43

Stop light switch Stop light switch signal
Valve relay signal Valve relay signal
Motor relay signal Motor relay signal
S4M0076A ABS operation signal from ABS
ABS signal to TCM
control module to TCM
쐌 *a* refers to the troubles in order of occurrence
ABS warning light ABS warning light
(Latest, Old, Older and Reference).
Valve relay monitor Valve relay operation monitor signal
Display screen Contents to be monitored Motor relay operation monitor signal
Motor relay monitor
The most recent trouble code appears
Latest
on the select monitor display. ABS operation signal from ABS
CCM signal
The second most recent trouble code control module to TCM
Old
appears on the select monitor display.
The third most recent trouble code AG: ABS SEQUENCE CONTROL
Older appears on the select monitor display. S006522E23
Display Index No.

A specified period of time proceeding Contents to be monitored
Reference trouble code appears on the select screen
monitor display. Perform ABS sequence
ABS <Ref. to ABS-11,
control by operating valve
sequence ABS Sequence
AD: CLEAR MEMORY S006522E33
control
and pump motor sequen-
Control.>
tially.
Contents to be monitored
Display screen
Function of clearing trouble code and

Clear memory?
freeze frame data.
ABS-88
ABS (DIAGNOSTICS)
AH: FREEZE FRAME DATA S006522E39
NOTE:
쐌 Data stored at the time of trouble occurrence is
shown on display.
쐌 Each time trouble occurs, the latest information
is stored in the freeze frame data in memory.
쐌 If freeze frame data is not properly stored in
memory (due to a drop in ABSCM power supply,
etc.), a trouble code, preceded by a question mark
“?”, appears on the select monitor display. This
shows it may be an unreliable reading.
Wheel speed detected by the Front
FR wheel speed Right ABS sensor is displayed in km/h
or mile/h.
Wheel speed detected by the Front Left
FL wheel speed ABS sensor is displayed in km/h or
mile/h.
Wheel speed detected by the Rear
RR wheel speed Right ABS sensor is displayed in km/h
or mile/h.
Wheel speed detected by the Rear Left
RL wheel speed ABS sensor is displayed in km/h or
mile/h.
Power (in volts) supplied to
ABSCM power
ABSCM&H/U appears on the select
voltage
monitor display.
Refers to vehicle acceleration detected
G sensor output
by the analog G sensor. It appears on
voltage
the select monitor display in volts.
Motor relay
Motor relay operation monitor signal
monitor
Stop light switch Stop light switch signal
ABS signal to ABS operation signal from ABS control
TCM module to TCM
ABS operation signal from ABS control
ABS-AT control module to TCM
ABS operation
ABS operation signal
signal
ABS-89
DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)
13. Diagnostics Chart with Subaru Select Monitor S006583
A: COMMUNICATION FOR INITIALIZING IMPOSSIBLE S006583E34
DIAGNOSIS:
TROUBLE SYMPTOM:
쐌 ABS warning light remains on.
ABS-90
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
S4M0564
ABS-91
ABS (DIAGNOSTICS)

1 CHECK IGNITION SWITCH. Is ignition switch ON? Go to step 2. Turn ignition
switch to ON, and
select ABS mode
using the select
monitor.
2 CHECK BATTERY. Is voltage more than 11 V? Go to step 3. Charge or replace
1) Turn ignition switch to OFF. battery.
2) Measure battery voltage.
3 CHECK BATTERY TERMINAL. Is there poor contact at Repair or tighten Go to step 4.
battery terminal? battery terminal.
4 CHECK COMMUNICATION OF SELECT Are the name and year of Go to step 10. Go to step 5.
MONITOR. the system displayed on
1) Turn ignition switch to OFF. the select monitor?
2) Using the select monitor, check whether
communication to other system (such as
engine, TCM, etc.) can be executed normally.
5 CHECK COMMUNICATION OF SELECT Are the name and year of Go to step 10. Go to step 6.
2) Disconnect ABSCM&H/U connector.
3) Check whether communication to other
systems (such as TCM, engine etc.) can be
executed normally.
6 CHECK COMMUNICATION OF SELECT Are the name and year of Inspect ECM. Go to step 7.
2) Connect ABSCM&H/U connector.
3) Disconnect ECM connector.
systems (such as TCM, engine etc.) can be
executed normally.
7 CHECK COMMUNICATION OF SELECT Are the name and year of Inspect TCM. Go to step 8.
2) Connect ECM connector.
3) Disconnect TCM connector.
systems (such as engine etc.) can be
executed normally.
8 CHECK COMMUNICATION OF SELECT Are the name and year of Inspect cruise Go to step 9.
MONITOR. the system displayed on control module.
2) Connect TCM connector.
3) Disconnect cruise control module connec-
tor.
systems (such as engine, TCM etc.) can be
executed normally.
NOTE:
If the vehicle is not equipped with cruise con-
trol: Go to step 9.
ABS-92
ABS (DIAGNOSTICS)

9 CHECK HARNESS CONNECTOR Is the resistance less than Go to step 10. Repair harness
BETWEEN EACH CONTROL MODULE AND 1 Ω? and connector
DATA LINK CONNECTOR. between each
1) Turn ignition switch to OFF. control module
2) Disconnect TCM, ECM, ABSCM&H/U, and, and data link con-
cruise control module connectors. nector.
10 CHECK OUTPUT SIGNAL FOR Is the voltage more than 1 Repair harness Go to step 11.
ABSCM&H/U. V? and connector
1) Turn ignition switch to ON. between each
2) Measure voltage between ABSCM&H/U control module
and chassis ground. and data link con-
Connector & terminal nector.
11 CHECK HARNESS/CONNECTOR Is the resistance less than Repair harness Go to step 12.
BETWEEN ABSCM&H/U AND DATA LINK 0.5 Ω? and connector
CONNECTOR. between
Measure resistance between ABSCM&H/U ABSCM&H/U and
connector and data link connector. data link connec-
(F49) No. 20 — (B40) No. 5:
(F49) No. 5 — (B40) No. 4:
12 CHECK INSTALLATION OF ABSCM&H/U Is ABSCM&H/U connector Go to step 13. Insert
CONNECTOR. inserted into ABSCM&H/U ABSCM&H/U con-
Turn ignition switch to OFF. until the clamp locks onto nector into
it? ABSCM&H/U.
14 CHECK POWER SUPPLY CIRCUIT. Is the voltage more than 10 Go to step 15. Repair open cir-
1) Turn ignition switch to ON (engine OFF). V? cuit in harness
2) Measure ignition power supply voltage between
between ABSCM&H/U connector and chassis ABSCM&H/U and
ground. fuse.
15 CHECK HARNESS CONNECTOR Is the resistance less than Go to step 16. Repair open cir-
BETWEEN ABSCM&H/U AND CHASSIS 1 Ω? cuit in harness
GROUND. between
2) Disconnect connector from ABSCM&H/U inhibitor side
and transmission. connector, and
3) Measure resistance of harness between poor contact in
ABSCM&H/U and chassis ground. coupling connec-
16 CHECK POOR CONTACT IN CONNEC- Is there poor contact in Repair connector. Replace
TORS. control module power ABSCM&H/U.
supply, ground line and <Ref. to ABS-7,
data link connector? ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
ABS-93
ABS (DIAGNOSTICS)
B: NO TROUBLE CODE S006583E41
DIAGNOSIS:
쐌 ABS warning light circuit is shorted.
TROUBLE SYMPTOM:
쐌 ABS warning light remains on.
쐌 NO TROUBLE CODE displayed on the select monitor.
NOTE:
When the ABS warning light is OFF and “NO TROUBLE CODE” is displayed on the select monitor, the
system is in normal condition.
ABS-94
ABS (DIAGNOSTICS)
S4M0553
ABS-95
ABS (DIAGNOSTICS)
S4M0554
ABS-96
ABS (DIAGNOSTICS)

1 CHECK WIRING HARNESS. Does the ABS warning light Go to step 2. Repair front wiring
1) Turn ignition switch to OFF. remain off? harness.
2) Disconnect connector (F45) or (F2) from
connector (B62) or (B100).
2 CHECK PROJECTION AT ABSCM&H/U. Are the projection broken? Go to step 3. Replace
1) Turn ignition switch to OFF. ABSCM&H/U.
2) Disconnect connector from ABSCM&H/U. <Ref. to ABS-7,
3) Check for broken projection at the ABS Control Mod-
ABSCM&H/U terminal. ule and Hydraulic
Control Unit
(ABSCM&H/U).>
3 CHECK ABSCM&H/U. Is the resistance more than Go to step 4. Replace
Control Unit
(ABSCM&H/U).>
4 CHECK WIRING HARNESS. Is the resistance less than Go to step 5. Repair harness.
Measure resistance between connector (F45) 0.5 Ω?
ground:
ground:
5 CHECK WIRING HARNESS. Is the resistance more than Go to step 6. Repair harness.
1) Connect connector to ABSCM&H/U. 1 MΩ?
(F45) or (F2) and chassis ground.
ground:
ground:
<Ref. to ABS-7,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
ABS-97
ABS (DIAGNOSTICS)
C: TROUBLE CODE 21
— OPEN OR SHORT CIRCUIT IN FRONT RIGHT ABS SENSOR CIRCUIT — S006583C50
NOTE:
For the diagnostic procedure, refer to TROUBLE CODE 27. <Ref. to ABS-98, TROUBLE CODE 27 — OPEN
OR SHORT CIRCUIT IN REAR LEFT ABS SENSOR CIRCUIT —, Diagnostics Chart with Subaru Select
Monitor.>
D: TROUBLE CODE 23
— OPEN OR SHORT CIRCUIT IN FRONT LEFT ABS SENSOR CIRCUIT — S006583C60
NOTE:
Monitor.>
E: TROUBLE CODE 25
— OPEN OR SHORT CIRCUIT IN REAR RIGHT ABS SENSOR CIRCUIT — S006583C69
NOTE:
Monitor.>
F: TROUBLE CODE 27
— OPEN OR SHORT CIRCUIT IN REAR LEFT ABS SENSOR CIRCUIT — S006583C78
DIAGNOSIS:
쐌 Faulty ABS sensor (Broken wire, input voltage too high)
TROUBLE SYMPTOM:
ABS-98
ABS (DIAGNOSTICS)
S4M0555
ABS-99
ABS (DIAGNOSTICS)
S4M0556
ABS-100
ABS (DIAGNOSTICS)

1 CHECK OUTPUT OF ABS SENSOR USING Does the speed indicated Go to step 2. Go to step 8.
SELECT MONITOR. on the display change in
1) Select “Current data display & Save” on response to the speedom-
the select monitor. eter reading during
2) Read the ABS sensor output correspondingacceleration/deceleration
when the steering wheel is
to the faulty system in the select monitor data
display mode. in the straight-ahead posi-
tion?
0.3 — 0.8 mm (0.012 — 0.031 in) (Part No.
correct the gap,
replace worn sen-
sor or worn tone
wheel.
<Ref. to ABS-21,
Front Tone
Wheel.> Rear:
<Ref. to ABS-22,
Rear Tone
Wheel.>
Turn ignition switch to OFF. ABSCM&H/U and ABS
sensor?
Control Unit
(ABSCM&H/U).>
and connectors
between
ABSCM&H/U and
ABS sensor.
8 CHECK ABS SENSOR. Is the resistance between 1 Go to step 9. Replace ABS sen-
1) Turn ignition switch to OFF. and 1.5 kΩ? sor. Front: <Ref.
3) Measure resistance of ABS sensor connec- ABS Sensor.>
tor terminals. Rear: <Ref. to
ABS-101
ABS (DIAGNOSTICS)

1) Disconnect connector from ABSCM&H/U. to ABS-14, Front
(−):
(−):
(−):
(−):
1) Turn ignition switch to ON. to ABS-14, Front
(−):
(−):
(−):
(−):
SOR. between
2) Connect connector to ABS sensor. ABS sensor.
12:
10:
15:
Measure voltage between ABSCM&H/U con- V? between
nector and chassis ground. ABSCM&H/U and
Connector & terminal ABS sensor.
Trouble code 21 / (F49) No. 11 (+) —
Trouble code 25 / (F49) No. 13 (+) —
ABS-102
ABS (DIAGNOSTICS)

1) Turn ignition switch to ON. V? between
2) Measure voltage between ABSCM&H/U ABSCM&H/U and
connector and chassis ground. ABS sensor.
Trouble code 21 / (F49) No. 11 (+) —
Trouble code 25 / (F49) No. 13 (+) —
0.3 — 0.8 mm (0.012 — 0.031 in) (Part No.
correct the gap,
replace worn sen-
sor or worn tone
wheel.
<Ref. to ABS-21,
Front Tone
Wheel.> Rear:
<Ref. to ABS-22,
Rear Tone
Wheel.>
SOR. 1 MΩ? sor and
2) Measure resistance between ABS sensor Front: <Ref. to
and chassis ground. ABS-14, Front
Terminal ABS Sensor.>
Front RH No. 1 — Chassis ground: Rear: <Ref. to
Front LH No. 1 — Chassis ground: ABS-18, Rear
Rear RH No. 1 — Chassis ground: ABS Sensor.> and
Rear LH No. 1 — Chassis ground: <Ref. to ABS-7,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
ABS-103
ABS (DIAGNOSTICS)

1) Turn ignition switch to OFF. 1 MΩ? between
3) Measure resistance between ABSCM&H/U ABS sensor.
connector terminal and chassis ground. And replace
Trouble code 21 / (F49) No. 11 — Chas- <Ref. to ABS-7,
sis ground: ABS Control Mod-
Trouble code 23 / (F49) No. 9 — Chas- ule and Hydraulic
sis ground: Control Unit
Trouble code 25 / (F49) No. 13 — Chas- (ABSCM&H/U).>
sis ground:
sis ground:
ABSCM&H/U and ABS
sensor?
2) Erase the memory. still being output?
3) Perform inspection mode.
4) Read out the trouble code.
and connectors
between
ABSCM&H/U and
ABS sensor.
ABS-104
ABS (DIAGNOSTICS)
MEMO:
ABS-105
ABS (DIAGNOSTICS)
G: TROUBLE CODE 22
— FRONT RIGHT ABNORMAL ABS SENSOR SIGNAL — S006583C54
NOTE:
REAR LEFT ABNORMAL ABS SENSOR SIGNAL —, Diagnostics Chart with Subaru Select Monitor.>
H: TROUBLE CODE 24
— FRONT LEFT ABNORMAL ABS SENSOR SIGNAL — S006583C64
NOTE:
I: TROUBLE CODE 26
— REAR RIGHT ABNORMAL ABS SENSOR SIGNAL — S006583C73
NOTE:
J: TROUBLE CODE 28
— REAR LEFT ABNORMAL ABS SENSOR SIGNAL — S006583C82
DIAGNOSIS:
TROUBLE SYMPTOM:
ABS-106
ABS (DIAGNOSTICS)
S4M0555
ABS-107
ABS (DIAGNOSTICS)
S4M0556
ABS-108
ABS (DIAGNOSTICS)

1 CHECK OUTPUT OF ABS SENSOR USING Does the speed indicated Go to step 2. Go to step 8.
SELECT MONITOR. on the display change in
1) Select “Current data display & Save” on response to the speedom-
the select monitor. eter reading during
2) Read the ABS sensor output corresponding acceleration/deceleration
to the faulty system in the select monitor data when the steering wheel is
display mode. in the straight-ahead posi-
tion?
Turn ignition switch to OFF. ABSCM&H/U and ABS
sensor?
transmitter.
harness.
1) Turn ignition switch to OFF. 0.5 Ω? ness.
2) Connect all connectors.
Trouble code 22 /
ground:
sis ground:
Trouble code 24 /
ground:
ground:
Trouble code 26 /
Trouble code 28 /
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-109
ABS (DIAGNOSTICS)

0.3 — 0.8 mm (0.012 — 0.031 in) No. 26755AA000).
replace worn sen-
sor or worn tone
wheel.
able?
NOTE:
code 29.
Trouble code 22 /
LHD turbo: (B62) No. 7 (+) — No. 18
(−):
14 (−):
RHD: (B100) No. 8 (+) — No. 20 (−):
Trouble code 24 /
LHD turbo: (B62) No. 9 (+) — No. 20
(−):
16 (−):
RHD turbo: (B100) No. 10 (+) — No. 22
(−):
Trouble code 26 /
LHD: (F55) No. 12 (+) — No. 11 (−):
RHD: (B98) No. 15 (+) — No. 16 (−):
Trouble code 28 /
LHD: (F55) No. 5 (+) — No. 4 (−):
RHD: (B98) No. 5 (+) — No. 6 (−):
Remove disc rotor or drum from hub in accor- nated by dirt or other for- other foreign mat-
dance with trouble code. eign matter? ter.
ABS-110
ABS (DIAGNOSTICS)

TONE WHEEL. aged in the ABS sensor sor or tone wheel.
piece or the tone wheel? Front: <Ref. to
ABS-14, Front
ABS Sensor.>
Rear: <Ref. to
ABS-18, Rear
ABS Sensor.> and
Front: <Ref. to
ABS-21, Front
Tone Wheel.>
Rear: <Ref. to
ABS-22, Rear
Tone Wheel.>
<Ref. to ABS-21,
Front Tone
Wheel.> Rear:
<Ref. to ABS-22,
Rear Tone
Wheel.>
15 CHECK RESISTANCE OF ABS SENSOR. Is the resistance between 1 Go to step 16. Replace ABS sen-
1) Turn ignition switch OFF. and 1.5 kΩ? sor. Front: <Ref.
3) Measure resistance between ABS sensor ABS Sensor.>
connector terminals. Rear: <Ref. to
SOR. 1 MΩ? sor. Front: <Ref.
Measure resistance between ABS sensor and to ABS-14, Front
chassis ground. ABS Sensor.>
Terminal Rear: <Ref. to
Front RH No. 1 — Chassis ground: ABS-18, Rear
Front LH No. 1 — Chassis ground: ABS Sensor.>
SOR. between
2) Disconnect connector from ABSCM&H/U. ABS sensor.
3) Measure resistance at ABSCM&H/U con-
nector terminals.
12:
10:
15:
ABS-111
ABS (DIAGNOSTICS)

18 CHECK GROUND SHORT OF HARNESS. Is the resistance more than Go to step 19. Repair harness/
Measure resistance between ABSCM&H/U 1 MΩ? connector
connector and chassis ground. between
Connector & terminal ABSCM&H/U and
Trouble code 22 / (F49) No. 11 — Chas- ABS sensor.
sis ground:
sis ground:
sis ground:
sis ground:
and chassis ground.
(F49) No. 23 — GND:
ABSCM&H/U and ABS
sensor?
transmitter.
harness.
1) Connect all connectors. 0.5 Ω? ness.
Trouble code 22 /
ground:
sis ground:
Trouble code 24 /
ground:
ground:
Trouble code 26 /
Trouble code 28 /
Control Unit
(ABSCM&H/U).>
ABS-112
ABS (DIAGNOSTICS)

sponding to the
trouble code.
ABS-113
ABS (DIAGNOSTICS)
K: TROUBLE CODE 29
— ABNORMAL ABS SENSOR SIGNAL ON ANY ONE OF FOUR SENSOR — S006583E78
DIAGNOSIS:
쐌 Faulty tone wheel
쐌 Wheels turning freely for a long time
TROUBLE SYMPTOM:
ABS-114
ABS (DIAGNOSTICS)
S4M0555
ABS-115
ABS (DIAGNOSTICS)
S4M0556
ABS-116
ABS (DIAGNOSTICS)

1 CHECK IF THE WHEELS HAVE TURNED Check if the wheels have The ABS is nor- Go to step 2.
FREELY FOR A LONG TIME. been turned freely for more mal. Erase the
than one minute, such as trouble code.
when the vehicle is jacked- NOTE:
up, under full-lock corner- When the wheels
ing or when tire is not in turn freely for a
contact with road surface. long time, such as
when the vehicle
is towed or
jacked-up, or
when steering
wheel is continu-
ously turned all
the way, this
trouble code may
sometimes occur.
2 CHECK TIRE SPECIFICATIONS. Are the tire specifications Go to step 3. Replace tire.
Turn ignition switch to OFF. correct?
3 CHECK WEAR OF TIRE. Is the tire worn exces- Replace tire. Go to step 4.
sively?
4 CHECK TIRE PRESSURE. Is the tire pressure correct? Go to step 5. Adjust tire pres-
sure.
0.3 — 0.8 mm (0.012 — 0.031 in) No. 26755AA000).
replace worn sen-
sor or worn tone
wheel.
able?
ABS-117
ABS (DIAGNOSTICS)

3) Connect the oscilloscope to the connector
(B99), (F95) or (F94) in accordance with
trouble code.
NOTE:
code 29.
Front RH
LHD turbo: (B62) No. 7 (+) — No. 18
(−):
14 (−):
RHD: (B100) No. 8 (+) — No. 20 (−):
Front LH
LHD turbo: (B62) No. 9 (+) — No. 20
(−):
16 (−):
RHD: (B100) No. 10 (+) — No. 22 (−):
Rear RH
LHD: (F55) No. 12 (+) — No. 11 (−):
RHD: (B98) No. 15 (+) — No. 16 (−):
Rear LH
LHD: (F55) No. 5 (+) — No. 4 (−):
RHD: (B98) No. 5 (+) — No. 6 (−):
Remove disc rotor from hub. nated by dirt or other for- other foreign mat-
eign matter? ter.
TONE WHEEL. aged teeth in the ABS sensor or tone wheel.
sor piece or the tone Front: <Ref. to
wheel? ABS-14, Front
ABS Sensor.>
Rear: <Ref. to
ABS-18, Rear
ABS Sensor.> and
Front: <Ref. to
ABS-21, Front
Tone Wheel.>
Rear: <Ref. to
ABS-22, Rear
Tone Wheel.>
<Ref. to ABS-21,
Front Tone
Wheel.> Rear:
<Ref. to ABS-22,
Rear Tone
Wheel.>
ABS-118
ABS (DIAGNOSTICS)

(ABSCM&H/U).>
sponding to the
trouble code.
ABS-119
ABS (DIAGNOSTICS)
L: TROUBLE CODE 31
— FRONT RIGHT INLET VALVE MALFUNCTION — S006583C93
NOTE:
REAR LEFT INLET VALVE MALFUNCTION —, Diagnostics Chart with Subaru Select Monitor.>
M: TROUBLE CODE 33
— FRONT LEFT INLET VALVE MALFUNCTION — S006583D03
NOTE:
N: TROUBLE CODE 35
— REAR RIGHT INLET VALVE MALFUNCTION — S006583D11
NOTE:
O: TROUBLE CODE 37
— REAR LEFT INLET VALVE MALFUNCTION — S006583D20
DIAGNOSIS:
쐌 Faulty inlet solenoid valve
TROUBLE SYMPTOM:
ABS-120
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
S4M0557
ABS-121
ABS (DIAGNOSTICS)

ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-122
ABS (DIAGNOSTICS)
MEMO:
ABS-123
ABS (DIAGNOSTICS)
P: TROUBLE CODE 32
— FRONT RIGHT OUTLET VALVE MALFUNCTION — S006583C99
NOTE:
REAR LEFT OUTLET VALVE MALFUNCTION —, Diagnostics Chart with Subaru Select Monitor.>
Q: TROUBLE CODE 34
— FRONT LEFT OUTLET VALVE MALFUNCTION — S006583D08
NOTE:
R: TROUBLE CODE 36
— REAR RIGHT OUTLET VALVE MALFUNCTION — S006583D15
NOTE:
S: TROUBLE CODE 38
— REAR LEFT OUTLET VALVE MALFUNCTION — S006583D24
DIAGNOSIS:
쐌 Faulty outlet solenoid valve
TROUBLE SYMPTOM:
ABS-124
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
S4M0557
ABS-125
ABS (DIAGNOSTICS)

ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-126
ABS (DIAGNOSTICS)
MEMO:
ABS-127
ABS (DIAGNOSTICS)
T: TROUBLE CODE 41
— ABS CONTROL MODULE MALFUNCTION — S006583D31
DIAGNOSIS:
쐌 Faulty ABSCM&H/U
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B4M1457
ABS-128
ABS (DIAGNOSTICS)

and chassis ground.
battery, ignition switch and
ABSCM&H/U?
transmitter.
harness.
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-129
ABS (DIAGNOSTICS)
U: TROUBLE CODE 42
— POWER SUPPLY VOLTAGE TOO LOW — S006583D36
DIAGNOSIS:
쐌 Power source voltage of the ABSCM&H/U is low.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
S4M0557
ABS-130
ABS (DIAGNOSTICS)

Terminal
ground:
clamped?
2) Run the engine at idle. between battery,
3) Measure voltage between ABSCM&H/U ignition switch and
connector and chassis ground. ABSCM&H/U.
ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-131
ABS (DIAGNOSTICS)
V: TROUBLE CODE 42
— POWER SUPPLY VOLTAGE TOO HIGH — S006583D35
DIAGNOSIS:
쐌 Power source voltage of the ABSCM&H/U is high.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
S4M0557
ABS-132
ABS (DIAGNOSTICS)

Terminal
ground:
clamped?
ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-133
ABS (DIAGNOSTICS)
W: TROUBLE CODE 44
— ABS-AT CONTROL (NON CONTROLLED) — S006583E79
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
S4M0558
ABS-134
ABS (DIAGNOSTICS)

1 CHECK SPECIFICATIONS OF THE Is an ABSCM&H/U for AT Replace Go to step 2.
ABSCM&H/U. model installed on a MT ABSCM&H/U.
Check specifications of the mark to the model? <Ref. to ABS-7,
ABSCM&H/U. ABS Control Mod-
C7: AT ule and Hydraulic
C8: MT Control Unit
(ABSCM&H/U).>
1) Turn ignition switch to OFF. 1 MΩ? between TCM and
3 CHECK TCM. Is the voltage between 10 Go to step 5. Go to step 4.
1) Connect all connectors to TCM. and 15 V?
3) Measure voltage between TCM connector
4 CHECK AT. Is the AT functioning nor- Replace TCM. Repair AT.
mally?
5 CHECK OPEN CIRCUIT OF HARNESS. Is the voltage more than 10 Go to step 6. Repair harness/
Measure voltage between ABSCM&H/U con- V? connector
nector and chassis ground. between TCM and
and ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-135
ABS (DIAGNOSTICS)
X: TROUBLE CODE 44
— ABS-AT CONTROL (CONTROLLED) — S006583E80
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
S4M0558
ABS-136
ABS (DIAGNOSTICS)

1) Turn ignition switch to OFF. V? between TCM and
1) Turn ignition switch to ON. V? between TCM and
3 CHECK OPEN CIRCUIT OF HARNESS. Is the voltage between 10 Go to step 4. Repair harness/
2) Connect all connectors to TCM. between TCM and
Turn ignition switch to OFF. and ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-137
ABS (DIAGNOSTICS)
Y: TROUBLE CODE 51
— VALVE RELAY MALFUNCTION — S006583E81
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
S4M0559
ABS-138
ABS (DIAGNOSTICS)

ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-139
ABS (DIAGNOSTICS)
Z: TROUBLE CODE 51
— VALVE RELAY ON FAILURE — S006583D63
DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
S4M0559
ABS-140
ABS (DIAGNOSTICS)

1 CHECK VALVE RELAY IN ABSCM&H/U. Is the resistance more than Go to step 2. Replace
No. 23 (+) — No. 24 (−): ule and Hydraulic
Control Unit
(ABSCM&H/U).>
ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-141
ABS (DIAGNOSTICS)
AA: TROUBLE CODE 52

— OPEN CIRCUIT IN MOTOR RELAY CIRCUIT — S006583E82
DIAGNOSIS:
쐌 Faulty motor
TROUBLE SYMPTOM:
ABS-142
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
S4M0560
ABS-143
ABS (DIAGNOSTICS)

connector and chassis ground. SBF6.
11, ABS Sequence Control.> rying out the check <Ref. to ABS-7,
NOTE: sequence? ABS Control Mod-
(ABSCM&H/U).>
TORS. connector between hydrau-
Turn ignition switch to OFF. lic unit, relay box and
ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-144
ABS (DIAGNOSTICS)
MEMO:
ABS-145
ABS (DIAGNOSTICS)
AB: TROUBLE CODE 52

— MOTOR RELAY ON FAILURE — S006583E83
DIAGNOSIS:
쐌 Faulty motor
TROUBLE SYMPTOM:
ABS-146
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
S4M0560
ABS-147
ABS (DIAGNOSTICS)

1 CHECK MOTOR RELAY IN ABSCM&H/U. Is the resistance more than Go to step 2. Replace
Control Unit
(ABSCM&H/U).>
(ABSCM&H/U).>
TORS. connector between hydrau-
Turn ignition switch to OFF. lic unit, relay box and
ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-148
ABS (DIAGNOSTICS)
MEMO:
ABS-149
ABS (DIAGNOSTICS)
AC: TROUBLE CODE 52

— MOTOR MALFUNCTION — S006583D68
DIAGNOSIS:
쐌 Faulty motor
TROUBLE SYMPTOM:
ABS-150
ABS (DIAGNOSTICS)
WIRING DIAGRAM:
S4M0560
ABS-151
ABS (DIAGNOSTICS)

connector and chassis ground. SBF6.
1) Run the engine at idle. and 15 V? connector
2) Measure voltage between ABSCM&H/U between battery,
connector and chassis ground. ignition switch and
(ABSCM&H/U).>
Turn ignition switch to OFF. generator, battery and
ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-152
ABS (DIAGNOSTICS)
MEMO:
ABS-153
ABS (DIAGNOSTICS)
AD: TROUBLE CODE 54

— STOP LIGHT SWITCH SIGNAL CIRCUIT MALFUNCTION — S006583E84
DIAGNOSIS:
쐌 Faulty stop light switch
TROUBLE SYMPTOM:
WIRING DIAGRAM:
S4M0561
ABS-154
ABS (DIAGNOSTICS)

1 CHECK OUTPUT OF STOP LIGHT SWITCH Is the reading indicated on Go to step 2. Go to step 3.
USING SELECT MONITOR. monitor display less than
1) Select “Current data display & Save” on 1.5 V?
the select monitor.
2) Release the brake pedal.
3) Read the stop light switch output in the
select monitor data display.
2 CHECK OUTPUT OF STOP LIGHT SWITCH Is the reading indicated on Go to step 5. Go to step 3.
USING SELECT MONITOR. monitor display between 10
1) Depress the brake pedal. and 15 V?
2) Read the stop light switch output in the
select monitor data display.
3 CHECK IF STOP LIGHTS COME ON. Do stop lights turn on? Go to step 4. Repair stop lights
Depress the brake pedal. circuit.
4 CHECK OPEN CIRCUIT IN HARNESS. Is the voltage between 10 Go to step 5. Repair harness
1) Turn ignition switch to OFF. and 15 V? between stop light
2) Disconnect connector from ABSCM&H/U. switch and
3) Depress brake pedal. ABSCM&H/U con-
4) Measure voltage between ABSCM&H/U nector.
TORS. connector between stop
light switch and
ABSCM&H/U?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-155
ABS (DIAGNOSTICS)
AE: TROUBLE CODE 56

— OPEN OR SHORT CIRCUIT IN G SENSOR CIRCUIT — S006583E85
DIAGNOSIS:
TROUBLE SYMPTOM:
S4M0562
ABS-156
ABS (DIAGNOSTICS)
S4M0563
ABS-157
ABS (DIAGNOSTICS)

1 CHECK OUTPUT OF G SENSOR USING Is the G sensor output on Go to step 2. Go to step 5.
SELECT MONITOR. the monitor display
1) Select “Current data display & Save” on between 2.1 and 2.5 V
the select monitor. when the G sensor is in
2) Read the G sensor output in select monitor horizontal position?
data display.
sor?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
nector terminals.
(R70) No. 1 (+) — No. 3 (−):
(F49) No. 6 — No. 28:
7 CHECK GROUND SHORT IN G SENSOR Is the resistance more than Go to step 8. Repair harness
OUTPUT HARNESS. 1 MΩ? between G sensor
1) Disconnect connector from G sensor. and ABSCM&H/U.
1) Connect connector to G sensor. and 2.5 V when G sensor sor. <Ref. to ABS-
2) Connect connector to ABSCM&H/U. is horizontal? 23, G Sensor.>
nector terminals.
(R70) No. 2 (+) — No. 3 (−):
(R70) No. 2 (+) — No. 3 (−):
ABS-158
ABS (DIAGNOSTICS)

(R70) No. 2 (+) — No. 3 (−):
Turn ignition switch to OFF. ABSCM&H/U and G sen-
sor?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-159
ABS (DIAGNOSTICS)
AF: TROUBLE CODE 56

— BATTERY SHORT IN G SENSOR CIRCUIT — S006583E86
DIAGNOSIS:
TROUBLE SYMPTOM:
S4M0562
ABS-160
ABS (DIAGNOSTICS)
S4M0563
ABS-161
ABS (DIAGNOSTICS)

the select monitor. when the G sensor is in
2) Read the G sensor output in select monitor horizontal position?
data display.
sor?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
5 CHECK FREEZE FRAME DATA. Is the front right wheel Go to step 6. Go to step 16.
1) Select “Freeze frame data” on the select speed on monitor display 0
monitor. km?
2) Read front right wheel speed on the select
monitor display.
6 CHECK FREEZE FRAME DATA. Is the front left wheel Go to step 7. Go to step 16.
Read front left wheel speed on the select speed on monitor display 0
monitor display. km?
7 CHECK FREEZE FRAME DATA. Is the rear right wheel Go to step 8. Go to step 16.
Read rear right wheel speed on the select speed on monitor display 0
monitor display. km?
8 CHECK FREEZE FRAME DATA. Is the rear left wheel speed Go to step 9. Go to step 16.
Read rear left wheel speed on the select on monitor display 0 km?
monitor display.
9 CHECK FREEZE FRAME DATA. Is the G sensor output on Go to step 10. Go to step 16.
Read G sensor output on the select monitor monitor display more than
display. 3.65 V?
(F49) No. 6 — No. 28:
1) Turn ignition switch to OFF. V? between G sensor
2) Remove console box. and ABSCM&H/U.
3) Disconnect connector from G sensor.
ABS-162
ABS (DIAGNOSTICS)

1) Turn ignition switch to ON. V? between G sensor
2) Measure voltage between ABSCM&H/U and ABSCM&H/U.
sor?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
nector terminals.
(R70) No. 1 (+) — No. 3 (−):
(F49) No. 6 — No. 28:
1) Connect connector to G sensor. and 2.5 V when G sensor sor. <Ref. to ABS-
2) Connect connector to ABSCM&H/U. is horizontal? 23, G Sensor.>
nector terminals.
(R70) No. 2 (+) — No. 3 (−):
(R70) No. 2 (+) — No. 3 (−):
(R70) No. 2 (+) — No. 3 (−):
ABS-163
ABS (DIAGNOSTICS)

sor?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-164
ABS (DIAGNOSTICS)
MEMO:
ABS-165
ABS (DIAGNOSTICS)
AG: TROUBLE CODE 56

— ABNORMAL G SENSOR HIGH µ OUTPUT — S006583E87
DIAGNOSIS:
TROUBLE SYMPTOM:
S4M0562
ABS-166
ABS (DIAGNOSTICS)
S4M0563
ABS-167
ABS (DIAGNOSTICS)

SELECT MONITOR. monitor display between
1) Select “Current data display & Save” on 2.1 and 2.5 V when the G
the select monitor. sensor is in horizontal posi-
2) Read G sensor output on the select moni- tion?
tor display.
sor?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
(F49) No. 6 — No. 28:
Measure resistance between ABSCM&H/U 1 MΩ? between G sensor
connector and chassis ground. and ABSCM&H/U.
Connector & terminal Replace
(F49) No. 28 — Chassis ground: ABSCM&H/U.
<Ref. to ABS-7,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
1) Remove console box. and 2.5 V when G sensor sor. <Ref. to ABS-
nector terminals.
(R70) No. 2 (+) — No. 3 (−):
(R70) No. 2 (+) — No. 3 (−):
(R70) No. 2 (+) — No. 3 (−):
ABS-168
ABS (DIAGNOSTICS)

(ABSCM&H/U).>
sponding to the
trouble code.
ABS-169
ABS (DIAGNOSTICS)
AH: TROUBLE CODE 56

— DETECTION OF G SENSOR STICK — S006583E88
DIAGNOSIS:
TROUBLE SYMPTOM:
S4M0562
ABS-170
ABS (DIAGNOSTICS)
S4M0563
ABS-171
ABS (DIAGNOSTICS)

1 CHECK ALL FOUR WHEELS FOR FREE Have the wheels been The ABS is nor- Go to step 2.
TURNING. turned freely such as when mal. Erase the
the vehicle is lifted up, or trouble code.
operated on a rolling road?
the select monitor. when the vehicle is in hori-
2) Read the select monitor display. zontal position?
3 CHECK OUTPUT OF G SENSOR USING Is the G sensor output on Go to step 4. Replace G sen-
SELECT MONITOR. the monitor display sor. <Ref. to ABS-
1) Turn ignition switch to OFF. between 3.7 and 4.1 V 23, G Sensor.>
2) Remove console box. when G sensor is inclined
3) Remove G sensor from vehicle. (Do not forwards to 90°?
5) Select “Current data display & Save” on
the select monitor.
6) Read the select monitor display.
4 CHECK OUTPUT OF G SENSOR USING Is the G sensor output on Go to step 5. Replace G sen-
SELECT MONITOR. the monitor display sor. <Ref. to ABS-
Read the select monitor display. between 0.5 and 0.9 V 23, G Sensor.>
when G sensor is inclined
backwards to 90°?
sor?
Control Unit
(ABSCM&H/U).>
sponding to the
trouble code.
(F49) No. 6 — No. 28:
1) Remove console box. and 2.5 V when G sensor sor. <Ref. to ABS-
nector terminals.
(R70) No. 2 (+) — No. 3 (−):
ABS-172
ABS (DIAGNOSTICS)

(R70) No. 2 (+) — No. 3 (−):
(R70) No. 2 (+) — No. 3 (−):
(ABSCM&H/U).>
sponding to the
trouble code.
ABS-173
GENERAL DIAGNOSTICS TABLE
ABS (DIAGNOSTICS)
14. General Diagnostics Table S006121
Symptom Probable faulty units/parts

쐌 ABSCM&H/U (solenoid valve)
쐌 ABS sensor
쐌 Brake (caliper & piston, pads)
Vehicle pulls to either side. 쐌 Wheel alignment
쐌 Tire specifications, tire wear and air pressures
쐌 Incorrect wiring or piping connections
Vehicle instability during braking 쐌 Road surface (uneven, camber)
쐌 ABS sensor
Vehicle spins. 쐌 Brake (pads)
쐌 Brake (pads)
Long braking/stopping distance 쐌 Air in brake line
쐌 ABSCM&H/U (solenoid valve, motor)
Wheel locks. 쐌 ABS sensor
쐌 ABS sensor
쐌 Master cylinder
Brake dragging 쐌 Brake (caliper & piston)
쐌 Parking brake
Poor braking 쐌 Axle & wheels
쐌 Brake pedal play
쐌 Air in brake line
Long brake pedal stroke
쐌 Brake pedal play
쐌 Suspension play or fatigue (reduced damping)
Vehicle pitching 쐌 Incorrect wiring or piping connections
쐌 Road surface (uneven)
쐌 ABS sensor
쐌 Brake (caliper & piston, pads)
Unstable or uneven braking
Excessive pedal vibration
쐌 ABSCM&H/U (mount bushing)
Noise from ABSCM&H/U 쐌 ABS sensor
쐌 Brake piping
쐌 ABSCM&H/U (mount bushing)
쐌 ABS sensor
쐌 Master cylinder
Vibration and/or noise
Noise from front of vehicle 쐌 Brake (caliper & piston, pads, rotor)
(while driving on slippery roads)
쐌 Brake piping
쐌 Brake booster & check valve
쐌 Suspension play or fatigue
쐌 ABS sensor
쐌 Brake (caliper & piston, pads, rotor)
Noise from rear of vehicle 쐌 Parking brake
쐌 Brake piping
쐌 Suspension play or fatigue
ABS-174
FUEL INJECTION (FUEL SYSTEMS)
FU(SOHC)
Page
2. Throttle Body .............................................................................................14
3. Intake Manifold ..........................................................................................15
4. Engine Coolant Temperature Sensor........................................................28
5. Crankshaft Position Sensor.......................................................................29
6. Camshaft Position Sensor.........................................................................30
7. Knock Sensor ............................................................................................31
8. Throttle Position Sensor............................................................................33
9. Intake Air Temperature and Pressure Sensor...........................................36
10. Atmospheric Pressure Sensor ..................................................................37
11. Idle Air Control Solenoid Valve .................................................................38
12. Air Assist Injector Solenoid Valve .............................................................39
13. Fuel Injector...............................................................................................40
14. Front Oxygen (A/F) Sensor.......................................................................45
15. Rear Oxygen Sensor.................................................................................47
16. Engine Control Module..............................................................................49
17. Main Relay ................................................................................................50
18. Fuel Pump Relay.......................................................................................51
19. Fuel............................................................................................................52
20. Fuel Tank...................................................................................................55
21. Fuel Filler Pipe ..........................................................................................58
22. Fuel Pump .................................................................................................62
23. Fuel Level Sensor .....................................................................................64
24. Fuel Sub Level Sensor..............................................................................65
25. Fuel Filter ..................................................................................................66
26. Fuel Cut Valve...........................................................................................67
27. Fuel Damper Valve....................................................................................68
28. Fuel Delivery, Return and Evaporation Lines ...........................................69
29. Fuel System Trouble in General ...............................................................72
GENERAL DESCRIPTION
Fuel Injection (Fuel Systems)
Model
Capacity 60 (15.9 US gal, 13.2 Imp gal)
Fuel tank
Location Under rear seat
Type Impeller
Shutoff discharge pressure 373 — 677 kPa (3.8 — 6.9 kg/cm2, 54 — 98 psi)
Fuel pump
More than 65 (17.2 US gal, 14.3 Imp gal)/h
Discharge flow
[12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)]
Fuel filter Cartridge type
FU(SOHC)-2
GENERAL DESCRIPTION
MEMO:
FU(SOHC)-3
GENERAL DESCRIPTION
1. INTAKE MANIFOLD S155001A0501
S2M2151A
FU(SOHC)-4
GENERAL DESCRIPTION
(1) Intake manifold gasket (15) O-ring (28) Plug (RHD model)
(2) Fuel injector pipe RH (16) Plug cord holder LH
(3) Fuel injector (17) Plug cord holder RH Tightening torque: N·m (kgf-m, ft-lb)
(4) O-ring (18) Fuel pipe ASSY T1: 3.4 (0.35, 2.5)
(5) O-ring (19) Fuel hose T2: 4.9 (0.50, 3.6)
(6) O-ring (20) Clip T3: 6.4 (0.65, 4.7)
(7) Plug (LHD model) (21) Clip T4: 19 (1.9, 13.7)
(8) PCV valve (22) Air assist injector solenoid valve T5: 16 (1.6, 12)
(9) Purge control solenoid valve (23) Air assist injector solenoid valve
T6: 25 (2.6, 18.8)
(10) Nipple (LHD model) bracket
T7: 7.35 (0.75, 5.421)
(11) Intake manifold (24) Guide pin
T8: 17 (1.7, 12)
(12) Fuel injector pipe LH (25) Atmospheric pressure sensor
(13) Accelerator cable bracket bracket T9: 1.5 (0.15, 1.1)
(14) Intake air temperature and pres- (26) Atmospheric pressure sensor
sure sensor (27) Nipple (RHD model)
FU(SOHC)-5
GENERAL DESCRIPTION
2. AIR INTAKE SYSTEM S155001A0502
B2M3455C
(1) Gasket (4) Throttle body Tightening torque: N·m (kgf-m, ft-lb)
(2) Throttle position sensor
T1: 1.6 (0.16, 1.2)
(3) Idle air control solenoid valve
T2: 22 (2.2, 16)
FU(SOHC)-6
GENERAL DESCRIPTION
3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS S155001A0503
B2M2282B
(1) Crankshaft position sensor Tightening torque: N·m (kgf-m, ft-lb)

(2) Knock sensor
T1: 6.4 (0.65, 4.7)
(3) Camshaft position sensor
T2: 24 (2.4, 17.4)
(4) Camshaft position sensor sup-
port
FU(SOHC)-7
GENERAL DESCRIPTION
4. FUEL TANK S155001A0504
S2M2152A
FU(SOHC)-8
GENERAL DESCRIPTION
(1) Heat sealed cover (13) Evaporation hose B (25) Fuel return hose B
(2) Fuel tank band (14) Joint pipe (26) Fuel sub level sensor gasket
(3) Protector LH (15) Evaporation hose C (27) Jet pump filter
(4) Protector RH (16) Evaporation pipe ASSY (28) Fuel sub level sensor
(5) Fuel tank (17) Evaporation hose D (29) Evaporation hose H
(6) Fuel pump gasket (18) Evaporation hose E (30) Evaporation hose I
(7) Fuel pump ASSY (19) Fuel return hose A
(8) Fuel level sensor (20) Retainer Tightening torque: N·m (kgf-m, ft-lb)
(9) Fuel cut valve gasket (21) Quick connector T1: 4.4 (0.45, 3.3)
(10) Fuel cut valve (22) Evaporation hose F T2: 7.4 (0.75, 5.4)
(11) Evaporation hose A (23) Fuel pipe ASSY T3: 33 (3.4, 25)
(12) Clip (24) Evaporation hose G
FU(SOHC)-9
GENERAL DESCRIPTION
5. FUEL LINE S155001A0505
S2M2153A
FU(SOHC)-10
GENERAL DESCRIPTION
(1) Clip (13) Canister hose A (25) Front canister bracket

(2) Fuel delivery hose A (14) Canister (26) Evaporation hose B
(3) Fuel filter bracket (15) Canister bracket plate (27) Roll over valve bracket
(4) Fuel filter holder (16) Cushion (28) Roll over valve
(5) Fuel filter cup (17) Canister bracket spacer (29) Evaporation hose C
(6) Fuel filter (18) Rear canister bracket (30) Evaporation pipe
(7) Evaporation hose A (19) Two-way valve return hose (31) Canister hose B
(8) Fuel damper (20) Two-way valve
(9) Fuel delivery hose B (21) Two-way valve drain hose A Tightening torque: N·m (kgf-m, ft-lb)
(10) Fuel return hose (22) Connector T: 23 (2.34, 17.0)
(11) Fuel pipe ASSY (23) Two-way valve drain hose B
(12) Grommet (24) Clamp
FU(SOHC)-11
GENERAL DESCRIPTION
6. FUEL FILLER PIPE S155001A0506
S2M2245A
(1) Fuel filler pipe ASSY (6) Air vent pipe (11) Fuel filler pipe protector
(2) Evaporation hose holder (7) Air vent pipe holder
(3) Clamp (8) Filler pipe packing Tightening torque: N·m (kgf-m, ft-lb)
(4) Clamp (9) Filler ring T: 7.5 (0.76, 5.53)
(5) Air vent hose (10) Filler cap
FU(SOHC)-12
GENERAL DESCRIPTION
C: CAUTION S155001A03 쐌 Be careful not to burn your hands, because each

쐌 Wear working clothing, including a cap, protec- 쐌 Be sure to tighten fasteners including bolts and
tive goggles, and protective shoes during opera- nuts to the specified torque.
tion.
sion before removal, installation or disassembly. fied points.
쐌 Keep the disassembled parts in order and pro- 쐌 Before disconnecting electrical connectors of
tect them from dust or dirt. sensors or units, be sure to disconnect negative
쐌 Before removal, installation or disassembly, be terminal from battery.
sure to clarify the failure. Avoid unnecessary 쐌 Place “NO FIRE” signs near the working area.
removal, installation, disassembly, and replace- 쐌 Be careful not to spill fuel on the floor.
ment.

24082AA150 CARTRIDGE Troubleshooting for electrical system.
B2M3876
B2M3877
FU(SOHC)-13
THROTTLE BODY
2. Throttle Body S155010

5) Disconnect connectors from idle air control
solenoid valve, throttle position sensor.
A: REMOVAL S155010A18 6) Disconnect air by-pass hose from throttle body.
B2M3457A
G6M0095 (A) Throttle position sensor

(B) Idle air control solenoid valve
2) Remove air cleaner case. (C) Air by-pass hose
7) Disconnect engine coolant hoses from throttle

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

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

NOTE:
Always use a new gasket.
Tightening torque:
Throttle body;
22 N·m (2.2 kgf-m, 15.9 ft-lb)
B2M4254A
Air cleaner case;
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
FU(SOHC)-14
INTAKE MANIFOLD
3. Intake Manifold S155034

NOTE:
Do not disconnect power steering hose.
1) Release fuel pressure. <Ref. to FU(SOHC)-52,

RELEASING OF FUEL PRESSURE,
OPERATION, Fuel.>
2) Open fuel flap lid, and remove fuel filler cap.
S2M1013
(4) Remove bolts which install power steering

pump bracket.
G6M0095
4) Remove air intake duct and air cleaner assem-

bly. <Ref. to IN(SOHC)-8, REMOVAL, Air Intake
Duct.> and <Ref. to IN(SOHC)-7, REMOVAL , Air
Cleaner Case.>
6) Disconnect cruise control cable (B). (With
S2M0488
(5) Disconnect connector from power steering
pump switch.
B2M4254A
7) Remove power steering pump and tank from

S2M0490
brackets.
(1) Remove resonator chamber. <Ref. to (6) Place power steering pump and tank on the
IN(SOHC)-9, REMOVAL, Resonator Chamber.> right side wheel apron.
(2) Remove front side V-belt. <Ref. to
ME(SOHC)-42, REMOVAL, V-belt.>
(3) Remove bolts which hold power steering
pipes brackets onto intake manifold.
S2M0491
8) Disconnect spark plug cords from spark plugs.
FU(SOHC)-15
INTAKE MANIFOLD
9) Disconnect PCV hose from intake manifold. 13) Disconnect connectors from engine coolant
temperature sensor.
B2M4258
B2M4261
10) Disconnect engine coolant hose from throttle
body. 14) Disconnect knock sensor connector.
B2M4255 B2M4262
11) Disconnect brake booster hose. 15) Disconnect connector from crankshaft position
sensor.
B2M4259
B2M1252
12) Remove air cleaner case stay RH and engine
harness bracket, and disconnect engine harness 16) Disconnect connector from oil pressure
connectors from bulkhead harness connectors. switch.
B2M4260 B2M1253
FU(SOHC)-16
INTAKE MANIFOLD
17) Disconnect connector from camshaft position 20) Remove intake manifold.
sensor.
B2M0160
B2M4263
18) Disconnect fuel hoses from fuel pipes. B: INSTALLATION S155034A11
WARNING: 1) Install intake manifold onto cylinder heads.

쐌 Do not spill fuel. NOTE:
쐌 Catch fuel from hoses in a container or cloth. Always use new gaskets.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
S2M0500F
(A) Fuel delivery hose

(B) Return hose S2M1660
(C) Evaporation hose
2) Connect fuel hoses.
19) Remove bolts which hold intake manifold onto
cylinder heads.
S2M0500F
S2M1660 (A) Fuel delivery hose

(B) Return hose
FU(SOHC)-17
INTAKE MANIFOLD
3) Connect connector to camshaft position sensor. 7) Connect connectors to engine coolant tempera-
ture sensor.
B2M4263
B2M4261
4) Connect connector to oil pressure switch.
8) Install air cleaner case stay RH and engine har-
ness bracket, and connect engine harness con-
nectors to bulkhead connectors.
B2M1253
5) Connect connector to crankshaft position sen-

sor. B2M4260
9) Connect brake booster hose.
B2M1252
6) Connect knock sensor connector. B2M4259
10) Connect engine coolant hose to throttle body.
B2M4262
B2M4255
FU(SOHC)-18
INTAKE MANIFOLD
11) Connect PCV hose to intake manifold. (3) Install power steering pipe brackets onto
right side intake manifold.
B2M4258
S2M1013
12) Connect spark plug cords to spark plugs.
13) Install power steering pump on brackets. (4) Install front side V-belt. <Ref. to
(1) Connect terminal to power steering pump ME(SOHC)-42, INSTALLATION, V-belt.>
switch. (5) Install resonator chamber.
Tightening torque:
33 N·m (3.4 kgf-m, 24.6 ft-lb)
S2M0490
(2) Tighten bolts which install power steering

pump on bracket. S2M0481A
Tightening torque: 14) Connect accelerator cable (A).

20.1 N·m (2.05 kgf-m, 14.8 ft-lb) 15) Connect cruise control cable (B). (With cruise
control models)
S2M0488
B2M4254A
16) Install air intake duct and air cleaner assem-

Duct.> and <Ref. to IN(SOHC)-7, INSTALLATION,
Air Cleaner Case.>
FU(SOHC)-19
INTAKE MANIFOLD
17) Connect connector to fuel pump relay. 3) Remove ignition coil and ignitor assembly.
S2M0093 B2M3473
18) Connect battery ground cable. 4) Disconnect connector from intake air tempera-
ture and pressure sensor.
G6M0095
B2M3474
C: DISASSEMBLY S155034A06 5) Remove intake air temperature and pressure

1) Disconnect engine ground terminal from intake sensor from intake manifold.
manifold.
B2M3475
B2M4265 6) Disconnect connectors from throttle position

2) Disconnect connector from ignition coil and sensor and idle air control solenoid valve.
ignitor assembly.
B2M3479
B2M3472
FU(SOHC)-20
INTAKE MANIFOLD
7) Disconnect air by-pass hose from throttle body. 12) Disconnect pressure regulator vacuum hose
from intake manifold.
B2M3480
H2M2961
8) Remove throttle body.
13) Disconnect connectors from fuel injectors.
H2M2951
B2M4270
9) Disconnect connector from air assist injector
solenoid valve. 14) Disconnect connector from purge control sole-
noid valve.
10) Disconnect air by-pass hoses from air assist
solenoid valve.
B2M3485
B2M4266 15) Disconnect air by-pass hose from purge con-

trol solenoid valve.
11) Remove air assist injector solenoid valve from 16) Remove harness bands (A) and harness
intake manifold. bracket (B) which hold engine harness onto intake
manifold.
B2M3478
B2M4271A
FU(SOHC)-21
INTAKE MANIFOLD
17) Remove engine harness from intake manifold. 22) Remove fuel injectors.
18) Remove purge control solenoid valve. (1) Remove fuel injector securing clip.
B2M3487 B2M3488
19) Remove bolt which installs injector pipe on (2) Remove fuel injector while lifting up fuel
intake manifold as shown in figure. injector pipe.
S2M2261 H2M2970
20) Remove bolt which installs injector pipe on 23) Disconnect air by-pass hoses from intake
intake manifold. manifold.
H2M2966 B2M4149A
21) Remove two bolts which hold fuel pipes on the 24) Loosen clamp which holds front left side fuel
left side of intake manifold. hose to injector pipe and remove the pipe from fuel
hose.
B2M4272
B2M4273
FU(SOHC)-22
INTAKE MANIFOLD
25) Loosen clamp which holds front right side fuel 2) Tighten bolt which installs fuel pipes on intake
hose to injector pipe and remove the pipe from fuel manifold.
hose. Tightening torque:
4.9 N·m (0.5 kgf-m, 3.6 ft-lb)
B2M4274
26) Remove fuel injector pipe. B2M3491
3) Connect right side fuel hose to injector pipe,

and tighten clamp screw.
H2M2975
27) Remove bolt which installs fuel pipes on

intake manifold. B2M4274
4) Install fuel injector pipe.
B2M3491
H2M2975
28) Remove fuel pipe assembly and pressure
regulator, from intake manifold. 5) Connect left side fuel hose to injector pipe, and
tighten clamp screw.
1) Install fuel pipe assembly and pressure

regulator, etc. to intake manifold.
B2M4273
FU(SOHC)-23
INTAKE MANIFOLD
6) Connect air assist hoses. 8) Tighten bolt which installs injector pipe on
intake manifold.
Tightening torque:
4.9 N·m (0.50 kgf-m, 3.6 ft-lb)
B2M4149A
7) Install fuel injectors.

NOTE: H2M2965
Always use new O-rings.
9) Tighten two bolts which install fuel pipes on the
left side of intake manifold.
Tightening torque:
4.9 N·m (0.50 kgf-m, 3.6 ft-lb)
B2M3492G
(A) O-ring
(B) Fuel injector
NOTE: B2M4272
Do not forget to install the fuel injector securing
clip. 10) Tighten bolt which installs injector pipe on
intake manifold.
Tightening torque:
4.9 N·m (0.50 kgf-m, 3.6 ft-lb)
B2M3488
H2M2966
FU(SOHC)-24
INTAKE MANIFOLD
11) Install purge control solenoid valve. 16) Connect pressure regulator vacuum hose to
Tightening torque: intake manifold.
16 N·m (1.6 kgf-m, 12 ft-lb)
H2M2961
B2M3487 17) Install air assist injector solenoid valve to

12) Connect hoses to purge control solenoid bracket.
valve. Tightening torque:
CAUTION: 4.9 N·m (0.50 kgf-m, 3.6 ft-lb)
Carefully connect the evaporation hoses.
B2M3478
B2M1893A 18) Connect air by-pass hoses to air assist sole-

13) Install engine harness onto intake manifold. noid valve.
14) Connect connectors to fuel injectors and
purge control solenoid valve.
15) Hold engine harness by harness band (A) and
harness bracket (B).
Tightening torque:
16 N·m (1.6 kgf-m, 12 ft-lb)
B2M4266
19) Connect connector to air assist solenoid

valve.
B2M4271B
FU(SOHC)-25
INTAKE MANIFOLD
20) Install throttle body to intake manifold. 23) Install intake air temperature and pressure
NOTE: sensor.
Replace gasket with a new one. Tightening torque:
Tightening torque: 3.4 N·m (0.35 kgf-m, 2.5 ft-lb)
22 N·m (2.2 kgf-m, 15.9 ft-lb)
B2M3475
H2M2951
NOTE:
21) Connect connector to throttle position sensor Replace O-ring with a new one.
and idle air control solenoid valve.
H2M2999
B2M3479
24) Connect connector to intake air temperature
22) Connect air by-pass hose to throttle body. and pressure sensor.
25) Install ignition coil and ignitor assembly.
B2M3480
B2M3473
FU(SOHC)-26
INTAKE MANIFOLD
26) Connect connector to ignition coil and ignitor

assembly.
27) Install engine ground terminal to intake mani-
fold.
Tightening torque:
19 N·m (1.9 kgf-m, 13.7 ft-lb)
B2M2779
Make sure the fuel pipe and fuel hoses are not
cracked and that connections are tight.
FU(SOHC)-27
ENGINE COOLANT TEMPERATURE SENSOR
4. Engine Coolant Temperature

Sensor S155047
G6M0095
2) Remove air intake duct and air cleaner assem-

Duct.> and <Ref. to IN(SOHC)-7, REMOVAL , Air
Cleaner Case.>
3) Disconnect connector from engine coolant tem-
perature sensor.
B2M4261
4) Remove engine coolant temperature sensor.

Tightening torque:
18 N·m (1.8 kgf-m, 13 ft-lb)
B2M4275
FU(SOHC)-28
CRANKSHAFT POSITION SENSOR
5. Crankshaft Position Sensor B: INSTALLATION S155043A11
S155043
A: REMOVAL S155043A18 Tightening torque:
T: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
B2M1252B
G6M0095
2) Remove bolt which installs crankshaft position

sensor to cylinder block.
G2M0408
3) Remove crankshaft position sensor, and dis-

connect connector from it.
G2M0409
FU(SOHC)-29
CAMSHAFT POSITION SENSOR
6. Camshaft Position Sensor 4) Remove bolt which installs camshaft position

sensor support to camshaft cap LH.
S155041
B2M2321
5) Remove camshaft position sensor and cam-

shaft position sensor support as a unit.
G6M0095 6) Remove camshaft position sensor itself.
2) Disconnect connector from camshaft position

sensor.
B2M2322
B2M4263

3) Remove bolt which installs camshaft position
sensor to camshaft position sensor support. Tightening torque:
쐌 Camshaft position sensor support;
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
쐌 Camshaft position sensor;
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
B2M2375
FU(SOHC)-30
KNOCK SENSOR
7. Knock Sensor S155042 B: INSTALLATION S155042A11
1) Install knock sensor to cylinder block.
1) Disconnect battery ground cable from battery Tightening torque:

ground terminal. 24 N·m (2.4 kgf-m, 17.4 ft-lb)
NOTE:
The extraction area of the knock sensor cord must
be positioned at a 60° angle relative to the engine
rear.
G6M0095
2) Remove air cleaner case.
H2M3511C
2) Connect knock sensor connector.
H2M2947
3) Disconnect knock sensor connector.
B2M4262
3) Install air cleaner case.
B2M4262
4) Remove knock sensor from cylinder block.
H2M2947
S2M1673
FU(SOHC)-31
KNOCK SENSOR
4) Connect battery ground cable.
G6M0095
FU(SOHC)-32
THROTTLE POSITION SENSOR
8. Throttle Position Sensor S155039 B: INSTALLATION S155039A11
Tightening torque:
1.6 N·m (0.16 kgf-m, 1.2 ft-lb)
CAUTION:
When installing throttle position sensor, adjust
to the specified data.
G6M0095
2) Disconnect connector from throttle position

sensor.
H2M2979
B2M3493
3) Remove throttle position sensor holding

screws, and remove it.
H2M2979
FU(SOHC)-33
C: ADJUSTMENT S155039A01 (2) Loosen throttle position sensor holding

screws.
2) Loosen throttle position sensor holding screws.
B2M3765
B2M3765
NOTE:
3) When using voltage meter; For detailed operation procedures, refer to the
(1) Take out ECM. Subaru Select Monitor Operation Manual.
(2) Turn ignition switch to ON. (3) Insert the cartridge to Subaru Select Moni-
(3) Adjust throttle position sensor to the proper tor.
position to allow the voltage signal to ECM to be
in specification.
Connector & terminal / Specified voltage
(B136) No. 15 — (B136) No. 17 / 0.45 —
0.55 V
[Fully closed.]
S2M0286A
(4) Connect Subaru Select Monitor to the data

link connector.
B2M4131A
(4) Tighten throttle position sensor holding

screws.
Tightening torque:
1.6 N·m (0.16 kgf-m, 1.2 ft-lb)
S2M2157
5) Turn ignition switch to ON, and Subaru Select

Monitor switch to ON.
6) Select {2. Each System Check} in Main Menu.
7) Select {Engine Control System} in Selection
Menu.
8) Select {1. Current Data Display & Save} in
Engine Control System Diagnosis.
B2M3765 9) Select {1.12 Data Display} in Data Display
Menu.
4) When using Subaru Select Monitor; 10) Adjust throttle position sensor to the proper
(1) Turn ignition switch to OFF. position to match with the following specifications.
FU(SOHC)-34
Condition: Throttle fully closed

Throttle opening angle 0.00%
Throttle sensor voltage 0.50 V
11) Tighten throttle position sensor holding
screws.
Tightening torque:
1.6 N·m (0.16 kgf-m, 1.2 ft-lb)
B2M3765
FU(SOHC)-35
INTAKE AIR TEMPERATURE AND PRESSURE SENSOR
9. Intake Air Temperature and 4) Remove intake air temperature and pressure
sensor.
Pressure Sensor S155044
B2M3497
G6M0095 Install in the reverse order of removal.

2) Disconnect spark plug cord from ignition coil Tightening torque:
and ignitor assembly. 3.4 N·m (0.35 kgf-m, 2.5 ft-lb)
B2M3497
B2M3495
3) Disconnect connector from intake air tempera- NOTE:

ture and pressure sensor. Replace O-ring with a new one.
H2M2999
B2M4276
FU(SOHC)-36
ATMOSPHERIC PRESSURE SENSOR
10. Atmospheric Pressure

Sensor S155045
G6M0095
2) Disconnect connector from atmospheric pres-

sure sensor.
3) Remove atmospheric pressure sensor from
bracket.
EN1001

Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
EN1001
FU(SOHC)-37
IDLE AIR CONTROL SOLENOID VALVE
11. Idle Air Control Solenoid B: INSTALLATION S155056A11
Valve S155056 Install in the reverse order of removal.
Tightening torque:
1.6 N·m (0.16 kgf-m, 1.2 ft-lb)
B2M3501
G6M0095
2) Disconnect connector from idle air control sole-

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

throttle body.
B2M3501
FU(SOHC)-38
AIR ASSIST INJECTOR SOLENOID VALVE
12. Air Assist Injector Solenoid B: INSTALLATION S155570A11
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
B2M3503
G6M0095
2) Disconnect connector from air assist injector

solenoid valve and disconnect air by-pass hoses.
B2M4266
3) Remove air assist injector solenoid valve from

intake manifold.
B2M3503
FU(SOHC)-39
FUEL INJECTOR
13. Fuel Injector S155051

pump switch.
1. RH SIDE S155051A1801
1) Release fuel pressure.

<Ref. to FU(SOHC)-52, RELEASING OF FUEL
PRESSURE, OPERATION, Fuel.>
S2M0490
(5) Place power steering pump and tank on the

right side wheel apron.
G6M0095
4) Remove resonator chamber. <Ref. to

IN(SOHC)-9, REMOVAL, Resonator Chamber.>
brackets.
(1) Remove front side V-belt. <Ref. to S2M0491
ME(SOHC)-42, REMOVAL, V-belt.>
(2) Remove bolts which hold power steering 6) Remove spark plug cords from spark plugs (#1
pipe bracket onto intake manifold. and #3 cylinders).
7) Disconnect connector from fuel injector.
S2M1013
B2M4280
pump to bracket.
S2M0488
FU(SOHC)-40
FUEL INJECTOR
8) Remove bolt which holds injector pipe to intake 2. LH SIDE S155051A1802
manifold.
OPERATION, Fuel.>
B2M4281
G6M0095
4) Remove two bolts which install washer tank on

body.
B2M4282
9) Remove fuel injector from intake manifold.

(1) Remove fuel injector securing clip.
B2M3139
5) Disconnect connector from front window

washer motor.
6) Disconnect connector from rear gate glass
washer motor.
B2M4283
(2) Remove fuel injector while lifting up fuel

injector pipe.
B6M0562
B2M3509
FU(SOHC)-41
FUEL INJECTOR
7) Disconnect rear window glass washer hose 12) Remove bolt which holds fuel pipe on the left
from washer motor, then plug connection with a side intake manifold.
suitable cap.
8) Move washer tank, and secure it away from
working area.
H2M2995
13) Remove fuel injector from intake manifold.

B2M3140
(1) Remove fuel injector securing clip.
9) Remove spark plug cords from spark plugs (#2

and #4 cylinders).
H2M2997
(2) Remove fuel injector while lifting up fuel

injector pipe.
B2M4294
11) Remove bolt which holds injector pipe to

intake manifold.
H2M3241
B2M4133
H2M2994
FU(SOHC)-42
FUEL INJECTOR
B: INSTALLATION S155051A11 2. LH SIDE S155051A1102
1. RH SIDE S155051A1101
Install in the reverse order of removal. NOTE:
Replace O-rings with new ones.
NOTE:
B2M3492G
B2M3492G (A) O-ring

(B) Fuel injector
(A) O-ring
(B) Fuel injector Tightening torque:
4.9 N·m (0.50 kgf-m, 3.6 ft-lb)
Tightening torque:
4.9 N·m (0.50 kgf-m, 3.6 ft-lb)
H2M2994
B2M4282
Tightening torque:
4.9 N·m (0.50 kgf-m, 3.6 ft-lb)
Tightening torque:
19 N·m (1.9 kgf-m, 13.7 ft-lb)
H2M2995
B2M4132
FU(SOHC)-43
FUEL INJECTOR
Tightening torque:
19 N·m (1.9 kgf-m, 13.7 ft-lb)
B2M4133
FU(SOHC)-44
FRONT OXYGEN (A/F) SENSOR
14. Front Oxygen (A/F) Sensor B: INSTALLATION S155642A11
S155642
1) Before installing front oxygen (A/F) sensor,
apply anti-seize compound only to threaded por-
tion of front oxygen (A/F) sensor to make the next
1) Disconnect battery ground cable. removal easier.
Anti-seize compound:
SS-30 by JET LUBE
CAUTION:
Never apply anti-seize compound to protector
of front oxygen (A/F) sensor.
G6M0095
2) Disconnect connector from front oxygen (A/F)

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

Tightening torque:
21 N·m (2.1 kgf-m, 15.2 ft-lb)
B2M4243

4) Apply SUBARU CRC or its equivalent to
threaded portion of front oxygen (A/F) sensor, and
leave it for one minute or more.
SUBARU CRC (Part No. 004301003)
5) Remove front oxygen (A/F) sensor. G2M0411
CAUTION: 3) Lower the vehicle.

When removing the oxygen (A/F) sensor, wait 4) Connect connector of front oxygen (A/F) sen-
until exhaust pipe cools, otherwise it will dam- sor.
age exhaust pipe.
B2M4243
G2M0411
FU(SOHC)-45
G6M0095
FU(SOHC)-46
REAR OXYGEN SENSOR
15. Rear Oxygen Sensor S155657 B: INSTALLATION S155657A11
1) Before installing rear oxygen sensor, apply anti-
seize compound only to threaded portion of rear
1) Disconnect battery ground cable. oxygen sensor to make the next removal easier.
CAUTION:
of rear oxygen sensor.
SS-30 by JET LUBE
G6M0095
2) Disconnect connector from rear oxygen sensor.
B2M0742A
2) Install rear oxygen sensor.

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

threaded portion of rear oxygen sensor, and leave
it for one minute or more.
5) Remove rear oxygen sensor.
CAUTION: B2M0741
When removing the oxygen sensor, wait until
exhaust pipe cools, otherwise it will damage 3) Lower the vehicle.
exhaust pipe. 4) Connect connector to rear oxygen sensor.
B2M0741 B2M4244
FU(SOHC)-47
REAR OXYGEN SENSOR
G6M0095
FU(SOHC)-48
ENGINE CONTROL MODULE
16. Engine Control Module S155049
G6M0095
2) Remove lower inner trim of passenger side.

<Ref. to EI-38, REMOVAL, Lower Inner Trim.>
3) Detach floor mat of front passenger seat.
4) Remove protect cover.
EN0532
5) Remove nuts (A) which hold ECM to bracket.

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

ECM.

CAUTION:
When replacing ECM, be careful not to use the
wrong spec. ECM to avoid any damage to the
fuel injection system.
FU(SOHC)-49
MAIN RELAY
17. Main Relay S155050

4) Remove main relay from mounting bracket.
S2M0137
G6M0095
2) Remove bolt which holds bracket of main relay
and fuel pump relay.
S2M0107
3) Disconnect connectors from relays.
S2M0108A
(A) Blower fan motor relay

(B) Main relay
(C) Fuel pump relay
FU(SOHC)-50
FUEL PUMP RELAY
18. Fuel Pump Relay S155048
G6M0095
2) Disconnect connector from fuel pump relay.
S2M0093
3) Remove fuel pump relay from mounting

bracket.
S2M0138
FU(SOHC)-51
FUEL
19. Fuel S155052

1. RELEASING OF FUEL PRESSURE

S155052A1601
WARNING:
쐌 Place “No fire” signs near the working area.
쐌 Disconnect ground terminal from battery.
G6M0095
4) Remove the floor box located just behind the

rear seats.
5) Remove access hole lid.
S2M0093
2) Start the engine, and run it until it stalls.

3) After the engine stalls, crank it for five more
seconds.
S2M0246
2. DRAINING OF FUEL S155052A1603
6) Disconnect connector from fuel pump.
WARNING:
쐌 Be careful not to spill fuel on the floor.
OPERATION, Fuel.>
S2M0172
7) Disconnect quick connector, and then discon-

nect fuel delivery hose (A). <Ref. to FU(SOHC)-69,
REMOVAL, Fuel Delivery, Return and Evaporation
Lines.>
H2M2535
FU(SOHC)-52
FUEL
8) Move clips, and then disconnect fuel return 12) Remove service hole cover.
hose (B) and jet pump hose (C).
G2M0863
S2M0060A
13) Disconnect connector from fuel sub meter.
9) Remove nuts which install fuel pump assembly 14) Disconnect fuel jet pump hose.
onto fuel tank.
S2M0151
S2M0061
15) Remove bolts which install fuel sub meter unit
10) Take off fuel pump from fuel tank. on fuel tank.
S2M0062 S2M0152
11) Drain fuel from fuel tank by using a hand 16) Remove fuel sub meter unit.
pump.
WARNING:
Do not use a motor pump when draining fuel.
S2M0153
S2M0163
FU(SOHC)-53
FUEL
17) Drain fuel from there.

WARNING:
S2M0247
FU(SOHC)-54
FUEL TANK
20. Fuel Tank S155053

8) Disconnect two-way valve hose (A) from two-
way valve and disconnect canister hose (B) from
A: REMOVAL S155053A18 canister.
WARNING:
쐌 Place “NO FIRE” signs near the working
area.
1) Set vehicle on the lift.
OPERATION, Fuel.>
3) Drain fuel from fuel tank. <Ref. to FU(SOHC)-
52, DRAINING FUEL, OPERATION, Fuel.> EN0840
4) Remove rear seat.
5) Disconnect connector of fuel tank cord to rear 9) Loosen clamp and disconnect fuel filler hose
harness. and air vent hose from fuel filler pipe.
S2M0164 EN0539
6) Push grommet which holds fuel tank cord on 10) Move clips, and disconnect quick connector.
floor panel into under the body. <Ref. to FU(SOHC)-69, REMOVAL, Fuel Delivery,
Return and Evaporation Lines.>
11) Disconnect fuel hoses.
S2M0165
7) Remove rear crossmember. <Ref. to RS-20, EN0540

REMOVAL, Rear Crossmember.>
FU(SOHC)-55
FUEL TANK
12) Support fuel tank with transmission jack, 4) Connect fuel filler hose and air vent hose.
remove bolts from bands and dismount fuel tank
from the vehicle.
WARNING:
A helper is required to perform this work.
EN0539
5) Connect fuel hoses, and hold then with clips

and quick connector. <Ref. to FU(SOHC)-69,
S2M2246 Lines.>
1) Support fuel tank with transmission jack and

push fuel tank harness into access hole with grom-
met.
2) Set fuel tank and temporarily tighten bolts of
fuel tank bands.
WARNING:
EN0540
6) Tighten band mounting bolts.

Tightening torque:
33 N·m (3.4 kgf-m, 25 ft-lb)
S2M2246
3) Connect two-way valve hose (A) to two-way

valve and connect canister hose (B) to canister.
S2M2246
7) Install rear crossmember. <Ref. to RS-20,

INSTALLATION, Rear Crossmember.>
EN0840
FU(SOHC)-56
FUEL TANK
8) Connect connectors to fuel tank cord and plug

service hole with grommet.
S2M0164
9) Set rear seat and floor mat.

10) Connect connector to fuel pump relay.
S2M0093
1) Make sure there are no cracks, holes, or other

damage on the fuel tank.
2) Make sure that the fuel hoses and fuel pipes
are not cracked and that connections are tight.
FU(SOHC)-57
FUEL FILLER PIPE
21. Fuel Filler Pipe S155022

8) Remove fuel filler pipe protector.
WARNING:
area.
OPERATION, Fuel.>
2) Open fuel filler flap lid and remove filler cap. B2M1894
9) Separate evaporation hoses from clip of fuel
filler pipe.
G6M0095
4) Remove screws holding packing in place. EN0545
10) Disconnect air vent hose from fuel filler pipe.
EN0542
5) Lift-up the vehicle. B2M1896

6) Remove rear right side wheel nuts.
7) Remove rear right side wheel. 11) Remove bolts which hold fuel filler pipe
bracket on body.
B2M1748
B2M1895
FU(SOHC)-58
FUEL FILLER PIPE
12) Loosen clamp and separate fuel filler hose (A) 3) Align holes in fuel filler pipe neck and set cup
from fuel filler pipe. (B), and tighten screws.
13) Move clip and separate air vent hose (B). NOTE:
If edges of rubber packing are folded toward the
inside, straighten it with a screwdriver.
EN0548
14) Remove fuel filler pipe to under side of the

vehicle. B2M1196A
15) Remove air vent pipe together with clip from 4) Install air vent pipe.
body.
EN0549
EN0549
5) Connect air vent hose to fuel filler pipe.
1) Hold fuel filler flap open.

2) Set fuel saucer (A) with rubber packing (C) and
insert fuel filler pipe into hole from the inner side of
apron.
B2M1896
B2M1196A
FU(SOHC)-59
FUEL FILLER PIPE
6) Insert fuel filler hose (A) approximately 35 to 40 9) Tighten bolts which hold evaporation hoses
mm (1.38 to 1.57 in) over the lower end of fuel filler onto clip of fuel filler pipe.
pipe and tighten clamp.
CAUTION:
Do not allow clips to touch air vent hose (B)
and rear suspension crossmember.
EN0545
10) Install fuel filler pipe protector.
EN0548
7) Insert 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 = 27.5±2.5 mm (1.083±0.098 in)
B2M1894
11) Install rear right wheel.
B2M1195A
(1) Hose
(2) Clip
(3) Pipe
B2M1748
8) Tighten bolt which holds fuel filler pipe bracket
on body. 12) Lower the vehicle.
Tightening torque: 13) Tighten wheel nuts.
7.5 N·m (0.75 kgf-m, 5.4 ft-lb) 14) Connect connector to fuel pump relay.
B2M1895 S2M0093
FU(SOHC)-60
FUEL FILLER PIPE
15) Connect battery ground terminal.
G6M0095
FU(SOHC)-61
FUEL PUMP
22. Fuel Pump S155025

WARNING:
OPERATION, Fuel.>
2) Open fuel filler flap lid, and remove fuel filler
cap. S2M0172
7) Move clips, and then disconnect fuel delivery

hose (A), return hose (B) and jet pump hose (C).
nect fuel delivery hose (A). <Ref. to FU(SOHC)-69,
Lines.>
H2M2535
S2M0060A
9) Remove nuts which install fuel pump assembly

onto fuel tank.
G6M0095

rear seats.
S2M0061
10) Take off fuel pump from fuel tank.
S2M0246
S2M0062
FU(SOHC)-62
FUEL PUMP
Install in the reverse order of removal. Do the fol-

lowing:
(1) Always use new gaskets.
(2) Ensure sealing portion is free from fuel or for-
eign particles before installation.
(3) Tighten nuts in alphabetical sequence shown
in the figure to specified torque.
Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
S2M0063A
Connect lead harness to connector terminal of fuel

pump, and apply battery power supply to check
whether the pump operate.
WARNING:
쐌 Wipe off the fuel completely.
쐌 Keep battery as far apart from fuel pump as
possible.
쐌 Be sure to turn the battery supply ON and
OFF on the battery side.
쐌 Do not run fuel pump for a long time under
non-load condition.
G2M0366
FU(SOHC)-63
FUEL LEVEL SENSOR
23. Fuel Level Sensor S155026
WARNING:
area.
NOTE:
Fuel level sensor is built in fuel pump assembly.
1) Remove fuel pump assembly. <Ref. to
FU(SOHC)-62, REMOVAL , Fuel Pump.>
2) Disconnect connector from fuel pump bracket.
S2M0145
3) Remove bolt which installs fuel level sensor on

mounting bracket.
S2M0855
FU(SOHC)-64
FUEL SUB LEVEL SENSOR
24. Fuel Sub Level Sensor S155023

on fuel tank.
WARNING:
area.
S2M0152
7) Remove fuel sub meter unit.
G6M0095

rear seats.
3) Remove service hole cover.
S2M0153

Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
G2M0863

5) Disconnect fuel jet pump hose.
S2M0152
S2M0151
FU(SOHC)-65
FUEL FILTER
25. Fuel Filter S155027
WARNING:
area.
OPERATION, Fuel.>
2) Disconnect fuel delivery hoses from fuel filter.
S2M0195
3) Remove filter from holder.
CAUTION:
쐌 If fuel hoses are damaged at the connecting
portion, replace it with a new one.
쐌 If clamps are badly damaged, replace with
new ones.
2) Tighten hose clamp screws.
Tightening torque:
12.5 N·m (1.27 kgf-m, 9.22 ft-lb)
S2M0195
1) Check the inside of fuel filter for dirt and water

sediment.
2) If it is clogged, or if replacement interval has
been reached, replace it.
3) If water is found in it, shake and expel the water
from inlet port.
FU(SOHC)-66
FUEL CUT VALVE
26. Fuel Cut Valve S155021
WARNING:
area.
1) Remove fuel tank. <Ref. to FU(SOHC)-55,
REMOVAL, Fuel Tank.>
2) Move clip and disconnect evaporation hose
from fuel cut valve.
S2M0176
3) Remove bolts which install fuel cut valve.

Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
S2M0177
FU(SOHC)-67
FUEL DAMPER VALVE
27. Fuel Damper Valve S155708

OPERATION, Fuel.>
2) Remove fuel damper valve from fuel return line.
EN0852
FU(SOHC)-68
FUEL DELIVERY, RETURN AND EVAPORATION LINES
28. Fuel Delivery, Return and 3) Open fuel filler flap lid and remove fuel filler
cap.
Evaporation Lines S155019
4) Remove floor mat. <Ref. to EI-43, REMOVAL,
Floor Mat.>
5) Remove fuel delivery pipes and hoses, fuel
1) Set vehicle on the lift. return pipes and hoses, evaporation pipes and
2) Release fuel pressure. <Ref. to FU(SOHC)-52, hoses.
OPERATION, Fuel.>
S2M2247
6) In engine compartment, detach fuel delivery 8) Disconnect two-way valve hose (A) from two-
hoses, return hoses and evaporation hose. way valve and disconnect canister hose (B) from
canister.
S2M0500F
EN0840
(B) Return hose
FU(SOHC)-69
9) Separate quick connector on fuel delivery and

return line.
(1) Clean pipe and connector, if they are cov-
ered with dust.
(2) Hold connector (A) and push retainer (B)
down.
(3) Pull out connector (A) from retainer (B).
CAUTION:
Replace retainers with new ones.
S2M0230A
(A) Connector
(B) Retainer
(C) Pipe
CAUTION:
쐌 Pull the connector to ensure it is connected
securely.
쐌 Ensure the two retainer pawls are engaged in
their mating positions in the connector.
S2M0228A
쐌 Be sure to inspect hoses and their connec-
(A) Connector tions for any leakage of fuel.
(B) Retainer
(C) Pipe
1) Connect quick connector on fuel delivery line.

CAUTION:
쐌 Always use a new retainer.
쐌 Make sure that the connected portion is not
damaged or has dust. If necessary, clean seal
surface of pipe. S2M0231A
(A) Connector
(B) Retainer
(C) Pipe
S2M0229A
(1) Set new retainer (B) to connector (A).

(2) Push pipe into connector completely.
NOTE:
At this time, two clicking sounds are heard.
FU(SOHC)-70
2) Connect fuel delivery hose to pipe with an over-

lap of 20 to 25 mm (0.79 to 0.98 in).
Type A: When fitting length is specified.
Type B: When fitting length is not specified.
: 2.5±1.5 mm (0.098±0.059 in)
L: 22.5±2.5 mm (0.886±0.098 in)
B2M1194B
(1) Fitting
(2) Clamp
(3) Hose
3) Connect evaporation hose to pipe by approx.

15 mm (0.59 in) from hose end.
L = 17.5±2.5 mm (0.689±0.098 in)
CAUTION:
Be sure to inspect hoses and their connections
for any leakage of fuel.
B2M1195A
(1) Hose
(2) Clip
(3) Pipe
1) Make sure that there are no cracks on the fuel

pipes and fuel hoses.
2) Make sure that the fuel pipe and fuel hose con-
nections are tight.
FU(SOHC)-71
FUEL SYSTEM TROUBLE IN GENERAL
29. Fuel System Trouble in General S155571

1. Insufficient fuel supply to the injector
1) Fuel pump will not operate.
Inspect connections, especially ground, and tighten
쎻 Defective terminal contact.
securely.
쎻 Trouble in electromagnetic or electronic circuit parts. Replace fuel pump.
2) Lowering of fuel pump function. Replace fuel pump.
3) Clogged dust or water in the fuel filter. Replace fuel filter, clean or replace fuel tank.
4) Clogged or bent fuel pipe or hose. Clean, correct or replace fuel pipe or hose.
5) Air is mixed in the fuel system. Inspect or retighten each connection part.
6) Clogged or bent breather tube or pipe. Clean, correct or replace air breather tube or pipe.
7) Damaged diaphragm of pressure regulator. Replace.
2. Leakage or blow out fuel
1) Loosened joints of the fuel pipe. Retightening.
2) Cracked fuel pipe, hose and fuel tank. Replace.
3) Defective welding part on the fuel tank. Replace.
4) Defective drain packing of the fuel tank. Replace.
Clean, correct or replace air breather tube or air vent
5) Clogged or bent air breather tube or air vent tube.
tube.
3. Gasoline smell inside of compartment
Loose joints at air breather tube, air vent tube and fuel
1) Retightening.
filler pipe.
2) Defective packing air tightness on the fuel saucer. Correct or replace packing.
3) Cracked fuel separator. Replace separator.
4) Inoperative fuel pump modulator or circuit. Replace.
4. Defective fuel meter indicator
1) Defective operation of fuel level sensor. Replace.
2) Defective operation of fuel meter. Replace.
5. Noise
1) Large operation noise or vibration of fuel pump. Replace.
NOTE: level drops to about one-half. After the winter

쐌 When the vehicle is left unattended for an season, drain water which may have accumu-
extended period of time, water may accumulate in lated in the fuel filter and fuel tank in the man-
the fuel tank. ner same as that described under Affected
To prevent water condensation: areas below.
(1) Top off the fuel tank or drain the fuel com- (2) Affected areas
pletely. When water condensation is notched in the fuel
(2) Drain water condensation from the fuel fil- filter, drain water from both the fuel filter and fuel
ter. tank or use a water removing agent (or anti-
쐌 Refilling the fuel tank. freeze solution) in the fuel tank.
Refill the fuel tank while there is still some fuel left 쐌 Observe the instructions, notes, etc., indicated
in the tank. on the label affixed to the anti-freeze solution
쐌 Protecting the fuel system against freezing and (water removing agent) container before use.
water condensation.
(1) Cold areas
In snow-covered areas, mountainous areas,
skiing areas, etc. where ambient temperatures
drop below 0°C (32°F) throughout the winter
season, use an anti-freeze solution in the cool-
ing system. Refueling will also complement the
effect of anti-freeze solution each time the fuel
FU(SOHC)-72
EMISSION CONTROL (AUX. EMISSION
CONTROL DEVICES)
EC(SOHC)
Page
2. Front Catalytic Converter ............................................................................3
3. Rear Catalytic Converter.............................................................................6
4. Canister .......................................................................................................7
5. Purge Control Solenoid Valve .....................................................................8
6. Two-way Valve ............................................................................................9
GENERAL DESCRIPTION
Emission Control (Aux. Emission Control Devices)

tion.
ment.
fied points.
EC(SOHC)-2
FRONT CATALYTIC CONVERTER
2. Front Catalytic Converter S150017

7) Separate center exhaust pipe from rear
exhaust pipe.
CAUTION:
1) Set the vehicle on the lift. Be careful, exhaust pipe is hot.
S2M0558
G6M0095
8) Remove bolts which hold front exhaust pipe
3) Disconnect front oxygen (A/F) sensor connec- onto cylinder heads.
tor.
B2M3200
B2M4243
9) Remove front exhaust pipe and center exhaust
4) Disconnect connector from rear oxygen sensor pipe from hanger bracket.
connector. CAUTION:
Be careful not to pull down front exhaust pipe
and center exhaust pipe.
B2M4244

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

S2M0923 Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
CAUTION:
Replace gaskets with new ones.
1) Install front catalytic converter to front exhaust
pipe.
Tightening torque:
30 N·m (3.1 kgf-m, 22.4 ft-lb)
S2M0558
5) Tighten bolt which holds center exhaust pipe to

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

pipe. And temporarily tighten bolt which installs
center exhaust pipe to hanger bracket.
B2M3111
6) Install under cover.
B2M3111
EC(SOHC)-4

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

nector.
B2M4244
G6M0095
NOTE:
The rear catalytic converter is integrated with front
catalytic converter. Therefore, the procedure for
installing rear catalytic converter is the same as the
description above.
1) Make sure there are no exhaust leaks from con-

nections and welds.
2) Make sure there are no holes or rusting.
EC(SOHC)-5
REAR CATALYTIC CONVERTER
3. Rear Catalytic Converter S150036
The front and rear catalytic converter and center

exhaust pipe are integrated into one unit.
Therefore, the removal and installation procedures
are the same as the those for the front catalytic
converter. <Ref. to EC(SOHC)-3 REMOVAL, Front
Catalytic Converter.>
B2M4164A
(A) Front catalytic converter

(B) Rear catalytic converter
The front and rear catalytic converter and center

exhaust pipe are integrated into one unit.
Therefore, the removal and installation procedures
are the same as the ones described under front
catalytic converter. <Ref. to EC(SOHC)-4
INSTALLATION, Front Catalytic Converter.>
B2M4164A
(A) Front catalytic converter

(B) Rear catalytic converter

nections and welds.
EC(SOHC)-6
CANISTER
4. Canister S150037

2) Loosen two clamps which hold two canister
hoses, and disconnect evaporation hose from can-
ister.
EN0898
3) Remove canister from body.
B2M4166

Tightening torque:
23 N·m (2.3 kgf-m, 17 ft-lb)
B2M4166
Make sure the canister and canister hoses are not

cracked or loose.
EC(SOHC)-7
PURGE CONTROL SOLENOID VALVE
5. Purge Control Solenoid B: INSTALLATION S150035A11

Tightening torque:
16 N·m (1.6 kgf-m, 11.6 ft-lb)
H2M2985
G6M0095
2) Remove bolt which installs purge control sole- CAUTION:

noid valve onto intake manifold. Carefully connect the evaporation hoses.
B2M1893A
H2M2985
3) Take out purge control solenoid valve through

the bottom of the intake manifold. C: INSPECTION S150035A10
4) Disconnect connector and hoses from purge Make sure hoses are not cracked or loose.
control solenoid valve.
H2M2986
EC(SOHC)-8
TWO-WAY VALVE
6. Two-way Valve S150707

2) Remove canister from body. <Ref. to
EC(SOHC)-7, REMOVAL, Canister.>
3) Remove two-way valve with bracket as a single
unit from body.
EN0901
4) Remove two-way valve from bracket.
Make sure that hoses are not cracked or loose.
EC(SOHC)-9
TWO-WAY VALVE
MEMO:
EC(SOHC)-10
INTAKE (INDUCTION)
IN(SOHC)
Page
2. Air Cleaner ..................................................................................................6
3. Air Cleaner Case.........................................................................................7
4. Air Intake Duct.............................................................................................8
5. Resonator Chamber ....................................................................................9
GENERAL DESCRIPTION
Intake (Induction)
1. MODEL WITH OBD S154001A0501
S2M2236A
IN(SOHC)-2
GENERAL DESCRIPTION
Intake (Induction)
(1) Spacer (11) Air cleaner element (19) Spacer

(2) Bushing (12) Air cleaner case B
(3) Resonator chamber (13) Air cleaner case stay LH (MT Tightening torque: N·m (kgf-m, ft-lb)
(4) Cushion rubber vehicles) T1: 33 (3.4, 24.4)
(5) Air intake duct A (14) Air cleaner case stay LH (AT T2: 6.5 (0.66, 4.8)
(6) Air intake duct B vehicles) T3: 7.5 (0.76, 5.5)
(7) Holder (15) Air cleaner case stay RH T4: 14 (1.4, 10)
(8) Cushion (16) Engine harness bracket T5: 16 (1.6, 11.6)
(9) Air cleaner case A (17) Clamp
T6: 3 (0.3, 2.2)
(10) Clip (18) Bushing
IN(SOHC)-3
GENERAL DESCRIPTION
Intake (Induction)
2. MODEL WITHOUT OBD S154001A0502
S2M2243A
(1) Spacer (11) Air cleaner case B (19) Spacer

(2) Bushing (12) Air cleaner case stay LH (MT
(3) Resonator chamber vehicles) Tightening torque: N·m (kgf-m, ft-lb)
(4) Cushion rubber (13) Air cleaner case stay LH (AT T1: 33 (3.4, 25)
(5) Air intake duct A vehicles) T2: 6.5 (0.66, 4.8)
(6) Air intake duct B (14) Air cleaner case stay RH T3: 7.5 (0.76, 5.5)
(7) Holder (15) Clamp T4: 14 (1.4, 10.1)
(8) Air cleaner case A (16) Intake air temperature sensor T5: 16 (1.6, 11.6)
(9) Clip (17) Rubber holder
(10) Air cleaner element (18) Bushing
IN(SOHC)-4
GENERAL DESCRIPTION
Intake (Induction)

tion.
ment.
fied points.
sensor or units, be sure to disconnect negative
IN(SOHC)-5
AIR CLEANER
Intake (Induction)
2. Air Cleaner S154087
1) Remove bolts (A) which secure air cleaner case

to stays.
2) Remove the clips (B) above the air cleaner
case.
쐌 Model without OBD
S2M1649A
쐌 Model with OBD
H2M2947A
3) Remove air cleaner element.

CAUTION:
Fasten with a clip after inserting the lower tab
of the case.
Replace if excessively damaged or dirty.
IN(SOHC)-6
AIR CLEANER CASE
Intake (Induction)
3. Air Cleaner Case S154089

쐌 Model with OBD
1) Disconnect battery ground cable. (Model with-

out OBD)
H2M2946
4) Disconnect hoses from air cleaner case.

5) Remove bolts which secure air cleaner case to
stays.
G6M0095 쐌 Model without OBD
2) Disconnect intake air temperature sensor con-

nector. (Model without OBD)
S2M1649
쐌 Model with OBD

S2M1647
3) Loosen clamp which connects air cleaner case

to throttle body.
H2M2947
S2M1648 Install in the reverse order of removal.
Inspect for cracks and loose connections.
IN(SOHC)-7
AIR INTAKE DUCT
Intake (Induction)
4. Air Intake Duct S154566

쐌 Model with OBD
1) Remove bolts which secure air intake duct on

the front side of body.
EN1004
3) Remove air intake ducts as a unit.

H2M2930
쐌 Model with OBD
S6M0353
쐌 Model with OBD
EN0061
2) Remove bolt which secures air intake duct on

body.
EN0063
B2M2284
1) Inspect for cracks and loose connections.
2) Inspect that no foreign objects are mixed in the
air intake duct.
IN(SOHC)-8
RESONATOR CHAMBER
Intake (Induction)
5. Resonator Chamber S154639 B: INSTALLATION S154639A11
1) Remove air intake duct. <Ref. to IN(SOHC)-8, Tightening torque:

REMOVAL, Air Intake Duct.> 33 N·m (3.4 kgf-m, 24.4 ft-lb)
2) Remove resonator chamber.
B6M1237
B6M1237
Inspect for cracks and loose connections.
IN(SOHC)-9
RESONATOR CHAMBER
Intake (Induction)
MEMO:
IN(SOHC)-10
MECHANICAL
ME(SOHC)
Page
2. Compression .............................................................................................23
3. Idle Speed .................................................................................................24
4. Ignition Timing ...........................................................................................25
5. Intake Manifold Vacuum............................................................................26
6. Engine Oil Pressure ..................................................................................27
7. Fuel Pressure ............................................................................................28
8. Valve Clearance ........................................................................................29
9. Engine Assembly.......................................................................................32
10. Engine Mounting .......................................................................................40
11. Preparation for Overhaul...........................................................................41
12. V-belt .........................................................................................................42
13. Crankshaft Pulley ......................................................................................44
14. Belt Cover..................................................................................................45
15. Timing Belt Assembly ................................................................................46
16. Camshaft Sprocket....................................................................................51
17. Crankshaft Sprocket..................................................................................53
18. Valve Rocker Assembly.............................................................................54
19. Camshaft ...................................................................................................56
20. Cylinder Head Assembly ...........................................................................60
21. Cylinder Block ...........................................................................................67
22. Engine Trouble in General ........................................................................87
23. Engine Noise .............................................................................................93
GENERAL DESCRIPTION
Mechanical
Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gaso-

Type
line engine
Valve arrangement Belt driven, single over-head camshaft, 4-valve/cylinder
Bore x Stroke mm (in) 92 x 75 (3.62 x 2.95)
Displacement cm3 (cu in) 1,994 (121.67)
Compression ratio 10.0
Compression pres-
sure (at 200 — 300 kPa (kg/cm2, psi) 1,020 — 1,275 (10.4 — 13.0, 148 — 185)
rpm)
Number of piston rings Pressure ring: 2, Oil ring: 1
Opening 4° BTDC
Intake valve timing
Closing 48° ABDC
Engine Exhaust valve tim- Opening 48° BBDC
ing Closing 4° ATDC
Intake mm (in) 0.20±0.02 (0.0079±0.0008)
Valve clearance
Exhaust mm (in) 0.25±0.02 (0.0098±0.0008)
700±100 (No load)
With OBD
Idling speed [At neutral position 850±100 (A/C switch ON)
on MT, or “P” or “N” position on rpm MT: 650±100 (No load)
AT] Without OBD AT: 675±100 (No load)
800±100 (A/C switch ON)
Firing order 1→3→2→4
With OBD 10°±10°/700
Ignition timing BTDC/rpm MT: 10°±10°/650
Without OBD
AT: 10°±10°/675
NOTE:
STD: Standard I.D.: Inner Diameter O.D.: Outer
Diameter US: Undersize OS: Oversize
Belt ten-
sioner Protrusion of adjuster rod 5.2 — 6.2 mm (0.205 — 0.244 in)
adjuster
Spacer O.D. 17.955 — 17.975 mm (0.7069 — 0.7077 in)
Tensioner bush I.D. 18.00 — 18.08 mm (0.7087 — 0.7118 in)
Belt ten- STD 0.025 — 0.125 mm (0.0010 — 0.0049 in)
Clearance between spacer and bush
sioner Limit 0.175 mm (0.0069 in)
STD 0.20 — 0.55 mm (0.0079 — 0.0217 in)
Side clearance of spacer
Limit 0.81 mm (0.0319 in)
Valve rocker STD 0.020 — 0.054 mm (0.0008 — 0.0021 in)
Clearance between shaft and arm
arm Limit 0.10 mm (0.0039 in)
ME(SOHC)-2
GENERAL DESCRIPTION
Mechanical
Bend limit 0.020 mm (0.0008 in)

STD 0.030 — 0.090 mm (0.0012 — 0.0035 in)
Thrust clearance
Limit 0.11 mm (0.0043 in)
STD 38.732 — 38.832 mm (1.5249 — 1.5288 in)
Intake
Limit 38.632 mm (1.5209 in)
Cam lobe height
Camshaft STD 39.257 — 39.357 mm (1.5455 — 1.5495 in)
Exhaust
Limit 39.157 mm (1.5416 in)
Camshaft journal O.D. 31.928 — 31.945 mm (1.2570 — 1.2577 in)
Camshaft journal hole I.D. 32.000 — 32.018 mm (1.2598 — 1.2605 in)
STD 0.055 — 0.090 mm (0.0022 — 0.0035 in)
Oil clearance
Limit 0.10 mm (0.0039 in)
Surface warpage limit 0.05 mm (0.0020 in)
Cylinder
Surface grinding limit 0.1 mm (0.004 in)
head
Standard height 97.5 mm (3.84 in)
Refacing angle 90°
STD 1.0 mm (0.039 in)
Intake
Valve set Limit 1.7 mm (0.067 in)
Contacting width
STD 1.4 mm (0.055 in)
Exhaust
Limit 2.1 mm (0.083 in)
Inner diameter 6.000 — 6.012 mm (0.2362 — 0.2367 in)
Valve guide Intake 20.0 — 20.5 mm (0.787 — 0.807 in)
Protrusion above head
Exhaust 16.5 — 17.0 mm (0.650 — 0.669 in)
STD 1.0 mm (0.039 in)
Intake
Limit 0.6 mm (0.024 in)
Head edge thickness
STD 1.2 mm (0.047 in)
Exhaust
Limit 0.6 mm (0.024 in)
Intake 5.950 — 5.965 mm (0.2343 — 0.2348 in)
Stem diameter
Valve Exhaust 5.945 — 5.960 mm(0.2341 — 0.2346 in)
Intake 0.035 — 0.062 mm (0.0014 — 0.0024 in)
STD
Stem oil clearance Exhaust 0.040 — 0.067 mm (0.0016 — 0.0026 in)
Limit — 0.15 mm (0.0059 in)
Intake 120.6 mm (4.75 in)
Overall length
Exhaust 121.7 mm (4.79 in)
Free length 54.30 mm (2.1378 in)
Squareness 2.5°, 2.4 mm (0.094 in)
Valve spring 218.7 — 242.5 N (22.3 — 24.7 kgf, 49.2 — 54.5 lb)/
Tension/spring height 45.0 mm (1.772 in) 526.6 — 581.6 N (53.7 — 59.3
kgf, 118.4 — 130.8 lb)/34.7 mm (1.366 in)
Surface warpage limit (mating with cylinder head) 0.05 mm (0.0020 in)
A 92.005 — 92.015 mm (3.6222 — 3.6226 in)
Cylinder bore STD
B 91.995 — 92.005 mm (3.6218 — 3.6222 in)
STD 0.015 mm (0.0006 in)
Cylinder Taper
Limit 0.050 mm (0.0020 in)
block
STD 0.010 mm (0.0004 in)
Out-of-roundness
Limit 0.050 mm (0.0020 in)
STD 0.010 — 0.030 mm (0.0004 — 0.0012 in)
Piston clearance
Limit 0.050 mm (0.0020 in)
Enlarging (boring) limit 0.5 mm (0.020 in)
ME(SOHC)-3
GENERAL DESCRIPTION
Mechanical
A 91.985 — 91.995 mm (3.6214 — 3.6218 in)

STD
B 91.975 — 91.985 mm (3.6211 — 3.6214 in)
Outer diameter
Piston 0.25 mm (0.0098 in) OS 92.225 — 92.235 mm (3.6309 — 3.6313 in)
0.50 mm (0.0197 in) OS 92.475 — 92.485 mm (3.6407 — 3.6411 in)
Standard inner diameter of piston pin hole 23.000 — 23.006 mm (0.9055 — 0.9057 in)
Outer diameter 22.994 — 23.000 mm (0.9053 — 0.9055 in)
Standard clearance between piston pin and hole in pis-
0.004 — 0.008 mm (0.0002 — 0.0003 in)
Piston pin ton
Piston pin must be fitted into position with thumb at
Degree of fit
20°C (68°F).
STD 0.20 — 0.35 mm (0.0079 — 0.0138 in)
Top ring
Limit 1.0 mm (0.039 in)
Second STD 0.35 — 0.50 mm (0.0138 — 0.0197 in)
Piston ring gap
ring Limit 1.0 mm (0.039 in)
STD 0.20 — 0.70 mm (0.0079 — 0.0276 in)
Piston ring Oil ring
Limit 1.5 mm (0.059 in)
Clearance STD 0.040 — 0.080 mm (0.0016 — 0.0031 in)
Top ring
between piston Limit 0.15 mm (0.0059 in)
ring and piston Second STD 0.030 — 0.070 mm (0.0012 — 0.0028 in)
ring groove ring Limit 0.15 mm (0.0059 in)
Bend twist per 100 mm (3.94
Limit 0.10 mm (0.0039 in)
Connecting in) in length
rod STD 0.070 — 0.330 mm (0.0028 — 0.0130 in)
Side clearance
Limit 0.4 mm (0.016 in)
STD 0.010 — 0.038 mm (0.0004 — 0.0015 in)
Oil clearance
Limit 0.05 mm (0.0020 in)
Connecting STD 1.492 — 1.501 mm (0.0587 — 0.0591 in)
rod bearing 0.03 mm (0.0012 in) US 1.510 — 1.513 mm (0.0594 — 0.0596 in)
Thickness at center portion
0.05 mm (0.0020 in) US 1.520 — 1.523 mm (0.0598 — 0.0600 in)
0.25 mm (0.0098 in) US 1.620 — 1.623 mm (0.0638 — 0.0639 in)
Connecting Clearance between piston pin STD 0 — 0.022 mm (0 — 0.0009 in)
rod bushing and bushing Limit 0.030 mm (0.0012 in)
Crank pin and Out-of-roundness 0.020 mm (0.0008 in) or less
crank journal Grinding limit 0.250 mm (0.0098 in)
STD 51.984 — 52.000 mm (2.0466 — 2.0472 in)
0.03 mm (0.0012 in) US 51.954 — 51.970 mm (2.0454 — 2.0461 in)
Crank pin outer diameter
0.05 mm (0.0020 in) US 51.934 — 51.950 mm (2.0446 — 2.0453 in)
0.25 mm (0.0098 in) US 51.734 — 51.750 mm (2.0368 — 2.0374 in)
STD 59.992 — 60.008 mm (2.3619 — 2.3625 in)
0.03 mm (0.0012 in) US 59.962 — 59.978 mm (2.3607 — 2.3613 in)
#1, #3
Crankshaft 0.05 mm (0.0020 in) US 59.942 — 59.958 mm (2.3599 — 2.3605 in)
Crank journal 0.25 mm (0.0098 in) US 59.742 — 59.758 mm (2.3520 — 2.3527 in)
outer diameter STD 59.992 — 60.008 mm (2.3619 — 2.3625 in)
0.03 mm (0.0012 in) US 59.962 — 59.978 mm (2.3607 — 2.3613 in)
#2, #4, #5
0.05 mm (0.0020 in) US 59.942 — 59.958 mm (2.3599 — 2.3605 in)
0.25 mm (0.0098 in) US 59.742 — 59.758 mm (2.3520 — 2.3527 in)
STD 0.030 — 0.115 mm (0.0012 — 0.0045 in)
Thrust clearance
Limit 0.25 mm (0.0098 in)
STD 0.010 — 0.030 mm (0.0004 — 0.0012 in)
Oil clearance
Limit 0.040 mm (0.0016 in)
ME(SOHC)-4
GENERAL DESCRIPTION
Mechanical
STD 1.998 — 2.011 mm (0.0787 — 0.0792 in)

0.03 mm (0.0012 in) US 2.017 — 2.020 mm (0.0794 — 0.0795 in)
#1, #3
0.05 mm (0.0020 in) US 2.027 — 2.030 mm (0.0798 — 0.0799 in)
Crankshaft Crankshaft bear- 0.25 mm (0.0098 in) US 2.127 — 2.130 mm (0.0837 — 0.0839 in)
bearing ing thickness STD 2.000 — 2.013 mm (0.0787 — 0.0793 in)
0.03 mm (0.0012 in) US 2.019 — 2.022 mm (0.0795 — 0.0796 in)
#2, #4, #5
0.05 mm (0.0020 in) US 2.029 — 2.032 mm (0.0799 — 0.0800 in)
0.25 mm (0.0098 in) US 2.129 — 2.132 mm (0.0838 — 0.0839 in)
ME(SOHC)-5
GENERAL DESCRIPTION
Mechanical
1. TIMING BELT S153001A0501
S2M2242A
(1) Belt cover No. 2 (RH) (9) Automatic belt tension adjuster Tightening torque: N·m (kgf-m, ft-lb)
(2) Timing belt guide (MT vehicles ASSY
T1: 5 (0.5, 3.6)
only) (10) Belt idler No. 2
T2: 9.8 (1.0, 7.2)
(3) Crankshaft sprocket (11) Camshaft sprocket No. 2
T3: 25 (2.5, 18.1)
(4) Belt cover No. 2 (LH) (12) Timing belt
(5) Camshaft sprocket No. 1 (13) Front belt cover T4: 39 (4.0, 28.9)
(6) Belt idler (No. 1) (14) Belt cover (LH) T5: 78 (8.0, 57.9)
(7) Tensioner bracket (15) Crankshaft pulley T6: 127 (13.0, 94)
(8) Belt idler (No. 2)
ME(SOHC)-6
GENERAL DESCRIPTION
Mechanical
2. CYLINDER HEAD AND CAMSHAFT

S153001A0502
B2M1954D
(1) Rocker cover (RH) (11) Cylinder head (LH) Tightening torque: N·m (kgf-m, ft-lb)
(2) Intake valve rocker ASSY (12) Camshaft (LH)
T1: <Ref. to ME(SOHC)-60,
(3) Exhaust valve rocker ASSY (13) Camshaft cap (LH) INSTALLATION, Cylinder
(4) Camshaft cap (RH) (14) Oil filler cap Head Assembly.>
(5) Oil seal (15) Gasket T2: 5 (0.5, 3.6)
(6) Camshaft (RH) (16) Oil filler pipe
T3: 10 (1.0, 7.2)
(7) Plug (17) O-ring
T4: 18 (1.8, 13.0)
(8) Spark plug pipe gasket (18) Rocker cover (LH)
T5: 25 (2.5, 18.1)
(9) Cylinder head (RH) (19) Stud bolt
(10) Cylinder head gasket T6: 6.4 (0.65, 4.7)
ME(SOHC)-7
GENERAL DESCRIPTION
Mechanical
3. VALVE ROCKER ASSEMBLY S153001A0503
B2M1956A
(1) Intake valve rocker arm (6) Intake rocker shaft Tightening torque: N·m (kgf-m, ft-lb)
(2) Valve rocker nut (7) Exhaust rocker shaft
T1: 5 (0.5, 3.6)
(3) Valve rocker adjust screw (8) Exhaust valve rocker arm
T2: 10 (1.0, 7.2)
(4) Spring
T3: 25 (2.5, 18.1)
(5) Rocker shaft support
ME(SOHC)-8
GENERAL DESCRIPTION
Mechanical
4. CYLINDER HEAD AND VALVE ASSEMBLY S153001A0504
B2M1955A
(1) Exhaust valve (5) Intake valve oil seal (9) Exhaust valve guide
(2) Intake valve (6) Valve spring (10) Exhaust valve spring seat
(3) Intake valve guide (7) Retainer (11) Exhaust valve oil seal
(4) Intake valve spring seat (8) Retainer key
ME(SOHC)-9
GENERAL DESCRIPTION
Mechanical
5. CYLINDER BLOCK S153001A0505
B2M4154A
(1) Oil pressure switch (14) Baffle plate Tightening torque: N·m (kgf-m, ft-lb)
(2) Cylinder block (RH) (15) Oil filter connector
T1: 5 (0.5, 3.6)
(3) Service hole plug (16) Oil strainer
T2: 6.4 (0.65, 4.7)
(4) Gasket (17) Gasket
T3: 10 (1.0, 7)
(5) Oil separator cover (18) Oil pan
(6) Water by-pass pipe (19) Drain plug T4: 25 (2.5, 18.1)
(7) Oil pump (20) Metal gasket T5: 47 (4.8, 34.7)
(8) Front oil seal (21) Oil level gauge guide T6: 69 (7.0, 50.6)
(9) Rear oil seal (22) Water pump sealing T7: First 12 (1.2, 8.7)
(10) O-ring (23) Oil filter Second 12 (1.2, 8.7)
(11) Service hole cover (24) Gasket T8: 16 (1.6, 11.6)
(12) Cylinder block (LH) (25) Water pump hose T9: 44 (4.5, 33)
(13) Water pump T10: 25 (2.5, 18.1)
ME(SOHC)-10
GENERAL DESCRIPTION
Mechanical
MEMO:
ME(SOHC)-11
GENERAL DESCRIPTION
Mechanical
6. CRANKSHAFT AND PISTON S153001A0506
B2M3429A
ME(SOHC)-12
GENERAL DESCRIPTION
Mechanical
(1) Flywheel (MT) (9) Circlip (17) Crankshaft bearing #2, #4

(2) Reinforcement (AT) (10) Connecting rod bolt (18) Crankshaft bearing #5
(3) Drive plate (AT) (11) Connecting rod
(4) Top ring (12) Connecting rod bearing Tightening torque: N·m (kgf-m, ft-lb)
(5) Second ring (13) Connecting rod cap T1: 44.6 (4.55, 32.9)
(6) Oil ring (14) Crankshaft T2: 72 (7.3, 52.8)
(7) Piston (15) Woodruff key
(8) Piston pin (16) Crankshaft bearing #1, #3
ME(SOHC)-13
GENERAL DESCRIPTION
Mechanical
7. ENGINE MOUNTING S153001A0507
EN1005
(1) Front cushion rubber Tightening torque: N·m (kgf-m, ft-lb)

(2) Front engine mounting bracket
T1: 35 (3.6, 25.8)
T2: 42 (4.2, 31.0)
T3: 85 (8.7, 63)
C: CAUTION S153001A03 쐌 All parts should be thoroughly cleaned, paying

special attention to the engine oil passages, pis-
쐌 Wear working clothing, including a cap, protec- tons and bearings.
tive goggles, and protective shoes during opera- 쐌 Rotating parts and sliding parts such as piston,
tion. bearing and gear should be coated with oil prior to
쐌 Remove contamination including dirt and corro- assembly.
sion before removal, installation or disassembly. 쐌 Be careful not to let oil, grease or coolant con-
쐌 Keep the disassembled parts in order and pro- tact the timing belt, clutch disc and flywheel.
tect them from dust or dirt. 쐌 All removed parts, if to be reused, should be
쐌 Before removal, installation or disassembly, be reinstalled in the original positions and directions.
sure to clarify the failure. Avoid unnecessary 쐌 Bolts, nuts and washers should be replaced with
removal, installation, disassembly, and replace- new ones as required.
ment. 쐌 Even if necessary inspections have been made
쐌 Be careful not to burn your hands, because each in advance, proceed with assembly work while
part in the vehicle is hot after running. making rechecks.
쐌 Be sure to tighten fasteners including bolts and 쐌 Remove or install engine in an area where chain
nuts to the specified torque. hoists, lifting devices, etc. are available for ready
쐌 Place shop jacks or safety stands at the speci- use.
fied points. 쐌 Be sure not to damage coated surfaces of body
쐌 Before disconnecting electrical connectors of panels with tools or stain seats and windows with
sensors or units, be sure to disconnect negative coolant or oil. Place a cover over fenders, as
terminal from battery. required, for protection.
쐌 Prior to starting work, prepare the following:
ME(SOHC)-14
GENERAL DESCRIPTION
Mechanical
Service tools, clean cloth, containers to catch cool- 쐌 Lift-up or lower the vehicle when necessary.
ant and oil, wire ropes, chain hoist, transmission Make sure to support the correct positions.
jacks, etc.

498267800 CYLINDER 쐌 Used for replacing valve guides.
HEAD TABLE 쐌 Used for removing and installing valve
springs.
B2M3850
498457000 ENGINE STAND Used with ENGINE STAND (499817000).
ADAPTER RH
B2M3851
ADAPTER LH
B2M3852
498497100 CRANKSHAFT Used for stopping rotation of flywheel when
STOPPER loosening and tightening crankshaft pulley bolt,
etc.
B2M3853
ME(SOHC)-15
GENERAL DESCRIPTION
Mechanical

498747100 PISTON GUIDE Used for installing piston in cylinder.
B2M3854
498857100 VALVE OIL Used for press-fitting of intake and exhaust
SEAL GUIDE valve guide oil seals.
B2M3855
499017100 PISTON PIN Used for installing piston pin, piston and con-
GUIDE necting rod.
B2M3856
499037100 CONNECTING Used for removing and installing connecting rod
ROD BUSHING bushing.
REMOVER &
INSTALLER
B2M3857
ME(SOHC)-16
GENERAL DESCRIPTION
Mechanical

499097700 PISTON PIN Used for removing piston pin.
REMOVER
ASSY
B2M3858
499207100 CAMSHAFT Used for removing and installing camshaft
SPROCKET sprocket. (LH side)
WRENCH
B2M3859
SPROCKET sprocket. (RH side)
WRENCH
B2M4158
499587700 CAMSHAFT OIL Used for installing cylinder head plug.
SEAL
INSTALLER
B2M3860
ME(SOHC)-17
GENERAL DESCRIPTION
Mechanical

499587200 CRANKSHAFT 쐌 Used for installing crankshaft oil seal.
OIL SEAL 쐌 Used with CRANKSHAFT OIL SEAL GUIDE
B2M3861
499597000 OIL SEAL 쐌 Used for installing camshaft oil seal.
GUIDE 쐌 Used with CAMSHAFT OIL SEAL INSTALLER
(499587100).
B2M3862
499597100 CRANKSHAFT 쐌 Used for installing crankshaft oil seal.
OIL SEAL 쐌 Used with CRANKSHAFT OIL SEAL
GUIDE INSTALLER (499587200).
B2M3863
499718000 VALVE SPRING Used for removing and installing valve spring.
REMOVER
B2M3864
ME(SOHC)-18
GENERAL DESCRIPTION
Mechanical

499767700 VALVE GUIDE Used for installing valve guides.
(Intake side) ADJUSTER
499767800
(Exhaust side)
B2M3865
499767200 VALVE GUIDE Used for removing valve guides.
REMOVER
B2M3867
499767400 VALVE GUIDE Used for reaming valve guides.
REAMER
B2M3868
499817100 ENGINE STAND 쐌 Stand used for engine disassembly and
assembly.
쐌 Used with ENGINE STAND ADAPTER RH
(498457000) & LH (498457100).
B2M3869
ME(SOHC)-19
GENERAL DESCRIPTION
Mechanical

499977300 CRANK PULLEY Used for stopping rotation of crankshaft pulley
WRENCH when loosening and tightening crankshaft pulley
bolts.
B2M4157
499987500 CRANKSHAFT Used for rotating crankshaft.
SOCKET
B2M3871
498547000 OIL FILTER Used for removing and installing oil filter.
WRENCH
B2M3872
499497000 TORX PLUS Used for removing and installing camshaft cap.
B2M3873
ME(SOHC)-20
GENERAL DESCRIPTION
Mechanical

499587500 OIL SEAL Used for installing front camshaft oil seal.
INSTALLER
B2M3874
499587100 OIL SEAL Used for installing oil pump oil seal.
INSTALLER
B2M3875
498277200 STOPPER SET Used for installing automatic transmission
assembly to engine.
B3M2043
(Newly adopted
tool)
B2M3876
ME(SOHC)-21
GENERAL DESCRIPTION
Mechanical

22771AA030 SELECT MONI- Troubleshooting for electrical systems.
TOR KIT 쐌 English: 22771AA030 (Without printer)
B2M3877
TOOL NAME REMARKS

Compression Gauge Used for measuring compression.
Tachometer (Secondary pick-up type) Used for measuring idle speed.
Timing Light Used for measuring ignition timing.
E: PROCEDURE S153001E45
It is possible to conduct the following service pro-

cedures with engine on the vehicle, however, the
procedures described in this section are based on
the condition that the engine is removed from the
vehicle.
쐌 V-belt
쐌 Timing Belt
쐌 Valve Rocker Assembly
쐌 Camshaft
쐌 Cylinder Head
ME(SOHC)-22
COMPRESSION
Mechanical
2. Compression S153081
CAUTION:
After warming-up, engine becomes very hot.
Be careful not to burn yourself during mea-
surement.
1) After warming-up the engine, turn ignition
switch to OFF.
2) Make sure that the battery is fully charged.
OPERATION, Fuel.> or <Ref. to FU(SOHCw/
oOBD)-41, RELEASING OF FUEL PRESSURE,
OPERATION, Fuel.>
4) Remove all the spark plugs. <Ref. to
IG(SOHC)-4, REMOVAL, Spark Plug.> or <Ref. to
IG(SOHCw/oOBD)-5, REMOVAL, Spark Plug.>
5) Fully open throttle valve.
6) Check the starter motor for satisfactory perfor-
mance and operation.
7) Hold the compression gauge tight against the
spark plug hole.
CAUTION:
When using a screw-in type compression
gauge, the screw (put into cylinder head spark
plug hole) should be less than 18 mm (0.71 in)
long.
8) Crank the engine by means of the starter motor,
and read the maximum value on the gauge when
the pointer is steady.
B2M3133
9) Perform at least two measurements per

cylinder, and make sure that the values are correct.
Compression (350 rpm and fully open
throttle):
Standard;
1,275 kPa (13.0 kg/cm2, 185 psi)
Limit;
1,020 kPa (10.4 kg/cm2, 148 psi)
Difference between cylinders;
49 kPa (0.5 kg/cm2, 7 psi), or less
ME(SOHC)-23
IDLE SPEED
Mechanical
3. Idle Speed S153082

5) When using tachometer (Secondary pick-up
type).
A: INSPECTION S153082A10 (1) Attach the pick-up clip to No. 1 cylinder
spark plug cord.
1) Before checking idle speed, check the follow- (2) Start the engine, and read engine idle
ing: speed.
(1) Ensure that air cleaner element is free from
clogging, ignition timing is correct, spark plugs
are in good condition, and that hoses are con-
nected properly.
(2) Ensure that malfunction indicator light
(CHECK ENGINE light) does not illuminate.
2) Warm-up the engine.
3) Stop the engine, and turn ignition switch to
OFF.
4) When using SUBARU SELECT MONITOR
<Ref. to ME(SOHC)-15, SPECIAL TOOLS, B2M3131
PREPARATION TOOL, General Description.>
(1) Insert the cartridge to SUBARU SELECT NOTE:
MONITOR. 쐌 When using the OBD-II general scan tool, care-
(2) Connect SUBARU SELECT MONITOR to fully read its operation manual.
the data link connector. 쐌 This ignition system provides simultaneous igni-
tion for #1 and #2 plugs. It must be noted that
some tachometers may register twice that of actual
engine speed.
6) Check idle speed when unloaded. (With
headlights, heater fan, rear defroster, radiator fan,
air conditioning, etc. OFF)
Idle speed (No load and gears in neutral (MT),
or N or P (AT) position):
With OBD Model;
700±100 rpm
S2M2157
Without OBD Model;
(3) Turn ignition switch to ON, and SUBARU MT: 650±100 rpm
SELECT MONITOR switch to ON. AT: 675±100 rpm
(4) Select {2. Each System Check} in Main 7) Check idle speed when loaded. (Turn air con-
Menu. ditioning switch to “ON” and operate compressor
(5) Select {Engine Control System} in Selection for at least one minute before measurement.)
Menu. Idle speed [A/C “ON”, no load and gears in
(6) Select {1. Current Data Display & Save} in neutral (MT) or N or P (AT) position]:
Engine Control System Diagnosis. With OBD Model;
(7) Select {1.12 Data Display} in Data Display 850±100 rpm
Menu. Without OBD Model;
(8) Start the engine, and read engine idle 800±100 rpm
speed.
CAUTION:
Never rotate idle adjusting screw. If idle speed
is out of specifications, refer to General On-
board Diagnosis Table under “Engine Control
System”. <Ref. to EN(SOHC)-2, Basic Diagnos-
tic Procedure.> or <Ref. to EN(SOHCw/
oOBD)-2, Basic Diagnostic Procedure.>
ME(SOHC)-24
IGNITION TIMING
Mechanical
4. Ignition Timing S153086
CAUTION:
surement.
2) To check the ignition timing, connect a timing
light to #1 cylinder spark plug cord, and illuminate
the timing mark with the timing light.
3) Start the engine at idle speed and check the
ignition timing.
Ignition timing [BTDC/rpm]:
With OBD Model;
10°±10°/700 rpm
Without OBD Model;
MT: 10°±10°/650 rpm
AT: 10°±10°/675 rpm
B2M3130
If the timing is not correct, check the ignition con-

trol system.
Refer to Engine Control System. <Ref. to
EN(SOHC)-2, Basic Diagnostic Procedure.> or
<Ref. to EN(SOHCw/oOBD)-2, Basic Diagnostic
Procedure.>
ME(SOHC)-25
INTAKE MANIFOLD VACUUM
Mechanical
5. Intake Manifold Vacuum S153654

By observing the gauge needle movement, the
internal condition of the engine can be diagnosed
A: INSPECTION S153654A10 as described below.
2) Disconnect the brake vacuum hose and install
the vacuum gauge to the hose fitting on the mani-
fold.
3) Keep the engine at the idle speed and read the
vacuum gauge indication.
B2M3134
Vacuum pressure (at idling, A/C “OFF”):

Less than −60.0 kPa (−450 mmHg, −17.72
inHg)
Diagnosis of engine condition by measurement of manifold vacuum

Vacuum gauge indication Possible engine condition
1. Needle is steady but lower than normal position. This ten- Leakage around intake manifold gasket or disconnection or
dency becomes more evident as engine temperature rises. damaged vacuum hose
2. When engine speed is reduced slowly from higher speed, Back pressure too high, or exhaust system clogged
needle stops temporarily when it is lowering or becomes
steady above normal position.
3. Needle intermittently drops to position lower than normal Leakage around cylinder
position.
4. Needle drops suddenly and intermittently from normal posi- Sticky valves
tion.
5. When engine speed is gradually increased, needle begins to Weak or broken valve springs
vibrate rapidly at certain speed, and then vibration increases
as engine speed increases.
6. Needle vibrates above and below normal position in narrow Defective ignition system or throttle chamber idle adjustment
range.
ME(SOHC)-26
ENGINE OIL PRESSURE
Mechanical
6. Engine Oil Pressure S153655

7) Start the engine, and measure oil pressure.
S2M0242
Oil pressure:
98 kPa (1.0 kg/cm2, 14 psi) or more at 800
G6M0095
rpm
2) Remove generator from bracket. 294 kPa (3.0 kg/cm2, 43 psi) or more at
(1) Loosen lock bolt and slider bolt, and remove 5,000 rpm
front side V-belt. <Ref. to ME(SOHC)-42, CAUTION:
REMOVAL, V-belt.> 쐌 If oil pressure is out of specification, check
(2) Remove generator lock bolt. oil pump, oil filter and lubrication line. <Ref. to
(3) Remove bolt which install generator on LU-25, INSPECTION, Engine Lubrication Sys-
bracket. tem Trouble in General.>
쐌 If oil pressure warning light is turned ON and
oil pressure is in specification, replace oil pres-
sure switch. <Ref. to LU-25, INSPECTION,
Engine Lubrication System Trouble in Gen-
eral.>
NOTE:
The specified data is based on an engine oil tem-
perature of 80°C (176°F).
8) After measuring oil pressure, install oil pressure
S6M0352 switch. <Ref. to LU-21, INSTALLATION, Oil Pres-
sure Switch.>
3) Disconnect connector from oil pressure switch.
4) Remove oil pressure switch from engine cylin- Tightening torque:
der block. <Ref. to LU-21, REMOVAL, Oil Pressure 25 N·m (2.5 kgf-m, 18.1 ft-lb)
Switch.> 9) Install generator and V-belt in the reverse order
5) Connect oil pressure gauge hose to cylinder of removal, and adjust the V-belt deflection. <Ref.
block. to ME(SOHC)-42, INSTALLATION, V-belt.>
G6M0095
ME(SOHC)-27
FUEL PRESSURE
Mechanical
7. Fuel Pressure S153656

6) Measure fuel pressure while disconnecting
A: INSPECTION S153656A10 pressure regulator vacuum hose from intake mani-
fold.
WARNING:
Before removing fuel pressure gauge, release Fuel pressure:
fuel pressure. Standard; 284 — 314 kPa (2.9 — 3.2
kg/cm2, 41 — 46 psi)
NOTE:
If out of specification, check or replace pressure
regulator and pressure regulator vacuum hose.
OPERATION, Fuel.>
S2M0554
7) After connecting pressure regulator vacuum

hose, measure fuel pressure.
Fuel pressure:
Standard; 206 — 235 kPa (2.1 — 2.4
kg/cm2, 30 — 34 psi)
B2M3197
3) Disconnect fuel delivery hoses from fuel

damper, and connect fuel pressure gauge.
S2M0554
NOTE:
The fuel pressure gauge registers 10 to 20 kPa
(0.1 to 0.2 kg/cm2, 1 to 3 psi) higher than standard
values during high-altitude operations.
S2M0195
4) Connect connector of fuel pump relay.
S2M0093
ME(SOHC)-28
VALVE CLEARANCE
Mechanical
8. Valve Clearance S153083

9) Set #1 cylinder piston to top dead center of
compression stroke by rotating crankshaft pulley
A: INSPECTION S153083A10 clockwise using ST.
CAUTION: ST 499977300 CRANKSHAFT PULLEY
Inspection and adjustment of valve clearance WRENCH
should be performed while engine is cold. NOTE:
1) Set the vehicle onto the lift. When arrow mark on camshaft sprocket (LH)
2) Lift-up the vehicle. comes exactly to the top, #1 cylinder piston is
3) Remove under cover. brought to the top dead center of compression
4) Disconnect battery ground cable. stroke.
B2M2027A
G6M0095
5) Lower the vehicle. 10) Measure #1 cylinder valve clearance by using

6) Remove timing belt cover (LH). thickness gauge.
CAUTION:
쐌 Insert the thickness gauge in as horizontal a
direction as possible with respect to the valve
stem end face.
쐌 Measure exhaust valve clearances while lift-
ing-up the vehicle.
Valve clearance:
Intake;
0.20±0.02 mm (0.0079±0.0008 in)
B2M2031 Exhaust;
0.25±0.02 mm (0.0098±0.0008 in)
7) When inspecting #1 and #3 cylinders;
(1) Disconnect spark plug cords from spark
plugs RH side. <Ref. to IG(SOHC)-4, RH SIDE,
REMOVAL, Spark Plug.> or <Ref. to
IG(SOHCw/oOBD)-5, RH SIDE, REMOVAL,
Spark Plug.>
(2) Disconnect PCV hose from rocker cover
(RH).
(3) Remove bolts, then remove rocker cover
(RH).
8) When inspecting #2 and #4 cylinders; B2M2028A
plugs (LH Side) <Ref. to IG(SOHC)-5, LH SIDE, 11) If necessary, adjust the valve clearance. <Ref.
REMOVAL, Spark Plug.> or <Ref. to to ME(SOHC)-30, ADJUSTMENT, Valve Clear-
IG(SOHCw/oOBD)-6, LH SIDE, REMOVAL, ance.>
Spark Plug.>. 12) Similar to measurement procedures used for
(2) Disconnect PCV hose from rocker cover #1 cylinder, measure #2, #3 and #4 cylinder valve
(LH). clearances.
(LH).
ME(SOHC)-29
VALVE CLEARANCE
Mechanical
NOTE: NOTE:
쐌 Be sure to set cylinder pistons to their respective When arrow mark on camshaft sprocket (LH)
top dead centers on compression stroke before comes exactly to the top, #1 cylinder piston is
measuring valve clearances. brought to the top dead center of compression
쐌 To set #3, #2 and #4 cylinder pistons to their top stroke.
dead centers on compression stroke, turn crank-
shaft pulley clockwise 90° at a time starting with
arrow mark on left-hand camshaft sprocket facing
up.
B2M2027A
2) Adjust the #1 cylinder valve clearance.

(1) Loosen the valve rocker nut and screw.
B2M2029A
(2) Place suitable thickness gauge.
(3) While noting valve clearance, tighten valve
13) After inspection, install the related parts in the rocker adjust screw.
reverse order of removal. (4) When specified valve clearance is obtained,
Tightening torque: tighten valve rocker nut.
Resonator chamber; Tightening torque:
33 N·m (3.4 kgf-m, 24 ft-lb) 10 N·m (1.0 kgf-m, 7.2 ft-lb)
CAUTION:
direction as possible with respect to the valve
stem end face.
쐌 Adjust exhaust valve clearances while lift-
ing-up the vehicle.
Valve clearance:
Intake;
0.20±0.02 mm (0.0079±0.0008 in)
Exhaust;
B6M1237
0.25±0.02 mm (0.0098±0.0008 in)
B: ADJUSTMENT S153083A01
CAUTION:
Adjustment of valve clearance should be per-
formed while engine is cold.
1) Set #1 cylinder piston to top dead center of
compression stroke by rotating crankshaft pulley
clockwise using ST.
ST 499977300 CRANKSHAFT PULLEY
WRENCH B2M2030
3) Ensure that valve clearances are within speci-

fications.
4) Turn crankshaft two complete rotations until #1
cylinder piston is again set to top dead center on
compression stroke.
5) Ensure that valve clearances are within speci-
fications. If necessary, readjust valve clearances.
ME(SOHC)-30
VALVE CLEARANCE
Mechanical
6) Similar to adjustment procedures used for #1

cylinder, adjust #2, #3 and #4 cylinder valve clear-
ances.
NOTE:
쐌 Be sure to set cylinder pistons to their respective
top dead centers on compression stroke before
adjusting valve clearances.
쐌 To set #3, #2 and #4 cylinder pistons to their top
dead centers on compression stroke, turn crank-
shaft pulley clockwise 90° at a time starting with
arrow mark on left-hand camshaft sprocket facing
up.
B2M2029A
ME(SOHC)-31
ENGINE ASSEMBLY
Mechanical
9. Engine Assembly S153079

(3) Disconnect A/C pressure hoses from A/C
compressor.
1) Set the vehicle on lift arms.

2) Open front hood fully and support with stay.
OPERATION, Fuel.>
4) Remove filler cap.
B2M3385
12) Remove air cleaner case stay.

쐌 MT model
G6M0095
6) Remove air intake duct and air cleaner case.

<Ref. to IN(SOHC)-8, REMOVAL, Air Intake Duct.>
S2M0900
and <Ref. to IN(SOHC)-7, REMOVAL , Air Cleaner
Case.> 쐌 AT model
7) Remove canister and bracket. (Without OBD)
B2M4251
S2M0574
13) Disconnect the following connectors and
8) Remove under cover. cables.
9) Remove radiator from vehicle. <Ref. to CO-25, (1) Front oxygen (A/F) sensor connector (With
REMOVAL, Radiator.> OBD)
10) Remove ATF cooler pipe from cylinder head.
<Ref. to AT-49, REMOVAL, ATF Cooler Pipe and
Hose.>
11) Collect refrigerant, and remove pressure
hoses. (With A/C)
(1) Place and connect the attachment hose to
the refrigerant recycle system.
(2) Collect refrigerant from A/C system.
B2M4243
ME(SOHC)-32
ENGINE ASSEMBLY
Mechanical
(2) Front oxygen sensor connector (Without (5) Generator connector, terminal and A/C
OBD) compressor connector
S2M0517 B2M3386B
(3) Engine ground terminal (A) Generator connector and terminal

(B) A/C compressor connector
(6) Accelerator cable and cruise control cable
S2M0731
(4) Engine harness connectors

B2M3415A
(A) Accelerator cable

(B) Cruise control cable
(7) Pressure switch
S2M0742
B2M4292
ME(SOHC)-33
ENGINE ASSEMBLY
Mechanical
(8) Engine control module connector (3) Remove pipe with bracket from intake mani-
fold.
S2M0533
S2M0903
14) Disconnect the following hoses.
(1) Brake booster vacuum hose (4) Remove bolts which install power steering
pump from bracket.
B2M3419
S2M0488
(2) Heater inlet outlet hose
(5) Remove bolt which installs power steering
pump bracket on cylinder head.
(6) Place power steering pump on the right side
wheel apron.
B2M3390
15) Remove power steering pump from bracket.

(1) Remove resonator chamber.
(2) Loosen lock bolt and slider bolt, and remove S2M0491
front side V-belt.<Ref. to ME(SOHC)-42,
FRONT SIDE BELT, REMOVAL, V-belt.> 16) Remove front and center exhaust pipe.
Pipe.> or <Ref. to EX(SOHCw/oOBD)-6,
REMOVAL, Front Exhaust Pipe.>
ME(SOHC)-34
ENGINE ASSEMBLY
Mechanical
17) Remove nuts which hold lower side of trans- 20) Remove pitching stopper.
mission to engine.
S2M0126
B3M2047
21) Disconnect fuel delivery hose, return hose and
18) Remove nuts which install front cushion rub- evaporation hose.
ber onto front crossmember. CAUTION:
쐌 Disconnect hose with its end wrapped with
cloth to prevent fuel from splashing.
쐌 Catch fuel from hose into container.
S2M1927
19) Separate torque converter clutch from drive

plate. (AT model)
(1) Lower the vehicle. S2M0500
(2) Remove service hole plug. 22) Support engine with a lifting device and wire
(3) Remove bolts which hold torque converter ropes.
clutch to drive plate.
(4) Remove other bolts while rotating the
engine using ST.
ST 499977100 CRANK PULLEY WRENCH
B2M3391
S2M0207
ME(SOHC)-35
ENGINE ASSEMBLY
Mechanical
23) Support transmission with a garage jack. (4) Slowly move engine away from engine
CAUTION: compartment.
Before moving engine away from transmission, CAUTION:
check to be sure no work has been overlooked. Be careful not to damage adjacent parts or
Doing this is very important in order to facili- body panels with crank pulley, oil level gauge,
tate re-installation and because transmission etc.
lowers under its own weight.
B2M3391
G2M0298 27) Remove front cushion rubbers.

24) Separation of engine and transmission.
(1) Remove starter. <Ref. to SC-5, REMOVAL,
Starter.>
(2) Remove bolts which hold upper side of
transmission to engine.
B3M2044
25) Install ST to torque converter clutch case. (AT

model)
ST 498277200 STOPPER SET
H2M1961A
26) Remove engine from vehicle.

(1) Slightly raise engine.
(2) Raise transmission with garage jack.
(3) Move engine horizontally until main shaft is
withdrawn from clutch cover.
ME(SOHC)-36
ENGINE ASSEMBLY
Mechanical
B: INSTALLATION S153079A11 6) Install pitching stopper.

1) Install front cushion rubbers. Tightening torque:
T1: 49 N·m (5.0 kgf-m, 36.2 ft-lb)
Tightening torque: T2: 57 N·m (5.8 kgf-m, 42 ft-lb)
34 N·m (3.5 kgf-m, 25.3 ft-lb)
2) Install engine onto transmission.
(1) Position engine in engine compartment and
align it with transmission.
CAUTION:
Be careful not to damage adjacent parts or
body panels with crank pulley, oil level gauge,
etc.
S2M0126C
7) Remove ST from torque converter clutch case.

(AT model)
NOTE:
Be careful not to drop the ST into the torque con-
verter clutch case when removing ST.
B2M3391 8) Install starter. <Ref. to SC-6, INSTALLATION,
Starter.>
(2) Apply a small amount of grease to spline of 9) Install torque converter clutch onto drive plate.
main shaft. (MT model) (AT model)
3) Tighten bolts which hold upper side of transmis- (1) Tighten bolts which hold torque converter
sion to engine. clutch to drive plate.
Tightening torque: (2) Tighten other bolts while rotating the engine
50 N·m (5.1 kgf-m, 36.9 ft-lb) by using ST.
CAUTION:
Be careful not to drop bolts into torque con-
verter clutch housing.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
B3M2044
4) Remove lifting device and wire ropes.
S2M0207
(3) Clog plug onto service hole.

10) Install power steering pump on bracket.
B2M3391
5) Remove garage jack.
ME(SOHC)-37
ENGINE ASSEMBLY
Mechanical
(1) Install power steering pump on bracket, and (5) Install resonator chamber.
tighten bolts. Tightening torque:
Tightening torque: 33 N·m (3.4 kgf-m, 24.6 ft-lb)
20.1 N·m (2.05 kgf-m, 14.8 ft-lb)
B6M1237
S2M0488
11) Tighten nuts which hold lower side of trans-
(2) Tighten bolt which installs power steering mission to engine.
pump bracket, and install spark plug codes. Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)
S2M0903
(3) Connect power steering switch connector. B3M2047
12) Tighten nuts which install front cushion rubber

onto crossmember.
Tightening torque:
85 N·m (8.7 kgf-m, 63 ft-lb)
CAUTION:
Make sure the front cushion rubber mounting
bolts (A) and locator (B) are securely installed.
S2M0742
(4) Install front side V-belt, and adjust it. <Ref.

to ME(SOHC)-42, FRONT SIDE BELT,
INSTALLATION, V-belt.>
B2M3880A
13) Install front and center exhaust pipe.

Exhaust Pipe.> and <Ref. to EX(SOHCw/oOBD)-7,
INSTALLATION, Front Exhaust Pipe.>
14) Connect the following hoses.
ME(SOHC)-38
ENGINE ASSEMBLY
Mechanical
(1) Fuel delivery hose, return hose and evapo- 25) Charge A/C system with refrigerant.
ration hose <Ref. to AC-20, OPERATION, Refrigerant Charg-
(2) Heater inlet and outlet hoses ing Procedure.>
(3) Brake booster vacuum hose 26) Remove front hood stay, and close front hood.
15) Connect the following connectors. 27) Take off the vehicle from lift arms.
(1) Engine ground terminals
Tightening torque:
14 N·m (1.4 kgf-m, 10.1 ft-lb) 1) Make sure pipes and hoses are installed cor-
rectly.
(2) Engine harness connectors 2) Make sure the engine coolant and ATF are at
(3) Generator connector and terminal specified levels.
(4) A/C compressor connectors
(5) Engine control module connector (Without
OBD)
16) Connect the following cables.
(2) Cruise control cables (With cruise control)
CAUTION:
After connecting each cable, adjust them.
17) Install air cleaner case stay.
Tightening torque:
16 N·m (1.6 kgf-m, 11.6 ft-lb)
18) Install A/C pressure hoses.
<Ref. to AC-38, INSTALLATION, Flexible Hose.>
CAUTION:
Use new O-rings.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
B2M3385
19) Install radiator to vehicle. <Ref. to CO-27,

INSTALLATION, Radiator.>
20) Install ATF cooler pipe to cylinder head. <Ref.
to AT-50, INSTALLATION, ATF Cooler Pipe and
Hose.>
22) Install battery in the vehicle, and connect
cables.
23) Fill coolant.
<Ref. to CO-14, FILLING OF ENGINE COOLANT,
REPLACEMENT, Engine Coolant.>
24) Check ATF level and correct if necessary. (AT
model)
<Ref. to AT-9, INSPECTION, Automatic Transmis-
sion Fluid.>
ME(SOHC)-39
ENGINE MOUNTING
Mechanical
10. Engine Mounting S153085
1) Remove engine assembly. <Ref. to

ME(SOHC)-32, REMOVAL, Engine Assembly.>
2) Remove engine mounting from engine assem-
bly.

Tightening torque:
Engine mounting;
35 N·m (3.6 kgf-m, 26.0 ft-lb)
Make sure there are no cracks or other damage.
ME(SOHC)-40
PREPARATION FOR OVERHAUL
Mechanical
11. Preparation for Overhaul S153091
1) After removing the engine from the body,

secure it in the ST shown below.
ST1 498457000 ENGINE STAND ADAPTER
RH
LH
ST3 499817100 ENGINE STAND
B2M2582A
2) In this section the procedures described under

each index are all connected and stated in order.
It will be the complete procedure for overhauling of
the engine itself when you go through all steps in
the process.
Therefore, in this section, to conduct the particular
procedure within the flow of a section, you need to
go back and conduct the procedure described pre-
viously in order to do that particular procedure.
ME(SOHC)-41
V-BELT
Mechanical
12. V-belt S153080

3) Remove the A/C belt.
4) Remove the A/C belt tensioner.
1. FRONT SIDE BELT S153080A1801
NOTE:
Perform the following procedures 1) to 4) with the
engine installed to the body.
1) Remove V-belt cover.
B2M2585
CAUTION:
B2M3401
1) Install a belt, and tighten the slider bolt so as to
2) Loosen the lock bolt (A). obtain the specified belt tension <Ref. to
3) Loosen the slider bolt (B). ME(SOHC)-43, INSPECTION, V-belt.>
4) Remove the front side belt (C). 2) Tighten the lock bolt (A)
3) Tighten slider bolt (B).
Tightening torque:
Lock bolt through bolt:
25 N·m (2.5 kgf-m, 18 ft-lb)
Slider bolt:
8 N·m (0.8 kgf-m, 5.5 ft-lb)
B2M4291A
2. REAR SIDE BELT S153080A1802

B2M4291A
4) Install V-belt cover.

1) Install a belt, and tighten the slider bolt (B) so

as to obtain the specified belt tension. <Ref. to
ME(SOHC)-43, INSPECTION, V-belt.>
B2M2584A
ME(SOHC)-42
V-BELT
Mechanical
2) Tighten the lock nut (A).

Tightening torque:
Lock nut (A);
22.6 N·m (2.3 kgf-m, 16.6 ft-lb)
B2M2584A
1) Replace belts, if cracks, fraying or wear is

found.
2) Check drive belt tension and adjust it if neces-
sary by changing generator installing position
and/or idler pulley installing position.
Belt tension
(A)
replaced: 7 — 9 mm (0.276 — 0.354 in)
reused: 9 — 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)
B2M4123B

GEN Generator
P/S Power steering oil pump pulley
I/P Idler pulley
ME(SOHC)-43
CRANKSHAFT PULLEY
Mechanical
13. Crankshaft Pulley S153098

CAUTION:
If the tightening angle of crankshaft pulley bolt
A: REMOVAL S153098A18 is less than 45 degrees, the bolt should be
damaged. In this case, the bolt must be
1) Remove V-belt. <Ref. to ME(SOHC)-42, replaced.
REMOVAL, V-belt.>
2) Remove crankshaft pulley bolt. To lock (1) Replace the crankshaft pulley bolts and
crankshaft, use ST. clean them.
ST 499977300 CRANKSHAFT PULLEY Crankshaft pulley bolt:
WRENCH 12369AA011
(2) Clean the crankshaft thread using an air
gun.
(3) Tighten the bolts temporarily with tightening
torque of 44 N·m (4.5 kgf-m, 33 ft-lb).
(4) Tighten the crankshaft pulley bolts keeping
them in an angle between 45 degrees and 60
degrees.
CAUTION:
Conduct the tightening procedures by confirm-
ing the turning angle of the crankshaft pulley
B2M2586A
bolt referring to the gauge indicated on the belt
3) Remove crankshaft pulley. cover.
4) Install A/C belt tensioner.
1) Install crankshaft pulley.

2) Install pulley bolt.
To lock crankshaft, use ST.
WRENCH
(1) Clean the crankshaft pulley thread using an
air gun.
(2) Apply engine oil to the crankshaft pulley bolt
seat and thread.
B2M2585
torque of 44 N·m (4.5 kgf-m, 33 ft-lb). 5) Install A/C belt.
(4) Tighten the crankshaft pulley bolts.
Tightening torque:
127 N·m (13.0 kgf-m, 94.0 ft-lb)
B2M2584
B2M2586A
1) Make sure the V-belt is not worn or otherwise
3) Confirm that the tightening angle of the crank- damaged.
shaft pulley bolt is 45 degrees or more. If not, con- 2) Check the tension of the belt. <Ref. to
duct the following procedures. ME(SOHC)-43, INSPECTION, V-belt.>
ME(SOHC)-44
BELT COVER
Mechanical
14. Belt Cover S153582
1) Remove V-belt. <Ref. to ME(SOHC)-42,

REMOVAL, V-belt.>
2) Remove crankshaft pulley. <Ref. to
ME(SOHC)-44, REMOVAL, Crankshaft Pulley.>
3) Remove belt cover (LH).
4) Remove front belt cover.
B2M2587A
1) Install front belt cover.

Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb)
2) Install belt cover (LH).
Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb)
B2M2587A
3) Install crankshaft pulley. <Ref. to ME(SOHC)-

44, INSTALLATION, Crankshaft Pulley.>
4) Install V-belt. <Ref. to ME(SOHC)-42,
Make sure the cover is not damaged.
ME(SOHC)-45
TIMING BELT ASSEMBLY
Mechanical
15. Timing Belt Assembly S153099

REMOVAL, V-belt.>
3) Remove belt cover. <Ref. to ME(SOHC)-45,
REMOVAL, Belt Cover.>
4) Remove timing belt guide. (MT vehicle only)
EN0621
S2M0294
(2) Using white paint, put alignment and/or
5) If alignment mark (a) and/or arrow mark (which arrow marks on timing belts in relation to the
indicates rotation direction) on timing belt fade crank sprocket and cam sprockets.
away, put new marks before removing timing belt
as shown in procedures below.
(1) Turn crankshaft using ST. Align mark (a) of
sprocket to cylinder block notch (b) and ensure
that right side cam sprocket mark (c), cam cap
and cylinder head matching surface (d) and/or
left side cam sprocket mark (e) and belt cover
notch (f) are properly adjusted.
B2M2591
Specified data:
Z1: 44 tooth length
Z2: 40.5 tooth length
B2M2590A
B2M2592A
ME(SOHC)-46
Mechanical
6) Remove belt idler (No. 2). B: INSTALLATION S153099A11
7) Remove belt idler No. 2.

1. AUTOMATIC BELT TENSION
ADJUSTER ASSEMBLY AND BELT IDLER
S153099A1101
1) Preparation for installation of automatic belt

tension adjuster assembly;
CAUTION:
쐌 Always use a vertical type pressing tool to
move the adjuster rod down.
쐌 Do not use a lateral type vise.
S2M1008
쐌 Push adjuster rod vertically.
쐌 Be sure to slowly move the adjuster rod
8) Remove timing belt. down applying a pressure of 294 N (30 kgf, 66
lb).
쐌 Press-in the push adjuster rod gradually tak-
ing more than three minutes.
쐌 Do not allow press pressure to exceed 9,807
N (1,000 kgf, 2,205 lb).
쐌 Press the adjuster rod as far as the end sur-
face of the cylinder. Do not press the adjuster
rod into the cylinder. Doing so may damage the
cylinder.
쐌 Do not release press pressure until stopper
B2M2594 pin is completely inserted.
(1) Attach the automatic belt tension adjuster
2. BELT IDLER AND AUTOMATIC BELT assembly to the vertical pressing tool.
TENSION ADJUSTER ASSEMBLY S153099A1802 (2) Slowly move the adjuster rod down with a
pressure of 294 N (30 kgf, 66 lb) until the
1) Remove belt idler (No. 1). adjuster rod is aligned with the stopper pin hole
in the cylinder.
B2M2596
2) Remove automatic belt tension adjuster assem- H2M2382
bly.
H2M2375
ME(SOHC)-47
Mechanical
(3) With a 2 mm (0.08 in) dia. stopper pin or a (1) Turn camshaft sprocket No. 2 using ST1,
2 mm (0.08 in) (nominal) dia. hex bar wrench and turn camshaft sprocket No. 1 using ST2 so
inserted into the stopper pin hole in the cylinder, that their alignment marks come to top posi-
secure the adjuster rod. tions.
ST1 499207100 CAMSHAFT SPROCKET
WRENCH
ST2 499207400 CAMSHAFT SPROCKET
WRENCH
H2M2383A
2) Install automatic belt tension adjuster assem-

bly.
Tightening torque: B2M2602A
25 N·m (2.5 kgf-m, 18.4 ft-lb)
(2) While aligning alignment mark on timing
belt with marks on sprockets, position timing
belt properly.
CAUTION:
Ensure belt’s rotating direction is correct.
H2M2384
3) Install belt idler (No. 1).

Tightening torque:
39 N·m (4.0 kgf-m, 28.9 ft-lb)
B2M2603A
3) Install belt idler No. 2.

Tightening torque:
39 N·m (4.0 kgf-m, 28.9 ft-lb)
4) Install belt idler (No. 2).
Tightening torque:
39 N·m (4.0 kgf-m, 28.9 ft-lb)
B2M2596

tension adjuster assembly. <Ref. to ME(SOHC)-
47, AUTOMATIC BELT TENSION ADJUSTER
ASSEMBLY AND BELT IDLER, INSTALLATION,
Timing Belt Assembly.>
2) Installation of timing belt S2M1008
ME(SOHC)-48
Mechanical
5) After ensuring that the marks on timing belt and (3) Tighten remaining bolts.
camshaft sprockets are aligned, remove stopper Tightening torque:
pin from belt tensioner adjuster. 9.8 N·m (1.0 kgf-m, 7.2 ft-lb)
H2M2387A
H2M2415
6) Install timing belt guide. (MT vehicles only) 7) Install belt cover. <Ref. to ME(SOHC)-45,
(1) Temporarily tighten remaining bolts. INSTALLATION, Belt Cover.>
1) Check timing belt teeth for breaks, cracks, and

wear. If any fault is found, replace belt.
S2M0294
2) Check the condition of back side of belt; if any
(2) Check and adjust clearance between timing crack is found, replace belt.
belt and timing belt guide by using thickness CAUTION:
gauge. 쐌 Be careful not to let oil, grease or coolant
Clearance: contact the belt. Remove quickly and thor-
1.0±0.5 mm (0.039±0.020 in) oughly if this happens.
쐌 Do not bend the belt sharply.
Bending radius: h
S2M0297
G2M0115
2. AUTOMATIC BELT TENSION

ADJUSTER S153099A1002
1) Visually check oil seals for leaks, and rod ends
for abnormal wear or scratches. If necessary,
replace faulty parts.
ME(SOHC)-49
Mechanical
CAUTION: 3) Check tension pulley for grease leakage.

Slight traces of oil at rod’s oil seal does not
indicate a problem. 4. BELT IDLER S153099A1004
2) Check that the adjuster rod does not move 1) Check belt idler for smooth rotation. Replace if
when a pressure of 294 N (30 kgf, 66 lb) is applied noise or excessive play is noted.
2) Check belt outer contacting surfaces of idler
to it. This is to check adjuster rod stiffness.
pulley for abnormal wear and scratches.
3) If the adjuster rod is not stiff and moves freely
3) Check belt idler for grease leakage.
when applying 294 N (30 kgf, 66 lb), check it using
the following procedures:
(1) Slowly press the adjuster rod down to the
end surface of the cylinder. Repeat this motion
2 or 3 times.
(2) With the adjuster rod moved all the way up,
apply a pressure of 294 N (30 kgf, 66 lb) to it.
Check adjuster rod stiffness.
(3) If the adjuster rod is not stiff and moves
down, replace the automatic belt tension
adjuster assembly with a new one.
CAUTION:
N (1,000 kgf, 2,205 lb).
cylinder.
4) Measure the extension of rod beyond the body.
If it is not within specifications, replace with a new
one.
Rod extension: H
5.7±0.5 mm (0.224±0.020 in)
H2M2381A
3. BELT TENSION PULLEY S153099A1003
1) Check mating surfaces of timing belt and con-

tact point of adjuster rod for abnormal wear or
scratches. Replace automatic belt tension adjuster
assembly if faulty.
2) Check tension pulley for smooth rotation.
Replace if noise or excessive play is noted.
ME(SOHC)-50
CAMSHAFT SPROCKET
Mechanical
16. Camshaft Sprocket S153097 B: INSTALLATION S153097A11
1) Install camshaft sprocket No. 1. To lock
camshaft, use ST.
1. REMOVAL S153097A1801 ST 499207400 CAMSHAFT SPROCKET
1) Remove V-belt. <Ref. to ME(SOHC)-42, WRENCH
REMOVAL, V-belt.> Tightening torque:
2) Remove crankshaft pulley. <Ref. to 78 N·m (8.0 kgf-m, 57.9 ft-lb)
CAUTION:
Do not confuse left and right side camshaft
sprockets during installation. The camshaft
4) Remove timing belt assembly. <Ref. to
sprocket No. 2 is identified by a projection
ME(SOHC)-46, REMOVAL, Timing Belt Assem-
used to monitor camshaft position sensor.
bly.>
5) Remove camshaft position sensor. (With OBD)
<Ref. to FU(SOHC)-30, REMOVAL, Camshaft
Position Sensor.>
6) Remove camshaft sprocket No. 2. To lock
camshaft, use ST.
ST 499207100 CAMSHAFT SPROCKET
WRENCH
B2M2599A
2) Install camshaft sprocket No. 2. To lock

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

camshaft, use ST.
WRENCH
H2M2377A
3) Install camshaft position sensor. (With OBD)

<Ref. to FU(SOHC)-30, INSTALLATION, Camshaft
Position Sensor.>
4) Install timing belt assembly. <Ref. to
B2M2599A
ME(SOHC)-47, INSTALLATION, Timing Belt
Assembly.>
5) Install belt cover. <Ref. to ME(SOHC)-45,
INSTALLATION, Belt Cover.>
ME(SOHC)-51
CAMSHAFT SPROCKET
Mechanical
1) Check sprocket teeth for abnormal wear and

scratches.
2) Make sure there is no free play between
sprocket and key.
3) Check camshaft sprocket notch for sensor for
damage and contamination of foreign matter.
ME(SOHC)-52
CRANKSHAFT SPROCKET
Mechanical
17. Crankshaft Sprocket S153101 C: INSPECTION S153101A10
scratches.
1) Remove V-belt. <Ref. to ME(SOHC)-42, 2) Make sure there is no free play between
REMOVAL, V-belt.> sprocket and key.
2) Remove crankshaft pulley. <Ref. to 3) Check crankshaft sprocket notch for sensor for
ME(SOHC)-44, REMOVAL, Crankshaft Pulley.> damage and contamination of foreign matter.
bly.>
5) Remove camshaft sprocket. <Ref. to
ME(SOHC)-51, REMOVAL, Camshaft Sprocket.>
6) Remove crankshaft sprocket.
S2M0414
1) Install crankshaft sprocket.
S2M0414
2) Install camshaft sprocket. <Ref. to ME(SOHC)-

51, INSTALLATION, Camshaft Sprocket.>
Assembly.>
ME(SOHC)-53
VALVE ROCKER ASSEMBLY
Mechanical
18. Valve Rocker Assembly S153094

(2) Tighten bolts (e) through (h) to specified
torque.
A: REMOVAL S153094A18 (3) Tighten bolts (a) through (d) to specified
torque.
REMOVAL, V-belt.> Tightening torque:
2) Remove crankshaft pulley. <Ref. to 25 N·m (2.5 kgf-m, 18.1 ft-lb)
bly.>
ME(SOHC)-51, REMOVAL, Camshaft Sprocket.>
6) Disconnect PCV hose and remove rocker
cover.
7) Removal of valve rocker assembly B2M2605A
(1) Remove bolts (a) through (h) in alphabetical 2) Adjust the valve clearances. <Ref. to
sequence. ME(SOHC)-30, ADJUSTMENT, Valve Clearance.>
CAUTION: 3) Install rocker cover and connect PCV hose.
Leave two or three threads of bolts (g and h) 4) Install camshaft sprocket. <Ref. to ME(SOHC)-
engaged to retain valve rocker assembly. 51, INSTALLATION, Camshaft Sprocket.>
Assembly.>
B2M2605F
1) Remove bolts which secure rocker shaft.
(2) Remove valve rocker assembly. 2) Extract rocker shaft. Remove valve rocker
arms, springs and shaft supports from rocker shaft.
CAUTION:
Arrange all removed parts in order so that they
can be installed in their original positions.
3) Remove nut and adjuster screw from valve
rocker.
1) Install adjuster screw and nut to valve rocker.

B2M2606 2) Arrange valve rocker arms, springs and shaft
supports in assembly order and insert valve rocker
shaft.
Tightening torque (Shaft supports installing
1) Installation of valve rocker assembly bolts):
(1) Temporarily tighten bolts (a) through (d) 5 N·m (0.5 kgf-m, 3.6 ft-lb)
equally as shown in figure. CAUTION:
CAUTION: Valve rocker arms, rocker shaft and shaft sup-
Do not allow valve rocker assembly to gouge ports have identification marks. Ensure parts
knock pins. with same markings are properly assembled.
ME(SOHC)-54
VALVE ROCKER ASSEMBLY
Mechanical
3) Install valve rocker shaft securing bolts. 4) If oil clearance exceeds the limit, replace rocker
shaft support or shaft, whichever shows greater
E: INSPECTION S153094A10 amount of wear.
1. VALVE ROCKER ARM S153094A1001
Rocker shaft support inside diameter:
22.005 — 22.026 mm (0.8663 — 0.8672 in)
1) Measure inside diameter of valve rocker arm
and outside diameter of valve rocker shaft, and Rocker shaft diameter:
determine the difference between the two (= oil 21.987 — 22.000 mm (0.8656 — 0.8661 in)
clearance). 5) If cam or valve contact surface of valve rocker
Clearance between arm and shaft: arm is worn or dented excessively, replace valve
rocker arm.
Standard
6) Check that valve rocker arm roller rotates
0.020 — 0.054 mm (0.0008 — 0.0021 in)
smoothly. If not, replace valve rocker arm.
Limit
0.10 mm (0.0039 in) 2. INTAKE AND EXHAUST VALVE
ROCKER SHAFT S153094A1002
Visually check oil relief valve of shaft end for any
of the following abnormalities.
쐌 Breaks in check ball body
쐌 Foreign particles caught in valve spring
쐌 Oil leakage at check ball
CAUTION:
Repair or replace valve rocker shaft as neces-
sary.
B2M0072
B2M0073
2) If oil clearance exceeds the limit, replace valve

rocker arm or shaft, whichever shows greater
amount of wear.
Rocker arm inside diameter:
22.020 — 22.041 mm (0.8669 — 0.8678 in)
Rocker shaft diameter:
21.987 — 22.000 mm (0.8656 — 0.8661 in)
3) Measure inside diameter of rocker shaft sup-
port and outside diameter of valve rocker shaft,
and determine the difference between the two (=
oil clearance).
Clearance between support and shaft:
Standard
0.005 — 0.039 mm (0.0002 — 0.0015 in)
Limit
0.05 mm (0.0020 in)
ME(SOHC)-55
CAMSHAFT
Mechanical
19. Camshaft S153092

(1) Remove bolts (a) through (b) in alphabetical
sequence.

bly.>
B2M2612B
ME(SOHC)-51, REMOVAL, Camshaft Sprocket.> (2) Equally loosen bolts (c) through (j) all the
6) Remove crankshaft sprocket. <Ref. to way in alphabetical sequence.
ME(SOHC)-53, REMOVAL, Crankshaft Sprocket.>
7) Remove belt cover No. 2 (LH).
8) Remove belt cover No. 2 (RH).
CAUTION:
Do not damage or lose the seal rubber when
removing belt covers.
B2M2612C
(3) Remove bolts (k) through (p) in alphabetical

sequence using ST.
ST 499497000 TORX PLUS
B2M2601
9) Remove tensioner bracket.
B2M2612D
(4) Remove camshaft cap.
H2M2380
10) Remove camshaft position sensor support.

(LH side only)
11) Remove oil level gauge guide. (LH side only)
12) Remove valve rocker assembly. <Ref. to
ME(SOHC)-54, REMOVAL, Valve Rocker Assem-
bly.>
13) Remove camshaft cap. B2M2613
14) Remove camshaft.

15) Remove oil seal.
ME(SOHC)-56
CAMSHAFT
Mechanical
16) Remove plug from rear side of camshaft. (3) Install valve rocker assembly.
CAUTION:
쐌 Do not remove oil seal unless necessary.
쐌 Do not scratch journal surface when remov-
ing oil seal.
1) Apply a coat of engine oil to camshaft journals

and install camshaft.
2) Install camshaft cap.
(1) Apply liquid gasket on the around of cam-
B2M2615
shaft cap.
Liquid gasket: (4) Tighten bolts (a) through (h) in alphabetical
THREE BOND 1280B sequence.
P/N K0877YA018 Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
B2M2619
B2M2621B
NOTE:
Apply a coat of 3 mm (0.12 in) dia. liquid gasket (5) Tighten TORX bolts (i) through (n) in alpha-
along edge of cam cap mating surface. betical sequence using ST.
ST 499427000 TORX PLUS
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
S2M1199A
(2) Temporarily tighten bolts (g) through (j) in

alphabetical sequence.
B2M2621C
B2M2612E
ME(SOHC)-57
CAMSHAFT
Mechanical
(6) Tighten bolts (o) through (v) in alphabetical 8) Install camshaft position sensor support. (LH
sequence. side only)
Tightening torque: 9) Install tensioner bracket.
10 N·m (1.0 kgf-m, 7.2 ft-lb) Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
B2M2621D
H2M2380
(7) Tighten bolts (w) through (x) in alphabetical
sequence. 10) Install belt cover No. 2 (RH).
Tightening torque: Tightening torque:
10 N·m (1.0 kgf-m, 7.2 ft-lb) 5 N·m (0.5 kgf-m, 3.6 ft-lb)
11) Install belt cover No. 2 (LH).
Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb)
B2M2621E
3) Apply a coat of grease to oil seal lips and install

oil seal (A) on camshaft using ST1 and ST2.
CAUTION: B2M2601
Use a new oil seal.
12) Install crankshaft sprocket. <Ref. to
ST1 499597000 OIL SEAL GUIDE ME(SOHC)-53, INSTALLATION, Crankshaft
Sprocket.>
13) Install camshaft sprocket. <Ref. to
ME(SOHC)-51, INSTALLATION, Camshaft
Sprocket.>
Assembly.>
S2M1123A
4) Install plug using ST. INSTALLATION, V-belt.>
5) Adjust the valve clearance. <Ref. to
ME(SOHC)-30, ADJUSTMENT, Valve Clearance.>
6) Install rocker cover and connect PCV hose.
7) Install oil level gauge guide. (LH side only)
ME(SOHC)-58
CAMSHAFT
Mechanical
C: INSPECTION S153092A10 Cam base circle diameter A:

IN: 34.00 mm (1.3386 in)
1. CAMSHAFT S153092A1001
EX: 34.00 mm (1.3386 in)
1) Measure the bend, and repair or replace if nec-
essary.
Limit:
0.025 mm (0.0010 in)
B2M1209A
2. CAMSHAFT SUPPORT S153092A1002
Measure the thrust clearance of camshaft with dial

B2M2617 gauge. If the clearance exceeds the limit, replace
camshaft support.
2) Check journal for damage and wear. Replace if
Standard:
faulty.
0.030 — 0.090 mm (0.0012 — 0.0035 in)
3) Measure outside diameter of camshaft journal
and inside diameter of cylinder head journal, and Limit:
determine the difference between the two (= oil 0.10 mm (0.0039 in)
clearance). If oil clearance exceeds specifications,
replace camshaft or cylinder head as necessary.
Unit: mm (in)
Clearance Standard 0.055 — 0.090 (0.0022 — 0.0035)
at journal Limit 0.10 (0.0039)
31.928 — 31.945 (1.2570 —
Camshaft journal O.D.
1.2577)
32.000 — 32.018 (1.2598 —
Journal hole I.D.
1.2605)
B2M2618A
4) Check cam face condition; remove minor faults
by grinding with oil stone. Measure the cam height
H; replace if the limit has been exceeded.
Cam height: H
Item Unit: mm (in)
38.732 — 38.832
STD
Intake (1.5249 — 1.528885)
Limit 39.632 (1.5209)
39.257 — 39.357
STD
Exhaust (1.5455 — 1.5495)
Limit 39.157 (1.5416)
ME(SOHC)-59
CYLINDER HEAD ASSEMBLY
Mechanical
20. Cylinder Head Assembly S153093

12) Remove bolts (a) and (b) to remove cylinder
head.

REMOVAL, V-belt.>
bly.>
S2M1589A
ME(SOHC)-51, REMOVAL, Camshaft Sprocket.> 13) Remove cylinder head gasket.
6) Remove intake manifold. <Ref. to FU(SOHC)-
15, REMOVAL, Intake Manifold.> or <Ref. to CAUTION:
FU(SOHCw/oOBD)-12, REMOVAL, Intake Mani- Do not scratch the mating surface of cylinder
fold.> head and cylinder block.
7) Remove bolt which installs A/C compressor 14) Similarly, remove right side cylinder head.
bracket on cylinder head.
8) Remove valve rocker assembly. <Ref. to B: INSTALLATION S153093A11
ME(SOHC)-54, REMOVAL, Valve Rocker Assem-

1) Install cylinder head and gaskets on cylinder
bly.>
block.
9) Remove camshaft. <Ref. to ME(SOHC)-56,
REMOVAL, Camshaft.> CAUTION:
10) Remove cylinder head bolts in alphabetical 쐌 Use new cylinder head gaskets.
sequence shown in figure. 쐌 Be careful not to scratch the mating surface
of cylinder block and cylinder head.
CAUTION:
Leave bolts (a) and (c) engaged by three or four 2) Tighten cylinder head bolts.
threads to prevent cylinder head from falling. (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-lb) in alphabetical sequence.
Then tighten all bolts to 69 N·m (7.0 kgf-m, 51
ft-lb) in alphabetical sequence.
(3) Back off all bolts by 180° first; back them off
by 180° again.
(4) Tighten bolts (a) and (b) to 34 N·m (3.5
kgf-m, 25 ft-lb).
(5) Tighten bolts (c), (d), (e) and (f) to 15 N·m
S2M1589A (1.5 kgf-m, 11 ft-lb).
(6) Tighten all bolts by 80 to 90° in alphabetical
11) While tapping cylinder head with a plastic sequence.
hammer, separate it from cylinder block.
CAUTION:
Do not tighten bolts more than 90°.
ME(SOHC)-60
Mechanical
(7) Further tighten all bolts by 80 to 90° in C: DISASSEMBLY S153093A06
alphabetical sequence shown in figure below.

1) Place cylinder head on ST.
CAUTION: ST 498267800 CYLINDER HEAD TABLE
Ensure that the total “re-tightening angle” [in 2) Set ST on valve spring. Compress valve spring
the former two steps], do not exceed 180°. and remove the valve spring retainer key. Remove
each valve and valve spring.
ST 499718000 VALVE SPRING REMOVER
CAUTION:
쐌 Mark each valve to prevent confusion.
쐌 Use extreme care not to damage the lips of
the intake valve oil seals and exhaust valve oil
seals.
S2M1589B
3) Install camshaft. <Ref. to ME(SOHC)-57,

INSTALLATION, Camshaft.>
4) Install valve rocker assembly. <Ref. to
ME(SOHC)-54, INSTALLATION, Valve Rocker
Assembly.>
5) Install A/C compressor bracket on cylinder
B2M2630A
head.
6) Install intake manifold. <Ref. to FU(SOHC)-17,
INSTALLATION, Intake Manifold.> or <Ref. to
FU(SOHCw/oOBD)-15, INSTALLATION, Intake
Manifold.>
7) Install camshaft sprocket. <Ref. to ME(SOHC)-
51, INSTALLATION, Camshaft Sprocket.>
Assembly.>
ME(SOHC)-61
Mechanical
B2M2629B
(1) Valve (6) Retainer (11) Plug

(2) Valve guide (7) Retainer key (12) Camshaft cap
(3) Valve spring seat (8) Spark plug gasket (13) Valve rocker ASSY
(4) Oil seal (9) Camshaft
(5) Valve spring (10) Oil seal
1) Installation of valve spring and valve (4) Set ST on valve spring.

(1) Place cylinder head on ST. ST 499718000 VALVE SPRING REMOVER
ST 498267800 CYLINDER HEAD TABLE
(2) Coat stem of each valve with engine oil and
insert valve into valve guide.
CAUTION:
When inserting valve into valve guide, use spe-
cial care not to damage the oil seal lip.
(3) Install valve spring and retainer.
CAUTION:
Be sure to install the valve springs with their
close-coiled end facing the seat on the cylinder B2M2630A
head.
ME(SOHC)-62
Mechanical
(5) Compress valve spring and fit valve spring CAUTION:

retainer key. 쐌 Apply engine oil to oil seal before press-fit-
ting.
쐌 When press-fitting oil seal, do not use ham-
mer or strike in.
쐌 Differentiate between intake valve oil seal
and exhaust valve oil seal by noting their dif-
ference in color.
ST1 498267800 CYLINDER HEAD TABLE
ST2 498857100 VALVE OIL SEAL GUIDE
Color of rubber part:
B2M2634A Intake [Black]
Exhaust [Brown]
(6) After installing, tap valve spring retainers
lightly with wooden hammer for better seating. Color of spring part:
Intake [Silver]
Exhaust [Silver]
1. VALVE SPRING S153093A1001
1) Check valve springs for damage, free length,

and tension. Replace valve spring if it is not to the
specifications presented below.
2) To measure the squareness of the valve spring,
stand the spring on a surface plate and measure
its deflection at the top using a try square.
Squareness 2.5°, 2.4 mm (0.094 in) B2M2633A
218.7 — 242.5 N
(22.3 — 24.7 kgf, 49.2 — 54.5 lb)/
Tension/spring 45.0 mm (1.772 in) F: ADJUSTMENT S153093A01
height 526.6 — 581.6 N

(53.7 — 59.3 kgf, 118.4 — 130.8 1. CYLINDER HEAD S153093A0101
lb)/34.7 mm (1.366 in) 1) Make sure that no crack or other damage

exists. In addition to visual inspection, inspect
important areas by means of red lead check.
Also make sure that gasket installing surface
shows no trace of gas and water leaks.
2) Place cylinder head on ST.
3) Measure the warping of the cylinder head sur-
face that mates with crankcase using a straight
edge and thickness gauge.
If the warping exceeds 0.05 mm (0.0020 in),
G2M0154
regrind the surface with a surface grinder.
Warping limit:
2. INTAKE AND EXHAUST VALVE OIL
0.05 mm (0.0020 in)
SEAL S153093A1002
Grinding limit:
Replace oil seal with new one, if lip is damaged or
0.1 mm (0.004 in)
spring out of place, or when the surfaces of intake
valve and valve seat are reconditioned or intake Standard height of cylinder head:
valve guide is replaced. Use pliers to pinch and 97.5 mm (3.839 in)
remove oil seal from valve.
1) Place cylinder head on ST1.
2) Press-fit oil seal to the specified dimension indi-
cated in the figure using ST2.
ME(SOHC)-63
Mechanical
CAUTION: 3. VALVE GUIDE S153093A0103
Uneven torque for the cylinder head bolts can

cause warping. When reassembling, pay spe- 1) Check the clearance between valve guide and
cial attention to the torque so as to tighten stem. The clearance can be checked by measur-
evenly. ing the outside diameter of valve stem and the
inside diameter of valve guide with outside and
inside micrometers respectively.
Clearance between the valve guide and valve
stem:
Standard
Intake 0.035 — 0.062 mm (0.0014 —
0.0024 in)
Exhaust 0.040 — 0.067 mm (0.0016 —
0.0026 in)
Limit
G2M0148 0.15 mm (0.0059 in)
2. VALVE SEAT S153093A0102
Inspect intake and exhaust valve seats, and cor-

rect the contact surfaces with valve seat cutter if
they are defective or when valve guides are
replaced.
Valve seat width: W
Intake
Limit 1.7 mm (0.067 in) B2M0387A
Exhaust
Limit 2.1 mm (0.083 in)
B2M0076A
G2M0149 2) If the clearance between valve guide and stem

exceeds the limit, replace valve guide or valve
itself whichever shows greater amount of wear.
See following procedure for valve guide replace-
ment.
Valve guide inner diameter:
6.000 — 6.012 mm (0.2362 — 0.2367 in)
Valve stem outer diameters:
Intake
5.950 — 5.965 mm (0.2343 — 0.2348 in)
Exhaust
B2M0074 5.945 — 5.960 mm (0.2341 — 0.2346 in)
(1) Place cylinder head on ST1 with the com-
bustion chamber upward so that valve guides
enter the holes in ST1.
ME(SOHC)-64
Mechanical
(2) Insert ST2 into valve guide and press it (5) Put new valve guide, coated with sufficient
down to remove valve guide. oil, in cylinder, and insert ST1 into valve guide.
ST1 498267800 CYLINDER HEAD TABLE Press in until the valve guide upper end is flush
ST2 499767200 VALVE GUIDE REMOVER with the upper surface of ST2.
ST1 499767200 VALVE GUIDE REMOVER
Intake side:
ST2 499767700 VALVE GUIDE ADJUSTER
Exhaust side:
ST2 499767800 VALVE GUIDE ADJUSTER
G2M0150
(3) Turn cylinder head upside down and place

ST as shown in the figure.
Intake side:
ST 499767700 VALVE GUIDE ADJUSTER B2M2632A
Exhaust side:
ST 499767800 VALVE GUIDE ADJUSTER (6) Check the valve guide protrusion.
Valve guide protrusion: L
Intake
20.0 — 20.5 mm (0.787 — 0.807 in)
Exhaust
16.5 — 17.0 mm (0.650 — 0.669 in)
B2M0077B
(4) Before installing new oversize valve guide,

make sure that neither scratches nor damages
exist on the inside surface of the valve guide
holes in cylinder head.
B2M0077A
ME(SOHC)-65
Mechanical
(7) Ream the inside of valve guide with ST. 4. INTAKE AND EXHAUST VALVE S153093A0104
Gently rotate the reamer clockwise while press- 1) Inspect the flange and stem of valve, and
ing it lightly into valve guide, and return it also replace if damaged, worn, or deformed, or if “H” is
rotating clockwise. After reaming, clean valve less than the specified limit.
guide to remove chips.
H:
CAUTION: Intake
쐌 Apply engine oil to the reamer when ream- Standard 1.0 mm (0.039 in)
ing. Limit 0.6 mm (0.024 in)
쐌 If the inner surface of the valve guide is torn, Exhaust
the edge of the reamer should be slightly Standard 1.2 mm (0.047 in)
ground with an oil stone. Limit 0.6 mm (0.024 in)
쐌 If the inner surface of the valve guide Valve overall length:
becomes lustrous and the reamer does not Intake
chips, use a new reamer or remedy the reamer. 120.6 mm (4.75 in)
ST 499767400 VALVE GUIDE REAMER Exhaust
121.7 mm (4.79 in)
B2M0078
(8) Recheck the contact condition between

valve and valve seat after replacing valve guide.
G2M0153
2) Put a small amount of grinding compound on

the seat surface and lap the valve and seat sur-
face. <Ref. to ME(SOHC)-64, Valve Seat,
ADJUSTMENT, Cylinder Head Assembly.> Install
a new intake valve oil seal after lapping.
ME(SOHC)-66
CYLINDER BLOCK
Mechanical
21. Cylinder Block S153090

12) Remove bolts (a) and (b) to remove cylinder
head.
NOTE:
Before conducting this procedure, drain engine oil
completely if applicable.
1) Remove intake manifold. <Ref. to FU(SOHC)-
15, REMOVAL, Intake Manifold.> or <Ref. to
FU(SOHCw/oOBD)-12, REMOVAL, Intake Mani-
fold.>
REMOVAL, V-belt.> B2M2628A
ME(SOHC)-44, REMOVAL, Crankshaft Pulley.> 13) Remove cylinder head gasket.
4) Remove belt cover. <Ref. to ME(SOHC)-45, CAUTION:
REMOVAL, Belt Cover.> Do not scratch the mating surface of cylinder
5) Remove timing belt assembly. <Ref. to head and cylinder block.
bly.> 14) Similarly, remove right side cylinder head.
6) Remove camshaft sprocket. <Ref. to 15) Remove clutch housing cover (MT vehicles
ME(SOHC)-51, REMOVAL, Camshaft Sprocket.> only).
7) Remove crankshaft sprocket. <Ref. to 16) Remove flywheel (MT vehicles only) or drive
ME(SOHC)-44, REMOVAL, Crankshaft Pulley.> plate (AT vehicles only).
8) Remove generator and A/C compressor with Using ST, lock crankshaft.
their brackets. ST 498497100 CRANKSHAFT STOPPER
9) Remove rocker cover.
10) Remove cylinder head bolts in alphabetical
sequence shown in figure.
CAUTION:
Leave bolts (a) and (b) engaged by three or four
threads to prevent cylinder head from falling.
S2M1818C
B2M2628A
11) While tapping cylinder head with a plastic

hammer, separate it from cylinder block.
S2M1870C
17) Remove oil separator cover.

18) Remove water by-pass pipe for heater.
19) Remove water pump.
ME(SOHC)-67
CYLINDER BLOCK
Mechanical
20) Remove oil pump from cylinder block. 22) Remove oil strainer stay.
Use a flat-bladed screwdriver as shown in figure 23) Remove oil strainer.
when removing oil pump. 24) Remove baffle plate.
CAUTION: 25) Remove oil filter using ST.
Be careful not to scratch the mating surface of ST 498547000 OIL FILTER WRENCH
cylinder block and oil pump.
B2M2611A
S2M1819
26) Remove water pipe.
21) Removal of oil pan
(1) Turn cylinder block with #2 and #4 piston
sides facing upward.
(2) Remove bolts which secure oil pan to cylin-
der block.
(3) Insert a oil pan cutter blade between cylin-
der block-to-oil pan clearance and remove oil
pan.
CAUTION:
Do not use a screwdriver or similar tool in
place of oil pan cutter. B2M2638
S2M1820
ME(SOHC)-68
CYLINDER BLOCK
Mechanical
S2M1590B
(1) Service hole plug (3) Circlip (5) Service hole cover
(2) Gasket (4) Piston pin (6) O-ring
27) Remove service hole cover and service hole 28) Rotate crankshaft to bring #1 and #2 pistons
plugs using hexagon wrench [14 mm (0.55 in)]. to bottom dead center position, then remove piston
circlip through service hole of #1 and #2 cylinders.
B2M2620
G2M0165
ME(SOHC)-69
CYLINDER BLOCK
Mechanical
29) Draw out piston pin from #1 and #2 pistons 30) Similarly remove piston pins from #3 and #4
using ST. pistons.
ST 499097700 PISTON PIN REMOVER 31) Remove bolts which connect cylinder block on
CAUTION: the side of #2 and #4 cylinders.
Be careful not to confuse original combination 32) Back off bolts which connect cylinder block on
of piston, piston pin and cylinder. the side of #1 and #3 cylinders two or three turns.
33) Set up cylinder block so that #1 and #3 cylin-
ders are on the upper side, then remove cylinder
block connecting bolts.
34) Separate left-hand and right-hand cylinder
blocks.
CAUTION:
When separating cylinder block, do not allow
the connecting rod to fall and damage the cyl-
inder block.
G2M0166
B2M2408A
(1) Cylinder block (3) Crankshaft (5) Piston

(2) Rear oil seal (4) Crankshaft bearing
35) Remove rear oil seal. CAUTION:

36) Remove crankshaft together with connecting Do not confuse combination of crankshaft
rod. bearings. Press bearing at the end opposite to
37) Remove crankshaft bearings from cylinder locking lip.
block using hammer handle. 38) Draw out each piston from cylinder block
using wooden bar or hammer handle.
ME(SOHC)-70
CYLINDER BLOCK
Mechanical
CAUTION:
Do not confuse combination of piston and cyl-
inder.
B2M2407A
(1) Crankshaft bearing (4) Rear oil seal Tightening torque: N·m (kgf-m, ft-lb)
(2) Crankshaft
T1: 25 (2.5, 18.1)
(3) Cylinder block
T2: 47 (4.8, 34.7)
CAUTION: CAUTION:
Remove oil in the mating surface of bearing Do not allow fluid packing to jut into O-ring
and cylinder block before installation. Also grooves, oil passages, bearing grooves, etc.
apply a coat of engine oil to crankshaft pins.
1) Position crankshaft on the #2 and #4 cylinder
block.
2) Apply fluid packing to the mating surface of #1
and #3 cylinder block, and position it on #2 and #4
cylinder block.
Fluid packing:
S2M1826A
ME(SOHC)-71
CYLINDER BLOCK
Mechanical
3) Temporarily tighten 10 mm cylinder block con- 6) Install rear oil seal using ST1 and ST2.
necting bolts in alphabetical sequence shown in ST1 499597100 OIL SEAL GUIDE
figure. ST2 499587200 OIL SEAL INSTALLER
B2M0088D S2M1827A
4) Tighten 10 mm cylinder block connecting bolts (A) Rear oil seal

in alphabetical sequence. (B) Flywheel attaching bolt
Tightening torque: 7) Position the top ring gap at (A) or (B) in the fig-
47 N·m (4.8 kgf-m, 34.7 ft-lb) ure.
B2M0088D S2M1529A
5) Tighten 8 mm and 6 mm cylinder block connect- 8) Position the second ring gap at 180° on the
ing bolts in alphabetical sequence shown in figure. reverse side for the top ring gap.
Tightening torque: 9) Position the upper rail gap at (C) or (D) in the
(A) — (G): 25 N·m (2.5 kgf-m, 18.1 ft-lb) figure.
(H): 6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
S2M1530A
B2M0089F
10) Position the expander gap at 180° of the
reverse side for the upper rail gap.
ME(SOHC)-72
CYLINDER BLOCK
Mechanical
11) Position the lower rail gap at (E) or (F) in the CAUTION:
figure. Use new circlips.
CAUTION:
쐌 Ensure ring gaps do not face the same direc-
tion.
쐌 Ensure ring gaps are not within the piston
skirt area.
B2M1403A
CAUTION:
Piston front mark faces towards the front of the
engine.
S2M1530A
12) Install circlip.

Install circlips in piston holes located opposite ser-
vice holes in cylinder block, when positioning all
pistons in the corresponding cylinders.
S2M1531C
B2M1322J
(1) Piston (4) Gasket Tightening torque: N·m (kgf-m, ft-lb)

(2) Piston pin (5) Service hole plug
T: 69 (7.0, 50.6)
(3) Circlip
ME(SOHC)-73
CYLINDER BLOCK
Mechanical
13) Installing piston CAUTION:

(1) Turn cylinder block so that #1 and #2 cylin- Use new circlips.
ders face upward.
(2) Using ST1, turn crankshaft so that #1 and
#2 connecting rods are set at bottom dead cen-
ter.
ST1 499987500 CRANKSHAFT SOCKET
(3) Apply a coat of engine oil to pistons and
cylinders and insert pistons in their cylinders
using ST2.
ST2 498747100 PISTON GUIDE
S2M1828
(4) Apply fluid packing around the service hole

plug.
Fluid packing:
S2M0306A
14) Installing piston pin

(1) Insert ST3 into service hole to align piston
pin hole with connecting rod small end.
CAUTION:
Apply a coat of engine oil to ST3 before inser-
tion.
B2M2625
ST3 499017100 PISTON PIN GUIDE
(5) Install service hole plug and gasket.
CAUTION:
Use a new gasket.
G2M0189
(2) Apply a coat of engine oil to piston pin and

insert piston pin into piston and connecting rod
through service hole. B2M2620
(3) Install circlip.
ME(SOHC)-74
CYLINDER BLOCK
Mechanical
B2M1323K
(1) Piston (5) Service hole plug Tightening torque: N·m (kgf-m, ft-lb)
(2) Piston pin (6) Service hole cover
T1: 6.4 (0.65, 4.7)
(3) Circlip (7) O-ring
T2: 69 (7.0, 50.6)
(4) Gasket
(6) Turn cylinder block so that #3 and #4 cylin-

ders face upward. Using the same procedures
as used for #1 and #2 cylinders, install pistons
and piston pins.
ME(SOHC)-75
CYLINDER BLOCK
Mechanical
15) Install water pipe. Tightening torque:

72 N·m (7.3 kgf-m, 52.8 ft-lb)
B2M2638
S2M1818C
16) Install baffle plate.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
17) Install oil strainer and O-ring
Tightening torque:
10 N·m (1.0 kgf-m, 7 ft-lb)
18) Install oil strainer stay.
19) Apply fluid packing to matching surfaces and
install oil pan.
Fluid packing: S2M1870C
22) Install housing cover.
23) Installation of oil pump.
(1) Discard front oil seal after removal. Replace
with a new one using ST.
S2M1833A
20) Apply fluid packing to matching surfaces and

install oil separator cover.
Fluid packing:
THREE BOND 1215 or equivalent S2M0235
S2M1834A
21) Install flywheel or drive plate.

ST 498497100 CRANKSHAFT STOPPER
ME(SOHC)-76
CYLINDER BLOCK
Mechanical
(2) Apply fluid packing to matching surface of CAUTION:

oil pump. 쐌 Be sure to use a new gasket.
쐌 When installing water pump, tighten bolts in
Fluid packing:
two stages in alphabetical sequence as shown
in figure.
S2M0739B
H2M1568B
(3) Apply a coat of engine oil to the inside of the 25) Install water by-pass pipe for heater.
oil seal. 26) Install oil filter using ST.
S2M0118B
B2M2611A
(4) Install oil pump on cylinder block. Be care-
ful not to damage oil seal during installation. 27) Tighten cylinder head bolts.
(1) Apply a coat of engine oil to washers and
Tightening torque:
bolt threads.
6.4 N·m (0.65 kgf-m, 4.7 ft-lb) (2) Tighten all bolts to 29 N·m (3.0 kgf-m, 22
CAUTION: ft-lb) in alphabetical sequence.
쐌 Do not forget to install O-ring and seal when Then tighten all bolts to 69 N·m (7.0 kgf-m, 51
installing oil pump. ft-lb) in alphabetical sequence.
쐌 Align flat surface of oil pump’s inner rotor (3) Back off all bolts by 180° first; back them off
with crankshaft before installation. by 180° again.
(4) Tighten bolts (a) and (b) to 34 N·m (3.5
24) Install water pump and gasket. kgf-m, 25 ft-lb).
Tightening torque: (5) Tighten bolts (c), (d), (e) and (f) to 15 N·m
First; 12 N·m (1.2 kgf-m, 8.7 ft-lb) (1.5 kgf-m, 11 ft-lb).
Second; 12 N·m (1.2 kgf-m, 8.7 ft-lb) (6) Tighten all bolts by 80 to 90° in alphabetical
sequence.
CAUTION:
Do not tighten bolts more than 90°.
(7) Further tighten all bolts by 80 to 90° in
ME(SOHC)-77
CYLINDER BLOCK
Mechanical
CAUTION:
Ensure that the total “re-tightening angle” [in
the former two steps], do not exceed 180°.
B2M2628B
28) Install oil level gauge guide and tighten attach-

ing bolt (left side only).
29) Install rocker cover.
ME(SOHC)-53, INSTALLATION, Crankshaft
Sprocket.>
31) Install camshaft sprocket. <Ref. to
ME(SOHC)-51, INSTALLATION, Camshaft
Sprocket.>
Assembly.>
35) Install generator and A/C compressor brackets
on cylinder head.
36) Install V-belt. <Ref. to FU(SOHC)-17,
INSTALLATION, Intake Manifold.> <Ref. to
ME(SOHC)-42, INSTALLATION, V-belt.>
37) Install intake manifold. <Ref. to FU(SOHC)-
17, INSTALLATION, Intake Manifold.> or <Ref. to
FU(SOHCw/oOBD)-15, INSTALLATION, Intake
Manifold.>
ME(SOHC)-78
CYLINDER BLOCK
Mechanical
B2M1320I
(1) Connecting rod cap (3) Top ring (5) Oil ring
(2) Connecting rod bearing (4) Second ring (6) Circlip
1) Remove connecting rod cap.

2) Remove connecting rod bearing.
CAUTION:
Arrange removed connecting rod, connecting
rod cap and bearing in order to prevent confu-
sion.
3) Remove piston rings using the piston ring
expander.
4) Remove the oil ring by hand.
CAUTION:
Arrange the removed piston rings in good
order to prevent confusion.
5) Remove circlip.
ME(SOHC)-79
CYLINDER BLOCK
Mechanical
B2M1320J
(1) Connecting rod bearing (5) Second ring Tightening torque: N·m (kgf-m, ft-lb)
(2) Connecting rod (6) Top ring
T: 44.6 (4.55, 32.9)
(3) Connecting rod cap (7) Circlip
(4) Oil ring
1) Install connecting rod bearings on connecting E: INSPECTION S153090A10

rods and connecting rod caps.
CAUTION:
Apply oil to the surfaces of the connecting rod 1) Visually check for cracks and damage.
bearings. Especially, inspect important parts by means of red
lead check.
2) Install connecting rod on crankshaft.
2) Check the oil passages for clogging.
CAUTION: 3) Inspect crankcase surface that mates with cyl-
Position each connecting rod with the side inder head for warping by using a straight edge,
marked facing forward. and correct by grinding if necessary.
3) Install connecting rod cap with connecting rod Warping limit:
nut. 0.05 mm (0.0020 in)
Ensure the arrow on connecting rod cap faces the
front during installation. Grinding limit:
0.1 mm (0.004 in)
CAUTION:
쐌 Each connecting rod has its own mating cap. Standard height of cylinder block:
Make sure that they are assembled correctly by 201.0 mm (7.91 in)
checking their matching number.
쐌 When tightening the connecting rod nuts,
apply oil on the threads.
4) Install oil ring spacer, upper rail and lower rail in
this order by hand. Then install second ring and top
ring with a piston ring expander.
ME(SOHC)-80
CYLINDER BLOCK
Mechanical
2. CYLINDER AND PISTON S153090A1002 2) How to measure the inner diameter of each
cylinder
1) The cylinder bore size is stamped on the cylin-
Measure the inner diameter of each cylinder in
der block’s front upper surface.
both the thrust and piston pin directions at the
CAUTION: heights shown in the figure, using a cylinder bore
Measurement should be performed at a tem- gauge.
perature 20°C (68°F).
CAUTION:
NOTE: Measurement should be performed at a tem-
Standard sized pistons are classified into two perature 20°C (68°F).
grades, “A” and “B”. These grades should be used
Taper:
as a guide line in selecting a standard piston.
Standard
Standard diameter: 0.015 mm (0.0006 in)
A: 92.005 — 92.015 mm (3.6222 — 3.6226 Limit
in) 0.050 mm (0.0020 in)
B: 91.995 — 92.005 mm (3.6218 — 3.6222
Out-of-roundness:
in)
Standard
0.010 mm (0.0004 in)
Limit
0.050 mm (0.0020 in)
H2M1732C
(A) Main jourual size mark

(B) Cylinder block RH-LH combination mark
(C) #1 cylinder bore size mark S2M1821A
(D) #2 cylinder bore size mark
(E) #3 cylinder bore size mark (A) Piston pin direction
(F) #4 cylinder bore size mark (B) Thrust direction
3) When piston is to be replaced due to general or

cylinder wear, determine a suitable sized piston by
measuring the piston clearance.
ME(SOHC)-81
CYLINDER BLOCK
Mechanical
4) How to measure the outer diameter of each (2) If the cylinder inner diameter exceeds the
piston limit after boring and honing, replace the crank-
Measure the outer diameter of each piston at the case.
height shown in the figure. (Thrust direction) CAUTION:
CAUTION: Immediately after reboring, the cylinder diam-
Measurement should be performed at a tem- eter may differ from its real diameter due to
perature of 20°C (68°F). temperature rise. Thus, pay attention to this
Piston grade point H: when measuring the cylinder diameter.
40.0 mm (1.575 in) Limit of cylinder enlarging (boring):
Piston outer diameter: 0.5 mm (0.020 in)
Standard 3. PISTON AND PISTON PIN S153090A1003
A: 91.985 — 91.995 mm
(3.6214 — 3.6218 in) 1) Check pistons and piston pins for damage,
B: 91.975 — 91.985 mm cracks, and wear and the piston ring grooves for
(3.6211 — 3.6214 in) wear and damage. Replace if defective.
0.25 mm (0.0098 in) oversize 2) Measure the piston-to-cylinder clearance at
92.225 — 92.235 mm each cylinder. <Ref. to ME(SOHC)-81, CYLINDER
(3.6309 — 3.6313 in) AND PISTON, INSPECTION, Cylinder Block.> If
0.50 mm (0.0197 in) oversize any of the clearances is not to specification,
92.475 — 92.485 mm replace the piston or bore the cylinder to use an
(3.6407 — 3.6411 in) oversize piston.
3) Make sure that piston pin can be inserted into
the piston pin hole with a thumb at 20°C (68°F).
Replace if defective.
Standard clearance between piston pin and
hole in piston:
Standard
0.004 — 0.008 mm (0.0002 — 0.0003 in)
Limit
0.020 mm (0.0008 in)
B2M1305A
5) Calculate the clearance between cylinder and

piston.
CAUTION:
Measurement should be performed at a tem-
Cylinder to piston clearance at 20°C (68°F):
Standard
0.010 — 0.030 mm (0.0004 — 0.0012 in)
B2M1401
Limit
0.050 mm (0.0020 in)
6) Boring and honing
(1) If the value of taper, out-of-roundness, or
cylinder-to-piston clearance measured exceeds
the specified limit or if there is any damage on
the cylinder wall, rebore it to use an oversize
piston.
CAUTION:
When any of the cylinders needs reboring, all
other cylinders must be bored at the same
time, and use oversize pistons. Do not perform B2M0084A
boring on one cylinder only, nor use an over-
size piston for one cylinder only.
ME(SOHC)-82
CYLINDER BLOCK
Mechanical
4) Check circlip installation groove on the piston 2) Squarely place piston ring and oil ring in
for burr (A). If necessary, remove burr from the cylinder, and measure the piston ring gap with a
groove so that piston pin can lightly move. thickness gauge.
Unit: mm (in)
Standard Limit
0.20 — 0.35
Top ring 1.0 (0.039)
(0.0079 — 0.0138)
Piston Second 0.35 — 0.50
1.0 (0.039)
ring gap ring (0.0138 — 0.0197)
Oil ring 0.20 — 0.70
1.5 (0.059)
rail (0.0079 — 0.0276)
B2M0420A
5) Check piston pin circlip for distortion, cracks

and wear.
4. PISTON RING S153090A1004
1) If piston ring is broken, damaged, or worn, or if

its tension is insufficient, or when the piston is
replaced, replace piston ring with a new one of the
same size as the piston. G2M0174
CAUTION: 3) Measure the clearance between piston ring and

쐌 Marks are shown on the end of the top and piston ring groove with a thickness gauge.
second rings. When installing the rings to the
piston, face these marks upward. CAUTION:
쐌 The oil ring is a combined ring consisting of Before measuring the clearance, clean the pis-
two rails and a spacer in between. When ton ring groove and piston ring.
installing, be careful to assemble correctly. Unit: mm (in)
Standard Limit
0.040 — 0.080
Clearance Top ring (0.0016 — 0.15 (0.0059)
between pis- 0.0031)
ton ring and
piston ring 0.030 — 0.070
Second
groove (0.0012 — 0.15 (0.0059)
ring
0.0028)
EN1006
(A) Top ring

(B) Second ring
(C) Oil ring
(a) Upper rail
(b) Spacer
(c) Lower rail
B2M1402A
5. CONNECTING ROD S153090A1005
1) Replace connecting rod, if the large or small

end thrust surface is damaged.
2) Check for bend or twist using a connecting rod
aligner. Replace connecting rod if the bend or twist
exceeds the limit.
ME(SOHC)-83
CYLINDER BLOCK
Mechanical
Limit of bend or twist per 100 mm (3.94 in) in 4) Inspect connecting rod bearing for scar,
length: peeling, seizure, melting, wear, etc.
0.10 mm (0.0039 in) 5) Measure the oil clearance on individual con-
necting rod bearings by means of plastigauge. If
any oil clearance is not within specification, replace
the defective bearing with a new one of standard
size or undersize as necessary. (See the table
below.)
Connecting rod oil clearance:
Standard
0.010 — 0.038 mm (0.0004 — 0.0015 in)
Limit
0.05 mm (0.0020 in)
Unit: mm (in)
Bearing size Outer diameter of
Bearing
(Thickness at center) crank pin
1.492 — 1.501 51.984 — 52.000
Standard
(0.0587 — 0.0591) (2.0466 — 2.0472)
0.03
1.510 — 1.513 51.954 — 51.970
(0.0012)
(0.0594 — 0.0596) (2.0454 — 2.0461)
undersize
0.05
1.520 — 1.523 51.934 — 51.950
(0.0020)
(0.0598 — 0.0600) (2.0446 — 2.0453)
undersize
B2M1184B
0.25
1.620 — 1.623 51.734 — 51.750
(A) Thickness gauge (0.0098)
(0.0638 — 0.0639) (2.0368 — 2.0374)
(B) Connecting rod undersize
3) Install connecting rod fitted with bearing to

crankshaft and measure the side clearance (thrust
clearance). Replace connecting rod if the side
clearance exceeds the specified limit.
Connecting rod side clearance:
Standard
0.070 — 0.330 mm (0.0028 — 0.0130 in)
Limit
0.4 mm (0.016 in)
EN0335
ME(SOHC)-84
CYLINDER BLOCK
Mechanical
6) Inspect bushing at connecting rod small end, 6. CRANKSHAFT AND CRANKSHAFT

and replace if worn or damaged. Also measure the BEARING S153090A1006
piston pin clearance at the connecting rod small
1) Clean crankshaft completely and check for
end.
cracks by means of red lead check etc., and
Clearance between piston pin and bushing: replace if defective.
Standard 2) Measure the crankshaft bend, and correct or
0 — 0.022 mm (0 — 0.0009 in) replace if it exceeds the limit.
Limit
CAUTION:
0.030 mm (0.0012 in)
If a suitable V-block is not available, install #1
and #5 crankshaft bearing on cylinder block,
position crankshaft on these bearings and
measure crankshaft bend using a dial gauge.
Crankshaft bend limit:
0.035 mm (0.0014 in)
B2M0085
EN0339
3) Inspect the crank journal and crank pin for

wear. If they are not within the specifications,
replace bearing with a suitable (undersize) one,
and replace or recondition crankshaft as neces-
EN0337 sary. When grinding crank journal or crank pin, fin-
ish them to the specified dimensions according to
7) Replacement procedure is as follows. the undersize bearing to be used.
(1) Remove bushing from connecting rod with
ST and press. Crank pin and crank journal:
(2) Press bushing with ST after applying oil on Out-of-roundness
the periphery of bushing. 0.020 mm (0.0008 in) or less
ST 499037100 CONNECTING ROD BUSH- Taper limit
ING REMOVER AND 0.07 mm (0.0028 in)
INSTALLER Grinding limit
0.250 mm (0.0098 in)
G2M0177
G2M0179
(3) Make two 3 mm (0.12 in) holes in bushing.
Ream the inside of bushing.
(4) After completion of reaming, clean bushing
to remove chips.
ME(SOHC)-85
CYLINDER BLOCK
Mechanical
Unit: mm (in)
Crank journal diameter
Crank pin diameter
#1, #3 #2, #4, #5
59.992 — 60.008 59.992 — 60.008 51.984 — 52.000
Journal O.D.
(2.3619 — 2.3625) (2.3619 — 2.3625) (2.0466 — 2.0472)
Standard Bearing size
1.998 — 2.011 2.000 — 2.013 1.492 — 1.501
(Thickness at cen-
(0.0787 — 0.0792) (0.0787 — 0.0793) (0.0587 — 0.0591)
ter)
59.962 — 59.978 59.962 — 59.978 51.954 — 51.970
Journal O.D.
(2.3607 — 2.3613) (2.3607 — 2.3613) (2.0454 — 2.0461)
0.03 (0.0012)
Bearing size
undersize 2.017 — 2.020 2.019 — 2.022 1.510 — 1.513
(Thickness at cen-
(0.0794 — 0.0795) (0.0795 — 0.0796) (0.0594 — 0.0596)
ter)
59.942 — 59.958 59.942 — 59.958 51.934 — 51.950
Journal O.D.
(2.3599 — 2.3605) (2.3599 — 2.3605) (2.0446 — 2.0453)
0.05 (0.0020)
undersize Bearing size
2.027 — 2.030 2.029 — 2.032 1.520 — 1.523
(Thickness at cen-
(0.0798 — 0.0799) (0.0799 — 0.0800) (0.0598 — 0.0600)
ter)
59.742 — 59.758 59.742 — 59.758 51.734 — 51.750
Journal O.D.
(2.3520 — 2.3527) (2.3520 — 2.3527) (2.0368 — 2.0374)
0.25 (0.0098)
Bearing size
undersize 2.127 — 2.130 2.129 — 2.132 1.620 — 1.623
(Thickness at cen-
(0.0837 — 0.0839) (0.0838 — 0.0839) (0.0638 — 0.0639)
ter)
O.D. ... Outer Diameter
4) Measure the thrust clearance of crankshaft at 6) Measure the oil clearance on each crankshaft
center bearing. If the clearance exceeds the limit, bearing by means of plastigauge. If the measure-
replace bearing. ment is not within the specification, replace defec-
tive bearing with an undersize one, and replace or
Crankshaft thrust clearance:
recondition crankshaft as necessary.
Standard
0.030 — 0.115 mm (0.0012 — 0.0045 in) Unit: mm (in)
Limit Crankshaft oil clearance
0.25 mm (0.0098 in) Standard 0.010 — 0.030 (0.0004 —
0.0012)
Limit 0.040 (0.0016)
EN0341
5) Inspect individual crankshaft bearings for signs

of flaking, seizure, melting, and wear.
ME(SOHC)-86
ENGINE TROUBLE IN GENERAL
Mechanical
22. Engine Trouble in General

S153095
NOTE:
“RANK” shown in the chart refer to the possibility of reason for the trouble in order (“Very often” to “Rarely”)
A — Very often
B — Sometimes
C — Rarely
TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK
1. Engine will not start.
1) Starter does not turn. 쐌 Starter 쐌 Defective battery-to-starter harness B
쐌 Defective starter switch C
쐌 Defective inhibitor switch or neutral switch C
쐌 Defective starter B
쐌 Battery 쐌 Poor terminal connection A
쐌 Run-down battery A
쐌 Defective charging system B
쐌 Friction 쐌 Seizure of crankshaft and connecting rod bearing C
쐌 Seized camshaft C
쐌 Seized or stuck piston and cylinder C
2) Initial combustion does 쐌 Starter 쐌 Defective starter C
not occur. 쐌 Engine control system <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> or A
<Ref. to EN(SOHCw/oOBD)-2, Basic Diagnostic Procedure.>
쐌 Fuel line 쐌 Defective fuel pump and relay A
쐌 Lack of or insufficient fuel B
쐌 Belt 쐌 Defective B
쐌 Defective timing B
쐌 Compression 쐌 Incorrect valve clearance C
쐌 Loosened spark plugs or defective gasket C
쐌 Loosened cylinder head bolts or defective gasket C
쐌 Improper valve seating C
쐌 Defective valve stem C
쐌 Worn or broken valve spring B
쐌 Worn or stuck piston rings, cylinder and piston C
쐌 Incorrect valve timing B
쐌 Improper engine oil (low viscosity) B
ME(SOHC)-87
Mechanical

3) Initial combustion occur. 쐌 Engine control system <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> or A
쐌 Intake system 쐌 Defective intake manifold gasket B
쐌 Defective throttle body gasket B
쐌 Fuel line 쐌 Defective fuel pump and relay C
쐌 Clogged fuel line C
4) Engine stalls after initial 쐌 Engine control system <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> or A
combustion. <Ref. to EN(SOHCw/oOBD)-2, Basic Diagnostic Procedure.>
쐌 Intake system 쐌 Loosened or cracked intake duct B
쐌 Loosened or cracked PCV hose C
쐌 Loosened or cracked vacuum hose C
쐌 Defective intake manifold gasket B
쐌 Dirty air cleaner element C
쐌 Fuel line 쐌 Clogged fuel line C
ME(SOHC)-88
Mechanical

2. Rough idle and engine 쐌 Engine control system <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> or A
stall <Ref. to EN(SOHCw/oOBD)-2, Basic Diagnostic Procedure.>
쐌 Intake system 쐌 Loosened or cracked intake duct A
쐌 Loosened or cracked PCV hose A
쐌 Loosened or cracked vacuum hose A
쐌 Defective PCV valve C
쐌 Loosened oil filter cap B
쐌 Belt 쐌 Defective timing C
쐌 Compression 쐌 Incorrect valve clearance B
쐌 Loosened spark plugs or defective gasket B
쐌 Loosened cylinder head bolts or defective gasket B
쐌 Improper valve seating B
쐌 Worn or stuck piston rings, cylinder and piston B
쐌 Incorrect valve timing A
쐌 Lubrication system 쐌 Incorrect oil pressure B
쐌 Defective rocker cover gasket C
쐌 Cooling system 쐌 Overheating C
쐌 Others 쐌 Malfunction of evaporative emission control system A
쐌 Stuck or damaged throttle valve B
쐌 Accelerator cable out of adjustment C
ME(SOHC)-89
Mechanical

3. Low output, hesitation and 쐌 Engine control system <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> or A
poor acceleration <Ref. to EN(SOHCw/oOBD)-2, Basic Diagnostic Procedure.>
쐌 Loosened or cracked vacuum hose B
쐌 Defective PCV valve B
쐌 Dirty air cleaner element A
쐌 Fuel line 쐌 Defective fuel pump and relay B
쐌 Clogged fuel line B
쐌 Lack of or insufficient fuel C
쐌 Belt 쐌 Defective timing B
쐌 Over cooling C
4. Surging 쐌 Engine control system <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> or A
<Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.>
쐌 Dirty air cleaner element B
쐌 Worn or broken valve spring C
쐌 Cooling system 쐌 Overheating B
쐌 Others 쐌 Malfunction of evaporative emission control system C
ME(SOHC)-90
Mechanical

5. Engine does not return to 쐌 Engine control system <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> or A
idle. <Ref. to EN(SOHCw/oOBD)-2, Basic Diagnostic Procedure.>
쐌 Intake system 쐌 Loosened or cracked vacuum hose A
쐌 Others 쐌 Stuck or damaged throttle valve A
쐌 Accelerator cable out of adjustment B
6. Dieseling (Run-on) 쐌 Engine control system <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> or A
쐌 Others 쐌 Malfunction of evaporative emission control system B
7. After burning in exhaust 쐌 Engine control system <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> or A
system <Ref. to EN(SOHCw/oOBD)-2, Basic Diagnostic Procedure.>
쐌 Intake system 쐌 Loosened or cracked intake duct C
쐌 Loosened oil filler cap C
쐌 Lubrication system 쐌 Incorrect oil pressure C
쐌 Cooling system 쐌 Over cooling C
8. Knocking 쐌 Engine control system <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> or A
쐌 Intake system 쐌 Loosened oil filter cap B
쐌 Cooling system 쐌 Overheating A
9. Excessive engine oil con- 쐌 Intake system 쐌 Loosened or cracked PCV hose A
sumption 쐌 Defective PCV valve B
쐌 Loosened oil filter cap C
쐌 Compression 쐌 Defective valve stem A
쐌 Worn or stuck piston rings, cylinder and piston A
쐌 Lubrication system 쐌 Loosened oil pump attaching bolts and defective B
gasket
쐌 Defective oil filter seal B
쐌 Defective crankshaft oil seal B
쐌 Defective rocker cover gasket B
쐌 Loosened oil drain plug or defective gasket B
쐌 Loosened oil pan fitting bolts or defective oil pan B
ME(SOHC)-91
Mechanical

10. Excessive fuel consump- 쐌 Engine control system <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> or A
tion <Ref. to EN(SOHCw/oOBD)-2, Basic Diagnostic Procedure.>
쐌 Intake system 쐌 Dirty air cleaner element A
쐌 Others 쐌 Accelerator cable out of adjustment B
ME(SOHC)-92
ENGINE NOISE
Mechanical
23. Engine Noise S153096
Type of sound Condition Possible cause

쐌 Valve mechanism is defective.
쐌 Incorrect valve clearance
Sound increases as engine
Regular clicking sound 쐌 Worn valve rocker
speed increases.
쐌 Worn camshaft
쐌 Broken valve spring
쐌 Worn crankshaft main bearing
Oil pressure is low.
쐌 Worn connecting rod bearing (big end)
Heavy and dull clank
쐌 Loose flywheel mounting bolts
Oil pressure is normal.
쐌 Damaged engine mounting
쐌 Ignition timing advanced
High-pitched clank (Spark Sound is noticeable when 쐌 Accumulation of carbon inside combustion chamber
knock) accelerating with an overload. 쐌 Wrong spark plug
쐌 Improper gasoline
Sound is reduced when fuel 쐌 Worn crankshaft main bearing
Clank when engine speed is injector connector of noisy cyl- 쐌 Worn bearing at crankshaft end of connecting rod
medium (1,000 to 2,000 rpm). inder is disconnected.
(NOTE*)
Sound is reduced when fuel 쐌 Worn cylinder liner and piston ring
injector connector of noisy cyl- 쐌 Broken or stuck piston ring
Knocking sound when engine inder is disconnected. 쐌 Worn piston pin and hole at piston end of connecting rod
is operating under idling speed (NOTE*)
and engine is warm Sound is not reduced if each 쐌 Unusually worn valve lifter
fuel injector connector is dis- 쐌 Worn cam gear
connected in turn. (NOTE*) 쐌 Worn camshaft journal bore in crankcase
Squeaky sound — 쐌 Insufficient generator lubrication
Rubbing sound — 쐌 Defective generator brush and rotor contact
Gear scream when starting 쐌 Defective ignition starter switch
—
engine 쐌 Worn gear and starter pinion
Sound like polishing glass with 쐌 Loose drive belt
—
a dry cloth 쐌 Defective water pump shaft
쐌 Loss of compression
Hissing sound — 쐌 Air leakage in air intake system, hoses, connections or
manifolds
쐌 Loose timing belt
Timing belt noise —
쐌 Belt contacting case/adjacent part
Valve tappet noise — 쐌 Incorrect valve clearance
NOTE*:
When disconnecting fuel injector connector, Malfunction Indicator Light (CHECK ENGINE light) illuminates and trouble code is
stored in ECM memory.
Therefore, carry out the CLEAR MEMORY MODE <Ref. to EN(SOHC)-45, OPERATION, Clear Memory Mode.> or <Ref. to
EN(SOHCw/oOBD)-31, OPERATION, Clear Memory Mode.> and INSPECTION MODE <Ref. to EN(SOHC)-42, OPERATION,
Inspection Mode.> or <Ref. to EN(SOHCw/oOBD)-29, OPERATION, Inspection Mode.> after connecting fuel injector connector.
ME(SOHC)-93
ENGINE NOISE
Mechanical
MEMO:
ME(SOHC)-94
EXHAUST
EX(SOHC)
Page
2. Front Exhaust Pipe......................................................................................5
3. Center Exhaust Pipe ...................................................................................8
4. Rear Exhaust Pipe ......................................................................................9
5. Muffler ........................................................................................................11
GENERAL DESCRIPTION
Exhaust
S2M2132A
EX(SOHC)-2
GENERAL DESCRIPTION
Exhaust
(1) Upper front exhaust pipe cover (10) Lower center exhaust pipe cover (21) Gasket
CTR (11) Gasket (22) Self-lock nut
(2) Lower front exhaust pipe cover (12) Upper rear catalytic converter (23) Muffler
CTR cover (24) Cushion rubber
(3) Front exhaust pipe (13) Lower rear catalytic converter
(4) Front oxygen (A/F) sensor cover Tightening torque: N·m (kgf-m, ft-lb)
(5) Front catalytic converter (14) Rear catalytic converter T1: 8 (0.8, 5.8)
(6) Upper front catalytic converter (15) Center exhaust pipe T2: 13 (1.3, 9.4)
cover (16) Protector T3: 18 (1.8, 13.0)
(7) Lower front catalytic converter (17) Rear oxygen sensor T4: 30 (3.1, 22.4)
cover (18) Gasket T5: 35 (3.6, 26.0)
(8) Clamp (19) Spring
T6: 48 (4.9, 35.4)
(9) Upper center exhaust pipe cover (20) Rear exhaust pipe
EX(SOHC)-3
GENERAL DESCRIPTION
Exhaust

tion.
ment.
fied points.
EX(SOHC)-4
FRONT EXHAUST PIPE
Exhaust
2. Front Exhaust Pipe S152065

6) Separate front and center exhaust pipe assem-
bly from rear exhaust pipe.
WARNING:
1) Disconnect battery ground cable. Be careful, exhaust pipe is hot.
G6M0095 B2M0055
2) Disconnect front oxygen (A/F) sensor connec- 7) Remove bolts which hold front exhaust pipe
tor. onto cylinder heads.
CAUTION:
Be careful not to pull down front and center
exhaust pipe assembly.
B2M4243
3) Disconnect rear oxygen sensor connector.

B2M3200
8) Remove bolt which installs front and center

exhaust pipe assembly to hanger bracket.
B2M4244

5) Remove under cover. <Ref. EI-11, REMOVAL,
Front Under Cover.>
B2M3111
9) Remove front and center exhaust pipe assem-

bly from the vehicle.
CAUTION:
쐌 Be careful not to let front and center exhaust
pipe assembly fall off when removing as it is
quite heavy.
쐌 After removing front and center exhaust
assembly, do not apply excessive pulling force
on rear exhaust pipe.
EX(SOHC)-5
FRONT EXHAUST PIPE
Exhaust
10) Separate front exhaust pipe from center 4) Tighten bolts which hold front exhaust pipe onto
exhaust pipe. cylinder heads.
Tightening torque:
30 N·m (3.1 kgf-m, 22.4 ft-lb)
S2M0923
B2M3200
1) Install front exhaust pipe to center exhaust 5) Tighten bolts which install front and center
pipe. exhaust pipe assembly to rear exhaust pipe.
CAUTION: Tightening torque:
Replace gaskets with new ones. 18 N·m (1.8 kgf-m, 13.0 ft-lb)
Tightening torque:
30 N·m (3.1 kgf-m, 22.4 ft-lb)
B2M0055
6) Tighten bolt which holds front and center

S2M0923 exhaust pipe assembly to hanger bracket.
2) Install front and center exhaust pipe assembly Tightening torque:
to the vehicle. 35 N·m (3.6 kgf-m, 26.0 ft-lb)
3) Temporarily tighten bolt which installs front and
center exhaust pipe assembly to hanger bracket.
B2M3111
B2M3111
7) Install under cover. <Ref. EI-11,
INSTALLATION, Front Under Cover.>
EX(SOHC)-6
FRONT EXHAUST PIPE
Exhaust
9) Connect rear oxygen sensor connector.
B2M4244
10) Connect front oxygen (A/F) sensor connector.
B2M4243
G6M0095

nections and welds.
EX(SOHC)-7
CENTER EXHAUST PIPE
Exhaust
3. Center Exhaust Pipe S152067
After removing the center and front exhaust pipes

as one unit, separate them. Refer to the procedure
for removing the front exhaust pipe. <Ref. to
EX(SOHC)-5 REMOVAL, Front Exhaust Pipe.>
Install the center exhaust pipe and front exhaust

pipe as one unit. Refer to the procedure for install-
ing the front exhaust pipe. <Ref. to EX(SOHC)-6

nections and welds.
EX(SOHC)-8
REAR EXHAUST PIPE
Exhaust
4. Rear Exhaust Pipe S152068 B: INSTALLATION S152068A11
CAUTION:
1) Separate rear exhaust pipe from center
1) Install rear exhaust pipe bracket to rubber cush-
exhaust pipe. ion.
CAUTION: NOTE:
Be careful, exhaust pipe is hot. To facilitate removal, apply a coat of SUBARU
CRC to mating area of rubber cushion in advance.
S2M0558
2) Separate rear exhaust pipe from muffler.

S2M0560
CAUTION:
Be careful not to pull down rear exhaust pipe. 2) Install rear exhaust pipe to muffler.
Tightening torque:
48 N·m (4.9 kgf-m, 35.4 ft-lb)
S2M0559
3) Remove rear exhaust pipe bracket from rubber

S2M0559
cushion.
NOTE: 3) Install rear exhaust pipe to center exhaust pipe.
To facilitate removal, apply a coat of SUBARU Tightening torque:
CRC to pipe bracket in advance. 18 N·m (1.8 kgf-m, 13.0 ft-lb)
S2M0558
S2M0560
EX(SOHC)-9
REAR EXHAUST PIPE
Exhaust

nections and welds.
3) Make sure the cushion rubber is not worn or
cracked.
EX(SOHC)-10
MUFFLER
Exhaust
5. Muffler S152066
3) Remove front rubber cushion, and detach muf-
fler assembly.
NOTE:
1) Separate muffler from rear exhaust pipe. To facilitate removal, apply a coat of SUBARU
CAUTION:
Be careful, exhaust pipe is hot. SUBARU CRC (Part No. 004301003)
S2M0609
S2M0559
2) Remove left and right rubber cushions.

CAUTION:
Be careful not to drop the muffler during
removal. CAUTION:
Replace gasket with a new one.
NOTE:
CRC to mating area of rubber cushions in 48 N·m (4.9 kgf-m, 35.4 ft-lb)
advance.
S2M0559
S2M0608 C: INSPECTION S152066A10

nections and welds.
cracked.
EX(SOHC)-11
MUFFLER
Exhaust
MEMO:
EX(SOHC)-12
COOLING
CO
Page
2. Radiator Main Fan System .........................................................................8
3. Radiator Sub Fan System .........................................................................11
4. Engine Coolant..........................................................................................14
5. Water Pump ..............................................................................................16
6. Thermostat ................................................................................................23
7. Radiator .....................................................................................................25
8. Radiator Cap .............................................................................................31
9. Radiator Main Fan and Fan Motor............................................................32
10. Radiator Sub Fan and Fan Motor .............................................................34
11. Reservoir Tank ..........................................................................................36
12. Coolant Filler Tank ....................................................................................37
13. Engine Cooling System Trouble in General..............................................38
GENERAL DESCRIPTION
Cooling
Model Non-turbo Turbo

Electric fan + Forced engine coolant circulation
Cooling system
system
AT: Approx. 6.3 (6.7,
5.5) Approx. 7.2
Total engine coolant capacity (US qt, Imp qt)
MT: Approx. 6.4 (6.8, (7.6, 6.3)
5.6)
Type Centrifugal impeller type
Discharge 20 (5.3 US gal, 4.4 Imp gal)/min.
Pump speed—total engine
Discharge performance I 700 rpm — 0.3 mAq (1.0 ftAq)
coolant head
Engine coolant temperature 85°C (185°F)
Discharge 100 (26.4 US gal, 22.0 Imp gal)/min.
Discharge performance II 3,000 rpm — 5.0 mAq (16.4 ftAq)
coolant head
Water pump Discharge 200 (52.8 US gal, 44.0 Imp gal)/min.
Discharge performance III 6,000 rpm — 23.0 mAq (75.5 ftAq)
coolant head
Impeller diameter 76 mm (2.99 in)
Number of impeller vanes 8
Pump pulley diameter 60 mm (2.36 in)
Clearance between impel- Standard 0.5 — 0.7 mm (0.020 — 0.028 in)
ler and case Limit 1.0 mm (0.039 in)
“Thrust” runout of impeller end 0.5 mm (0.020 in)
Type Wax pellet type
Starts to open 76 — 80°C (169 — 176°F)
Thermostat Fully opened 91°C (196°F)
Valve lift 9.0 mm (0.354 in) or more
Valve bore 35 mm (1.38 in)
Main fan 70 W
Motor
Sub fan 70 W
Radiator fan
320 mm (12.60 in) × 5 (main fan)
Fan diameter × Blade
320 mm (12.60 in) × 7 (sub fan)
Type Down flow, pressure type
691.5 × 340 × 16 mm
Core dimensions
(27.22 × 13.39 × 0.63 in)
Radiator Above: 108±15 kPa
(1.1±0.15 kg/cm2, 16±2 psi)
Pressure range in which cap valve is open
Below: −1.0 to −4.9 kPa
(−0.01 to −0.05 kg/cm2, −0.1 to −0.7 psi)
Fins Corrugated fin type
Reservoir tank Capacity 0.45 (0.5 US qt, 0.4 Imp qt)
CO-2
GENERAL DESCRIPTION
Cooling
1. WATER PUMP S176001A0501
쐌 NON-TURBO MODEL
H2M2354A
(1) Water pump ASSY (5) Gasket Tightening torque: N·m (kgf-m, ft-lb)
(2) Gasket (6) Thermostat cover
T1: First 12 (1.2, 8.7)
(3) Heater by-pass hose Second 12 (1.2, 8.7)
(4) Thermostat
T2: 6.4 (0.65, 4.7)
CO-3
GENERAL DESCRIPTION
Cooling
쐌 TURBO MODEL
H2M1785B
(1) Thermostat case (6) Header by-pass hose Tightening torque: N·m (kgf-m, ft-lb)
(2) Gasket (7) Coolant filler tank by-pass hose
T1: First 12 (1.2, 8.7)
(3) Thermostat (8) Water by-pass pipe Second 12 (1.2, 8.7)
(4) Water pump ASSY
T2: 6.4 (0.65, 4.7)
(5) Gasket
CO-4
GENERAL DESCRIPTION
Cooling
2. RADIATOR AND RADIATOR FAN S176001A0502
쐌 NON-TURBO MODEL
S2M1739A
(1) Radiator lower cushion (13) Main fan shroud (21) ATF inlet hose B (AT vehicles
(2) Radiator (14) Radiator main fan only)
(3) Radiator upper cushion (15) Radiator main fan motor (22) Radiator outlet hose
(4) Radiator upper bracket (16) ATF hose clamp (AT vehicles (23) Radiator drain plug
(5) Clamp only)
(6) Radiator inlet hose (17) ATF inlet hose A (AT vehicles Tightening torque: N·m (kgf-m, ft-lb)
(7) Engine coolant reservoir tank only) T1: 4.4 (0.45, 3.3)
cap (18) ATF outlet hose A (AT vehicles T2: 12 (1.2, 8.7)
(8) Over flow hose only) T3: 18 (1.8, 13.0)
(9) Engine coolant reservoir tank (19) ATF pipe (AT vehicles only) T4: 3.4 (0.35, 2.5)
(10) Sub fan shroud (20) ATF outlet hose B (AT vehicles T5: 4.9 (0.50, 3.6)
(11) Radiator sub fan only)
(12) Radiator sub fan motor
CO-5
GENERAL DESCRIPTION
Cooling
쐌 TURBO MODEL
S2M1740A
(1) Radiator lower cushion (12) Radiator sub fan motor (24) Engine coolant filler tank
(2) Radiator (13) Main fan shroud (25) Engine coolant hose
(3) Radiator upper cushion (14) Radiator main fan (26) Engine coolatn filler tank cap
(4) Radiator upper bracket (15) Radiator main fan motor (27) Radiator under cover (AT
(5) Clamp (16) Oil cooler hose clamp vehicle)
(6) Radiator inlet hose (17) Oil cooler inlet hose A
(7) Engine coolant reservoir tank (18) Oil cooler outlet hose A Tightening torque: N·m (kgf-m, ft-lb)
cap (19) Oil cooler pipe T1: 4.4 (0.45, 3.3)
(8) Over flow hose (20) Oil cooler outlet hose B T2: 18 (1.8, 13.0)
(9) Engine coolant reservoir tank (21) Oil cooler inlet hose B T3: 3.4 (0.35, 2.5)
(10) Sub fan shroud (22) Radiator outlet hose T4: 4.9 (0.50, 3.6)
(11) Radiator sub fan (23) Radiator drain plug
CO-6
GENERAL DESCRIPTION
Cooling

tion.
ment.

499977300 CRANK PULLEY Used for stopping crankshaft pulley when loos-
WRENCH ening and tightening crankshaft pulley bolts.
B2M4157
SPROCKET sprocket. (Non-turbo LH side only)
WRENCH
B2M3859
SPROCKET sprocket.
WRENCH
B2M4158
CO-7
RADIATOR MAIN FAN SYSTEM
Cooling
2. Radiator Main Fan System S176732
S2M2148
CO-8
Cooling
B: INSPECTION S176732A10 쐌 Vehicle speed is below 19 km/h (12 MPH).

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

1 CHECK POWER SUPPLY TO MAIN FAN Is the voltage more than 10 Go to step 2. Go to step 5.
MOTOR. V?
CAUTION:
Be careful not to overheat engine during
repair.
2) Disconnect connector from main fan motor.
3) Start the engine, and warm it up until
engine coolant temperature increases over
95°C (203°F).
4) Stop the engine and turn ignition switch to
ON.
5) Measure voltage between main fan motor
2 CHECK GROUND CIRCUIT OF MAIN FAN Is the resistance less than Go to step 3. Repair open cir-
MOTOR. 5 Ω? cuit in harness
1) Turn ignition switch to OFF. between main fan
2) Measure resistance between main fan motor connector
motor connector and chassis ground. and chassis
Connector & terminal ground.
3 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Go to step 4.
Check poor contact in main fan motor con- main fan motor connector? tact in main fan
nector. motor connector.
4 CHECK MAIN FAN MOTOR. Does the main fan rotate? Repair poor con- Replace main fan
Connect battery positive (+) terminal to termi- tact in main fan motor with a new
nal No. 2, and negative (−) terminal to termi- motor connector. one.
nal No. 1 of main fan motor connector.
RELAY. V?
2) Remove main fan relay from A/C relay
holder.
3) Measure voltage between main fan relay
RELAY. V?
2) Measure voltage between main fan relay
7 CHECK 20 A FUSE. Is the fuse blown-out? Replace fuse. Go to step 8.
1) Remove 20 A fuse from A/C relay holder.
2) Check condition of fuse.
CO-9
Cooling

8 CHECK POWER SUPPLY TO A/C RELAY Is the voltage more than 10 Repair open cir- Repair open cir-
HOLDER 20 A FUSE TERMINAL. V? cuit in harness cuit in harness
Measure voltage of harness between A/C between 20 A between main
relay holder 20 A fuse terminal and chassis fuse and main fan fuse box connec-
ground. relay terminal. tor and 20 A fuse
Connector & terminal terminal.
9 CHECK FUSE. Is the fuse blown-out? Replace fuse. Repair open cir-
1) Turn ignition switch to OFF. cuit in harness
2) Remove fuse No. 18 from joint box. between main fan
3) Check condition of fuse. relay and ignition
switch.
10 CHECK MAIN FAN RELAY. Is the resistance more than Go to step 11. Replace main fan
1) Turn ignition switch to OFF. 1 MΩ? relay.
2) Remove main fan relay.
3) Measure resistance of main fan relay.
Terminal
No. 26 — No. 25:
11 CHECK MAIN FAN RELAY. Is the resistance less than Go to step 12. Replace main fan
1) Connect battery to terminals No. 27 and 1 Ω? relay.
No. 28 of main fan relay.
Terminal
No. 26 — No. 25:
12 CHECK HARNESS BETWEEN MAIN FAN Is the resistance less than Go to step 13. Repair open cir-
RELAY TERMINAL AND MAIN FAN MOTOR 1 Ω? cuit in harness
CONNECTOR. between main fan
Measure resistance of harness between main motor connector
fan motor connector and main fan relay termi- and main fan
nal. relay terminal.
(F17) No. 2 — (F66) No. 25:
13 CHECK HARNESS BETWEEN MAIN FAN Is the resistance less than Go to step 14. Repair open cir-
RELAY AND ECM. 1 Ω? cuit in harness
1) Turn ignition switch to OFF. between main fan
2) Disconnect connector from ECM. relay and ECM.
main fan relay connector and ECM connector.
(F66) No. 27 — (B134) No. 3 (SOHC
MODEL):
(F66) No. 27 — (B84) No. 2 (SOHC w/o
OBD MODEL):
(F66) No. 27 — (B137) No. 17 (DOHC
TURBO MODEL):
14 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Contact your
Check poor contact in connector between connector between main tact connector. Subaru distributor.
main fan and ECM. fan motor and ECM?
NOTE:
Inspection by your Subaru distributor is required,
because probable cause is deterioration of multiple
parts.
CO-10
RADIATOR SUB FAN SYSTEM
Cooling
3. Radiator Sub Fan System S176733
S2M2148
CO-11
Cooling
B: INSPECTION S176733A10 쐌 Vehicle speed is below 19 km/h (12 MPH).

NOTE: Condition (2):
System for A/C equipped vehicles only. 쐌 Engine coolant temperature is above 100°C
(212°F).
DETECTING CONDITION: 쐌 A/C switch is turned OFF.
Condition (1): 쐌 Vehicle speed is below 19 km/h (12 MPH).
쐌 Engine coolant temperature is below 95°C TROUBLE SYMPTOM:
(203°F). 쐌 Radiator sub fan does not rotate under condi-
쐌 A/C switch is turned ON. tions (1) and (2) above.

1 CHECK POWER SUPPLY TO SUB FAN Is the voltage more than 10 Go to step 2. Go to step 5.
MOTOR. V?
CAUTION:
Be careful not to overheat engine during
repair.
2) Disconnect connector from sub fan motor
and main fan motor.
3) Start the engine, and warm it up until
engine coolant temperature increases over
100°C (212°F).
4) Stop the engine and turn ignition switch to
ON.
5) Measure voltage between sub fan motor
2 CHECK GROUND CIRCUIT OF SUB FAN Is the resistance less than Go to step 3. Repair open cir-
MOTOR. 5 Ω? cuit in harness
1) Turn ignition switch to OFF. between sub fan
2) Measure resistance between sub fan motor motor connector
connector and chassis ground. and chassis
Connector & terminal ground.
3 CHECK POOR CONTACT. Is there poor contact in sub Repair poor con- Go to step 4.
Check poor contact in sub fan motor connec- fan motor connector? tact in sub fan
tor. motor connector.
4 CHECK SUB FAN MOTOR. Does the sub fan rotate? Repair poor con- Replace sub fan
Connect battery positive (+) terminal to termi- tact in sub fan motor with a new
nal No. 2, and negative (−) terminal to termi- motor connector. one.
nal No. 1 of sub fan motor connector.
RELAY. V?
2) Remove sub fan relay from A/C relay
holder.
3) Measure voltage between sub fan relay
RELAY. V?
2) Measure voltage between sub fan relay
CO-12
Cooling

7 CHECK 20 A FUSE. Is the fuse blown-out? Replace fuse. Go to step 8.
1) Remove 20 A fuse from A/C relay holder.
2) Check condition of fuse.
8 CHECK POWER SUPPLY TO A/C RELAY Is the voltage more than 10 Repair open cir- Repair open cir-
HOLDER 20 A FUSE TERMINAL. V? cuit in harness cuit in harness
Measure voltage of harness between A/C between 20 A between main
relay holder 20 A fuse terminal and chassis fuse and sub fan fuse box connec-
ground. relay terminal. tor and 20 A fuse
Connector & terminal terminal.
9 CHECK FUSE. Is the fuse blown-out? Replace fuse. Repair open cir-
1) Turn ignition switch to OFF. cuit in harness
2) Remove fuse No. 17 from joint box. between sub fan
3) Check condition of fuse. relay and ignition
switch.
10 CHECK SUB FAN RELAY. Is the resistance more than Go to step 11. Replace sub fan
2) Measure resistance of sub fan relay.
Terminal
No. 23 — No. 24:
11 CHECK SUB FAN RELAY. Is the resistance less than Go to step 12. Replace sub fan
No. 22 of sub fan relay.
2) Measure resistance of sub fan relay.
Terminal
No. 23 — No. 24:
12 CHECK HARNESS BETWEEN SUB FAN Is the resistance less than Go to step 13. Repair open cir-
RELAY TERMINAL AND SUB FAN MOTOR 1 Ω? cuit in harness
CONNECTOR. between sub fan
Measure resistance of harness between sub motor and sub fan
fan motor connector and sub fan relay termi- relay connector.
nal.
(F16) No. 2 — (F28) No. 24:
13 CHECK HARNESS BETWEEN SUB FAN Is the resistance less than Go to step 14. Repair open cir-
RELAY AND ECM. 1 Ω? cuit in harness
1) Turn ignition switch to OFF. between sub fan
2) Disconnect connector from ECM. relay and ECM.
sub fan relay connector and ECM connector.
(F28) No. 22 — (B134) No. 12 (SOHC
MODEL):
(F28) No. 22 — (B84) No. 10 (SOHC w/o
OBD MODEL):
(F28) No. 22 — (B137) No. 28 (DOHC
TURBO MODEL):
Check poor contact in connector between sub connector between sub fan tact connector. Subaru distributor.
fan and ECM. motor and ECM?
NOTE:
Inspection by your Subaru distributor is required,
because probable cause is deterioration of multiple
parts.
CO-13
ENGINE COOLANT
Cooling
4. Engine Coolant S176060

2) Fill engine coolant into reservoir tank up to
upper level.
1. DRAINING OF ENGINE COOLANT

S176060A2001

3) Remove drain cock to drain engine coolant into
container.
NOTE:
Remove radiator cap so that engine coolant will
S2M0552A
drain faster.
3) Warm-up engine completely for more than five
minutes at 2,000 to 3,000 rpm.
4) If engine coolant level drops in radiator, add
engine coolant to filler neck position.
5) If engine coolant level drops from upper level of
reservoir tank, add engine coolant to upper level.
6) Attach radiator cap and reservoir tank cap prop-
erly.
EN0073
1. RELATIONSHIP OF SUBARU COOLANT
2. FILLING OF ENGINE COOLANT S176060A2002
CONCENTRATION AND FREEZING
TEMPERATURE S176060A1001
1) Fill engine coolant into radiator up to filler neck
position. The concentration and safe operating temperature
of the SUBARU coolant is shown in the diagram.
Coolant capacity (fill up to “FULL” level):
Measuring the temperature and specific gravity of
Non-turbo AT model
the coolant will provide this information.
Non-turbo MT model
Turbo model
CAUTION:
The SUBARU Genuine Coolant containing anti-
freeze and anti-rust agents is especially made
for SUBARU engine, which has an aluminum
crankcase. Always use SUBARU Genuine
Coolant, since other coolant may cause corro-
sion.
CO-14
ENGINE COOLANT
Cooling
[Example] [Example]
If the coolant temperature is 25°C (77°F) and its Assume that the coolant concentration must be
specific gravity is 1.054, the concentration is 35% increased from 25% to 40%. Find point A, where
(point A), the safe operating temperature is −14°C the 25% line of coolant concentration intersects
(7°F) (point B), and the freezing temperature is with the 40% curve of the necessary coolant
−20°C (−4°F) (point C). concentration, and read the scale on the vertical
axis of the graph at height A. The quantity of cool-
ant to be drained is 2.1 liters (2.2 US qt, 1.8 Imp
qt). Drain 2.1 liters (2.2 US qt, 1.8 Imp qt) of cool-
ant from the cooling system and add 2.1 liters (2.2
US qt, 1.8 Imp qt) of the undiluted solution of
SUBARU coolant.
If a coolant concentration of 50% is needed, drain
all the coolant and refill with the undiluted solution
only.
B2M3128A
2. PROCEDURE TO ADJUST THE

CONCENTRATION OF THE COOLANT
S176060A1002
To adjust the concentration of the coolant accord-

ing to temperature, find the proper fluid concentra-
tion in the above diagram and replace the neces- B2M3129A
sary amount of coolant with an undiluted solution
of SUBARU genuine coolant (concentration 50%).
The amount of coolant that should be replaced can
be determined using the diagram.
CO-15
WATER PUMP
Cooling
5. Water Pump S176061

8) Disconnect over flow hose.
1) Disconnect ground cable from the battery.
S2M0930
9) Remove reservoir tank.
G6M0095

4) Drain engine coolant completely.
<Ref. to CO-14, DRAINING OF ENGINE
COOLANT, REPLACEMENT, Engine Coolant.>
5) Disconnect connectors from radiator main fan
(A) and sub fan (B) motors. S2M0931
10) Remove radiator main fan and sub fan assem-

blies. <Ref. to CO-32, REMOVAL, Radiator Main
Fan and Fan Motor.> and <Ref. to CO-34,
REMOVAL, Radiator Sub Fan and Fan Motor.>
11) Remove V-belts.
<Ref. to ME(SOHC)-42, REMOVAL, V-belt.>
12) Remove timing belt.
<Ref. to ME(SOHC)-46, TIMING BELT,
REMOVAL, Timing Belt Assembly.>
S2M0893A 13) Remove automatic belt tension adjuster.
6) Disconnect radiator outlet hose and heater

hose from water pump.
H2M2375
H2M1794
CO-16
WATER PUMP
Cooling
14) Remove belt idler No. 2. 19) Remove water pump.
S2M0024 B2M3894
15) Remove left-hand camshaft sprocket by using

ST. 2. TURBO MODEL S176061A1802
ST 499207100 CAMSHAFT SPROCKET WARNING:

WRENCH The radiator is pressurized. Wait until engine
cools down before working on the radiator.
2) Disconnect ground cable from the battery.
B2M2039A
16) Remove left-hand belt cover No. 2.
G6M0095

5) Drain engine coolant completely. <Ref. to
CO-14, DRAINING OF ENGINE COOLANT,
6) Disconnect connectors from radiator main fan
and sub fan motors.
7) Remove bolt which installs water by-pass pipe
B2M2040
of oil cooler onto oil pump.
S2M0027
H2M2380
8) Disconnect radiator outlet hose (A) and heater
18) Disconnect heater hose from water pump. hose (B) from water pump.
CO-17
WATER PUMP
Cooling
9) Disconnect water by-pass hose (C) and oil 20) Remove left-hand camshaft sprockets by
cooler hose (D). using ST.
WRENCH
S2M1159A
10) Lower the vehicle. S2M1161A

12) Remove reservoir tank. 21) Remove left-hand belt cover No. 2.
S2M1162
S2M0931

13) Remove radiator main fan and sub fan assem-
blies. <Ref. to CO-32, REMOVAL, Radiator Main
Fan and Fan Motor.> and <Ref. to CO-34,
REMOVAL, Radiator Sub Fan and Fan Motor.>
14) Remove V-belts. <Ref. to ME(DOHC
TURBO)-44, REMOVAL, V-belt.>
15) Remove timing belt. <Ref. to ME(DOHC
TURBO)-48, REMOVAL, Timing Belt Assembly.>
16) Remove automatic belt tension adjuster (A).
17) Remove belt idler (B).
18) Remove belt idler No. 2 (C). S2M1163
23) Disconnect heater hose from water pump.

S2M1160A
19) Remove camshaft position sensor. <Ref. to

FU(DOHC TURBO)-31, REMOVAL, Camshaft S2M1829
Position Sensor.>
CO-18
WATER PUMP
Cooling
B: INSTALLATION S176061A11 4) Install left-hand camshaft sprockets by using

ST.
1) Install water pump onto left-hand cylinder head. WRENCH
쐌 Replace gasket with a new one. 78 N·m (8.0 kgf-m, 57.9 ft-lb)
in figure.
Tightening torque:
First:
12 N·m (1.2 kgf-m, 8.7 ft-lb)
Second:
12 N·m (1.2 kgf-m, 8.7 ft-lb)
B2M2039A
5) Install belt idler No. 2.

Tightening torque:
39 N·m (4.0 kgf-m, 28.9 ft-lb)
S2M0760A
2) Install left-hand belt cover No. 2.

Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb)
S2M0024
6) Install automatic belt tension adjuster which

tension rod is holded with pin. <Ref. to ME(SOHC)-
47, AUTOMATIC BELT TENSION ADJUSTER
ASSEMBLY AND BELT IDLER, INSTALLATION,
Timing Belt Assembly.>
7) Install timing belt. <Ref. to ME(SOHC)-48, TIM-
B2M2040 ING BELT, INSTALLATION, Timing Belt Assem-
bly.>
3) Install tensioner bracket. 8) Install V-belts. <Ref. to ME(SOHC)-42,
Tightening torque: INSTALLATION, V-belt.>
25 N·m (2.5 kgf-m, 18.1 ft-lb) 9) Install radiator main fan and sub fan motor
assemblies. <Ref. to CO-32, INSTALLATION,
Radiator Main Fan and Fan Motor.> and <Ref. to
CO-34, INSTALLATION, Radiator Sub Fan and
Fan Motor.>
H2M2380
CO-19
WATER PUMP
Cooling
10) Install reservoir tank. 17) Connect battery ground cable.
S2M0931 G6M0095
11) Connect over flow hose. 18) Fill coolant. <Ref. to CO-14, FILLING OF
ENGINE COOLANT, REPLACEMENT, Engine
Coolant.>
1) Install water pump onto left-hand cylinder head.

CAUTION:
쐌 Replace gasket with a new one.
in figure.
S2M0930
Tightening torque:
12) Lift-up the vehicle. First:
13) Connect radiator outlet hose and heater hose 12 N·m (1.2 kgf-m, 8.7 ft-lb)
to water pump. Second:
12 N·m (1.2 kgf-m, 8.7 ft-lb)
H2M1794
H2M1846C
14) Connect connectors to radiator main fan (A)
and sub fan (B) motors. 2) Install left-hand belt cover No. 2.
Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb)
S2M0893A

S2M1162
CO-20
WATER PUMP
Cooling
3) Install tensioner bracket. Tightening torque:

Tightening torque: 39.4 N·m (4.0 kgf-m, 28.9 ft-lb)
25 N·m (2.5 kgf-m, 18.1 ft-lb)
S2M1160A
S2M1163 9) Install timing belt. <Ref. to ME(DOHC TURBO)-

4) Install left-hand camshaft sprockets by using 50, TIMING BELT, INSTALLATION, Timing Belt
ST. Assembly.>
ST 499207400 CAMSHAFT SPROCKET 10) Install V-belts. <Ref. to ME(DOHC TURBO)-
WRENCH 44, INSTALLATION, V-belt.>
11) Install radiator main fan and sub fan motor
Tightening torque: assemblies. <Ref. to CO-32, INSTALLATION,
98 N·m (10.0 kgf-m, 72.4 ft-lb) Radiator Main Fan and Fan Motor.> and <Ref. to
CO-34, INSTALLATION, Radiator Sub Fan and
Fan Motor.>
12) Install reservoir tank.
S2M1161A
5) Install camshaft position sensor. <Ref. to

FU(DOHC TURBO)-31, INSTALLATION, Cam-
S2M0931
shaft Position Sensor.>
6) Install belt idler No. 2 (C). 13) Connect over flow hose.
7) Install belt idler (B). 14) Lift-up the vehicle.
8) Install automatic belt tension adjuster (A) which 15) Connect radiator outlet hose (A) and heater
has a tension rod held by a pin. <Ref. to ME(DOHC hose (B) to water pump.
TURBO)-49, AUTOMATIC BELT TENSION 16) Connect water by-pass hose (C) and oil cooler
ADJUSTER ASSEMBLY AND BELT IDLER, hose (D).
INSTALLATION, Timing Belt Assembly.>
S2M1159A
CO-21
WATER PUMP
Cooling
17) Install bolt which installs water by-pass pipe 4) Check clearance between impeller and pump
onto oil pump. case.
Clearance between impeller and pump case:
Standard
0.5 — 0.7 mm (0.020 — 0.028 in)
Limit
1.0 mm (0.039 in)
S2M0027
18) Connect connectors to radiator main fan and

sub fan motors.
20) Lower the vehicle. G2M0212
5) After water pump installation, check pulley shaft
for engine coolant leaks. If leaks are noted, replace
water pump assembly.
G6M0095
22) Fill coolant. <Ref. to CO-14, FILLING OF

Coolant.>
1) Check water pump bearing for smooth rotation.

2) Check water pump pulley for abnormalities.
3) Using a dial gauge, measure impeller runout in
thrust direction while rotating the pulley.
“Thrust” runout limit:
0.5 mm (0.020 in)
G2M0211
CO-22
THERMOSTAT
Cooling
6. Thermostat S176062
5) Remove thermostat cover and gasket, and pull
out the thermostat.

G2M0214
1) Install the thermostat in the water pump, and

install the thermostat cover together with a gasket.
EN0073 CAUTION:
쐌 When reinstalling the thermostat, use a new
4) Disconnect radiator outlet hose from thermostat gasket.
cover. 쐌 The thermostat must be installed with the
쐌 Non-Turbo model jiggle pin (A) facing to front side.
쐌 At this time, set the jiggle pin of thermostat
for front side.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
EN0112
쐌 Turbo model
EN0100

Coolant.>
Replace the thermostat if the valve does not close

EN0107 completely at an ambient temperature or if the fol-
lowing test shows unsatisfactory results.
Immerse the thermostat and a thermometer in
water. Raise water temperature gradually, and
measure the temperature and valve lift when the
valve begins to open and when the valve is fully
opened. During the test, agitate the water for even
temperature distribution. The measurement should
be to the specification.
CO-23
THERMOSTAT
Cooling
Starts to open:
76 — 80°C (169 — 176°F)
Fully opens:
91°C (196°F)
H2M2357A
(A) Thermometer
(B) Thermostat
CO-24
RADIATOR
Cooling
7. Radiator S176058
8) Remove V-belt covers.
S2M0896
G6M0095

4) Disconnect connectors of radiator main fan (A)
and sub fan (B) motor.
S2M0930
S2M0893A
5) Disconnect radiator outlet hose (A) from ther-

mostat cover. S2M0934
6) Disconnect ATF cooler hoses (B) from radiator.
(AT vehicles only) 11) Disconnect radiator inlet hose from radiator.
S2M2150A S2M0897
CO-25
RADIATOR
Cooling
12) Remove radiator upper brackets. 6) Disconnect connectors of radiator main fan (A)
and sub fan motor (B).
S2M1167
EN0077
13) While slightly lifting radiator, slide it to left.
14) Lift radiator up and away from vehicle.
WARNING:
The radiator is pressurized. Wait until engine
EN0078
7) Disconnect oil cooler hoses from oil cooler

pipes. (if equipped)
G6M0095

S2M1743
8) Disconnect radiator outlet hose from thermostat
cover.
EN0107

CO-26
RADIATOR
Cooling
11) Remove reservoir tank. B: INSTALLATION S176058A11
1) Attach radiator mounting cushions to pins on

the lower side of radiator.
S2M0931
12) Remove V-belt covers.
S2M0944
2) Install radiator while fitting radiator pins to cush-

ions.
NOTE:
Fit pins on lower side of radiator into cushions on
body side.
S2M2235
13) Disconnect radiator inlet hose (A) and water

tank hose (B) from radiator.
S2M0033
3) Install radiator brackets and tighten bolts.

Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
S2M1166A
14) Remove radiator upper brackets.
S2M1167
S2M1167
15) While slightly lifting radiator, slide it to left.

16) Lift radiator up and away from vehicle.
CO-27
RADIATOR
Cooling
4) Connect radiator inlet hose. 9) Connect connectors to radiator main fan motor
(A) and sub fan motor (B).
S2M0897
S2M0893A
5) Install reservoir tank.
Tightening torque: 10) Install under cover.
4.9 N·m (0.50 kgf-m, 3.6 ft-lb) 11) Lower the vehicle.
12) Install V-belt covers.
S2M0934
S2M0896
7) Connect radiator outlet hose (A). 13) Connect battery ground cable.
8) Connect ATF cooler hoses (B). (AT vehicles
only)
G6M0095

S2M2150A ENGINE COOLANT, REPLACEMENT, Engine
Coolant.>
15) Check ATF level. <Ref. to AT-9, INSPECTION,
Automatic Transmission Fluid.>
CO-28
RADIATOR
Cooling
2. TURBO MODEL S176058A1102 4) Install reservoir tank.

1) Attach radiator mounting cushions (A) to pins Tightening torque:
on the lower side of radiator under cover (B). 4.9 N·m (0.50 kgf-m, 3.6 ft-lb)
S2M1168B S2M0934
2) Install radiator brackets and tighten bolts. 5) Connect over flow hose.
Tightening torque:
7) Connect connectors to radiator main fan motor
18 N·m (1.8 kgf-m, 13.0 ft-lb)
(A) and sub fan motor (B).
S2M1167
EN0077
3) Connect radiator inlet hose (A) and water tank

hose (B).
EN0078
S2M1166A 8) Connect oil cooler hoses. (if equipped)
S2M1743
CO-29
RADIATOR
Cooling
9) Connect radiator outlet hose. C: INSPECTION S176058A10
1) Remove radiator cap, top off radiator, and

attach tester to radiator in place of cap.
쐌 Non-Turbo model
EN0107

12) Install V-belt covers. S2M2149
쐌 Turbo model
S2M2235
EN0116
2) Apply a pressure of 157 kPa (1.6 kg/cm2, 23
psi) to radiator to check if:
(1) Engine coolant leaks at/around radiator.
(2) Engine coolant leaks at/around hoses or
connections.
CAUTION:
쐌 Engine should be off.
쐌 Wipe engine coolant from check points in
advance.
쐌 Be careful to prevent engine coolant from
G6M0095 spurting out when removing tester.
쐌 Be careful also not to deform filler neck of
14) Fill coolant. <Ref. to CO-14, FILLING OF radiator when installing or removing tester.
Coolant.>
CO-30
RADIATOR CAP
Cooling
8. Radiator Cap S176064
1) Attach radiator cap to tester.
G2M0223
2) Increase pressure until tester gauge pointer

stops. Radiator cap is functioning properly if it
holds the service limit pressure for five to six sec-
onds.
Standard pressure:
93 — 123 kPa (0.95 — 1.25 kg/cm2, 14 —
18 psi)
Service limit pressure:
83 kPa (0.85 kg/cm2, 12 psi)
CAUTION:
Be sure to remove foreign matter and rust from
the cap in advance otherwise, results of pres-
sure test will be incorrect.
CO-31
RADIATOR MAIN FAN AND FAN MOTOR
Cooling
9. Radiator Main Fan and Fan 9) Remove reservoir tank.

Motor S176059
S2M0931
10) Lift-up radiator main fan motor assembly.

11) While lifting up radiator main fan motor
assembly, detach oil cooler hose attached to a clip
G6M0095 under the radiator main fan shroud. (Oil cooler
equipped vehicles only)
4) Disconnect connector of main fan motor.
5) Remove bolts which install radiator onto radia-
tor cover. (Turbo model)
H2M3592
12) Remove radiator main fan motor assembly.
S2M1169 Install in the reverse order of removal.

6) Lower the vehicle. NOTE:
7) Remove V-belt cover. When the main fan motor assembly cannot be
installed as is, loosen the sub fan motor assembly
securing bolts to install it.
Tightening torque:
4.9 N·m (0.50 kgf-m, 3.6 ft-lb)
S2M2235
S2M0933
CO-32
RADIATOR MAIN FAN AND FAN MOTOR
Cooling
Tightening torque: 3) Remove bolts which install fan motor onto

4.9 N·m (0.50 kgf-m, 3.6 ft-lb) shroud.
S2M0934 H2M3593
1) Remove clip which holds motor connector onto Assemble in the reverse order of disassembly.
shroud. Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
S2M0937
H2M3593
2) Remove nut which holds fan itself onto fan
motor and shroud assembly. Tightening torque:
3.4 N·m (0.35 kgf-m, 2.5 ft-lb)
S2M0936
S2M0936
CO-33
RADIATOR SUB FAN AND FAN MOTOR
Cooling
10. Radiator Sub Fan and Fan C: DISASSEMBLY S176074A06
Motor S176074 1) Remove clip which holds motor harness onto

shroud.
S2M0937
2) Remove nut which holds fan itself onto fan

G6M0095
motor and shroud assembly.
4) Disconnect connector of sub fan motor.
6) Remove bolts which hold sub fan shroud to
radiator.
7) Remove radiator sub fan shroud through the
under side of vehicle.
S2M0939
3) Remove bolts which install fan motor onto

shroud.
S2M0935

Tightening torque: H2M3593
4.9 N·m (0.50 kgf-m, 3.6 ft-lb)
S2M0935
CO-34
RADIATOR SUB FAN AND FAN MOTOR
Cooling

Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
H2M3593
Tightening torque:
3.4 N·m (0.35 kgf-m, 2.5 ft-lb)
S2M0939
CO-35
RESERVOIR TANK
Cooling
11. Reservoir Tank S176075
1) Disconnect over flow hose from radiator filler

neck position.
2) Remove bolts which install reservoir tank onto
radiator main fan shroud.
S2M0934

Tightening torque:
4.9 N·m (0.50 kgf-m, 3.6 ft-lb)
S2M0934
Make sure the engine coolant level is between full

and low.
CO-36
COOLANT FILLER TANK
Cooling
12. Coolant Filler Tank S176764 B: INSTALLATION S176764A11
Tightening torque:
WARNING:
T1: 19 N·m (1.9 kgf-m, 13.7 ft-lb)
The radiator is pressurized. Wait until engine T2: 21 N·m (2.1 kgf-m, 15.2 ft-lb)
1) Drain coolant about 3.0 (3.2 US qt, 2.6 lmp qt).
<Ref. to CO-14, DRAINING OF ENGINE
COOLANT, REPLACEMENT, Engine Coolant.>
2) Remove air cleaner upper cover and air intake
boot. <Ref. to IN(DOHC TURBO)-7, REMOVAL,
Air Cleaner.>
4) Disconnect engine coolant hoses from coolant
filler tank.
EN0125
EN0127
5) Remove bolts and nut which install coolant filler
tank. 2) Fill engine coolant. <Ref. to CO-14, FILLING
6) Disconnect engine coolant hose which con- OF ENGINE COOLANT, REPLACEMENT, Engine
nects the under side of coolant filler tank. Coolant.>
7) Remove coolant filler tank.
EN0126
CO-37
ENGINE COOLING SYSTEM TROUBLE IN GENERAL
Cooling
13. Engine Cooling System Trouble in General S176078

Replenish engine coolant, inspect for leakage, and
a. Insufficient engine coolant
repair.
b. Loose timing belt Repair or replace timing belt tensioner.
c. Oil on drive belt Replace.
d. Malfunction of thermostat Replace.
e. Malfunction of water pump Replace.
f. Clogged engine coolant passage Clean.
Inspect and repair ignition control system.
g. Improper ignition timing or <Ref. to EN(SOHCw/oOBD)-2, Basic Diagnostic
Procedure.> or <Ref. to EN(DOHC TURBO)-2,
PROCEDURE, Basic Diagnostic Procedure.>
h. Clogged or leaking radiator Clean or repair, or replace.
Over-heating i. Improper engine oil in engine coolant Replace engine coolant.
Inspect and repair fuel injection system.
j. Air/fuel mixture ratio too lean or <Ref. to EN(SOHCw/oOBD)-2, Basic Diagnostic
Procedure.> or <Ref. to EN(DOHC TURBO)-2,
PROCEDURE, Basic Diagnostic Procedure.>
k. Excessive back pressure in exhaust system Clean or replace.
l. Insufficient clearance between piston and cylinder Adjust or replace.
m. Slipping clutch Repair or replace.
n. Dragging brake Adjust.
o. Improper transmission oil Replace.
p. Defective thermostat Replace.
Inspect radiator fan relay, engine coolant temperature
q. Malfunction of electric fan
sensor or radiator motor and replace there.
a. Atmospheric temperature extremely low Partly cover radiator front area.
Over-cooling
b. Defective thermostat Replace.
a. Loosened or damaged connecting units on hoses Repair or replace.
b. Leakage from water pump Replace.
c. Leakage from water pipe Repair or replace.
Engine coolant d. Leakage around cylinder head gasket Retighten cylinder head bolts or replace gasket.
leaks. e. Damaged or cracked cylinder head and crank-
Repair or replace.
case
f. Damaged or cracked thermostat case Repair or replace.
g. Leakage from radiator Repair or replace.
a. Defective drive belt Replace.
b. Defective radiator fan Replace.
Noise
c. Defective water pump bearing Replace water pump.
d. Defective water pump mechanical seal Replace water pump.
CO-38
LUBRICATION
LU
Page
2. Oil Pressure System ...................................................................................7
3. Engine Oil..................................................................................................10
4. Oil Pump....................................................................................................12
5. Oil Pan and Strainer..................................................................................16
6. Oil Pressure Switch...................................................................................21
7. Engine Oil Cooler ......................................................................................22
8. Engine Oil Filter.........................................................................................24
9. Engine Lubrication System Trouble in General ........................................25
GENERAL DESCRIPTION
Lubrication
Lubrication method Forced lubrication

Pump type Trochoid type
Inner rotor 9
Number of teeth
Outer rotor 10
Outer rotor diameter × thick- Non-Turbo model 78 × 9 mm (3.07 × 0.35 in)
ness Turbo-model 79 × 10 mm (3.11 × 0.39 in)
STANDARD 0.04 — 0.14 mm (0.0016 — 0.0055 in)
Tip clearance between inner and outer rotor
LIMIT 0.18 mm (0.0071 in)
Oil pump Side clearance between inner rotor and pump STANDARD 0.02 — 0.07 mm (0.0008 — 0.0028 in)
case LIMIT 0.12 mm (0.0047 in)
Case clearance between outer rotor and pump STANDARD 0.10 — 0.175 mm (0.0039 — 0.0069 in)
case LIMIT 0.20 mm (0.0079 in)
- pressure 98 kPa (1.0 kg/cm2, 14 psi)
700 rpm Discharge
Capacity at - quantity 4.2 (4.4 US qt, 3.7 Imp qt)/min.
80°C (176°F) - pressure 294 kPa (3.0 kg/cm2, 43 psi)
5,000 rpm Discharge
- quantity 42.0 (11.10 US gal, 9.24 Imp gal)/min.
Relief valve operation pressure 490 kPa (5.0 kg/cm2, 71 psi)
Type Full-flow filter type
Filtration area 1,000 cm2 (155 sq in)
Oil filter By-pass valve opening pressure 157 kPa (1.6 kg/cm2, 23 psi)
Outer diameter × width 80 × 70 mm (3.15 × 2.76 in)
Oil filter to engine thread size M 20 × 1.5
Relief valve (on rocker shaft) operation pressure 69 kPa (0.7kg/cm2, 10 psi)
Type Immersed contact point type
Oil pressure Working voltage — wattage 12 V — 3.4 W or less
switch Warning light activation pressure 14.7 kPa (0.15 kg/cm2, 2.1 psi)
Proof pressure More than 981 kPa (10 kg/cm2, 142 psi)
Non-Turbo model 4.0 (4.2 US qt, 3.5 Imp qt)
Oil capacity (at replacement)
Turbo model 4.5 (4.8 US qt, 4.0 Imp qt)
LU-2
GENERAL DESCRIPTION
Lubrication
B2M2235E
(1) Plug (13) Oil pressure switch (25) Drain plug

(2) Washer (14) Oil filler duct (26) Metal gasket
(3) Relief valve spring (15) O-ring (27) Gasket
(4) Relief valve (16) Oil filler cap
(5) Oil seal (17) O-ring Tightening torque: N·m (kgf-m, ft-lb)
(6) Oil pump case (18) Baffle plate T1: 5 (0.5, 3.6)
(7) Inner rotor (19) O-ring T2: 5 (0.5, 3.6)
(8) Outer rotor (20) Oil strainer T3: 6.4 (0.65, 4.7)
(9) Oil pump cover (21) Oil level gauge guide T4: 10 (1.0, 7.2)
(10) Oil filter (22) O-ring T5: 44 (4.5, 33)
(11) O-ring (23) Oil pan
T6: 25 (2.5, 18.1)
(12) Oil pump ASSY (24) Oil level gauge
LU-3
GENERAL DESCRIPTION
Lubrication
S2M4233A
(1) Plug (15) Oil pump ASSY (29) O-ring

(2) Washer (16) Oil pressure switch
(3) Relief valve spring (17) Oil filler duct Tightening torque: N·m (kgf-m, ft-lb)
(4) Relief valve (18) O-ring T1: 5 (0.5, 3.6)
(5) Oil seal (19) Cylinder head cover T2: 5 (0.5, 3.6)
(6) Oil pump case (20) Baffle plate T3: 6.4 (0.65, 4.7)
(7) Inner rotor (21) O-ring T4: 10 (1.0, 7.0)
(8) Outer rotor (22) Oil strainer T5: 44 (4.5, 33)
(9) Oil pump cover (23) Gasket
T6: 69 (7.0, 50.6)
(10) Oil filter (24) Oil level gauge guide
T7: 25 (2.5, 18.1)
(11) Connector (25) Oil pan
T8: 54 (5.5, 40)
(12) Water by-pass pipe (26) Oil level gauge
(13) Oil cooler (27) Metal gasket
(14) O-ring (28) Drain plug
LU-4
GENERAL DESCRIPTION
Lubrication

tion.
ment.
fied points.
LU-5
GENERAL DESCRIPTION
Lubrication

bolt.
B2M4157
WRENCH
B2M3872
INSTALLER
B2M3875
LU-6
OIL PRESSURE SYSTEM
Lubrication
2. Oil Pressure System S178076
S2M2141
LU-7
OIL PRESSURE SYSTEM
Lubrication
S2M2142
LU-8
OIL PRESSURE SYSTEM
Lubrication

1 CHECK COMBINATION METER. Does the warning lights go Go to step 2. Repair or replace
1) Turn ignition switch to ON. (engine OFF) on? the combination
2) Check other warning lights. meter. <Ref. to
IDI-7,
INSPECTION,
Combination
Meter System, .>
2 CHECK HARNESS CONNECTOR Is the voltage more than 10 Replace oil pres- Go to step 3.
BETWEEN COMBINATION METER AND OIL V? sure switch.
PRESSURE SWITCH.
2) Disconnect connector from the oil pressure
switch.
4) Measure the voltage of harness between
the combination meter connector and chassis
ground.
(E11) No. 1 — Chassis ground:
3 CHECK COMBINATION METER. Is the resistance less than Replace the har- Repair or replace
1) Turn ignition switch to OFF. 10 Ω? ness connector the combination
2) Remove the combination meter. between combina- meter and the oil
3) Measure the resistance of the combination tion meter and oil pressure switch
meter. pressure switch. warning light bulb.
Terminal
No. A2 — No. B14:
LU-9
ENGINE OIL
Lubrication
3. Engine Oil S178077

2) Open engine oil filler cap for quick draining of
the engine oil.
1) Park vehicle on a level surface.

2) Remove oil level gauge and wipe it clean.
3) Reinsert the level gauge all the way. Be sure
proper orientation.
4) Remove it again and note the reading. If the
engine oil level is below the “L” line, add oil to bring
the level up to the “F” line.
5) After turning off the engine, wait a few minutes
B2M3883A
for the oil to drain back into the oil pan before
checking the level. 3) Replace drain plug gasket.
6) Just after driving or while the engine is warm, 4) Tighten engine oil drain plug after draining
engine oil level may show in the range between the engine oil.
“F” line and the notch mark. This is caused by
thermal expansion of the engine oil. Tightening torque:
7) To prevent overfilling the engine oil, do not add 44 N·m (4.5 kgf-m, 33 ft-lb)
oil above the “F” line when the engine is cold.
S2M2143
B2M3883A
5) Fill engine oil through filler pipe up to upper
point on level gauge. Make sure that vehicle is
placed level when checking oil level. Use engine oil
of proper quality and viscosity, selected in accor-
1) Drain engine oil by loosening engine oil drain dance with the table in figure.
plug.
Recommended oil
API classification
SJ or SH with the words “Energy Con-
serving or Energy conserving II”, CCMC
specification G4 or G5, ACEA specifica-
tion A1, A2 or A3, or New API mark dis-
played on the container (If it is impos-
sible to get SJ or SH grade, you may use
SG grade.)
Engine oil capacity: (Non-Turbo model)
S2M2143 Upper level
4.0 (4.2 US qt, 3.5 Imp qt)
Lower level
3.0 (3.2 US qt, 2.6 Imp qt)
LU-10
ENGINE OIL
Lubrication
Engine oil capacity: (Turbo model)

Upper level
4.5 (4.8 US qt, 4.0 Imp qt)
Lower level
3.5 (3.7 US qt, 3.1 Imp qt)
B2M3885A
The proper viscosity helps vehicle get good cold

and hot starting by reducing viscous friction and
thus increasing cranking speed.
CAUTION:
When replenishing oil, it does not matter if the
oil to be added is a different brand from that in
the engine; however, use oil having the API
classification and SAE viscosity No. desig-
nated by SUBARU.
NOTE:
If vehicle is used in desert areas with very high
temperatures or for other heavy duty applications,
the following viscosity oils may be used: API clas-
sification: SJ or SH
SAE Viscosity No.: 30, 40, 10W-50, 20W-40, 20W-
50.
6) Close engine oil filler cap.
7) Start engine and warm it up for a time.
8) After engine stops, recheck the oil level. If
necessary, add engine oil up to upper level on level
gauge.
B2M3883A
LU-11
OIL PUMP
Lubrication
4. Oil Pump S178070

7) Remove crankshaft position sensor.
B2M1252
8) Remove V-belts. <Ref. to ME(SOHC)-42,

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

S2M0027 WRENCH
5) Remove water pipe and hoses between oil
cooler and water pump. (Turbo model)
S2M0114
11) Remove water pump. <Ref. to CO-16,

S2M0112 REMOVAL, Water Pump.>
6) Remove radiator. <Ref. to CO-25, REMOVAL,
Radiator.>
LU-12
OIL PUMP
Lubrication
12) Remove timing belt guide. (MT vehicles only) B: INSTALLATION S178070A11

Do the following:
1) Apply fluid packing to matching surfaces of oil
pump.
Fluid packing:
2) Replace O-ring (A) with a new one.
S2M0115
13) Remove crankshaft sprocket.
S2M0739B
3) Apply a coat of engine oil to the inside of the oil

seal.
S2M0116
14) Remove bolts which install oil pump onto cyl-

inder block.
S2M0118B
4) Be careful not to scratch oil seal when installing

oil pump on cylinder block.
5) Position the oil pump, aligning the notched area
with the crankshaft, and push the oil pump straight.
S2M0117
CAUTION:
15) Remove oil pump by using flat bladed screw- Make sure the oil seal lip is not folded.
driver.
6) Install oil pump.
CAUTION:
Be careful not to scratch mating surfaces of Tightening torque:
cylinder block and oil pump. 6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
S2M0740B
S2M1819
LU-13
OIL PUMP
Lubrication
C: DISASSEMBLY S178070A06 D: ASSEMBLY S178070A02
Remove screws which secure oil pump cover and 1) Install front oil seal by using ST.
disassemble oil pump. Inscribe alignment marks ST 499587100 OIL SEAL INSTALLER
on inner and outer rotors so that they can be CAUTION:
replaced in their original positions during reassem- Use a new oil seal.
bly.
CAUTION:
Before removing relief valve, loosen plug when
removing oil pump from cylinder block.
S2M0235A
2) Apply a coat of engine oil to inner and outer

rotors.
3) Install inner and outer rotors in their original
positions.
4) Install oil relief valve and relief valve spring.
5) Install oil pump cover.
Tightening torque:
T1: 5 N·m (0.5 kgf-m, 3.6 ft-lb)
T2: 44 N·m (4.5 kgf-m, 33 ft-lb)
S2M0735A
(A) Oil seal

(B) Pump case
(C) Inner rotor
(D) Outer rotor
(E) Pump cover
(F) Relief valve
(G) Relief valve spring
(H) Plug
(I) Washer
S2M0735B
LU-14
OIL PUMP
Lubrication
E: INSPECTION S178070A10 3. SIDE CLEARANCE S178070A1003
1. TIP CLEARANCE S178070A1001

Measure clearance between oil pump inner rotor
and pump cover. If the clearance exceeds the limit,
Measure the tip clearance of rotors. If the clear- replace rotor or pump body.
ance exceeds the limit, replace rotors as a
matched set. Side clearance:
Standard
Tip clearance: 0.02 — 0.07 mm (0.0008 — 0.0028 in)
Standard Limit
0.04 — 0.14 mm (0.0016 — 0.0055 in) 0.12 mm (0.0047 in)
Limit
0.18 mm (0.0071 in)
S2M0738
S2M0736 4. OIL RELIEF VALVE S178070A1004
Check the valve for fitting condition and damage,

2. CASE CLEARANCE S178070A1002 and the relief valve spring for damage and deterio-
Measure the clearance between the outer rotor ration. Replace the parts if defective.
and the cylinder block rotor housing. If the clear- Relief valve spring:
ance exceeds the limit, replace the rotor. Free length
Case clearance: 71.8 mm (2.827 in)
Installed length
Standard
54.7 mm (2.154 in)
0.10 — 0.175 mm (0.0039 — 0.0069 in)
Load when installed
Limit 77.08 N (7.86 kgf, 17.33 lb)
0.20 mm (0.0079 in)
5. OIL PUMP CASE S178070A1005
Check the oil pump case for worn shaft hole,

clogged oil passage, worn rotor chamber, cracks,
and other faults.
6. OIL SEAL S178070A1006
Check the oil seal lips for deformation, hardening,

wear, etc. and replace if defective.
S2M0737
LU-15
OIL PAN AND STRAINER
Lubrication
5. Oil Pan and Strainer S178071

8) Remove pitching stopper.

2) Remove front wheels.
S2M0126
9) Remove radiator upper brackets.
G6M0095

(Non-Turbo model)
and <Ref. to IN(SOHC)-7, REMOVAL, Air Cleaner
Case.>
5) Disconnect connector from mass air flow sen-
S2M1167
sor. (Turbo model)
10) Support engine with a lifting device and wire
ropes.
EN0031
6) Remove air intake boot and air cleaner upper

G2M0297
cover. (Turbo model)
CAUTION:
At this time, raise up wire ropes.
EN0032
7) Remove intercooler (Turbo model) <Ref. to

LU-16
Lubrication
13) Drain engine oil. 쐌 Non-Turbo model

Set container under the vehicle, and remove drain
plug from oil pan.
쐌 Non-Turbo model
EN0040
쐌 Turbo model
EN0009
쐌 Turbo model
EN0041
18) Remove oil strainer.

EN0010
(A) Gasket
(B) Drain plug
14) Remove front and center exhaust pipes. (Non-

Turbo model) <Ref. to EX(SOHC)-5, REMOVAL,
Front Exhaust Pipe.> or <Ref. to EX(SOHCw/
oOBD)-6, REMOVAL, Front Exhaust Pipe.>
15) Remove nuts which install front cushion rub-
ber onto front crossmember.
S2M0238
19) Remove baffle plate.
S2M1831
16) Remove bolts which install oil pan on cylinder

S2M0309
block while raising up engine.
17) Insert oil pan cutter blade between cylinder
block-to-oil pan clearance.
CAUTION:
place of oil pan cutter.
LU-17
Lubrication
B: INSTALLATION S178071A11 4) Tighten bolts which install oil pan onto engine
block.
CAUTION:
Before installing oil pan, clean sealant from oil Tightening torque:
pan and engine block. 5 N·m (0.5 kgf-m, 3.6 ft-lb)
1) Install baffle plate. 쐌 Non-Turbo model
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
EN0040
쐌 Turbo model
S2M0309
2) Install oil strainer onto baffle plate.

CAUTION:
Replace O-ring with a new one.
Tightening torque:
10 N·m (1.0 kgf-m, 7 ft-lb)
EN0041
5) Lower engine onto front crossmember.

6) Tighten nuts which install front cushion rubber
onto front crossmember.
Tightening torque:
69 N·m (7.0 kgf-m, 51 ft-lb)
S2M0238
3) Apply fluid packing to mating surfaces and

install oil pan.
Fluid packing:
S2M1831
S2M1833A
LU-18
Lubrication
7) Install front and center exhaust pipes. (Non- 12) Install radiator upper brackets.
Turbo model)
Exhaust Pipe.> or <Ref. to EX(SOHCw/oOBD)-7,
CAUTION:
Always use the new gaskets.
S2M1167
13) Install air intake duct and air cleaner case.

(Non-Turbo model)
<Ref. to IN(SOHC)-7, INSTALLATION, Air Cleaner
Case.> and <Ref. to IN(SOHC)-8, INSTALLATION,
Air Intake Duct.>
B2M3200 14) Install intercooler. (Turbo model) <Ref. to
8) Install under cover. IN(DOHC TURBO)-10, INSTALLATION, Inter-
9) Lower the vehicle. cooler.>
15) Install air intake boot and air cleaner upper
CAUTION: cover. (Turbo model)
At this time, lower lifting device and release
steel cables.
10) Remove lifting device and steel cables.
EN0032
16) Connect connector to mass air flow sensor.

(Turbo model)
G2M0297
11) Install pitching stopper.

Tightening torque:
T1: 50 N·m (5.1 kgf-m, 37 ft-lb)
T2: 58 N·m (5.9 kgf-m, 43 ft-lb)
EN0031
17) Install front wheels.
S2M0126D
LU-19
Lubrication
G6M0095
19) Fill engine oil. <Ref. to LU-10, INSPECTION,

Engine Oil.>
By visual check make sure oil pan, oil strainer, oil

strainer stay and baffle plate are not damaged.
LU-20
OIL PRESSURE SWITCH
Lubrication
6. Oil Pressure Switch S178069 B: INSTALLATION S178069A11
1) Apply fluid packing to oil pressure switch
threads.
1) Remove generator from bracket. <Ref. to
SC-12, REMOVAL, Generator.> Fluid packing:
2) Disconnect terminal from oil pressure switch. THREE BOND 1215 or equivalent
S2M0124B
G2M0091
3) Remove oil pressure switch. 2) Install oil pressure switch onto engine block.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
S2M0119
S2M0119
3) Connect terminal of oil pressure switch.
G2M0091
4) Install generator on bracket. <Ref. to SC-13,

INSTALLATION, Generator.>
Make sure oil does not leak or seep from where the
oil pressure switch is installed.
LU-21
ENGINE OIL COOLER
Lubrication
7. Engine Oil Cooler S178768

7) Remove connector and remove oil cooler.

3) Drain engine oil. Set container under the
vehicle, and remove drain plug from oil pan.
EN0010
(A) Metal gasket

(B) Drain plug
4) Drain coolant. S2M1835A

5) Remove water by-pass pipe between oil cooler
and water pump. (A) O-ring
(B) Oil cooler
(C) Connector
S2M0112
6) Remove engine oil filter. <Ref. to LU-24,

REMOVAL, Engine Oil Filter.>
LU-22
ENGINE OIL COOLER
Lubrication

Tightening torque:
T: 54 N·m (5.5 kgf-m, 39.8 ft-lb)
CAUTION:
Always use a new O-ring.
G2M0784
1) Check that coolant passages are not clogged

using air blow method.
2) Check mating surfaces of cylinder block, O-ring
groove and oil filter for damage.
LU-23
ENGINE OIL FILTER
Lubrication
8. Engine Oil Filter S178585

2) Remove oil filter with ST.
쐌 Non-Turbo model
EN0055
쐌 Turbo model
EN0056
1) Get a new oil filter and apply a thin coat of

engine oil to the seal rubber.
2) Install oil filter by turning it by hand, being care-
ful not to damage seal rubber.
3) Tighten more (approximately 2/3 to 3/4 turn)
after the seal rubber contacts the oil pump case.
Do not tighten excessively, or oil may leak.
1) After installing oil filter, run engine and make

sure that no oil is leaking around seal rubber.
NOTE:
The filter element and filter case are permanently
jointed; therefore, interior cleaning is not neces-
sary.
2) Check the engine oil level. <Ref. to LU-10,
INSPECTION, Engine Oil.>
LU-24
ENGINE LUBRICATION SYSTEM TROUBLE IN GENERAL
Lubrication
9. Engine Lubrication System Trouble in General S178100
Before performing diagnostics, make sure that the engine oil level is correct and no oil leakage exists.
1) Oil pressure switch Cracked diaphragm or oil leakage within switch Replace.
failure Broken spring or seized contacts Replace.
Clogged oil filter Replace.
Malfunction of oil by-pass valve of oil filter Clean or replace.
Malfunction of oil relief valve of oil pump Clean or replace.
1. Warning light remains 2) Low oil pressure Clogged oil passage Clean.
on. Excessive tip clearance and side clearance of oil
Replace.
pump rotor and gear
Clogged oil strainer or broken pipe Clean or replace.
Insufficient engine oil Replenish.
3) No oil pressure Broken pipe of oil strainer Replace.
Stuck oil pump rotor Replace.
1) Burn-out bulb Replace.
2. Warning light does
2) Poor contact of switch contact points Replace.
not go on.
3) Disconnection of wiring Repair.
1) Poor contact at terminals Repair.
2) Defective wiring harness Repair.
3. Warning light flickers
momentarily. Check for the same
3) Low oil pressure possible causes as
listed in 1.—2).
LU-25
ENGINE LUBRICATION SYSTEM TROUBLE IN GENERAL
Lubrication
MEMO:
LU-26
SPEED CONTROL SYSTEMS
SP
Page
2. Accelerator Pedal ........................................................................................5
3. Accelerator Control Cable .........................................................................12
GENERAL DESCRIPTION
Speed Control Systems
A: SPECIFICATION S177001A22
Free play At pedal pad 1 — 4 mm (0.04 — 0.16 in)

Accelerator pedal
Stroke At pedal pad 50 — 55 mm (1.97 — 2.17 in)
B2M4176A
(1) Accelerator bracket (7) Accelerator pedal lever (13) Kick-down switch (AT model)
(2) Stopper (8) Spring pin
(3) Bushing (9) Accelerator pedal Tightening torque: N·m (kgf-m, ft-lb)
(4) Clip (10) Accelerator stopper T: 18 (1.8, 13.0)
(5) Accelerator spring (11) Accelerator plate
(6) Accelerator pedal spring (12) Clip
SP-2
GENERAL DESCRIPTION
S4M0321A
(1) Accelerator pedal (9) Clip (17) Brake pedal pad

(2) Accelerator pedal spring (10) Stop light switch (18) Snap pin
(3) Spring pin (11) Accelerator spring
(4) Accelerator pedal pad (12) Brake pedal spring Tightening torque: N·m (kgf-m, ft-lb)
(5) Stopper (13) Brake spacer T1: 8 (0.8, 5.8)
(6) Bushing (14) Brake pedal T2: 18 (1.8, 13.0)
(7) Kick-down switch (15) Spacer T3: 29 (3.0, 21.7)
SP-3
GENERAL DESCRIPTION
쐌 Wear work clothing, including a cap, protective

goggles, and protective shoes during operation.
쐌 Remove contamination, including dirt and
corrosion, before removal, installation or disas-
sembly.
tect them from dust and dirt.
ment.
fied points.
SP-4
ACCELERATOR PEDAL
2. Accelerator Pedal S177005

쐌 SOHC model

2) Remove lock nut from accelerator cable
bracket.
3) Separate accelerator cable from bracket.
4) Remove accelerator cable end from throttle
cam.
5) Disconnect accelerator cable from throttle body. EN0920
CAUTION: 쐌 DOHC TURBO model

쐌 SOHC model
EN0922
(A) Toe board

B4M2316A
(B) Accelerator cable
쐌 DOHC TURBO model (C) To accelerator pedal
(D) Brake booster
(E) Clip

instrument panel, and connector.
8) Disconnect connector from kick-down switch.
(AT model)
9) Remove brake and clutch pedal bracket. <Ref.
to BR-54, REMOVAL, Brake Pedal.>
10) Disconnect accelerator cable from accelerator
pedal lever.
EN0919
(A) Lock nut

(B) Accelerator cable bracket
(C) Accelerator cable
(D) Throttle cam
6) Remove clip inside engine compartment.
S4M0482A
SP-5
ACCELERATOR PEDAL
11) Working inside engine compartment, remove 쐌 DOHC TURBO model

casing cap out of the toe board by turning it clock-
wise.
EN0919
(A) Lock nut

G4M0335
(B) Accelerator cable bracket
12) Pull out the cable from the toe board hole. (C) Accelerator cable
13) Remove accelerator pedal connecting bolt (D) Throttle cam
from accelerator pedal bracket.
6) Remove clip inside engine compartment.
쐌 SOHC model
G4M0321
EN0921
쐌 DOHC TURBO model
2) Remove lock nut from accelerator cable
bracket.
3) Separate accelerator cable from bracket.
4) Remove accelerator cable end from throttle
cam.
5) Disconnect accelerator cable from throttle body.
CAUTION:
쐌 SOHC model
EN0923
(A) Toe board

(B) Accelerator cable
(C) To accelerator pedal
(D) Brake booster
(E) Clip

instrument panel, and connector.
8) Disconnect connector from kick-down switch.
B4M2316A
(AT model)
9) Remove clevis pin which secures brake pedal
to brake booster operating rod. Also disconnect
electrical connectors (for stop light switch, etc.).
SP-6
ACCELERATOR PEDAL
10) Disconnect accelerator cable from accelerator 13) Remove nuts and bolts which secure pedal
pedal lever. bracket.
S4M0482A
11) Remove the casing cap out of the toe board by

turning it clockwise.
B4M0157B

(2) Brake pedal
B4M0156B B: INSTALLATION S177005A11
(1) Accelerator cable Install in the reverse order of removal.

(2) Toe board hole
(3) Casing cap
CAUTION:
쐌 If cable clamp is damaged, replace it with a
12) Pull out the cable from the toe board hole. new one.
쐌 Never fail to cover outer cable end with boot.
쐌 Be careful not to kink accelerator cable.
쐌 Always use new clevis pins. (RHD model
only)
쐌 Make sure that holder and casing cap are
securely connected.
B4M0159B
(1) Casing cap

(3) Toe board
(4) Accelerator pedal bracket
(5) Holder
SP-7
ACCELERATOR PEDAL
C: DISASSEMBLY S177005A06 2) Pull out the spring pin, and then remove the
accelerator pedal from the accelerator pedal lever.
1) Remove the clip, and then remove the accel-
erator pedal from the bracket.
쐌 LHD model
B2M4176B
(1) Accelerator bracket (6) Accelerator pedal spring (11) Accelerator plate
(2) Stopper (7) Accelerator pedal lever (12) Clip
(3) Bushing (8) Spring pin (13) Kick-down switch (AT model)
(4) Clip (9) Accelerator pedal
(5) Accelerator spring (10) Accelerator stopper
SP-8
ACCELERATOR PEDAL
쐌 RHD model
S4M0321B
(1) Accelerator pedal (7) Kick-down switch (13) Brake spacer

(2) Accelerator pedal spring (8) Pedal bracket (14) Brake pedal
(3) Spring pin (9) Clip (15) Spacer
(4) Accelerator pedal pad (10) Stop light switch (16) Clevis pin
(5) Stopper (11) Accelerator spring (17) Brake pedal pad
(6) Bushing (12) Brake pedal spring (18) Snap pin
SP-9
ACCELERATOR PEDAL
D: ASSEMBLY S177005A02 F: ADJUSTMENT S177005A01
Assemble in the reverse order of disassembly. 1) Check pedal stroke and free play by operating
CAUTION: accelerator pedal by hand.
Clean and apply grease to spacer and inside If it is not within specified value, adjust it by turn-
bore of a accelerator pedal. ing nut connecting accelerator cable to throttle
body.
Free play at pedal pad: L
1. ACCELERATOR PEDAL S177005A1001 1 — 4 mm (0.04 — 0.16 in)
Lightly move pedal pad in lateral the direction to Stroke at pedal pad: A
ensure pedal deflection is in specified range. 50 — 55 mm (1.97 — 2.17 in)
CAUTION:
If excessive deflection is noted, replace bush-
ing and clip with new ones.
Deflection of accelerator pedal:
Service limit
G4M0333
2. KICK-DOWN SWITCH S177005A1002
If kick-down switch does not operate properly (or if

it does not stop at the specified position), replace B4M1739A
with a new one. (A) Accelerator pedal

Specified position: A (B) Accelerator pedal bracket
2+1.5/0 mm (0.079 +0.059
/0 in) Accelerator cable lock nut tightening torque:
14 N·m (1.4 kgf-m, 10.1 ft-lb)
B4M0155A
SP-10
ACCELERATOR PEDAL
2) Check to ensure the kick-down switch operates

at the specified value in relation to the stroke of the
accelerator pedal.
position of kick-down switch.
CAUTION:
Be careful not to rotate kick-down switch.
Kick-down switch stroke: A
48±1 mm (1.89±0.04 in)
Kick-down switch tightening torque:
8 N·m (0.8 kgf-m, 5.8 ft-lb)
B4M1758A
SP-11
ACCELERATOR CONTROL CABLE
3. Accelerator Control Cable S177759
1) Remove accelerator pedal. <Ref. to SP-5,

REMOVAL, Accelerator Pedal.>
2) Separate accelerator cable and accelerator
pedal.

CAUTION:
쐌 If cable clamp is damaged, replace it with a
new one.
쐌 Never fail to cover outer cable end with boot.
쐌 Be careful not to kink accelerator cable.
쐌 Do not apply grease to the throttle cable on
the engine side.
2) Adjustment after pedal installation <Ref. to
SP-7, INSTALLATION, Accelerator Pedal.>
1) Make sure the inner cable is not twisted or

frayed.
2) Make sure the outer cable is not cracked.
SP-12
IGNITION
IG(SOHC)
Page
2. Spark Plug...................................................................................................4
3. Ignition Coil and Ignitor Assembly...............................................................8
4. Spark Plug Cord........................................................................................10
GENERAL DESCRIPTION
Ignition
Item Designation
Model FH0137
Manufacturer DIAMOND
Ignition coil
Primary coil resistance 0.73 Ω±10%
and ignitor
assembly Secondary coil resistance 12.8 kΩ±15%
Insulation resistance between primary
More than 10 MΩ
terminal and case
RC10YC4 .......... CHAMPION
Type and manufacturer
Alternate BKR5E-11 .......... NGK
Spark plug
Thread size mm 14, P = 1.25
Spark gap mm (in) 1.0 — 1.1 (0.039 — 0.043)
IG(SOHC)-2
GENERAL DESCRIPTION
Ignition
S6M0329B
(1) Spark plug (4) Spark plug cord (#2, #4) Tightening torque: N·m (kgf-m, ft-lb)
(2) Spark plug cord (#1, #3)
T1: 21 (2.1, 15)
(3) Ignition coil and ignitor ASSY
T2: 6.4 (0.65, 4.7)
C: CAUTION S151001A03 removal, installation, disassembly, and replace-

ment.
쐌 Wear working clothing, including a cap, protec- 쐌 Be careful not to burn your hands, because each
tive goggles, and protective shoes during opera- part on the vehicle is hot after running.
tion. 쐌 Be sure to tighten fasteners including bolts and
쐌 Remove contamination including dirt and corro- nuts to the specified torque.
sion before removal, installation or disassembly. 쐌 Place shop jacks or safety stands at the speci-
쐌 Keep the disassembled parts in order and pro- fied points.
tect them from dust or dirt. 쐌 Before disconnecting electrical connectors of
쐌 Before removal, installation or disassembly, be sensors or units, be sure to disconnect negative
sure to clarify the failure. Avoid unnecessary terminal from battery.
IG(SOHC)-3
SPARK PLUG
Ignition
2. Spark Plug S151003

(3) Remove air intake duct as a unit.
CAUTION:
All spark plugs installed on an engine, must be
of the same heat range.
Spark plug:
CHAMPION: RC10YC4
(Alternate)
NGK: BKR5E-11
S6M0353
1. RH SIDE S151003A1805
1) Disconnect battery ground cable. (4) Remove resonator chamber.
B2M2306
G6M0095
2) Remove air intake duct and resonator chamber. 3) Remove spark plug cords by pulling boot, not
cord itself.
(1) Remove bolt which installs air intake duct
on the front side of body.
B2M4127
S6M0708 4) Remove spark plugs with the spark plug socket.

on body.
B2M4286
B2M2284
IG(SOHC)-4
SPARK PLUG
Ignition
2. LH SIDE S151003A1806 5) Remove spark plugs cord by pulling boot, not

cord itself.
B2M4287
G6M0095
6) Remove spark plug with the spark plugs socket.

2) Disconnect washer motor connector.
B6M0926
S2M0546
3) Disconnect rear window glass washer hose

from washer motor, then plug connection with a
suitable cap. 1. RH SIDE S151003A1105
4) Remove the two bolts which hold the washer Install in the reverse order of removal.
tank, then take the tank away from the working
area. Tightening torque (Spark plug):
20.6 N·m (2.10 kgf-m, 15.2 ft-lb)
CAUTION:
The above torque should be only applied to
new spark plugs without oil on their threads.
In case their threads are lubricated, the torque
should be reduced by approximately 1/3 of the
specified torque in order to avoid over-stress-
ing.
Tightening torque (Resonator chamber):
B2M2023
32 N·m (3.3 kgf-m, 24 ft-lb)
2. LH SIDE S151003A1106

Tightening torque (Spark plug):
20.6 N·m (2.10 kgf-m, 15.2 ft-lb)
CAUTION:
ing.
IG(SOHC)-5
SPARK PLUG
Ignition
C: INSPECTION S151003A10 3) Oil fouled

Wet black deposits show excessive oil entrance
Check electrodes and inner and outer porcelain of into combustion chamber through worn rings and
plugs, noting the type of deposits and the degree pistons or excessive clearance between valve
of electrode erosion. guides and stems. If same condition remains after
repair, use a hotter plug.
S6M0420A
G6M0089
(A) Electrode gap
(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
results 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.
G6M0087 G6M0090
2) Carbon fouled
Dry fluffy carbon deposits on insulator and elec- D: CLEANING S151003E56
trode are mostly caused by slow speed driving in Clean spark plugs in a sand blast type cleaner.
city, weak ignition, too rich fuel mixture, dirty air Avoid excessive blasting. Clean and remove car-
cleaner, etc. bon or oxide deposits, but do not wear away por-
It is advisable to replace with plugs having hotter celain.
heat range. If deposits are too stubborn, replace plugs.
G6M0088
IG(SOHC)-6
SPARK PLUG
Ignition
Correct it if the spark plug gap is measured with a

gap gauge, and it is necessary.
Spark plug gap: L
1.0 — 1.1 mm (0.039 — 0.043 in)
S6M0412A
NOTE:
Replace with new spark plug if this area is worn to
“ball” shape.
IG(SOHC)-7
IGNITION COIL AND IGNITOR ASSEMBLY
Ignition
3. Ignition Coil and Ignitor 4) Remove ignition coil and ignitor assembly.
Assembly S151015
B6M0930

G6M0095
Tightening torque:
2) Disconnect spark plug cords from ignition coil 6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
and ignitor assembly. CAUTION:
Be sure to connect wires to their proper posi-
tions. Failure to do so will damage unit.
S6M0373
3) Disconnect connector from ignition coil and B6M0930

ignitor assembly.
B6M0932
IG(SOHC)-8
Ignition
Using accurate tester, inspect the following items,

and replace if defective.
1) Primary resistance
2) Secondary coil resistance
CAUTION:
If the resistance is extremely low, this indicates
the presence of a short-circuit.
Specified resistance:
[Primary side]
Between terminal No. 1 and No. 2
0.73 Ω±10%
Between terminal No. 2 and No. 4
0.73 Ω±10%
B6M0931C
[Secondary side]
Between (A) and (B)
12.8 kΩ±15%
Between (C) and (D)
12.8 kΩ±15%
B6M0773G
3) Insulation between primary terminal and case:

10 MΩ or more.
IG(SOHC)-9
SPARK PLUG CORD
Ignition
4. Spark Plug Cord S151014
Check for:
1) Damage to cords, deformation, burning or rust
formation of terminals
2) Resistance values of cords
Resistance value:
#1 cord: 5.6 — 10.6
#2 cord: 7.3 — 13.7
#3 cord: 5.9 — 11.1
#4 cord: 7.3 — 13.7
S6M0337
IG(SOHC)-10
STARTING/CHARGING SYSTEMS
SC
Page
2. Starter..........................................................................................................5
3. Generator ..................................................................................................12
4. Battery .......................................................................................................18
GENERAL DESCRIPTION
Starting/Charging Systems
Item Designation
Type Reduction type
Vehicle type MT vehicles AT vehicles
Model M000T83981 M001T86481
Manufacturer Mitsubishi Electric
Voltage and output 12 V — 1.0 kW 12 V — 1.4 kW
Direction of rotation Counterclockwise (when observed from pinion)
Number of pinion teeth 8 9
Voltage 11 V
No-load charac-
Current 90 A or less
teristics
Starter Rotating speed 2,800 rpm or more 2,400 rpm or more
Voltage 7.5 V 7.7 V
Current 300 A 400 A
Load character-
istics 8.6 N·m (0.88 kgf-m, 6.4 ft-lb) or 16.0 N·m (1.63 kgf-m, 11.8 ft-lb) or
Torque
more more
Rotating speed 920 rpm or more 740 rpm or more
Voltage 4V 3.5 V
Lock characteris- Current 650 A or less 940 A or less
tics 14.7 N·m (1.50 kgf-m, 10.8 ft-lb) or 28.9 N·m (2.95 kgf-m, 21.3 ft-lb) or
Torque
more more
Rotating-field three-phase type, Voltage regulator built-in type, with load
Type
response control system
Model A2TB6291
Manufacturer Mitsubishi Electric
Voltage and output 12 V — 75 A
Polarity on ground side Negative
Generator
Rotating direction Clockwise (when observed from pulley side)
Armature connection 3-phase Y-type
1,500 rpm — 30 A or more
Output current 2,500 rpm — 64 A or more
5,000 rpm — 76 A or more
Regulated voltage 14.1 — 14.8 V [20°C (68°F)]
For Europe 12 V — 48 AH 12 V — 52 AH
Type and capac-
Battery For Australia 12 V — 40 AH
ity
Others 12 V — 40 AH
SC-2
GENERAL DESCRIPTION
1. STARTER S179001A0501
H6M0492C
(1) Sleeve bearing (7) Internal gear ASSY (13) Armature

(2) Front bracket (8) Shaft ASSY (14) Brush holder
(3) Lever set (9) Gear ASSY (15) Brush
(4) Magnet switch ASSY (10) Ball (16) Sleeve bearing
(5) Stopper set (11) Packing (17) Rear bracket
(6) Over running clutch (12) Yoke
SC-3
GENERAL DESCRIPTION
2. GENERATOR S179001A0502
H6M0493C
(1) Pulley (5) Rotor (9) Brush

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

ment.
tive goggles, and protective shoes during opera- part in the vehicle is hot after running.
SC-4
STARTER
2. Starter S179012
쐌 AT vehicles
EN0370
5) Disconnect connector and terminal from starter.
G6M0095
2) Remove air cleaner case. (Non-Turbo Model)
S6M0002A
(A) Terminal
(B) Connector
B6M1221
6) Remove starter from transmission.
3) Remove intercooler. (Turbo Model) <Ref. to
IN(DOHC TURBO) -10, REMOVAL, Intercooler.>
4) Remove air cleaner case stay. (Non-Turbo
Model)
쐌 MT vehicles
EN1007
EN0369
SC-5
STARTER
B: INSTALLATION S179012A11 3) Remove both through-bolts and brush holder

screws, and detach rear bracket and brush holder.
Tightening torque:
50 N·m (5.1 kgf-m, 37 ft-lb)
H6M0494B
(A) Brush holder

(B) Rear bracket
EN1007
4) Remove armature and yoke. Ball used as a

bearing will then be removed from the end of arma-
ture.
1. STARTER ASSEMBLY S179012A0601
CAUTION:
1) Loosen nut which holds terminal M of switch Be sure to mark an alignment mark on yoke
assembly, and disconnect connector. and front bracket before removing yoke.
2) Remove bolts which hold switch assembly, and
remove switch assembly, plunger and plunger
spring from starter as a unit.
CAUTION:
Be careful because pinion gap adjustment
washer may sometimes be used on the mount-
ing surface of switch assembly.
H6M0495B
(A) Front bracket

(B) Yoke
(C) Ball
(D) Awature
S6M0396A
(A) Switch ASSY

(B) Plunger
SC-6
STARTER
5) Remove packing A, three planetary gears,

packing B and plate.
S6M0399A
(A) Stopper
S6M0397A (B) Tool
(C) Ring
(A) Packing A
(D) Shaft
(B) Planetary gear
(C) Plate 2. BRUSH HOLDER S179012A0602
(D) Packing B
Slightly open the metal fitting holding the insulating
6) Remove shaft assembly and overrunning clutch plate to the brush holder. Remove the insulating
as a unit. plate.
CAUTION: NOTE:
Record the direction of lever before removing. The brush and spring can be easily removed from
the brush holder at this time.
S6M0398A
H6M0497B
(A) Shaft ASSY
(B) Overrunning clutch (A) Brush holder
(C) Lever (B) Insulating plate
(C) Metal fitting
7) Remove overrunning clutch from shaft assem-
bly as follows: D: ASSEMBLY S179012A02
(1) Remove stopper from ring by lightly tapping
a fit tool placed on stopper. Assembly is in the reverse order of disassembly
(2) Remove ring, stopper and clutch from shaft. procedures. Do the following:
1) Carefully assemble all parts in the order of
assembly and occasionally inspect nothing has
been overlooked.
2) Apply grease to the following parts during
assembly.
쐌 Front and rear bracket sleeve bearing
쐌 Armature shaft gear
쐌 Outer periphery of plunger
쐌 Mating surface of plunger and lever
쐌 Gear shaft splines
쐌 Mating surface of lever and clutch
쐌 Ball at the armature shaft end
쐌 Internal and planetary gears
SC-7
STARTER
3) After assembling parts correctly, make sure 4) Armature short-circuit test

starter operates properly. Check armature for short-circuit by placing it on
growler tester. Hold a hacksaw blade against
E: INSPECTION S179012A10 armature core while slowly rotating armature. A
short-circuited armature will cause the blade to
1. ARMATURE S179012A1001
vibrate and to be attracted to core. If the hacksaw
1) Check commutator for any sign of burns of blade is attracted or vibrates, the armature, which
rough surfaces or stepped wear. If wear is of a is short-circuited, must be replaced or repaired.
minor nature, correct it by using sand paper.
2) Run-out test
Check the commutator run-out and replace if it
exceeds the limit.
Commutator run-out:
Standard
0.05 mm (0.0020 in)
Service limit
S6M0402A
(A) Iron sheet

(B) Grower
5) Armature ground test

Using circuit tester, touch one probe to the com-
mutator segment and the other to shaft. There
should be no continuity. If there is a continuity,
armature is grounded.
S6M0400A Replace armature if it is grounded.
(A) V-block
3) Depth of segment mold

Check the depth of segment mold.
Depth of segment mold:
0.5 mm (0.020 in)
G6M0041
2. YOKE S179012A1002
Make sure pole is set in position.

3. OVERRUNNING CLUTCH S179012A1003
S6M0401A Inspect teeth of pinion for wear and damage.

Replace if it is damaged. Rotate pinion in direction
(A) Depth of mold
(B) Segment
of rotation (counterclockwise). It should rotate
(C) Mold
smoothly. But in opposite direction, it should be
locked.
CAUTION:
Do not clean overrunning clutch with oil to pre-
vent grease from flowing out.
SC-8
STARTER
4. BRUSH AND BRUSH HOLDER S179012A1004 Terminal / Specified resistance:

S — M / Less than 1 Ω
1) Brush length
S — Ground / Less than 1 Ω
Measure the brush length and replace if it exceeds
M — B / More than 1 MΩ
the service limit.
Replace if abnormal wear or cracks are noticed.
Brush length:
Standard
12.3 mm (0.484 in)
Service limit
7.0 mm (0.276 in)
S6M0403
6. SWITCH ASSEMBLY OPERATION

S179012A1006
1) Connect terminal S of switch assembly to posi-

tive terminal of battery with a lead wire, and starter
H6M0496B body to ground terminal of battery. Pinion should
be forced endwise on shaft.
(A) Service limit line
(B) Brush CAUTION:
With pinion forced endwise on shaft, starter
2) Brush movement motor can sometimes rotate because current
Be sure brush moves smoothly inside brush flows, through pull-in coil, to motor. This is not
holder. a problem.
3) Brush spring force
2) Disconnect connector from terminal M, and
Measure brush spring force with a spring scale. If
connect positive terminal of battery and terminal M
it is less than the service limit, replace brush
using a lead wire and ground terminal to starter
holder.
body.
Brush spring force: In this test set up, pinion should return to its origi-
Standard nal position even when it is pulled out with a screw-
21.6 N (2.2 kgf, 4.9 lb) (when new) driver.
Service limit
5.9 N (0.6 kgf, 1.3 lb)
5. SWITCH ASSEMBLY S179012A1005
Be sure there is continuity between terminals S

and M, and between terminal S and ground. Use
a circuit tester (set in “ohm”).
Also check to be sure there is no continuity
between terminal M and B.
S6M0393A
(A) Terminal S
(B) Terminal M
SC-9
STARTER
7. PINION GAP S179012A1007
1) Measure pinion gap while the pinion is pulled

out as shown in the figure.
Pinion gap:
0.5 — 2.0 mm (0.020 — 0.079 in)
S6M0395A
(A) Variable resistance

(B) Magnetic switch
(C) Starter body
1) No-load test
S6M0394A With switch on, adjust the variable resistance to
obtain 11 V, take the ammeter reading and mea-
(A) Pinion sure the starter speed. Compare these values with
(B) Gap the specifications.
(C) Stopper
No-load test (Standard):
If motor is running with the pinion forced endwise
Voltage / Current
on the shaft, disconnect connector from terminal M
11 V / 90 A max.
of switch assembly and connect terminal M to
ground terminal (−) of battery with a lead wire. Rotating speed
Next, gently push pinion back with your fingertips MT vehicles
and measure pinion gap. 2,800 rpm or more
2) If pinion gap is outside specified range, remove AT vehicles
or add number of adjustment washers used on the 2,400 rpm or more
mounting surface of switch assembly until correct 2) Load test
pinion gap is obtained. Apply the specified braking torque to starter. The
8. PERFORMANCE TEST S179012A1008
condition is satisfactory if the current draw and
starter speed are within specifications.
The starter should be submitted to performance
tests whenever it has been overhauled, to assure Load test (Standard):
its satisfactory performance when installed on the Voltage / Load
engine. MT vehicles
Three performance tests, no-load test, load test, 7.5 V/8.6 N·m (0.88 kgf-m, 6.4 ft-lb)
and lock test, are presented here; however, if the AT vehicles
load test and lock test cannot be performed, carry 7.7 V/16.0 N·m (1.63 kgf-m, 11.8 ft-lb)
out at least the no-load test. Current / Speed
For these performance tests, use the circuit shown MT vehicles
in figure. 300 A/920 rpm or more
AT vehicles
400 A/740 rpm or more
SC-10
STARTER
3) Lock test
With starter stalled, or not rotating, measure the
torque developed and current draw when the volt-
age is adjusted to the specified voltage.
Lock test (Standard):
Voltage / Current
MT vehicles
4 V/650 A or less
AT vehicles
3.5 V/940 A or less
Torque
MT vehicles
14.7 N·m (1.50 kgf-m, 10.8 ft-lb) or more
AT vehicles
28.9 N·m (2.95 kgf-m, 21.3 ft-lb) or more
SC-11
GENERATOR
3. Generator S179008
쐌 Non-Turbo Model
S2M0896
쐌 Turbo Model
G6M0095
2) Disconnect connector and terminal from gen-

erator.
쐌 Non-Turbo Model
S2M2235
4) Remove front side V-belt.

<Ref. to ME(SOHC) -42, FRONT SIDE,
REMOVAL, V-belt.> or <Ref. to ME(DOHC
TURBO) -44, FRONT SIDE, REMOVAL, V-belt.>
S2M0941 5) Remove bolts which install generator onto
쐌 Turbo Model bracket.
S6M0352
S2M2234
SC-12
GENERATOR
B: INSTALLATION S179008A11 3) Hold rotor with a vise and remove pulley nut.
CAUTION:
Check and adjust V-belt tension. <Ref. to
ME(SOHC) -43, INSPECTION, V-belt.> and <Ref.
to ME(DOHC TURBO) -45, INSPECTION,
V-belt.>
G6M0066
CAUTION:
When holding rotor with vise, insert aluminum
plates or wood pieces on the contact surfaces
of the vise to prevent rotor from damage.
S6M0352
1) Heat the portion (A) of rear cover to 50°C

(122°F) with heater drier.
H6M0498B
(A) Front bracket

(B) Pulley
(C) Nut
(D) Rotor
4) Unsolder connection between rectifier and sta-

B6M0476B tor coil to remove stator coil.
2) Remove the four through bolts. Then insert the CAUTION:
tip of a flat-head screwdriver into the gap between Finish the work rapidly (less than three sec-
the stator core and front bracket. Pry then apart to onds) because the rectifier cannot withstand
disassemble. heat very well.
G6M0065 G6M0068
SC-13
GENERATOR
5) Remove screws which secure IC regulator to CAUTION:

rear cover, and unsolder connection between IC Be sure to remove the wire after reassembly.
regulator and rectifier to remove IC regulator.
S6M0411A
G6M0069
2) Heat the bearing box in the rear bracket [50 to
6) Remove the brushes by unsoldering at the pig- 60°C (122 to 140°F)] and press the rear bearing
tails. into the rear bracket.
CAUTION:
Grease should not be applied for the rear bear-
ing. Remove oil completely if it is found on the
bearing box.
3) After reassembly, turn the pulley by hand to
check that the rotor turns smoothly.
1. DIODE S179008A1001
G6M0070 CAUTION:
Never use a megger tester (measuring use for
7) Remove the nut and insulating bushing at ter- high voltage) or any other similar measure for
minal B, and remove rectifier. this test; otherwise, the diodes may be dam-
aged.
1) Checking positive diode
Check for continuity between the diode lead and
the positive side heat sink. The positive diode is in
good condition if continuity (1 Ω or less) exists only
in the direction from the diode lead to the heat sink.
S6M0405A
(A) Ractifier
(B) Rear cover
(C) Nut
S6M0406A
To assemble, reverse order of disassembly.
1) Pulling up brush (A) Diode lead
Before assembling, press the brush down into the (B) Heat sink (Positive side)
brush holder with your finger and secure in that
position by passing a [2 mm (0.08 in) dia. length 4 2) Checking negative diode
to 5 cm (1.6 to 2.0 in)] wire (A) through the hole Check for continuity between the negative side
shown in the figure. heat sink and diode lead. The negative diode is in
good condition if continuity (1 Ω or less) exists only
in the direction from the heat sink to the diode lead.
SC-14
GENERATOR
4) Insulation test
Check continuity between slip ring and rotor core
or shaft. If continuity (1 Ω or less) exists, the rotor
coil is grounded, and so replace rotor assembly.
S6M0407A
(A) Diode lead

(B) Heat sink (Negative side)
2. ROTOR S179008A1002 G6M0076
1) Slip ring surface 5) Ball bearing (rear side)

Inspect slip rings for contamination or any rough- (1) Check rear ball bearing. Replace if it is
ness of the sliding surface. Repair slip ring surface noisy or if rotor does not turn smoothly.
using a lathe or sand paper. (2) The rear bearing can be removed by using
2) Slip ring outer diameter common bearing puller.
Measure slip ring outer diameter. If slip ring is worn
replace rotor assembly.
Slip ring outer diameter:
Standard
22.7 mm (0.894 in)
Limit
22.1 mm (0.870 in)
3) Continuity test
Check resistance between slip rings using circuit
tester.
G6M0077
If the resistance is not within specification, replace
rotor assembly.
Specified resistance: 3. STATOR S179008A1003
Approx. 2.7 — 3.2 Ω 1) Continuity test

Inspect stator coil for continuity between each end
of the lead wires. If there is no continuity (1 Ω or
more) between individual lead wires, the lead wire
is broken, and so replace stator assembly.
G6M0075
G6M0078
SC-15
GENERATOR
2) Insulation test 2) Checking brush spring for proper pressure

Inspect stator coil for continuity (1 Ω or less) Using a spring pressure indicator, push the brush
between stator core and each end of the lead wire. into the brush holder until its tip protrudes 2 mm
If there is continuity, the stator coil is grounded, (0.08 in). Then measure the pressure of the brush
and so replace stator assembly. spring. If the pressure is less than 2.648 N (270 g,
9.52 oz), replace the brush spring with a new one.
The new spring must have a pressure of 4.609 to
5.786 N (470 to 590 g, 16.58 to 20.81 oz).
G6M0079
4. BRUSH S179008A1004
G6M0143
1) Measure the length of each brush. If wear
exceeds the service limit, replace the brush. Each
brush has the service limit mark (A) on it. 5. BEARING (FRONT SIDE) S179008A1005
Brush length: 1) Check front ball bearing. If resistance is felt

Standard while rotating, or if abnormal noise is heard,
18.5 mm (0.728 in) replace the ball bearing.
Service limit 2) Replacing front bearing
5.0 mm (0.197 in) (1) Remove front bearing retainer.
(2) Closely install a fit tool on the bearing inner
race. Press the bearing down out of front
bracket with a hand press or vise. A socket
wrench can serve as the tool.
H6M0499B
S6M0409A
(A) Front bracket

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

tool on the bearing outer race. Press the bear-
ing down into place with a hand press or vise.
A socket wrench can serve as the tool.
(4) Install front bearing retainer.
SC-16
GENERATOR
S6M0410A
(A) Bearing
(B) Socket wrench
(C) Front bracket
SC-17
BATTERY
4. Battery S179011 C: INSPECTION S179011A10
WARNING:
쐌 Electrolyte has toxicity; be careful handling
1) Disconnect the positive (+) terminal after dis- the fluid.
connecting the negative (−) terminal of battery. 쐌 Avoid contact with skin, eyes or clothing.
2) Remove flange nuts from battery rods and take Especially at contact with eyes, blush with
off battery holder. water for 15 minutes and get prompt medical
attention.
쐌 Batteries produce explosive gasses. Keep
sparks, flame, cigarettes away.
쐌 Ventilate when charging or using in enclosed
space.
쐌 For safety, in case an explosion does occur,
wear eye protection or shield your eyes when
working near any battery. Never lean over a
battery.
쐌 Do not let battery fluid contact eyes, skin,
B6M1506
fabrics, or paint-work because battery fluid is
3) Remove battery. corrosive acid.
쐌 To lessen the risk of sparks, remove rings,
B: INSTALLATION S179011A11 metal watch-bands, and other metal jewelry.
Never allow metal tools to contact the positive
battery terminal and anything connected to it
Tightening torque: while you are at the same time in contact with
3.4 N·m (0.35 kgf-m, 2.5 ft-lb) any other metallic portion of the vehicle
NOTE: because a short circuit will be caused.
쐌 Clean battery cable terminals and apply grease 1. EXTERNAL PARTS: S179011A1001
to retard the formation of corrosion.
쐌 Connect the positive (+) terminal of battery and Check for the existence of dirt or cracks on the
then the negative (−) terminal of the battery. battery case, top cover, vent plugs, and terminal
posts. If necessary, clean with water and wipe with
a dry cloth.
Apply a thin coat of grease on the terminal posts
to prevent corrosion.
2. ELECTROLYTE LEVEL: S179011A1002
Check the electrolyte level in each cell. If the level

is below MIN LEVEL, bring the level to MAX
LEVEL by pouring distilled water into the battery
cell. Do not fill beyond MAX LEVEL.
3. SPECIFIC GRAVITY OF
ELECTROLYTE: S179011A1003
1) Measure specific gravity of electrolyte using a
hydrometer and a thermometer.
Specific gravity varies with temperature of electro-
lyte so that it must be corrected at 20°C (68°F)
using the following equation:
SC-18
BATTERY
S20 = St + 0.0007 × (t − 20) 2. CHECK HYDROMETER FOR STATE OF

S20: Specific gravity corrected at electro- CHARGE S179011A1402
lyte temperature of 20°C
St : Measured specific gravity Hydrometer
State of charge Required action
t : Measured temperature (°C) indicator
Determine whether or not battery must Green dot Above 65% Load test
be charged, according to corrected spe- Dark dot Below 65% Charge battery
cific gravity. Replace battery*
Standard specific gravity: 1.220 — 1.290 Clear dot Low electrolyte (If cranking complaint)
[at 20°C (68°F)]
*: Check electrical system before replacement.
3. NORMAL CHARGING S179011A1403
Charge the battery at current value specified by

manufacturer or at approximately 1/10 of battery’s
ampere-hour rating.
4. QUICK CHARGING S179011A1404
Quick charging is a method in which the battery is

charged in a short period of time with a relatively
G6M0103 large current by using a quick charger.
Since a large current flow raises electrolyte
2) Measuring the specific gravity of the electrolyte temperature, the battery is subject to damage if the
in the battery will disclose the state of charge of the large current is used for prolonged time. For this
battery. The relation between the specific gravity reason, the quick charging must be carried out
and the state of charge is as shown in figure. within a current range that will not increase the
electrolyte temperature above 40°C (104°F).
D: MEASUREMENT S179011A14
It should be also remembered that the quick charg-
WARNING: ing is a temporary means to bring battery voltage
쐌 Do not bring an open flame close to the bat- up to a fair value and, as a rule, a battery should
tery at this time. be charged slowly with a low current.
CAUTION: CAUTION:
쐌 Prior to charging, corroded terminals should 쐌 Observe the items in 1. NORMAL CHARG-
be cleaned with a brush and common baking ING.
soda solution. 쐌 Never use more than 10 amperes when
쐌 Be careful since battery electrolyte over- charging the battery because that will shorten
flows while charging the battery. battery life.
쐌 Observe instructions when handling battery
charger.
쐌 Before charging the battery on vehicle, dis-
connect battery ground terminal. Failure to fol-
low this rule may damage alternator’s diodes
or other electrical units.
1. JUDGMENT OF BATTERY IN
CHARGED CONDITION S179011A1401
1) Specific gravity of electrolyte is held at a spe-
cific value in a range from 1.250 to 1.290 for more
than one hour.
2) Voltage per battery cell is held at a specific
value in a range from 2.5 to 2.8 volts for more than
one hour.
SC-19
BATTERY
MEMO:
SC-20
ENGINE (DIAGNOSTICS)
EN(SOHC)
Page
5. Engine Control Module (ECM) I/O Signal.................................................24
6. Engine Condition Data ..............................................................................27
7. Transmission Control Module (TCM) I/O Signal .......................................28
8. Data Link Connector .................................................................................31
9. OBD-II General Scan Tool ........................................................................32
12. Inspection Mode ........................................................................................42
14. Compulsory Valve Operation Check Mode...............................................46
15. Engine Malfunction Indicator Lamp (MIL) .................................................48
16. Diagnostics for Engine Starting Failure ....................................................59
17. List of Diagnostic Trouble Code (DTC).....................................................80
18. Diagnostic Procedure with Diagnostic Trouble Code (DTC) ....................86
Engine (Diagnostics)

S058501
1. ENGINE S058501E4501

1 CHECK ENGINE START FAILURE. Does the engine start? Go to step 2. Inspection using
1) Ask the customer when and how the “Diagnostics for
trouble occurred using the interview check list. Engine Start Fail-
<Ref. to EN(SOHC)-4, CHECK, Check List for ure”. <Ref. to
Interview.> EN(SOHC)-59,
2) Start the engine. Diagnostics for
Engine Starting
Failure.>
2 CHECK ILLUMINATION OF CHECK ENGINE Does CHECK ENGINE Go to step 3. Inspection using
MALFUNCTION INDICATOR LAMP (MIL). malfunction indicator lamp “General Diagnos-
illuminate? tics Table”. <Ref.
to EN(SOHC)-
294,
INSPECTION,
General Diagnos-
tic Table.>
3 CHECK INDICATION OF DTC ON DISPLAY. Does the Subaru Select Record diagnostic Repair the related
1) Turn ignition switch to OFF. Monitor or OBD-II general trouble code. parts.
2) Connect the Subaru Select Monitor or the scan tool indicate DTC? Repair the trouble NOTE:
OBD-II general scan tool to data link connec- cause. <Ref. to If DTC is not
tor. EN(SOHC)-80, shown on display
3) Turn ignition switch to ON and the Subaru OPERATION, List although the MIL
Select Monitor or OBD-II general scan tool of Diagnostic illuminates, per-
switch to ON. Trouble Code form diagnostics
4) Read DTC on the Subaru Select Monitor or (DTC).> Go to of MIL (CHECK
OBD-II general scan tool. step 4. ENGINE malfunc-
tion indicator
lamp) circuit or
combination
meter. <Ref. to
EN(SOHC)-48,
Engine Malfunc-
tion Indicator
Lamp (MIL).>
4 PERFORM THE DIAGNOSIS. Does the Subaru Select Inspect using Complete the
1) Perform the clear memory mode. <Ref. to Monitor or OBD-II general “Diagnostics Pro- diagnosis.
EN(SOHC)-45, Clear Memory Mode.> scan tool indicate DTC? cedure with Diag-
2) Perform the inspection mode. <Ref. to nostic Trouble
EN(SOHC)-42, Inspection Mode.> Code (DTC)”.
<Ref. to
EN(SOHC)-86,
Diagnostic Proce-
dure with Diag-
nostic Trouble
Code (DTC).>
EN(SOHC)-2
2. AUTOMATIC TRANSMISSION S058501E4502
When trouble code about automatic transmission

is shown on display, carry out the following basic
check. After that, carry out the replacement or
repair work.
1) ATF level check <Ref. to AT-9, Automatic Trans-
mission Fluid.>
2) Differential gear oil level check <Ref. to AT-11,
Differential Gear Oil.>
3) ATF leak check <Ref. to AT-9, Automatic Trans-
mission Fluid.>
4) Differential gear oil leak check <Ref. to AT-11,
5) Stall test <Ref. to AT-13, Stall Test.>
6) Line pressure test <Ref. to AT-16, Line Pres-
sure 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(SOHC)-3

Check the following items when problem has
occurred.
A: CHECK S058502A04
NOTE:
1. CHECK LIST NO. 1 S058502A0401 Use copies of this page for interviewing customers.
Customer’s name Engine no.

Date of sale Fuel brand
Date of repair Odometer reading km
Vin no. miles
Weather 쏔 Fine
쏔 Cloudy
쏔 Rainy
쏔 Snowy
쏔 Various/Others:
Outdoor temperature °C (°F)
쏔 Hot
쏔 Warm
쏔 Cool
쏔 Cold
Place 쏔 Highway
쏔 Suburbs
쏔 Inner city
쏔 Uphill
쏔 Downhill
쏔 Rough road
쏔 Others:
Engine temperature 쏔 Cold
쏔 Warming-up
쏔 After warming-up
쏔 Any temperature
쏔 Others:
Engine speed rpm
Vehicle speed MPH
Driving conditions 쏔 Not affected
쏔 At starting
쏔 While idling
쏔 At racing
쏔 While accelerating
쏔 While cruising
쏔 While decelerating
쏔 While turning (RH/LH)
Headlight 쏔 ON/쏔 OFF Rear defogger 쏔 ON/쏔 OFF
Blower 쏔 ON/쏔 OFF Radio 쏔 ON/쏔 OFF
A/C compressor 쏔 ON/쏔 OFF CD/Cassette 쏔 ON/쏔 OFF
Cooling fan 쏔 ON/쏔 OFF Car phone 쏔 ON/쏔 OFF
Front wiper 쏔 ON/쏔 OFF CB 쏔 ON/쏔 OFF
Rear wiper 쏔 ON/쏔 OFF
EN(SOHC)-4
2. CHECK LIST NO. 2 S058502A0402 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. 쏔 Yes/쏔 No

쏔 Low fuel warning light
쏔 Charge indicator light
쏔 AT diagnostics indicator light
쏔 ABS warning light
쏔 VDC warning light
쏔 Engine oil pressure warning light
b) Fuel level
쐌 Lack of gasoline: 쏔 Yes/쏔 No
쐌 Indicator position of fuel gauge:
c) Intentional connecting or disconnecting of harness connectors or spark plug cords: 쏔 Yes/쏔 No
쐌 What:
d) Intentional connecting or disconnecting of hoses: 쏔 Yes/쏔 No
쐌 What:
e) Installing of parts other than genuine parts: 쏔 Yes/쏔 No
쐌 What:
쐌 Where:
f) Occurrence of noise: 쏔 Yes/쏔 No
쐌 From where:
쐌 What kind:
g) Occurrence of smell: 쏔 Yes/쏔 No
쐌 From where:
쐌 What kind:
h) Intrusion of water into engine compartment or passenger compartment: 쏔 Yes/쏔 No
i) Troubles occurred
쏔 Engine does not start.
쏔 Engine stalls during idling.
쏔 Engine stalls while driving.
쏔 Engine speed decreases.
쏔 Engine speed does not decrease.
쏔 Rough idling
쏔 Poor acceleration
쏔 Back fire
쏔 After fire
쏔 No shift
쏔 Excessive shift shock
EN(SOHC)-5
GENERAL DESCRIPTION

8) Use ECM mounting stud bolts at the body head
grounding point when measuring voltage and
A: CAUTION S058001A03 resistance inside the passenger compartment.
1) Airbag system wiring harness is routed near the
engine control module (ECM), main relay and fuel
pump relay.
CAUTION:
cal test equipment on these circuit.
ing harness when servicing the engine control
module (ECM), transmission control module H2M1154A
(TCM), main relay and fuel pump relay.
9) Use engine grounding terminal or engine
2) Never connect the battery in reverse polarity.
proper as the grounding point to the body when
쐌 The ECM will be destroyed instantly.
measuring voltage and resistance in the engine
쐌 The fuel injector and other part will be damaged
compartment.
in just a few minutes more.
3) Do not disconnect the battery terminals while
the engine is running.
쐌 A large counter electromotive force will be gen-
erated in the alternator, and this voltage may dam-
age electronic parts such as ECM, etc.
4) Before disconnecting the connectors of each
sensor and the ECM, be sure to turn OFF the igni-
tion switch.
5) Poor contact has been identified as a primary
cause of this problem. To measure the voltage
B2M2779
and/or resistance of individual sensors or all elec-
trical control modules at the harness side 10) Use TCM mounting stud bolts at the body
connector, use a tapered pin with a diameter of head grounding point when measuring voltage and
less than 0.64 mm (0.025 in). Do not insert the pin resistance inside the passenger compartment.
more than 5 mm (0.20 in) into the part.
6) Before removing ECM from the located
position, disconnect two cables on battery.
쐌 Otherwise, the ECM may be damaged.
CAUTION:
wrong spec. ECM to avoid any damage on fuel
injection system.
7) The connectors to each sensor in the engine
compartment and the harness connectors on the B3M1666E
engine side and body side are all designed to be
waterproof. However, it is still necessary to take 11) Every MFI-related part is a precision part. Do
care not to allow water to get into the connectors not drop them.
when washing the vehicle, or when servicing the 12) Observe the following cautions when installing
vehicle on a rainy day. a radio in MFI equipped models.
CAUTION:
쐌 The antenna must be kept as far apart as
possible from the control unit.
(The ECM is located under the steering column,
inside of the instrument panel lower trim
panel.)
EN(SOHC)-6
GENERAL DESCRIPTION
쐌 The antenna feeder must be placed as far 2. ENGINE GROUNDING S058001A1002
apart as possible from the ECM and MFI har-

ness. Make sure the engine grounding terminal is prop-
쐌 Carefully adjust the antenna for correct erly connected to the engine.
matching.
쐌 When mounting a large power type radio,
pay special attention to the three items above
mentioned.
쐌 Incorrect installation of the radio may affect
the operation of the ECM.
13) Before disconnecting the fuel hose, discon-
nect the fuel pump connector and crank the engine
for more than five seconds to release pressure in
the fuel system. If engine starts during this
B2M2779
operation, run it until it stops.
14) Problems in the electronic-controlled auto-
matic transmission may be caused by failure of the C: NOTE S058001A15
engine, the electronic control system, the transmis-
sion proper, or by a combination of these. These 1. DESCRIPTION S058001A1501
three causes must be distinguished clearly when

쐌 The on-board diagnostics (OBD) system detects
performing diagnostics.
and indicates a fault in various inputs and outputs
15) Diagnostics should be conducted by rotating
with simple, easy operations and proceeding to of the complex electronic control. CHECK ENGINE
complicated, difficult operations. The most impor- malfunction indicator lamp (MIL) in the combina-
tant thing in diagnostics is to understand the cus- tion meter indicates occurrence of a fault or
tomer’s complaint, and distinguish between the trouble.
three causes. 쐌 Further, against such a failure or sensors as
16) In AT vehicles, do not continue the stall for may disable the drive, the fail-safe function is pro-
more than five seconds at a time (from closed vided to ensure the minimal driveability.
throttle, fully open throttle to stall engine speed). 쐌 The OBD system incorporated with the vehicles
17) On ABS vehicle, when performing driving test within this engine family complies with Section
in jacked-up or lifted-up position, sometimes the 1968.1, California Code of Regulations (OBD-II
warning light may be lit, but this is not a malfunc- regulation). The OBD system monitors the compo-
tion of the system. The reason for this is the speed nents and the system malfunction listed in Engine
difference between the front and rear wheels. After Section which affects on emissions.
diagnosis of engine control system, perform the 쐌 When the system decides that a malfunction
ABS memory clearance procedure of self-diagno- occurs, MIL illuminates. At the same time of the
sis system. MIL illumination or blinking, a diagnostic trouble
code (DTC) and a freeze frame engine conditions
are stored into on-board computer.
쐌 The OBD system stores freeze frame engine
Before performing diagnostics, check the following condition data (engine load, engine coolant
items which might affect engine problems: temperature, fuel trim, engine speed and vehicle
speed, etc.) into on-board computer when it
1. BATTERY S058001A1001
detects a malfunction first.
1) Measure battery voltage and specific gravity of 쐌 If the OBD system detects the various malfunc-
electrolyte. tions including the fault of fuel trim or misfire, the
Standard voltage: 12 V OBD system first stores freeze frame engine con-
ditions about the fuel trim or misfire.
Specific gravity: Above 1.260 쐌 When the malfunction does not occur again for
2) Check the condition of the main and other three consecutive driving cycles, MIL is turned off,
fuses, and harnesses and connectors. Also check but DTC remains at on-board computer.
for proper grounding. 쐌 The OBD-II system is capable of communication
with a general scan tool (OBD-II general scan tool)
formed by ISO 9141 CARB.
쐌 The OBD-II diagnostics procedure is different
from the usual diagnostics procedure. When
troubleshooting OBD-II vehicles, connect Subaru
EN(SOHC)-7
GENERAL DESCRIPTION
Select Monitor or the OBD-II general scan tool to 쐌 Reduced emission of harmful exhaust gases.
the vehicle. 쐌 Reduced in fuel consumption.
쐌 Increased engine output.
2. ENGINE AND EMISSION CONTROL 쐌 Superior acceleration and deceleration.
SYSTEM S058001A1502 쐌 Superior startability and warm-up perfor-
쐌 The Multipoint Fuel Injection (MFI) system is a mance in cold weather since compensation is
system that supplies the optimum air-fuel mixture made for coolant and intake air temperature.
to the engine for all the various operating condi-
tions through the use of the latest electronic tech- 3. AUTOMATIC TRANSMISSION AND
nology. ELECTRONIC-HYDRAULIC CONTROL
With this system fuel, which is pressurized at a SYSTEM S058001A1503
constant pressure, is injected into the intake air
The electronic-hydraulic control system consists of
passage of the cylinder head. The injection quan-
tity of fuel is controlled by an intermittent injection various sensors and switches, a transmission con-
system where the electro-magnetic injection valve trol module (TCM) and the hydraulic controller
(fuel injector) opens only for a short period of time, including solenoid valves. The system controls the
depending on the quantity of air required for one transmission proper including shift control, lock-up
cycle of operation. In actual operation, the injection control, overrunning clutch control, line pressure
quantity is determined by the duration of an elec- control and shift timing control. It also controls the
tric pulse applied to the fuel injector and this per- AWD transfer clutch. In other words, the system
mits simple, yet highly precise metering of the fuel. detects various operating conditions from various
쐌 Further, all the operating conditions of the input signals and sends output signals to shift sole-
engine are converted into electric signals, and this noids 1, 2 and low clutch timing solenoid and 2-4
results in additional features of the system, such as brake timing solenoid, line pressure duty solenoid,
large improved adaptability, easier addition of com- lock-up duty solenoid, transfer duty solenoid and
pensating element, etc. 2-4 brake duty solenoid (a total of eight solenoids).
The MFI system also has the following features:

B2M3876
쐌 French: 22771AA080
(Without printer)
B2M3877
EN(SOHC)-8
GENERAL DESCRIPTION
MEMO:
EN(SOHC)-9
Location S058507
1. ENGINE S058507A1301
쐌 MODULE
S2M2069A
S2M2070A
(1) Engine control module (ECM) (3) Test mode connector (4) Data link connector (for Subaru
(2) CHECK ENGINE malfunction Select Monitor and OBD-II gen-
indicator lamp (MIL) eral scan tool)
EN(SOHC)-10
B3M1575A S2M2104C
S2M2240A S2M2157D
EN(SOHC)-11
쐌 SENSOR
H2M3526A
(1) Atmospheric pressure sensor (3) Engine coolant temperature sen- (5) Knock sensor
(2) Intake air temperature and pressor (6) Camshaft position sensor
sure sensor (4) Throttle position sensor (7) Crankshaft position sensor
EN(SOHC)-12
B2M3713A B2M3714A
S2M1248B B2M2240A
B2M2241A B2M2242A
B2M0213J
EN(SOHC)-13
S2M2222A
(1) Front oxygen (A/F) sensor (3) Front catalytic converter

(2) Rear oxygen sensor (4) Rear catalytic converter
S2M0264A S2M0265A
OBD0524G OBD0525G
EN(SOHC)-14
S2M2069B
S2M2070B
(1) Fuel level sensor (2) Fuel sub level sensor
S2M2080A S2M0270B
EN(SOHC)-15
쐌 SOLENOID VALVE, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM

PARTS
H2M3526B
(1) Air assist injector solenoid valve (3) Purge control solenoid valve
(2) Idle air control solenoid valve (4) Ignition coil & ignitor ASSY
EN(SOHC)-16
B2M3715A H2M3259A
H2M3258B B2M3720A
EN(SOHC)-17
S2M2069C
S2M2070C
(1) Inhibitor switch (4) Fuel pump relay (7) Starter

(2) Fuel pump (5) Radiator main fan relay
(3) Main relay (6) Radiator sub fan relay
EN(SOHC)-18
B2M2246A S2M1184A
S2M0278A S2M0279A
B2M2247E
EN(SOHC)-19
2. TRANSMISSION S058507A1302
쐌 MODULE
S2M2069D
S2M2070D
(1) Transmission Control Module (2) AT diagnostic indicator light (for

(TCM) (for AT vehicles) AT vehicles)
EN(SOHC)-20
B3M1666G B3M1652B
S2M2104B
EN(SOHC)-21
쐌 SENSOR
B2M2258A B2M2259A
B2M2260A B2M2261A
OBD0653B
(1) Rear vehicle speed sensor (for AT vehicles)

(2) Front vehicle speed sensor (for MT vehicles)
(3) Front vehicle speed sensor (for AT vehicles)
(4) Torque converter turbine speed sensor
(5) ATF temperature sensor (for AT vehicles)
(6) Brake light switch
EN(SOHC)-22
쐌 SOLENOID VALVE AND SWITCH (AT VEHICLES)
B2M2246F B2M2263K
B2M2264F
(1) Inhibitor switch

(2) Shift solenoid valve 1
(4) Line pressure duty solenoid
(5) Lock-up duty solenoid
(6) Transfer duty solenoid
(7) 2-4 brake duty solenoid
(8) Low clutch timing solenoid valve
(9) 2-4 brake timing solenoid valve
쐌 SOLENOID VALVE AND SWITCH (MT VEHICLES)
B2M2265A
(1) Neutral position switch
EN(SOHC)-23
ENGINE CONTROL MODULE (ECM) I/O SIGNAL
5. Engine Control Module (ECM) I/O Signal S058526
B2M2267A
Con- Signal (V)

Termi-
Content nector Ignition SW ON Note
nal No. Engine ON (Idling)
No. (Engine OFF)
Crankshaft Signal (+) B135 2 0 −7 — +7 Sensor output waveform
position Signal (−) B135 9 0 0 —
sensor Shield B135 10 0 0 —
Camshaft Signal (+) B135 1 0 −7 — +7 Sensor output waveform
Fully closed: 0.2 — 1.0
Signal B136 17 —
Fully opened: 4.2 — 4.7
Throttle
Power sup-
position B136 15 5 5 —
ply
sensor
GND (sen-
B136 16 0 0 —
sor)
Signal B136 18 0 0 — 0.9 —
Rear oxy- Shield B136 24 0 0 —
gen sensor GND (sen-
B136 16 0 0 —
sor)
Front oxy-
Signal 1 B134 22 0 — 1.0 0 — 1.0 —
gen (A/F)
sensor
Signal 2 B134 23 0 — 1.0 0 — 1.0 —
heater
Rear oxygen sensor
B134 21 0 — 1.0 0 — 1.0 —
heater signal
Engine Signal B136 14 1.0 — 1.4 1.0 — 1.4 After warm-up the engine.
coolant
tempera- GND (sen-
B136 16 0 0 After warm-up the engine.
ture sensor sor)
“5” and “0” are repeatedly dis-
Vehicle speed signal B135 24 0 or 5 0 or 5
played when vehicle is driven.
Starter switch B135 28 0 0 Cranking: 8 — 14
EN(SOHC)-24
Con- Signal (V)

Termi-
No. (Engine OFF)
ON: 10 — 13 ON: 13 — 14
A/C switch B135 27 —
OFF: 0 OFF: 0
Ignition switch B135 7 10 — 13 13 — 14 —
On MT vehicle; Switch is ON
ON: 12±0.5
MT B135 26 when gear is in neutral posi-
Neutral OFF: 0
tion.
position
switch ON AT vehicle; Switch is ON
ON: 0
AT B135 26 when shift is in “N” or “P” posi-
OFF: 12±0.5
tion.
Test mode connector B135 20 5 5 When connected: 0
Knock sen- Signal B136 4 2.8 2.8 —
sor Shield B136 25 0 0 —
Back-up power supply B136 9 10 — 13 13 — 14 Ignition switch “OFF”: 10 — 13
Control unit power sup- B136 1 10 — 13 13 — 14 —
ply B136 2 10 — 13 13 — 14 —
Sensor power supply B136 15 5 5 —
Line end check 1 B135 14 0 0 —
Ignition #1, #2 B134 25 0 1 — 3.4 Waveform
control #3, #4 B134 26 0 1 — 3.4 Waveform
#1 B134 4 10 — 13 1 — 14 Waveform
Fuel injec- #2 B134 13 10 — 13 1 — 14 Waveform
tor #3 B134 14 10 — 13 1 — 14 Waveform
#4 B134 15 10 — 13 1 — 14 Waveform
Signal 1 B134 5 — 1 — 13 Waveform
Idle air Signal 2 B134 6 — 1 — 13 Waveform
control Signal 3 B134 19 — 1 — 13 Waveform
solenoid Signal 4 B134 20 — 1 — 13 Waveform
valve Power sup-
B136 2 10 — 13 13 — 14 —
ply
ON: 0.5, or less
Fuel pump relay control B134 29 0.5, or less —
OFF: 10 — 13
ON: 0.5, or less ON: 0.5, or less
A/C relay control B134 17 —
OFF: 10 — 13 OFF: 13 — 14
Radiator fan relay 1 ON: 0.5, or less ON: 0.5, or less
B134 3 —
control OFF: 10 — 13 OFF: 13 — 14
B134 12 With A/C vehicles only
control OFF: 10 — 13 OFF: 13 — 14
Malfunction indicator Light “ON”: 1, or less
B134 11 — —
lamp Light “OFF”: 10 — 14
Engine speed output B134 30 — 0 — 13, or more Waveform
Torque control 1 signal B135 16 5 5 —
Torque control 2 signal B135 17 5 5 —
Torque control cut sig-
B134 31 8 8 —
nal
Purge control solenoid ON: 1, or less ON: 1, or less
B134 2 —
valve OFF: 10 — 13 OFF: 13 — 14
Signal B136 29 3.9 — 4.1 2.0 — 2.3
Atmo-
Power sup-
spheric B136 15 5 5
ply —
pressure
sensor GND (sen-
B136 16 0 0
sor)
Fuel level sensor B136 27 0.12 — 4.75 0.12 — 4.75 —
EN(SOHC)-25
Con- Signal (V)

Termi-
No. (Engine OFF)
AT diagnosis input sig- Less than 1 ←→ More Less than 1 ←→ More
B135 4 Waveform
nal than 4 than 4
ON: 0 ON: 0
Small light switch B136 3 —
OFF: 10 — 13 OFF: 13 — 14
ON: 0 ON: 0
Blower fan switch B136 30 —
OFF: 10 — 13 OFF: 13 — 14
ON: 0 ON: 0
Rear defogger switch B135 21 —
OFF: 10 — 13 OFF: 13 — 14
Front oxygen (A/F) sen-
B136 19 2.8 — 3.2 2.8 — 3.2 —
sor signal 1
B136 6 2.4 — 2.7 2.4 — 2.7 —
sor signal 2
B136 7 0.2 — 4.9 0.2 — 4.9 —
sor signal 3
B136 20 0.2 — 4.9 0.2 — 4.9 —
sor signal 4
Pressure sensor B136 5 2.4 — 4.8 0.4 — 1.8 —
Intake air temperature
B136 13 2.3 — 2.5 1.4 — 1.6 —
sensor
SSM/GST communica- Less than 1 ←→ More Less than 1 ←→ More
B135 3 —
tion line than 4 than 4
GND (sensors) B136 16 0 0 —
GND (injectors) B134 7 0 0 —
GND (ignition system) B134 27 0 0 —
GND (power supply) B134 8 0 0 —
B136 21 0 0 —
GND (control systems)
B136 22 0 0 —
GND (oxygen sensor
B134 35 0 0 —
heater 1)
GND (oxygen sensor
B134 34 0 0 —
heater 2)
EN(SOHC)-26
ENGINE CONDITION DATA
6. Engine Condition Data S058530
A: ELECTRICAL SPECIFICATION
S058530A08
Content Specified data

1.6 — 2.9 (%): Idling
Engine load
6.4 — 12.8 (%): 2,500 rpm racing
Measuring condition:
쐌 After warm-up the engine.
쐌 Gear position is in “N” or “P” position.
쐌 A/C is turned OFF.
쐌 All accessory switches are turned OFF.
EN(SOHC)-27
TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL
7. Transmission Control Module (TCM) I/O Signal S058506
S2M2131
Check with ignition switch ON.

Connec- Terminal Resistance to
Content Measuring conditions Voltage (V)
tor No. No. body (ohms)
Back-up power supply B56 1 Ignition switch OFF 10 — 16 —
B54 23 Ignition switch ON (with
Ignition power supply 10 — 16 —
B54 24 engine OFF)
Select lever in “P” range Less than 1
“P” range Select lever in any other
B55 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
B55 14 —
switch than “N” range (except “P” More than 8
range)
Select lever in “R” range Less than 1
“R” range
B55 3 Select lever in any other —
switch More than 9.5
than “R” range
Inhibitor Select lever in “D” range Less than 1
switch “D” range
than “D” range
Select lever in “3” range Less than 1
“3” range
than “3” range
“2” range
than “2” range
“1” range
than “1” range
Brake pedal depressed. More than 10.5
Brake switch B55 12 —
Brake pedal released. Less than 1
ABS switch ON Less than 1
ABS signal B55 21 —
ABS switch OFF 6.5 — 15
EN(SOHC)-28

Hold switch ON Less than 1
Hold switch B55 16 —
Hold switch OFF More than 8
Power switch ON Less than 1
Power switch B55 23 —
Power switch OFF More than 10
Throttle fully opened. Less than 1
Kick-down switch B55 11 —
Throttle fully closed. More than 6.5
Light ON Less than 1
POWER indicator light B56 11 —
Light OFF More than 9
AT OIL TEMP indicator light B56 10 —
Throttle fully closed. 0.3 — 0.7
Throttle position sensor B54 3 —
Throttle fully open. 4.0 — 4.6
Throttle position sensor Ignition switch ON (With
B54 2 4.8 — 5.3 —
power supply engine OFF)
ATF temperature 20°C
1.6 — 2.0 2.1 — 2.9 k
(68°F)
ATF temperature sensor B54 11
0.4 — 0.9 275 — 375
(176°F)
Vehicle stopped. 0
Rear vehicle speed sensor B55 24 Vehicle speed at least 20 450 — 650
More than 1 (AC range)
km/h (12 MPH)
Vehicle speed at least 20
Front vehicle speed sensor B55 18 More than 1 (AC range) 450 — 650
km/h (12 MPH)
Engine idling after warm-up.
0
Torque converter turbine (D range)
B55 8 450 — 650
speed sensor Engine idling after warm-up.
(N range)
Vehicle speed at most 10 Less than 1←
Vehicle speed output signal B56 17 —
km/h (6 MPH) →More than 4
Ignition switch ON (with
More than 10.5
engine OFF)
Engine speed signal B55 17 —
8 — 11
engine ON)
When cruise control is set
Less than 1
(SET lamp ON)
Cruise set signal B55 22 —
When cruise control is not
More than 6.5
set (SET lamp OFF)
Torque control signal 1 B56 5 4 —
engine ON)
engine ON)
Torque control cut signal B55 10 Ignition switch ON 8 —
Intake manifold pressure sig-
B54 1 Engine idling after warm-up. 1.2 — 1.8 —
nal
1st or 4th gear More than 9
Shift solenoid 1 B54 22 10 — 16
2nd or 3rd gear Less than 1
1st or 2nd gear More than 9
3rd or 4th gear Less than 1
EN(SOHC)-29

engine OFF)
1.5 — 4.0
Throttle fully closed after
warm-up.
Line pressure duty solenoid B54 9 2.0 — 4.5
engine OFF)
Less than 0.5
Throttle fully open after
warm-up.
When lock up occurs. More than 8.5
Lock-up duty solenoid B54 7 10 — 17
When lock up is released. Less than 0.5
Fuse on FWD switch More than 8.5
Fuse removed from FWD
Transfer duty solenoid B54 6 switch (with throttle fully 10 — 17
Less than 0.5
open and with select lever
in 1st gear).
engine OFF)
1.5 — 4.0
warm-up.
2-4 brake duty solenoid B54 18 2.0 — 4.5
engine OFF)
Less than 0.5
warm-up.
1st gear Less than 1
2-4 brake timing solenoid B54 16 10 — 16
3rd gear More than 9
2nd gear Less than 1
Low clutch timing solenoid B54 15 10 — 16
4th gear More than 9
Sensor ground line 1 B54 20 — 0 Less than 1
B56 19
System ground line — 0 Less than 1
B54 20
Fuse removed. 6 — 9.1
FWD switch B55 20 —
Fuse installed. Less than 1
Fuse ON FWD switch Less than 1
FWD indicator light B56 2 Fuse removed from FWD —
More than 9
switch
Data link signal (Subaru 15 — —
B56 —
Select Monitor) 6 — —
EN(SOHC)-30
DATA LINK CONNECTOR
8. Data Link Connector S058505
A: NOTE S058505A15
1) This connector is used both for OBD-II general scan tools and the Subaru Select Monitor.
2) Terminal No. 4 to No. 6 of the data link connector is used for the Subaru Select Monitor signal.
CAUTION:
Do not connect any scan tools other than the OBD-II general scan tools and the Subaru Select
Monitor, because the circuit for the Subaru Select Monitor may be damaged.
H2M1280
Terminal No. Contents Terminal No. Contents

1 Power supply 9 Blank
2 Blank 10 K line of ISO 9141 CARB
3 Blank 11 Blank
Subaru Select Monitor signal (ECM to
4 12 Ground
Subaru Select Monitor)*
Subaru Select Monitor signal (Subaru Select
5 13 Ground
Monitor to ECM)*
6 Line end check signal 1 14 Blank
7 Blank 15 Blank
8 Blank 16 Blank
*: Circuit only for Subaru Select Monitor
EN(SOHC)-31
OBD-II GENERAL SCAN TOOL
9. OBD-II General Scan Tool S058527

3) Using the OBD-II general scan tool, call up
diagnostic trouble code(s) and freeze frame data.
A: OPERATION S058527A16 OBD-II general scan tool functions consist of:
1. HOW TO USE OBD-II GENERAL SCAN (1) MODE $01: Current powertrain diagnostic
data
TOOL S058527A1601
(2) MODE $02: Powertrain freeze frame data
1) Prepare a general scan tool (OBD-II general (3) MODE $03: Emission-related powertrain
scan tool) required by SAE J1978. diagnostic trouble codes
2) Connect the OBD-II general scan tool to the (4) MODE $04: Clear/Reset emission-related
data link connector (A) located in the lower portion diagnostic information
of the instrument panel (on the driver’s side). Read out data according to repair procedures. (For
detailed operation procedures, refer to the OBD-II
General Scan Tool Operation Manual.)
NOTE:
For details concerning diagnostic trouble codes,
refer to the List of Diagnostic Trouble Code (DTC).
<Ref. to EN(SOHC)-80, List of Diagnostic Trouble
Code (DTC).>
S2M2157B
2. MODE $01 (CURRENT POWERTRAIN DIAGNOSTIC DATA) S058527A1602
Refers to data denoting the current operating condition of analog input/output, digital input/output and/or
the powertrain system.
A list of the support data and PID (Parameter Identification) codes are shown in the following table.
PID Data Unit of measure
01 Number of emission-related powertrain trouble codes and MIL status ON/OFF
03 Fuel system control status —
04 Calculated engine load value %
05 Engine coolant temperature °C
06 Short term fuel trim %
07 Long term fuel trim %
0B Intake manifold absolute pressure kPa
0C Engine revolution rpm
0D Vehicle speed km/h
0E Ignition timing advance °
0F Intake air temperature °C
10 Air flow rate from pressure sensor g/sec
11 Throttle valve opening angle %
13 Check whether oxygen sensor is installed. —
Oxygen sensor output voltage and short term fuel trim associated with oxygen
15 V and %
sensor—bank 2
24 A/F sensor 1 output voltage and short term fuel trim associated with A/F sensor 1 V and %
1C On-board diagnosis system —
NOTE:
Refer to OBD-II general scan tool manufacturer’s instruction manual to access generic OBD-II PIDs (MODE
$01).
EN(SOHC)-32
3. MODE $02 (POWERTRAIN FREEZE FRAME DATA) S058527A1603
Refers to data denoting the operating condition when trouble is sensed by the on-board diagnosis system.
02 Trouble code that caused CARB required freeze frame data storage —
NOTE:
Refer to OBD-II general scan tool manufacturer’s instruction manual to access freeze frame data (MODE
$02).
4. MODE $03 (EMISSION-RELATED POWERTRAIN DIAGNOSTIC TROUBLE CODE) S058527A1604
Refer to Read Diagnostic Trouble Code for information about data denoting emission-related powertrain
diagnostic trouble codes. <Ref. to EN(SOHC)-41, Read Diagnostic Trouble Code.>
5. MODE $04 (CLEAR/RESET EMISSION-RELATED DIAGNOSTIC INFORMATION) S058527A1605
Refers to the mode used to clear or reset emission-related diagnostic information (OBD-II trouble diagnos-
tic information).
NOTE:
Refer to OBD-II general scan tool manufacturer’s instruction manual to clear or reset emission-related
diagnostic information (MODE $04).
EN(SOHC)-33

CAUTION:
A: OPERATION S058503A16 Select Monitor and OBD-II general scan tool.
1) Prepare Subaru Select Monitor kit. <Ref. to
EN(SOHC)-8, PREPARATION TOOL, General
Description.>
S2M0288A
6) Using Subaru Select Monitor, call up diagnostic

S2M0285
them.
2) Connect diagnosis cable to Subaru Select 2. READ DIAGNOSTIC TROUBLE CODE

Monitor. (DTC) FOR ENGINE. (NORMAL MODE)
S058503A1602
3) Insert cartridge into Subaru Select Monitor.
<Ref. to EN(SOHC)-8, PREPARATION TOOL, Refer to Read Diagnostic Trouble Code for infor-
General Description.> mation about how to indicate DTC. <Ref. to
EN(SOHC)-41, Read Diagnostic Trouble Code.>
(DTC) FOR ENGINE. (OBD MODE) S058503A1603
mation about how to indicate DTC. <Ref. to
EN(SOHC)-41, Read Diagnostic Trouble Code.>
S2M0286A
4) Connect Subaru Select Monitor to data link

connector.
(1) Data link connector (A) located in the lower
portion of the instrument panel (on the driver’s
side).
S2M2157B

nector.
EN(SOHC)-34
4. READ CURRENT DATA FOR ENGINE. (NORMAL MODE) S058503A1604
[YES] key.
4) On the ⰆEngine DiagnosisⰇ display screen, select the {Current Data Display & Save} and press the
[YES] key.
5) On the ⰆData Display MenuⰇ display screen, select the {Data Display} and press the [YES] key.
Contents Display Unit of measure
Battery voltage Battery Voltage V
Vehicle speed signal Vehicle Speed km/h or MPH
Engine speed signal Engine Speed rpm
Engine coolant temperature signal Coolant Temp. °C or °F
Ignition timing signal Ignition Timing deg
Throttle position signal Throttle Opening Angle %
Throttle position signal Throttle Sensor Voltage V
Injection pulse width Fuel Injection #1 Pulse ms
Idle air control signal ISC Valve Step STEP
Engine load data Engine Load %
Front oxygen (A/F) sensor output signal A/F Sensor #1 —
Rear oxygen sensor output signal Rear O2 Sensor V
Short term fuel trim A/F Correction #1 %
Knock sensor signal Knocking Correction deg
mmHg or kPa or inHg or
Atmospheric absolute pressure signal Atmosphere Pressure
psi
Intake manifold relative pressure signal Mani. Relative Pressure
psi
Intake manifold absolute pressure signal Mani. Absolute Pressure
psi
A/F correction (short term fuel trim) by rear oxygen sensor A/F Correction #3 %
Long term whole fuel trim A/F Learning #1 %
Front oxygen (A/F) sensor heater current Front O2 Heater #1 A
Rear oxygen sensor heater current Rear O2 Heater Current A
Canister purge control solenoid valve duty ratio CPC Valve Duty Ratio %
Fuel level signal Fuel Level V
Intake air temperature signal Intake Air Temp. °C or °F
Learned ignition timing Learned Ignition Timing deg
Ignition switch signal Ignition Switch ON or OFF
Test mode connector signal Test Mode Signal ON or OFF
Neutral position switch signal Neutral Position Switch ON or OFF
Air conditioning switch signal A/C Switch ON or OFF
Air conditioning signal A/C Compressor Signal ON or OFF
Radiator main fan relay signal Radiator Fan Relay #1 ON or OFF
Fuel pump relay signal Fuel Pump Relay ON or OFF
Knocking signal Knocking Signal ON or OFF
Radiator sub fan relay signal Radiator Fan Relay #2 ON or OFF
Power steering switch signal P/S Switch ON or OFF
Engine torque control signal #1 Torque Control Signal #1 ON or OFF
Engine torque control permission signal Torque Permission Signal ON or OFF
Rear oxygen sensor rich signal Rear O2 Rich Signal ON or OFF
EN(SOHC)-35

Starter switch signal Starter Switch Signal ON or OFF
Idle switch signal Idle Switch Signal ON or OFF
Crankshaft position sensor signal Crankshaft Position Sig. ON or OFF
Camshaft position sensor signal Camshaft Position Sig. ON or OFF
Rear defogger switch signal Rear Defogger Switch ON or OFF
Blower fan switch signal Blower Fan Switch ON or OFF
Small light switch signal Light Switch ON or OFF
Air assist injector solenoid valve signal Assist Air Sol. Valve ON or OFF
AT vehicle ID signal AT Vehicle ID Signal ON or OFF
NOTE:
EN(SOHC)-36
5. READ CURRENT DATA FOR ENGINE. (OBD MODE) S058503A1605
[YES] key.
4) On the ⰆEngine DiagnosisⰇ display screen, select the {OBD System} and press the [YES] key.
5) On the ⰆOBD MenuⰇ display screen, select the {Current Data Display & Save} and press the [YES]
key.
Number of diagnosis code Number of Diagnosis Code —
Malfunction indicator lamp status MI (MIL) Complete or incomplete
Monitoring test of misfire Misfire monitoring Complete or incomplete
Monitoring test of fuel system Fuel system monitoring Complete or incomplete
Monitoring test of comprehensive component Component monitoring Complete or incomplete
Test of catalyst Catalyst Diagnosis No support
Test of heated catalyst Heated catalyst No support
Test of evaporative emission purge control system Evaporative purge system No support
Test of secondary air system Secondary air system No support
Test of air conditioning system refrigerant A/C system refrigerant No support
Test of oxygen sensor Oxygen sensor Complete or incomplete
Test of oxygen sensor heater O2 Heater Diagnosis Complete or incomplete
Test of EGR system EGR system No support
Air fuel ratio control system for bank 1 Fuel System for Bank 1 —
Engine load data Calculated load value %
Short term fuel trim by front oxygen (A/F) sensor Short term fuel trim B1 %
Long term fuel trim by front oxygen (A/F) sensor Long term fuel trim B1 %
psi
Ignition timing advance for #1 cylinder Ignition timing adv. #1 °
Intake air amount Mass Air Flow g/s
A/F sensor equipment A/F sensor ON or OFF
Rear oxygen sensor output signal Oxygen Sensor #12 V
Air fuel ratio correction by rear oxygen sensor Short term fuel trim #12 %
On-board diagnostic system OBD System —
NOTE:
EN(SOHC)-37
6. READ FREEZE FRAME DATA FOR ENGINE. (OBD MODE) S058503A1606
[YES] key.
5) On the ⰆOBD MenuⰇ display screen, select the {Freeze Frame Data} and press the [YES] key.
Diagnostic trouble code (DTC) for freeze frame data Freeze frame data DTC
Air fuel ratio control system for bank 1 Fuel system for Bank1 ON or OFF
psi
NOTE:
7. READ OXYGEN SENSOR MONITORING TEST RESULTS DATA FOR ENGINE. (OBD
MODE) S058503A1607
[YES] key.
5) On the ⰆOBD MenuⰇ display screen, select the {O2 Sensor Monitor} and press the [YES] key.
6) On the ⰆO2 Sensor SelectⰇ display screen, select the {Bank 1-Sensor1} or {Bank 1-Sensor2} and press
the [YES] key.
쐌 Bank 1-Sensor1 indicates the front oxygen or A/F sensor, and Bank 1-Sensor2 indicates the rear oxy-
gen sensor.
Oxygen sensor for monitoring test <O2 Sensor Monitor (-------)> —
Rich to lean oxygen sensor threshold voltage Rich to lean sensor volt V
Lean to rich oxygen sensor threshold voltage Lean to rich sensor volt V
Low oxygen sensor voltage for switch time calculation Low sensor voltage V
High oxygen sensor voltage for switch time calculation High sensor voltage V
Rich to lean oxygen sensor switch time Rich to lean switch time sec
Lean to rich oxygen sensor switch time Lean to rich switch time sec
Maximum oxygen sensor voltage for test cycle Maximum sensor Voltage V
Minimum oxygen sensor voltage for test cycle Minimum sensor Voltage V
NOTE:
EN(SOHC)-38
8. LED OPERATION MODE FOR ENGINE S058503A1608
[YES] key.
[YES] key.
5) On the ⰆData Display MenuⰇ display screen, select the {Data & LED Display} and press the [YES] key.
Contents Display Message LED “ON” requirements
Ignition switch signal Ignition Switch ON or OFF When ignition switch is turned ON.
Test mode connector signal Test Mode Signal ON or OFF When test mode connector is connected.
Neutral position switch signal Neutral Position Switch ON or OFF When neutral position signal is entered.
Air conditioning switch signal A/C Switch ON or OFF When air conditioning switch is turned ON.
Air conditioning relay signal A/C Relay ON or OFF When air conditioning relay is in function.
Radiator main fan relay signal Radiator Fan Relay #1 ON or OFF When radiator main fan relay is in function.
Fuel pump relay signal Fuel Pump Relay ON or OFF When fuel pump relay is in function.
Knocking signal Knocking Signal ON or OFF When knocking signal is entered.
Radiator sub fan relay signal Radiator Fan Relay #2 ON or OFF When radiator sub fan relay is in function.
When engine torque control signal 1 is
entered.
entered.
Engine torque control permission When engine torque control permission sig-
Torque Control Permit ON or OFF
signal nal is entered.
Front oxygen (A/F) sensor rich When front oxygen (A/F) sensor mixture
Front O2 Rich Signal #1 ON or OFF
signal ratio is rich.
When rear oxygen sensor mixture ratio is
rich.
Starter switch signal Starter Switch Signal ON or OFF When starter switch signal is entered.
Idle switch signal Idle Switch Signal ON or OFF When idle switch signal is entered.
When crankshaft position sensor signal is
entered.
When camshaft position sensor signal is
entered.
NOTE:
EN(SOHC)-39
9. READ CURRENT DATA FOR AT. S058503A1609
2) On the ⰆSystem Selection MenuⰇ display screen, select the {Transmission Control System} and press
the [YES] key.
3) Press the [YES] key after displayed the information of transmission type.
4) On the ⰆTransmission DiagnosisⰇ display screen, select the {Current Data Display & Save} and press
the [YES] key.
Rear vehicle speed sensor signal Vehicle Speed #1 km/h or MPH
Front vehicle speed sensor signal Vehicle Speed #2 km/h or MPH
Automatic transmission fluid temperature signal ATF Temp. °C or °F
Gear position Gear Position —
Line pressure control duty ratio Line Pressure Duty Ratio %
Lock up clutch control duty ratio Lock Up Duty Ratio %
Transfer clutch control duty ratio Transfer Duty Ratio %
Power supply for throttle position sensor Throttle Sensor Power V
Torque converter turbine speed signal AT Turbine Speed rpm
2-4 brake timing pressure control duty ratio 2-4B Duty Ratio %
Intake manifold pressure sensor voltage Mani. Pressure Voltage V
2 wheel drive switch signal 2WD Switch ON or OFF
Kick down switch signal Kick Down Switch ON or OFF
Stop lamp switch signal Stop Lamp Switch ON or OFF
Anti lock brake system signal ABS Signal ON or OFF
Cruise control system signal Cruise Control Signal ON or OFF
Neutral/Parking range signal N/P Range Signal ON or OFF
Reverse range signal R Range Signal ON or OFF
Drive range signal D Range Signal ON or OFF
3rd range signal 3rd Range Signal ON or OFF
2nd range signal 2nd Range Signal ON or OFF
1st range signal 1st Range Signal ON or OFF
Shift control solenoid A Shift Solenoid #1 ON or OFF
Shift control solenoid B Shift Solenoid #2 ON or OFF
Torque control output signal #1 Torque Control Signal #1 ON or OFF
Torque control cut signal Torque Control Cut Sig. ON or OFF
2-4 brake timing control solenoid valve 2-4 Brake Timing Sol. ON or OFF
Low clutch timing control solenoid valve Low Clutch Timing Sol. ON or OFF
Automatic transmission diagnosis indicator lamp AT Diagnosis Lamp ON or OFF
NOTE:
EN(SOHC)-40
11. Read Diagnostic Trouble 3. OBD-II GENERAL SCAN TOOL S058508A1603
Code S058508
Refers to data denoting emission-related power-
train diagnostic trouble codes.
A: OPERATION S058508A16 For details concerning diagnostic trouble codes,
1. SUBARU SELECT MONITOR (NORMAL
<Ref. to EN(SOHC)-80, List of Diagnostic Trouble
MODE) S058508A1601 Code (DTC).>
1) On the ⰆMain MenuⰇ display screen, select NOTE:
the {Each System Check} and press the [YES] key. Refer to OBD-II general scan tool manufacturer’s
2) On the ⰆSystem Selection MenuⰇ display instruction manual to access emission-related
screen, select the {Engine Control System} and powertrain diagnostic trouble codes (MODE $03).
press the [YES] key.
select the {Diagnostic Code(s) Display} and press
the [YES] key.
key.
NOTE:
MANUAL.
codes, refer to the List of Diagnostic Trouble Code
(DTC). <Ref. to EN(SOHC)-80, List of Diagnostic
Trouble Code (DTC).>
2. SUBARU SELECT MONITOR (OBD
MODE) S058508A1602
the {2. Each System Check} and press the [YES]
key.
screen, select the {Engine Control System} and
select the {OBD System} and press the [YES] key.
5) On the ⰆOBD MenuⰇ display screen, select
the {Diagnosis Code(s) Display} and press the
[YES] key.
6) Make sure that a diagnostic trouble code (DTC)
is shown on the display screen.
NOTE:
MANUAL.
EN(SOHC)-41
INSPECTION MODE

A: OPERATION S058510A16 Description.>
1. PREPARATION FOR THE INSPECTION
MODE S058510A1601
Raise the vehicle using a garage jack and place on
safety stands or drive the vehicle onto free rollers.
WARNING:
쐌 Before raising the vehicle, ensure parking
brakes are applied.
쐌 Do not use a pantograph jack in place of a
safety stand.
쐌 Secure a rope or wire to the front and rear S2M0285
towing or tie-down hooks to prevent the lateral 2) Connect diagnosis cable to Subaru Select
runout of front wheels. Monitor.
쐌 Do not abruptly depress/release clutch pedal 3) Insert cartridge into Subaru Select Monitor.
or accelerator pedal during works even when <Ref. to EN(SOHC)-8, PREPARATION TOOL,
engine is operating at low speeds since this General Description.>
may cause vehicle to jump off free rollers.
쐌 In order to prevent the vehicle from slipping
due to vibration, do not place any wooden
blocks or similar items between the safety
stands and the vehicle.
쐌 Since the rear wheels will also rotate, do not
place anything near them. Also, make sure that
nobody goes in front of the vehicle.
S2M0286A
4) Connect test mode connector (A) at the lower

portion of instrument panel (on the driver’s side), to
the side of the center console box.
S2M2244A
B2M2969A
2. SUBARU SELECT MONITOR S058510A1602
After performing diagnostics and clearing the

memory, check for any remaining unresolved
trouble data.
EN(SOHC)-42
INSPECTION MODE
5) Connect Subaru Select Monitor to data link NOTE:

connector. 쐌 For detailed operation procedure, refer to the
(1) Connect Subaru Select Monitor to data link SUBARU SELECT MONITOR OPERATION
connector located in the lower portion of the MANUAL.
instrument panel (on the driver’s side). 쐌 For detailed concerning diagnostic trouble
쐌 Release the parking brake.
쐌 The speed difference between front and rear
wheels may light either the ABS warning light, but
this indicates no malfunctions. When engine con-
trol diagnosis is finished, perform the ABS memory
clearance procedure of self-diagnosis system.
3. OBD-II GENERAL SCAN TOOL S058510A1603
S2M2157
(2) Connect diagnosis cable to data link con- memory, check for any remaining unresolved
nector. trouble data:
CAUTION: 1) Connect test mode connector (A) at the lower
Do not connect scan tools except for Subaru side of the instrument panel (on the driver’s side),
Select Monitor and OBD-II general scan tool. to the side of the center console box.
S2M2244A
2) Connect the OBD-II general scan tool to its data

S2M0288A link connector (A) in the lower portion of the instru-
ment panel (on the driver’s side).
the {2. Each System Check} and press the [YES] CAUTION:
key. Do not connect the scan tools except for
8) On the ⰆSystem Selection MenuⰇ display Subaru Select Monitor and OBD-II general scan
screen, select the {Engine Control System} and tool.
select the {Dealer Check Mode Procedure} and
11) When the “Perform Inspection (Dealer Check)
Mode?” is shown on the display screen, press the
[YES] key.
12) Perform subsequent procedures as instructed
on the display screen. S2M2157B
쐌 If trouble still remains in the memory, the corre-

sponding diagnostic trouble code (DTC) appears
on the display screen.
EN(SOHC)-43
INSPECTION MODE

NOTE:
쐌 Ensure the selector lever is placed in the “P”
position before starting. (AT vehicles)
쐌 Depress clutch pedal when starting the engine.
(MT vehicles)
4) Using the selector lever or shift lever, turn the
“P” position switch and the “N” position switch to
ON.
5) Depress the brake pedal to turn the brake
switch ON. (AT vehicles)
6) Keep engine speed in the 2,500 — 3,000 rpm
range for 40 seconds.
NOTE:
On models without tachometer, use the tachom-
eter (Secondary pickup type).
7) Place the selector lever or shift lever in the “D”
position (AT vehicles) or “1st” gear (MT vehicles)
and drive the vehicle at 5 to 10 km/h (3 to 6 MPH).
NOTE:
쐌 On AWD vehicles, release the parking brake.
wheels may light the ABS warning light, but this
indicates no malfunctions. When engine control
diagnosis is finished, perform the ABS memory
8) Using the OBD-II general scan tool, check for
diagnostic trouble code(s) and record the result(s).
NOTE:
쐌 For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual.
EN(SOHC)-44
CLEAR MEMORY MODE

For clear memory procedures using the OBD-II

general scan tool, refer to the OBD-II General
1. SUBARU SELECT MONITOR (NORMAL Scan Tool Instruction Manual.
MODE) S058513A1601 After the memory has been cleared, the idle air
control solenoid valve must be initialized. To do
1) On the ⰆMain MenuⰇ display screen, select this, turn the ignition switch to the ON position.
the {2. Each System Check} and press the [YES] Wait 3 seconds before starting the engine.
key.
key.
Select Monitor and ignition switch to OFF.
NOTE:
쐌 After the memory has been cleared, the idle air
this, turn the ignition switch to the ON position.
Wait 3 seconds before starting the engine.
MANUAL.
MODE) S058513A1602
key.
the {4. Diagnosis Code(s) Cleared} and press the
[YES] key.
6) When the ‘Clear Diagnostic Code?’ is shown on
the display screen, press the [YES] key.
7) Turn Subaru Select Monitor and ignition switch
to OFF.
NOTE:
쐌 After the memory has been cleared, the idle air
this, turn the ignition switch to the ON position.
Wait 3 seconds before starting the engine.
MANUAL.
EN(SOHC)-45
COMPULSORY VALVE OPERATION CHECK MODE
14. Compulsory Valve 5) Connect Subaru Select Monitor to data link

connector.
Operation Check Mode S058528
(1) Connect Subaru Select Monitor to data link
connector located in the lower portion of the
instrument panel (on the driver’s side).
Description.>
S2M2157

nector.
S2M0285
CAUTION:
2) Connect diagnosis cable to Subaru Select Do not connect scan tools except for Subaru
Monitor. Select Monitor and OBD-II general scan tool.
3) Insert cartridge into Subaru Select Monitor. 6) Turn ignition switch to ON (engine OFF) and
<Ref. to EN(SOHC)-8, PREPARATION TOOL, Subaru Select Monitor switch to ON.
S2M0288A
S2M0286A
4) Connect test mode connector (A) at the lower the {2. Each System Check} and press the [YES]
portion of instrument panel (on the driver’s side), to key.
the side of the center console box. 8) On the ⰆSystem Selection MenuⰇ display
select the {System Operation Check Mode} and
11) On the ⰆSystem Operation Check ModeⰇ
display screen, select the {Actuator ON/OFF
Operation} and press the [YES] key.
12) Select the desired compulsory actuator on the
S2M2244A
ⰆActuator ON/OFF OperationⰇ display screen
13) Pressing the [NO] key completes the compul-
sory operation check mode. The display will then
return to the ⰆActuator ON/OFF OperationⰇ
screen.
EN(SOHC)-46

Contents Display
Compulsory fuel pump relay operation check Fuel Pump Relay
Compulsory radiator fan relay operation check Radiator Fan Relay
Compulsory air conditioning relay operation check A/C Compressor Relay
Compulsory purge control solenoid valve operation check CPC Solenoid Valve
Compulsory air assist injector solenoid valve operation check AAI Solenoid Valve
NOTE:
쐌 The following parts will be displayed but not functional because they are not installed on the vehicle.
Display
EGR Solenoid Valve
ASV Solenoid Valve
PCV Solenoid Valve
Vent Control Solenoid Valve
FICD Solenoid
Pressure Switching Sol. 1
Fuel Tank Sensor Control Valve
EN(SOHC)-47
ENGINE MALFUNCTION INDICATOR LAMP (MIL)
15. Engine Malfunction

Indicator Lamp (MIL) S058653
1. Activation of check engine malfunction indicator lamp (MIL). <Ref. to EN(SOHC)-49, ACTIVATION OF CHECK ENGINE
MALFUNCTION INDICATOR LAMP (MIL), Engine Malfunction Indicator Lamp (MIL).>
↓
2. Check engine malfunction indicator lamp (MIL) does not come on. <Ref. to EN(SOHC)-50, CHECK ENGINE MALFUNC-
TION INDICATOR LAMP (MIL) DOES NOT COME ON., Engine Malfunction Indicator Lamp (MIL).>
↓
3. Check engine malfunction indicator lamp (MIL) does not go off. <Ref. to EN(SOHC)-53, CHECK ENGINE MALFUNCTION
INDICATOR LAMP (MIL) DOES NOT GO OFF., Engine Malfunction Indicator Lamp (MIL).>
↓
4. Check engine malfunction indicator lamp (MIL) does not blink at a cycle of 3 Hz. <Ref. to EN(SOHC)-54, CHECK
ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT BLINK AT A CYCLE OF 3 HZ., Engine Malfunction Indicator
Lamp (MIL).>
↓
5. Check engine malfunction indicator lamp (MIL) remains blinking at a cycle of 3 Hz. <Ref. to EN(SOHC)-56, CHECK
ENGINE MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINKING AT A CYCLE OF 3 HZ., Engine Malfunction Indicator
Lamp (MIL).>
EN(SOHC)-48
B: ACTIVATION OF CHECK ENGINE 3) If the diagnosis system senses a misfire which

could damage the catalyzer, the MIL will blink at a
MALFUNCTION INDICATOR LAMP cycle of 1 Hz.
(MIL) S058653E89
1) When ignition switch is turned to ON (engine

off), the CHECK ENGINE malfunction indicator
lamp (MIL) in the combination meter illuminates.
NOTE:
If the MIL does not illuminate, perform diagnostics
of the CHECK ENGINE light circuit or the combi-
nation meter circuit. <Ref. to EN(SOHC)-50,
CHECK ENGINE MALFUNCTION INDICATOR
LAMP (MIL) DOES NOT COME ON., Engine Mal- OBD0054A
function Indicator Lamp (MIL).>
off) or to “START” with the test mode connector
connected, the MIL blinks at a cycle of 3 Hz.
S2M2104A
(A) Malfunction indicator lamp (MIL)

OBD0055A
2) After starting the engine, the MIL goes out. If it
does not, either the engine or the emission control
system is malfunctioning.
OBD0053A
EN(SOHC)-49
C: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT

COME ON. S058653E90
쐌 DIAGNOSIS:
쐌 The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted.
쐌 TROUBLE SYMPTOM:
쐌 When ignition switch is turned ON (engine OFF), MIL does not come on.
쐌 WIRING DIAGRAM:
S2M2071

1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage less than 1 Go to step 4. Go to step 2.
1) Turn ignition switch to ON. V?
2) Measure voltage between ECM connector
and chassis ground.
(−):
EN(SOHC)-50

2 CHECK POOR CONTACT. Does the MIL come on Repair poor con- Go to step 3.
when shaking or pulling tact in ECM con-
ECM connector and har- nector.
ness?
3 CHECK ECM CONNECTOR. Is ECM connector correctly Replace ECM. Repair connection
connected? <Ref. to of ECM connec-
FU(SOHC)-49, tor.
Engine Control
Module.>
4 CHECK HARNESS BETWEEN COMBINA- Is resistance less than 1 Go to step 5. Repair harness
TION METER AND ECM CONNECTOR. Ω? and connector.
1) Turn ignition switch to OFF. NOTE:
2) Remove combination meter. <Ref. to IDI- In this case,
15, Combination Meter Assembly.> repair the follow-
3) Disconnect connector from ECM and coming:
bination meter. 쐌 Open circuit in
4) Measure resistance of harness between harness between
ECM and combination meter connector. ECM and combi-
Connector & terminal nation meter con-
(B134) No. 11 — (i10) No. 9: nector
쐌 Poor contact in
coupling connec-
tor (i2)
Check poor contact in combination meter con- combination meter connec- tact in combina-
nector. tor? tion meter con-
nector.
6 CHECK HARNESS BETWEEN COMBINA- Is voltage more than 10 V? Go to step 7. Check the follow-
TION METER AND IGNITION SWITCH CON- ing and repair if
NECTOR. necessary.
1) Turn ignition switch to ON. NOTE:
2) Measure voltage between combination 쐌 Broken down
meter connector and chassis ground. ignition relay.
Connector & terminal 쐌 Blown out fuse
(i10) No. 2 (+) — Chassis ground (−): (No. 5).
쐌 If replaced fuse
(No. 5) blows
easily, check the
harness for short
circuit of harness
between fuse (No.
5) and ignition
relay connector.
쐌 Open or short
circuit in harness
between fuse (No.
5) and battery ter-
minal
쐌 Open circuit in
harness between
fuse (No. 5) and
ignition relay con-
nector
쐌 Poor contact in
ignition relay con-
nector
쐌 Poor contact in
ignition switch
connector
EN(SOHC)-51

7 CHECK LAMP BULB. Is lamp bulb condition OK? Repair combina- Replace lamp
Remove engine malfunction indicator lamp tion meter con- bulb.
bulb. nector.
EN(SOHC)-52
D: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT GO

OFF. S058653E91
쐌 DIAGNOSIS:
쐌 The CHECK ENGINE malfunction indicator lamp (MIL) circuit is shorted.
쐌 Although MIL comes on when engine runs, trouble code is not shown on Subaru select monitor or
OBD-II general scan tool display.
쐌 WIRING DIAGRAM:
S2M2071

1 CHECK HARNESS BETWEEN COMBINA- Does the MIL come on? Repair short cir- Replace ECM.
TION METER AND ECM CONNECTOR. cuit in harness <Ref. to
1) Turn ignition switch to OFF. between combina- FU(SOHC)-49,
2) Disconnect connector from ECM. tion meter and Engine Control
3) Turn ignition switch to ON. ECM connector. Module.>
EN(SOHC)-53
E: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT

BLINK AT A CYCLE OF 3 Hz. S058653E92
쐌 DIAGNOSIS:
쐌 Test mode connector circuit is in open.
쐌 When inspection mode, MIL does not blink at a cycle of 3 Hz.
쐌 WIRING DIAGRAM:
S2M2072
EN(SOHC)-54

1 CHECK STATUS OF CHECK ENGINE MAL- Does the MIL come on? Go to step 2. Repair the MIL
FUNCTION INDICATOR LAMP (MIL). circuit. <Ref. to
1) Turn ignition switch to OFF. EN(SOHC)-50,
2) Disconnect test mode connector. CHECK ENGINE
3) Turn ignition switch to ON. (engine OFF) MALFUNCTION
INDICATOR
LAMP (MIL)
DOES NOT
COME ON.,
Engine Malfunc-
tion Indicator
Lamp (MIL).>
2 CHECK HARNESS BETWEEN COMBINA- Does the MIL come on? Repair ground Go to step 3.
TION METER AND ECM CONNECTOR. short circuit in
1) Turn ignition switch to OFF. harness between
2) Disconnect connector from ECM. combination meter
3) Turn ignition switch to ON. and ECM connec-
tor.
3 CHECK HARNESS BETWEEN TEST MODE Is resistance less than 1 Go to step 4. Repair harness
CONNECTOR AND CHASSIS GROUND. Ω? and connector.
2) Disconnect connector from ECM. In this case,
3) Measure resistance of harness between repair the follow-
test mode connector and chassis ground. ing:
Connector & terminal 쐌 Open circuit in
(B76) No. 1 — Chassis ground: harness between
test mode con-
nector and chas-
sis ground
Check poor contact in ECM connector. ECM connector? tact in ECM con-
nector.
5 CHECK HARNESS BETWEEN ECM AND Is resistance less than 1 Go to step 6. Repair open cir-
TEST MODE CONNECTOR. Ω? cuit in harness
1) Connect test mode connector. between ECM
2) Measure resistance of harness between and test mode
ECM and chassis ground. connector.
6 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace ECM.
Check poor contact in ECM connector. ECM connector? tact in ECM con- <Ref. to
nector. FU(SOHC)-49,
Engine Control
Module.>
EN(SOHC)-55
F: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) REMAINS

BLINKING AT A CYCLE OF 3 Hz. S058653E93
쐌 DIAGNOSIS:
쐌 Test mode connector circuit is shorted.
쐌 MIL blinks at a cycle of 3 Hz when ignition switch is turned to ON.
쐌 WIRING DIAGRAM:
S2M2072

1 CHECK TEST MODE CONNECTOR. Does MIL flash on and off? Go to step 2. System is in good
1) Disconnect test mode connector. order.
MIL blinks at a
cycle of 3 Hz
when test mode
connector is con-
nected.
EN(SOHC)-56

2 CHECK HARNESS BETWEEN ECM CON- Is resistance less than 5 Repair short cir- Replace ECM.
NECTOR AND ENGINE GROUNDING TER- Ω? cuit in harness <Ref. to
MINAL. between ECM FU(SOHC)-49,
1) Turn ignition switch to OFF. and test mode Engine Control
2) Disconnect connector from ECM. connector. Module.>
ECM connector and chassis ground.
EN(SOHC)-57
MEMO:
EN(SOHC)-58
DIAGNOSTICS FOR ENGINE STARTING FAILURE
16. Diagnostics for Engine Starting Failure S058533
1. Inspection of starter motor circuit. <Ref. to EN(SOHC)-60, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting
Failure.>
↓
2. Inspection of ECM power supply and ground line. <Ref. to EN(SOHC)-64, CONTROL MODULE POWER SUPPLY AND
GROUND LINE, Diagnostics for Engine Starting Failure.>
↓
3. Inspection of ignition control system. <Ref. to EN(SOHC)-68, IGNITION CONTROL SYSTEM, Diagnostics for Engine
Starting Failure.>
↓
4. Inspection of fuel pump circuit. <Ref. to EN(SOHC)-72, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.>
↓
5. Inspection of fuel injector circuit. <Ref. to EN(SOHC)-76, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting Fail-
ure.>
EN(SOHC)-59
B: STARTER MOTOR CIRCUIT S058533E94
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN(SOHC)-45,
Clear Memory Mode.> and INSPECTION MODE <Ref. to EN(SOHC)-42, Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2073
EN(SOHC)-60

1 CHECK OPERATION OF STARTER MOTOR. Does starter motor operate Go to step 2. Go to step 3.
when the switch starts?
2 CHECK DTC. Is the trouble code stored Record DTC. Go to step 3.
<Ref. to EN(SOHC)-41, OPERATION, Read in memory? <Ref. to Repair the trouble
Diagnostic Trouble Code.> EN(SOHC)-80, LIST, List of case. <Ref. to
Diagnostic Trouble Code EN(SOHC)-86,
(DTC).> Engine Control
Module (ECM) I/O
Signal.>
3 CHECK INPUT SIGNAL FOR STARTER Is the voltage more than 10 Go to step 4. Go to step 5.
MOTOR. V?
2) Disconnect connector from starter motor.
3) Turn ignition switch to ST.
4) Measure power supply voltage between
starter motor connector terminal and engine
ground.
NOTE:
On AT vehicles, place the selector lever in the
“P” or “N” position.
4 CHECK GROUND CIRCUIT OF STARTER Is resistance less than 5 Check starter Repair open cir-
MOTOR. Ω? motor. <Ref. to cuit of ground
1) Turn ignition switch to OFF. SC-5, Starter.> cable.
2) Disconnect terminal from starter motor.
3) Measure resistance of ground cable
between ground cable terminal and engine
ground.
5 CHECK HARNESS BETWEEN ECM AND Is resistance less than 1 Repair ground Go to step 6.
STARTER MOTOR CIRCUIT. Ω? short circuit.
2) Measure resistance between starter motor
and ECM.
(B14) No. 1 — Engine ground:
6 CHECK HARNESS BETWEEN ECM AND Is resistance less than 1 Go to step 7. Repair ground
1) Turn ignition switch to START.
2) Measure resistance of fuse.
7 CHECK HARNESS BETWEEN BATTERY Is the voltage more than 10 Go to step 8. Repair open cir-
AND IGNITION SWITCH CONNECTOR. V? cuit in harness
1) Ignition switch to OFF. between ignition
2) Disconnect connector from ignition switch. switch and bat-
3) Measure power supply voltage between tery.
ignition switch connector and chassis ground.
8 CHECK HARNESS BETWEEN BATTERY Is the voltage more than 10 Go to step 9. Replace ignition
AND IGNITION SWITCH CONNECTOR. V? switch.
1) Connect connector to ignition switch.
3) Measure voltage between ignition switch
and chassis ground.
EN(SOHC)-61

9 CHECK TRANSMISSION TYPE. Is the vehicle AT? Go to step 10. Repair open cir-
cuit between igni-
tion switch and
starter motor cir-
cuit.
10 CHECK INHIBITOR SWITCH CIRCUIT. Is the resistance less than Repair open cir- Go to step 11.
1) Turn ignition switch to OFF. 1 Ω? cuit in harness
2) Place the selector lever in the “P” or “N” between starter
position. motor and ignition
3) Separate transmission harness connector. switch connector.
harness connector receptacle’s terminals.
(T3) No. 11 — No. 12:
11 CHECK TRANSMISSION HARNESS. Is the resistance less than Go to step 12. Repair open cir-
1) Disconnect connector from inhibitor switch. 1 Ω? cuit in harness
2) Measure resistance of harness between between transmis-
transmission harness and inhibitor switch con- sion harness and
nector. inhibitor switch
Connector & terminal connector.
(T3) No. 11 — (T7) No. 7:
12 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace inhibitor
Check poor contact in inhibitor switch connec- inhibitor switch connector? tact in inhibitor switch.
tor. switch connector.
EN(SOHC)-62
MEMO:
EN(SOHC)-63
C: CONTROL MODULE POWER SUPPLY AND GROUND LINE S058533E37
CAUTION:
Clear Memory Mode.> and INSPECTION MODE. <Ref. to EN(SOHC)-42, Inspection Mode.>
쐌 WIRING DIAGRAM:
S2M2074

1 CHECK MAIN RELAY. Is the resistance less than Go to step 2. Replace main
1) Turn the ignition switch to OFF. 10 Ω? relay.
2) Remove main relay.
3) Connect battery to main relay terminals No.
1 and No. 2.
4) Measure resistance between main relay
terminals.
Terminals
No. 3 — No. 5:
No. 4 — No. 6:
EN(SOHC)-64

2 CHECK GROUND CIRCUIT OF ECM. Is the resistance less than Go to step 3. Repair open cir-
1) Disconnect connector from ECM. 5 Ω? cuit in harness
2) Measure resistance of harness between between ECM
ECM and chassis ground. connector and
Connector & terminal engine grounding
(B136) No. 21 — Chassis ground: terminal.
3 CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 10 Go to step 4. Repair open or
Measure voltage between ECM connector V? ground short cir-
and chassis ground. cuit of power sup-
Connector & terminal ply circuit.
1) Turn ignition switch to ON. V? ground short cir-
2) Measure voltage between ECM connector cuit of power sup-
and chassis ground. ply circuit.
5 CHECK HARNESS BETWEEN ECM AND Is the resistance more than Go to step 6. Repair ground
MAIN RELAY CONNECTOR. 1 MΩ? short circuit in
2) Measure resistance between ECM and ECM connector
chassis ground. and main relay
Connector & terminal connector, then
(B135) No. 19 — Chassis ground: replace ECM.
6 CHECK OUTPUT VOLTAGE FROM ECM. Is the voltage more than 10 Go to step 7. Replace ECM.
1) Connect connector to ECM. V?
and chassis ground.
(–):
7 CHECK INPUT VOLTAGE OF MAIN RELAY. Is the voltage more than 10 Go to step 8. Repair open cir-
Check voltage between main relay connector V? cuit in harness
and chassis ground. between ECM
Connector & terminal connector and
(B47) No. 2 (+) — Chassis ground (–): main relay con-
nector.
8 CHECK GROUND CIRCUIT OF MAIN Is the resistance less than Go to step 9. Repair open cir-
RELAY. 5 Ω? cuit between main
1) Turn ignition switch to OFF. relay and chassis
2) Measure resistance between main relay ground.
9 CHECK INPUT VOLTAGE OF MAIN RELAY. Is the voltage more than 10 Go to step 10. Repair open or
Measure voltage between main relay connec- V? ground short cir-
tor and chassis ground. cuit in harness of
Connector & terminal power supply cir-
(B47) No. 5 (+) — Chassis ground (−): cuit.
EN(SOHC)-65

10 CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 10 Check ignition Repair open or
1) Connect main relay connector. V? control system. ground short cir-
2) Turn ignition switch to ON. <Ref. to cuit in harness
3) Measure voltage between ECM connector EN(SOHC)-68, between ECM
and chassis ground. IGNITION CON- connector and
Connector & terminal TROL SYSTEM, main relay con-
(B136) No. 1 (+) — Chassis ground (–): Diagnostics for nector.
(B136) No. 2 (+) — Chassis ground (–): Engine Starting
Failure.>
EN(SOHC)-66
MEMO:
EN(SOHC)-67
D: IGNITION CONTROL SYSTEM S058533E95
CAUTION:
쐌 WIRING DIAGRAM:
B2M4187
EN(SOHC)-68

1 CHECK IGNITION SYSTEM FOR SPARKS. Does spark occur at each Check fuel pump Go to step 2.
1) Remove plug cord cap from each spark cylinder? system. <Ref. to
plug. EN(SOHC)-72,
2) Install new spark plug on plug cord cap. FUEL PUMP
CAUTION: CIRCUIT, Diag-
Do not remove spark plug from engine. nostics for Engine
3) Contact spark plug’s thread portion on Starting Failure.>
engine.
4) While opening throttle valve fully, crank
engine to check that spark occurs at each
cylinder.
2 CHECK POWER SUPPLY CIRCUIT FOR Is the voltage more than 10 Go to step 3. Repair harness
IGNITION COIL & IGNITOR ASSEMBLY. V? and connector.
2) Disconnect connector from ignition coil & In this case,
ignitor assembly. repair the follow-
3) Turn ignition switch to ON. ing:
4) Measure power supply voltage between 쐌 Open circuit in
ignition coil & ignitor assembly connector and harness between
engine ground. ignition coil & igni-
Connector & terminal tor assembly, and
(E12) No. 2 (+) — Engine ground (−): ignition switch
connector
쐌 Poor contact in
coupling connec-
tors (B22)
3 CHECK HARNESS OF IGNITION COIL & Is the resistance between Go to step 4. Repair harness
IGNITOR ASSEMBLY GROUND CIRCUIT. less than 5 Ω? and connector.
2) Measure resistance between ignition coil & In this case,
ignitor assembly connector and engine repair the follow-
ground. ing:
(E12) No. 3 — Engine ground: harness between
ignition coil & igni-
tor assembly con-
nector and engine
grounding termi-
nal
4 CHECK IGNITION COIL & IGNITOR ASSEM- Is the resistance between Go to step 5. Replace ignition
BLY. 10 and 15 kΩ? coil & ignitor
1) Remove spark plug cords. assembly. <Ref.
2) Measure resistance between spark plug to IG(SOHC)-8,
cord contact portions to check secondary coil. Ignition Coil and
Terminals Ignitor Assembly.>
No. 1 — No. 2:
BLY. 10 and 15 kΩ? coil & ignitor
Measure resistance between spark plug cord assembly. <Ref.
contact portions to check secondary coil. to IG(SOHC)-8,
Terminals Ignition Coil and
No. 3 — No. 4: Ignitor Assembly.>
EN(SOHC)-69

6 CHECK INPUT SIGNAL FOR IGNITION Is the voltage more than 10 Go to step 7. Replace ignition
COIL & IGNITOR ASSEMBLY. V? coil & ignitor
1) Connect connector to ignition coil & ignitor assembly. <Ref.
assembly. to IG(SOHC)-8,
2) Check if voltage varies synchronously with Ignition Coil and
engine speed when cranking, while monitoring Ignitor Assembly.>
voltage between ignition coil & ignitor assem-
bly connector and engine ground.
(E12) No. 1 (+) — Engine ground (–):
Check if voltage varies synchronously with assembly. <Ref.
engine speed when cranking, while monitoring to IG(SOHC)-8,
voltage between ignition coil & ignitor assem- Ignition Coil and
bly connector and engine ground. Ignitor Assembly.>
8 CHECK HARNESS BETWEEN ECM AND Is the resistance less than Go to step 9. Repair harness
IGNITION COIL & IGNITOR ASSEMBLY 1 Ω? and connector.
CONNECTOR. NOTE:
1) Turn ignition switch to OFF. In this case,
2) Disconnect connector from ECM. repair the follow-
3) Disconnect connector from ignition coil & ing:
ignitor assembly. 쐌 Open circuit in
ECM and ignition coil & ignitor assembly con- ECM and ignition
nector. coil & ignitor
Connector & terminal assembly connec-
(B134) No. 25 — (E12) No. 1: tor
쐌 Poor contact in
coupling connec-
tor (B22)
CONNECTOR. NOTE:
Measure resistance of harness between ECM In this case,
and ignition coil & ignitor assembly connector. repair the follow-
Connector & terminal ing:
(B134) No. 26 — (E12) No. 4: 쐌 Open circuit in
harness between
ECM and ignition
coil & ignitor
assembly connec-
tor
쐌 Poor contact in
coupling connec-
tor (B22)
IGNITION COIL & IGNITOR ASSEMBLY 1 MΩ? short circuit in
CONNECTOR. harness between
Measure resistance of harness between ECM ECM and ignition
and engine ground. coil & ignitor
Connector & terminal: assembly connec-
(B134) No. 25 — Engine ground: tor.
EN(SOHC)-70

12 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Check fuel pump
Check poor contact in ECM connector. ECM connector? tact in ECM con- circuit. <Ref. to
nector. EN(SOHC)-72,
FUEL PUMP
CIRCUIT, Diag-
nostics for Engine
Starting Failure.>
EN(SOHC)-71
E: FUEL PUMP CIRCUIT S058533E96
CAUTION:
쐌 WIRING DIAGRAM:
S2M2075
EN(SOHC)-72

1 CHECK OPERATING SOUND OF FUEL Does fuel pump produce Check fuel injec- Go to step 2.
PUMP. operating sound? tor circuit. <Ref. to
Make sure that fuel pump is in operation for EN(SOHC)-76,
two seconds when turning ignition switch to FUEL INJECTOR
ON. CIRCUIT, Diag-
NOTE: nostics for Engine
Fuel pump operation can also be executed Starting Failure.>
using Subaru Select Monitor (Function mode:
FD01).
For the procedure, refer to “Compulsory Valve
Operation Check Mode”. <Ref. to EN(SOHC)-
46, Compulsory Valve Operation Check
Mode.>
2 CHECK GROUND CIRCUIT OF FUEL PUMP. Is the resistance less than Go to step 3. Repair harness
1) Turn ignition switch to OFF. 5 Ω? and connector.
2) Remove fuel pump access hole lid located NOTE:
on the right rear of trunk compartment floor In this case,
(Sedan) or luggage compartment floor repair the follow-
(Wagon). ing:
3) Disconnect connector from fuel pump. 쐌 Open circuit in
4) Measure resistance of harness connector harness between
between fuel pump and chassis ground. fuel pump con-
Connector & terminal nector and chas-
(R58) No. 4 — Chassis ground: sis grounding ter-
minal
쐌 Poor contact in
coupling connec-
tor (R15)
3 CHECK POWER SUPPLY TO FUEL PUMP. Is the voltage more than 10 Replace fuel Go to step 4.
1) Turn ignition switch to ON. V? pump. <Ref. to
2) Measure voltage of power supply circuit FU(SOHC)-62,
between fuel pump connector and chassis Fuel Pump.>
ground.
(R58) No. 1 (+) — Chassis ground (−):
4 CHECK HARNESS BETWEEN FUEL PUMP Is the resistance less than Go to step 5. Repair harness
AND FUEL PUMP RELAY CONNECTOR. 1 Ω? and connector.
2) Measure resistance of harness connector In this case,
between fuel pump and fuel pump relay. repair the follow-
(R58) No. 1 — (B46) No. 4: 쐌 Open circuit in
harness between
fuel pump con-
nector and chas-
sis grounding ter-
minal
쐌 Poor contact in
coupling connec-
tors
R15 and B97
5 CHECK HARNESS BETWEEN FUEL PUMP Is the resistance more than Go to step 6. Repair short cir-
AND FUEL PUMP RELAY CONNECTOR. 1 MΩ? cuit in harness
Measure resistance of harness between fuel between fuel
pump and fuel pump relay connector. pump and fuel
Connector & terminal pump relay con-
(R58) No. 1 — Chassis ground: nector.
EN(SOHC)-73

6 CHECK FUEL PUMP RELAY. Is the resistance less than Go to step 7. Replace fuel
1) Disconnect connectors from fuel pump 10 Ω? pump relay. <Ref.
relay and main relay. to FU(SOHC)-51,
2) Remove fuel pump relay and main relay Fuel Pump
with bracket. Relay.>
3) Connect battery to fuel pump relay connec-
tor terminals No. 1 and No. 3.
terminals of fuel pump relay.
Terminals
No. 2 — No. 4:
7 CHECK HARNESS BETWEEN ECM AND Is the resistance less than Go to step 8. Repair open cir-
FUEL PUMP RELAY CONNECTOR. 1 Ω? cuit in harness
1) Disconnect connectors from ECM. between ECM
2) Measure resistance of harness between and fuel pump
ECM and fuel pump relay connector. relay connector.
(B134) No. 29 — (B46) No. 3:
8 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Check fuel injec-
Check poor contact in ECM connector. ECM connector? tact in ECM con- tor circuit. <Ref. to
nector. EN(SOHC)-76,
FUEL INJECTOR
CIRCUIT, Diag-
nostics for Engine
Starting Failure.>
EN(SOHC)-74
MEMO:
EN(SOHC)-75
F: FUEL INJECTOR CIRCUIT S058533E97
CAUTION:
쐌 Check or repair only faulty parts.
쐌 After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN(SOHC)-
45, Clear Memory Mode.> and INSPECTION MODE. <Ref. to EN(SOHC)-42, Inspection Mode.>
쐌 WIRING DIAGRAM:
S2M2076

1 CHECK OPERATION OF EACH FUEL Is the fuel injector emits Check fuel pres- Go to step 2.
INJECTOR. “operating” sound? sure. <Ref. to
While cranking the engine, check that each ME(SOHC)-28,
fuel injector emits “operating” sound. Use a INSPECTION,
sound scope or attach a screwdriver to injec- Fuel Pressure.>
tor for this check.
EN(SOHC)-76

2 CHECK POWER SUPPLY TO EACH FUEL Is the voltage more than 10 Go to step 3. Repair harness
INJECTOR. V? and connector.
2) Disconnect connector from #1 cylinder fuel In this case,
injector. repair the follow-
4) Measure power supply voltage between the 쐌 Open circuit in
fuel injector terminal and engine ground. harness between
Connector & terminal main relay and
#1 (E5) No. 2 (+) — Engine ground (–): fuel injector con-
#2 (E16) No. 2 (+) — Engine ground nector
(−): 쐌 Poor contact in
#3 (E6) No. 2 (+) — Engine ground (–): main relay con-
(–): 쐌 Poor contact in
coupling connec-
tor (B22)
쐌 Poor contact in
fuel injector con-
nector
3 CHECK HARNESS BETWEEN ECM AND Is the resistance between 5 Go to step 4. Repair harness
FUEL INJECTOR CONNECTOR. and 20 Ω? and connector.
1) Disconnect connector from ECM. NOTE:
2) Measure resistance of harness between In this case,
ECM and fuel injector connector. repair the follow-
(B134) No. 4 — (B136) No. 2: 쐌 Open circuit in
harness between
ECM and fuel
injector connector
쐌 Poor contact in
coupling connec-
tor (B22)
4 CHECK HARNESS BETWEEN ECM AND Is the resistance less than Repair ground Go to step 5.
FUEL INJECTOR CONNECTOR. 1 Ω? short circuit in
Measure resistance of harness between ECM harness between
and fuel injector connector. ECM and fuel
Connector & terminal injector connector.
Measure resistance of harness between ECM NOTE:
and fuel injector connector. In this case,
Connector & terminal repair the follow-
(B134) No. 13 — (B136) No. 2: ing:
쐌 Open circuit in
harness between
ECM and fuel
injector connector
쐌 Poor contact in
coupling connec-
tor (B22)
EN(SOHC)-77

(B134) No. 14 — (B136) No. 2: ing:
쐌 Open circuit in
harness between
ECM and fuel
injector connector
쐌 Poor contact in
coupling connec-
tor (B22)
(B134) No. 15 — (B136) No. 2: ing:
쐌 Open circuit in
harness between
ECM and fuel
injector connector
쐌 Poor contact in
coupling connec-
tor (B22)
11 CHECK EACH FUEL INJECTOR. Is the resistance between 5 Go to step 12. Replace faulty
1) Turn ignition switch to OFF. and 20 Ω? fuel injector.
2) Measure resistance between each fuel
injector terminals.
Terminals
No. 1 — No. 2:
12 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Inspection using
Check poor contact in ECM connector. ECM connector? tact in ECM con- “General Diagnos-
nector. tic Table”. <Ref. to
EN(SOHC)-294,
INSPECTION,
Genera Diagnos-
tic Table.>
EN(SOHC)-78
MEMO:
EN(SOHC)-79
LIST OF DIAGNOSTIC TROUBLE CODE (DTC)
17. List of Diagnostic Trouble

Code (DTC) S058525
A: LIST S058525A12
DTC
Item Index
No.
P0031 Front oxygen (A/F) sensor heater <Ref. to EN(SOHC)-86, DTC P0031 — FRONT OXYGEN (A/F) SENSOR
circuit low input HEATER CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic
P0032 Front oxygen (A/F) sensor heater <Ref. to EN(SOHC)-90, DTC P0032 — FRONT OXYGEN (A/F) SENSOR
circuit high input HEATER CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic
P0037 Rear oxygen sensor heater circuit <Ref. to EN(SOHC)-92, DTC P0037 — REAR OXYGEN SENSOR
malfunction HEATER CIRCUIT MALFUNCTION —, Diagnostic Procedure with Diag-
nostic Trouble Code (DTC).>
P0038 Rear oxygen sensor heater circuit <Ref. to EN(SOHC)-96, DTC P0038 — REAR OXYGEN SENSOR
high input HEATER CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic
P0066 Air assist injector solenoid valve cir- <Ref. to EN(SOHC)-98, DTC P0066 — AIR ASSIST INJECTOR SOLE-
cuit low input NOID VALVE CIRCUIT LOW INPUT —, Diagnostic Procedure with Diag-
P0067 Air assist injector solenoid valve cir- <Ref. to EN(SOHC)-100, DTC P0067 — AIR ASSIST INJECTOR SOLE-
cuit high input NOID VALVE CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diag-
P0106 Pressure sensor circuit range/ <Ref. to EN(SOHC)-102, DTC P0106 — PRESSURE SENSOR CIRCUIT
performance problem (low input) RANGE/PERFORMANCE PROBLEM (LOW INPUT) —, Diagnostic Proce-
dure with Diagnostic Trouble Code (DTC).>
P0107 Pressure sensor circuit low input <Ref. to EN(SOHC)-106, DTC P0107 — PRESSURE SENSOR CIRCUIT
LOW INPUT —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0108 Pressure sensor circuit high input <Ref. to EN(SOHC)-110, DTC P0108 — PRESSURE SENSOR CIRCUIT
HIGH INPUT —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0111 Intake air temperature sensor circuit <Ref. to EN(SOHC)-114, DTC P0111 — INTAKE AIR TEMPERATURE
range/performance problem SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM —, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
low input SENSOR CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic
high input SENSOR CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic
P0117 Engine coolant temperature sensor <Ref. to EN(SOHC)-122, DTC P0117 — ENGINE COOLANT TEMPERA-
circuit low input TURE SENSOR CIRCUIT LOW INPUT —, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>
P0118 Engine coolant temperature sensor <Ref. to EN(SOHC)-124, DTC P0118 — ENGINE COOLANT TEMPERA-
circuit high input TURE SENSOR CIRCUIT HIGH INPUT —, Diagnostic Procedure with
P0121 Throttle position sensor circuit <Ref. to EN(SOHC)-128, DTC P0121 — THROTTLE POSITION SENSOR
range/performance problem (high CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT) —, Diag-
input) nostic Procedure with Diagnostic Trouble Code (DTC).>
P0122 Throttle position sensor circuit low <Ref. to EN(SOHC)-130, DTC P0122 — THROTTLE POSITION SENSOR
input CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0123 Throttle position sensor circuit high <Ref. to EN(SOHC)-134, DTC P0123 — THROTTLE POSITION SENSOR
input CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
EN(SOHC)-80
DTC
Item Index
No.
P0125 Insufficient coolant temperature for<Ref. to EN(SOHC)-136, DTC P0125 — INSUFFICIENT COOLANT TEM-
closed loop fuel control PERATURE FOR CLOSED LOOP FUEL CONTROL -, Diagnostic Proce-
P0130 Front oxygen (A/F) sensor circuit <Ref. to EN(SOHC)-138, DTC P0130 — FRONT OXYGEN (A/F) SENSOR
range/performance problem (Lean) CIRCUIT RANGE/PERFORMANCE PROBLEM (LEAN) —, Diagnostic Pro-
cedure with Diagnostic Trouble Code (DTC).>
malfunction (open circuit) CIRCUIT MALFUNCTION (OPEN CIRCUIT) —, Diagnostic Procedure with
malfunction (short circuit) CIRCUIT MALFUNCTION (SHORT CIRCUIT) —, Diagnostic Procedure
with Diagnostic Trouble Code (DTC).>
slow response CIRCUIT SLOW RESPONSE —, Diagnostic Procedure with Diagnostic
P0136 Rear oxygen sensor circuit malfunc- <Ref. to EN(SOHC)-148, DTC P0136 — REAR OXYGEN SENSOR CIR-
tion CUIT MALFUNCTION —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0139 Rear oxygen sensor circuit slow <Ref. to EN(SOHC)-152, DTC P0139 — REAR OXYGEN SENSOR CIR-
response CUIT SLOW RESPONSE —, Diagnostic Procedure with Diagnostic
P0170 Fuel trim malfunction <Ref. to EN(SOHC)-154, DTC P0170 — FUEL TRIM MALFUNCTION —,
Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0301 Cylinder 1 misfire detected <Ref. to EN(SOHC)-156, DTC P0301 — CYLINDER 1 MISFIRE
DETECTED —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
(DTC).>
(DTC).>
(DTC).>
P0327 Knock sensor circuit low input <Ref. to EN(SOHC)-166, DTC P0327 — KNOCK SENSOR CIRCUIT LOW
INPUT —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0328 Knock sensor circuit high input <Ref. to EN(SOHC)-168, DTC P0328 — KNOCK SENSOR CIRCUIT
(DTC).>
P0335 Crankshaft position sensor circuit <Ref. to EN(SOHC)-170, DTC P0335 — CRANKSHAFT POSITION SEN-
malfunction SOR CIRCUIT MALFUNCTION —, Diagnostic Procedure with Diagnostic
P0336 Crankshaft position sensor circuit <Ref. to EN(SOHC)-172, DTC P0336 — CRANKSHAFT POSITION SEN-
range/performance problem SOR CIRCUIT RANGE/PERFORMANCE PROBLEM —, Diagnostic Proce-
P0340 Camshaft position sensor circuit <Ref. to EN(SOHC)-174, DTC P0340 — CAMSHAFT POSITION SENSOR
malfunction CIRCUIT MALFUNCTION —, Diagnostic Procedure with Diagnostic
P0341 Camshaft position sensor circuit <Ref. to EN(SOHC)-176, DTC P0341 — CAMSHAFT POSITION SENSOR
range/performance problem CIRCUIT RANGE/PERFORMANCE PROBLEM —, Diagnostic Procedure
P0420 Catalyst system efficiency below <Ref. to EN(SOHC)-180, DTC P0420 — CATALYST SYSTEM EFFI-
threshold CIENCY BELOW THRESHOLD —, Diagnostic Procedure with Diagnostic
EN(SOHC)-81
DTC
Item Index
No.
P0444 Evaporative emission control system <Ref. to EN(SOHC)-182, DTC P0444 — EVAPORATIVE EMISSION CON-
purge control valve circuit low input TROL SYSTEM PURGE CONTROL VALVE CIRCUIT LOW INPUT —,
P0445 Evaporative emission control system <Ref. to EN(SOHC)-186, DTC P0445 — EVAPORATIVE EMISSION CON-
purge control valve circuit high input TROL SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH INPUT —,
P0461 Fuel level sensor circuit range/ <Ref. to EN(SOHC)-188, DTC P0461 — FUEL LEVEL SENSOR CIRCUIT
performance problem RANGE/PERFORMANCE PROBLEM —, Diagnostic Procedure with Diag-
P0462 Fuel level sensor circuit low input <Ref. to EN(SOHC)-190, DTC P0462 — FUEL LEVEL SENSOR CIRCUIT
(DTC).>
P0463 Fuel level sensor circuit high input <Ref. to EN(SOHC)-194, DTC P0463 — FUEL LEVEL SENSOR CIRCUIT
(DTC).>
P0464 Fuel level sensor intermittent input <Ref. to EN(SOHC)-198, DTC P0464 — FUEL LEVEL SENSOR INTER-
MITTENT INPUT —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0480 Cooling fan relay 1 circuit low input <Ref. to EN(SOHC)-200, DTC P0480 — COOLING FAN RELAY 1 CIR-
CUIT LOW INPUT —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0483 Cooling fan function problem <Ref. to EN(SOHC)-204, DTC P0483 — COOLING FAN FUNCTION
PROBLEM —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0500 Vehicle speed sensor malfunction <Ref. to EN(SOHC)-208, DTC P0500 — VEHICLE SPEED SENSOR MAL-
FUNCTION —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0506 Idle control system RPM lower than <Ref. to EN(SOHC)-210, DTC P0506 — IDLE CONTROL SYSTEM RPM
expected LOWER THAN EXPECTED —, Diagnostic Procedure with Diagnostic
P0507 Idle control system RPM higher than <Ref. to EN(SOHC)-212, DTC P0507 — IDLE CONTROL SYSTEM RPM
expected HIGHER THAN EXPECTED —, Diagnostic Procedure with Diagnostic
P0512 Starter switch circuit high input <Ref. to EN(SOHC)-214, DTC P0512 — STARTER SWITCH CIRCUIT
(DTC).>
P0513 Incorrect immobilizer key <Ref. to IM-34, DTC P0153 — INCORRECT IMMOBILIZER KEY (USE OF
UNREGISTERED KEY) —, Diagnostics Chart with Trouble Code.>
P0562 Charge system cricuit low input <Ref. to EN(SOHC)-216, DTC P0562 — CHARGE SYSTEM CIRCUIT
(DTC).>
P0563 Charge system cricuit high input <Ref. to EN(SOHC)-218, DTC P0563 — CHARGE SYSTEM CIRCUIT
(DTC).>
P0604 Internal control module memory <Ref. to EN(SOHC)-220, DTC P0604 — INTERNAL CONTROL MODULE
check sum error MEMORY CHECK SUM ERROR —, Diagnostic Procedure with Diagnostic
P0703 Brake switch input malfunction <Ref. to EN(SOHC)-222, DTC P0703 — BRAKE SWITCH INPUT MAL-
FUNCTION —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0705 Transmission range sensor circuit <Ref. to AT-122, CHECK INHIBITOR SWITCH., Diagnostic Procedure for
malfunction No-trouble Code.>
P0710 Transmission fluid temperature sen- <Ref. to AT-46, TROUBLE CODE 27 — ATF TEMPERATURE SENSOR
sor circuit malfunction —, Diagnostic Procedure with Trouble Code.>
P0715 Torque converter turbine speed sen- <Ref. to AT-64, TROUBLE CODE 36 — TORQUE CONVERTER TURBINE
sor circuit malfunction SPEED SENSOR —, Diagnostic Procedure with Trouble Code.>
EN(SOHC)-82
DTC
Item Index
No.
P0720 Output speed sensor (Front vehicle <Ref. to AT-58, TROUBLE CODE 33 — FRONT VEHICLE SPEED SEN-
speed sensor) circuit malfunction SOR —, Diagnostic Procedure with Trouble Code.>
P0725 Engine speed input circuit malfunc- <Ref. to AT-42, TROUBLE CODE 11 — ENGINE SPEED SIGNAL —,
tion Diagnostic Procedure with Trouble Code.>
P0731 Gear 1 incorrect ratio <Ref. to EN(SOHC)-224, DTC P0731 — GEAR 1 INCORRECT RATIO —,
P0741 Torque converter clutch system mal- <Ref. to EN(SOHC)-226, DTC P0741 — TORQUE CONVERTER CLUTCH
function SYSTEM MALFUNCTION —, Diagnostic Procedure with Diagnostic
P0743 Torque converter clutch system <Ref. to AT-96, TROUBLE CODE 77 — LOCK-UP DUTY SOLENOID —,
(Lock-up duty solenoid) electrical Diagnostic Procedure with Trouble Code.>
P0748 Pressure control solenoid (Line <Ref. to AT-88, TROUBLE CODE 75 — LINE PRESSURE DUTY SOLE-
pressure duty solenoid) electrical NOID —, Diagnostic Procedure with Trouble Code.>
P0753 Shift solenoid A (Shift solenoid 1) <Ref. to AT-72, TROUBLE CODE 71 — SHIFT SOLENOID 1 —, Diagnos-
electrical tic Procedure with Trouble Code.>
P0758 Shift solenoid B (Shift solenoid 2) <Ref. to AT-76, TROUBLE CODE 72 — SHIFT SOLENOID 2 —, Diagnos-
P0778 2-4 brake pressure control solenoid <Ref. to AT-92, TROUBLE CODE 76 — 2-4 BRAKE DUTY SOLENOID —,
valve circuit malfunction Diagnostic Procedure with Trouble Code.>
P0785 2-4 brake timing control solenoid <Ref. to AT-84, TROUBLE CODE 74 — 2-4 BRAKE TIMING SOLENOID
valve circuit malfunction —, Diagnostic Procedure with Trouble Code.>
P1110 Atmospheric pressure sensor low <Ref. to EN(SOHC)-228, DTC P1110 — ATMOSPHERIC PRESSURE
input SENSOR CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic
P1111 Atmospheric pressure sensor high <Ref. to EN(SOHC)-232, DTC P1111 — ATMOSPHERIC PRESSURE
input SENSOR CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic
P1112 Atmospheric pressure sensor range/ <Ref. to EN(SOHC)-236, DTC P1112 — ATMOSPHERIC PRESSURE
performance problem SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM —, Diagnostic
range/perfomance problem CIRCUIT RANGE/PERFORMANCE PROBLEM —, Diagnostic Procedure
P1142 Throttle position sensor circuit <Ref. to EN(SOHC)-242, DTC P1142 — THROTTLE POSITION SENSOR
range/performance problem (low CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT) —, Diag-
input) nostic Procedure with Diagnostic Trouble Code (DTC).>
P1146 Pressure sensor circuit range/ <Ref. to EN(SOHC)-244, DTC P1146 — PRESSURE SENSOR CIRCUIT
performance problem (high input) RANGE/PERFORMANCE PROBLEM (HIGH INPUT) —, Diagnostic Proce-
dure with Diagnostic Trouble Code (DTC) for.>
P1442 Fuel level sensor circuit range/ <Ref. to EN(SOHC)-248, DTC P1442 — FUEL LEVEL SENSOR CIRCUIT
performance problem 2 RANGE/PERFORMANCE PROBLEM 2 —, Diagnostic Procedure with
P1480 Cooling fan relay 1 circuit high input <Ref. to EN(SOHC)-250, DTC P1480 — COOLING FAN RELAY 1 CIR-
CUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P1507 Idle control system malfunction (fail- <Ref. to EN(SOHC)-254, DTC P1507 — IDLE CONTROL SYSTEM MAL-
safe) FUNCTION (FAIL-SAFE) —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
EN(SOHC)-83
DTC
Item Index
No.
P1510 Idle air control solenoid valve signal <Ref. to EN(SOHC)-256, DTC P1510 — IDLE AIR CONTROL SOLENOID
1 circuit low input VALVE SIGNAL 1 CIRCUIT LOW INPUT —, Diagnostic Procedure with
1 circuit high input VALVE SIGNAL 1 CIRCUIT HIGH INPUT —, Diagnostic Procedure with
P1518 Starter switch circuit low input <Ref. to EN(SOHC)-264, DTC P1518 — STARTER SWITCH CIRCUIT
(DTC).>
P1540 Vehicle speed sensor malfunction 2 <Ref. to EN(SOHC)-266, DTC P1540 — VEHICLE SPEED SENSOR MAL-
FUNCTION 2 —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P1560 Back-up voltage circuit malfunction <Ref. to EN(SOHC)-268, DTC P1560 — BACK-UP VOLTAGE CIRCUIT
MALFUNCTION —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P1570 Antennna <Ref. to IM-35, DTC P1570 — ANTENNA —, Diagnostics Chart with
Trouble Code.>
P1571 Reference code incompatibility <Ref. to IM-26, DTC P1571 — REFERENCE CODE INCOMPATIBILITY
—, Diagnostics Chart with Trouble Code.>
P1572 IMM circuit failure except antenna <Ref. to IM-27, DTC P1572 — IMM CIRCUIT FAILURE (EXCEPT
circuit ANTENNA CIRCUIT) —, Diagnostics Chart with Trouble Code.>
P1574 Key communication failure <Ref. to IM-33, DTC P1574 — KEY COMMUNICATION FAILURE —,
Diagnostics Chart with Trouble Code.>
P1576 EGI control module EEPROM <Ref. to IM-34, DTC P1576 — EGI CONTROL MODULE EEPROM —,
P1577 IMM control module EEPROM <Ref. to IM-34, DTC P1577 — IMM CONTROL MODULE EEPROM —,
P1590 Neutral position switch circuit high <Ref. to EN(SOHC)-270, DTC P1590 — NEUTRAL POSITION SWITCH
input (AT model) CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P1591 Neutral position switch circuit low <Ref. to EN(SOHC)-274, DTC P1591 — NEUTRAL POSITION SWITCH
input (AT model) CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P1592 Neutral position switch circuit (MT <Ref. to EN(SOHC)-276, DTC P1592 — NEUTRAL POSITION SWITCH
model) CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
EN(SOHC)-84
DTC
Item Index
No.
P1594 Automatic transmission diagnosis <Ref. to EN(SOHC)-278, DTC P1594 — AUTOMATIC TRANSMISSION
input signal circuit malfunction DIAGNOSIS INPUT SIGNAL CIRCUIT MALFUNCTION —, Diagnostic Pro-
input signal circuit low input DIAGNOSIS INPUT SIGNAL CIRCUIT LOW INPUT —, Diagnostic Proce-
input signal circuit high input DIAGNOSIS INPUT SIGNAL CIRCUIT HIGH INPUT —, Diagnostic Proce-
P1698 Engine torque control cut signal cir- <Ref. to EN(SOHC)-284, DTC P1698 — ENGINE TORQUE CONTROL
cuit low input CUT SIGNAL CIRCUIT LOW INPUT —, Diagnostic Procedure with Diag-
P1699 Engine torque control cut signal cir- <Ref. to EN(SOHC)-286, DTC P1699 — ENGINE TORQUE CONTROL
cuit high input CUT SIGNAL CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diag-
P1700 Throttle position sensor circuit mal- <Ref. to AT-50, TROUBLE CODE 31 — THROTTLE POSITION SENSOR
function for automatic transmission —, Diagnostic Procedure with Trouble Code.>
P1701 Cruise control set signal circuit mal- <Ref. to EN(SOHC)-288, DTC P1701 — CRUISE CONTROL SET SIGNAL
function for automatic transmission CIRCUIT MALFUNCTION FOR AUTOMATIC TRANSMISSION —, Diag-
nostic Procedure with Diagnostic Trouble Code (DTC).>
P1703 Low clutch timing control solenoid <Ref. to AT-80, TROUBLE CODE 73 — LOW CLUTCH TIMING SOLE-
valve circuit malfunction NOID —, Diagnostic Procedure with Trouble Code.>
P1711 Engine torque control signal 1 circuit <Ref. to EN(SOHC)-290, DTC P1711 — ENGINE TORQUE CONTROL
malfunction SIGNAL 1 CIRCUIT MALFUNCTION —, Diagnostic Procedure with Diag-
P1712 Engine torque control signal 2 circuit <Ref. to EN(SOHC)-292, DTC P1712 — ENGINE TORQUE CONTROL
malfunction SIGNAL 2 CIRCUIT MALFUNCTION —, Diagnostic Procedure with Diag-
EN(SOHC)-85
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
18. Diagnostic Procedure with Diagnostic Trouble Code (DTC) S058521
A: DTC P0031 — FRONT OXYGEN (A/F) SENSOR HEATER CIRCUIT LOW

INPUT — S058521F83
쐌 DTC DETECTING CONDITION:

쐌 Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(SOHC)-45,
OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)-42, OPERATION,
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2077
EN(SOHC)-86

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Go to step 2. Go to step 5.
Monitor or OBD-II general
scan tool indicate DTC
P0031 and P0037 at the
same time?
2 CHECK POWER SUPPLY TO FRONT OXY- Is the voltage more than 10 Go to step 3. Repair power sup-
GEN (A/F) SENSOR. V? ply line.
2) Disconnect connector from front oxygen In this case,
(A/F) sensor. repair the follow-
4) Measure voltage between front oxygen 쐌 Open circuit in
(A/F) sensor connector and engine ground. harness between
(E24) No. 2 (+) — Engine ground (−): front oxygen (A/F)
sensor connector
쐌 Poor contact in
front oxygen (A/F)
sensor connector
쐌 Poor contact in
main relay con-
nector
3 CHECK GROUND CIRCUIT OF ECM. Is the resistance less than Go to step 4. Repair harness
Measure resistance of harness between ECM 5 Ω? and connector.
connector and chassis ground. NOTE:
Connector & terminal In this case,
(B134) No. 35 — Chassis ground: repair the follow-
(B134) No. 34 — Chassis ground: ing:
쐌 Open circuit in
harness between
ECM and engine
ground terminal
쐌 Poor contact in
ECM connector
Poor contact in
coupling connec-
tor (B22)
4 CHECK CURRENT DATA. Is the value more than 0.2 Repair poor con- Go to step 5.
1) Start engine A? tact in connector.
2) Read data of front oxygen (A/F) sensor NOTE:
heater current using Subaru Select Monitor or In this case,
OBD-II general scan tool. repair the follow-
NOTE: ing:
쐌 Subaru Select Monitor 쐌 Poor contact in
For detailed operation procedure, refer to the front oxygen (A/F)
“READ CURRENT DATA FOR ENGINE”. sensor connector
<Ref. to EN(SOHC)-34, Subaru Select Moni- 쐌 Poor contact in
tor.> ECM connector
쐌 OBD-II scan tool
For detailed operation procedures, refer to the
5 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage less than 1.0 Go to step 7. Go to step 6.
1) Start and idle the engine. V?
and chassis ground.
(−):
EN(SOHC)-87

6 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change Repair poor con- Go to step 7.
Measure voltage between ECM connector less than 1.0 V by shaking tact in ECM con-
and chassis ground. harness and connector of nector.
Connector & terminal ECM while monitoring the
(B134) No. 22 (+) — Chassis ground value with voltage meter?
(−):
Measure voltage between ECM connector V?
and chassis ground.
(−):
(−):
9 CHECK FRONT OXYGEN (A/F) SENSOR. Is the resistance less than Repair harness Replace front oxy-
1) Turn ignition switch to OFF. 10 Ω? and connector. gen (A/F) sensor.
2) Measure resistance between front oxygen NOTE: <Ref. to
(A/F) sensor connector terminals. In this case, FU(SOHC)-45,
Terminals repair the follow- Front Oxygen
No. 2 — No. 5: ing: (A/F) Sensor.>
쐌 Open or ground
short circuit in
harness between
front oxygen (A/F)
sensor and ECM
connector
쐌 Poor contact in
front oxygen (A/F)
sensor connector
쐌 Poor contact in
ECM connector
EN(SOHC)-88
MEMO:
EN(SOHC)-89
B: DTC P0032 — FRONT OXYGEN (A/F) SENSOR HEATER CIRCUIT HIGH

INPUT — S058521F84

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2077
EN(SOHC)-90

1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 8 Go to step 3. Go to step 2.
and chassis ground.
(−):
and chassis ground.
(−):
3 CHECK FRONT OXYGEN (A/F) SENSOR Is the value more than 2.3 Replace ECM. END
HEATER CURRENT. A? <Ref. to
1) Turn ignition switch to OFF. FU(SOHC)-49,
2) Repair battery short circuit in harness Engine Control
between ECM and front oxygen (A/F) sensor Module.>
connector.
4) Read data of front oxygen (A/F) sensor
heater current using Subaru Select Monitor or
the OBD-II general scan tool.
NOTE:
쐌 Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE”.
<Ref. to EN(SOHC)-34, Subaru Select Moni-
tor.>
쐌 OBD-II general scan tool
4 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change Repair battery Go to step 5.
Measure voltage between ECM connector more than 8 V by shaking short circuit in
and chassis ground. harness and connector of harness between
Connector & terminal ECM while monitoring the ECM and front
(B134) No. 23 (+) — Chassis ground value with voltage meter? oxygen (A/F) sen-
(−): sor connector.
5 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change Repair battery END
(B134) No. 22 (+) — Chassis ground value with voltage meter? oxygen (A/F) sen-
EN(SOHC)-91
C: DTC P0037 — REAR OXYGEN SENSOR HEATER CIRCUIT MALFUNCTION

— S058521F85

쐌 Two consecutive driving cycles with fault
CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2078
EN(SOHC)-92

1 CHECK GROUND CIRCUIT OF ECM. Is the resistance less than Go to step 3. Go to step 2.
1) Turn ignition switch to OFF. 5 Ω?
2) Disconnect connector from ECM.
1) Repair harness and connector. 5 Ω? and connector.
NOTE: NOTE:
In this case, repair the following: In this case,
쐌 Open circuit in harness between ECM and repair the follow-
engine ground terminal ing:
쐌 Poor contact in ECM connector 쐌 Open circuit in
쐌 Poor contact in coupling connector (B22) harness between
2) Measure resistance of harness between ECM and engine
ECM connector and chassis ground. ground terminal
Connector & terminal 쐌 Poor contact in
(B134) No. 34 — Chassis ground: ECM connector
쐌 Poor contact in
coupling connec-
tor (B22)
3 CHECK CURRENT DATA. Is the value more than 0.2 Repair connector. Go to step 4.
1) Start engine. A? NOTE:
2) Read data of rear oxygen sensor heater In this case,
current using Subaru Select Monitor or OBD-II repair the follow-
general scan tool. ing:
NOTE: 쐌 Poor contact in
쐌 Subaru Select Monitor rear oxygen sen-
For detailed operation procedure, refer to the sor connector
“READ CURRENT DATA FOR ENGINE”. 쐌 Poor contact in
<Ref. to EN(SOHC)-34, Subaru Select Moni- rear oxygen sen-
tor.> sor connecting
쐌 OBD-II scan tool harness connector
For detailed operation procedures, refer to the 쐌 Poor contact in
OBD-II General Scan Tool Instruction Manual. ECM connector
and chassis ground.
(−):
(−):
6 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage less than 1.0 Replace ECM. Repair battery
1) Disconnect connector from rear oxygen V? <Ref. to short circuit in
sensor. FU(SOHC)-49, harness between
2) Measure voltage between ECM connector Engine Control ECM and rear
and chassis ground. Module.> oxygen sensor
Connector & terminal connector. After
(B134) No. 21 (+) — Chassis ground repair, replace
(−): ECM. <Ref. to
FU(SOHC)-49,
Engine Control
Module.>
EN(SOHC)-93

7 CHECK POWER SUPPLY TO REAR OXY- Is the voltage more than 10 Go to step 8. Repair power sup-
GEN SENSOR. V? ply line.
2) Disconnect connector from rear oxygen In this case,
sensor. repair the follow-
4) Measure voltage between rear oxygen sen- 쐌 Open circuit in
sor connector and engine ground or chassis harness between
ground. main relay and
Connector & terminal rear oxygen sen-
(E25) No. 2 (+) — Chassis ground (−): sor connector
쐌 Poor contact in
rear oxygen sen-
sor connector
쐌 Poor contact in
coupling connec-
tor (E1)
8 CHECK REAR OXYGEN SENSOR. Is the resistance less than Repair harness Replace rear oxy-
1) Turn ignition switch to OFF. 30 Ω? and connector. gen sensor. <Ref.
2) Measure resistance between rear oxygen NOTE: to FU(SOHC)-47,
sensor connector terminals. In this case, Rear Oxygen
Terminals repair the follow- Sensor.>
No. 1 — No. 2: ing:
쐌 Open circuit in
harness between
rear oxygen sen-
sor and ECM con-
nector
쐌 Poor contact in
rear oxygen sen-
sor connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (E1)
EN(SOHC)-94
MEMO:
EN(SOHC)-95
D: DTC P0038 — REAR OXYGEN SENSOR HEATER CIRCUIT HIGH INPUT —

S058521F86

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2078

1 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 8 Go to step 2. Go to step 3.
and chassis ground.
(−):
EN(SOHC)-96

2 CHECK CURRENT DATA. Is the value more than 7 Replace ECM. END
1) Turn ignition switch to OFF. A? <Ref. to
2) Repair battery short circuit in harness FU(SOHC)-49,
between ECM and rear oxygen sensor con- Engine Control
nector. Module.>
4) Read data of rear oxygen sensor heater
current using Subaru Select Monitor or the
OBD-II general scan tool.
NOTE:
tor.>
3 CHECK POOR CONTACT. Is there poor contact in Repair poor con- END
nector.
EN(SOHC)-97
E: DTC P0066 — AIR ASSIST INJECTOR SOLENOID VALVE CIRCUIT LOW

INPUT — S058521F88

쐌 Erroneous idling
쐌 Engine stalls.
CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2079
EN(SOHC)-98

1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 10 Repair poor con- Go to step 2.
1) Turn ignition switch to ON. V? tact in ECM con-
2) Measure voltage between ECM and chas- nector.
sis ground.
(−):
2 CHECK POWER SUPPLY TO AIR ASSIST Is the voltage more than 10 Go to step 3. Repair harness
INJECTOR SOLENOID VALVE. V? and connector.
2) Disconnect connector from air assist injec- In this case,
tor solenoid valve. repair the follow-
4) Measure voltage between air assist injector 쐌 Open circuit in
solenoid valve and engine ground. harness between
Connector & terminal air assist injector
(E42) No. 2 (+) — Engine ground (−): solenoid valve
and main relay
connector
쐌 Poor contact in
coupling connec-
tor (B22)
AIR ASSIST INJECTOR SOLENOID VALVE 1 Ω? and connector.
CONNECTOR. NOTE:
3) Measure resistance of harness between ing:
ECM and air assist injector solenoid valve 쐌 Open circuit in
connector. harness between
Connector & terminal ECM and air
(B134) No. 24 — (E42) No. 1: assist injector
solenoid valve
connector
쐌 Poor contact in
coupling connec-
tor (B22)
AIR ASSIST INJECTOR SOLENOID VALVE 10 Ω? short circuit in
Measure resistance of harness between ECM ECM and air
and chassis ground. assist injector
Connector & terminal solenoid valve
(B134) No. 24 — Chassis ground: connector.
5 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace air assist
Check poor contact in ECM and air assist ECM and air assist injector tact in ECM and injector solenoid
injector solenoid valve connectors. solenoid valve connectors? air assist injector valve. <Ref. to
solenoid valve FU(SOHC)-39, Air
connectors. Assist Injector
Solenoid Valve.>
EN(SOHC)-99
F: DTC P0067 — AIR ASSIST INJECTOR SOLENOID VALVE CIRCUIT HIGH

INPUT — S058521G72

쐌 Engine stalls.
CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2079
EN(SOHC)-100

2) Measure voltage between ECM and chas-
sis ground.
(−):
2 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 10 Repair battery Replace air assist
1) Turn ignition switch to OFF. V? short circuit in injector solenoid
2) Disconnect connector from air assist injec- harness between valve <Ref. to
tor solenoid valve. ECM and air FU(SOHC)-39, Air
3) Turn ignition switch to ON. assist injector Assist Injector
4) Measure voltage between ECM and chas- solenoid valve Solenoid Valve.>
sis ground. connector. After and ECM <Ref. to
Connector & terminal repair, replace FU(SOHC)-49,
(B134) No. 24 (+) — Chassis ground ECM. <Ref. to Engine Control
(−): FU(SOHC)-49, Module.>
Engine Control
Module.>
3 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change Repair battery Contact your
Measure voltage between ECM and chassis more than 10 V by shaking short circuit in Subaru distributor.
ground. harness and connector of harness between NOTE:
Connector & terminal ECM while monitoring the ECM and air Inspection by
(B134) No. 24 (+) — Chassis ground value with voltage meter? assist injector DTM is required,
(−): solenoid valve because probable
connector. After cause is deterio-
repair, replace ration of multiple
ECM. <Ref. to parts.
FU(SOHC)-49,
Engine Control
Module.>
EN(SOHC)-101
G: DTC P0106 — PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM (LOW INPUT) — S058521F90

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2097
EN(SOHC)-102

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Go to step 2.
NOTE: Monitor or OBD-II general P0107, P0108 or
In this case, it is not necessary to inspect scan tool indicate DTC P1112 using “17.
DTC P0106. P0107, P0108 or P1112? List of Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN(SOHC)-80,
List of Diagnostic
Trouble Code
(DTC).>
2 CHECK AIR INTAKE SYSTEM. Are there holes, loose bolts Repair air intake Go to step 3.
or disconnection of hose on system.
air intake system?
3 CHECK PRESSURE SENSOR. Is the value within the Go to step 4. Replace intake air
1) Start the engine and warm-up engine until specifications? temperature sen-
coolant temperature is greater than 60°C sor and pressure
(140°F). sensor. <Ref. to
2) Place the shift lever in the selector lever in FU(SOHC)-36,
“N” or “P” position. Intake Air Tem-
3) Turn A/C switch to OFF. perature and
4) Turn all accessory switches to OFF. Pressure Sensor.>
5) Read data of intake manifold pressure sen-
sor signal using Subaru Select Monitor or
NOTE:
tor.>
Specification:
쐌 Intake manifold absolute pressure
Ignition ON
73.3 — 106.6 kPa (550 — 800 mmHg,
21.65 — 31.50 inHg)
Idling
20.0 — 46.7 kPa (150 — 350 mmHg,
5.91 — 13.78 inHg)
4 CHECK THROTTLE POSITION. Is throttle positioning ratio Go to step 5. Adjust or replace
Read data of throttle position signal using equal to or less than 5% throttle position
Subaru Select Monitor or OBD-II general scan when throttle is fully sensor. <Ref. to
tool. closed? FU(SOHC)-33
NOTE: Throttle Position
쐌 Subaru Select Monitor Sensor.>
tor.>
EN(SOHC)-103

5 CHECK THROTTLE POSITION. Is throttle positioning ratio Replace intake air Replace throttle
equal to or more than 85% temperature and position sensor.
when throttle is fully open? pressure sensor. <Ref. to
<Ref. to FU(SOHC)-33,
FU(SOHC)-36, Throttle Position
Intake Air Tem- Sensor.>
perature and
Pressure Sensor.>
EN(SOHC)-104
MEMO:
EN(SOHC)-105
H: DTC P0107 — PRESSURE SENSOR CIRCUIT LOW INPUT — S058521B12

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2097
EN(SOHC)-106

1 CHECK CURRENT DATA. Is the value less than 13.3 Go to step 3. Go to step 2.
1) Start engine. kPa (100 mmHg, 3.94
2) Read the data of intake manifold absolute inHg)?
pressure signal using Subaru Select Monitor
or OBD-II general scan tool.
NOTE:
tor.>
2 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Even if MIL lights
Check poor contact in ECM and pressure ECM or pressure sensor tact in ECM or up, the circuit has
sensor connector. connector? pressure sensor returned to a nor-
connector. mal condition at
this time.
3 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than Go to step 5. Go to step 4.
Measure voltage between ECM connector 4.5 V?
and chassis ground.
(−):
4 CHECK INPUT SIGNAL FOR ECM. Does the voltage change Repair poor con- Contact your
Measure voltage between ECM connector more than 4.5 V by shaking tact in ECM con- Subaru distributor.
and chassis ground. harness and connector of nector. NOTE:
Connector & terminal ECM while monitoring the Inspection by
(B136) No. 15 (+) — Chassis ground value with voltage meter? DTM is required,
(−): because probable
cause is deterio-
ration of multiple
parts.
5 CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 0.2 Go to step 7. Go to step 6.
Measure voltage between ECM and chassis V?
ground.
6 CHECK INPUT SIGNAL FOR ECM. (USING Does the value change Repair poor con- Go to step 7.
SUBARU SELECT MONITOR.) more than 13.3 kPa (100 tact in ECM con-
Read data of atmospheric absolute pressure mmHg, 3.94 inHg) by shak- nector.
signal using Subaru Select Monitor. ing harness and connector
NOTE: of ECM while monitoring
쐌 Subaru Select Monitor the value with Subaru
For detailed operation procedure, refer to the Select Monitor?
tor.>
EN(SOHC)-107

7 CHECK HARNESS BETWEEN ECM AND Is the voltage more than Go to step 8. Repair open cir-
INTAKE AIR TEMPERATURE AND PRES- 4.5 V? cuit in harness
SURE SENSOR CONNECTOR. between ECM
1) Turn ignition switch to OFF. and intake air
2) Disconnect connector from intake air tem- temperature and
perature and pressure sensor. pressure sensor
3) Turn ignition switch to ON. connector.
4) Measure voltage between intake air tem-
perature sensor and pressure sensor connec-
tor and engine ground.
(E20) No. 3 (+) — Engine ground (−):
INTAKE AIR TEMPERATURE AND PRES- 1 Ω? cuit in harness
2) Disconnect connector from ECM. temperature and
3) Measure resistance of harness between pressure sensor
ECM and intake air temperature and pressure connector.
sensor connector.
(B136) No. 16 — (E20) No. 1:
INTAKE AIR TEMPERATURE AND PRES- 500 kΩ? short circuit in
SURE SENSOR CONNECTOR. harness between
Measure resistance of harness between ECM and intake
intake air temperature and pressure sensor air temperature
connector and engine ground. and pressure sen-
Connector & terminal sor connector.
(E20) No. 4 — Engine ground:
10 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace intake air
Check poor contact in intake manifold pres- intake manifold pressure tact in intake air temperature and
sure sensor connector. sensor connector? temperature and pressure sensor.
pressure sensor <Ref. to
connector. FU(SOHC)-36,
Intake Air Tem-
perature and
Pressure Sensor.>
EN(SOHC)-108
MEMO:
EN(SOHC)-109
I: DTC P0108 — PRESSURE SENSOR CIRCUIT HIGH INPUT — S058521B13

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2097
EN(SOHC)-110

1 CHECK CURRENT DATA. Is the value more than Go to step 10. Go to step 2.
1) Start engine. 119.5 kPa (896.5 mmHg,
2) Read the data of intake manifold absolute 35.29 inHg)?
NOTE:
tor.>
and chassis ground.
(−):
cause is deterio-
ration of multiple
parts.
and chassis ground.
SUBARU SELECT MONITOR.) more than 13.3 kPa (100 tact in ECM con-
Read data of atmospheric absolute pressure mmHg, 3.94 inHg) by shak- nector.
signal using Subaru Select Monitor. ing harness and connector
NOTE: of ECM while monitoring
쐌 Subaru Select Monitor the value with Subaru
For detailed operation procedure, refer to the Select Monitor?
tor.>
INTAKE AIR TEMPERATURE AND PRES- 4.5 V? cuit in harness
2) Disconnect connector from intake air tem- temperature and
3) Turn ignition switch to ON. connector.
4) Measure voltage between intake air tem-
perature and pressure sensor connector and
engine ground.
EN(SOHC)-111

2) Disconnect connector from ECM. temperature and
3) Measure resistance of harness between pressure sensor
ECM and intake air temperature and pressure connector.
sensor connector.
(B136) No. 5 — (E20) No. 4:
Measure resistance of harness between ECM and intake air
and intake air temperature and pressure sen- temperature and
sor connector. pressure sensor
(B136) No. 16 — (E20) No. 1:
9 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace intake air
Check poor contact in intake air temperature intake manifold pressure tact in intake airtemperature and
and pressure sensor connector. sensor connector? temperature and pressure sensor.
pressure sensor <Ref. to
Intake Air Tem-
perature and
Pressure Sensor.>
10 CHECK HARNESS BETWEEN ECM AND Is the value more than Repair battery Replace intake air
INTAKE AIR TEMPERATURE AND PRES- 119.5 kPa (896.5 mmHg, short circuit in temperature and
SURE SENSOR CONNECTOR. 35.29 inHg)? harness between pressure sensor.
1) Turn ignition switch to OFF and Subaru ECM and intake <Ref. to
Select Monitor or the OBD-II general scan air temperature FU(SOHC)-36,
tool switch to OFF. and pressure sen- Intake Air Tem-
2) Disconnect connector from intake air tem- sor connector. perature and
perature and pressure sensor. Pressure Sensor.>
3) Turn ignition switch to ON and Subaru
Select Monitor or the OBD-II general scan
tool switch to ON.
4) Read data of intake manifold absolute
NOTE:
tor.>
EN(SOHC)-112
MEMO:
EN(SOHC)-113
J: DTC P0111 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT

RANGE/PERFORMANCE PROBLEM — S058521B14

쐌 Poor driving performance
CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2097
EN(SOHC)-114

Monitor or OBD-II general P0112, P0113,
scan tool indicate DTC P0117, P0118 or
P0112, P0113, P0117, P0125 using “17.
P0118 or P0125? List of Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN(SOHC)-80,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0111.
2 CHECK ENGINE COOLANT TEMPERA- Is the engine coolant tem- Replace intake air Inspect DTC
TURE. perature between 75°C temperature and P0125 using “17.
1) Start the engine and warm it up completely. (167°F) and 95°C (203°F)? pressure sensor. List of Diagnostic
2) Measure engine coolant temperature using <Ref. to Trouble Code
Subaru Select Monitor or OBD-II general scan FU(SOHC)-36, (DTC)”. <Ref. to
tool. Intake Air Tem- EN(SOHC)-80,
NOTE: perature and List of Diagnostic
쐌 Subaru Select Monitor Pressure Sensor.> Trouble Code
For detailed operation procedure, refer to the (DTC).>
tor.>
EN(SOHC)-115
K: DTC P0112 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW INPUT

— S058521B15

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2097
EN(SOHC)-116

1 CHECK CURRENT DATA. Is the value greater than Go to step 2. Repair poor con-
1) Start engine. 120°C (248°F)? tact.
2) Read data of intake air temperature sensor NOTE:
signal using Subaru Select Monitor or the In this case,
NOTE: ing:
For detailed operation procedure, refer to the intake air tem-
“READ CURRENT DATA FOR ENGINE”. perature and
<Ref. to EN(SOHC)-34, Subaru Select Moni- pressure sensor
tor.> 쐌 Poor contact in
쐌 OBD-II general scan tool ECM
For detailed operation procedure, refer to the 쐌 Poor contact in
OBD-II General Scan Tool Instruction Manual. coupling connec-
tor (B21)
쐌 Poor contact in
joint connector
(B83, B122)
2 CHECK HARNESS BETWEEN INTAKE AIR Is the value less than Replace intake air Repair ground
TEMPERATURE AND PRESSURE SENSOR −40°C (−40°F)? temperature and short circuit in
AND ECM CONNECTOR. pressure sensor. harness between
1) Turn ignition switch to OFF. <Ref. to intake air tem-
2) Disconnect connector from intake air tem- FU(SOHC)-36, perature sensor
perature and pressure sensor. Intake Air Tem- and ECM connec-
3) Turn ignition switch to ON. perature and tor.
4) Read data of intake air temperature sensor Pressure Sensor.>
signal using Subaru Select Monitor or the
NOTE:
tor.>
EN(SOHC)-117
L: DTC P0113 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH INPUT

— S058521B16

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2097
EN(SOHC)-118

1 CHECK CURRENT DATA. Is the value less than Go to step 2. Repair poor con-
1) Start engine. −40°C (−40°F)? tact.
NOTE: ing:
For detailed operation procedure, refer to the intake air tem-
“READ CURRENT DATA FOR ENGINE”. perature and
<Ref. to EN(SOHC)-34, Subaru Select Moni- pressure sensor
tor (B21)
쐌 Poor contact in
joint connector
(B83, B122)
2 CHECK HARNESS BETWEEN INTAKE AIR Is the voltage more than 10 Repair battery Go to step 3.
TEMPERATURE AND PRESSURE SENSOR V? short circuit in
AND ECM CONNECTOR. harness between
1) Turn ignition switch to OFF. intake air tem-
2) Disconnect connector from intake air temperature and
3) Measure voltage between intake air tem- and ECM connec-
perature and pressure sensor connector and tor.
engine ground.
1) Turn ignition switch to ON. intake air tem-
2) Measure voltage between intake air temperature and
perature and pressure sensor connector and pressure sensor
engine ground. and ECM connec-
EN(SOHC)-119

4 CHECK HARNESS BETWEEN INTAKE AIR Is the voltage more than 3 Go to step 5. Repair harness
TEMPERATURE AND PRESSURE SENSOR V? and connector.
AND ECM CONNECTOR. NOTE:
Measure voltage between intake air tempera- In this case,
ture and pressure sensor connector and repair the follow-
engine ground. ing:
(E20) No. 2 (+) — Engine ground (−): harness between
intake air tem-
perature and
pressure sensor
and ECM connec-
tor
쐌 Poor contact in
intake air tem-
perature and
pressure sensor
쐌 Poor contact in
ECM
쐌 Poor contact in
coupling connec-
tor (B21)
쐌 Poor contact in
joint connector
(B83, B122)
5 CHECK HARNESS BETWEEN INTAKE AIR Is the resistance less than Replace intake air Repair harness
TEMPERATURE AND PRESSURE SENSOR 5 Ω? temperature and and connector.
AND ECM CONNECTOR. pressure sensor. NOTE:
1) Turn ignition switch to OFF. <Ref. to In this case,
2) Measure resistance of harness between FU(SOHC)-36, repair the follow-
intake air temperature and pressure sensor Intake Air Tem- ing:
connector and engine ground. perature and 쐌 Open circuit in
Connector & terminal Pressure Sensor.> harness between
(E20) No. 1 — Engine ground: intake air tem-
perature and
pressure sensor
and ECM connec-
tor
쐌 Poor contact in
intake air tem-
perature and
pressure sensor
쐌 Poor contact in
ECM
쐌 Poor contact in
coupling connec-
tor (B21)
쐌 Poor contact in
joint connector
(B83, B122)
EN(SOHC)-120
MEMO:
EN(SOHC)-121
M: DTC P0117 — ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT

LOW INPUT — S058521F91

쐌 Hard to start
CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2081
EN(SOHC)-122

2) Read data of engine coolant temperature NOTE:
sensor signal using Subaru Select Monitor or In this case,
NOTE: ing:
For detailed operation procedure, refer to the engine coolant
“READ CURRENT DATA FOR ENGINE”. temperature sen-
<Ref. to EN(SOHC)-34, Subaru Select Moni- sor
tor (B21)
쐌 Poor contact in
joint connector
LHD: B122
RHD: B83
2 CHECK HARNESS BETWEEN ENGINE Is the value less than Replace engine Repair ground
COOLANT TEMPERATURE SENSOR AND −40°C (−40°F)? coolant tempera- short circuit in
ECM CONNECTOR. ture sensor. <Ref. harness between
1) Turn ignition switch to OFF. to FU(SOHC)-28, engine coolant
2) Disconnect connector from engine coolant Engine Coolant temperature sen-
temperature sensor. Temperature Sen- sor and ECM con-
3) Turn ignition switch to ON. sor.> nector.
4) Read data of engine coolant temperature
sensor signal using Subaru Select Monitor or
NOTE:
tor.>
EN(SOHC)-123
N: DTC P0118 — ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT

HIGH INPUT — S058521F92

쐌 Hard to start
CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2081
EN(SOHC)-124

NOTE: ing:
<Ref. to EN(SOHC)-34, Subaru Select Moni- sor
tor (B21)
쐌 Poor contact in
joint connector
LHD: B122
RHD: B83
2 CHECK HARNESS BETWEEN ENGINE Is the voltage more than 10 Repair battery Go to step 3.
COOLANT TEMPERATURE SENSOR AND V? short circuit in
ECM CONNECTOR. harness between
1) Turn ignition switch to OFF. ECM and engine
2) Disconnect connector from engine coolant coolant tempera-
temperature sensor. ture sensor con-
3) Measure voltage between engine coolant nector.
temperature sensor connector and engine
ground.
1) Turn ignition switch to ON. ECM and engine
2) Measure voltage between engine coolant coolant tempera-
temperature sensor connector and engine ture sensor con-
ground. nector.
EN(SOHC)-125

4 CHECK HARNESS BETWEEN ENGINE Is the voltage more than 4 Go to step 5. Repair harness
COOLANT TEMPERATURE SENSOR AND V? and connector.
ECM CONNECTOR. NOTE:
Measure voltage between engine coolant tem- In this case,
perature sensor connector and engine repair the follow-
ground. ing:
ECM and engine
coolant tempera-
ture sensor con-
nector
쐌 Poor contact in
engine coolant
temperature sen-
sor connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
쐌 Poor contact in
joint connector
LHD: B122
RHD: B83
5 CHECK HARNESS BETWEEN ENGINE Is the resistance less than Replace engine Repair harness
COOLANT TEMPERATURE SENSOR AND 5 Ω? coolant tempera- and connector.
ECM CONNECTOR. ture sensor. <Ref. NOTE:
1) Turn ignition switch to OFF. to FU(SOHC)-28, In this case,
2) Measure resistance of harness between Engine Coolant repair the follow-
engine coolant temperature sensor connector Temperature Sen- ing:
and engine ground. sor.> 쐌 Open circuit in
Connector & terminal harness between
(E8) No. 2 — Engine ground: ECM and engine
coolant tempera-
ture sensor con-
nector
쐌 Poor contact in
engine coolant
temperature sen-
sor connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
쐌 Poor contact in
joint connector
LHD: B122
RHD: B83
EN(SOHC)-126
MEMO:
EN(SOHC)-127
O: DTC P0121 — THROTTLE POSITION SENSOR CIRCUIT

RANGE/PERFORMANCE PROBLEM (HIGH INPUT) — S058521B19

쐌 Engine stalls.
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(SOHC)-45
OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)-42 OPERATION,
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2082
EN(SOHC)-128

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Replace throttle
Monitor or OBD-II general P0122 or P0123 position sensor.
scan tool indicate DTC using “17. List of <Ref. to
P0122 or P0123? Diagnostic FU(SOHC)-33,
Trouble Code Throttle Position
(DTC)”. <Ref. to Sensor.>
EN(SOHC)-80,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0121.
EN(SOHC)-129
P: DTC P0122 — THROTTLE POSITION SENSOR CIRCUIT LOW INPUT — S058521B20

쐌 Engine stalls.
CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2082
EN(SOHC)-130

1 CHECK CURRENT DATA. Is the value less than 0.1 Go to step 2. Even if MIL lights
1) Start engine. V? up, the circuit has
2) Read data of throttle position sensor signal returned to a nor-
using Subaru Select Monitor or OBD-II gen- mal condition at
eral scan tool. this time. A tem-
NOTE: porary poor con-
쐌 Subaru Select Monitor tact of the con-
For detailed operation procedure, refer to the nector may be the
“READ CURRENT DATA FOR ENGINE”. cause.
<Ref. to EN(SOHC)-34, Subaru Select Moni- NOTE:
tor.> In this case,
쐌 OBD-II general scan tool repair the follow-
For detailed operation procedures, refer to the ing:
OBD-II General Scan Tool Instruction Manual. 쐌 Poor contact in
throttle position
sensor connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
and chassis ground while throttle valve is fully
closed.
(−):
cause is deterio-
ration of multiple
parts.
and chassis ground.
(−):
5 CHECK INPUT SIGNAL FOR ECM. (USING Does the voltage change Repair poor con- Go to step 6.
SUBARU SELECT MONITOR.) more than 0.1 V by shaking tact in ECM con-
Measure voltage between ECM connector harness and connector of nector.
and chassis ground. ECM while monitoring the
value with Subaru Select
Monitor?
EN(SOHC)-131

6 CHECK HARNESS BETWEEN ECM AND Is the voltage more than Go to step 7. Repair harness
THROTTLE POSITION SENSOR CONNEC- 4.5 V? and connector.
TOR. NOTE:
2) Disconnect connectors from throttle posi- repair the follow-
tion sensor. ing:
3) Turn ignition switch to ON. 쐌 Open circuit in
4) Measure voltage between throttle position harness between
sensor connector and engine ground. throttle position
Connector & terminal sensor and ECM
(E13) No. 4 (+) — Engine ground (−): connector
쐌 Poor contact in
throttle position
sensor connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
쐌 Poor contact in
joint connector
LHD: B122
RHD: B83
THROTTLE POSITION SENSOR CONNEC- 1 Ω? and connector.
TOR. NOTE:
ECM connector and throttle position sensor ing:
connector. 쐌 Open circuit in
(B136) No. 17 — (E13) No. 3: throttle position
sensor and ECM
connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
throttle position
sensor connector
쐌 Poor contact in
coupling connec-
tor (B21)
THROTTLE POSITION SENSOR CONNEC- 10 Ω? short circuit in
TOR. harness between
Measure resistance of harness between throttle position
throttle position sensor connector and engine sensor and ECM
ground. connector.
9 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace throttle
Check poor contact in throttle position sensor throttle position sensor contact in throttle position sensor.
connector. nector? position sensor <Ref. to
Throttle Position
Sensor.>
EN(SOHC)-132
MEMO:
EN(SOHC)-133
Q: DTC P0123 — THROTTLE POSITION SENSOR CIRCUIT HIGH INPUT — S058521B21

쐌 Engine stalls.
CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2082
EN(SOHC)-134

1 CHECK CURRENT DATA. Is the value more than 4.9 Go to step 2. Even if MIL lights
<Ref. to EN(SOHC)-34, Subaru Select Moni- NOTE:
tor.> In this case,
throttle position
sensor connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
2 CHECK HARNESS BETWEEN THROTTLE Is the resistance less than Go to step 3. Repair harness
POSITION SENSOR AND ECM CONNEC- 5 Ω? and connector.
TOR. NOTE:
2) Disconnect connector from throttle position repair the follow-
sensor. ing:
3) Measure resistance of harness between 쐌 Open circuit in
throttle position sensor connector and engine harness between
ground. throttle position
(E13) No. 2 — Engine ground: connector
쐌 Poor contact in
coupling connec-
tor (B21)
쐌 Poor contact in
joint connector
LHD: B122
RHD: B83
3 CHECK HARNESS BETWEEN THROTTLE Is the voltage more than Repair battery Replace throttle
POSITION SENSOR AND ECM CONNEC- 4.9 V? short circuit in position sensor.
TOR. harness between <Ref. to
1) Turn ignition switch to ON. throttle position FU(SOHC)-33
2) Measure voltage between throttle position sensor and ECM Throttle Position
sensor connector and engine ground. connector. After Sensor.>
Connector & terminal repair, replace
(E13) No. 3 (+) — Engine ground (−): ECM. <Ref. to
FU(SOHC)-49,
Engine Control
Module.>
EN(SOHC)-135
R: DTC P0125 — INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED

LOOP FUEL CONTROL — S058521B22

쐌 Engine would not return to idling.
CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2081
EN(SOHC)-136

Monitor or OBD-II general P0117 or P0118
scan tool indicate DTC using “17. List of
P0117 or P0118? Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN(SOHC)-80,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0125.
2 CHECK THERMOSTAT. Does thermostat remain Replace thermo- Replace engine
opened? stat. <Ref. to coolant tempera-
CO-23, Thermo- ture sensor. <Ref.
stat.> to FU(SOHC)-28,
Engine Coolant
Temperature Sen-
sor.>
EN(SOHC)-137
S: DTC P0130 — FRONT OXYGEN (A/F) SENSOR CIRCUIT

RANGE/PERFORMANCE PROBLEM (LEAN) — S058521G44

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2077
EN(SOHC)-138

scan tool indicate DTC P0031 or P0032
P0131, P0132, P0031 or using “17. List of
P0032? Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN(SOHC)-80,
List of Diagnostic
Trouble Code
(DTC).>
2 CHECK FRONT OXYGEN (A/F) SENSOR Is the value equal to or Go to step 3. Go to step 4.
DATA. more than 0.85 and equal
1) Start engine. to less than 1.15 in idling?
2) While observing the Subaru Select Monitor
or OBD-II general scan tool screen, warm-up
the engine until coolant temperature is above
70°C (160°F).
If the engine is already warmed-up, operate at
idle speed for at least 1 minute.
signal using Subaru Select Monitor or OBD-II
general scan tool.
NOTE:
tor.>
3 CHECK FRONT OXYGEN (A/F) SENSOR Is the value more than 1.1 Go to step 6. Go to step 4.
DATA. for a moment?
Race engine at speeds from idling to 5,000
rpm for a total of 5 cycles.
NOTE:
To increase engine speed to 5,000 rpm,
slowly depress accelerator pedal, taking
approximately 5 seconds, and quickly release
accelerator pedal to decrease engine speed.
FRONT OXYGEN (A/F) SENSOR. 5 Ω? cuit between ECM
1) Turn ignition switch to OFF. and front oxygen
2) Disconnect connector from ECM and front (A/F) sensor.
oxygen (A/F) sensor connector.
3) Measure resistance between ECM and
front oxygen (A/F) sensor.
Connector & terminals
(B136) No. 6 — (E24) No. 1:
(B136) No. 7 — (E24) No. 6:
(B136) No. 19 — (E24) No. 3:
(B136) No. 20 — (E24) No. 4:
EN(SOHC)-139

FRONT OXYGEN (A/F) SENSOR. 1 MΩ? short circuit
Measure resistance between ECM and chas- between ECM
sis ground. and front oxygen
Connector & terminals (A/F) sensor.
6 CHECK EXHAUST SYSTEM. Is there a fault in exhaust Repair or replace Replace front oxy-
Check exhaust system parts. system? faulty parts. gen (A/F) sensor.
NOTE: <Ref. to
Check the following items. FU(SOHC)-45,
쐌 Loose installation of portions Front Oxygen
쐌 Damage (crack, hole etc.) of parts (A/F) Sensor.>
쐌 Looseness of front oxygen (A/F) sensor
쐌 Looseness and ill fitting of parts between
front oxygen (A/F) sensor and rear oxygen
sensor
EN(SOHC)-140
MEMO:
EN(SOHC)-141
T: DTC P0131 — FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION

(OPEN CIRCUIT) — S058521G45

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2077
EN(SOHC)-142

FRONT OXYGEN (A/F) SENSOR CONNEC- 1 Ω? and connector.
TOR. NOTE:
2) Disconnect connectors from ECM and front repair the follow-
oxygen (A/F) sensor connector. ing:
ECM and front oxygen (A/F) sensor connec- harness between
tor. ECM and front
Connector & terminal oxygen (A/F) sen-
(B136) No. 6 — (E24) No. 1: sor connector
(B136) No. 7 — (E24) No. 6: 쐌 Poor contact in
(B136) No. 19 — (E24) No. 3: front oxygen (A/F)
(B136) No. 20 — (E24) No. 4: sensor connector
쐌 Poor contact in
ECM connector
2 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace front oxy-
Check poor contact in front oxygen (A/F) sen- front oxygen (A/F) sensor tact in front oxygen (A/F) sensor.
sor connector. connector? gen (A/F) sensor <Ref. to
Front Oxygen
(A/F) Sensor.>
EN(SOHC)-143
U: DTC P0132 — FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION

(SHORT CIRCUIT) — S058521G46

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2077
EN(SOHC)-144

1 CHECK HARNESS BETWEEN ECM AND Is the resistance more than Replace front oxy- Repair ground
FRONT OXYGEN (A/F) SENSOR CONNEC- 10 Ω? gen (A/F) sensor. short circuit in
TOR. <Ref. to harness between
1) Turn ignition switch to OFF. FU(SOHC)-45, ECM and front
2) Disconnect connector from ECM. Front Oxygen oxygen (A/F) sen-
3) Measure resistance of harness between (A/F) Sensor.> sor connector.
EN(SOHC)-145
V: DTC P0133 — FRONT OXYGEN (A/F) SENSOR CIRCUIT SLOW

RESPONSE — S058521B26

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2077
EN(SOHC)-146

P0032? Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN(SOHC)-80,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0133.
2 CHECK EXHAUST SYSTEM. Is there a fault in exhaust Repair exhaust Replace front oxy-
NOTE: system? system. gen (A/F) sensor.
Check the following items. <Ref. to
쐌 Loose installation of front portion of exhaust FU(SOHC)-45,
pipe onto cylinder heads Front Oxygen
쐌 Loose connection between front exhaust (A/F) Sensor.>
pipe and front catalytic converter
쐌 Damage of exhaust pipe resulting in a hole
EN(SOHC)-147
W: DTC P0136 — REAR OXYGEN SENSOR CIRCUIT MALFUNCTION — S058521B28

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2078

P0131 or P0132?
EN(SOHC)-148

2 CHECK FAILURE CAUSE OF P0131 or Is the failure cause of Check fuel sys- Go to step 3.
P0132. P0131 or P0132 in the fuel tem.
Inspect DTC P0131 or P0132 using “17. List system? NOTE:
of Diagnostic Trouble Code (DTC)”. <Ref. to In this case, it is
EN(SOHC)-80, List of Diagnostic Trouble not necessary to
Code (DTC).> inspect DTC
P0136.
3 CHECK REAR OXYGEN SENSOR DATA. Does the value fluctuate? Go to step 7. Go to step 4.
1) Warm-up the engine until engine coolant
temperature is above 70°C (158°F), and keep
the engine speed at 2,000 rpm to 3,000 rpm
for two minutes.
2) Read data of rear oxygen sensor signal
using Subaru Select Monitor or OBD-II gen-
eral scan tool.
NOTE:
“READ CURRENT DATA SHOWN ON DIS-
PLAY FOR ENGINE”. <Ref. to EN(SOHC)-34,
4 CHECK REAR OXYGEN SENSOR DATA. Is the value fixed between Go to step 5. Replace rear oxy-
Read data of rear oxygen sensor signal using 0.2 and 0.4 V? gen sensor. <Ref.
Subaru Select Monitor or OBD-II General to FU(SOHC)-47,
Scan Tool. Rear Oxygen
Sensor.>
5 CHECK HARNESS BETWEEN ECM AND Is the resistance more than Repair open cir- Go to step 6.
REAR OXYGEN SENSOR CONNECTOR. 3 Ω? cuit in harness
1) Turn ignition switch to OFF. between ECM
2) Disconnect connectors from ECM and rear and rear oxygen
oxygen sensor. sensor connector.
ECM and rear oxygen sensor connector.
(B136) No. 16 — (E25) No. 3:
6 CHECK HARNESS BETWEEN REAR OXY- Is the voltage more than Replace rear oxy- Repair harness
GEN SENSOR AND ECM CONNECTOR. 0.2 V? gen sensor. <Ref. and connector.
1) Turn ignition switch to OFF. to FU(SOHC)-47, NOTE:
2) Disconnect connector from rear oxygen Rear Oxygen In this case,
sensor. Sensor.> repair the follow-
sor harness connector and engine ground or harness between
chassis ground. rear oxygen sen-
Connector & terminal sor and ECM con-
(E25) No. 4 (+) — Engine ground (−): nector
쐌 Poor contact in
rear oxygen sen-
sor connector
쐌 Poor contact in
ECM connector
EN(SOHC)-149

7 CHECK EXHAUST SYSTEM. Is there a fault in exhaust Repair or replace Replace rear oxy-
Check exhaust system parts. system? faulty parts. gen sensor. <Ref.
NOTE: to FU(SOHC)-47,
Check the following items. Rear Oxygen
쐌 Loose installation of portions Sensor.>
쐌 Damage (crack, hole etc.) of parts
sensor
EN(SOHC)-150
MEMO:
EN(SOHC)-151
X: DTC P0139 — REAR OXYGEN SENSOR CIRCUIT SLOW RESPONSE — S058521B29

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2078
EN(SOHC)-152

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Replace rear oxy-
Monitor or OBD-II general P0136 using “17. gen sensor. <Ref.
scan tool indicate DTC List of Diagnostic to FU(SOHC)-47,
P0136? Trouble Code Rear Oxygen
EN(SOHC)-80,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0139.
EN(SOHC)-153
Y: DTC P0170 — FUEL TRIM MALFUNCTION — S058521B31

쐌 Engine stalls.
CAUTION:
Inspection Mode.>.
1 CHECK EXHAUST SYSTEM. Are there holes or loose Repair exhaust Go to step 2.
bolts on exhaust system? system.
air intake system?
3 CHECK FUEL PRESSURE. Is fuel pressure between Go to step 4. Repair the follow-
WARNING: 284 and 314 kPa (2.9 — ing items.
쐌 Place “NO FIRE” signs near the working 3.2 kg/cm2, 41 — 46 psi)? Fuel pressure
area. too high
쐌 Be careful not to spill fuel on the floor. 쐌 Clogged fuel
1) Release fuel pressure. return line or bent
(1) Disconnect connector from fuel pump hose
relay. Fuel pressure
(2) Start the engine and run it until it stalls. too low
(3) After the engine stalls, crank it for five 쐌 Improper fuel
more seconds. pump discharge
(4) Turn ignition switch to OFF. 쐌 Clogged fuel
2) Connect connector to fuel pump relay. supply line
3) Disconnect fuel delivery hose from fuel
filter, and connect fuel pressure gauge.
4) Install fuel filler cap.
5) Start the engine and idle while gear posi-
tion is neutral.
pressure regulator vacuum hose from intake
manifold.
WARNING:
Before removing fuel pressure gauge,
release fuel pressure.
NOTE:
If fuel pressure does not increase, squeeze
fuel return hose 2 to 3 times, then measure
fuel pressure again.
EN(SOHC)-154

After connecting pressure regulator vacuum 206 and 235 kPa (2.1 — ing items.
hose, measure fuel pressure. 2.4 kg/cm2, 30 — 34 psi)? Fuel pressure
WARNING: too high
Before removing fuel pressure gauge, 쐌 Faulty pressure
release fuel pressure. regulator
NOTE: 쐌 Clogged fuel
쐌 If fuel pressure does not increase, squeeze return line or bent
fuel return hose 2 to 3 times, then measure hose
fuel pressure again. Fuel pressure
쐌 If out of specification as measured at this too low
step, check or replace pressure regulator and 쐌 Faulty pressure
pressure regulator vacuum hose. regulator
쐌 Improper fuel
pump discharge
쐌 Clogged fuel
supply line
5 CHECK ENGINE COOLANT TEMPERA- Is temperature between Go to step 6. Replace engine
TURE SENSOR. 70°C (158°F) and 100°C coolant tempera-
1) Start the engine and warm-up completely. (212°F)? ture sensor. <Ref.
2) Read data of engine coolant temperature to FU(SOHC)-28,
sensor signal using Subaru Select Monitor or Engine Coolant
OBD-II general scan tool. Temperature Sen-
NOTE: sor.>
tor.>
6 CHECK INTAKE MANIFOLD PRESSURE Is the voltage within the Contact your Replace intake air
SENSOR SIGNAL. specifications? Subaru distributor. temperature and
1) Start the engine and warm-up engine until NOTE: pressure sensor.
coolant temperature is greater than 60°C Inspection by <Ref. to
(140°F). DTM is required, FU(SOHC)-36,
2) Place the selector lever in “N” or “P” posi- because probable Intake Air Tem-
tion. cause is deterio- perature and
3) Turn A/C switch to OFF. ration of multiple Pressure Sensor.>
4) Turn all accessory switches to OFF. parts.
NOTE:
tor.>
Specification:
Idling
24.0 — 41.3 kPa (180 — 310 mmHg,
7.09 — 12.20 inHg)
Ignition ON
73.3 — 106.6 kPa (550 — 800 mmHg,
21.65 — 31.50 inHg)
EN(SOHC)-155
Z: DTC P0301 — CYLINDER 1 MISFIRE DETECTED — S058521B37
NOTE:
For the diagnostic procedure, refer to DTC P0304. <Ref. to EN(SOHC)-158, DTC P0304 — CYLINDER 4
MISFIRE DETECTED —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AA: DTC P0302 — CYLINDER 2 MISFIRE DETECTED — S058521B38
NOTE:
AB: DTC P0303 — CYLINDER 3 MISFIRE DETECTED — S058521B39
NOTE:
EN(SOHC)-156
MEMO:
EN(SOHC)-157
AC: DTC P0304 — CYLINDER 4 MISFIRE DETECTED — S058521B40

쐌 Immediately at fault recognition (A misfire which could damage catalyst occurs.)
쐌 Engine stalls.
쐌 Rough driving
CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2083
EN(SOHC)-158
S2M2084

scan tool indicate DTC P0108, P0117,
P0106, P0107, P0108, P0118 or P0125
P0117, P0118 or P0125? using “17. List of
Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN(SOHC)-80,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0301, P0302,
P0303 and
P0304.
EN(SOHC)-159

and chassis ground on faulty cylinders.
#1 (B134) No. 4 (+) — Chassis ground
(−):
(−):
(−):
(−):
3 CHECK HARNESS BETWEEN FUEL INJEC- Is the resistance less than Repair ground Go to step 4.
TOR AND ECM CONNECTOR. 10 Ω? short circuit in
2) Disconnect connector from fuel injector on fuel injector and
faulty cylinders. ECM connector.
and engine ground on faulty cylinders.
#1 (E5) No. 1 — Engine ground:
4 CHECK HARNESS BETWEEN FUEL INJEC- Is the resistance less than Go to step 5. Repair harness
TOR AND ECM CONNECTOR. 1 Ω? and connector.
Measure resistance of harness connector NOTE:
between ECM connector and fuel injector on In this case,
faulty cylinders. repair the follow-
#1 (B134) No. 4 — (E5) No. 1: 쐌 Open circuit in
#2 (B134) No. 13 — (E16) No. 1: harness between
#3 (B134) No. 14 — (E6) No. 1: ECM and fuel
#4 (B134) No. 15 — (E17) No. 1: injector connector
쐌 Poor contact in
coupling connec-
tor (B22)
5 CHECK FUEL INJECTOR. Is the resistance between 5 Go to step 6. Replace faulty
Measure resistance between fuel injector ter- and 20 Ω? fuel injector. <Ref.
minals on faulty cylinder. to FU(SOHC)-40,
Terminals Fuel Injector.>
No. 1 — No. 2:
EN(SOHC)-160

6 CHECK POWER SUPPLY LINE. Is the voltage more than 10 Repair poor con- Repair harness
1) Turn ignition switch to ON. V? tact in all connec- and connector.
2) Measure voltage between fuel injector and tors in fuel injector NOTE:
engine ground on faulty cylinders. circuit. In this case,
#1 (E5) No. 2 (+) — Engine ground (−): ing:
#2 (E16) No. 2 (+) — Engine ground 쐌 Open circuit in
(−): harness between
#3 (E6) No. 2 (+) — Engine ground (−): main relay and
#4 (E17) No. 2 (+) — Engine ground fuel injector con-
(−): nector on faulty
cylinders
쐌 Poor contact in
coupling connec-
tor
쐌 Poor contact in
main relay con-
nector
쐌 Poor contact in
fuel injector con-
nector on faulty
cylinders
7 CHECK HARNESS BETWEEN FUEL INJEC- Is the voltage more than 10 Repair battery Go to step 8.
TOR AND ECM CONNECTOR. V? short circuit in
2) Disconnect connector from fuel injector on ECM and fuel
faulty cylinder. injector. After
3) Turn ignition switch to ON. repair, replace
4) Measure voltage between ECM connector ECM. <Ref. to
and chassis ground on faulty cylinders. FU(SOHC)-49,
Connector & terminal Engine Control
#1 (B134) No. 4 (+) — Chassis ground Module.>
(−):
(−):
(−):
(−):
8 CHECK FUEL INJECTOR. Is the resistance less than Replace faulty Go to step 9.
1) Turn ignition switch to OFF. 1 Ω? fuel injector <Ref.
2) Measure resistance between fuel injector to FU(SOHC)-40,
terminals on faulty cylinder. Fuel Injector .>
Terminals and ECM <Ref. to
No. 1 — No. 2: FU(SOHC)-49,
Engine Control
Module.>.
9 CHECK INSTALLATION OF CAMSHAFT Is camshaft position sensor Tighten camshaft Go to step 10.
POSITION SENSOR/CRANKSHAFT POSI- or crankshaft position sen- position sensor or
TION SENSOR. sor loosely installed? crankshaft posi-
tion sensor.
10 CHECK CRANKSHAFT SPROCKET. Is crankshaft sprocket Replace crank- Go to step 11.
Remove timing belt cover. rusted or does it have bro- shaft sprocket.
ken teeth? <Ref. to
ME(SOHC)-53,
Crankshaft
Sprocket.>
EN(SOHC)-161

11 CHECK INSTALLATION CONDITION OF Is timing belt dislocated Repair installation Go to step 12.
TIMING BELT. from its proper position? condition of timing
Turn crankshaft using ST, and align alignment belt. <Ref. to
mark on crankshaft sprocket with alignment ME(SOHC)-46,
mark on cylinder block. Timing Belt
ST 499987500 CRANKSHAFT SOCKET Assembly.>
12 CHECK FUEL LEVEL. Is the fuel meter indication Go to step 13. Replenish fuel so
higher than the “Lower” fuel meter indica-
level? tion is higher than
the “Lower” level.
After replenishing
fuel, Go to step
13.
13 CHECK STATUS OF CHECK ENGINE MAL- Is the MIL coming on or Go to step 15. Go to step 14.
FUNCTION INDICATOR LAMP (MIL). blinking?
1) Clear memory using Subaru Select Moni-
tor.
<Ref. to EN(SOHC)-45, Clear Memory
Mode.>
2) Start engine, and drive the vehicle more
than 10 minutes.
14 CHECK CAUSE OF MISFIRE DIAGNOSED. Was the cause of misfire Finish diagnostics Repair poor con-
diagnosed when the engine operation, if the tact.
is running? engine has no NOTE:
abnormality. In this case,
NOTE: repair the follow-
Ex. Remove spark ing:
plug cord, etc. 쐌 Poor contact in
ignitor connector
쐌 Poor contact in
ignition coil con-
nector
쐌 Poor contact in
fuel injector con-
nector on faulty
cylinders
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor
15 CHECK AIR INTAKE SYSTEM. Is there a fault in air intake Repair air intake Go to step 16.
system? system.
NOTE:
Check the follow-
ing items:
쐌 Are there air
leaks or air suc-
tion caused by
loose or dislo-
cated nuts and
bolts?
쐌 Are there
cracks or any dis-
connection of
hoses?
EN(SOHC)-162

16 CHECK MISFIRE SYMPTOM. Does the Subaru Select Go to step 21. Go to step 17.
1) Turn ignition switch to ON. Monitor or OBD-II general
2) Read diagnostic trouble code (DTC). scan tool indicate only one
쐌 Subaru Select Monitor DTC?
tor.>
OBD-II General Scan Tool Operation Manual.
NOTE:
Perform diagnosis according to the items
listed below.
17 CHECK DIAGNOSTIC TROUBLE CODE Does the Subaru Select Go to step 22. Go to step 18.
(DTC) ON DISPLAY. Monitor or OBD-II general
P0301 and P0302?
P0303 and P0304?
P0301 and P0303?
P0302 and P0304?
21 ONLY ONE CYLINDER Is there a fault in that cylin- Repair or replace Go to DTC
der? faulty parts. P0170. <Ref. to
NOTE: EN(SOHC)-154,
Check the follow- DTC P0170 —
ing items. FUEL TRIM MAL-
쐌 Spark plug FUNCTION —,
쐌 Spark plug cord Diagnostic Proce-
쐌 Fuel injector dure with Diag-
쐌 Compression nostic Trouble
ratio Code (DTC).>
22 GROUP OF #1 AND #2 CYLINDERS Are there faults in #1 and Repair or replace Go to DTC
#2 cylinders? faulty parts. P0170. <Ref. to
NOTE: EN(SOHC)-154,
쐌 Check the fol- DTC P0170 —
lowing items. FUEL TRIM MAL-
Spark plugs FUNCTION —,
Fuel injectors Diagnostic Proce-
Ignition coil dure with Diag-
Compression ratio nostic Trouble
쐌 If no abnormal Code (DTC).>
is discovered,
check for “IGNI-
TION CONTROL
SYSTEM” of #1
and #2 cylinders
side. <Ref. to
EN(SOHC)-68,
IGNITION CON-
TROL SYSTEM,
Diagnostics for
Engine Starting
Failure.>
EN(SOHC)-163

NOTE: EN(SOHC)-154,
쐌 Check the fol- DTC P0170 —
lowing items. FUEL TRIM MAL-
Spark plugs FUNCTION —,
Fuel injectors Diagnostic Proce-
Ignition coil dure with Diag-
쐌 If no abnormal nostic Trouble
is discovered, Code (DTC).>
check for “16. D:
IGNITION CON-
TROL SYSTEM”
of #3 and #4 cyl-
inders side. <Ref.
to EN(SOHC)-68,
IGNITION CON-
TROL SYSTEM,
Diagnostics for
Engine Starting
Failure.>
NOTE: EN(SOHC)-154,
쐌 Spark plugs FUNCTION —,
쐌 Fuel injectors Diagnostic Proce-
쐌 Skipping timing dure with Diag-
belt teeth nostic Trouble
Code (DTC).>
NOTE: EN(SOHC)-154,
쐌 Spark plugs FUNCTION —,
쐌 Fuel injectors Diagnostic Proce-
쐌 Compression dure with Diag-
ratio nostic Trouble
쐌 Skipping timing Code (DTC).>
belt teeth
26 CYLINDER AT RANDOM Is the engine idle rough? Go to DTC Repair or replace
P0170. <Ref. to faulty parts.
EN(SOHC)-154, NOTE:
DTC P0170 — Check the follow-
FUEL TRIM MAL- ing items.
FUNCTION —, 쐌 Spark plugs
Diagnostic Proce- 쐌 Fuel injectors
dure with Diag- 쐌 Compression
nostic Trouble ratio
Code (DTC).>
EN(SOHC)-164
MEMO:
EN(SOHC)-165
AD: DTC P0327 — KNOCK SENSOR CIRCUIT LOW INPUT — S058521F94

쐌 Knocking occurs.
CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2085
EN(SOHC)-166

1 CHECK HARNESS BETWEEN KNOCK Is the resistance more than Go to step 2. Repair harness
SENSOR AND ECM CONNECTOR. 700 kΩ? and connector.
3) Measure resistance between ECM harness repair the follow-
connector and chassis ground. ing:
knock sensor and
ECM connector
쐌 Poor contact in
knock sensor con-
nector
쐌 Poor contact in
coupling connec-
tor (B21)
2 CHECK KNOCK SENSOR. Is the resistance more than Go to step 3. Repair harness
1) Disconnect connector from knock sensor. 700 kΩ? and connector.
2) Measure resistance between knock sensor NOTE:
connector terminal and engine ground. In this case,
Terminal repair the follow-
No. 2 — Engine ground: ing:
쐌 Open circuit in
harness between
knock sensor and
ECM connector
쐌 Poor contact in
knock sensor con-
nector
쐌 Poor contact in
coupling connec-
tor (B21)
3 CHECK CONDITION OF KNOCK SENSOR Is the knock sensor instal- Replace knock Tighten knock
INSTALLATION. lation bolt tightened sensor. <Ref. to sensor installation
securely? FU(SOHC)-31, bolt securely.
Knock Sensor.>
EN(SOHC)-167
AE: DTC P0328 — KNOCK SENSOR CIRCUIT HIGH INPUT — S058521F95

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2085
EN(SOHC)-168

1 CHECK HARNESS BETWEEN KNOCK Is the resistance less than Go to step 2. Go to step 3.
SENSOR AND ECM CONNECTOR. 400 kΩ?
Measure resistance of harness between ECM
2 CHECK KNOCK SENSOR. Is the resistance less than Replace knock Repair ground
1) Disconnect connector from knock sensor. 400 kΩ? sensor. <Ref. to short circuit in
2) Measure resistance between knock sensor FU(SOHC)-31, harness between
connector terminal and engine ground. Knock Sensor.> knock sensor con-
Terminal nector and ECM
No. 2 — Engine ground: connector.
NOTE:
The harness
between both
connectors is
shielded. Repair
short circuit of
harness together
with shield.
3 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 2 Even if MIL lights Repair poor con-
1) Connect connectors to ECM and knock V? up, the circuit has tact in ECM con-
sensor. returned to a nor- nector.
2) Turn ignition switch to ON. mal condition at
3) Measure voltage between ECM and chas- this time.
sis ground. (However, the
Connector & terminal possibility of poor
(B136) No. 4 (+) — Chassis ground (−): contact still
remains.)
NOTE:
In this case,
repair the follow-
ing:
쐌 Poor contact in
knock sensor con-
nector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
EN(SOHC)-169
AF: DTC P0335 — CRANKSHAFT POSITION SENSOR CIRCUIT

MALFUNCTION — S058521B42

쐌 Engine stalls.
쐌 Failure of engine to start
CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2086
EN(SOHC)-170

1 CHECK HARNESS BETWEEN CRANK- Is the resistance more than Repair harness Go to step 2.
SHAFT POSITION SENSOR AND ECM 100 kΩ? and connector.
CONNECTOR. NOTE:
2) Disconnect connector from crankshaft posi- repair the follow-
tion sensor. ing:
crankshaft position sensor connector and harness between
engine ground. crankshaft posi-
Connector & terminal tion sensor and
(E10) No. 1 — Engine ground: ECM connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
2 CHECK HARNESS BETWEEN CRANK- Is the resistance less than Repair ground Go to step 3.
SHAFT POSITION SENSOR AND ECM 10 Ω? short circuit in
Measure resistance of harness between crankshaft posi-
crankshaft position sensor connector and tion sensor and
engine ground. ECM connector.
Connector & terminal NOTE:
(E10) No. 1 — Engine ground: The harness
between both
connectors are
shielded. Repair
ground short cir-
cuit in harness
together with
shield.
3 CHECK HARNESS BETWEEN CRANK- Is the resistance less than Go to step 4. Repair harness
SHAFT POSITION SENSOR AND ECM 5 Ω? and connector.
CONNECTOR. NOTE:
Measure resistance of harness between In this case,
crankshaft position sensor connector and repair the follow-
engine ground. ing:
crankshaft posi-
tion sensor and
ECM connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
4 CHECK CONDITION OF CRANKSHAFT Is the crankshaft position Go to step 5. Tighten crankshaft
POSITION SENSOR. sensor installation bolt position sensor
tightened securely? installation bolt
securely.
5 CHECK CRANKSHAFT POSITION SENSOR. Is the resistance between 1 Repair poor con- Replace crank-
1) Remove crankshaft position sensor. and 4 kΩ? tact in crankshaft shaft position sen-
2) Measure resistance between connector position sensor sor. <Ref. to
terminals of crankshaft position sensor. connector. FU(SOHC)-29,
Terminals Crankshaft Posi-
No. 1 — No. 2: tion Sensor.>
EN(SOHC)-171
AG: DTC P0336 — CRANKSHAFT POSITION SENSOR CIRCUIT


쐌 Engine stalls.
CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2086
EN(SOHC)-172

Monitor or OBD-II general P0335 using “17.
scan tool indicate DTC List of Diagnostic
P0335? Trouble Code
(DTC)”. <Ref. to
EN(SOHC)-80,
List of Diagnostic
Trouble Code
(DTC).>
Turn ignition switch to OFF. tightened securely? installation bolt
securely.
3 CHECK CRANKSHAFT SPROCKET. Are crankshaft sprocket Replace crank- Go to step 4.
Remove front belt cover. teeth cracked or damaged? shaft sprocket.
<Ref. to
ME(SOHC)-46,
Crankshaft
Sprocket.>
4 CHECK INSTALLATION CONDITION OF Is timing belt dislocated Repair installation Replace crank-
TIMING BELT. from its proper position? condition of timing shaft position sen-
Turn crankshaft using ST, and align alignment belt. <Ref. to sor. <Ref. to
mark on crankshaft sprocket with alignment ME(SOHC)-46, FU(SOHC)-29,
mark on cylinder block. Timing Belt Crankshaft Posi-
ST 499987500 CRANKSHAFT SOCKET Assembly.> tion Sensor.>
EN(SOHC)-173
AH: DTC P0340 — CAMSHAFT POSITION SENSOR CIRCUIT MALFUNCTION

— S058521B44

쐌 Engine stalls.
CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
B2M4312
EN(SOHC)-174

1 CHECK HARNESS BETWEEN CAMSHAFT Is the resistance more than Repair harness Go to step 2.
POSITION SENSOR AND ECM CONNEC- 100 kΩ? and connector.
TOR. NOTE:
2) Disconnect connector from camshaft posi- repair the follow-
tion sensor. ing:
camshaft position sensor connector and harness between
engine ground. camshaft position
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
2 CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than Repair ground Go to step 3.
POSITION SENSOR AND ECM CONNEC- 10 Ω? short circuit in
Measure resistance of harness between cam- camshaft position
shaft position sensor connector and engine sensor and ECM
ground. connector.
between both
connectors are
shielded. Repair
ground short cir-
cuit in harness
together with
shield.
3 CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than Go to step 4. Repair harness
TOR. NOTE:
Measure resistance of harness between cam- In this case,
shaft position sensor connector and engine repair the follow-
ground. ing:
camshaft position
sensor and ECM
connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
4 CHECK CONDITION OF CAMSHAFT POSI- Is the camshaft position Go to step 5. Tighten camshaft
TION SENSOR. sensor installation bolt position sensor
securely.
5 CHECK CAMSHAFT POSITION SENSOR. Is the resistance between 1 Repair poor con- Replace camshaft
1) Remove camshaft position sensor. and 4 kΩ? tact in camshaft position sensor.
2) Measure resistance between connector position sensor <Ref. to
terminals of camshaft position sensor. connector. FU(SOHC)-30,
Terminals Camshaft Position
No. 1 — No. 2: Sensor.>
EN(SOHC)-175
AI: DTC P0341 — CAMSHAFT POSITION SENSOR CIRCUIT


쐌 Engine stalls.
CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
B2M4312
EN(SOHC)-176

1 CHECK ANY OTHER DTC ON DISPLAY. Inspect DTC
Does the Subaru Select Go to step 2.
P0340 using “17.
List of Diagnostic
P0340? Trouble Code
(DTC)”. <Ref. to
EN(SOHC)-80,
List of Diagnostic
Trouble Code
(DTC).>
TOR. NOTE:
tion sensor. ing:
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
ground. connector.
between both
connectors are
shielded. Repair
ground short cir-
cuit in harness
together with
shield.
TOR. NOTE:
ground. ing:
camshaft position
sensor and ECM
connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B21)
securely.
EN(SOHC)-177

6 CHECK CAMSHAFT POSITION SENSOR. Is the resistance between 1 Go to step 7. Replace camshaft
1) Remove camshaft position sensor. and 4 kΩ? position sensor.
2) Measure resistance between connector <Ref. to
terminals of camshaft position sensor. FU(SOHC)-30,
Terminals Camshaft Position
No. 1 — No. 2: Sensor.>
securely.
8 CHECK CAMSHAFT SPROCKET. Are camshaft sprocket Replace camshaft Go to step 9.
Remove front belt cover. <Ref. to ME(SOHC)- teeth cracked or damaged? sprocket. <Ref. to
45, Belt Cover.> ME(SOHC)-51,
Camshaft
Sprocket.>
9 CHECK INSTALLATION CONDITION OF Is timing belt dislocated Repair installation Replace camshaft
TIMING BELT. from its proper position? condition of timing position sensor.
Turn camshaft using ST, and align alignment belt. <Ref. to <Ref. to
mark on camshaft sprocket with alignment ME(SOHC)-46, FU(SOHC)-30,
mark on timing belt cover LH. Timing Belt Camshaft Position
ST 499207100 CAMSHAFT SPROCKET Assembly.> Sensor.>
WRENCH
EN(SOHC)-178
MEMO:
EN(SOHC)-179
AJ: DTC P0420 — CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD —

S058521B46

쐌 Engine stalls.
쐌 Idle mixture is out of specifications.
CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2087
EN(SOHC)-180

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect the rel- Go to step 2.
Monitor or OBD-II general evant DTC using
scan tool indicate DTC “17. List of Diag-
P0130, P0133, P0136, nostic Trouble
P0139, P0037, P0301, Code (DTC)”.
P0302, P0303, P0304, <Ref. to
P1130, P1131, P0031, EN(SOHC)-80,
P0032 and P0038? List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0420.
2 CHECK EXHAUST SYSTEM. Is there a fault in exhaust Repair or replace Go to step 3.
Check for gas leaks or air suction caused by system? exhaust system.
loose or dislocated nuts and bolts, and open <Ref. to
hole at exhaust pipes. EX(SOHC)-2,
NOTE: General Descrip-
Check the following positions. tion.>
쐌 Between cylinder head and front exhaust
pipe
쐌 Between front exhaust pipe and front cata-
lytic converter
쐌 Between front catalytic converter and rear
catalytic converter
3 CHECK REAR CATALYTIC CONVERTER. Is there damage at rear Replace front Go to step 4.
Separate rear catalytic converter from rear face of rear catalyst? catalytic converter
exhaust pipe. <Ref. to
EC(SOHC)-3.
Front Catalytic
Converter.> and
rear catalytic con-
verter <Ref. to
EC(SOHC)-6,
Rear Catalytic
Converter.>.
4 CHECK FRONT CATALYTIC CONVERTER. Is there damage at rear Replace front Contact your
Remove front catalytic converter. face or front face of front catalytic con- Subaru distributor.
catalyst? verter. <Ref. to NOTE:
EC(SOHC)-3, Inspection by
Front Catalytic DTM is required,
Converter.> because probable
cause is deterio-
ration of multiple
parts.
EN(SOHC)-181
AK: DTC P0444 — EVAPORATIVE EMISSION CONTROL SYSTEM PURGE

CONTROL VALVE CIRCUIT LOW INPUT — S058521G47

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2088
EN(SOHC)-182

1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 10 Even if MIL lights Go to step 2.
1) Turn ignition switch to ON. V? up, the circuit has
2) Measure voltage between ECM and chas- returned to a nor-
sis ground. mal condition at
Connector & terminal this time. Contact
(B134) No. 2 (+) — Chassis ground (−): with your Subaru
distributor.
NOTE:
Inspection by
DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
2 CHECK HARNESS BETWEEN PURGE Is the resistance less than Repair ground Go to step 3.
CONTROL SOLENOID VALVE AND ECM 10 Ω? short circuit in
1) Turn ignition switch to OFF. ECM and purge
2) Disconnect connectors from purge control control solenoid
solenoid valve and ECM. valve connector.
purge control solenoid valve connector and
engine ground.
3 CHECK HARNESS BETWEEN PURGE Is the resistance less than Go to step 4. Repair open cir-
CONTROL SOLENOID VALVE AND ECM 1 Ω? cuit in harness
CONNECTOR. between ECM
Measure resistance of harness between ECM and purge control
and purge control solenoid valve of harness solenoid valve
connector. connector.
(B134) No. 2 — (E4) No. 2: In this case,
repair the follow-
ing:
쐌 Open circuit in
harness between
ECM and purge
control solenoid
valve connector
쐌 Poor contact in
coupling connec-
tor (B22)
4 CHECK PURGE CONTROL SOLENOID Is the resistance between Go to step 5. Replace purge
VALVE. 10 and 100 Ω? control solenoid
1) Remove purge control solenoid valve. valve. <Ref. to
2) Measure resistance between purge control EC(SOHC)-8,
solenoid valve terminals. Purge Control
Terminals Solenoid Valve.>
No. 1 — No. 2:
5 CHECK POWER SUPPLY TO PURGE CON- Is the voltage more than 10 Go to step 6. Repair open cir-
TROL SOLENOID VALVE. V? cuit in harness
1) Turn ignition switch to ON. between main
2) Measure voltage between purge control relay and purge
solenoid valve and engine ground. control solenoid
Connector & terminal valve connector.
EN(SOHC)-183

Check poor contact in purge control solenoid purge control solenoid tact in purge con- Subaru distributor.
valve connector. valve connector? trol solenoid valve NOTE:
connector. Inspection by
DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
EN(SOHC)-184
MEMO:
EN(SOHC)-185
AL: DTC P0445 — EVAPORATIVE EMISSION CONTROL SYSTEM PURGE

CONTROL VALVE CIRCUIT HIGH INPUT — S058521G48

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2088
EN(SOHC)-186

1 CHECK OUTPUT SIGNAL FROM ECM. Does voltage change Go to step 2. Even if MIL light
1) Turn ignition switch to OFF. between 0 and 10 V? up, the circuit has
2) Connect test mode connector at the lower returned to a nor-
portion of instrument panel (on the driver’s mal condition at
side), to the side of the center console box. this time. In this
3) Turn ignition switch to ON. case, repair poor
4) While operating purge control solenoid contact in ECM
valve, measure voltage between ECM and connector.
chassis ground.
NOTE:
Purge control solenoid valve operation can be
executed using Subaru Select Monitor. For
procedure, refer to “Compulsory Valve Opera-
tion Check Mode”. <Ref. to EN(SOHC)-46,
Compulsory Valve Operation Check Mode.>
sis ground.
Engine Control
Module.>
4 CHECK HARNESS BETWEEN PURGE Is the voltage more than 10 Repair battery Go to step 5.
CONTROL SOLENOID VALVE AND ECM V? short circuit in
2) Disconnect connector from purge control control solenoid
solenoid valve. valve connector.
3) Turn ignition switch to ON. After repair,
4) Measure voltage between ECM and chas- replace ECM.
sis ground. <Ref. to
Connector & terminal FU(SOHC)-49,
(B134) No. 2 (+) — Chassis ground (−): Engine Control
Module.>
5 CHECK PURGE CONTROL SOLENOID Is the resistance less than Replace purge Go to step 6.
VALVE. 1 Ω? control solenoid
1) Turn ignition switch to OFF. valve <Ref. to
2) Measure resistance between purge control EC(SOHC)-8,
solenoid valve terminals. Purge Control
Terminals Solenoid Valve.>
No. 1 — No. 2: and ECM <Ref. to
FU(SOHC)-49,
Engine Control
Module.>
Engine Control
Module.>
EN(SOHC)-187
AM: DTC P0461 — FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM — S058521B54

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2089
EN(SOHC)-188

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Replace fuel level
Monitor or OBD-II general P0462 or P0463 sensor <Ref. to
scan tool indicate DTC using “17. List of FU(SOHC)-64,
P0462 or P0463? Diagnostic Fuel Level Sen-
Trouble Code sor.> and fuel sub
(DTC)”. <Ref. to level sensor <Ref.
EN(SOHC)-80, to FU(SOHC)-65,
List of Diagnostic Fuel Sub Level
Trouble Code Sensor.>.
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect this
trouble.
EN(SOHC)-189
AN: DTC P0462 — FUEL LEVEL SENSOR CIRCUIT LOW INPUT — S058521B55

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2089

1 CHECK SPEEDOMETER AND TACHOM- Does speedometer and Go to step 2. Repair or replace
ETER OPERATION IN COMBINATION tachometer operate nor- combination
METER. mally? meter. <Ref. to
IDI-4, Combina-
tion Meter Sys-
tem.>
EN(SOHC)-190

2 CHECK INPUT SIGNAL FOR ECM. Is the voltage less than Go to step 6. Go to step 3.
1) Turn ignition switch to ON. (Engine OFF) 0.12 V?
and chassis ground.
(−):
3 CHECK INPUT SIGNAL FOR ECM. (USING Does the value change Repair poor con- Even if MIL lights
SUBARU SELECT MONITOR.) less than 0.12 V by shak- tact in ECM con- up, the circuit has
Read data of fuel level sensor signal using ing harness and connector nector. returned to a nor-
Subaru Select Monitor. of ECM while monitoring mal condition at
NOTE: the value with Subaru this time. A tem-
쐌 Subaru Select Monitor Select Monitor? porary poor con-
For detailed operation procedure, refer to the tact of the con-
“READ CURRENT DATA FOR ENGINE”. nector may be the
<Ref. to EN(SOHC)-34, Subaru Select Moni- cause.
tor.> NOTE:
In this case,
repair the follow-
ing:
쐌 Poor contact in
combination meter
connector
쐌 Poor contact in
ECM connector
4 CHECK INPUT VOLTAGE OF ECM. Is the voltage more than Go to step 4. Go to step 7.
1) Turn ignition switch to OFF. 0.12 V?
2) Separate fuel tank cord connector (R57)
and rear wiring harness connector (R15).
4) Measure voltage of harness between ECM
(−):
COMBINATION METER. 1 MΩ? short circuit in
2) Disconnect connector from connector (i11) ECM and combi-
and ECM connector. nation meter con-
3) Measure resistance between ECM and nector.
chassis ground.
6 CHECK HARNESS BETWEEN ECM AND Is the resistance less than Repair or replace Repair open cir-
COMBINATION METER. 10 Ω? combination cuit between ECM
Measure resistance between ECM and combi- meter. <Ref. to and combination
nation meter connector. IDI-4, Combina- meter connector.
Connector & terminal tion Meter Sys- NOTE:
(B136) No. 27 — (i11) No. 1: tem.> In this case,
repair the follow-
ing:
Poor contact in
coupling connec-
tor (i2)
EN(SOHC)-191

7 CHECK FUEL TANK CORD. Is the resistance more than Go to step 8. Repair ground
1) Turn ignition switch to OFF. 1 MΩ? short circuit in fuel
2) Disconnect connector from fuel sub level tank cord.
sensor.
sensor and chassis ground.
1) Disconnect connector from fuel pump 1 MΩ? short circuit in fuel
assembly. tank cord.
2) Measure resistance between fuel pump
assembly and chassis ground.
9 CHECK FUEL LEVEL SENSOR. Is the resistance between Go to step 10. Replace fuel level
WARNING: 0.5 and 2.5 Ω? sensor.
During work procedures, if fuel tank is
more than 3/4 full, be careful because fuel
may spill.
FU(SOHC)-62 Fuel Pump.>
sor and terminals with its float set to the full
position.
Terminals
No. 3 — No. 5:
10 CHECK FUEL SUB LEVEL SENSOR. Is the resistance between Repair poor con- Replace fuel sub
WARNING: 0.5 and 2.5 Ω? tact in harness level sensor.
During work procedures, if fuel tank is between ECM
more than 3/4 full, be careful because fuel and combination
may spill. meter connector.
1) Remove fuel sub level sensor. <Ref. to
FU(SOHC)-65, Fuel Sub Level Sensor.>
sensor and terminals with its float set to the
full position.
Terminals
No. 1 — No. 2:
EN(SOHC)-192
MEMO:
EN(SOHC)-193
AO: DTC P0463 — FUEL LEVEL SENSOR CIRCUIT HIGH INPUT — S058521B56

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2089

IDI-4, Combina-
tion Meter Sys-
tem.>
EN(SOHC)-194

2 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than Go to step 3. Even if MIL lights
1) Turn ignition switch to ON. (Engine OFF) 4.75 V? up, the circuit has
2) Measure voltage between ECM connector returned to a nor-
and chassis ground. mal condition at
Connector & terminal this time. A tem-
(B136) No. 27 (+) — Chassis ground porary poor con-
(−): tact of the con-
nector may be the
cause.
NOTE:
In this case,
repair the follow-
ing:
쐌 Poor contact in
fuel pump con-
nector
쐌 Poor contact in
coupling connec-
tor (B22, B37 and
R57)
3 CHECK INPUT VOLTAGE OF ECM. Is the voltage more than Go to step 4. Repair battery
1) Turn ignition switch to OFF. 4.75 V? short circuit
2) Disconnect combination meter connector between ECM
(i11) and ECM connector. and combination
3) Turn ignition switch to ON. meter connector.
and chassis ground.
(−):
FUEL TANK CORD. 5 Ω? cuit between ECM
1) Turn ignition switch to OFF. and fuel tank
2) Separate fuel tank cord connector (R57) cord.
3) Measure resistance between ECM and fuel
tank cord.
(B136) No. 27 — (R15) No. 2:
5 CHECK HARNESS BETWEEN FUEL TANK Is the resistance less than Go to step 6. Repair open cir-
CORD AND CHASSIS GROUND. 5 Ω? cuit between fuel
Measure resistance between fuel tank cord tank cord and
and chassis ground. chassis ground.
(R15) No. 6 — Chassis ground: In this case,
repair the follow-
ing:
Poor contact in
coupling connec-
tors (B22 and
B99)
6 CHECK FUEL TANK CORD. Is the resistance less than Go to step 7. Repair open cir-
1) Disconnect connector from fuel level sen- 10 Ω? cuit between cou-
sor. pling connector
2) Measure resistance between fuel level sen- and fuel level sen-
sor and coupling connector. sor.
(R57) No. 6 — (R58) No. 5:
EN(SOHC)-195

1) Disconnect connector from fuel sub level 10 Ω? cuit between fuel
sensor. level sensor and
2) Measure resistance between fuel level sen- fuel sub level sen-
sor and fuel sub level sensor. sor.
(R58) No. 3 — (R59) No. 2:
Measure resistance between fuel sub level 10 Ω? cuit between cou-
sensor and coupling connector. pling connector
Connector & terminal and fuel sub level
(R57) No. 2 — (R59) No. 1: sensor.
9 CHECK FUEL LEVEL SENSOR. Is the resistance more than Replace fuel level Go to step 10.
WARNING: 54.5 Ω? sensor. <Ref. to
During work procedures, if fuel tank is FU(SOHC)-64,
more than 3/4 full, be careful because fuel Fuel Level Sen-
may spill. sor.>
FU(SOHC)-62, Fuel Pump.>
2) While moving fuel level sensor float up and
down, measure resistance between fuel level
sensor terminals.
Terminals
No. 3 — No. 5:
10 CHECK FUEL SUB LEVEL SENSOR. Is the resistance more than Replace fuel sub Replace combina-
WARNING: 41.5 Ω? level sensor. tion meter. <Ref.
During work procedures, if fuel tank is <Ref. to to IDI-15, Combi-
more than 3/4 full, be careful because fuel FU(SOHC)-65, nation Meter
may spill. Fuel Sub Level Assembly.>
1) Remove fuel sub level sensor. <Ref. to Sensor.>
2) While moving fuel sub level sensor float up
and down, measure resistance between fuel
sub level sensor terminals.
Terminals
No. 1 — No. 2:
EN(SOHC)-196
MEMO:
EN(SOHC)-197
AP: DTC P0464 — FUEL LEVEL SENSOR INTERMITTENT INPUT— S058521G01

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2089
EN(SOHC)-198

scan tool indicate DTC using “17. List of
Trouble Code
(DTC)”. <Ref. to
EN(SOHC)-80,
List of Diagnostic
Trouble Code
(DTC).>
2 CHECK FUEL LEVEL SENSOR. Does the resistance Go to step 3. Replace fuel level
WARNING: change smoothly? sensor. <Ref. to
During work procedures, if fuel tank is FU(SOHC)-64,
more than 3/4 full, be careful because fuel Fuel Level Sen-
may spill. sor.>
FU(SOHC)-62, Fuel Pump.>
2) While moving fuel level sensor float up and
down, make sure that the resistance between
fuel level sensor terminals changes smoothly.
Terminals
No. 3 — No. 5:
3 CHECK FUEL SUB LEVEL SENSOR. Does the resistance Repair poor con- Replace fuel sub
WARNING: change smoothly? tact in ECM, com- level sensor.
During work procedures, if fuel tank is bination meter <Ref. to
more than 3/4 full, be careful because fuel and coupling con- FU(SOHC)-65,
may spill. nectors. Fuel Sub Level
1) Remove fuel sub level sensor. <Ref. to Sensor.>
2) While moving fuel sub level sensor float up
and down, make sure that the resistance
between fuel level sensor terminals changes
smoothly.
Terminals
No. 1 — No. 2:
EN(SOHC)-199
AQ: DTC P0480 — COOLING FAN RELAY 1 CIRCUIT LOW INPUT — S058521B57

쐌 Radiator fan does not operate properly.
쐌 Overheating
CAUTION:
Inspection Mode.>.
EN(SOHC)-200
쐌 WIRING DIAGRAM:
S2M2090
EN(SOHC)-201

1 CHECK OUTPUT SIGNAL FROM ECM. Does voltage change Repair poor con- Go to step 2.
1) Turn ignition switch to OFF. between 0 and 10 V? tact in ECM con-
2) Connect test mode connector at the lower nector.
portion of instrument panel (on the driver’s
side), to the side of the center console box.
4) While operating radiator fan relay, measure
voltage between ECM terminal and ground.
NOTE:
Radiator fan relay operation can be executed
using Subaru Select Monitor. For procedure,
refer to “Compulsory Valve Operation Check
Mode”. <Ref. to EN(SOHC)-34, Subaru Select
Monitor.>
2 CHECK GROUND SHORT CIRCUIT IN Is the resistance less than Repair ground Go to step 3.
RADIATOR MAIN FAN RELAY CONTROL 10 Ω? short circuit in
CIRCUIT. radiator main fan
1) Turn ignition switch to OFF. relay control cir-
2) Disconnect connectors from ECM. cuit.
3 CHECK POWER SUPPLY FOR RELAY. Is the voltage more than 10 Go to step 4. Repair open cir-
1) Remove main fan relay from A/C relay V? cuit in harness
holder. between ignition
2) Turn ignition switch to ON. switch and fuse
3) Measure voltage between fuse and relay and relay box
box (F/B) connector and chassis ground. (F/B) connector.
4 CHECK MAIN FAN RELAY. Is the resistance between Go to step 5. Replace main fan
1) Turn ignition switch to OFF. 87 and 107 Ω? relay.
2) Measure resistance between main fan
relay terminals.
Terminal
No. 28 — No. 27:
5 CHECK OPEN CIRCUIT IN MAIN FAN Is the resistance less than Go to step 6. Repair harness
RELAY CONTROL CIRCUIT. 1 Ω? and connector.
and main fan relay connector. In this case,
(B134) No. 3 — (F66) No. 27: ing:
쐌 Open circuit in
harness between
ECM and main
fan relay connec-
tor
쐌 Poor contact in
coupling connec-
tor (F45, F46)
Check poor contact in ECM or main fan relay ECM or main fan relay contact in ECM or Subaru distributor.
connector. nector? main fan relay
connector.
EN(SOHC)-202
MEMO:
EN(SOHC)-203
AR: DTC P0483 — COOLING FAN FUNCTION PROBLEM — S058521B58

쐌 Occurrence of noise
쐌 Overheating
CAUTION:
Inspection Mode.>.
NOTE:
If the vehicle, with the engine idling, is placed very close to a wall or another vehicle, preventing normal
cooling function, the OBD system may detect malfunction.
EN(SOHC)-204
쐌 WIRING DIAGRAM:
S2M2090
EN(SOHC)-205

1 CHECK ANY OTHER DTC ON DISPLAY. Is there any other DTC on Inspect the rel- Check radiator fan
display? evant DTC using and fan motor.
“17. List of Diag- <Ref. to CO-8,
nostic Trouble Radiator Main
Code (DTC)”. Fan System.> and
<Ref. to <Ref. to CO-11,
EN(SOHC)-80, Radiator Sub Fan
List of Diagnostic System.>
Trouble Code
(DTC).>
EN(SOHC)-206
MEMO:
EN(SOHC)-207
AS: DTC P0500 — VEHICLE SPEED SENSOR MALFUNCTION — S058521B59

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2091

AT?
EN(SOHC)-208

2 CHECK DTC P0720 ON DISPLAY. Does the Subaru Select Check front Go to step 3.
Monitor or OBD-II general vehicle speed
scan tool indicate DTC sensor signal cir-
P0720? cuit. <Ref. to
AT-58, TROUBLE
CODE 33 —
FRONT VEHICLE
SPEED SENSOR
—, Diagnostic
Procedure with
Trouble Code.>
3 CHECK SPEEDOMETER OPERATION IN Does speedometer operate Go to step 4. Check speedom-
COMBINATION METER. normally? eter and vehicle
speed sensor.
<Ref. to IDI-17,
Speedometer.>
and <Ref. to
AT-32, Front
Vehicle Speed
Sensor.> and
<Ref. to AT-36,
Rear Vehicle
Speed Sensor.>
and <Ref. to
AT-37, Torque
Converter Turbine
Speed Sensor.>
4 CHECK HARNESS BETWEEN ECM AND Is the resistance less than Repair poor con- Repair harness
COMBINATION METER CONNECTOR. 10 Ω? tact in ECM con- and connector.
1) Turn ignition switch to OFF. nector. NOTE:
2) Disconnect connector from combination In this case,
meter. repair the follow-
3) Measure resistance between ECM and ing:
combination meter. 쐌 Open circuit in
(B135) No. 24 — (i10) No. 7: ECM and combi-
nation meter con-
nector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
combination meter
connector
쐌 Poor contact in
coupling connec-
tor (i2)
EN(SOHC)-209
AT: DTC P0506 — IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED
— S058521B61

쐌 Engine is difficult to start.
쐌 Engine does not start.
쐌 Engine stalls.
CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2092
EN(SOHC)-210

P1510, P1511, P1512, P1514, P1515,
P1513, P1514, P1515, P1516 or P1517
P1516 or P1517? using “17. List of
Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN(SOHC)-80,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0506.
2 CHECK AIR BY-PASS LINE. Does air flow out? Replace idle air Replace throttle
1) Turn ignition switch to OFF. control solenoid body. <Ref. to
2) Remove idle air control solenoid valve from valve. <Ref. to FU(SOHC)-14,
throttle body. <Ref. to FU(SOHC)-38, FU(SOHC)-38, INSTALLATION,
REMOVAL, Idle Air Control Solenoid Valve.> INSTALLATION, Throttle Body.>
3) Remove throttle body from intake manifold. Idle Air Control
<Ref. to FU(SOHC)-14, REMOVAL, Throttle Solenoid Valve.>
Body.>
4) Using an air gun, force air into idle air con-
trol solenoid valve installation area. Confirm
that forced air subsequently escapes from
throttle body interior.
EN(SOHC)-211
AU: DTC P0507 — IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED
— S058521B62

쐌 Engine keeps running at higher revolution than specified idling revolution.
CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2092
EN(SOHC)-212

P1510, P1511, P1512, P1514, P1515,
P1513, P1514, P1515, P1516 or P1517
Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN(SOHC)-80,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0507.
2 CHECK AIR INTAKE SYSTEM. Is there a fault in air intake Repair air suction Go to step 3.
1) Turn ignition switch to ON. system? and leaks.
2) Start engine, and idle it.
3) Check the following items.
쐌 Loose installation of intake manifold, idle air
control solenoid valve and throttle body
쐌 Cracks of intake manifold gasket, idle air
control solenoid valve gasket and throttle
body gasket
쐌 Disconnections of vacuum hoses
3 CHECK THROTTLE CABLE. Does throttle cable have Go to step 4. Adjust throttle
play for adjustment? cable. <Ref. to
SP-12,
INSTALLATION,
Accelerator Con-
trol Cable.>
4 CHECK AIR BY-PASS LINE. Are foreign particles in by- Remove foreign Replace idle air
1) Turn ignition switch to OFF. pass air line? particles from by- control solenoid
2) Remove idle air control solenoid valve from pass air line. valve. <Ref. to
throttle body. <Ref. to FU(SOHC)-38, FU(SOHC)-38,
REMOVAL, Idle Air Control Solenoid Valve.> INSTALLATION,
3) Confirm that there are no foreign particles Idle Air Control
in by-pass air line. Solenoid Valve.>
EN(SOHC)-213
AV: DTC P0512 — STARTER SWITCH CIRCUIT HIGH INPUT — S058521G02

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2093
EN(SOHC)-214

1 CHECK OPERATION OF STARTER MOTOR. Does starter motor operate Repair battery Check starter
NOTE: when ignition switch to short circuit in motor circuit.
Place the inhibitor switch in each position. “ON”? starter motor cir- <Ref. to
cuit. After repair, EN(SOHC)-60,
replace ECM. STARTER
<Ref. to MOTOR CIRCUIT,
FU(SOHC)-49, Diagnostics for
Engine Control Engine Starting
Module.> Failure.>
EN(SOHC)-215
AW: DTC P0562 — CHARGE SYSTEM CIRCUIT LOW INPUT — S058521G81

쐌 Power source voltage of the ECM is low.
쐌 Charge warning light comes on.
CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2094
EN(SOHC)-216

1 CHECK GENERATOR. Is the voltage less than Go to step 2. Repair generator.
1) Start engine. 10.8 V? <Ref. to SC-12,
Terminal
ground (–):
2 CHECK GENERATOR. Is the voltage less than Go to step 3. Repair generator.
1) Run engine at 5,000 rpm. 10.8 V? <Ref. to SC-12,
2) Measure voltage between generator B ter- Generator.>
Terminal
ground (−):
clamped?
4 CHECK INPUT VOLTAGE OF ECM. Is the voltage less than Go to step 5. Repair harness
1) Run the engine at idle. 10.8 V? connector
2) Measure voltage between ECM connector between battery,
and chassis ground. main relay and
Connector & terminal ECM.
ECM?
6 CHECK ECM. Is the same trouble code Replace genera- Go to step 7.
1) Connect all connectors. as in the current diagnosis tor.
2) Erase the memory. <Ref. to EN(SOHC)-45, still being output?
Clean Memory Mode.>
3) Perform inspection mode. <Ref. to
EN(SOHC)-42, Inspection Mode.>
4) Read out the trouble code. <Ref. to
EN(SOHC)-41, Read Diagnostic Trouble
Code.>
sponding to the
trouble code.
EN(SOHC)-217
AX: DTC P0563 — CHARGE SYSTEM CIRCUIT HIGH INPUT — S058521G82

쐌 Power source voltage of the ECM is high.
CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2094
EN(SOHC)-218

1 CHECK GENERATOR. Is the voltage more than Go to step 2. Repair generator.
1) Start engine. 16.2 V? <Ref. to SC-12,
Terminal
ground (–):
2 CHECK GENERATOR. Is the voltage more than Go to step 3. Repair generator.
1) Run engine at 5,000 rpm. 16.2 V? <Ref. to SC-12,
Terminal
ground (−):
clamped?
4 CHECK INPUT VOLTAGE OF ECM. Is the voltage more than Go to step 5. Repair harness
1) Run the engine at idle. 16.2 V? connector
2) Measure voltage between ECM connector between battery,
and chassis ground. main relay and
Connector & terminal ECM.
ECM?
2) Erase the memory. <Ref. to EN(SOHC)-45, still being output?
Clear Memory Mode.>
EN(SOHC)-42, Inspection Mode.>
EN(SOHC)-41, Read Diagnostic Trouble
Code.>
sponding to the
trouble code.
EN(SOHC)-219
AY: DTC P0604 — INTERNAL CONTROL MODULE MEMORY CHECK SUM

ERROR — S058521G03

쐌 Engine stalls.
CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2095
EN(SOHC)-220

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Replace ECM. It is not necessary
Monitor or OBD-II general <Ref. to to inspect DTC
scan tool indicate DTC FU(SOHC)-49, P0601.
P0601? Engine Control
Module.>
EN(SOHC)-221
AZ: DTC P0703 — BRAKE SWITCH INPUT MALFUNCTION — S058521B64

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2102

1 CHECK OPERATION OF BRAKE LIGHT. Does brake light come on Go to step 2. Repair or replace
when depressing the brake brake light circuit.
pedal?
EN(SOHC)-222

2 CHECK HARNESS BETWEEN TCM AND Is the resistance less than Go to step 3. Repair or replace
BRAKE LIGHT SWITCH CONNECTOR. 1 Ω? harness and con-
1) Disconnect connectors from TCM and nector.
brake light switch. NOTE:
TCM and brake light switch connector. repair the follow-
(B55) No. 12 — (B64) No. 2: 쐌 Open circuit in
(B55) No. 12 — (B65) No. 3 (With harness between
cruise control): TCM and brake
light switch con-
nector
쐌 Poor contact in
TCM connector
쐌 Poor contact in
brake light switch
connector
3 CHECK HARNESS BETWEEN TCM AND Is the resistance more than Go to step 4. Repair ground
BRAKE LIGHT SWITCH CONNECTOR. 1 MΩ? short circuit in
Measure resistance of harness between TCM harness between
and chassis ground. TCM and brake
Connector & terminal light switch con-
(B55) No. 12 — Chassis ground: nector.
4 CHECK INPUT SIGNAL FOR TCM. Is the voltage less than 1 V Go to step 5. Adjust or replace
1) Connect connectors to TCM and brake when releasing the brake brake light switch.
light switch. pedal? <Ref. to LI-31,
2) Measure voltage between TCM and chas- STOP LIGHT
sis ground. SWITCH,
Connector & terminal INSPECTION,
(B55) No. 12 (+) — Chassis ground (−): Stop Light Sys-
tem.>
5 CHECK INPUT SIGNAL FOR TCM. Is the voltage more than 10 Go to step 6. Adjust or replace
Measure voltage between TCM and chassis V when depressing the brake light switch.
ground. brake pedal? <Ref. to LI-31,
Connector & terminal STOP LIGHT
(B55) No. 12 (+) — Chassis ground (−): SWITCH,
INSPECTION,
Stop Light Sys-
tem.>
6 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace TCM.
Check poor contact in TCM connector. TCM connector? tact in TCM con- <Ref. to AT-48,
nector. Transmission
Control Module.>
EN(SOHC)-223
BA: DTC P0731 — GEAR 1 INCORRECT RATIO — S058521B70
NOTE:
For the diagnostic procedure, refer to DTC P0734. <Ref. to EN(SOHC)-225, DTC P0734 — GEAR 4
INCORRECT RATIO —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
BB: DTC P0732 — GEAR 2 INCORRECT RATIO — S058521B71
NOTE:
BC: DTC P0733 — GEAR 3 INCORRECT RATIO — S058521B72
NOTE:
EN(SOHC)-224
BD: DTC P0734 — GEAR 4 INCORRECT RATIO — S058521B73

쐌 Shift point too high or too low; engine brake not effected in “3” range; excessive shift shock; exces-
sive tight corner “braking”
CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
1 CHECK ANY OTHER DTC ON DISPLAY. Is there any other DTC on Inspect relevant Go to step 2.
display? DTC using “17.
List of Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN(SOHC)-80,
List of Diagnostic
Trouble Code
(DTC).>
2 CHECK THROTTLE POSITION SENSOR Is there any trouble in Repair or replace Go to step 3.
CIRCUIT. throttle position sensor cir- throttle position
Check throttle position sensor circuit. <Ref. to cuit? sensor circuit.
AT-50, TROUBLE CODE 31 — THROTTLE
POSITION SENSOR —, Diagnostic Proce-
dure with Trouble Code.>
3 CHECK FRONT VEHICLE SPEED SENSOR Is there any trouble in Repair or replace Go to step 4.
CIRCUIT. vehicle speed sensor 2 cir- vehicle speed
Check front vehicle speed sensor circuit. cuit? sensor 2 circuit.
<Ref. to AT-58, TROUBLE CODE 33 —
FRONT VEHICLE SPEED SENSOR —, Diag-
nostic Procedure with Trouble Code.>
4 CHECK TORQUE CONVERTER TURBINE Is there any trouble in Repair or replace Go to step 5.
SPEED SENSOR CIRCUIT. torque converter turbine torque converter
Check torque converter turbine speed sensor speed sensor circuit? turbine speed
circuit. <Ref. to AT-64, TROUBLE CODE 36 sensor circuit.
— TORQUE CONVERTER TURBINE SPEED
SENSOR —, Diagnostic Procedure with
Trouble Code.>
Check poor contact in TCM connector. TCM connector? tact in TCM con-
nector.
6 CHECK MECHANICAL TROUBLE. Is there any mechanical Repair or replace Replace TCM.
Check mechanical trouble in automatic trans- trouble in automatic trans- automatic trans- <Ref. to AT-48,
mission. mission? mission. <Ref. to Transmission
AT-12, Control Module
INSPECTION, (TCM).>
Road Test.>
EN(SOHC)-225
BE: DTC P0741 — TORQUE CONVERTER CLUTCH SYSTEM MALFUNCTION

— S058521G04

쐌 No lock-up (after engine warm-up)
쐌 No shift or excessive tight corner “braking”
CAUTION:
Inspection Mode.>.
1 CHECK ANY OTHER DTC ON DISPLAY. Is there any other DTC on Inspect the rel- Go to step 2.
display? evant DTC using
“17. List of Diag-
nostic Trouble
Code (DTC)”.
<Ref. to
EN(SOHC)-80,
List of Diagnostic
Trouble Code
(DTC).>
2 CHECK LOCK-UP DUTY SOLENOID CIR- Is there any trouble in Repair or replace Go to step 3.
CUIT. lock-up duty solenoid cir- lock-up duty sole-
Check lock-up duty solenoid circuit. <Ref. to cuit? noid circuit.
AT-96, TROUBLE CODE 77 — LOCK-UP
DUTY SOLENOID —, Diagnostic Procedure
with Trouble Code.>
Trouble Code.>
5 CHECK ENGINE SPEED INPUT CIRCUIT. Is there any trouble in Repair or replace Go to step 6.
Check engine speed input circuit. <Ref. to engine speed input circuit? engine speed
AT-42, TROUBLE CODE 11 — ENGINE input circuit.
SPEED SIGNAL —, Diagnostic Procedure
with Trouble Code.>
6 CHECK INHIBITOR SWITCH CIRCUIT. Is there any trouble in Repair or replace Go to step 7.
Check inhibitor switch circuit. <Ref. to AT-122, inhibitor switch circuit? inhibitor switch
CHECK INHIBITOR SWITCH, Diagnostic Pro- circuit.
cedure for No-trouble Code.>
7 CHECK BRAKE LIGHT SWITCH CIRCUIT. Is there any trouble in Repair or replace Go to step 8.
Check brake light switch circuit. <Ref. to brake light switch circuit? brake light switch
AT-111, CHECK BRAKE SWITCH, Diagnostic circuit.
Procedure for No-trouble Code.>
EN(SOHC)-226

8 CHECK ATF TEMPERATURE SENSOR CIR- Is there any trouble in ATF Repair or replace Go to step 9.
CUIT. temperature sensor circuit? ATF temperature
Check ATF temperature sensor circuit. <Ref. sensor circuit.
to AT-46, TROUBLE CODE 27 — ATF TEM-
PERATURE SENSOR —, Diagnostic Proce-
nector.
INSPECTION, (TCM).>
Road Test.>
EN(SOHC)-227
BF: DTC P1110 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT LOW

INPUT — S058521B84

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2096
EN(SOHC)-228

1 CHECK CURRENT DATA. Is the value less than 0 Go to step 3. Go to step 2.
1) Start engine. kPa (0 mmHg, 0 inHg)?
2) Read the data of intake manifold absolute
NOTE:
tor.>
sensor connector. connector? atmospheric pres- returned to a nor-
sure sensor con- mal condition at
nector. this time.
and chassis ground.
(−):
cause is deterio-
ration of multiple
parts.
Measure voltage between ECM and chassis V?
ground.
(−):
SUBARU SELECT MONITOR.) more than 0 kPa (0 mmHg, tact in ECM con-
Read data of atmospheric absolute pressure 0 inHg) by shaking harness nector.
signal using Subaru Select Monitor. and connector of ECM
NOTE: while monitoring the value
쐌 Subaru Select Monitor with Subaru select moni-
For detailed operation procedure, refer to the tor?
tor.>
EN(SOHC)-229

ATMOSPHERIC PRESSURE SENSOR CON- 4.5 V? and connector.
NECTOR. NOTE:
2) Disconnect connector from atmospheric repair the follow-
pressure sensor. ing:
4) Measure voltage between atmospheric harness between
pressure sensor connector and engine ECM and atmo-
ground. spheric pressure
Connector & terminal sensor connector
(B2) No. 3 (+) — Engine ground (−): 쐌 Poor contact in
joint connector
LHD: (B122)
RHD: (B83)
ATMOSPHERIC PRESSURE SENSOR CON- 1 Ω? and connector.
NECTOR. NOTE:
ECM and pressure sensor connector. 쐌 Open circuit in
(B136) No. 16 — (B2) No. 1: ECM and pres-
sure sensor con-
nector
ATMOSPHERIC PRESSURE SENSOR CON- 500 kΩ? short circuit in
NECTOR. harness between
Measure resistance of harness between pres- ECM and pres-
sure sensor connector and engine ground. sure sensor con-
10 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace atmo-
Check poor contact in pressure sensor con- pressure sensor connec- tact in atmospheric pressure
nector. tor? spheric pressure sensor. <Ref. to
sensor connector. FU(SOHC)-37,
Atmospheric Pres-
sure Sensor .>
EN(SOHC)-230
MEMO:
EN(SOHC)-231
BG: DTC P1111 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT HIGH

INPUT — S058521B85

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2096
EN(SOHC)-232

1 CHECK CURRENT DATA. Is the value more than 140 Go to step 10. Go to step 2.
1) Start engine. kPa (1,050 mmHg, 41.34
NOTE:
tor.>
and chassis ground.
(−):
cause is deterio-
ration of multiple
parts.
and chassis ground.
(−):
SUBARU SELECT MONITOR.) more than 0 kPa (0 mmHg, tact in ECM con-
Read data of atmospheric absolute pressure 0 inHg) by shaking harness nector.
signal using Subaru Select Monitor. and connector of ECM
NOTE: while monitoring the value
쐌 Subaru Select Monitor with Subaru select moni-
For detailed operation procedure, refer to the tor?
tor.>
PRESSURE SENSOR CONNECTOR. 4.5 V? and connector.
2) Disconnect connector from atmospheric In this case,
pressure sensor. repair the follow-
4) Measure voltage between atmospheric 쐌 Open circuit in
pressure sensor connector and engine harness between
ground. ECM and pres-
Connector & terminal sure sensor con-
(B2) No. 3 (+) — Engine ground (−): nector
쐌 Poor contact in
joint connector
LHD: B122
RHD: B83
EN(SOHC)-233

PRESSURE SENSOR CONNECTOR. 1 Ω? and connector.
ECM and pressure sensor connector. ing:
(B136) No. 29 — (B2) No. 2: harness between
ECM and pres-
sure sensor con-
nector
쐌 Poor contact in
joint connector
LHD: B122
RHD: B83
PRESSURE SENSOR CONNECTOR. 1 Ω? and connector.
and pressure sensor connector. In this case,
(B136) No. 16 — (B2) No. 1: ing:
쐌 Open circuit in
harness between
ECM and pres-
sure sensor con-
nector
쐌 Poor contact in
joint connector
LHD: B122
RHD: B83
9 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace atmo-
Check poor contact in pressure sensor con- pressure sensor connec- tact in atmospheric pressure
nector. tor? spheric pressure sensor. <Ref. to
sensor connector. FU(SOHC)-37,
Atmospheric Pres-
sure Sensor .>
10 CHECK CURRENT DATA. Is the value more than 140 Repair battery Replace atmo-
1) Turn ignition switch to OFF. kPa (1,050 mmHg, 41.34 short circuit in spheric pressure
2) Disconnect connector from atmospheric inHg)? harness between sensor. <Ref. to
pressure sensor. ECM and atmo- FU(SOHC)-37,
3) Turn ignition switch to ON. spheric pressure Atmospheric Pres-
4) Read data of intake manifold absolute sensor connector. sure Sensor.>
pressure signal using Subaru select monitor
NOTE:
tor.>
EN(SOHC)-234
MEMO:
EN(SOHC)-235
BH: DTC P1112 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT RANGE/

PERFORMANCE PROBLEM — S058521B86

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2096
EN(SOHC)-236

NOTE: Monitor or OBD-II general P0106, P0107,
In this case, it is not necessary to inspect scan tool indicate DTC P0108, P1110 or
DTC P0106. P0106, P0107, P0108, P1111 using “17.
P1110 or P1111? List of Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN(SOHC)-80,
List of Diagnostic
Trouble Code
(DTC).>
2 CHECK ATMOSPHERIC PRESSURE SEN- Is atmospheric pressure Replace atmo- Go to step 3.
SOR FILTER. sensor filter non-functional? spheric pressure
1) Turn ignition switch to OFF. (Check for contamination, sensor filter.
2) Disconnect connector from atmospheric damage, water leakage,
pressure sensor. etc.)
3) Remove atmospheric pressure sensor.
4) Check atmospheric pressure sensor filter.
3 CHECK CURRENT DATA. Is the value between 73.3 Replace atmo- Replace intake air
1) Turn ignition switch to ON. kPa (550 mmHg, 21.65 spheric pressure temperature and
2) Read data of intake manifold absolute inHg) and 106.6 kPa (800 sensor. <Ref. to pressure sensor.
pressure signal using Subaru Select Monitor mmHg, 31.50 inHg)? FU(SOHC)-37, <Ref. to
or OBD-II general scan tool. Atmospheric Pres- FU(SOHC)-36,
NOTE: sure Sensor .> Intake Air Tem-
쐌 Subaru Select Monitor perature and
For detailed operation procedure, refer to the Pressure Sensor.>
tor.>
EN(SOHC)-237
BI: DTC P1137 — FRONT OXYGEN (A/F) SENSOR CIRCUIT

RANGE/PERFORMANCE PROBLEM — S058521G49

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2077
EN(SOHC)-238

P0032? Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN(SOHC)-80,
List of Diagnostic
Trouble Code
(DTC).>
2 CHECK FRONT OXYGEN (A/F) SENSOR Is the value equal to or Go to step 3. Go to step 4.
70°C (160°F).
general scan tool.
NOTE:
tor.>
3 CHECK FRONT OXYGEN (A/F) SENSOR Is the value more than 1.1 Go to step 6. Go to step 4.
DATA. for a moment?
Race engine at speeds from idling to 5,000
rpm for a total of 5 cycles.
NOTE:
To increase engine speed to 5,000 rpm,
slowly depress accelerator pedal, taking
FRONT OXYGEN (A/F) SENSOR. 5 Ω? cuit between ECM
1) Turn ignition switch to OFF. and front oxygen
2) Disconnect connector from ECM and front (A/F) sensor.
oxygen (A/F) sensor connector.
3) Measure resistance between ECM and
front oxygen (A/F) sensor.
Connector & terminals
(B136) No. 6 — (E24) No. 1:
(B136) No. 7 — (E24) No. 6:
(B136) No. 19 — (E24) No. 3:
(B136) No. 20 — (E24) No. 4:
EN(SOHC)-239

FRONT OXYGEN (A/F) SENSOR. 1 MΩ? short circuit
Measure resistance between ECM and chas- between ECM
sis ground. and front oxygen
Connector & terminals (A/F) sensor.
NOTE: <Ref. to
Check the following items. FU(SOHC)-45,
쐌 Loose installation of portions Front Oxygen
쐌 Damage (crack, hole etc.) of parts (A/F) Sensor.>
쐌 Looseness of front oxygen (A/F) sensor
sensor
EN(SOHC)-240
MEMO:
EN(SOHC)-241
BJ: DTC P1142 — THROTTLE POSITION SENSOR CIRCUIT

RANGE/PERFORMANCE PROBLEM (LOW INPUT) — S058521B99

쐌 Engine stalls.
CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2082
EN(SOHC)-242

scan tool indicate DTC using “17. List of <Ref. to
P0122 or P0123? Diagnostic FU(SOHC)-33
Trouble Code Throttle Position
EN(SOHC)-80,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P1142.
EN(SOHC)-243
BK: DTC P1146 — PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM (HIGH INPUT) — S058521G07

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2097
EN(SOHC)-244

In this case, it is not necessary to inspect scan tool indicate DTC P1112 using “17.
DTC P0106. P0107, P0108 or P1112? List of Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN(SOHC)-80,
List of Diagnostic
Trouble Code
(DTC).>
air intake system?
3 CHECK PRESSURE SENSOR. Is the value within the Go to step 4. Replace intake air
1) Start the engine and warm-up engine until specifications? temperature sen-
coolant temperature is greater than 60°C sor and pressure
(140°F). sensor. <Ref. to
2) Place the shift lever in the selector lever in FU(SOHC)-36,
“N” or “P” position. Intake Air Tem-
3) Turn A/C switch to OFF. perature and
4) Turn all accessory switches to OFF. Pressure Sensor.>
NOTE:
tor.>
Specification:
Ignition ON
73.3 — 106.6 kPa (550 — 800 mmHg,
21.65 — 31.50 inHg)
Idling
20.0 — 46.7 kPa (150 — 350 mmHg,
5.91 — 13.78 inHg)
4 CHECK THROTTLE POSITION. Is throttle positioning ratio Go to step 5. Adjust or replace
Read data of throttle position signal using equal to or less than 5% throttle position
Subaru Select Monitor or OBD-II general scan when throttle is fully sensor. <Ref. to
tool. closed? FU(SOHC)-33,
NOTE: Throttle Position
쐌 Subaru Select Monitor Sensor.>
tor.>
EN(SOHC)-245

5 CHECK THROTTLE POSITION. Is throttle positioning ratio Replace intake air Replace throttle
equal to or more than 85% temperature and position sensor.
when throttle is fully open? pressure sensor. <Ref. to
<Ref. to FU(SOHC)-33,
FU(SOHC)-36, Throttle Position
Intake Air Tem- Sensor.>
perature and
Pressure Sensor.>
EN(SOHC)-246
MEMO:
EN(SOHC)-247
BL: DTC P1442 — FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM 2 — S058521C11

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2089
EN(SOHC)-248

Monitor or OBD-II general P0461, P0462 or sensor <Ref. to
scan tool indicate DTC P0463 using “17. FU(SOHC)-64,
P0461, P0462 or P0463? List of Diagnostic Fuel Level Sen-
Trouble Code sor.> and fuel sub
(DTC)”. <Ref. to level sensor.
EN(SOHC)-80, <Ref. to
List of Diagnostic FU(SOHC)-65,
Trouble Code Fuel Sub Level
(DTC).> Sensor.>
NOTE:
In this case, it is
not necessary to
inspect this
trouble.
EN(SOHC)-249
BM: DTC P1480 — COOLING FAN RELAY 1 CIRCUIT HIGH INPUT — S058521G08

쐌 Overheating
CAUTION:
Inspection Mode.>.
EN(SOHC)-250
쐌 WIRING DIAGRAM:
S2M2090
EN(SOHC)-251

1 CHECK OUTPUT SIGNAL FROM ECM. Does voltage change Even if MIL lights Go to step 2.
4) While operating radiator fan relay, measure contact in ECM
voltage between ECM and chassis ground. connector.
NOTE:
Mode”. <Ref. to EN(SOHC)-46, Compulsory
Valve Operation Check Mode.>
2 CHECK SHORT CIRCUIT IN RADIATOR Is the voltage more than 10 Repair battery Go to step 3.
FAN RELAY CONTROL CIRCUIT. V? short circuit in
1) Turn ignition switch to OFF. radiator fan relay
2) Remove main fan relay and sub fan relay. control circuit.
(with A/C models) After repair,
3) Disconnect test mode connector. replace ECM.
4) Turn ignition switch to ON. <Ref. to
5) Measure voltage between ECM and chas- FU(SOHC)-49,,
sis ground. Engine Control
Connector & terminal Module.>
3 CHECK MAIN FAN RELAY. Is the resistance less than Replace main fan Go to step 4.
1) Turn ignition switch to OFF. 1 Ω? relay and ECM.
2) Remove main fan relay. <Ref. to
3) Measure resistance between main fan FU(SOHC)-49,
relay terminals. Engine Control
Terminal Module.>
No. 25 — No. 26:
4 CHECK SUB FAN RELAY. Is the resistance less than Replace sub fan Go to step 5.
1) Remove sub fan relay. 1 Ω? relay and ECM.
2) Measure resistance between sub fan relay <Ref. to
terminals. FU(SOHC)-49,
Terminal Engine Control
No. 23 — No. 24 Module.>
Engine Control
Module.>
EN(SOHC)-252
MEMO:
EN(SOHC)-253
BN: DTC P1507 — IDLE CONTROL SYSTEM MALFUNCTION (FAIL-SAFE) —

S058521C16

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2098
EN(SOHC)-254

P1510, P1511, P1512, P1514, P1515,
P1513, P1514, P1515, P1516 or P1517
Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN(SOHC)-80,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0507.
body gasket
SP-12,
INSTALLATION,
Accelerator Con-
trol Cable.>
throttle body. <Ref. to FU(SOHC)-38, Idle Air FU(SOHC)-38,
Control Solenoid Valve.> Idle Air Control
3) Confirm that there are no foreign particles Solenoid Valve.>
in by-pass air line.
EN(SOHC)-255
BO: DTC P1510 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 1

CIRCUIT LOW INPUT — S058521C17
NOTE:
For the diagnostic procedure, refer to DTC P1516. <Ref. to EN(SOHC)-258, DTC 1516 — IDLE AIR CON-
TROL SOLENOID VALVE SIGNAL 4 CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic
BP: DTC P1511 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 1
CIRCUIT HIGH INPUT — S058521C18
NOTE:
TROL SOLENOID VALVE SIGNAL 4 CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic
BQ: DTC P1512 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 2
NOTE:
BR: DTC P1513 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 2
NOTE:
BS: DTC P1514 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 3
NOTE:
BT: DTC P1515 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 3
NOTE:
EN(SOHC)-256
MEMO:
EN(SOHC)-257
BU: DTC P1516 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 4


쐌 Engine stalls.
쐌 Engine breathing
CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2098
EN(SOHC)-258

1 CHECK POWER SUPPLY TO IDLE AIR Is the voltage more than 10 Go to step 2. Repair harness
CONTROL SOLENOID VALVE. V? and connector.
2) Disconnect connector from idle air control In this case,
solenoid valve. repair the follow-
4) Measure voltage between idle air control 쐌 Open circuit in
solenoid valve connector and engine ground. harness between
Connector & terminal idle air control
and main relay
connector
쐌 Poor contact in
coupling connec-
tor (B22)
Measure voltage between idle air control sole- NOTE:
noid valve connector and engine ground. In this case,
(E7) No. 5 (+) — Engine ground (−): ing:
쐌 Open circuit in
harness between
idle air control
solenoid valve
and main relay
connector
쐌 Poor contact in
coupling connec-
tor (B22)
IDLE AIR CONTROL SOLENOID VALVE 1 Ω? and connector.
CONNECTOR. NOTE:
2) Measure resistance between ECM and idle repair the follow-
air control solenoid valve connector. ing:
DTC P1510; (B134) No. 5 — (E7) No. 4: harness between
DTC P1512; (B134) No. 6 — (E7) No. 1: ECM and idle air
DTC P1514; (B134) No. 19 — (E7) No. control solenoid
6: valve connector
DTC P1516; (B134) No. 20 — (E7) No. 쐌 Poor contact in
3: coupling connec-
tor (B21)
IDLE AIR CONTROL SOLENOID VALVE 10 Ω? short circuit in
1) Disconnect connector from ECM. ECM and idle air
2) Measure resistance between ECM connec- control solenoid
tor and chassis ground. valve connector.
DTC P1510; (B134) No. 5 — Chassis
ground:
ground:
ground:
ground:
EN(SOHC)-259

5 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace idle air
Check poor contact in ECM connector and ECM connector or idle air tact in ECM con- control solenoid
idle air control solenoid valve connector. control solenoid valve connector or idle air valve. <Ref. to
nector? control solenoid FU(SOHC)-38,
valve connector. Idle Air Control
Solenoid Valve.>
EN(SOHC)-260
MEMO:
EN(SOHC)-261
BV: DTC P1517 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 4


쐌 Engine stalls.
CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2098
EN(SOHC)-262

P1511, P1513, P1515 and
P1517 at same time?
2 CHECK GROUND CIRCUIT FOR ECM. Is the resistance less than Go to step 3. Repair harness
2) Measure resistance between ECM connec- NOTE:
tor and chassis ground. In this case,
쐌 Open circuit in
harness between
ECM connector
and engine
ground terminal
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor (B22)
3 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 10 Repair battery Replace ECM.
IDLE AIR CONTROL SOLENOID VALVE V? short circuit in <Ref. to
CONNECTOR. harness between FU(SOHC)-49,
1) Turn ignition switch to OFF. ECM and idle air Engine Control
2) Disconnect connector from idle air control control solenoid Module.>
4) Measure voltage between ECM connector replace ECM.
and chassis ground. <Ref. to
DTC P1511; (B134) No. 5 (+) — Chassis Engine Control
ground (–): Module.>
DTC P1513; (B134) No. 6 (+) — Chassis
ground (–):
DTC P1515; (B134) No. 19 (+) — Chas-
sis ground (–):
DTC P1517; (B134) No. 20 (+) — Chas-
sis ground (–):
EN(SOHC)-263
BW: DTC P1518 — STARTER SWITCH CIRCUIT LOW INPUT — S058521G09

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2099
EN(SOHC)-264

1 CHECK OPERATION OF STARTER MOTOR. Does starter motor operate Repair harness Check starter
NOTE: when ignition switch to and connector. motor circuit.
Place the inhibitor switch in the “P” or “N” “ST”? NOTE: <Ref. to
position. In this case, EN(SOHC)-60,
repair the follow- STARTER
ing: MOTOR CIRCUIT,
쐌 Open or ground Diagnostic for
short circuit in Engine Starting
harness between Failure.>
ECM and starter
motor connector.
쐌 Poor contact in
ECM connector.
EN(SOHC)-265
BX: DTC P1540 — VEHICLE SPEED SENSOR MALFUNCTION 2 — S058521C26

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2100
EN(SOHC)-266

AT-58, TROUBLE
CODE 33 —
FRONT VEHICLE
SPEED SENSOR
—, Diagnostic
Procedure with
Trouble Code.>
speed sensor.
<Ref. to IDI-17,
Speedometer.>
nation meter con-
nector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
combination meter
connector
쐌 Poor contact in
coupling connec-
tor (i2)
EN(SOHC)-267
BY: DTC P1560 — BACK-UP VOLTAGE CIRCUIT MALFUNCTION — S058521C27

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2101

1 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 10 Repair poor con- Go to step 2.
1) Turn ignition switch to OFF. V? tact in ECM con-
sis ground.
EN(SOHC)-268

MAIN FUSE BOX CONNECTOR. 10 Ω? short circuit in
1) Disconnect connector from ECM. harness between
2) Measure resistance of harness between ECM connector
ECM and chassis ground. and battery termi-
Connector & terminal nal.
3 CHECK FUSE SBF-5. Is fuse blown? Replace fuse. Repair harness
and connector.
NOTE:
In this case,
repair the follow-
ing:
쐌 Open circuit in
harness between
ECM and battery
쐌 Poor contact in
ECM connector
쐌 Poor contact in
battery terminal
EN(SOHC)-269
BZ: DTC P1590 — NEUTRAL POSITION SWITCH CIRCUIT HIGH INPUT (AT
MODEL) — S058521G83

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2099
EN(SOHC)-270

1 CHECK DTC P0705 ON DISPLAY. Does the Subaru Select Inspect DTC Go to step 2.
P0705? Trouble Code
(DTC)”. <Ref. to
EN(SOHC)-80,
List of Diagnostic
Trouble Code
(DTC).>
2 CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 1 Go to step 3. Go to step 5.
sis ground in selector lever “N” and “P” posi-
tions.
(−):
3 CHECK INPUT SIGNAL FOR ECM. Is the voltage between 4.5 Go to step 4. Go to step 5.
Measure voltage between ECM and chassis and 5.5 V?
ground in selector lever except for “N” and “P”
positions.
(−):
Check poor contact in ECM connector. ECM connector? tact in ECM con- Subaru distributor.
nector. NOTE:
Inspection by
DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
5 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 10 Repair battery Go to step 6.
Measure voltage between ECM and chassis V? short circuit in
ground. harness between
Connector & terminal ECM and inhibitor
(B135) No. 26 (+) — Chassis ground switch connector.
(−):
INHIBITOR SWITCH CONNECTOR. 1 Ω? and connector.
2) Disconnect connectors from ECM and In this case,
inhibitor switch. repair the follow-
ECM and inhibitor switch connector. 쐌 Open circuit in
(B135) No. 26 — (T7) No. 12: ECM and inhibitor
switch connector
쐌 Poor contact in
coupling connec-
tor (B12)
쐌 Poor contact in
inhibitor switch
connector
쐌 Poor contact in
ECM connector
EN(SOHC)-271

7 CHECK INHIBITOR SWITCH GROUND Is the resistance less than Go to step 8. Repair open cir-
LINE. 5 Ω? cuit in harness
Measure resistance of harness between between inhibitor
inhibitor switch connector and engine ground. switch connector
Connector & terminal and starter motor
(T7) No. 7 — Engine ground: ground line.
NOTE:
In this case,
repair the follow-
ing:
쐌 Open circuit in
harness between
inhibitor switch
connector and
starter motor
ground line
쐌 Poor contact in
starter motor con-
nector
쐌 Poor contact in
starter motor
ground
쐌 Starter motor
8 CHECK INHIBITOR SWITCH. Is the resistance less than Go to step 9. Replace inhibitor
Measure resistance between inhibitor switch 1 Ω? switch. <Ref. to
connector receptacle’s terminals in selector AT-28, Inhibitor
lever “N” and “P” positions. Switch.>
Terminals
No. 7 — No. 12:
9 CHECK SELECTOR CABLE CONNECTION. Is there any fault in selec- Repair selector Contact your
tor cable connection to cable connection. Subaru distributor.
inhibitor switch? <Ref. to CS-11, NOTE:
INSPECTION, Inspection by
Select Cable.> DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
EN(SOHC)-272
MEMO:
EN(SOHC)-273
CA: DTC P1591 — NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT (AT
MODEL) — S058521G84

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2099
EN(SOHC)-274

P0705? Trouble Code
(DTC)”. <Ref. to
EN(SOHC)-80,
List of Diagnostic
Trouble Code
(DTC).>
2 CHECK INPUT SIGNAL FOR ECM. Is the voltage between 4.5 Even if MIL lights Go to step 3.
1) Turn ignition switch to ON. and 5.5 V at except “N” up, the circuit has
2) Measure voltage between ECM and chas- and “P” positions? returned to a nor-
Connector & terminal this time.
(−):
TRANSMISSION HARNESS CONNECTOR. 10 Ω? short circuit in
2) Disconnect connectors from ECM and ECM and trans-
transmission harness connector (T3). mission harness
3) Measure resistance of harness between connector.
4 CHECK TRANSMISSION HARNESS CON- Is the resistance less than Repair ground Go to step 5.
NECTOR. 10 Ω? short circuit in
1) Disconnect connector from inhibitor switch. harness between
2) Measure resistance of harness between transmission har-
transmission harness connector and engine ness and inhibitor
ground. switch connector.
(T3) No. 12 — Engine ground:
5 CHECK INHIBITOR SWITCH. Is the resistance more than Go to step 6. Replace inhibitor
Measure resistance between inhibitor switch 1 MΩ at except “N” and “P” switch. <Ref. to
connector receptacle’s terminals in selector positions? AT-28, Inhibitor
lever except for “N” position. Switch.>
Terminals
No. 7 — No. 12:
INSPECTION, Inspection by
Select Cable.> DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
EN(SOHC)-275
CB: DTC P1592 — NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT (MT
MODEL) — S058521G85

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2103
EN(SOHC)-276

1) Turn ignition switch to ON. 10V in neutral position?
sis ground.
(−):
2 CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 1V Go to step 3. Go to step 4.
Measure voltage between ECM and chassis in other position?
ground.
(−):
3 CHECK POOR CONTACT. Is the poor contact in ECM Repair poor con- Contact your dis-
Check poor contact in ECM connector. connector? tact in ECM con- tributor.
nector.
4 CHECK NEUTRAL POSITION SWITCH. Is the resistance more than Go to step 5. Repair short cir-
1) Turn ignition switch to OFF. 1MΩ in neutral position? cuit in transmis-
2) Disconnect connector from transmission sion harness or
harness. replace neutral
3) Measure resistance between transmission position switch.
harness and connector terminals.
(T2) No. 1 — No. 2:
5 CHECK NEUTRAL POSITION SWITCH. Is the resistance less than Go to step 6. Repair short cir-
Measure resistance between transmission 1Ω in other positions? cuit in transmis-
harness connector terminals. sion harness or
replace neutral
position switch.
NEUTRAL POSITION SWITCH CONNEC- 10 Ω? short circuit in
Measure resistance between ECM and chas- ECM and trans-
sis ground. mission harness
NEUTRAL POSITION SWITCH CONNEC- 1 Ω? cuit in harness
TOR. between ECM
1) Disconnect connector from ECM. and transmission
2) Measure resistance of harness between harness connec-
ECM and transmission harness connector. tor.
LHD: (B135) No. 26 — (B25) No. 1:
RHD: (B135) No. 26 — (B25) No. 2:
NEUTRAL POSITION SWITCH CONNEC- 5 Ω? cuit between
TOR. transmission har-
Measure resistance of harness between ness connector
transmission harness connector and engine and engine
ground. ground terminal.
9 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Contact your dis-
Check poor contact in transmission harness transmission harness contact in transmis- tributor.
connector. nector? sion harness con-
nector.
EN(SOHC)-277
CC: DTC P1594 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL

CIRCUIT MALFUNCTION — S058521G12

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
B2M3963

1 CHECK DRIVING CONDITION. Is AT shift control function- Go to step 2. Replace TCM.
1) Start and warm-up the engine until the ing properly? <Ref. to AT-48,
radiator fan makes one complete rotation. Transmission
2) Drive the vehicle. Control Module
(TCM).>
EN(SOHC)-278

2 CHECK ACCESSORY. Are car phone and/or CB Repair grounding Replace TCM.
installed on vehicle? line of car phone <Ref. to AT-48,
or CB system. Transmission
Control Module
(TCM).>
EN(SOHC)-279
CD: DTC P1595 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL

CIRCUIT LOW INPUT — S058521G13

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
B2M3963
EN(SOHC)-280

1 CHECK HARNESS BETWEEN ECM AND Is the voltage less than 1 Go to step 2. Even if MIL lights
TCM CONNECTOR. V? up, the circuit has
1) Turn ignition switch to ON. returned to a nor-
2) Measure voltage between ECM and chas- mal condition at
sis ground. this time.
(B135) No. 4 (+) — Chassis ground (−): In this case,
repair the follow-
ing:
쐌 Poor contact in
ECM connector
쐌 Poor contact in
TCM connector
TCM CONNECTOR. 10 Ω? short circuit in
2) Disconnect connector from ECM and TCM. ECM and TCM
ECM and chassis ground.
3 CHECK OUTPUT SIGNAL FOR ECM. Is the voltage more than 5 Go to step 4. Repair poor con-
1) Connect connector to ECM. V? tact in ECM con-
2) Turn ignition switch to ON. nector.
sis ground.
4 CHECK TROUBLE CODE FOR AUTOMATIC Does trouble code appear Inspect trouble Replace TCM.
TRANSMISSION. for automatic transmission? code for auto- <Ref. to AT-48,
Read trouble code for automatic transmission. matic transmis- Transmission
<Ref. to AT-22, Read Diagnostic Trouble sion. <Ref. to Control Module
Code.> AT-42, Diagnostic (TCM).>
Procedure with
Trouble Code.>
EN(SOHC)-281
CE: DTC P1596 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL

CIRCUIT HIGH INPUT — S058521G14

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
B2M3963
EN(SOHC)-282

1 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 10 Repair battery Go to step 2.
TCM CONNECTOR. V? short circuit in
1) Turn ignition switch to ON. harness between
2) Measure voltage between ECM and chas- ECM and TCM
sis ground. connector. After
(B135) No. 4 (+) — Chassis ground (−): ECM. <Ref. to
FU(SOHC)-49,
Engine Control
Module.>
2 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 4 Go to step 5. Go to step 3.
TCM CONNECTOR. V?
Measure voltage between ECM connector
and chassis ground.
3 CHECK HARNESS BETWEEN ECM AND Is the voltage less than 1 Repair poor con- Go to step 4.
TCM CONNECTOR. V? tact in ECM con-
Measure voltage between ECM connector nector.
and chassis ground.
4 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change Even if MIL lights Contact your
Measure voltage between ECM and chassis from 1 V to 4 V while moni- up, the circuit has Subaru distributor.
ground. toring the value with volt- returned to a nor- NOTE:
Connector & terminal age meter? mal condition at Inspection by
(B135) No. 4 (+) — Chassis ground (−): this time. DTM is required,
NOTE: because probable
In this case, cause is deterio-
repair the follow- ration of multiple
ing: parts.
쐌 Poor contact in
ECM connector
쐌 Poor contact in
TCM connector
5 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 4 Go to step 6. Repair open cir-
TCM CONNECTOR. V? cuit in harness
Measure voltage between TCM and chassis between ECM
ground. and TCM connec-
6 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Check TCM
Check poor contact in TCM connector. TCM connector? tact in TCM con- power supply line
nector. and grounding
line.
EN(SOHC)-283
CF: DTC P1698 — ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT LOW
INPUT — S058521G15

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
B2M3960
EN(SOHC)-284

1) Start engine, and warm-up the engine. V? tact in ECM con-
2) Turn ignition switch to OFF. nector.
sis ground.
(−):
2) Disconnect connectors from ECM and ECM and TCM
TCM. connector.
3 CHECK HARNESS BETWEEN ECM AND Is the resistance less than Repair poor con- Repair open cir-
TCM CONNECTOR. 1 Ω? tact in ECM or cuit in harness
Measure resistance of harness between ECM TCM connector. between ECM
and TCM connector. and TCM connec-
(B134) No. 31 — (B54) No. 2:
EN(SOHC)-285
CG: DTC P1699 — ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT HIGH
INPUT — S058521G16

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
B2M3960
EN(SOHC)-286

1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage less than 3 Go to step 2. Repair battery
1) Start engine, and warm-up the engine. V? short circuit in
3) Disconnect connector from TCM. ECM and TCM
4) Turn ignition switch to ON. connector. After
5) Measure voltage between ECM and chas- repair, replace
sis ground. ECM. <Ref. to
(B134) No. 31 (+) — Chassis ground Engine Control
(−): Module.>
2 CHECK HARNESS BETWEEN ECM AND Does the voltage change Repair battery Contact your
TCM CONNECTOR. more than 10 V by shaking short circuit in Subaru distributor.
1) Turn ignition switch to OFF. harness and connector of harness between NOTE:
2) Measure voltage between ECM and chas- ECM while monitoring the ECM and TCM Inspection by
sis ground. value with voltage meter? connector. After DTM is required,
Connector & terminal repair, replace because probable
(B134) No. 31 (+) — Chassis ground ECM. <Ref. to cause is deterio-
(−): FU(SOHC)-49, ration of multiple
Engine Control parts.
Module.>
EN(SOHC)-287
CH: DTC P1701 — CRUISE CONTROL SET SIGNAL CIRCUIT MALFUNCTION

FOR AUTOMATIC TRANSMISSION — S058521C29

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
B2M3962
EN(SOHC)-288

1 CHECK HARNESS BETWEEN TCM AND Is the resistance less than Go to step 2. Repair open cir-
CCM CONNECTOR. 1 Ω? cuit in harness
1) Turn ignition switch to OFF. between TCM and
2) Disconnect connectors from TCM and CCM connector.
CCM.
TCM and CCM connector.
(B54) No. 11 — (B94) No. 3:
2 CHECK HARNESS BETWEEN TCM AND Is the resistance less than Repair short cir- Go to step 3.
Measure resistance of harness between TCM between TCM and
and chassis ground. CCM connector.
3 CHECK INPUT SIGNAL FOR TCM. Is the resistance less than Go to step 4. Check cruise con-
1) Connect connector to TCM and CCM. 1 V? trol command
2) Lift-up the vehicle or set the vehicle on free switch circuit.
rollers. <Ref. to CC-10,
CAUTION: INSPECTION,
On AWD models, raise all wheels off Cruise Control
ground. Command
3) Start the engine. Switch.>
4) Cruise control main switch to ON.
5) Move selector lever to “D” and slowly
increase vehicle speed to 50 km/h (31 MPH).
6) Cruise control command switch to ON.
7) Measure voltage between TCM and chas-
sis ground.
Control Module
(TCM).>
EN(SOHC)-289
CI: DTC P1711 — ENGINE TORQUE CONTROL SIGNAL 1 CIRCUIT

MALFUNCTION — S058521G17

쐌 Excessive shift shock
CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
B2M3957
EN(SOHC)-290

1) Turn ignition switch to ON. 4.5 V?
sis ground.
(−):
Connector & terminal ECM and TCM
(B135) No. 16 (+) — Chassis ground connector.
(−):
Engine Control
Module.>
TCM CONNECTOR. 1 Ω? cuit in harness
2) Disconnect connectors from ECM and and TCM connec-
TCM. tor.
ECM and TCM connector.
(B135) No. 16 — (B54) No. 13:
and chassis ground. ECM and TCM
Control Module
(TCM).>
EN(SOHC)-291
CJ: DTC P1712 — ENGINE TORQUE CONTROL SIGNAL 2 CIRCUIT


CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
B2M3958
EN(SOHC)-292

sis ground.
(−):
(−):
Engine Control
Module.>
TCM. tor.
(B135) No. 17 — (B54) No. 21:
Control Module
(TCM).>
EN(SOHC)-293
19. General Diagnostic Table

S058257
1. ENGINE S058257A1001
NOTE:
Malfunction of parts other than those listed is also possible. <Ref. to ME(SOHC)-87, Engine Trouble in
General.>
Symptom Problem parts
1) Idle air control solenoid valve
2) Intake air temperature and pressure sensor
3) Ignition parts (*1)
1. Engine stalls during idling. 4) Engine coolant temperature sensor (*2)
5) Crankshaft position sensor (*3)
6) Camshaft position sensor (*3)
7) Fuel injection parts (*4)
3) Engine coolant temperature sensor (*2)
5) Air intake system (*5)
2. Rough idling 6) Fuel injection parts (*4)
7) Throttle position sensor
10) Oxygen sensor
11) Fuel pump and fuel pump relay
2) Engine coolant temperature sensor
3. Engine does not return to idle. 3) Accelerator cable (*6)
4. Poor acceleration
8) A/C switch and A/C cut relay
9) Engine torque control signal circuit
5. Engine stalls or engine sags or hesitates at 4) Camshaft position sensor (*3)
acceleration. 5) Purge control solenoid valve
EN(SOHC)-294

1) Intake manifold pressure sensor
2) Intake air temperature sensor
6. Surge 5) Crankshaft position sensor (*3)
7. Spark knock 4) Engine coolant temperature sensor
5) Knock sensor
8. After burning in exhaust system
*1: Check ignition coil & ignitor assembly and spark plug.
*2: Indicate the symptom occurring only in cold temperatures.
*3: Ensure the secure installation.
*4: Check fuel injector, fuel pressure regulator and fuel filter.
*5: Inspect air leak in air intake system.
*6: Adjust accelerator cable.
2. AUTOMATIC TRANSMISSION S058257A1002
NOTE:
Check general diagnostics table with non-conformity symptom for automatic transmission. <Ref. to AT-2,
Basic Diagnostic Procedure.>
EN(SOHC)-295
MEMO:
EN(SOHC)-296
ENGINE2 SECTION

SUBARU vehicles.
ine parts.

G8050GE3
FU(SOHCw/oOBD)
Page
2. Throttle Body .............................................................................................11
3. Intake Manifold ..........................................................................................12
6. Knock Sensor ............................................................................................25
8. Pressure Sensor........................................................................................29
9. Intake Air Temperature Sensor .................................................................30
11. Fuel Injector...............................................................................................32
12. Oxygen Sensor..........................................................................................36
14. Main Relay ................................................................................................39
15. Fuel Pump Relay.......................................................................................40
16. Fuel............................................................................................................41
17. Fuel Tank...................................................................................................44
18. Fuel Filler Pipe ..........................................................................................47
19. Fuel Pump .................................................................................................50
22. Fuel Filter ..................................................................................................54
23. Fuel Cut Valve...........................................................................................55
GENERAL DESCRIPTION
Model
Fuel tank
Type Impeller
Shutoff discharge pressure 373 — 677 kPa (3.8 — 6.9 kg/cm2, 54 — 98 psi)
Fuel pump
Discharge flow
[12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)]
FU(SOHCw/oOBD)-2
GENERAL DESCRIPTION
S2M1856B
(1) Intake manifold gasket (10) Nipple (LHD models) Tightening torque: N·m (kgf-m, ft-lb)
(2) Insulator A (11) Plug (RHD models)
T1: 4.9 (0.5, 3.6)
(3) Insulator B (12) Intake manifold
T2: 15.7 (1.6, 11.6)
(4) Fuel injector (13) Fuel pipe ASSY
T3: 19 (1.9, 13.7)
(5) O-ring (14) Fuel hose
(6) Nipple (RHD models) (15) Clip T4: 17 (1.7, 12)
(7) Plug (LHD models) (16) Fuel injector pipe RH T5: 25 (2.5, 18.1)
(8) PCV valve (17) Fuel injector pipe LH
(9) Purge control solenoid valve
FU(SOHCw/oOBD)-3
GENERAL DESCRIPTION
S2M1524A
(1) Gasket (5) Pressure sensor Tightening torque: N·m (kgf-m, ft-lb)
(2) Throttle position sensor (6) Throttle body
T1: 2.0 (0.2, 1.4)
(3) Gasket
T2: 3.4 (0.35, 2.5)
T3: 22 (2.2, 15.9)
FU(SOHCw/oOBD)-4
GENERAL DESCRIPTION
S2M1646A
(1) Crankshaft position sensor (2) Knock sensor Tightening torque: N·m (kgf-m, ft-lb)
T1: 6.4 (0.65, 4.7)
T2: 24 (2.4, 17)
FU(SOHCw/oOBD)-5
GENERAL DESCRIPTION
S2M0634A
FU(SOHCw/oOBD)-6
GENERAL DESCRIPTION
(1) Heat sealed cover (13) Evaporation hose C (25) Fuel return hose B
(3) Protector LH (15) Evaporation hose B (27) Jet pump filter
(5) Fuel tank (17) Evaporation hose D
(6) Fuel pump gasket (18) Jet pump hose A Tightening torque: N·m (kgf-m, ft-lb)
(7) Fuel pump ASSY (19) Fuel return tube T1: 4.4 (0.45, 3.3)
(8) Fuel level sensor (20) Retainer T2: 7.4 (0.75, 5.4)
(9) Fuel cut valve gasket (21) Quick connector T3: 33 (3.4, 25)
(10) Fuel cut valve (22) Jet pump hose B
(11) Evaporation hose A (23) Fuel pipe ASSY
(12) Clip (24) Evaporation hose E
FU(SOHCw/oOBD)-7
GENERAL DESCRIPTION
S2M2168A
(1) Clamp (7) Evaporation hose (13) Canister hose A

(2) Fuel delivery hose A (8) Clip (14) Two-way valve
(3) Fuel filter bracket (9) Fuel delivery hose B (15) Canister hose B
(4) Fuel filter holder (10) Fuel return hose (16) Canister hose C
(5) Fuel filter cup (11) Air vent hose (17) Canister bracket
(6) Fuel filter (12) Canister (18) Fuel pipe ASSY
FU(SOHCw/oOBD)-8
GENERAL DESCRIPTION
S2M2169A
(1) Fuel filler pipe ASSY (4) Filler pipe packing (7) Filler cap
(2) Clamp (5) Filler ring A (8) Filler pipe protector
(3) Fuel filler valve (6) Filler ring B
FU(SOHCw/oOBD)-9
GENERAL DESCRIPTION

tion.
ment.

B2M3876
B2M3877
498307600 CHECK BOARD KIT Troubleshooting for engine electrical system.
(1) CHECK BOARD: 498307610
(2) CHECK BOARD ADAPTER: 498307620
S2M2170A
FU(SOHCw/oOBD)-10
THROTTLE BODY

sensor.
S2M1651

G6M0095 body.
2) Remove air cleaner case. <Ref. to IN(SOHC)-7,
REMOVAL, Air Cleaner Case.>
S2M1652
8) Remove bolts which install throttle body to

intake manifold.
B2M2302A
5) Disconnect connectors from idle air control

solenoid valve (A) and intake manifold pressure
sensor (B).
S2M1653

NOTE:
Always use a new gasket.
S2M1650A
Tightening torque:
Throttle body;
22 N·m (2.2 kgf-m, 15.9 ft-lb)
Air cleaner case;
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
FU(SOHCw/oOBD)-11
INTAKE MANIFOLD

(3) Remove bolts which secure power steering
pipe brackets to intake manifold.
CAUTION:
1) Release fuel pressure. <Ref. to FU(SOHCw/ Do not disconnect power steering hose.
OPERATION, Fuel.>
S2M1013

pump to bracket.
G6M0095
4) Remove air cleaner case and air intake duct.

Case.> and <Ref. to IN(SOHC)-8, REMOVAL, Air
Intake Duct.>
S2M0488
(5) Disconnect terminal from power steering

pump switch.
B2M2302A

(1) Remove resonator chamber.
S2M0490
S2M0486
(2) Remove V-belts.

FU(SOHCw/oOBD)-12
INTAKE MANIFOLD
(6) Place power steering pump on the right side 11) Disconnect engine coolant hose from throttle
wheel apron. body.
S2M0491 S2M1652
8) Disconnect spark plug cords from spark plugs. 12) Remove bolt which installs ground terminal
onto cylinder head.
S6M0142
S2M1655
9) Disconnect PCV hose from intake manifold.
13) Disconnect brake booster hose.
S2M1654
S2M1656
10) Disconnect vacuum hose to cruise control dia-
phragm. (With cruise control models) 14) Disconnect canister hoses from pipes.
S2M0493C S2M0496
FU(SOHCw/oOBD)-13
INTAKE MANIFOLD
15) Remove air cleaner case stay RH and engine 19) Disconnect connector from crankshaft position
harness bracket (A), and disconnect engine har- sensor.
ness connectors (B) from bulkhead harness con-
nectors.
16) Pull out engine harness connector from
bracket.
B2M1252
20) Disconnect connector from oil pressure

switch.
S2M1657B
17) Disconnect connector from engine coolant

temperature sensor.
B2M1253
21) Disconnect fuel hoses from fuel pipes.

WARNING:
S2M1658 Catch fuel from hoses in a container.
S2M0500G
S2M1659 (A) Fuel delivery hose

(B) Return hose
FU(SOHCw/oOBD)-14
INTAKE MANIFOLD
22) Remove bolts which hold intake manifold onto B: INSTALLATION S165034A11
cylinder heads.
1) Install intake manifold onto cylinder heads.
NOTE:
Always use new gaskets.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
S2M1660
23) Remove intake manifold.
S2M1660
2) Connect fuel hoses.
B2M0160
S2M0500D

(B) Fuel return hose
(C Evaporation hose
3) Connect connector to oil pressure switch.
B2M1253
FU(SOHCw/oOBD)-15
INTAKE MANIFOLD
4) Connect connector to crankshaft position sen- 9) Tighten bolt which installs engine harness
sor. ground terminal.
B2M1252 S2M1655
5) Connect knock sensor connector. 10) Connect canister hoses to pipes.
S2M1659 S2M0496
6) Connect connectors to engine coolant tempera- 11) Connect brake booster hose.
ture sensor.
S2M1656
S2M1658
12) Connect engine coolant hose to throttle body.
7) Hold engine harness connector onto bracket.
8) Install air cleaner case stay RH and engine har-
ness bracket (A), and connect engine harness con-
nectors (B) to bulkhead connectors.
S2M1652
S2M1657B
FU(SOHCw/oOBD)-16
INTAKE MANIFOLD
13) Connect vacuum hose to cruise control dia- (2) Tighten bolts which install power steering
phragm. (With cruise control models) pump on bracket.
Tightening torque:
20.1 N·m (2.05 kgf-m, 14.8 ft-lb)
S2M0493C
14) Connect PCV hose to intake manifold.

S2M0488
(3) Install power steering pipe brackets on right

side intake manifold.
S2M1654
15) Connect spark plug cords to spark plugs.

S2M1013
(4) Install power steering pump drive V-belt.

<Ref. to ME(SOHC)-42, INSTALLATION,
V-belt.>
(5) Install resonator chamber.
Tightening torque:
T: 33 N·m (3.4 kgf-m, 25 ft-lb)
S6M0142

(1) Connect terminal to power steering pump
switch.
S2M0481A
S2M0490
FU(SOHCw/oOBD)-17
INTAKE MANIFOLD
17) Connect accelerator cable (A). 3) Disconnect connectors from throttle position
18) Connect cruise control cable (B). (With cruise sensor (A), idle air control solenoid valve (B) and
control models) pressure sensor (C).
B2M2302A S2M1663A
19) Install air cleaner case and air intake duct. 4) Remove throttle body.
Case.> and <Ref. to N(SOHC)-8, INSTALLATION,
Air Intake Duct.>
<Ref. to FU(SOHCw/oOBD)-40, INSTALLATION,
Fuel Pump Relay.>
S2M1653
5) Disconnect connectors from fuel injectors.
G6M0095
1) Disconnect connector from ignition coil and

ignitor assembly.
S2M1664
2) Remove ignition coil and ignitor assembly.
6) Disconnect connector from purge control sole-
noid valve.
S2M1662
S2M1665
FU(SOHCw/oOBD)-18
INTAKE MANIFOLD
7) Remove harness bands which hold engine har- 13) Remove the four bolts which install injector
ness onto intake manifold. pipe on intake manifold.
S2M1666 S2M1669
8) Remove engine harness from intake manifold. 14) Remove fuel injectors.
9) Remove purge control solenoid valve.
CAUTION:
Replace O-rings and insulators with new ones.
S2M1667
10) Disconnect pressure regulator vacuum hose S2M1687A

(B) from intake manifold.
11) Remove bolt (A) which installs injector pipe on (A) O-ring
intake manifold. (B) Insulator A
(C) Fuel injector
(D) Insulator B
15) Loosen clamp which holds front left side fuel

hose to injector pipe and remove the pipe from
clamp.
S2M1668B
12) Remove bolts which hold fuel pipes on the left

side of intake manifold.
S2M1670
B2M2786
FU(SOHCw/oOBD)-19
INTAKE MANIFOLD
16) Loosen clamp which holds front right side fuel 4) Connect right side fuel hose to injector pipe,
hose to injector pipe and remove the pipe from and tighten clamp screw.
clamp.
S2M1671
S2M1671
5) Connect left side fuel hose to injector pipe, and
17) Remove the bolt which installs fuel pipes on tighten clamp screw.
intake manifold.
S2M1670
S2M1672
6) Install fuel injectors.
18) Remove fuel injector pipe. NOTE:
19) Remove fuel pipe assembly, pressure Always use new O-rings and insulators.
regulator, etc. from intake manifold.
1) Install fuel pipe assembly, pressure regulator,

etc. to intake manifold.
2) Install fuel injector pipe.
3) Tighten the bolt which installs fuel pipes on
intake manifold.
Tightening torque:
4.9 N·m (0.5 kgf-m, 3.6 ft-lb)
S2M1687A
(A) O-ring
(B) Insulator A
(C) Fuel injector
(D) Insulator B
S2M1672
FU(SOHCw/oOBD)-20
INTAKE MANIFOLD
7) Tighten bolt (A) which installs injector pipe on 10) Install purge control solenoid valve.
intake manifold and connect pressure regulator
vacuum hose (B).
Tightening torque:
4.9 N·m (0.5 kgf-m, 3.6 ft-lb)
S2M1667
11) Connect hoses to purge control solenoid

valve.
S2M1668B
CAUTION:
8) Tighten the two bolts which install fuel pipes on
the left side of intake manifold.
Tightening torque:
4.9 N·m (0.5 kgf-m, 3.6 ft-lb)
B2M1893C
(A) To fuel pipe

(B) To intake manifold
B2M2786 12) Install engine harness onto intake manifold.

13) Connect connectors and pipes to fuel injectors
9) Tighten the four bolts which install injector pipe and purge control solenoid valve.
on intake manifold. 14) Hold engine harness by harness bands.
Tightening torque:
19 N·m (1.9 kgf-m, 13.7 ft-lb)
S2M1666
S2M1669
FU(SOHCw/oOBD)-21
INTAKE MANIFOLD
15) Assemble throttle body to intake manifold. E: INSPECTION S165034A10
NOTE: Make sure the fuel pipe and fuel hoses are not
Replace gasket with a new one. cracked and that connections are tight.
Tightening torque:
22 N·m (2.2 kgf-m, 15.9 ft-lb)
S2M1653
16) Connect connectors to throttle position sensor

(A), idle air control solenoid valve (B) and pressure
sensor (C).
S2M1663A
17) Install ignition coil and ignitor assembly.

Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
NOTE:
Do not forget to installs ground terminal on ignition
coil and ignitor assembly.
S2M1662
18) Connect connector to ignition coil and ignitor

assembly.
FU(SOHCw/oOBD)-22
4. Engine Coolant Temperature B: INSTALLATION S165047A11
Sensor S165047 Install in the reverse order of removal.

Tightening torque:
18 N·m (1.8 kgf-m, 13 ft-lb)
B2M4275
G6M0095

Case.>
perature sensor.
B2M4261
FU(SOHCw/oOBD)-23
S165043
T: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
B2M1252B
G6M0095
2) Remove bolt which install crankshaft position

G2M0408

G2M0409
FU(SOHCw/oOBD)-24
KNOCK SENSOR
Tightening torque:
1) Disconnect battery ground cable from battery
24 N·m (2.4 kgf-m, 17.4 ft-lb)
ground terminal.
NOTE:
rear.
G6M0095

Case.> H2M3511C
B2M4262
B2M4262
4) Remove knock sensor from cylinder block. 3) Install air cleaner case.
Case.>
S2M1673
G6M0095
FU(SOHCw/oOBD)-25
Tightening torque:
1.6 N·m (0.16 kgf-m, 1.2 ft-lb)
CAUTION:
When installing throttle position sensor, adjust
to the specified data.
G6M0095

sensor.
S2M1675
S2M1651

S2M1675
FU(SOHCw/oOBD)-26
C: ADJUSTMENT S165039A01 (6) Adjust throttle position sensor so that signal

voltage on CHECK BOARD may be in specifi-
1) Turn ignition switch to OFF. cation.
2) Loosen throttle position sensor holding screws.
Terminal / Specified voltage
(C) No. 23 — (C) No. 24 / 0.45 — 0.55 V
[Fully closed.]
S2M0520
3) When using voltage meter;

(1) Disconnect battery ground cable. S2M0522A

screws.
Tightening torque:
1.6 N·m (0.16 kgf-m, 1.2 ft-lb)
CAUTION:
When removing ST from ECM, disconnect bat-
tery ground cable.
G6M0095
(2) Disconnect connectors from ECM.
S2M1760
4) When using Subaru Select Monitor;

NOTE:
S2M0533 Subaru Select Monitor Operation Manual.
(3) Set ST to ECM. (1) Insert the cartridge to Subaru Select Moni-
ST 498307600 CHECK BOARD KIT tor. <Ref. to FU(SOHCw/oOBD)-10,
(4) Connect battery ground cable. PREPARATION, General Description.>
(5) Turn ignition switch to ON.
S2M0286A
FU(SOHCw/oOBD)-27
(2) Connect Subaru Select Monitor to the data

link connector.
(3) Turn ignition switch to ON, and Subaru
Select Monitor switch to ON.
(4) Select {2. Each System Check} in Main
Menu.
(5) Select {Engine Control System} in Selection
Menu.
(6) Select {1. Current Data Display & Save} in
Engine Diagnosis.
(7) Select {1.12 Data Display} in Data Display
Menu.
(8) Adjust throttle position sensor to the proper
position to match with the following specifica-
tions.
Condition: Throttle fully closed
Throttle opening angle 0.00%
Throttle sensor voltage 0.50 V
S2M0098

screws.
Tightening torque:
1.6 N·m (0.16 kgf-m, 1.2 ft-lb)
S2M1760
FU(SOHCw/oOBD)-28
PRESSURE SENSOR
8. Pressure Sensor S165765 B: INSTALLATION S165765A11
1) Disconnect battery ground cable. Tightening torque:

2.0 N·m (0.2 kgf-m, 1.4 ft-lb)
G6M0095
S2M1677
2) Disconnect connector from pressure sensor.
S2M1676
3) Remove pressure sensor from throttle body.
S2M1677
FU(SOHCw/oOBD)-29
INTAKE AIR TEMPERATURE SENSOR
9. Intake Air Temperature B: INSTALLATION S165569A11
Sensor S165569 Install in the reverse order of removal.

S2M1678
G6M0095
2) Disconnect connector from intake air tempera-

ture sensor.
S2M1647
3) Remove intake air temperature sensor from air

cleaner case.
S2M1678
FU(SOHCw/oOBD)-30
NOTE:
Always use new gasket.
Tightening torque:
1.6 N·m (0.16 kgf-m, 1.2 ft-lb)
G6M0095
S2M1680
noid valve.
S2M1679

throttle body.
S2M1680
FU(SOHCw/oOBD)-31
FUEL INJECTOR

(2) Remove bolts which hold power steering
1. RH SIDE S165051A1801

<Ref. to FU(SOHCw/oOBD)-41, RELEASING OF
FUEL PRESSURE, OPERATION, Fuel.>
S2M1013

pump to bracket.
G6M0095

Case.>
5) Remove resonator chamber. S2M0086

pump switch.
B2M2306

and #3 cylinders). S2M0490
(5) Place power steering pump and tank on the

right side wheel apron.
B2M2014

brackets. S2M0491
(1) Remove V-belt.
FU(SOHCw/oOBD)-32
FUEL INJECTOR
8) Disconnect connector from fuel injector. 3) Disconnect battery ground cable.
S2M1664 G6M0095
9) Remove bolts (A) and (B) which install injector 4) Remove two bolts which install washer tank on
pipe to intake manifold. body.
S2M1682A B2M2764
10) Pull up injector pipe, and remove fuel injectors 5) Disconnect connector from front window
from intake manifold. washer motor.
6) Disconnect connector from rear gate glass
washer motor.
S2M1683
B6M0562
2. LH SIDE S165051A1802
1) Release fuel pressure. <Ref. to FU(SOHCw/

OPERATION, Fuel.>
FU(SOHCw/oOBD)-33
FUEL INJECTOR
7) Disconnect rear window glass washer hose 12) Remove bolt which holds fuel pipe on the left
from washer motor, then plug connection with a side intake manifold.
suitable cap.
8) Move washer tank, and secure it away from
working area.
S2M1684
13) Pull up injector pipe, and remove fuel injectors

B2M2023
from intake manifold.

and #4 cylinders).
B2M2768
B2M2024
S2M1681
11) Remove bolt which installs injector pipe to

intake manifold.
B2M2767
FU(SOHCw/oOBD)-34
FUEL INJECTOR
B: INSTALLATION S165051A11 2. LH SIDE S165051A1102
1. RH SIDE S165051A1101
Install in the reverse order of removal. NOTE:
NOTE:
S2M1687A
S2M1687A
(A) O-ring
(B) Insulator A
(A) O-ring (C) Fuel injector
(B) Insulator A (D) Insulator B
(C) Fuel injector
Tightening torque:
(D) Insulator B
4.9 N·m (0.50 kgf-m, 3.6 ft-lb)
Tightening torque:
Bolt (A) 4.9 N·m (0.50 kgf-m, 3.6 ft-lb)
Bolt (B) 19 N·m (1.9 kgf-m, 13.7 ft-lb)
S2M1684
Tightening torque:
S2M1682A 19 N·m (1.9 kgf-m, 13.7 ft-lb)
Tightening torque:
32 N·m (3.3 kgf-m, 23.9 ft-lb)
B2M2767
B2M2306
FU(SOHCw/oOBD)-35
OXYGEN SENSOR
12. Oxygen Sensor S165712 B: INSTALLATION S165712A11
1) Before installing oxygen sensor, apply anti-
seize compound only to threaded portion of oxy-
1) Disconnect battery ground cable. gen sensor to make the next removal easier.
SS-30 by JET LUBE
CAUTION:
of oxygen sensor.
G6M0095
2) Disconnect connector from oxygen sensor.
G2M0412
2) Install oxygen sensor.

Tightening torque:
21 N·m (2.1 kgf-m, 15.2 ft-lb)
H2M2977

threaded portion of oxygen sensor, and leave it for
one minute or more.
5) Remove oxygen sensor.
G2M0411
CAUTION:
When removing the oxygen sensor, wait until 3) Lower the vehicle.
exhaust pipe cools, otherwise it will damage 4) Connect connector of oxygen sensor.
exhaust pipe.
H2M2977
G2M0411
FU(SOHCw/oOBD)-36
OXYGEN SENSOR
G6M0095
FU(SOHCw/oOBD)-37

5) Take off ECM from engine compartment.
S2M0535
G6M0095
2) Remove air intake duct. Tightening torque:
<Ref. to IN(SOHC)-8, REMOVAL, Air Intake Duct.> 23 N·m (2.3 kgf-m, 16.6 ft-lb)
3) Disconnect the two connectors from ECM.
S2M1686
S2M1685
4) Remove bolts which install ECM on right side

cylinder head.
S2M1686
FU(SOHCw/oOBD)-38
MAIN RELAY

S2M0137
G6M0095
S2M0107
S2M0108A

(B) Main relay
(C) Fuel pump relay
FU(SOHCw/oOBD)-39
FUEL PUMP RELAY
G6M0095
S2M0093

bracket.
S2M0138
FU(SOHCw/oOBD)-40
FUEL
16. Fuel S165052


S165052A1601
WARNING:
<Ref. to FU(SOHCw/oOBD)-40, REMOVAL, Fuel
S2M0172
Pump Relay.>
2) Start the engine, and run it until it stalls. 7) Disconnect quick connector, and then discon-
3) After the engine stalls, crank it for five more nect fuel delivery hose (A). <Ref. to FU(SOHCw/
seconds. oOBD)-56, REMOVAL, Fuel Delivery, Return and
4) Turn ignition switch OFF. Evaporation Lines.>
8) Move clips, and then disconnect fuel return
WARNING:
OPERATION, Fuel.>
S2M0060A

onto fuel tank.
G6M0095

rear seats.
S2M0061
S2M0246
S2M0062
FU(SOHCw/oOBD)-41
FUEL
11) Drain fuel from fuel tank by using a hand 16) Remove fuel sub meter unit.
pump.
WARNING:
S2M0153

S2M0163
WARNING:
S2M0247
G2M0863
18) After draining fuel, reinstall fuel pump and fuel
13) Disconnect connector from fuel sub meter. sub meter unit.
14) Disconnect fuel jet pump hose. Tighten nuts of fuel pump in alphabetical sequence
shown in figure to specified torque.
Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
S2M0151

on fuel tank.
S2M0063A
S2M0152
FU(SOHCw/oOBD)-42
FUEL
Tightening torque:
T: 4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
S2M0152A
FU(SOHCw/oOBD)-43
FUEL TANK

8) Remove rear exhaust pipe. <Ref. to
EX(SOHCw/oOBD)-10, REMOVAL Rear Exhaust
A: REMOVAL S165053A18 Pipe.>
1) Set vehicle on the lift. NOTE:
2) Release fuel pressure. <Ref. to FU(SOHCw/ To facilitate the removal of parts, apply a coat of
oOBD)-41, RELEASING OF FUEL PRESSURE, SUBARU CRC to matching area of rubber cush-
OPERATION, Fuel.> ions in advance.
3) Drain fuel from fuel tank. <Ref. to FU(SOHCw/ SUBARU CRC (Part No. 004301003)
oOBD)-41, DRAINING OF FUEL, OPERATION, 9) Remove heat sealed cover.
Fuel.>
4) Remove rear seat cushion, and turn up cover.
S2M0166
S2M0064 10) Remove muffler assembly.

<Ref. to EX(SOHCw/oOBD)-12, REMOVAL Muf-
5) Disconnect connector of fuel tank cord from fler.>
rear harness.
NOTE:
To facilitate the removal of parts, apply a coat of
SUBARU CRC to matching area of rubber cush-
ions in advance.
11) Remove bolts which hold parking brake cable
holding bracket.
S2M0164
6) Push grommet which holds fuel tank cord on

floor panel into under the body.
S2M0191
12) Remove rear differential assembly. <Ref. to

DI-25, REMOVAL, Rear Differential for T-type.>
and <Ref. to DI-42, REMOVAL, Rear Differential
for VA-type.>
13) Remove rear crossmember. <Ref. to RS-20,
S2M0165 REMOVAL, Rear Crossmember.>
FU(SOHCw/oOBD)-44
FUEL TANK
14) Loosen clamp, and disconnect fuel filler hose 2) Set fuel tank, and temporary tighten bolts for
(A) and air vent hose (B) from fuel filler pipe. installing fuel tank bands.
S2M0193A S2M0169
15) Move clips, and disconnect fuel return hose 3) Connect fuel filler hose (A) and air vent hose
(B) and evaporation hose (C). (B).
nect fuel delivery hose (A). <Ref. to FU(SOHCw/
oOBD)-56, REMOVAL, Fuel Delivery, Return and
Evaporation Lines.>
S2M0193A
4) Connect fuel hoses, and hold them with clips

and quick connector. <Ref. to FU(SOHCw/oOBD)-
S2M0168A
57, INSTALLATION, Fuel Delivery, Return and
Evaporation Lines.>
17) While holding fuel tank, remove bolts from 5) Tighten band mounting bolts.
bands and dismount fuel tank. Tightening torque:
WARNING: 33 N·m (3.4 kgf-m, 25 ft-lb)
S2M0169
S2M0169
B: INSTALLATION S165053A11 7) Install rear differential assembly. <Ref. to DI-27,
1) While a helper holds fuel tank, push fuel tank INSTALLATION, Rear Differential for T-type.> and
harness into access hole with grommet. <Ref. to DI-43, INSTALLATION Rear Differential
for VA-type.>
FU(SOHCw/oOBD)-45
FUEL TANK
8) Install bolts which hold parking brake holding 17) Connect battery ground cable.
bracket.
G6M0095
S2M0191
9) Install muffler assembly. <Ref. to EX(SOHCw/ C: INSPECTION S165053A10
oOBD)-12, INSTALLATION, Muffler.> 1) Make sure there are no cracks, holes, or other
10) Install heat sealed cover. damage on the fuel tank.
S2M0166
11) Install rear exhaust pipe. <Ref. to EX(SOHCw/

oOBD)-10, INSTALLATION, Rear Exhaust Pipe.>
13) Connect connectors to fuel tank harness, and
plug access hole with grommet.
S2M0164
14) Install rear seat cushion.

Fuel Pump Relay.>
FU(SOHCw/oOBD)-46
FUEL FILLER PIPE

9) Move clip, and disconnect air vent hose from air
vent pipe.
WARNING:
2) Drain fuel from fuel tank. <Ref. to FU(SOHCw/
OPERATION, Fuel.>
3) Remove screws holding packing in place.
4) Remove wheel nuts of rear right side. B2M1896
6) Remove rear right side wheel. 10) Loosen clamp, and separate fuel filler hose
(A) from fuel filler pipe.
11) Move clip, and separate air vent hose (B).
B2M1748
7) Remove fuel filler pipe protector. S2M0193A

vehicle.
B2M1894
8) Remove bolts which hold fuel filler pipe bracket

on body. B2M1756
B2M1895
FU(SOHCw/oOBD)-47
FUEL FILLER PIPE
B: INSTALLATION S165022A11 5) Insert air vent hose approximately 25 to 30 mm

1) Hold fuel filler flap open. and hold clip.
2) Set fuel saucer (A) with rubber packing (C), and
insert fuel filler pipe into hole from the inner side of L = 27.5±2.5 mm (1.083±0.098 in)
apron.
B2M1195A
B2M1196A
(1) Hose
3) Align holes in fuel filler pipe neck and set cup (2) Clip
(3) Pipe
(B), and tighten screws.
NOTE: 6) Tighten bolt which holds fuel filler pipe bracket
If edges of rubber packing are folded toward the on body.
inside, straighten it with a screwdriver. Tightening torque:
22.6 N·m (2.3 kgf-m, 16.6 ft-lb)
B2M1196A
B2M1895
4) Insert fuel filler hose (A) approximately 25 to 30
mm (0.98 to 1.18 in) over the lower end of fuel filler 7) Connect air vent hose to air vent pipe.
CAUTION:
B2M1896
S2M0193A
FU(SOHCw/oOBD)-48
FUEL FILLER PIPE
S2M0171
B2M1748

11) Tighten wheel nuts.
Fuel Pump Relay.>
G6M0095
FU(SOHCw/oOBD)-49
FUEL PUMP

A: REMOVAL S165025A18 8) Disconnect quick connector, and then discon-
WARNING: nect fuel delivery hose (A). <Ref. to FU(SOHCw/
쐌 Place “No fire” signs near the working area. oOBD)-56, REMOVAL, Fuel Delivery, Return and
쐌 Be careful not to spill fuel on the floor. Evaporation Lines.>

OPERATION, Fuel.>
cap.
S2M0060A

onto fuel tank.
G6M0095

rear seats.
S2M0061
S2M0246
S2M0062
S2M0172
FU(SOHCw/oOBD)-50
FUEL PUMP

lowing:
in Figure to specified torque.
Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
S2M0063A

WARNING:
possible.
non-load condition.
G2M0366
FU(SOHCw/oOBD)-51
FUEL LEVEL SENSOR
20. Fuel Level Sensor S165026 B: INSTALLATION S165026A11
WARNING:
area.
NOTE:
FU(SOHCw/oOBD)-50, REMOVAL, Fuel Pump.>
S2M0145

mounting bracket.
S2M0855
FU(SOHCw/oOBD)-52

on fuel tank.
WARNING:
area.
S2M0152
7) Remove fuel sub meter unit.
G6M0095

rear seats.
S2M0153

Tightening torque:
T: 4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
G2M0863

S2M0152A
S2M0151
FU(SOHCw/oOBD)-53
FUEL FILTER
22. Fuel Filter S165027 B: INSTALLATION S165027A11
CAUTION:
WARNING: portion, replace it with a new one.
쐌 Place “No fire” signs near the working area. 쐌 If clamps are badly damaged, replace with
쐌 Be careful not to spill fuel on the floor. new ones.
1) Release fuel pressure. <Ref. to FU(SOHCw/ 1) Install in the reverse order of removal.
oOBD)-41, RELEASING OF FUEL PRESSURE, 2) Tighten hose clamp screws.
OPERATION, Fuel.>
2) Open fuel flap lid, and remove fuel filler cap. Tightening torque:
3) Disconnect battery ground cable. 1 N·m (0.1 kgf-m, 0.7 ft-lb)
S2M0195
G6M0095
4) Disconnect fuel hoses from fuel filter.


sediment.
from inlet port.
S2M0195
FU(SOHCw/oOBD)-54
FUEL CUT VALVE
1) Remove fuel tank. <Ref. to FU(SOHCw/oOBD)-

44, REMOVAL, Fuel Tank.>
S2M0176

Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
S2M0177
FU(SOHCw/oOBD)-55
cap.
3) Remove inner trim, insulator and rear seat.
return pipes and hoses, evaporation pipes and
1) Release fuel pressure. <Ref. to FU(SOHCw/ hoses.
OPERATION, Fuel.>
S2M0635
5) In engine compartment, detach fuel delivery 7) Separate quick connector on fuel delivery and
hoses, return hoses and evaporation hose. return line.
ered with dust.
down.
CAUTION:
Replace retainer with new ones.
S2M0500
6) In the engine compartment, detach canister

hose from canister.
S2M0228A
(A) Connector
(B) Retainer
(C) Pipe
S2M0574
FU(SOHCw/oOBD)-56
B: INSTALLATION S165019A11 CAUTION:

1) Connect quick connector on fuel delivery and securely.
return line. 쐌 Ensure the two retainer pawls are engaged in
CAUTION: their mating positions in the connector.
쐌 Always use a new retainer. 쐌 Be sure to inspect hoses and their connec-
쐌 Make sure that the connected portion is not tions for any leakage of fuel.
surface of pipe (A).
S2M0231A
(A) Connector
S2M0229B
(B) Retainer
(C) Pipe
(2) Push pipe into connector completely. 2) Connect fuel delivery hose to pipe with an over-
NOTE: lap of 20 to 25 mm (0.79 to 0.98 in).
At this time, two clicking sounds are heard. Type A: When fitting length is specified.
: 2.5±1.5 mm (0.098±0.059 in)
L: 22.5±2.5 mm (0.886±0.098 in)
S2M0230A
(A) Connector
(B) Retainer
(C) Pipe B2M1194B
(1) Fitting
(2) Clamp
(3) Hose
FU(SOHCw/oOBD)-57

L = 17.5±2.5 mm (0.689±0.098 in)
CAUTION:
B2M1195A
(1) Hose
(2) Clip
(3) Pipe

nections are tight.
FU(SOHCw/oOBD)-58
25. Fuel System Trouble in

General S165571

securely.
tube.
1) Retightening.
filler pipe.
5. Noise
NOTE: ing system. Refueling will also complement the

쐌 When the vehicle is left unattended for an effect of anti-freeze solution each time the fuel
extended period of time, water may accumulate in level drops to about one-half. After the winter
the fuel tank. season, drain water which may have accumu-
To prevent water condensation. lated in the fuel filter and fuel tank in the man-
(1) Top off the fuel tank or drain the fuel com- ner same as that described under Affected
pletely. areas below.
(2) Drain water condensation from the fuel fil- (2) Affected areas
ter. When water condensation is notched in the fuel
쐌 Refilling the fuel tank. filter, drain water from both the fuel filter and fuel
Refill the fuel tank while there is still some fuel left tank or use a water removing agent (or anti-
freeze solution) in the fuel tank.
in the tank.
쐌 Observe the instructions, notes, etc., indicated
쐌 Protecting the fuel system against freezing and
on the label affixed to the anti-freeze solution
water condensation.
(water removing agent) container before use.
(1) Cold areas
FU(SOHCw/oOBD)-59
MEMO:
FU(SOHCw/oOBD)-60
ENGINE2 SECTION

SUBARU vehicles.
ine parts.

G8050GE3
CONTROL DEVICES)
EC(SOHCw/oOBD)
Page
3. Canister .......................................................................................................6
5. Two-way Valve ............................................................................................8
GENERAL DESCRIPTION

tion.
ment.
fied points.
EC(SOHCw/oOBD)-2

onto cylinder heads.

B2M3200
8) Remove front exhaust pipe and center exhaust

pipe from hanger bracket.
G6M0095
CAUTION:
3) Disconnect front oxygen sensor connector. Be careful not to pull down front exhaust pipe
and center exhaust pipe.
B2M1979
B2M3111
5) Remove under cover. 9) Separate front catalytic converter from front
6) Separate center exhaust pipe from rear exhaust pipe.
exhaust pipe.
CAUTION:
Be careful, exhaust pipe is hot.
S2M0923
S2M0558
EC(SOHCw/oOBD)-3
B: INSTALLATION S160017A11 4) Install center exhaust pipe to rear exhaust pipe.

Replace gaskets with new ones. 18 N·m (1.8 kgf-m, 13.0 ft-lb)
1) Install front catalytic converter to front exhaust
pipe.
Tightening torque:
30 N·m (3.1 kgf-m, 22.4 ft-lb)
S2M0558
5) Tighten bolt which holds center exhaust pipe to

hanger bracket.
Tightening torque:
S2M0923 35 N·m (3.6 kgf-m, 26.0 ft-lb)
2) Install front exhaust pipe and center exhaust
pipe. And temporarily tighten bolt which installs
center exhaust pipe to hanger bracket.
B2M3111

B2M3111 8) Connect front oxygen sensor connector.
3) Tighten bolts which hold front exhaust pipe onto
cylinder heads.
Tightening torque:
30 N·m (3.1 kgf-m, 22.4 ft-lb)
B2M1979
B2M3200
EC(SOHCw/oOBD)-4
G6M0095

nections and welds.
EC(SOHCw/oOBD)-5
CANISTER
3. Canister S160037
1) Remove air intake duct as a unit.
S6M0353
2) Disconnect canister hoses from evaporation

pipes.
3) Remove canister with bracket.
S2M0574

CAUTION:
Insert air vent hose of canister into the hole on
body.

cracked or loose.
EC(SOHCw/oOBD)-6

Tightening torque:
16 N·m (1.6 kgf-m, 11.6 ft-lb)
S2M1198
G6M0095
2) Remove bolt which installs purge control sole- CAUTION:

noid valve onto intake manifold. Carefully connect the evaporation hoses.
B2M1893B
S2M1198
(A) To fuel pipe

3) Take out purge control solenoid valve through
(B) To intake manifold
the bottom of the intake manifold.
4) Disconnect connector and hoses from purge C: INSPECTION S160035A10
Make sure hoses are not cracked or loose.
H2M2986
EC(SOHCw/oOBD)-7
TWO-WAY VALVE
Disconnect hoses from two-way valve, and remove

it.
S2M0578
EC(SOHCw/oOBD)-8
ENGINE2 SECTION

SUBARU vehicles.
ine parts.

G8050GE3
EXHAUST
EX(SOHCw/oOBD)
Page
4. Rear Exhaust Pipe ....................................................................................10
5. Muffler........................................................................................................12
GENERAL DESCRIPTION
Exhaust
1. WITH CATALYTIC CONVERTER S162001A0504
S2M1837A
EX(SOHCw/oOBD)-2
GENERAL DESCRIPTION
Exhaust
(1) Upper front exhaust pipe cover (10) Spring (25) Center exhaust pipe
CTR (11) Chamber (26) Lower front catalytic converter
(2) Lower front exhaust pipe cover (12) Rear exhaust pipe cover cover
CTR (13) Gasket (27) Upper front catalytic converter
(3) Clamp (14) Self-locking nut cover
(4) Upper front exhaust pipe cover (15) Muffler (28) Rear exhaust pipe
LH (16) Cushion rubber
(5) Lower front exhaust pipe cover (17) Upper clamp Tightening torque: N·m (kgf-m, ft-lb)
LH (18) Lower clamp T1: 13 (1.3, 9.4)
(6) Front exhaust pipe (19) Upper center exhaust pipe cover T2: 18 (1.8, 13.0)
(7) Lower front exhaust pipe cover (20) Lower center exhaust pipe cover T3: 30 (3.1, 22.4)
RH (21) Protector T4: 35 (3.6, 26.0)
(8) Upper front exhaust pipe cover (22) Gasket T5: 48 (4.9, 35.4)
RH (23) Oxygen sensor
(9) Gasket (24) Front catalytic converter
EX(SOHCw/oOBD)-3
GENERAL DESCRIPTION
Exhaust
2. WITHOUT CATALYTIC CONVERTER

S162001A0503
S2M1836A
(1) Upper front exhaust pipe cover (9) Gasket (22) Lower front catalytic converter
CTR (10) Spring cover
(2) Lower front exhaust pipe cover (11) Chamber (23) Upper front catalytic converter
CTR (12) Rear exhaust pipe cover cover
(3) Clamp (13) Gasket (24) Rear exhaust pipe
(4) Upper front exhaust pipe cover (14) Self-locking nut
LH (15) Muffler Tightening torque: N·m (kgf-m, ft-lb)
(5) Lower front exhaust pipe cover (16) Cushion rubber T1: 13 (1.3, 9.4)
LH (17) Upper clamp T2: 18 (1.8, 13.0)
(6) Front exhaust pipe (18) Lower clamp T3: 30 (3.1, 22.4)
(7) Lower front exhaust pipe cover (19) Protector T4: 35 (3.6, 26.0)
RH (20) Gasket T5: 48 (4.9, 35.4)
(8) Upper front exhaust pipe cover (21) Center exhaust pipe
RH
EX(SOHCw/oOBD)-4
GENERAL DESCRIPTION
Exhaust

tion.
ment.
fied points.
EX(SOHCw/oOBD)-5
FRONT EXHAUST PIPE
Exhaust

onto cylinder heads.
CAUTION:
1) Disconnect battery ground cable. Be careful not to pull down front and center
exhaust pipe assembly.
G6M0095
B2M3200
2) Disconnect front oxygen sensor connector.
(With catalytic converter) 7) Remove bolt which installs front and center
B2M1979
B2M3111
4) Remove under cover. <Ref. to EI-11, 8) Remove front and center exhaust pipe assem-
REMOVAL, Front Under Cover.> bly from the vehicle.
5) Separate front and center exhaust pipe assem- CAUTION:
bly from rear exhaust pipe. 쐌 Be careful not to let front and center exhaust
WARNING: pipe assembly fall off when removing as it is
Be careful, exhaust pipe is hot. quite heavy.
쐌 After removing front and center exhaust
assembly, do not apply excessive pulling force
on rear exhaust pipe.
9) Separate front exhaust pipe from center
exhaust pipe.
B2M0055
S2M0923
EX(SOHCw/oOBD)-6
FRONT EXHAUST PIPE
Exhaust
B: INSTALLATION S162065A11 5) Tighten bolts which install front and center

exhaust pipe assembly to rear exhaust pipe.
1) Install front exhaust pipe to center exhaust
pipe. Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
CAUTION:
Tightening torque:
30 N·m (3.1 kgf-m, 22.4 ft-lb)
B2M0055
6) Tighten bolt which holds front and center

S2M0923 Tightening torque:
35 N·m (3.6 kgf-m, 26.0 ft-lb)
2) Install front and center exhaust pipe assembly
to the vehicle.
3) Temporarily tighten bolt which installs front and
center exhaust pipe assembly to hanger bracket.
B2M3111
7) Install under cover. <Ref. to EI-11,

INSTALLATION, Front Under Cover.>
B2M3111 8) Lower the vehicle.
9) Connect front oxygen sensor connector. (With
4) Tighten bolts which hold front exhaust pipe onto catalytic converter)
cylinder heads.
Tightening torque:
30 N·m (3.1 kgf-m, 22.4 ft-lb)
B2M1979
B2M3200
EX(SOHCw/oOBD)-7
FRONT EXHAUST PIPE
Exhaust
G6M0095

nections and welds.
EX(SOHCw/oOBD)-8
CENTER EXHAUST PIPE
Exhaust
After removing the center and front exhaust pipes

as one unit, separate them. Refer to the procedure
for removing the front exhaust pipe. <Ref. to
EX(SOHCw/oOBD)-6 REMOVAL, Front Exhaust
Pipe.>
Install the center exhaust pipe and front exhaust

pipe as one unit. Refer to the procedure for install-
ing the front exhaust pipe. <Ref. to EX(SOHCw/
oOBD)-7 INSTALLATION, Front Exhaust Pipe.>

nections and welds.
EX(SOHCw/oOBD)-9
REAR EXHAUST PIPE
Exhaust
CAUTION:
1) Separate rear exhaust pipe from center
1) Install rear exhaust pipe bracket to rubber cush-
exhaust pipe. ion.
CAUTION: NOTE:
Be careful, exhaust pipe is hot. To facilitate removal, apply a coat of SUBARU
S2M0558
2) Separate rear exhaust pipe from muffler.

S2M0560
CAUTION:
Be careful not to pull down rear exhaust pipe. 2) Install rear exhaust pipe to muffler.
Tightening torque:
48 N·m (4.9 kgf-m, 35.4 ft-lb)
S2M0559
3) Remove rear exhaust pipe bracket from rubber

S2M0559
cushion.
NOTE: 3) Install rear exhaust pipe to center exhaust pipe.
CRC to pipe bracket in advance. 18 N·m (1.8 kgf-m, 13.0 ft-lb)
S2M0558
S2M0560
EX(SOHCw/oOBD)-10
REAR EXHAUST PIPE
Exhaust

nections and welds.
cracked.
EX(SOHCw/oOBD)-11
MUFFLER
Exhaust
5. Muffler S162066
3) Remove front rubber cushion, and detach muf-
fler assembly.
NOTE:
1) Separate muffler from rear exhaust pipe. To facilitate removal, apply a coat of SUBARU
CAUTION:
Be careful, exhaust pipe is hot. SUBARU CRC (Part No. 004301003)
S2M0609
S2M0559
2) Remove left and right rubber cushions.

CAUTION:
removal. CAUTION:
NOTE:
CRC to mating area of rubber cushions in 48 N·m (4.9 kgf-m, 35.4 ft-lb)
advance.
S2M0559
S2M0608 C: INSPECTION S162066A10

nections and welds.
cracked.
EX(SOHCw/oOBD)-12
ENGINE2 SECTION

SUBARU vehicles.
ine parts.

G8050GE3
IGNITION
IG(SOHCw/oOBD)
Page
2. Spark Plug...................................................................................................5
4. Spark Plug Cord ........................................................................................11
GENERAL DESCRIPTION
Ignition
Item Designation
Model CM12–100B
Manufacturer HITACHI
Ignition coil and ignitor Primary coil resistance 0.7 Ω±10%
assembly Secondary coil resistance 13.0 kΩ±20%
Insulation resistance between primary terminal
More than 10 MΩ
and case
BKR6E* .......... NGK
Type and manufacturer RC10YC4** .......... CHAMPION
BKR5E-11** .......... NGK (Alternate)
Spark plug
Thread size mm 14, P = 1.25
0.7 — 0.8 mm (0.028 — 0.031 in)*
Spark gap mm (in)
1.0 — 1.1 mm (0.039 — 0.043 in)**
*: Without catalytic converter

**: With catalytic converter
IG(SOHCw/oOBD)-2
GENERAL DESCRIPTION
Ignition
S6M0139B
(1) Spark plug (4) Spark plug cord (#2, #4) Tightening torque: N·m (kgf-m, ft-lb)
(2) Spark plug cord (#1, #3)
T1: 6.4 (0.65, 4.7)
T2: 21 (2.1, 15)

ment.
IG(SOHCw/oOBD)-3
GENERAL DESCRIPTION
Ignition

498307600 CHECK BOARD KIT Troubleshooting for engine electrical systems
(1) CHECK BOARD: 498307610
(2) CHECK BOARD ADAPTER: 498307620
S2M2137A
IG(SOHCw/oOBD)-4
SPARK PLUG
Ignition

(3) Remove air intake duct as a unit.
CAUTION:
Spark plug:
With catalyst model: CHAMPION
RC10YC4
Without catalyst model: NGK BKR6E
B2M2012
1. RH SIDE S161003A1805
1) Disconnect battery ground cable. (4) Remove resonator chamber.
B2M2306
G6M0095
2) Remove air intake duct and resonator chamber. 3) Remove spark plug cords by pulling boot, not
cord itself.
on the front side of body.
S2M2135
S6M0708 4) Remove spark plugs with the spark plug socket.

on body.
B6M0923
B6M1302
IG(SOHCw/oOBD)-5
SPARK PLUG
Ignition
2. LH SIDE S161003A1806 5) Remove spark plugs cord by pulling boot, not

cord itself.
S2M2136
G6M0095
6) Remove spark plug with the spark plug socket.

2) Disconnect washer motor connector.
B6M0926
S2M0546

suitable cap. 1. RH SIDE S161003A1105
4) Remove the two bolts which hold the washer Install in the reverse order of removal.
area. Tightening torque (Spark plug):
21 N·m (2.1 kgf-m, 15 ft-lb)
CAUTION:
ing.
Tightening torque (Resonator chamber):
B2M2023
32 N·m (3.3 kgf-m, 24 ft-lb)
2. LH SIDE S161003A1106

21 N·m (2.1 kgf-m, 15 ft-lb)
CAUTION:
ing.
IG(SOHCw/oOBD)-6
SPARK PLUG
Ignition

S6M0420A
G6M0089
(A) Electrode gap
(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
results 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.
G6M0087 G6M0090
2) Carbon fouled
Dry fluffy carbon deposits on insulator and elec- D: CLEANING S161003E56
trode are mostly caused by slow speed driving in Clean spark plugs in a sand blast type cleaner.
city, weak ignition, too rich fuel mixture, dirty air Avoid excessive blasting. Clean and remove car-
cleaner, etc. bon or oxide deposits, but do not wear away por-
It is advisable to replace with plugs having hotter celain.
heat range. If deposits are too stubborn, replace plugs.
G6M0088
IG(SOHCw/oOBD)-7
SPARK PLUG
Ignition
Correct it if the spark plug gap is measured with a

gap gauge, and it is necessary.
Spark plug gap: L
With catalyst:
1.0 — 1.1 mm (0.039 — 0.043 in)
Without catalyst:
0.7 — 0.8 mm (0.028 — 0.031 in)
S6M0412A
NOTE:
“ball” shape.
IG(SOHCw/oOBD)-8
Ignition
3. Ignition Coil and Ignitor 4) Remove ignition coil and ignitor assembly.
Assembly S161015
S6M0371

G6M0095
Tightening torque:
2) Disconnect spark plug cords from ignition coil 6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
and ignitor assembly. CAUTION:
Be sure to connect wires to their proper posi-
tions. Failure to do so will damage unit.
S6M0372
3) Disconnect connector from ignition coil and S6M0371

ignitor assembly.
S6M0366
IG(SOHCw/oOBD)-9
Ignition
C: INSPECTION S161015A10 CAUTION:

If the resistance is extremely low, this indicates
Using oscilloscope and accurate tester, inspect the the presence of a ground short circuit.
following items, and replace if defective.
쐌 Ignitor input signal
쐌 Secondary coil resistance
쐌 Poor contact in ignition coil and ignitor assembly
connector
2) Disconnect connector from ECM, then connect
ST. <Ref. to EN(SOHCw/oOBD)-23, HOW TO
CHECK I/O SIGNAL FOR ECM, Engine Control
Module (ECM) I/O Signal.>
ST 498307600 CHECK BOARD KIT B6M0810B
4) Measure voltage between ignition coil and igni- 9) Check poor contact in ignition coil and ignitor
tion assembly and body. assembly connector.
(A) No. 5 — Engine ground
(A) No. 12 — Engine ground
S6M0378A
Specified voltage: 3 — 4 V
B2M0224B

6) Disconnect connector from ignition coil and
ignitor assembly.
7) Remove spark plug cords.
8) Measure resistance between spark plug cord
contact portions to check secondary coil.
Terminals / Specified resistance:
(A) — (B) / 13.0 ±2.6 kΩ
(C) — (D) / 13.0 ±2.6 kΩ
IG(SOHCw/oOBD)-10
SPARK PLUG CORD
Ignition
4. Spark Plug Cord S161014
Check for:
1) Damage to cords, deformation, burning or rust
formation of terminals
2) Resistance values of cords
Resistance value:
5.24 — 12.23 kΩ
S6M0145
IG(SOHCw/oOBD)-11
SPARK PLUG CORD
Ignition
IG(SOHCw/oOBD)-12
SPARK PLUG CORD
Ignition
MEMO:
IG(SOHCw/oOBD)-13
SPARK PLUG CORD
Ignition
IG(SOHCw/oOBD)-14
EN(SOHCw/oOBD)
Page
8. Inspection Mode ........................................................................................29

S068501
1. WITH SUBARU SELECT MONITOR S068501E4501

trouble occurred using the interview check list. Engine Starting
<Ref. to EN(SOHCw/oOBD)-4 CHECK, Check Failure”. <Ref. to
List for Interview.> EN(SOHCw/
2) Start the engine. oOBD)-47 Diag-
nostics for Engine
Starting Failure.>
2 CHECK ILLUMINATION OF CHECK ENGINE Does MIL illuminate? Go to step 3. Inspection using
MALFUNCTION INDICATOR LAMP (MIL). “General Diagnos-
<Ref. to EN(SOHCw/oOBD)-33 ACTIVATION tic Table”. <Ref. to
OF CHECK ENGINE MALFUNCTION INDI- EN(SOHCw/
CATOR LAMP (MIL), Engine Malfunction Indi- oOBD)-113
cator Lamp (MIL).> INSPECTION,
General Diagnos-
tic Table.>
1) Turn ignition switch to OFF. Monitor indicate DTC? trouble code. parts.
2) Connect the Subaru Select Monitor to data <Ref. to EN(SOHCw/ Repair the trouble NOTE:
link connector. oOBD)-65 LIST, List of cause. <Ref. to If DTC is not
3) Turn ignition switch to ON and the Subaru Diagnostic Trouble Code EN(SOHCw/ shown on display
Select Monitor switch to ON. (DTC).> oOBD)-68 Diag- although the MIL
4) Read DTC on the Subaru Select Monitor. nostic Procedure illuminates, per-
<Ref. to EN(SOHCw/oOBD)-27 WITH with Diagnostic form diagnostics
SUBARU SELECT MONITOR, OPERATION, Trouble Code of MIL (CHECK
Read Diagnostic Trouble Code.> (DTC).> Go to ENGINE malfunc-
step 4. tion indicator
lamp) circuit or
combination
meter. <Ref. to
EN(SOHCw/
oOBD)-33 Engine
Malfunction Indi-
cator Lamp
(MIL).>
4 PERFORM THE DIAGNOSIS. Does the Subaru Select Record diagnostic Complete the
1) Perform the clear memory mode. <Ref. to Monitor indicate DTC? trouble code. diagnosis.
EN(SOHCw/oOBD)-31 OPERATION, Clear <Ref. to EN(SOHCw/ Repair the trouble
Memory Mode.> oOBD)-65 LIST, List of cause. <Ref. to
2) Perform the inspection mode. <Ref. to Diagnostic Trouble Code EN(SOHCw/
EN(SOHCw/oOBD)-29 OPERATION, Inspec- (DTC).> oOBD)-68 Diag-
tion Mode.> nostic Procedure
with Diagnostic
Trouble Code
(DTC).> Go to
step 4.
EN(SOHCw/oOBD)-2
2. WITHOUT SUBARU SELECT MONITOR 쐌 Be sure to check again from the beginning in
S068501E4502 order to prevent secondary trouble caused by
CAUTION: repair work.
쐌 Check the connector while it is connected
unless specified otherwise.

trouble occurred using the interview check list. Engine Starting
<Ref. to EN(SOHCw/oOBD)-4 CHECK, Check Failure”. <Ref. to
List for Interview.> EN(SOHCw/
nostics for Engine
Starting Failure.>
2 CHECK ILLUMINATION OF CHECK ENGINE Does MIL illuminate? Go to step 3. Inspection using
MALFUNCTION INDICATOR LAMP (MIL). “9. General Diag-
<Ref. to EN(SOHCw/oOBD)-33 ACTIVATION nostic Table”.
OF CHECK ENGINE MALFUNCTION INDI- <Ref. to EN(SO-
CATOR LAMP (MIL), Engine Malfunction Indi- HCw/oOBD)-113
cator Lamp (MIL).> INSPECTION,
General Diagnos-
tic Table.>
3 CHECK INDICATION OF DTC ON MIL. Does the MIL indicate Repair the trouble Repair the related
1) Perform the read diagnostic trouble code DTC? <Ref. to EN(SOHCw/ cause. Go to step parts.
(read memory mode). <Ref. to EN(SOHCw/ oOBD)-65 LIST, List of 4. NOTE:
oOBD)-27 WITHOUT SUBARU SELECT Diagnostic Trouble Code If DTC is not
MONITOR, OPERATION, Read Diagnostic (DTC).> shown on MIL
Trouble Code.> although the MIL
2) Read DTC on MIL. illuminates, per-
form diagnostics
of MIL (CHECK
ENGINE malfunc-
tion indicator
lamp) circuit or
combination
meter. <Ref. to
EN(SOHCw/
oOBD)-33 Engine
Malfunction Indi-
cator Lamp
(MIL).>
4 PERFORM THE DIAGNOSIS. Does the MIL indicate Repair the trouble Complete the
1) Perform the clear memory mode. <Ref. to DTC? <Ref. to EN(SOHCw/ cause. Go to step diagnosis.
EN(SOHCw/oOBD)-31 OPERATION, Clear oOBD)-65 LIST, List of 4.
Memory Mode.> Diagnostic Trouble Code
2) Perform the inspection mode. <Ref. to (DTC).>
EN(SOHCw/oOBD)-29 OPERATION, Inspec-
tion Mode.>
EN(SOHCw/oOBD)-3
A: CHECK S068502A04
1. CHECK LIST NO. 1 S068502A0401
Check the following items when problem has occurred.

NOTE:
Use copies of this page for interviewing customers.
Vin no. miles
Weather 쏔 Fine
쏔 Cloudy
쏔 Rainy
쏔 Snowy
쏔 Various/Others:
Outdoor temperature °F (°C)
쏔 Hot
쏔 Warm
쏔 Cool
쏔 Cold
Place 쏔 Highway
쏔 Suburbs
쏔 Inner city
쏔 Uphill
쏔 Downhill
쏔 Rough road
쏔 Others:
쏔 Warming-up
쏔 Any temperature
쏔 Others:
Engine speed rpm
Vehicle speed MPH
쏔 At starting
쏔 While idling
쏔 At racing
쏔 While cruising
EN(SOHCw/oOBD)-4
Check the following items about the vehicle’s state when MIL turns on.
NOTE:
b) Fuel level
쐌 What:
쐌 What:
쐌 What:
쐌 Where:
쐌 From where:
쐌 What kind:
쐌 From where:
쐌 What kind:
쏔 Rough idling
쏔 Back fire
쏔 After fire
쏔 No shift
EN(SOHCw/oOBD)-5
GENERAL DESCRIPTION

A: CAUTION S068001A03 measuring voltage and resistance in the engine
1) Airbag system wiring harness is routed near the compartment.
pump relay.
CAUTION:
module (ECM), transmission control module
(TCM), main relay and fuel pump relay. S2M1246
2) Never connect the battery in reverse polarity. 9) Use TCM mounting stud bolts at the body head
쐌 The ECM will be destroyed instantly. grounding point when measuring voltage and
쐌 The fuel injector and other part will be damaged resistance inside the passenger compartment.
tion switch.
cause of this problem. To measure the voltage B3M1666E
trical control modules at the harness side 10) Every MFI-related part is a precision part. Do
connector, use a tapered pin with a diameter of not drop them.
less than 0.64 mm (0.025 in). Do not insert the pin 11) Observe the following cautions when installing
more than 5 mm (0.20 in) into the part. a radio in MFI equipped models.
6) Before removing ECM from the located CAUTION:
position, disconnect two cables on battery. 쐌 The antenna must be kept as far apart as
쐌 Otherwise, the ECM may be damaged. possible from the control unit.
(The ECM is located in the engine compart-
CAUTION:
ment.)
쐌 The antenna feeder must be placed as far
wrong spec. ECM to avoid any damage on fuel apart as possible from the ECM and MFI har-
injection system. ness.
7) The connectors to each sensor in the engine 쐌 Carefully adjust the antenna for correct
compartment and the harness connectors on the matching.
engine side and body side are all designed to be 쐌 When mounting a large power type radio,
waterproof. However, it is still necessary to take pay special attention to the three items above
care not to allow water to get into the connectors mentioned.
when washing the vehicle, or when servicing the 쐌 Incorrect installation of the radio may affect
vehicle on a rainy day. the operation of the ECM.
matic transmission may be caused by failure of the
EN(SOHCw/oOBD)-6
GENERAL DESCRIPTION
engine, the electronic control system, the transmis- 2. ENGINE GROUNDING S068001A1002
sion proper, or by a combination of these. These

Make sure the engine grounding terminal is prop-
erly connected to the engine.
with simple, easy operations and proceeding to
complicated, difficult operations. The most impor-
tant thing in diagnostics is to understand the cus-
tomer’s complaint, and distinguish between the
three causes.
15) In AT vehicles, do not continue the stall for
more than five seconds at a time (from closed
throttle, fully open throttle to stall engine speed).
16) On ABS vehicle, when performing driving test
in jacked-up or lifted-up position, sometimes the S2M1246
warning light may be lit, but this is not a malfunc-
tion of the system. The reason for this is the speed
difference between the front and rear wheels. After C: NOTE S068001A15
diagnosis of engine control system, perform the 1. ENGINE AND EMISSION CONTROL
ABS memory clearance procedure of self-diagno- SYSTEM S068001A1501
sis system.
쐌 The Multipoint Fuel Injection (MFI) system is a
system that supplies the optimum air-fuel mixture
Before performing diagnostics, check the following tions through the use of the latest electronic tech-
items which might affect engine problems: nology.
With this system fuel, which is pressurized at a
1. BATTERY S068001A1001
1) Measure battery voltage and specific gravity of passage of the cylinder head. The injection quan-
electrolyte. tity of fuel is controlled by an intermittent injection
system where the electro-magnetic injection valve
Standard voltage: 12 V
(fuel injector) opens only for a short period of time,
Specific gravity: Above 1.260 depending on the quantity of air required for one
2) Check the condition of the main and other cycle of operation. In actual operation, the injection
fuses, and harnesses and connectors. Also check quantity is determined by the duration of an elec-
for proper grounding. tric pulse applied to the fuel injector and this per-
mits simple, yet highly precise metering of the fuel.
쐌 Further, all the operating conditions of the
engine are converted into electric signals, and this
results in additional features of the system, such as
large improved adaptability, easier addition of com-
pensating element, etc.
쐌 Reduced emission of harmful exhaust gases.
쐌 Reduced in fuel consumption.
쐌 Superior acceleration and deceleration.
쐌 Superior startability and warm-up perfor-
mance in cold weather since compensation is
made for coolant and intake air temperature.
EN(SOHCw/oOBD)-7
GENERAL DESCRIPTION

B2M3876
쐌 French: 22771AA080
(Without printer)
B2M3877
EN(SOHCw/oOBD)-8
GENERAL DESCRIPTION
MEMO:
EN(SOHCw/oOBD)-9
1. MODULE S068507A1301
S2M2105A
S2M2106A
(1) Engine control module (ECM) (3) Read memory connector (6) Transmission control module
(2) CHECK ENGINE malfunction (4) Test mode connector (TCM)
indicator lamp (MIL) (5) Data link connector
EN(SOHCw/oOBD)-10
S2M0533D S2M2107A
S2M2108A S2M2157C
B3M1666H B3M1652C
EN(SOHCw/oOBD)-11
2. SENSOR S068507A1302
S2M1247A
(1) Engine coolant temperature sen- (3) Throttle position sensor (6) Crankshaft position sensor
sor (4) Pressure sensor
(2) Intake air temperature sensor (5) Knock sensor
EN(SOHCw/oOBD)-12
S2M1248A S2M1249A
S2M1250A S2M1250B
S2M0515B
S2M0213K
EN(SOHCw/oOBD)-13
S2M2257A
(1) Front exhaust pipe RH (4) Oxygen sensor (7) Rear catalytic converter
(2) Front exhaust pipe LH (5) Center exhaust pipe (8) Rear exhaust pipe
(3) Front catalytic converter (6) Resonance chamber (9) Muffler
EN(SOHCw/oOBD)-14
S2M0264C S2M0267C
S2M0654C
EN(SOHCw/oOBD)-15
3. SOLENOID VALVE, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM

PARTS S068507A1303
S2M1782A
(1) CO resistor (General spec. (2) Purge control solenoid valve (4) Ignition coil and ignitor ASSY
vehicles) (3) Idle air control solenoid valve
EN(SOHCw/oOBD)-16
S2M1764A S2M1252A
S2M1250C S2M1253A
EN(SOHCw/oOBD)-17
S2M2105B
S2M2106B
(1) Fuel pump (2) Main relay (3) Fuel pump relay
EN(SOHCw/oOBD)-18
S2M0277B S2M0278C
EN(SOHCw/oOBD)-19
S2M0669A
S2M0861A
EN(SOHCw/oOBD)-20
ECM CHECK BOARD Signal (V)

Content Connec- Terminal Connec- Terminal Ignition SW ON Engine ON Note
tor No. No. tor No. No. (Engine OFF) (Idling)
Signal Sensor output
E22 20 B 26 0 −7 to +7
Crankshaft (+) waveform
position Signal
E22 14 B 19 0 0 —
sensor (−)
Shield E22 21 B 25 0 0 —
Signal E22 18 A 15 3.4 — 3.6 1.2 — 1.8 —
Pressure Power
E22 25 B 21 5 5 —
sensor supply
GND E22 22 B 24 0 0 —
Signal E22 23 B 23 —
Throttle Fully open: 4.2 — 4.7
position Power
E22 25 B 21 5 5 —
sensor supply
GND E22 22 B 24 0 0 —
Oxygen Signal B84 22 D 47 0.6, or less 0 — 0.9 —
sensor Shield B84 15 C 38 0 0 —
Engine coolant tem-
E22 24 B 22 0.4 — 2.4 0.4 — 2.4 After warm-up
perature sensor
“5” and “0” are
Vehicle speed sen- repeatedly dis-
B84 33 D 53 0 or 5 0 or 5
sor played when vehicle
is driven.
Intake air tempera-
E22 17 B 16 2.3 — 2.5 1.4 — 1.6 After warm-up
ture sensor
ON: 10 — 13 ON: 13 — 14
A/C switch B84 27 D 59 —
OFF: 0 OFF: 0
Ignition switch B84 28* 19 D 58* 50 10 — 13 13 — 14 —
쐌 On MT vehicles;
Neutral position ON: 10 — 13 switch is ON when
switch (MT) OFF: 0 gear is in neutral
position.
B84 26 D 60
쐌 On AT vehicles;
ST: 10 — 13
Neutral position switch is ON when
ON: 0
switch (AT) shift is in “N” or “P”
OFF: 13 — 14
position
Knock Signal E22 16 B 17 2.5 2.5
—
sensor Shield E22 21 B 25 0 0
Test mode connec-
B84 19* 28 D 50* 58 10 — 13 13 — 14 When connected: 0
tor
Read memory con-
B84 20 D 49 10 — 13 13 — 14 When connected: 0
nector
Back-up power sup- Ignition switch
B84 34 D 52 10 — 13 13 — 14
ply “OFF”: 10 — 13
Control unit power 9 B 27
B84 10 — 13 13 — 14 —
supply 17 C 36
Ignition # 1, # 2 E22 3 A 5 0 1 — 3.4 —
control # 3, # 4 E22 9 A 12 0 1 — 3.4 —
Fuel injec- # 1, # 2 E22 7 A 1 10 — 13 1 — 14 Waveform
tor # 3, # 4 E22 6 A 2 10 — 13 1 — 14 Waveform
EN(SOHCw/oOBD)-21
ECM CHECK BOARD Signal (V)

Content Connec- Terminal Connec- Terminal Ignition SW ON Engine ON Note
tor No. No. tor No. No. (Engine OFF) (Idling)
Idle air control sole-
E22 4 A 4 — 1 — 13 Waveform
noid valve
Fuel pump relay ON: 0.5, or less
B84 3 C 33 0.5, or less —
control OFF: 10 — 13
A/C relay control B84 11 C 42 —
OFF: 10 — 13 OFF: 13 — 14
Radiator fan relay 1 B84 2 C 34 —
OFF: 10 — 13 OFF: 13 — 14
ON: 0.5, or less ON: 0.5, or lessWith A/C vehicles
Radiator fan relay 2 B84 10 C 43
OFF: 10 — 13 OFF: 13 — 14 only
Self-shutoff control B84 5 C 31 10 — 13 13 — 14 —
Light “ON”: 1, or
Malfunction indicator less
B84 13 C 40 — —
lamp Light “OFF”: 10 —
14
Engine speed output B84 6 B 30 — 0 — 13, or more Waveform
Torque control signal B84 18 D 51 8 8—9 —
AT and without cata-
VCC signal B84 1 C 35 5 5
lyst vehicles only
AT load signal B84 29 D 57 3.4 — 3.6 1.2 — 1.8 —
쐌 Waveform
Purge control sole- ON: 1, or less
E22 5 A 3 13 — 14 쐌 When connecting
noid valve OFF: 10 — 13
test mode connector
Power steering pres- ON: 0
E22 26 B 20 10 — 13 —
sure switch OFF: 13 — 14
MT: 0 MT: 0
MT/AT identification B84 16 C 37 —
AT: 5 AT: 5
Select monitor sig- 24 C 45
B84 — — —
nal 32 D 54
GND (ignition sys-
E22 10 A 11 0 0 —
tem)
11 10
GND (power supply) E22 A 0 0 —
12 9
GND (control sys-
E22 21 B 25 0 0 —
tems)
Immobilizer serial 23 46
B84 D — — —
line 31 55
*: RHD
EN(SOHCw/oOBD)-22
B: HOW TO CHECK I/O SIGNAL

FOR ECM S068526H57
쐌 When checking I/O signal, connect ST between

ECM and ECM connector.
1) Prepare the ST.
ST 498307600 CHECK BOARD KIT
S2M0859A
(1) CHECK BOARD

(2) CHECK BOARD ADAPTER

3) Disconnect connectors from ECM.
4) Connect connectors of CHECK BOARD
ADAPTER to ECM and CHECK BOARD.
5) Connect engine harness and bulkhead harness
connectors to CHECK BOARD.
EN(SOHCw/oOBD)-23

1. HOW TO USE SUBARU SELECT

MONITOR S068503A1601
S2M0288A

them.
S2M0285 2. READ DIAGNOSTIC TROUBLE CODE
(DTC) FOR ENGINE. S068503A1602
2) Connect diagnosis cable to Subaru Select
Monitor. Refer to Read Diagnostic Trouble Code for infor-
3) Insert cartridge into Subaru Select Monitor. mation about how to indicate DTC. <Ref. to
EN(SOHCw/oOBD)-27 Read Diagnostic Trouble
Code.>
S2M0286A

connector.
side).
S2M2157

nector.
CAUTION:
Select Monitor.
EN(SOHCw/oOBD)-24
3. READ CURRENT DATA SHOWN ON DISPLAY. S068503A1603
1) On the ⰆMain MenuⰇ display screen, select the {2. Each System Check} and press the [YES] key.
[YES] key.
4) On the ⰆEngine DiagnosisⰇ display screen, select the {1. Current Data Display & Save} and press the
[YES] key.
5) On the ⰆData Display MenuⰇ display screen, select the {1. 12 Data Display} and press the [YES] key.
Contents Unit of measure
Battery voltage V
Vehicle speed signal km/h or MPH
Engine speed signal rpm
Engine coolant temperature signal °C or °F
Ignition timing signal deg
Throttle position signal %
Throttle position signal V
Injection pulse width ms
Idle air control signal %
Engine load data %
Front oxygen sensor output signal V
A/F correction coefficient %
Knock sensor signal deg
CO resistor V
Intake manifold absolute/relative pressure signal mmHg or kPa or inHg
Intake air temperature signal °C or °F
Canister purge control solenoid valve duty ratio %
Idle air control solenoid valve current mA
Ignition switch signal ON or OFF
Test mode connector signal ON or OFF
Neutral position switch signal ON or OFF
Air conditioning switch signal ON or OFF
Air conditioning relay signal ON or OFF
Radiator main fan relay signal ON or OFF
Fuel pump relay signal ON or OFF
Knocking signal ON or OFF
Radiator sub fan relay signal ON or OFF
Engine torque control signal ON or OFF
Front oxygen sensor rich signal ON or OFF
Crankshaft position sensor signal ON or OFF
Electrical load signal ON or OFF
Read memory connector signal ON or OFF
Power steering pressure signal ON or OFF
AT vehicle ID signal ON or OFF
Idle switch ON or OFF
Canister purge control solenoid valve ON or OFF
Torque permission signal ON or OFF
NOTE:
EN(SOHCw/oOBD)-25
Contents Message LED “ON” requirements

Ignition switch signal ON or OFF When ignition switch is turned ON.
Test mode connector signal ON or OFF When test mode connector is connected.
Neutral position switch signal ON or OFF When neutral position signal is entered.
Air conditioning switch signal ON or OFF When air conditioning switch is turned ON.
Air conditioning relay signal ON or OFF When air conditioning relay is in function.
Radiator main fan relay signal ON or OFF When radiator main fan relay is in function.
Fuel pump relay signal ON or OFF When fuel pump relay is in function.
Knocking signal ON or OFF When knocking signal is entered.
Radiator sub fan relay signal ON or OFF When radiator sub fan relay is in function.
Engine torque control signal ON or OFF When engine torque control signal is entered.
Front oxygen sensor rich signal ON or OFF When front oxygen sensor mixture ratio is rich.
Crankshaft position sensor signal ON or OFF When crankshaft position sensor signal is entered.
When the lighting switch, blower fan switch or rear defog-
Electrical load signal ON or OFF
ger switch is turned ON.
Read memory connector signal ON or OFF When read memory connector is connected.
Power steering pressure signal ON or OFF When steering wheel is turned.
AT vehicle ID signal ON or OFF When AT identification signal is entered.
When throttle sensor sends signal that throttle opening
Idle switch ON or OFF
angle is in idle position.
Canister purge control solenoid valve ON or OFF When canister purge control solenoid valve is in function.
Torque permission signal ON or OFF When torque permission signal is entered.
NOTE:
EN(SOHCw/oOBD)-26
[YES] key.
4) On the ⰆEngine DiagnosisⰇ display screen, select the {Diagnostic Code(s) Display} and press the [YES]
key.
5) On the ⰆDiagnostic Code(s) DisplayⰇ display screen, select the {Current Diagnostic Code(s)} or {His-
tory Diagnostic Code(s)} and press the [YES] key.
NOTE:
<Ref. to EN(SOHCw/oOBD)-65 LIST, LIST of Diagnostic Trouble Code (DTC).>

2) Connect read memory connector. <Ref. to NOTE:
EN(SOHCw/oOBD)-10 LOCATION, Electrical 쐌 Open or short
Components Location.> circuit in engine
3) Turn ignition switch to ON. control module
power supply or
ground line
쐌 Open or short
circuit in CHECK
ENGINE malfunc-
tion indicator lamp
2 CHECK DIAGNOSTIC TROUBLE CODE Does the MIL indicate diag- Record diagnostic Complete read
(DTC). nostic trouble code (DTC)? trouble code diagnostic trouble
(DTC). Then turn code. Turn ignition
ignition switch to switch to OFF and
OFF, disconnect disconnect read
read memory con- memory connec-
nector. tor.
EN(SOHCw/oOBD)-27
The CHECK ENGINE malfunction indicator lamp (MIL) flashes the code corresponding to the faulty parts.
The long segment (1.3 seconds ON) indicates a “ten”, and the short segment (0.2 seconds ON) signifies
“one”. And middle segment (0.5 seconds ON) means OK code.
NOTE:
<Ref. to EN(SOHCw/oOBD)-65 LIST, LIST of Diagnostic Trouble Code (DTC).>
S2M1768A
EN(SOHCw/oOBD)-28
INSPECTION MODE

2. WITH SUBARU SELECT MONITOR
S068510A1602
1. PREPARATIONS FOR THE memory, check for any remaining unresolved
INSPECTION MODE S068510A1601 trouble data.
Raise the vehicle using a garage jack and place on 1) Connect test mode connector (green).
WARNING:
brakes are applied.
safety stand.
쐌 Secure a rope or wire to the front and rear
towing or tie-down hooks to prevent the lateral
runout of front wheels.
쐌 Do not abruptly depress/release clutch pedal
or accelerator pedal during works even when S2M2146
engine is operating at low speeds since this 2) Connect Subaru select monitor to data link con-
nector. <Ref. to EN(SOHCw/oOBD)-10
LOCATION, Electrical Components Location.>
blocks or similar items between the safety 3) Turn ignition switch to ON (engine OFF) and
stands and the vehicle. Subaru select monitor switch to ON.
S2M0288A

key.
select the {6. Dealer Check Mode Procedure} and
B2M2969A
[YES] key.
9) Perform subsequent procedures as instructed
sponding diagnostic trouble code (DTC) appears
EN(SOHCw/oOBD)-29
INSPECTION MODE
NOTE: 쐌 On AWD vehicles, release the parking brake.

쐌 For detailed operation procedure, refer to the 쐌 The speed difference between front and rear
SUBARU SELECT MONITOR OPERATION wheels may light either the ABS warning light, but
MANUAL. this indicates no malfunctions. When engine con-
쐌 For detailed concerning diagnostic trouble trol diagnosis is finished, perform the ABS memory
codes, refer to the DIAGNOSTIC TROUBLE clearance procedure of self-diagnosis system.
CODE (DTC) LIST. <Ref. to EN(SOHCw/
oOBD)-65 LIST, List of Diagnostic Trouble Code
(DTC).>

1) Start and warm-up the engine. necessary.
3) Set shift lever to neutral position (MT 쐌 Open or short
vehicles), or set selector lever to “P” position circuit in engine
(AT vehicles). control module
4) Connect test mode connector (green). power supply or
쐌 Open or short
circuit in CHECK
ENGINE malfunc-
tion indicator lamp
2 CHECK DIAGNOSTIC TROUBLE CODE Does the MIL indicate diag- Record diagnostic Go to step 3.
(DTC). nostic trouble code (DTC)? trouble code
1) Set selector lever to “N” position, and then (DTC) and inspect
set selector lever to “P” position again (AT using DTC. <Ref.
vehicles only). to EN(SOHCw/
nostic Procedure
with Diagnostic
Trouble Code
(DTC).>
(DTC). nostic trouble code (DTC)? trouble code switch to OFF.
1) Drive vehicle at speed greater than 11 (DTC) and inspect Disconnect test
km/h (7 MPH) for at least one minute. using DTC. <Ref. mode connector.
2) Warm-up engine above 2,000 rpm. to EN(SOHCw/ Complete inspec-
oOBD)-68 Diag- tion mode.
nostic Procedure NOTE:
with Diagnostic When on-board
Trouble Code diagnosis system
(DTC).> indicates no
trouble, the
trouble is in a dif-
ferent symptom.
EN(SOHCw/oOBD)-30
CLEAR MEMORY MODE
1) On the ⰆMain MenuⰇ display screen, select the {2. Each System Check} and press the [YES] key.
[YES] key.
4) On the ⰆEngine DiagnosisⰇ display screen, select the {Clear Memory} and press the [YES] key.
5) When the ‘Done’ and ‘Turn Ignition Switch OFF’ are shown on the display screen, turn the Subaru Select
Monitor and ignition switch to OFF.
NOTE:
쐌 After the memory has been cleared, the ISC must be initialized. To do this, turn the ignition switch to the
ON position. Wait 3 seconds before starting the engine.

2) Set shift lever to neutral position (MT NOTE:
vehicles), or set selector lever to “P” position 쐌 Open or short
(AT vehicles). circuit in engine
3) Connect test mode connector and read control module
memory connector. power supply or
쐌 Open or short
circuit in CHECK
ENGINE malfunc-
tion indicator lamp
(DTC). nostic trouble code (DTC)? trouble code. switch to OFF.
1) Set selector lever to “N” position, and then <Ref. to EN(SOHCw/ Repair the trouble Disconnect read
set selector lever to “P” position again (AT oOBD)-65 LIST, List of cause. <Ref. to memory connec-
vehicles only). Diagnostic Trouble Code EN(SOHCw/ tor and test mode
2) Start the engine. (DTC).> oOBD)-68 Diag- connector. Com-
3) Drive vehicle at speed greater than 11 nostic Procedure plete clear
km/h (7 MPH) for at least one minute. with Diagnostic memory mode.
4) Warm-up engine above 2,000 rpm. Trouble Code
(DTC).>
EN(SOHCw/oOBD)-31
10. Compulsory Valve

1) Connect test mode connector at the lower por-

tion of instrument panel (on the driver’s side), to
S2M2146
2) Each valve functions when ignition switch is

turned to ON (engine OFF).
쐌 A list of the support portion is shown in the fol-
lowing table.
Contents
Compulsory fuel pump relay operation check
Compulsory purge control solenoid valve operation check
Compulsory radiator fan relay operation check
Compulsory air conditioning relay operation check
EN(SOHCw/oOBD)-32
11. Engine Malfunction Indicator Lamp (MIL) S068653
1. Activation of check engine malfunction indicator lamp (MIL). <Ref. to EN(SOHCw/oOBD)-33 ACTIVATION OF CHECK
ENGINE MALFUNCTION INDICATOR LAMP (MIL), Engine Malfunction Indicator Lamp (MIL).>
↓
2. Check engine malfunction indicator lamp (MIL) does not come on. <Ref. to EN(SOHCw/oOBD)-34 CHECK ENGINE MAL-
FUNCTION INDICATOR LAMP (MIL) DOES NOT COME ON., Engine Malfunction Indicator Lamp (MIL).>
↓
3. Check engine malfunction indicator lamp (MIL) does not go off. <Ref. to EN(SOHCw/oOBD)-38 CHECK ENGINE MAL-
FUNCTION INDICATOR LAMP (MIL) DOES NOT GO OFF., Engine Malfunction Indicator Lamp (MIL).>
↓
4. Check engine malfunction indicator lamp (MIL) does not blink at a cycle of 3 Hz. <Ref. to EN(SOHCw/oOBD)-40 CHECK
Lamp (MIL).>
↓
5. Check engine malfunction indicator lamp (MIL) remains blinking at a cycle of 3 Hz. <Ref. to EN(SOHCw/oOBD)-44
CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINKING AT A CYCLE OF 3 HZ., Engine Malfunction
Indicator Lamp (MIL).>
B: ACTIVATION OF CHECK ENGINE 2) After starting the engine, the MIL goes out. If it
MALFUNCTION INDICATOR LAMP system is malfunctioning. <Ref. to EN(SOHCw/
(MIL) S068653E89
oOBD)-2 PROCEDURE, Basic Diagnostic Proce-
1) When ignition switch is turned to ON (engine dure.>
lamp (MIL) in the combination meter illuminates.
NOTE:
nation meter circuit. <Ref. to IDI-15 Combination
Meter Assembly.>
OBD0053A

connected, the MIL blinks at a cycle of 3 Hz.
S2M2107
OBD0055A
EN(SOHCw/oOBD)-33

COME ON. S068653E90
쐌 DIAGNOSIS:
쐌 WIRING DIAGRAM:
S2M2109
EN(SOHCw/oOBD)-34

1) Disconnect connector from ECM, then con- V?
nect check board. <Ref. to EN(SOHCw/
oOBD)-23, HOW TO CHECK I/O SIGNAL
FOR ECM, Engine Control Module (ECM) I/O
Signal.>
and engine ground.
(C) No. 40 (+) — Engine ground (−):
ness?
FU(SOHCw/ tor.
oOBD)-38, Engine
Control Module.>
(B84) No. 13 — (i10) No. 9: nector
쐌 Poor contact in
coupling connec-
tor (i2)
nector. <Ref. to IDI-15, Combination Meter tor? tion meter con-
Assembly.> nector.
EN(SOHCw/oOBD)-35

NECTOR. necessary.
(No. 5) blows
easily, check the
harness for short
circuit of harness
between fuse (No.
5) and ignition
relay connector.
쐌 Open or short
circuit in harness
between fuse (No.
5) and battery ter-
minal
쐌 Open circuit in
harness between
fuse (No. 5) and
ignition relay con-
nector
쐌 Poor contact in
coupling connec-
tor (i1)
쐌 Poor contact in
ignition relay con-
nector
쐌 Poor contact in
ignition switch
connector
7 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace bulb or
Check poor contact in combination meter con- combination meter connec- tact in combina- combination
nector. <Ref. to IDI-15, Combination Meter tor? tion meter con- meter.
Assembly.> nector.
EN(SOHCw/oOBD)-36
MEMO:
EN(SOHCw/oOBD)-37

OFF. S068653E91
쐌 DIAGNOSIS:
쐌 WIRING DIAGRAM:
S2M2109

1) Turn ignition switch to OFF. between combina- FU(SOHCw/
2) Disconnect connector from ECM. tion meter and oOBD)-38, Engine
3) Turn ignition switch to ON. ECM connector. Control Module.>
EN(SOHCw/oOBD)-38
MEMO:
EN(SOHCw/oOBD)-39

쐌 DIAGNOSIS:
EN(SOHCw/oOBD)-40
쐌 WIRING DIAGRAM:
S2M2110

1) Turn ignition switch to OFF. EN(SOHCw/
2) Disconnect test mode connector. oOBD)-34,
3) Turn ignition switch to ON. CHECK ENGINE
MALFUNCTION
INDICATOR
LAMP (MIL)
DOES NOT
COME ON.,
Engine Malfunc-
tion Indicator
Lamp (MIL).>
EN(SOHCw/oOBD)-41

2 CHECK OUTPUT SIGNAL FROM ECM. Is voltage less than 1 V? Go to step 3. Go to step 5.
Measure voltage between test mode connec-
tor and chassis ground.
3 CHECK HARNESS BETWEEN ECM AND Is resistance less than 1 Go to step 4. Repair harness
TEST MODE CONNECTOR. Ω? and connector.
ECM and test mode connector. ing:
ECM and test
mode connector
쐌 Poor contact in
coupling connec-
tor (B180)
nector. FU(SOHCw/
oOBD)-38, Engine
Control Module.>
5 CHECK HARNESS BETWEEN ECM AND Is resistance less than 1 Go to step 6. Repair harness
TEST MODE CONNECTOR. Ω? and connector.
ECM and test mode connector. ing:
ECM and test
mode connector
쐌 Poor contact in
coupling connec-
tor (B138)
nector. FU(SOHCw/
oOBD)-38, Engine
Control Module.>
EN(SOHCw/oOBD)-42
MEMO:
EN(SOHCw/oOBD)-43

쐌 DIAGNOSIS:
쐌 Even though test mode connector is disconnected, MIL blinks at a cycle of 3 Hz when ignition switch
is turned to ON.
쐌 WIRING DIAGRAM:
S2M2110
EN(SOHCw/oOBD)-44

MINAL. between ECM FU(SOHCw/
1) Turn ignition switch to OFF. and test mode oOBD)-38, Engine
2) Disconnect connector from ECM. connector. Control Module.>
ECM connector and engine ground.
EN(SOHCw/oOBD)-45
MEMO:
EN(SOHCw/oOBD)-46
1. Inspection of starter motor circuit. <Ref. to EN(SOHCw/oOBD)-48 STARTER MOTOR CIRCUIT, Diagnostics
for Engine Starting Failure.>
↓
2. Inspection of ECM power supply and ground line. <Ref. to EN(SOHCw/oOBD)-52 CONTROL MODULE POWER SUPPLY
AND GROUND LINE, Diagnostics for Engine Starting Failure.>
↓
3. Inspection of ignition control system. <Ref. to EN(SOHCw/oOBD)-54 IGNITION CONTROL SYSTEM, Diagnostics for
Engine Starting Failure.>
↓
4. Inspection of fuel pump circuit. <Ref. to EN(SOHCw/oOBD)-58 FUEL PUMP CIRCUIT, Diagnostics for Engine Starting
Failure.>
↓
5. Inspection of fuel injector circuit. <Ref. to EN(SOHCw/oOBD)-62 FUEL INJECTOR CIRCUIT, Diagnostics for Engine Start-
ing Failure.>
EN(SOHCw/oOBD)-47
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES.
<Ref. to EN(SOHCw/oOBD)-31 OPERATION, Clear Memory Mode.> and <Ref. to EN(SOHCw/
oOBD)-29 OPERATION, Inspection Mode.>
쐌 WIRING DIAGRAM:
S2M2111
EN(SOHCw/oOBD)-48

MOTOR. V?
ground.
NOTE:
On AT vehicles, place the select lever in the
1) Turn ignition switch to OFF. SC-8, cable.
2) Disconnect terminal from starter motor. INSPECTION,
3) Measure resistance of ground cable Starter.>
ground.
and ECM.
4 CHECK HARNESS BETWEEN BATTERY Is the voltage more than 10 Go to step 5. NOTE:
AND IGNITION SWITCH CONNECTOR. V? Check the follow-
1) Ignition switch to OFF. ing and repair if
2) Disconnect connector from ignition switch. necessary.
3) Measure power supply voltage between 쐌 Blown out fuse
ignition switch connector and chassis ground. (SBF-1, SBF-4)
Connector & terminal 쐌 If replaced fuse
(B72) No. 1 (+) — Chassis ground (−): (SBF-1, SBF-4)
blows easily,
check the harness
for short circuit of
harness between
fuse and ignition
switch connector.
쐌 Open circuit in
harness between
ignition switch and
battery
and chassis ground.
cuit between igni-
tion switch and
starter motor cir-
cuit.
EN(SOHCw/oOBD)-49

2) Place the select lever in the “P” or “N” between starter
(T3) No. 11 — No. 12:
(T3) No. 11 — (T7) No. 7:
(T3) No. 12 — (T7) No. 12:
EN(SOHCw/oOBD)-50
MEMO:
EN(SOHCw/oOBD)-51
CAUTION:
쐌 WIRING DIAGRAM:
S2M2112

1) Turn ignition switch to OFF. 10 Ω? relay.
1 and No. 2.
terminals.
Terminals
No. 3 — No. 5:
EN(SOHCw/oOBD)-52

Measure resistance between main relay termi- 10 Ω? relay.
nals.
Terminals
No. 4 — No. 6:
1) Disconnect connectors from ECM. 5 Ω? cuit in harness
ECM and engine ground. connector and
(E22) No. 10 — Engine ground: terminal.
1) Turn ignition switch to ON. V? ground short cir-
2) Measure voltage between ECM connector cuit of power sup-
and engine ground. ply circuit.
(B84) No. 28 (+) — Engine ground (–):
tor and chassis ground. cuit of power sup-
and engine ground. cuit of power sup-
1) Turn ignition switch to OFF. V? ground short cir-
2) Connect main relay connector. cuit between ECM
3) Measure voltage between ECM connector connector and
and engine ground. main relay con-
1) Connect ST. <Ref. to EN(SOHCw/oOBD)- V? control system. ground short cir-
23, HOW TO CHECK I/O SIGNAL FOR ECM, <Ref. to cuit between ECM
Engine Control Module (ECM) I/O Signal.> EN(SOHCw/ connector and
ST 498307600 CHECK BOARD KIT oOBD)-54, IGNI- main relay con-
2) Measure voltage between ECM connector TION CONTROL nector.
and engine ground. SYSTEM, Diag-
Connector & terminal nostics for Engine
(B) No. 27 (+) — Engine ground (–): Starting Failure.>
(C) No. 36 (+) — Engine ground (–):
EN(SOHCw/oOBD)-53
CAUTION:
쐌 WIRING DIAGRAM:
S2M2113
EN(SOHCw/oOBD)-54

1) Remove plug cord cap from each spark cylinder? system. <Ref. to
plug. EN(SOHCw/
2) Install new spark plug on plug cord cap. oOBD)-58, FUEL
CAUTION: PUMP CIRCUIT,
Do not remove spark plug from engine. Diagnostics for
3) Contact spark plug’s thread portion on Engine Starting
engine. Failure.>
4) While opening throttle valve fully, crank
cylinder.
connector
쐌 Poor contact in
coupling connec-
tor (B20)
ground. ing:
ignition coil & igni-
tor assembly con-
nector and engine
grounding termi-
nal
BLY. 10 and 15 Ω? coil & ignitor
1) Remove spark plug cords. assembly. <Ref.
2) Measure resistance between spark plug to IG(SOHCw/
cord contact portions to check secondary coil. oOBD)-9, Ignition
Terminals Coil and Ignitor
No. 1 — No. 2: Assembly.>
No. 3 — No. 4:
Check if voltage varies synchronously with assembly.
engine speed when cranking, while monitoring
voltage between ignition coil & ignitor assem-
bly connector and engine ground.
EN(SOHCw/oOBD)-55

IGNITION COIL & IGNITOR ASSEMBLY 1 Ω? cuit in harness
1) Disconnect connector from ECM. and ignition coil &
2) Measure resistance of harness between ignitor assembly
ECM and ignition coil & ignitor assembly con- connector.
nector.
(E22) No. 9 — (E12) No. 4:
(E22) No. 3 — (E12) No. 2:
(E22) No. 10 — (E12) No. 3:
(E22) No. 3 — Engine ground: tor.
8 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Check fuel pump
Check poor contact in ECM connector. ECM connector? tact in ECM con- circuit. <Ref. to
nector. EN(SOHCw/
oOBD)-58, FUEL
PUMP CIRCUIT,
Diagnostics for
Engine Starting
Failure.>
EN(SOHCw/oOBD)-56
MEMO:
EN(SOHCw/oOBD)-57
CAUTION:
쐌 WIRING DIAGRAM:
S2M2114
EN(SOHCw/oOBD)-58

1 CHECK OPERATING SOUND OF FUEL Does fuel pump produce Check fuel injec- Go to step 2.
PUMP. operating sound? tor circuit. <Ref. to
1) Connect test mode connector. EN(SOHCw/
2) Turn ignition switch to ON. oOBD)-62, FUEL
3) Make sure that fuel pump is in operation. INJECTOR
NOTE: CIRCUIT, Diag-
For the procedure, refer to the “COMPUL- nostics for Engine
SORY VALVE OPERATION CHECK MODE”. Starting Failure.>
<Ref. to EN(SOHCw/oOBD)-32, Compulsory
Valve Operation Check Mode.>
2 CHECK GROUND CIRCUIT OF FUEL PUMP. Is the resistance less than Go to step 3. Repair harness
2) Remove fuel pump access hole lid located NOTE:
on the luggage compartment floor. In this case,
3) Disconnect connector from fuel pump. repair the follow-
4) Measure resistance of harness connector ing:
between fuel pump and chassis ground. 쐌 Open circuit in
(R58) No. 4 — Chassis ground: fuel pump con-
nector and chas-
sis grounding ter-
minal
쐌 Poor contact in
coupling connec-
tor (R15)
3 CHECK POWER SUPPLY TO FUEL PUMP. Is the voltage more than 10 Replace fuel Go to step 4.
1) Turn ignition switch to ON. V? pump. <Ref. to
2) Measure voltage of power supply circuit FU(SOHCw/
between fuel pump connector and chassis oOBD)-50, Fuel
ground. Pump.>
(R58) No. 1 (+) — Chassis ground (−):
4 CHECK HARNESS BETWEEN FUEL PUMP Is the resistance less than Go to step 5. Repair harness
AND FUEL PUMP RELAY CONNECTOR. 1 Ω? and connector.
fuel pump and fuel pump relay connector. repair the follow-
(R58) No. 1 — (B46) No. 4: 쐌 Open circuit in
harness between
fuel pump and
fuel pump relay
connector
쐌 Poor contact in
coupling connec-
tors (R15) and
(B97)
5 CHECK HARNESS BETWEEN FUEL PUMP Is the resistance more than Go to step 6. Repair ground
AND FUEL PUMP RELAY CONNECTOR. 1 MΩ? short circuit in
Measure resistance of harness between fuel harness between
pump and fuel pump relay connector. fuel pump and
Connector & terminal fuel pump relay
(R58) No. 1 — Chassis ground: connector.
EN(SOHCw/oOBD)-59

6 CHECK FUEL PUMP RELAY. Is the resistance less than Go to step 7. Replace fuel
1) Disconnect connector from fuel pump relay. 10 Ω? pump relay. <Ref.
2) Remove fuel pump relay from bracket. to FU(SOHCw/
3) Connect battery to fuel pump relay connec- oOBD)-40, Fuel
tor terminals No. 1 and No. 3. Pump Relay.>
terminals of fuel pump relay.
Terminals
No. 2 — No. 4:
FUEL PUMP RELAY CONNECTOR. 1 Ω? cuit in harness
1) Disconnect connectors from ECM. between ECM
2) Measure resistance of harness between and fuel pump
ECM and fuel pump relay connector. relay connector.
(B84) No. 3 — (B46) No. 3:
8 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Check fuel injec-
Check poor contact in ECM connector. ECM connector? tact in ECM con- tor circuit. <Ref. to
nector. EN(SOHCw/
oOBD)-62, FUEL
INJECTOR
CIRCUIT, Diag-
nostics for Engine
Starting Failure.>
EN(SOHCw/oOBD)-60
MEMO:
EN(SOHCw/oOBD)-61
CAUTION:
쐌 After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES.
쐌 WIRING DIAGRAM:
S2M2115

While cranking the engine, check that each ME(SOHC)-28,
fuel injector emits “operating” sound. Use a Fuel Pressure.>
sound scope or attach a screwdriver to injec-
tor for this check.
EN(SOHCw/oOBD)-62

2) Disconnect connector from fuel injector. In this case,
3) Turn ignition switch to ON. repair the follow-
4) Measure power supply voltage between the ing:
fuel injector terminal and engine ground. 쐌 Open circuit in
#1 (E5) No. 2 (+) — Engine ground (–): main relay and
(–): nector
#3 (E6) No. 2 (+) — Engine ground (–): 쐌 Poor contact in
#4 (E17) No. 2 (+) — Engine ground main relay con-
(–): nector
쐌 Poor contact in
coupling connec-
tor (B20)
쐌 Poor contact in
fuel injector con-
nector
3 CHECK EACH FUEL INJECTOR. Is the resistance between Go to step 4. Replace faulty
1) Turn ignition switch to OFF. 11 and 12 Ω? fuel injector. <Ref.
2) Measure resistance between each fuel to FU(SOHCw/
injector terminals. oOBD)-32, Fuel
Terminals Injector.>
No. 1 — No. 2:
FUEL INJECTOR CONNECTOR. 1 Ω? cuit in harness
1) Disconnect connector from ECM. between ECM
2) Measure resistance of harness between and fuel injector
ECM and fuel injector connector. connector.
(E22) No. 7 — #1 (E5) No. 1:
(E22) No. 7 — #2 (E16) No. 1:
(E22) No. 6 — #3 (E6) No. 1:
(E22) No. 6 — #4 (E17) No. 1:
FUEL INJECTOR CONNECTOR. 1 MΩ? short in harness
Measure resistance of harness between ECM between ECM
and fuel injector connector. and fuel injector
6 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Check crankshaft
Check poor contact in ECM connector. ECM connector? tact in ECM con- position sensor
nector. circuit. <Ref. to
EN(SOHCw/
oOBD)-64,
CRANKSHAFT
POSITION SEN-
SOR CIRCUIT,
Diagnostics for
Engine Starting
Failure.>
EN(SOHCw/oOBD)-63
G: CRANKSHAFT POSITION SENSOR CIRCUIT S068533E98
CAUTION:
<Ref. to EN(SOHCw/oOBD)-31, Clear Memory Mode.>, <Ref. to EN(SOHCw/oOBD)-29, Inspection
Mode.>
NOTE:
Check crankshaft position sensor circuit. <Ref. to EN(SOHCw/oOBD)-68, DTC 11 CRANKSHAFT POSI-
TION SENSOR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(SOHCw/oOBD)-64
13. List of Diagnostic Trouble Code (DTC) S068525
A: LIST S068525A12
DTC No. Item Contents of diagnosis Index

11 Crankshaft position sensor 쐌 No signal entered from crankshaft position sensor when <Ref. to EN(SOHCw/
ignition switch is ON. oOBD)-68, DTC 11
쐌 The harness connector between ECM and crankshaft CRANKSHAFT POSI-
position sensor is in short or open. TION SENSOR, Diag-
nostic Procedure with
Diagnostic Trouble
Code (DTC).>
21 Engine coolant tempera- 쐌 The engine coolant temperature sensor signal is abnor- <Ref. to EN(SOHCw/
ture sensor mal. oOBD)-70, DTC 21
쐌 The harness connector between ECM and engine coolant ENGINE COOLANT
temperature sensor is in short or open. TEMPERATURE
SENSOR, Diagnostic
Procedure with Diag-
nostic Trouble Code
(DTC).>
22 Knock sensor 쐌 The knock sensor signal is abnormal. <Ref. to EN(SOHCw/
쐌 The harness connector between ECM and knock sensor oOBD)-74, DTC 22
is in short or open. KNOCK SENSOR,
Diagnostic Procedure
with Diagnostic Trouble
Code (DTC).>
45 Pressure sensor 쐌 The pressure sensor signal is abnormal. <Ref. to EN(SOHCw/
쐌 The harness connector between ECM and pressure sen- oOBD)-78, DTC 45
sor is in short or open. PRESSURE SENSOR,
Code (DTC).>
24 Idle air control solenoid 쐌 The idle air control solenoid valve is not in function. <Ref. to EN(SOHCw/
valve 쐌 The harness connector between ECM and idle air control oOBD)-80, DTC 24
solenoid valve is in short or open. IDLE AIR CONTROL
SOLENOID VALVE,
Code (DTC).>
26 Intake air temperature 쐌 The intake air temperature sensor signal is abnormal. <Ref. to EN(SOHCw/
sensor 쐌 The harness connector between ECM and intake air tem- oOBD)-84, DTC 26
perature sensor is in short or open. INTAKE AIR TEM-
PERATURE SENSOR,
Code (DTC).>
31 Throttle position sensor 쐌 The throttle position sensor signal is abnormal. <Ref. to EN(SOHCw/
쐌 The throttle position sensor is installed abnormally. oOBD)-86, DTC 31
쐌 The harness connector between ECM and throttle position THROTTLE POSITION
sensor is in short or open. SENSOR, Diagnostic
nostic Trouble Code
(DTC).>
32 Oxygen sensor (With cata- 쐌 The oxygen sensor is not in function. <Ref. to EN(SOHCw/
lyst vehicles) 쐌 The harness connector between ECM and oxygen sensor oOBD)-90, DTC 32
is in short or open. OXYGEN SENSOR,
Code (DTC).>
EN(SOHCw/oOBD)-65
DTC No. Item Contents of diagnosis Index

33 Vehicle speed signal 쐌 The vehicle speed signal is abnormal. <Ref. to EN(SOHCw/
쐌 The harness connector between ECM and combination oOBD)-94, DTC 33
meter is in short or open. VEHICLE SPEED
SIGNAL, Diagnostic
nostic Trouble Code
(DTC).>
35 Purge control solenoid 쐌 The purge control solenoid valve is not in function. <Ref. to EN(SOHCw/
valve 쐌 The harness connector between ECM and purge control oOBD)-96, DTC 35
solenoid valve is in short or open. PURGE CONTROL
SOLENOID VALVE,
Code (DTC).>
38 Torque control signal 쐌 Abnormal signal entered from TCM. <Ref. to EN(SOHCw/
쐌 The harness connector between ECM and TCM is in oOBD)-100, DTC 38
short. TORQUE CONTROL
SIGNAL, Diagnostic
nostic Trouble Code
(DTC).>
46 CO resistor (General 쐌 The CO resistor signal is abnormal. <Ref. to EN(SOHCw/
spec. vehicles) 쐌 The harness connector between ECM and CO resistor is oOBD)-102, DTC 46
in short or open. CO RESISTOR (GEN-
쐌 The CO value is not adjusted to specifications. ERAL SPEC.
VEHICLES), Diagnostic
nostic Trouble Code
(DTC).>
51 Neutral position switch 쐌 The neutral position switch signal is abnormal. <Ref. to EN(SOHCw/
쐌 The harness connector between ECM and neutral position oOBD)-104, DTC 51
switch is in short or open. NEUTRAL POSITION
SWITCH, Diagnostic
nostic Trouble Code
(DTC).>
53 Immobiliser system Faulty immobiliser system. <Ref. to IM-2, Basic
Diagnostic Procedure.>
54 Air intake system Because the ducts and hoses on air intake line are loosened <Ref. to EN(SOHCw/
or damaged, the pressure sensor signal is abnormal. oOBD)-108, DTC 54 —
AIR INTAKE SYSTEM
—, Diagnostic Proce-
dure with Diagnostic
85 Charge system Charge system is abnormal. <Ref. to EN(SOHCw/
oOBD)-111, DTC 85
CHARGE SYSTEM,
Code (DTC).>
EN(SOHCw/oOBD)-66
MEMO:
EN(SOHCw/oOBD)-67
A: DTC 11 CRANKSHAFT POSITION SENSOR S068521G55
쐌 DIAGNOSIS:
쐌 No signal entered from crankshaft position sensor when ignition switch is ON.
쐌 The harness connector between ECM and crankshaft position sensor is in short or open.
쐌 Engine stalls.
쐌 Restarting impossible
CAUTION:
쐌 WIRING DIAGRAM:
S2M2116
EN(SOHCw/oOBD)-68

1 CHECK CONDITION OF CRANKSHAFT Are the crankshaft position Go to step 2. Tighten crankshaft
POSITION SENSOR INSTALLATION. sensor installing bolts tight- position sensor
ened securely? installing bolts
securely.
2 CHECK CRANKSHAFT POSITION SENSOR. Is the resistance between 1 Go to step 3. Replace crank-
1) Remove crankshaft position sensor. and 4 kΩ? shaft position sen-
2) Measure resistance between connector sor.
terminals of crankshaft position sensor.
Terminals
No. 1 — No. 2:
CRANKSHAFT POSITION SENSOR CON- and 5 kΩ? and connector.
NECTOR. NOTE:
1) Connect connector to crankshaft position In this case,
2) Disconnect connector from ECM. ing:
ECM. crankshaft posi-
(E22) No. 14 — (E22) No. 20: ECM connector
CRANKSHAFT POSITION SENSOR CON- 10 Ω? short circuit in
NECTOR. harness between
Measure resistance of harness between ECM crankshaft posi-
connector and chassis ground. tion sensor and
Connector & terminal ECM connector.
5 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than Go to step 6. Replace crank-
1) Turn ignition switch to OFF. 400 mV? shaft position sen-
2) Disconnect connector from ECM, then con- sor.
nect ST. <Ref. to EN(SOHCw/oOBD)-23,
HOW TO CHECK I/O SIGNAL FOR ECM,
Engine Control Module (ECM) I/O Signal.>
3) Set the positive (+) probe and ground lead
of oscilloscope at ECM connector terminals.
4) Measure voltage indicated on oscilloscope
while cranking the engine.
(B) No. 26 (+) — (B) No. 19 (−):
nector.
2) Erase the memory. <Ref. to EN(SOHCw/ still being output?
oOBD)-31, Clear Memory Mode.>
EN(SOHCw/oOBD)-29, Inspection Mode.>
EN(SOHCw/oOBD)-27, Read Diagnostic
Trouble Code.>
sponding to the
trouble code.
EN(SOHCw/oOBD)-69
B: DTC 21 ENGINE COOLANT TEMPERATURE SENSOR S068521G58
쐌 DIAGNOSIS:
쐌 The engine coolant temperature sensor signal is abnormal.
쐌 The harness connector between ECM and engine coolant temperature sensor is in short or open.
쐌 Hard to start
CAUTION:
쐌 WIRING DIAGRAM:
S2M2117
EN(SOHCw/oOBD)-70

2) Remove air intake duct and air cleaner coolant tempera-
assembly. ture sensor con-
3) Disconnect connector from engine coolant nector.
temperature sensor.
4) Measure voltage between engine coolant
ground.
ground. nector.
ground. ing:
ECM and engine
coolant tempera-
ture sensor con-
nector
쐌 Poor contact in
engine coolant
temperature sen-
sor connector
쐌 Poor contact in
ECM connector
4 CHECK HARNESS BETWEEN ENGINE Is the resistance less than Go to step 5. Repair harness
COOLANT TEMPERATURE SENSOR AND 5 Ω? and connector.
engine coolant temperature sensor connector ing:
and engine ground. 쐌 Open circuit in
coolant tempera-
ture sensor con-
nector
쐌 Poor contact in
engine coolant
temperature sen-
sor connector
쐌 Poor contact in
ECM connector
EN(SOHCw/oOBD)-71

5 CHECK ENGINE COOLANT TEMPERA- Is the resistance between 2 Go to step 6. Replace engine
TURE SENSOR. and 3 kΩ at 20°C (68°F)? coolant tempera-
Measure resistance between engine coolant ture sensor. <Ref.
temperature sensor terminals. to FU(SOHCw/
Terminals oOBD)-23, Engine
No. 1 — No. 2: Coolant Tempera-
ture Sensor.>
6 CHECK ENGINE COOLANT TEMPERA- Is the resistance between Go to step 7. Replace engine
TURE SENSOR. 0.35 and 0.4 kΩ at 80°C coolant tempera-
Measure resistance between engine coolant (176°F)? ture sensor. <Ref.
temperature sensor terminals. to FU(SOHCw/
Terminals oOBD)-23, Engine
ture Sensor.>
7 CHECK ENGINE COOLANT TEMPERA- Is the resistance between Replace ECM. Replace engine
TURE SENSOR. 0.2 and 0.3 kΩ at 90°C <Ref. to coolant tempera-
Measure resistance between engine coolant (194°F)? FU(SOHCw/ ture sensor. <Ref.
temperature sensor terminals. oOBD)-38, Engine to FU(SOHCw/
Terminals Control Module.> oOBD)-23, Engine
ture Sensor.>
EN(SOHCw/oOBD)-72
MEMO:
EN(SOHCw/oOBD)-73
C: DTC 22 KNOCK SENSOR S068521G59
쐌 DIAGNOSIS:
쐌 The knock sensor signal is abnormal.
쐌 The harness connector between ECM and knock sensor is in short or open.
CAUTION:
쐌 WIRING DIAGRAM:
S2M2118
EN(SOHCw/oOBD)-74

1 CHECK HARNESS BETWEEN KNOCK Is the resistance more than Go to step 3. Go to step 2.
ECM connector and engine ground.
connector and engine ground.
쐌 Open circuit in
harness between
knock sensor and
ECM connector
쐌 Poor contact in
knock sensor con-
nector
securely? FU(SOHCw/ bolt securely.
oOBD)-25, Knock
Sensor.>
1) Disconnect connector from knock sensor. 400 kΩ? sensor. short circuit in
2) Measure resistance between knock sensor harness between
connector terminal and engine ground. knock sensor con-
Terminal nector and ECM
NOTE:
The harness
between both
connectors is
shielded. Repair
short circuit of
harness together
with shield.
EN(SOHCw/oOBD)-75

1) Connect ST. <Ref. to EN(SOHCw/oOBD)- V? up, the circuit has tact in ECM con-
23, HOW TO CHECK I/O SIGNAL FOR ECM, returned to a nor- nector.
Engine Control Module (ECM) I/O Signal.> mal condition at
ST 498307600 CHECK BOARD KIT this time.
2) Turn ignition switch to ON. (However, the
3) Measure voltage between ECM and engine possibility of poor
ground. contact still
Connector & terminal remains.)
(B) No. 17 (+) — Engine ground (−): NOTE:
In this case,
repair the follow-
ing:
쐌 Poor contact in
knock sensor con-
nector
쐌 Poor contact in
ECM connector
EN(SOHCw/oOBD)-76
MEMO:
EN(SOHCw/oOBD)-77
D: DTC 45 PRESSURE SENSOR S068521G67
쐌 DIAGNOSIS:
쐌 The pressure sensor signal is abnormal.
쐌 The harness connector between ECM and pressure sensor is in short or open.
쐌 Engine stalls.
CAUTION:
쐌 WIRING DIAGRAM:
S2M2126
EN(SOHCw/oOBD)-78

1 CHECK HARNESS BETWEEN ECM AND Is the voltage between 4.5 Go to step 2. Repair open cir-
PRESSURE SENSOR CONNECTOR. V and 5.5 V? cuit in harness
1) Disconnect connector from pressure sen- between ECM
sor. and pressure sen-
2) Turn ignition switch to ON. sor.
3) Measure voltage between pressure sensor
PRESSURE SENSOR CONNECTOR. 1 Ω? cuit in harness
1) Disconnect connector from ECM. between ECM
2) Measure resistance of harness between and pressure sen-
ECM and pressure sensor connector. sor connector.
(E22) No. 22 — (E21) No. 2:
(E22) No. 25 — (E21) No. 3:
(E22) No. 18 — (E21) No. 1:
PRESSURE SENSOR CONNECTOR. 1 MΩ? short circuit in
connector and engine ground. ECM and pres-
Connector & terminal sure sensor con-
(E22) No. 25 — Engine ground: nector.
4 CHECK INPUT SIGNAL FOR ECM. Is the voltage between 2.3 Go to step 5. Replace pressure
1) Turn ignition switch to OFF. V and 2.5 V? sensor. <Ref. to
2) Disconnect connector from ECM, then con- FU(SOHCw/
nect ST. <Ref. to EN(SOHCw/oOBD)-23, oOBD)-29, Pres-
HOW TO CHECK I/O SIGNAL FOR ECM, sure Sensor.>
4) Measure voltage between ECM and engine
ground.
(A) No. 15 (+) — Engine ground (–):
1) Start engine, and idle it. V and 1.8 V? sensor. <Ref. to
2) Measure voltage between ECM and engine FU(SOHCw/
ground. oOBD)-29, Pres-
Connector & terminal sure Sensor.>
6 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace pressure
Check poor contact in pressure sensor con- pressure sensor connec- tact in pressure sensor. <Ref. to
nector. tor? sensor connector. FU(SOHCw/
oOBD)-29, Pres-
sure Sensor.>
EN(SOHCw/oOBD)-79
E: DTC 24 IDLE AIR CONTROL SOLENOID VALVE S068521G60
쐌 DIAGNOSIS:
쐌 The idle air control solenoid valve is not in function.
쐌 The harness connector between ECM and idle air control solenoid valve is in short or open.
쐌 Hard to start
CAUTION:
쐌 WIRING DIAGRAM:
S2M2119
EN(SOHCw/oOBD)-80

1 CHECK AIR INTAKE SYSTEM. Is there a fault in air intake Repair or replace Go to step 2.
1) Turn ignition switch to ON. system? air intake system.
2) Start engine and idle it.
3) Check the following item.
body gasket
쐌 Loose control connection and cracks of idle
air control solenoid valve by-pass hose
쐌 Disconnection of vacuum hoses
IDLE AIR CONTROL SOLENOID VALVE 1 Ω? cuit in harness
1) Turn ignition switch to OFF. and idle air con-
2) Disconnect connector from ECM and idle trol solenoid valve
air control solenoid valve. connector.
ECM and idle air control solenoid valve con-
nector.
(E22) No. 4 — (E7) No. 1:
IDLE AIR CONTROL SOLENOID VALVE 1 Ω? cuit in harness
Measure resistance of harness between ECM and idle air con-
and idle air control solenoid valve connector. trol solenoid valve
(E22) No. 11 — (E7) No. 3:
4 CHECK HARNESS BETWEEN ECM AND Is the resistance more than Repair ground Go to step 5.
IDLE AIR CONTROL SOLENOID VALVE 1 MΩ? short in harness
Measure resistance of harness between ECM and idle air con-
connector and engine ground. trol solenoid
Connector & terminal valve.
5 CHECK HARNESS BETWEEN ECM AND Is the resistance more than Repair ground Go to step 6.
IDLE AIR CONTROL SOLENOID VALVE 1 MΩ? short circuit in
Measure resistance of harness between ECM ECM and idle air
connector and engine ground. control solenoid
nector.
1 and No. 2.
terminals.
Terminals
No. 4 — No. 6:
EN(SOHCw/oOBD)-81

1) Disconnect connector from idle air control NOTE:
solenoid valve. In this case,
3) Measure voltage between idle air control ing:
solenoid valve connector and engine ground. 쐌 Open circuit in
(E7) No. 2 (+) — Engine ground (–): idle air control
solenoid valve
and battery
쐌 Poor contact in
coupling connec-
tor (B20)
9 CHECK POOR CONTACT. Is there poor contact in idle Repair poor con- Contact your
Check poor contact in idle air control solenoid air control solenoid valve tact in idle air Subaru distributor.
valve connector. connector? control solenoid NOTE:
valve connector. Inspection by your
Subaru distributor
is required,
because probable
cause is deterio-
ration of multiple
parts.
EN(SOHCw/oOBD)-82
MEMO:
EN(SOHCw/oOBD)-83
F: DTC 26 INTAKE AIR TEMPERATURE SENSOR S068521G61
쐌 DIAGNOSIS:
쐌 The intake air temperature sensor signal is abnormal.
쐌 The harness connector between ECM and intake air temperature sensor is in short or open.
쐌 Hard to start
CAUTION:
쐌 WIRING DIAGRAM:
S2M2120
EN(SOHCw/oOBD)-84

1 CHECK INTAKE AIR TEMPERATURE SEN- Is the resistance between 2 Go to step 2. Replace intake air
SOR. and 3 kΩ at 20°C (68°F)? temperature sen-
1) Turn ignition switch to OFF. sor. <Ref. to
2) Disconnect connector from intake air tem- FU(SOHCw/
perature sensor. oOBD)-30, Intake
3) Measure resistance between intake air Air Temperature
temperature sensor terminals. Sensor.>
Terminals
No. 1 — No. 2:
2 CHECK INTAKE AIR TEMPERATURE SEN- Is the resistance between 2 Go to step 3. Replace intake air
SOR. and 3 kΩ at 50°C (122°F)? temperature sen-
Measure resistance between intake air tem- sor. <Ref. to
perature sensor terminals. FU(SOHCw/
Terminals oOBD)-30, Intake
No. 1 — No. 2: Air Temperature
Sensor.>
INTAKE AIR TEMPERATURE SENSOR 1 Ω? cuit in harness
1) Disconnect connector from ECM. and intake air
2) Measure resistance of harness connector temperature sen-
between ECM and intake air temperature sensor connector.
sor connector.
(E22) No. 17 — (E20) No. 1:
(E22) No. 22 — (E20) No. 2:
INTAKE AIR TEMPERATURE SENSOR 1 MΩ? short circuit in
connector and engine ground. control solenoid
nector. NOTE:
Inspection by your
Subaru distributor
is required,
because probable
cause is deterio-
ration of multiple
parts.
EN(SOHCw/oOBD)-85
G: DTC 31 THROTTLE POSITION SENSOR S068521G62
쐌 DIAGNOSIS:
쐌 The throttle position sensor signal is abnormal.
쐌 The throttle position sensor is installed abnormally.
쐌 The harness connector between ECM and throttle position sensor is in short or open.
쐌 Engine stalls
CAUTION:
쐌 WIRING DIAGRAM:
S2M2121
EN(SOHCw/oOBD)-86

2) Disconnect connector from ECM, then con-
ground while throttle valve is fully closed.
(B) No. 23 (+) — Engine ground (−):
Measure voltage between ECM and engine more than 4.5 V by shaking tact in ECM con- Subaru distributor.
ground. harness and connector of nector. NOTE:
Connector & terminal ECM while monitoring the Inspection by your
(B) No. 23 (+) — Engine ground (−): value with voltage meter? Subaru distributor
is required,
because probable
cause is deterio-
ration of multiple
parts.
3 CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 0.1 Go to step 4. Repair poor con-
Measure voltage between ECM connector V? tact in ECM con-
and engine ground. nector.
(B) No. 24 (+) — Engine ground (−):
TOR. NOTE:
tion sensor. ing:
쐌 Poor contact in
throttle position
sensor connector
쐌 Poor contact in
ECM connector
TOR. NOTE:
2) Disconnect ECM connector from CHECK repair the follow-
BOARD. ing:
ECM and throttle position sensor connector. harness between
Connector & terminal throttle position
(E22) No. 22 — (E13) No. 2: sensor and ECM
connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
throttle position
sensor connector
EN(SOHCw/oOBD)-87

ground. connector.
Check poor contact in throttle position sensor throttle position sensor contact in throttle
connector. nector? position sensor
connector.
8 CHECK CONDITION OF THROTTLE POSI- Are the throttle position Replace throttle Adjust throttle
TION SENSOR INSTALLATION. sensor installing screws position sensor. position sensor
tightened securely? and tighten
throttle position
sensor installing
screws securely.
EN(SOHCw/oOBD)-88
MEMO:
EN(SOHCw/oOBD)-89
H: DTC 32 OXYGEN SENSOR S068521G63
쐌 DIAGNOSIS:
쐌 The oxygen sensor is not in function.
쐌 The harness connector between ECM and oxygen sensor is in short or open.
쐌 Engine stalls.
CAUTION:
쐌 WIRING DIAGRAM:
S2M2122
EN(SOHCw/oOBD)-90

1 CHECK FOR OTHER CAUSES AFFECTING Is CO% more than 2% Check fuel sys- Go to step 2.
EXHAUST GAS. after engine warm-up? tem.
NOTE:
쐌 Check for use of improper fuel.
쐌 Check if engine oil or coolant level is
extremely low.
2 CHECK EXHAUST SYSTEM. Is there a fault in exhaust Repair exhaust Go to step 3.
system? system.
NOTE:
쐌 Loose installa-
tion of front por-
tion of exhaust
pipe onto cylinder
heads
쐌 Loose connec-
tion between front
exhaust pipe and
front catalytic con-
verter
쐌 Damage of
exhaust pipe
resulting in hole
3 CHECK HARNESS BETWEEN OXYGEN Is the voltage more than Go to step 4. Repair harness
SENSOR AND ECM CONNECTOR. 0.2 V? and connector.
2) Disconnect connector from oxygen sensor. In this case,
4) Measure voltage between front oxygen ing:
sensor harness connector and engine ground. 쐌 Open circuit in
(B18) No. 4 (+) — Engine ground (−): ECM and oxygen
sensor connector
쐌 Poor contact in
the ECM connec-
tor
Check poor contact in oxygen sensor connec- oxygen sensor connector? tact in oxygen
tor. sensor connector.
1 and No. 2.
terminals.
Terminals
No. 4 — No. 6:
EN(SOHCw/oOBD)-91

6 CHECK POWER SUPPLY TO OXYGEN Is the voltage more than 10 Go to step 7. Repair power sup-
SENSOR. V? ply line.
2) Measure voltage between oxygen sensor In this case,
connector. repair the follow-
(B18) No. 2 (+) — Engine ground (−): 쐌 Open circuit in
harness between
battery and oxy-
gen sensor con-
nector
쐌 Poor contact in
oxygen sensor
connector
쐌 Poor contact in
main relay con-
nector
7 CHECK OXYGEN SENSOR. Is the resistance less than Repair poor con- Replace oxygen
1) Turn ignition switch to OFF. 30 Ω? tact. sensor. <Ref. to
2) Measure resistance between oxygen sen- NOTE: FU(SOHCw/
sor terminals. In this case, oOBD)-36, Oxy-
Terminals repair the follow- gen Sensor.>
No. 1 — No. 2: ing:
쐌 Poor contact in
ECM connector
쐌 Poor contact in
oxygen sensor
connector
EN(SOHCw/oOBD)-92
MEMO:
EN(SOHCw/oOBD)-93
I: DTC 33 VEHICLE SPEED SIGNAL S068521G64
쐌 DIAGNOSIS:
쐌 The vehicle speed signal is abnormal.
쐌 The harness connector between ECM and vehicle speed sensor is in short or open.
쐌 Engine stalls.
CAUTION:
쐌 WIRING DIAGRAM:
S2M2123
EN(SOHCw/oOBD)-94

speed sensor.
<Ref. to IDI-7,
INSPECTION,
Combination
Meter System.>
1) Disconnect connector from ECM, then con- V?
3) Set the positive (+) terminal and earth lead
of the oscilloscope at ECM connector termi-
nals.
(D) No. 53 — Engine ground:
5) Shift the gear position, and travel at a con-
stant speed.
6) Measure the signal voltage indicated on
the oscilloscope.
3 CHECK POOR CONTACT. Is there poor contact at the Repair poor con- Replace ECM.
Check for poor contact at ECM connector. ECM connector? tact at ECM. <Ref. to
FU(SOHCw/
oOBD)-38, Engine
Control Module.>
4 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 2 Repair harness Go to step 5.
COMBINATION METER CONNECTOR. V? and connector.
Measure voltage between ECM and engine NOTE:
ground. In this case,
(D) No. 53 (+) — Engine ground (−): ing:
쐌 Battery short
circuit in harness
between ECM
and combination
meter connector
COMBINATION METER CONNECTOR. 10 Ω? short circuit in
2) Disconnect check board. ECM and combi-
3) Measure resistance of harness between nation meter con-
ECM connector and engine ground. nector.
Check poor contact in ECM connector. ECM connector? tact in ECM. <Ref. to
FU(SOHCw/
oOBD)-38, Engine
Control Module.>
EN(SOHCw/oOBD)-95
J: DTC 35 PURGE CONTROL SOLENOID VALVE S068521G65
쐌 DIAGNOSIS:
쐌 The purge control solenoid valve is not in function.
쐌 The harness connector between ECM and purge control solenoid valve is in short or open.
CAUTION:
쐌 WIRING DIAGRAM:
S2M2124
EN(SOHCw/oOBD)-96

1 CHECK OPERATION SOUND OF PURGE Does purge control sole- Go to step 2. Go to step 3.
CONTROL SOLENOID VALVE. noid valve produce operat-
1) Turn ignition switch to OFF. ing sound?
2) Connect test mode connector.
4) Make sure that the ON/OFF operating
sound of purge control solenoid valve occurs
at about 10 Hz.
Check poor contact in ECM connector. ECM connector? tact in ECM. <Ref. to
FU(SOHCw/
oOBD)-38, Engine
Control Module.>
2) Disconnect test mode connector. control solenoid
3) Disconnect connector from ECM, then con- valve connector.
nect ST. <Ref. to EN(SOHCw/oOBD)-23, After repair,
HOW TO CHECK I/O SIGNAL FOR ECM, replace ECM.
4) Disconnect connector from purge control
solenoid valve.
ground.
1) Turn ignition switch to OFF. and purge control
2) Disconnect ECM connector from CHECK solenoid valve
BOARD. connector.
ECM and purge control solenoid valve of har-
ness connector.
(E22) No. 5 — (E4) No. 2:
2) Measure resistance between purge control EC(SOHCw/
solenoid valve terminals. oOBD)-7, Purge
Terminal Control Solenoid
No. 1 — No. 2: Valve.>
1 and No. 2.
terminals.
Terminals
No. 4 — No. 6:
EN(SOHCw/oOBD)-97

7 CHECK POWER SUPPLY TO PURGE CON- Is the voltage more than 10 Go to step 8. Repair harness
TROL SOLENOID VALVE. V? and connector.
2) Measure voltage between purge control In this case,
solenoid valve and engine ground. repair the follow-
(E4) No. 1 (+) — Engine ground (−): 쐌 Open circuit in
harness between
battery and purge
control solenoid
valve connector
쐌 Poor contact in
main relay con-
nector
쐌 Poor contact in
coupling connec-
tor (B20)
connector. Inspection by your
Subaru distributor
is required,
because probable
cause is deterio-
ration of multiple
parts.
EN(SOHCw/oOBD)-98
MEMO:
EN(SOHCw/oOBD)-99
K: DTC 38 TORQUE CONTROL SIGNAL S068521G66
쐌 DIAGNOSIS:
쐌 Abnormal signal entered from TCM
쐌 The harness connector between ECM and TCM is in short.
CAUTION:
쐌 WIRING DIAGRAM:
S2M2125
EN(SOHCw/oOBD)-100

1) Disconnect connectors from ECM and harness between
TCM. ECM and TCM
ECM and engine ground.
2 CHECK HARNESS BETWEEN ECM AND Is there resistance less Repair ground Replace TCM.
TCM CONNECTOR. than 10 Ω? short circuit in <Ref. to AT-48
Measure resistance of harness between ECM harness between Transmission
and engine ground. ECM and TCM Control Module
Connector & terminal connector. (TCM).>
EN(SOHCw/oOBD)-101
L: DTC 46 CO RESISTOR (GENERAL SPEC. VEHICLES) S068521G68
쐌 DIAGNOSIS:
쐌 The CO resistor signal is abnormal.
쐌 The harness connector between ECM and CO resistor is in short or open.
쐌 The CO value is not adjusted to specifications.
쐌 Mixture ratio is too rich or too lean.
CAUTION:
쐌 WIRING DIAGRAM:
S2M2127
EN(SOHCw/oOBD)-102

1) Turn ignition switch to OFF. V and 4.5 V?
2) Disconnect connector from ECM, then con-
ground.
(D) No. 56 (+) — Engine ground (−):
ECM connector? tact in ECM con- <Ref. to
nector. FU(SOHCw/
oOBD)-38, Engine
Control Module.>
3 CHECK HARNESS BETWEEN CO RESIS- Is the resistance less than Go to step 4. Repair open cir-
TOR AND ECM CONNECTOR. 1 Ω? cuit in harness
2) Disconnect connector from ECM and CO and CO resistor
resistor. connector.
ECM and CO resistor connector.
(B84) No. 1 — (B155) No. 3:
(B84) No. 30 — (B155) No. 2:
(B84) No. 15 — (B155) No. 1:
4 CHECK HARNESS BETWEEN CO RESIS- Is the resistance more than Go to step 5. Repair short cir-
TOR AND ECM CONNECTOR. 1 MΩ? cuit in harness
connector and engine ground. and CO resistor
5 CHECK CO RESISTOR. Is the resistance between 4 Go to step 6. Replace CO resis-
Measure resistance between CO resistor ter- and 6 kΩ? tor.
minals.
Terminals
No. 1 — No. 3:
6 CHECK CO RESISTOR. Is the resistance between 0 Replace ECM. Replace CO resis-
Measure variable resistance between CO and 6 kΩ? tor.
resistor terminals while rotating the screw of NOTE:
CO resistor. Ensure resistance
Terminals varies in response
No. 1 — No. 2: to screw rotation.
EN(SOHCw/oOBD)-103
M: DTC 51 NEUTRAL POSITION SWITCH S068521H58
쐌 DIAGNOSIS:
쐌 The neutral position switch signal is abnormal.
쐌 The harness connector between ECM and neutral position switch is in short or open.
CAUTION:
쐌 WIRING DIAGRAM:
S2M2128
EN(SOHCw/oOBD)-104

1) Turn ignition switch to OFF. and 5.5 V in neutral posi-
2) Disconnect connector from ECM, then con- tion?
ground.
2 CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 1 V Go to step 3. Go to step 4.
Measure voltage between ECM and engine in other positions?
ground.
nector.
4 CHECK NEUTRAL POSITION SWITCH. Is the resistance more than Go to step 5. Repair short cir-
1) Turn ignition switch to OFF. 1 MΩ in neutral position? cuit in transmis-
2) Disconnect connector from transmission sion harness or
harness. replace neutral
3) Measure resistance between transmission position switch.
harness and connector terminals.
(T2) No. 1 — No. 2:
5 CHECK NEUTRAL POSITION SWITCH. Is the resistance less than Go to step 6. Repair open cir-
Measure resistance between transmission 1 Ω in other positions? cuit in transmis-
harness connector terminals. sion harness or
Connector & terminal replace neutral
(T2) No. 1 — No. 2: position switch.
NEUTRAL POSITION SWITCH CONNEC- 1 Ω? cuit in harness
TOR. between ECM
1) Disconnect ECM connector from CHECK and transmission
BOARD. harness connec-
2) Measure resistance of harness between tor.
ECM and transmission harness connector.
(B84) No. 26 — (B25) No. 1:
NEUTRAL POSITION SWITCH CONNEC- 10 Ω? short circuit in
Measure resistance between ECM connector ECM and trans-
and engine ground. mission harness
EN(SOHCw/oOBD)-105

8 CHECK NEUTRAL POSITION SWITCH Is the resistance less than Go to step 9. Repair harness
GROUND CIRCUIT. 5 Ω? and connector.
Measure resistance of harness between NOTE:
transmission harness connector and engine In this case,
ground. repair the follow-
(B25) No. 2 — Engine ground: 쐌 Open circuit in
harness between
transmission har-
ness connector
and engine
grounding termi-
nal
쐌 Poor contact in
coupling connec-
tor (B138)
Check poor contact in transmission harness transmission harness contact in transmis- Subaru distributor.
connector. nector? sion harness con- NOTE:
nector. Inspection by your
Subaru distributor
is required,
because probable
cause is deterio-
ration of multiple
parts.
EN(SOHCw/oOBD)-106
MEMO:
EN(SOHCw/oOBD)-107
N: DTC 54 — AIR INTAKE SYSTEM — S068521H59
쐌 DIAGNOSIS:
쐌 Intake duct, hose, nipple, etc., looseness, displacement, detachment
쐌 High idling revs
쐌 Poor engine pick up
CAUTION:
<Ref. to EN(SOHCw/oOBD)-31, Clear Memory Mode.>, <Ref. to EN(SOHCw/oOBD)-29, Inspection
Mode.>
쐌 WIRING DIAGRAM:
S2M2129
EN(SOHCw/oOBD)-108

1 CHECK AIR INTAKE SYSTEM. Is there a fault in the air Repair or replace Go to step 2.
1) Turn ignition switch to ON. intake system? air intake system.
3) Check the following items:
쐌 Cracks of air intake duct
쐌 Disconnections of air intake duct
쐌 Check for looseness, displacement of the
intake manifold.
쐌 Check that the intake manifold is connected
in the instructed manner. (Gasket detachment,
insufficient fastening torque of nuts and bolts)
쐌 Check for looseness, detachment of hose,
nipple etc.
1) Turn ignition to OFF. V and 3.6 V? sensor. <Ref. to
2) Disconnect connector from ECM, then con- FU(SOHCw/
nect ST. <Ref. to EN(SOHCw/oOBD)-23, oOBD)-29, Pres-
HOW TO CHECK I/O SIGNAL FOR ECM, sure Sensor.>
ground.
(D) No. 51 (+) — Engine ground (–):
1) Start engine, and idle it. V and 1.8 V? sensor. <Ref. to
2) Measure voltage between ECM and engine FU(SOHCw/
ground. oOBD)-29, Pres-
Connector & terminal sure Sensor.>
(D) No. 51 (+) — Engine ground (–):
4 CHECK INPUT SIGNAL FOR ECM. Is the voltage between 0.2 Go to step 5. Replace throttle
1) Stop engine, and turn ignition switch to V and 1.0 V? position sensor.
ON. <Ref. to
2) Measure voltage between ECM terminals FU(SOHCw/
while throttle valve is fully closed. oOBD)-26,
Terminal Throttle Position
No. 23 (+) — No. 21 (–): Sensor.>
5 CHECK INPUT SIGNAL FOR ECM. Is the voltage between 4.2 Go to step 6. Replace throttle
Measure voltage between ECM terminals V and 4.7 V? position sensor.
while throttle valve is fully opened. <Ref. to
Terminal FU(SOHCw/
No. 23 (+) — No. 21 (–): oOBD)-26,
Throttle Position
Sensor.>
6 CHECK IDLE AIR CONTROL SOLENOID Does engine revolution Go to step 7. Replace idle air
VALVE. change? control solenoid
1) Start engine, and idle it. valve. <Ref. to
2) Disconnect connector from idle air control FU(SOHCw/
solenoid valve. oOBD)-31, Idle Air
Control Solenoid
Valve.>
EN(SOHCw/oOBD)-109

nector. NOTE:
Inspection by your
Subaru distributor
is required,
because probable
cause is deterio-
ration of multiple
parts.
EN(SOHCw/oOBD)-110
O: DTC 85 CHARGE SYSTEM S068521G71
쐌 DIAGNOSIS:
쐌 Power source voltage of the ECM is low or high.
CAUTION:
쐌 WIRING DIAGRAM:
S2M2130
EN(SOHCw/oOBD)-111

1 CHECK GENERATOR. Is the voltage between 10.8 Go to step 2. Repair generator.
1) Start engine. V and 16.2 V? <Ref. to SC-12,
Terminal
ground:
2 CHECK GENERATOR. Is the voltage between 10.8 Go to step 3. Repair generator.
1) Run the engine at 5,000 rpm. V and 16.2 V? <Ref. to SC-12,
Terminal
ground (−):
clamped?
4 CHECK INPUT VOLTAGE OF ECM. Is the voltage between 10.8 Go to step 5. Repair harness
1) Disconnect connector from ECM, then con- V and 16.2 V? connector
nect ST. <Ref. to EN(SOHCw/oOBD)-23, between battery,
HOW TO CHECK I/O SIGNAL FOR ECM, main relay and
Engine Control Module (ECM) I/O Signal.> ECM.
2) Run the engine at idle.
and chassis ground.
(B) No. 27 (+) — Chassis ground (−):
(C) No. 36 (+) — Chassis ground (−):
ECM?
2) Erase the memory. still being output?
3) Perform inspection mode.
4) Read out the trouble code.
sponding to the
trouble code.
EN(SOHCw/oOBD)-112
NOTE:
쐌 Malfunction of parts other than those listed is also possible.
쐌 The right-hand priority column indicates the inspection priority of probable causes of the symptom. Carry
out the check starting from A.
Symptom Problem parts Priority
1. Engine does not start. (internal combustion does 1) ECM power supply A
not occur.) 2) Engine ground terminal A
3) Crankshaft position sensor B
4) Fuel pump B
5) Pressure regulator B
6) Engine coolant temperature sensor C
7) Ignition coil & ignitor C
8) Spark plug C
9) Fuel injector C
10) Idle air control solenoid valve C
2. Engine does not start. (internal combustion 1) ECM power supply A
occurs.) 2) Spark plug A
3) Engine coolant temperature sensor B
5) Pressure sensor C
6) Fuel pump C
7) Fuel injector C
3. Engine does not start. (engine stalls after inter- 1) ECM power supply A
nal combustion.) 2) Pressure sensor A
4) Spark plug B
5) Ignition coil C
6) Fuel pump C
7) Pressure regulator C
8) Fuel injector C
4. Engine stalls. 1) Pressure sensor B
2) Spark plug B
3) Accelerator cable is out of adjustment B
4) ECM power supply C
5) Throttle position sensor C
6) Crankshaft position sensor C
7) Vehicle speed sensor C
8) Ignition coil C
9) Fuel pump C
5. Rough idling 1) Spark plug A
2) Pressure sensor B
5) Idle air control solenoid valve B
6) Air leak in air intake system B
7) ECM power supply C
9) Intake air temperature sensor C
10) Oxygen sensor C
11) Fuel pump C
12) Fuel injector C
13) Test mode or read memory connectors are con- C
nected.
EN(SOHCw/oOBD)-113
Symptom Problem parts Priority

6. Hard to drive at constant speed 1) Pressure regulator A
2) Fuel injector B
6) Fuel pump C
7. Poor acceleration/deceleration 1) Spark plug A
2) Throttle position sensor B
3) Ignition coil B
4) Fuel pump B
6) Fuel injector B
10) Knock sensor C
8. Poor return to idling 1) Accelerator cable is out of adjustment A
3) Idle air control solenoid valve B
9. Back fire 1) Spark plug A
2) Fuel injector B
3) Ignition coil and ignitor C
4) Fuel pump C
5) Pressure regulator C
10. Knocking 1) Fuel pump B
4) Knock sensor C
11. Excessive fuel consumption 1) Engine coolant temperature sensor A
3) Intake air temperature sensor B
12. Shocks while driving 1) Pressure regulator A
2) ECM power supply B
13. Poor engine revving 1) Pressure regulator A
4) Throttle sensor B
5) Intake air temperature sensor B
6) Fuel pump B
14. Remarks 1) ECM power supply A*
2) Pressure sensor B*
3) Pressure regulator B*
4) Idle air control solenoid valve B*
5) Air leak in air intake system B*
A*: Including ECM ground circuit
B*: Check hoses.
EN(SOHCw/oOBD)-114
ENGINE2 SECTION

SUBARU vehicles.
ine parts.

G8050GE3
FU(DOHC TURBO)
Page
2. Throttle Body .............................................................................................14
3. Intake Manifold ..........................................................................................15
6. Camshaft Position Sensor.........................................................................31
7. Knock Sensor ............................................................................................32
9. Mass Air Flow and Intake Air Temperature Sensor ..................................34
10. Pressure Sensor........................................................................................35
12. Fuel Injector...............................................................................................37
13. Tumble Generator Valve Assembly...........................................................40
14. Wastegate Control Solenoid Valve............................................................41
15. Front Oxygen (A/F) Sensor.......................................................................42
16. Rear Oxygen Sensor.................................................................................44
17. Exhaust Temperature Sensor....................................................................46
19. Main Relay ................................................................................................48
20. Fuel Pump Relay.......................................................................................49
21. Fuel............................................................................................................50
22. Fuel Tank...................................................................................................53
23. Fuel Filler Pipe ..........................................................................................56
24. Fuel Pump .................................................................................................60
27. Fuel Filter ..................................................................................................64
28. Fuel Cut Valve...........................................................................................65
29. Fuel Damper Valve....................................................................................66
GENERAL DESCRIPTION
Model
Fuel tank
Type Impeller
Shutoff discharge pressure 450 — 677 kPa (4.59 — 6.9 kg/cm2, 65.27 — 98.2 psi)
Fuel pump
Discharge flow
[12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)]
FU(DOHC TURBO)-2
GENERAL DESCRIPTION
MEMO:
FU(DOHC TURBO)-3
GENERAL DESCRIPTION
S2M2173A
FU(DOHC TURBO)-4
GENERAL DESCRIPTION
(1) Fuel pipe ASSY (13) Accelerator cable bracket Tightening torque: N·m (kgf-m, ft-lb)
(2) Fuel hose (14) Fuel injector
T1: 5 (0.50, 3.7)
(3) Clip (15) Insulator
T2: 6.4 (0.65, 4.7)
(4) Purge control solenoid valve (16) Fuel injector pipe
T3: 8.25 (0.84, 6.1)
(5) Vacuum hose (17) Pressure regulator
(6) Vacuum control hose (18) Pressure regulator hose T4: 16 (1.63, 11.8)
(7) Purge valve (19) Blow-by hose stay T5: 17 (1.73, 12.5)
(8) Purge hose (20) Intake manifold T6: 19 (1.94, 14.0)
(9) Intake manifold gasket (21) Wastegate control solenoid valve T7: 25 (2.55, 18.4)
(10) Guide pin ASSY
(11) Tumble generator valve ASSY (22) Nipple
(12) Tumble generator valve gasket (23) Fuel pipe protector
FU(DOHC TURBO)-5
GENERAL DESCRIPTION
EN0779
(1) Gasket (5) Pressure sensor Tightening torque: N·m (kgf-m, ft-lb)
(2) Throttle position sensor
T1: 1.6 (0.16, 1.2)
T2: 2.8 (0.29, 2.1)
(4) Throttle body
T3: 22 (2.2, 16)
FU(DOHC TURBO)-6
GENERAL DESCRIPTION
EN0780
(1) Crankshaft position sensor Tightening torque: N·m (kgf-m, ft-lb)

(2) Knock sensor
T1: 6.4 (0.65, 4.7)
(3) Camshaft position sensor
T2: 24 (2.4, 17.4)
FU(DOHC TURBO)-7
GENERAL DESCRIPTION
S2M2152A
FU(DOHC TURBO)-8
GENERAL DESCRIPTION
(1) Heat sealed cover (13) Evaporation hose B (25) Fuel return hose B
(3) Protector LH (15) Evaporation hose C (27) Jet pump filter
(5) Fuel tank (17) Evaporation hose D (29) Evaporation hose H
(6) Fuel pump gasket (18) Evaporation hose E (30) Evaporation hose I
(7) Fuel pump ASSY (19) Fuel return hose A
(8) Fuel level snsor (20) Retainer Tightening torque: N·m (kgf-m, ft-lb)
(9) Fuel cut valve gasket (21) Quick connector T1: 4.4 (0.45, 3.3)
(10) Fuel cut valve (22) Evaporation hose F T2: 7.4 (0.75, 5.4)
(11) Evaporation hose A (23) Fuel pipe ASSY T3: 33 (3.4, 25)
(12) Clip (24) Evaporation hose G
FU(DOHC TURBO)-9
GENERAL DESCRIPTION
S2M2153A
FU(DOHC TURBO)-10
GENERAL DESCRIPTION
(1) Clip (13) Canister hose A (25) Front canister bracket

(2) Fuel delivery hose A (14) Canister (26) Evaporation hose B
(3) Fuel filter bracket (15) Canister bracket plate (27) Roll over valve bracket
(4) Fuel filter holder (16) Cushion (28) Roll over valve
(5) Fuel filter cup (17) Canister bracket spacer (29) Evaporation hose C
(6) Fuel filter (18) Rear canister bracket (30) Evaporation pipe
(7) Evaporation hose A (19) Two-way valve return hose (31) Canister hose B
(8) Fuel damper (20) Two-way valve
(9) Fuel delivery hose B (21) Two-way valve drain hose A Tightening torque: N·m (kgf-m, ft-lb)
(10) Fuel return hose (22) Connector T1: 23 (2.34, 17.0)
(11) Fuel pipe ASSY (23) Two-way valve drain hose B
(12) Grommet (24) Clamp
FU(DOHC TURBO)-11
GENERAL DESCRIPTION
S2M2245A
(1) Fuel filter pipe ASSY (6) Air vent pipe (11) Fuel pipe protector
(2) Evaporation hose holder (7) Air vent pipe holder
(3) Clamp (8) Filler pipe packing Tightening torque: N·m (kgf-m, ft-lb)
(4) Clamp (9) Filler ring T: 7.5 (0.76, 5.5)
(5) Air vent hose (10) Filler cap
FU(DOHC TURBO)-12
GENERAL DESCRIPTION

tion.
ment.

24082AA150 CARTRIDGE Troubleshooting for electrical system.
B2M3876
B2M3877
FU(DOHC TURBO)-13
THROTTLE BODY

body.
EN0784
6) Remove bolts which secure throttle body to

G6M0095 intake manifold.
2) Remove intercooler. <Ref. to IN(DOHC B: INSTALLATION S185010A11
TURBO)-10, REMOVAL, Intercooler.>
3) Disconnect connector from throttle position Install in the reverse order of removal.
sensor (A) and idle air control solenoid valve (B) NOTE:
and pressure sensor (C). Always use new gaskets.
Tightening torque:
22 N·m (2.2 kgf-m, 15.9 ft-lb)
EN0782
4) Disconnect accelerator cable.

EN0785
H2M1890
FU(DOHC TURBO)-14
INTAKE MANIFOLD

(1) Remove front side V-belt. <Ref. to
ME(DOHC TURBO)-44, REMOVAL, V-belt.>
A: REMOVAL S185034A18 (2) Disconnect the power steering switch con-
1) Release fuel pressure. <Ref. to FU(DOHC nector.
TURBO)-50, RELEASING OF FUEL PRESSURE,
OPERATION, Fuel.>
EN0360

G6M0095
NOTE:
3) Lift up vehicle. Do not disconnect power steering hose.
5) Drain coolant about 3.0 (3.2 US qt, 2.6 Imp
qt).
S2M2248

EN0073
pump.
6) Remove air cleaner upper cover and air intake

boot. <Ref. to IN(DOHC TURBO)-7, REMOVAL,
Air Cleaner.>
8) Remove intercooler. <Ref. to IN(DOHC
9) Disconnect accelerator cable.
H2M1954
H2M1890
10) Remove coolant filler tank. <Ref. to CO-37,

REMOVAL, Coolant Filler Tank.>
FU(DOHC TURBO)-15
INTAKE MANIFOLD
(5) Remove power steering tank from the 14) Disconnect brake booster hose.
bracket by pulling it upward.
EN0204
EN0361
15) Disconnect Pressure hose from intake duct.
(6) Place power steering pump on the right side
wheel apron.
EN0787
EN0208
16) Disconnect engine harness connectors from
bulkhead harness connectors.
12) Disconnect emission hose from PCV valve.
EN0788
EN0789

body.
S2M2260
EN0784
FU(DOHC TURBO)-16
INTAKE MANIFOLD
17) Disconnect connectors from engine coolant 21) Remove harness secured by clip (A) from the
temperature sensor (A), oil pressure switch (B) and bracket.
crankshaft position sensor (C).
S2M2256A
EN0790
18) Disconnect knock sensor connector. evaporation hose.
WARNING:
Catch fuel from hoses in a container.
S2M1613

sensor. EN0214
23) Remove bolts which secure intake manifold to

cylinder heads.
B2M1251
20) Disconnect connector from ignition coil.

EN0792
24) Remove intake manifold.
1) Install intake manifold onto cylinder heads.

NOTE:
Always use new gaskets.
EN0854
FU(DOHC TURBO)-17
INTAKE MANIFOLD
Tightening torque: 5) Connect connector to camshaft position sensor.

25 N·m (2.5 kgf-m, 18.1 ft-lb)
B2M1251
EN0792
6) Connect connector to ignition coil.
2) Connect fuel delivery hose, return hose, and
evaporation hose.
EN0854
EN0214
7) Secure harness to the bracket with clip (A).
3) Connect connector to oil pressure switch (B),

crankshaft position sensor (C) and engine coolant
temperature sensor (A).
S2M2256A
EN0790
4) Connect connector to knock sensor.
S2M1613
FU(DOHC TURBO)-18
INTAKE MANIFOLD
8) Connect engine harness connector to bulkhead 11) Connect emission hose to PCV valve.
harness connectors.
EN0789
EN0788
12) Connect pressure hose to intake duct.
S2M2260 EN0787
9) Connect brake booster vacuum hose. 13) Install power steering pump on bracket.
(1) Install power steering tank on bracket.
EN0204
EN0361
10) Connect engine coolant hoses to throttle body.
(2) Connect connector to power steering pump
switch.
EN0784
EN0360
FU(DOHC TURBO)-19
INTAKE MANIFOLD
(3) Install power steering pump, and tighten 19) Connect connector to fuel pump relay.
bolts.
Tightening torque:
20.1 N·m (2.05 kgf-m, 14.8 ft-lb)
S2M0093

21) Lift up vehicle.
H2M1954 22) Install under cover.
(4) Install power steering pipe brackets on right 23) Fill coolant. <Ref. to CO-14, FILLING OF
side intake manifold. ENGINE COOLANT, REPLACEMENT, Engine
Coolant.>
S2M2248
(5) Install front side V-belt. <Ref. to ME(DOHC

TURBO)-44, INSTALLATION, V-belt.>
14) Install coolant filler tank. <Ref. to CO-37,
INSTALLATION, Coolant Filler Tank.>
15) Connect accelerator cable.
H2M1890
16) Install intercooler. <Ref. to IN(DOHC

TURBO)-10, INSTALLATION, Intercooler.>
17) Install air cleaner element.
18) Install air cleaner upper cover and air intake
duct as a unit. <Ref. to IN(DOHC TURBO)-7,
INSTALLATION, Air Cleaner.>
FU(DOHC TURBO)-20
INTAKE MANIFOLD
C: DISASSEMBLY S185034A06 5) Remove throttle body from intake manifold.

1) Remove fuel pipe protector.
EN0785
EN0794 6) Disconnect connector from fuel injector.

2) Remove engine ground terminal from intake
manifold.
EN0798
7) Disconnect connector from tumble generator

EN0795 valve actuator.
EN0799
EN0796
3) Disconnect connector from throttle position 8) Disconnect connector from tumble generator
sensor (A), idle air control solenoid valve (B) and valve sensor.
pressure sensor (C).
4) Separate engine harness secured to the intake
manifold by clip (D).
EN0800
S2M2249A
FU(DOHC TURBO)-21
INTAKE MANIFOLD
9) Disconnect connector from purge control sole- 13) Remove two bolts which hold fuel pipes on the
noid valve. left side of intake manifold.
EN0801 EN0805
10) Remove purge control solenoid valve. 14) Remove bolt which hold fuel injector pipe onto
intake manifold.
쐌 LH SIDE
EN0802
11) Disconnect evaporation hose from intake EN0806

manifold.
EN0803 EN0807
12) Disconnect evaporation hoses from purge

valve.
EN0804
FU(DOHC TURBO)-22
INTAKE MANIFOLD
쐌 RH SIDE 18) Loosen clamp which holds front left side fuel
hose to injector pipe and remove the pipe from
clamp.
EN0808
EN0812
19) Remove fuel injector pipe LH.

20) Remove bolts which installs fuel pipe on
intake manifold.
EN0809
15) Remove fuel injector.
EN0813
21) Remove fuel pipe assembly and pressure

regulator, from intake manifold.
22) Remove intake duct from intake manifold.
EN0810
16) Remove harness bracket which hold engine

harness onto intake manifold.
EN0814
EN0811
17) Remove engine harness from intake manifold.
FU(DOHC TURBO)-23
INTAKE MANIFOLD
23) Remove tumble generator valve assembly 3) Install fuel pipe assembly and pressure
from intake manifold. regulator, to intake manifold.
Tightening torque:
5 N·m (0.51 kgf-m, 3.69 ft-lb)
EN0815
EN0813
NOTE: 4) Install fuel injector pipe LH.

Replace gasket with a new one. 5) Connect left side fuel hose to injector pipe, and
1) Install tumble generator valve assembly to tighten clamp screw.
intake manifold.
Tightening torque:
8.25 N·m (0.84 kgf-m, 6.08 ft-lb)
EN0812
6) Install engine harness to intake manifold.

7) Install harness bracket which hold engine har-
EN0815 ness onto intake manifold.
2) Install air intake duct to intake manifold. Tightening torque:

19 N·m (1.94 kgf-m, 14.0 ft-lb)
Tightening torque:
19 N·m (1.94 kgf-m, 14.0 ft-lb)
EN0811
EN0814
FU(DOHC TURBO)-24
INTAKE MANIFOLD
8) Install fuel injector. 쐌 RH SIDE
EN0810 EN0808
9) Tighten bolt which install fuel injector pipe onto

intake manifold.
Tightening torque:
19 N·m (1.94 kgf-m, 14.0 ft-lb)
쐌 LH SIDE
EN0809
10) Tighten two bolts which install fuel pipes on

the left side of intake manifold.
Tightening torque:
5 N·m (0.51 kgf-m, 3.69 ft-lb)
EN0806
EN0805
EN0807
FU(DOHC TURBO)-25
INTAKE MANIFOLD
11) Connect evaporation hoses to purge valve. 13) Install purge control solenoid valve.
Carefully connect the evaporation hoses. 16 N·m (0.16 kgf-m, 1.2 ft-lb)
EN0802
14) Connect hoses to purge control solenoid

valve.
CAUTION:
EN0816
(A) To fuel pipe ASSY

(B) To intake duct
(C) To purge control solenoid valve
(D) To intake manifold
EN0817
12) Connect evaporation hose to intake manifold. (A) To intake manifold

(B) To purge valve
15) Connect connector to purge control solenoid

valve.
EN0803
EN0801
FU(DOHC TURBO)-26
INTAKE MANIFOLD
16) Connect connector to tumble generator valve 19) Install throttle body to intake manifold.
sensor. NOTE:
Tightening torque:
22 N·m (2.2 kgf-m, 16 ft-lb)
EN0800
17) Connect connector to tumble generator valve

actuator.
EN0785
20) Connect connector to throttle position sensor

(A), idle air control solenoid valve (B) and pressure
sensor (C).
21) Secure engine harness to the intake manifold
with clip (D).
EN0799
18) Connect connector to fuel injector.
S2M2249A
22) Install engine ground terminal to intake mani-

fold.
Tightening torque:
19 N·m (1.94 kgf-m, 14.0 ft-lb)
EN0798
EN0795
FU(DOHC TURBO)-27
INTAKE MANIFOLD
EN0796
23) Install fuel pipe protector.

Tightening torque:
19 N·m (1.94 kgf-m, 14.0 ft-lb)
EN0794
Make sure the fuel pipe and fuel hoses are not
cracked and that connections are tight.
FU(DOHC TURBO)-28
4. Engine Coolant Temperature

Sensor S185047
G6M0095
2) Remove the generator <Ref. to SC-12,

REMOVAL, Generator.>
perature sensor.
EN0851

Tightening torque:
18 N·m (1.8 kgf-m, 13 ft-lb)
FU(DOHC TURBO)-29
S185043
T: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
B2M1252B
G6M0095
2) Remove bolt which install crankshaft position

G2M0408

G2M0409
FU(DOHC TURBO)-30
CAMSHAFT POSITION SENSOR
6. Camshaft Position Sensor B: INSTALLATION S185041A11
S185041
T: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
G2M0417
G6M0095

sensor.
G2M0416
3) Remove camshaft position sensor from cam-

shaft support LH.
G2M0417
FU(DOHC TURBO)-31
KNOCK SENSOR
1) Disconnect battery ground cable from battery Tightening torque:

ground terminal. 24 N·m (2.4 kgf-m, 17.4 ft-lb)
NOTE:
rear.
G6M0095

3) Disconnect knock sensor connector. H2M3511C
B2M4262
4) Remove knock sensor from cylinder block. B2M4262
3) Install intercooler. <Ref. to IN(DOHC TURBO)-

10, INSTALLATION, Intercooler.>
S2M1673
G6M0095
FU(DOHC TURBO)-32
Tightening torque:
1.6 N·m (0.16 kgf-m, 1.2 ft-lb)
G6M0095
EN0820
2) Remove inter cooler. <Ref. to IN(DOHC

sensor.
EN0819

EN0820
FU(DOHC TURBO)-33
MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR
9. Mass Air Flow and Intake Air

Temperature Sensor S185770
G6M0095
2) Disconnect connector mass air flow and intake

air temperature sensor.
3) Remove mass air flow and intake air tempera-
ture sensor.
EN1045

Tightening torque:
7.5 N·m (0.76 kgf-m, 5.5 ft-lb)
FU(DOHC TURBO)-34
PRESSURE SENSOR
10. Pressure Sensor S185765
G6M0095
2) Remove idle air control solenoid valve. <Ref. to

FU(SOHC)-38, REMOVAL, Idle Air Control Sole-
noid Valve.>
3) Disconnect connectors from pressure sensor.
EN0821
4) Remove pressure sensor from throttle body.

NOTE:
Replace gaskets for idle air control solenoid valve
with new ones.
Tightening torque:
Pressure sensor
1.6 N·m (0.16 kgf-m, 1.2 ft-lb)
Idler air control solenoid valve
2.8 N·m (0.29 kgf-m, 2.1 ft-lb)
FU(DOHC TURBO)-35
NOTE:
Always use new gasket.
Tightening torque:
2.8 N·m (0.29 kgf-m, 2.1 ft-lb)
G6M0095
EN0823
noid valve.
EN0822

throttle body.
EN0823
FU(DOHC TURBO)-36
FUEL INJECTOR

4) Remove bolts which hold injector pipe to intake
manifold.
1. RH SIDE S185051A1801
1) Remove intake manifold. <Ref. to FU(DOHC

TURBO)-15, REMOVAL, Intake Manifold.>
2) Remove fuel pipe protector.
EN0808
EN0794
EN0809
5) Remove fuel injector while lifting up fuel injec-

tor pipe.
EN0798
EN0810
FU(DOHC TURBO)-37
FUEL INJECTOR
2. LH SIDE S185051A1802 4) Remove fuel injector while lifting up fuel injec-

tor pipe.
EN0824
EN0798 B: INSTALLATION S185051A11
3) Remove bolts which hold injector pipe to intake 1. RH SIDE S185051A1101
manifold. Install in the reverse order of removal.

NOTE:
Replace O-ring and insulators with new ones.
EN0805
S2M2250A
(A) O-ring
(B) Fuel injector
(C) Insulator
Tightening torque:
19 N·m (1.94 kgf-m, 14.0 ft-lb)
EN0807
EN0808
EN0806
FU(DOHC TURBO)-38
FUEL INJECTOR

EN0809 EN0805

EN0806
EN0794
Tightening torque:
2. LH SIDE S185051A1102 19 N·m (1.94 kgf-m, 14.0 ft-lb)
NOTE:
Replace O-ring and insulators with new ones.
EN0807
S2M2250A
(A) O-ring
(B) Fuel injector
(C) Insulator
FU(DOHC TURBO)-39
TUMBLE GENERATOR VALVE ASSEMBLY
13. Tumble Generator Valve 6) Remove tumble generator valve body from
intake manifold.
Assembly S185766
EN0815
G6M0095 Install in the reverse order of removal.

2) Remove intake manifold. <Ref. to FU(DOHC NOTE:
TURBO)-15, REMOVAL, Intake Manifold.> Always use new gaskets.
3) Disconnect connector from tumble generator Tightening torque:
valve sensor. 8.25 N·m (0.84 kgf-m, 6.1 ft-lb)
EN0800 EN0815
4) Disconnect connector from tumble generator

valve actuator.
EN0799
5) Remove fuel injector. <Ref. to FU(DOHC

TURBO)-37, REMOVAL, Fuel Injector.>
FU(DOHC TURBO)-40
WASTEGATE CONTROL SOLENOID VALVE
14. Wastegate Control Solenoid

Valve S185057
G6M0095
2) Disconnect connector (A) from wastegate con-

trol solenoid valve.
3) Disconnect pressure hoses (B) from wastegate
4) Remove wastegate control solenoid valve from
bracket
S2M2251A

Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
S2M2251
FU(DOHC TURBO)-41
15. Front Oxygen (A/F) Sensor 6) Remove service hole cover.

S185642
EN0832

threaded portion of front oxygen (A/F) sensor, and
leave it for one minute or more.
G6M0095
2) Disconnect connector from front oxygen (A/F) 8) Remove front oxygen (A/F) sensor.
sensor. CAUTION:
When removing the oxygen (A/F) sensor, wait
until exhaust pipe cools, otherwise it will dam-
age exhaust pipe.
S2M2252
3) Remove harness secured by clip (A) from the

bracket (B).
EN0833
S2M2253A
4) Remove front right side wheel.

FU(DOHC TURBO)-42
B: INSTALLATION S185642A11 7) Connect connector of front oxygen (A/F) sen-

sor.
1) Before installing front oxygen (A/F) sensor,
tion of front oxygen (A/F) sensor to make the next
removal easier.
SS-30 by JET LUBE
CAUTION:
of front oxygen (A/F) sensor.
2) Install front oxygen (A/F) sensor. S2M2252
Tightening torque: 8) Connect battery ground cable.

30N·m (3.1 kgf-m, 22 ft-lb)
G6M0095
EN0833
3) Install service hole cover.
EN0832

5) Install front right side wheel.
6) Secure a harness to bracket (B) by clip (A).
S2M2253A
FU(DOHC TURBO)-43
REAR OXYGEN SENSOR
16. Rear Oxygen Sensor S185657

6) Remove rear oxygen sensor.
CAUTION:
1) Disconnect battery ground cable. exhaust pipe cools, otherwise it will damage
exhaust pipe.
G6M0095
EN0835
3) Disconnect connector from rear oxygen sensor.
EN0834
4) Vertically draw out clip (A) from crossmember

(B).
S2M2254

threaded portion of rear oxygen sensor, and leave
it for one minute or more.
FU(DOHC TURBO)-44
REAR OXYGEN SENSOR
B: INSTALLATION S185657A11 6) Connect battery ground cable.

1) Before installing rear oxygen sensor, apply anti-
seize compound only to threaded portion of rear
oxygen sensor to make the next removal easier.
CAUTION:
of rear oxygen sensor.
SS-30 by JET LUBE
2) Install rear oxygen sensor. G6M0095
Tightening torque:
21 N·m (2.1 kgf-m, 15.2 ft-lb)
EN0835
3) Connect connector to rear oxygen sensor.
EN0834
4) Secure clip (A) on the crossmember.
S2M2254
FU(DOHC TURBO)-45
EXHAUST TEMPERATURE SENSOR
17. Exhaust Temperature B: INSTALLATION S185763A11
Sensor S185763 1) Before installing exhaust temperature sensor,

tion of rear oxygen sensor to make the next
1) Disconnect battery ground cable. removal easier.
CAUTION:
of exhaust temperature sensor.
SS-30 by JET LUBE
2) Install exhaust temperature sensor.
NOTE:
Align mark (A) on the exhaust temperature sensor
side with the joint pipe side mark (B) and tighten.
G6M0095
Tightening torque:
2) Remove joint pipe. <Ref. to EX(DOHC 21 N·m (2.1 kgf-m, 15.2 ft-lb)
TURBO)-13, REMOVAL, Joint Pipe.>
threaded portion of exhaust temperature sensor,
and leave it for one minute or more.
4) Remove exhaust temperature sensor.
CAUTION:
exhaust pipe cools, otherwise it will damage
exhaust pipe. S2M2255A
3) Install joint pipe <Ref. to EX(DOHC TURBO)-

13, INSTALLATION, Joint Pipe.>.
EN0836
G6M0095
FU(DOHC TURBO)-46
G6M0095
2) Remove lower inner trim of passenger side.

<Ref. to EI-38, REMOVAL, Lower Inner Trim.>
3) Detach floor mat of front passenger seat.
4) Remove protect cover.
EN0532
5) Remove nuts (A) which hold ECM to bracket.

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

ECM.

CAUTION:
wrong spec. ECM to avoid any damage to the
fuel injection system.
FU(DOHC TURBO)-47
MAIN RELAY

S2M0137
G6M0095
S2M0107
S2M0108A

(B) Main relay
(C) Fuel pump relay
FU(DOHC TURBO)-48
FUEL PUMP RELAY
G6M0095
S2M0093

bracket.
S2M0138
FU(DOHC TURBO)-49
FUEL
21. Fuel S185052


S185052A1601
WARNING:
area.
G6M0095

rear seats.
S2M0093
2) Start the engine, and run it until it stalls.

3) After the engine stalls, crank it for five more
seconds.
S2M0246
WARNING:
area.
1) Release fuel pressure. <Ref. to FU(DOHC
OPERATION, Fuel.>
S2M0172

nect fuel delivery hose (A). <Ref. to FU(DOHC
TURBO)-67, REMOVAL, Fuel Delivery, Return and
Evaporation Lines.>
B2M3197
FU(DOHC TURBO)-50
FUEL
8) Move clips, and then disconnect fuel return 12) Remove service hole cover.
G2M0863
S2M0060A
13) Disconnect connector from fuel sub level sen-
9) Remove nuts which install fuel pump assembly sor.
onto fuel tank. 14) Disconnect fuel jet pump hose.
S2M0061 S2M0151
10) Take off fuel pump from fuel tank. 15) Remove bolts which install fuel sub level sen-
sor on fuel tank.
S2M0062
S2M0152
11) Drain fuel from fuel tank by using a hand
pump. 16) Remove fuel sub level sensor.
WARNING:
S2M0153
S2M0163
FU(DOHC TURBO)-51
FUEL

WARNING:
S2M0247
FU(DOHC TURBO)-52
FUEL TANK

8) Disconnect two-way valve hose (A) from two-
way valve and disconnect canister hose (B) from
A: REMOVAL S185053A18 canister.
WARNING:
area.
1) Set vehicle on the lift.
OPERATION, Fuel.>
3) Drain fuel from fuel tank. <Ref. to FU(DOHC
TURBO)-50, DRAINING FUEL, OPERATION, EN0840
Fuel.>
4) Remove rear seat. 9) Loosen clamp and disconnect fuel filler hose
5) Disconnect connector of fuel tank cord to rear (A) and air vent hose (B) from fuel filler pipe.
harness.
EN0539
S2M0164
10) Move clips, and disconnect quick connector.
6) Push grommet which holds fuel tank cord on <Ref. to FU(DOHC TURBO)-67, REMOVAL, Fuel
floor panel into under the body. Delivery, Return and Evaporation Lines.>
11) Disconnect fuel hoses.
S2M0165
EN0540
7) Remove rear crossmember. <Ref. to RS-20,
REMOVAL, Rear Crossmember.>
FU(DOHC TURBO)-53
FUEL TANK
12) Support fuel tank with transmission jack, 4) Connect fuel filler hose (A) and air vent hose
remove bolts from bands and dismount fuel tank (B).
from the vehicle.
WARNING:
EN0539
5) Connect fuel hoses, and hold then with clips

and quick connector. <Ref. to FU(DOHC TURBO)-
S2M2246 68, INSTALLATION, Fuel Delivery, Return and
Evaporation Lines.>
1) Support fuel tank with transmission jack and

push fuel tank harness into access hole with grom-
met.
2) Set fuel tank and temporarily tighten bolts of
fuel tank bands.
WARNING:
EN0540
6) Tighten band mounting bolts.

Tightening torque:
33 N·m (3.4 kgf-m, 25 ft-lb)
S2M2246
3) Connect two-way valve hose (A) to two-way

valve and connect canister hose (B) to canister.
S2M2246

EN0840
FU(DOHC TURBO)-54
FUEL TANK
8) Connect connectors to fuel tank cord and plug

service hole with grommet.
S2M0164
9) Set rear seat and floor mat.

S2M0093
1) Make sure there are no cracks, holes, or other

damage on the fuel tank.
FU(DOHC TURBO)-55
FUEL FILLER PIPE

8) Remove fuel filler pipe protector.
WARNING:
area.
OPERATION, Fuel.>
2) Open fuel filler flap lid and remove filler cap. B2M1894
9) Separate evaporation hoses from clip of fuel
filler pipe.
G6M0095
4) Remove screws holding packing in place. EN0545
10) Disconnect air vent hose from fuel filler pipe.
EN0542
5) Lift-up the vehicle. B2M1896

6) Remove rear right side wheel nuts.
7) Remove rear right side wheel. 11) Remove bolts which hold fuel filler pipe
bracket on body.
B2M1748
B2M1895
FU(DOHC TURBO)-56
FUEL FILLER PIPE
12) Loosen clamp and separate fuel filler hose (A) 3) Align holes in fuel filler pipe neck and set cup
from fuel filler pipe. (B), and tighten screws.
13) Move clip and separate air vent hose (B). NOTE:
If edges of rubber packing are folded toward the
inside, straighten it with a screwdriver.
EN0548

vehicle. B2M1196A
15) Remove air vent pipe together with clip from 4) Install air vent pipe.
body.
EN0549
EN0549
5) Connect air vent hose to fuel filler pipe.
1) Hold fuel filler flap open.

2) Set fuel saucer (A) with rubber packing (C) and
insert fuel filler pipe into hole from the inner side of
apron.
B2M1896
B2M1196A
FU(DOHC TURBO)-57
FUEL FILLER PIPE
6) Insert fuel filler hose (A) approximately 35 to 40 9) Tighten bolts which hold evaporation hoses
mm (1.38 to 1.57 in) over the lower end of fuel filler onto clip of fuel filler pipe.
CAUTION:
EN0545
EN0548
7) Insert air vent hose approximately 25 to 30 mm

and hold clip.
L = 27.5±2.5 mm (1.083±0.098 in)
B2M1894
B2M1195A
(1) Hose
(2) Clip
(3) Pipe
B2M1748
8) Tighten bolt which holds fuel filler pipe bracket
on body. 12) Lower the vehicle.
Tightening torque: 13) Tighten wheel nuts.
7.5 N·m (0.75 kgf-m, 5.4 ft-lb) 14) Connect connector to fuel pump relay.
B2M1895 S2M0093
FU(DOHC TURBO)-58
FUEL FILLER PIPE
G6M0095
FU(DOHC TURBO)-59
FUEL PUMP

WARNING:
OPERATION, Fuel.>
cap. S2M0172

nect fuel delivery hose (A). <Ref. to FU(DOHC
TURBO)-67, REMOVAL, Fuel Delivery, Return and
Evaporation Lines.>
B2M3197
S2M0060A

onto fuel tank.
G6M0095

rear seats.
S2M0061
S2M0246
S2M0062
FU(DOHC TURBO)-60
FUEL PUMP

lowing:
in the figure to specified torque.
Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
S2M0063A

WARNING:
possible.
non-load condition.
G2M0366
FU(DOHC TURBO)-61
FUEL LEVEL SENSOR
25. Fuel Level Sensor S185026
WARNING:
area.
NOTE:
FU(DOHC TURBO)-60, REMOVAL , Fuel Pump.>
S2M0145

mounting bracket.
S2M0855
FU(DOHC TURBO)-62

6) Remove bolts which install fuel sub level sensor
on fuel tank.
WARNING:
area.
S2M0152
7) Remove fuel sub level sensor.
G6M0095

rear seats.
S2M0153

Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
G2M0863
4) Disconnect connector from fuel sub level sen-

sor.
S2M0152
S2M0151
FU(DOHC TURBO)-63
FUEL FILTER
27. Fuel Filter S185027
WARNING:
area.
OPERATION, Fuel.>
2) Disconnect fuel delivery hoses from fuel filter.
S2M0195
CAUTION:
portion, replace it with a new one.
쐌 If clamps are badly damaged, replace with
new ones.
2) Tighten hose clamp screws.
Tightening torque:
12.5 N·m (1.27 kgf-m, 9.22 ft-lb)
S2M0195

sediment.
from inlet port.
FU(DOHC TURBO)-64
FUEL CUT VALVE
WARNING:
area.
1) Remove fuel tank. <Ref. to FU(DOHC
TURBO)-53, REMOVAL, Fuel Tank.>
S2M0176

Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
S2M0177
FU(DOHC TURBO)-65
FUEL DAMPER VALVE
29. Fuel Damper Valve S185708

OPERATION, Fuel.>
2) Remove fuel damper valve from fuel return line.
EN0852
FU(DOHC TURBO)-66
cap.
4) Remove floor mat. <Ref. to EI-43, REMOVAL,
Floor Mat.>
1) Set vehicle on the lift. return pipes and hoses, evaporation pipes and
2) Release fuel pressure. <Ref. to FU(DOHC hoses.
OPERATION, Fuel.>
S2M2247
6) In engine compartment, detach fuel delivery 8) Disconnect two-way valve hose (A) from two-
hoses, return hoses and evaporation hose. way valve and disconnect canister hose (B) from
canister.
S2M0500F
EN0840
(B) Return hose
FU(DOHC TURBO)-67
9) Separate quick connector on fuel delivery and

return line.
ered with dust.
down.
CAUTION:
Replace retainers with new ones.
S2M0230A
(A) Connector
(B) Retainer
(C) Pipe
CAUTION:
securely.
쐌 Ensure the two retainer pawls are engaged in
their mating positions in the connector.
S2M0228A
쐌 Be sure to inspect hoses and their connec-
(A) Connector tions for any leakage of fuel.
(B) Retainer
(C) Pipe
1) Connect quick connector on fuel delivery line.

CAUTION:
쐌 Always use a new retainer.
쐌 Make sure that the connected portion is not
surface of pipe. S2M0231A
(A) Connector
(B) Retainer
(C) Pipe
S2M0229A

(2) Push pipe into connector completely.
NOTE:
At this time, two clicking sounds are heard.
FU(DOHC TURBO)-68
2) Connect fuel delivery hose to pipe with an over-

lap of 20 to 25 mm (0.79 to 0.98 in).
Type A: When fitting length is specified.
: 2.5±1.5 mm (0.098±0.059 in)
L: 22.5±2.5 mm (0.886±0.098 in)
B2M1194B
(1) Fitting
(2) Clamp
(3) Hose

L = 17.5±2.5 mm (0.689±0.098 in)
CAUTION:
B2M1195A
(1) Hose
(2) Clip
(3) Pipe

nections are tight.
FU(DOHC TURBO)-69
31. Fuel System Trouble in

General S185571

securely.
tube.
1) Retightening.
filler pipe.
5. Noise
NOTE: ing system. Refueling will also complement the

쐌 When the vehicle is left unattended for an effect of anti-freeze solution each time the fuel
extended period of time, water may accumulate in level drops to about one-half. After the winter
the fuel tank. season, drain water which may have accumu-
To prevent water condensation: lated in the fuel filter and fuel tank in the man-
(1) Top off the fuel tank or drain the fuel com- ner same as that described under Affected
pletely. areas below.
(2) Drain water condensation from the fuel fil- (2) Affected areas
ter. When water condensation is notched in the fuel
쐌 Refilling the fuel tank. filter, drain water from both the fuel filter and fuel
Refill the fuel tank while there is still some fuel left tank or use a water removing agent (or anti-
freeze solution) in the fuel tank.
in the tank.
쐌 Observe the instructions, notes, etc., indicated
쐌 Protecting the fuel system against freezing and
on the label affixed to the anti-freeze solution
water condensation.
(water removing agent) container before use.
(1) Cold areas
FU(DOHC TURBO)-70
ENGINE2 SECTION

SUBARU vehicles.
ine parts.

G8050GE3
CONTROL DEVICES)
EC(DOHC TURBO)
Page
3. Rear Catalytic Converter.............................................................................4
4. Precatalytic Converter .................................................................................5
5. Canister .......................................................................................................6
7. Two-way Valve ............................................................................................8
GENERAL DESCRIPTION

tion.
ment.
fied points.
EC(DOHC TURBO)-2
1) Remove center exhaust pipe. <Ref. to

EX(DOHC TURBO)-9, REMOVAL, Center Exhaust
Pipe.>
2) Separate front catalytic converter (A) from rear
catalytic converter (B).
EN0993
NOTE:

nections and welds.
EC(DOHC TURBO)-3
REAR CATALYTIC CONVERTER
3. Rear Catalytic Converter S180036

Pipe.>
2) Separate rear catalytic converter (B) from front
catalytic converter (A).
EN0993
NOTE:

nections and welds.
EC(DOHC TURBO)-4
PRECATALYTIC CONVERTER
4. Precatalytic Converter S180767
Precatalytic converter (A) is built in joint pipe. Refer

to removal of joint pipe for removal procedure.
<Ref. to EX(DOHC TURBO)-13, REMOVAL, Joint
Pipe.>
EN0994
Precatalytic converter is built in joint pipe. Refer to

installation of joint pipe for installation procedure.
<Ref. to EX(DOHC TURBO)-13, INSTALLATION,
Joint Pipe.>

nections and welds.
EC(DOHC TURBO)-5
CANISTER
5. Canister S180037

2) Loosen two clamps which hold two canister
hoses, and disconnect evaporation three hoses
from canister.
EN0898
3) Remove canister from body.
B2M4166

Tightening torque:
23 N·m (2.3 kgf-m, 17 ft-lb)
B2M4166

cracked or loose.
EC(DOHC TURBO)-6

Tightening torque:
16 N·m (1.6 kgf-m, 11.6 ft-lb)
EN0899
G6M0095
2) Disconnect connector and hoses from purge CAUTION:

control solenoid valve. Carefully connect the evaporation hoses.
3) Remove bolt which installs purge control sole-
noid valve onto intake manifold.
EN0817
(A) To intake manifold

EN0899 (B) To purge value
Make sure hoses are not cracked or loose.
EC(DOHC TURBO)-7
TWO-WAY VALVE

2) Remove canister from body. <Ref. to
EC(DOHC TURBO)-6, REMOVAL, Canister.>
3) Remove two-way valve with bracket as a single
unit from body.
EN0901
4) Remove two-way valve from bracket.
EC(DOHC TURBO)-8
ENGINE2 SECTION

SUBARU vehicles.
ine parts.

G8050GE3
INTAKE (INDUCTION)
IN(DOHC 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)
1. AIR CLEANER S184001A0501
S2M2164A
(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 (11) Cushion rubber
T3: 2.5 (0.25, 1.8)
(5) Bushing (12) Clamp
(6) Clip (13) Air intake boot T4: 1.7 (0.17, 1.2)
(7) Air cleaner lower case (14) Cushion
IN(DOHC TURBO)-2
GENERAL DESCRIPTION
Intake (Induction)
2. INTAKE DUCT S184001A0502
EN0903
(1) Clamp (4) Air by-pass hose C Tightening torque: N·m (kgf-m, ft-lb)
(2) Air by-pass hose A (5) Air by-pass hose D
T1: 15.7 (1.6, 11.6)
(3) Air by-pass hose B (6) Intake duct
IN(DOHC TURBO)-3
GENERAL DESCRIPTION
Intake (Induction)
3. INTER COOLER S184001A0503
S2M2165A
(1) PVC pipe (9) Gasket Tightening torque: N·m (kgf-m, ft-lb)
(2) Air by-pass hose C (10) Intercooler duct A
T1: 3 (0.22, 1.6)
(3) Stay (11) Intercooler duct B
T2: 6.4 (0.65, 4.7)
(4) Clamp (12) Intercooler duct C
T3: 16 (1.6, 11.7)
(5) Air intake hose (13) Air by-pass hose A
(6) Intercooler (14) Clamp
(7) Intercooler bracket (15) Air by-pass pipe
(8) Air by-pass valve (16) Air by-pass hose B
IN(DOHC TURBO)-4
GENERAL DESCRIPTION
Intake (Induction)
4. TURBOCHARGER S184001A0504
H2M1608C
(1) Oil inlet pipe (8) Oil outlet pipe Tightening torque: N·m (kgf-m, ft-lb)
(2) Metal gasket (9) Clip
T1: 4.4 (0.45, 3.3)
(3) Turbocharger (10) Oil outlet hose
T2: 4.9 (0.50, 3.6)
(4) Water pipe (11) Turbocharger bracket RH
T3: 29 (3.0, 21.7)
(5) Clamp (12) Turbocharger bracket LH
(6) Engine coolant hose T4: 30 (3.1, 22.4)
(7) Gasket T5: 33 (3.4, 24.6)
IN(DOHC TURBO)-5
GENERAL DESCRIPTION
Intake (Induction)

tion.
ment.
fied points.
sensor or units, be sure to disconnect negative
IN(DOHC TURBO)-6
AIR CLEANER
Intake (Induction)
2. Air Cleaner S184087

7) Remove air cleaner lower case.
1) Disconnect connector battery ground cable.
EN0905
G6M0095
2) Disconnect connector from mass air flow sen- Tightening torque:
sor. 33 N·m (3.4 kgf-m, 25 ft-lb)
EN0031 EN0905
3) Loosen clamp (A) which connects air intake CAUTION:

boot to intake duct. Before installing air cleaner upper cover, align
4) Remove the two clips (B) from air cleaner upper holes with protruding portions of air cleaner
cover. lower case, then secure upper cover to lower
case.
EN0992
EN0906
5) Remove air cleaner upper cover.
Replace if excessively damaged or dirty.
IN(DOHC TURBO)-7
AIR INTAKE DUCT
Intake (Induction)
3. Air Intake Duct S184566
Remove bolts which install air intake duct on the

front side of body.
S2M2166
1) Inspect for cracks and loose connections.

2) Inspect that no foreign objects are mixed in the
air intake duct.
IN(DOHC TURBO)-8
INTAKE DUCT
Intake (Induction)
4. Intake Duct S184760
G6M0095

3) Remove sensor, engine harness, and fuel pipe
attached to the intake manifold. <Ref. to FU(DOHC
TURBO)-21, DISASSEMBLY, Intake Manifold.>
4) Remove intake duct from intake manifold.
EN0814
IN(DOHC TURBO)-9
INTERCOOLER
Intake (Induction)
5. Intercooler S184761
5) Separate intercooler from throttle body.
1) Remove air by-pass hoses from intercooler.
S2M2230
S2M2226
2) Loosen clamp, and remove hoses from air by- Tightening torque:
pass valve. 16 N·m (1.6 kgf-m, 11.7 ft-lb)
S2M2227
S2M2228
3) Remove bolts which secure intercooler to

bracket.
S2M2229
S2M2228
S2M2229
4) Separate intercooler air duct from turbocharger.
IN(DOHC TURBO)-10
INTERCOOLER
Intake (Induction)
C: DISASSEMBLY S184761A06 D: ASSEMBLY S184761A02
1) Loosen clamps, then remove intercooler duct. Assemble in the reverse order of disassembly.
Tightening torque:
16 N·m (1.6 kgf-m, 11.7 ft-lb)
H2M1884
2) Remove intercooler ducts from intercooler.

H2M1886
H2M1885
3) Remove air by-pass valve. S2M2231
S2M2231
IN(DOHC TURBO)-11
TURBOCHARGER
Intake (Induction)
6. Turbocharger S184762
7) Loosen clamp which secures turbocharger to
air inlet duct.

H2M1936
8) Remove bolt which secures bracket of oil pipe

to turbocharger.
G6M0095 9) Remove oil pipe from turbocharger.
Pipe.>
5) Separate turbocharger joint pipe from turbo-
charger.
EN0913
10) Remove turbocharger bracket.
EN0911
6) Disconnect engine coolant hose which is con-

nected to coolant filler tank.
H2M1940
11) Disconnect oil outlet hose from pipe.
EN0912
H2M1941
12) Take out turbocharger from engine compart-

ment.
IN(DOHC TURBO)-12
TURBOCHARGER
Intake (Induction)
B: INSTALLATION S184762A11 4) Install joint pipe to turbocharger.

1) Connect oil outlet hose to outlet pipe. CAUTION:
Tightening torque:
30 N·m (3.1 kgf-m, 22.4 ft-lb)
H2M1941
2) Install turbocharger to air intake duct.

EN0911
5) Install turbocharger bracket.
H2M1936
3) Install oil pipe to turbocharger.

H2M1940
6) Connect engine coolant hose which is con-

nected to coolant filler tank.
EN0913
EN0912

8) Install center exhaust pipe. <Ref. to EX(DOHC
TURBO)-10, INSTALLATION, Center Exhaust
Pipe.>
IN(DOHC TURBO)-13
AIR BY-PASS VALVE
Intake (Induction)
7. Air By-pass Valve S184016
1) Disconnect air by-pass hoses from air by-pass

valve.
S2M2232
2) Remove air by-pass valve from intercooler.
S2M2231

Tightening torque:
16 N·m (1.6 kgf-m, 11.7 ft-lb)
S2M2231
IN(DOHC TURBO)-14
ENGINE2 SECTION

SUBARU vehicles.
ine parts.

G8050GE3
MECHANICAL
ME(DOHC TURBO)
Page
2. Compression .............................................................................................22
3. Idle Speed .................................................................................................23
4. Ignition Timing ...........................................................................................24
5. Intake Manifold Vacuum............................................................................25
6. Engine Oil Pressure ..................................................................................26
7. Fuel Pressure ............................................................................................27
8. Valve Clearance ........................................................................................28
9. Engine Assembly.......................................................................................33
10. Engine Mounting .......................................................................................42
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....................................................................................56
17. Crankshaft Sprocket..................................................................................57
18. Camshaft ...................................................................................................58
19. Cylinder Head Assembly ...........................................................................63
20. Cylinder Block ...........................................................................................70
21. Engine Trouble in General ........................................................................91
22. Engine Noise .............................................................................................97
GENERAL DESCRIPTION
Mechanical
Horizontally opposed, liquid cooled, 4-cylinder,

Type
4-stroke gasoline engine
Belt driven, double overhead camshaft, 4-valve/
Valve arrangement
cylinder
Bore x Stroke mm (in) 92 x 75 (3.62 x 2.95)
Piston displacement cm3 (cu in) 1,994 (121.67)
Compression ratio 8.0
Compression pres-
sure (at 200 — 300 kPa (kg/cm2, psi) 981 — 1,177 (10 — 12, 142 — 171)
rpm)
Engine Number of piston rings Pressure ring: 2, Oil ring: 1
Opening 3° BTDC
Intake valve timing
Closing 33° ABDC
Opening 33° BBDC
Exhaust valve timing
Closing 3° ATDC
Intake mm (in) 0.20±0.02 (0.0079±0.0008)
Valve clearance
Exhaust mm (in) 0.25±0.02 (0.0098±0.0008)
Idling speed [At neutral position on 700±100 (No load)
rpm
MT; “P” or “N” position on AT] 800±150 (A/C switch ON)
Firing order 1→3→2→4
Ignition timing BTDC/rpm 12°±10°/700 rpm
NOTE:
STD: Standard I.D.: Inner Diameter O.D.: Outer Diameter OS: Oversize US: Undersize
ME(DOHC TURBO)-2
GENERAL DESCRIPTION
Mechanical
Belt tension
Protrusion of adjuster rod 5.2 — 6.2 mm (0.205 — 0.244 in)
adjuster
Spacer O.D. 17.955 — 17.975 mm (0.7069 — 0.7077 in)
Tensioner bush I.D. 18.0 — 18.08 mm (0.7087 — 0.7118 in)
Belt ten- STD 0.025 — 0.125 mm (0.0010 — 0.0049 in)
Clearance between spacer and bush
sioner Limit 0.175 mm (0.0069 in)
STD 0.2 — 0.55 mm (0.0079 — 0.0217 in)
Side clearance of spacer
Limit 0.81 mm (0.0319 in)
STD 0.015 — 0.070 mm (0.0006 — 0.0028 in)
Thrust clearance
Limit 0.10 mm (0.0039 in)
STD 44.75 — 44.85 mm (1.7618 — 1.7657 in)
Intake
Limit 44.65 mm (1.759 in)
Cam lobe height
Camshaft STD 44.60 — 44.70 mm (1.7559 — 1.7598 in)
Exhaust
Limit 44.50 mm (1.7520 in)
Jounal O.D. Front 37.946 — 37.963 mm (1.4939 — 1.4946 in)
STD
Center rear 29.946 — 29.963 mm (1.1790 — 1.1796 in)
STD 0.037 — 0.072 mm (0.0015 — 0.0028 in)
Oil clearance
Limit 0.10 mm (0.0039 in)
Surface warpage limit 0.05 mm (0.0020 in)
Cylinder
head
Standard height 127.5 mm (5.02 in)
Refacing angle 90°
STD 1.0 mm (0.039 in)
Intake
Valve seat Limit 1.7 mm (0.067 in)
Contacting width
STD 1.5 mm (0.059 in)
Exhaust
Limit 2.2 mm (0.087 in)
Inner diameter 6.000 — 6.015 mm (0.2362 — 0.2368 in)
Valve guide
Protrusion above head 12.0 — 12.4 mm (0.472 — 0.488 in)
STD 1.2 mm (0.047 in)
Intake
Limit 0.8 mm (0.031 in)
Head edge thickness
STD 1.5 mm (0.059 in)
Exhaust
Limit 0.8 mm (0.031 in)
Intake 5.950 — 5.965 mm (0.2343 — 0.2348 in)
Stem diameter
Valve Exhaust 5.950 — 5.965 mm(0.2343 — 0.2348 in)
Intake 0.035 — 0.062 mm (0.0014 — 0.0024 in)
STD
Stem oil clearance Exhaust 0.040 — 0.067 mm (0.0016 — 0.0026 in)
Limit — 0.15 mm (0.0059 in)
Intake 104.4 mm (4.110 in)
Overall length
Exhaust 104.7 mm (4.122 in)
Squareness 2.5°, 2.0 mm (0.079 in)
Valve spring 220.7±15.7 N (22.5±1.6 kgf, 49.6±3.5 lb)/36.0 mm (1.417
in)
Tension/spring height
510.9±25.5 N (52.1±2.6 kgf, 114.9±5.7 lb)/26.6 mm
(1.0.47 in)
ME(DOHC TURBO)-3
GENERAL DESCRIPTION
Mechanical
Surface warpage limit (mating with cylinder head) 0.05 mm (0.0020 in)
A 92.005 — 92.015 mm (3.6222 — 3.6226 in)
Cylinder bore STD
B 91.995 — 92.005 mm (3.6218 — 3.6222 in)
STD 0.015 mm (0.0006 in)
Cylinder Taper
Limit 0.050 mm (0.0020 in)
block
STD 0.010 mm (0.0004 in)
Out-of-roundness
Limit 0.050 mm (0.0020 in)
STD 0.010 — 0.030 mm (0.0004 — 0.0012 in)
Piston clearance
Limit 0.050 mm (0.0020 in)
Enlarging (boring) limit 0.5 mm (0.020 in)
A 91.985 — 91.995 mm (3.6214 — 3.6218 in)
STD
B 91.975 — 91.985 mm (3.6211 — 3.6214 in)
Piston Outer diameter
0.25 mm (0.0098 in) OS 92.225 — 92.235 mm (3.6309 — 3.6313 in)
0.50 mm (0.0197 in) OS 92.475 — 92.485 mm (3.6407 — 3.6411 in)
Piston pin 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 must be fitted into position with thumb at 20°C
Degree of fit
(68°F).
STD 0.20 — 0.26 mm (0.0079 — 0.0102 in)
Top ring
Limit 1.0 mm (0.039 in)
Second STD 0.35 — 0.50 mm (0.0138 — 0.0197 in)
Piston ring gap
STD 0.20 — 0.70 mm (0.0079 — 0.0276 in)
Piston ring Oil ring
Limit 1.5 mm (0.059 in)
STD 0.040 — 0.080 mm (0.0016 — 0.0031 in)
Clearance between piston Top ring Limit 0.15 mm (0.0059 in)
ring and piston ring
groove Second STD 0.030 — 0.070 mm (0.0012 — 0.0028 in)
Bend twist per 100 mm (3.94 in) in
Limit 0.10 mm (0.0039 in)
Connecting length
rod STD 0.070 — 0.330 mm (0.0028 — 0.0130 in)
Side clearance
Limit 0.4 mm (0.016 in)
STD 0.020 — 0.046 mm (0.0008 — 0.0018 in)
Oil clearance
Limit 0.05 mm (0.0020 in)
STD 1.492 — 1.501 mm (0.0587 — 0.0591 in)
0.03 mm
(0.0012 in) 1.510 — 1.513 mm (0.0594 — 0.0596 in)
Connecting US
rod bearing 0.05 mm
Thickness at center portion
(0.0020 in) 1.520 — 1.523 mm (0.0598 — 0.0600 in)
US
0.25 mm
(0.0098 in) 1.620 — 1.623 mm (0.0638 — 0.0639 in)
US
Connecting Clearance between piston pin and STD 0 — 0.022 mm (0 — 0.0009 in)
rod bushing bushing Limit 0.030 mm (0.0012 in)
ME(DOHC TURBO)-4
GENERAL DESCRIPTION
Mechanical

Crank pin and crank jour- Out-of-roundness 0.020 mm (0.0008 in) or less
nal Grinding limit 0.25 mm (0.0098 in)
STD 51.984 — 52.000 mm (2.0466 — 2.0472 in)
0.03 mm
(0.0012 in) 51.954 — 51.970 mm (2.0454 — 2.0461 in)
US
Crank pin outer diameter 0.05 mm
(0.0020 in) 51.934 — 51.950 mm (2.0466 — 2.0453 in)
US
0.25 mm
(0.0098 in) 51.734 — 51.750 mm (2.0368 — 2.0374 in)
US
STD 59.992 — 60.008 mm (2.3619 — 2.3625 in)
0.03 mm
(0.0012 in) 59.962 — 59.978 mm (2.3607 — 2.3613 in)
US
#1, #3, #5 0.05 mm
Crankshaft (0.0020 in) 59.942 — 59.958 mm (2.3599 — 2.3605 in)
US
0.25 mm
(0.0098 in) 59.742 — 59.758 mm (2.3520 — 2.3527 in)
Crank journal outer diam- US
eter STD 59.992 — 60.008 mm (2.3619 — 2.3625 in)
0.03 mm
(0.0012 in) 59.962 — 59.978 mm (2.3607 — 2.3613 in)
US
0.05 mm
#2, #4
(0.0020 in) 59.942 — 59.958 mm (2.3599 — 2.3605 in)
US
0.25 mm
(0.0098 in) 59.742 — 59.758 mm (2.3520 — 2.3527 in)
US
STD 0.030 — 0.115 mm (0.0012 — 0.0045 in)
Thrust clearance
Limit 0.25 mm (0.0098 in)
STD 0.010 — 0.030 mm (0.0004 — 0.0012 in)
Oil clearance
Limit 0.040 mm (0.0016 in)
STD 1.998 — 2.011 mm (0.0787 — 0.0792 in)
0.03 mm
(0.0012 in) 2.017 — 2.020 mm (0.0794 — 0.0795 in)
US
0.05 mm
#1, #3
(0.0020 in) 2.027 — 2.030 mm (0.0798 — 0.0799 in)
US
0.25 mm
(0.0098 in) 2.127 — 2.130 mm (0.0837 — 0.0839 in)
Crankshaft Crankshaft bearing thick- US
bearing ness STD 2.000 — 2.013 mm (0.0787 — 0.0793 in)
0.03 mm
(0.0012 in) 2.019 — 2.022 mm (0.0795 — 0.0796 in)
US
#2, #4, #5 0.05 mm
(0.0020 in) 2.029 — 2.032 mm (0.0799 — 0.0800 in)
US
0.25 mm
(0.0098 in) 2.129 — 2.132 mm (0.0838 — 0.0839 in)
US
ME(DOHC TURBO)-5
GENERAL DESCRIPTION
Mechanical
MEMO:
ME(DOHC TURBO)-6
GENERAL DESCRIPTION
Mechanical
S2M2241A
(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) (10) Left-hand intake camshaft
(3) Crankshaft sprocket sprocket Tightening torque: N·m (kgf-m, ft-lb)
(4) Left-hand belt cover No. 2 (11) Left-hand exhaust camshaft T1: 5 (0.5, 3.6)
(5) Tensioner bracket sprocket T2: 10 (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: 127 (13, 94.0)
sprocket (16) Front belt cover
ME(DOHC TURBO)-7
GENERAL DESCRIPTION
Mechanical
2. CYLINDER HEAD AND CAMSHAFT S183001A0502
S2M1188A
ME(DOHC TURBO)-8
GENERAL DESCRIPTION
Mechanical
(1) Rocker cover (RH) (14) Oil seal (28) Rocker cover (LH)
(2) Rocker cover gasket (RH) (15) Cylinder head (RH) (29) Oil filler cap
(3) Oil separator cover (16) Cylinder head gasket (RH) (30) Gasket
(4) Gasket (17) Cylinder head gasket (LH) (31) Oil filler duct
(5) Intake camshaft cap (Front RH) (18) Cylinder head (LH) (32) O-ring
(6) Intake camshaft cap (Center RH) (19) Intake camshaft (LH) (33) Stud bolt
(7) Intake camshaft cap (Rear RH) (20) Exhaust camshaft (LH)
(8) Intake camshaft (RH) (21) Intake camshaft cap (Front LH) Tightening torque: N·m (kgf-m, ft-lb)
(9) Exhaust camshaft cap (Front (22) Intake camshaft cap (Center LH) T1: <Ref. to ME(DOHC TURBO)-
RH) (23) Intake camshaft cap (Rear LH) 63, INSTALLATION, Cylinder
(10) Exhaust camshaft cap (Center (24) Exhaust camshaft (Front LH) Head Assembly.>
RH) (25) Exhaust camshaft cap (Center T2: 5 (0.5, 3.6)
(11) Exhaust camshaft cap (Rear RH) LH) T3: 10 (1.0, 7)
(12) Exhaust camshaft (RH) (26) Exhaust camshaft cap (Rear LH) T4: 6.4 (0.65, 4.7)
(13) Cylinder head bolt (27) Rocker cover gasket (LH)
ME(DOHC TURBO)-9
GENERAL DESCRIPTION
Mechanical
3. CYLINDER HEAD AND VALVE ASSEMBLY S183001A0503
S2M1197A
(1) Exhaust valve (6) Valve spring (11) Exhaust valve oil seal
(2) Intake valve (7) Retainer (12) Intake valve guide
(3) Cylinder head (8) Retainer key (13) Exhaust valve guide
(4) Valve spring seat (9) Valve lifter
(5) Intake valve oil seal (10) Shim
ME(DOHC TURBO)-10
GENERAL DESCRIPTION
Mechanical
EN0144
(1) Oil pressure switch (15) Oil cooler Tightening torque: N·m (kgf-m, ft-lb)
(2) Cylinder block (RH) (16) Waster by-pass pipe
T1: 5 (0.5, 3.6)
(3) Service hole plug (17) Connector
T2: 6.4 (0.65, 4.7)
(4) Gasket (18) Oil strainer
T3: 10 (1.0, 7)
(5) Oil separator cover (19) Gasket
(6) Water by-pass pipe (20) Oil pan T4: 25 (2.5, 18.1)
(7) Oil pump (21) Drain plug T5: 47 (4.8, 34.7)
(8) Front oil seal (22) Metal gasket T6: 69 (7.0, 50.6)
(9) Rear oil seal (23) Oil level gauge guide T7: First 12 (1.2, 8.7)
(10) O-ring (24) Oil filter Second 12 (1.2, 8.7)
(11) Service hole cover (25) Gasket T8: 16 (1.6, 11.6)
(12) Cylinder block (LH) (26) Water pump hose T9: 44 (4.5, 33)
(13) Water pump (27) Plug T10: 25 (2.5, 18.1)
(14) Baffle plate T11: 55 (5.5, 40)
ME(DOHC TURBO)-11
GENERAL DESCRIPTION
Mechanical
5. CRANKSHAFT AND PISTON S183001A0505
EN0415
(1) Flywheel (MT vehicles only) (9) Piston pin (17) Crankshaft bearing #1, #3
(2) Ball bearing (MT vehicles only) (10) Circlip (18) Crankshaft bearing #2, #4
(3) Reinforcement (AT vehicles only) (11) Connecting rod bolt (19) Crankshaft bearing #5
(4) Drive plate (AT vehicles only) (12) Connecting rod
(5) Top ring (13) Connecting rod bearing Tightening torque: N·m (kgf-m, ft-lb)
(6) Second ring (14) Connecting rod cap T1: 44.6 (4.55, 32.9)
(7) Oil ring (15) Crankshaft T2: 72 (7.3, 52.8)
(8) Piston (16) Woodruff key
ME(DOHC TURBO)-12
GENERAL DESCRIPTION
Mechanical
6. ENGINE MOUNTING S183001A0506
S2M1783A
(1) Hear shield cover Tightening torque: N·m (kgf-m, ft-lb)

(2) Front cushion rubber
T1: 35 (3.6, 25.8)
(3) Front engine mounting bracket
T2: 42 (4.3, 30.9)
T3: 85 (8.7, 62.7)
ME(DOHC TURBO)-13
GENERAL DESCRIPTION
Mechanical
C: CAUTION S183001A03 쐌 Be careful not to let oil, grease or coolant con-

tact the timing belt, clutch disc and flywheel.
쐌 Wear working clothing, including a cap, protec- 쐌 All removed parts, if to be reused, should be
tive goggles, and protective shoes during opera- reinstalled in the original positions and directions.
tion.
쐌 Bolts, nuts and washers should be replaced with
sion before removal, installation or disassembly. new ones as required.
쐌 Keep the disassembled parts in order and pro- 쐌 Even if necessary inspections have been made
tect them from dust or dirt. in advance, proceed with assembly work while
쐌 Before removal, installation or disassembly, be making rechecks.
sure to clarify the failure. Avoid unnecessary 쐌 Remove or install engine in an area where chain
removal, installation, disassembly, and replace- hoists, lifting devices, etc. are available for ready
ment. use.
쐌 Be careful not to burn your hands, because each 쐌 Be sure not to damage coated surfaces of body
part in the vehicle is hot after running. panels with tools or stain seats and windows with
쐌 Be sure to tighten fasteners including bolts and coolant or oil. Place a cover over fenders, as
nuts to the specified torque. required, for protection.
쐌 Place shop jacks or safety stands at the speci- 쐌 Prior to starting work, prepare the following:
fied points. Service tools, clean cloth, containers to catch cool-
쐌 Before disconnecting electrical connectors of ant and oil, wire ropes, chain hoist, transmission
sensors or units, be sure to disconnect negative jacks, etc.
terminal from battery. 쐌 Lift-up or lower the vehicle when necessary.
쐌 All parts should be thoroughly cleaned, paying Make sure to support the correct positions.
special attention to the engine oil passages, pis-
tons and bearings.
쐌 Rotating parts and sliding parts such as piston,
bearing and gear should be coated with oil prior to
assembly.

498267600 CYLINDER HEAD 쐌 Used for replacing valve guides.
TABLE 쐌 Used for removing and installing valve
springs.
EN0147
ADAPTER RH
B2M3851
ME(DOHC TURBO)-14
GENERAL DESCRIPTION
Mechanical

ADAPTER LH
B2M3852
498497100 CRANKSHAFT Used for stopping rotation of flywheel when

STOPPER loosening and tightening crankshaft pulley bolt,
etc.
B2M3853
498277200 STOPPER SET Used for removing and installing automatic
transmission assembly to engine
B3M2043
398744300 PISTON GUIDE Used for installing piston in cylinder.
B2M3854
ME(DOHC TURBO)-15
GENERAL DESCRIPTION
Mechanical

498857100 VALVE OIL SEAL Used for press-fitting of intake and exhaust
GUIDE valve guide oil seals.
B2M3855
499017100 PISTON PIN GUIDE Used for installing piston pin, piston and con-
necting rod.
B2M3856
499037100 CONNECTING ROD Used for removing and installing connecting rod
BUSHING bushing.
REMOVER &
INSTALLER
B2M3857
499097700 PISTON PIN Used for removing piston pin.
REMOVER ASSY
B2M3858
ME(DOHC TURBO)-16
GENERAL DESCRIPTION
Mechanical

SPROCKET sprocket.
WRENCH
B2M4158
499587700 CAMSHAFT OIL Used for installing cylinder head plug.
SEAL INSTALLER
B2M3860
499587200 CRANKSHAFT OIL 쐌 Used for installing crankshaft oil seal.
SEAL INSTALLER 쐌 Used with CRANKSHAFT OIL SEAL GUIDE
(499597100).
B2M3861
499597100 CRANKSHAFT OIL 쐌 Used for installing crankshaft oil seal.
SEAL GUIDE 쐌 Used with CRANKSHAFT OIL SEAL
B2M3863
ME(DOHC TURBO)-17
GENERAL DESCRIPTION
Mechanical

499718000 VALVE SPRING Used for removing and installing valve spring.
REMOVER
B2M3864
498267700 VALVE GUIDE Used for installing intake and exhaust valve
ADJUSTER guides.
B2M3865
499767200 VALVE GUIDE Used for removing valve guides.
REMOVER
B2M3867
499767400 VALVE GUIDE Used for reaming valve guides.
REAMER
B2M3868
ME(DOHC TURBO)-18
GENERAL DESCRIPTION
Mechanical

499817000 ENGINE STAND 쐌 Stand used for engine disassembly and
assembly.
쐌 Used with ENGINE STAND ADAPTER RH
(498457000) & LH (498457100).
B2M3869
bolts.
B2M4157
499987500 CRANKSHAFT Used for rotating crankshaft.
SOCKET
B2M3871
WRENCH
B2M3872
ME(DOHC TURBO)-19
GENERAL DESCRIPTION
Mechanical

INSTALLER
B2M3875
499587600 OIL SEAL GUIDE Used for installing camshaft oil seal.
S1H0136
499597200 OIL SEAL GUIDE Used for installing camshaft oil seal.
Used with OIL SEAL GUIDE (499587600).
EN0168
49818200 SHIM REPLACER Used for correct valve clearance.
EN0169
ME(DOHC TURBO)-20
GENERAL DESCRIPTION
Mechanical

B2M3876
B2M3877
TOOL NAME REMARKS

Compression Gauge Used for measuring compression.
Timing Light Used for measuring ignition timing.
E: PROCEDURE S183001E45
It is possible to conduct the following service pro-

cedures with engine on the vehicle, however, the
procedures described in this section are based on
the condition that the engine is removed from the
vehicle.
쐌 V-belt
쐌 Timing Belt
쐌 Camshaft
쐌 Cylinder Head
ME(DOHC TURBO)-21
COMPRESSION
Mechanical
2. Compression S183081
CAUTION:
surement.
1) After warming-up the engine, turn ignition
switch to OFF.
2) Make sure that the battery is fully charged.
OPERATION, Fuel.>
4) Remove all the spark plugs. <Ref. to IG(DOHC
TURBO)-4, REMOVAL, Spark Plug.>
5) Fully open throttle valve.
6) Check the starter motor for satisfactory perfor-
mance and operation.
7) Hold the compression gauge tight against the
spark plug hole.
CAUTION:
When using a screw-in type compression
gauge, the screw (put into cylinder head spark
plug hole) should be less than 18 mm (0.71 in)
long.
8) Crank the engine by means of the starter motor,
and read the maximum value on the gauge when
the pointer is steady.
EN0172
9) Perform at least two measurements per

cylinder, and make sure that the values are correct.
Compression (350 rpm and fully open
throttle):
Standard;
981 — 1,177 kPa (10.0 — 12.0 kg/cm2, 142
— 171 psi)
Limit;
981 kPa (10.0 kg/cm2, 142 psi)
Difference between cylinders;
49 kPa (0.5 kg/cm2, 7 psi)
ME(DOHC TURBO)-22
IDLE SPEED
Mechanical
3. Idle Speed S183082
1) Before checking idle speed, check the follow-

ing:
clogging, ignition timing is correct, spark plugs
are in good condition, and that hoses are con-
nected properly.
OFF.
4) Insert the cartridge to SUBARU SELECT
MONITOR.
5) Connect SUBARU SELECT MONITOR to the
data link connector.
6) Turn ignition switch to ON, and SUBARU
SELECT MONITOR switch to ON.
Menu.
10) Select {1.12 Data Display} in Data Display
Menu.
11) Start the engine, and read engine idle speed.
12) Check idle speed when unloaded. (With
headlights, heater fan, rear defroster, radiator fan,
air conditioning, etc. OFF)
Idle speed [No load and gears in neutral (MT),
or N or P position (AT)]:
700±100 rpm
13) Check idle speed when loaded. (Turn air con-
ditioning switch to “ON” and operate compressor
for at least one minute before measurement.)
Idle speed [A/C “ON”, no load and gears in
neutral]:
800±150 rpm
CAUTION:
Never rotate idle adjusting screw. If idle speed
is out of specifications, refer to General On-
board Diagnosis Table under “Engine Control
System”. <Ref. to EN(DOHC TURBO)-2, Basic
Diagnostic Procedure.>
ME(DOHC TURBO)-23
IGNITION TIMING
Mechanical
4. Ignition Timing S183086
1) Before checking ignition timing speed, check

the following:
clogging, spark plugs are in good condition, and
that hoses are connected properly.
OFF.
4) Insert the cartridge to SUBARU SELECT
MONITOR.
5) Connect SUBARU SELECT MONITOR to the
data link connector.
6) Turn ignition switch to ON, and SUBARU
SELECT MONITOR switch to ON.
Menu.
10) Select {1.12 Data Display} in Data Display
Menu.
11) Start the engine, at idle speed and check the
ignition timing.
Ignition timing [BTDC/rpm]:
12°±10°/700
If the timing is not correct, check the ignition con-
trol system. Refer to Engine Control System. <Ref.
to EN(DOHC TURBO)-2, Basic Diagnostic Proce-
dure.>
ME(DOHC TURBO)-24
INTAKE MANIFOLD VACUUM
Mechanical
5. Intake Manifold Vacuum S183654

3) Keep the engine at the idle speed and read the
vacuum gauge indication.
A: INSPECTION S183654A10 By observing the gauge needle movement, the
1) Warm-up the engine. internal condition of the engine can be diagnosed
2) Disconnect the brake vacuum hose and install as described below.
the vacuum gauge to the hose fitting on the mani-
fold.
H2M1767
Vacuum pressure (at idling, A/C “OFF”):

Less than −60.0 kPa (−450 mmHg, −17.72
inHg)
Diagnosis of engine condition by measurement of manifold vacuum

Vacuum gauge indication Possible engine condition
1. Needle is steady but lower than normal position. This ten- Leakage around intake manifold gasket or disconnection or
dency becomes more evident as engine temperature rises. damaged vacuum hose
2. When engine speed is reduced slowly from higher speed, Back pressure too high, or exhaust system clogged
needle stops temporarily when it is lowering or becomes
steady above normal position.
3. Needle intermittently drops to position lower than normal Leakage around cylinder
position.
4. Needle drops suddenly and intermittently from normal posi- Sticky valves
tion.
5. When engine speed is gradually increased, needle begins to Weak or broken valve springs
vibrate rapidly at certain speed, and then vibration increases
as engine speed increases.
6. Needle vibrates above and below normal position in narrow Defective ignition system or throttle chamber idle adjustment
range.
4) After measuring intake manifold vacuum, install

brake vacuum hose.
ME(DOHC TURBO)-25
ENGINE OIL PRESSURE
Mechanical
6. Engine Oil Pressure S183655

Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
1) Remove oil pressure switch from engine cylin-

der block. <Ref. to LU-21, REMOVAL, Oil Pressure
Switch.>
2) Connect oil pressure gauge hose to cylinder
block.
G6M0095
4) Start the engine, and measure oil pressure.
S2M0242
Oil pressure:
98 kPa (1.0 kg/cm2, 14 psi) or more at 800
rpm
294 kPa (3.0 kg/cm2, 43 psi) or more at
5,000 rpm
CAUTION:
쐌 If oil pressure is out of specification, check
oil pump, oil filter and lubrication line. <Ref. to
LU-25, INSPECTION, Engine Lubrication Sys-
tem Trouble in General.>
쐌 If oil pressure warning light is turned ON and
oil pressure is in specification, replace oil pres-
sure switch. <Ref. to LU-25, INSPECTION,
Engine Lubrication System Trouble in Gen-
eral.>
NOTE:
The specified data is based on an engine oil tem-
5) After measuring oil pressure, install oil pressure
switch. <Ref. to LU-21, INSTALLATION, Oil Pres-
sure Switch.>
ME(DOHC TURBO)-26
FUEL PRESSURE
Mechanical
7. Fuel Pressure S183656

A: INSPECTION S183656A10 pressure regulator vacuum hose from intake mani-
fold.
WARNING:
Before removing fuel pressure gauge, release Fuel pressure:
fuel pressure. Standard; 284 — 314 kPa (2.9 — 3.2
kg/cm2, 41 — 46 psi)
NOTE:
If out of specification, check or replace pressure
regulator and pressure regulator vacuum hose.
OPERATION, Fuel.>
S2M0554
7) After connecting pressure regulator vacuum

hose, measure fuel pressure.
Fuel pressure:
Standard; 230 — 260 kPa (2.35 — 2.65
kg/cm2, 33 — 38 psi)
B2M3135
3) Disconnect fuel delivery hoses from fuel filter,

and connect fuel pressure gauge.
S2M0554
NOTE:
The fuel pressure gauge registers 10 to 20 kPa
S2M0195 (0.1 to 0.2 kg/cm2, 1 to 3 psi) higher than standard
values during high-altitude operations.
4) Connect connector of fuel pump relay.
S2M0093
ME(DOHC TURBO)-27
VALVE CLEARANCE
Mechanical
8. Valve Clearance S183083

10) When inspecting #2 and #4 cylinders;
(1) Disconnect battery cables, and then
A: INSPECTION S183083A10 remove 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 bolt which secures engine harness

bracket onto body.
G6M0095
3) Remove air intake duct. <Ref. to IN(DOHC

TURBO)-8, REMOVAL , Air Intake Duct.>
4) Remove one bolt which secures timing belt
cover (RH).
7) Loosen remaining bolts which secure timing H6M0429
belt cover (RH), then remove belt cover.
8) Lower the vehicle. (3) Remove washer tank mounting bolts.
9) When inspecting #1 and #3 cylinders:
(1) Pull out engine harness connector with
bracket from air cleaner upper cover.
B6M0561
(4) Disconnect washer motor connectors.

H2M1958
(2) Remove air cleaner case. <Ref. to

IN(DOHC TURBO)-7, REMOVAL, Air Cleaner.>
plugs (#1 and #3 cylinders).
(4) Place suitable container under the vehicle.
(5) Disconnect PCV hose from rocker cover
(RH).
(RH). H6M0430
ME(DOHC TURBO)-28
VALVE CLEARANCE
Mechanical
(5) Move 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.
H6M0431

plugs (#2 and #4 cylinders). B2M1234B
(7) Place suitable container under the vehicle.
(8) Disconnect PCV hose from rocker cover 13) If necessary, adjust the valve clearance. <Ref.
(LH). to ME(DOHC TURBO)-30, ADJUSTMENT, Valve
(9) Remove bolts, then remove rocker cover Clearance.>
(LH). 14) Further turn crankshaft pulley clockwise.
11) Turn crankshaft pulley clockwise until arrow Using the same procedures described previously,
mark on camshaft sprocket is set to position shown then measure valve clearances again.
in figure. (1) Set arrow mark on camshaft sprocket to
NOTE: position shown in figure, and measure #2 cylin-
Turn crankshaft using ST. der exhaust valve and #3 cylinder intake valve
ST 499987500 CRANKSHAFT SOCKET clearances.
S2M1192B S2M1194B
12) Measure #1 cylinder intake valve and #3 cyl- (2) Set arrow mark on camshaft sprocket to
inder exhaust valve clearance by using thickness position shown in figure, and measure #2 cylin-
gauge (A). der intake valve and #4 cylinder exhaust valve
clearances.
CAUTION:
direction as possible with respect to the shim.
쐌 Measure exhaust valve clearances while lift-
ing-up the vehicle.
Valve clearance:
Intake: 0.20±0.02 mm (0.0079±0.0008 in)
Exhaust: 0.25±0.02 mm (0.0098±0.0008 in)
S2M1195B
ME(DOHC TURBO)-29
VALVE CLEARANCE
Mechanical
(3) Set arrow mark on camshaft sprocket to (1) Prepare the ST.
position shown in figure, and measure #1 cylin- ST 498187200 SHIM REPLACER
der exhaust valve and #4 cylinder intake valve
clearances.
H2M3622
S2M1196B
(2) Rotate the notch of the valve lifter outward
by 45.
15) After inspection, install the related parts in the
reverse order of removal.
Tightening torque:
32 N·m (3.3 kgf-m, 24 ft-lb)
H2M1777A
(3) Adjust SHIM REPLACER notch to valve

lifter and set it.
EN0191
B: ADJUSTMENT S183083A01
CAUTION:
Adjustment of valve clearance should be per-
formed while engine is cold.
1) Measure all valve clearances. <Ref. to
ME(DOHC TURBO)-28, INSPECTION, Valve
Clearance.> H2M3628
NOTE:
Record each valve clearance after it has been NOTE:
measured. When setting, be careful SHIM REPLACER edge
does not touch shim.
(4) Tighten bolt (A) and install it to the cylinder
head.
B2M1234
2) Remove shim from valve lifter.
ME(DOHC TURBO)-30
VALVE CLEARANCE
Mechanical
(5) Tighten bolt (B) and insert the valve lifter. 4) Select a shim of suitable thickness using mea-
sured valve clearance and shim thickness, by
referring to the following table.
5) Set 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
H2M3623A
(6) Insert tweezers into the notch of the valve 13218 AK010 2.00 (0.0787)
lifter, and take the shim out.
13218 AK020 2.02 (0.0795)
13218 AK030 2.04 (0.0803)
13218 AK040 2.06 (0.0811)
13218 AK050 2.08 (0.0819)
13218 AK060 2.10 (0.0827)
13218 AK070 2.12 (0.0835)
13218 AK080 2.14 (0.0843)
13218 AK090 2.16 (0.0850)
13218 AK100 2.18 (0.0858)
13218 AK110 2.20 (0.0866)
H2M3629 13218 AE710 2.22 (0.0874)
13218 AE730 2.24 (0.0882)
NOTE: 13218 AE750 2.26 (0.0890)
By using a magnet (A), the shim (B) can be taken 13218 AE770 2.28 (0.0898)
out without dropping it. 13218 AE790 2.30 (0.0906)
13218 AE810 2.32 (0.0913)
13218 AE830 2.34 (0.0921)
13218 AE850 2.36 (0.0929)
13218 AE870 2.38 (0.0937)
13218 AE890 2.40 (0.0945)
13218 AE910 2.42 (0.0953)
13218 AE920 2.43 (0.0957)
13218 AE930 2.44 (0.0961)
13218 AE940 2.45 (0.0965)
13218 AE950 2.46 (0.0969)
H2M3624A
13218 AE960 2.47 (0.0972)
13218 AE970 2.48 (0.0976)
3) Measure thickness of shim with micrometer. 13218 AE980 2.49 (0.0980)
13218 AE990 2.50 (0.0984)
13218 AF000 2.51 (0.0988)
13218 AF010 2.52 (0.0992)
13218 AF020 2.53 (0.0996)
13218 AF030 2.54 (0.1000)
13218 AF040 2.55 (0.1004)
13218 AF050 2.56 (0.1008)
13218 AF060 2.57 (0.1012)
13218 AF070 2.58 (0.1016)
B2M1240
13218 AF090 2.60 (0.1024)
13218 AF110 2.62 (0.1031)
ME(DOHC TURBO)-31
VALVE CLEARANCE
Mechanical
13218 AF130 2.64 (0.1039)

13218 AF150 2.66 (0.1047)
13218 AF170 2.68 (0.1055)
13218 AF190 2.70 (0.1063)
6) Inspect all valves for clearance again at this

stage. If the valve clearance is not correct, repeat
the procedure over again from the first step.
7) After inspection, install the related parts in the
reverse order of removal.
ME(DOHC TURBO)-32
ENGINE ASSEMBLY
Mechanical
9. Engine Assembly S183079

(3) Disconnect A/C pressure hoses from A/C
compressor.

2) Open front hood fully and support with stay.
3) Raise rear seat, and turn floor mat up.
(1) Disconnect fuel pump relay connector.
S2M1584

11) Disconnect the following connectors and
cable.
(1) Engine harness connector
S2M0093
(2) Start the engine, and run until stalls.

(3) After the engine stalls, crank it for five sec-
onds more.
(4) Turn ignition switch to “OFF”.
5) Remove filler cap.
S2M1929
(2) Engine ground terminal
G6M0095
7) Remove radiator from vehicle. <Ref. to CO-25,

REMOVAL, Radiator.>
8) Remove coolant filler tank. <Ref. to CO-37,
REMOVAL, Coolant Filler Tank.>
S2M0731
9) Collect refrigerant, and remove pressure hoses.
(1) Place and connect the attachment hose to (3) Engine harness connector
the refrigerant recycle system.
(2) Collect refrigerant from A/C system.
S2M1930
ME(DOHC TURBO)-33
ENGINE ASSEMBLY
Mechanical
(4) Generator connector, terminal and A/C (2) Heater inlet outlet hose
compressor connectors
EN0205
B2M1291I
(A) A/C compressor connector (1) Loosen lock bolt and slider bolt, and remove
(B) Generator connector and terminal front side V-belt. <Ref. to ME(DOHC TURBO)-
44, FRONT SIDE BELT, REMOVAL, V-belt.>
(5) Accelerator cable (2) Disconnect the power steering switch con-
nector.
S2M1931
EN0360
(6) Clutch release spring
(3) Remove pipe with bracket from intake mani-
fold.
S2M1932
12) Disconnect the following hoses S2M0903

(1) Brake booster vacuum hose
(4) Remove power steering pump from engine.
EN0204
H2M1954
ME(DOHC TURBO)-34
ENGINE ASSEMBLY
Mechanical
(5) Remove power steering tank from the 16) Remove nuts which install front cushion rub-
bracket by pulling it upward. ber onto front crossmember.
EN0361 S2M1927
(6) Place power steering pump on the right side 17) Separate clutch release fork from release
wheel apron. bearing. (MT vehicles)
(1) Remove clutch operating cylinder from
transmission.
(2) Remove plug using 10 mm hexagon
wrench.
EN0208

Pipe.> S2M1935
15) Remove nuts which hold lower side of trans-
mission to engine.
B3M2047
ME(DOHC TURBO)-35
ENGINE ASSEMBLY
Mechanical
(3) Screw 6 mm dia. bolt into release fork shaft, 19) Remove pitching stopper.
and remove it.
S2M0126

evaporation hose.
CAUTION:
쐌 Catch fuel from hose into container.
쐌 Disconnect hose with its end wrapped with
cloth to prevent fuel from splashing.
S2M1936A
(A) Shaft
(B) Bolt
(4) Raise release fork and unfasten release

bearing tabs to free release fork.
EN0214
CAUTION:
Step (4) is required to prevent interference with 21) Remove fuel filter and bracket.
engine when removing engine from transmis-
sion.
18) Select torque converter clutch from drive
plate. (AT vehicles)
(1) Lower the vehicle.
(2) Remove service hole plug.
(3) Remove bolts which hold torque converter
(4) Remove other bolts while rotating tha
engine using ST.
G2M0818
S2M0207
ME(DOHC TURBO)-36
ENGINE ASSEMBLY
Mechanical
22) Support engine with a lifting device and wire 24) Separation of engine and transmission.
ropes. (1) Remove starter. <Ref. to SC-5, REMOVAL,
Starter.>
(2) Install ST to torque converter clutch case.
(AT vehicles)
G2M0297
23) Support transmission with a garage jack.

CAUTION:
Before moving engine away from transmission, H2M1961A
check to be sure no work has been overlooked.
Doing this is very important in order to facili- (3) Remove bolt which holds right upper side of
tate re-installation and because transmission transmission to engine.
lowers under its own weight.
B3M2044
S2M1928 25) Remove engine from vehicle.

(1) Slightly raise engine.
(2) Raise transmission with garage jack.
(3) Move engine horizontally until mainshaft is
withdrawn from clutch cover.
(4) Slowly move engine away from engine
compartment.
CAUTION:
body panels with crank pulley, oil pressure
gauge, etc.
26) Remove front cushion rubbers.
1) Install clutch release fork and bearing onto

transmission. (MT vehicles)
ME(DOHC TURBO)-37
ENGINE ASSEMBLY
Mechanical
(1) Remove release bearing from clutch cover (4) Apply grease to specified points.
with flat type screw driver. 쐌 Spline FX2200
쐌 Shaft SUNLIGHT 2
S2M1843
(2) Install release bearing on transmission.

(3) Install release fork into release bearing tab.
S2M1938A
S2M1937A (A) Spline (FX2200)

(B) Shaft (SUNLIGHT 2)
(A) Release fork
(B) Release bearing (5) Insert release fork shaft into release fork.
CAUTION:
Make sure the cutout portion of release fork
shaft contacts spring pin.
S2M1845A
(A) Release fork

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

Tightening torque:
44 N·m (4.5 kgf-m, 32.5 ft-lb)
G2M0297
7) Install pitching stopper.

S2M1846
Tightening torque:
2) Install front cushion rubbers to engine. T1: 49 N·m (5.0 kgf-m, 36.2 ft-lb)
Tightening torque: T2: 57 N·m (5.8 kgf-m, 42 ft-lb)
34 N·m (3.5 kgf-m, 25.3 ft-lb)
3) Install engine onto transmission.
(1) Position engine in engine compartment and
align it with transmission.
CAUTION:
body panels with crank pulley, oil pressure
gauge, etc.
(2) Apply a small amount of grease to splines S2M0126E
of mainshaft. (MT vehicles)
4) Tighten bolt which hold right upper side of 8) Remove ST from torque converter clutch case.
transmission to engine. (AT vehicles)
Tightening torque: NOTE:
50 N·m (5.1 kgf-m, 36.9 ft-lb) Be careful not to drop the ST into the torque con-
verter clutch case when removing ST.
9) Install starter. <Ref. to SC-6, INSTALLATION,
Starter.>
10) Install torque converter clutch onto drive plate.
(AT vehicles)
(1) Tighten bolts which hold torque converter
B2M2791
5) Remove lifting device and wire ropes.
ME(DOHC TURBO)-39
ENGINE ASSEMBLY
Mechanical
(2) Tighten other bolts while rotating the engine (1) Install the power steering tank on bracket.
by using ST.
CAUTION:
Be careful not to drop bolts into torque con-
verter clutch housing.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
EN0361
(2) Install power steering pump on bracket, and

tighten bolts.
Tightening torque:
20.1 N·m (2.05 kgf-m, 14.8 ft-lb)
S2M0207
(3) Clog plug onto service hole.

11) Push clutch release lever to fit bearing into
clutch cover.
H2M1954
(3) Install power steering pipe bracket on right

side intake manifold, and install spark plug
codes.
H2M1818
12) Install fuel filter and bracket.
S2M0903
(4) Connect power steering switch connector.
G2M0818
EN0360
ME(DOHC TURBO)-40
ENGINE ASSEMBLY
Mechanical
(5) Install front side V-belt, and adjust it. <Ref. CAUTION:
to ME(SOHC)-42, FRONT SIDE BELT, After connecting each cable, adjust them.
INSTALLATION, V-belt.> 20) Install air intake system.
14) Tighten nuts which hold lower side of trans- (1) Install intercooler. <Ref. to IN(DOHC
mission to engine. TURBO)-10, INSTALLATION, Intercooler.>
Tightening torque: (2) Install air cleaner element and air cleaner
50 N·m (5.1 kgf-m, 36.9 ft-lb) upper cover.
(3) Install engine harness connector bracket.
(4) Install filler hose to air cleaner case.
B2M2790
15) Tighten nuts which install front cushion rubber H2M1962B

onto crossmember.
(A) Filler hose
Tightening torque: (B) Connector bracket
83 N·m (8.5 kgf-m, 61 ft-lb)
21) Install A/C pressure hoses. (With A/C)
CAUTION:
Make sure the front cushion rubber mounting CAUTION:
Use new O-rings.
bolts (A) and locator (B) are securely installed.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
B2M3880A
16) Install center exhaust pipe. S2M1584

Front Exhaust Pipe.> 22) Install radiator. <Ref. to CO-27,
17) Connect the following hoses. INSTALLATION, Radiator.>
(1) Fuel delivery hose, return hose and evapo- 23) Install coolant filler tank. <Ref. to CO-27,
INSTALLATION, Radiator.>
ration hose
24) Install window washer tank.
(2) Heater inlet and outlet hoses
25) Install battery in the vehicle, and connect
(3) Brake booster vacuum hose cables.
18) Connect the following connectors and termi- 26) Fill coolant.
nals. <Ref. to CO-27, INSTALLATION, Radiator.>
(1) Engine ground terminal 27) Charge A/C system with refrigerant.
(2) Engine harness connectors <Ref. to AC-20, OPERATION, Refrigerant Charg-
(3) Generator connector and terminal ing Procedure.>
(4) A/C compressor connectors (With A/C) 28) Remove front hood stay, and close front hood.
19) Connect the following cables. 29) Take off the vehicle from lift arms.
(2) Clutch release spring
ME(DOHC TURBO)-41
ENGINE MOUNTING
Mechanical
10. Engine Mounting S183085
1) Remove engine assembly. <Ref. to ME(DOHC

TURBO)-33, REMOVAL, Engine Assembly.>
2) Remove engine mounting from engine assem-
bly.

Tightening torque:
Engine mounting;
35 N·m (3.6 kgf-m, 25.8 ft-lb)
Make sure there are no cracks or other damage.
ME(DOHC TURBO)-42
PREPARATION FOR OVERHAUL
Mechanical
11. Preparation for Overhaul S183091
1) After removing the engine from the body,

secure it in the ST shown below.
RH
LH
ST3 499817000 ENGINE STAND
S2M1876A
2) In this section the procedures described under

each index are all connected and stated in order.
It will be the complete procedure for overhauling of
the engine itself when you go through all steps in
the process.
Therefore, in this section, to conduct the particular
procedure within the flow of a section, you need to
go back and conduct the procedure described pre-
viously in order to do that particular procedure.
ME(DOHC TURBO)-43
V-BELT
Mechanical
12. V-belt S183080

3) Remove the A/C belt.
4) Remove the A/C belt tensioner.
NOTE:
Perform the following procedures 1) to 4) with the
engine installed to the body.
S2M0113
CAUTION:
S2M2235 1) Install a belt, and tighten the slider bolt so as to
2) Loosen the lock bolt (A). obtain the specified belt tension <Ref. to
ME(DOHC TURBO)-45, INSPECTION, V-belt.>
2) Tighten the lock bolt (A)
4) Remove the front side belt (C). 3) Tighten slider bolt (B).
Tightening torque:
Lock bolt through bolt:
25 N·m (2.5 kgf-m, 18 ft-lb)
Slider bolt:
8 N·m (0.8 kgf-m, 5.5 ft-lb)
EN0225

EN0225
EN0226
ME(DOHC TURBO)-44
V-BELT
Mechanical
2. REAR SIDE BELT S183080A1102 C: INSPECTION S183080A10
1) Install a belt, and tighten the slider bolt (B) so 1) Replace belts, if cracks, fraying or wear is
as to obtain the specified belt tension. <Ref. to found.
ME(DOHC TURBO)-45, INSPECTION, V-belt.> 2) Check drive belt tension and adjust it if neces-
2) Tighten the lock nut (A). sary by changing generator installing position
Tightening torque: and/or idler pulley installing position.
Lock nut (A); Belt tension
22.6 N·m (2.3 kgf-m, 16.6 ft-lb) (A)
replaced: 7 — 9 mm (0.276 — 0.354 in)
reused: 9 — 11 mm (0.354 — 0.433 in)
(B)*
replaced: 7.5 — 8.5 mm (0.295 — 0.335
in)
reused: 9.0 — 10.0 mm (0.354 — 0.394 in)
*: With Air conditioner
EN0226
B2M4123A

GEN Generator
P/S Power steering oil pump pulley
I/P Idler pulley
ME(DOHC TURBO)-45
CRANKSHAFT PULLEY
Mechanical
13. Crankshaft Pulley S183098

CAUTION:
If the tightening angle of crankshaft pulley bolt
A: REMOVAL S183098A18 is less than 45 degrees, the bolt should be
damaged. In this case, the bolt must be
1) Remove V-belt. <Ref. to ME(DOHC TURBO)- replaced.
44, REMOVAL, V-belt.>
2) Remove crankshaft pulley bolt. To lock (1) Replace the crankshaft pulley bolts and
crankshaft, use ST. clean them.
ST 499977300 Crankshaft pulley bolt:
CRANKSHAFT PULLEY WRENCH 12369AA011
(2) Clean the crankshaft thread using an air
gun.
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:
Conduct the tightening procedures by confirm-
ing the turning angle of the crankshaft pulley
H2M2393C
bolt referring to the gauge indicated on the belt
3) Remove crankshaft pulley. cover.
4) Install A/C belt tensioner.
1) Install crankshaft pulley.

2) Install pulley bolt.
WRENCH
(1) Clean the crankshaft pulley thread using an
air gun.
(2) Apply engine oil to the crankshaft pulley bolt
seat and thread.
S2M0113
torque of 44 N·m (4.5 kgf-m, 33 ft-lb). 5) Install A/C belt.
(4) Tighten the crankshaft pulley bolts.
Tightening torque:
127 N·m (13.0 kgf-m, 94.0 ft-lb)
EN0226
H2M2393A
1) Make sure the V-belt is not worn or otherwise
3) Confirm that the tightening angle of the crank- damaged.
shaft pulley bolt is 45 degrees or more. If not, con- 2) Check the tension of the belt. <Ref. to
duct the following procedures (1) through (4). ME(DOHC TURBO)-45, INSPECTION, V-belt.>
ME(DOHC TURBO)-46
BELT COVER
Mechanical
14. Belt Cover S183582
1) Remove V-belt. <Ref. to ME(DOHC TURBO)-

2) Remove crankshaft pulley. <Ref. to ME(DOHC
TURBO)-46, REMOVAL, Crankshaft Pulley.>
3) Remove left-hand belt cover (A).
4) Remove right-hand belt cover (B).
5) Remove front belt cover (C).
S2M1221A
1) Install front belt cover (C).

Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb)
2) Install right-hand belt cover (B).
Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb)
3) Install left-hand belt cover (A).
Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb)
S2M1221A
4) Install crankshaft pulley. <Ref. to ME(DOHC

TURBO)-46, INSTALLATION, Crankshaft Pulley.>
5) Install V-belt. <Ref. to ME(DOHC TURBO)-44,
Make sure the cover is not damaged.
ME(DOHC TURBO)-47
Mechanical
15. Timing Belt Assembly S183099

3) Remove belt cover. <Ref. to ME(DOHC
EN0259
TURBO)-47, REMOVAL, Belt Cover.>
4) Remove timing belt guides. (MT vehicle only) 5) If alignment mark and/or arrow mark (which
indicates rotation direction) on timing belt fade
away, put new marks before removing timing belt
as follows:
(1) Turn crankshaft using ST, and align align-
ment marks on crankshaft sprocket, left-hand
intake camshaft sprocket, left-hand exhaust
camshaft sprocket, right-hand intake camshaft
sprocket and right hand exhaust camshaft
sprocket with notches of belt cover and cylinder
block.
S2M0294
S2M1878A
EN0257
(2) Using white paint, put alignment and/or

arrow marks on timing belts in relation to the
sprockets.
EN0258
EN0233
ME(DOHC TURBO)-48
Mechanical
2. BELT IDLER AND AUTOMATIC BELT

TENSION ADJUSTER ASSEMBLY S183099A1802
1) Remove belt idler (B) and (C).
S2M1225
Z1: 54.5 tooth length

Z2: 51 tooth length
Z3: 28 tooth length S2M1226A
2) Remove belt idler No. 2.
S2M1223A
6) Remove belt idler (A). S2M0411
3) Remove automatic belt tension adjuster assem-

bly.
S2M1226A
7) Remove timing belt.

CAUTION: S2M0412
After timing belt has been removed, never
rotate intake and exhaust, camshaft sprocket.
If camshaft sprocket is rotated, the intake and
exhaust valve heads strike together and valve 1. AUTOMATIC BELT TENSION
stems are bent. ADJUSTER ASSEMBLY AND BELT IDLER
S183099A1101

tension adjuster assembly:
CAUTION:
ME(DOHC TURBO)-49
Mechanical
쐌 Be sure to slowly move the adjuster rod 2) Install automatic belt tension adjuster assem-
down applying a pressure of 294 N (30 kgf, 66 bly.
lb). Tightening torque:
쐌 Press-in the push adjuster rod gradually tak- 39 N·m (4.0 kgf-m, 28.9 ft-lb)
N (1,000 kgf, 2,205 lb).
cylinder.
쐌 Do not release press pressure until stopper
pin is completely inserted.
(1) Attach the automatic belt tension adjuster
assembly to the vertical pressing tool. S2M0416
(2) Slowly move the adjuster rod down with a
pressure of 294 N (30 kgf, 66 lb) until the 3) Install belt idler No. 2.
adjuster rod is aligned with the stopper pin hole Tightening torque:
in the cylinder. 39 N·m (4.0 kgf-m, 28.9 ft-lb)
H2M2382 S2M0411
(3) With a 2 mm (0.08 in) dia. stopper pin or a 4) Install belt idler.
2 mm (0.08 in) (nominal) dia. hex bar wrench
Tightening torque:
inserted into the stopper pin hole in the cylinder,
39 N·m (4.0 kgf-m, 28.9 ft-lb)
secure the adjuster rod.
S2M0410
H2M2383

tension adjuster assembly. <Ref. to ME(DOHC
TURBO)-49, AUTOMATIC BELT TENSION
ADJUSTER ASSEMBLY AND BELT IDLER,
INSTALLATION, Timing Belt Assembly.>
2) Crankshaft and camshaft sprocket alignment.
ME(DOHC TURBO)-50
Mechanical
(1) Align mark (A) on crankshaft sprocket with (4) Align single line mark (A) on left-hand
mark on the oil pump cover at cylinder block. exhaust camshaft sprocket with notch (B) on
belt cover by turning sprocket counterclockwise
(as viewed from front of engine).
EN0243
(2) Align single line mark (A) on right-hand S2M1229B

exhaust camshaft sprocket with notch (B) on
belt cover. (5) Align single line mark (A) on left-hand intake
camshaft sprocket with notch (B) on belt cover
by turning sprocket clockwise (as viewed from
front of engine).
Ensure double lines (C) on intake and exhaust
camshaft sprockets are aligned.
S2M1227B
(3) Align single line mark (A) on right-hand

intake camshaft sprocket with notch (B) on belt
cover.
(Make sure double lines (C) on intake camshaft S2M1230B
and exhaust camshaft sprockets are aligned.)
(6) Ensure camshaft and crankshaft sprockets
are positioned properly.
S2M1228B
ME(DOHC TURBO)-51
Mechanical
CAUTION: timing belt is to be installed at as small an

쐌 Intake and exhaust camshafts for this DOHC angle as possible, in order to prevent mutual
engine can be independently rotated with tim- interference of intake and exhaust valve heads.
ing belts removed. As can be seen from the 쐌 Do not allow camshafts to rotate in the direc-
figure, if intake and exhaust valves are lifted tion shown in the figure as this causes both
simultaneously, their heads will interfere with intake and exhaust valves to lift
each other, resulting in bent valves. simultaneously, resulting in interference with
their heads.
B2M1392B
S2M1231A
(A) Intake camshaft
(B) Exhaust camshaft
3) Installation of timing belt
쐌 When timing belts are not installed, four
camshafts are held at the “zero-lift” position,
where all cams on camshafts do not push
intake and exhaust valves down. (Under this
condition, all valves remain unlifted.)
쐌 When camshafts are rotated to install timing
belts, #2 intake and #4 exhaust cam of left-hand
camshafts are held to push their correspond-
ing valves down. (Under this condition, these
valves are held lifted.) Right-side camshafts
are held so that their cams do not push valves S2M0418
down.
쐌 Left-hand camshafts must be rotated from
the “zero-lift” position to the position where
ME(DOHC TURBO)-52
Mechanical
Align alignment mark on timing belt with marks on sprockets in the alphabetical order shown in figure. While
aligning marks, position timing belt properly.
CAUTION:
쐌 Disengagement of more than three timing belt teeth may result in interference between the valve
and piston.
쐌 Ensure belt’s rotating direction is correct.
S2M1232A
4) Install belt idlers. Clearance:

Tightening torque: 1.0±0.5 mm (0.039±0.020 in)
39 N·m (4.0 kgf-m, 28.9 ft-lb)
CAUTION:
Make sure that the marks on timing belt and
sprockets are aligned.
S2M0297
H2M2398
5) After ensuring that the marks on timing belt and

sprockets are aligned, remove stopper pin from
tensioner adjuster.
6) Install timing belt guide. (MT vehicle only)
(1) Temporarily tighten remaining bolts.
(2) Check and adjust clearance between timing EN0254
belt and timing belt guide.
ME(DOHC TURBO)-53
Mechanical
EN0255 EN0258
EN0256 EN0259
(3) Tighten remaining bolts. 7) Install belt cover. <Ref. to ME(DOHC TURBO)-
Tightening torque: 47, INSTALLATION, Belt Cover.>
9.8 N·m (1.0 kgf-m, 7.2 ft-lb) 8) Install crankshaft pulley. <Ref. to ME(DOHC
1) Check timing belt teeth for breaks, cracks, and

wear. If any fault is found, replace belt.
2) Check the condition of back side of belt; if any
crack is found, replace belt.
S2M0294
CAUTION:
쐌 Be careful not to let oil, grease or coolant
contact the belt. Remove quickly and thor-
oughly if this happens.
쐌 Do not bend the belt sharply.
Bending radius: h
EN0257
G2M0115
ME(DOHC TURBO)-54
Mechanical
2. AUTOMATIC BELT TENSION 3. BELT TENSION PULLEY S183099A1003
ADJUSTER S183099A1002 1) Check mating surfaces of timing belt and con-

1) Visually check oil seals for leaks, and rod ends tact point of adjuster rod for abnormal wear or
for abnormal wear or scratches. If necessary, scratches. Replace belt tension pulley if faulty.
replace automatic belt tension adjuster assembly. 2) Check belt tension pulley for smooth rotation.
Replace if noise or excessive play is noted.
CAUTION: 3) Check belt tension pulley for grease leakage.
Slight traces of oil at rod’s oil seal does not
indicate a problem. 4. BELT IDLER S183099A1004
2) Check that the adjuster rod does not move 1) Check idler for smooth rotation. Replace if
when a pressure of 294 N (30 kgf, 66 lb) is applied noise or excessive play is noted.
to it. This is to check adjuster rod stiffness. 2) Check outer contacting surfaces of idler pulley
3) If the adjuster rod is not stiff and moves freely for abnormal wear and scratches.
when applying 294 N (30 kgf, 66 lb), check it using 3) Check idler for grease leakage.
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 lb) to it.
Check adjuster rod stiffness.
(3) If the adjuster rod is not stiff and moves
down, replace the automatic belt tension
adjuster assembly with a new one.
CAUTION:
N (1,000 kgf, 2,205 lb).
cylinder.
4) Measure the extension of rod beyond the body.
If it is not within specifications, replace with a new
one.
Rod extension: H
5.7±0.5 mm (0.224±0.020 in)
H2M2381A
ME(DOHC TURBO)-55
CAMSHAFT SPROCKET
Mechanical
16. Camshaft Sprocket S183097 B: INSTALLATION S183097A11
1) Install camshaft sprocket No. 1. and No. 2. To
lock camshaft, use ST.
1) Remove V-belt. <Ref. to ME(DOHC TURBO)- ST 499207100 CAMSHAFT SPROCKET
44, REMOVAL, V-belt.> WRENCH
TURBO)-46, REMOVAL, Crankshaft Pulley.> Tightening torque:
3) Remove belt cover. <Ref. to ME(DOHC 98 N·m (10 kgf-m, 72.4 ft-lb)
TURBO)-47, REMOVAL, Belt Cover.> CAUTION:
4) Remove timing belt assembly. <Ref. to Do not confuse left and right side camshaft
ME(DOHC TURBO)-48, REMOVAL, Timing Belt sprockets during installation. The camshaft
Assembly.> sprocket No. 2 is identified by a projection
5) Remove camshaft position sensor. <Ref. to used to monitor camshaft position sensor.
FU(DOHC TURBO)-31, REMOVAL, Camshaft
Position Sensor.>
6) Remove camshaft sprockets. To lock camshaft,
use ST.
WRENCH
S2M1879A
2) Install camshaft position sensor. <Ref. to

FU(DOHC TURBO)-31, INSTALLATION, Cam-
shaft Position Sensor.>
3) Install timing belt assembly. <Ref. to ME(DOHC
S2M1879A
TURBO)-49, INSTALLATION, Timing Belt Assem-
bly.>
4) Install belt cover. <Ref. to ME(DOHC TURBO)-
47, INSTALLATION, Belt Cover.>

scratches.
sprocket and key.
3) Check crankshaft sprocket notch for sensor for
ME(DOHC TURBO)-56
CRANKSHAFT SPROCKET
Mechanical
17. Crankshaft Sprocket S183101 B: INSTALLATION S183101A11
1) Install crankshaft sprocket.

ME(DOHC TURBO)-48, REMOVAL, Timing Belt
Assembly.>
EN0263
ME(DOHC TURBO)-56, REMOVAL, Camshaft
Sprocket.> 2) Install camshaft sprocket. <Ref. to ME(DOHC
6) Remove crankshaft sprocket. TURBO)-56, INSTALLATION, Camshaft
Sprocket.>
bly.>
EN0263

scratches.
sprocket and key.
3) Check crankshaft sprocket notch for sensor for
ME(DOHC TURBO)-57
CAMSHAFT
Mechanical
18. Camshaft S183092

10) Remove oil level gauge guide. (LH side only)
11) Remove spark plug cord.
A: REMOVAL S183092A18 12) Remove rocker cover and gasket.
13) Loosen intake camshaft cap bolts equally, a
1) Remove V-belt. <Ref. to ME(DOHC TURBO)- little at a time in alphabetical sequence shown in
44, INSTALLATION, V-belt.> figure.
Assembly.>
Sprocket.>
6) Remove crankshaft sprocket. <Ref. to S2M1233A
ME(DOHC TURBO)-57, REMOVAL, Crankshaft
Sprocket.> 14) Remove camshaft caps and intake camshaft.
7) Remove left-hand belt cover No. 2. 15) Loosen exhaust camshaft cap bolts equally, a
little at a time in alphabetical sequence shown in
figure.
S2M1162
8) Remove right-hand belt cover No.2. S2M1234A
16) Remove 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 right-hand camshafts and
related parts.
B2M0738
S2M1163
ME(DOHC TURBO)-58
CAMSHAFT
Mechanical
B: INSTALLATION S183092A11 Fluid packing:

1) Camshaft installation Apply engine oil to cylin-
der head at camshaft bear-ing location before
installing camshaft. Install cam-shaft so that each
valves is close to or in contact with “base circle” of
cam lobe.
CAUTION:
쐌 When camshafts are positioned as shown in
figure, camshafts need to be rotated at a mini-
mum to align with timing belt during installa-
tion.
쐌 Right-hand camshaft need not be rotated S2M1839A
when set at position shown in figure. Left-hand
intake camshaft: Rotate 80° clock-wise. (2) Apply engine oil to cap bearing surface and
Left-hand exhaust camshaft: Rotate 45° coun- install cap on camshaft as shown by identifica-
terclockwise. tion mark (A).
(3) Gradually tighten cap in at least two stages
in alphabetical sequence shown in figure, and
then tighten to specified torque.
Tightening torque:
20 N·m (2.0 kgf-m, 14.5 ft-lb)
S2M1233A
(4) Similarly, tighten cap on exhaust side. After

tightening cap, ensure camshaft rotates only
slightly while holding it at “base” circle.
Tightening torque:
B2M1200B 20 N·m (2.0 kgf-m, 14.5 ft-lb)
A Left side cylinder head
B Right side cylinder head
(a) Intake camshaft
(b) Exhaust camshaft
2) Camshaft cap installation

(1) Apply fluid packing sparingly to cap mating
surface.
CAUTION:
Do not apply fluid packing excessively. Failure
to do so may cause excess packing to come
out and flow toward oil seal, resulting in oil
leaks.
ME(DOHC TURBO)-59
CAMSHAFT
Mechanical
3) Camshaft oil seal installation Apply grease to 7) Install right-hand belt cover No. 2.
new oil seal lips and press onto front end of cam- Tightening torque:
shaft by using ST1 and ST2. 5 N·m (0.5 kgf-m, 3.6 ft-lb)
CAUTION:
Use a new oil seal.
ST2 499597200 OIL SEAL GUIDE
B2M0738
8) Install left-hand belt cover No. 2.

Tightening torque:
S2M1880A
5 N·m (0.5 kgf-m, 3.6 ft-lb)
4) Rocker cover installation

(1) Install gasket on rocker cover. Install periph-
eral gasket and ignition coil gasket.
(2) Apply fluid packing to four front open edges
of peripheral gasket.
Fluid packing:
S2M1162
9) Install tensioner bracket.

Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
S2M0300B
(3) Install rocker cover on cylinder head.

Ensure gasket is properly positioned during
installation.
5) Install spark plug cord.
6) Similarly, install parts on right-hand side.
S2M1163

ME(DOHC TURBO)-56, INSTALLATION, Cam-
shaft Sprocket.>
11) Install camshaft sprockets. <Ref. to
ME(DOHC TURBO)-56, INSTALLATION, Cam-
shaft Sprocket.>
ME(DOHC TURBO)-49, INSTALLATION, Timing
Belt Assembly.>
13) Install belt cover. <Ref. to ME(DOHC
TURBO)-47, INSTALLATION, Belt Cover.>
ME(DOHC TURBO)-60
CAMSHAFT
Mechanical
14) Install crankshaft pulley. <Ref. to ME(DOHC Tightening torque:

TURBO)-46, INSTALLATION, Crankshaft Pulley.> 20 N·m (2.0 kgf-m, 14.5 ft-lb)
1) Measure the bend, and repair or replace if nec-

essary.
Limit:
0.020 mm (0.0008 in)
S2M1233A
CAUTION:
Do not turn the camshaft.
(5) Remove the bearing caps.
(6) Measure the widest point of the plastigauge
on each journal. If the oil clearance exceeds the
limit, replace the camshaft. If necessary, replace
G2M0746
the camshaft caps and cylinder head as a set.
Standard:
2) Check journal for damage and wear. Replace if 0.037 — 0.072 mm (0.0015 — 0.0028 in)
faulty.
3) Measure outside diameter of camshaft journal. Limit:
If the journal diameter is not as specified, check the 0.10 mm (0.0039 in)
oil clearance.
Camshaft journal
Front Center, rear
37.946 — 37.963 29.946 — 29.963
Standard
(1.4939 — 1.4946 in) (1.1790 — 1.1796 in)
4) Measurement of the camshaft journal oil clear-

ance
(1) Clean the bearing caps and camshaft jour-
nals.
B2M1216
(2) Place the camshafts on the cylinder head.
(Without installing valve rocker.) (7) Completely remove the plastigauge.
(3) Place plastigauge across each of the cam- 5) Check cam face condition; remove minor faults
shaft journals. by grinding with oil stone. Measure the cam height
(4) Gradually tighten cap in at least two stages H; replace if the limit has been exceeded.
in alphabetical sequence shown in figure, and
then tighten to specified torque.
ME(DOHC TURBO)-61
CAMSHAFT
Mechanical
Cam height: H Standard:

Intake:
44.75 — 44.85 mm (1.7618 — 1.7657 in)
Exhaust:
44.60 — 44.70 mm (1.7559 — 1.7598 in)
Limit:
Intake:
44.65 mm (1.7579 in)
Exhaust:
44.50 mm (1.7520 in)
Cam base circle diameter A:
37.0 mm (1.457 in)
B2M1209A
6) Measure the thrust clearance of camshaft with

dial gauge. If the clearance exceeds the limit,
replace caps and cylinder head as a set. If neces-
sary replace camshaft.
Standard:
0.015 — 0.070 mm (0.0006 — 0.0028 in)
Limit:
0.1 mm (0.004 in)
B2M1217
ME(DOHC TURBO)-62
Mechanical
19. Cylinder Head Assembly S183093

CAUTION:
Do not scratch the mating surface of cylinder
A: REMOVAL S183093A18 head and cylinder block.
1) Remove V-belt. <Ref. to ME(DOHC TURBO)- 12) Similarly, remove right side cylinder head.
2) Remove crankshaft pulley. <Ref. to ME(DOHC B: INSTALLATION S183093A11
TURBO)-46, REMOVAL, Crankshaft Pulley.> 1) Install cylinder head and gaskets on cylinder
3) Remove belt cover. <Ref. to ME(DOHC block.
4) Remove timing belt assembly. <Ref. to CAUTION:
ME(DOHC TURBO)-48, REMOVAL, Timing Belt 쐌 Use new cylinder head gaskets.
Assembly.> 쐌 Be careful not to scratch the mating surface
5) Remove camshaft sprocket. <Ref. to of cylinder head and cylinder block.
ME(DOHC TURBO)-56, REMOVAL, Camshaft 2) Tighten cylinder head bolts.
Sprocket.> (1) Apply a coat of engine oil to washers and
6) Remove intake manifold. <Ref. to FU(DOHC bolt threads.
TURBO)-15, REMOVAL, Intake Manifold.> (2) Tighten all bolts to 29 N·m (3.0 kgf-m, 22
7) Remove bolt which installs A/C compressor ft-lb) in alphabetical sequence.
bracket on cylinder head. Then tighten all bolts to 69 N·m (7.0 kgf-m, 51
8) Remove camshaft. <Ref. to ME(DOHC ft-lb) in alphabetical sequence.
TURBO)-58, REMOVAL, Camshaft.> (3) Back off all bolts by 180° first; back them off
9) Remove cylinder head bolts in alphabetical by 180° again.
sequence shown in figure. (4) Tighten bolts (A) and (B) to 34 N·m (3.5
kgf-m, 25 ft-lb).
CAUTION:
Leave bolts (A) and (D) engaged by three or
four threads to prevent cylinder head from fall-
ing.
B2M1397D
(5) Tighten bolts (C), (D), (E) and (F) to 15 N·m

(1.5 kgf-m, 11 ft-lb).
B2M1397C
10) While tapping cylinder head with a plastic

hammer, separate it from cylinder block. Remove
bolts (A) and (D) to remove cylinder head.
B2M1397D
(6) Tighten all bolts by 80 to 90° in alphabetical

sequence.
CAUTION:
B2M1397C Do not tighten bolts more than 90°.
11) Remove cylinder head gasket. (7) Further tighten all bolts by 80 to 90° in
ME(DOHC TURBO)-63
Mechanical
CAUTION:
Ensure that the total “re-tightening angle” [in
the two previous steps] do not exceed 180°.
3) Install camshaft. <Ref. to ME(DOHC TURBO)-
59, INSTALLATION, Camshaft.>
4) Install A/C compressor bracket on cylinder
head.
5) Install intake manifold. <Ref. to ME(DOHC
TURBO)-59, INSTALLATION, Camshaft.>
6) Install camshaft sprocket. <Ref. to ME(DOHC
TURBO)-56, INSTALLATION, Camshaft
Sprocket.>
bly.>
1) Remove valve shims and valve lifters.

2) Compress the valve spring and remove the
valve spring retainer key. Remove each valve and
valve spring.
CAUTION:
쐌 Keep removed parts in order for re-installing
in their original positions.
쐌 Mark each valve to prevent confusion.
쐌 Use extreme care not to damage the lips of
the intake valve oil seals and exhaust valve oil
seals.
S2M1881A
ME(DOHC TURBO)-64
Mechanical
S2M1197A
(1) Exhaust valve (6) Valve spring (11) Exhaust valve oil seal
(2) Intake valve (7) Retainer (12) Intake valve guide
(3) Cylinder head (8) Retainer key (13) Exhaust valve guide
(4) Valve spring seat (9) Valve lifter
(5) Intake valve oil seal (10) Shim
1) Installation of valve spring and valve

(1) Coat stem of each valve with engine oil and
insert valve into valve guide.
CAUTION:
When inserting valve into valve guide, use spe-
cial care not to damage the oil seal lip.
(2) Set cylinder head on ST1.
(3) Install valve spring and retainer using ST2.
ME(DOHC TURBO)-65
Mechanical
CAUTION: CAUTION:
Be sure to install the valve springs with their Uneven torque for the cylinder head nuts can
close-coiled end facing the seat on the cylinder cause warping. When reassembling, pay spe-
head. cial attention to the torque so as to tighten
evenly.
S2M1881A
S2M1840A
(4) Compress valve spring and fit valve spring
retainer key.
(5) After installing, tap valve spring retainers 2. VALVE SEAT S183093A1002
lightly with wooden hammer for better seating. Inspect intake and exhaust valve seats, and cor-
2) Apply oil to the surface of the valve lifter and rect the contact surfaces with valve seat cutter if
valve shim. they are defective or when valve guides are
3) Install valve lifter and valve shim. replaced.
Valve seat width: W
Intake
1. CYLINDER HEAD S183093A1001 Standard 1.0 mm (0.039 in)
1) Make sure that no crack or other damage Limit 1.7 mm (0.067 in)
exists. In addition to visual inspection, inspect Exhaust
important areas by means of red check. Standard 1.5 mm (0.059 in)
2) Measure the warping of the cylinder head sur- Limit 2.2 mm (0.087 in)
face that mates with crankcase by using a straight
edge (A) and thickness gauge (B).
If the warping exceeds 0.05 mm (0.0020 in),
regrind the surface with a surface grinder.
Warping limit:
0.05 mm (0.0020 in)
Grinding limit:
0.3 mm (0.012 in)
Standard height of cylinder head: G2M0761
127.5 mm (5.02 in)
3. VALVE GUIDE S183093A1003
1) Check the clearance between valve guide and

stem. The clearance can be checked by measur-
ing the outside diameter of valve stem and the
inside diameter of valve guide with outside and
inside micrometers respectively.
ME(DOHC TURBO)-66
Mechanical
Clearance between the valve guide and valve (4) Before installing new valve guide, make
stem: sure that neither scratches nor damages exist
Standard on the inside surface of the valve guide holes in
Intake 0.035 — 0.062 mm (0.0014 — cylinder head.
0.0024 in) (5) Put new valve guide, coated with sufficient
Exhaust 0.040 — 0.067 mm (0.0016 — oil, in cylinder, and insert ST1 into valve guide.
0.0026 in) Press in until the valve guide upper end is flush
Limit with the upper surface of ST2.
0.15 mm (0.0059 in) ST1 499767200 VALVE GUIDE REMOVER
2) If the clearance between valve guide and stem ST2 498267700 VALVE GUIDE ADJUSTER
exceeds the limit, replace valve guide or valve
itself whichever shows greater amount of wear.
See following procedure for valve guide replace-
ment.
Valve guide inner diameter:
6.000 — 6.012 mm (0.2362 — 0.2367 in)
Valve stem outer diameters:
Intake
5.950 — 5.965 mm (0.2343 — 0.2348 in)
Exhaust S2M1883A
5.945 — 5.960 mm (0.2341 — 0.2346 in)

(6) Check the valve guide protrusion.
(1) Place cylinder head on ST1 with the com-
Valve guide protrusion: L
bustion chamber upward so that valve guides
12.0 — 12.4 mm (0.472 — 0.488 in)
enter the holes in ST1.
(2) Insert ST2 into valve guide and press it (7) Ream the inside of valve guide with ST.
down to remove valve guide. Gently rotate the reamer clockwise while press-
ST1 498267600 CYLINDER HEAD TABLE ing it lightly into valve guide, and return it also
ST2 499767200 VALVE GUIDE REMOVER rotating clockwise. After reaming, clean valve
guide to remove chips.
ST 499767400 VALVE GUIDE REAMER
CAUTION:
쐌 Apply engine oil to the reamer when ream-
ing.
쐌 If the inner surface of the valve guide is torn,
the edge of the reamer should be slightly
ground with an oil stone.
쐌 If the inner surface of the valve guide
becomes lustrous and the reamer does not
S2M1882A chips, use a new reamer or remedy the reamer.
(3) Turn cylinder head upside down and place (8) Recheck the contact condition between
ST as shown in the figure. valve and valve seat after replacing valve guide.
ST 498767700 VALVE GUIDE ADJUSTER
G2M0763
ME(DOHC TURBO)-67
Mechanical
4. INTAKE AND EXHAUST VALVE S183093A1004 5. VALVE SPRINGS S183093A1005
1) Inspect the flange and stem of valve, and 1) Check valve springs for damage, free length,
replace if damaged, worn, or deformed, or if “H” is and tension. Replace valve spring if it is not to the
less than the specified limit. specifications presented in the table.
2) To measure the squareness of the valve spring,
H: stand the spring on a surface plate and measure
Intake its deflection at the top using a try square.
Limit 0.8 mm (0.031 in) Valve spring
Exhaust Free length 44.67 mm (1.7587 in)
Standard 1.5 mm (0.059 in) 220.7±15.7 N
Limit 0.8 mm (0.031 in) (22.5±1.6 kgf, 49.6±3.5 lb)/36.0 mm
Tension/spring (1.417 in)
Valve overall length:
height 510.9±25.5 N
Intake (52.1±2.6 kgf, 114.9±5.7 lb)/26.6
104.4 mm (4.110 in) mm (1.047 in)
Exhaust Squareness 2.5°, 2.0 mm (0.079 in)
104.7 mm (4.122 in)
G2M0154
G2M0153
2) Put a small amount of grinding compound on

the seat surface and lap the valve and seat sur-
face. Install a new intake valve oil seal after lap-
ping.
ME(DOHC TURBO)-68
Mechanical
6. INTAKE AND EXHAUST VALVE OIL 7. VALVE LIFTER S183093A1007
SEAL S183093A1006 1) Check valve lifter visually.

Replace oil seal with new one, if lip is damaged or 2) Measure outer diameter of valve lifter.
spring out of place, or when the surfaces of intake Outer diameter:
valve and valve seat are reconditioned or intake 34.959 — 34.975 mm (1.3763 — 1.3770 in)
valve guide is replaced.
1) Place cylinder head on ST1.
2) Press in oil seal to the specified dimension indi-
cated in the figure by using ST2.
ST1 498267600 CYLINDER HEAD TABLE
ST2 498857100 VALVE GUIDE REMOVER
CAUTION:
쐌 Apply engine oil to oil seal before force-fit-
ting.
쐌 Differentiate between intake valve oil seal
and exhaust valve oil seal by noting their dif- B2M1222
ference in color.
3) Measure inner diameter of valve lifter mating
Color of rubber part:
part on cylinder head.
Intake [Black]
Exhaust [Brown] Inner diameter:
34.994 — 35.016 mm (1.3777 — 1.3786 in)
Color of spring part:
Intake [Silver]
Exhaust [Silver]
B2M1400
S2M1924A
CAUTION:
If difference between outer diameter of valve
lifter and inner diameter of valve lifter mating
part is over the limit, replace cylinder head.
Standard:
0.019 — 0.057 mm (0.0007 — 0.0022 in)
Limit:
0.100 mm (0.0039 in)
ME(DOHC TURBO)-69
CYLINDER BLOCK
Mechanical
20. Cylinder Block S183090

11) Remove flywheel (MT vehicle) or drive plate
(AT vehicle).
A: REMOVAL S183090A18 Using ST, lock crankshaft.
NOTE: ST 498497100 CRANKSHAFT STOPPER
Before conducting this procedure, drain engine oil 쐌 MT VEHICLES
completely if applicable.
5) Remove timing belt assembly. <Ref. to S2M1818B
Assembly.> 쐌 AT VEHICLES
Sprocket.>
7) Remove crankshaft sprocket. <Ref. to
ME(DOHC TURBO)-57, REMOVAL, Crankshaft
Sprocket.>
8) Remove generator and A/C compressor with
their brackets.
9) Remove cylinder head assembly. <Ref. to
ME(DOHC TURBO)-63, REMOVAL, Cylinder
Head Assembly.> S2M1870B
10) Remove clutch housing cover. (MT vehicles
only) 12) Remove oil separator cover.
13) Remove water by-pass pipe for heater.
14) Remove oil filter.
ME(DOHC TURBO)-70
CYLINDER BLOCK
Mechanical
15) Remove oil cooler. 17) Remove oil strainer stay.

18) Remove oil strainer.
19) Remove baffle plate.
20) Remove water pips.
22) Remove oil pump from cylinder block.
Use a flat-bladed screwdriver as shown in figure
when removing oil pump.
CAUTION:
Be careful not to scratch the mating surface of
cylinder block and oil pump.
S2M1819
S2M1835B
(A) Gasket
(B) Oil cooler
(C) Connector
16) Removal of oil pan

(1) Turn cylinder block with #2 and #4 piston
sides facing upward.
(2) Remove bolts which secure oil pan to cylin-
der block.
(3) Insert a oil pan cutter blade between cylin-
der block-to-oil pan clearance and remove oil
pan.
CAUTION:
place of oil pan cutter.
S2M1820
ME(DOHC TURBO)-71
CYLINDER BLOCK
Mechanical
EN0294
(1) Service hole plug (3) Circlip (5) Service hole cover
(2) Gasket (4) Piston pin (6) O-ring
23) Remove service hole cover and service hole 24) Rotate crankshaft to bring #1 and #2 pistons
plugs using hexagon wrench [14 mm (0.55 in)]. to bottom dead center position, then remove piston
circlip through service hole of #1 and #2 cylinders.
B2M2620
G2M0165
ME(DOHC TURBO)-72
CYLINDER BLOCK
Mechanical
25) Draw out piston pin from #1 and #2 pistons 26) Similarly remove piston pins from #3 and #4
using ST. pistons.
ST 499097700 PISTON PIN REMOVER 27) Remove bolts which connect cylinder block on
CAUTION: the side of #2 and #4 cylinders.
Be careful not to confuse original combination 28) Back off bolts which connect cylinder block on
of piston, piston pin and cylinder. the side of #1 and #3 cylinders two or three turns.
29) Set up cylinder block so that #1 and #3 cylin-
ders are on the upper side, then remove cylinder
block connecting bolts.
30) Separate left-hand and right-hand cylinder
blocks.
CAUTION:
When separating cylinder block, do not allow
the connecting rod to fall and damage the cyl-
inder block.
G2M0166
B2M2408A
(1) Cylinder block (3) Crankshaft (5) Piston

(2) Rear oil seal (4) Crankshaft bearing
31) Remove rear oil seal. CAUTION:

32) Remove crankshaft together with connecting Do not confuse combination of crankshaft
rod. bearings. Press bearing at the end opposite to
33) Remove crankshaft bearings from cylinder locking lip.
block using hammer handle. 34) Draw out each piston from cylinder block
using wooden bar or hammer handle.
ME(DOHC TURBO)-73
CYLINDER BLOCK
Mechanical
CAUTION:
Do not confuse combination of piston and cyl-
inder.
B2M2407A
(1) Crankshaft bearing (4) Rear oil seal Tightening torque: N·m (kgf-m, ft-lb)
(2) Crankshaft
T1: 25 (2.5, 18.1)
(3) Cylinder block
T2: 47 (4.8, 34.7)
CAUTION: CAUTION:
Remove oil in the mating surface of bearing Do not allow fluid packing to jut into O-ring
and cylinder block before installation. Also grooves, oil passages, bearing grooves, etc.
apply a coat of engine oil to crankshaft pins.
1) Position crankshaft on the #2 and #4 cylinder
block.
2) Apply fluid packing to the mating surface of #1
and #3 cylinder block, and position it on #2 and #4
cylinder block.
Fluid packing:
S2M1826A
ME(DOHC TURBO)-74
CYLINDER BLOCK
Mechanical
3) Temporarily tighten 10 mm cylinder block con- 6) Install rear oil seal using ST1 and ST2.
necting bolts in alphabetical sequence shown in ST1 499597100 OIL SEAL GUIDE
figure. ST2 499587200 OIL SEAL INSTALLER
B2M0088D G2M0186
4) Tighten 10 mm cylinder block connecting bolts 7) Position the top ring gap at (A) or (B) in the fig-
in alphabetical sequence. ure.
Tightening torque:
47 N·m (4.8 kgf-m, 34.7 ft-lb)
EN0304
8) Position the second ring gap at 180° on the

B2M0088D reverse side for the top ring gap.
5) Tighten 8 mm and 6 mm cylinder block connect- 9) Position the upper rail gap at (C) or (D) in the
ing bolts in alphabetical sequence shown in figure. figure.
Tightening torque:
(A) — (G): 25 N·m (2.5 kgf-m, 18.1 ft-lb)
(H): 6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
EN0305
10) Position the expander gap at 180° of the

reverse side for the upper rail gap.
B2M0089F
ME(DOHC TURBO)-75
CYLINDER BLOCK
Mechanical
11) Position the lower rail gap at (E) or (F) in the

figure.
CAUTION:
쐌 Ensure ring gaps do not face the same direc-
tion.
쐌 Ensure ring gaps are not within the piston
skirt area.
EN0305
12) Install circlip.

Install circlips in piston holes located opposite ser-
vice holes in cylinder block, when positioning all
pistons in the corresponding cylinders.
CAUTION:
Use new circlips.
B2M1403A
CAUTION:
Piston front mark faces towards the front of the
engine.
EN0307
(A) Front mark
ME(DOHC TURBO)-76
CYLINDER BLOCK
Mechanical
B2M1322J
(1) Piston (4) Gasket Tightening torque: N·m (kgf-m, ft-lb)

(2) Piston pin (5) Service hole plug
T: 69 (7.0, 50.6)
(3) Circlip
13) Installing piston (1) Insert ST3 into service hole to align piston
(1) Turn cylinder block so that #1 and #2 cylin- pin hole with connecting rod small end.
ders face upward. CAUTION:
(2) Using ST1, turn crankshaft so that #1 and Apply a coat of engine oil to ST3 before inser-
#2 connecting rods are set at bottom dead cen- tion.
ter.
ST1 499987500 CRANKSHAFT SOCKET ST3 499017100 PISTON PIN GUIDE
(3) Apply a coat of engine oil to pistons and
cylinders and insert pistons in their cylinders
using ST2.
ST2 498744300 PISTON GUIDE
G2M0189
(2) Apply a coat of engine oil to piston pin and

insert piston pin into piston and connecting rod
through service hole.
S2M0306A
14) Installing piston pin
ME(DOHC TURBO)-77
CYLINDER BLOCK
Mechanical
(3) Install circlip.

CAUTION:
Use new circlips.
G2M0190
(4) Apply fluid packing around the service hole

plug.
Fluid packing:
B2M2625
(5) Install service hole plug and gasket.

CAUTION:
Use a new gasket.
B2M2620
ME(DOHC TURBO)-78
CYLINDER BLOCK
Mechanical
B2M1323K
(1) Piston (5) Service hole plug Tightening torque: N·m (kgf-m, ft-lb)
(2) Piston pin (6) Service hole cover
T1: 6.4 (0.65, 4.7)
(3) Circlip (7) O-ring
T2: 69 (7.0, 50.6)
(4) Gasket
(6) Turn cylinder block so that #3 and #4 cylin- 19) Apply fluid packing to matching surfaces and
ders face upward. Using the same procedures install oil pan.
as used for #1 and #2 cylinders, install pistons Fluid packing:
and piston pins. THREE BOND 1215 or equivalent
15) Install water pipe.
16) Install baffle plate.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
17) Install oil strainer and O-ring
Tightening torque:
10 N·m (1.0 kgf-m, 7 ft-lb)
18) Install oil strainer stay.
S2M1833A
ME(DOHC TURBO)-79
CYLINDER BLOCK
Mechanical
20) Apply fluid packing to matching surfaces and ST 499587100 OIL SEAL INSTALLER
install oil separator cover.
Fluid packing:
S2M0235
(2) Apply fluid packing to matching surface of

oil pump.
S2M1834A
Fluid packing:
21) Install flywheel (MT vehicles) or drive plate (AT THREE BOND 1215 or equivalent
vehicles).
ST 498497100 CRANKSHAFT STOPPER
Tightening torque:
72 N·m (7.3 kgf-m, 52.8 ft-lb)
쐌 MT VEHICLES
B2M0390B
(A) O-ring
(3) Apply a coat of engine oil to the inside of the

oil seal.
S2M1818B
쐌 AT VEHICLES
S2M0118B
(4) Install oil pump on cylinder block. Be care-

ful not to damage oil seal during installation.
S2M1870B Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
22) Install clutch housing cover.
23) Installation of oil pump CAUTION:
(1) Discard front oil seal after removal. Replace 쐌 Do not forget to install O-ring and seal when
with a new one using ST. installing oil pump.
쐌 Align flat surface of oil pump’s inner rotor
with crankshaft before installation.
24) Install water pump and gasket.
ME(DOHC TURBO)-80
CYLINDER BLOCK
Mechanical
Tightening torque: 28) Install water by-pass pipe between oil cooler
First; 12 N·m (1.2 kgf-m, 8.7 ft-lb) and water pump.
Second; 12 N·m (1.2 kgf-m, 8.7 ft-lb)
CAUTION:
쐌 Be sure to use a new gasket.
in figure.
EN0321
29) Install water pipe.

CAUTION:
Always use a new O-ring.
30) Install cylinder head assembly. <Ref. to
H2M1846D
ME(DOHC TURBO)-63, INSTALLATION, Cylinder
Head Assembly.>
25) Install water by-pass pipe for heater. 31) Install oil level gauge guide and tighten attach-
26) Install oil cooler. ing bolt (left side only).
32) Install rocker cover.
Tightening torque: 33) Install crankshaft sprocket. <Ref. to
T1: 55 N·m (5.5 kgf-m, 40 ft-lb) ME(DOHC TURBO)-57, INSTALLATION, Crank-
T2: 69 N·m (7.0 kgf-m, 50.6 ft-lb) shaft Sprocket.>
34) Install camshaft sprocket. <Ref. to ME(DOHC
TURBO)-56, INSTALLATION, Camshaft
Sprocket.>
ME(DOHC TURBO)-49, INSTALLATION, Timing
Belt Assembly.>
36) Install belt cover. <Ref. to ME(DOHC
TURBO)-47, INSTALLATION, Belt Cover.>
38) Install generator and A/C compressor brackets
on cylinder head.
40) Install intake manifold. <Ref. to FU(DOHC
EN0320
(A) O-ring
(B) Oil cooler
(C) Connector
27) Install oil filter using ST.

ME(DOHC TURBO)-81
CYLINDER BLOCK
Mechanical
B2M1320I
(1) Connecting rod cap (3) Top ring (5) Oil ring
(2) Connecting rod bearing (4) Second ring (6) Circlip
1) Remove connecting rod cap.

2) Remove connecting rod bearing.
CAUTION:
Arrange removed connecting rod, connecting
rod cap and bearing in order to prevent confu-
sion.
3) Remove piston rings using the piston ring
expander.
4) Remove the oil ring by hand.
CAUTION:
Arrange the removed piston rings in good
order to prevent confusion.
5) Remove circlip.
ME(DOHC TURBO)-82
CYLINDER BLOCK
Mechanical
B2M1320J
(1) Connecting rod bearing (5) Second ring Tightening torque: N·m (kgf-m, ft-lb)
(2) Connecting rod (6) Top ring
T: 44.6 (4.55, 32.9)
(3) Connecting rod cap (7) Circlip
(4) Oil ring
1) Install connecting rod bearings on connecting E: INSPECTION S183090A10

rods and connecting rod caps.
CAUTION:
Apply oil to the surfaces of the connecting rod 1) Visually check for cracks and damage.
bearings. Especially, inspect important parts by means of red
lead check.
2) Install connecting rod on crankshaft.
2) Check the oil passages for clogging.
CAUTION: 3) Inspect crankcase surface that mates with cyl-
Position each connecting rod with the side inder head for warping by using a straight edge,
marked facing forward. and correct by grinding if necessary.
3) Install connecting rod cap with connecting rod Warping limit:
nut. 0.05 mm (0.0020 in)
Ensure the arrow on connecting rod cap faces the
front during installation. Grinding limit:
0.1 mm (0.004 in)
CAUTION:
쐌 Each connecting rod has its own mating cap. Standard height of cylinder block:
Make sure that they are assembled correctly by 201.0 mm (7.91 in)
checking their matching number.
쐌 When tightening the connecting rod nuts,
apply oil on the threads.
4) Install oil ring spacer, upper rail and lower rail in
this order by hand. Then install second ring and top
ring with a piston ring expander.
ME(DOHC TURBO)-83
CYLINDER BLOCK
Mechanical
2. CYLINDER AND PISTON S183090A1002 2) How to measure the inner diameter of each
cylinder
1) The cylinder bore size is stamped on the cylin-
Measure the inner diameter of each cylinder in
der block’s front upper surface.
both the thrust and piston pin directions at the
CAUTION: heights shown in the figure, using a cylinder bore
Measurement should be performed at a tem- gauge.
perature 20°C (68°F).
CAUTION:
NOTE: Measurement should be performed at a tem-
Standard sized pistons are classified into two perature 20°C (68°F).
grades, “A” and “B”. These grades should be used
Taper:
as a guide line in selecting a standard piston.
Standard
Standard diameter: 0.015 mm (0.0006 in)
A: 92.005 — 92.015 mm (3.6222 — 3.6226 Limit
in) 0.050 mm (0.0020 in)
B: 91.995 — 92.005 mm (3.6218 — 3.6222
Out-of-roundness:
in)
Standard
0.010 mm (0.0004 in)
Limit
0.050 mm (0.0020 in)
H2M1732C
(A) Main jourual size mark

(B) Cylinder block RH-LH combination mark
(C) #1 cylinder bore size mark S2M1821A
(D) #2 cylinder bore size mark
(E) #3 cylinder bore size mark (A) Piston pin direction
(F) #4 cylinder bore size mark (B) Thrust direction
3) When piston is to be replaced due to general or

cylinder wear, determine a suitable sized piston by
measuring the piston clearance.
4) How to measure the outer diameter of each
piston
Measure the outer diameter of each piston at the
height shown in the figure. (Thrust direction)
CAUTION:
ME(DOHC TURBO)-84
CYLINDER BLOCK
Mechanical
Piston grade point H: CAUTION:

37.0 mm (1.457 in) Immediately after reboring, the cylinder diam-
Piston outer diameter: eter may differ from its real diameter due to
Standard temperature rise. Thus, pay attention to this
A: 91.985 — 91.995 mm when measuring the cylinder diameter.
(3.6214 — 3.6218 in) Limit of cylinder enlarging (boring):
B: 91.975 — 91.985 mm 0.5 mm (0.020 in)
(3.6211 — 3.6214 in)
3. PISTON AND PISTON PIN S183090A1003
0.25 mm (0.0098 in) oversize
92.225 — 92.235 mm 1) Check pistons and piston pins for damage,
(3.6309 — 3.6313 in) cracks, and wear and the piston ring grooves for
0.50 mm (0.0197 in) oversize wear and damage. Replace if defective.
92.475 — 92.485 mm 2) Measure the piston-to-cylinder clearance at
(3.6407 — 3.6411 in) each cylinder. <Ref. to ME(DOHC TURBO)-84,
CYLINDER AND PISTON, INSPECTION, Cylinder
Block.> If any of the clearances is not to
specification, replace the piston or bore the cylin-
der to use an oversize piston.
3) Make sure that piston pin can be inserted into
the piston pin hole with a thumb at 20°C (68°F).
Replace if defective.
Standard clearance between piston pin and
hole in piston:
Standard
B2M1305A 0.004 — 0.008 mm (0.0002 — 0.0003 in)
5) Calculate the clearance between cylinder and Limit
piston. 0.020 mm (0.0008 in)
CAUTION:
Cylinder to piston clearance at 20°C (68°F):
Standard
0.010 — 0.030 mm (0.0004 — 0.0012 in)
Limit
0.050 mm (0.0020 in)
6) Boring and honing B2M1401
(1) If the value of taper, out-of-roundness, or
cylinder-to-piston clearance measured exceeds
the specified limit or if there is any damage on
the cylinder wall, rebore it to use an oversize
piston.
CAUTION:
When any of the cylinders needs reboring, all
other cylinders must be bored at the same
time, and use oversize pistons. Do not perform
boring on one cylinder only, nor use an over-
size piston for one cylinder only.
B2M0084A
(2) If the cylinder inner diameter exceeds the
limit after boring and honing, replace the crank-
case.
ME(DOHC TURBO)-85
CYLINDER BLOCK
Mechanical
4) Check circlip installation groove on the piston 쐌 The oil ring is a combined ring consisting of
for burr (A). If necessary, remove burr from the two rails and a spacer in between. When
groove so that piston pin can lightly move. installing, be careful to assemble correctly.
B2M0420B EN0331
5) Check piston pin circlip for distortion, cracks (A) Top ring
and wear. (B) Second ring
(C) Oil ring
4. PISTON RING S183090A1004 (a) Upper rail
1) If piston ring is broken, damaged, or worn, or if (b) Spacer
(c) Lower rail
its tension is insufficient, or when the piston is
replaced, replace piston ring with a new one of the 2) Squarely place piston ring and oil ring in
same size as the piston. cylinder, and measure the piston ring gap with a
CAUTION: thickness gauge.
쐌 “N” is marked on the end of the top and sec-
Unit: mm (in)
ond rings. When installing the rings to the
Standard Limit
piston, face this mark upward.
0.20 — 0.35
Top ring 1.0 (0.039)
(0.0079 — 0.0138)
Piston Second 0.35 — 0.50
1.0 (0.039)
ring gap ring (0.0138 — 0.0197)
Oil ring 0.20 — 0.70
1.5 (0.059)
rail (0.0079 — 0.0276)
EN0330
G2M0174
ME(DOHC TURBO)-86
CYLINDER BLOCK
Mechanical
3) Measure the clearance between piston ring and 5. CONNECTING ROD S183090A1005
piston ring groove with a thickness gauge.

1) Replace connecting rod, if the large or small
CAUTION: end thrust surface is damaged.
Before measuring the clearance, clean the pis- 2) Check for bend or twist using a connecting rod
ton ring groove and piston ring. aligner. Replace connecting rod if the bend or twist
exceeds the limit.
Unit: mm (in)
Standard Limit Limit of bend or twist per 100 mm (3.94 in) in
0.040 — 0.080 length:
Clearance Top ring (0.0016 — 0.15 (0.0059) 0.10 mm (0.0039 in)
between pis- 0.0031)
ton ring and
piston ring 0.030 — 0.070
Second
groove (0.0012 — 0.15 (0.0059)
ring
0.0028)
B2M1402A
B2M1184B
(A) Thickness gauge

(B) Connecting rod
3) Install connecting rod fitted with bearing to

crankshaft and measure the side clearance (thrust
clearance). Replace connecting rod if the side
clearance exceeds the specified limit.
Connecting rod side clearance:
Standard
0.070 — 0.330 mm (0.0028 — 0.0130 in)
Limit
0.4 mm (0.016 in)
EN0335
ME(DOHC TURBO)-87
CYLINDER BLOCK
Mechanical
4) Inspect connecting rod bearing for scar, 6) Inspect bushing at connecting rod small end,
peeling, seizure, melting, wear, etc. and replace if worn or damaged. Also measure the
5) Measure the oil clearance on individual con- piston pin clearance at the connecting rod small
necting rod bearings by means of plastigauge. If end.
any oil clearance is not within specification, replace Clearance between piston pin and bushing:
the defective bearing with a new one of standard Standard
size or undersize as necessary. (See the table 0 — 0.022 mm (0 — 0.0009 in)
below.) Limit
Connecting rod oil clearance: 0.030 mm (0.0012 in)
Standard
0.020 — 0.046 mm (0.0008 — 0.0018 in)
Limit
0.05 mm (0.0020 in)
Unit: mm (in)
Bearing size
Outer diameter of
Bearing (Thickness at cen-
crank pin
ter)
1.492 — 1.501 51.984 — 52.000
Standard
(0.0587 — 0.0591) (2.0466 — 2.0472)
B2M0085
0.03 (0.0012) 1.510 — 1.513 51.954 — 51.970
undersize (0.0594 — 0.0596) (2.0454 — 2.0461)
0.05 (0.0020) 1.520 — 1.523 51.934 — 51.950
undersize (0.0598 — 0.0600) (2.0446 — 2.0453)
0.25 (0.0098) 1.620 — 1.623 51.734 — 51.750
undersize (0.0638 — 0.0639) (2.0368 — 2.0374)
B2M0084
7) Replacement procedure is as follows.

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

Ream the inside of bushing.
(4) After completion of reaming, clean bushing
to remove chips.
ME(DOHC TURBO)-88
CYLINDER BLOCK
Mechanical
6. CRANKSHAFT AND CRANKSHAFT 3) Inspect the crank journal and crank pin for
BEARING S183090A1006 wear. If they are not within the specifications,
replace bearing with a suitable (undersize) one,
1) Clean crankshaft completely and check for
cracks by means of red lead check etc., and and replace or recondition crankshaft as neces-
replace if defective. sary. When grinding crank journal or crank pin, fin-
2) Measure the crankshaft bend, and correct or ish them to the specified dimensions according to
replace if it exceeds the limit. the undersize bearing to be used.
CAUTION: Crank pin and crank journal:
If a suitable V-block is not available, install #1 Out-of-roundness
and #5 crankshaft bearing on cylinder block, 0.020 mm (0.0008 in) or less
position crankshaft on these bearings and Taper limit
measure crankshaft bend using a dial gauge. 0.07 mm (0.0028 in)
Grinding limit
Crankshaft bend limit:
0.035 mm (0.0014 in) 0.250 mm (0.0098 in)
G2M0179
EN0339
Unit: mm (in)
Crank journal diameter
Crank pin diameter
#1, #3, #5 #2, #4
59.992 — 60.008 59.992 — 60.008 51.984 — 52.000
Journal O.D.
(2.3619 — 2.3625) (2.3619 — 2.3625) (2.0466 — 2.0472)
Standard Bearing size
1.998 — 2.011 2.000 — 2.013 1.492 — 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 51.954 — 51.970
Journal O.D.
(2.3607 — 2.3613) (2.3607 — 2.3613) (2.0454 — 2.0461)
0.03 (0.0012)
Bearing size
undersize 2.017 — 2.020 2.019 — 2.022 1.510 — 1.513
(Thickness at cen-
(0.0794 — 0.0795) (0.0795 — 0.0796) (0.0594 — 0.0596)
ter)
59.942 — 59.958 59.942 — 59.958 51.934 — 51.950
Journal O.D.
(2.3599 — 2.3605) (2.3599 — 2.3605) (2.0446 — 2.0453)
0.05 (0.0020)
undersize Bearing size
2.027 — 2.030 2.029 — 2.032 1.520 — 1.523
(Thickness at cen-
(0.0798 — 0.0799) (0.0799 — 0.0800) (0.0598 — 0.0600)
ter)
59.742 — 59.758 59.742 — 59.758 51.734 — 51.750
Journal O.D.
(2.3520 — 2.3527) (2.3520 — 2.3527) (20368 — 2.0374)
0.25 (0.0098)
Bearing size
undersize 2.127 — 2.130 2.129 — 2.132 1.620 — 1.623
(Thickness at cen-
(0.0837 — 0.0839) (0.0838 — 0.0839) (0.0638 — 0.0639)
ter)
O.D. ... Outer Diameter
ME(DOHC TURBO)-89
CYLINDER BLOCK
Mechanical
4) Measure the thrust clearance of crankshaft at 5) Inspect individual crankshaft bearings for signs
center bearing. If the clearance exceeds the limit, of flaking, seizure, melting, and wear.
replace bearing. 6) Measure the oil clearance on each crankshaft
Crankshaft thrust clearance: bearing by means of plastigauge. If the measure-
Standard ment is not within the specification, replace defec-
0.030 — 0.115 mm (0.0012 — 0.0045 in) tive bearing with an undersize one, and replace or
Limit recondition crankshaft as necessary.
0.25 mm (0.0098 in)
Unit: mm (in)
Crankshaft oil clearance
0.010 — 0.030 (0.0004 —
Standard
0.0012)
Limit 0.040 (0.0016)
EN0341
ME(DOHC TURBO)-90
Mechanical
21. Engine Trouble in General S183095
NOTE:
“RANK” shown in the chart refer to the possibility of reason for the trouble in order (“Very often” to “Rarely”)
A — Very often
B — Sometimes
C — Rarely
1. Engine will not start.
1) Starter does not turn. 쐌 Starter 쐌 Defective battery-to-starter harness B
쐌 Defective starter switch C
쐌 Defective inhibitor switch or neutral switch C
쐌 Defective starter B
쐌 Battery 쐌 Poor terminal connection A
쐌 Run-down battery A
쐌 Defective charging system B
쐌 Friction 쐌 Seizure of crankshaft and connecting rod bearing C
쐌 Seized camshaft C
쐌 Seized or stuck piston and cylinder C
2) Initial combustion does 쐌 Starter 쐌 Defective starter C
not occur. 쐌 Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Proce- A
dure.>
쐌 Fuel line 쐌 Defective fuel pump and relay A
ME(DOHC TURBO)-91
Mechanical

3) Initial combustion occur. 쐌 Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Proce- A
dure.>
쐌 Intake system 쐌 Defective intake manifold gasket B
4) Engine stalls after initial 쐌 Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Proce- A
combustion. dure.>
쐌 Intake system 쐌 Loosened or cracked intake duct B
쐌 Loosened or cracked vacuum hose C
쐌 Fuel line 쐌 Clogged fuel line C
ME(DOHC TURBO)-92
Mechanical

2. Rough idle and engine 쐌 Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Proce- A
stall dure.>
쐌 Defective PCV valve C
쐌 Loosened oil filler cap B
쐌 Belt 쐌 Defective timing C
쐌 Defective rocker cover gasket C
쐌 Stuck or damaged throttle valve B
쐌 Accelerator cable out of adjustment C
ME(DOHC TURBO)-93
Mechanical

3. Low output, hesitation and 쐌 Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Proce- A
poor acceleration dure.>
쐌 Dirty air cleaner element A
쐌 Over cooling C
4. Surging 쐌 Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Proce- A
dure.>
쐌 Dirty air cleaner element B
ME(DOHC TURBO)-94
Mechanical

5. Engine does not return to 쐌 Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Proce- A
idle. dure.>
쐌 Intake system 쐌 Loosened or cracked vacuum hose A
쐌 Others 쐌 Stuck or damaged throttle valve A
쐌 Accelerator cable out of adjustment B
6. Dieseling (Run-on) 쐌 Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Proce- A
dure.>
쐌 Others 쐌 Malfunction of evaporative emission control system B
7. After burning in exhaust 쐌 Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Proce- A
system dure.>
쐌 Intake system 쐌 Loosened or cracked intake duct C
8. Knocking 쐌 Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Proce- A
dure.>
쐌 Intake system 쐌 Loosened oil filler cap B
쐌 Cooling system 쐌 Overheating A
9. Excessive engine oil con- 쐌 Intake system 쐌 Loosened or cracked PCV hose A
sumption 쐌 Defective PCV valve B
쐌 Compression 쐌 Defective valve stem A
쐌 Worn or stuck piston rings, cylinder and piston A
쐌 Lubrication system 쐌 Loosened oil pump attaching bolts and defective B
gasket
쐌 Defective oil filter seal B
쐌 Defective crankshaft oil seal B
쐌 Defective rocker cover gasket B
쐌 Loosened oil drain plug or defective gasket B
쐌 Loosened oil pan fitting bolts or defective oil pan B
ME(DOHC TURBO)-95
Mechanical

10. Excessive fuel consump- 쐌 Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Proce- A
tion dure.>
쐌 Intake system 쐌 Dirty air cleaner element A
쐌 Others 쐌 Accelerator cable out of adjustment B
ME(DOHC TURBO)-96
ENGINE NOISE
Mechanical
22. Engine Noise S183096
Type of sound Condition Possible cause

쐌 Valve mechanism is defective.
쐌 Incorrect valve clearance
Sound increases as engine
Regular clicking sound 쐌 Worn valve rocker
speed increases.
쐌 Worn camshaft
쐌 Broken valve spring
쐌 Worn crankshaft main bearing
Oil pressure is low.
쐌 Worn connecting rod bearing (big end)
Heavy and dull clank
쐌 Loose flywheel mounting bolts
Oil pressure is normal.
쐌 Damaged engine mounting
쐌 Ignition timing advanced
High-pitched clank (Spark Sound is noticeable when 쐌 Accumulation of carbon inside combustion chamber
knock) accelerating with an overload. 쐌 Wrong spark plug
쐌 Improper gasoline
Sound is reduced when fuel
Clank when engine speed is injector connector of noisy cyl- 쐌 Worn crankshaft main bearing
medium (1,000 to 2,000 rpm). inder is disconnected. 쐌 Worn bearing at crankshaft end of connecting rod
(NOTE*)
Sound is reduced when fuel
쐌 Worn cylinder liner and piston ring
injector connector of noisy cyl-
쐌 Broken or stuck piston ring
Knocking sound when engine inder is disconnected. 쐌 Worn piston pin and hole at piston end of connecting rod
is operating under idling speed (NOTE*)
and engine is warm Sound is not reduced if each 쐌 Unusually worn valve lifter
fuel injector connector is dis- 쐌 Worn cam gear
connected in turn. (NOTE*) 쐌 Worn camshaft journal bore in crankcase
Squeaky sound — 쐌 Insufficient generator lubrication
Rubbing sound — 쐌 Defective generator brush and rotor contact
Gear scream when starting 쐌 Defective ignition starter switch
—
engine 쐌 Worn gear and starter pinion
Sound like polishing glass with 쐌 Loose drive belt
—
a dry cloth 쐌 Defective water pump shaft
쐌 Loss of compression
Hissing sound — 쐌 Air leakage in air intake system, hoses, connections or
manifolds
쐌 Loose timing belt
Timing belt noise —
쐌 Belt contacting case/adjacent part
Valve tappet noise — 쐌 Incorrect valve clearance
NOTE*:
When disconnecting fuel injector connector, Malfunction Indicator Light (CHECK ENGINE light) illuminates and trouble code is
stored in ECM memory.
Therefore, carry out the CLEAR MEMORY MODE <Ref. to EN(DOHC TURBO)-47, OPERATION, Clear Memory Mode.> and
INSPECTION MODE <Ref. to EN(DOHC TURBO)-44, OPERATION, Inspection Mode.> after connecting fuel injector connector.
ME(DOHC TURBO)-97
ENGINE NOISE
Mechanical
MEMO:
ME(DOHC TURBO)-98
ENGINE2 SECTION

SUBARU vehicles.
ine parts.

G8050GE3
EXHAUST
EX(DOHC TURBO)
Page
4. Joint Pipe...................................................................................................13
5. Rear Exhaust Pipe ....................................................................................14
6. Muffler........................................................................................................15
GENERAL DESCRIPTION
Exhaust
1. FRONT EXHAUST PIPE S182001A0501
S2M2237A
EX(DOHC TURBO)-2
GENERAL DESCRIPTION
Exhaust
(1) Gasket (11) Front exhaust pipe lower insula- (21) Turbocharger joint pipe
(2) Upper exhaust manifold cover tor (RH) (22) Gasket
(RH) (12) Front exhaust pipe lower insula- (23) Front oxygen (A/F) sensor
(3) Exhaust manifold (RH) tor (LH) (24) Precatalytic converter
(4) Lower exhaust manifold cover (13) Front exhaust pipe lower cover (25) Exhaust temperature sensor
(RH) (14) Front exhaust pipe lower clamp
(5) Front exhaust pipe upper clamp (15) Gasket Tightening torque: N·m (kgf-m, ft-lb)
(6) Front exhaust pipe upper cover (16) Gasket T1: 18.6 (1.9, 13.7)
(7) Front exhaust pipe upper insula- (17) Upper exhaust manifold cover T2: 25 (2.5, 18.1)
tor (RH) (LH) T3: 35 (3.6, 26.0)
(8) Front exhaust pipe upper insula- (18) Exhaust manifold (LH) T4: 39 (4, 28.9)
tor (LH) (19) Lower exhaust manifold cover
(9) Gasket (LH)
(10) Front exhaust pipe (20) Gasket
EX(DOHC TURBO)-3
GENERAL DESCRIPTION
Exhaust
2. CENTER AND REAR EXHAUST PIPE, AND MUFFLER S182001A0502
쐌 AUSTRALIA SPEC. VEHICLES
S2M2239A
(1) Gasket (10) Lower cover (19) Muffler cutter

(2) Rear oxygen converter (11) Upper cover A
(3) Upper center pipe cover (12) Lower cover A Tightening torque: N·m (kgf-m, ft-lb)
(4) Center exhaust pipe (13) Spring T1: 18 (1.8, 13.0)
(5) Lower center pipe cover (14) Bolt T2: 30 (3.1, 22.4)
(6) Bracket (MT) (15) Cushion T3: 35 (3.6, 26.0)
(7) Gasket (16) Gasket T4: 48 (4.9, 35.4)
(8) Rear exhaust pipe (17) Cushion
(9) Upper cover (18) Muffler
EX(DOHC TURBO)-4
GENERAL DESCRIPTION
Exhaust
쐌 EXCEPT AUSTRALIA SPEC. VEHICLES
S2M2176B
(1) Gasket (14) Rear catalytic converter (25) Upper rear exhaust pipe cover
(2) Front catalytic converter (15) Upper clamp (Rear)
(3) Upper center pipe cover (Front) (16) Gasket (26) Gasket
(4) Center exhaust pipe (Front) (17) Rear exhaust pipe (27) Muffler
(5) Lower center pipe cover (Front) (18) Lower rear exhaust pipe cover (28) Cushion
(6) Bracket (Front) (29) Muffler cutter
(7) Gasket (19) Chamber (30) Center exhaust pipe (Rear)
(8) Upper center pipe cover (Rear) (20) Lower rear exhaust pipe cover
(9) Lower center pipe cover (Rear) (Rear) Tightening torque: N·m (kgf-m, ft-lb)
(10) Upper rear catalytic converter (21) Cushion T1: 18 (1.8, 13.0)
cover (22) Spring T2: 30 (3.1, 22.4)
(11) Lower clamp (23) Bolt T3: 35 (3.6, 26.0)
(12) Lower rear catalytic converter (24) Upper rear exhaust pipe cover T4: 48 (4.9, 35.4)
cover (Front)
(13) Rear oxygen sensor
EX(DOHC TURBO)-5
GENERAL DESCRIPTION
Exhaust

tion.
ment.
fied points.
EX(DOHC TURBO)-6
FRONT EXHAUST PIPE
Exhaust

10) Separate front exhaust pipe from exhaust
mani-folds.
G2M0854
G6M0095 B: INSTALLATION S182065A11
2) Remove front oxygen (A/F) sensor. <Ref. to CAUTION:

FU(DOHC TURBO)-42, REMOVAL, Front Oxygen Replace gaskets with new ones.
(A/F) Sensor.> 1) Assemble front exhaust pipe and exhaust mani-
3) Remove under cover. folds.
4) Remove lower exhaust manifold cover (RH).
5) Remove lower and upper exhaust manifold Tightening torque:
covers (LH). 39 N·m (4 kgf-m, 28.9 ft-lb)
G2M0852 G2M0854
6) Remove bolts and nuts which hold front 2) Install front exhaust pipe covers.
exhaust pipe assembly to turbocharger joint pipe. Tightening torque:
7) While holding front exhaust pipe assembly with 25 N·m (2.5 kgf-m, 18.1 ft-lb)
one hand, remove nuts which hold front exhaust
pipe assembly to cylinder head exhaust port. 3) Install upper exhaust manifold cover (RH).
Tightening torque:
18.6 N·m (1.9 kgf-m, 13.7 ft-lb)
4) Install front exhaust pipe assembly.
Tightening torque:
35 N·m (3.6 kgf-m, 26.0 ft-lb)
G2M0853
8) Remove front exhaust pipe assembly.

9) Remove covers from exhaust manifold and
front exhaust pipe.
EX(DOHC TURBO)-7
FRONT EXHAUST PIPE
Exhaust
5) Connect exhaust manifold (RH) to turbocharger

joint pipe.
Tightening torque:
35 N·m (3.6 kgf-m, 26.0 ft-lb)
G2M0853
6) Install upper and lower exhaust manifold covers

(LH).
Tightening torque:
18.6 N·m (1.9 kgf-m, 13.7 ft-lb)
7) Install lower exhaust manifold cover (RH).
Tightening torque:
18.6 N·m (1.9 kgf-m, 13.7 ft-lb)
G2M0852
8) Install front oxygen (A/F) sensor. <Ref. to

FU(DOHC TURBO)-43, INSTALLATION, Front
Oxygen (A/F) Sensor.>
G6M0095
EX(DOHC TURBO)-8
CENTER EXHAUST PIPE
Exhaust

8) Remove bolts which install the lower side of
turbocharger upper cover.
CAUTION:
1) Set the vehicle on the lift. Be careful, turbocharger and exhaust pipe are
2) Disconnect battery ground cable. hot.
4) Remove intercooler bracket.
H2M1929

H2M1928 10) Remove turbocharger upper cover.
7) Remove universal joint bolts and then remove
universal joint (RHD model only).
CAUTION:
Scribe alignment marks on universal joint so
that it can be reassembled at the original ser-
ration.
H2M1733
11) Remove bolts which install the upper side of

turbocharger lower cover, and remove it.
H2M1950
H2M1931
EX(DOHC TURBO)-9
CENTER EXHAUST PIPE
Exhaust
12) Separate center exhaust pipe from turbo- 17) Remove intercooler bracket.
charger. 18) Remove bolt which holds center exhaust pipe
to hanger bracket.
CAUTION:
Be careful not to pull down center exhaust
pipe.
H2M1745

14) Disconnect connector from rear oxygen sen-
sor.
S2M1723
19) Remove center exhaust pipe.
EN0834
15) Separate center exhaust pipe from rear

exhaust pipe. H2M1762
CAUTION:
1) Install center exhaust pipe and temporarily
tighten bolt which holds center exhaust pipe to
hanger bracket.
2) Temporarily tighten bolt which holds center pipe
to transmission.
G2M0855 3) Connect center exhaust pipe to turbocharger.
16) Remove bolt which holds center exhaust pipe Tightening torque:
bracket to transmission. 35 N·m (3.6 kgf-m, 26.0 ft-lb)
H2M1746 H2M1745
EX(DOHC TURBO)-10
CENTER EXHAUST PIPE
Exhaust
4) Install center exhaust pipe to rear exhaust pipe. 7) Tighten bolt which holds center exhaust pipe to
Tightening torque: hanger bracket.
18 N·m (1.8 kgf-m, 13.0 ft-lb) Tightening torque:
35 N·m (3.6 kgf-m, 26 ft-lb)
G2M0855
S2M1723
5) Connect connector to rear oxygen sensor.
8) Tighten bolts which hold intercooler bracket.
Tightening torque:
35 N·m (3.6 kgf-m, 26.0 ft-lb)
10) Place turbocharger lower cover, and tighten
bolts which install the upper side of lower cover.
Tightening torque:
7.4 N·m (0.75 kgf-m, 5.4 ft-lb)
EN0834
6) Tighten bolt which holds center exhaust pipe

bracket to transmission.
Tightening torque:
30 N·m (3.1 kgf-m, 22.4 ft-lb)
H2M1931
11) Place turbocharger upper cover, and tighten

bolts which install the upper side of upper cover.
Tightening torque:
7.4 N·m (0.75 kgf-m, 5.4 ft-lb)
H2M1746
H2M1930
EX(DOHC TURBO)-11
CENTER EXHAUST PIPE
Exhaust
13) Tighten bolts which install the under side of 17) Install intercooler bracket.
turbocharger upper cover.
Tightening torque:
7.4 N·m (0.75 kgf-m, 5.4 ft-lb)
S2M1928
18) Install intercooler. <Ref. to IN(DOHC

TURBO)-10, INSTALLATION, Intercooler.>
H2M1929 19) Align center of roll connector. (With airbag
model) <Ref. to AB-11, ROLL CONNECTOR,
14) Install universal joint (RHD model only). INSPECTION, Inspection Locations After a Colli-
(1) Align bolt hole on the long yoke side of uni- sion.>
versal joint with the cutout at the serrated sec-
tion of shaft end, and insert universal joint.
(2) Align bolt hole on the short yoke side of
universal joint with the cutout at the serrated
section of gearbox assembly. Lower universal
joint completely.
(3) Temporarily tighten bolt on the short yoke
side. Raise universal joint to make sure the bolt
is properly passing through the cutout at the
serrated section.
(4) Tighten bolt on the long yoke side, then that
on the short yoke side.
Tightening torque:
24 N·m (2.4 kgf-m, 17.4 ft-lb)
CAUTION:
쐌 Make sure that universal joint bolts are tight-
ened through notches in shaft serration.
쐌 Excessively large tightening torque of uni-
versal joint bolts may lead to heavy steering
wheel operation.
Standard clearance between gearbox to DOJ:
Over 15 mm (0.59 in)
H2M1950

EX(DOHC TURBO)-12
JOINT PIPE
Exhaust
4. Joint Pipe S182771

6) Remove lower exhaust manifold cover (RH).
G2M0852
7) Remove nuts. Which hold front exhaust mani-

fold to joint pipe.
G6M0095
2) Remove solenoid valve cover.
EN0917

EN0828 EX(DOHC TURBO)-9, REMOVAL, Center Exhaust
Pipe.>
3) Disconnect from exhaust temperature sensor 9) Remove turbocharger. <Ref. to IN(DOHC
connector. TURBO)-12, REMOVAL, Turbocharger.>
10) Take off joint pipe in the upward direction.

Tightening torque:
35 N·m (3.6 kgf-m, 26.0 ft-lb)
EN0896
4) Remove front oxygen (A/F) sensor. <Ref. to

FU(DOHC TURBO)-42, REMOVAL, Front Oxygen
(A/F) Sensor.>
H2M1747A
EX(DOHC TURBO)-13
REAR EXHAUST PIPE
Exhaust
CAUTION:
1) Install rear exhaust pipe to muffler.
Tightening torque:
48 N·m (4.9 kgf-m, 35.4 ft-lb)
G6M0095
2) Lift up the vehicle.

3) Separate rear exhaust pipe from center S2M0559
exhaust pipe.
2) Install rear exhaust pipe to center exhaust pipe.
CAUTION:
Tightening torque:
Be careful, exhaust pipe is hot.
18 N·m (1.8 kgf-m, 13.0 ft-lb)
S2M0558
S2M0558
4) Separate rear exhaust pipe from muffler. 3) Lower the vehicle.

CAUTION: 4) Connect battery ground cable.
Be careful not to pull down rear exhaust pipe.
G6M0095
S2M0559
5) Remove rear exhaust pipe. C: INSPECTION S182068A10

nections and welds.
cracked.
EX(DOHC TURBO)-14
MUFFLER
Exhaust
6. Muffler S182066 B: INSTALLATION S182066A11
1) Separate muffler from rear exhaust pipe. CAUTION:

CAUTION:
Be careful, exhaust pipe is hot. Tightening torque:
48 N·m (4.9 kgf-m, 35.4 ft-lb)
S2M0559
S2M0559
2) Remove rubber cushions, and detach muffler.
CAUTION: C: INSPECTION S182066A10
removal. 1) Make sure there are no exhaust leaks from con-
nections and welds.
NOTE: 2) Make sure there are no holes or rusting.
To facilitate removal, apply a coat of SUBARU 3) Make sure the cushion rubber is not worn or
CRC to mating area of rubber cushions in cracked.
advance.
S2M2177
EX(DOHC TURBO)-15
MUFFLER
Exhaust
MEMO:
EX(DOHC TURBO)-16
ENGINE2 SECTION

SUBARU vehicles.
ine parts.

G8050GE3
IGNITION
IG(DOHC TURBO)
Page
2. Spark Plug...................................................................................................4
GENERAL DESCRIPTION
Ignition
Item Designation
Ignition coil Model FK0140
and ignitor
assembly Manufacturer DIAMOND
Type and manufacturer PFR6G .......... NGK
Spark plug Thread size mm 14, P = 1.25
Spark gap mm (in) 0.7 — 0.8 (0.028 — 0.031)
IG(DOHC TURBO)-2
GENERAL DESCRIPTION
Ignition
EN0853
(1) Spark plug Tightening torque: N·m (kgf-m, ft-lb)

T1: 21 (2.1, 15)
T2: 16 (1.6, 11.7)

ment.
IG(DOHC TURBO)-3
SPARK PLUG
Ignition

5) Remove spark plugs with the spark plug socket.
CAUTION:
Spark plug:
NGK: PFR6G
1. RH SIDE S181003A1801
1) Disconnect battery ground cable. EN0856
2. LH SIDE S181003A1802
1) Disconnect battery cables, and then remove

battery and battery carrier.
G6M0095
2) Remove air cleaner lower case. <Ref. to

IN(DOHC TURBO)-7, REMOVAL, Air Cleaner.>
3) Disconnect connector from ignition coil.
G6M0095
2) Disconnect washer motor connector (A).
EN0854
4) Remove ignition coil.

B6M0562D

suitable cap.
EN0855
IG(DOHC TURBO)-4
SPARK PLUG
Ignition
4) Remove the two bolts which hold the washer B: INSTALLATION S181003A11

area. 1. RH SIDE S181003A1101

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:
B2M2023 should be reduced by approximately 1/3 of the
5) Disconnect connector from ignition coil. ing.
2. LH SIDE S181003A1102

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:
EN0857 new spark plugs without oil on their threads.
6) Remove ignition coil. should be reduced by approximately 1/3 of the
ing.
EN0858
7) Remove spark plug with the spark plugs socket.
EN0859
IG(DOHC TURBO)-5
SPARK PLUG
Ignition

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
(E) Damaged gasket
brown spots and bluish burnt electrodes indicate
engine overheating. Moreover, the appearance
1) Normal results from incorrect ignition timing, loose spark
Brown to grayish-tan deposits and slight electrode plugs, wrong selection of fuel, hotter range plug,
wear indicate correct spark plug heat range. etc. It is advisable to replace with plugs having
colder heat range.
G6M0087
G6M0090
2) Carbon fouled
Dry fluffy carbon deposits on insulator and elec-
trode are mostly caused by slow speed driving in
city, weak ignition, too rich fuel mixture, dirty air
cleaner, etc.
It is advisable to replace with plugs having hotter
heat range.
G6M0088
IG(DOHC TURBO)-6
SPARK PLUG
Ignition
Clean spark plugs in a sand blast type cleaner.

Avoid excessive blasting. Clean and remove car-
bon or oxide deposits, but do not wear away por-
celain.
If deposits are too stubborn, replace plugs.
After cleaning spark plugs, recondition firing sur-
face 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:
“ball” shape.
IG(DOHC TURBO)-7
Ignition
3. Ignition Coil and Ignitor

Assembly S181015
Direct ignition type has been adopted. Refer to the

“Spark Plug Removal” for removal procedure.
<Ref. to IG(DOHC TURBO)-4, REMOVAL, Spark
Plug.>

Tightening torque:
16 N·m (1.63 kgf-m, 11.8 ft-lb)
Because ignition coil is a direct ignition type, the

resistance cannot be measured in a single unit. For
inspection procedure of ignition system, refer to
the following. <Ref. to EN(DOHC TURBO)-72,
IGNITION CONTROL SYSTEM, Diagnostics for
IG(DOHC TURBO)-8
ENGINE2 SECTION

SUBARU vehicles.
ine parts.

G8050GE3
EN(DOHC TURBO)
Page
8. Data Link Connector .................................................................................33
9. OBD-II General Scan Tool ........................................................................34
12. Inspection Mode ........................................................................................44

S088501
1. ENGINE S088501E4501

trouble occurred using the interview check list. Engine Start Fail-
<Ref. to EN(DOHC TURBO)-4, CHECK, ure”. <Ref. to
Check List for Interview.> EN(DOHC
2) Start the engine. TURBO)-63, Diag-
nostics for Engine
Starting Failure.>
2 CHECK ILLUMINATION OF CHECK ENGINE Does CHECK ENGINE Go to step 3. Inspection using
MALFUNCTION INDICATOR LAMP (MIL). malfunction indicator lamp “General Diagnos-
illuminate? tics Table”. <Ref.
to EN(DOHC
TURBO)-344,
General Diagnos-
tic Table.>
1) Turn ignition switch to OFF. Monitor or OBD-II general trouble code. parts.
2) Connect the Subaru Select Monitor or the scan tool indicate DTC? Repair the trouble NOTE:
OBD-II general scan tool to data link connec- cause. <Ref. to If DTC is not
tor. EN(DOHC shown on display
3) Turn ignition switch to ON and the Subaru TURBO)-82, List although the MIL
Select Monitor or OBD-II general scan tool of Diagnostic illuminates, per-
switch to ON. Trouble Code form diagnostics
4) Read DTC on the Subaru Select Monitor or (DTC).> Go to of MIL (CHECK
OBD-II general scan tool. step 4. ENGINE malfunc-
tion indicator
lamp) circuit or
combination
meter. <Ref. to
EN(DOHC
TURBO)-50,
Engine Malfunc-
tion Indicator
Lamp (MIL).>
4 PERFORM THE DIAGNOSIS. Does the Subaru Select Inspect using Complete the
1) Perform the clear memory mode. <Ref. to Monitor or OBD-II general “Diagnostics Pro- diagnosis.
EN(DOHC TURBO)-47, Clear Memory scan tool indicate DTC? cedure with Diag-
Mode.> nostic Trouble
2) Perform the inspection mode. <Ref. to Code (DTC)”.
EN(DOHC TURBO)-44, Inspection Mode.> <Ref. to
EN(DOHC
TURBO)-90, Diag-
nostic Procedure
with Diagnostic
Trouble Code
(DTC).>
EN(DOHC TURBO)-2
2. AUTOMATIC TRANSMISSION S088501E4502
When trouble code about automatic transmission

is shown on display, carry out the following basic
check. After that, carry out the replacement or
repair work.
1) ATF level check <Ref. to AT-9, Automatic Trans-
mission Fluid.>
2) Differential gear oil level check <Ref. to AT-11,
3) ATF leak check <Ref. to AT-9, Automatic Trans-
mission Fluid.>
4) Differential gear oil leak check <Ref. to AT-11,
5) Stall test <Ref. to AT-11, Differential Gear Oil.>
6) Line pressure test <Ref. to AT-16, Line Pres-
sure 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(DOHC TURBO)-3
A: CHECK S088502A04
Check the following items when problem has occurred.

NOTE:
Vin no. miles
Weather 쏔 Fine
쏔 Cloudy
쏔 Rainy
쏔 Snowy
쏔 Various/Others:
Outdoor temperature °C (°F)
쏔 Hot
쏔 Warm
쏔 Cool
쏔 Cold
Place 쏔 Highway
쏔 Suburbs
쏔 Inner city
쏔 Uphill
쏔 Downhill
쏔 Rough road
쏔 Others:
쏔 Warming-up
쏔 Any temperature
쏔 Others:
Engine speed rpm
Vehicle speed MPH
쏔 At starting
쏔 While idling
쏔 At racing
쏔 While cruising
EN(DOHC TURBO)-4
2. CHECK LIST NO. 2 S088502A0402 NOTE:

Check the following items about the vehicle’s state Use copies of this page for interviewing customers.
when MIL turns on.

b) Fuel level
쐌 What:
쐌 What:
쐌 What:
쐌 Where:
쐌 From where:
쐌 What kind:
쐌 From where:
쐌 What kind:
쏔 Rough idling
쏔 Back fire
쏔 After fire
쏔 No shift
EN(DOHC TURBO)-5
GENERAL DESCRIPTION

8) Use ECM mounting stud bolts at the body head
grounding point when measuring voltage and
A: CAUTION S088001A03 resistance inside the passenger compartment.
1) Airbag system wiring harness is routed near the
pump relay.
CAUTION:
module (ECM), transmission control module H2M1154A
(TCM), main relay and fuel pump relay.
2) Never connect the battery in reverse polarity.
쐌 The ECM will be destroyed instantly.
measuring voltage and resistance in the engine
쐌 The fuel injector and other part will be damaged
compartment.
tion switch.
cause of this problem. To measure the voltage
EN0945
trical control modules at the harness side 10) Use TCM mounting stud bolts at the body
connector, use a tapered pin with a diameter of head grounding point when measuring voltage and
less than 0.64 mm (0.025 in). Do not insert the pin resistance inside the passenger compartment.
more than 5 mm (0.20 in) into the part.
6) Before removing ECM from the located
position, disconnect two cables on battery.
쐌 Otherwise, the ECM may be damaged.
CAUTION:
wrong spec. ECM to avoid any damage on fuel
injection system.
7) The connectors to each sensor in the engine
compartment and the harness connectors on the B3M1666E
engine side and body side are all designed to be
waterproof. However, it is still necessary to take 11) Every MFI-related part is a precision part. Do
care not to allow water to get into the connectors not drop them.
when washing the vehicle, or when servicing the 12) Observe the following cautions when installing
vehicle on a rainy day. a radio in MFI equipped models.
CAUTION:
쐌 The antenna must be kept as far apart as
possible from the control unit.
(The ECM is located under the steering column,
inside of the instrument panel lower trim
panel.)
EN(DOHC TURBO)-6
GENERAL DESCRIPTION
쐌 The antenna feeder must be placed as far 2. ENGINE GROUNDING S088001A1002
apart as possible from the ECM and MFI har-

ness. Make sure the engine grounding terminal is prop-
쐌 Carefully adjust the antenna for correct erly connected to the engine.
matching.
쐌 When mounting a large power type radio,
pay special attention to the three items above
mentioned.
쐌 Incorrect installation of the radio may affect
the operation of the ECM.
EN0945
matic transmission may be caused by failure of the C: NOTE S088001A15
engine, the electronic control system, the transmis-
sion proper, or by a combination of these. These 1. DESCRIPTION S088001A1501

쐌 The on-board diagnostics (OBD) system detects
and indicates a fault in various inputs and outputs
with simple, easy operations and proceeding to of the complex electronic control. CHECK ENGINE
complicated, difficult operations. The most impor- malfunction indicator lamp (MIL) in the combina-
tant thing in diagnostics is to understand the cus- tion meter indicates occurrence of a fault or
tomer’s complaint, and distinguish between the trouble.
three causes. 쐌 Further, against such a failure or sensors as
16) On ABS vehicle, when performing driving test may disable the drive, the fail-safe function is pro-
in jacked-up or lifted-up position, sometimes the vided to ensure the minimal driveability.
warning light may be lit, but this is not a malfunc- 쐌 The OBD system incorporated with the vehicles
tion of the system. The reason for this is the speed within this engine family complies with Section
difference between the front and rear wheels. After 1968.1, California Code of Regulations (OBD-II
diagnosis of engine control system, perform the regulation). The OBD system monitors the compo-
ABS memory clearance procedure of self-diagno- nents and the system malfunction listed in Engine
sis system. Section which affects on emissions.
쐌 When the system decides that a malfunction
occurs, MIL illuminates. At the same time of the
MIL illumination or blinking, a diagnostic trouble
Before performing diagnostics, check the following code (DTC) and a freeze frame engine conditions
items which might affect engine problems: are stored into on-board computer.
쐌 The OBD system stores freeze frame engine
1. BATTERY S088001A1001
condition data (engine load, engine coolant
1) Measure battery voltage and specific gravity of temperature, fuel trim, engine speed and vehicle
electrolyte. speed, etc.) into on-board computer when it
Standard voltage: 12 V detects a malfunction first.
쐌 If the OBD system detects the various malfunc-
Specific gravity: Above 1.260 tions including the fault of fuel trim or misfire, the
2) Check the condition of the main and other OBD system first stores freeze frame engine con-
fuses, and harnesses and connectors. Also check ditions about the fuel trim or misfire.
for proper grounding. 쐌 When the malfunction does not occur again for
three consecutive driving cycles, MIL is turned off,
but DTC remains at on-board computer.
쐌 The OBD-II system is capable of communication
with a general scan tool (OBD-II general scan tool)
formed by ISO 9141 CARB.
쐌 The OBD-II diagnostics procedure is different
from the usual diagnostics procedure. When
troubleshooting OBD-II vehicles, connect Subaru
EN(DOHC TURBO)-7
GENERAL DESCRIPTION
Select Monitor or the OBD-II general scan tool to 쐌 Reduced emission of harmful exhaust gases.
the vehicle. 쐌 Reduced in fuel consumption.
2. ENGINE AND EMISSION CONTROL 쐌 Superior acceleration and deceleration.
SYSTEM S088001A1502 쐌 Superior startability and warm-up perfor-
쐌 The Multipoint Fuel Injection (MFI) system is a mance in cold weather since compensation is
system that supplies the optimum air-fuel mixture made for coolant and intake air temperature.
tions through the use of the latest electronic tech- 3. AUTOMATIC TRANSMISSION AND
nology. ELECTRONIC-HYDRAULIC CONTROL
With this system fuel, which is pressurized at a SYSTEM S088001A1503
The electronic-hydraulic control system consists of
passage of the cylinder head. The injection quan-
tity of fuel is controlled by an intermittent injection various sensors and switches, a transmission con-
system where the electro-magnetic injection valve trol module (TCM) and the hydraulic controller
(fuel injector) opens only for a short period of time, including solenoid valves. The system controls the
depending on the quantity of air required for one transmission proper including shift control, lock-up
cycle of operation. In actual operation, the injection control, overrunning clutch control, line pressure
quantity is determined by the duration of an elec- control and shift timing control. It also controls the
tric pulse applied to the fuel injector and this per- AWD transfer clutch. In other words, the system
mits simple, yet highly precise metering of the fuel. detects various operating conditions from various
쐌 Further, all the operating conditions of the input signals and sends output signals to shift sole-
engine are converted into electric signals, and this noids 1, 2 and low clutch timing solenoid and 2-4
results in additional features of the system, such as brake timing solenoid, line pressure duty solenoid,
large improved adaptability, easier addition of com- lock-up duty solenoid, transfer duty solenoid and
pensating element, etc. 2-4 brake duty solenoid (a total of eight solenoids).

(New adopted tool)
B2M3876
B2M3877
EN(DOHC TURBO)-8
GENERAL DESCRIPTION
MEMO:
EN(DOHC TURBO)-9
Location S088507
1. ENGINE S088507A1301
쐌 MODULE
S2M0226H
S2M1401E
(1) Engine control module (ECM) (3) Data link connector

(2) CHECK ENGINE malfunction (4) Test mode connector
indicator lamp (MIL)
EN(DOHC TURBO)-10
B3M1575A S2M2215A
S2M2157A S2M2244B
EN(DOHC TURBO)-11
쐌 SENSOR
S2M2216A
(1) Pressure sensor (4) Knock sensor (7) Mass air flow and intake air tem-
(2) Engine coolant temperature sen- (5) Camshaft position sensor perature sensor
sor (6) Crankshaft position sensor (8) Tumble generator valve position
(3) Throttle position sensor sensor
EN(DOHC TURBO)-12
EN1008 EN1009
EN1010 EN1011
EN1012 EN1013
EN1014 EN1015
EN(DOHC TURBO)-13
쐌 Australia Model
S2M2258A
쐌 Except Australia Model
S2M2259A
(1) Front oxygen (A/F) sensor (4) Front catalytic converter (6) Rear catalytic converter
(2) Precatalytic converter (5) Rear oxygen sensor (Except Australia model)
(3) Exhaust temperature sensor
EN(DOHC TURBO)-14
EN1016 EN1017
EN0949 EN1018
EN0950
EN(DOHC TURBO)-15
S2M2217A
S2M2218A
(1) Fuel level sensor (2) Fuel sub level sensor
EN1036 EN1037
EN(DOHC TURBO)-16
MEMO:
EN(DOHC TURBO)-17
쐌 SOLENOID VALVE, ACTUATOR, EMISSION CONTROL SYSTEM PARTS AND IGNITION

SYSTEM PARTS
S2M2216B
(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(DOHC TURBO)-18
EN1021 EN1022
EN1023 EN1024
EN0952
EN(DOHC TURBO)-19
S2M2217B
S2M2218B
(1) Fuel pump (4) Inhibitor switch (7) Starter

(2) Main relay (5) Radiator main fan relay
(3) Fuel pump relay (6) Radiator sub fan relay
EN(DOHC TURBO)-20
EN0953 S2M0278B
S2M0663A B2M2246G
EN0746 EN1030
EN(DOHC TURBO)-21
2. TRANSMISSION S088507A1302
쐌 MODULE
S2M2217C
S2M2218C
(1) Transmission Control Module (2) AT diagnostic indicator light (for

(TCM) (for AT vehicles) AT vehicles)
EN(DOHC TURBO)-22
B3M1592D B3M1652B
S2M2215B
EN(DOHC TURBO)-23
쐌 SENSOR
B2M2258A B2M2259A
B2M2260A B2M2261A
OBD0653B
(1) Rear vehicle speed sensor (for AT vehicles)

(2) Front vehicle speed sensor (for MT vehicles)
(3) Front vehicle speed sensor (for AT vehicles)
(4) Torque converter turbine speed sensor
(5) ATF temperature sensor (for AT vehicles)
(6) Brake light switch
EN(DOHC TURBO)-24
쐌 SOLENOID VALVE AND SWITCH (AT VEHICLES)
B2M2246F B2M2263K
B2M2264F
(1) Inhibitor switch

(4) Line pressure duty solenoid
(5) Lock-up duty solenoid
(6) Transfer duty solenoid
(7) 2-4 brake duty solenoid
(8) Low clutch timing solenoid valve
(9) 2-4 brake timing solenoid valve
쐌 SOLENOID VALVE AND SWITCH (MT VEHICLES)
B2M2265A
(1) Neutral position switch
EN(DOHC TURBO)-25
EN0955
Con- Signal (V)

Termi-
No. (Engine OFF)
Crankshaft Signal (+) B135 2 0 −7 — +7 Sensor output waveform
Camshaft Signal (+) B135 1 0 −7 — +7 Sensor output waveform
Signal B135 7 —
Throttle
Power sup-
position B135 9 5 5 —
ply
sensor
GND (sen-
B135 19 0 0 —
sor)
Signal B135 17 0 0 — 0.9 —
Rear oxy- Shield B135 26 0 0 —
gen sensor GND (sen-
B135 19 0 0 —
sor)
Front oxy-
Signal 1 B137 4 0 — 1.0 0 — 1.0 —
gen (A/F)
sensor
Signal 2 B137 5 0 — 1.0 0 — 1.0 —
heater
Rear oxygen sensor
B136 13 0 — 1.0 0 — 1.0 —
heater signal
Engine Signal B135 18 1.0 — 1.4 1.0 — 1.4 After warm-up the engine.
coolant
tempera- GND (sen-
B135 19 0 0 After warm-up the engine.
ture sensor sor)
“5” and “0” are repeatedly dis-
Vehicle speed signal B134 1 0 or 5 0 or 5
played when vehicle is driven.
EN(DOHC TURBO)-26
Con- Signal (V)

Termi-
No. (Engine OFF)
Signal B84 13 — 0.3 — 4.5 —
Mass air
Shield B84 8 0 0 —
flow sensor
GND B84 7 0 0 —
Intake air temperature
B135 27 — — —
sensor signal
Exhaust Signal B135 16 — — —
gas tem-
perature GND
B135 19 0 0 —
sensor (sensor)
Tumble Signal B84 23 —
generator
Power sup-
valve posi- B135 9 5 5 —
ply
tion sensor
RH GND
B135 19 0 0 —
(sensor)
Tumble Signal B84 13 —
generator
Power sup-
valve posi- B135 9 5 5 —
ply
tion sensor
LH GND
B135 19 0 0 —
(sensor)
Tumble generator valve
B84 4 0 or 5 0 or 5 —
RH (open)
B84 5 0 or 5 0 or 5 —
RH (close)
B84 11 0 or 5 0 or 5 —
LH (open)
B84 10 0 or 5 0 or 5 —
LH (close)
Wastegate control sole-
B137 24 10 — 13 13 — 14 —
noid valve
Starter switch B134 16 0 0 Cranking: 8 — 14
ON: 10 — 13 ON: 13 — 14
A/C switch B134 6 —
OFF: 0 OFF: 0
Ignition switch B134 14 10 — 13 13 — 14 —
ON: 12±0.5 Switch is ON when gear is in
Neutral MT B135 8
OFF: 0 neutral position.
position
switch ON: 0 Switch is ON when shift is in
AT B135 8
OFF: 12±0.5 “N” or “P” position.
Test mode connector B134 5 5 5 When connected: 0
Knock sen- Signal B135 4 2.8 2.8 —
sor Shield B135 22 0 0 —
Back-up power supply B137 10 10 — 13 13 — 14 Ignition switch “OFF”: 10 — 13
Control unit power sup- B137 2 10 — 13 13 — 14 —
ply B137 3 10 — 13 13 — 14 —
Sensor power supply B135 9 5 5 —
Line end check 1 B134 10 0 0 —
#1 B136 24 0 13 — 14 Waveform
Ignition #2 B136 23 0 13 — 14 Waveform
control #3 B136 22 0 13 — 14 Waveform
#4 B136 21 0 13 — 14 Waveform
EN(DOHC 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
tor #3 B136 5 10 — 13 1 — 14 Waveform
#4 B136 4 10 — 13 1 — 14 Waveform
Idle air
control
Signal B136 10 0 or 13 — 14 0 or 13 — 14 Waveform
solenoid
valve
A/C relay control B137 27 —
OFF: 10 — 13 OFF: 13 — 14
B137 17 —
control OFF: 10 — 13 OFF: 13 — 14
B137 28 With A/C vehicles only
control OFF: 10 — 13 OFF: 13 — 14
Malfunction indicator Light “ON”: 1, or less
B137 15 — —
lamp Light “OFF”: 10 — 14
Engine speed output B136 9 — 0 — 13, or more Waveform
Purge control solenoid ON: 1, or less ON: 1, or less
B137 16 —
valve OFF: 10 — 13 OFF: 13 — 14
Signal B135 8 1.7 — 2.4 1.1 — 1.6
Power sup-
Pressure B135 9 5 5
ply —
sensor
GND (sen-
B135 19 0 0
sor)
Fuel level sensor B135 25 0.12 — 4.75 0.12 — 4.75 —
ON: 0 ON: 0
Small light switch B134 17 —
OFF: 10 — 13 OFF: 13 — 14
ON: 0 ON: 0
Blower fan switch B134 9 —
OFF: 10 — 13 OFF: 13 — 14
ON: 0 ON: 0
Rear defogger switch B134 3 —
OFF: 10 — 13 OFF: 13 — 14
Power steering oil pres- ON: 0
B135 24 10 — 13 —
sure switch OFF: 13 — 14
B137 19 2.8 — 3.2 2.8 — 3.2 —
sor signal (+)
B137 29 2.4 — 2.7 2.4 — 2.7 —
sor signal (−)
B136 7 0 0 —
sor shield
SSM/GST communica- Less than 1 ←→ More Less than 1 ←→ More
B134 21 —
tion line than 4 than 4
GND (sensors) B135 19 0 0 —
GND (injectors) B136 8 0 0 —
GND (ignition system) B136 18 0 0 —
B136 17 0 0 —
GND (power supply)
B134 22 0 0 —
B134 7 0 0 —
GND (control systems)
B134 15 0 0 —
GND (oxygen sensor
B137 9 0 0 —
heater 1)
GND (oxygen sensor
B137 8 0 0 —
heater 2)
EN(DOHC TURBO)-28
A: ELECTRICAL SPECIFICATION
S088530A08
Content Specified data

1.6 — 2.9 (%): Idling
Engine load
6.4 — 12.8 (%): 2,500 rpm racing
Measuring condition:
쐌 After warm-up the engine.
쐌 Gear position is in neutral position.
쐌 A/C is turned OFF.
쐌 All accessory switches are turned OFF.
EN(DOHC TURBO)-29
TR0532

Con-
Termi- Resistance to
Content nector Measuring conditions Voltage (V)
nal No. body (ohms)
No.
Back-up power supply B56 1 Ignition switch OFF 10 — 16 —
B54 23 Ignition switch ON (with
Ignition power supply 10 — 16 —
B54 24 engine OFF)
Select lever in “P” range Less than 1
“P” range Select lever in any other
B55 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
B55 14 —
switch than “N” range (except “P” More than 8
range)
Select lever in “R” range Less than 1
“R” range
switch More than 8
than “R” range
Inhibitor Select lever in “D” range Less than 1
switch “D” range
switch More than 8
than “D” range
“3” range
switch More than 8
than “3” range
“2” range
switch More than 8
than “2” range
“1” range
switch More than 8
than “1” range
Brake pedal depressed. More than 10.5
Brake switch B55 12 —
Brake pedal released. Less than 1
EN(DOHC TURBO)-30

Con-
nal No. body (ohms)
No.
ABS switch ON Less than 1
ABS signal B55 21 —
ABS switch OFF 6.5 — 15
Hold switch ON Less than 1
Hold switch B55 16 —
Hold switch OFF More than 8
Power switch ON Less than 1
Power switch B55 23 —
Power switch OFF More than 10
Throttle fully opened. Less than 1
Kick-down switch B55 11 —
Throttle fully closed. More than 6.5
POWER indicator light B56 11 —
AT OIL TEMP indicator light B56 10 —
Throttle fully closed. 0.3 — 0.7
Throttle position sensor B54 3 —
Throttle fully open. 4.0 — 4.6
Throttle position sensor power Ignition switch ON (With
B54 2 4.8 — 5.3 —
supply engine OFF)
1.6 — 2.0 2.1 — 2.9 k
(68°F)
ATF temperature sensor B54 11
0.4 — 0.9 275 — 375
(176°F)
Vehicle stopped. 0
Rear vehicle speed sensor B55 24 Vehicle speed at least 20 450 — 650
km/h (12 MPH)
Vehicle speed at least 20
Front vehicle speed sensor B55 18 More than 1 (AC range) 450 — 650
km/h (12 MPH)
Engine idling after warm-up.
0
Torque converter turbine (D range)
B55 8 450 — 650
speed sensor Engine idling after warm-up.
(N range)
Vehicle speed at most 10 Less than 1←
Vehicle speed output signal B56 17 —
km/h (6 MPH) →More than 4
More than 10.5
engine OFF)
Engine speed signal B55 17 —
8 — 11
engine ON)
When cruise control is set
Less than 1
(SET lamp ON)
Cruise set signal B55 22 —
When cruise control is not
More than 6.5
set (SET lamp OFF)
engine ON)
engine ON)
Torque control cut signal B55 10 Ignition switch ON 8 —
Mass air flow signal B54 1 Engine idling after warm-up. 0.5 — 1.2 —
1st or 4th gear More than 9
2nd or 3rd gear Less than 1
1st or 2nd gear More than 9
3rd or 4th gear Less than 1
EN(DOHC TURBO)-31

Con-
nal No. body (ohms)
No.
engine OFF)
1.5 — 4.0
warm-up.
Line pressure duty solenoid B54 9 2.0 — 4.5
engine OFF)
Less than 0.5
warm-up.
When lock up occurs. More than 8.5
Lock-up duty solenoid B54 7 10 — 17
When lock up is released. Less than 0.5
Fuse on FWD switch More than 8.5
Fuse removed from FWD
Transfer duty solenoid B54 6 switch (with throttle fully 10 — 17
Less than 0.5
open and with select lever in
1st gear).
engine OFF)
1.5 — 4.0
warm-up.
2-4 brake duty solenoid B54 18 2.0 — 4.5
engine OFF)
Less than 0.5
warm-up.
1st gear Less than 1
2-4 brake timing solenoid B54 16 10 — 16
3rd gear More than 9
2nd gear Less than 1
Low clutch timing solenoid B54 15 10 — 16
4th gear More than 9
B56 19
System ground line — 0 Less than 1
B54 21
Fuse removed. 6 — 9.1
FWD switch B55 20 —
Fuse installed. Less than 1
Fuse ONFWD switch Less than 1
FWD indicator light B56 2 Fuse removed from FWD —
More than 9
switch
Data link signal (Subaru 15 — —
B56 —
Select Monitor) 6 — —
EN(DOHC TURBO)-32
DATA LINK CONNECTOR
8. Data Link Connector S088505
A: NOTE S088505A15
This connector is used both for OBD-II general scan tools and the Subaru Select Monitor.
CAUTION:
Do not connect any scan tools other than the OBD-II general scan tools and the Subaru Select
Monitor, because the circuit for the Subaru Select Monitor may be damaged.
H2M1280
Terminal No. Contents Terminal No. Contents

1 Power supply 9 Blank
2 Blank 10 K line of ISO 9141 CARB
3 Blank 11 Blank
4 Blank 12 Ground
5 Blank 13 Ground
7 Blank 15 Blank
EN(DOHC TURBO)-33
9. OBD-II General Scan Tool S088527

3) Using the OBD-II general scan tool, call up
diagnostic trouble code(s) and freeze frame data.
A: OPERATION S088527A16 OBD-II general scan tool functions consist of:
1. HOW TO USE OBD-II GENERAL SCAN (1) MODE $01: Current powertrain diagnostic
data
TOOL S088527A1601
(2) MODE $02: Powertrain freeze frame data
1) Prepare a general scan tool (OBD-II general (3) MODE $03: Emission-related powertrain
scan tool) required by SAE J1978. diagnostic trouble codes
2) Open the cover and connect the OBD-II general (4) MODE $04: Clear/Reset emission-related
scan tool to the data link connector (A) located in diagnostic information
the lower portion of the instrument panel (on the Read out data according to repair procedures. (For
driver’s side). detailed operation procedures, refer to the OBD-II
General Scan Tool Operation Manual.)
NOTE:
For details concerning diagnostic trouble codes,
<Ref. to EN(DOHC TURBO)-82, List of Diagnostic
S2M2157B
2. MODE $01 (CURRENT POWERTRAIN DIAGNOSTIC DATA) S088527A1602
Refers to data denoting the current operating condition of analog input/output, digital input/output and/or
the powertrain system.
01 Number of emission-related powertrain trouble codes and MIL status ON/OFF
0E Ignition timing advance °
0F Intake air temperature °C
10 Air flow rate from pressure sensor g/sec
11 Throttle valve opening angle %
13 Check whether oxygen sensor is installed. —
Oxygen sensor output voltage and short term fuel trim associated with oxygen
15 V and %
sensor—bank 2
24 A/F sensor 1 output voltage and short term fuel trim associated with A/F sensor 1 V and %
1C On-board diagnosis system —
NOTE:
Refer to OBD-II general scan tool manufacturer’s instruction manual to access generic OBD-II PIDs (MODE
$01).
EN(DOHC TURBO)-34
3. MODE $02 (POWERTRAIN FREEZE FRAME DATA) S088527A1603
Refers to data denoting the operating condition when trouble is sensed by the on-board diagnosis system.
02 Trouble code that caused CARB required freeze frame data storage —
NOTE:
Refer to OBD-II general scan tool manufacturer’s instruction manual to access freeze frame data (MODE
$02).
4. MODE $03 (EMISSION-RELATED POWERTRAIN DIAGNOSTIC TROUBLE CODE) S088527A1604
Refer to Read Diagnostic Trouble Code for information about data denoting emission-related powertrain
diagnostic trouble codes. <Ref. to EN(DOHC TURBO)-43, Read Diagnostic Trouble Code.>
5. MODE $04 (CLEAR/RESET EMISSION-RELATED DIAGNOSTIC INFORMATION) S088527A1605
Refers to the mode used to clear or reset emission-related diagnostic information (OBD-II trouble diagnos-
tic information).
NOTE:
Refer to OBD-II general scan tool manufacturer’s instruction manual to clear or reset emission-related
diagnostic information (MODE $04).
EN(DOHC TURBO)-35

CAUTION:
A: OPERATION S088503A16 Select Monitor and OBD-II general scan tool.
EN(DOHC TURBO)-8, PREPARATION TOOL,
S2M0288A

S2M0285
them.
2) Connect diagnosis cable to Subaru Select 2. READ DIAGNOSTIC TROUBLE CODE

Monitor. (DTC) FOR ENGINE. (NORMAL MODE)
S088503A1602
3) Insert cartridge into Subaru Select Monitor.
<Ref. to EN(DOHC TURBO)-8, PREPARATION Refer to Read Diagnostic Trouble Code for infor-
TOOL, General Description.> mation about how to indicate DTC. <Ref. to
EN(DOHC TURBO)-43, Read Diagnostic Trouble
Code.>
(DTC) FOR ENGINE. (OBD MODE) S088503A1603
mation about how to indicate DTC. <Ref. to
EN(DOHC TURBO)-43, Read Diagnostic Trouble
Code.>
S2M0286A

connector.
(1) Data link connector located (A) in the lower
portion of the instrument panel (on the driver’s
side).
S2M2157B

nector.
EN(DOHC TURBO)-36
4. READ CURRENT DATA FOR ENGINE. (NORMAL MODE) S088503A1604
[YES] key.
[YES] key.
Ignition timing signal Ignition Timing deg
Injection pulse width Fuel Injection #1 Pulse ms
Idle air control signal ISC Valve Duty Ratio %
Alternator duty control signal ALT Duty %
Fuel pump duty control signal Fuel Pump Duty %
A/F sensor current A/F Sensor #1 Current mA
A/F sensor resistance A/F Sensor #1 Resistance Ω
Front oxygen (A/F) sensor output signal A/F Sensor #1 —
Rear oxygen sensor output signal Rear O2 Sensor V
Short term fuel trim A/F Correction #1 %
Knock sensor signal Knocking Correction deg
Atmospheric absolute pressure signal Atmosphere Pressure
psi
Intake manifold relative pressure signal Mani. Relative Pressure
psi
psi
A/F correction (short term fuel trim) by rear oxygen sensor A/F Correction #3 %
Long term whole fuel trim A/F Learning #1 %
Front oxygen (A/F) sensor heater current A/F Heater Current 1 A
Rear oxygen sensor heater voltage Rear O2 Heater Voltage V
Canister purge control solenoid valve duty ratio CPC Valve Duty Ratio %
Primary supercharged pressure control signal Primary Control %
Tumble generator valve position sensor signal (right side) TGV Position Sensor R V
Tumble generator valve position sensor signal (left side) TGV Position Sensor L V
Tumble generator valve drive signal TGV Drive OPEN or CLOSE
Fuel level signal Fuel Level V
Learned ignition timing Learned Ignition Timing deg
Mass air flow sensor signal Mass Air Flow g/s
Mass air flow sensor signal Air Flow Sensor Voltage V
Ignition switch signal Ignition Switch ON or OFF
Test mode connector signal Test Mode Signal ON or OFF
Neutral position switch signal Neutral Position Switch ON or OFF
Air conditioning switch signal A/C Switch ON or OFF
Air conditioning signal A/C Compressor Signal ON or OFF
EN(DOHC TURBO)-37

Radiator main fan relay signal Radiator Fan Relay #1 ON or OFF
Fuel pump relay signal Fuel Pump Relay ON or OFF
Knocking signal Knocking Signal ON or OFF
Radiator sub fan relay signal Radiator Fan Relay #2 ON or OFF
Power steering switch signal P/S Switch ON or OFF
Engine torque control permission signal Torque Permission Signal ON or OFF
Starter switch signal Starter Switch ON or OFF
Idle switch signal Idle Switch ON or OFF
Rear defogger switch signal Rear Defogger SW ON or OFF
Blower fan switch signal Blower Fan SW ON or OFF
Small light switch signal Light Switch ON or OFF
Tumble generator valve output signal TGV Output ON or OFF
NOTE:
EN(DOHC TURBO)-38
5. READ CURRENT DATA FOR ENGINE. (OBD MODE) S088503A1605
[YES] key.
5) On the ⰆOBD MenuⰇ display screen, select the {Current Data Display & Save} and press the [YES]
key.
Number of diagnosis code Number of Diagnosis Code —
Malfunction indicator lamp status MI (MIL) Complete or incomplete
Monitoring test of misfire Misfire monitoring Complete or incomplete
Monitoring test of fuel system Fuel system monitoring Complete or incomplete
Monitoring test of comprehensive component Component monitoring Complete or incomplete
Test of catalyst Catalyst Diagnosis No support
Test of heated catalyst Heated catalyst No support
Test of evaporative emission purge control system Evaporative purge system No support
Test of secondary air system Secondary air system No support
Test of air conditioning system refrigerant A/C system refrigerant No support
Test of oxygen sensor Oxygen sensor Complete or incomplete
Test of oxygen sensor heater O2 Heater Diagnosis Complete or incomplete
Test of EGR system EGR system No support
Air fuel ratio control system for bank 1 Fuel System for Bank 1 —
Engine load data Calculated load value %
psi
Ignition timing advance for #1 cylinder Ignition timing adv. #1 °
Intake air amount Mass Air Flow g/s
A/F sensor equipment A/F sensor ON or OFF
Rear oxygen sensor output signal Oxygen Sensor #12 V
Air fuel ratio correction by rear oxygen sensor Short term fuel trim #12 %
On-board diagnostic system OBD System —
NOTE:
EN(DOHC TURBO)-39
6. READ FREEZE FRAME DATA FOR ENGINE. (OBD MODE) S088503A1606
[YES] key.
5) On the ⰆOBD MenuⰇ display screen, select the {Freeze Frame Data} and press the [YES] key.
Diagnostic trouble code (DTC) for freeze frame data Freeze frame data DTC
Air fuel ratio control system for bank 1 Fuel system for Bank1 ON or OFF
psi
NOTE:
7. READ OXYGEN SENSOR MONITORING TEST RESULTS DATA FOR ENGINE. (OBD
MODE) S088503A1607
[YES] key.
5) On the ⰆOBD MenuⰇ display screen, select the {O2 Sensor Monitor} and press the [YES] key.
6) On the ⰆO2 Sensor SelectⰇ display screen, select the {Bank 1-Sensor1} or {Bank 1-Sensor2} and press
the [YES] key.
쐌 Bank 1-Sensor1 indicates the front oxygen or A/F sensor, and Bank 1-Sensor2 indicates the rear oxy-
gen sensor.
Oxygen sensor for monitoring test <O2 Sensor Monitor (-------)> —
Rich to lean oxygen sensor threshold voltage Rich to lean sensor volt V
Lean to rich oxygen sensor threshold voltage Lean to rich sensor volt V
Low oxygen sensor voltage for switch time calculation Low sensor voltage V
High oxygen sensor voltage for switch time calculation High sensor voltage V
Rich to lean oxygen sensor switch time Rich to lean switch time sec
Lean to rich oxygen sensor switch time Lean to rich switch time sec
Maximum oxygen sensor voltage for test cycle Maximum sensor Voltage V
Minimum oxygen sensor voltage for test cycle Minimum sensor Voltage V
NOTE:
EN(DOHC TURBO)-40
[YES] key.
[YES] key.
5) On the ⰆData Display MenuⰇ display screen, select the {Data & LED Display} and press the [YES] key.
Contents Display Message LED “ON” requirements
Ignition switch signal Ignition Switch ON or OFF When ignition switch is turned ON.
Test mode connector signal Test Mode Signal ON or OFF When test mode connector is connected.
Neutral position switch signal Neutral SW ON or OFF When neutral position signal is entered.
Air conditioning switch signal A/C SW ON or OFF When air conditioning switch is turned ON.
Air conditioning relay signal A/C Relay ON or OFF When air conditioning relay is in function.
Radiator main fan relay signal Radiator Fan Relay #1 ON or OFF When radiator main fan relay is in function.
Knocking signal Knocking Signal ON or OFF When knocking signal is entered.
Radiator sub fan relay signal Radiator Fan Relay #2 ON or OFF When radiator sub fan relay is in function.
entered.
entered.
Engine torque control permission When engine torque control permission sig-
Torque Control Permit ON or OFF
signal nal is entered.
When rear oxygen sensor mixture ratio is
rich.
Starter switch signal Starter Switch Signal ON or OFF When starter switch signal is entered.
Idle switch signal Idle Switch Signal ON or OFF When idle switch signal is entered.
When crankshaft position sensor signal is
entered.
When camshaft position sensor signal is
entered.
Power steering switch signal P/S SW ON or OFF When power steering switch is entered.
Rear defogger switch signal Rear Defogger SW ON or OFF When rear defogger switch is turned ON.
Blower fan switch signal Blower Fan SW ON or OFF When blower fan switch is turned ON.
Light switch signal Light SW ON or OFF When small light switch is turned ON.
Tumble generator valve actuator
TGV Signal ON or OFF When TGV actuator signal is entered.
signal
Tumble generator valve drive sig-
TGV Drive ON or OFF When TGV moves and valve opens.
nal
NOTE:
EN(DOHC TURBO)-41
9. READ CURRENT DATA FOR AT. S088503A1609
2) On the ⰆSystem Selection MenuⰇ display screen, select the {Transmission Control System} and press
the [YES] key.
3) Press the [YES] key after displayed the information of transmission type.
4) On the ⰆTransmission DiagnosisⰇ display screen, select the {Current Data Display & Save} and press
the [YES] key.
Rear vehicle speed sensor signal Vehicle Speed #1 km/h or MPH
Front vehicle speed sensor signal Vehicle Speed #2 km/h or MPH
Automatic transmission fluid temperature signal ATF Temp. °C or °F
Gear position Gear Position —
Line pressure control duty ratio Line Pressure Duty Ratio %
Lock up clutch control duty ratio Lock Up Duty Ratio %
Transfer clutch control duty ratio Transfer Duty Ratio %
Power supply for throttle position sensor Throttle Sensor Power V
Torque converter turbine speed signal AT Turbine Speed rpm
2-4 brake timing pressure control duty ratio 2-4B Duty Ratio %
Intake manifold pressure sensor voltage Mani. Pressure Voltage V
2 wheel drive switch signal 2WD Switch ON or OFF
Kick down switch signal Kick Down Switch ON or OFF
Stop lamp switch signal Stop Lamp Switch ON or OFF
Anti lock brake system signal ABS Signal ON or OFF
Cruise control system signal Cruise Control Signal ON or OFF
Neutral/Parking range signal N/P Range Signal ON or OFF
Reverse range signal R Range Signal ON or OFF
Drive range signal D Range Signal ON or OFF
3rd range signal 3rd Range Signal ON or OFF
2nd range signal 2nd Range Signal ON or OFF
1st range signal 1st Range Signal ON or OFF
Shift control solenoid A Shift Solenoid #1 ON or OFF
Shift control solenoid B Shift Solenoid #2 ON or OFF
Torque control cut signal Torque Control Cut Sig. ON or OFF
2-4 brake timing control solenoid valve 2-4 Brake Timing Sol. ON or OFF
Low clutch timing control solenoid valve Low Clutch Timing Sol. ON or OFF
Automatic transmission diagnosis indicator lamp AT Diagnosis Lamp ON or OFF
NOTE:
EN(DOHC TURBO)-42
11. Read Diagnostic Trouble 3. OBD-II GENERAL SCAN TOOL S088508A1603
Code S088508
Refers to data denoting emission-related power-
train diagnostic trouble codes.
A: OPERATION S088508A16 For details concerning diagnostic trouble codes,
1. SUBARU SELECT MONITOR (NORMAL
<Ref. to EN(DOHC TURBO)-82, List of Diagnostic
MODE) S088508A1601 Trouble Code (DTC).>
1) On the ⰆMain MenuⰇ display screen, select NOTE:
the {Each System Check} and press the [YES] key. Refer to OBD-II general scan tool manufacturer’s
2) On the ⰆSystem Selection MenuⰇ display instruction manual to access emission-related
screen, select the {Engine Control System} and powertrain diagnostic trouble codes (MODE $03).
select the {Diagnostic Code(s) Display} and press
the [YES] key.
key.
NOTE:
MANUAL.
(DTC). <Ref. to EN(DOHC TURBO)-82, List of
MODE) S088508A1602
key.
the {Diagnosis Code(s) Display} and press the
[YES] key.
6) Make sure that a diagnostic trouble code (DTC)
is shown on the display screen.
NOTE:
MANUAL.
EN(DOHC TURBO)-43
INSPECTION MODE

A: OPERATION S088510A16 General Description.>
1. PREPARATION FOR THE INSPECTION
MODE S088510A1601
Raise the vehicle using a garage jack and place on
WARNING:
brakes are applied.
safety stand.
쐌 Secure a rope or wire to the front and rear S2M0285
towing or tie-down hooks to prevent the lateral 2) Connect diagnosis cable to Subaru Select
runout of front wheels. Monitor.
쐌 Do not abruptly depress/release clutch pedal 3) Insert cartridge into Subaru Select Monitor.
or accelerator pedal during works even when <Ref. to EN(DOHC TURBO)-8, PREPARATION
engine is operating at low speeds since this TOOL, General Description.>
blocks or similar items between the safety
stands and the vehicle.
S2M0286A

portion of instrument panel (on the driver’s side), to
S2M2244A
B2M2969A
2. SUBARU SELECT MONITOR S088510A1602

memory, check for any remaining unresolved
trouble data.
EN(DOHC TURBO)-44
INSPECTION MODE
5) Connect Subaru Select Monitor to data link NOTE:

connector. 쐌 For detailed operation procedure, refer to the
(1) Connect Subaru Select Monitor to data link SUBARU SELECT MONITOR OPERATION
connector (A) located in the lower portion of the MANUAL.
instrument panel (on the driver’s side). 쐌 For detailed concerning diagnostic trouble
쐌 Release the parking brake.
wheels may light either the ABS warning light, but
this indicates no malfunctions. When engine con-
trol diagnosis is finished, perform the ABS memory
S2M2157B
(2) Connect diagnosis cable to data link con- memory, check for any remaining unresolved
nector. trouble data:
CAUTION: side of the instrument panel (on the driver’s side),
Do not connect scan tools except for Subaru to the side of the center console box.
Select Monitor and OBD-II general scan tool.
S2M2244A
2) Connect the OBD-II general scan tool to its data

link connector (A) in the lower portion of the instru-
S2M0288A ment panel (on the driver’s side).
7) On the ⰆMain MenuⰇ display screen, select CAUTION:
the {2. Each System Check} and press the [YES] Do not connect the scan tools except for
key. Subaru Select Monitor and OBD-II general scan
8) On the ⰆSystem Selection MenuⰇ display tool.
select the {Dealer Check Mode Procedure} and
[YES] key.
12) Perform subsequent procedures as instructed S2M2157B
on the display screen. 3) Start the engine.

sponding diagnostic trouble code (DTC) appears NOTE:
on the display screen. 쐌 Ensure the selector lever is placed in the “P”
position before starting. (AT vehicles)
EN(DOHC TURBO)-45
INSPECTION MODE
쐌 Depress clutch pedal when starting the engine.

(MT vehicles)
4) Using the selector lever or shift lever, turn the
“P” position switch and the “N” position switch to
ON.
5) Depress the brake pedal to turn the brake
switch ON. (AT vehicles)
6) Keep engine speed in the 2,500 — 3,000 rpm
range for 40 seconds.
NOTE:
On models without tachometer, use the tachom-
eter (Secondary pickup type).
7) Place the selector lever or shift lever in the “D”
position (AT vehicles) or “1st” gear (MT vehicles)
and drive the vehicle at 5 to 10 km/h (3 to 6 MPH).
NOTE:
쐌 On AWD vehicles, release the parking brake.
wheels may light the ABS warning light, but this
indicates no malfunctions. When engine control
diagnosis is finished, perform the ABS memory
8) Using the OBD-II general scan tool, check for
diagnostic trouble code(s) and record the result(s).
NOTE:
쐌 For detailed operation procedures, refer to the
EN(DOHC TURBO)-46
CLEAR MEMORY MODE

For clear memory procedures using the OBD-II

general scan tool, refer to the OBD-II General
1. SUBARU SELECT MONITOR (NORMAL Scan Tool Instruction Manual.
MODE) S088513A1601
key.
key.
Select Monitor and ignition switch to OFF.
NOTE:
MANUAL.
MODE) S088513A1602
key.
the {4. Diagnosis Code(s) Cleared} and press the
[YES] key.
6) When the ‘Clear Diagnostic Code?’ is shown on
the display screen, press the [YES] key.
7) Turn Subaru Select Monitor and ignition switch
to OFF.
NOTE:
MANUAL.
EN(DOHC TURBO)-47
14. Compulsory Valve 5) Connect Subaru Select Monitor to data link

connector.
(1) Connect Subaru Select Monitor to data link
connector (A) located in the lower portion of the
instrument panel (on the driver’s side).
S2M2157B

nector.
S2M0285
CAUTION:
2) Connect diagnosis cable to Subaru Select Do not connect scan tools except for Subaru
Monitor. Select Monitor and OBD-II general scan tool.
3) Insert cartridge into Subaru Select Monitor. 6) Turn ignition switch to ON (engine OFF) and
<Ref. to EN(DOHC TURBO)-8, PREPARATION Subaru Select Monitor switch to ON.
TOOL, General Description.>
S2M0288A
S2M0286A
4) Connect test mode connector (A) at the lower the {2. Each System Check} and press the [YES]
portion of instrument panel (on the driver’s side), to key.
the side of the center console box. 8) On the ⰆSystem Selection MenuⰇ display
select the {System Operation Check Mode} and
11) On the ⰆSystem Operation Check ModeⰇ
display screen, select the {Actuator ON/OFF
Operation} and press the [YES] key.
12) Select the desired compulsory actuator on the
S2M2244A
ⰆActuator ON/OFF OperationⰇ display screen
13) Pressing the [NO] key completes the compul-
sory operation check mode. The display will then
return to the ⰆActuator ON/OFF OperationⰇ
screen.
EN(DOHC TURBO)-48

Contents Display
Compulsory fuel pump relay operation check Fuel Pump Relay
Compulsory radiator fan relay operation check Radiator Fan Relay
Compulsory air conditioning relay operation check A/C Compressor Relay
Compulsory purge control solenoid valve operation check CPC Solenoid Valve
NOTE:
쐌 The following parts will be displayed but not functional because they are not installed on the vehicle.
Display
EGR Solenoid Valve
ASV Solenoid Valve
PCV Solenoid Valve
Vent Control Solenoid Valve
FICD Solenoid
AAI Solenoid Valve
Fuel Tank Sensor Control Valve
EN(DOHC TURBO)-49
15. Engine Malfunction Indicator Lamp (MIL) S088653
1. Activation of check engine malfunction indicator lamp (MIL). <Ref. to EN(DOHC TURBO)-51, ACTIVATION OF CHECK
ENGINE MALFUNCTION INDICATOR LAMP (MIL), Engine Malfunction Indicator Lamp (MIL).>
↓
2. Check engine malfunction indicator lamp (MIL) does not come on. <Ref. to EN(DOHC TURBO)-52, CHECK ENGINE
MALFUNCTION INDICATOR LAMP (MIL) DOES NOT COME ON., Engine Malfunction Indicator Lamp (MIL).>
↓
3. Check engine malfunction indicator lamp (MIL) does not go off. <Ref. to EN(DOHC TURBO)-55, CHECK ENGINE MAL-
FUNCTION INDICATOR LAMP (MIL) DOES NOT GO OFF., Engine Malfunction Indicator Lamp (MIL).>
↓
4. Check engine malfunction indicator lamp (MIL) does not blink at a cycle of 3 Hz. <Ref. to EN(DOHC TURBO)-56, CHECK
Lamp (MIL).>
↓
5. Check engine malfunction indicator lamp (MIL) remains blinking at a cycle of 3 Hz. <Ref. to EN(DOHC TURBO)-60,
CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINKING AT A CYCLE OF 3 HZ., Engine Malfunction
Indicator Lamp (MIL).>
EN(DOHC TURBO)-50
B: ACTIVATION OF CHECK ENGINE 4) When ignition switch is turned to ON (engine

MALFUNCTION INDICATOR LAMP connected, the MIL blinks at a cycle of 3 Hz.
(MIL) S088653E89

lamp (MIL) (A) in the combination meter illumi-
nates.
NOTE:
nation meter circuit. <Ref. to EN(DOHC TURBO)-
52, CHECK ENGINE MALFUNCTION INDICATOR OBD0055A
LAMP (MIL) DOES NOT COME ON., Engine Mal-
function Indicator Lamp (MIL).>
S2M2215C
2) After starting the engine, the MIL goes out. If it

system is malfunctioning.
OBD0053A
3) If the diagnosis system senses a misfire which

could damage the catalyzer, the MIL will blink at a
cycle of 1 Hz.
OBD0054A
EN(DOHC TURBO)-51

COME ON. S088653E90
쐌 DIAGNOSIS:
쐌 WIRING DIAGRAM:
S2M2179
EN(DOHC TURBO)-52

and chassis ground.
(−):
ness?
FU(DOHC tor.
TURBO)-47,
Engine Control
Module.>
(B137) No. 15 — (i10) No. 9: nector
쐌 Poor contact in
coupling connec-
tor
nector. tor? tion meter con-
nector.
EN(DOHC TURBO)-53

NECTOR. necessary.
(No. 5) blows
easily, check the
harness for short
circuit of harness
between fuse (No.
5) and ignition
relay connector.
쐌 Open or short
circuit in harness
between fuse (No.
5) and battery ter-
minal
쐌 Open circuit in
harness between
fuse (No. 5) and
ignition relay con-
nector
쐌 Poor contact in
ignition relay con-
nector
쐌 Poor contact in
ignition switch
connector
7 CHECK LAMP BULB. Is lamp bulb condition OK? Repair combina- Replace lamp
Remove engine malfunction indicator lamp tion meter con- bulb.
bulb. nector.
EN(DOHC TURBO)-54

OFF. S088653E91
쐌 DIAGNOSIS:
쐌 WIRING DIAGRAM:
S2M2179

1) Turn ignition switch to OFF. between combina- FU(DOHC
2) Disconnect connector from ECM. tion meter and TURBO)-47,
3) Turn ignition switch to ON. ECM connector. Engine Control
Module.>
EN(DOHC TURBO)-55

쐌 DIAGNOSIS:
EN(DOHC TURBO)-56
쐌 WIRING DIAGRAM:
S2M2180
EN(DOHC TURBO)-57

1) Turn ignition switch to OFF. EN(DOHC
2) Disconnect test mode connector. TURBO)-52,
3) Turn ignition switch to ON. (engine OFF) CHECK ENGINE
MALFUNCTION
INDICATOR
LAMP (MIL)
DOES NOT
COME ON.,
Engine Malfunc-
tion Indicator
Lamp (MIL).>
2 CHECK HARNESS BETWEEN COMBINA- Does the MIL come on? Repair ground Go to step 3.
TION METER AND ECM CONNECTOR. short circuit in
2) Disconnect connector from ECM. combination meter
3) Turn ignition switch to ON. and ECM connec-
tor.
3 CHECK HARNESS BETWEEN TEST MODE Is resistance less than 1 Go to step 4. Repair harness
CONNECTOR AND CHASSIS GROUND. Ω? and connector.
test mode connector and chassis ground. ing:
test mode con-
nector and chas-
sis ground
nector.
5 CHECK HARNESS BETWEEN ECM AND Is resistance less than 1 Go to step 6. Repair open cir-
TEST MODE CONNECTOR. Ω? cuit in harness
1) Connect test mode connector. between ECM
2) Measure resistance of harness between and test mode
ECM and chassis ground. connector.
nector. FU(DOHC
TURBO)-47,
Engine Control
Module.>
EN(DOHC TURBO)-58
MEMO:
EN(DOHC TURBO)-59

쐌 DIAGNOSIS:
쐌 MIL blinks at a cycle of 3 Hz when ignition switch is turned to ON.
쐌 WIRING DIAGRAM:
S2M2180
EN(DOHC TURBO)-60

1 CHECK TEST MODE CONNECTOR. Does MIL flash on and off? Go to step 2. System is in good
1) Disconnect test mode connector. order.
MIL blinks at a
cycle of 3 Hz
when test mode
connector is con-
nected.
MINAL. between ECM FU(DOHC
1) Turn ignition switch to OFF. and test mode TURBO)-47,
2) Disconnect connector from ECM. connector. Engine Control
3) Measure resistance of harness between Module.>
EN(DOHC TURBO)-61
MEMO:
EN(DOHC TURBO)-62
1. Inspection of starter motor circuit. <Ref. to EN(DOHC TURBO)-64, STARTER MOTOR CIRCUIT, Diagnostics for Engine
Starting Failure.>
↓
2. Inspection of ECM power supply and ground line. <Ref. to EN(DOHC TURBO)-68, CONTROL MODULE POWER SUP-
PLY AND GROUND LINE, Diagnostics for Engine Starting Failure.>
↓
3. Inspection of ignition control system. <Ref. to EN(DOHC TURBO)-72, IGNITION CONTROL SYSTEM, Diagnostics for
↓
4. Inspection of fuel pump circuit. <Ref. to EN(DOHC TURBO)-76, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting
Failure.>
↓
5. Inspection of fuel injector circuit. <Ref. to EN(DOHC TURBO)-78, FUEL INJECTOR CIRCUIT, Diagnostics for Engine
Starting Failure.>
EN(DOHC TURBO)-63
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN(DOHC
TURBO)-47, Clear Memory Mode.> and INSPECTION MODE <Ref. to EN(DOHC TURBO)-44, Inspec-
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2181
EN(DOHC TURBO)-64

1 CHECK OPERATION OF STARTER MOTOR. Does starter motor operate Go to step 2. Go to step 3.
when the switch starts?
2 CHECK DTC. Is the trouble code stored Record DTC. Go to step 3.
<Ref. to EN(DOHC TURBO)-43, in memory? <Ref. to Repair the trouble
OPERATION, Read Diagnostic Trouble EN(DOHC TURBO)-82, case. <Ref. to
Code.> LIST, List of Diagnostic EN(DOHC
Trouble Code (DTC).> TURBO)-90, Diag-
nostic Procedure
with Diagnostic
Trouble Code
(DTC).>
MOTOR. V?
ground.
NOTE:
On AT vehicles, place the selector lever in the
1) Turn ignition switch to OFF. SC-5, Starter.> cable.
2) Disconnect terminal from starter motor.
3) Measure resistance of ground cable
ground.
and ECM.
6 CHECK HARNESS BETWEEN ECM AND Is resistance less than 1 Go to step 7. Repair ground
2) Measure resistance of fuse.
7 CHECK HARNESS BETWEEN BATTERY Is the voltage more than 10 Go to step 8. Repair open cir-
AND IGNITION SWITCH CONNECTOR. V? cuit in harness
1) Ignition switch to OFF. between ignition
2) Disconnect connector from ignition switch. switch and bat-
3) Measure power supply voltage between tery.
ignition switch connector and chassis ground.
and chassis ground.
EN(DOHC TURBO)-65

cuit between igni-
tion switch and
starter motor cir-
cuit.
2) Place the selector lever in the “P” or “N” between starter
(T3) No. 11 — No. 12:
(T3) No. 11 — (T7) No. 1:
EN(DOHC TURBO)-66
MEMO:
EN(DOHC TURBO)-67
CAUTION:
TURBO)-47, Clear Memory Mode.> and INSPECTION MODE. <Ref. to EN(DOHC TURBO)-44, Inspec-
tion Mode.>
쐌 WIRING DIAGRAM:
쐌 LHD MODEL
S2M2182
EN(DOHC TURBO)-68
쐌 RHD MODEL
S2M2183
EN(DOHC TURBO)-69

1) Turn the ignition switch to OFF. 10 Ω? relay.
1 and No. 2.
terminals.
Terminals
No. 3 — No. 5:
No. 4 — No. 6:
1) Disconnect connector from ECM. 5 Ω? cuit in harness
ECM and chassis ground. connector and
(B134) No. 7 — Chassis ground: terminal.
(B84) No. 1 — Chassis ground: (MT
model)
and chassis ground. cuit of power sup-
(–):
(–):
MAIN RELAY CONNECTOR. 1 MΩ? short circuit in
2) Measure resistance between ECM and ECM connector
chassis ground. and main relay
Connector & terminal connector, then
(B134) No. 2 — Chassis ground: replace ECM.
5 CHECK OUTPUT VOLTAGE FROM ECM. Is the voltage more than 10 Go to step 6. Replace ECM.
1) Connect connector to ECM. V? <Ref. to
2) Turn ignition switch to ON. FU(DOHC
3) Measure voltage between ECM connector TURBO)-47,
and chassis ground. Engine Control
Connector & terminal Module.>
6 CHECK INPUT VOLTAGE OF MAIN RELAY. Is the voltage more than 10 Go to step 7. Repair open cir-
Check voltage between main relay connector V? cuit in harness
and chassis ground. between ECM
Connector & terminal connector and
(B47) No. 2 (+) — Chassis ground (–): main relay con-
nector.
7 CHECK GROUND CIRCUIT OF MAIN Is the resistance less than Go to step 8. Repair open cir-
RELAY. 5 Ω? cuit between main
1) Turn ignition switch to OFF. relay and chassis
2) Measure resistance between main relay ground.
EN(DOHC TURBO)-70

tor and chassis ground. cuit in harness of
Connector & terminal power supply cir-
(B47) No. 5 (+) — Chassis ground (−): cuit.
1) Connect main relay connector. V? control system. ground short cir-
2) Turn ignition switch to ON. <Ref. to cuit in harness
3) Measure voltage between ECM connector EN(DOHC between ECM
and chassis ground. TURBO)-72, IGNI- connector and
Connector & terminal TION CONTROL main relay con-
(B137) No. 2 (+) — Chassis ground (–): SYSTEM, Diag- nector.
(B137) No. 3 (+) — Chassis ground (–): nostics for Engine
Starting Failure.>
EN(DOHC TURBO)-71
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
쐌 LHD MODEL
S2M2184
EN(DOHC TURBO)-72
쐌 RHD MODEL
EN0962

1 CHECK SPARK PLUG CONDITION. Is spark plug’s status OK? Go to step 2. Replace spark
1) Remove spark plug. <Ref. to IG(DOHC plug
TURBO)-4, Spark Plug.>
2) Check spark plug condition. <Ref. to
IG(DOHC TURBO)-4, Spark Plug.>
1) Connect spark plug to ignition coil. cylinder? system. <Ref. to
2) Release fuel pressure. <Ref. to FU(DOHC EN(DOHC
TURBO)-50, RELEASING OF FUEL TURBO)-76,
PRESSURE, OPERATION, Fuel.> FUEL PUMP
3) Contact spark plug’s thread portion on CIRCUIT, Diag-
engine. nostics for Engine
4) While opening throttle valve fully, crank Starting Failure.>
cylinder.
EN(DOHC TURBO)-73

(E33) No. 3 (+) — Engine ground (−): 쐌 Poor contact in
(E34) No. 3 (+) — Engine ground (−): coupling connec-
tors
ground. ing:
(E32) No. 2 — Engine ground: ignition coil & igni-
(E33) No. 2 — Engine ground: tor assembly con-
(E34) No. 2 — Engine ground: nector and engine
grounding termi-
nal
CONNECTOR. NOTE:
3) Disconnect connector from ignition coil & ing:
ignitor assembly. 쐌 Open circuit in
ECM and ignition coil & ignitor assembly con- ECM and ignition
nector. coil & ignitor
(B136) No. 21 — (E34) No. 1: tor
(B136) No. 22 — (E33) No. 1: 쐌 Poor contact in
(B136) No. 23 — (E32) No. 1: coupling connec-
(B136) No. 24 — (E31) No. 1: tor
7 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace ignition
Check poor contact in ECM connector. ECM connector? tact in ECM con- coil and ignitor
nector. assembly.
EN(DOHC TURBO)-74
MEMO:
EN(DOHC TURBO)-75
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2185
EN(DOHC TURBO)-76

1 CHECK OPERATING SOUND OF FUEL Does fuel pump produce Check fuel injec- Record DTC.
PUMP. operating sound? tor circuit. <Ref. to Repair the trouble
Make sure that fuel pump is in operation for EN(DOHC case. <Ref. to
two seconds when turning ignition switch to TURBO)-78, EN(DOHC
ON. FUEL INJECTOR TURBO)-90, Diag-
NOTE: CIRCUIT, Diag- nostic Procedure
Fuel pump operation can also be executed nostics for Engine with Diagnostic
using Subaru Select Monitor (Function mode: Starting Failure.> Trouble Code
FD01). (DTC).>
For the procedure, refer to “Compulsory Valve
Operation Check Mode”. <Ref. to EN(DOHC
TURBO)-48, Compulsory Valve Operation
Check Mode.>
EN(DOHC TURBO)-77
CAUTION:
쐌 After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN(DOHC
TURBO)-47, Clear Memory Mode.> and INSPECTION MODE. <Ref. to EN(DOHC TURBO)-44, Inspec-
tion Mode.>
EN(DOHC TURBO)-78
쐌 WIRING DIAGRAM:
쐌 LHD MODEL
S2M2186
EN(DOHC TURBO)-79
쐌 RHD MODEL
EN0965

While cranking the engine, check that each ME(DOHC
fuel injector emits “operating” sound. Use a TURBO)-27,
sound scope or attach a screwdriver to injec- INSPECTION,
tor for this check. Fuel Pressure.>
EN(DOHC TURBO)-80

2) Disconnect connector from #1 cylinder fuel In this case,
injector. repair the follow-
4) Measure power supply voltage between the 쐌 Open circuit in
fuel injector terminal and engine ground. harness between
#1 (E5) No. 2 (+) — Engine ground (–): fuel injector con-
(−): 쐌 Poor contact in
#3 (E6) No. 2 (+) — Engine ground (–): main relay con-
(–): 쐌 Poor contact in
coupling connec-
tor
쐌 Poor contact in
fuel injector con-
nector
FUEL INJECTOR CONNECTOR. 1 Ω? and connector.
ECM and fuel injector connector. repair the follow-
(B137) No. 1 — (E5) No. 1: 쐌 Open circuit in
(B136) No. 6 — (E16) No. 1: harness between
(B136) No. 5 — (E6) No. 1: ECM and fuel
(B136) No. 4 — (E6) No. 1: injector connector
쐌 Poor contact in
coupling connec-
tor
5 CHECK EACH FUEL INJECTOR. Is the resistance between 5 Go to step 6. Replace faulty
1) Turn ignition switch to OFF. and 20 Ω? fuel injector.
2) Measure resistance between each fuel
injector terminals.
Terminals
No. 1 — No. 2:
6 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Inspection using
Check poor contact in ECM connector. ECM connector? tact in ECM con- “General Diagnos-
nector. tic Table”. <Ref. to
EN(DOHC
TURBO)-344,
INSPECTION,
General Diagnos-
tic Table.>
EN(DOHC TURBO)-81
17. List of Diagnostic Trouble

Code (DTC) S088525
A: LIST S088525A12
DTC
Item Index
No.
P0031 Front oxygen (A/F) sensor heater <Ref. to EN(DOHC TURBO)-90, DTC P0031 — FRONT OXYGEN (A/F)
circuit low input SENSOR HEATER CIRCUIT LOW INPUT —, Diagnostic Procedure with
P0032 Front oxygen (A/F) sensor heater <Ref. to EN(DOHC TURBO)-94, DTC P0032 — FRONT OXYGEN (A/F)
circuit high input SENSOR HEATER CIRCUIT HIGH INPUT —, Diagnostic Procedure with
P0037 Rear oxygen sensor heater circuit <Ref. to EN(DOHC TURBO)-96, DTC P0037 — REAR OXYGEN SEN-
malfunction SOR HEATER CIRCUIT MALFUNCTION —, Diagnostic Procedure with
P0038 Rear oxygen sensor heater circuit <Ref. to EN(DOHC TURBO)-100, DTC P0038 — REAR OXYGEN SEN-
high input SOR HEATER CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diag-
P0101 Mass air flow sensor circuit range/ <Ref. to EN(DOHC TURBO)-102, DTC P0101 — MASS AIR FLOW SEN-
performance problem (high input) SOR CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT) —,
P0102 Mass air flow sensor circuit low <Ref. to EN(DOHC TURBO)-104, DTC P0102 — MASS AIR FLOW SEN-
input SOR CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic
P0103 Mass air flow sensor circuit high <Ref. to EN(DOHC TURBO)-108, DTC P0103 — MASS AIR FLOW SEN-
input SOR CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic
P0106 Pressure sensor circuit range/ <Ref. to EN(DOHC TURBO)-110, DTC P0106 — PRESSURE SENSOR
performance problem (low input) CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT) —, Diag-
P0107 Pressure sensor circuit low input <Ref. to EN(DOHC TURBO)-114, DTC P0107 — PRESSURE SENSOR
CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0108 Pressure sensor circuit high input <Ref. to EN(DOHC TURBO)-118, DTC P0108 — PRESSURE SENSOR
CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0111 Intake air temperature sensor circuit <Ref. to EN(DOHC TURBO)-122, DTC P0111 — INTAKE AIR TEMPERA-
range/performance problem TURE SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM —, Diag-
low input TURE SENSOR CIRCUIT LOW INPUT —, Diagnostic Procedure with
high input TURE SENSOR CIRCUIT HIGH INPUT —, Diagnostic Procedure with
P0117 Engine coolant temperature sensor <Ref. to EN(DOHC TURBO)-130, DTC P0117 — ENGINE COOLANT
circuit low input TEMPERATURE SENSOR CIRCUIT LOW INPUT —, Diagnostic Proce-
P0118 Engine coolant temperature sensor <Ref. to EN(DOHC TURBO)-132, DTC P0118 — ENGINE COOLANT
circuit high input TEMPERATURE SENSOR CIRCUIT HIGH INPUT —, Diagnostic Proce-
P0121 Throttle position sensor circuit <Ref. to EN(DOHC TURBO)-136, DTC P0121 — THROTTLE POSITION
range/performance problem (high SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT)
input) —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0122 Throttle position sensor circuit low <Ref. to EN(DOHC TURBO)-138, DTC P0122 — THROTTLE POSITION
input SENSOR CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic
EN(DOHC TURBO)-82
DTC
Item Index
No.
P0123 Throttle position sensor circuit high<Ref. to EN(DOHC TURBO)-142, DTC P0123 — THROTTLE POSITION
input SENSOR CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic
P0125 Insufficient coolant temperature for <Ref. to EN(DOHC TURBO)-146, DTC P0125 — INSUFFICIENT COOL-
closed loop fuel control ANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL —, Diag-
P0131 Front oxygen (A/F) sensor circuit <Ref. to EN(DOHC TURBO)-148, DTC P0131 — FRONT OXYGEN (A/F)
range/performance problem (low SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT)
range/performance problem (high SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT)
slow response SENSOR CIRCUIT SLOW RESPONSE —, Diagnostic Procedure with
P0136 Rear oxygen sensor circuit malfunc- <Ref. to EN(DOHC TURBO)-154, DTC P0136 — REAR OXYGEN SEN-
tion SOR CIRCUIT MALFUNCTION —, Diagnostic Procedure with Diagnostic
P0139 Rear oxygen sensor circuit slow <Ref. to EN(DOHC TURBO)-158, DTC P0139 — REAR OXYGEN SEN-
response SOR CIRCUIT SLOW RESPONSE —, Diagnostic Procedure with Diag-
P0171 Fuel trim malfunction (A/F too lean) <Ref. to EN(DOHC TURBO)-160, DTC P0171 — FUEL TRIM MALFUNC-
TION (A/F TOO LEAN) —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0172 Fuel trim malfunction (A/F too rich) <Ref. to EN(DOHC TURBO)-161, DTC P0172 — FUEL TRIM MALFUNC-
TION (A/F TOO RICH) —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0244 Wastegate control solenoid valve <Ref. to EN(DOHC TURBO)-164, DTC P0244 — WASTEGATE CON-
malfunction (high input) TROL SOLENOID VALVE MALFUNCTION (HIGH INPUT) —, Diagnostic
circuit low input TROL SOLENOID VALVE CIRCUIT LOW INPUT —, Diagnostic Procedure
circuit high input TROL SOLENOID VALVE CIRCUIT HIGH INPUT —, Diagnostic Proce-
P0301 Cylinder 1 misfire detected <Ref. to EN(DOHC TURBO)-172, DTC P0301 — CYLINDER 1 MISFIRE
(DTC).>
(DTC).>
(DTC).>
(DTC).>
P0327 Knock sensor circuit low input <Ref. to EN(DOHC TURBO)-182, DTC P0327 — KNOCK SENSOR CIR-
(DTC).>
P0328 Knock sensor circuit high input <Ref. to EN(DOHC TURBO)-184, DTC P0328 — KNOCK SENSOR CIR-
(DTC).>
P0335 Crankshaft position sensor circuit <Ref. to EN(DOHC TURBO)-186, DTC P0335 — CRANKSHAFT POSI-
malfunction TION SENSOR CIRCUIT MALFUNCTION —, Diagnostic Procedure with
EN(DOHC TURBO)-83
DTC
Item Index
No.
P0336 Crankshaft position sensor circuit <Ref. to EN(DOHC TURBO)-188, DTC P0336 — CRANKSHAFT POSI-
range/performance problem TION SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM —, Diag-
P0340 Camshaft position sensor circuit <Ref. to EN(DOHC TURBO)-190, DTC P0340 — CAMSHAFT POSITION
malfunction SENSOR CIRCUIT MALFUNCTION —, Diagnostic Procedure with Diag-
P0341 Camshaft position sensor circuit <Ref. to EN(DOHC TURBO)-192, DTC P0341 — CAMSHAFT POSITION
range/performance problem SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM —, Diagnostic
P0420 Catalyst system efficiency below <Ref. to EN(DOHC TURBO)-196, DTC P0420 — CATALYST SYSTEM
threshold EFFICIENCY BELOW THRESHOLD —, Diagnostic Procedure with Diag-
P0444 Evaporative emission control system <Ref. to EN(DOHC TURBO)-198, DTC P0444 — EVAPORATIVE EMIS-
purge control valve circuit low input SION CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT LOW
P0445 Evaporative emission control system <Ref. to EN(DOHC TURBO)-202, DTC P0445 — EVAPORATIVE EMIS-
purge control valve circuit high input SION CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH
P0461 Fuel level sensor circuit range/ <Ref. to EN(DOHC TURBO)-206, DTC P0461 — FUEL LEVEL SENSOR
performance problem CIRCUIT RANGE/PERFORMANCE PROBLEM —, Diagnostic Procedure
P0462 Fuel level sensor circuit low input <Ref. to EN(DOHC TURBO)-210, DTC P0462 — FUEL LEVEL SENSOR
Code (DTC).>
P0463 Fuel level sensor circuit high input <Ref. to EN(DOHC TURBO)-214, DTC P0463 — FUEL LEVEL SENSOR
Code (DTC).>
P0464 Fuel level sensor intermittent input <Ref. to EN(DOHC TURBO)-218, DTC P0464 — FUEL LEVEL SENSOR
INTERMITTENT INPUT —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0480 Cooling fan relay 1 circuit low input <Ref. to EN(DOHC TURBO)-222, DTC P0480 — COOLING FAN RELAY 1
Code (DTC).>
P0483 Cooling fan function problem <Ref. to EN(DOHC TURBO)-226, DTC P0483 — COOLING FAN FUNC-
TION PROBLEM —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0500 Vehicle speed sensor malfunction <Ref. to EN(DOHC TURBO)-230, DTC P0500 — VEHICLE SPEED SEN-
SOR MALFUNCTION —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0506 Idle control system RPM lower than <Ref. to EN(DOHC TURBO)-232, DTC P0506 — IDLE CONTROL SYS-
expected TEM RPM LOWER THAN EXPECTED —, Diagnostic Procedure with
P0507 Idle control system RPM higher than <Ref. to EN(DOHC TURBO)-234, DTC P0507 — IDLE CONTROL SYS-
expected TEM RPM HIGHER THAN EXPECTED —, Diagnostic Procedure with
P0508 Idle control system circuit low input <Ref. to EN(DOHC TURBO)-236, DTC P0508 — IDLE CONTROL SYS-
TEM CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic
P0509 Idle control system circuit high input <Ref. to EN(DOHC TURBO)-238, DTC P0509 — IDLE CONTROL SYS-
TEM CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic
P0512 Starter switch circuit high input <Ref. to EN(DOHC TURBO)-240, DTC P0512 — STARTER SWITCH CIR-
(DTC).>
P0153 Incorrect immobilizer key <Ref. to IM-34, DTC P0153 — INCORRECT IMMOBILIZER KEY (USE OF
UNREGISTERED KEY) —, Diagnostics Chart with Trouble Code.>
EN(DOHC TURBO)-84
DTC
Item Index
No.
P0545 Exhaust gas temperature sensor <Ref. to EN(DOHC TURBO)-242, DTC P0545 — EXHAUST GAS TEM-
circuit low input PERATURE SENSOR CIRCUIT LOW INPUT —, Diagnostic Procedure
P0546 Exhaust gas temperature sensor <Ref. to EN(DOHC TURBO)-244, DTC P0546 — EXHAUST GAS TEM-
circuit high input PERATURE SENSOR CIRCUIT HIGH INPUT —, Diagnostic Procedure
P0604 Internal control module memory <Ref. to EN(DOHC TURBO)-248, DTC P0604 — INTERNAL CONTROL
check sum error MODULE MEMORY CHECK SUM ERROR —, Diagnostic Procedure with
P0703 Brake switch input malfunction <Ref. to EN(DOHC TURBO)-252, DTC P0703 — BRAKE SWITCH INPUT
MALFUNCTION —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0705 Transmission range sensor circuit <Ref. to AT-122, CHECK INHIBITOR SWITCH., Diagnostic Procedure for
malfunction No-trouble Code.>
P0710 Transmission fluid temperature sen- <Ref. to AT-46, TROUBLE CODE 27 — ATF TEMPERATURE SENSOR
sor circuit malfunction —, Diagnostic Procedure with Trouble Code.>
P0715 Torque converter turbine speed sen- <Ref. to AT-64, TROUBLE CODE 36 — TORQUE CONVERTER TUR-
sor circuit malfunction BINE SPEED SENSOR —, Diagnostic Procedure with Trouble Code.>
P0720 Output speed sensor (vehicle speed <Ref. to AT-58, TROUBLE CODE 33 — FRONT VEHICLE SPEED SEN-
sensor 2) circuit malfunction SOR —, Diagnostic Procedure with Trouble Code.>
P0725 Engine speed input circuit malfunc- <Ref. to AT-42, TROUBLE CODE 11 — ENGINE SPEED SIGNAL —,
tion Diagnostic Procedure with Trouble Code.>
P0731 Gear 1 incorrect ratio <Ref. to EN(DOHC TURBO)-254, DTC P0731 — GEAR 1 INCORRECT
RATIO —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0741 Torque converter clutch system mal- <Ref. to EN(DOHC TURBO)-256, DTC P0741 — TORQUE CONVERTER
function CLUTCH SYSTEM MALFUNCTION —, Diagnostic Procedure with Diag-
P0743 Torque converter clutch system <Ref. to AT-96, TROUBLE CODE 77 — LOCK-UP DUTY SOLENOID —,
(Lock-up duty solenoid) electrical Diagnostic Procedure with Trouble Code.>
P0748 Pressure control solenoid (Line <Ref. to AT-88, TROUBLE CODE 75 — LINE PRESSURE DUTY SOLE-
pressure duty solenoid) electrical NOID —, Diagnostic Procedure with Trouble Code.>
P0753 Shift solenoid A (Shift solenoid 1) <Ref. to AT-72, TROUBLE CODE 71 — SHIFT SOLENOID 1 —, Diagnos-
P0758 Shift solenoid B (Shift solenoid 2) <Ref. to AT-76, TROUBLE CODE 72 — SHIFT SOLENOID 2 —, Diagnos-
P0778 2-4 brake pressure control solenoid <Ref. to AT-92, TROUBLE CODE 76 — 2- BRAKE DUTY SOLENOID —,
valve circuit malfunction Diagnostic Procedure with Trouble Code.>
P0785 2-4 brake timing control solenoid <Ref. to AT-84, TROUBLE CODE 74 — 2-4 BRAKE TIMING SOLENOID
valve circuit malfunction —, Diagnostic Procedure with Trouble Code.>
P1086 Tumble generator valve #2 (LH) <Ref. to EN(DOHC TURBO)-258, DTC P1086 — TUMBLE GENERATOR
position sensor circuit low input VALVE #2 (LH) POSITION SENSOR CIRCUIT LOW INPUT —, Diagnostic
P1087 Tumble generator valve #2 (LH) <Ref. to EN(DOHC TURBO)-262, DTC P1087 — TUMBLE GENERATOR
position sensor circuit high input VALVE #2 (LH) POSITION SENSOR CIRCUIT HIGH INPUT —, Diagnos-
tic Procedure with Diagnostic Trouble Code (DTC).>
P1088 Tumble generator valve #1 (RH) <Ref. to EN(DOHC TURBO)-266, DTC P1088 — TUMBLE GENERATOR
position sensor circuit low input VALVE #1 (RH) POSITION SENSOR CIRCUIT LOW INPUT —, Diagnostic
EN(DOHC TURBO)-85
DTC
Item Index
No.
P1089 Tumble generator valve #1 (RH) <Ref. to EN(DOHC TURBO)-270, DTC P1089 — TUMBLE GENERATOR
position sensor circuit high input VALVE #1 (RH) POSITION SENSOR CIRCUIT HIGH INPUT —, Diagnos-
P1090 Tumble generator valve #1(RH) <Ref. to EN(DOHC TURBO)-273, DTC P1090 — TUMBLE GENERATOR
malfunction (stuck open) VALVE SYSTEM #1 (RH) MALFUNCTION (STUCK OPEN) —, Diagnostic
P1091 Tumble generator valve #1(RH) <Ref. to EN(DOHC TURBO)-274, DTC P1091 — TUMBLE GENERATOR
malfunction (stuck close) VALVE SYSTEM #1 (RH) MALFUNCTION (STUCK CLOSE) —, Diagnos-
P1092 Tumble generator valve #2(LH) mal- <Ref. to EN(DOHC TURBO)-275, DTC P1092 — TUMBLE GENERATOR
function (stuck open) VALVE SYSTEM #2 (LH) MALFUNCTION (STUCK OPEN) —, Diagnostic
P1093 Tumble generator valve #2(LH) mal- <Ref. to EN(DOHC TURBO)-276, DTC P1093 — TUMBLE GENERATOR
function (stuck close) VALVE SYSTEM #2 (LH) MALFUNCTION (STUCK CLOSE) —, Diagnostic
P1094 Tumble generator valve circuit #1 <Ref. to EN(DOHC TURBO)-278, DTC P1094 — TUMBLE GENERATOR
(opencircuit) VALVE CIRCUIT #1 (OPEN CIRCUIT) —, Diagnostic Procedure with Diag-
(overcurrent) VALVE CIRCUIT #1 (OVERCURRENT) —, Diagnostic Procedure with
(opencircuit) VALVE CIRCUIT #2 (OPEN CIRCUIT) —, Diagnostic Procedure with Diag-
(overcurrent) VALVE CIRCUIT #2 (OVERCURRENT) —, Diagnostic Procedure with
P1110 Atmospheric pressure sensor low <Ref. to EN(DOHC TURBO)-286, DTC P1110 — ATMOSPHERIC PRES-
input SURE SENSOR CIRCUIT LOW INPUT —, Diagnostic Procedure with
P1111 Atmospheric pressure sensor high <Ref. to EN(DOHC TURBO)-286, DTC P1111 — ATMOSPHERIC PRES-
input SURE SENSOR CIRCUIT HIGH INPUT —, Diagnostic Procedure with
P1112 Atmospheric pressure sensor range/ <Ref. to EN(DOHC TURBO)-287, DTC P1112 — ATMOSPHERIC PRES-
performance problem SURE SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM —, Diag-
P1130 Front oxygen sensor circuit malfunc- <Ref. to EN(DOHC TURBO)-288, DTC P1130 — FRONT OXYGEN (A/F)
tion (open circuit) SENSOR CIRCUIT MALFUNCTION (OPEN CIRCUIT) —, Diagnostic Pro-
P1131 Front oxygen sensor circuit malfunc- <Ref. to EN(DOHC TURBO)-290, DTC P1131 — FRONT OXYGEN (A/F)
tion (short circuit) SENSOR CIRCUIT MALFUNCTION (SHORT CIRCUIT) —, Diagnostic
P1134 Front oxygen (A/F) sensor micro- <Ref. to EN(DOHC TURBO)-292, 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(DOHC TURBO)-294, DTC P1139 — FRONT OXYGEN (A/F)
circuit perfomance/range problem SENSOR #1 HEATER CIRCUIT RANGE/PERFORMANCE PROBLEM —,
P1141 Mass air flow sensor circuit range/ <Ref. to EN(DOHC TURBO)-296, DTC P1141 — MASS AIR FLOW SEN-
perfomance problem (low input) SOR CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT) —,
P1142 Throttle position sensor circuit <Ref. to EN(DOHC TURBO)-298, DTC P1142 — THROTTLE POSITION
range/performance problem (low SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT)
P1146 Pressure sensor circuit range/ <Ref. to EN(DOHC TURBO)-300, DTC P1146 — PRESSURE SENSOR
performance problem (high input) CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT) —, Diag-
EN(DOHC TURBO)-86
DTC
Item Index
No.
malfunction (low input) TROL SOLENOID VALVE RANGE/PERFORMANCE PROBLEM (LOW
INPUT) —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
malfunction (fail-safe) TROL SOLENOID VALVE MALFUNCTION (FAIL-SAFE) —, Diagnostic
P1301 Fire due to increased exhaust tem- <Ref. to EN(DOHC TURBO)-308, DTC P1301 — FIRE DUE TO
perature INCREASED EXHAUST TEMPERATURE —, Diagnostic Procedure with
P1312 Exhaust temperature sensor mal- <Ref. to EN(DOHC TURBO)-310, DTC P1312 — EXHAUST GAS TEM-
function PERATURE CIRCUIT MALFUNCTION —, Diagnostic Procedure with
P1480 Cooling fan relay 1 circuit high input <Ref. to EN(DOHC TURBO)-312, DTC P1480 — COOLING FAN RELAY 1
Code (DTC).>
P1507 Idle control system malfunction (fail- <Ref. to EN(DOHC TURBO)-316, DTC P1507 — IDLE CONTROL SYS-
safe) TEM MALFUNCTION (FAIL-SAFE) —, Diagnostic Procedure with Diag-
P1518 Starter switch circuit low input <Ref. to EN(DOHC TURBO)-318, DTC P1518 — STARTER SWITCH CIR-
(DTC).>
P1544 High exhaust temperature detected <Ref. to EN(DOHC TURBO)-320, DTC P1544 — HIGH EXHAUST TEM-
PERATURE DETECTED —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P1560 Back-up voltage circuit malfunction <Ref. to EN(DOHC TURBO)-322, DTC P1560 — BACK-UP VOLTAGE
CIRCUIT MALFUNCTION —, Diagnostic Procedure with Diagnostic
P1570 Antennna <Ref. to IM-35, DTC P1570 — ANTENNA —, Diagnostics Chart with
Trouble Code.>
P1571 Reference code incompatibility <Ref. to IM-26, DTC P1571 — REFERENCE CODE INCOMPATIBILITY
—, Diagnostics Chart with Trouble Code.>
P1572 IMM circuit failure except antenna <Ref. to IM-27, DTC P1572 — IMM CIRCUIT FAILURE (EXCEPT
circuit ANTENNA CIRCUIT) —, Diagnostics Chart with Trouble Code.>
P1574 Key communication failure <Ref. to IM-33, DTC P1574 — KEY COMMUNICATION FAILURE —,
P1576 EGI control module EEPROM <Ref. to IM-34, DTC P1576 — EGI CONTROL MODULE EEPROM —,
P1577 IMM control module EEPROM <Ref. to IM-34, DTC P1577 — IMM CONTROL MODULE EEPROM —,
P1590 Neutral position switch circuit high <Ref. to EN(DOHC TURBO)-326, DTC P1590 — NEUTRAL POSITION
input (AT model) SWITCH CIRCUIT HIGH INPUT (AT MODEL) —, Diagnostic Procedure
P1591 Neutral position switch circuit low <Ref. to EN(DOHC TURBO)-330, DTC P1591 — NEUTRAL POSITION
input (AT model) SWITCH CIRCUIT LOW INPUT (AT MODEL) —, Diagnostic Procedure
P1594 Automatic transmission diagnosis <Ref. to EN(DOHC TURBO)-332, DTC P1594 — AUTOMATIC TRANS-
input signal circuit malfunction MISSION DIAGNOSIS INPUT SIGNAL CIRCUIT MALFUNCTION —,
input signal circuit low input MISSION DIAGNOSIS INPUT SIGNAL CIRCUIT LOW INPUT —, Diag-
input signal circuit high input MISSION DIAGNOSIS INPUT SIGNAL CIRCUIT HIGH INPUT —, Diag-
P1700 Throttle position sensor circuit mal- <Ref. to AT-50, TROUBLE CODE 31 — THROTTLE POSITION SENSOR
function for automatic transmission —, Diagnostic Procedure with Trouble Code.>
EN(DOHC TURBO)-87
DTC
Item Index
No.
P1701 Cruise control set signal circuit mal- <Ref. to EN(DOHC TURBO)-338, DTC P1701 — CRUISE CONTROL SET
function for automatic transmission SIGNAL CIRCUIT MALFUNCTION FOR AUTOMATIC TRANSMISSION
—, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P1703 Low clutch timing control solenoid <Ref. to AT-80, TROUBLE CODE 73 — LOW CLUTCH TIMING SOLE-
valve circuit malfunction NOID —, Diagnostic Procedure with Trouble Code.>
P1711 Engine torque control signal 1 circuit <Ref. to EN(DOHC TURBO)-340, DTC P1711 — ENGINE TORQUE CON-
malfunction TROL SIGNAL 1 CIRCUIT MALFUNCTION —, Diagnostic Procedure with
P1712 Engine torque control signal 2 circuit <Ref. to EN(DOHC TURBO)-342, DTC P1712 — ENGINE TORQUE CON-
malfunction TROL SIGNAL 2 CIRCUIT MALFUNCTION —, Diagnostic Procedure with
EN(DOHC TURBO)-88
MEMO:
EN(DOHC TURBO)-89
A: DTC P0031 — FRONT OXYGEN (A/F) SENSOR HEATER CIRCUIT LOW

INPUT — S088521F83

CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(DOHC TURBO)-
47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspec-
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2187
EN(DOHC TURBO)-90

P0031 and P0037 at the
same time?
2 CHECK POWER SUPPLY TO FRONT OXY- Is the voltage more than 10 Go to step 3. Repair power sup-
GEN (A/F) SENSOR. V? ply line.
2) Disconnect connector from front oxygen In this case,
(A/F) sensor. repair the follow-
4) Measure voltage between front oxygen 쐌 Open circuit in
(A/F) sensor connector and engine ground. harness between
(B18) No. 2 (+) — Engine ground (−): front oxygen (A/F)
sensor connector
쐌 Poor contact in
front oxygen (A/F)
sensor connector
쐌 Poor contact in
main relay con-
nector
Measure resistance of harness between ECM 5 Ω? and connector.
connector and chassis ground. NOTE:
Connector & terminal In this case,
(B137) No. 8 — Chassis ground: repair the follow-
쐌 Open circuit in
harness between
ECM and engine
ground terminal
쐌 Poor contact in
ECM connector
Poor contact in
coupling connec-
tor
4 CHECK CURRENT DATA. Is the value more than 0.2 Repair poor con- Go to step 5.
1) Start engine A? tact in connector.
2) Read data of front oxygen (A/F) sensor NOTE:
heater current using Subaru Select Monitor or In this case,
NOTE: ing:
For detailed operation procedure, refer to the front oxygen (A/F)
“READ CURRENT DATA FOR ENGINE”. sensor connector
<Ref. to EN(DOHC TURBO)-36, Subaru 쐌 Poor contact in
Select Monitor.> ECM connector
쐌 OBD-II scan tool
and chassis ground.
EN(DOHC TURBO)-91

(B137) No. 4 (+) — Chassis ground (−): value with voltage meter?
7 CHECK FRONT OXYGEN (A/F) SENSOR. Is the resistance less than Repair harness Replace front oxy-
1) Turn ignition switch to OFF. 10 Ω? and connector. gen (A/F) sensor.
2) Measure resistance between front oxygen NOTE: <Ref. to
(A/F) sensor connector terminals. In this case, FU(DOHC
Terminals repair the follow- TURBO)-42, Front
No. 2 — No. 1: ing: Oxygen (A/F)
쐌 Open or ground Sensor.>
short circuit in
harness between
front oxygen (A/F)
sensor and ECM
connector
쐌 Poor contact in
front oxygen (A/F)
sensor connector
쐌 Poor contact in
ECM connector
EN(DOHC TURBO)-92
MEMO:
EN(DOHC TURBO)-93
B: DTC P0032 — FRONT OXYGEN (A/F) SENSOR HEATER CIRCUIT HIGH

INPUT — S088521F84

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2187
EN(DOHC TURBO)-94

and chassis ground.
2 CHECK FRONT OXYGEN (A/F) SENSOR Is the value more than 2.3 Replace ECM. END
HEATER CURRENT. A? <Ref. to
1) Turn ignition switch to OFF. FU(DOHC
2) Repair battery short circuit in harness TURBO)-47,
between ECM and front oxygen (A/F) sensor Engine Control
connector. Module.>
heater current using Subaru Select Monitor or
the OBD-II general scan tool.
NOTE:
<Ref. to EN(DOHC TURBO)-36, Subaru
Select Monitor.>
3 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change Repair battery END
(B137) No. 4 (+) — Chassis ground (−): value with voltage meter? oxygen (A/F) sen-
(B137) No. 5 (+) — Chassis ground (−): sor connector.
EN(DOHC TURBO)-95
C: DTC P0037 — REAR OXYGEN SENSOR HEATER CIRCUIT MALFUNCTION

— S088521F85

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2188
EN(DOHC TURBO)-96

ECM connector and chassis ground. repair the follow-
(B137) No. 8 — Chassis ground: 쐌 Open circuit in
ECM and engine
ground terminal
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor
2 CHECK CURRENT DATA. Is the value more than 0.2 Repair connector. Go to step 3.
1) Start engine. A? NOTE:
2) Read data of rear oxygen sensor heater In this case,
current using Subaru Select Monitor or OBD-II repair the follow-
general scan tool. ing:
NOTE: 쐌 Poor contact in
쐌 Subaru Select Monitor rear oxygen sen-
For detailed operation procedure, refer to the sor connector
“READ CURRENT DATA FOR ENGINE”. 쐌 Poor contact in
<Ref. to EN(DOHC TURBO)-36, Subaru rear oxygen sen-
Select Monitor.> sor connecting
쐌 OBD-II scan tool harness connector
OBD-II General Scan Tool Instruction Manual. ECM connector
and chassis ground.
(−):
(−):
5 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage less than 1.0 Replace ECM. Repair battery
1) Disconnect connector from rear oxygen V? <Ref. to short circuit in
sensor. FU(DOHC harness between
2) Measure voltage between ECM connector TURBO)-47, ECM and rear
and chassis ground. Engine Control oxygen sensor
Connector & terminal Module.> connector. After
(B136) No. 13 (+) — Chassis ground repair, replace
(−): ECM. <Ref. to
FU(DOHC
TURBO)-47,
Engine Control
Module.>
EN(DOHC TURBO)-97

6 CHECK POWER SUPPLY TO REAR OXY- Is the voltage more than 10 Go to step 7. Repair power sup-
GEN SENSOR. V? ply line.
2) Disconnect connector from rear oxygen In this case,
sor connector and engine ground or chassis harness between
ground. main relay and
Connector & terminal rear oxygen sen-
(B19) No. 2 (+) — Chassis ground (−): sor connector
쐌 Poor contact in
rear oxygen sen-
sor connector
쐌 Poor contact in
coupling connec-
tor
7 CHECK REAR OXYGEN SENSOR. Is the resistance less than Repair harness Replace rear oxy-
1) Turn ignition switch to OFF. 30 Ω? and connector. gen sensor. <Ref.
2) Measure resistance between rear oxygen NOTE: to FU(DOHC
sensor connector terminals. In this case, TURBO)-44, Rear
Terminals repair the follow- Oxygen Sensor.>
No. 1 — No. 2: ing:
쐌 Open circuit in
harness between
rear oxygen sen-
sor and ECM con-
nector
쐌 Poor contact in
rear oxygen sen-
sor connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor
EN(DOHC TURBO)-98
MEMO:
EN(DOHC TURBO)-99
D: DTC P0038 — REAR OXYGEN SENSOR HEATER CIRCUIT HIGH INPUT —

S088521F86

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2188
EN(DOHC TURBO)-100

and chassis ground.
(−):
2 CHECK CURRENT DATA. Is the value more than 7 Replace ECM. END
1) Turn ignition switch to OFF. A? <Ref. to
2) Repair battery short circuit in harness FU(DOHC
between ECM and rear oxygen sensor con- TURBO)-47,
nector. Engine Control
3) Turn ignition switch to ON. Module.>
4) Read data of rear oxygen sensor heater
current using Subaru Select Monitor or the
NOTE:
Select Monitor.>
3 CHECK POOR CONTACT. Is there poor contact in Repair poor con- END
nector.
EN(DOHC TURBO)-101
E: DTC P0101 — MASS AIR FLOW SENSOR CIRCUIT


쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2189
EN(DOHC TURBO)-102

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Replace mass air
Monitor or OBD-II general P0102 or P0103 flow and intake air
scan tool indicate DTC using “List of temperature sen-
P0102 or P0103 Diagnostic sor. <Ref. to
Trouble Code FU(DOHC
(DTC)”. <Ref. to TURBO)-34, Mass
EN(DOHC Air Flow and
TURBO)-82, List Intake Air Tem-
of Diagnostic perature Sensor.>
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0101.
EN(DOHC TURBO)-103
F: DTC P0102 — MASS AIR FLOW SENSOR CIRCUIT LOW INPUT — S088521B09

쐌 Engine stalls.
쐌 WIRING DIAGRAM:
S2M2189
EN(DOHC TURBO)-104

1 CONNECT SUBARU SELECT MONITOR OR Is the value equal to or Even if MIL lights Go to step 2.
THE OBD-II GENERAL SCAN TOOL, AND more than 1.3 g/sec (0.172 up, the circuit has
READ DATA. lb/min) or 0.3 V and equal returned to a nor-
1) Turn ignition switch to OFF. to or less than 240 g/sec mal condition at
2) Connect Subaru Select Monitor or the (32 lb/min) or 4.58 V? this time. A tem-
OBD-II general scan tool to data link connec- porary poor con-
tor. tact of the con-
3) Turn ignition switch to ON and Subaru nector or harness
Select Monitor or the OBD-II general scan may be the
tool switch to ON. cause. Repair
4) Start engine. harness or con-
5) Read data of mass air flow sensor signal nector in the
using Subaru Select Monitor or OBD-II gen- mass air flow sen-
eral scan tool. sor.
NOTE: NOTE:
쐌 Subaru Select Monitor In this case,
For detailed operation procedure, refer to the repair the follow-
“READ CURRENT DATA FOR ENGINE”. ing:
<Ref. to EN(DOHC TURBO)-36, Subaru 쐌 Open or ground
Select Monitor.> short circuit in
쐌 OBD-II general scan tool harness between
For detailed operation procedures, refer to the mass air flow sen-
OBD-II General Scan Tool Instruction Manual. sor and ECM con-
nector
쐌 Poor contact in
mass air flow sen-
sor or ECM con-
nector
and chassis ground while engine is idling.
3 CHECK INPUT SIGNAL FOR ECM (USING Does the voltage change Repair poor con- Contact your
SUBARU SELECT MONITOR). more than 0.2 V by shaking tact in ECM con- Subaru distributor.
Measure voltage between ECM connector harness and connector of nector. NOTE:
and chassis ground while engine is idling. ECM while monitoring the Inspection by
value with Subaru select DTM is required,
monitor? because probable
cause is deterio-
ration of multiple
parts.
4 CHECK POWER SUPPLY TO MASS AIR Is the voltage more than Go to step 5. Repair open cir-
FLOW SENSOR. 10V? cuit between
1) Turn ignition switch to OFF. mass air flow sen-
2) Disconnect connector from mass air flow sor and main
sensor. relay
4) Measure voltage between mass air flow
sensor connector and chassis ground.
EN(DOHC TURBO)-105

MASS AIR FLOW SENSOR CONNECTOR. 1Ω? cuit between ECM
1) Turn ignition switch to OFF. and mass air flow
2) Disconnect connector from ECM. sensor connector.
ECM and mass air flow sensor connector.
(B84) No. 13 — (B3) No. 3:
(B135) No. 27 — (B3) No. 4:
(B135) No. 19 — (B3) No. 5:
MASS AIR FLOW SENSOR CONNECTOR 1MΩ? short circuit
and chassis ground. and mass air flow
Connector & terminal sensor connector.
7 CHECK POOR CONTACT Is there poor contact in Repair poor con- Replace mass air
Check poor contact in mass air flow sensor mass air flow sensor contact in mass air flow and intake air
connector. nector? flow sensor con- temperature sen-
nector. sor. <Ref. to
FU(DOHC
TURBO)-34, Mass
Air Flow and
Intake Air Tem-
perature Sensor.>
EN(DOHC TURBO)-106
MEMO:
EN(DOHC TURBO)-107
G: DTC P0103 — MASS AIR FLOW SENSOR CIRCUIT HIGH INPUT — S088521B10

쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2189
EN(DOHC TURBO)-108

1 CONNECT SUBARU SELECT MONITOR OR Is the value equal to or Even if MIL lights Go to step 2.
THE OBD-II GENERAL SCAN TOOL, AND more than 1.3 g/sec (0.172 up, the circuit has
READ DATA. lb/min) or 0.3 V and equal returned to a nor-
1) Turn ignition switch to OFF. to or less than 240 g/sec mal condition at
2) Connect Subaru Select Monitor or the (32 lb/min) or 4.58 V? this time.
OBD-II general scan tool to data link connec-
tor.
tool switch to ON.
4) Start engine.
5) Read data of mass air flow sensor signal
eral scan tool.
NOTE:
Select Monitor.>
2 CHECK HARNESS BETWEEN ECM AND Is the value more than 240 Repair battery Replace mass air
MASS AIR FLOW SENSOR CONNECTOR. g/sec (32 lb/min) or 4.58 V short circuit in flow sensor.
1) Turn ignition switch to OFF and Subaru in function mode F06? harness between
Select Monitor or the OBD-II general scan mass air flow sen-
tool switch to OFF. sor and ECM con-
2) Disconnect connector from mass air flow nector. After
sensor. repair, replace
3) Turn ignition switch to ON and Subaru ECM.
tool switch to ON.
4) Read data of mass air flow sensor signal
using Subaru select monitor or OBD-II gen-
eral scan tool.
NOTE:
Select Monitor.>
EN(DOHC TURBO)-109
H: DTC P0106 — PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM (LOW INPUT) — S088521F90

CAUTION:
tion Mode.>.
쐌 LHD MODEL:
S2M2190
EN(DOHC TURBO)-110
쐌 RHD MODEL:
S2M2191
EN(DOHC TURBO)-111

1 CHECK IDLE SWITCH SIGNAL. Does the LED of {Idle Go to step 2. Check throttle
1) Turn ignition switch to ON. Switch Signal} come on? position sensor
2) Operate the LED operation mode for circuit. <Ref. to
engine using Subaru Select Monitor. EN(DOHC
NOTE: TURBO)-136,
쐌 Subaru Select Monitor DTC P0121 -
For detailed operation procedure, refer to the THROTTLE
“LED OPERATION MODE FOR ENGINE”. POSITION SEN-
<Ref. to EN(DOHC TURBO)-36, Subaru SOR CIRCUIT
Select Monitor.> RANGE/
PERFORMANCE
PROBLEM (HIGH
INPUT) -, Diag-
nostic Procedure
with Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0106.
scan tool indicate DTC using “List of
Trouble Code
(DTC)”. <Ref. to
EN(DOHC
TURBO)-82, List
of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0106.
3 CHECK CONDITION OF INTAKE MANIFOLD Is the pressure sensor Go to step 4. Tighten pressure
PRESSURE SENSOR. installation bolt tightened sensor installation
securely? bolt securely.
4 CHECK CONDITION OF THROTTLE BODY. Is the throttle body installa- Replace pressure Tighten throttle
tion bolt tightened sensor. <Ref. to body installation
securely? FU(DOHC bolt securely.
TURBO)-35, Pres-
sure Sensor.>
EN(DOHC TURBO)-112
MEMO:
EN(DOHC TURBO)-113
I: DTC P0107 — PRESSURE SENSOR CIRCUIT LOW INPUT — S088521B12

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
쐌 LHD MODEL
S2M2190
EN(DOHC TURBO)-114
쐌 RHD MODEL
S2M2191
EN(DOHC TURBO)-115

1 CHECK CURRENT DATA. Is the value less than −7.2 Go to step 3. Go to step 2.
1) Start engine. kPa (−54 mmHg, −2.1
NOTE:
Select Monitor.>
sensor connector. connector? pressure sensor returned to a nor-
connector. mal condition at
this time.
and chassis ground.
(B135) No. 9 (+) — Chassis ground (−): value with voltage meter? DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
5 CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 0.7 Go to step 6. Contact your
Measure voltage between ECM and chassis V? Subaru distributor.
ground. NOTE:
Connector & terminal Inspection by
(B135) No. 8 (+) — Chassis ground (−): DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
PRESSURE SENSOR CONNECTOR. 4.5 V? cuit in harness
2) Disconnect connector from pressure sen- and intake mani-
sor. fold pressure sen-
3) Turn ignition switch to ON. sor connector.
EN(DOHC TURBO)-116

2) Disconnect connector from ECM. and intake mani-
3) Measure resistance of harness between fold pressure sen-
ECM and intake manifold pressure sensor sor connector.
connector.
(B135) No. 19 — (E21) No. 2:
PRESSURE SENSOR CONNECTOR. 1 MΩ? short circuit in
Measure resistance of harness between harness between
intake manifold pressure sensor connector ECM and intake
and engine ground. manifold pressure
Connector & terminal sensor connector.
9 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace pressure
Check poor contact in pressure sensor con- pressure sensor connec- tact in pressure sensor. <Ref. to
nector. tor? sensor connector. FU(DOHC
TURBO)-35, Pres-
sure Sensor.>
EN(DOHC TURBO)-117
J: DTC P0108 — PRESSURE SENSOR CIRCUIT HIGH INPUT — S088521B13

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
쐌 LHD MODEL
S2M2190
EN(DOHC TURBO)-118
쐌 RHD MODEL
S2M2191
EN(DOHC TURBO)-119

1 CHECK CURRENT DATA. Is the value more than 282 Go to step 9. Go to step 2.
1) Start engine. kPa (2,121 mmHg, 83.50
NOTE:
Select Monitor.>
and chassis ground.
because probable
cause is deterio-
ration of multiple
parts.
4 CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 0.7 Go to step 5. Contact your
Measure voltage between ECM connector V? Subaru distributor.
and chassis ground. NOTE:
Connector & terminal Inspection by
(B135) No. 8 (+) — Chassis ground (−): DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
PRESSURE SENSOR CONNECTOR. 4.5 V? cuit in harness
2) Disconnect connector from pressure sen- and pressure sen-
sor. sor connector.
2) Disconnect connector from ECM. and pressure sen-
3) Measure resistance of harness between sor connector.
ECM and pressure sensor connector.
(B135) No. 8 — (E21) No. 1:
EN(DOHC TURBO)-120

INTAKE MANIFOLD PRESSURE SENSOR 1 Ω? cuit in harness
Measure resistance of harness between ECM and pressure sen-
and pressure sensor connector. sor connector.
(B135) No. 19 — (E21) No. 2:
8 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace intake
Check poor contact in pressure sensor con- pressure sensor connec- tact in pressure manifold pressure
nector. tor? sensor connector. sensor. <Ref. to
FU(DOHC
TURBO)-35, Pres-
sure Sensor.>
9 CHECK HARNESS BETWEEN ECM AND Is the value more than 282 Repair battery Replace pressure
PRESSURE SENSOR CONNECTOR. kPa (2,121 mmHg, 83.50 short circuit in sensor. <Ref. to
1) Turn ignition switch to OFF and Subaru inHg)? harness between FU(DOHC
Select Monitor or the OBD-II general scan ECM and pres- TURBO)-35, Pres-
tool switch to OFF. sure sensor con- sure Sensor.>
2) Disconnect connector from pressure sen- nector.
sor.
tool switch to ON.
4) Read data of intake manifold absolute
NOTE:
Select Monitor.>
EN(DOHC TURBO)-121
K: DTC P0111 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT RANGE/


CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2189
EN(DOHC TURBO)-122

P0112, P0113, P0117, P0125 using “List
P0118 or P0125? of Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN(DOHC
TURBO)-82, List
of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0111.
2 CHECK ENGINE COOLANT TEMPERA- Is the engine coolant tem- Replace mass air Inspect DTC
TURE. perature between 75°C flow and intake air P0125 using “List
1) Start the engine and warm it up completely. (167°F) and 95°C (203°F)? temperature sen- of Diagnostic
2) Measure engine coolant temperature using sor. <Ref. to Trouble Code
Subaru Select Monitor or OBD-II general scan FU(DOHC (DTC)”. <Ref. to
tool. TURBO)-34, Mass EN(DOHC
NOTE: Air Flow and TURBO)-82, List
쐌 Subaru Select Monitor Intake Air Tem- of Diagnostic
For detailed operation procedure, refer to the perature Sensor.> Trouble Code
“READ CURRENT DATA FOR ENGINE”. (DTC).>
Select Monitor.>
EN(DOHC TURBO)-123
L: DTC P0112 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW INPUT

— S088521B15

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2189
EN(DOHC TURBO)-124

NOTE: ing:
쐌 Subaru Select Monitor 쐌 Poor contact
For detailed operation procedure, refer to the mass air flow and
“READ CURRENT DATA FOR ENGINE”. intake air tem-
<Ref. to EN(DOHC TURBO)-36, Subaru perature sensor
Select Monitor.> 쐌 Poor contact in
OBD-II General Scan Tool Instruction Manual. joint connector
2 CHECK HARNESS BETWEEN MASS AIR Is the value less than Replace mass air Repair ground
FLOW AND INTAKE AIR TEMPERATURE −36°C (−33°F)? flow and intake air short circuit in
SENSOR AND ECM CONNECTOR. temperature sen- harness between
1) Turn ignition switch to OFF. sor. <Ref. to mass air flow and
2) Disconnect connector from mass air flow FU(DOHC intake air tem-
and intake air temperature sensor. TURBO)-34, Mass perature sensor
3) Turn ignition switch to ON. Air Flow and and ECM connec-
4) Read data of intake air temperature sensor Intake Air Tem- tor.
signal using Subaru Select Monitor or the perature Sensor.>
NOTE:
Select Monitor.>
EN(DOHC TURBO)-125
M: DTC P0113 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH

INPUT — S088521B16

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2189
EN(DOHC TURBO)-126

NOTE: ing:
For detailed operation procedure, refer to the mass air flow and
“READ CURRENT DATA FOR ENGINE”. intake air tem-
<Ref. to EN(DOHC TURBO)-36, Subaru perature sensor
OBD-II General Scan Tool Instruction Manual. joint connector
2 CHECK HARNESS BETWEEN MASS AIR Is the voltage more than 10 Repair battery Go to step 3.
FLOW AND INTAKE AIR TEMPERATURE V? short circuit in
SENSOR AND ECM CONNECTOR. harness between
1) Turn ignition switch to OFF. mass air flow and
2) Disconnect connector from mass air flow intake air tem-
and intake air temperature sensor. perature sensor
3) Measure voltage between mass air flow and ECM connec-
and intake air temperature sensor connector tor.
and engine ground.
1) Turn ignition switch to ON. mass air flow and
2) Measure voltage between mass air flow intake air tem-
and intake air temperature sensor connector perature sensor
and engine ground. and ECM connec-
4 CHECK HARNESS BETWEEN MASS AIR Is the voltage more than 3 Go to step 5. Repair harness
FLOW AND INTAKE AIR TEMPERATURE V? and connector.
SENSOR AND ECM CONNECTOR. NOTE:
Measure voltage between mass air flow and In this case,
intake air temperature sensor and pressure repair the follow-
sensor connector and engine ground. ing:
(B3) No. 2 (+) — Engine ground (−): harness between
mass air flow and
intake air tem-
perature sensor
and ECM connec-
tor
쐌 Poor contact in
mass air flow and
intake air tem-
perature sensor
쐌 Poor contact in
ECM
쐌 Poor contact in
joint connector
EN(DOHC TURBO)-127

5 CHECK HARNESS BETWEEN MASS AIR Is the resistance less than Replace mass air Repair harness
FLOW AND INTAKE AIR TEMPERATURE 5 Ω? flow and intake air and connector.
SENSOR AND ECM CONNECTOR. temperature sen- NOTE:
1) Turn ignition switch to OFF. sor. <Ref. to In this case,
2) Measure resistance of harness between FU(DOHC repair the follow-
mass air flow and intake air temperature sen- TURBO)-34, Mass ing:
sor and engine ground. Air Flow and 쐌 Open circuit in
Connector & terminal Intake Air Tem- harness between
(B3) No. 5 — Engine ground: perature Sensor.> mass air flow and
intake air tem-
perature sensor
and ECM connec-
tor
쐌 Poor contact in
mass air flow and
intake air tem-
perature sensor
쐌 Poor contact in
ECM
쐌 Poor contact in
joint connector
EN(DOHC TURBO)-128
MEMO:
EN(DOHC TURBO)-129
N: DTC P0117 — ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW

INPUT — S088521F91

쐌 Hard to start
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2192
EN(DOHC TURBO)-130

NOTE: ing:
<Ref. to EN(DOHC TURBO)-36, Subaru sor
tor
쐌 Poor contact in
joint connector
2 CHECK HARNESS BETWEEN ENGINE Is the value less than Replace engine Repair ground
COOLANT TEMPERATURE SENSOR AND −40°C (−40°F)? coolant tempera- short circuit in
ECM CONNECTOR. ture sensor. <Ref. harness between
1) Turn ignition switch to OFF. to FU(DOHC engine coolant
2) Disconnect connector from engine coolant TURBO)-29, temperature sen-
temperature sensor. Engine Coolant sor and ECM con-
3) Turn ignition switch to ON. Temperature Sen- nector.
4) Read data of engine coolant temperature sor.>
NOTE:
Select Monitor.>
EN(DOHC TURBO)-131
O: DTC P0118 — ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT

HIGH INPUT — S088521F92

쐌 Hard to start
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2192
EN(DOHC TURBO)-132

NOTE: ing:
<Ref. to EN(DOHC TURBO)-36, Subaru sor
tor
쐌 Poor contact in
joint connector
2) Disconnect connector from engine coolant coolant tempera-
temperature sensor. ture sensor con-
3) Measure voltage between engine coolant nector.
ground.
ground. nector.
ground. ing:
ECM and engine
coolant tempera-
ture sensor con-
nector
쐌 Poor contact in
engine coolant
temperature sen-
sor connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor
쐌 Poor contact in
joint connector
EN(DOHC TURBO)-133

5 CHECK HARNESS BETWEEN ENGINE Is the resistance less than Replace engine Repair harness
COOLANT TEMPERATURE SENSOR AND 5 Ω? coolant tempera- and connector.
ECM CONNECTOR. ture sensor. <Ref. NOTE:
1) Turn ignition switch to OFF. to FU(DOHC In this case,
2) Measure resistance of harness between TURBO)-29, repair the follow-
engine coolant temperature sensor connector Engine Coolant ing:
and engine ground. Temperature Sen- 쐌 Open circuit in
Connector & terminal sor.> harness between
coolant tempera-
ture sensor con-
nector
쐌 Poor contact in
engine coolant
temperature sen-
sor connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor
쐌 Poor contact in
joint connector
EN(DOHC TURBO)-134
MEMO:
EN(DOHC TURBO)-135
P: DTC P0121 — THROTTLE POSITION SENSOR CIRCUIT


쐌 Engine stalls.
쐌 Fuel is cut.
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode < Ref. to EN(DOHC TURBO)-
tion Mode.>.
쐌 WIRING DIAGRAM:
쐌 LHD MODEL
S2M2193
EN(DOHC TURBO)-136
쐌 RHD MODEL
S2M2194

Monitor or OBD-II general P0122, P0123 or position sensor.
scan tool indicate DTC P1507 using “ List <Ref. to
P0122, P0123 or P1507? of Diagnostic FU(DOHC
Trouble Code TURBO)-33,
(DTC)”. <Ref. to Throttle Position
EN(DOHC Sensor.>
TURBO)-82, List
of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0121.
EN(DOHC TURBO)-137
Q: DTC P0122 — THROTTLE POSITION SENSOR CIRCUIT LOW INPUT —

S088521B20

쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
쐌 LHD MODEL
S2M2193
EN(DOHC TURBO)-138
쐌 RHD MODEL
S2M2194
EN(DOHC TURBO)-139

<Ref. to EN(DOHC TURBO)-36, Subaru NOTE:
Select Monitor.> In this case,
throttle position
sensor connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor
closed.
because probable
cause is deterio-
ration of multiple
parts.
and chassis ground.
Monitor?
EN(DOHC TURBO)-140

TOR. NOTE:
tion sensor. ing:
쐌 Poor contact in
throttle position
sensor connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor
쐌 Poor contact in
joint connector
TOR. NOTE:
ECM connector and throttle position sensor ing:
connector. 쐌 Open circuit in
(B135) No. 7 — (E13) No. 3: throttle position
sensor and ECM
connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
throttle position
sensor connector
쐌 Poor contact in
coupling connec-
tor
ground. connector.
9 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace throttle
Check poor contact in throttle position sensor throttle position sensor contact in throttle position sensor.
connector. nector? position sensor <Ref. to
connector. FU(DOHC
TURBO)-33,
Throttle Position
Sensor.>
EN(DOHC TURBO)-141
R: DTC P0123 — THROTTLE POSITION SENSOR CIRCUIT HIGH INPUT — S088521B21

쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
쐌 LHD MODEL
S2M2193
EN(DOHC TURBO)-142
쐌 RHD MODEL
S2M2194
EN(DOHC TURBO)-143

throttle position
sensor connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor
2 CHECK HARNESS BETWEEN THROTTLE Is the resistance less than Go to step 3. Repair harness
TOR. NOTE:
2) Disconnect connector from throttle position repair the follow-
sensor. ing:
throttle position sensor connector and engine harness between
ground. throttle position
쐌 Poor contact in
coupling connec-
tor
쐌 Poor contact in
joint connector
3 CHECK HARNESS BETWEEN THROTTLE Is the voltage more than Repair battery Replace throttle
POSITION SENSOR AND ECM CONNEC- 4.9 V? short circuit in position sensor.
TOR. harness between <Ref. to
1) Turn ignition switch to ON. throttle position FU(DOHC
2) Measure voltage between throttle position sensor and ECM TURBO)-33,
sensor connector and engine ground. connector. After Throttle Position
Connector & terminal repair, replace Sensor.>
FU(DOHC
TURBO)-47,
Engine Control
Module.>
EN(DOHC TURBO)-144
MEMO:
EN(DOHC TURBO)-145
S: DTC P0125 — INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED

LOOP FUEL CONTROL — S088521B22

쐌 Engine would not return to idling.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2192
EN(DOHC TURBO)-146

Trouble Code
(DTC)”. <Ref. to
EN(DOHC
TURBO)-82, List
of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0125.
2 CHECK ENGINE COOLING SYSTEM. Is there a fault in engine Replace thermo- Replace engine
NOTE: cooling system? stat. <Ref. to coolant tempera-
Check the following items. CO-23, Thermo- ture sensor. <Ref.
쐌 Thermostat open stuck stat.> to FU(DOHC
쐌 Coolant level TURBO)-29,
쐌 Coolant freeze Engine Coolant
쐌 Tire diameter Temperature Sen-
sor.>
EN(DOHC TURBO)-147
T: DTC P0131 — FRONT OXYGEN (A/F) SENSOR CIRCUIT

NOTE:
For the diagnostic procedure, refer to DTC P0132. <Ref. to EN(DOHC TURBO)-150, DTC P0132 — FRONT
OXYGEN (A/F) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT) —, Diagnostic
EN(DOHC TURBO)-148
MEMO:
EN(DOHC TURBO)-149
U: DTC P0132 — FRONT OXYGEN (A/F) SENSOR CIRCUIT


CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2187
EN(DOHC TURBO)-150

P0031, P0032, P1131, P1139 using “List
Trouble Code
(DTC)”.<Ref. to
EN(DOHC
TURBO)-82, List
of Diagnostic
Trouble Code
(DTC).>
2 CHECK FRONT (A/F) OXYGEN SENSOR Is the value equal to or Go to step 3. Go to step 4.
70°C (158°F).
general scan tool.
NOTE:
Select Monitor.>
3 CHECK REAR OXYGEN SENSOR SIGNAL. Does the LED of {Rear O2 Repair poor con- Check rear oxy-
1) Race engine at speeds from idling to 5,000 Rich Signal} blink? tact in front oxygen sensor circuit.
rpm for a total of 5 cycles. gen (A/F) sensor <Ref. to
NOTE: and rear oxygen FU(DOHC
To increase engine speed to 5,000 rpm, sensor connector. TURBO)-44, Rear
slowly depress accelerator pedal, taking Oxygen Sensor.>
2) Operate the LED operation mode for
engine.
NOTE:
“LED OPERATION MODE FOR ENGINE”.
Select Monitor.>
NOTE: <Ref. to
Check the following items. FU(DOHC
쐌 Loose installation of portions TURBO)-42, Front
쐌 Damage (crack, hole etc.) of parts Oxygen (A/F)
쐌 Looseness of front oxygen (A/F) sensor Sensor.>
sensor
EN(DOHC TURBO)-151
V: DTC P0133 — FRONT OXYGEN (A/F) SENSOR CIRCUIT SLOW

RESPONSE — S088521B26

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2187
EN(DOHC TURBO)-152

P0031, P0032, P0131, P1130, P1131,
P0132, P1130, P1131, P1134 or P1139
P1134 or P1139? using “List of
Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN(DOHC
TURBO)-82, List
of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0133.
2 CHECK EXHAUST SYSTEM. Is there a fault in exhaust Repair exhaust Replace front oxy-
NOTE: system? system. gen (A/F) sensor.
Check the following items. <Ref. to
쐌 Loose installation of front portion of exhaust FU(DOHC
pipe onto cylinder heads TURBO)-42, Front
쐌 Loose connection between front exhaust Oxygen (A/F)
pipe and front catalytic converter Sensor.>
쐌 Damage of exhaust pipe resulting in a hole
EN(DOHC TURBO)-153
W: DTC P0136 — REAR OXYGEN SENSOR CIRCUIT MALFUNCTION — S088521B28

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2188
EN(DOHC TURBO)-154

P0131 or P0132?
2 CHECK FAILURE CAUSE OF P0131 or Is the failure cause of Check fuel sys- Go to step 3.
P0132. P0131 or P0132 in the fuel tem.
Inspect DTC P0131 or P0132 using “List of system? NOTE:
Diagnostic Trouble Code (DTC)”. <Ref. to In this case, it is
EN(DOHC TURBO)-82, List of Diagnostic not necessary to
Trouble Code (DTC).> inspect DTC
P0136.
3 CHECK REAR OXYGEN SENSOR DATA. Does the value fluctuate? Go to step 7. Go to step 4.
1) Warm-up the engine until engine coolant
temperature is above 70°C (158°F), and keep
the engine speed at 2,000 rpm to 3,000 rpm
for two minutes.
2) Read data of rear oxygen sensor signal
eral scan tool.
NOTE:
“READ CURRENT DATA SHOWN ON DIS-
PLAY FOR ENGINE”. <Ref. to EN(DOHC
TURBO)-36, Subaru Select Monitor.>
4 CHECK REAR OXYGEN SENSOR DATA. Is the value fixed between Go to step 5. Replace rear oxy-
Read data of rear oxygen sensor signal using 0.2 and 0.4 V? gen sensor. <Ref.
Subaru Select Monitor or OBD-II General to FU(DOHC
Scan Tool. TURBO)-44, Rear
Oxygen Sensor.>
5 CHECK HARNESS BETWEEN ECM AND Is the resistance more than Repair open cir- Go to step 6.
REAR OXYGEN SENSOR CONNECTOR. 3 Ω? cuit in harness
2) Disconnect connectors from ECM and rear and rear oxygen
oxygen sensor. sensor connector.
ECM and rear oxygen sensor connector.
(B135) No. 26 — (B19) No. 4:
6 CHECK HARNESS BETWEEN REAR OXY- Is the voltage more than Replace rear oxy- Repair harness
GEN SENSOR AND ECM CONNECTOR. 0.2 V? gen sensor. <Ref. and connector.
1) Turn ignition switch to OFF. to FU(DOHC NOTE:
2) Disconnect connector from rear oxygen TURBO)-44, Rear In this case,
sensor. Oxygen Sensor.> repair the follow-
sor harness connector and engine ground or harness between
chassis ground. rear oxygen sen-
Connector & terminal sor and ECM con-
(B19) No. 3 (+) — Engine ground (−): nector
쐌 Poor contact in
rear oxygen sen-
sor connector
쐌 Poor contact in
ECM connector
EN(DOHC TURBO)-155

7 CHECK EXHAUST SYSTEM. Is there a fault in exhaust Repair or replace Replace rear oxy-
Check exhaust system parts. system? faulty parts. gen sensor. <Ref.
NOTE: to FU(DOHC
Check the following items. TURBO)-44, Rear
쐌 Loose installation of portions Oxygen Sensor.>
쐌 Damage (crack, hole etc.) of parts
sensor
EN(DOHC TURBO)-156
MEMO:
EN(DOHC TURBO)-157
X: DTC P0139 — REAR OXYGEN SENSOR CIRCUIT SLOW RESPONSE — S088521B29

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2188
EN(DOHC TURBO)-158

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Replace rear oxy-
Monitor or OBD-II general P0136 using “List gen sensor. <Ref.
scan tool indicate DTC of Diagnostic to FU(DOHC
P0136? Trouble Code TURBO)-44, Rear
(DTC)”. <Ref. to Oxygen Sensor.>
EN(DOHC
TURBO)-82, List
of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0139.
EN(DOHC TURBO)-159
Y: DTC P0171 — FUEL TRIM MALFUNCTION (A/F TOO LEAN) — S088521B33
NOTE:
For the diagnostic procedure, refer to DTC P0172. <Ref. to EN(DOHC TURBO)-161, DTC P0172 — FUEL
TRIM MALFUNCTION (A/F TOO RICH) —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(DOHC TURBO)-160
Z: DTC P0172 — FUEL TRIM MALFUNCTION (A/F TOO RICH) — S088521B32

쐌 Engine stalls.
CAUTION:
tion Mode.>.
1 CHECK EXHAUST SYSTEM. Are there holes or loose Repair exhaust Go to step 2.
bolts on exhaust system? system.
air intake system?
WARNING: 284 and 314 kPa (2.9 — ing items.
쐌 Place “NO FIRE” signs near the working 3.2 kg/cm2, 41 — 46 psi)? Fuel pressure
area. too high
쐌 Be careful not to spill fuel on the floor. 쐌 Clogged fuel
1) Release fuel pressure. return line or bent
(1) Disconnect connector from fuel pump hose
relay. Fuel pressure
(2) Start the engine and run it until it stalls. too low
(3) After the engine stalls, crank it for five 쐌 Improper fuel
more seconds. pump discharge
(4) Turn ignition switch to OFF. 쐌 Clogged fuel
2) Connect connector to fuel pump relay. supply line
3) Disconnect fuel delivery hose from fuel
filter, and connect fuel pressure gauge.
5) Start the engine and idle while gear posi-
tion is neutral.
pressure regulator vacuum hose from intake
manifold.
WARNING:
Before removing fuel pressure gauge,
release fuel pressure.
NOTE:
If fuel pressure does not increase, squeeze
fuel return hose 2 to 3 times, then measure
fuel pressure again.
EN(DOHC TURBO)-161

After connecting pressure regulator vacuum 206 and 235 kPa (2.1 — ing items.
hose, measure fuel pressure. 2.4 kg/cm2, 30 — 34 psi)? Fuel pressure
WARNING: too high
Before removing fuel pressure gauge, 쐌 Faulty pressure
release fuel pressure. regulator
NOTE: 쐌 Clogged fuel
쐌 If fuel pressure does not increase, squeeze return line or bent
fuel return hose 2 to 3 times, then measure hose
fuel pressure again. Fuel pressure
쐌 If out of specification as measured at this too low
step, check or replace pressure regulator and 쐌 Faulty pressure
pressure regulator vacuum hose. regulator
쐌 Improper fuel
pump discharge
쐌 Clogged fuel
supply line
5 CHECK ENGINE COOLANT TEMPERA- Is temperature greater than Go to step 6. Replace engine
TURE SENSOR. 60°C (140°F)? coolant tempera-
1) Start the engine and warm-up completely. ture sensor. <Ref.
2) Read data of engine coolant temperature to FU(DOHC
sensor signal using Subaru Select Monitor or TURBO)-29,
OBD-II general scan tool. Engine Coolant
NOTE: Temperature Sen-
쐌 Subaru Select Monitor sor.>
Select Monitor.>
6 CHECK INTAKE MANIFOLD PRESSURE Is the value within the Go to step 7. Replace mass air
SENSOR. specifications? flow and intake
1) Start the engine and warm-up engine until manifold pressure
coolant temperature is greater than 60°C sensor. <Ref. to
(140°F). FU(DOHC
2) Place the shift lever in neutral position. TURBO)-34, Mass
3) Turn A/C switch to OFF. Air Flow and
4) Turn all accessory switches to OFF. Intake Air Tem-
5) Read data of intake manifold pressure sen- perature Sensor.>
NOTE:
Select Monitor.>
Specification:
Ignition ON
73.3 — 106.6 kPa (550 — 800 mmHg,
21.65 — 31.50 inHg)
Idling
24.0 — 41.3 kPa (180 — 310 mmHg,
7.09 — 12.20 inHg)
EN(DOHC TURBO)-162

7 CHECK INTAKE AIR TEMPERATURE SEN- Is value obtained when Contact your Check mass air
SOR. ambient temperature is Subaru distributor. flow and intake air
1) Start the engine and warm-up engine until subtracted from intake air NOTE: temperature sen-
coolant temperature is greater than 60°C temperature greater than Inspection by sor. <Ref. to
(140°F). −10°C (14°F) and less than DTM is required, FU(DOHC
2) Place the shift lever in neutral position. 50°C (122°F)? because probable TURBO)-34, Mass
3) Turn A/C switch to OFF. cause is deterio- Air Flow and
4) Turn all accessory switches to OFF. ration of multiple Intake Air Tem-
5) Open front hood. parts. perature Sensor.>
6) Measure ambient temperature.
NOTE:
Select Monitor.>
EN(DOHC TURBO)-163
AA: DTC P0244 — WASTEGATE CONTROL SOLENOID VALVE

MALFUNCTION (HIGH INPUT) — S088521H65

쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2195
EN(DOHC TURBO)-164

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Replace waste-
Monitor or OBD-II general P0245 or P0246 gate control sole-
scan tool indicate DTC using “List of noid valve. <Ref.
P0245 or P0246? Diagnostic to FU(DOHC
(DTC)”. <Ref. to Wastegate Control
EN(DOHC Solenoid Valve.>
TURBO)-82, List
of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0121.
EN(DOHC TURBO)-165
AB: DTC P0245 — WASTEGATE CONTROL SOLENOID VALVE CIRCUIT LOW

INPUT — S088521H66

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2195
EN(DOHC TURBO)-166

(B137) No. 24 (+) — Chassis ground with your Subaru
(−): distributor.
NOTE:
Inspection by
DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
2 CHECK HARNESS BETWEEN WASTEGATE Is the resistance less than Repair ground Go to step 3.
1) Turn ignition switch to OFF. ECM and waste-
2) Disconnect connectors from wastegate gate control sole-
control solenoid valve and ECM. noid valve con-
3) Measure resistance of harness between nector.
wastegate control solenoid valve connector
and engine ground.
3 CHECK HARNESS BETWEEN WASTEGATE Is the resistance less than Go to step 4. Repair open cir-
Measure resistance of harness between ECM and wastegate
and wastegate control solenoid valve of har- control solenoid
ness connector. valve connector.
(B137) No. 24 — (B127) No. 1: In this case,
repair the follow-
ing:
쐌 Open circuit in
harness between
ECM and waste-
gate control sole-
noid valve con-
nector
4 CHECK WASTEGATE CONTROL SOLE- Is the resistance between Go to step 5. Replace waste-
NOID VALVE. 30 and 34 Ω? gate control sole-
1) Remove wastegate control solenoid valve. noid valve. <Ref.
2) Measure resistance between purge control to FU(DOHC
solenoid valve terminals. TURBO)-41,
Terminals Wastegate Control
No. 1 — No. 2: Solenoid Valve.>
5 CHECK POWER SUPPLY TO WASTEGATE Is the voltage more than 10 Go to step 6. Repair open cir-
CONTROL SOLENOID VALVE. V? cuit in harness
2) Measure voltage between wastegate con- relay and waste-
trol solenoid valve and engine ground. gate control sole-
Connector & terminal noid valve con-
(B127) No. 2 (+) — Engine ground (−): nector.
EN(DOHC TURBO)-167

Check poor contact in wastegate control sole- wastegate control solenoid tact in wastegate Subaru distributor.
noid valve connector. valve connector? control solenoid NOTE:
valve connector. Inspection by
DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
EN(DOHC TURBO)-168
MEMO:
EN(DOHC TURBO)-169
AC: DTC P0246 — WASTEGATE CONTROL SOLENOID VALVE CIRCUIT HIGH

INPUT — S088521H67

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2195
EN(DOHC TURBO)-170

sis ground.
(−):
nector. FU(DOHC
TURBO)-47,
Engine Control
Module.>
3 CHECK HARNESS BETWEEN WASTEGATE Is the voltage more than 10 Repair battery Go to step 4.
1) Turn ignition switch to OFF. ECM and waste-
2) Disconnect connector from wastegate con- gate control sole-
trol solenoid valve. noid valve con-
3) Turn ignition switch to ON. nector. After
4) Measure voltage between ECM and chas- repair, replace
sis ground. ECM. <Ref. to
Connector & terminal FU(DOHC
(B137) No. 24 (+) — Chassis ground TURBO)-47,
(−): Engine Control
Module.>
4 CHECK WASTEGATE CONTROL SOLE- Is the resistance less than Replace waste- Go to step 5.
NOID VALVE. 1 Ω? gate control sole-
1) Turn ignition switch to OFF. noid valve <Ref.
2) Measure resistance between wastegate to FU(DOHC
control solenoid valve terminals. TURBO)-41,
Terminals Wastegate Control
No. 1 — No. 2: Solenoid Valve.>
and ECM <Ref. to
FU(DOHC
TURBO)-47,
Engine Control
Module.>
nector. FU(DOHC
TURBO)-47,
Engine Control
Module.>
EN(DOHC TURBO)-171
AD: DTC P0301 — CYLINDER 1 MISFIRE DETECTED — S088521B37
NOTE:
For the diagnostic procedure, refer to DTC P0304. <Ref. to EN(DOHC TURBO)-172, DTC P0304 — CYL-
INDER 4 MISFIRE DETECTED —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AE: DTC P0302 — CYLINDER 2 MISFIRE DETECTED — S088521B38
NOTE:
AF: DTC P0303 — CYLINDER 3 MISFIRE DETECTED — S088521B39
NOTE:
AG: DTC P0304 — CYLINDER 4 MISFIRE DETECTED — S088521B40

쐌 Immediately at fault recognition (A misfire which could damage catalyst occurs.)
쐌 Engine stalls.
쐌 Rough driving
CAUTION:
tion Mode.>.
EN(DOHC TURBO)-172
쐌 WIRING DIAGRAM:
쐌 LHD MODEL
S2M2186
EN(DOHC TURBO)-173
쐌 RHD MODEL
EN0965
EN(DOHC TURBO)-174

P0106, P0107, P0108, P0118 or P0125
P0117, P0118 or P0125? using “List of
Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN(DOHC
TURBO)-82, List
of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0301, P0302,
P0303 and
P0304.
and chassis ground on faulty cylinders.
(−):
(−):
(−):
(−):
3 CHECK HARNESS BETWEEN FUEL INJEC- Is the resistance less than Repair ground Go to step 4.
TOR AND ECM CONNECTOR. 10 Ω? short circuit in
2) Disconnect connector from fuel injector on fuel injector and
faulty cylinders. ECM connector.
and engine ground on faulty cylinders.
4 CHECK HARNESS BETWEEN FUEL INJEC- Is the resistance less than Go to step 5. Repair harness
TOR AND ECM CONNECTOR. 1 Ω? and connector.
Measure resistance of harness connector NOTE:
between ECM connector and fuel injector on In this case,
faulty cylinders. repair the follow-
#1 (B137) No. 1 — (E5) No. 1: 쐌 Open circuit in
#2 (B136) No. 6 — (E16) No. 1: harness between
#3 (B136) No. 5 — (E6) No. 1: ECM and fuel
#4 (B136) No. 4 — (E17) No. 1: injector connector
쐌 Poor contact in
coupling connec-
tor
EN(DOHC TURBO)-175

5 CHECK FUEL INJECTOR. Is the resistance between 5 Go to step 6. Replace faulty
Measure resistance between fuel injector ter- and 20 Ω? fuel injector. <Ref.
minals on faulty cylinder. to FU(DOHC
Terminals TURBO)-37, Fuel
No. 1 — No. 2: Injector.>
6 CHECK POWER SUPPLY LINE. Is the voltage more than 10 Repair poor con- Repair harness
1) Turn ignition switch to ON. V? tact in all connec- and connector.
2) Measure voltage between fuel injector and tors in fuel injector NOTE:
engine ground on faulty cylinders. circuit. In this case,
#1 (E5) No. 2 (+) — Engine ground (−): ing:
#2 (E16) No. 2 (+) — Engine ground 쐌 Open circuit in
(−): harness between
#3 (E6) No. 2 (+) — Engine ground (−): main relay and
(−): nector on faulty
cylinders
쐌 Poor contact in
coupling connec-
tor
쐌 Poor contact in
main relay con-
nector
쐌 Poor contact in
fuel injector con-
nector on faulty
cylinders
7 CHECK HARNESS BETWEEN FUEL INJEC- Is the voltage more than 10 Repair battery Go to step 8.
TOR AND ECM CONNECTOR. V? short circuit in
2) Disconnect connector from fuel injector on ECM and fuel
faulty cylinder. injector. After
3) Turn ignition switch to ON. repair, replace
4) Measure voltage between ECM connector ECM. <Ref. to
and chassis ground on faulty cylinders. FU(DOHC
Connector & terminal TURBO)-47,
#1 (B137) No. 1 (+) — Chassis ground Engine Control
(−): Module.>
(−):
(−):
(−):
8 CHECK FUEL INJECTOR. Is the resistance less than Replace faulty Go to step 9.
1) Turn ignition switch to OFF. 1 Ω? fuel injector <Ref.
2) Measure resistance between fuel injector to FU(DOHC
terminals on faulty cylinder. TURBO)-37, Fuel
Terminals Injector.> and
No. 1 — No. 2: ECM <Ref. to
FU(DOHC
TURBO)-47,
Engine Control
Module.>
9 CHECK INSTALLATION OF CAMSHAFT Is camshaft position sensor Tighten camshaft Go to step 10.
POSITION SENSOR/CRANKSHAFT POSI- or crankshaft position sen- position sensor or
TION SENSOR. sor loosely installed? crankshaft posi-
tion sensor.
EN(DOHC TURBO)-176

10 CHECK CRANKSHAFT SPROCKET. Is crankshaft sprocket Replace crank- Go to step 11.
Remove timing belt cover. rusted or does it have bro- shaft sprocket.
ken teeth? <Ref. to
ME(DOHC
TURBO)-57,
Crankshaft
Sprocket.>
11 CHECK INSTALLATION CONDITION OF Is timing belt dislocated Repair installation Go to step 12.
TIMING BELT. from its proper position? condition of timing
Turn crankshaft using ST, and align alignment belt. <Ref. to
mark on crankshaft sprocket with alignment ME(DOHC
mark on cylinder block. TURBO)-48, Tim-
ST 499987500 CRANKSHAFT SOCKET ing Belt Assem-
bly.>
12 CHECK FUEL LEVEL. Is the fuel meter indication Go to step 13. Replenish fuel so
higher than the “Lower” fuel meter indica-
level? tion is higher than
the “Lower” level.
After replenishing
fuel, Go to step
13.
13 CHECK STATUS OF CHECK ENGINE MAL- Is the MIL coming on or Go to step 15. Go to step 14.
FUNCTION INDICATOR LAMP (MIL). blinking?
1) Clear memory using Subaru Select Moni-
tor.
<Ref. to EN(DOHC TURBO)-47, Clear
Memory Mode.>
2) Start engine, and drive the vehicle more
than 10 minutes.
14 CHECK CAUSE OF MISFIRE DIAGNOSED. Was the cause of misfire Finish diagnostics Repair poor con-
diagnosed when the engine operation, if the tact.
is running? engine has no NOTE:
abnormality. In this case,
NOTE: repair the follow-
Ex. Remove spark ing:
plug cord, etc. 쐌 Poor contact in
ignitor connector
쐌 Poor contact in
ignition coil con-
nector
쐌 Poor contact in
fuel injector con-
nector on faulty
cylinders
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor
EN(DOHC TURBO)-177

15 CHECK AIR INTAKE SYSTEM. Is there a fault in air intake Repair air intake Go to step 16.
system? system.
NOTE:
Check the follow-
ing items:
쐌 Are there air
leaks or air suc-
tion caused by
loose or dislo-
cated nuts and
bolts?
쐌 Are there
cracks or any dis-
connection of
hoses?
16 CHECK MISFIRE SYMPTOM. Does the Subaru Select Go to step 21. Go to step 17.
1) Turn ignition switch to ON. Monitor or OBD-II general
2) Read diagnostic trouble code (DTC). scan tool indicate only one
쐌 Subaru Select Monitor DTC?
Select Monitor.>
OBD-II General Scan Tool Operation Manual.
NOTE:
Perform diagnosis according to the items
listed below.
P0301 and P0302?
P0303 and P0304?
P0301 and P0303?
P0302 and P0304?
21 ONLY ONE CYLINDER Is there a fault in that cylin- Repair or replace Go to DTC P0171
der? faulty parts. and P0172. <Ref.
NOTE: to EN(DOHC
Check the follow- TURBO)-160,
ing items. DTC P0171 -
쐌 Spark plug FUEL TRIM MAL-
쐌 Fuel injector FUNCTION (A/F
쐌 Compression TOO LEAN) -,
ratio Diagnostic Proce-
dure with Diag-
nostic Trouble
Code (DTC).>
EN(DOHC TURBO)-178

22 GROUP OF #1 AND #2 CYLINDERS Are there faults in #1 and Repair or replace Go to DTC P0171
#2 cylinders? faulty parts. and P0172. <Ref.
NOTE: to EN(DOHC
쐌 Check the fol- TURBO)-160,
lowing items. DTC P0171 -
Spark plugs FUEL TRIM MAL-
Fuel injectors FUNCTION (A/F
Ignition coil TOO LEAN) -,
Compression ratio Diagnostic Proce-
쐌 If no abnormal dure with Diag-
is discovered, nostic Trouble
check for “IGNI- Code (DTC).>
TION CONTROL
SYSTEM” of #1
and #2 cylinders
side. <Ref. to
EN(DOHC
TURBO)-72, IGNI-
TION CONTROL
SYSTEM, Diag-
nostics for Engine
Starting Failure.>
NOTE: to EN(DOHC
쐌 Check the fol- TURBO)-160,
lowing items. DTC P0171 -
Spark plugs FUEL TRIM MAL-
Fuel injectors FUNCTION (A/F
Ignition coil TOO LEAN) -,
쐌 If no abnormal Diagnostic Proce-
is discovered, dure with Diag-
check for “16. D: nostic Trouble
IGNITION CON- Code (DTC).>
TROL SYSTEM”
of #3 and #4 cyl-
inders side. <Ref.
to EN(DOHC
TURBO)-72, IGNI-
TION CONTROL
SYSTEM, Diag-
nostics for Engine
Starting Failure.>
NOTE: to EN(DOHC
ing items. DTC P0171 —
쐌 Spark plugs FUEL TRIM MAL-
쐌 Fuel injectors FUNCTION (A/F
쐌 Skipping timing TOO LEAN) —,
belt teeth Diagnostic Proce-
dure with Diag-
nostic Trouble
Code (DTC).>
EN(DOHC TURBO)-179

NOTE: to EN(DOHC
ing items. DTC P0171 —
쐌 Spark plugs FUEL TRIM MAL-
쐌 Fuel injectors FUNCTION (A/F
쐌 Compression TOO LEAN) —,
ratio Diagnostic Proce-
쐌 Skipping timing dure with Diag-
belt teeth nostic Trouble
Code (DTC).>
26 CYLINDER AT RANDOM Is the engine idle rough? Go to DTC P0171 Repair or replace
and P0172. <Ref. faulty parts.
to EN(DOHC NOTE:
TURBO)-160, Check the follow-
DTC P0171 — ing items.
FUEL TRIM MAL- 쐌 Spark plugs
FUNCTION (A/F 쐌 Fuel injectors
TOO LEAN) —, 쐌 Compression
Diagnostic Proce- ratio
dure with Diag-
nostic Trouble
Code (DTC).>
EN(DOHC TURBO)-180
MEMO:
EN(DOHC TURBO)-181
AH: DTC P0327 — KNOCK SENSOR CIRCUIT LOW INPUT — S088521F94

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
EN0975
EN(DOHC TURBO)-182

1 CHECK HARNESS BETWEEN KNOCK Is the resistance more than Go to step 2. Repair harness
SENSOR AND ECM CONNECTOR. 700 kΩ? and connector.
3) Measure resistance between ECM harness repair the follow-
connector and chassis ground. ing:
knock sensor and
ECM connector
쐌 Poor contact in
knock sensor con-
nector
쐌 Poor contact in
coupling connec-
tor
쐌 Open circuit in
harness between
knock sensor and
ECM connector
쐌 Poor contact in
knock sensor con-
nector
쐌 Poor contact in
coupling connec-
tor
securely? FU(DOHC bolt securely.
TURBO)-32,
Knock Sensor.>
EN(DOHC TURBO)-183
AI: DTC P0328 — KNOCK SENSOR CIRCUIT HIGH INPUT — S088521F95

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
EN0975
EN(DOHC TURBO)-184

1) Disconnect connector from knock sensor. 400 kΩ? sensor. <Ref. to short circuit in
2) Measure resistance between knock sensor FU(DOHC harness between
connector terminal and engine ground. TURBO)-32, knock sensor con-
Terminal Knock Sensor.> nector and ECM
NOTE:
The harness
between both
connectors is
shielded. Repair
short circuit of
harness together
with shield.
1) Connect connectors to ECM and knock V? up, the circuit has tact in ECM con-
sensor. returned to a nor- nector.
2) Turn ignition switch to ON. mal condition at
3) Measure voltage between ECM and chas- this time.
sis ground. (However, the
Connector & terminal possibility of poor
(B135) No. 4 (+) — Chassis ground (−): contact still
remains.)
NOTE:
In this case,
repair the follow-
ing:
쐌 Poor contact in
knock sensor con-
nector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor
EN(DOHC TURBO)-185
AJ: DTC P0335 — CRANKSHAFT POSITION SENSOR CIRCUIT

MALFUNCTION — S088521B42

쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
EN0976
EN(DOHC TURBO)-186

1 CHECK HARNESS BETWEEN CRANK- Is the resistance more than Repair harness Go to step 2.
SHAFT POSITION SENSOR AND ECM 100 kΩ? and connector.
CONNECTOR. NOTE:
2) Disconnect connector from crankshaft posi- repair the follow-
tion sensor. ing:
engine ground. crankshaft posi-
(E10) No. 1 — Engine ground: ECM connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor
2 CHECK HARNESS BETWEEN CRANK- Is the resistance less than Repair ground Go to step 3.
SHAFT POSITION SENSOR AND ECM 10 Ω? short circuit in
Measure resistance of harness between crankshaft posi-
crankshaft position sensor connector and tion sensor and
engine ground. ECM connector.
between both
connectors are
shielded. Repair
ground short cir-
cuit in harness
together with
shield.
3 CHECK HARNESS BETWEEN CRANK- Is the resistance less than Go to step 4. Repair harness
SHAFT POSITION SENSOR AND ECM 5 Ω? and connector.
CONNECTOR. NOTE:
Measure resistance of harness between In this case,
crankshaft position sensor connector and repair the follow-
engine ground. ing:
crankshaft posi-
tion sensor and
ECM connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor
securely.
5 CHECK CRANKSHAFT POSITION SENSOR. Is the resistance between 1 Repair poor con- Replace crank-
1) Remove crankshaft position sensor. and 4 kΩ? tact in crankshaft shaft position sen-
2) Measure resistance between connector position sensor sor. <Ref. to
terminals of crankshaft position sensor. connector. FU(DOHC
Terminals TURBO)-30,
No. 1 — No. 2: Crankshaft Posi-
tion Sensor.>
EN(DOHC TURBO)-187
AK: DTC P0336 — CRANKSHAFT POSITION SENSOR CIRCUIT


쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
EN0976
EN(DOHC TURBO)-188

Monitor or OBD-II general P0335 using “List
scan tool indicate DTC of Diagnostic
P0335? Trouble Code
(DTC)”. <Ref. to
EN(DOHC
TURBO)-82, List
of Diagnostic
Trouble Code
(DTC).>
securely.
3 CHECK CRANKSHAFT SPROCKET. Are crankshaft sprocket Replace crank- Go to step 4.
Remove front belt cover. teeth cracked or damaged? shaft sprocket.
<Ref. to
FU(DOHC
TURBO)-30,
Crankshaft Posi-
tion Sensor.>
4 CHECK INSTALLATION CONDITION OF Is timing belt dislocated Repair installation Replace crank-
TIMING BELT. from its proper position? condition of timing shaft position sen-
Turn crankshaft using ST, and align alignment belt. <Ref. to sor. <Ref. to
mark on crankshaft sprocket with alignment ME(DOHC FU(DOHC
mark on cylinder block. TURBO)-48, Tim- TURBO)-30,
ST 499987500 CRANKSHAFT SOCKET ing Belt Assem- Crankshaft Posi-
bly.> tion Sensor.>
EN(DOHC TURBO)-189
AL: DTC P0340 — CAMSHAFT POSITION SENSOR CIRCUIT MALFUNCTION

— S088521B44

쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
EN0977
EN(DOHC TURBO)-190

TOR. NOTE:
tion sensor. ing:
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor
ground. connector.
between both
connectors are
shielded. Repair
ground short cir-
cuit in harness
together with
shield.
TOR. NOTE:
ground. ing:
camshaft position
sensor and ECM
connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor
securely.
5 CHECK CAMSHAFT POSITION SENSOR. Is the resistance between 1 Repair poor con- Replace camshaft
1) Remove camshaft position sensor. and 4 kΩ? tact in camshaft position sensor.
2) Measure resistance between connector position sensor <Ref. to
terminals of camshaft position sensor. connector. FU(DOHC
No. 1 — No. 2: Camshaft Position
Sensor.>
EN(DOHC TURBO)-191
AM: DTC P0341 — CAMSHAFT POSITION SENSOR CIRCUIT


쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
EN0977
EN(DOHC TURBO)-192

1 CHECK ANY OTHER DTC ON DISPLAY. Inspect DTC
Does the Subaru Select Go to step 2.
P0340 using “List
of Diagnostic
P0340? Trouble Code
(DTC)”. <Ref. to
EN(DOHC
TURBO)-82, List
of Diagnostic
Trouble Code
(DTC).>
TOR. NOTE:
tion sensor. ing:
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor
ground. connector.
between both
connectors are
shielded. Repair
ground short cir-
cuit in harness
together with
shield.
TOR. NOTE:
ground. ing:
camshaft position
sensor and ECM
connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor
EN(DOHC TURBO)-193

securely.
6 CHECK CAMSHAFT POSITION SENSOR. Is the resistance between 1 Go to step 7. Replace camshaft
1) Remove camshaft position sensor. and 4 kΩ? position sensor.
2) Measure resistance between connector <Ref. to
terminals of camshaft position sensor. FU(DOHC
No. 1 — No. 2: Camshaft Position
Sensor.>
securely.
8 CHECK CAMSHAFT SPROCKET. Are camshaft sprocket Replace camshaft Go to step 9.
Remove front belt cover. <Ref. to ME(DOHC teeth cracked or damaged? sprocket. <Ref. to
TURBO)-47, Belt Cover.> ME(DOHC
TURBO)-56,
Camshaft
Sprocket.>
9 CHECK INSTALLATION CONDITION OF Is timing belt dislocated Repair installation Replace camshaft
TIMING BELT. from its proper position? condition of timing position sensor.
Turn camshaft using ST, and align alignment belt. <Ref. to <Ref. to
mark on camshaft sprocket with alignment ME(DOHC FU(DOHC
mark on timing belt cover LH. TURBO)-48, Tim- TURBO)-31,
ST 499207400 CAMSHAFT SPROCKET ing Belt Assem- Camshaft Position
WRENCH bly.> Sensor.>
EN(DOHC TURBO)-194
MEMO:
EN(DOHC TURBO)-195
AN: DTC P0420 — CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD

— S088521B46

쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2196
EN(DOHC TURBO)-196

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect the rel- Go to step 2.
Monitor or OBD-II general evant DTC using
scan tool indicate DTC “List of Diagnostic
P0031, P0032, P0131, Trouble Code
P0132, P0133, P1130, (DTC)”. <Ref. to
P1131, P1134, P1139, EN(DOHC
P0037, P0038, P0136 and TURBO)-82, List
P0139? of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0420.
2 CHECK EXHAUST SYSTEM. Is there a fault in exhaust Repair or replace Go to step 3.
Check for gas leaks or air suction caused by system? exhaust system.
loose or dislocated nuts and bolts, and open <Ref. to
hole at exhaust pipes. EX(DOHC
NOTE: TURBO)-2, Gen-
Check the following positions. eral Description.>
쐌 Between cylinder head and front exhaust
pipe
쐌 Between front exhaust pipe and front cata-
lytic converter
쐌 Between front catalytic converter and rear
catalytic converter
3 CHECK REAR CATALYTIC CONVERTER. Is there damage at rear Replace front Go to step 4.
Separate rear catalytic converter from rear face of rear catalyst? catalytic converter
exhaust pipe. <Ref. to
EC(DOHC
TURBO)-3, Front
Catalytic Con-
verter.> and rear
catalytic con-
verter. <Ref. to
EC(DOHC
TURBO)-4, Rear
Catalytic Con-
verter.>
4 CHECK FRONT CATALYTIC CONVERTER. Is there damage at rear Replace front Contact your
Remove front catalytic converter. face or front face of front catalytic con- Subaru distributor.
catalyst? verter. <Ref. to NOTE:
EC(DOHC Inspection by
TURBO)-3, Front DTM is required,
Catalytic Con- because probable
verter.> cause is deterio-
ration of multiple
parts.
EN(DOHC TURBO)-197
AO: DTC P0444 — EVAPORATIVE EMISSION CONTROL SYSTEM PURGE

CONTROL VALVE CIRCUIT LOW INPUT — S088521G47

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2197
EN(DOHC TURBO)-198

(B137) No. 16 (+) — Chassis ground your Subaru dis-
(−): tributor.
NOTE:
Inspection by
DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
2 CHECK HARNESS BETWEEN PURGE Is the resistance less than Repair ground Go to step 3.
2) Disconnect connectors from purge control control solenoid
solenoid valve and ECM. valve connector.
purge control solenoid valve connector and
engine ground.
Measure resistance of harness between ECM and purge control
and purge control solenoid valve of harness solenoid valve
connector. connector.
(B137) No. 16 — (E4) No. 2: In this case,
repair the follow-
ing:
쐌 Open circuit in
harness between
ECM and purge
control solenoid
valve connector
쐌 Poor contact in
coupling connec-
tor
2) Measure resistance between purge control EC(DOHC
solenoid valve terminals. TURBO)-7, Purge
Terminals Control Solenoid
No. 1 — No. 2: Valve.>
5 CHECK POWER SUPPLY TO PURGE CON- Is the voltage more than 10 Go to step 6. Repair open cir-
TROL SOLENOID VALVE. V? cuit in harness
2) Measure voltage between purge control relay and purge
solenoid valve and engine ground. control solenoid
EN(DOHC TURBO)-199

connector. Inspection by
DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
EN(DOHC TURBO)-200
MEMO:
EN(DOHC TURBO)-201
AP: DTC P0445 — EVAPORATIVE EMISSION CONTROL SYSTEM PURGE

CONTROL VALVE CIRCUIT HIGH INPUT — S088521G48

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2197
EN(DOHC TURBO)-202

1 CHECK OUTPUT SIGNAL FROM ECM. Does voltage change Go to step 2. Even if MIL light
4) While operating purge control solenoid contact in ECM
valve, measure voltage between ECM and connector.
chassis ground.
NOTE:
Purge control solenoid valve operation can be
executed using Subaru Select Monitor. For
procedure, refer to “Compulsory Valve Opera-
tion Check Mode”. <Ref. to EN(DOHC
TURBO)-48, Compulsory Valve Operation
Check Mode.>
(−):
sis ground.
(−):
nector. FU(DOHC
TURBO)-47,
Engine Control
Module.>
2) Disconnect connector from purge control control solenoid
4) Measure voltage between ECM and chas- replace ECM.
sis ground. <Ref. to
(B137) No. 16 (+) — Chassis ground TURBO)-47,
(−): Engine Control
Module.>
5 CHECK PURGE CONTROL SOLENOID Is the resistance less than Replace purge Go to step 6.
VALVE. 1 Ω? control solenoid
1) Turn ignition switch to OFF. valve <Ref. to
2) Measure resistance between purge control EC(DOHC
solenoid valve terminals. TURBO)-7, Purge
Terminals Control Solenoid
No. 1 — No. 2: Valve.> and ECM
<Ref. to
FU(DOHC
TURBO)-47,
Engine Control
Module.>
EN(DOHC TURBO)-203

nector. FU(DOHC
TURBO)-47,
Engine Control
Module.>
EN(DOHC TURBO)-204
MEMO:
EN(DOHC TURBO)-205
AQ: DTC P0461 — FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE


CAUTION:
tion Mode.>.
EN(DOHC TURBO)-206
쐌 WIRING DIAGRAM:
S2M2198
EN(DOHC TURBO)-207

Monitor or OBD-II general P0462 or P0463 sensor <Ref. to
scan tool indicate DTC using “List of FU(DOHC
P0462 or P0463? Diagnostic TURBO)-62, Fuel
Trouble Code Level Sensor.>
(DTC)”. <Ref. to and fuel sub level
EN(DOHC sensor <Ref. to
TURBO)-82, List FU(DOHC
of Diagnostic TURBO)-63, Fuel
Trouble Code Sub Level Sen-
(DTC).> sor.>
NOTE:
In this case, it is
not necessary to
inspect this
trouble.
EN(DOHC TURBO)-208
MEMO:
EN(DOHC TURBO)-209
AR: DTC P0462 — FUEL LEVEL SENSOR CIRCUIT LOW INPUT — S088521B55

CAUTION:
tion Mode.>.
EN(DOHC TURBO)-210
쐌 WIRING DIAGRAM:
S2M2198
EN(DOHC TURBO)-211

IDI-4, Combina-
tion Meter Sys-
tem.>
2 CHECK INPUT SIGNAL FOR ECM. Is the voltage less than Go to step 6. Go to step 3.
1) Turn ignition switch to ON. (Engine OFF) 0.12 V?
and chassis ground.
(−):
3 CHECK INPUT SIGNAL FOR ECM. (USING Does the value change Repair poor con- Even if MIL lights
SUBARU SELECT MONITOR.) less than 0.12 V by shak- tact in ECM con- up, the circuit has
Read data of fuel level sensor signal using ing harness and connector nector. returned to a nor-
Subaru Select Monitor. of ECM while monitoring mal condition at
NOTE: the value with Subaru this time. A tem-
쐌 Subaru Select Monitor Select Monitor? porary poor con-
For detailed operation procedure, refer to the tact of the con-
“READ CURRENT DATA FOR ENGINE”. nector may be the
<Ref. to EN(DOHC TURBO)-36, Subaru cause.
Select Monitor.> NOTE:
In this case,
repair the follow-
ing:
쐌 Poor contact in
combination meter
connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tors
4 CHECK INPUT VOLTAGE OF ECM. Is the voltage more than Go to step 4. Go to step 7.
2) Separate fuel tank cord connector (R57)
(−):
COMBINATION METER. 1 MΩ? short circuit in
2) Disconnect connector from connector (i10), ECM and combi-
(i12) and ECM connector. nation meter con-
3) Measure resistance between ECM and nector.
chassis ground.
EN(DOHC TURBO)-212

6 CHECK HARNESS BETWEEN ECM AND Is the resistance less than Repair or replace Repair open cir-
COMBINATION METER. 10 Ω? combination cuit between ECM
Measure resistance between ECM and combi- meter. <Ref. to and combination
nation meter connector. IDI-4, Combina- meter connector.
Connector & terminal tion Meter Sys- NOTE:
(B135) No. 25 — (i11) No. 1: tem.> In this case,
repair the follow-
ing:
Poor contact in
coupling connec-
tor
1) Turn ignition switch to OFF. 1 MΩ? short circuit in fuel
2) Disconnect connector from fuel sub level tank cord.
sensor.
sensor and chassis ground.
1) Disconnect connector from fuel pump 1 MΩ? short circuit in fuel
assembly. tank cord.
2) Measure resistance between fuel pump
assembly and chassis ground.
9 CHECK FUEL LEVEL SENSOR. Is the resistance between Go to step 10. Replace fuel level
1) Remove fuel pump assembly. <Ref. to 0.5 and 2.5 Ω? sensor.
FU(DOHC TURBO)-60, Fuel Pump.>
sor and terminals with its float set to the full
position.
Terminals
No. 3 — No. 5:
10 CHECK FUEL SUB LEVEL SENSOR. Is the resistance between Repair poor con- Replace fuel sub
1) Remove fuel sub level sensor. <Ref. to 0.5 and 2.5 Ω? tact in harness level sensor.
FU(DOHC TURBO)-63, Fuel Sub Level Sen- between ECM
sor.> and combination
2) Measure resistance between fuel sub level meter connector.
sensor and terminals with its float set to the
full position.
Terminals
No. 1 — No. 2:
EN(DOHC TURBO)-213
AS: DTC P0463 — FUEL LEVEL SENSOR CIRCUIT HIGH INPUT — S088521B56

CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref. to EN(DOHC TURBO)-
tion Mode.>.
EN(DOHC TURBO)-214
쐌 WIRING DIAGRAM:
S2M2198
EN(DOHC TURBO)-215

IDI-4, Combina-
tion Meter Sys-
tem.>
2 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than Go to step 3. Even if MIL lights
1) Turn ignition switch to ON. (Engine OFF) 4.75 V? up, the circuit has
2) Measure voltage between ECM connector returned to a nor-
and chassis ground. mal condition at
Connector & terminal this time. A tem-
(B135) No. 25 (+) — Chassis ground porary poor con-
(−): tact of the con-
nector may be the
cause.
NOTE:
In this case,
repair the follow-
ing:
쐌 Poor contact in
fuel pump con-
nector
쐌 Poor contact in
coupling connec-
tor
3 CHECK INPUT VOLTAGE OF ECM. Is the voltage more than Go to step 4. Repair battery
1) Turn ignition switch to OFF. 4.75 V? short circuit
2) Disconnect combination meter connector between ECM
(i10) and ECM connector. and combination
3) Turn ignition switch to ON. meter connector.
and chassis ground.
(−):
FUEL TANK CORD. 5 Ω? cuit between ECM
1) Turn ignition switch to OFF. and fuel tank
2) Separate fuel tank cord connector (R57) cord.
3) Measure resistance between ECM and fuel
tank cord.
(B135) No. 25 — (R15) No. 2:
5 CHECK HARNESS BETWEEN FUEL TANK Is the resistance less than Go to step 6. Repair open cir-
CORD AND CHASSIS GROUND. 5 Ω? cuit between fuel
Measure resistance between fuel tank cord tank cord and
and chassis ground. chassis ground.
(R15) No. 6 — Chassis ground: In this case,
repair the follow-
ing:
Poor contact in
coupling connec-
tors
EN(DOHC TURBO)-216

1) Disconnect connector from fuel level sen- 10 Ω? cuit between cou-
sor. pling connector
2) Measure resistance between fuel level sen- and fuel level sen-
sor and coupling connector. sor.
(R57) No. 6 — (R58) No. 5:
1) Disconnect connector from fuel sub level 10 Ω? cuit between fuel
sensor. level sensor and
2) Measure resistance between fuel level sen- fuel sub level sen-
sor and fuel sub level sensor. sor.
(R58) No. 3 — (R59) No. 2:
Measure resistance between fuel sub level 10 Ω? cuit between cou-
sensor and coupling connector. pling connector
Connector & terminal and fuel sub level
(R57) No. 2 — (R59) No. 1: sensor.
9 CHECK FUEL LEVEL SENSOR. Is the resistance more than Replace fuel level Go to step 10.
1) Remove fuel pump assembly. <Ref. to 53 Ω? sensor. <Ref. to
FU(DOHC TURBO)-60, Fuel Pump.> FU(DOHC
2) While moving fuel level sensor float up and TURBO)-62, Fuel
down, measure resistance between fuel level Level Sensor.>
sensor terminals.
Terminals
No. 3 — No. 5:
10 CHECK FUEL SUB LEVEL SENSOR. Is the resistance more than Replace fuel sub Replace combina-
1) Remove fuel sub level sensor. <Ref. to 45 Ω? level sensor. tion meter. <Ref.
FU(DOHC TURBO)-63, Fuel Sub Level Sen- <Ref. to to IDI-15, Combi-
sor.> FU(DOHC nation Meter
2) While moving fuel sub level sensor float up TURBO)-63, Fuel Assembly.>
and down, measure resistance between fuel Sub Level Sen-
sub level sensor terminals. sor.>
Terminals
No. 1 — No. 2:
EN(DOHC TURBO)-217
AT: DTC P0464 — FUEL LEVEL SENSOR INTERMITTENT INPUT— S088521G01

CAUTION:
tion Mode.>.
EN(DOHC TURBO)-218
쐌 WIRING DIAGRAM:
S2M2198
EN(DOHC TURBO)-219

Trouble Code
(DTC)”. <Ref. to
EN(DOHC
TURBO)-82, List
of Diagnostic
Trouble Code
(DTC).>
2 CHECK FUEL LEVEL SENSOR. Does the resistance Go to step 3. Replace fuel level
1) Remove fuel pump assembly. <Ref. to change smoothly between sensor. <Ref. to
FU(DOHC TURBO)-60, Fuel Pump.> approx. 0.5 Ω and approx. FU(DOHC
2) While moving fuel level sensor float up and 52 Ω? TURBO)-62, Fuel
down, make sure that the resistance between Level Sensor.>
fuel level sensor terminals changes smoothly.
Terminals
No. 3 — No. 5:
3 CHECK FUEL SUB LEVEL SENSOR. Does the resistance Repair poor con- Replace fuel sub
1) Remove fuel sub level sensor. <Ref. to change smoothly between tact in ECM, com- level sensor.
FU(DOHC TURBO)-63, Fuel Sub Level Sen- approx. 0.5 Ω and approx. bination meter <Ref. to
sor.> 44 Ω? and coupling con- FU(DOHC
2) While moving fuel sub level sensor float up nectors. TURBO)-63, Fuel
and down, make sure that the resistance Sub Level Sen-
between fuel level sensor terminals changes sor.>
smoothly.
Terminals
No. 1 — No. 2:
EN(DOHC TURBO)-220
MEMO:
EN(DOHC TURBO)-221
AU: DTC P0480 — COOLING FAN RELAY 1 CIRCUIT LOW INPUT — S088521B57

쐌 Overheating
CAUTION:
tion Mode.>.
EN(DOHC TURBO)-222
쐌 WIRING DIAGRAM:
S2M2199
EN(DOHC TURBO)-223

1 CHECK OUTPUT SIGNAL FROM ECM. Does voltage change Repair poor con- Go to step 2.
1) Turn ignition switch to OFF. between 0 and 10 V? tact in ECM con-
2) Connect test mode connector at the lower nector.
portion of instrument panel (on the driver’s
side), to the side of the center console box.
4) While operating radiator fan relay, measure
voltage between ECM terminal and ground.
NOTE:
Mode”. < Ref. to EN(DOHC TURBO)-36,
(−):
2 CHECK GROUND SHORT CIRCUIT IN Is the resistance less than Repair ground Go to step 3.
RADIATOR MAIN FAN RELAY CONTROL 10 Ω? short circuit in
CIRCUIT. radiator fan relay
1) Turn ignition switch to OFF. control circuit.
2) Disconnect connectors from ECM.
3 CHECK POWER SUPPLY FOR RELAY. Is the voltage more than 10 Go to step 4. Repair open cir-
1) Remove main fan relay from A/C relay V? cuit in harness
holder. between ignition
2) Turn ignition switch to ON. switch and fuse
3) Measure voltage between fuse and relay and relay box
box (F/B) connector and chassis ground. (F/B) connector.
2) Remove main fan relay.
Terminal
No. 26 — No. 25:
No. 28 of main fan relay.
Terminal
No. 26 — No. 25:
6 CHECK OPEN CIRCUIT IN MAIN FAN Is the resistance less than Go to step 7. Repair harness
RELAY CONTROL CIRCUIT. 1 Ω? and connector.
and main fan relay connector. In this case,
(B137) No. 17 — (F66) No. 27: ing:
쐌 Open circuit in
harness between
ECM and main
fan relay connec-
tor
쐌 Poor contact in
coupling connec-
tor
EN(DOHC TURBO)-224

Check poor contact in ECM or main fan relay ECM or main fan relay contact in ECM or Subaru distributor.
connector. nector? main fan relay
connector.
EN(DOHC TURBO)-225
AV: DTC P0483 — COOLING FAN FUNCTION PROBLEM — S088521B58

쐌 Occurrence of noise
쐌 Overheating
CAUTION:
tion Mode.>.
NOTE:
If the vehicle, with the engine idling, is placed very close to a wall or another vehicle, preventing normal
cooling function, the OBD system may detect malfunction.
EN(DOHC TURBO)-226
쐌 WIRING DIAGRAM:
S2M2199
EN(DOHC TURBO)-227

1 CHECK ANY OTHER DTC ON DISPLAY. Is there any other DTC on Inspect the rel- Check radiator
display? evant DTC using fan, fan motor and
“List of Diagnostic thermostat. <Ref.
Trouble Code to CO-8, Radiator
(DTC)”. <Ref. to Main Fan Sys-
EN(DOHC tem.> and <Ref.
TURBO)-82, List to CO-11, Radia-
of Diagnostic tor Sub Fan Sys-
Trouble Code tem.> If thermo-
(DTC).> stat is stuck,
replace thermo-
stat.
EN(DOHC TURBO)-228
MEMO:
EN(DOHC TURBO)-229
AW: DTC P0500 — VEHICLE SPEED SENSOR MALFUNCTION — S088521B59

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2200

AT?
EN(DOHC TURBO)-230

AT-58, TROUBLE
CODE 33 —
FRONT VEHICLE
SPEED SENSOR
—, Diagnostic
Procedure with
Trouble Code.>
speed sensor.
<Ref. to IDI-17,
Speedometer.>
and <Ref. to
AT-32, Front
Vehicle Speed
Sensor.> and
<Ref. to AT-36,
Rear Vehicle
Speed Sensor.>
and <Ref. to
AT-37, Torque
Converter Turbine
Speed Sensor.>
nation meter con-
nector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
combination meter
connector
쐌 Poor contact in
coupling connec-
tor
EN(DOHC TURBO)-231
AX: DTC P0506 — IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED
— S088521B61

쐌 Engine is difficult to start.
쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2201
EN(DOHC TURBO)-232

P0508 or P0509 Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN(DOHC
TURBO)-82, List
of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0506.
2 CHECK IDLE AIR CONTROL SOLENOID Does air flow out? Go to step 4. Replace idle air
VALVE. control solenoid
1) Turn ignition switch to OFF. valve. <Ref. to
2) Remove idle air control solenoid valve from FU(DOHC
throttle body. <Ref. to FU(DOHC TURBO)-36, TURBO)-36, Idle
REMOVAL, Idle Air Control Solenoid Valve.> Air Control Sole-
3) Using an air gun, force air into idle air con- noid Valve.> After
trol solenoid valve by-pass air inlet. Confirm replace, Go to
that forced air subsequently escapes from step 3.
both main air passage and assist air passage.
3 CHECK IDLE AIR CONTROL SOLENOID Is the value more than Go to step 4. END.
VALVE DUTY RATIO. 60%?
2) Start engine, and warm-up the engine.
3) Turn all accessory switches to OFF.
4) Read data of idle air control solenoid valve
duty ratio using Subaru Select Monitor or
NOTE:
Select Monitor.>
4 CHECK BY-PASS AIR LINE. Does air flow out? Replace idle air Replace throttle
1) Turn ignition switch to OFF. control solenoid body. <Ref. to
2) Remove idle air control solenoid valve from valve. <Ref. to FU(DOHC
throttle body. <Ref. to FU(DOHC TURBO)-36, FU(DOHC TURBO)-14,
REMOVAL, Idle Air Control Solenoid Valve.> TURBO)-36, Idle Throttle Body.>
3) Remove throttle body to intake manifold. Air Control Sole-
<Ref. to FU(DOHC TURBO)-14, REMOVAL, noid Valve.>
Throttle Body.>
4) Using an air gun, force air into solenoid
valve installation area and throttle valve inte-
rior. Confirm that forced air subsequently
escapes from both these areas.
EN(DOHC TURBO)-233
AY: DTC P0507 — IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED
— S088521B62

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2201
EN(DOHC TURBO)-234

P0508 or P0509 Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN(DOHC
TURBO)-82, List
of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0507.
SP-12,
INSTALLATION,
Accelerator Con-
trol Cable.>
3 CHECK AIR INTAKE SYSTEM. Is there a fault in air intake Repair air suction Replace idle air
1) Turn ignition switch to ON. system? and leaks. control solenoid
2) Start engine, and idle it. valve. <Ref. to
3) Check the following items. FU(DOHC
쐌 Loose installation of intake manifold, idle air TURBO)-36, Idle
control solenoid valve and throttle body Air Control Sole-
쐌 Cracks of intake manifold gasket, idle air noid Valve.>
body gasket
EN(DOHC TURBO)-235
AZ: DTC P0508 — IDLE CONTROL SYSTEM CIRCUIT LOW INPUT — S088521H68

쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2201
EN(DOHC TURBO)-236

1) Turn ignition switch to ON. V? tact in ECM con-
sis ground.
(−):
2) Disconnect connector from idle air control In this case,
solenoid valve. repair the follow-
4) Measure voltage between idle air control 쐌 Open circuit in
solenoid valve and engine ground. harness between
Connector & terminal idle air control
and main relay
connector
쐌 Poor contact in
coupling connec-
tor
IDLE AIR CONTROL SOLENOID VALVE 1 Ω? and connector.
CONNECTOR. NOTE:
ECM and idle air control solenoid valve con- 쐌 Open circuit in
nector. harness between
Connector & terminal ECM and idle air
(B136) No. 10 — (E7) No. 1: control solenoid
valve connector
쐌 Poor contact in
coupling connec-
tor
IDLE AIR CONTROL SOLENOID VALVE 10 Ω? short circuit in
and chassis ground. control solenoid
5 CHECK GROUND CIRCUIT OF IDLE AIR Is the resistance less than Go to step 6. Repair open cir-
CONTROL SOLENOID VALVE. 5 Ω? cuit in harness
Measure resistance of harness between idle between idle air
air control solenoid valve connector and control solenoid
engine ground. valve connector
Connector & terminal and engine
(E7) No. 3 — Engine ground: ground terminal.
6 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace idle air
Check poor contact in ECM and idle air con- ECM and idle air control tact in ECM and control solenoid
trol solenoid valve connectors. solenoid valve connectors? idle air control valve. <Ref. to
solenoid valve FU(DOHC
connectors. TURBO)-36, Idle
Air Control Sole-
noid Valve.>
EN(DOHC TURBO)-237
BA: DTC P0509 — IDLE CONTROL SYSTEM CIRCUIT HIGH INPUT — S088521H10

쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2201
EN(DOHC TURBO)-238

SP-12,
INSTALLATION,
Accelerator Con-
trol Cable.>
sis ground.
(−):
3 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 10 Repair battery Replace idle air
1) Turn ignition switch to OFF. V? short circuit in control solenoid
2) Disconnect connector from idle air control harness between valve <Ref. to
solenoid valve. ECM and idle air FU(DOHC
3) Turn ignition switch to ON. control solenoid TURBO)-36, Idle
4) Measure voltage between ECM and chas- valve connector. Air Control Sole-
sis ground. After repair, noid Valve.> and
Connector & terminal replace ECM. ECM <Ref. to
(B136) No. 10 (+) — Chassis ground <Ref. to FU(DOHC
(−): FU(DOHC TURBO)-47,
TURBO)-47, Engine Control
Engine Control Module.>.
Module.>
4 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change Repair battery Contact your
Measure voltage between ECM and chassis more than 10 V by shaking short circuit in Subaru distributor.
ground. harness and connector of harness between NOTE:
Connector & terminal ECM while monitoring the ECM and idle air Inspection by
(B136) No. 10 (+) — Chassis ground value with voltage meter? control solenoid DTM is required,
(−): valve connector. because probable
After repair, cause is deterio-
replace ECM. ration of multiple
<Ref. to parts.
FU(DOHC
TURBO)-47,
Engine Control
Module.>
EN(DOHC TURBO)-239
BB: DTC P0512 — STARTER SWITCH CIRCUIT HIGH INPUT — S088521G02

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2181
EN(DOHC TURBO)-240

1 CHECK OPERATION OF STARTER MOTOR. Does starter motor operate Repair battery Check starter
NOTE: when ignition switch to short circuit in motor circuit.
Place the inhibitor switch in each position. (AT “ON”? starter motor cir- <Ref. to
model) cuit. EN(DOHC
TURBO)-64,
STARTER
MOTOR CIRCUIT,
Diagnostics for
Engine Starting
Failure.>
EN(DOHC TURBO)-241
BC: DTC P0545 — EXHAUST GAS TEMPERATURE SENSOR CIRCUIT LOW

INPUT — S088521H69

쐌 Hard to start
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2202
EN(DOHC TURBO)-242

2) Read data of exhaust gas temperature NOTE:
NOTE: ing:
For detailed operation procedure, refer to the exhaust gas tem-
“READ CURRENT DATA FOR ENGINE”. perature sensor
Select Monitor.> ECM
쐌 OBD-II general scan tool 쐌 Poor contact in
For detailed operation procedures, refer to the joint connector
2 CHECK HARNESS BETWEEN EXHAUST Is the value less than Replace exhaust Repair ground
GAS TEMPERATURE SENSOR AND ECM 372°C (702°F)? gas temperature short circuit in
CONNECTOR. sensor. <Ref. to harness between
1) Turn ignition switch to OFF. FU(DOHC exhaust gas tem-
2) Disconnect connector from exhaust gas TURBO)-46, perature sensor
temperature sensor. Exhaust Tempera- and ECM connec-
3) Turn ignition switch to ON. ture Sensor.> tor.
4) Read data of exhaust gas temperature
NOTE:
Select Monitor.>
EN(DOHC TURBO)-243
BD: DTC P0546 — EXHAUST GAS TEMPERATURE SENSOR CIRCUIT HIGH

INPUT — S088521H70

쐌 Hard to start
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2202
EN(DOHC TURBO)-244

2) Read data of exhaust gas temperature NOTE:
NOTE: ing:
For detailed operation procedure, refer to the exhaust gas tem-
“READ CURRENT DATA FOR ENGINE”. perature sensor
Select Monitor.> ECM
쐌 OBD-II general scan tool 쐌 Poor contact in
For detailed operation procedures, refer to the joint connector
2 CHECK HARNESS BETWEEN EXHAUST Is the voltage more than 10 Repair battery Go to step 3.
GAS TEMPERATURE SENSOR AND ECM V? short circuit in
1) Turn ignition switch to OFF. ECM and exhaust
2) Disconnect connector from exhaust gas gas temperature
temperature sensor. sensor connector.
3) Measure voltage between exhaust gas
ground.
3 CHECK HARNESS BETWEEN EXHAUST Is the voltage more than 10 Repair battery Go to step 4.
GAS TEMPERATURE SENSOR AND ECM V? short circuit in
1) Turn ignition switch to ON. ECM and exhaust
2) Measure voltage between exhaust gas gas temperature
temperature sensor connector and engine sensor connector.
ground.
4 CHECK HARNESS BETWEEN EXHAUST Is the voltage more than 4 Go to step 5. Repair harness
GAS TEMPERATURE SENSOR AND ECM V? and connector.
CONNECTOR. NOTE:
Measure voltage between exhaust gas tem- In this case,
ground. ing:
(B279) No. 1 (+) — Engine ground (−): harness between
ECM and exhaust
gas temperature
sensor connector
쐌 Poor contact in
exhaust gas tem-
perature sensor
connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
joint connector
EN(DOHC TURBO)-245

5 CHECK HARNESS BETWEEN EXHAUST Is the resistance less than Replace exhaust Repair harness
GAS TEMPERATURE SENSOR AND ECM 5 Ω? gas temperature and connector.
CONNECTOR. sensor. <Ref. to NOTE:
1) Turn ignition switch to OFF. FU(DOHC In this case,
2) Measure resistance of harness between TURBO)-46, repair the follow-
exhaust gas temperature sensor connector Exhaust Tempera- ing:
and engine ground. ture Sensor.> 쐌 Open circuit in
(B279) No. 2 — Engine ground: ECM and exhaust
gas temperature
sensor connector
쐌 Poor contact in
exhaust gas tem-
perature sensor
connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
joint connector
EN(DOHC TURBO)-246
MEMO:
EN(DOHC TURBO)-247
BE: DTC P0604 — INTERNAL CONTROL MODULE MEMORY CHECK SUM

ERROR — S088521G03

쐌 Engine stalls.
CAUTION:
tion Mode.>.
EN(DOHC TURBO)-248
쐌 WIRING DIAGRAM:
쐌 LHD MODEL
S2M2182
EN(DOHC TURBO)-249
쐌 RHD MODEL
S2M2183

scan tool indicate DTC FU(DOHC P0604.
P0604? TURBO)-47,
Engine Control
Module.>
EN(DOHC TURBO)-250
MEMO:
EN(DOHC TURBO)-251
BF: DTC P0703 — BRAKE SWITCH INPUT MALFUNCTION — S088521B64

CAUTION:
47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44,
OPERATION, Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2203

1 CHECK OPERATION OF BRAKE LIGHT. Does brake light come on Go to step 2. Repair or replace
when depressing the brake brake light circuit.
pedal?
EN(DOHC TURBO)-252

2 CHECK HARNESS BETWEEN TCM AND Is the resistance less than Go to step 3. Repair or replace
BRAKE LIGHT SWITCH CONNECTOR. 1 Ω? harness and con-
1) Disconnect connectors from TCM and nector.
brake light switch. NOTE:
TCM and brake light switch connector. repair the follow-
Without cruise control 쐌 Open circuit in
With cruise control TCM and brake
(B55) No. 12 — (B65) No. 3: light switch con-
nector
쐌 Poor contact in
TCM connector
쐌 Poor contact in
brake light switch
connector
3 CHECK HARNESS BETWEEN TCM AND Is the resistance more than Go to step 4. Repair ground
BRAKE LIGHT SWITCH CONNECTOR. 1 MΩ? short circuit in
Measure resistance of harness between TCM harness between
and chassis ground. TCM and brake
Connector & terminal light switch con-
(B55) No. 12 — Chassis ground: nector.
4 CHECK INPUT SIGNAL FOR TCM. Is the voltage less than 1 V Go to step 5. Adjust or replace
1) Connect connectors to TCM and brake when releasing the brake brake light switch.
light switch. pedal? <Ref. to LI-31,
2) Measure voltage between TCM and chas- STOP LIGHT
sis ground. SWITCH,
Connector & terminal INSPECTION,
(B55) No. 12 (+) — Chassis ground (−): Stop Light Sys-
tem.>
5 CHECK INPUT SIGNAL FOR TCM. Is the voltage more than 10 Go to step 6. Adjust or replace
Measure voltage between TCM and chassis V when depressing the brake light switch.
ground. brake pedal? <Ref. to LI-31,
Connector & terminal STOP LIGHT
(B55) No. 12 (+) — Chassis ground (−): SWITCH,
INSPECTION,
Stop Light Sys-
tem.>
Control Module
(TCM).>
EN(DOHC TURBO)-253
BG: DTC P0731 — GEAR 1 INCORRECT RATIO — S088521B70
NOTE:
For the diagnostic procedure, refer to DTC P0734. <Ref. to EN(DOHC TURBO)-255, DTC P0734 — GEAR
4 INCORRECT RATIO —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
BH: DTC P0732 — GEAR 2 INCORRECT RATIO — S088521B71
NOTE:
BI: DTC P0733 — GEAR 3 INCORRECT RATIO — S088521B72
NOTE:
EN(DOHC TURBO)-254
BJ: DTC P0734 — GEAR 4 INCORRECT RATIO — S088521B73

쐌 Shift point too high or too low; engine brake not effected in “3” range; excessive shift shock; exces-
sive tight corner “braking”
CAUTION:
쐌 WIRING DIAGRAM:
1 CHECK ANY OTHER DTC ON DISPLAY. Is there any other DTC on Inspect relevant Go to step 2.
display? DTC using “List of
Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN(DOHC
TURBO)-82, List
of Diagnostic
Trouble Code
(DTC).>
3 CHECK FRONT VEHICLE SPEED SENSOR Is there any trouble in Repair or replace Go to step 4.
CIRCUIT. vehicle speed sensor 2 cir- vehicle speed
Check front vehicle speed sensor circuit. cuit? sensor 2 circuit.
<Ref. to AT-58, TROUBLE CODE 33 —
FRONT VEHICLE SPEED SENSOR —, Diag-
nostic Procedure with Trouble Code.>
Trouble Code.>
nector.
INSPECTION, (TCM).>
Road Test.>
EN(DOHC TURBO)-255
BK: DTC P0741 — TORQUE CONVERTER CLUTCH SYSTEM MALFUNCTION

— S088521G04

쐌 No lock-up (after engine warm-up)
쐌 No shift or excessive tight corner “braking”
CAUTION:
1 CHECK ANY OTHER DTC ON DISPLAY. Is there any other DTC on Inspect the rel- Go to step 2.
display? evant DTC using
“List of Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN(DOHC
TURBO)-82, List
of Diagnostic
Trouble Code
(DTC).>
2 CHECK LOCK-UP DUTY SOLENOID CIR- Is there any trouble in Repair or replace Go to step 3.
CUIT. lock-up duty solenoid cir- lock-up duty sole-
Check lock-up duty solenoid circuit. <Ref. to cuit? noid circuit.
AT-96, TROUBLE CODE 77 — LOCK-UP
DUTY SOLENOID —, Diagnostic Procedure
with Trouble Code.>
Trouble Code.>
5 CHECK ENGINE SPEED INPUT CIRCUIT. Is there any trouble in Repair or replace Go to step 6.
Check engine speed input circuit. <Ref. to engine speed input circuit? engine speed
AT-42, TROUBLE CODE 11 — ENGINE input circuit.
SPEED SIGNAL —, Diagnostic Procedure
with Trouble Code.>
6 CHECK INHIBITOR SWITCH CIRCUIT. Is there any trouble in Repair or replace Go to step 7.
Check inhibitor switch circuit. <Ref. to AT-122, inhibitor switch circuit? inhibitor switch
CHECK INHIBITOR SWITCH., Diagnostic circuit.
7 CHECK BRAKE LIGHT SWITCH CIRCUIT. Is there any trouble in Repair or replace Go to step 8.
Check brake light switch circuit. <Ref. to brake light switch circuit? brake light switch
AT-111, CHECK BRAKE SWITCH., Diagnostic circuit.
EN(DOHC TURBO)-256

8 CHECK ATF TEMPERATURE SENSOR CIR- Is there any trouble in ATF Repair or replace Go to step 9.
CUIT. temperature sensor circuit? ATF temperature
Check ATF temperature sensor circuit. <Ref. sensor circuit.
to AT-46, TROUBLE CODE 27 - ATF TEM-
PERATURE SENSOR —, Diagnostic Proce-
nector.
INSPECTION, (TCM).>
Road Test.>
EN(DOHC TURBO)-257
BL: DTC P1086 — TUMBLE GENERATOR VALVE #2 (LH) POSITION

SENSOR CIRCUIT LOW INPUT — S088521H71

쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
쐌 LHD MODEL
S2M2204
EN(DOHC TURBO)-258
쐌 RHD MODEL
S2M2205
EN(DOHC TURBO)-259

2) Read data of tumble generator valve posi- returned to a nor-
tion sensor signal using Subaru Select Moni- mal condition at
tor or OBD-II general scan tool. this time. A tem-
throttle position
sensor connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor
and chassis ground while tumble generator
valve is fully closed.
because probable
cause is deterio-
ration of multiple
parts.
and chassis ground.
(−):
Monitor?
EN(DOHC TURBO)-260

TUMBLE GENERATOR VALVE POSITION 4.5 V? and connector.
SENSOR CONNECTOR. NOTE:
2) Disconnect connectors from tumble gen- repair the follow-
erator valve position sensor. ing:
4) Measure voltage between tumble generator harness between
valve position sensor connector and engine tumble generator
ground. valve position
쐌 Poor contact in
tumble generator
valve position
sensor connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor
쐌 Poor contact in
joint connector
TUMBLE GENERATOR VALVE POSITION 1 Ω? and connector.
ECM connector and tumble generator valve ing:
position sensor connector. 쐌 Open circuit in
(B135) No. 13 — (E50) No. 3: tumble generator
valve position
sensor and ECM
connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
tumble generator
valve position
sensor connector
쐌 Poor contact in
coupling connec-
tor
TUMBLE GENERATOR VALVE POSITION 10 Ω? short circuit in
SENSOR CONNECTOR. harness between
Measure resistance of harness between tumble generator
tumble generator valve position sensor con- valve position
nector and engine ground. sensor and ECM
9 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Replace tumble
Check poor contact in tumble generator valve tumble generator valve tact in tumble generator valve
position sensor connector. position sensor connector? generator valve assembly. <Ref.
position sensor to FU(DOHC
connector. TURBO)-40,
Tumble Generator
Valve Assembly.>
EN(DOHC TURBO)-261
BM: DTC P1087 — TUMBLE GENERATOR VALVE #2 (LH) POSITION

SENSOR CIRCUIT HIGH INPUT — S088521H72

쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
쐌 LHD MODEL
S2M2204
EN(DOHC TURBO)-262
쐌 RHD MODEL
S2M2205
EN(DOHC TURBO)-263

tumble generator
valve position
sensor connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor
2 CHECK HARNESS BETWEEN TUMBLE Is the resistance less than Go to step 3. Repair harness
GENERATOR VALVE POSITION SENSOR 5 Ω? and connector.
2) Disconnect connector from tumble genera- repair the follow-
tor valve position sensor. ing:
tumble generator valve position sensor con- harness between
nector and engine ground. tumble generator
Connector & terminal valve position
(E50) No. 2 — Engine ground: sensor and ECM
connector
쐌 Poor contact in
coupling connec-
tor
쐌 Poor contact in
joint connector
3 CHECK HARNESS BETWEEN TUMBLE Is the voltage more than Repair battery Replace tumble
GENERATOR VALVE POSITION SENSOR 4.9 V? short circuit in generator valve
AND ECM CONNECTOR. harness between assembly. <Ref.
1) Turn ignition switch to ON. tumble generator to FU(DOHC
2) Measure voltage between tumble generator valve position TURBO)-40,
valve position sensor connector and engine sensor and ECM Tumble Generator
ground. connector. After Valve Assembly.>
FU(DOHC
TURBO)-47,
Engine Control
Module.>
EN(DOHC TURBO)-264
MEMO:
EN(DOHC TURBO)-265
BN: DTC P1088 — TUMBLE GENERATOR VALVE #1 (RH) POSITION

SENSOR CIRCUIT LOW INPUT — S088521H75

쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
쐌 LHD MODEL
S2M2206
EN(DOHC TURBO)-266
쐌 RHD MODEL
S2M2207
EN(DOHC TURBO)-267

tumble generator
valve position
sensor connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor
closed.
because probable
cause is deterio-
ration of multiple
parts.
and chassis ground.
(−):
Monitor?
EN(DOHC TURBO)-268

TUMBLE GENERATOR VALVE POSITION 4.5 V? and connector.
2) Disconnect connectors from tumble gen- repair the follow-
erator valve position sensor. ing:
4) Measure voltage between tumble generator harness between
valve position sensor connector and engine tumble generator
ground. valve position
쐌 Poor contact in
throttle position
sensor connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor
쐌 Poor contact in
joint connector
TUMBLE GENERATOR VALVE POSITION 1 Ω? and connector.
ECM connector and tumble generator valve ing:
position sensor connector. 쐌 Open circuit in
(B135) No. 23 — (E54) No. 3: tumble generator
valve position
sensor and ECM
connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
tumble generator
valve position
sensor connector
쐌 Poor contact in
coupling connec-
tor
TUMBLE GENERATOR VALVE POSITION 10 Ω? short circuit in
SENSOR CONNECTOR. harness between
Measure resistance of harness between tumble generator
tumble generator valve position sensor con- valve position
nector and engine ground. sensor and ECM
position sensor connector. position sensor connector? generator valve assembly. <Ref.
position sensor to FU(DOHC
connector. TURBO)-40,
Tumble Generator
Valve Assembly.>
EN(DOHC TURBO)-269
BO: DTC P1089 — TUMBLE GENERATOR VALVE #1 (RH) POSITION

SENSOR CIRCUIT HIGH INPUT — S088521H76

쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
쐌 LHD MODEL
S2M2206
EN(DOHC TURBO)-270
쐌 RHD MODEL
S2M2207
EN(DOHC TURBO)-271

tumble generator
valve position
sensor connector
쐌 Poor contact in
ECM connector
쐌 Poor contact in
coupling connec-
tor
2 CHECK HARNESS BETWEEN TUMBLE Is the resistance less than Go to step 3. Repair harness
GENERATOR VALVE POSITION SENSOR 5 Ω? and connector.
2) Disconnect connector from tumble genera- repair the follow-
tor valve position sensor. ing:
tumble generator valve position sensor con- harness between
nector and engine ground. tumble generator
Connector & terminal valve position
(E54) No. 2 — Engine ground: sensor and ECM
connector
쐌 Poor contact in
coupling connec-
tor
쐌 Poor contact in
joint connector
3 CHECK HARNESS BETWEEN TUMBLE Is the voltage more than Repair battery Replace tumble
GENERATOR VALVE POSITION SENSOR 4.9 V? short circuit in generator valve
AND ECM CONNECTOR. harness between assembly. <Ref.
1) Turn ignition switch to ON. tumble generator to FU(DOHC
2) Measure voltage between tumble generator valve position TURBO)-40,
valve position sensor connector and engine sensor and ECM Tumble Generator
ground. connector. After Valve Assembly.>
FU(DOHC
TURBO)-47,
Engine Control
Module.>
EN(DOHC TURBO)-272
BP: DTC P1090 — TUMBLE GENERATOR VALVE SYSTEM #1 (RH)

MALFUNCTION (STUCK OPEN) — S088521H77

CAUTION:
tion Mode.>.
scan tool indicate P1088, P1094 or P1095
P1089, P1094 or P1095? using List of Diag-
nostic Trouble
Code (DTC) <Ref.
to EN(DOHC
TURBO)-82, List
of Diagnostic
Trouble Code
(DTC).>
2 CHECK TUMBLE GENERATOR VALVE RH Does tumble generator Replace tumble Clean tumble gen-
1) Remove tumble generator valve assembly. valve move smoothly? (No generator valve erator valve.
2) Check tumble generator valve body. dirt or foreign materials assembly. <Ref.
clogged) to FU(DOHC
TURBO)-40,
Tumble Generator
Valve Assembly.>
EN(DOHC TURBO)-273
BQ: DTC P1091 — TUMBLE GENERATOR VALVE SYSTEM #1 (RH)

MALFUNCTION (STUCK CLOSE) — S088521H78

CAUTION:
tion Mode.>.
nostic Trouble
Code (DTC) <Ref.
to EN(DOHC
TURBO)-82, List
of Diagnostic
Trouble Code
(DTC).>
clogged) to FU(DOHC
TURBO)-40,
Tumble Generator
Valve Assembly.>
EN(DOHC TURBO)-274
BR: DTC P1092 — TUMBLE GENERATOR VALVE SYSTEM #2 (LH)

MALFUNCTION (STUCK OPEN) — S088521H79

CAUTION:
tion Mode.>.
nostic Trouble
Code (DTC) <Ref.
to EN(DOHC
TURBO)-82, List
of Diagnostic
Trouble Code
(DTC).>
clogged) to FU(DOHC
TURBO)-40,
Tumble Generator
Valve Assembly.>
EN(DOHC TURBO)-275
BS: DTC P1093 — TUMBLE GENERATOR VALVE SYSTEM #2 (LH)

MALFUNCTION (STUCK CLOSE) — S088521H80

CAUTION:
tion Mode.>.
nostic Trouble
Code (DTC) <Ref.
to EN(DOHC
TURBO)-82, List
of Diagnostic
Trouble Code
(DTC).>
clogged) to FU(DOHC
TURBO)-40,
Tumble Generator
Valve Assembly.>
EN(DOHC TURBO)-276
MEMO:
EN(DOHC TURBO)-277
BT: DTC P1094 — TUMBLE GENERATOR VALVE CIRCUIT #1 (OPEN

CIRCUIT) — S088521H81

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2208
EN(DOHC TURBO)-278

TUMBLE GENERATOR VALVE ACTUATOR 1Ω? cuit between ECM
CONNECTOR. and tumble gen-
1) Turn ignition switch to OFF. erator valve con-
2) Disconnect connector from tumble genera- nector.
tor valve actuator and ECM connector. NOTE:
3) Measure resistance between tumble gen- In this case,
erator valve actuator and ECM connector. repair the follow-
(E55) No. 1 — (B84) No. 4: 쐌 Open circuit in
(E55) No. 2 — (B84) No. 5: harness between
ECM and tumble
generator valve
actuator connec-
tor.
쐌 Poor contact in
coupling connec-
tor.
actuator connector. actuator connector. generator valve assembly. <Ref.
actuator connec- to FU(DOHC
tor. TURBO)-40,
Tumble Generator
Valve Assembly.>
EN(DOHC TURBO)-279
BU: DTC P1095 — TUMBLE GENERATOR VALVE CIRCUIT #1

(OVERCURRENT) — S088521H82

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2208
EN(DOHC TURBO)-280

1 CHECK HARNESS BETWEEN ECM AND Is the voltage less than Replace tumble Repair battery
TUMBLE GENERATOR VALVE ACTUATOR 5V? generator valve short circuit
CONNECTOR. assembly. <Ref. between ECM
1) Turn ignition switch to OFF. to FU(DOHC and tumble gen-
2) Disconnect connector from tumble genera- TURBO)-40, erator valve
tor valve connector. Tumble Generator actuator.
3) Measure voltage between tumble generator Valve Assembly.>
valve actuator and chassis ground.
(E55) No. 1 (+) — Chassis ground (–):
EN(DOHC TURBO)-281
BV: DTC P1096 — TUMBLE GENERATOR VALVE CIRCUIT #2 (OPEN

CIRCUIT) — S088521H83

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2209
EN(DOHC TURBO)-282

TUMBLE GENERATOR VALVE ACTUATOR 1Ω? cuit between ECM
CONNECTOR. and tumble gen-
1) Turn ignition switch to OFF. erator valve con-
2) Disconnect connector from tumble genera- nector.
tor valve and ECM connector. NOTE:
3) Measure resistance between tumble gen- In this case,
erator valve actuator and ECM connector. repair the follow-
(E51) No. 1 — (B84) No. 10: 쐌 Open circuit in
(E51) No. 2 — (B84) No. 11: harness between
ECM and tumble
generator valve
actuator connec-
tor.
쐌 Poor contact in
coupling connec-
tor.
actuator connector. actuator connector. generator valve assembly. <Ref.
actuator connec- to FU(DOHC
tor. TURBO)-40,
Tumble Generator
Valve Assembly.>
EN(DOHC TURBO)-283
BW: DTC P1097 — TUMBLE GENERATOR VALVE CIRCUIT #2

(OVERCURRENT) — S088521H84

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2209
EN(DOHC TURBO)-284

1 CHECK HARNESS BETWEEN ECM AND Is the voltage less than Replace tumble Repair battery
TUMBLE GENERATOR VALVE ACTUATOR 5V? generator valve short circuit
CONNECTOR. assembly. <Ref. between ECM
1) Turn ignition switch to OFF. to FU(DOHC and tumble gen-
2) Disconnect connector from tumble genera- TURBO)-40, erator valve
tor valve connector. Tumble Generator actuator.
3) Measure voltage between tumble generator Valve Assembly.>
valve actuator and chassis ground.
EN(DOHC TURBO)-285
BX: DTC P1110 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT LOW

INPUT — S088521B84

CAUTION:
tion Mode.>.
P1110? TURBO)-47,
Engine Control
Module.>
NOTE:
Atmospheric pres-
sure sensor is
built into ECM.
BY: DTC P1111 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT HIGH

INPUT — S088521B85

CAUTION:
tion Mode.>.
P1111? TURBO)-47,
Engine Control
Module.>
NOTE:
Atmospheric pres-
sure sensor is
built into ECM.
EN(DOHC TURBO)-286
BZ: DTC P1112 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT RANGE/


CAUTION:
tion Mode.>.
1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Replace ECM.
Monitor or OBD-II general P0106, P0107, <Ref. to
scan tool indicate DTC P0108, P1110 or FU(DOHC
P0106, P0107, P0108, P1111 using “List TURBO)-47,
P1110 or P1111? of Diagnostic Engine Control
Trouble Code Module.>
(DTC)”.<Ref. to NOTE:
EN(DOHC Atmospheric pres-
TURBO)-82, List sure sensor is
of Diagnostic built into ECM.
Trouble Code
(DTC).>
EN(DOHC TURBO)-287
CA: DTC P1130 — FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION

(OPEN CIRCUIT) — S088521B92

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2187
EN(DOHC TURBO)-288

FRONT OXYGEN (A/F) SENSOR CONNEC- 1 Ω? and connector.
TOR. NOTE:
2) Disconnect connectors from ECM and front repair the follow-
oxygen (A/F) sensor connector. ing:
ECM and front oxygen (A/F) sensor connec- harness between
tor. ECM and front
Connector & terminal oxygen (A/F) sen-
(B137) No. 29 — (B18) No. 3: sor connector
(B137) No. 19 — (B18) No. 4: 쐌 Poor contact in
front oxygen (A/F)
sensor connector
쐌 Poor contact in
ECM connector
Check poor contact in front oxygen (A/F) sen- front oxygen (A/F) sensor tact in front oxygen (A/F) sensor.
sor connector. connector? gen (A/F) sensor <Ref. to
connector. FU(DOHC
TURBO)-42, Front
Oxygen (A/F)
Sensor.>
EN(DOHC TURBO)-289
CB: DTC P1131 — FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION

(SHORT CIRCUIT) — S088521B93

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2187
EN(DOHC TURBO)-290

FRONT OXYGEN (A/F) SENSOR CONNEC- 10 Ω? short circuit in
1) Turn ignition switch to OFF. ECM and front
2) Disconnect connector from ECM. oxygen (A/F) sen-
3) Measure resistance of harness between sor connector.
FRONT OXYGEN (A/F) SENSOR CONNEC- 10 Ω? short circuit in
Measure resistance of harness between ECM ECM and front
connector and chassis ground. oxygen (A/F) sen-
Connector & terminal sor connector.
3 CHECK OUTPUT SIGNAL FOR ECM. Is the voltage more than Go to step 4. Go to step 5.
1) Connect connector to ECM. 4.5 V?
and chassis ground.
(−):
4 CHECK OUTPUT SIGNAL FOR ECM. Is the voltage more than 10 Repair battery Repair poor con-
Measure voltage between ECM connector V? short circuit in tact in ECM con-
and chassis ground. harness between nector.
Connector & terminal ECM and front
(B137) No. 19 (+) — Chassis ground oxygen (A/F) sen-
After repair,
replace ECM.
<Ref. to
FU(DOHC
TURBO)-47,
Engine Control
Module.>
5 CHECK OUTPUT SIGNAL FOR ECM. Is the voltage more than Go to step 6. Replace front oxy-
Measure voltage between ECM connector 4.95 V? gen (A/F) sensor.
and chassis ground. <Ref. to
(B137) No. 29 (+) — Chassis ground TURBO)-42, Front
(−): Oxygen (A/F)
Sensor.>
6 CHECK OUTPUT SIGNAL FOR ECM. Is the voltage more than 10 Repair battery Repair poor con-
Measure voltage between ECM connector V? short circuit in tact in ECM con-
and chassis ground. harness between nector.
Connector & terminal ECM and front
(B137) No. 29 (+) — Chassis ground oxygen (A/F) sen-
After repair,
replace ECM.
<Ref. to
FU(DOHC
TURBO)-47,
Engine Control
Module.>
EN(DOHC TURBO)-291
CC: DTC P1134 — FRONT OXYGEN (A/F) SENSOR MICRO-COMPUTER


CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2187
EN(DOHC TURBO)-292

P1134? TURBO)-47,
Engine Control
Module.>
EN(DOHC TURBO)-293
CD: DTC P1139 — FRONT OXYGEN (A/F) SENSOR #1 HEATER CIRCUIT


CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2187
EN(DOHC TURBO)-294

FRONT OXYGEN (A/F) SENSOR CONNEC- 1 Ω? cuit in harness
TOR. between ECM
1) Start engine, and warm-up the engine. and front oxygen
2) Turn ignition switch to OFF. (A/F) sensor con-
3) Disconnect connectors from ECM and front nector.
oxygen (A/F) sensor.
ECM and front oxygen (A/F) sensor connec-
tor.
(B137) No. 5 — (B18) No. 1:
(B137) No. 4 — (B18) No. 1:
TOR. between ECM
Measure resistance of harness between ECM and front oxygen
and front oxygen (A/F) sensor connector. (A/F) sensor con-
(B137) No. 19 — (B18) No. 4:
(B137) No. 29 — (B18) No. 3:
TOR. between ECM
Measure resistance of harness between main and front oxygen
relay and front oxygen (A/F) sensor connec- (A/F) sensor con-
tor. nector.
(B47) No. 4 — (B18) No. 2:
4 CHECK FRONT OXYGEN (A/F) SENSOR. Is the resistance less than Go to step 5. Replace front oxy-
Measure resistance between front oxygen 5 Ω? gen (A/F) sensor.
(A/F) sensor connector terminals. <Ref. to
Terminals FU(DOHC
No. 2 — No. 1: TURBO)-42, Front
Oxygen (A/F)
Sensor.>
Check poor contact in ECM and front oxygen ECM or front oxygen (A/F) tact in ECM or gen (A/F) sensor.
(A/F) sensor connector. sensor connector? front oxygen (A/F) <Ref. to
sensor connector. FU(DOHC
TURBO)-42, Front
Oxygen (A/F)
Sensor.>
EN(DOHC TURBO)-295
CE: DTC P1141 — MASS AIR FLOW SENSOR CIRCUIT


쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2189
EN(DOHC TURBO)-296

1 CHECK ANY OTHER DTC ON DISPLAY. Does Subaru select moni- Inspect DTC Replace mass air
tor or OBD-II general scan P0102 or P0103 flow and intake air
tool indicate DTC P0102 or using “List of temperature sen-
P0103? Diagnostic sor.
Trouble Code
(DTC)”. <Ref. to
EN(DOHC
TURBO)-82, List
of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P1141.
EN(DOHC TURBO)-297
CF: DTC P1142 — THROTTLE POSITION SENSOR CIRCUIT


쐌 Engine stalls.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
쐌 LHD MODEL
S2M2193
EN(DOHC TURBO)-298
쐌 RHD MODEL
S2M2194

scan tool indicate DTC using “List of <Ref. to
P0122 or P0123? Diagnostic FU(DOHC
(DTC)”. <Ref. to Throttle Position
EN(DOHC Sensor.>
TURBO)-82, List
of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P1142.
EN(DOHC TURBO)-299
CG: DTC P1146 — PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM (HIGH INPUT) — S088521G07

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
쐌 LHD MODEL
S2M2190
EN(DOHC TURBO)-300
쐌 RHD MODEL
S2M2191

In this case, it is not necessary to inspect scan tool indicate DTC P1112 using “List
DTC P0106. P0107, P0108 or P1112? of Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN(DOHC
TURBO)-82, List
of Diagnostic
Trouble Code
(DTC).>
air intake system?
EN(DOHC TURBO)-301

3 CHECK PRESSURE SENSOR. Is the value within the Go to step 4. Replace pressure
1) Start the engine and warm-up engine until specifications? sensor. <Ref. to
coolant temperature is greater than 60°C FU(DOHC
(140°F). TURBO)-35, Pres-
2) Place the shift lever in the selector lever in sure Sensor.>
“N” or “P” position.
3) Turn A/C switch to OFF.
4) Turn all accessory switches to OFF.
NOTE:
Select Monitor.>
Specification:
Ignition ON
73.3 — 106.6 kPa (550 — 800 mmHg,
21.65 — 31.50 inHg)
Idling
20.0 — 46.7 kPa (150 — 350 mmHg,
5.91 — 13.78 inHg)
4 CHECK THROTTLE POSITION. Is throttle positioning ratio Go to step 5. Replace throttle
Read data of throttle position signal using equal to or less than 5% position sensor.
Subaru Select Monitor or OBD-II general scan when throttle is fully <Ref. to
tool. closed? FU(DOHC
NOTE: TURBO)-33,
쐌 Subaru Select Monitor Throttle Position
For detailed operation procedure, refer to the Sensor.>
Select Monitor.>
5 CHECK THROTTLE POSITION. Is throttle positioning ratio Replace pressure Replace throttle
equal to or more than 85% sensor. <Ref. to position sensor.
when throttle is fully open? FU(DOHC <Ref. to
TURBO)-35, Pres- FU(DOHC
sure Sensor.> TURBO)-33,
Throttle Position
Sensor.>
EN(DOHC TURBO)-302
MEMO:
EN(DOHC TURBO)-303
CH: DTC P1244 — WASTEGATE CONTROL SOLENOID VALVE

RANGE/PERFORMANCE PROBLEM (LOW INPUT) — S088521H86

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2195
EN(DOHC TURBO)-304

Monitor or OBD-II general P0245 or P0246 gate control sole-
scan tool indicate DTC using “List of noid valve. <Ref.
P0245 or P0246? Diagnostic to FU(DOHC
(DTC)”. <Ref. to Wastegate Control
EN(DOHC Solenoid Valve.>
TURBO)-82, List
of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P1142.
EN(DOHC TURBO)-305
CI: DTC P1245 — WASTEGATE CONTROL SOLENOID VALVE

MALFUNCTION (FAIL-SAFE) — S088521H87

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2195
EN(DOHC TURBO)-306

Monitor or OBD-II general P0244, P0245, gate control sole-
scan tool indicate DTC P0246 or P1244 noid valve. <Ref.
P0244, P0245, P0246 or using “List of to FU(DOHC
P1244? Diagnostic TURBO)-41,
Trouble Code Wastegate Control
(DTC)”. <Ref. to Solenoid Valve.>
EN(DOHC
TURBO)-82, List
of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0507.
EN(DOHC TURBO)-307
CJ: DTC P1301 — FIRE DUE TO INCREASED EXHAUST TEMPERATURE —

S088521H88

쐌 Engine stalls
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2202
EN(DOHC TURBO)-308

1 CHECK ANY OTHER DTC. Does failure for repair or Repair or replace Contact your
Conduct troubleshooting for all DTC P0301, replacement exist? failure, then Subaru distributor.
P0302, P0303 and P0304. <Ref. to EN(DOHC replace precata- NOTE:
TURBO)-82, List of Diagnostic Trouble Code lytic converter. Inspection by
(DTC).> DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
EN(DOHC TURBO)-309
CK: DTC P1312 — EXHAUST GAS TEMPERATURE CIRCUIT MALFUNCTION

— S088521H89

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2202
EN(DOHC TURBO)-310

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Inspect DTC Replace exhaust
Monitor or OBD-II general P0545, P0546 or gas temperature
scan tool indicate DTC P1544 using “List sensor. <Ref. to
P0545, P0546 or P1544? of Diagnostic FU(DOHC
(DTC)”. <Ref. to Exhaust Tempera-
EN(DOHC ture Sensor.>
TURBO)-82, List
of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P1312.
EN(DOHC TURBO)-311
CL: DTC P1480 — COOLING FAN RELAY 1 CIRCUIT HIGH INPUT — S088521G08

쐌 Overheating
CAUTION:
tion Mode.>.
EN(DOHC TURBO)-312
쐌 WIRING DIAGRAM:
S2M2199
EN(DOHC TURBO)-313

1 CHECK OUTPUT SIGNAL FROM ECM. Does voltage change Even if MIL lights Go to step 2.
4) While operating radiator fan relay, measure contact in ECM
voltage between ECM and chassis ground. connector.
NOTE:
Mode”.<Ref. to EN(DOHC TURBO)-48, Com-
pulsory Valve Operation Check Mode.>
(−):
(−):
2 CHECK SHORT CIRCUIT IN RADIATOR Is the voltage more than 10 Repair battery Go to step 3.
FAN RELAY CONTROL CIRCUIT. V? short circuit in
1) Turn ignition switch to OFF. radiator fan relay
2) Remove main fan relay and sub fan relay. control circuit.
(with A/C models) After repair,
3) Disconnect test mode connector. replace ECM.
4) Turn ignition switch to ON. <Ref. to
5) Measure voltage between ECM and chas- FU(DOHC
sis ground. TURBO)-47,
Connector & terminal Engine Control
(B137) No. 17 (+) — Chassis ground Module.>
(−):
(−):
1) Turn ignition switch to OFF. 1 MΩ? relay and ECM.
2) Remove main fan relay. <Ref. to
3) Measure resistance of main fan relay. FU(DOHC
Terminal TURBO)-47,
No. 26 — No. 25: Engine Control
Module.>
1) Connect battery to terminals No. 27 and 1 Ω? relay and ECM.
No. 28 of main fan relay. <Ref. to
Terminal TURBO)-47,
No. 26 — No. 25: Engine Control
Module.>
5 CHECK SUB FAN RELAY. Is the resistance more than Go to step 6. Replace sub fan
1) Turn ignition switch to OFF. 1 MΩ? relay and ECM.
2) Measure resistance of main fan relay. <Ref. to
Terminal FU(DOHC
No. 17 — No. 18: TURBO)-47,
Engine Control
Module.>
EN(DOHC TURBO)-314

6 CHECK SUB FAN RELAY. Is the resistance less than Go to step 7. Replace sub fan
1) Connect battery to terminals No. 20 and 1 Ω? relay and ECM.
No. 19 of sub fan relay. <Ref. to
Terminal TURBO)-47,
No. 17— No. 18: Engine Control
Module.>
nector. FU(DOHC
TURBO)-47,
Engine Control
Module.>
EN(DOHC TURBO)-315
CM: DTC P1507 — IDLE CONTROL SYSTEM MALFUNCTION (FAIL-SAFE) —

S088521C16

쐌 Fuel is cut according to fail-safe function.
CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2201
EN(DOHC TURBO)-316

P0506, P0507, P0508, P1142 using “List
Trouble Code
(DTC)”. <Ref. to
EN(DOHC
TURBO)-82, List
of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0507.
body gasket
SP-12, Accelera-
tor Control
Cable.>
throttle body. <Ref. to FU(DOHC TURBO)-36, FU(DOHC
Idle Air Control Solenoid Valve.> TURBO)-36, Idle
3) Confirm that there are no foreign particles Air Control Sole-
in by-pass air line. noid Valve.>
EN(DOHC TURBO)-317
CN: DTC P1518 — STARTER SWITCH CIRCUIT LOW INPUT — S088521G09

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2181
EN(DOHC TURBO)-318

1 CHECK OPERATION OF STARTER MOTOR. Does starter motor operate Repair harness Check starter
NOTE: when ignition switch to and connector. motor circuit.
Place the inhibitor switch in the “P” or “N” “ST”? NOTE: <Ref. to
position (AT model). In this case, EN(DOHC
repair the follow- TURBO)-64,
ing: STARTER
쐌 Open or ground MOTOR CIRCUIT,
short circuit in Diagnostics for
harness between Engine Starting
ECM and starter Failure.>
motor connector.
쐌 Poor contact in
ECM connector.
EN(DOHC TURBO)-319
CO: DTC P1544 — HIGH EXHAUST TEMPERATURE DETECTED — S088521H90

CAUTION:
tion Mode.>.
쐌 WIRING DIAGRAM:
S2M2202
EN(DOHC TURBO)-320

P0335, P0336, P0340, P0545, P0546,
P0341, P0545, P0546, P1312, P0102,
P1312, P0102, P0103, P0103, P0101,
P0101, P1141, P0301, P1141, P0301,
P0302, P0303, P0304, P0302, P0303,
P1301, P0171, P0133, P0304, P1301,
P1134, P0131, P0132, P0171, P0133,
P1130, P1131, P1139, P1134, P0131,
P0031, P0032, P0139, P0132, P1130,
P0136, P0039 or P0037? P1131, P1139,
P0031, P0032,
P0139, P0136,
P0039 or P0037
using List of Diag-
nostic Trouble
Code (DTC).
<Ref. to
EN(DOHC
TURBO)-82, List
of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P1544.
2 CHECK EXHAUST SYSTEM. Is there a fault in exhaust Repair or replace Contact your
Check exhaust system parts. system? failure, then Subaru distributor.
NOTE: replace precata- NOTE:
Check the following items. lytic converter. Inspection by
쐌 Loose installation of exhaust manifold DTM is required,
쐌 Cracks or hole of exhaust manifold because probable
쐌 Loose installation of front oxygen (A/F) sen- cause is deterio-
sor ration of multiple
parts.
EN(DOHC TURBO)-321
CP: DTC P1560 — BACK-UP VOLTAGE CIRCUIT MALFUNCTION — S088521C27

CAUTION:
tion Mode.>.
EN(DOHC TURBO)-322
쐌 WIRING DIAGRAM:
쐌 LHD MODEL
S2M2182
EN(DOHC TURBO)-323
쐌 RHD MODEL
S2M2183
EN(DOHC TURBO)-324

1 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 10 Repair poor con- Go to step 2.
1) Turn ignition switch to OFF. V? tact in ECM con-
sis ground.
(−):
MAIN FUSE BOX CONNECTOR. 10 Ω? short circuit in
1) Disconnect connector from ECM. harness between
2) Measure resistance of harness between ECM connector
ECM and chassis ground. and battery termi-
Connector & terminal nal.
3 CHECK FUSE SBF-5. Is fuse blown? Replace fuse. Repair harness
and connector.
NOTE:
In this case,
repair the follow-
ing:
쐌 Open circuit in
harness between
ECM and battery
쐌 Poor contact in
ECM connector
쐌 Poor contact in
battery terminal
EN(DOHC TURBO)-325
CQ: DTC P1590 — NEUTRAL POSITION SWITCH CIRCUIT HIGH INPUT (AT
MODEL) — S088521G83

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2210
EN(DOHC TURBO)-326

P0705? Trouble Code
(DTC)”. <Ref. to
EN(SOHC)-82,
List of Diagnostic
Trouble Code
(DTC).>
2 CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 1 Go to step 3. Go to step 5.
sis ground in selector lever “N” and “P” posi-
tions.
Measure voltage between ECM and chassis and 5.5 V?
ground in selector lever except for “N” and “P”
positions.
nector. NOTE:
Inspection by
DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
Connector & terminal ECM and inhibitor
(B134) No. 8 (+) — Chassis ground (−): switch connector.
INHIBITOR SWITCH CONNECTOR. 1 Ω? and connector.
2) Disconnect connectors from ECM and In this case,
inhibitor switch. repair the follow-
ECM and inhibitor switch connector. 쐌 Open circuit in
(B134) No. 8 — (T7) No. 12: ECM and inhibitor
switch connector
쐌 Poor contact in
coupling connec-
tor
쐌 Poor contact in
inhibitor switch
connector
쐌 Poor contact in
ECM connector
EN(DOHC TURBO)-327

7 CHECK INHIBITOR SWITCH GROUND Is the resistance less than Go to step 8. Repair open cir-
LINE. 5 Ω? cuit in harness
Measure resistance of harness between between inhibitor
inhibitor switch connector and engine ground. switch connector
Connector & terminal and starter motor
(T7) No. 7 — Engine ground: ground line.
NOTE:
In this case,
repair the follow-
ing:
쐌 Open circuit in
harness between
inhibitor switch
connector and
starter motor
ground line
쐌 Poor contact in
starter motor con-
nector
쐌 Poor contact in
starter motor
ground
쐌 Starter motor
8 CHECK INHIBITOR SWITCH. Is the resistance less than Go to step 9. Replace inhibitor
Measure resistance between inhibitor switch 1 Ω? switch. <Ref. to
connector receptacle’s terminals in selector AT-28, Inhibitor
lever “N” and “P” positions. Switch.>
Terminals
No. 7 — No. 12:
Select Cable.> Inspection by
DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
EN(DOHC TURBO)-328
MEMO:
EN(DOHC TURBO)-329
CR: DTC P1591 — NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT (AT
MODEL) — S088521G84

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2210
EN(DOHC TURBO)-330

P0705? Trouble Code
(DTC)”. <Ref. to
EN(SOHC)-82,
List of Diagnostic
Trouble Code
(DTC).>
2 CHECK INPUT SIGNAL FOR ECM. Is the voltage between 4.5 Even if MIL lights Go to step 3.
1) Turn ignition switch to ON. and 5.5 V at except “N” up, the circuit has
2) Measure voltage between ECM and chas- and “P” positions? returned to a nor-
Connector & terminal this time.
TRANSMISSION HARNESS CONNECTOR. 10 Ω? short circuit in
2) Disconnect connectors from ECM and ECM and trans-
transmission harness connector (T3). mission harness
4 CHECK TRANSMISSION HARNESS CON- Is the resistance less than Repair ground Go to step 5.
NECTOR. 10 Ω? short circuit in
1) Disconnect connector from inhibitor switch. harness between
2) Measure resistance of harness between transmission har-
transmission harness connector and engine ness and inhibitor
ground. switch connector.
(T3) No. 12 — Engine ground:
5 CHECK INHIBITOR SWITCH. Is the resistance more than Go to step 6. Replace inhibitor
Measure resistance between inhibitor switch 1 MΩ at except “N” and “P” switch. <Ref. to
connector receptacle’s terminals in selector positions? AT-28, Inhibitor
lever except for “N” position. Switch.>
Terminals
No. 7 — No. 12:
Select Cable.> Inspection by
DTM is required,
because probable
cause is deterio-
ration of multiple
parts.
EN(DOHC TURBO)-331
CS: DTC P1594 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL

CIRCUIT MALFUNCTION — S088521G12

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2211

1 CHECK DRIVING CONDITION. Is AT shift control function- Go to step 2. Replace TCM.
1) Start and warm-up the engine until the ing properly? <Ref. to AT-48,
radiator fan makes one complete rotation. Transmission
2) Drive the vehicle. Control Module
(TCM).>
EN(DOHC TURBO)-332

2 CHECK ACCESSORY. Are car phone and/or CB Repair grounding Replace TCM.
installed on vehicle? line of car phone <Ref. to AT-48,
or CB system. Transmission
Control Module
(TCM).>
EN(DOHC TURBO)-333
CT: DTC P1595 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL

CIRCUIT LOW INPUT — S088521G13

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2211
EN(DOHC TURBO)-334

1 CHECK HARNESS BETWEEN ECM AND Is the voltage less than 1 Go to step 2. Even if MIL lights
TCM CONNECTOR. V? up, the circuit has
1) Turn ignition switch to ON. returned to a nor-
2) Measure voltage between ECM and chas- mal condition at
sis ground. this time.
(B135) No. 20 (+) — Chassis ground In this case,
(−): repair the follow-
ing:
쐌 Poor contact in
ECM connector
쐌 Poor contact in
TCM connector
2) Disconnect connector from ECM and TCM. ECM and TCM
3 CHECK OUTPUT SIGNAL FOR ECM. Is the voltage more than 5 Go to step 4. Repair poor con-
1) Connect connector to ECM. V? tact in ECM con-
2) Turn ignition switch to ON. nector.
sis ground.
(−):
4 CHECK TROUBLE CODE FOR AUTOMATIC Does trouble code appear Inspect trouble Replace TCM.
TRANSMISSION. for automatic transmission? code for auto- <Ref. to AT-48,
Read trouble code for automatic transmission. matic transmis- Transmission
<Ref. to AT-22, Read Diagnostic Trouble sion. <Ref. to Control Module
Code.> AT-42, Diagnostic (TCM).>
Procedure with
Trouble Code.>
EN(DOHC TURBO)-335
CU: DTC P1596 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL

CIRCUIT HIGH INPUT — S088521G14

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2211
EN(DOHC TURBO)-336

1 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 10 Repair battery Go to step 2.
TCM CONNECTOR. V? short circuit in
1) Turn ignition switch to ON. harness between
2) Measure voltage between ECM and chas- ECM and TCM
sis ground. connector.
(−):
2 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 4 Go to step 5. Go to step 3.
TCM CONNECTOR. V?
Measure voltage between ECM connector
and chassis ground.
(−):
3 CHECK HARNESS BETWEEN ECM AND Is the voltage less than 1 Repair poor con- Go to step 4.
TCM CONNECTOR. V? tact in ECM con-
Measure voltage between ECM connector nector.
and chassis ground.
(−):
4 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change Even if MIL lights Contact your
Measure voltage between ECM and chassis from 1 V to 4 V while moni- up, the circuit has Subaru distributor.
ground. toring the value with volt- returned to a nor- NOTE:
Connector & terminal age meter? mal condition at Inspection by
(B135) No. 20 (+) — Chassis ground this time. DTM is required,
(−): NOTE: because probable
In this case, cause is deterio-
repair the follow- ration of multiple
ing: parts.
쐌 Poor contact in
ECM connector
쐌 Poor contact in
TCM connector
5 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 4 Go to step 6. Repair open cir-
TCM CONNECTOR. V? cuit in harness
Measure voltage between TCM and chassis between ECM
ground. and TCM connec-
6 CHECK POOR CONTACT. Is there poor contact in Repair poor con- Check TCM
Check poor contact in TCM connector. TCM connector? tact in TCM con- power supply line
nector. and grounding
line.
EN(DOHC TURBO)-337
CV: DTC P1701 — CRUISE CONTROL SET SIGNAL CIRCUIT MALFUNCTION

FOR AUTOMATIC TRANSMISSION — S088521C29

CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2212
EN(DOHC TURBO)-338

1 CHECK HARNESS BETWEEN TCM AND Is the resistance less than Go to step 2. Repair open cir-
1) Turn ignition switch to OFF. between TCM and
2) Disconnect connectors from TCM and CCM connector.
CCM.
TCM and CCM connector.
(B55) No. 22 — (B94) No. 3:
2 CHECK HARNESS BETWEEN TCM AND Is the resistance less than Repair short cir- Go to step 3.
Measure resistance of harness between TCM between TCM and
and chassis ground. CCM connector.
3 CHECK INPUT SIGNAL FOR TCM. Is the resistance less than Go to step 4. Check cruise con-
1) Connect connector to TCM and CCM. 1 V? trol command
2) Lift-up the vehicle or set the vehicle on free switch circuit.
rollers. <Ref. to CC-10,
CAUTION: Cruise Control
On AWD models, raise all wheels off Command
ground. Switch.>
4) Cruise control main switch to ON.
5) Move selector lever to “D” and slowly
increase vehicle speed to 50 km/h (31 MPH).
6) Cruise control command switch to ON.
7) Measure voltage between TCM and chas-
sis ground.
Control Module
(TCM).>
EN(DOHC TURBO)-339
CW: DTC P1711 — ENGINE TORQUE CONTROL SIGNAL 1 CIRCUIT


CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2213
EN(DOHC TURBO)-340

sis ground.
(−):
(−):
nector. FU(DOHC
TURBO)-49,
Engine Control
Module.>
TCM. tor.
(B134) No. 19 — (B56) No. 5:
Control Module
(TCM).>
EN(DOHC TURBO)-341
CX: DTC P1712 — ENGINE TORQUE CONTROL SIGNAL 2 CIRCUIT


CAUTION:
Inspection Mode.>.
쐌 WIRING DIAGRAM:
S2M2214
EN(DOHC TURBO)-342

sis ground.
(−):
(−):
nector. FU(DOHC
TURBO)-49,
Engine Control
Module.>
TCM. tor.
(B134) No. 18 — (B56) No. 14:
Control Module
(TCM).>
EN(DOHC TURBO)-343
1. ENGINE S088257A1001
NOTE:
Malfunction of parts other than those listed is also possible. <Ref. to ME(DOHC TURBO)-91, Engine Trouble
in General.>
2) Pressure sensor
3) Mass air flow and intake temperature sensor
1. Engine stalls during idling.
2) Pressure sensor
6) Air intake system (*5)
2. Rough idling
11) Oxygen sensor
3) Accelerator cable (*6)
3. Engine does not return to idle.
5) Pressure sensor
6) Mass air flow and intake air temperature sensor
1) Pressure sensor
4. Poor acceleration 6) Engine coolant temperature sensor (*2)
9) A/C switch and A/C cut relay
10) Engine torque control signal circuit
1) Pressure sensor
5. Engine stalls or engine sags or hesitates at
acceleration.
6) Purge control solenoid valve
EN(DOHC TURBO)-344

1) Pressure sensor
6. Surge
1) Pressure sensor
7. Spark knock
4) Knock sensor
1) Pressure sensor
8. After burning in exhaust system 3) Engine coolant temperature sensor (*2)
*1: Check ignition coil & ignitor assembly and spark plug.
*2: Indicate the symptom occurring only in cold temperatures.
*3: Ensure the secure installation.
*4: Check fuel injector, fuel pressure regulator and fuel filter.
*5: Inspect air leak in air intake system.
*6: Adjust accelerator cable.
EN(DOHC TURBO)-345
MEMO:
EN(DOHC TURBO)-346

SUBARU vehicles.
ine parts.

G8050GE4
CHASSIS SECTION

SUBARU vehicles.
ine parts.

G8050GE5
BODY SECTION

SUBARU vehicles.
ine parts.

G8050GE6
BODY SECTION
G8050GE6
CONTROL SYSTEMS
CS
Page
2. Select Lever ................................................................................................7
3. Select Cable ..............................................................................................10
4. MT Gear Shift Lever..................................................................................13
5. MT Drive Select Lever ..............................................................................19
6. Drive Select Cable ....................................................................................21
GENERAL DESCRIPTION
Control Systems
Item Specification
Vibration torque of rod against lever N·m (kgf-m, ft-lb) 0.7 (0.07, 0.5) or less
CS-2
GENERAL DESCRIPTION
Control Systems
1. AT SELECT LEVER S501001A0501
S3M0584A
(1) Button A (10) Detent spring (19) Nut (rear)

(2) Button B (11) Selector lever upper (20) Front cover
(3) Spring (button) (12) Rod
(4) Grip (13) Indicator light bulb Tightening torque: N·m (kgf-m, ft-lb)
(5) Indicator cover (14) Clip T1: 5.9 (0.6, 4.3)
(6) Selector lever lower (15) Snap pin T2: 25 (2.5, 18.1)
(7) Pin (16) Outer cable T3: 32 (3.3, 24)
(8) Packing (17) Inner cable
(9) Plate (18) Nut (front)
CS-3
GENERAL DESCRIPTION
Control Systems
2. MT GEAR SHIFT LEVER S501001A0502
S3M0537B
(1) Gear shift knob (11) Bush C (21) Boot plate (Turbo model)
(2) Console boot (12) Straight pin (22) Boot and insulator
(3) Boot plate (Non-Turbo model) (13) Cushion rubber (23) Front cover
(4) Lever (14) Bush D
(5) Bush A (15) Joint Tightening torque: N·m (kgf-m, ft-lb)
(6) Bush B (16) Rod T1: 4.5 (0.46, 3.3)
(7) Locking wire (17) Bracket T2: 11.8 (1.20, 8.7)
(8) Boot (18) Washer T3: 18 (1.8, 13.0)
(9) Snap ring (19) Stay T4: 24.5 (2.5, 18.1)
(10) O-ring (20) Spacer
CS-4
GENERAL DESCRIPTION
Control Systems
3. DRIVE SELECT LEVER S501001A0503
S3M0642A
(1) Knob (6) Spring Tightening torque: N·m (kgf-m, ft-lb)

(2) Cap (7) Lever
T1: 1.6 (0.16, 1.2)
(3) Plate (8) Clamp
T2: 18 (1.8, 13.0)
(4) Bushing (9) Clevis pin
(5) Cable (10) Snap ring
CS-5
GENERAL DESCRIPTION
Control Systems

tion.
ment.
fied points.
deformation.
쐌 Before disconnecting electrical connectors, be
sure to disconnect negative terminal from battery.
CS-6
SELECT LEVER
Control Systems
2. Select Lever S501548 B: INSTALLATION S501548A11
1) Install the select indicator light connector.

tery.
3) Move the select lever to the “N” position.
5) Remove heat shield cover. (Non-Turbo model)
S3M0548
2) Install the select lever to vehicle.

NOTE:
Do not allow the select lever to catch on the wiring
harnesses, etc. during installation.
S3M0025
Tightening torque:
5.9 N·m (0.6 kgf-m, 4.3 ft-lb)
6) Disconnect cable from select lever and then
remove cable bracket.
S3M0539
S3M0538B
3) Install the front cover. <Ref. to EI-30,
INSTALLATION, Console Box.>
(A) Adjusting nuts 4) Lift-up the vehicle.
(B) Cable bracket 5) Move the select lever to the “N” position, then
adjust the select cable position. <Ref. to CS-11,
7) Remove front cover. <Ref. to EI-30, REMOVAL,
ADJUSTMENT, Select Cable.>
Consol Box.>
6) Install heat shield cover. (Non-Turbo model)
8) Disconnect connectors, and remove the stay.
9) Remove the six bolts to take out the select lever
assembly from body.
S3M0025
S3M0539
CS-7
SELECT LEVER
Control Systems
7) Inspect the following items. If the following 2) Remove indicator light.

inspection reveals problems, adjust the select NOTE:
cable and inhibitor switch. <Ref. to CS-11, Be careful not to break the indicator light during
ADJUSTMENT, Select Cable.> and <Ref. to AT-28, removal.
ADJUSTMENT, Inhibitor Switch.>
(1) The engine starts operating when select
lever is in position “P” or “N”, but not in other
positions.
(2) The back-up light is lit when the select lever
is in position “R”, but not in other positions.
(3) Check select lever operation.
WARNING:
Stop the engine while checking operation of
select lever.
쐌 Check that select lever does not move from “N” S3M0541
to “R” without pushing the button. 3) Detach indicator cover from plate, and remove
쐌 Check that select lever does not move from “R” clip.
to “P” without pushing the button.
쐌 Check that select lever does not move from “P”
to “R” without pushing the button.
쐌 Check that select lever does not move from “3”
to “2” without pushing the button.
S3M0542
4) Remove clip.
G3M0717
1) Remove connector from plate.
S3M0543
5) Remove the two screws.
S3M0540
CS-8
SELECT LEVER
Control Systems
6) While pressing select lever button, remove D: ASSEMBLY S501548A02
select lever grip and indicator cover from upper

select lever, and then remove the select lever but- 1) Clean all parts before assembly.
2) Apply grease [NIGTIGHT LYW No. 2 or equiva-
ton and spring.
lent] to each parts. <Ref. to CS-3 AT SELECT
CAUTION: LEVER, COMPONENT, General Description.>
Position the select lever grip carefully so that 3) Assembly is in the reverse order of disassem-
the select lever button does not jump out. bly.
NOTE:
쐌 Install indicator cover so that harness does not
interfere with select lever operation.
S3M0544A
(A) Select lever grip

(B) Harness
S3M0546
(C) Upper select lever
(D) Button 쐌 Be careful to install the spring and button into
(E) Spring the select lever grip in the correct direction.
(F) Indicator cover
7) Remove cap and then the straight pin.

8) Remove lower select lever, and then lift upper
select lever from plate.
S3M0547A
4) After completion of fitting, transfer select lever

to range “P” — “1”, then check whether the indica-
tor and select lever agree, whether the pointer and
S3M0545A
position mark agree and what the operating force
(A) Lower select lever is.
(B) Upper select lever
(C) Plate E: INSPECTION S501548A10
(D) Cap 1) Inspect removed parts by comparing with new

(E) Straight pin ones for deformation, damage and wear. Correct
or replace if defective.
2) Make sure the following parts operate properly
before assembly.
(1) Button in the grip: It should slide smoothly.
(2) Grip on the select lever: When pushing the
grip on the select lever by hand, screw holes
should be aligned.
(3) Select lever and rod: They should move
smoothly.
CS-9
SELECT CABLE
Control Systems
3. Select Cable S501549

8) Disconnect cable from select lever and then
remove cable bracket.

tery.
3) Prior to removal, set lever to “N” position.
5) Remove heat shield cover. (Non-turbo model)
S3M0538B
(A) Adjusting nuts

(B) Cable bracket
9) Remove select cable from plate assembly.
S3M0025
6) Remove snap pin from range select lever.
B3M1029B
(A) Range select lever

(B) Snap pin
(C) Select cable
(D) Clamp
7) Remove plate assembly from transmission

case.
B3M1030E
(A) Select cable

(B) Plate ASSY
(C) Clamp
CS-10
SELECT CABLE
Control Systems
B: INSTALLATION S501549A11 6) Install heat shield cover. (Non-turbo model)

1) Install select cable to plate assembly.
Tightening torque:
32 N·m (3.3 kgf-m, 24 ft-lb)
2) Install select cable to range select lever.
3) Install plate assembly to transmission.
Tightening torque:
T: 24.5 N·m (2.5 kgf-m, 18.1 ft-lb)
S3M0025
Check the removed cable and replace if damaged,

rusty, or malfunctioning.
1) Check for smooth operation of the cable.
2) Check the inner cable for damage and rust.
3) Check the outer cable for damage, bends, and
B3M1030G cracks.
4) Check the boot for damage, cracks, and dete-
(A) Select cable rioration.
(B) Plate ASSY 5) Move select lever from “P” position to “1” posi-
tion. You should be able to feel the detentes in
4) Install snap pin to range select lever. each position. If the detentes cannot be felt or the
position pointer is improperly aligned, adjust the
cable.
1) Set lever to “N” position.

3) Remove heat shield cover.
B3M1029B
(A) Range select lever

(B) Snap pin
(C) Select cable
(D) Clamp
5) Move the select lever to the “N” position, then

adjust the select cable position. <Ref. to CS-11 S3M0025
ADJUSTMENT, Select Cable.>
CS-11
SELECT CABLE
Control Systems
4) Loosen the adjusting nut on each side. 7) After completion of fitting, make sure that the
select lever operates smoothly all across the oper-
ating range.
B3M1792A
(A) Adjusting nut A

(B) Adjusting nut B
5) Turn adjusting nut B until it lightly touches the

connector.
B3M1793A
(A) Front side

(B) Select lever
(C) Connector
(D) Adjusting nut B
(E) Contact point
(F) Adjusting nut A
6) While preventing adjusting nut B from moving

with a wrench, tighten adjusting nut A.
Tightening torque:
7.5 N·m (0.76 kgf-m, 5.5 ft-lb)
B3M1794A
(A) Adjusting nut A

(B) Adjusting nut B
CS-12
MT GEAR SHIFT LEVER
Control Systems
4. MT Gear Shift Lever S501236

9) Remove stay from transmission bracket.

2) Remove gear shift knob.
3) Remove front cover. <Ref. to EI-30, REMOVAL,
Console Box.>
4) Remove the four screws to take out the boot
and insulator assembly from boot plate. (Turbo
model)
5) Remove boot plate from body.
B3M1823A
(A) Stay
(B) Transmission bracket
10) Remove rod from joint.
B3M0615

<Ref. to EX(SOHC)-9, REMOVAL, Rear Exhaust.> B3M1824A
and <Ref. to EX(SOHC)-11, REMOVAL, Muffler.>
Non-turbo model without OBD: (A) Stay
<Ref. to EX(SOHCw/oOBD)-10, REMOVAL, Rear (B) Rod
Exhaust.> and <Ref. to EX(SOHCw/oOBD)-12, 11) Remove cushion rubber from body.
REMOVAL, Muffler.>
Turbo model:
Exhaust.> and <Ref. to EX(DOHC TURBO)-15,
REMOVAL, Muffler.>
8) Remove heat shield cover. (Non-turbo model)
B3M1825A
(A) Stay
(B) Cushion rubber
S2M0215
CS-13
MT GEAR SHIFT LEVER
Control Systems
12) Remove joint and then extract straight pin. 4) Mount cushion rubber on the body.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
B3M1826A
(A) Joint
(B) Straight pin B3M1825A
13) Lower the vehicle. (A) Cushion rubber

14) Remove gear shift lever. (B) Stay
5) Connect rod to the joint.

Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
B3M1827
B3M1824A
1) Install the joint to the transmission and secure
with the straight pin. (A) Joint
2) Insert gear shift lever from room side. (B) Rod
NOTE:
6) Connect stay to transmission bracket.
After inserting rod and stay, temporarily put them
onto transmission mount. Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
B3M1827
B3M1823A

(A) Stay
(B) Transmission bracket
CS-14
MT GEAR SHIFT LEVER
Control Systems
7) Install heat shield cover. (Non-turbo model) C: DISASSEMBLY S501236A06
1) Disassemble locking wire.
S2M0215
8) Install rear exhaust pipe and muffler. B3M0617C

(A) Locking wire
<Ref. to EX(SOHC)-9, INSTALLATION, Rear
(B) Stay
Exhaust.> and <Ref. to EX(SOHC)-11,
INSTALLATION, Muffler.> 2) Remove rod from gear shift lever.
<Ref. to EX(SOHCw/oOBD)-10, INSTALLATION,
Rear Exhaust.> and <Ref. to EX(SOHCw/oOBD)-
12, INSTALLATION, Muffler.>
Turbo model:
Rear Exhaust.> and <Ref. to EX(DOHC TURBO)-
15, INSTALLATION, Muffler.>
9) Mount boot plate on body.
Tightening torque:
4.5 N·m (0.46 kgf-m, 3.3 ft-lb) B3M1828A
(A) Rod
(B) Gear shift lever
(C) Stay
3) Remove snap ring from bushing D, then discon-

nect stay.
B3M0615
10) Install boot and insulator assembly on boot

plate. (Turbo model)
11) Install front cover, gear shift knob. <Ref. to
EI-30, INSTALLATION, Console Box.>
B3M0619B
(A) Snap ring

(B) Bushing D
(C) Boot
4) Remove boot from gear shift lever.
CS-15
MT GEAR SHIFT LEVER
Control Systems
5) Remove bushing and cushion rubber from stay. D: ASSEMBLY S501236A02
1) Clean all parts before assembly.

2) Mount the bushing B and cushion rubber on the
stay.
B3M0830D
(A) Bushing
(B) Stay
(C) Cushion rubber B3M0830C
6) Remove O-ring, then disconnect bushing D. (A) Bushing

(B) Cushion rubber
3) Mount each part; boot, O-ring, bushing A,

spacer, bushing B, bushing D and straight pin on
the gear shift lever.
CAUTION:
쐌 Always use new O-rings.
쐌 Apply grease [DNIGTIGHT LYW No. 2 or
equivalent] to the inner and side surfaces of
the bushing when installing the spacer.
B3M0620C
(A) O-ring A
(B) O-ring B
(C) Bushing D
7) Draw out straight pin, then remove bushing C

from gear shift lever.
B3M0623C
(A) Boot
(B) O-ring B
(C) Bushing A
(D) Spacer
(E) Bushing C
(F) Bushing D
B3M0621B (G) Straight pin
(H) O-ring A
(A) Straight pin
(B) Bushing C
CS-16
MT GEAR SHIFT LEVER
Control Systems
4) Insert the gear shift lever into the boot hole. 9) Check the swing torque of the rod in relation to
5) Install snap ring and stay to the bushing D. the gear shift lever.
If the torque exceeds the specification, replace
bushing or retighten nuts.
Rocking torque:
0.7 N·m (0.07 kgf-m, 0.5 ft-lb) or less
B3M0619C
(A) Snap ring

(B) Bushing D
6) Tighten with locking wire to the extent that the B3M1829C

boot will not come off.
(A) Center of rotation
CAUTION: (B) Swing torque
Always use new locking wire.
10) Check that there is no excessive play and that
parts move smoothly.
B3M0617C
(A) Locking wire

(B) Stay
7) Insert the rod into the boot hole.

8) Connect rod to gear shift lever.
Tightening torque:
11.8 N·m (1.2 kgf-m, 8.7 ft-lb)
B3M1828A
(A) Rod
(B) Shift lever
(C) Stay
CS-17
MT GEAR SHIFT LEVER
Control Systems
1) Check each part (bushing A, cushion rubber,

spacer, boot, stay and rod, etc.) for deformation,
damage and wear. Repair or replace any defective
part. Determine defective parts by comparing with
new parts.
B3M1765A
(A) Bushing A
(B) Cushion rubber
(C) Spacer
(D) Boot
(E) Stay
(F) Rod
2) Check the swing torque of the rod in relation of

the gear shift lever.
If the torque exceeds the specification, replace
bushing or retighten nuts.
Rocking torque:
0.7 N·m (0.07 kgf-m, 0.5 ft-lb) or less
B3M1829C
(A) Center of rotation

(B) Swing torque
CS-18
MT DRIVE SELECT LEVER
Control Systems
5. MT Drive Select Lever S501235 B: INSTALLATION S501235A11
1) Install drive select lever.
1) To immobilize vehicle, put the select lever in Tightening torque:

“1st” and block the tires. 18 N·m (1.8 kgf-m, 13.0 ft-lb)
2) Disconnect battery ground terminal from bat- 2) Set drive select lever to HI position.
tery.
3) Set drive select lever to HI position.
4) Remove the drive select lever knob.
B3M1516A
(A) HI position
S3M0086A 3) Be sure to insert cable end bolt into lever arm
(A) Drive select lever knob slit.
5) Remove console box. <Ref. to EI-30 Console

Box.>
6) Remove the bolt installing drive select lever
assembly on body.
B3M1517A
(A) Cable end bolt

(B) Lever arm
4) Tighten nut where cable end bolt comes to a

G3M0766 stop.
7) Remove nut, clamp and then disconnect the Tightening torque:
cable from drive select lever assembly. 18 N·m (1.8 kgf-m, 13.0 ft-lb)
B3M1846A
(A) Nut
(B) Drive select lever
(C) Clamp
CS-19
MT DRIVE SELECT LEVER
Control Systems
1) Remove spring.
B3M2132A
(A) Spring
2) Remove lever, cap and bushing.
B3M2133A
(A) Washer
(B) Bushing
(C) Plate
(D) Cap
(E) Lever
1) Assemble in the reverse order of disassembly.

Tightening torque:
1.6 N·m (0.16 kgf-m, 1.2 ft-lb)
2) Make sure the select lever moves smoothly.
1) Make sure the select lever moves smoothly. If

it does not move smoothly, repair or replace it.
2) Make sure the drive select lever is not dam-
aged. If it is damaged, repair or replace it.
CS-20
DRIVE SELECT CABLE
Control Systems
6. Drive Select Cable S501717 D: ADJUSTMENT S501717A01
1) Set the drive select lever to HI position.
2) Remove the drive select lever knob.
1) Remove the drive select lever. <Ref. to CS-19
REMOVAL, MT Drive Select Lever.>
2) Remove intake duct. <Ref. to IN(SOHC)-8,
REMOVAL, Air Intake Duct.>
3) Remove air cleaner case. <Ref. to IN(SOHC)-7,
REMOVAL, Air Cleaner Case.>
4) Remove snap pin and clevis pin.
5) Loosen the nut and disconnect the cable from
cable bracket.
S3M0086A
3) Remove console box. <Ref. to EI-30, Console

Box.>
4) Loosen the nut.
5) Make sure transmission is in HI position. If isn’t,
pull on cable to put transmission in HI position.
6) Tighten the nut in the location where the cable
end bolt stops naturally.
S3M0641A
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
(A) Snap pin
7) Make sure to move transmission to HI or LO
(B) Clevis pin
position by moving the drive select lever. If it
(C) Nut
doesn’t, readjust cable.
6) Remove cable from the under side of vehicle.
G3M0769

2) Make sure the drive select lever operates prop-
erly.
1) Make sure to move transmission to HI or LO

position by moving the drive select lever. If it
doesn’t, adjust the cable.<Ref. to CS-21
ADJUSTMENT, Drive Select Cable.>
2) Make sure cable operates smoothly. If it
catches or fails to work properly, repair or replace
it.
3) Check cable for damage.
CS-21
Control Systems

1. AT select lever (1) Starter does not run. Adjust select cable and inhibitor switch, or
inspect circuit.
(2) Back-up light does not light up. Adjust select cable and inhibitor switch, or
inspect circuit.
CS-22

SUBARU vehicles.
ine parts.

G8050GE4
AUTOMATIC TRANSMISSION
AT
Page
2. Automatic Transmission Fluid .....................................................................9
3. Differential Gear Oil ...................................................................................11
4. Road Test ..................................................................................................12
5. Stall Test....................................................................................................13
6. Time Lag Test............................................................................................15
7. Line Pressure Test ....................................................................................16
8. Transfer Clutch Pressure Test...................................................................18
9. Automatic Transmission Assembly............................................................19
10. Transmission Mounting System ................................................................25
11. Extension Case Oil Seal ...........................................................................27
12. Inhibitor Switch ..........................................................................................28
13. Front Vehicle Speed Sensor .....................................................................32
14. Rear Vehicle Speed Sensor......................................................................36
15. Torque Converter Turbine Speed Sensor .................................................37
16. Control Valve Body....................................................................................38
17. Shift Solenoids, Duty Solenoids and ATF Temperature Sensor ...............41
18. ATF Filter...................................................................................................46
19. Transmission Control Module (TCM) ........................................................48
20. ATF Cooler Pipe and Hose .......................................................................49
GENERAL DESCRIPTION
Automatic Transmission

5. PLANETARY GEAR AND PLATE S502001E4905
A: SPECIFICATIONS S502001E49 Non-turbo model Turbo model

Tooth number of
1. TORQUE CONVERTER CLUTCH S502001E4901
front sun gear
33
Tooth number of
Model Non-turbo model Turbo model 21
front pinion
Symmetric, 3 element, single stage, 2
Type Tooth number of
phase torque converter 75
front internal gear
Stall torque ratio 2.0 — 2.2 1.9 — 2.1
Tooth number of
Nominal diameter 236 mm (9.29 in) 246 mm (9.69 in) 42
rear sun gear
Stall speed (at 2,100 — 2,600 2,150 — 2,950 Tooth number of
sea level) rpm rpm 17
rear pinion
One-way clutch Sprague type one-way clutch Tooth number of
75
rear internal gear
2. OIL PUMP S502001E4902
Drive & driven
Type Pracoid constant-displacement pump plate number of 4 5
high clutch
Driving method Driven by engine
Drive & driven
Inner rotor 9
Number of teeth plate number of 4 7
Outer rotor 10 low clutch
3. TRANSMISSION CONTROL ELEMENT Drive & driven
plate number of 2
S502001E4903
reverse clutch
4-forward, 1-reverse, double-row Drive & driven
Type plate number of 3 4
planetary gears
Multi-plate clutch 3 sets 2-4 brake
Multi-plate brake 2 sets Drive & driven
plate number of
One-way clutch 4 7
1 sets low & reverse
(sprague type)
brake
4. TRANSMISSION GEAR RATIO S502001E4904
Gear ratio
1st 2.785
2nd 1.545
3rd 1.000
4th 0.694
Rev 2.272
AT-2
GENERAL DESCRIPTION
6. SELECTOR POSITION S502001E4906 8. COOLING AND HARNESS S502001E4908
Transmission in neutral, output member Liquid-cooled cooler incorporated in

P (Park) Cooling system
immovable, and engine start possible radiator
R ATF cooling sys-
Transmission in reverse for backing
(Reverse) tem (Radiation 4.630 kW (3,981 kcal/h, 15,797 BTU/h)
Transmission in neutral and engine start pos- capacity)
N (Neutral)
sible Inhibitor switch 12 poles
Automatic gear change 1st ← → 2nd ←→ 3rd Transmission
D (Drive) ← 20 poles
→ 4th harness
Automatic gear change 1st ← → 2nd ←→ 3rd
3 (3rd) 9. TRANSFER
← 4th S502001E4909
Automatic gear change 1st ← → 2nd ← 3rd

2 (2nd) Model Non-turbo model Turbo model
← 4th
Transfer clutch Hydraulic multi-plate clutch
1st gear locked (Deceleration possible 1st ←
1 (1st) Drive & driven
2nd ← 3rd ← 4th)
plate number of 4 6
Control
Hydraulic remote control transfer clutch
method
Control method Electronic, hydraulic type
7. HYDRAULIC CONTROL AND Lubricant
The same Automatic transmission fluid
LUBRICATION S502001E4907 used in automatic transmission
1st reduction
1.000 (53/53)
Electronic/hydraulic control gear ratio
[Four forward speed
changes by electrical sig-
Type
nals of vehicle speed and
accelerator (throttle) open-
ing]
Dexron III type Automatic
Fluid
transmission fluid
Non-turbo 8.4 — 8.7 (8.9 — 9.2 US
model qt, 7.4 — 7.7 Imp qt)
Fluid capacity
9.3 — 9.6 (9.8 — 10.1
Turbo model
US qt, 8.2 — 8.4 Imp qt)
Forced feed lubrication with
Lubrication system
oil pump
Automatic transmission
Oil
fluid (above mentioned)
10. FINAL REDUCTION S502001E4910
Model Turbo model Non-turbo model

Front final gear ratio 4.111 (37/9) 4.444 (40/9)
Lubrication oil
H3M1235A
Front differential oil capacity 1.2 (1.3 US qt, 1.1 Imp qt)
AT-3
GENERAL DESCRIPTION
NOTE:
For information about other transmission mounting components, refer to “AUTOMATIC TRANSMISSION”
<Pub. No. G0853ZE> a separate publication.
1. TRANSMISSION MOUNTING S502001A0501
S2M0197A
(1) Pitching stopper Tightening torque: N·m (kgf-m, ft-lb)

(2) Rear cushion rubber
T1: 35 (3.6, 26)
(3) Crossmember
T2: 39 (4.0, 29)
(4) Stopper
T3: 50 (5.1, 37)
T4: 58 (5.9, 43)
T5: 70 (7.1, 51)
AT-4
GENERAL DESCRIPTION
C: CAUTION S502001A03 that of another grade or from other manufacturers.

쐌 Wear working clothing, including a cap, protec- nuts to the specified torque.
tive goggles, and protective shoes during opera- 쐌 Place shop jacks or safety stands at the speci-
tion.
fied points.
sion before removal, installation, and disassembly. 쐌 Apply gear oil onto sliding or revolution surfaces
쐌 Keep the disassembled parts in order and pro- before installation.
tect them from dust or dirt. 쐌 Replace deformed or otherwise damaged snap
쐌 Until the oil pan is removed, do not place with rings with new ones.
the oil pan side facing up to prevent foreign matter 쐌 Before installing O-rings or oil seals, apply suf-
from entering the valve body. ficient amount of ATF fluid to avoid damage and
쐌 Before removal, installation or disassembly, be deformation.
sure to clarify the failure. Avoid unnecessary 쐌 Be careful not to incorrectly install or fail to install
removal, installation, disassembly and replace- O-rings, snap rings and other such parts.
ment. 쐌 Before securing a part on a vise, place cushion-
쐌 When disassembling the case and other light ing material such as wood blocks, aluminum plate,
alloy parts, use a plastic hammer to force it apart. or shop cloth between the part and the vise.
Do not pry it apart with a screwdriver or other tool. 쐌 Avoid damaging the mating surface of the case.
쐌 Be careful not to burn your hands, because each 쐌 Before applying sealant, completely remove the
part on the vehicle is hot after running. old seal.
쐌 Use SUBARU genuine gear oil, grease etc. or
the equivalent. Do not mix gear oil, grease etc. with

398527700 PULLER ASSY Used for removing extension case oil seal.
B3M1977
498057300 INSTALLER Used for installing extension oil seal.
B3M1972
AT-5
GENERAL DESCRIPTION

498575400 OIL PRESSURE Used for measuring oil pressure.
GAUGE ASSY
B3M2040
498897200 ADAPTER Used oil pump housing when measuring
reverse clutch pressure and line pressure.
B3M2041
498545400 FILTER WRENCH Used for removing and installing ATF filter.
B3M2042
498277200 STOPPER SET Used for removing and installing automatic
transmission assembly to engine.
B3M2043
AT-6
GENERAL DESCRIPTION

41099AA020 ENGINE SUPPORT Used for supporting engine.
B3M1976
41099AA010 ENGINE SUPPORT Used for supporting engine.
BRACKET
B3M1975
499977300 CRANK PULLEY Used for removing and installing bolts which
WRENCH secure torque converter to the drive plate.
B2M4157
B2M3876
AT-7
GENERAL DESCRIPTION

KIT 쐌 English:
쐌 German:
쐌 French:
쐌 Spanish:
B2M3877
TOOL NAME REMARKS

AT-8
AUTOMATIC TRANSMISSION FLUID
2. Automatic Transmission Time for temperature rise to 60°C (140°F) with

atmospheric temperature of 0°C (32°F): More than
Fluid S502248
25 minutes
<Reference>
Time for temperature rise to 30°C (86°F) with
1) Check the level of the ATF. atmospheric temperature of 0°C (32°F): Approx. 8
(1) Raise ATF temperature to 60 to 80°C (140 minutes
to 176°F) from 40 to 60°C (104 to 140°F) (when 쐌 By running the vehicle
cold) by driving a distance of 5 to 10 km (3 to 6 Time for temperature rise to 60°C (140°F) with
miles). atmospheric temperature of 0°C (32°F): More than
NOTE: 10 minutes
The level of ATF varies with fluid temperature. Pay (5) Method for checking fluid level upon deliv-
attention to the fluid temperature when checking oil ery or at periodic inspection
level. Check fluid level after a warm-up run of approx.
10 minutes. During the warm-up period, the
automatic 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.
1) Lift vehicle.
B3M1020B 2) Drain ATF completely.
(A) ATF level gauge CAUTION:
(B) Upper level Directly after the engine has been running, the
(C) Lower level ATF is hot. Be careful not to burn yourself.
(2) Make sure the vehicle is level. After select- NOTE:
ing all positions (P, R, N, D, 3, 2, 1), set the Tighten ATF drain plug after draining ATF.
select leveler in “P” range. Measure fluid level Tightening torque:
with the engine idling. 25 N·m (2.5 kgf-m, 18.1 ft-lb)
NOTE:
After running, idle the engine for one or two min-
utes before measurement.
(3) If the fluid level is below the center between
upper and lower marks, add the recommended
ATF until the fluid level is found within the speci-
fied 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 B3M1036B
should be found below the center of these two
marks. (A) Oil pan
(B) Drain plug
CAUTION:
(C) Differential oil drain plug
쐌 Use care not to exceed the upper limit level.
쐌 ATF level varies with temperature. Remem- 3) Lower the vehicle.
ber that the addition of fluid to the upper limit 4) Pour ATF into the oil charge pipe.
mark when the transmission is cold will result
in the overfilling of fluid. Recommended fluid:
Dexron III type automatic transmission
(4) Fluid temperature rising speed fluid
쐌 By idling the engine
AT-9
AUTOMATIC TRANSMISSION FLUID
Capacity:
Fill the same amount of fluid drained
from drain plug hole.
Capacity when transmission is overhauled:
Non-turbo model:
8.4 — 8.7 (8.9 — 9.2 US qt, 7.4 — 7.71
Imp qt)
Turbo model:
9.3 — 9.6 (9.8 — 10.1 US qt, 8.2 — 8.4
Imp qt)
5) Check the level and leaks of the ATF.
<Ref. to AT-9 INSPECTION, Automatic Transmis-
sion Fluid.>
AT-10
3. Differential Gear Oil S502150

4) Pour gear oil into the gauge hole.
Recommended fluid:
1) Park vehicle on a level surface. Use GL-5 or equivalent.
2) Remove oil level gauge and wipe it clean. Gear oil capacity:
3) Reinsert the level gauge all the way. Be sure 1.2 (1.3 US qt, 1.1 Imp qt)
5) Check the level of the differential gear oil.
proper orientation.
<Ref. to AT-11 INSPECTION, Differential Gear
4) Remove it again and note the reading. If the Oil.>
differential gear oil level is below the “L” line, add
oil to bring the level up to the “F” line.
5) To prevent overfilling the differential gear oil, do
not add oil above the “F” line.
S3M0478A
(A) Upper level

(B) Lower level
1) Lift vehicle.
2) Drain differential gear oil completely.
CAUTION:
Directly after the engine has been running, the
differential gear oil is hot. Be careful not to
burn yourself.
NOTE:
Tighten differential gear oil drain plug after draining
differential gear oil.
Tightening torque:
44 N·m (4.5 kgf-m, 32.5 ft-lb)
B3M1036B
(A) Oil pan

(B) Drain plug
(C) Differential oil drain plug
AT-11
ROAD TEST
4. Road Test S502247

10. OIL LEAKS S502247A1010
After the driving test, inspect for oil leaks.

1. GENERAL PRECAUTION S502247A1001
Road tests should be conducted to properly diag-

nose the condition of the automatic transmission.
CAUTION:
When performing test, do not exceed posted
speed limit.
2. D RANGE SHIFT FUNCTION S502247A1002
Check shifting between 1st ⇔ 2nd ⇔ 3rd ⇔ 4th

while driving on normal city streets.
3. D RANGE SHIFT SHOCK S502247A1003
Check the shock level when shifting up during nor-

mal driving.
4. KICK-DOWN FUNCTION S502247A1004
Check kick-down for each gear. Also check the

kick-down shock level.
5. ENGINE BRAKE OPERATION S502247A1005
쐌 Check the 3rd gear engine brake when shifting

between D ⇔ 3rd range while driving in 4th gear
of D range [50 to 60 km/h (31 to 37 MPH)].
쐌 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)].
쐌 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 S502247A1006
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 S502247A1007
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
S502247A1008
Check for unusual sounds and vibration while driv-

ing and during shifting.
9. CLIMBING CONTROL FUNCTION S502247A1009
쐌 Check that gear remains in 3rd when going up

a grade.
쐌 Check that gear remains in 3rd when applying
the brakes while going down a grade.
AT-12
STALL TEST
5. Stall Test S502246

9) If stall speed in 2 range is higher than
specifications, low clutch slipping and 2-4 brake
A: INSPECTION S502246A10 slipping may occur. To identify it, conduct the same
test as above in D range.
1. GENERAL INFORMATION S502246A1001
10) Perform the stall tests with the select lever in
The stall test is of extreme importance in diagnos- the R range.
ing the condition of the automatic transmission and NOTE:
the engine. It should be conducted to measure the 쐌 Do not continue the stall test for MORE THAN
engine stall speeds in R and 2 ranges. FIVE SECONDS at a time (from closed throttle,
Purposes of the stall test: fully open throttle to stall speed reading). Failure to
1) To check the operation of the automatic trans- follow this instruction causes the engine oil and
mission clutch. ATF to deteriorate and the clutch and brake to be
2) To check the operation of the torque converter adversely affected.
clutch. Be sure to cool down the engine for at least one
3) To check engine performance. minute after each stall test with the select lever set
in the P or N range and with the idle speed lower
2. TEST METHODS S502246A1002
than 1,200 rpm.
1) Preparations before test: 쐌 If the stall speed is higher than the specified
(1) Check that throttle valve opens fully. range, attempt to finish the stall test in as short a
(2) Check that engine oil level is correct. time as possible, in order to prevent the automatic
(3) Check that coolant level is correct. transmission from sustaining damage.
(4) Check that ATF level is correct. Stall speed (at sea level):
(5) Check that differential gear oil level is cor- Non-turbo model: 2,100 — 2,600 rpm
rect. Turbo model: 2,150 — 2,950 rpm
(6) Increase ATF temperature to 50 to 80°C
(122 to 176°F) by idling the engine for approxi-
mately 30 minutes (with select lever set to “N”
or “P”).
2) Install an engine tachometer at a location vis-
ible 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.
B3M0286C
(A) Brake pedal

(B) Accelerator pedal
6) When the engine speed is stabilized, read that

speed quickly and release the accelerator pedal.
7) Shift the select lever to Neutral, and cool down
the engine by idling it for more than one minute.
8) Record the stall speed.
AT-13
STALL TEST
3. EVALUATION S502246A1003
Stall speed (at sea level) Position Cause

쐌 Throttle valve not fully open
2,
Less than specifications 쐌 Erroneous engine operation
R
쐌 Torque converter clutch’s one-way clutch slipping
쐌 Line pressure too low
D 쐌 Low clutch slipping
쐌 One-way clutch malfunctioning
쐌 Line pressure too low
Greater than specifications R 쐌 Reverse clutch slipping

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2001 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX

This service manual has been prepared

All information, illustration and specifica-

This service manual has been prepared

All information, illustration and specifica-

This service manual has been prepared

All information, illustration and specifica-

This service manual has been prepared

All information, illustration and specifica-

This service manual has been prepared

All information, illustration and specifica-

This service manual has been prepared

All information, illustration and specifica-

WIRING SYSTEM SECTION

This service manual has been prepared

All information, illustration and specifica-

These manuals are used when performing

Applied model: SF***** from 2001MY.

The additional manuals below are also available:

The manuals contain the latest information at the

1. How to Use This Manuals SA02675

A: HOW TO USE THIS MANUALS

Each section consists of SCT that are broken down

The first page has an index with tabs. And at the

For each component, a composition drawing is

If necessary, specifications are also included

Inspections are included to be carried out before

Maintenance instructions are provided for each

Tables showing a step-by-step process make it

Measurements in these manuals are according to

Model 2.0 L Non-TURBO 2.0 L TURBO

Model 2.0 L Non-TURBO 2.0 L TURBO

Model 2.0 L Non-TURBO 2.0 L TURBO

Model 2.0 L Non-TURBO 2.0 L TURBO

Model LHD RHD

Front MacPherson strut type, Independent, Coil spring

Model Australia spec. vehicles and 2000 Others

Rim size 15 × 6J 16 × 61/2JJ

Model 2.0 L Non-TURBO 2.0 L TURBO

1. EXCEPT AUSTRALIA SPEC. VEHICLE SA08758G3706

Model 2.0 L Non-TURBO

Model 2.0 L TURBO

2. AUSTRALIA SPEC. VEHICLE SA08758G3704

Model 2.0 L Non-TURBO 2.0 L TURBO

Adhere to the following when handing and storing

Always conduct road tests in accordance with traf-

To prevent bodily injury from unexpected deploy-

To prevent bodily injury from unexpected airbag

This is information that can improve efficiency of

Fasteners are used to prevent parts from damage

Do not touch the ECM, connectors, logic boards,

When removing the battery cables, always be sure

Use authentic service parts for maximum perfor-

5. LIFTS AND JACKS SA03676A1505

6. TIE DOWNS SA03676A1506

Tie downs are used when transporting vehicles

Avoid towing vehicles except when the vehicle

For information about training, contact a dealer or

Using general scan tools will greatly improve effi-

1. IDENTIFICATION NUMBER AND LABEL LOCATIONS SA06679F7001

The VIN (Vehicle Identification Numbers) is used to classify the vehicle.

2. MEANING OF V.I.N. SA06679F7002

The meaning of the VIN is as follows: