Subaru Forester 2007 Service Manual

Foreword
FOREWORD
1. Foreword
A: FOREWORD
These manuals are used when performing maintenance, repair or diagnosis of Subaru Forester.
Application model: 2007 MY SG*****
The manuals contain the latest information at the
time of publication. Changes in the specifications,
methods, etc. may be made without notice.
FW-2
How To Use This Manuals

HOW TO USE THIS MANUALS
1. How To Use This Manuals

A: HOW TO USE THIS MANUALS
1. STRUCTURE
Each section consists of SCT that are broken down
into SC that are divided into sections for each component. The specification, maintenance and other
information for the components are included, and
the diagnostic information has also been added
where necessary.
2. INDEX
The first page has an index with tabs.
HU-2

3. COMPONENT
Illustrations are provided for each component. The information necessary for repair work (tightening torque,
grease up points, etc.) is described on these illustrations. Information is described using symbol.
To order parts, refer to parts catalogue.
Example:
(7)
(5)
(20)
(21)
T2
(5)
T6
(8)
(1)
T1
T3
(4)
(2)
T8
T2
(3) (6)
T3
T10
(1)
T5
T3
T2
T3
(2)
T4
(4)
(4)
(3)
(12) (22)
(23)
(16)
(14)
(9)
(6)
(10)
(11)
(11)
(18)
T1
(13)
(10)
(9)
T3
(15)
T2
(17)
(19)
T6
(4)
(3)
(7)
T4
(10)
(4)
(15)
T2
T11
T5
(22)
T6
(3)
(12)
(35)
T4
(8)
(10)
T3
(26)
(23)
(14)
T2
T5
(27)
T2
(34)
(24)
(25)
T7
(24)
(36)
(25)
(13)
(31)
(30)
T2
T5
(29)
(10)
(17)
(16)
(37)
(32)
(28)
(18)
T3
(33)
T4
T1
: Selective part
: Replacement part
T1
(21)
: Sealing point
: Should be lubricated with oil.
(20)
T9
: Should be lubricated with grease.
(19)
T1
T2
....
: Tightening torque
HU-00017
HU-3

4. SPECIFICATION
If necessary, specifications are also included.
5. INSPECTION
Inspections to be carried out before and after maintenance are included.
6. MAINTENANCE
Maintenance instructions for serviceable parts describe work area and detailed step with illustration. It also
describes the use of special tool, tightening torque, caution for each procedure.
If many serviceable parts are included in one service procedure, appropriate reference is provided for each
parts.
Example:
15.Main Shaft Assembly for Single-Range

A: REMOVAL
(A)
(B)
1) Remove the manual transmission assembly

from vehicie. <Ref. to MT-33, REMOVAL, Manual
Transmission Assembly.>
(C)
11) Tighten the lock nuts to the specified torque using ST1 and ST2.
NOTE:
Secure the lock nuts in two Places after tightening.
ST1 498937000
TRANSMISSION HOLDER
ST2 499987003
SOCKET WRENCH (35)
(E)
(D)
(F)
Tightening torque:
118 N m (12.0 kgf-m, 86.8 ft-lb)
(G)
(H)
ST2
ST1
HU-00020
(A)
Component
(D)
Cautions
(G)
Tightening torque
(B)
(C)
Process
Reference
(E)
(F)
Tool number of special tool

Name of special tool
(H)
Illustration
HU-4

7. DIAGNOSIS
Tables showing a step-by-step process make it easy to conduct diagnosis.
8. SI UNITS
Measurements in these manuals are according to the SI units. Metric and yard/pound measurements are
also included.
Example:
Tightening torque:
44 Nm (4.5 kgf-m, 33 ft-lb)
HU-5

HU-6
Forester
SPECIFICATIONS
1. Forester
A: DIMENSION
2.5 L
Model
AWD
Non-turbo
Overall length
Overall width
mm (in)
mm (in)
Total height (at C.W.)
mm (in)
1,590 (62.6)
1,585 (62.4)
1,012 (39.8)
992 (39.0)*1
998 (39.3)
938 (36.9)*1
Front
mm (in)
Rear
mm (in)
Leg room
Front
Rear
mm (in)
mm (in)
1,108 (43.6)
856 (33.7)
Shoulder room
Front
Rear
mm (in)
mm (in)
1,356 (53.4)
1,361 (53.6)
mm (in)
mm (in)
2,525 (99.4)
1,495 (58.9)
Head-room
Compartment
Wheelbase
Tread
Turbo
4,485 (176.6)
1,735 (68.3)
Front
Rear
mm (in)
mm (in)
Minimum road clearance
1,485 (58.5)
205 (8.07)
200 (7.87)
*1: Model with sunroof
B: ENGINE
Model
2.5 L Non-turbo
2.5 L Turbo
Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline
engine
SOHC
DOHC
Engine type
Valve system mechanism
Bore stroke
Displacement
Compression ratio
Ignition order
Idling speed [at neutral position on
MT, or P or N position on AT]
Maximum output
Maximum torque
Method
Number of valves
Intake 2/Exhaust 2
99.5 79
(3.92 3.11)
mm (in)
cm3 (cu in)
2,457 (149.94)
10.00.2
8.40.2
1324
MT: 650100
AT: 700100
129 (173)/6,000
172 (230)/5,600
226 (23.0, 166)/4,400
319 (32.5, 235)/3,600
rpm
kW (HP)/rpm
Nm (kgf-m, ft-lb)/rpm
700100
C: ELECTRICAL
Model
Ignition timing/Idle speed
Spark plug
Generator
BTDC/rpm
2.5 L Non-turbo
MT: 108/650
AT: 158/700
NGK: FR5AP-11
12 V 90 A
2.5 L Turbo
1710/700
NGK: ILFR6B
12 V 110 A
MT: 12 V 48 AH (55D23L)
AT: 12 V 52 AH (75D23L)
Battery
SPC-2
Forester
SPECIFICATIONS
D: TRANSMISSION
Model
Transmission
2.5 L Non-turbo
5MT
4AT
Clutch type
Gear ratio
First deceleration
Reduction gear (Front)
1st
DSPD
3.454
TCC
2.785
DSPD
3.454
TCC
2.785
2nd
3rd
2.062
1.448
1.545
1.000
1.947
1.366
1.545
1.000
4th
5th
1.088
0.780
0.694
0.972
0.738
0.694
Rev.
Type
3.333
2.272
Helical
3.333
2.272
Helical
1.000
1.000
Gear ratio
Final deceleration
Type
Gear ratio
4.111
Transfer reduction
Type
Gear ratio
Helical
1.000
Final deceleration
Type
Gear ratio
Reduction gear (Rear)
2.5 L Turbo
5MT
4AT
Hypoid
4.444
4.111
Helical
1.000
Hypoid
4.444
4.111
4.111
5MT: 5-forward speeds with synchromesh and 1-reverse

4AT: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse
DSPD: Dry Single Plate Diaphragm
TCC: Torque Converter Clutch
E: STEERING
Model
Type
2.5 L Non-turbo
2.5 L Turbo
Rack and Pinion, Integral
Turns, lock to lock

Minimum turning
diameter
m (ft)
Curb to curb
3.1
10.6 (34.8)
3.0
10.8 (35.4)
Wall to wall
11.4 (37.4)
11.6 (38.1)
F: SUSPENSION
Front
Rear
Macpherson strut type independent suspension

Dual link strut type independent suspension
G: BRAKE
Model
Service brake system
Front
Rear
Parking brake
2.5 X
2.5 XS, 2.5 XT, CROSS SPORTS 2.5 XT,

L.L.Bean
Dual circuit hydraulic with vacuum suspension and power unit

Ventilated disc brake
Drum brake
Disc brake
Mechanical on rear brakes
H: TIRE
16 61 /2JJ,
16 61 /2J
P215/60R16 94H
Wheel size
Tire size
Type
17 7JJ
P215/55R17 93H
Steel belted radial, tubeless
SPC-3
Forester
SPECIFICATIONS
I:
CAPACITY
Model
Transmission
2.5 L Non-turbo
5MT
4AT
2 (US gal, Imp gal)
Total capacity (Overhaul)
Fuel tank
Engine oil
2 (US qt, Imp qt)
Filling amount of
engine oil
2.5 L Turbo
5MT
4AT
60 (15.9, 13.2)
5.0 (5.3, 4.4)
When replacing engine

oil and oil filter
When replacing only
engine oil
4.2
(4.4, 3.7)
4.3
(4.5, 3.8)
4.0 (4.2, 3.5)
Transmission oil
2 (US qt, Imp qt)
3.5
(3.7, 3.1)
3.5
(3.7, 3.1)
ATF
2 (US qt, Imp qt)
9.3
(9.8, 8.2)
9.3
(9.8, 8.2)
Front differential gear oil
2 (US qt, Imp qt)
1.2
(1.3, 1.1)
1.2
(1.3, 1.1)
Rear differential gear oil

Power steering fluid
2 (US qt, Imp qt)

2 (US qt, Imp qt)
Engine coolant
2 (US qt, Imp qt)
Approx. 7.4
(Approx. 7.8,
6.5)
Approx. 7.3
(Approx. 7.7,
6.4)
SPC-4
0.8 (0.8, 0.7)

0.7 (0.7, 0.6)
Approx. 6.9
(Approx. 7.3,
6.1)
Approx. 6.8
(Approx. 7.2,
6.0)
Forester
SPECIFICATIONS
J: WEIGHT
1. FOR U.S. MODEL
Option code
U5ZK
U5FK
Engine type
Grade
Transmission
Vehicle weight
(C.W.)
Total axle
weight
(G.A.W.)
U6ZK
U6FK
2.5 L Non-turbo
2.5 X
Front axle
kg (lb)
Rear axle
kg (lb)
Total
kg (lb)
Front axle
kg (lb)
Rear axle
kg (lb)
Total vehicle weight (G.V.W.)
kg (lb)
Aluminum wheel
Leather seats and
leather door trim center
decoration
5MT
796
(1,755)
4AT
814
(1,795)
5MT
789
(1,740)
4AT
807
(1,779)
5MT
796
(1,755)
4AT
814
(1,795)
5MT
789
(1,740)
4AT
807
(1,779)
639
(1,410)
639
(1,410)
632
(1,394)
632
(1,394)
639
(1,410)
639
(1,410)
632
(1,394)
632
(1,394)
1,435
(3,165)
930
(2,050)
998
(2,200)
1,882
(4,150)
1,453
(3,205)
930
(2,050)
998
(2,200)
1,882
(4,150)
1,421
(3,133)
930
(2,050)
998
(2,200)
1,882
(4,150)
1,439
(3,173)
930
(2,050)
998
(2,200)
1,882
(4,150)
1,435
(3,165)
930
(2,050)
998
(2,200)
1,882
(4,150)
1,453
(3,205)
930
(2,050)
998
(2,200)
1,882
(4,150)
1,421
(3,133)
930
(2,050)
998
(2,200)
1,882
(4,150)
1,439
(3,173)
930
(2,050)
998
(2,200)
1,882
(4,150)
Leather package base

Sunroof
VDC+VTD
Seat heater
Cold zone package

Side airbag
De-icer
Front fog light

Cruise control
Option
Fully automatic air

conditioner
Manual air conditioner
1: For option codes, refer to the ID section. <Ref. to ID-4, MODEL NUMBER PLATE, IDENTIFICATION, Identification.>
SPC-5
Forester
SPECIFICATIONS
Option code
Engine type
U5SW
Grade
Transmission
Vehicle weight
(C.W.)
Total axle
weight
(G.A.W.)
U5SL
U5SM
2.5 L Non-turbo
2.5 XS
5MT
5MT
4AT
5MT
4AT
796
(1,755)
644
(1,420)
1,440
(3,175)
930
(2,050)
814
(1,795)
644
(1,420)
1,458
(3,215)
930
(2,050)
795
(1,753)
645
(1,422)
1,440
(3,175)
930
(2,051)
815
(1,797)
645
(1,422)
1,460
(3,219)
930
(2,051)
U6SW
4AT
5MT
4AT
789
(1,740)
635
(1,400)
1,424
(3,140)
930
(2,050)
810
(1,785)
635
(1,400)
1,444
(3,185)
930
(2,050)
789
(1,740)
635
(1,400)
1,424
(3,140)
930
(2,050)
810
(1,785)
635
(1,400)
1,444
(3,185)
930
(2,050)
Front axle
kg (lb)
Rear axle
kg (lb)
Total
kg (lb)
Front axle
kg (lb)
Rear axle
kg (lb)
998
(2,200)
998
(2,200)
1,000
(2,205)
1,000
(2,205)
998
(2,200)
998
(2,200)
998
(2,200)
998
(2,200)
kg (lb)
1,882
(4,150)
1,882
(4,150)
1,880
(4,145)
1,880
(4,145)
1,882
(4,150)
1,882
(4,150)
1,882
(4,150)
1,882
(4,150)

Aluminum wheel
Leather seats and

decoration
Front fog light
Cruise control
Option
Sunroof
VDC+VTD
Seat heater
Fully automatic air
conditioner

Cold zone package
Side airbag
De-icer
SPC-6
Forester
SPECIFICATIONS
Option code
Engine type
U6SL
Grade
U6SM
2.5 L Non-turbo
2.5 XS
Transmission
5MT
U5TL
U6TL
L.L.Bean
4AT
5MT
4AT
4AT
U4TL
2.5 L Turbo
U483
U484
2.5 L Turbo
2.5 XT
4AT
CROSS
SPORTS 2.5XT
5MT
4AT
5MT
Front
axle
kg
795
(lb) (1,753)
815
(1,797)
789
(1,740)
810
(1,785)
814
814
830
(1,795) (1,795) (1,830)
880
(1,940)
830
880
(1,830) (1,940)
Rear
axle
kg
645
(lb) (1,422)
645
(1,422)
635
(1,400)
635
(1,400)
651
651
650
(1,435) (1,435) (1,433)
649
(1,432)
650
649
(1,433) (1,432)
Front
axle
Rear
axle
kg 1,440
(lb) (3,175)
kg
930
(lb) (2,051)
kg 1,000
(lb) (2,205)
1,460
(3,219)
930
(2,051)
1,000
(2,205)
1,424
(3,140)
930
(2,050)
998
(2,200)
1,444
(3,185)
930
(2,050)
998
(2,200)
1,465
1,465
1,480
(3,230) (3,230) (3,263)
930
930
990
(2,050) (2,050) (2,183)
998
998
1,020
(2,200) (2,200) (2,249)
1,529
(3,372)
993
(2,190)
1,020
(2,250)
1,480
1,529
(3,263) (3,372)
990
993
(2,183) (2,190)
1,020
1,020
(2,249) (2,250)
Total vehicle weight

(G.V.W.)
kg 1,880
(lb) (4,145)
1,880
(4,145)
1,882
(4,150)
1,882
(4,150)
1,882
1,882
1,960
(4,150) (4,150) (4,322)
1,959
(4,320)
1,960
1,959
(4,322) (4,320)
Vehicle
weight
(C.W.)
Total
Total axle
weight
(G.A.W.)
Aluminum wheel
Leather seats
and leather door
trim center decoration
Front fog light

Cruise control

Option
Sunroof
VDC+VTD
Seat heater
Fully automatic
air
conditioner
Cold zone package
Side airbag
De-icer
SPC-7
Forester
SPECIFICATIONS
2. FOR CANADA MODEL

Option code
COZK
Engine type
Grade
Total axle
weight
(G.A.W.)
Front axle
kg (lb)
Rear axle
kg (lb)
Total
kg (lb)
Front axle
kg (lb)
Rear axle
kg (lb)
kg (lb)
COSL
COSM
2.5 L Non-turbo
2.5 XS
2.5 X
Transmission
Vehicle weight
(C.W.)
COTL
5MT
795
(1,753)
640
(1,411)
4AT
815
(1,797)
640
(1,411)
5MT
795
(1,753)
650
(1,433)
4AT
815
(1,797)
650
(1,433)
5MT
795
(1,753)
645
(1,422)
4AT
815
(1,797)
645
(1,422)
5MT
790
(1,742)
635
(1,400)
4AT
810
(1,786)
635
(1,400)
1,435
(3,164)
1,455
(3,208)
1,445
(3,186)
1,465
(3,230)
1,440
(3,175)
1,460
(3,219)
1,425
(3,142)
1,445
(3,186)
930
(2,051)
1,000
(2,205)
1,880
(4,145)
930
(2,051)
1,000
(2,205)
1,880
(4,145)
930
(2,051)
1,000
(2,205)
1,880
(4,145)
930
(2,051)
1,000
(2,205)
1,880
(4,145)
930
(2,051)
1,000
(2,205)
1,880
(4,145)
930
(2,051)
1,000
(2,205)
1,880
(4,145)
930
(2,051)
1,000
(2,205)
1,880
(4,145)
930
(2,051)
1,000
(2,205)
1,880
(4,145)
Aluminum wheel
Leather seats and

decoration
Front fog light

Cruise control
Option

Sunroof
VDC+VTD
Seat heater
Fully automatic air

conditioner

Cold zone package
Side airbag
De-icer
SPC-8
Forester
SPECIFICATIONS
Option code
Engine type
CO66
2.5 L Non-turbo
Grade
Transmission
Vehicle weight
(C.W.)
Total axle
weight
(G.A.W.)
2.5 XS
5MT
4AT
COTL
2.5 L Turbo
5MT
4AT
2.5 XT
5MT
4AT
COSM
5MT
4AT
790
(1,742)
635
(1,400)
1,425
(3,142)
930
(2,051)
810
(1,786)
635
(1,400)
1,445
(3,186)
930
(2,051)
845
(1,863)
655
(1,444)
1,500
(3,308)
990
(2,183)
865
(1,907)
655
(1,444)
1,520
(3,352)
990
(2,183)
830
(1,830)
650
(1,433)
1,480
(3,263)
990
(2,183)
850
(1,874)
650
(1,433)
1,500
(3,308)
990
(2,183)
825
(1,819)
635
(1,400)
1,460
(3,219)
990
(2,183)
845
(1,863)
635
(1,400)
1,480
(3,263)
990
(2,183)
kg (lb)
1,000
(2,205)
1,000
(2,205)
1,020
(2,249)
1,020
(2,249)
1,020
(2,249)
1,020
(2,249)
1,020
(2,249)
1,020
(2,249)
kg (lb)
1,880
(4,145)
1,880
(4,145)
1,960
(4,322)
1,960
(4,322)
1,960
(4,322)
1,960
(4,322)
1,960
(4,322)
1,960
(4,322)
Front axle
kg (lb)
Rear axle
kg (lb)
Total
kg (lb)
Front axle
kg (lb)
Rear axle
COSL
Aluminum wheel
Leather seats and
decoration
Front fog light
Cruise control
Option
Sunroof
VDC+VTD
Seat heater
Fully automatic air
conditioner

Cold zone package
Side airbag
De-icer
SPC-9
Forester
SPECIFICATIONS
3. OPTION
Option
Aluminum wheel
Leather seats and leather door trim
center decoration
Front fog light
Front
kg (lb)
Rear
kg (lb)
Total
kg (lb)
6.6 (14.6)
6.6 (14.6)
13.2 (29.1)
1.2 (2.6)
3.0 (6.6)
4.2 (9.3)
0.7 (1.5)
0.1 (0.2)
0.6 (1.3)
Cruise control
1.5 (3.3)
0.0 (0.0)
0.2 (0.4)
0.0 (0.0)
1.7 (3.7)
0.0 (0.0)
Sunroof
VDC+VTD
3.5 (7.7)
3.0 (6.6)
13.2 (29.1)
1.0 (2.2)
16.7 (36.8)
4.0 (8.8)
Seat heater
0.2 (0.4)
0.3 (0.7)
0.5 (1.1)
16.9 (37.3)
16.9 (37.3)
1.4 (3.1)
1.4 (3.1)
15.5 (34.2)
15.5 (34.2)
Cold zone package

Side airbag
0.1 (0.2)
2.0 (4.4)
0.2 (0.4)
2.4 (5.3)
0.3 (0.7)
4.4 (9.7)
De-icer
0.0 (0.0)
0.0 (0.0)
0.0 (0.0)
Fully automatic air conditioner

SPC-10
Precaution
PRECAUTION
1. Precaution
7. AIRBAG MODULE AND SEAT BELT

PRETENSIONER DISPOSAL
A: CAUTION
Please clearly understand and adhere to the following. They must be strictly followed to avoid minor or
serious injury to the person doing the work or people in the area.
To prevent bodily injury from unexpected airbag

deployment, do not dispose the airbag modules
and seat belt pretensioner in the same way as other waste. Follow all government regulations concerning disposal of refuse.
1. ABS
8. AIRBAG MODULE
Handle the ABS as a total system. Do not disassemble or attempt to repair individual parts. Follow
the directions in this manual when performing
maintenance on the ABSCM&H/U When parts other than those specified are disassembled, the ABS
system may not operate when needed, or may operate incorrectly and result in injury.
Adhere to the following when handing and storing

the airbag module to prevent bodily injury from unexpected deployment:
Do not hold the harnesses or connectors to carry
the module.
Do not face the bag in the direction that it opens
towards yourself or other people.
Do not face the bag in the direction that it opens
towards the floor or walls.
2. VEHICLE DYNAMICS CONTROL (VDC)

Handle the VDC as a total system. Do not disassemble or attempt to repair individual parts. Doing
so could prevent the VDC system from operating
when needed, or the system may operate incorrectly and result in injury.
3. BRAKE FLUID
If brake fluid gets in your eyes or on your skin, do
the following:
Wash out your eyes and seek immediate medical attention.
Wash your skin with soap and then rinse thoroughly with water.
4. RADIATOR FAN
The radiator 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.
5. ROAD TEST
Always conduct road tests in accordance with traffic rules and regulations to avoid bodily injury and
traffic interruption.
6. AIRBAG
To prevent bodily injury from unexpected deployment of airbags and unnecessary maintenance, follow the instructions in this manual when performing
maintenance on the airbag components or nearby,
around front of the vehicle (radiator panel, front
wheel apron, front side frame, front bumper, front
hood panel, front fender panel), around side of the
vehicle (front door panel, center pillar, side sill), and
the airbag wiring harnesses or nearby.
To prevent unexpected deployment, turn the ignition switch to OFF and disconnect the ground cable
from battery, then wait at least 20 seconds to discharge electricity before starting work.
9. AIRBAG SPECIAL TOOLS

To prevent unexpected deployment, only use special tools.
10.WINDOW
Always wear safety glasses when working around
any glass to prevent glass fragments from damaging your eyes.
11.WINDOW ADHESIVE
Always use the recommended or equivalent adhesive when attaching glass to prevent it from coming
loose and falling, resulting in accidents and injury.
12.OIL
When handling oil, adhere to the following to prevent from unexpected accident.
Prepare a container and cloth when performing
work which oil possibly spills. If oil spills, wipe it off
immediately to prevent from penetrating into floor
or flowing out for environmental protection.
Follow all government and local regulations concerning disposal of refuse when disposing.
13.FUEL
When handling and storing fuel, adhere to the following to prevent from unexpected accident.
Be careful with fire.
Prepare a container and cloth to prevent scattering of fuels when performing work where fuels can
be spilled. If the fuel spills, wipe it off immediately to
prevent from penetrating into floor or flowing out for
environmental protection.
PC-2
Precaution
PRECAUTION
14.ENGINE COOLANT
When handling engine coolant, adhere to the following to prevent from unexpected accident.
Never remove the radiator cap since engine
coolant may blow out when it is hot.
Prepare a container and cloth to prevent scattering of engine coolant when performing work where
engine coolant can be spilled. If the fuel spills, wipe
it off immediately to prevent from penetrating into
floor or flowing out for environmental protection.
15.AIR CONDITIONER REFRIGERANT

In order to prevent from global warming, avoid releasing air conditioner refrigerant into the atmosphere. Using a refrigerant recovery system,
discharge and reuse it.
PC-3
Precaution
PRECAUTION
PC-4
Note
NOTE
1. Note
A: NOTE
This is the information that can improve the efficiency of maintenance and assure the sound work.
1. FASTENER NOTICE
Replace the nonreusable parts with new parts.
Check the tightening torque and tighten to the
specified torque.
Do not apply paint, lubricant, rust retardant or other
substance to the surface around bolts, nuts, etc.
Doing so will make it difficult to obtain the correct
torque and result in looseness and other problem.
2. STATIC ELECTRICITY DAMAGE

Do not touch the control modules, 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 for the elimination of static electricity before conducting work.
3. BATTERY
When removing the battery cables, always be sure
to turn the ignition switch to OFF to prevent electrical damage to the control module from overcurrent.
4. SERVICE PARTS
Use genuine parts for maximum performance and
maintenance when conducting repairs. Subaru/FHI
will not be responsible for poor performance resulting from the use of parts except for genuine parts.
5. PROTECTING VEHICLE UNDER MAINTENANCE

Make sure to attach the fender cover, seat covers,
etc. before work.
6. ENSURING SAFETY DURING WORK

When working in a group of two or more, perform
the work with calling each other to ensure mutual
safety.
NT-2
Note
NOTE
7. LIFTS AND JACKS

When using a lift or shop jack to raise a vehicle or using rigid racks to support 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 that the vehicle is balanced before raising it. Be sure to set the wheel stoppers
when jacking-up only the front or rear side of the vehicle.
SUPPORT LOCATIONS
NT-00155
PANTOGRAPH JACK
NT-00002
NT-3
Note
NOTE
LIFT
NT-00003
RIGID RACK
NT-00004
NT-4
Note
NOTE
JACK-UP POINT
(A)
(B)
NT-00005
(A)
Front
(B)
Rear
NT-5
Note
NOTE
8. TIE-DOWNS
Tie-downs are used when transporting vehicles and when using the chassis dynamo. Attach tie-down only
to the specified place on the vehicle.
(A)
(B)
(C)
(D)
(C)
(B)
NT-00006
(A)
(B)
Front
Hook for tie-down and towing
(C)
Hook for tie-down
NT-6
(D)
Rear
Note
NOTE
CHAIN DIRECTION AT TIE-DOWN CONDITION
VEHICLE SINKING VOLUME AT TIE-DOWN

CONDITION
Measure the distance between the highest tire
point and highest arch point before and after tiedown. Difference of measured values (sinking volume) should be within 50 mm (1.97 in) and make
sure to fix the vehicle securely.
NT-00082
9. TOWING
NT-00007
CHAIN PULLING RANGE AT TIE-DOWN CONDITION
: (A)
Avoid towing vehicles except when the vehicle cannot be driven. For models with AWD or AT, use a
loader instead of towing. When towing other vehicles, pay attention to the following to prevent hook
or vehicle damage resulting from excessive weight.
Do not tow other vehicles with a front tie-down
hook.
Make sure the vehicle towing is heavier than the
vehicle being towed.
NT-00008
(A) Chain pulling range at tie-down condition
NT-7
Note
NOTE
10.FRONT HOOD STAY INSTALLATION

AT THE CHECK AND GENERAL MAINTENANCE
NT-00009
WHEN WIDER HOOD OPENING IS NECESSARY

Set stay into the hole of hood inner as shown in the figure below.
NOTE:
Before setting the front hood in this position, remove the windshield washer hose attaching clip from the front
hood.
NT-00129
11.TRAINING
For an information about training, contact a dealer
or agent.
12.GENERAL SCAN TOOL

Using general scan tools will greatly improve the efficiency of repairing engine electronic controls.
Subaru Select Monitor can be used to diagnose the
engine, ABS, air conditioner and other parts.
NT-8
Identification
IDENTIFICATION
1. Identification
A: IDENTIFICATION
1. IDENTIFICATION NUMBER AND LABEL LOCATIONS
The Vehicle Identification Numbers (V.I.N.) is used to classify the vehicle.
POSITIONING OF THE PLATE LABEL FOR IDENTIFICATION
Emission control label
Vehicle identification number plate
Vehicle identification
number
Bar cord label

(America spec. vehicles only)
Tire inflation
pressure label
Model number plate
ID-00101
ENGINE
MANUAL TRANSMISSION
(1)
(1)
(2)
(2)
ID-00059
ID-00118
(1) Engine serial number (Punch mark)
(1) Transmission serial number
(2) Engine type (Crankcase upper side)
(2) MT type label
AUTOMATIC TRANSMISSION
(1)
ID-00129
(1) AT type and transmission serial number label
ID-2
Identification
IDENTIFICATION
REAR DIFFERENTIAL
(1)
ID-00056
(1) Type (white paint)
Model number plate
FUJI HEAVY INDUSTRIES LTD.

VIN
J F 1 SG6 3 6 X 7 G7 0 0 0 0 1
U5ZK
applied model
SG 9 DY 4 J
trim code
410
engine type
E J 2 5 3 BS RH B
Color code
230
transmission type
TY 7 5 5VC7AA
option code
ID-00152
ID-3
Identification
IDENTIFICATION
2. MEANING OF V.I.N.
The meaning of the V.I.N. is as follows:
]JF1SG636X7G700001[
The large parentheses (][) located in front and back are stop marks.
Digits
13
JF1
Code
Details
JF1: FHI manufactured passenger car
Meaning
Origin of manufacture of
body
Car line
4
5
6
G
6
Body type
Displacement class
G: Wagon
6: 2.5 L AWD
Grade
3: 2.5 X
5: 2.5 XS
7: L.L. Bean
9: 2.5 XT
8
9
6
X
Restraint
Check numbers
6: Manual belt, dual airbags, side airbags

X or 0 9
10
11
7
G
Model year
Transmission type
7: 2007MY
G: Full-time AWD 5 speed MT
H: Full-time AWD 4 speed AT
12 17
700001
Serial number
S: Forester
3. MODEL NUMBER PLATE

The model number plate indicates: the applied model, the option code, the trim code, the engine type, the
transmission type, and the exterior color code. This information is helpful when placing orders for parts.
SG9EY4J
Digits
Code
Meaning
Details
1
2
S
G
Series
Body type
S: Forester
G: Wagon
Total engine displacement

Drive system
9: 2.5 L AWD
4
5
E
Y
Model year
Destination
E: 2007MY
Y: U.S.A., Canada
Grade
Transmission, fuel feed

system
4: 2.5 X
6: 2.5 XS
9: 2.5 XT
C: L.L Bean
D: DOHC turbo MFI 5 speed MT
J: SOHC MFI 5 speed MT
P: DOHC turbo MFI 4 speed AT
R: SOHC MFI 4 speed AT
ID-4
Identification
IDENTIFICATION
The engine and transmission type are as follows.

Engine
EJ253ASQFB
Digits
Code
Meaning
Details
1 and 2
3 and 4
EJ
25
Engine type symbol

Displacement class
EJ: 4 cylinder
25: 2.5 L
Fuel feed system
Exhaust regulations
3: MFI non-turbo (SOHC)

5: MFI DOHC turbo
A: For states not using California emission standards
B: For all states
C: For states using California emission standards
Mounted transmission
8 10
QFB
Detailed specifications
P: AT
S: MT
Used for ordering parts. Refer to parts catalog for details.
Transmission
TY755VC7AA
Digits
Code
Meaning
Details
1
2
T
Y
Transmission
Transmission system
T: Transmission
V: Full-time AWD AT center differential (VTD)
Y: Full-time AWD MT center differential
Z: Full-time AWD AT MPT
1B: AT
75: MT
5: MT, AT
3 and 4
75
Classification
Series
Transmission basic
specifications
Installed body
8 10
7AA
Detailed specifications
L: MP-T full-time AWD direct 4 speed AT

M: VTD center differential full-time AWD direct 4 speed AT
V: Full-time AWD 5 speed MT single range with viscous coupling center differential
C: 2.5 L SOHC
B: 2.5 L DOHC turbo 5 speed MT
W: 2.5 L DOTC turbo 4 speed AT
Used for ordering parts. Refer to parts catalog for details.
Rear differential
T2
Code
Reduction gear ratio
LSD
T2
JP
4.111
4.111
None
Viscous
TP
CF
4.444
4.444
None
Viscous
Option code
U5ZK
Digits
Code
Meaning
12
U5
Destination
34
ZK
Vehicle main options
Details
U5: U.S. (for states using California emission standards)
U6: U.S. (for states not using California emission standards)
U4: U.S. (for all states)
CO: Canada
ID-5
Identification
IDENTIFICATION
ID-6
Recommended Materials
RECOMMENDED MATERIALS
1. Recommended Materials
A: RECOMMENDED MATERIALS
1. GENERAL
To insure the best performance, always use the
specified oil, gasoline, adhesive, sealant, etc. or a
substitute of equivalent quality.
2. FUEL
Use unleaded gasoline to reduce air pollution,
because using leaded gasoline will damage the
catalytic converter.
Do not use the low quality gasoline, or improper
fuel such as diesel fuel, fuel alcohol, or gasoline additive because they will adversely affect on engine
components.
Always use gasoline that is equivalent to that
prescribed in the instruction manual or that of high
octane value. There is the possibility of damaging
or improper operation of the engine and fuel injection system if the specifications are not observed.
Use the prescribed gasoline type to maintain proper vehicle performance.
RM-2
3. LUBRICANTS
Use the lubricants shown in the table below, or equivalent. See the table below to choose the correct SAE
viscosity.
Recommended materials
Lubricants
API spec.
SM grade Energy conservation
SERVICE S
PI
AM ER I CA
NG
VI
ER
T I F IE
RM-00049
TUTE
CONS E
FOR
GASOLINE
ENGINES
ST I
GY
TR OLEUM
PE
IN
EN
SAE
5W-30
R
ILSAC spec.
GF-4
Engine oil
D
RM-00002
Manual transmission oil

Front differential oil
GL-5
GL-5
Rear differential oil
GL-5
SAE viscosity No. and applicable temperature SAE J300

Engine oil
(C)
30
20
10
10
20
30
40
(F)
22
14
32
50
68
86
104
10W-30 or 10W-40
5W-30 Recommend
RM-00059
Manual transmission oil and rear differential oil
RM-3
(C)
30
20
10
10
20
30
40
(F)
22
14
32
50
68
86
104
90
85W
80W
75W-90
RM-00004

Front differential (AT)
(C)
30
20
10
10
20
30
40
(F)
22
14
32
50
68
86
104
90
85W
80W
75W-90
RM-00029
4. FLUID
Use the fluids specified in the table below. Do not mix two different kinds or makes of fluid.
Fluid
Automatic transmission fluid
Power steering fluid

Brake fluid
Clutch fluid
Item number
Alternative
SUBARU ATF HP
DEXRON III
Idemitsu: ATF HP
Castrol: Transmax J
Pennzoil Quakerstate:
Pennzoil ATF-J
FMVSS No. 116 DOT3

FMVSS No. 116 DOT3
FMVSS No. 116 DOT4

FMVSS No. 116 DOT4
RM-4
5. ENGINE COOLANT
Use genuine engine coolant to protect the engine.
Engine coolant
Coolant
Water for dilution
Cooling system protecting
agent
Item number
Alternative
SUBARU coolant
000016218
Distilled water
Phosphoric acid (non-amine)

type
Soft water or tap water
Cooling system conditioner
SOA345001
None
6. REFRIGERANT
Standard air conditioners on Subaru vehicles use HFC134a refrigerant. Do not mix it with other refrigerants.
Also, do not use any air compressor oil other than ZXL200PG.
Air conditioner
Refrigerant
Compressor oil
Item number
Alternative
HFC134a
ZXL200PG
None
None
7. GREASE
Use the grease and supplementary lubricants shown in the table below.
Grease
Supplementary lubricants
Grease
Application point
Recommended
materials
Spray type lubricant
Item number
Alternative
NICHIMOLY N-130
Clutch master cylinder

push rod
Gear shift lever
Select lever
Clutch activating
cylinder
Accelerator pedal
Clutch pedal
Brake pedal
Hill holder
Clutch bearing
Clutch release lever
Steering shaft
bearing
Silicone grease G-40M
004404003
KOPR-KOTE
003603001
Selector lever lock plate

unit
Steering gearbox
Suncall GLO-244
0029408040
Variant grease M-2
003608001
Niglube RX-2
K0779GA102
One luber MO or
One luber SG
Molykote No. 7439
003602001
Oxygen sensor
Bolts etc.
MT main shaft
Disc brake
Drum brake wheel
cylinder
Drum brake
Brake shoe
Brake pad
Molykote AS-880N
K0777YA010
Front axle AARi

Front axle AC
One luber C
Olistamoly
28395SA000
28395SA020
Rear axle BJ, EBJ

Rear axle DOJ
NTG2218-M
NGK205
28395AG010
28495AG000
Silicone grease G-30M
004404002
Water pump
Door latch
Door striker
RM-5
8. ADHESIVES
Use the adhesives shown in the table below, or equivalent.
Adhesive
Adhesive
Application point
Item number
Alternative
Windshield, rear window

glass, rear quarter
glass, rear gate and
body
Dow Automotives
Adhesive: ESSEX U-400 HV
or equivalent
Glass primer: U-401 and
No. U-402
Paint surface primer: U-413
REPAIR KIT IN MR
Cemedine 540
65029FC000
3Ms EC-776, EC-847 or EC-1022

(Spray type)
Cemedine 3000
Armstrongs Eastman 910
Rearview mirror base

Soft vinyl
Momentary sealant
9. SEAL MATERIAL
Use the seal material shown in the table below, or equivalent.
Seal material
Seal material
Recommended
materials
Item number
Alternative
MT transmission case
Cylinder block
DOHC cam cap
(Turbo model)
Torque converter
clutch case
Oil pump
THREE BOND 1215B

THREE BOND 1215
004403007
Dow cornings No. 7038
Engine oil pan

ATF oil pan
THREE BOND 1207C

THREE BOND 1217B
004403012
K0877YA020
Rear differential
Engine oil pressure
switch
Cylinder head (Nipple)
Rear differential
Service hole plug
THREE BOND 1324
004403042
THREE BOND 1105
004403010
Dow cornings No. 7038
Weather strip
Steering adjusting
screw
PCV Valve
Star caulking B-33A

THREE BOND 1141
000018901
004403006
Butyl rubber sealant
THREE BOND 1280B
K0877YA018
THREE BOND 1217G
3M Butyl Rubber 8626
Application point
SOHC cam cap

DOHC rocker cover
Separator cover
DOHC semicircular
plug
Front sealing cover
Rear sealing cover
RM-6
Pre-delivery Inspection
PRE-DELIVERY INSPECTION
1. Pre-delivery Inspection
A: GENERAL DESCRIPTION
The purposes of the pre-delivery inspection (PDI)
are as follows.
Remove the additional parts used for ensuring
the vehicle quality during transportation and restore
the vehicle to its normal condition.
Check that the vehicle before shipment is in normal condition.
Check that there are no scratches on the vehicle
and that none of the vehicle protective parts are
missing when shipping or in storage.
Make sure to deliver a complete vehicle to customer.
For above reasons, all SOA service centers must
carry out the PDIs before delivery of vehicle.
Furthermore, all SOA service centers and PDI centers must inspect the status of all vehicles and clarify the responsible party.
PI-2
B: PRE-DELIVERY INSPECTION (PDI) PROCEDURE

Follow the procedures shown in the table below.
Static Checks Just After Vehicle Receipt
Step
Check point
1. Appearance check
1. If the vehicle is covered with protective coating, visually check the vehicle
body for damage and dents. If the protective coating has been removed,
visually inspect the body paints for small areas of damage or rust.
2. Visually check the glass and light lenses for any damage, cracks or excessive gaps between body sheet metal.
3. Visually check the plated parts for any damage.
2. Tire check
1. Check the tires for damage, defective, and dents on wheels.

2. Check the tire air pressure.
3. Fuse installation
4. Air conditioner harness connection
If the vehicle is about to be shipped to the customer, attach a room light fuse.
If the vehicle is about to be shipped to the customer, connect the air conditioner harness.
5. Lock/unlock and open/close operation checks

of doors.
1. Using the key, check the trunk lid can be locked or unlocked normally.
2. Open and close all doors to check that there are no defective.
6. Operation check of child safety lock system

7. Lock/unlock and open/close operation checks
of the rear doors.
Check the child safety lock system operates normally.

1. Open and close the rear gate to see that there are no abnormal conditions.
2. Check if the rear gate can be unlocked normally through the emergency
hole.
3. Operate the power door lock switch to check that the rear gate is locked
and unlocked normally.
Operate the fuel lid opener to check that the fuel lid is unlocked normally.
8. Operation check of fuel lid opener lock release

lever
9. Accessory check
12. Brake fluid
Check that the following accessories are provided.

Owners manual
Warranty booklet
Maintenance note
Spare key
Key number plate
Jack
Tool set
Spare tire
Operate the front hood lock release lever to check that the front hood opens
normally.
Check the battery for any abnormal conditions such as rust and trace of battery fluid leaks.
Check the fluid amount.
13. Engine oil

14. Transmission fluid
Check the oil amount.

Check the fluid amount.
15. AT front differential oil

16. Engine coolant
Check the AT front differential oil amount.

Check the engine coolant amount.
17. Clutch fluid

18. Window washer fluid
Check the clutch fluid amount.

Check the window washer fluid amount.
19. Front hood latch check

20. Keyless entry system
Check that the hood is closed and latched completely.

Check that the keyless entry system operates normally.
21. Alarm system

22. Seat
Check that the alarm system operates normally.

1. Check the seat surfaces for stains or dirt.
2. Check the seat installation conditions and functionality.
3. Check that the passengers seat occupant detection system operates normally.
23. Seat belt
1. Check the seat belt installation conditions and functionality.

2. Check the seat belt warning functionality for normal operations.
10. Operation check of front hood lock release

system
11. Battery
PI-3
Checks with the Engine Running

Step
Check point
24. Test mode connector

25. Starting condition
Test mode connector

Start the engine and check that the engine starts smoothly.
26. Exhaust system

27. Indicator and warning lights
Check that the exhaust noise is normal and no leaks are found.
Check that all indicator lights and warning lights operate normally.
28. Clock
29. Radio
Check that the clock operates normally.

Check that the radio system operates normally.
30. Accessory power socket

31. Lighting system
Check that the accessory power socket operates normally.

Check that the lighting system operates normally.
32. Window washer

33. Wiper
Check that the window washer system operates normally.

Check that the wiper system operates normally.
34. Power window operation check
Check the power window for normal operations.
Dynamic Test with the Vehicle Running

Step
Check point
35. Brake test

36. Parking brake
Check the foot brake for normal operations.

Check the parking brake for normal operations.
37. AT shift control

38. Heater & ventilation
Check that the AT shifts normally.

Check that the heater & ventilation system operates normally.
39. Air conditioner

40. Cruise control
Check that the air conditioner operates normally.

Check that the cruise control system operates normally.
Checks after Dynamic Test

Step
Check point
41. ATF level

42. Power steering fluid level
Check that the ATF level is correct.

Check that the power steering fluid level is normal.
43. Fluid leak check

44. Water leak check
Check for fluid/oil leaks.

Spray the vehicle with water and check for water leaks.
45. Appearance check 2
1. Remove the protective coating (if any).

2. Check the body paints for damage and stain.
3. Check the plated parts for damage and rust.
PI-4
1. APPEARANCE CHECK
4. CONNECTION OF AIR CONDITIONER

HARNESS
1) If the vehicle is covered with protective coating,

visually check the vehicle body for damage and
dents.
2) When there is no protective coating, check the
body paints for damage or stains in detail and repair as necessary.
3) Check the window glass, door glass, and lights
for any cracks or damage and replace the parts as
necessary.
4) Check the plated parts, such as the grilles and
door knobs, for damage or loss of gloss and replace the parts as necessary.
A vehicle just delivered has its air conditioner harness disconnected to protect the air conditioner
compressor. Connect the harness as shown in the
figure.
2. TIRE CHECK
Check the outer side surface of the tire damage.
Check the tire air pressure by referring to the following table.
Tire size
PI-00002
5. CHECK THE DOORS FOR LOCK/UNLOCK AND OPEN/CLOSE OPERATIONS
Tire inflation pressure

kPa (kg/cm2, psi)
P215/60R16
Front
200 (2.0, 29)
Rear
190 (1.9, 28)
P215/55R17
220 (2.2, 32)
210 (2.1, 30)
1) Using the key, lock and unlock the door several

times to check for normal operation. Open and
close the door several times for smooth movement.
3. FUSE INSTALLATION
A vehicle just delivered has no fuse for the room
light circuit to prevent battery discharge. Attach a
15 A fuse (A) as shown in the figure.
(A)
(B)
PI-00070
(A) Unlock
(B) Lock
(A)
PI-00001
PI-5
7. CHECK THE REAR GATE FOR LOCK/

UNLOCK AND OPEN/CLOSE OPERATIONS
2) Close the door of driver seat completely, and

place the door lock knob (A) to the lock position.
Then pull the inner remote (B) to ensure that doors
will not open.
For other doors, place the door lock knob (A) to lock
position and then pull the inner remote (B) to ensure that doors will not open.
1) Open and close the rear gate several times for

smooth movement.
2) Operate the rear gate emergency lever to check
that the rear gate is locked and unlocked normally.
(1) Remove the cover inside the rear gate.
(A)
(B)
PI-00004
PI-00006
(2) Operate the driver to check that the rear

gate is locked and unlocked normally.
(A) Door lock knob

(B) Inner remote
6. CHECK THE OPERATION OF CHILD

SAFETY LOCKS
1) Set the child safety lock on both rear doors to the
lock position.
2) Close the rear doors completely.
3) Check that the lock levers of the rear doors are in
the unlock position. Then, pull inner remote of rear
doors to ensure that doors will not open.
4) Pull the outer handles of the rear doors to ensure
that doors will open.
(B)
(A)
PI-00263
(A) Lock
(B) Unlock
(C)
8. OPERATION CHECK OF FUEL LID

OPENER LOCK RELEASE LEVER
(A)
Operate the fuel lid opener to check that the fuel lid
opens normally. Check that the filler cap is securely
closed.
(B)
PI-00084
(A) Unlock
(B) Lock
(C) Child safety lock
PI-6
9. ACCESSORY CHECK
10.OPERATION CHECK OF FRONT HOOD

LOCK RELEASE SYSTEM
Check that the following accessories are provided.

Owners manual
Warranty booklet
Maintenance note
Spare key
Key number plate
Jack
Tool set
Spare tire
Operate the front hood release knob to check that

the front hood is locked normally.
PI-00071
(A)
Operate the lever (A) and check that the front hood
is opened normally. Support the front hood with
hood stay.
PI-00008
(A) Jack
(A)
(A)
PI-00009
(A) Jack handle
PI-00307
PI-7
11.BATTERY
14.TRANSMISSION FLUID
Check the battery terminals to make sure that no

rust or corrosions due to fluid leaks are found.
Check that the battery caps are securely tightened.
Check the transmission fluid amount. If the amount

of fluid is inappropriate, check that no leaks are
found. Then, add the necessary amount of specified fluid.
(A)
(A)
(B)
(B)
(C)
(C)
PI-00012
PM-00030
(A) Cap
(B) Upper level
(A) Oil level gauge

(B) Upper level
(C) Lower level
(C) Lower level
12.BRAKE FLUID
15.AT FRONT DIFFERENTIAL OIL
Check the brake fluid amount. If the amount is insufficient, carry out a brake line test to identify
brake fluid leaks and check the brake operation. After that, refill the brake fluid tank with the specified
type of fluid.
Check the AT front differential oil amount. If the

amount of oil is inappropriate, check that no leaks
are found. Then, add the necessary amount of the
specified AT front differential oil.
13.ENGINE OIL
Check the engine oil amount. If the amount of oil is
insufficient, check that no leaks are found. Then,
add the necessary amount of the specified engine
oil.
(A)
(B)
(A)
(C)
(B)
(C)
PM-00035
(E)
(A) Oil level gauge

(B) Upper level
(D)
(C) Lower level
16.ENGINE COOLANT
LU-00213
Check the coolant amount on the reservoir. If the

amount of engine coolant is insufficient, check that
no leaks are found. Then, add the necessary
amount of coolant with the specified concentration.
(A) Engine oil level gauge

(B) Engine oil filler cap
(C) Upper level
(D) Lower level
(E) Approx. 1 2 (1.1 US qt, 0.9 Imp qt)
PI-8
17.CLUTCH FLUID
20.KEYLESS ENTRY SYSTEM
Check the clutch fluid amount. If the amount of fluid

is insufficient, check that no leaks are found. Then,
add the necessary amount of specified fluid.
Check the keyless entry system operations as follows:

1) Fully open all the door windows.
2) Remove the key from the ignition switch and
close all the doors including rear gate.
3) Press the LOCK/ARM button once on the keyless transmitter. Check if all the doors are locked,
the buzzer rings once and hazard light blinks once.
(A )
(C)
(B )
PM-00076
(A) Reservoir tank

(B) MIN. level
(C) MAX. level
PI-00269
18.WINDOW WASHER FLUID
4) Press the UNLOCK/DISARM button once on

the keyless transmitter. Check if the drivers side
door is unlocked, the buzzer rings twice and hazard
light blinks twice.
Check the window washer fluid amount. If the

amount is insufficient, check that no leaks are
found. Then, add the necessary amount of washer
fluid commercially available.
(A)
(B)
PI-00270
PI-00279

the keyless transmitter within 5 seconds. Check
that all doors (including rear gate) are unlocked.
6) Press the LOCK/ARM button on the keyless
transmitter for approximately 2 seconds. Check
whether a panic state (horn continuously honks)
occurs. Also, check whether that state continues
for 30 seconds or until the keyless transmitter button is pressed.
7) Press the LOCK/ARM button once on the keyless transmitter with one door (including the rear
gate) open. Check that the buzzer rings five times
and the door open warning is issued. Next, close all
the doors including rear gate. Check if all the doors
are locked, the buzzer rings once and hazard light
blinks once.
(A) Window washer tank

(B) FULL level
19.FRONT HOOD LATCH CHECK

Retract the front hood stay and close the front
hood. Check that the front hood is completely
latched.
PI-9
8) Press the LOCK side of the power door switch

with one door (including the rear gate) open. Next,
close all the doors including rear gate. Check if all
the doors are locked, the buzzer rings once and
hazard light blinks once.
Drivers side
21.ALARM SYSTEM
Check that the alarm system is operating as shown
below.
1) Fully open all the door windows.
2) Remove the key from the ignition switch and
close all the doors including rear gate.
3) Press the LOCK/ARM button once on the keyless transmitter.
PI-00074
Passengers side
PI-00269
4) If all the doors are locked, the buzzer rings once,

the hazard light blinks once and security indicator
light blinks as shown in the figure, the alarm system
is in the arming preparatory state.
PI-00075
CHECK ALARM OPERATION

The system uses a buzzer to ring an alarm when
the doors are locked or unlocked. The alarm can be
turned off if desired. To turn off the alarm, execute
the unlocking procedures of the keyless entry system. Press the LOCK/ARM button and the UNLOCK/DISARM button simultaneously for more
than 2 seconds. The buzzer will ring twice, the hazard light will blink twice, and the alarm will show that
it is OFF. To turn ON the alarm, execute the unlocking procedures of the keyless entry system. Press
the LOCK/ARM button and the UNLOCK/DISARM button simultaneously for more than 2 seconds. The buzzer will ring once, the hazard light will
blink once, and the alarm will show that it is on.
PI-00264
Alarm system arming state
(A)
(B)
(C)
PI-00315
(A) Light ON
(B) Light OFF
(C) 2 seconds
PI-10
5) Check that the condition described in 4) lasts for

30 seconds and then the system is brought into the
arming state.
Alarm system arming state (all models)
Alarm system unarming preparatory state

(model with immobilizer)
(A)
(B)
(A)
(C)
(B)
(C)
PI-00266
(A) Light ON
PI-00265
(B) Light OFF

(C) 3 seconds
(A) Light ON
(B) Light OFF
(C) 2 seconds

the keyless transmitter.
8) Press the LOCK/ARM button once on the keyless transmitter with one door (including the rear
gate) open.
PI-00269
PI-00270
7) The drivers side door is unlocked, the buzzer

rings twice and hazard light blinks twice, the room
light is lit and if the security indicator light is extinguished, the alarm system has been disarmed.
NOTE:
After pressing the UNLOCK/DISARM button on
the keyless transmitter, the security indicator light
does not blink on models without an immobilizer.
9) Check that the buzzer rings five times and the

door open warning is issued.
10) Close all the doors including rear gate.
11) Check that it is in the arming state (all the doors
are locked, the buzzer rings once and hazard light
blinks once).
Alarm system arming preparatory state
(A)
(B)
(C)
PI-00315
(A) Light ON
(B) Light OFF
PI-00264
(C) 2 seconds
PI-11
12) Check that the condition described in 11) lasts

for 30 seconds and then the system is brought into
the arming state.
Alarm system arming preparatory state
(A)
(B)
(A)
(B)
(C)
(C)
PI-00315
(A) Light ON
PI-00265
(B) Light OFF

(C) 2 seconds
(A) Light ON
(B) Light OFF
(C) 2 seconds
13) Press the LOCK side of the power door switch

with all doors (including the rear gate) open.
Drivers side
16) Check that the condition described in 15) lasts

for 30 seconds and then the system is brought into
the arming state.
(A)
(B)
(C)
PI-00265
(A) Light ON
(B) Light OFF
PI-00074
Passengers side
(C) 2 seconds
PI-00075
14) Close all the doors including rear gate.

15) If all the doors are locked, the buzzer rings
once and hazard light blinks once, the alarm system is in the arming preparatory state.
17) Use the inner lock knob or key to unlock the

door, and open the door while the alarm system is
in the arming state.
18) Check whether the alarm state (horn continuously honks, hazard light blinks, and security indicator light illuminates) has occurred.
19) Check that the state described in 18) lasts for
30 seconds or more, or until the keyless transmitter
button UNLOCK/DISARM is pressed.
20) Also, check that the starter motor does not operate and the engine does not start even if the ignition key is turned to the START position while in
the arming state.
21) For model with impact sensor, manually tap on
the windshield glass to cause an alarm to occur
while the alarm system is in the arming state.
22) Perform troubleshooting on the security system
if the above does not apply. <Ref. to SL-22, INSPECTION, Security System.>
PI-12
22.SEAT
23.SEAT BELT
1) Check that each seat provides full functionality in

sliding and reclining. Check all of the functions of
the rear seat.
2) Check that the passengers seat occupant detection system.
(1) Empty the passengers seat and turn the ignition switch to ON.
(2) Check the ON and OFF of passengers airbag indicator light come on simultaneously for
about 6 seconds and go off for 2 seconds, and
then only OFF comes on again.
U.S. model
1) Pull out the seat belt and then release it. Check
that the belt retracts smoothly.
2) Check seat belt warning system
(1) Turn the ignition switch to ON without fastening drivers and passengers seat belts.
(2) Check if the seat belt warning lights of drivers and passengers side blink for about 6 seconds and the buzzer beeps intermittently.
(3) Then, check that the seat belt warning light
comes on and blinks, and buzzer beeps in 15
second cycles. (If the passengers seat is empty, seat belt warning light for passengers side
does not operate.)
24.TEST MODE CONNECTOR
(1)
Turn the ignition switch to ON and check that the

engine malfunction indicator light starts blinking. If
the light blinks, return the ignition key to LOCK and
disconnect the test mode connector. Then, turn the
ignition key to ON again. If the engine malfunction
indicator light blinks at that time in spite of the disconnected test mode connector, carry out an engine diagnosis.
(2)
OD-00038
(1) Passengers airbag OFF indicator light

(2) Passengers airbag ON indicator light
(A)
Canada model
PI-00076
(1)
(A) Test mode connector (Green)
(2)
25.STARTING CONDITION
OD-00039
(1) Passengers airbag OFF indicator light

(2) Passengers airbag ON indicator light
(3) Have an adult sit down in the passengers

seat, and check if the passengers airbag indicator lump lights in about 4 seconds.
(4) Empty the passengers seat and check if the
OFF of passengers airbag indicator light
comes on in about 2 seconds.
Start the engine and check that the engine starts

smoothly. If the battery voltage is low, recharge or
replace the battery. If any noises are observed, immediately stop the engine and check and repair the
abnormal components.
26.EXHAUST SYSTEM
Listen to the exhaust noise to see if no noises are
observed.
27.INDICATOR AND WARNING LIGHTS

Check that all the indicator and warning lights are
gone out.
28.CLOCK
Check the clock for normal operations and enough
accuracy.
PI-13
29.RADIO
33.WIPER
Check the radio for full functionality and normal

noise level. Also check the CD unit operations.
Check the front and rear wipers for normal operations.
30.ACCESSORY POWER SOCKET
34.POWER WINDOW OPERATION CHECK
1) Check the lighting system operations.

2) Check operation of the accessory power socket
in console box.
3) Check operation of the accessory power socket
in luggage room.
Operate the power window switches one by one to

check that each of the power windows goes up and
down without noises.
31.LIGHTING SYSTEM
1) Check the headlight operations.
2) Check the stop light operation.
3) For model with manual headlight beam levelizer,
check the operation of headlight beam levelizer.
4) Check other lights for normal operations.
32.WINDOW WASHER
Check that the window washer system injects
washer fluid to the specified area of the windshield
and rear window glass shown in the figure.
Front injection position:
A: 250 mm (9.84 in)
B: 345 mm (13.58 in)
A
35.BRAKE TEST
Check the foot brake for normal operations.
36.PARKING BRAKE
Check the parking brake for normal operations.
37.AT SHIFT CONTROL

1) Turn the ignition switch to ON.
2) While brake pedal is not depressed, check if the
select lever does not move from P range.
3) While brake pedal is depressed, check if the select lever moves from P range.
4) Set the select lever to other than P range.
5) When the ignition switch is turned OFF, check if
the ignition key switch cannot be removed.
6) Set the AT selector lever to each gear position
while checking that the demanded gear position is
correctly attained.
P
R
N
D
3
2
1
B
(2)
(1)
PI-00262
PI-00077
(1) Nozzle
(2) Ceramic line
Rear injection position:

A: 35 mm (1.38 in)
B: 72
(1)
Selector
position
1st
Gear position
2nd
3rd
4th
D
3
OK
OK
OK
OK
OK
OK
OK
2
1
OK
OK
38.HEATER & VENTILATION

Operate the heater & ventilation system to check
for normal airflow outlet control, air inlet control, airflow capacity and heating performance.
39.AIR CONDITIONER
PI-00081
(1) Nozzle
Operate the air conditioner. Check that the A/C

compressor operates normally and enough cooling
is provided.
PI-14
40.CRUISE CONTROL
44.WATER LEAK TEST
Operate the cruise control system. Check whether

operating and canceling of other systems can be
executed correctly.
Spray the vehicle with water using a hose and

check that no water enters the passenger compartment.
Before performing the water leakage test, remove anything that may obstruct the operation or
which must be kept dry.
Close all the windows and doors securely. Close
the hood before starting the test.
Connect a hose to a tap, and spray water on the
vehicle. The rate of water spray must be approx. 20
to 25 2 (5.3 6.6 US gal, 4.4 5.5 Imp gal) per
minute.
When spraying water on areas adjacent to the floor
and wheel house, increase the pressure. When
spraying water on areas other than the floor and
wheel house, decrease the pressure. But the force
of water must be made strong occasionally by
pressing the end of the hose.
41.ATF LEVEL
After selecting all positions (P, R, N, D, 3, 2, 1), set
the select lever in P range. Measure the ATF level
with engine idling for one or two minutes. If the
amount of ATF is insufficient, check that no leaks
are found. Then, add the necessary amount of the
specified ATF.
(C)
(E)
COLD
L
(D)
L
F
HOT
(A)
(B)
(C)
(D)
PI-00105
(A) Level gauge

(B) Inspection position when HOT (70 80C
(158 176F))
(C) Upper level
(D) Lower level
(E) Inspection position when COLD (20 30C
(68 86F))
42.POWER STEERING FLUID LEVEL

Check that the power steering fluid level is normal.
If insufficient, check for leaks. Then add the necessary amount of the specified power steering fluid.
NOTE:
Be sure to keep the hose at least 10 cm (3.9 in)
from vehicle.
Check the following areas.
Front window and body framework mating portion
Door mating portions
Glass mating portions
Rear quarter window mating portions
Rear window and body framework mating portion
Around roof drips
If any dampness in the compartments is discovered
after the water has been applied, carefully check all
the areas that may have possibly contributed to the
leak.
(A)
(C)
(B)
PI-00326
(A) Reservoir tank

(B) MIN. level
(C) MAX. level
43.FLUID LEAK CHECK

Check entire areas of the vehicle for any trace of
coolant/oil/fluid leaks.
PI-15
45.APPEARANCE CHECK 2
1) When vehicle body is covered with protective
film (wrap guard), peel it off.
NOTE:
It is easier to remove the wrap guard using
steam.
For the vehicle left for a long time or at low temperature, sprinkle some water heated 50 60C
(122 140F) over the vehicle to raise its surface
temperature before peeling off the wrap guard. Do
not use the water heated to over 60C (140F).
If the adhesive remains exists on the coated surface, soak a flannel rag, etc. with a small amount of
coating wax or solvent such as oil benzene and
IPA, put the soaked cloth on the remains lightly,
and then wipe them off with a flannel rag etc.
Keep solvent from touching the resin or rubber
parts. Do not use coating wax or solvent while the
component surface temperature is high due to hot
weather etc.
If the coated surface is swollen out due to seams
or moisture, expose the vehicle to the sunlight for a
few hours or heat the seam and swollen portions
using a dryer etc.
Dispose of the peeled wrap guard as burnable
industrial garbage.
If a yellow label is attached to the fog light lens,
remove it.
2) Check the whole vehicle body for flaking paint,
damage by transportation, corrosion, dirt, cracks or
blisters.
NOTE:
It is better to determine an inspection pattern in
order to avoid missing an area, since the total inspection area is wide.
Do not repair the body paint unless absolutely
necessary. Also, if the vehicle is in need of repair to
remove scratches or corroded paint, the repair area
must be limited to the minimum. Re-painting and
spray painting must be avoided as possible.
3) Check each window glass for scratches carefully. Slight damage may be removed by polishing
with cerium oxide. (Fill a cup half with cerium oxide,
and add warm water to it. Then agitate the content
until it turns to wax. Apply this wax to a soft cloth,
and polish the glass with it.)
4) Check each portion of the vehicle body and underside components for the formation of rust. If rust
is discovered, remove it with sandpaper of #80 to
#180 and treat the surface with rust preventive. After this treatment is completed, flush the portion
thoroughly, and prepare the surface for repair
painting.
5) Check each portion of body and all of the exterior parts for deformation or distortion. Also, check
each light lens for cracks.
PI-16
General Description
PERIODIC MAINTENANCE SERVICES
1. General Description
A: GENERAL DESCRIPTION
Be sure to perform periodic maintenance in order to
maintain vehicle performance and find problems
before they occur.
PM-2
Schedule
2. Schedule
A: MAINTENANCE SCHEDULE 1
1. FOR U.S. MODEL
Months
1,000 km
1,000 miles
1
2
Engine oil
Engine oil filter
Spark plug
MAINTENANCE INTERVAL
[Number of months or km (miles), whichever occurs first]
7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5 120
4.8 12 24 36 48 60 72 81.4 96 108 120 132 144 156 168 180 192 Remarks
3 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5 120
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
4
Drive belt
5
6
Timing belt
Fuel line
7
8
Fuel filter
Air cleaner element
9 Cooling system
10 Engine coolant
11 Clutch system
12 Transmission oil
I
(I)
I
(I)
I
(I)
R
R
I
R
I
R
I
I
13 ATF
14 Front & rear differential
gear oil
I
I
I
I
15 Brake line
16 Brake fluid
I
R
Non-turboModel
Turbo
Model
Note (1)
Note (1)
Note (2)
I
R
I
R
I
I
I
I
I
I
R
R
R
I
I
I
I
R
R
I
I
I
R
I
R
17 Disc brake pads and

discs
18 Brake linings and

drums
19 Parking brake
20 Suspension
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
21 Wheel bearing
22 Axle boots and joints
(I)
I
(I)
I
23 Tire rotation
24 Steering system
(Power steering)
I
I
I
I
I
I
I
I
I
I
I
I
25 Airbag system
26 ATF filter assembly
10th-year inspection
Annual inspection
27 Air conditioner filter
Every 12 months or 12,000 km (7,500 miles) inspection
I
I
I
I
Note (4)
Note (3)
Symbol
R: Replace
I: Inspect
(R) or (I): Inspections recommended for vehicle safety
NOTE:
1. This inspection is not necessary to observe exhaust gas regulations or is the responsibility of the manufacturer under the current
basic EPA regulations that must observed by law.
2. Replace the air cleaner element more frequently than the periodic replacement if the vehicle is being used in an excessively dusty
environment.
3. The ATF filter needs replacement when it is physically damaged, rusty or ATF leaked.
4. Replace the tires if the tread-wear indicator has cause a bar-shaped cut across the tread. The indicator will appear when the remaining amount of tread is less than 1.6 (0.063 in).
PM-3
Schedule
2. FOR CANADA MODEL
Months
MAINTENANCE INTERVAL
[Number of months or km (miles), whichever occurs first]
7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5 120
1,000 km
1,000 miles
4.8 12 24 36 48 60 72 81.4 96 108 120 132 144 156 168 180 192 Remarks
3 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5 120
1
2
Engine oil
Engine oil filter
R
R
Spark plug
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
4
Drive belt
5
6
Timing belt
Fuel line
7
8
Fuel filter
Air cleaner element
9 Cooling system
10 Engine coolant
11 Clutch system
12 Transmission oil
13 ATF
14 Front & rear differential
gear oil
15 Brake line
I
(I)
I
(I)
I
(I)
R
R
I
R
I
R
I
I
I
I
I
I
I
Nonturbo
Model
Turbo
Model
Note (1)
Note (1)
Note (2)
I
R
I
R
I
I
I
I
I
R
R
I
I
I
I
R
R
I
I
16 Brake fluid
17 Disc brake pads and discs
R
I
R
I
R
I
R
I
18 Brake linings and drums

19 Parking brake
I
I
I
I
I
I
I
I
20 Suspension
21 Wheel bearing
22 Axle boots and joints
23 Tire rotation
24 Steering system
(Power steering)
I
I
I
I
I
I
I
I
I
(I)
I
I
I
I
I
I
I
I
I
25 Airbag system
26 ATF filter assembly
10th-year inspection
Annual inspection
27 Air conditioner filter
Every 12 months or 12,000 km (7,500 miles) inspection
I
I
I
I
(I)
I
I
I
Note (4)
Note (3)
Symbol
R: Replace
I: Inspect
(R) or (I): Inspections recommended for vehicle safety
NOTE:
1. This inspection is not necessary to observe exhaust gas regulations or is the responsibility of the manufacturer under the current
basic EPA regulations that must observed by law.
2. Replace the air cleaner element more frequently than the periodic replacement if the vehicle is being used in an excessively dusty
environment.
3. The ATF filter needs replacement when it is physically damaged, rusty or ATF leaked.
4. Replace the tires if the tread-wear indicator has cause a bar-shaped cut across the tread. The indicator will appear when the remaining amount of tread is less than 1.6 (0.063 in).
PM-4
Schedule
B: MAINTENANCE SCHEDULE 2
Item
Engine oil
Every
3.75 months
Repeat
short
distance
drive
R
Repeat
rough
muddy road
drives
Extremely
cold weather
area
Salt or other
corrosive
used or
coastal area
High
humidity or
mountain
area
Repeat
towing trailer
6,000 km
3,750 miles
Engine oil filter
Fuel filter
3.75 months
6,000 km
3,750 miles
15 months
24,000 km
Fuel line
15,000 miles
15 months
24,000 km
15,000 miles
Transmission oil
ATF
15 months
24,000 km
15,000 miles
15 months
24,000 km
15,000 miles
Front & rear
differential gear oil
15 months
24,000 km
Brake line
15,000 miles
15 months
24,000 km
15,000 miles
Brake fluid
Disc brake pads and

discs
15 months
24,000 km
15,000 miles
15 months
24,000 km
15,000 miles
Brake linings and

drums
15 months
24,000 km
Parking brake
15,000 miles
15 months
24,000 km
15,000 miles
Suspension
Axle boots and joints
7.5 months
12,000 km
7,500 miles
7.5 months
12,000 km
7,500 miles
Steering system
(Power steering)
7.5 months
12,000 km
7,500 miles
PM-5
Engine Oil
3. Engine Oil
4) Drain engine oil by loosening the engine oil drain

plug.
A: REPLACEMENT
1) Open the engine oil filter cap for quick draining of
engine oil.
(A)
(B)
(A)
(B)
PM-00305
(A) Engine oil drain plug

(B) Oil filter
PM-00161
CAUTION:
Be careful not to spill engine oil on the exhaust
pipe to prevent it from emitting smoke or causing a fire. If engine oil spilled, wipe it off completely.
5) Replace the drain plug gasket with a new part.
6) Tighten the engine oil drain plug after draining
engine oil.
(A) Oil level gauge

2) Remove the service hole cover clip.
Tightening torque:
44 Nm (4.5 kgf-m, 33 ft-lb)
PM-00303
3) Turn the service hole cover in the counterclockwise direction (looking from the bottom side of the
vehicle).
(A)
(B)
PM-00305

(B) Oil filter
PM-00304
PM-6
Engine Oil
7) Fill engine oil through the level gauge up to center between the upper level and lower level. Place
the vehicle on a level surface when checking oil
level. Use engine oil of proper quality and viscosity,
selected in accordance with the table in figure.
Recommended oil:
API standard
SM specifications marked with Energy saver or Energy saver II (If an SM grade product
is difficult to obtain, use an SL grade product.)
ILSAC standard
GF-4 specifications with the mark of Star
burst
B: INSPECTION
1) Park the vehicle on a level surface.
2) Remove the oil level gauge and wipe away all of
the oil.
3) Reinsert the level gauge all the way. Be sure that
the level gauge is correctly inserted and in the correct position.
4) Remove the level gauge again and record the oil
level. If the oil level is below the L line, add oil to
bring the level up to the F line.
(A)
(B)
(F)
(C)
Engine oil capacity:

Upper level:
Approx. 4.0 2 (4.2 US qt, 3.5 Imp qt)
Lower level:
(E)
(D)
PM-00350
SAE (A)
( C) -30 -20 -15
( F) -22 -4 5
0
32
15
59
(A) Engine oil level gauge

30 40
86 104
(C) Upper level

(D) Lower level
10W-30,10W-40
5W-30
(E) Approx. 1 2 (1.1 US qt, 0.9 Imp qt)

(F) Notch mark
(B)
PM-00347
(A) Viscosity No. and applicable temperature

(B) Recommended
The vehicle will start well even when temperatures

are low or high by increasing the cranking speed by
reducing viscous friction for the appropriate viscosity.
5) Wait for several minutes until the oil has returned

to the oil pan after stopping the engine.
6) Immediately after driving or while the engine is
warm, the engine oil level may be shown between
the F line and the notch mark. This is caused by
thermal expansion of engine oil.
7) To prevent overfilling of engine oil, do not add oil
above F line when the engine is cold.
NOTE:
Do not use any oil from a different manufacturer
than that is in the engine when replacing oil. Use oil
that matches the API standards and SAE viscosity
number set by Subaru.
It is acceptable to use oil having the viscosities
described below if the vehicle is being used in
desert locations or in excessive environments
where temperatures are extremely high.
API standard: SM or SL
SAE viscosity No.: 30, 40, 10W-50, 20W-40, 20W50
8) Close the engine oil filler cap.
9) Start the engine and warm it up for a time.
10) Stop the engine to inspect the oil level again.
<Ref. to PM-7, INSPECTION, Engine Oil.>
PM-7
Engine Oil Filter

4. Engine Oil Filter
4) Install the oil filter by turning it by hand, being

careful not to damage seal rubber.
Tighten the oil filter 68 mm (2.68 in) in diameter
(approx. 1 rotation) after the seal rubber of the oil
filter comes in contact with cylinder block or oil
cooler. When using a torque wrench, tighten to the
following torque values.
A: REPLACEMENT
1) Remove the engine oil filter.
Tightening torque:
14 Nm (1.4 kgf-m, 10.3 ft-lb)
(approx. 2/3 3/4 rotation) after the seal rubber of
the oil filter comes in contact with cylinder block or
oil cooler. When using a torque wrench, tighten to
the following torque values.
(A)
(B)
PM-00305
Tightening torque:

(B) Oil filter
ST
ST
12 Nm (1.2 kgf-m, 8.8 ft-lb)
18332AA000 OIL FILTER WRENCH (OUTER DIAMETER: 68 mm (2.68

in) FOR OIL FILTER)
18332AA010 OIL FILTER WRENCH (OUTER DIAMETER: 65 mm (2.56
in) FOR OIL FILTER)
CAUTION:
Be careful not to spill engine oil on the exhaust
pipe to prevent it from emitting smoke or causing a fire. If engine oil spilled, wipe it off completely.
2) Clean the oil filter installation surface on cylinder
block or oil cooler.
3) Obtain a new engine oil filter and apply a thin
coat of engine oil to the seal rubber.
CAUTION:
Do not tighten excessively, or oil may leak.
5) After mounting the oil filter, fill the prescribed
amount of engine oil. <Ref. to PM-6, REPLACEMENT, Engine Oil.>
NOTE:
The filter element and filter case are permanently
jointed, therefore, interior cleaning is not necessary.
6) After installing the oil filter, run the engine and
make sure that no oil is leaking around seal rubber.
7) Check the engine oil level. <Ref. to LU (H4SO)10, REPLACEMENT, Engine Oil.>
CAUTION:
Be careful because the oil filters having an outer diameter of 80 mm (3.15 in) cannot be used.
PM-8
Spark Plug
5. Spark Plug
A: REPLACEMENT
1) Remove the intake duct and intake chamber.
2) Remove the washer tank and set to the side.
3) Disconnect the spark plug cord.
4) Remove the spark plug with a plug-wrench.
PM-00001
5) Install a new spark plug.

Spark plug:
Non-turbo model
NGK: FR5AP-11
Turbo model:
NGK: ILFR6B
Spark plug gap:
Non-turbo model
1.0 1.1 mm (0.039 0.043 in)
Turbo model
0.7 0.8 mm (0.028 0.031 in)
6) Tighten the spark plug lightly with hand, and
then secure with a plug-wrench to the specified
torque.
Tightening torque:
21 Nm (2.14 kgf-m, 15.49 ft-lb)
NOTE:
Be sure to place the gasket between the cylinder
head and spark plug.
If the torque wrench is not available, tighten the
spark plug until gasket contacts cylinder head, then
tighten further 1/4 to 1/2 turns.
PM-9
V-belt
6. V-belt
B: REPLACEMENT
A: INSPECTION
1. V-BELT COVER
1) Replace the belts, if crack, fraying or wear is

found.
2) Check the V-belt tension and adjust it if necessary by changing the generator installing position
or idler pulley installing position. <Ref. to PM-10,
REPLACEMENT, V-belt.>
Remove the V-belt covers.

Non-turbo model
Belt tension (A):

When replaced: 7.0 9.0 mm (0.276 0.354
in)
When reused: 9.0 11.0 mm (0.354 0.433
in)
Belt tension (B):
When replaced: 7.5 8.5 mm (0.295 0.335
in)
When reused: 9.0 10.0 mm (0.354 0.394
in)
PM-00348
Turbo model
98 N (10 kg, 22 lb)

P/S
GEN
(A) (B)
A/C
PM-00344
I/P
C/P
PM-00002
(A) Front side belt

(B) Rear side belt
C/P Crank pulley
GEN Generator
P/S Power steering oil pump pulley
A/C A/C compressor pulley
I/P Idler pulley
2. FRONT SIDE BELT (FOR POWER

STEERING OIL PUMP AND GENERATOR)
NOTE:
Wipe off any oil or water on the belt and pulley.
1) Loosen the lock bolt (A).
2) Loosen the slider bolt (B).
3) Remove the front side bolt (C).
4) Install a new belt, and tighten the slider bolt so as
to obtain the specified belt tension.
5) Tighten the lock bolt (A).
6) Tighten the slider bolt (B).
Tightening torque:
Lock bolt
25 Nm (2.5 kgf-m, 18 ft-lb)
Slider bolt
8 Nm (0.8 kgf-m, 5.8 ft-lb)
(C)
(B)
(A)
PM-10
PM-00004
V-belt
3. REAR SIDE BELT (FOR AIR CONDITIONER)

NOTE:
Wipe off any oil or water on the belt and pulley.
1) Remove the front side belts.
2) Loosen the lock nut (A).
4) Remove the rear side belt.
5) Install a new belt, and tighten the slider bolt so as
to obtain the specified belt tension.
6) Tighten the lock nut (A).
7) Install the front side belt. <Ref. to ME(H4SO)-40,
FRONT SIDE BELT, INSTALLATION, V-belt.>
Tightening torque:
23 Nm (2.3 kgf-m, 17.0 ft-lb)
(B)
(A)
PM-00005
PM-11
Timing Belt
7. Timing Belt
11) Turn the crankshaft and align the alignment

marks on crankshaft, and left and right cam sprockets with notches of belt cover and cylinder block.
ST 499987500
CRANKSHAFT SOCKET
A: REPLACEMENT
1. NON-TURBO MODEL
1) Remove the radiator fan and air conditioner fan.
<Ref. to CO(H4SO)-34, Radiator Main Fan and
Fan Motor.> <Ref. to CO(H4SO)-41, Radiator Sub
Fan and Fan Motor.>
2) Protect the radiator with cardboard and blanket.
3) Remove the V-belt covers.
(B)
(B)
(A)
(B)
PM-00348
4) Remove the V-belts. <Ref. to ME(H4SO)-40, Vbelt.>

5) Remove the A/C compressor V-belt tensioner.
6) Using the ST, lock the crankshaft and remove
pulley bolt.
ST 499977100
CRANK PULLEY WRENCH
ST
PM-00009
(A) Notch
(B) Alignment mark
12) Remove the belt idler.

13) Remove the belt idler (No. 2).
PM-00007
7) Remove the crank pulley.

8) Remove the belt cover LH.
9) Remove the front timing belt cover.
10) Remove the timing belt guide. (MT model)
PM-00010
14) Remove the timing belt.

15) Remove the automatic belt tension adjuster assembly.
PM-00008
PM-00011
PM-12
Timing Belt
16) Install in the reverse order of removal. <Ref. to

ME(H4SO)-45, INSTALLATION, Timing Belt.>
2. TURBO MODEL
1) Remove the radiator fan and air conditioner fan.
<Ref. to CO(H4SO)-35, TURBO MODEL, REMOVAL, Radiator Main Fan and Fan Motor.> <Ref. to
CO(H4SO)-41, Radiator Sub Fan and Fan Motor.>
2) Protect the radiator with cardboard and blanket.
3) Remove the V-belts. <Ref. to ME(H4SO)-40, Vbelt.>
4) Remove the A/C compressor V-belt tensioner.
5) Using the ST, lock the crankshaft and remove
pulley bolt.
ST 499977100
CRANK PULLEY WRENCH
PM-00008
ME-00727
ST
PM-00093

7) Remove the belt cover (LH).
8) Remove the belt cover (RH).
9) Remove the front belt cover.
ME-00728
ME-00729
PM-13
Timing Belt
11) Turn the crankshaft and align the alignment

marks on crankshaft, and left and right cam sprockets with notches of belt cover and cylinder block.
Use the ST to turn crankshaft.
ST 499987500
CRANKSHAFT SOCKET
15) Install in the reverse order of removal. <Ref. to

ME(H4DOTC)-46, INSTALLATION, Timing Belt.>
CAUTION:
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.
ME-00070
PM-00310
12) Remove the belt idler.
PM-00095

PM-00096
PM-14
Timing Belt
B: INSPECTION
1. SOHC MODEL
1) Remove the front timing belt cover and timing
belt cover (LH).
2) While cranking engine at least four rotations,
check the timing belt back surface for cracks or
damage. Replace the faulty timing belt as needed.
3) If the surface of timing belt (surface indicated by
the arrow in the figure) is worn abnormally (scuffing
and coming out of core) or damaged, inspect the
idlers, tensioner, water pump pulley and cam
sprocket and check the idler alignment for squareness. Replace the worn or damaged timing belt.
PM-00342
4) Install the front timing belt cover and timing belt

cover (LH).
2. DOHC MODEL
1) Remove the timing belt cover (LH).
2) While cranking engine at least four rotations,
check the timing belt back surface for cracks or
damage. Replace the faulty timing belt as needed.
3) If the surface of timing belt (surface indicated by
the arrow in the figure) is worn abnormally (scuffing
and coming out of core) or damaged, inspect the
idlers, tensioner, water pump pulley and cam
sprocket and check the idler alignment for squareness. Replace the worn or damaged timing belt.
PM-00343
4) Install the timing belt cover (LH).
PM-15
Fuel Line
8. Fuel Line
A: INSPECTION
Check the pipes and for rust around the pipe, damage to the hose, and for looseness of the band. If
faulty parts are found, repair or replace them. <Ref.
to FU(H4SO)-59, Fuel Delivery, Return and Evaporation Lines.>
PM-16
Fuel Filter
9. Fuel Filter
A: REPLACEMENT
For fuel filter replacement procedure, refer to FU
section.
<Ref. to FU(H4SO)-56, Fuel Filter.>
B: INSPECTION
1) If the filter is clogged, or if the replacement interval has been reached, replace it.
PM-17
Air Cleaner Element

10.Air Cleaner Element
B: INSTALLATION
A: REMOVAL
1. NON-TURBO MODEL
Install in the reverse order of removal.
1. NON-TURBO MODEL
1) Remove the clips (B) on air cleaner case.
(B)
NOTE:
The air cleaner element differs depending on the
destination market. For the specification of U5
model, refer to the NOTE (A) on the upper side of
air cleaner upper cover.
PM-00340
2) Remove the air cleaner element.

(A)
IN-02198
Fasten with a clip after inserting the lower tab of

case.
PM-00098
2. TURBO MODEL
PM-00247
(B)
2. TURBO MODEL
CAUTION:
Position the protrusion on the air cleaner upper
cover with the hole in the air cleaner lower case
to mount the upper cover on the case.
PM-00341
PM-00100
C: INSPECTION
PM-00098
Replace with a new part if the air cleaner element

is extremely damaged or dirty.
Replace the air cleaner upper cover when the
HC adsorption filter is damaged. (U5 model)
PM-18
Cooling System
11.Cooling System
A: INSPECTION
1) To check the radiator for leakage, fill it with engine coolant, and attach the radiator cap tester (A)
to the filler neck, and apply pressure.
Pressure:
Non-turbo model
157 kPa (1.6 kg/cm2, 23 psi)
Turbo model
122 kPa (1.2 kg/cm2, 18 psi)
Check the following points:
Leak from radiator
Hose joints and other connections for leakage
2) Check the radiator cap valve open pressure using radiator cap tester.
Raise the pressure until the needle of gauge stops
and see if the pressure can be retained for five to
six seconds. The radiator cap is normal if a pressure above the service limit value has been maintained for this period.
CAUTION:
Rust or dirt on the cap may prevent valve from
functioning normally: be sure to clean the cap
before testing.
CAUTION:
For Turbo model, inspection must be carried
out at the side of coolant filler tank, not at the
side of radiator.
Be particularly careful not to deform the filler
neck of radiator when installing and removing
the tester and after testing.
When performing this check, be sure to keep
the engine stationary and fill radiator with coolant.
Wipe off check points before applying pressure.
Use care not to spill coolant when detaching
tester from radiator.
Non-turbo model
Non-turbo model radiator side and turbo model

coolant filler tank side
Specification:
93 123 kPa (0.95 1.25 kg/cm2, 14 18
psi)
Service limit pressure:
83 kPa (0.85 kg/cm2, 12 psi)
Radiator side on turbo models
Specification:
122 152 kPa (1.24 1.55 kg/cm2, 18
22 psi)
112 kPa (1.14 kg/cm2, 16 psi)
(A)
PM-00023
PM-00255
Turbo model
(A)
(A)
(B)
PM-00089
(A) Check points for deformation

(B) Check points for deformation, damage, rust
CO-02168
PM-19
Cooling System
3) Start the engine, and then inspect that it does

not overheat or it is cooled excessively. If it overheats or it is cooled excessively, check the cooling
system. <Ref. to CO(H4SO)-24, INSPECTION,
Water Pump.> <Ref. to CO(H4SO)-26, INSPECTION, Thermostat.> <Ref. to CO(H4SO)-27, Radiator.> <Ref. to CO(H4SO)-33, Radiator Cap.>
4) Check the radiator fan operates using Subaru
Select Monitor, when the coolant temperature exceeds 95C (203F). If it does not operate, check
the radiator fan system. <Ref. to CO(H4SO)-12,
Radiator Fan System.>
PM-20
Engine Coolant
12.Engine Coolant
A: REPLACEMENT
1. REPLACEMENT OF ENGINE COOLANT
WARNING:
The radiator is of the pressurized type. Do not
attempt to remove the radiator cap immediately
after the engine has been stopped.
1) Lift-up the vehicle.
2) Remove the under cover.
3) Place a container under drain pipe.
4) Loosen and remove the drain cock to drain engine coolant into container.
CO-00009
5) For quick draining, remove the radiator cap.

CAUTION:
Be careful not to spill coolant on the floor.
6) Drain the coolant from reservoir tank.
7) Tighten the drain cock securely after draining
coolant.
8) Pour cooling system conditioner through the filler neck.
Cooling system protecting agent:
(Part No. SOA635071)
9) Slowly pour the coolant from radiator filler port to
neck of filler. Then, pour the coolant into reservoir
tank up to FULL level.
Coolant capacity (fill up to FULL level)
Turbo AT model
Turbo MT model
Non-turbo AT model
Non-turbo MT model
NOTE:
The SUBARU Genuine Coolant containing antifreeze and anti-rust agents is especially made for
SUBARU engine, which has an aluminum crankcase. Always use SUBARU genuine coolant or
phosphoric acid type coolant of equivalent quality,
since other coolant may cause corrosion.
CAUTION:
Be careful not to spill engine coolant on the exhaust pipe to prevent it from emitting smoke or
causing a fire. If engine coolant spilled, wipe it
off completely.
10) Close the radiator cap (on non-turbo models) or
the coolant filler tank cap (on turbo models), start
the engine and race 5 to 6 times at less than 3,000
rpm, then stop the engine. (Complete this operation
within 40 seconds.)
11) Wait for one minute after the engine stops, then
open the radiator cap (on non-turbo models) or the
coolant filler tank cap (on turbo models). If the engine coolant level drops, add engine coolant into
the radiator filler neck (on non-turbo models) or the
coolant filler tank filler neck (on turbo models) up to
the filler neck position.
12) Perform the procedures 10) and 11) again.
the coolant filler tank cap (on turbo models), and
the reservoir tank cap.
14) Start the engine and operate the heater at maximum hot position and the blower speed setting to
LO.
15) Run the engine at 2,000 rpm or less until radiator fan starts and stops.
NOTE:
Be careful with the engine coolant temperature
gauge to prevent overheating.
16) Stop the engine and wait until the engine coolant temperature lowers to 30C (86F).
17) Open the radiator cap (on non-turbo models) or
the coolant filler tank cap (on turbo models). If the
engine coolant level drops, add engine coolant into
Then, pour the coolant into reservoir tank up to
FULL level.
19) Set the heater setting to maximum hot position
and the blower speed setting to LO and start the
engine. Perform racing at less than 3,000 rpm. If
the flowing sound is heard, repeat the procedures
from 15) again.
PM-21
Engine Coolant
2. RELATIONSHIP OF SUBARU COOLANT

CONCENTRATION AND FREEZING TEMPERATURE
Safe operating temperature

Concentration
of coolant
1.100
1.090
60%
1.080
1.070
C
1.060
50%
(1.054)
1.050
1.040
1.030
To adjust the concentration of coolant according to

temperature, find the proper fluid concentration in
the above diagram and replace the necessary
amount of coolant with an undiluted solution of
SUBARU genuine coolant (concentration 50%).
The amount of engine coolant that should be replaced can be determined using the diagram.
[Example]
Assume that the engine coolant concentration must
be increased from 25% to 40%. Find point A, where
the 25% line of engine coolant concentration intersects with the 40% curve of the necessary engine
coolant concentration, and read the scale on the
vertical axis of the graph at height A. The quantity
of coolant to be drained is 2.1 2 (2.2 US qt, 1.8 Imp
qt). Drain 2.1 2 (2.2 US qt, 1.8 Imp qt) of coolant
from the cooling system and add 2.1 2 (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.
40%
Quantity of coolant to be
drained (US qt, Imp qt)
Specific gravity
of coolant
The concentration and safe operating temperature

of the SUBARU coolant is shown in the diagram.
Measuring the temperature and specific gravity of
the coolant will provide this information.
[Example]
If the coolant temperature is 25C (77F) and its
specific gravity is 1.054, the concentration is 35%
(point A), the safe operating temperature is 14C
(7F) (point B), and the freezing temperature is
20C (4F) (point C).
3. PROCEDURE TO ADJUST THE CONCENTRATION OF THE COOLANT
30%
Freezing
temperature
20%
1.010
1.000
25 C
(77 F)
1.020
10%
0
10 20 30 40
-40 -30 -20 -10
(-40) (-22) (-4) (14) (32) (50) (68) (86) (104)
Coolant temperature C ( F)
CO-02172
Necessary Concentration
of coolant
3
(3.2,
2.6)
2
(2.1,
1.8)
1
(1.1,
0.9)
0
45%
A
35%
40%
30%
25%
20%
10% 15%
10
20
30
40
50
Concentration of coolant in
the vehicie cooling system %
Concentration of coolant in vehicie
and quantity to be drained
CO-00012
PM-22
Clutch System
13.Clutch System
A: INSPECTION AND ADJUSTMENT
1) Push the release lever to retract the push rod of
the operating cylinder and check if the fluid level in
the clutch reservoir tank rises.
(A)
(B)
CAUTION:
Prevent the clutch fluid from being splashed
over vehicle body. If the clutch fluid is splashed
over vehicle body, flush it, and then wipe it up.
If the fluid spilled on the exhaust pipe, wipe it
off completely.
Avoid mixing different brands of brake fluid
to prevent degradation of the fluid.
Be careful not to allow dirt or dust to get into
the reservoir tank.
(A)
(C)
(C)
PM-00075
(B)
(A) Release lever

(B) Push rod
PM-00076
(C) Operating cylinder
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-24, Clutch Pedal.>
4) Check the fluid level using the scale on the outside of the clutch reservoir tank (A). If the level is
below MIN (B), inspect the clutch master cylinder,
operating cylinder and hydraulic line for fluid leaks.
If fluid leaks are found, repair or replace. If fluid
leaks are not found, add clutch fluid to bring it up to
MAX (C) of clutch reservoir tank.
Recommended clutch fluid:
FMVSS No. 116, New part DOT3 or DOT4
brake fluid
PM-23
(A) Reservoir tank

(B) MIN. level
(C) MAX. level
Transmission Gear Oil

14.Transmission Gear Oil

A: REPLACEMENT
1. MANUAL TRANSMISSION
1) Drain the gear oil by removing drain plug.
CAUTION:
Before starting work, cool off the transmission gear oil well.
If transmission gear oil adheres to the exhaust pipe, wipe it off completely.
PM-00166
2) Replace the gasket with new part, and then tighten the drain plug to specified torque.
Tightening torque:
Copper gasket
70 Nm (7.1 kgf-m, 51.6 ft-lb)
Aluminum gasket
44 Nm (4.5 kgf-m, 32.5 ft-lb)
3) Fill the transmission gear oil through the oil level
gauge hole up to the upper point of level gauge.
CAUTION:
Each oil manufacturer has its base oil and additives. Thus, do not mix two or more brands.
Gear oil capacity:
3.5 2 (3.7 US qt, 3.1 Imp qt)
(A)
(B)
(C)
PM-00030
(A) Oil level gauge

(B) Upper level
(C) Lower level
PM-24
Hill-holder System
15.Hill-holder System
A: INSPECTION AND ADJUSTMENT
1) Move the hill holder up an inclination of more
than 3 to confirm the stopping and starting functions.
(1) When the vehicle does not stop:
Tighten the PHV cable adjustment nuts.
(2) When the vehicle does not start:
A: When the hill holder is released later than engagement of clutch (engine tends to stall):
Loosen the adjusting nut gradually until smooth
starting is enabled.
B: When the hill holder is released earlier than
engagement to clutch (vehicle slips down slightly): Tighten the adjusting nut so that hill holder
is released later than engagement of clutch
(status in A). Then make adjustment the same
as in A.
CAUTION:
When turning the adjusting nuts, use a pliers
to hold the inner cable to prevent over-turning.
Replace the pressure hold valve (PHV) or
PHV cable with new parts if there is a problem
or damage.
(B)
(A)
(C)
PM-00077
(A) Lock nut

(B) Adjusting nut
(C) Pressure hold valve
PM-25
ATF
16.ATF
A: INSPECTION
CAUTION:
The level of ATF varies with fluid temperature.
Pay attention to the fluid temperature when
checking ATF level.
1) Raise the ATF temperature by driving a distance
of 5 10 km (3 6 miles). Otherwise, idle the engine to raise ATF temperature to 70 80C (158
176F) on Subaru Select Monitor.<Ref. to
4AT(D)(diag)-14, READ CURRENT DATA, OPERATION, Subaru Select Monitor.>
2) Make sure the vehicle is level.
3) After selecting all positions (P, R, N, D, 3, 2, 1),
set the select lever in P range. Idle the engine for
1 or 2 minutes, and measure the ATF level.
6) Check the ATF level as instructed in step 3), after raising ATF temperature to 70 80C (158
176F) by running the vehicle or by idling the engine again.
7) Check the ATF for leaks.
Check for leaks inside of the transmission. If there
are leaks, repair or replace the gasket, oil seals,
plugs or other parts.
(C)
(E)
COLD
L
(D)
L
F
HOT
(A)
(B)
(C)
(D)
PI-00105
(A) Level gauge

(158 176F))
(C) Upper level
(D) Lower level
(68 86F))
4) Make sure that ATF level is between the upper

level and lower level.
NOTE:
When the transmission is hot, the level should be
above the center of upper and lower marks, and
when it is cold, the level should be found below the
center of these two marks.
5) If the ATF level is below the center between upper and lower marks, add the recommended ATF
until the ATF level reaches the upper level.
CAUTION:
Use care not to exceed the upper limit level.
Be sure not to add ATF up to the upper limit
mark when the transmission is cold because
that will be the cause for excessive filling of
ATF, and will cause transmission failure.
PM-26
ATF
B: REPLACEMENT
4) Check the ATF level. <Ref. to PM-26, INSPECTION, ATF.>
1. AUTOMATIC TRANSMISSION FLUID
(A)
1) Drain the ATF by removing drain plug.
(C)
(E)
COLD
L
(D)
L
F
HOT
NOTE:
Before starting work, cool off the ATF well.
(B)
(C)
(D)
PI-00105
(B)
(A) Level gauge

(158 176F))
(A)
PM-00167
(C) Upper level

(D) Lower level
(A) Front differential drain plug

(68 86F))
(B) ATF drain plug
CAUTION:
Be careful not to spill ATF on the exhaust pipe
to prevent it from emitting smoke or causing a
fire. If ATF spilled, wipe it off completely.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
3) Pour ATF through gauge hole.
2. ATF FILTER
NOTE:
ATF filter needs replacement when it is physically
damaged or ATF leaked.
For the replacement procedure of ATF filter, refer
to ATF FILTER. <Ref. to 4AT-60, ATF Filter.>
Recommended fluid:
SUBARU ATF <Ref. to RM-4, FLUID, RECOMMENDED MATERIALS, Recommended Materials.>
Fluid capacity:
Fill the same amount of ATF drained from
ATF drain plug hole.
PM-27
Front & Rear Differential Gear Oil

17.Front & Rear Differential Gear

Oil
A: REPLACEMENT
1. FRONT DIFFERENTIAL (MT MODEL)
3) Fill differential gear oil through the oil level

gauge hole up to the upper point of level gauge.
CAUTION:
For MT model, differential gear oil works as manual

transmission gear oil to lubricate differential. <Ref.
to PM-24, Transmission Gear Oil.>
Recommended oil:
<Ref. to RM-3, LUBRICANTS, RECOMMENDED MATERIALS, Recommended Materials.>
2. FRONT DIFFERENTIAL (AT MODEL)
Gear oil capacity:

1.1 1.3 2 (1.2 1.4 US qt, 1.0 1.1 Imp qt)
1) Drain the differential gear oil by removing drain

plug using TORX T70.
CAUTION:
Before starting work, cool off the differential
gear oil well.
Be careful not to spill oil on the exhaust pipe
to prevent it from emitting smoke or causing a
fire. If the oil spilled, wipe it off completely.
(B)
(A)
(C)
PM-00035
(A) Oil level gauge

(B) Upper level
(C) Lower level
PM-00169
Tightening torque:
Aluminum gasket
44 Nm (4.5 kgf-m, 32.5 ft-lb)
Copper gasket
70 Nm (7.1 kgf-m, 51.6 ft-lb)
PM-28
Front & Rear Differential Gear Oil

3. REAR DIFFERENTIAL
1) Remove the drain plug, and drain the differential
gear oil.
2) Remove the filler plug for quick draining oil.
3) Install the drain plug after draining oil.
NOTE:
Apply liquid gasket to the drain plug threads.
Liquid gasket:
THREE BOND 1105 (Part No. 004403010)
Tightening torque:
49.0 Nm (5.0 kgf-m, 36.2 ft-lb)
4) After installing drain plug onto rear differential
gear case firmly, fill oil up fully to the mouth of filler
plug.
(A)
(B)
PM-00037
(A) Filler plug

(B) Drain plug
Oil capacity:
0.8 2 (0.8 US qt, 0.7 Imp qt)
CAUTION:
5) Install the filler plug onto rear differential gear
case firmly.
NOTE:
Apply liquid gasket to the threads of the filler plug
screws.
Liquid gasket:
Tightening torque:
49.0 Nm (5.0 kgf-m, 36.2 ft-lb)
PM-29
Brake Line
18.Brake Line
2. SERVICE BRAKE
A: INSPECTION
1) Check the free play of brake pedal with a force of

less than 10 N (1 kgf, 2 lb).
1. BRAKE LINE
1) Check for scratches, swelling, corrosion, traces
of fluid leakage on the brake hoses or pipe joints.
2) Check the possibility of adjacent parts interfering
with brake pipes/hoses during driving, and loose
connections/clamps.
3) Check any trace of fluid leakage, scratches, etc.
on master cylinder, wheel cylinder and pressure
control valve.
NOTE:
When the brake fluid level in the reservoir tank is
lower than specified limit, the brake warning light
on the combination meter will come on.
Visually check the brake hose for damage. (Use
a mirror where it is difficult to see)
(1)
(3)
(2)
PM-00349
(1) Front brake hose

(2) Front brake pipe
(3) Clamp
Brake pedal free play:

0.5 2.0 mm (0.02 0.08 in)
(A)
PM-00078
(A) Pedal free play
2) If the free play is out of the specifications values,

adjust the brake pedal as follows.
(1) Make sure the engine is off. (No vacuum is
applied to brake booster.)
(2) Inspect that there is 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 0.5 to 2.0
mm (0.02 to 0.08 in).]
(3) Depress the surface of brake pad by hand.
(4) If there is no free play between clevis pin
and clevis, turn brake switch adjusting nut until
the clearance between stopper and screw of
brake switch becomes 0.3 mm (0.012 in).
(A)
(2)
(B)
(H)
(C)
(1)
(3)
(3)
(D)
(E)
(F)
(I)
(J)
(G)
PM-00041
BR-00096
(A) Brake switch
(1) Brake pipe

(2) Rear brake hose
(B) Adjusting nut

(C) 0.3 mm (0.012 in)
(3) Clamp
(D) Stopper
(E) Clevis pin
(F) Clevis
(G) Pedal free play
(H) Lock nut
(I) Brake booster operating rod
(J) Play at pin
PM-30
Brake Line
3) Check the pedal stroke.

While the engine is idling, depress the brake pedal
with a 490 N (50 kgf, 110 lb) load and measure the
distance between the brake pedal and steering
wheel. With the brake pedal released, measure the
distance between pedal and steering wheel again.
The difference between the two measured values
must be less than specified value. If the measured
value is more than specification, there is possibility
of entering air in hydraulic unit.
Brake pedal stroke A
105 mm (4.13 in) or less/ 490 N (50 kgf, 110 lb)
1
=A
(A)
1
2
3. BRAKE SERVO SYSTEM

1) With the engine off, depress the brake pedal
several times applying the same pedal force. Make
sure the travel distance should not change.
2) With the brake pedal depressed, start the engine. Check that the pedal moves slightly toward
the floor.
3) With the brake pedal depressed, stop the engine
and keep the pedal depressed for 30 seconds.
Check that the pedal height does not change.
4) A check valve is built into the vacuum hose. Remove the vacuum hose to inspect function of the
check valve.
Blow air into vacuum hose from its brake booster
side. Check that the air flows out to the engine side
of the air hose. Next blow air into hose from engine
side: Check that the air does not flow out to the
brake booster side.
Replace the both check valve and vacuum hose if
the check valve is faulty. Engine side of vacuum
hose is indicated by marking ENG as shown.
(B)
PM-00045
(A) Steering wheel

(B) Toe board
(A)
(B)
(C)
4) Check to see if air is in the hydraulic brake line

by the feel of pedal operation. If air appears to exist
in the line, bleed it from the system.
5) Check for even operation of all brakes, using a
brake tester or by driving the vehicle for a short distance on a straight road.
PM-00046
(A) Engine side

(B) Brake booster side
(C) ENG
5) Check the vacuum hose for cracks or other damage.

CAUTION:
When installing the vacuum hose on the engine
and brake booster, do not use soapy water or
lubricating oil on their connections.
6) Check that the vacuum hose is securely mounted.
PM-31
Brake Fluid
19.Brake Fluid
A: INSPECTION
1) Check that the brake fluid level remains between
MIN and MAX. If out of the specified range, refill or
drain fluid. If the fluid level becomes close to MIN,
check the brake pad for wear and refill fluid.
CAUTION:
If the brake fluid spilled on the exhaust pipe,
wipe it off completely.
2) Check the fluid for discoloration. If the fluid color
has excessively changed, drain the fluid and refill
with new fluid.
B: REPLACEMENT
CAUTION:
Do not let brake fluid come into contact with
the painted surface of the vehicle body. Wash
away with water immediately and wipe off if it is
spilled by accident.
Avoid mixing brake fluid of different brands
to prevent fluid performance from degrading.
Be careful not to allow dirt or dust to enter
into reservoir tank.
NOTE:
While working, keep the reservoir tank filled with
brake fluid to eliminate entry of air.
Operate the brake pedal slowly.
For convenience and safety, perform work with 2
people.
The required amount of brake fluid is approximately 500 m2 (16.9 US fl oz, 17.6 Imp fl oz) for
entire brake system.
1) Lift-up the vehicle and set rigid racks at the specified locations, or keep the vehicle lifted.
2) Remove both the front and rear wheels.
3) Drain the brake fluid from the reservoir tank.
4) Refill the reservoir tank with recommended
brake fluid.
Recommended brake fluid:
Refer to SPECIFICATION of General Description. <Ref. to BR-2, SPECIFICATION, General
Description.>
Repeat the same procedure as for bleeding air
from the brake line, until new brake fluid comes out
from vinyl tube. <Ref. to BR-42, PROCEDURE, Air
Bleeding.>
PM-32
Disc Brake Pad and Disc

20.Disc Brake Pad and Disc

A: INSPECTION
1. DISC BRAKE PADS AND DISCS
1) Lift up the vehicle, and remove the wheels.
2) Visually check the pad thickness through inspection hole of disc brake assembly. Replace the pad if
necessary.
CAUTION:
When replacing a pad, always replace the pads
for both the left and right wheels at the same
time. Also replace the pad clips if they are twisted or worn.
4) Remove the caliper body. <Ref. to BR-18, Front

Disc Brake Assembly.> <Ref. to BR-24, Rear Disc
Brake Assembly.>
5) Tighten the wheel nuts to secure disc rotor.
6) Set a dial gauge at a point less than 10 mm (0.39
in) from outer periphery of the rotor, and then measure the disc rotor runout.
Disc rotor runout limit:
Front
0.075 mm (0.0030 in)
Rear
0.070 mm (0.0028 in)
(A)
PM-00051
PM-00049
(A) Inspection hole

Pad thickness
mm (in)
Standard
Front
11 (0.43)
Rear
9 (0.35)
Wear limit
1.5 (0.059)
1.5 (0.059)
(A)
(C)
(B)
PM-00140
(A) Pad thickness

(B) Back metal
(C) Lining
3) Check the disc rotor, and correct or replace if it is

damaged or worn.
Brake disc thickness
mm (in)
Standard
Front
24 (0.94)
Rear
10 (0.39)
Wear limit
22 (0.87)
8.5 (0.335)
PM-33
Brake Lining and Drum

21.Brake Lining and Drum

A: INSPECTION
1. REAR DRUM BRAKE
1) Remove the brake drum and check for fluid
leaks from the wheel cylinder.
If fluid leaks are found in the wheel cylinder, check
the wheel cylinder and repair or replace it.
2) Inspect the brake shoes for damage or deformation and check the brake linings for wear beyond
limit values.
CAUTION:
Always replace the wheel leading and trailing
brake shoes for the left and right wheels at the
same time.
When replacing either the left or the right
brake assembly, always replace the leading
shoe and the trailing shoe of one side.
3) Check the 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 or tapered, or the outer surface
of the brake drum is damaged, repair or replace it.
Brake drum inside diameter:
Standard:
228.6 mm (9.000 in)
Service limit:
230.6 mm (9.079 in)
If the deformation or wear of back plate, shoe, etc.
is noticeable, replace problem parts.
Thickness of lining (except for back metal)

Standard:
4.1 mm (0.161 in)
Service limit:
1.5 mm (0.059 in)
(B)
(A)
PM-00053
(A) Inside diameter

(C)
(A)
2. PARKING BRAKE (REAR DISC BRAKE)

(D)
(E)
(G)
(F)
PM-00052
(A) Direction of drum rotation (Forward)

(B) Wheel cylinder
(C) Upper shoe return spring
Inspect the brake linings and disc rotor of both

sides of the rear brake at the same time by removing disc rotor.
1) Inspect the brake shoes for damage or deformation and check the brake linings for wear beyond
limit values.
CAUTION:
Always replace both primary and secondary
brake shoes for the left and right wheels at the
same time.
(D) Adjusting lever

(E) Trailing shoe
(F) Lower shoe return spring
(G) Leading shoe
PM-34
Brake Lining and Drum

Thickness of brake lining (except for back metal):

Standard:
3.2 mm (0.126 in)
Service limit:
1.5 mm (0.059 in)
B: ADJUSTMENT
1. REAR DRUM BRAKE
The main brake automatically adjusts itself, so no
adjustments are needed.

For rear disc brake, adjust the parking brake after
bleeding air.
1) Remove the rear cover (rubber) installed at back
plate.
2) Turn the adjuster toward arrow mark (upward)
until it is locked slightly, by using flat-tip screwdriver
as shown in the figure.
(A)
(B)
(C)
(A)
PM-00054
(B)
(A) Forward
(B) Brake shoe (Primary side)
(C) Brake shoe (Secondary side)
2) Check the inside of disc rotor for wear, dents or

other damage. If the inside surface of dick rotor is
streaked, correct the surface with emery cloth
(#200 or more). If it is unevenly worn or tapered,
correct or replace it.
Brake drum inside diameter:
Standard:
170 mm (6.69 in)
Service limit:
171 mm (6.73 in)
(C)
PM-00056
(A) Adjuster
(B) Rear cover (rubber)
(C) Back plate
3) Turn back (downward) the adjuster 3 to 4 notches.

4) Install the rear cover (rubber) in original position
correctly.
(B)
(A)
PM-00055
(A) Inside diameter

(B) Disc
3) If the deformation or wear of back plate, shoe,

etc. is noticeable, replace problem parts.
4) When the shoe return spring tension is excessively weakened, replace it.
PM-35
Suspension
22.Suspension
NOTE:
When the transverse link ball joint has been removed or replaced, check the toe-in of front wheel.
If it is not within the specified value, adjust the toein. <Ref. to FS-6, Wheel Alignment.>
A: INSPECTION
1. SUSPENSION BALL JOINT
1) Lift up the vehicle until front wheels are off
ground.
2) Grasp the bottom of tire and move it in and out.
If relative movement (B) is observed between the
brake disc cover (A) and end of transverse link (D),
ball joint (C) may be excessively worn.
(A)
PM-00059
(A) Dust seal

(A)
2. TRANSVERSE LINK REAR BUSHING
(D)
(C)
Check around the rear bushing for oil leaks. If oil

leaks, replace bushing.
(B)
PM-00057
3) Next, grasp the end of transverse link (C) and

move it up and down. Relative movement (A) between the housing (D) and transverse link (C) boss
indicates ball joint (B) may be excessively worn.
(A)
(D)
(B)
PM-00060
(A)
(A) Rear bushing

(C)
(B)
(B) Transverse link

PM-00058
4) If the relative movement is observed in the preceding two steps, remove and inspect the ball joint.
If the free play exceeds standard value, replace the
ball joint. <Ref. to FS-16, Front Ball Joint.>
5) Damage of dust seal
Visually inspect the ball joint dust seal. When there
is damage, remove the transverse link to measure
the play of ball joint. <Ref. to FS-14, Front Transverse Link.> <Ref. to FS-16, Front Ball Joint.>
(1) When looseness exceeds standard value,
replace the ball joint.
(2) If the dust seal is damaged, replace it with a
new ball joint.
3. WHEEL ARCH HEIGHT

1) Unload the cargoes and set the vehicle in curb
weight (empty) condition.
2) Then, check the wheel arch height of front and
rear suspensions to ensure that they are within
specified values. <Ref. to FS-6, Wheel Alignment.>
3) When the wheel arch height is out of standard,
visually inspect the following components and replace deformed parts.
Suspension components [Front strut assembly
and rear strut assembly]
Parts connecting suspension and body
4) When no components are deformed, adjust
wheel arch height by replacing coil spring in the
suspension whose wheel arch height is out of standard. <Ref. to FS-6, Wheel Alignment.> <Ref. to
RS-6, Wheel Alignment.>
PM-36
Suspension
4. WHEEL ALIGNMENT OF FRONT SUSPENSION
8. DAMAGE TO SUSPENSION PARTS
1) Check the alignment of front suspension to

make sure the following items are within tolerance.
Toe-in
Camber
Caster
Steering angle
<Ref. to FS-6, Wheel Alignment.>
2) When the caster angle does not conform to the
reference value obviously, visually inspect the following components and replace deformed parts.
Suspension components [Strut assembly, crossmember, transverse link, etc.]
3) When the toe-in and camber are out of tolerance
value, adjust them so that they conform to tolerance value.
4) If steering is not within the specified value, adjust
it to standard value.
5. WHEEL ALIGNMENT OF REAR SUSPENSION
Check the following parts and the fastening portion

of the vehicle body for deformation or excessive
rusting which impairs the suspension. If necessary,
replace the damaged parts with new parts. If minor
rust, pitting, etc. are noted, remove the rust and
take rust prevention measure.
Front suspension
Transverse link
Crossmember
Strut
Rear suspension
Crossmember
Lateral link
Trailing link
Strut
In the area where salt is sprayed to melt snow on
a road in winter, check suspension parts for damage caused by rust every 12 months after lapse of
60 months. Also, take rust prevention measure as
required.
1) Check the alignment of rear suspension to make

sure the following items are within tolerance.
Toe-in
Camber
Thrust angle
<Ref. to RS-6, Wheel Alignment.>
2) When the camber is out of the tolerance value,
visually inspect the following components and replace deformed parts.
Suspension components [Shock absorber, front
lateral link, rear lateral link, and trailing link]
3) When the toe-in and thrust angle are out of tolerance value, adjust them so that they conform to tolerance value.
6. OIL LEAKAGE OF STRUT

Visually inspect the front strut and rear strut for oil
leakage. If there is a bad oil leak, replace the front
strut and rear strut.
7. TIGHTNESS OF BOLTS AND NUTS

Check the bolts and nuts for looseness. Retighten
the bolts and nuts to specified torque. If the selflocking nuts and bolts are removed, replace them
with new parts.
Front suspension: <Ref. to FS-2, General Description.>
Rear suspension: <Ref. to RS-2, General Description.>
PM-37
Wheel Bearing
23.Wheel Bearing
2. REAR WHEEL BEARING
A: INSPECTION
1. FRONT WHEEL BEARING
NOTE:
Inspect the condition of front wheel bearing grease.
2) While holding the front wheel by hand, swing it in
and out to check that there is no bearing free play.
3) Loosen the wheel nuts, and remove the front
wheel.
4) If the bearing free play exists in step 2) above,
attach a dial gauge to hub and measure the looseness in the axial direction.
Service limit:
0.05 mm (0.0020 in) Max.
5) Remove the bolts and self-locking nuts, and extract transverse link from the front crossmember.
6) Remove the AARi of front drive shaft from transmission. <Ref. to DS-16, Front Axle.>
7) While supporting the front drive shaft horizontally with one hand, turn the hub with the other hand to
check for noise or binding.
If the hub is noisy or binds, disassemble the front
axle and replace the oil seals or bearing.

2) While holding the rear wheel by hand, swing it in
and out to check that there is no bearing free play.
3) Loosen the wheel nuts, and remove the rear
wheel.
4) If the bearing free play exists in step 2) above,
attach a dial gauge to hub COMPL and measure
the looseness in the axial direction.
Service limit:
0.05 mm (0.0020 in) Max.
5) Remove the DOJ of rear drive shaft from rear differential. <Ref. to DS-34, Rear Drive Shaft.>
6) While supporting rear drive shaft horizontally
with one hand, turn the hub COMPL with the other
to check for noise or binding.
If the hub COMPL is noisy or binds, disassemble
the rear axle and replace the oil seals or bearing.
(A)
(F)
(G)
(H)
(I)
(B)
(C)
(D)
(E)
(A)
(F)
PM-00062
(A) Inner oil seal

(B) Rear housing
(G)
(B)
(C) Bearing
(D) Snap ring
(C)
(D)
(E) Outer oil seal

(F) Tone wheel
(E)
PM-00061
(G) Hub bolt

(H) Hub
(A) Inner oil seal

(B) Snap ring
(I) Socket bolt
(C) Bearing
(D) Housing
(E) Outer oil seal
(F) Hub bolt
(G) Hub
PM-38
Axle Boots & Joints

24.Axle Boots & Joints

A: INSPECTION
1. FRONT AND REAR AXLE BOOTS
Inspect the front axle boots (A) and rear axle boots
(B) for deformation, damage or failure. If faulty, replace with new part. <Ref. to DS-29, Front Drive
Shaft.> <Ref. to DS-34, Rear Drive Shaft.>
(A)
PM-00063
(B)
PM-00064
2. PROPELLER SHAFT
Inspect the propeller shaft for damage or failure. If
faulty, replace with new part. <Ref. to DS-12, Propeller Shaft.>
PM-39
Tire Rotation
25.Tire Rotation
A: INSPECTION
1) If the depth of tread is less than 1.6 mm (0.063
in), or the tread wear indicator has appeared
across the tire tread, replace the tire.
CAUTION:
Replace the left and right sides at the same
time.
2) If unevenly worn, adjust the alignment.
3) To make tire wear uniform, rotate the front and
rear tires as shown in the figure below every 12,500
km (7,500 miles).
PM-00079
(A)
(B)
(C)
PM-00080
(A) New tread

(B) Worn tread
(C) Tread wear indicator
PM-40
Steering System (Power Steering)

26.Steering System (Power

Steering)
2. STEERING SHAFT JOINT
A: INSPECTION
1. STEERING WHEEL
1) Set the steering wheel in a straight-ahead position, and check the wheel spokes to make sure
they are correctly set in their specified positions.
2) Lightly turn the steering wheel to the left and
right to determine the point where front wheels start
to move.
Measure the distance of the movement of steering
wheel (outer periphery).
When the steering wheel free play is excessive,

disconnect the universal joint of steering shaft and
check it for any play and yawing torque (at the point
of the crossing direction). Also inspect for any damage to sealing or worn serrations. If the joint is
loose, retighten the mounting bolts to the specified
torque.
Tightening torque:
24 Nm (2.4 kgf-m, 17.4 ft-lb)
Steering wheel free play:

0 17 mm (0 0.67 in)
(1)
PM-00066
3. GEARBOX
1) Set the steering wheel in the straight position,
then rotate it 90 in both the left and right directions.
While steering wheel is being rotated, check the
looseness of the gear box.
PS-00450
Tightening torque:
60 Nm (6.1 kgf-m, 44.3 ft-lb)
(1) Steering wheel free play
Move the steering wheel vertically toward the shaft

to check if there is play in the direction.
Limit of play:
0.5 mm (0.020 in)
3) Drive the vehicle and check the following items.
(1) Steering force:
The effort required for steering should be
smooth and even at all points, and should not
vary.
(2) Pulled 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
runout.
(4) Return shape:
The steering wheel should return to its original
position after it has been turned by hand and
then released.
(A)
(B)
PM-00067
(A) Boot
(B) Gearbox mounting bolt
2) Check the boot for damage, cracks or deterioration.

3) With the vehicle stopped on a level surface,
quickly turn the steering wheel to the left and right.
While steering wheel is being rotated, check the
gear backlash. If any noise is noticed, adjust the
gear backlash in the following manner.
(1) Tighten the adjusting screw to 9.8 Nm (0.99
kgf-m, 7.2 ft-lb) and then loosen.
kgf-m, 3.6 ft-lb) and then loosen.
PM-41


kgf-m, 3.6 ft-lb) and then loosen 26.
(4) Apply liquid gasket to at least 1/3 of entire
perimeter of adjusting screw thread.
3) Check the lock nut on the tie-rod end for tightness. If it is loose, retighten it to the specified value.
Tightening torque:
83 Nm (8.5 kgf-m, 61.5 ft-lb)
5. POWER STEERING FLUID LEVEL

NOTE:
When power steering fluid temperature is 20C
(68F), read the fluid level on the COLD side.
When power steering fluid temperature is 80C
(176F), read the fluid level on the HOT side.
1) Stop the engine to park the vehicle on a level
surface.
2) Check the fluid level using the scale on the outside of the reservoir tank (A). If the level is below
MIN (B), add fluid to bring it up to MAX (C).
(A)
PM-00068
(A) Apply liquid gasket to at least 1/3 of entire

thread.
(A)
(5) Install the lock nut. While holding the adjusting screw with a wrench, tighten the lock nut using ST.
ST 926230000
SPANNER
(C)
Tightening torque (lock nut):

39 Nm (4.0 kgf-m, 29 ft-lb)
Hold the adjusting screw with a wrench to prevent it from turning while tightening the lock nut.
4. TIE-ROD
1) Check the tie-rod and tie-rod ends for bends,
scratches or other damage.
(B)
PI-00326
NOTE:
If fluid level is at MAX level or above, drain fluid to
keep the level in the specified range of indicator by
using a syringe or the like.
Recommended fluid:
DEXRON III
Fluid capacity:
0.7 2 (0.7 US qt, 0.6 Imp qt)
6. POWER STEERING FLUID FOR LEAKS
(A)
(B)
Inspect the underside of oil pump and gearbox of

power steering system, hoses, pipes and their couplings for fluid leaks.
If the fluid leaks are found, retighten their fitting
bolts (or nuts) and/or replace their parts.
PM-00069
(A) Tie-rod end

(B) Knuckle arm
2) Check the connections of the knuckle ball joints

for play, inspect for damage on dust seals, and
check that there is no free play in the ball studs. If
castle nut is loose, retighten it to the specified
torque, then tighten further up to a maximum of 60
until the cotter pin hole is aligned.
Tightening torque:
27 Nm (2.75 kgf-m, 19.9 ft-lb)
CAUTION:
Be careful not to spill the power steering fluid
on exhaust pipe, to prevent causing a fire. If the
power steering fluid spilled, wipe it off completely.
Also pay attention to interference between
hoses or pipes and other parts when inspecting
fluid leaks.
PM-42

7. HOSES OF OIL PUMP FOR DAMAGES
9. GEARBOX BOOTS
Check the pressure hose and return hose of oil

pump for crack, swell or damage. Replace the hose
with a new part if necessary.
Inspect both sides of the gearbox boot as follows,

and correct the defects if necessary.
1) The (A) and (B) positions of the gearbox boot are
fitted in (A) and (C) grooves of gearbox and the rod.
2) Clips are fitted outside of positions (A) and (B) of
boot.
3) Check that there is no cracks or holes in the
boot.
CAUTION:
Prevent hoses from turning and/or bending
when installing hoses.
NOTE:
Rotate (B) position of gearbox boot against the torsion produced by the adjustment of toe-in etc. Apply grease to the groove (C).
(1)
(2)
(C)
(B)
(A)
PM-00090
10.FITTING BOLTS AND NUTS

Inspect the installation bolts and nuts of the oil
pump and bracket for looseness, and retighten
them if necessary.
PM-00312
NOTE:
Inspect and/or retighten the bolts and nuts when
the engine is cold.
(1) Pressure hose

(2) Return hose
8. POWER STEERING PIPES FOR DAMAGES

Check the power steering pipes for corrosion and
damage.
Replace the pipes with new parts if necessary.
PM-43
Airbag System
27.Airbag System
A: INSPECTION
Check the airbag system according to the results of
the self-diagnosis. <Ref. to AB(diag)-2, Basic Diagnostic Procedure.>
1) Make sure the airbag connector is connected. If
not connected, connect correctly. When disconnected, and the ignition switch is ON, a problem occurs and the airbag warning light blinks.
PM-00249
2) Turn on the ignition switch and connect the service connector airbag diagnostics terminal (mounted below the lower cover) to the ground terminal.
3) The warning light blinks and the DTC is displayed to identify the problem. When the airbag
system is in good condition (when no trouble codes
are stored in memory), the warning light blinks in
0.6 second intervals while the diagnostics terminal
is connected to the ground terminal.
4) When the warning light displays the DTC, inspect the airbag system according to the diagnostic
procedure. <Ref. to AB(diag)-2, Basic Diagnostic
Procedure.>
PM-44
ATF Filter
28.ATF Filter
A: REMOVAL
2) Using the ST, remove the ATF filter.
ST 498545400
OIL FILTER WRENCH
(A)
ST
AT-00091
(A) ATF filter
B: INSTALLATION
1) Apply a thin coat of ATF to the oil seal part of
new ATF filter.
2) Install the ATF filter. Turn it by hand, being careful not to damage oil seal.
3) Tighten the ATF filter using ST.
Calculate the ATF filter tightening torque using following formula.
T2 = L2/(L1 + L2) T1
T1: 14 Nm (1.4 kgf-m, 10.1 ft-lb)
[Required torque setting]
T2: Tightening torque
L1: ST length 78 mm (3.07 in)
L2: Torque wrench length
Example:
Torque wrench length
mm (in)
100 (3.94)
Tightening torque
Nm (kgf-m, ft-lb)
7.7 (0.79, 5.7)
150 (5.91)
200 (7.87)
9.0 (0.92, 6.7)

9.8 (1.0, 7.2)
NOTE:
Align the ST with the torque wrench while tightening the ATF filter.
ST 498545400
OIL FILTER WRENCH
4) Fill ATF.
5) Inspect the level of ATF. <Ref. to 4AT-28, Automatic Transmission Fluid.>
C: INSPECTION
1) Check for rust, holes, ATF leaks or other damage.
2) Replace the part if any damage is found in the inspection.
PM-45
ATF Filter
PM-46
General Description
FUEL INJECTION (FUEL SYSTEMS)
A: SPECIFICATION
Item
Fuel tank
Fuel pump
Specification
60 2 (15.9 US gal, 13.2 Imp gal)
Under rear seat
Capacity
Locations
Type
Shutoff discharge pressure
Discharge rate
Impeller
370 677 kPa (3.77 6.9 kg/cm2, 53.6 98 psi)
105 2 (27.7 US gal, 23.1 Imp gal)/h or more
[300 kPa, 12 V (3.06 kg/cm2, 43.5 psi)]
Fuel filter
Intank type
FU(H4SO)-2
General Description
B: COMPONENT
1. INTAKE MANIFOLD
T3
T3
(8)
(7)
T1
T1
T2
(4)
(12)
(10)
(9)
(11)
(12)
T1
(15)
(15)
T2
T1
(10)
(14)
T3
(5)
T1
(9)
T3
T3
(14)
(1)
(11)
T3
T3
T3
(17)
T3
(20)
(13)
T4
(12)
(6)
(12)
(10)
T4
T3
(10)
(9)
(11)
(3)
(9)
T3
(3)
(11)
(2)
(3)
(18)
(3)
T1
(16)
T1
FU-02708
FU(H4SO)-3
General Description
(1)
(2)
Intake manifold
Gasket RH
(9)
(10)
Fuel injector
O-ring
(17)
(18)
Fuel injector pipe LH

Gasket LH
(3)
(4)
Guide pin
PCV pipe
(11)
(12)
O-ring
O-ring
Tightening torque:Nm (kgf-m, ft-lb)
(5)
(6)
EGR valve
Fuel pipe protector RH
(13)
(14)
Purge control solenoid valve

Plug cord holder
T1: 6.4 (0.65, 4.7)

T2: 17 (1.7, 12.5)
(7)
(8)
Fuel pipe protector LH

Fuel injector pipe RH
(15)
(16)
Nipple
Fuel pipe
T3: 19 (1.9, 14.0)

T4: 25 (2.5, 18.1)
2. AIR INTAKE SYSTEM

T2
T1
(3)
(4)
(1)
(2)
FU-02560
(1)
Gasket
(3)
Manifold absolute pressure sensor Tightening torque:Nm (kgf-m, ft-lb)
(2)
Throttle body
(4)
O-ring
FU(H4SO)-4
T1: 2.0 (0.20, 1.5)

T2: 8 (0.8, 5.8)
General Description
3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS
T1
T2
(1)
(2)
T1
(4)
(3)
T1
FU-00414
(1)
(2)
Crankshaft position sensor

Knock sensor
(3)
(4)
Camshaft position sensor

Camshaft position sensor support

T1: 6.4 (0.65, 4.7)
T2: 24 (2.4, 17.4)
FU(H4SO)-5
General Description
4. FUEL TANK
(43)
T1
(13)
(12)
T1
(9)
B
A
(13)
(14)
(11)
(23)
(13)
(15)
(10)
(13)
(13)
(15)
(8)
(7)
(18)
(12)
(30)
T1
(13)
(13)
T1
(13)
(39)
(6)
T4
(17)
(31)
(19)
(11)
(6)
D
(10)
(7)
(22)
T1
(13)
(33)
(42)
T2
D
(5)
(13)
(34)
(35)
(36)
(20)
(29)
(13)
(21)
(40)
(32)
(28)
(13)
(27)
(16)
(25)
(24)
(2)
(20)
(21)
T3
T3
(26)
(40)
T2
(4)
(41)
T2
(38)
(3)
(37)
(1)
T2
(37)
T2
T2
FU-02987
FU(H4SO)-6
General Description
(1)
(2)
Heat shield cover

Fuel tank band RH
(18)
(19)
Evaporation hose C
Evaporation pipe ASSY
(34)
(35)
Fuel tank pressure sensor hose

Vent valve gasket
(3)
(4)
Protector LH
Protector RH
(20)
(21)
Retainer
Quick connector
(36)
(37)
Purge hose
Clip
(5)
(6)
Fuel tank
Canister hose A
(22)
(23)
Jet pump hose A

Fuel level sensor
(38)
(39)
Cover bracket
Filler hose
(7)
(8)
Clamp
Fuel pump gasket
(24)
(25)
Fuel pipe ASSY

Jet pump hose B
(40)
(41)
Clip
Fuel tank band LH
(9)
(10)
Fuel pump ASSY

Fuel cut valve gasket
(26)
(27)
Evaporation hose D
Fuel sub level sensor gasket
(42)
(43)
Evaporation hose E
Evaporation hose F
(11)
Fuel cut valve
(28)
Jet pump filter
(12)
(13)
Evaporation hose A
Clip
(29)
(30)
Fuel sub level sensor

Protect cover
(14)
(15)
Joint pipe
Evaporation hose B
(31)
(32)
Evaporation hose D
Vent valve
T2: 7.4 (0.75, 5.4)

T3: 33 (3.4, 25)
(16)
(17)
Fuel delivery tube

Clamp
(33)
Fuel tank pressure sensor
T4: 1.96 (0.20, 1.45)
FU(H4SO)-7

T1: 4.4 (0.45, 3.3)
General Description
5. FUEL LINE
(33)
(18) (35)
(15)
(28)
(17)
(16)
(29)
(19)
T1
(20)
(30)
(34)
(32)
(31)
(12)
(33)
(23)
(32)
(24)
(22)
(13)
(14)
(21)
T2
(25)
(10)
(27)
T2
(26)
(8)
(8)
(33)
(5)
(4)
(11)
(7)
(6)
(2)
(1)
(1)
(9)
(3)
T3
T3
FU-02988
FU(H4SO)-8
General Description
(1)
Clamp
(15)
Pressure control solenoid valve
(28)
(2)
Fuel delivery hose A
(16)
(29)
(3)
Fuel damper valve bracket
(17)

bracket
Drain hose C

hose
Clamp
(30)
Clamp
(4)
(5)
Fuel damper valve

Evaporation hose A
(18)
(19)
Canister upper bracket

Cushion rubber
(31)
(32)
Retainer
Clamp
(6)
(7)
Clip
Fuel delivery hose B
(20)
(21)
Canister lower bracket

Canister
(33)
(34)
Clamp
Drain pipe
(8)
(9)
Clip
Clip
(22)
(23)
Drain valve
Drain filter
(35)
Canister bracket spacer
(10)
Clamp
(24)
(11)
Fuel pipe ASSY
(25)

tube
Drain hose A
(12)
(13)
Evaporation hose B
Joint pipe
(26)
(27)
Drain connector
Drain hose B
(14)
Canister hose A
FU(H4SO)-9
T1: 25 (2.5, 18.1)

T2: 23 (2.3, 16.6)
T3: 1.25 (0.13, 0.94)
General Description
6. FUEL FILLER PIPE
(10)
(9)
(8)
(16)
(11)
(15)
(1)
T1
T2
(12)
(13)
T2
(3)
(16)
T2
(5)
(16)
(2)
(3)
T2
(14)
(6)
(4)
T2
(7)
FU-02989
(1)
(2)
Fuel filler pipe ASSY

Evaporation hose holder
(8)
(9)
Filler pipe packing

Filler ring
(3)
(4)
Clamp
Clamp
(10)
(11)
Filler cap
Shut valve
(5)
(6)
Evaporation hose A
Evaporation pipe
(12)
(13)
Evaporation hose B
Evaporation hose C
(7)
Evaporation pipe holder
(14)
Joint pipe
FU(H4SO)-10
(15)
(16)
Fuel filler pipe protector

Clamp

T1: 4.4 (0.45, 3.3)
T2: 7.5 (0.76, 5.5)
General Description
C: CAUTION
Wear appropriate work clothing, including a cap,
protective goggles and protective shoes when performing any work.
Remove contamination including dirt and corrosion before removal, installation or disassembly.
Keep the disassembled parts in order and protect them from dust and dirt.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement.
Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts.
Be sure to tighten fasteners including bolts and

nuts to the specified torque.
Place shop jacks or rigid racks at the specified
points.
Before disconnecting connectors of sensors or
units, be sure to disconnect the ground cable from
the battery.
Place NO FIRE signs near the working area.
Follow all government and local regulations concerning disposal of refuse when disposing fuel.
D: PREPARATION TOOL
ILLUSTRATION
TOOL NUMBER
42099AE000
DESCRIPTION
CONNECTOR
REMOVER
REMARKS
Used for removing the quick connector.
ST42099AE000
FU(H4SO)-11
Throttle Body
2. Throttle Body
A: REMOVAL
1) Disconnect the ground cable from the battery.
FU-00009
2) Remove the air intake chamber. <Ref. to IN

(H4SO)-6, REMOVAL, Air Intake Chamber.>
3) Disconnect the connectors from throttle position
sensor and manifold absolute pressure sensor.
4) Disconnect the engine coolant hoses from throttle body.
5) Remove the bolts which install throttle body to
the intake manifold.
(B)
(C)
(C)
(A)
FU-02711
(A) Throttle position sensor

(B) Manifold absolute pressure sensor
(C) Engine coolant hose
B: INSTALLATION
NOTE:
Use a new gasket.
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
FU(H4SO)-12
Intake Manifold
3. Intake Manifold
(2) Remove the installation bolt installing the

power steering pump bracket.
A: REMOVAL
1) Release the fuel pressure.
<Ref. to FU(H4SO)-44, RELEASING OF FUEL
PRESSURE, PROCEDURE, Fuel.>
FU-00139
(3) Disconnect the connector (A) from power

steering pump switch.
FU-00009
3) Open the fuel filler flap lid, and remove the fuel
filler cap.
4) Remove the air intake duct, air cleaner case and
air intake chamber. <Ref. to IN (H4SO)-7, REMOVAL, Air Intake Duct.> <Ref. to IN (H4SO)-5, REMOVAL, Air Cleaner Case.> <Ref. to IN (H4SO)-6,
REMOVAL, Air Intake Chamber.>
5) Remove the generator. <Ref. to SC (H4SO)-14,
REMOVAL, Generator.>
6) Remove the power steering pump and power
steering reservoir tank.
(1) Remove the bolts which hold the power
steering pipes onto the fuel pipe protector RH.
(A)
FU-02433
(4) Remove the power steering reservoir tank

from the bracket by pulling it upward.
NOTE:
Do not disconnect the power steering hose.
FU-02572
(5) Place the power steering pump on the right

side wheel apron.
FU-02807
FU-00021
7) Remove the spark plug cords from the spark

plugs by pulling the plug caps. (Do not pull the
cord.)
FU(H4SO)-13
Intake Manifold
8) Disconnect the engine coolant hoses (A) from

throttle body.
13) Disconnect the knock sensor connector.
(A)
FU-02713
(A)
FU-01085
9) Disconnect the brake booster hose (A).
14) Disconnect the connector from crankshaft position sensor.
(A)
FU-02320
10) Disconnect the PCV hose (A) from intake manifold.

11) Disconnect the engine harness connectors (B)
from bulkhead harness connectors.
FU-00056
15) Disconnect the connector from the oil pressure

switch (A).
(B)
(A)
FU-02434
(A)
FU-02712
16) Disconnect the connector from camshaft position sensor.
12) Disconnect the connectors from the engine

coolant temperature sensor.
FU-02714
FU-00055
FU(H4SO)-14
Intake Manifold
17) Remove the EGR pipe from intake manifold.
B: INSTALLATION
1) Install the intake manifold onto cylinder heads.
NOTE:
Use a new gasket.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
FU-02974
18) Disconnect the fuel hoses from fuel pipe.

(1) Disconnect the quick connector on the fuel
delivery line by pushing the ST in the direction
of the arrow.
ST 42099AE000 CONNECTOR REMOVER
(2) Remove the clip and disconnect the evaporation hose from the pipe.
CAUTION:
Be careful not to spill fuel.
Catch the fuel from hoses using a container
or cloth.
FU-02716
2) Connect the fuel hose and evaporation hose to

the fuel pipe.
NOTE:
If fuel hoses are damaged, replace them with new
parts.
3) Install the EGR pipe to intake manifold.
Tightening torque:
34 Nm (3.4 kgf-m, 24.6 ft-lb)
(A)
(B)
FU-02715
(A) Fuel delivery hose

(B) Evaporation hose
19) Remove the bolts which secure intake manifold

to cylinder head.
FU-02974
4) Connect the connectors to camshaft position

sensor.
FU-02716
20) Remove the intake manifold.
FU-02714
5) Connect the connector to the power steering

pump switch.
FU(H4SO)-15
Intake Manifold
6) Connect the connector to oil pressure switch (A).
11) Connect the engine harness connectors (B) to

bulkhead harness connectors.
(B)
(A)
(A)
FU-02434
7) Connect the connector to crankshaft position

sensor.
FU-02712
12) Connect the brake booster hose (A).
(A)
FU-02320
FU-00056
13) Connect the engine coolant hoses (A) to throttle body.
8) Connect the knock sensor connector.
(A)
FU-02713
9) Connect the connector to engine coolant temperature sensor.
(A)
FU-01085
14) Connect the spark plug cords to spark plugs.

15) Install the power steering pump and power
(1) Install the power steering reservoir tank to
the bracket.
FU-00055
10) Connect the PCV hose (A) to intake manifold.

FU-02572
FU(H4SO)-16
Intake Manifold
(2) Connect the power steering pump switch to

the connector (A).
19) Connect the ground cable to the battery.
(A)
FU-00009
FU-02433
(3) Install the installation bolt of the power

steering pump bracket.
C: DISASSEMBLY
1) Disconnect the engine ground terminal from intake manifold.
Tightening torque:
22 Nm (2.2 kgf-m, 15.9 ft-lb)
FU-01090
FU-00139
(4) Install the power steering pipes onto the fuel

pipe protector RH.
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
2) Remove the ignition coil and ignitor assembly.

<Ref. to IG(H4SO)-6, REMOVAL, Ignition Coil and
Ignitor Assembly.>
3) Remove the throttle body. <Ref. to FU(H4SO)12, REMOVAL, Throttle Body.>
4) Remove the EGR valve. <Ref. to FU(H4SO)-29,
REMOVAL, EGR Valve.>
5) Remove the PCV pipe.
FU-02807
16) Install the generator. <Ref. to SC (H4SO)-14,

INSTALLATION, Generator.>
17) Install the air intake duct, air cleaner case and
air intake chamber. <Ref. to IN (H4SO)-7, INSTALLATION, Air Intake Duct.> <Ref. to IN (H4SO)-5,
INSTALLATION, Air Cleaner Case.> <Ref. to IN
(H4SO)-6, INSTALLATION, Air Intake Chamber.>
18) Connect the connector to fuel pump relay.
FU(H4SO)-17
FU-01091
Intake Manifold
6) Remove the fuel pipe protector LH.
12) Remove the bolts which hold engine harness to

intake manifold.
FU-02325
FU-01097
7) Remove the fuel pipe protector RH.
13) Remove the engine harness from intake manifold.

14) Remove the bolts which install injector pipe on
the intake manifold as shown in the figure.
RH side
FU-02326
8) Disconnect the connectors (A) from fuel injector.

9) Remove the harness band (B) which holds the
engine harness to injector pipe.
FU-02717
LH side
(B)
(A)
FU-02729
10) Remove the purge control solenoid valve.

<Ref. to EC(H4SO)-7, REMOVAL, Purge Control
Solenoid Valve.>
11) Remove the harness band clips which install
the engine harness.
FU-02718
FU-02719
15) Remove the fuel injectors from injector pipe.

FU-02329
FU(H4SO)-18
Intake Manifold
16) Disconnect the quick connector that fastens the

fuel injector pipe RH to the fuel pipe.
D: ASSEMBLY
NOTE:
When assembling the nipple, apply liquid gasket.
Liquid gasket:
1) Tighten the bolts which install fuel pipes on intake manifold.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
FU-02720
17) Disconnect the quick connector that fastens the

fuel injector pipe LH to the fuel pipe.
FU-02722
2) Connect the fuel injector pipe LH to the fuel pipe.

FU-02721
NOTE:
Connect the quick connector securely.
18) Remove the fuel injector pipe RH and LH.

19) Remove the bolts which install fuel pipes on intake manifold.
FU-02721
3) Connect the fuel injector pipe RH to the fuel

pipe.
FU-02722
20) Remove the fuel pipe from intake manifold.
NOTE:
Connect the quick connector securely.
FU-02720
4) Install the fuel injector.
FU(H4SO)-19
Intake Manifold
5) Tighten the bolts which install injector pipe on intake manifold.

RH side
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
7) Tighten the bolts which install engine harness on

intake manifold.
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
FU-01097
FU-02717
LH side
8) Hold the engine harness using the harness band

clips.
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
FU-02329
FU-02718
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
9) Install the purge control solenoid valve. <Ref. to

EC(H4SO)-7, INSTALLATION, Purge Control Solenoid Valve.>
10) Connect the connectors (A) to fuel injector.
11) Hold the engine harness to injector pipe by harness band (B).
(B)
FU-02719
6) Install the engine harness onto intake manifold.
FU(H4SO)-20
(A)
FU-02729
Intake Manifold
12) Install the fuel pipe protector RH.
15) Install the EGR valve. <Ref. to FU(H4SO)-29,

INSTALLATION, EGR Valve.>
16) Install the throttle body to the intake manifold.
<Ref. to FU(H4SO)-12, INSTALLATION, Throttle
Body.>
17) Install the ignition coil and ignitor assembly.
<Ref. to IG(H4SO)-6, INSTALLATION, Ignition Coil
and Ignitor Assembly.>
18) Install the engine ground terminal to intake
manifold.
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
FU-02326
13) Install the fuel pipe protector LH.

Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
FU-01090
E: INSPECTION
Make sure the fuel pipe and fuel hoses are not
damaged and the connections are tightened firmly.
FU-02325
14) Install the PCV pipe.

(1) Connect the hose (A) and (B) to intake manifold.
(2) Tighten the bolts (C) through (E) in alphabetical sequence.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
(E)
(C)
(B)
(D)
(A)
FU-02723
FU(H4SO)-21
Engine Coolant Temperature Sensor

4. Engine Coolant Temperature

Sensor
A: REMOVAL
FU-00009

3) Disconnect the connectors from the engine coolant temperature sensor.
FU-00055
4) Remove the engine coolant temperature sensor.
B: INSTALLATION
NOTE:
Use a new gasket.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
FU(H4SO)-22
Crankshaft Position Sensor

5. Crankshaft Position Sensor
B: INSTALLATION
A: REMOVAL
Tightening torque:
T: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
FU-00009

3) Remove the bolt which installs crankshaft position sensor to cylinder block.
FU-00056
4) Remove the crankshaft position sensor, and

then disconnect the connector from it.
FU-00057
FU(H4SO)-23
FU-00058
Camshaft Position Sensor

6. Camshaft Position Sensor

A: REMOVAL
6) Remove the camshaft position sensor from the

support.
FU-00179
B: INSTALLATION
FU-00009

Tightening torque:
Camshaft position sensor support
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
FU-02714
3) Remove the bolt which installs camshaft position

sensor to support.
FU-02724
4) Remove the bolt which installs camshaft position

sensor support to camshaft cap LH.
FU-02725
5) Remove the camshaft position sensor and the

support as a unit.
FU(H4SO)-24
Knock Sensor
7. Knock Sensor
B: INSTALLATION
A: REMOVAL
1) Install the knock sensor to cylinder block.
NOTE:
Extraction area of knock sensor cord must be positioned at a 60 angle relative to the engine rear.
Tightening torque:
24 Nm (2.4 kgf-m, 17.4 ft-lb)
(A)
FU-00009

60
FU-02727
(A) Front side
FU-02713
4) Remove the knock sensor from cylinder block.
FU-02713
3) Install the air intake chamber.

<Ref. to IN (H4SO)-6, INSTALLATION, Air Intake
Chamber.>
FU-02726
FU-00009
FU(H4SO)-25
Throttle Position Sensor

8. Throttle Position Sensor

A: SPECIFICATION
Throttle body is a non-disassembled part, so do not
remove the throttle position sensor from throttle
body.
Refer to Throttle Body for removal and installation
procedures. <Ref. to FU(H4SO)-12, REMOVAL,
Throttle Body.> <Ref. to FU(H4SO)-12, INSTALLATION, Throttle Body.>
FU(H4SO)-26
Manifold Absolute Pressure Sensor

9. Manifold Absolute Pressure

Sensor
A: REMOVAL
FU-00009
2) Disconnect the connector from manifold absolute pressure sensor.
FU-02728
3) Remove the manifold absolute pressure sensor

from throttle body.
B: INSTALLATION
NOTE:
Use new O-rings.
Tightening torque:
2.0 Nm (0.20 kgf-m, 1.5 ft-lb)
FU(H4SO)-27
Mass Air Flow and Intake Air Temperature Sensor

10.Mass Air Flow and Intake Air

Temperature Sensor
A: REMOVAL
FU-00009
2) Disconnect the connector from the mass air flow

and intake air temperature sensor.
3) Remove the mass air flow and intake air temperature sensor.
FU-02416
B: INSTALLATION
Tightening torque:
1.0 Nm (0.10 kgf-m, 0.74 ft-lb)
FU(H4SO)-28
EGR Valve
11.EGR Valve
A: REMOVAL
FU-00009
2) Disconnect the connector from EGR valve.
FU-01152
3) Remove the EGR valve from intake manifold.
FU-01153
B: INSTALLATION
NOTE:
Use a new gasket.
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
FU(H4SO)-29
Fuel Injector
12.Fuel Injector
(3) Remove the bolts which install the power

steering pump to the bracket.
A: REMOVAL
1. RH SIDE
FU-00139
(4) Disconnect the connector from power steering pump switch (A).
(A)
FU-00009
filler cap.
4) Remove the air intake duct and air cleaner case.
<Ref. to IN (H4SO)-7, REMOVAL, Air Intake Duct.>
<Ref. to IN (H4SO)-5, REMOVAL, Air Cleaner
Case.>
5) Remove the power steering pump and power
(1) Remove the front side V-belt. <Ref. to
ME(H4SO)-40, REMOVAL, V-belt.>
steering pipes onto the intake manifold protector RH.
FU-02433

from the bracket by pulling it upward.
NOTE:
FU-02572
(6) Place the power steering pump and tank on

the right side wheel apron.
FU-02807
FU-00021
6) Remove the spark plug cords from spark plugs

(#1 and #3 cylinders).
FU(H4SO)-30
Fuel Injector
FU-02326

FU-02325

(B)
(B)
(A)
(A)
FU-02730
10) Remove the bolt which holds fuel injector pipe

onto intake manifold.
FU-02729

FU-02717
FU-02718
11) Remove the fuel injector while lifting up the fuel

injector pipe.
2. LH SIDE
2) Remove the battery. <Ref. to SC (H4SO)-20,
REMOVAL, Battery.>
filler cap.
4) Remove the spark plug cords from spark plugs
(#2 and #4 cylinders).
FU-02719

injector pipe.
FU(H4SO)-31
Fuel Injector
B: INSTALLATION
2. LH SIDE
1. RH SIDE
NOTE:
Use new O-rings.

NOTE:
Use new O-rings.
(A)
(B)
(A)
(B)
(C)
(D)
(C)
(D)
FU-02157
(A) O-ring
FU-02157
(B) O-ring
(C) Fuel injector
(A) O-ring
(B) O-ring
(D) O-ring
(C) Fuel injector

(D) O-ring
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
FU-02719
FU-02717
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
FU-02718
FU-02326
FU(H4SO)-32
Fuel Injector
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
FU-02325
FU(H4SO)-33
Variable Valve Lift Diagnosis Oil Pressure Switch

13.Variable Valve Lift Diagnosis

Oil Pressure Switch
B: INSTALLATION
A: REMOVAL
NOTE:
Apply liquid gasket to the variable valve lift diagnosis oil pressure switch threads.
Liquid gasket:
THREE BOND 1324 (Part No. 004403042) or
equivalent
Tightening torque:
17 Nm (1.7 kgf-m, 12.5 ft-lb)
FU-00009

3) Remove the engine harness connector from the
bracket.
4) Disconnect the connector from the variable
valve lift diagnosis oil pressure switch.
5) Remove the variable valve lift diagnosis oil pressure switch.
LH side
FU-02731
RH side
FU-02732
FU(H4SO)-34
Oil Temperature Sensor

14.Oil Temperature Sensor

A: REMOVAL
FU-00009

bracket.
4) Disconnect the connector from engine oil temperature sensor.
5) Remove the oil temperature sensor.
FU-02733
B: INSTALLATION
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
FU(H4SO)-35
Front Oxygen (A/F) Sensor

15.Front Oxygen (A/F) Sensor
B: INSTALLATION
A: REMOVAL
1) Before installing front oxygen (A/F) sensor, apply anti-seize compound only to the threaded portion of front oxygen (A/F) sensor to make the next
removal easier.
1) Set the vehicle on a lift.

CAUTION:
Never apply anti-seize compound to the protector of front oxygen (A/F) sensor.
Anti-seize compound:
NEVER-SEEZ NSN, JET LUBE SS-30 or the
equivalent
2) Install the front oxygen (A/F) sensor.
FU-00009
Tightening torque:
21 Nm (2.1 kgf-m, 15.2 ft-lb)
3) Remove the clip fastening the harness and disconnect the front oxygen (A/F) sensor connector.
(B)
(A)
(A)
FU-02735
(B)
(A) Front oxygen (A/F) sensor

(B) Rear oxygen sensor
FU-02734
(A) Front oxygen (A/F) sensor connector

(B) Rear oxygen sensor connector

6) Apply spray-type lubricant to the threaded portion of front oxygen (A/F) sensor, and leave it for
one minute or more.
7) Remove the front oxygen (A/F) sensor.
3) Install the under cover.

4) Lower the vehicle.
5) Connect the connector of front oxygen (A/F)
sensor connector and fasten the harness with clips.
CAUTION:
When removing the front oxygen (A/F) sensor,
wait until exhaust pipe cools, because it can
damage the exhaust pipe.
(A)
(B)
FU-02734

(B)
(A)
FU-02735

FU(H4SO)-36

FU-00009
FU(H4SO)-37
Rear Oxygen Sensor

16.Rear Oxygen Sensor
B: INSTALLATION
A: REMOVAL
1) Before installing rear oxygen sensor, apply the

anti-seize compound only to the threaded portion of
rear oxygen sensor to make the next removal easier.

CAUTION:
Never apply anti-seize compound to the protector of rear oxygen sensor.
equivalent
2) Install the rear oxygen sensor.
FU-00009
Tightening torque:
21 Nm (2.1 kgf-m, 15.2 ft-lb)
3) Remove the clip fastening the harness and disconnect the rear oxygen sensor connector.
(B)
(A)
(A)
FU-02735
(B)

FU-02734


6) Apply spray-type lubricant to the threaded portion of rear oxygen sensor, and leave it for one
minute or more.
7) Remove the rear oxygen sensor.

5) Connect the connector to rear oxygen sensor
and mount the harness clips to the bracket for fastening.
(A)
CAUTION:
When removing the rear oxygen sensor, wait
until exhaust pipe cools, because it can damage the exhaust pipe.
(B)
FU-02734
(B)

(A)
FU-02735

FU(H4SO)-38
Rear Oxygen Sensor

FU-00009
FU(H4SO)-39
Engine Control Module (ECM)

17.Engine Control Module (ECM)
B: INSTALLATION
A: REMOVAL
NOTE:
When replacing the ECM, be careful not to use
the ECM for wrong specifications to avoid any damage to fuel injection system.
When replacing the ECM, be careful not to damage the harnesses and connectors.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
FU-00009
2) Remove the lower inner trim of passengers

side.
<Ref. to EI-43, REMOVAL, Lower Inner Trim.>
3) Detach the floor mat of passengers seat.
4) Remove the protect cover.
FU-01029
5) Remove the nuts (A) which hold ECM to bracket.

6) Remove the clip (B) from bracket.
(A)
(A)
(B)
FU-00316
7) Disconnect the ECM connectors, and take out

the ECM.
FU(H4SO)-40
Main Relay
18.Main Relay
A: REMOVAL
FU-00009
2) Remove the glove box. <Ref. to EI-36, REMOVAL, Glove Box.>

3) Remove the passengers side front side sill cover.
4) Disconnect the connectors from main relay.
FU-02736
5) Remove the main relay from the mounting

bracket.
B: INSTALLATION
FU(H4SO)-41
Fuel Pump Relay

19.Fuel Pump Relay

A: REMOVAL
FU-00009

4) Disconnect the connector from fuel pump relay.
FU-02737
5) Remove the fuel pump relay from the mounting

bracket.
B: INSTALLATION
FU(H4SO)-42
Electronic Throttle Control Relay

20.Electronic Throttle Control

Relay
A: REMOVAL
FU-00009

4) Disconnect the connector from electric throttle
control relay.
FU-02738
5) Remove the electronic throttle control relay from

the mounting bracket.
B: INSTALLATION
FU(H4SO)-43
Fuel
21.Fuel
5) Drain fuel from fuel tank.

Set a container under the vehicle and remove the
fuel drain plug from the fuel tank.
A: PROCEDURE
1. RELEASING OF FUEL PRESSURE
WARNING:
CAUTION:
FU-02704
6) Tighten the fuel drain plugs.

NOTE:
Use a new gasket.
Tightening torque:
26 Nm (2.65 kgf-m, 19.2 ft-lb)
FU-02737
2) Start the engine and run it until it stalls.

3) After the engine stalls, crank it for five more seconds.
4) Turn the ignition switch to OFF.
2. DRAINING FUEL
WARNING:
CAUTION:
FU-00009
filler cap.
FU(H4SO)-44
Fuel Tank
22.Fuel Tank
(B)
A: REMOVAL
WARNING:
CAUTION:
<Ref. to FU(H4SO)-44, DRAINING FUEL, PROCEDURE, Fuel.>
4) Remove the rear seat.
5) Disconnect the connector (A) between the fuel
tank cord and the rear harness.
6) Push the grommet (B) which holds the fuel tank
cord on the floor panel into under the body.
FU-02373
11) Move the retainer for fuel delivery tube, and

disconnect the quick connector. <Ref. to
FU(H4SO)-59, REMOVAL, Fuel Delivery, Return
and Evaporation Lines.>
12) Move the clips, and disconnect the fuel hose.
(A)
(B)
FU-02740
13) Support the fuel tank with transmission jack, remove the bolts from bands and dismount the fuel
tank from the vehicle.
FU-02739
7) Remove the rear crossmember. <Ref. to RS-16,

REMOVAL, Rear Crossmember.>
8) Remove the canisters. <Ref. to EC(H4SO)-6,
REMOVAL, Canister.>
9) Disconnect the connector from the pressure
control solenoid valve.
10) Loosen the clamp and disconnect the fuel filler
hose (A) and evaporation hose (B) from the fuel filler pipe.
WARNING:
A helper is required to perform this work.
Fuel may remain undrained in the side of the
fuel tank without the drain plug. Be careful not
to lose balance and drop the fuel tank when removing it, as this remaining fuel may offset the
weight balance of the tank.
(B)
(A)
FU-00411
(B)
FU-02372
FU(H4SO)-45
Fuel Tank
B: INSTALLATION
1) Support the fuel tank with transmission jack and
push the fuel tank harness into access hole along
with the grommet.
2) Set the fuel tank and temporarily tighten the
bolts of fuel tank bands.
5) Connect the fuel hoses, and hold them with clips

and quick connector. <Ref. to FU(H4SO)-59, REMOVAL, Fuel Delivery, Return and Evaporation
Lines.>
WARNING:
FU-02740
FU-00411
3) Insert the fuel filler hose (A) approx. 35 to 40 mm

(1.38 to 1.57 in) over the lower end of fuel filler pipe
and tighten the clamp.
4) Insert the evaporation hose (B) into the lower
end of evaporation pipe, and secure the clamps
and clips.
6) Connect the connector to pressure control solenoid valve.

7) Install the canister. <Ref. to EC(H4SO)-6, INSTALLATION, Canister.>
8) Tighten the band mounting bolts.
Tightening torque:
33 Nm (3.4 kgf-m, 25 ft-lb)
(B)
(A)
FU-00411
(B)
FU-02372
CAUTION:
Do not allow clips to touch hose (A) and rear
suspension crossmember.
9) Install the rear crossmember. <Ref. to RS-16,

INSTALLATION, Rear Crossmember.>
10) Connect the connector (A) to the fuel tank cord
and plug the service hole with grommet (B).
(A)
(A)
(B)
FU-02739
11) Set the rear seat and floor mats.

FU-02424
FU(H4SO)-46
Fuel Tank
FU-02737
C: INSPECTION
1) Check that there are no cracks, holes, or other
damage on the fuel tank.
2) Make sure that the fuel pipe and fuel hose are
not cracked and those connections are tight.
FU(H4SO)-47
Fuel Filler Pipe

23.Fuel Filler Pipe
9) Disconnect the evaporation hose from the clip of

fuel filler pipe.
A: REMOVAL
WARNING:
CAUTION:
FU-00098
10) Disconnect the evaporation hose from fuel

pipe.
FU-00009
3) Open the fuel filler flap lid, and remove the filler
cap.
4) Remove the screws which secure packing.
FU-00325
11) Remove the bolts which hold fuel filler pipe

bracket on the body.
FU-00095
5) Remove the rear wheel RH.

8) Remove the fuel filler pipe protector.
FU-00326
12) Loosen the clamp and separate the fuel filler

hose (A) from the fuel filler pipe.
13) Move the clip and disconnect the evaporation
hose (B).
(B)
FU-00772
(A)
FU-00327
14) Remove the fuel filler pipe to the underside of

the vehicle.
FU(H4SO)-48
Fuel Filler Pipe

15) Remove the evaporation pipe together with clip

from the body.
5) Connect the evaporation hose to the fuel pipe.
FU-00325
FU-00328
B: INSTALLATION
1) Open the fuel filler flap lid.
2) Set the fuel saucer (A) with rubber packing (C),
and insert the fuel filler pipe into hole from the inner
side of apron.
3) Align the holes in fuel filler pipe neck and set the
cup (B), and tighten the screws.
6) Connect the fuel filler hose (A) to the pipe with an

overlap of 35 to 40 mm (1.38 to 1.57 in).
7) Connect the evaporation hose (B) to the pipe
with an overlap of 25 to 30 mm (0.98 to 1.18 in).
CAUTION:
Do not allow clips to touch evaporation hose
(B) and rear suspension crossmember.
(B)
NOTE:
If the edges of rubber packing are folded toward the
inside, straighten it with a screwdriver.
(A)
(A)
FU-00327
(B)
(C)
(2)
(1)
(3)
FU-00103
4) Install the evaporation pipe.

L/2
L
FU-00104
(1) Hose
(2) Clip
(3) Pipe
FU-00328
FU(H4SO)-49
Fuel Filler Pipe

8) Tighten the bolts which hold fuel filler pipe bracket on the body.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
C: DISASSEMBLY
1) Move the clamp and disconnect the evaporation
hose from the joint pipe.
FU-00329
FU-00326
9) Fasten the evaporation hoses to the clip of fuel

filler pipe.
2) Remove the bolts which install the joint pipe to

the fuel filler pipe.
FU-00330
FU-00098
10) Install the fuel filler pipe protector.
3) Disconnect the evaporation hose from fuel filler

pipe.
FU-00331
FU-00772
4) Remove the shut valve from the fuel filler pipe.

<Ref. to EC(H4SO)-16, REMOVAL, Shut Valve.>

12) Install the rear wheel RH.
Tightening torque:
100 Nm (10.2 kgf-m, 73.8 ft-lb)
FU-00009
FU(H4SO)-50
Fuel Filler Pipe

D: ASSEMBLY
1) Install the shut pipe to the fuel filler pipe. <Ref. to
EC(H4SO)-16, INSTALLATION, Shut Valve.>
2) Connect the evaporation hose to the fuel filler
pipe.
FU-00331
3) Connect the evaporation hose to the evaporation pipe.
FU-00329
4) Install the evaporation pipe to the fuel filler pipe.
FU-00330
FU(H4SO)-51
Fuel Pump
24.Fuel Pump
9) Disconnect the connector from fuel pump.
A: REMOVAL
WARNING:
CAUTION:
NOTE:
Fuel pump assembly consists of fuel pump, fuel filter and fuel level sensor.
FU-02741
10) Disconnect the quick connector, then disconnect the fuel delivery hose. <Ref. to FU(H4SO)-59,
REMOVAL, Fuel Delivery, Return and Evaporation
Lines.>
11) Move the clips, and disconnect the jet pump
hose (A).
FU-00009
filler cap.
7) Remove the luggage floor mat. <Ref. to EI-49,
REMOVAL, Luggage Floor Mat.>
8) Remove the service hole cover.
(A)
FU-02742
12) Remove the nuts which install fuel pump assembly onto fuel tank.
FU-02743
13) Remove the fuel pump assembly from the fuel

tank.
FU-00105
FU(H4SO)-52
Fuel Pump
B: INSTALLATION
Install in the reverse order of removal while being
careful of the following.
Make sure the sealing portion is free from fuel or
foreign matter before installation.
Tighten the nuts in alphabetical sequence as
shown in the figure to the specified torque.
NOTE:
Use a new gasket and retainer.
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
(C)
(A)
(E)
(G)
(H)
(F)
(B)
(D)
FU-02744
C: INSPECTION
Connect the lead harness to the connector terminal
of fuel pump, and apply the battery power supply to
check whether the pump operates.
CAUTION:
Wipe off fuel completely.
Keep the battery as far apart from fuel pump
as possible.
Be sure to turn the battery supply ON and
OFF on the battery side.
Do not run the fuel pump for a long time under non-load condition.
3 2 1
6 5 4
FU-00332
FU(H4SO)-53
Fuel Level Sensor

25.Fuel Level Sensor

A: REMOVAL
WARNING:
CAUTION:
NOTE:
The fuel level sensor is built in fuel pump assembly.
1) Remove the fuel pump assembly.
<Ref. to FU(H4SO)-52, REMOVAL, Fuel Pump.>
2) Disconnect the connector from fuel pump bracket.
FU-01065
3) Remove the fuel temperature sensor (A).

4) Remove the bolt (B) which installs the fuel level
sensor on the mounting bracket.
(B)
(A)
FU-02745
B: INSTALLATION
FU(H4SO)-54
Fuel Sub Level Sensor

26.Fuel Sub Level Sensor
9) Remove the bolts which install fuel sub level

sensor on fuel tank.
A: REMOVAL
WARNING:
CAUTION:
FU-00115
10) Remove the fuel sub level sensor.
FU-00009

FU-00116
B: INSTALLATION
Tighten the bolts in the sequence shown in the
figure to the specified torque.
NOTE:
Use a new gasket.
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
FU-00113
7) Disconnect the connector from the fuel sub level

sensor.
8) Disconnect the fuel jet pump hose.
FU-00114
FU(H4SO)-55
Fuel Filter
27.Fuel Filter
A: REMOVAL
WARNING:
CAUTION:
NOTE:
The fuel filter is assembled in fuel pump assembly.
1) Remove the fuel pump assembly. <Ref. to
FU(H4SO)-52, REMOVAL, Fuel Pump.>
2) Separate the fuel pump and fuel filter.
(A)
(B)
FU-01064
(A) Fuel filter

(B) Fuel pump
B: INSTALLATION
CAUTION:
If fuel hoses or clamps are damaged, replace
them with new parts.
C: INSPECTION
1) Check the inside of fuel filter for dirt and water
sediment.
2) If it is clogged, or if the replacement interval has
been reached, replace it.
FU(H4SO)-56
Fuel Cut Valve

28.Fuel Cut Valve
B: INSTALLATION
A: REMOVAL

WARNING:
CAUTION:
1) Remove the fuel tank.
<Ref. to FU(H4SO)-45, REMOVAL, Fuel Tank.>
NOTE:
Use a new gasket.
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
FU-02748
FU-02746
3) Move the clip and disconnect the evaporation

hose from the fuel cut valve.
FU-02747
4) Remove the bolts which install the fuel cut valve.
FU(H4SO)-57
Fuel Damper Valve

29.Fuel Damper Valve

A: REMOVAL
CAUTION:
or cloth.
2) Remove the fuel damper valve from the fuel delivery line.
FU-02749
B: INSTALLATION
CAUTION:
Tightening torque:
1.25 Nm (0.13 kgf-m, 0.94 ft-lb)
FU(H4SO)-58
Fuel Delivery, Return and Evaporation Lines

30.Fuel Delivery, Return and Evaporation Lines

A: REMOVAL
WARNING:
CAUTION:
2) Release the fuel pressure. <Ref. to FU(H4SO)-44, RELEASING OF FUEL PRESSURE, PROCEDURE,
Fuel.>
3) Open the fuel filler flap lid, and remove the fuel filler cap.
4) Remove the floor mat. <Ref. to EI-48, REMOVAL, Floor Mat.>
5) Disconnect the fuel delivery pipes and hoses, and then disconnect the evaporation pipes and hoses.
FU-02750
6) In the engine room, disconnect the fuel delivery

hose and evaporation hose.
of the arrow.
CAUTION:
or cloth.
FU(H4SO)-59
(A)
(B)
FU-02715



8) Disconnect the quick connector on the fuel line.
(1) Clean the pipe and connector, if they are
covered with dust.
(2) To prevent from damaging or entering foreign matter, wrap the pipes and connectors with
plastic bag etc.
B: INSTALLATION
NOTE:
Replace the retainer other than in the engine room
with a new part.
1) Connect the quick connector on fuel line.
CAUTION:
Make sure there are no damage or dust on connections. If necessary, clean seal surface of
pipe.
(A)
(B)
FU-01333
(3) Hold the connector (A) and push the retainer

(B) down.
(4) Pull out the connector (A) from the retainer
(B).
FU-00125
(A) Seal surface

(B) Pipe
(1) Set the new retainer (B) to connector (A).

(2) Push the pipe into the connector completely.
(B)
(A)
(A)
(C)
(B)
FU-00124
(C)
(A) Connector
(B) Retainer
(C) Pipe
FU-00126
(A) Connector
(B) Retainer
(C) Pipe
FU(H4SO)-60

CAUTION:
Pull the connector to ensure it is connected
securely.
Make sure the two retainer pawls are engaged in their mating positions in the connector.
Be sure to inspect hoses and their connections for any leakage of fuel.
3) Connect the evaporation hose to the pipe with

an overlap of 15 to 20 mm (0.59 to 0.79 in).
Fuel evaporation hose
L = 17.52.5 mm (0.6890.098 in)
(2)
(1)
(3)
L/2
L
(A)
FU-00129
(1) Hose
(B)
(C)
(2) Clip
(3) Pipe
FU-00127
(A) Connector
(B) Retainer
C: INSPECTION
(C) Pipe
2) Connect the fuel delivery hose to the pipe with

Type A: When the amount of inserting is specified.
Type B: When the amount to be inserted is not
specified.
1) Make sure that there are no cracks on the fuel

pipes and fuel hoses.
2) Make sure the fuel pipe and fuel hose connections are tightened firmly.
2: 2.51.5 mm (0.0980.059 in)

L: 22.52.5 mm (0.8860.098 in)
CAUTION:
Be sure to inspect hoses and their connections
for any leakage of fuel.
(3)
(4)
(5)
(1)
L
(2)
FU-00128
(1) Type A
(2) Type B
(3) Pipe
(4) Clamp
(5) Hose
FU(H4SO)-61
Fuel System Trouble in General

31.Fuel System Trouble in General

A: INSPECTION
Trouble and possible cause
Corrective action
1. Insufficient fuel supply to injector

1)
Fuel pump does not operate.
Inspect contact, especially ground, and tighten it
securely.
Defective terminal contact
2)
Trouble in electromagnetic or electronic circuit parts

Decline of fuel pump function
Replace the faulty part.

Replace the fuel pump.
3)
4)
Clogged dust or water in the fuel filter

Clogged or bent fuel pipe or hose
Replace the fuel filter.

Clean, correct or replace fuel pipe or hose.
5)
Air is mixed in fuel system
Inspect or retighten each connection part.
6)
7)
Clogged or bent air breather tube or pipe

Damaged diaphragm of pressure regulator
Clean, correct or replace the air breather tube or pipe.

Replace.
2. Leakage or blow out of fuel

1)
Loose joints of the fuel pipe
Retighten.
2)
3)
Cracked fuel pipe, hose and fuel tank

Defective welding part on the fuel tank
Replace.
Replace.
4)
Defective drain packing of the fuel tank
5)
Clogged or bent air breather tube or air vent tube
Replace.
Clean, correct or replace the air breather tube or air vent
tube.
3. Gasoline smell inside of compartment

1)
Loose joints at air breather tube, air vent tube and fuel filler
pipe
Retighten.
2)
3)
Problem in tightening of the fuel saucer packing air

Fuel pump trouble
Correct or replace the packing.

Replace.
4. Defective fuel meter indicator

1)
Defective operation of fuel level sensor
Replace.
2)
Defective operation of fuel meter
5. Noise
1)
Replace.
Large operation noise or vibration of fuel pump
Replace.
NOTE:
When the vehicle is left unattended for an extended period of time, water may accumulate in the fuel tank.
Fill fuel fully to prevent the problem.
In snow-covered areas, mountainous areas, skiing areas, etc. where ambient temperatures drop below
0C (32F) throughout the winter season, use an water removing agent in the fuel system to prevent freezing
fuel system and accumulating water.
When water is accumulated in fuel filter, fill the water removing agent in the fuel tank.
Before using water removing agent, follow the cautions noted on the bottle.
FU(H4SO)-62
General Description
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)
A: CAUTION
points.
the battery.
B: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
18353AA000
DESCRIPTION
CLAMP PLIERS
ST18353AA000
EC(H4SO)-2
REMARKS
Used for removing and installing the PCV
hose.
This is a general tool made by the French
company CAILLAU. (code) 54.0.000.205
To make this easier to obtain in the same way as
genuine Subaru parts, it has been provided with
a tool number as an ST.
Front Catalytic Converter

2. Front Catalytic Converter

A: REMOVAL
The front catalytic converter is integrated into front
exhaust pipe as one unit; therefore, refer to Front
Exhaust Pipe for removal procedure. <Ref. to EX
(H4SO)-4, REMOVAL, Front Exhaust Pipe.>
B: INSTALLATION
The front catalytic converter is integrated into front
exhaust pipe as one unit; therefore, refer to Front
Exhaust Pipe for installation procedure. <Ref. to
EX (H4SO)-5, INSTALLATION, Front Exhaust
Pipe.>
C: INSPECTION
1) Check the connections and welds for exhaust
leaks.
2) Make sure there are no holes or rusting.
EC(H4SO)-3
Rear Catalytic Converter

3. Rear Catalytic Converter

A: REMOVAL
The rear catalytic converter is integrated into center
exhaust pipe as one unit; therefore, refer to Center
Exhaust Pipe for removal procedure. <Ref. to EX
(H4SO)-7, REMOVAL, Center Exhaust Pipe.>
B: INSTALLATION
The rear catalytic converter is integrated into center
exhaust pipe as one unit; therefore, refer to Center
Exhaust Pipe for installation procedure. <Ref. to
EX (H4SO)-7, INSTALLATION, Center Exhaust
Pipe.>
C: INSPECTION
leaks.
EC(H4SO)-4
EGR Valve
4. EGR Valve
A: SPECIFICATION
Refer to EGR valve for removal and installation
procedure. <Ref. to FU(H4SO)-29, EGR Valve.>
EC(H4SO)-5
Canister
5. Canister
B: INSTALLATION
A: REMOVAL
NOTE:
Replace the retainer of quick connector with a
new part.
Tightening torque:
23 Nm (2.3 kgf-m, 17 ft-lb)
FU-00009

3) Disconnect the connector (A) from drain valve.
4) Disconnect the evaporation hoses (B) and (C)
from the canister.
EC-02073
C: INSPECTION
Make sure the canister and canister hoses are not
cracked or loose.
(C)
(A)
(B)
EC-02072
5) Disconnect the quick connector (A) from the

canister.
6) Disconnect the drain hose (B) from the canister.
(B)
(A)
EC-02114
7) Remove the canister from the body.
EC-02073
EC(H4SO)-6
Purge Control Solenoid Valve

6. Purge Control Solenoid Valve
B: INSTALLATION
A: REMOVAL
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
FU-00009
2) Disconnect the connector and evaporation hoses of purge control solenoid valve, and then remove the purge control solenoid valve.
EC-00223
NOTE:
Connect the evaporation hose as shown in the figure.
(B)
(A)
EC-00223
EC-00224
(A) To fuel pipe (evaporation line)

(B) To intake manifold
C: INSPECTION
Make sure the hoses are not cracked or loose.
EC(H4SO)-7
Fuel Level Sensor

7. Fuel Level Sensor

A: REMOVAL
Refer to the FU section for removal procedure.
<Ref. to FU(H4SO)-54, REMOVAL, Fuel Level
Sensor.>
B: INSTALLATION
Refer to the FU section for installation procedure.
<Ref. to FU(H4SO)-54, INSTALLATION, Fuel Level Sensor.>
EC(H4SO)-8
Fuel Temperature Sensor

8. Fuel Temperature Sensor

A: REMOVAL
The fuel temperature sensor and fuel level sensor
are integrated into one unit; therefore, refer to Fuel
Level Sensor for removal procedure. <Ref. to
FU(H4SO)-54, REMOVAL, Fuel Level Sensor.>
B: INSTALLATION
The fuel temperature sensor is integrated into fuel
level sensor as one unit; therefore, refer to Fuel
Level Sensor for installation procedure. <Ref. to
FU(H4SO)-54, INSTALLATION, Fuel Level Sensor.>
EC(H4SO)-9

9. Fuel Sub Level Sensor

A: REMOVAL
Refer to the FU section for removal procedure.
<Ref. to FU(H4SO)-55, REMOVAL, Fuel Sub Level
Sensor.>
B: INSTALLATION
Refer to the FU section for installation procedure.
<Ref. to FU(H4SO)-55, INSTALLATION, Fuel Sub
Level Sensor.>
EC(H4SO)-10
Fuel Tank Pressure Sensor

10.Fuel Tank Pressure Sensor

A: REMOVAL
6) Disconnect the pressure hose from the fuel tank

pressure sensor.
WARNING:
CAUTION:
1) Remove the fuel tank. <Ref. to FU(H4SO)-45,
REMOVAL, Fuel Tank.>
EC-02146
B: INSTALLATION
Tightening torque:
7.4 Nm (0.75 kgf-m, 5.4 ft-lb)
T
EC-02143
3) Disconnect the connector from the fuel tank

pressure sensor.
4) Remove the clip which holds the fuel pipe to the
fuel tank.
EC-02160
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
T
T
EC-02150
5) Remove the bolt and nut which secures the fuel

tank pressure sensor to the bracket.
EC-02147
C: INSPECTION
EC-02145
EC(H4SO)-11
Pressure Control Solenoid Valve

11.Pressure Control Solenoid

Valve
8) Disconnect the two evaporation hoses from the

pressure control solenoid valve.
A: REMOVAL
EC-00056
9) Remove the pressure control solenoid valve

from the bracket.
FU-00009

REMOVAL, Canister.>
5) Remove the bolt which installs the pressure control solenoid valve holding bracket to the body.
EC-00057
10) Disconnect the hose from the pressure control

solenoid valve.
EC-02078
6) Remove the pressure control solenoid valve and

the bracket as a unit.
EC-00058
EC-00055
EC(H4SO)-12

B: INSTALLATION
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
EC-02078
C: INSPECTION
EC(H4SO)-13
Drain Filter
12.Drain Filter
A: SPECIFICATION
The drain filter is embedded in the canister and
therefore cannot be disassembled.
EC(H4SO)-14
Vent Valve
13.Vent Valve
B: INSTALLATION
A: REMOVAL
WARNING:
CAUTION:
1) Remove the fuel tank. <Ref. to FU(H4SO)-45,
REMOVAL, Fuel Tank.>
NOTE:
Use a new gasket.
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
T
(A)
EC-00038
(A) Gasket
EC-02143
3) Remove the clip and disconnect the hose from

the vent valve.
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
T
T
EC-02147
EC-02148
4) Remove the nut and then remove the vent valve.
C: INSPECTION
EC-02149
EC(H4SO)-15
Shut Valve
14.Shut Valve
A: REMOVAL
WARNING:
CAUTION:
1) Remove the fuel filler pipe.
<Ref. to FU(H4SO)-48, REMOVAL, Fuel Filler
Pipe.>
2) Disconnect the evaporation hose from the shut
valve.
EC-00041
EC-00050
B: INSTALLATION
Tightening torque:
4.5 Nm (0.46 kgf-m, 3.3 ft-lb)
EC-00050
C: INSPECTION
EC(H4SO)-16
Drain Valve
15.Drain Valve
A: REMOVAL
FU-00009

REMOVAL, Canister.>
5) Disengage the clip (A), then remove the drain
valve (B) from the canister.
(A)
(A)
(B)
EC-00266
B: INSTALLATION
NOTE:
Replace clip (A) with a new part.
(A)
(A)
(B)
EC-00266
C: INSPECTION
1) Make sure that all hoses are properly connected.
2) Make sure the hoses are not cracked or loose.
EC(H4SO)-17
PCV Hose Assembly

16.PCV Hose Assembly

A: REMOVAL
CAUTION:
Do not remove PCV hose assembly except
when the PCV hose, diagnostics connector and
PCV valve are damaged.
1) Remove the air intake chamber.
<Ref. to IN (H4SO)-6, REMOVAL, Air Intake
Chamber.>
2) Fit the depression in the ST with the protrusion
on the clamp to unlock.
3) Remove the PCV hose assembly.
ST 18353AA000 CLAMP PLIERS
EC-02151
B: INSTALLATION
NOTE:
Replace the clamp with a new part.
1) Install the PCV hose assembly, then lock by fitting the ST on the clamp protrusion.
EC-02152
2) Install the air intake chamber.

Chamber.>
EC(H4SO)-18
General Description
INTAKE (INDUCTION)
A: COMPONENT
T2
(16)
T2
(17)
(15)
(13)
(16)
T6
(15)
(14)
(13)
T6
T4
T6
T4
(18)
(13)
(20)
T4
(19)
(11)
(12)
T5
(21)
(10)
(4)
T3
T3
(9)
(2)
T1
(5)
T3
(8)
(7)
T3
(6)
(3)
(1)
IN-02202
IN (H4SO)-2
General Description
INTAKE (INDUCTION)
(1)
(2)
Resonator chamber
Cushion
(11)
Air cleaner upper cover (with a HC

adsorption filter: U5 model)
(20)
(21)
(3)
(4)
Air intake duct

Cushion
(12)
(13)
Air flow sensor

Clamp
Tightening torque: Nm (kgf-m, ft-lb)
(5)
(6)
Clip
Air cleaner lower case
(14)
(15)
Intake duct
Cushion
T1: 33 (3.4, 24.6)

T2: 6.5 (0.66, 4.8)
(7)
(8)
Cushion
Spacer
(16)
(17)
Spacer
Air intake chamber
T3: 7.5 (0.76, 5.5)

T4: 16 (1.6, 11.6)
(9)
(10)
Air cleaner element

Guide
(18)
(19)
Stay LH (MT model)

Stay LH (AT model)
T5: 1.0 (0.10, 0.7)

T6: 3.0 (0.3, 2.1)
B: CAUTION
points.
the battery.
IN (H4SO)-3
Stay RH
Duct
Air Cleaner Element

INTAKE (INDUCTION)
2. Air Cleaner Element

A: REMOVAL
(B)
PM-02090
B: INSTALLATION
NOTE:
The air cleaner element differs depending on the
destination market. For the specification of U5
model, refer to the NOTE (A) on the upper side of
air cleaner upper cover.
(A)
IN-02198
Fasten with a clip after inserting the lower tab of

case.
PM-00247
C: INSPECTION
1) Replace with a new part if the air cleaner element is extremely damaged or dirty.
2) Replace the air cleaner upper cover when the
HC adsorption filter is damaged. (U5 model)
IN (H4SO)-4
Air Cleaner Case

INTAKE (INDUCTION)
3. Air Cleaner Case
B: INSTALLATION
A: REMOVAL
Tightening torque:
33 Nm (3.4 kgf-m, 24.6 ft-lb)
FU-00009
2) Loosen the clamps (A) which connect the air

cleaner case and the intake duct.
3) Remove the clips (B) from air cleaner case.
4) Disconnect the connector (C) from mass air flow
C: INSPECTION
1) Check for cracks or loose connection.
2) Replace the air cleaner upper cover when the
duct is damaged. (U5 model)
NOTE:
Do not remove the duct as it cannot be reinstalled.
(U5 model)
(B)
(A)
(C)
IN-00032
IN-02091
5) Remove the intake duct and upper cover from air

cleaner case.
7) Remove the bolts which install air cleaner case
to vehicle body.
IN-00032
8) Remove the air cleaner case.
IN (H4SO)-5
Air Intake Chamber

INTAKE (INDUCTION)
4. Air Intake Chamber

A: REMOVAL
1) Loosen the clamp (A) which connects air intake
chamber to throttle body.
2) Loosen the clamp (B) which connects the duct to
air intake chamber.
3) Remove the bolt (C) which secures air intake
chamber to the stay.
4) Disconnect the connector (D).
(C)
(B)
(C)
(D)
(A)
IN-02141
5) Disconnect the blow-by hoses, and then remove

air intake chamber.
B: INSTALLATION
Tightening torque:
Clamp (A), (B)
3.0 Nm (0.3 kgf-m, 2.1 ft-lb)
Bolt (C)
6.5 Nm (0.66 kgf-m, 4.8 ft-lb)
(C)
(B)
(C)
(A)
IN-02142
C: INSPECTION
2) Inspect that no foreign objects are mixed in the
air intake chamber.
IN (H4SO)-6
Air Intake Duct

INTAKE (INDUCTION)
5. Air Intake Duct

A: REMOVAL
1) Remove the bolts which install the air intake duct
on the front side of body.
2) Remove the air intake duct.
IN-02069
B: INSTALLATION
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
C: INSPECTION
2) Inspect that no foreign objects in the air intake
duct.
IN (H4SO)-7
Resonator Chamber
INTAKE (INDUCTION)
6. Resonator Chamber
A: REMOVAL
3) Remove the air cleaner lower case.
Case.>
4) Remove the resonator chamber attaching bolts
on the right side of the engine room.
IN-02070
5) Remove the front wheel RH, and lift-up the vehicle.

6) Remove the front mudguard RH.
7) Remove the resonator chamber from the inside
front fender.
IN-02071
B: INSTALLATION
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
C: INSPECTION
2) Check that no foreign objects are mixed in the
resonator.
IN (H4SO)-8
General Description
MECHANICAL
A: SPECIFICATION
Model
2.5 L
Horizontally opposed, liquid cooled, 4-cylinder,
4-stroke gasoline engine
Cylinder arrangement

Bore Stroke
mm (in)
Displacement
Compression ratio
Compression pressure (at 350 rpm)
cm (cu in)
2,457 (150)
10.0
1,020 1,275 (10.4 13.0, 148 185)
kPa (kg/cm , psi)
Number of piston rings

Constant
Engine
Intake valve timing
Low speed
High speed
Exhaust valve timing

Valve clearance
Idling speed [at neutral position on MT,

or P or N position on AT]
mm (in)
Open
Pressure ring: 2, Oil ring: 1

BTDC 0
Close
Open
ABDC 58
BTDC 0
Close
Open
ABDC 50
BTDC 14
Close
Open
ABDC 62
BBDC 54
Close
Intake
ATDC 14
0.200.04 (0.00790.0016)
Exhaust
0.250.04 (0.00980.0016)
650100 (No load)
850100 (A/C ON)
700100 (No load)
850100 (A/C ON)
1324
MT
rpm
AT
Ignition order
Ignition timing
BTDC/rpm
Belt driven
Single overhead camshaft
4-valve/cylinder
99.5 79.0 (3.917 3.110)
MT
AT
ME(H4SO)-2
108/650
158/700
General Description
MECHANICAL
NOTE:
US: undersize OS: oversize
Belt tension
adjuster
Protrusion of adjuster rod

Spacer O.D.
Tensioner bushing I.D.
Belt tensioner
Valve rocker arm
Clearance between spacer and bushing
mm (in)
Side clearance of spacer
mm (in)
Clearance between shaft and arm
mm (in)
Bending limit
Thrust clearance
mm (in)
Constant
Camshaft
Cam lobe
height
Intake
Low speed
mm (in)
High speed
Exhaust
Oil clearance
Cylinder head
mm (in)
Surface warpage limit

(Mating surface with cylinder block)
Grinding limit
Standard height
Seating angle
Valve seat
Contacting width
Limit
Standard
0.175 (0.0069)
0.20 0.55 (0.0079 0.0217)
Limit
Standard
0.81 (0.0319)
0.020 0.054 (0.0008 0.0021)
Limit
mm (in)
Standard
Limit
Standard
0.10 (0.0039)
40.075 40.175 (1.5778 1.5817)
Limit
Standard
39.975 (1.5738)
35.182 35.282 (1.3851 1.3891)
Limit
Standard
35.082 (1.3812)
40.315 40.415 (1.5872 1.5911)
Limit
Standard
40.215 (1.5833)
40.149 40.249 (1.5807 1.5846)
Limit
mm (in)
40.049 (1.5767)
31.928 31.945 (1.2570 1.2577)
mm (in)
Standard
32.000 32.018 (1.2598 1.2605)

0.055 0.090 (0.0022 0.0035)
Limit
0.10 (0.0039)
mm (in)
0.03 (0.001)
mm (in)
0.1 (0.004)
mm (in)
97.5 (3.84)
90
1.2 1.8 (0.047 0.071)

2.2 (0.087)
mm (in)
Stem outer diameter
mm (in)
Standard
Limit
Overall length
0.025 (0.0010)
0.030 0.090 (0.0012 0.0035)
Standard
Limit
mm (in)
mm (in)
0.10 (0.0039)
Exhaust
mm (in)
Exhaust
Valve stem gap
18.00 18.08 (0.7087 0.7118)

0.025 0.125 (0.0010 0.0049)
0.8 1.4 (0.03 0.055)

1.7 (0.067)
Intake
Valve
17.955 17.975 (0.7069 0.7077)
Standard
Limit
Protrusion above head
Head edge thickness
mm (in)
Intake
Inside diameter
Valve guide
5.2 6.2 (0.205 0.244)
mm (in)
Standard
Camshaft journal O.D.

Camshaft journal hole I.D.
mm (in)
mm (in)
ME(H4SO)-3
mm (in)
Intake
6.000 6.012 (0.2362 0.2367)

20.0 21.0 (0.787 0.827)
Exhaust
Standard
16.5 17.5 (0.650 0.689)

0.8 1.2 (0.03 0.047)
Limit
Standard
0.6 (0.024)
1.0 1.4 (0.039 0.055)
Limit
Intake
0.6 (0.024)
5.950 5.965 (0.2343 0.2348)
Exhaust
Intake
5.945 5.960 (0.2341 0.2346)

0.035 0.062 (0.0014 0.0024)
Exhaust
0.040 0.067 (0.0016 0.0026)

0.15 (0.0059)
Intake
Exhaust
120.6 (4.75)
121.7 (4.79)
General Description
MECHANICAL
Free length
mm (in)
Squareness
Valve spring
Set
Tension/
spring height
N (kgf, lb)/mm (in)

Lift
Surface warpage limit (mating with cylinder head)

Grinding limit
mm (in)
mm (in)
0.025 (0.00098)
0.1 (0.004)
mm (in)
A
201.0 (7.91)
99.505 99.515 (3.9175 3.9179)
B
Standard
99.495 99.505 (3.9171 3.9175)

0.015 (0.0006)
Limit
Standard
0.050 (0.0020)
0.010 (0.0004)
Standard height
Cylinder inner diameter
Cylinder block
mm (in) Standard
Taper
mm (in)
Out-of-roundness
mm (in)
Piston clearance
mm (in)
Limit
Standard
Limit
Cylinder inner boring limit (diameter)
mm (in)
Standard
Piston
Outer diameter
mm (in)
B
0.25 (0.0098) OS
Piston pin
Clearance between piston and piston

pin:
mm (in)
99.995 100.015 (3.9368 3.9376)

23.000 23.006 (0.9055 0.9057)
mm (in)
Standard
22.994 23.000 (0.9053 0.9055)

0.004 0.008 (0.0002 0.0003)
Limit
0.020 (0.0008)
Piston pin must be fitted into position
with thumb at 20C (68F).
Standard
Limit
0.20 0.35 (0.0079 0.0138)

1.0 (0.039)
Standard
Limit
0.37 0.52 (0.0144 0.0203)

1.0 (0.039)
Oil ring
Standard
Limit
0.20 0.50 (0.0079 0.0197)

1.5 (0.059)
Top ring
Standard
Limit
0.040 0.080 (0.0016 0.0031)

0.15 (0.0059)
Second ring
Standard
Limit
0.030 0.070 (0.0012 0.0028)

0.15 (0.0059)
Top ring
mm (in) Second ring
Piston ring
Ring groove gap
Connecting rod
Bearing of large
end
Bushing of small
end
mm (in)
Bend or twist per 100 mm (3.94 in) in

length
mm (in) Limit
Side clearance of large end
mm (in)
Oil clearance
Bearing size
(Thickness at center)
mm (in)
mm (in)
Clearance between piston pin and

bushing
To 100.005 (3.9372)
99.505 99.515 (3.9175 3.9179)
mm (in)
Degree of fit
Ring closed gap
0.050 (0.0020)
0.010 0.010
(0.00039 0.00039)
0.030 (0.0012)
99.495 99.505 (3.9171 3.9175)

99.745 99.765 (3.9270 3.9278)
0.50 (0.0197) OS
Piston pin specified diameter
Outer diameter
55.2 (2.173)
2.5, 2.4 mm (0.094 in) or less
235.3 270.7 (24 27.6,
52.9 60.8)/45.0 (1.772)
578.9 639.9 (59.1 65.3,
130.3 143.9)/34.7 (1.366)
Standard
Limit
0.10 (0.0039)
0.070 0.330 (0.0028 0.0130)
0.4 (0.016)
Standard
Limit
0.016 0.044 (0.00063 0.0017)

0.05 (0.0020)
Standard
0.03 (0.0012) US
1.492 1.501 (0.0587 0.0591)

1.510 1.513 (0.0594 0.0596)
0.05 (0.0020) US
0.25 (0.0098) US
1.520 1.523 (0.0598 0.0600)

1.620 1.623 (0.0638 0.0639)
mm (in) Standard
Limit
ME(H4SO)-4
0 0.022 (0 0.0009)
0.030 (0.0012)
General Description
MECHANICAL
Bend limit
Crank pin
Crank journal
Crankshaft
Crank pin outer

diameter
mm (in)
0.035 (0.0014)
Out-of-roundness
Cylindricality
mm (in)
mm (in)
0.003 (0.0001)
0.004 (0.0002)
Grinding limit (dia.)

Out-of-roundness
mm (in)
mm (in)
To 51.750 (2.0374)
0.005 (0.0002)
Cylindricality
mm (in)
mm (in)
0.006 (0.0002)
To 59.758 (2.3527)
mm (in)
51.984 52.000 (2.0466 2.0472)

51.954 51.970 (2.0454 2.0461)
0.05 (0.0020) US
0.25 (0.0098) US
51.934 51.950 (2.0446 2.0453)

51.734 51.750 (2.0368 2.0374)
Standard
0.03 (0.0012) US
59.992 60.008 (2.3619 2.3625)

59.962 59.978 (2.3607 2.3613)
0.05 (0.0020) US
0.25 (0.0098) US
59.942 59.958 (2.3599 2.3605)

59.742 59.758 (2.3520 2.3527)
Crank journal outer

diameter
mm (in)
Thrust clearance
mm (in)
Standard
Limit
0.030 0.115 (0.0012 0.0045)

0.25 (0.0098)
Oil clearance
mm (in)
Standard
Limit
0.010 0.030 (0.0001 0.0012)

0.40 (0.016)
Standard
0.03 (0.0012) US
1.998 2.011 (0.0787 0.0792)

2.017 2.020 (0.0794 0.0795)
0.05 (0.0020) US
0.25 (0.0098) US
2.027 2.030 (0.0798 0.0799)

2.127 2.130 (0.0837 0.0839)
Standard
0.03 (0.0012) US
2.000 2.013 (0.0787 0.0793)

2.019 2.022 (0.0795 0.0796)
0.05 (0.0020) US
0.25 (0.0098) US
2.029 2.032 (0.0799 0.0800)

2.129 2.132 (0.0838 0.0839)
#1, #3
Main bearing
Standard
0.03 (0.0012) US
Main bearing
mm (in)
#2, #4, #5
ME(H4SO)-5
General Description
MECHANICAL
B: COMPONENT
1. TIMING BELT
(5)
T1
(1)
(2)
T2
(3)
T5
(6)
(4)
(7)
T4
(8)
(12)
T3
T1
(9)
T4
T1
T4
(10)
(13)
(15)
(11)
T5
(14)
T6
T1
ME-02972
(1)
(2)
Timing belt cover No. 2 (RH)

Timing belt guide (MT model)
(9)
Automatic belt tension adjuster

ASSY
(3)
(4)
Crank sprocket
Timing belt cover No. 2 (LH)
(10)
(11)
Belt idler No. 2

Cam sprocket No. 2
T2: 9.75 (1.0, 7.2)

T3: 24.5 (2.5, 18.1)
(5)
(6)
Cam sprocket No. 1

Belt idler (No. 1)
(12)
(13)
Timing belt
Front timing belt cover
T4: 39 (4.0, 28.9)

T5: 78 (8.0, 57.9)
(7)
(8)
Tensioner bracket
Belt idler (No. 2)
(14)
(15)
Timing belt cover (LH)

Crank pulley
T6: <Ref. to ME(H4SO)-42, INSTALLATION, Crank Pulley.>
ME(H4SO)-6

T1: 5 (0.5, 3.6)
General Description
MECHANICAL
2. CYLINDER HEAD AND CAMSHAFT

(1)
(20)
(2)
T3
T2
T6
(26)
(4)
T4
(22)
(25)
T8
(7)
T5
(8)
(3)
(23)
T3
(24)
(6)
(5)
(8)
T1
(9)
(10)
(30)
(19)
(8)
(14)
(15)
T1
(16)
(7)
T6
T4
(10)
T8
(2)
(17)
(29)
(21)
(18)
(11)
(28) (27)
T7
(19)
(12)
T3
(5)
(13)
T4
T2
(31)
T5
T3
(3)
T5
ME(H4SO)-7
T2
ME-02998
General Description
MECHANICAL
(1)
(2)
Rocker cover (RH)

Intake valve rocker ASSY
(17)
(18)
O-ring
Rocker cover (LH)
(30)
Variable valve lift diagnosis oil

pressure switch (LH)
(3)
(4)
Exhaust valve rocker ASSY

Camshaft cap (RH)
(19)
(20)
Stud bolt
Rocker cover gasket (RH)
(31)
Seal washer
(5)
(6)
Oil seal
Camshaft (RH)
(21)
(22)
Rocker cover gasket (LH)

Oil switching solenoid valve (RH)
(7)
(8)
Plug
Spark plug pipe gasket
(23)
Oil switching solenoid valve holder

(RH)

T1: <Ref. to ME(H4SO)-58, INSTALLATION, Cylinder Head.>
(9)
(10)
Cylinder head (RH)

Cylinder head gasket
(24)
(25)
Gasket
Oil temperature sensor
(11)
Cylinder head (LH)
(26)
(12)
(13)
Camshaft (LH)
Camshaft cap (LH)

pressure switch (RH)
(27)
Oil switching solenoid valve (LH)
T4: 18 (1.8, 13.0)

T5: 25 (2.5, 18.1)
(14)
(15)
Oil filler cap

Gasket
(28)
Oil switching solenoid valve holder

(LH)
T6: 6.4 (0.65, 4.7)

T7: 8 (0.8, 5.9)
(16)
Oil filler duct
(29)
Gasket
T8: 10 (1.0, 7.4)
ME(H4SO)-8
T2: <Ref. to ME(H4SO)-51, INSTALLATION, Valve Rocker Assembly.>

T3: 9.75 (1.0, 7.2)
General Description
MECHANICAL
3. VALVE ROCKER ASSEMBLY
T2
T3
(1)
(1)
T1
(5)
(2)
(2)
(4)
T2
T2
(3)
(3)
T3
ME-02691
(1)
(2)
Intake valve rocker arm ASSY

Valve rocker nut
(3)
Valve rocker adjusting screw
(4)
(5)
Exhaust rocker shaft

Exhaust valve rocker arm

T1: 6 (0.6, 4.3)
T2: 9.75 (1.0, 7.2)
T3: 25 (2.5, 18.1)
ME(H4SO)-9
General Description
MECHANICAL
4. CYLINDER HEAD AND VALVE ASSEMBLY
(1)
(1)
(3)
(4)
(5)
(6)
(7)
(8)
(2)
(2)
(3)
(4)
(9)
(6)
(7)
(8)
ME-02743
(1)
(2)
Exhaust valve
Intake valve
(4)
(5)
Valve spring seat

Intake valve oil seal
(7)
(8)
Retainer
Retainer key
(3)
Valve guide
(6)
Valve spring
(9)
Exhaust valve oil seal
ME(H4SO)-10
General Description
MECHANICAL
5. CYLINDER BLOCK
T2
T2
T6
T4
(7)
(1)
(5)
T5
(29)
(2)
(6)
(3)
(4)
T2
T4
(28)
T10
T2
(10)
(8)
(11)
(9)
T2
(27)
T2
(10)
(4)
(3)
T4
(14)
(15)
(10)
T9
T10
(26)
T2
(23)
(10)
(4)
(28)
T10
(3)
(12)
(22)
(29)
T5
(16)
T2
T2
T3
T4
(24)
T7
(17)
T2
(13)
(25)
T1
(30)
(21)
(18)
(20)
(19)
T8
ME-03000
ME(H4SO)-11
General Description
MECHANICAL
(1)
(2)
Oil pressure switch

Cylinder block (RH)
(16)
(17)
Oil strainer
Gasket
(3)
(4)
Service hole plug

Gasket
(18)
(19)
Oil pan
Drain plug
T2: 6.4 (0.65, 4.7)

T3: 9.75 (1.0, 7.2)
(5)
(6)
Oil separator cover

Water by-pass pipe
(20)
(21)
Metal gasket
Oil level gauge guide
(7)
(8)
Oil pump
Front oil seal
(22)
(23)
Water pump sealing

Oil filter
T4: 25 (2.5, 18.1)

T5: <Ref. to ME(H4SO)-69, INSTALLATION, Cylinder Block.>
(9)
(10)
Rear oil seal

O-ring
(24)
(25)
Gasket
Water pump hose
T7: First 12 (1.2, 8.7)

Second 12 (1.2, 8.7)
(11)
Service hole cover
(26)
Plug
T8: 44 (4.5, 33)
(12)
(13)
Cylinder block (LH)

Water pump
(27)
(28)
Seal
Seal washer
(14)
(15)
Baffle plate
Oil filter connector
(29)
(30)
Washer
O-ring
ME(H4SO)-12

T1: 5 (0.5, 3.6)
T6: 16 (1.6, 11.6)
T9: 45 (4.6, 33.3)

T10: 70 (7.1, 50.6)
General Description
MECHANICAL
6. CRANKSHAFT AND PISTON
(1)
T2
(4)
(5)
(6)
(9)
(8)
(10)
(3)
T2
(11)
(9)
(7)
(13)
T1
(11)
(2)
(12)
T1
(9)
(11)
(7)
(10)
(14)
(17)
(8)
(9)
(6)
(4)
(5)
(16)
(15)
(15)
(16)
ME-02974
(1)
(2)
Flywheel (MT model)

Reinforcement (AT model)
(8)
(9)
Piston pin
Snap ring
(15)
(16)
Crankshaft bearing #1, #3

(3)
(4)
Drive plate (AT model)

Top ring
(10)
(11)
Connecting rod
Connecting rod bearing
(17)
Crankshaft bearing #5
(5)
(6)
Second ring
Oil ring
(12)
(13)
Connecting rod cap

Crankshaft

T1: 45 (4.6, 33.3)
(7)
Piston
(14)
Woodruff key
ME(H4SO)-13
T2: 72 (7.3, 52.8)
General Description
MECHANICAL
7. ENGINE MOUNTING
T2
T2
(2)
(2)
T1
(1)
(1)
T1
T3
T3
ME-00413
(1)
Front cushion rubber
(2)
Front engine mounting bracket

T1: 35 (3.6, 25.8)
T2: 42 (4.3, 31.0)
T3: 85 (8.7, 63)
ME(H4SO)-14
General Description
MECHANICAL
C: CAUTION
points.
the battery.
All parts should be thoroughly cleaned, paying
special attention to engine oil passages, pistons
and bearings.
Rotating parts and sliding parts such as piston,
bearing and gear should be coated with oil prior to
assembly.
Be careful not to let oil, grease or coolant contact
the timing belt, clutch disc and flywheel.
All removed parts, if to be reused, should be reinstalled in the original positions and directions.
Bolts, nuts and washers should be replaced with
new parts as required.
Even if necessary inspections have been made
in advance, proceed with assembly work while
making rechecks.
Remove or install the engine in an area where
chain hoists, lifting devices, etc. are available for
ready use.
Be sure not to damage coated surfaces of body
panels with tools, or not to stain seats and windows
with coolant or oil. Place a cover over fender, as required, for protection.
Prior to starting work, prepare the following:
Service tools, clean cloth, containers to catch coolant and oil, wire ropes, chain hoist, transmission
jacks, etc.
Lift-up or lower the vehicle when necessary.
Make sure to support the correct positions.
ME(H4SO)-15
General Description
MECHANICAL
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
18231AA010
CAM SPROCKET
WRENCH
Used for removing and installing cam sprocket.

(LH side)
CAMSHAFT SPROCKET WRENCH
(499207100) can also be used.
1B020XU0
SUBARU SELECT
MONITOR KIT
Used for troubleshooting the electrical system.
498267800
CYLINDER HEAD
TABLE
Used for replacing valve guides.

Used for removing and installing valve spring.
498277200
STOPPER SET
Used for installing automatic transmission

assembly to engine.
ST18231AA010
ST1B020XU0
ST-498267800
ST-498277200
ME(H4SO)-16
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
498457000
ENGINE STAND
ADAPTER RH
Used together with ENGINE STAND

(499817100).
498457100
ENGINE STAND
ADAPTER LH

(499817100).
498497100
CRANKSHAFT
STOPPER
Used for removing and installing the flywheel

and the drive plate.
498747300
PISTON GUIDE
Used for installing piston in cylinder.
498857100
VALVE OIL SEAL

GUIDE
Used for press-fitting of intake and exhaust valve

guide oil seals.
ST-498457000
ST-498457100
ST-498497100
ST-498747300
ST-498857100
ME(H4SO)-17
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
499017100
PISTON PIN GUIDE
Used for installing piston pin, piston and connecting rod.
REMARKS
499037100
CONNECTING ROD
BUSHING
REMOVER AND
INSTALLER
Used for removing and installing connecting rod

bushing.
499587200
CRANKSHAFT OIL
SEAL INSTALLER
Used for installing crankshaft oil seal.

Used together with CRANKSHAFT OIL SEAL
GUIDE (499597100).
499587500
OIL SEAL
INSTALLER
Used for installing camshaft oil seal.

Used together with OIL SEAL GUIDE
(499597000).
499587700
CAMSHAFT OIL
SEAL INSTALLER
Used for installing cylinder head plug.
ST-499017100
ST-499037100
ST-499587200
ST-499587500
ST-499587700
ME(H4SO)-18
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
499097700
PISTON PIN
REMOVER ASSY
Used for removing piston pin.
499207400
CAM SPROCKET
WRENCH

(RH side)
499497000
TORX PLUS
Used for removing and installing camshaft cap.
499587100
OIL SEAL
INSTALLER
Used for installing oil pump oil seal.
499597000
OIL SEAL GUIDE
Used for installing camshaft oil seal.

Used together with camshaft OIL SEAL
INSTALLER (499587500).
ST-499097700
ST-499207400
ST-499497000
ST-499587100
ST-499597000
ME(H4SO)-19
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
499597100
CRANKSHAFT OIL
SEAL GUIDE

499718000
VALVE SPRING
REMOVER
499767200
VALVE GUIDE
REMOVER
Used for removing valve guides.
499767400
VALVE GUIDE
REAMER
Used for reaming valve guides.
499767700
VALVE GUIDE
ADJUSTER
Used for installing valve guides. (Intake side)
ST-499597100
ST-499718000
ST-499767200
ST-499767400
ST-499767700
ME(H4SO)-20
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
499767800
VALVE GUIDE
ADJUSTER
Used for installing valve guides. (Exhaust side)
499817100
ENGINE STAND
Stand used for engine disassembly and

assembly.
ADAPTER RH (498457000) & LH (498457100).
499977100
CRANK PULLEY
WRENCH
Used for stopping rotation of crank pulley when

loosening/tightening crank pulley bolt.
18332AA000
OIL FILTER
WRENCH
Used for removing and installing oil filter.

(Outer diameter: 68 mm (2.68 in))
18332AA010
OIL FILTER
WRENCH
Used for removing and installing oil filter. (Outer

diameter: 65 mm (2.56 in))
ST-499767800
ST-499817100
ST-499977100
ST18332AA000
ST18332AA010
ME(H4SO)-21
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
499987500
CRANKSHAFT
SOCKET
Used for rotating crankshaft.
42099AE000
CONNECTOR
REMOVER
Used for removing the quick connector.
18354AA000
VALVE ROCKER
HOLDER
Used for installing the valve rocker assembly

(intake). (2 sets)
18258AA000
SPRING
INSTALLER
Used for installing the valve rocker assembly

(intake).
ST-499987500
ST42099AE000
ST18354AA000
ST18258AA000
2. GENERAL TOOL
TOOL NAME
REMARKS
Compression gauge
Vacuum gauge
Used for measuring compression.

Used for measuring negative pressure.
Oil pressure gauge

Fuel pressure gauge
Used for measuring oil pressure.

Used for measuring fuel pressure.
Timing light
Used for measuring ignition timing.
ME(H4SO)-22
General Description
MECHANICAL
E: PROCEDURE
It is possible to conduct the following service procedures with engine on vehicle, however, the procedures
described in this section are based on the condition that the engine is removed from vehicle.
V-belt
Timing belt
Valve rocker assembly
Camshaft
Cylinder head
ME(H4SO)-23
Compression
MECHANICAL
2. Compression
A: INSPECTION
CAUTION:
After warming-up, engine becomes very hot. Be
careful not to burn yourself during measurement.
1) After warming-up the engine, turn the ignition
switch to OFF.
2) Make sure that the battery is fully charged.
4) Remove all spark plugs. <Ref. to IG(H4SO)-4,
REMOVAL, Spark Plug.>
5) Fully open the throttle valve.
6) Check the starter motor for satisfactory performance and operation.
7) Hold the compression gauge tightly against the
spark plug hole.
NOTE:
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.
ME-00192
9) Perform at least two measurements per cylinder,

and make sure that the values are correct.
Compression (350 rpm and fully open throttle):
Standard:
1,020 1,275 kPa (10.4 13.0 kgf/cm2,
148 185 psi)
Service limit:
1,020 kPa (10.4 kgf/cm2, 148 psi)
Difference between cylinders:
49 kPa (0.5 kgf/cm2, 7 psi), or less
ME(H4SO)-24
Idle Speed
MECHANICAL
3. Idle Speed
12) Check the idle speed when loaded. (Turn the A/

C switch ON and operate the compressor for at
least one minute before measurement.)
A: INSPECTION
1) Before checking the idle speed, check the following item:
(1) Check the air cleaner element is free from
clogging, ignition timing is correct, spark plugs
are in good condition, and hoses are connected
properly.
(2) Check the malfunction indicator light does
not illuminate.
2) Warm up the engine.
3) Stop the engine, and turn the ignition switch to
OFF.
4) Connect the Subaru Select Monitor to the data
link connector.
Idle speed [A/C ON and gears in N or P

range]:
850100 rpm
NOTE:
Idle speed cannot be adjusted manually, because
the idle speed is automatically adjusted. If the prescribed idle speed cannot be maintained, refer to
the General On-board Diagnosis Table under Engine Control System. <Ref. to EN(H4SO)(diag)-2,
Basic Diagnostic Procedure.>
ME-00325
5) Turn the ignition switch to ON and run the Subaru Select Monitor.
6) Select {Each System Check} in Main Menu.
7) Select {Engine Control System} in Selection
Menu.
8) Select {Current Data Display & Save} in Engine
Control System Diagnosis.
9) Select {Data Display} in Data Display Menu.
10) Start the engine, and read the engine idle
speed.
11) Check the idle speed when no-loaded. (Headlight, heater fan, rear defroster, radiator fan, A/C
and etc. are OFF)
Idle speed [No load and gears in N or P
range]:
650100 rpm (MT model)
700100 rpm (AT model)
ME(H4SO)-25
Ignition Timing
MECHANICAL
4. Ignition Timing
A: INSPECTION
CAUTION:
careful not to burn yourself at measurement.
1) Before checking the ignition timing, check the
following item:
clogging, spark plugs are in good condition, and
hoses are connected properly.
(2) Make sure that the malfunction indicator
light does not illuminate.
2) Warm-up the engine.
3) When checking the ignition timing, connect the
timing light to the #1 cylinder spark plug cord and illuminate the timing mark with the timing light.
4) Start the engine and check the ignition timing at
idle speed as shown below.
Ignition timing [BTDC/rpm]:
108/650 (MT model)
158/700 (AT model)
20
10
ME-02676
If the timing is not correct, check the ignition control

system. <Ref. to EN(H4SO)(diag)-2, Basic Diagnostic Procedure.>
ME(H4SO)-26
Intake Manifold Vacuum

MECHANICAL
5. Intake Manifold Vacuum

A: INSPECTION
2) Disconnect the brake vacuum hose from intake manifold, and then install the vacuum gauge.
3) Keep the engine at idle speed and read the vacuum gauge indication.
By observing the gauge needle movement, internal condition of the engine can be diagnosed as described
below.
ME-02694
Vacuum pressure (at idling, A/C OFF):

60.0 kPa (450 mmHg, 17.72 inHg) or less
Diagnosis of engine condition by measurement of intake manifold vacuum
Vacuum gauge indication
1. Needle is steady but lower than normal position. This tendency becomes more evident as engine temperature rises.
2. Needle intermittently drops to position lower than normal
position.
Possible engine condition

Air leakage around intake manifold gasket, disconnection or
damage of vacuum hose
Leakage around cylinder
3. Needle drops suddenly and intermittently from normal position.
Sticky valve
4. When engine speed is gradually increased, needle begins to

vibrate rapidly at certain speed, and then vibration increases as
engine speed increases.
Weak or broken valve springs
5. Needle vibrates above and below normal position in narrow

range.
Defective ignition system
ME(H4SO)-27
Engine Oil Pressure

MECHANICAL
6. Engine Oil Pressure

A: INSPECTION
1) Remove the oil pressure switch. <Ref. to LU
(H4SO)-21, REMOVAL, Oil Pressure Switch.>
2) Connect the oil pressure gauge to cylinder block.
FU-00009
4) Start the engine, and measure the oil pressure.
ME-00196
Oil pressure:
Standard:
98 kPa (1.0 kg/cm2, 14 psi) or more at 600 rpm
294 kPa (3.0 kg/cm2, 43 psi) or more at 5,000
rpm
CAUTION:
If the oil pressure is out of standard values,
check the oil pump, oil filter and lubrication
line. <Ref. to LU (H4SO)-25, INSPECTION, Engine Lubrication System Trouble in General.>
If the oil pressure warning light is turned on
and oil pressure is in the specified range, check
the oil pressure switch. <Ref. to LU (H4SO)-25,
INSPECTION, Engine Lubrication System Trouble in General.>
NOTE:
Standard value is based on an engine oil temperature of 80C (176F).
5) After measuring the oil pressure, install the oil
pressure switch. <Ref. to LU (H4SO)-21, INSTALLATION, Oil Pressure Switch.>
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
ME(H4SO)-28
Fuel Pressure
MECHANICAL
7. Fuel Pressure
A: INSPECTION
CAUTION:
Before removing the fuel pressure gauge, release the fuel pressure.
NOTE:
If the fuel pressure is out of specification, check or
replace the fuel pump and fuel delivery line.
2) Disconnect the fuel delivery hose from fuel
damper, and connect fuel pressure gauge.
ME-02695
3) Connect the connector of fuel pump relay.
FU-02737
4) Start the engine.

5) Measure the fuel pressure after warming up the
engine.
Fuel pressure:
Standard:
339.5 360.5 kPa (3.5 3.7 kg/cm2, 49
52 psi)
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.
ME(H4SO)-29
Valve Clearance
MECHANICAL
8. Valve Clearance
10) Set #1 cylinder piston to top dead center of

compression stroke by rotating the crank pulley
clockwise using the socket wrench.
A: INSPECTION
NOTE:
Inspection and adjustment of valve clearance
should be performed while engine is cold.
NOTE:
When the arrow mark (A) on cam sprocket (LH)
comes exactly to the top, #1 cylinder piston is
brought to the top dead center of compression
stroke.
(A)
ME-00200
11) Measure #1 cylinder valve clearance by using

thickness gauge (A).
FU-00009
NOTE:
Insert a thickness gauge in as horizontally as
possible with respect to the valve stem end face.
Lift-up the vehicle and measure the exhaust
valve clearance.
Valve clearance (standard):
Intake
0.200.04 mm (0.00790.0016 in)
Exhaust
0.250.04 mm (0.00980.0016 in)
(A)
ME-00199
7) Remove the fuel injector. <Ref. to FU(H4SO)30, REMOVAL, Fuel Injector.>

8) When inspecting #1 and #3 cylinders:
(1) Disconnect the spark plug cords from spark
plugs RH side. <Ref. to IG(H4SO)-4, RH SIDE,
(2) Disconnect the PCV hose from rocker cover
(RH).
(3) Remove the bolts, then remove the rocker
cover (RH).
(1) Disconnect the spark plug cords from spark
plugs (LH side). <Ref. to IG(H4SO)-4, LH SIDE,
(LH).
cover (LH).
ME-02696
12) If necessary, adjust the valve clearance. <Ref.

to ME(H4SO)-31, ADJUSTMENT, Valve Clearance.>
ME(H4SO)-30
Valve Clearance
MECHANICAL
13) Measure the valve clearance in #3, #2 and #4

cylinder in the same measurement procedure as #1
cylinder.
NOTE:
Be sure to set the cylinder pistons to their respective top dead centers on compression stroke
before measuring valve clearances.
By rotating the crank pulley clockwise every 180
from the state that #1 cylinder piston is on the top
dead center of compression stroke, #3, #2 and #4
cylinder pistons come to the top dead center of
compression stroke in this order.
14) After inspection, install the related parts in the
reverse order of removal.
B: ADJUSTMENT
NOTE:
Adjustment of valve clearance should be performed while engine is cold.
1) Set #1 cylinder piston to top dead center of compression stroke by rotating the crank pulley clockwise using the socket wrench.
2) Adjust the #1 cylinder valve clearance.

(1) Loosen the valve rocker nut and screw.
(2) Set a suitable thickness gauge.
(3) While noting the valve clearance, tighten the
valve rocker adjusting screw.
(4) When the specified valve clearance is obtained, tighten the valve rocker nut.
Tightening torque:
9.75 Nm (1.0 kgf-m, 7.2 ft-lb)
NOTE:
Insert a thickness gauge in as horizontally as
possible with respect to the valve stem end face.
Lift-up the vehicle and adjust the exhaust valve
clearance.
Valve clearance:
Intake
0.200.04 mm (0.00790.0016 in)
Exhaust
0.250.04 mm (0.00980.0016 in)
NOTE:
When the arrow mark (A) on cam sprocket (LH)
comes exactly to the top, #1 cylinder piston is
brought to the top dead center of compression
stroke.
(A)
ME-00203
3) Adjust the valve clearance in #3, #2 and #4 cylinder in the same adjustment procedure as #1 cylinder.
ME-00200
NOTE:
Be sure to set the cylinder pistons to their respective top dead centers on compression stroke
before adjusting valve clearances.
By rotating the crank pulley clockwise every 180
from the state that #1 cylinder piston is on the top
dead center of compression stroke, #3, #2 and #4
cylinder pistons come to the top dead center of
compression stroke in this order.
4) Ensure the valve clearances of each cylinder are
within specifications. If necessary, readjust the
valve clearances.
ME(H4SO)-31
Engine Assembly
MECHANICAL
9. Engine Assembly
A: REMOVAL
2) Open the front hood fully and support with the
front food stay.
3) Collect the refrigerant from the A/C system.
<Ref. to AC-19, PROCEDURE, Refrigerant Recovery Procedure.>
12) Disconnect the following connectors and cables.

(1) Front oxygen (A/F) sensor connector
(2) Rear oxygen sensor connector
(A)
(B)
FU-02734

(3) Engine ground cable
FU-00009
filler cap.
7) Remove the air intake duct, air cleaner case and
air intake chamber.
<Ref. to IN (H4SO)-7, REMOVAL, Air Intake Duct.>
Case.> <Ref. to IN (H4SO)-6, REMOVAL, Air Intake Chamber.>
9) Remove the radiator from the vehicle. <Ref. to
CO(H4SO)-27, REMOVAL, Radiator.>
10) Disconnect the A/C pressure hoses from A/C
compressor.
11) Remove the air intake chamber stay.
ME-00206
(4) Engine harness connectors
ME-02697
(5) Generator connector and terminal

(A)
ME-00816
(B)
ME-00818
(A) Terminals
(B) Generator connector
ME(H4SO)-32
Engine Assembly
MECHANICAL
(6) A/C compressor connector
(3) Remove the bolts which secure the power

steering pump to the bracket.
ME-00819
FU-00139
(7) Power steering switch connector

from the bracket by pulling it upwards.
ME-03004
13) Disconnect the following hoses.

(1) Brake booster vacuum hose
FU-02572

side wheel apron.
ME-02698
(2) Heater inlet and outlet hoses

14) Remove the power steering pump.
(1) Remove the front side V-belts. <Ref. to
ME(H4SO)-40, FRONT SIDE BELT, REMOVAL, V-belt.>
steering pipes onto the fuel pipe protector RH.
FU-00140
15) Remove the front and center exhaust pipes.

<Ref. to EX (H4SO)-4, REMOVAL, Front Exhaust
Pipe.>
16) Remove the bolts and nuts which hold lower
side of transmission to engine.
FU-02807
ME(H4SO)-33
ME-00210
Engine Assembly
MECHANICAL
17) Remove the nuts which install front cushion

rubber onto front crossmember.
20) Disconnect the fuel hoses from fuel pipe.

of the arrow.
CAUTION:
or cloth.
ME-02650
18) Separate the torque converter clutch from drive

plate. (AT model)
(1) Lower the vehicle.
(2) Remove the service hole plug.
(3) Remove the bolts which hold torque converter clutch to drive plate.
(4) Remove other bolts while rotating the crankshaft using socket wrench.
(A)
(B)
FU-02715

21) Support the engine with a lifting device and

wire ropes.
ME-00212
19) Remove the pitching stopper.
LU-00222
ME-00213
ME(H4SO)-34
Engine Assembly
MECHANICAL
22) Support the transmission with a garage jack.

CAUTION:
Be sure to always perform this work, in order to
prevent the transmission from lowering for its
own weight.
25) Remove the engine from vehicle.

(1) Slightly raise the engine.
(2) Raise the transmission with garage jack.
(3) Move the engine horizontally until main
shaft is withdrawn from clutch cover.
(4) Slowly lift the engine away from the engine
compartment.
NOTE:
Be careful not to damage adjacent parts or body
panels with crank pulley, oil level gauge, etc.
26) Remove the front cushion rubbers.
(A)
(B)
B: INSTALLATION
1) Install the front cushion rubbers.
ME-00215
(A) Transmission
(B) Garage jack
CAUTION:
Before removing the engine away from transmission, check to be sure no work has been
overlooked.
23) Separation of engine and transmission.
(1) Remove the starter. <Ref. to SC (H4SO)-6,
REMOVAL, Starter.>
(2) Remove the bolts which hold upper side of
transmission to engine.
Tightening torque:
35 Nm (3.6 kgf-m, 25.8 ft-lb)
2) Apply a small amount of grease to splines of
mainshaft. (MT model)
3) Position the engine in engine compartment and
connect the engine to the transmission.
NOTE:
LU-00222
4) Tighten the bolts which hold upper side of transmission to engine.

ME-00216
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
24) Attach the ST to converter case. (AT model)

ST 498277200
STOPPER SET
ME-00216
ST
ME-00217
5) Remove the lifting device and wire ropes.

6) Remove the garage jack.
ME(H4SO)-35
Engine Assembly
MECHANICAL
7) Install the pitching stopper.
11) Install the power steering pump.

(1) Install the power steering reservoir tank to
the bracket.
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
T2: 58 Nm (5.9 kgf-m, 42.8 ft-lb)
FU-02572
T2
T1
ME-00218
8) Remove the ST from converter case. (AT model)

NOTE:
Be careful not to drop the ST into the converter
case when removing the ST.
ST 498277200
STOPPER SET
9) Install the starter. <Ref. to SC (H4SO)-6, INSTALLATION, Starter.>
10) Install the torque converter clutch to drive plate.
(AT model)
(1) Tighten the bolts which hold torque converter clutch to drive plate.
(2) Tighten other bolts while rotating the crankshaft using socket wrench.
NOTE:
Be careful not to drop bolts into the torque converter clutch housing.
(2) Install the power steering pump to the bracket, and tighten the bolts.
Tightening torque:
22 Nm (2.2 kgf-m, 16 ft-lb)
FU-00139
(3) Install the pipe along with the bracket.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
FU-02807
(4) Connect the power steering switch connector.

ME-00212
(3) Install the service hole plug to prevent getting foreign matter inside.
ME-03004
ME(H4SO)-36
Engine Assembly
MECHANICAL
(5) Install and adjust the front side belt. <Ref. to

ME(H4SO)-40, FRONT SIDE BELT, INSTALLATION, V-belt.>
13) Tighten the bolts and nuts which hold lower
side of the transmission to engine.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
ME-00219
14) Tighten the nuts which install the front cushion

rubber onto crossmember.
Tightening torque:
85 Nm (8.7 kgf-m, 63 ft-lb)
NOTE:
Make sure the front cushion rubber mounting bolts
(A) and locator (B) are securely installed.
20) Tighten the engine ground cable.

Tightening torque:
14 Nm (1.4 kgf-m, 10.1 ft-lb)
21) Install the A/C pressure hoses. <Ref. to AC-34,
INSTALLATION, Hose and Tube.>
22) Install the radiator to vehicle. <Ref. to
CO(H4SO)-29, INSTALLATION, Radiator.>
23) Install the air intake duct, air cleaner case and
air intake chamber. <Ref. to IN (H4SO)-7, INSTALLATION, Air Intake Duct.> <Ref. to IN (H4SO)-5,
INSTALLATION, Air Cleaner Case.> <Ref. to IN
25) Install the battery in the vehicle, and connect
cables.
26) Fill engine coolant.
<Ref. to CO(H4SO)-18, FILLING OF ENGINE
COOLANT, REPLACEMENT, Engine Coolant.>
27) Check the ATF level and replenish it if necessary.
<Ref. to 4AT-28, INSPECTION, Automatic Transmission Fluid.>
28) Charge the A/C system with refrigerant. <Ref.
to AC-20, PROCEDURE, Refrigerant Charging
Procedure.>
29) Remove the front hood stay, and close the front
hood.
30) Lower the vehicle from lift.
C: INSPECTION
(B)
(A)
(A)
(B)
ME-02651
1) Check that pipes, hoses, connectors and clamps

are installed firmly.
2) Check the engine coolant and ATF are at specified levels.
3) Start the engine and check for exhaust gas, engine coolant, leaks of fuel, etc. Also check for noise
and vibrations.
15) Install the front and center exhaust pipe.

<Ref. to EX (H4SO)-5, INSTALLATION, Front Exhaust Pipe.>
17) Connect the following hoses.
(1) Fuel delivery hose, and evaporation hose
18) Connect the following connectors.
19) Install the air intake chamber stay.
Tightening torque:
16 Nm (1.6 kgf-m, 11.6 ft-lb)
ME(H4SO)-37
Engine Mounting
MECHANICAL
10.Engine Mounting
A: REMOVAL
1) Remove the engine unit. <Ref. to ME(H4SO)-32,
REMOVAL, Engine Assembly.>
2) Remove the engine mounting from engine assembly.
B: INSTALLATION
Tightening torque:
Engine mounting
35 Nm (3.6 kgf-m, 25.8 ft-lb)
C: INSPECTION
Make sure that no crack or other damages do not
exist.
ME(H4SO)-38
Preparation for Overhaul

MECHANICAL
11.Preparation for Overhaul

A: PROCEDURE
1) After removing the engine from body, secure it to
ST in the following procedure.
ST1 498457000 ENGINE STAND ADAPTER
RH
LH
ST3 499817100 ENGINE STAND
ST3
ST2
ST1
ME-00221
2) In this section the procedures described under

each index are all connected and stated in order.
The procedure for overhauling of the engine will be
completed 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 previously in order to do that particular procedure.
ME(H4SO)-39
V-belt
MECHANICAL
12.V-belt
4) Remove the belt tensioner.
A: REMOVAL
NOTE:
Perform the work with the engine installed to body
when replacing a single part.
1. FRONT SIDE BELT

ME-00225
B: INSTALLATION
CAUTION:
Wipe off any oil and water on the belt and pulley.
1. FRONT SIDE BELT

ME-03005

4) Remove the front side belt (C).
(C)
1) Install the front side belt (C), and tighten the slider bolt so as to obtain the specified belt tension.
<Ref. to ME(H4SO)-41, INSPECTION, V-belt.>
Tightening torque:
Lock bolt (A)
25 Nm (2.5 kgf-m, 18.1 ft-lb)
Slider bolt (B)
8 Nm (0.8 kgf-m, 5.8 ft-lb)
(B)
(A)
ME-02699
(C)
(B)
2. REAR SIDE BELT

(A)
(B)
ME-02699
(A)
ME-00224
ME(H4SO)-40
V-belt
MECHANICAL
2. REAR SIDE BELT

1) Install the belt tensioner.
2) Install a rear side belt, and tighten the slider bolt
(B) so as to obtain the specified belt tension.
<Ref. to ME(H4SO)-41, INSPECTION, V-belt.>
(B)
When installing new parts
650 750 N (66 76 kgf, 146 169 lb)
At inspection
350 450 N (36 46 kgf, 78 101 lb)
(A)
Tightening torque:
Lock nut (A)
23 Nm (2.3 kgf-m, 17.0 ft-lb)
P/S
A/C
GEN
(B)
(B)
I/P
C/P
PM-00154
(A)
(A) Front side belt

(B) Rear side belt
ME-00224
C/P Crank pulley

GEN Generator
C: INSPECTION
1) Replace the belts, if crack, fraying or wear is found.
2) Remove the V-belt cover and reservoir tank.
(with belt tension gauge)
3) Check the V-belt tension and adjust it if necessary by changing the generator installing position
or idler pulley installing position.
Belt tension (with belt tension gauge):
(A)
640 780 N (65 80 kgf, 144 175 lb)
At inspection
490 640 N (50 65 kgf, 110 144 lb)

A/C Air conditioning compressor pulley
I/P Idler pulley
Belt tension (without belt tension gauge):

(A)
7 9 mm (0.276 0.354 in)
At inspection
9 11 mm (0.354 0.433 in)
(B)
7.5 8.5 mm (0.295 0.335 in)
At inspection
9.0 10.0 mm (0.354 0.394 in)
98 N (10 kg, 22 Ib)
P/S
GEN
(A) (B)
A/C
I/P
C/P
ME-00226
(A) Front side belt

(B) Rear side belt
C/P Crank pulley
GEN Generator
I/P Idler pulley
ME(H4SO)-41
Crank Pulley
MECHANICAL
13.Crank Pulley
3) Check that the tightening angle of the clamp pulley bolt is a minimum of 65. Perform the following
procedure when less than 65.
A: REMOVAL
NOTE:
1) Remove the V-belts. <Ref. to ME(H4SO)-40,
REMOVAL, V-belt.>
2) Remove the crank pulley bolt. To lock the crankshaft, use ST.
ST 499977100
CRANK PULLEY WRENCH
ST
ME-00227
B: INSTALLATION
1) Install the crank pulley.
2) Install the pulley bolt.
To lock the crankshaft, use ST.
ST 499977100
CRANK PULLEY WRENCH
(1) Clean the crankshaft thread using compressed air.
(2) Apply engine oil to the crank pulley bolt seat
and thread.
(3) Tighten the bolts temporarily with tightening
torque of 44 Nm (4.5 kgf-m, 33 ft-lb).
(4) Tighten the crank pulley bolts.
Tightening torque:
180 Nm (18.4 kgf-m, 132.8 ft-lb)
CAUTION:
If the tightening angle of crank pulley bolt is
less than 65, the bolt is damaged. In this case,
the bolt must be replaced.
(1) Replace the crank pulley bolts and clean
them.
Crank pulley bolt:
12369AA011
and thread.
(5) Tighten the crank pulley bolt keeping them
in an angle between 65 and 75.
NOTE:
Conduct the tightening procedures by confirming
the turning angle of crank pulley bolt referring to the
gauge indicated on timing belt cover.
ME-00225
5) Install the V-belts. <Ref. to ME(H4SO)-40, INSTALLATION, V-belt.>
C: INSPECTION
1) Make sure the V-belt is not worn or otherwise
damaged.
2) Check the tension of the belt. <Ref. to
ME(H4SO)-41, INSPECTION, V-belt.>
ST
ME-00227
ME(H4SO)-42
Timing Belt Cover

MECHANICAL
14.Timing Belt Cover

A: REMOVAL
NOTE:
REMOVAL, V-belt.>
2) Remove the crank pulley. <Ref. to ME(H4SO)42, REMOVAL, Crank Pulley.>
4) Remove the front timing belt cover.
(B)
(A)
ME-00821
(A) Timing belt cover (LH)

(B) Front timing belt cover
B: INSTALLATION
1) Install the front timing belt cover.
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
2) Install the timing belt cover (LH).
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
(B)
(A)
ME-00821
(A) Timing belt cover (LH)

(B) Front timing belt cover
3) Install the crank pulley. <Ref. to ME(H4SO)-42,

INSTALLATION, Crank Pulley.>
C: INSPECTION
Check the cover for damage.
ME(H4SO)-43
Timing Belt
MECHANICAL
15.Timing Belt
A: REMOVAL
(d)
1. TIMING BELT
(c)
NOTE:
when replacing a single part. For operation procedures, refer to Timing Belt of the PM section.
<Ref. to PM-12, Timing Belt.>
REMOVAL, V-belt.>
3) Remove the timing belt cover. <Ref. to
ME(H4SO)-43, REMOVAL, Timing Belt Cover.>
(b)
(a)
(f)
(e)
ME-00232
(2) Using white paint, put an alignment mark

and an arrow mark on timing belts in relation to
the crank sprocket and cam sprockets.
ME-00065
5) If the alignment mark or arrow mark (which indicates the direction of rotation) on timing belt fade
away, put new marks before removing the timing
belt as shown in procedures below.
(1) Use the ST to turn crankshaft. Align the
mark (a) of sprocket to the cylinder block notch
(b), and then ensure the right side cam sprocket
mark (c), cam cap and cylinder head matching
surface (d) or left side cam sprocket mark (e),
timing belt cover notch (f) are properly adjusted.
ST 499987500
CRANKSHAFT SOCKET
ME-02967
Specified data:
Z1: Length of 46.8-teeth
Z2: Length of 43.7-teeth
Z1
Z2
ST
ME-00231
ME-00234
6) Remove the belt idler (A).
ME(H4SO)-44
Timing Belt
MECHANICAL
B: INSTALLATION
7) Remove the belt idler (B).
1. AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER

1) Preparation for installation of automatic belt tension adjuster assembly.
(A)
(B)
ME-02968
ME-00236
2. BELT IDLER AND AUTOMATIC BELT

TENSION ADJUSTER ASSEMBLY
1) Remove the belt idler (No. 1).
CAUTION:
Always use a vertical type pressing tool to
move the adjuster rod down.
Do not use a lateral type vise.
Push the adjuster rod vertically.
Press-in the push adjuster rod gradually taking more than three minutes.
Do not allow press pressure to exceed 9,807
N (1,000 kgf, 2,205 lb).
Press the adjuster rod as far as the end surface of the cylinder. Do not press the adjuster
rod into cylinder. Doing so may damage the cylinder.
Do not release the press pressure until stopper pin is completely inserted.
(1) Attach the automatic belt tension adjuster
assembly to vertical pressing tool.
(2) Slowly move the adjuster rod down with a
pressure of more than 294 N (30 kgf, 66 lb) until
the adjuster rod is aligned with the stopper pin
hole in the cylinder.
ME-02404
ME-00239
(3) With a 2 mm (0.08 in) dia. stopper pin or a 2

mm (0.08 in) (nominal) dia. hex wrench inserted
into the stopper pin hole in cylinder, secure the
adjuster rod.
ME-00238
ME-00350
ME(H4SO)-45
Timing Belt
MECHANICAL
2) Install the automatic belt tension adjuster assembly.

Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
3) While aligning the alignment mark (B) on timing

belt with the mark (A) on sprockets, position the
timing belt properly.
ME-00244
ME-00241
4) Install the belt idler (A) and (B).

Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
3) Install the belt idler (No. 1).

Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
(A)
(B)
ME-02404
2. TIMING BELT
5) After ensuring the marks on timing belt and camshaft sprockets are aligned, remove the stopper pin
from belt tension adjuster.
1) Prepare for installation of the automatic belt tension adjuster assembly. <Ref. to ME(H4SO)-45,
AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER, INSTALLATION,
Timing Belt.>
2) Turn the camshaft sprocket No. 2 using ST1,
and turn the camshaft sprocket No. 1 using ST2 so
that their alignment marks (A) come to top positions.
ST1 18231AA010 CAM SPROCKET WRENCH
NOTE:
CAM SPROCKET WRENCH (499207100) can
also be used.
ST2 499207400 CAM SPROCKET WRENCH
ME-02968
ME-00245
6) Install the timing belt guide. (MT model)

(1) Temporarily tighten the bolts mounting the
timing belt guide.
(A)
ME-00230
ME-00243
ME(H4SO)-46
Timing Belt
MECHANICAL
(2) Check and adjust the clearance between

timing belt and timing belt guide by using thickness gauge.
C: INSPECTION
1. TIMING BELT
1) Check the timing belt teeth for breaks, cracks or
wear. If any fault is found, replace the belt.
2) Check the condition of the backside of belt. If
cracks are found, replace the belt.
Clearance:
1.00.5 mm (0.0390.020 in)
CAUTION:
Be careful not to let oil, grease or coolant
contact the belt. Remove quickly and thoroughly if this happens.
Do not bend the timing belt sharply.
In radial diameter h:
60 mm (2.36 in) or more
ME-00246
(3) Tighten the bolts mounting the timing belt

guide.
Tightening torque:
9.75 Nm (1.0 kgf-m, 7.2 ft-lb)
ME-00248
ME-00247
7) Install the timing belt cover.

<Ref. to ME(H4SO)-43, INSTALLATION, Timing
Belt Cover.>
ME(H4SO)-47
Timing Belt
MECHANICAL
2. AUTOMATIC BELT TENSION ADJUSTER

1) Visually check the oil seals for leaks, and rod
ends for abnormal wear and scratches. If necessary, replace the automatic belt tension adjuster
assembly.
NOTE:
Slight traces of oil at rods oil seal does not indicate
a problem.
2) Check that the adjuster rod does not move when
a pressure of 294 N (30 kgf, 66 lb) is applied to it.
This is to check the adjuster rod stiffness.
3) If the adjuster rod is not stiff enough and moves
freely when applying a pressure of 294 N (30 kgf,
66 lb), check it using the following procedures.
(1) Slowly press the adjuster rod down to the
end surface of cylinder. Repeat this operation
two to three times.
(2) With the adjuster rod moved all the way up,
apply a pressure of 294 N (30 kgf, 66 lb) to it.
Check the adjuster rod movement.
(3) If the adjuster rod is not stiff enough and
moves down, replace the automatic belt tension
adjuster assembly with a new part.
3. BELT TENSION PULLEY

1) Check the mating surfaces of timing belt and
contact point of adjuster rod for abnormal wear or
scratches. Replace the automatic belt tension adjuster assembly if faulty.
2) Check the belt tension pulley for smooth rotation. Replace if noise or excessive play occurs.
3) Check the belt tension pulley for grease leakage.
4. BELT IDLER
1) Check the belt idler for smooth rotation. Replace
if noise or excessive play occurs.
2) Check the outer contacting surfaces of idler pulley for abnormal wear and scratches.
3) Check the belt idler for grease leakage.
CAUTION:
Press the adjuster rod gradually taking more
than three minutes.
N (1,000 kgf, 2,205 lb).
Press the adjuster rod to the end surface of
the cylinder. Do not press the adjuster rod into
cylinder. Doing so may damage the cylinder.
4) Measure the rod protrusion amount (H) from the
body edge. If it is not within specified range, replace with new part.
Amount of rod protrusion H:
5.2 6.2 mm (0.204 0.244 in)
ME-00249
ME(H4SO)-48
Cam Sprocket
MECHANICAL
16.Cam Sprocket
NOTE:
Do not confuse left and right side cam sprockets
during installation. Identify by L or R markings.
A: REMOVAL
NOTE:
REMOVAL, V-belt.>
4) Remove the timing belt. <Ref. to ME(H4SO)-44,
REMOVAL, Timing Belt.>
5) Remove the camshaft position sensor. <Ref. to
FU(H4SO)-24, REMOVAL, Camshaft Position
Sensor.>
6) Remove the cam sprocket No. 2. To lock the
camshaft, use the ST.
ST 18231AA010 CAM SPROCKET WRENCH
NOTE:
also be used.
ST
ME-00251
2) Install the cam sprocket No. 2. To lock the camshaft, use the ST.
NOTE:
also be used.
Tightening torque:
78 Nm (8.0 kgf-m, 57.9 ft-lb)
ST
ME-00250
ST
ME-00250
7) Remove the cam sprocket No. 1. To lock the

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

FU(H4SO)-24, INSTALLATION, Camshaft Position
Sensor.>
4) Install the timing belt. <Ref. to ME(H4SO)-45,
INSTALLATION, Timing Belt.>
Belt Cover.>
C: INSPECTION
ME-00251
B: INSTALLATION
1) Install the cam sprocket No. 1. To lock the camshaft, use the ST.
ST 499207400
CAM SPROCKET WRENCH
Tightening torque:
78 Nm (8.0 kgf-m, 57.9 ft-lb)
1) Check the cam sprocket teeth for abnormal wear

and scratches.
2) Make sure there is no free play between cam
sprocket and key.
3) Check the cam sprocket protrusion used for sensor for damage and contamination of foreign matter.
ME(H4SO)-49
Crank Sprocket
MECHANICAL
17.Crank Sprocket
C: INSPECTION
A: REMOVAL
1) Check the crank sprocket teeth for abnormal

wear and scratches.
2) Make sure there is no free play between crank
sprocket and key.
3) Check the crank sprocket protrusion used for
sensor for damage and contamination of foreign
matter.
NOTE:
REMOVAL, V-belt.>
5) Remove the crank sprocket.
ME-00103
B: INSTALLATION
1) Install the crank sprocket.
ME-00103

Belt Cover.>
ME(H4SO)-50
Valve Rocker Assembly

MECHANICAL
18.Valve Rocker Assembly
(2) Remove the bolts (a) through (j) in alphabetical sequence.
A: REMOVAL
NOTE:
when replacing a single part. Refer to Valve Clearance for preparation. <Ref. to ME(H4SO)-30,
Valve Clearance.>
REMOVAL, V-belt.>
5) Remove the cam sprocket. <Ref. to ME(H4SO)49, REMOVAL, Cam Sprocket.>
6) Disconnect the PCV hose and remove the rocker cover.
7) Remove the valve rocker assembly.
(1) Use the ST to rotate the spring stopper in
the direction of the arrow to remove it from adjuster pin.
ST 18258AA000 SPRING INSTALLER
NOTE:
Leave two or three threads of bolts (i) and (j) engaged in order to retain the valve rocker assembly.
(d)
(a)
(j)
(h)
(b)
(f)
(c)
(e)
(g)
(i)
ME-02975
(3) Remove the valve rocker assembly.

NOTE:
Set the ST in the position shown in the drawing to
remove the intake valve rocker assembly.
ST 18354AA000 VALVE ROCKER HOLDER
ST
ME-02702
B: INSTALLATION
ST
ME-02704
1) Install the valve rocker assembly.

(1) Temporarily tighten the bolts equally in alphabetical order as shown in the figure.
NOTE:
Do not temporarily tighten the bolts (i) and (j).
Set the ST in the position shown in the drawing to
mount the intake valve rocker assembly.
ST 18354AA000 VALVE ROCKER HOLDER
(A)
(B)
(C)
ME-02744
(A) Adjuster pin

(B) Spring stopper
(C) Spring
ST
ME(H4SO)-51
ME-02702

MECHANICAL
(2) Tighten the bolts (a) through (h) to specified

torque.
5) Install the rocker cover and rocker cover gasket,

and then connect PCV hose.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
(3) Tighten the bolts (i) through (j) to specified
torque.
NOTE:
Use a new rocker cover gasket.
Tighten the bolts in two stages in alphabetical
sequence as shown in figure.
Tightening torque:
6 Nm (0.6 kgf-m, 4.3 ft-lb)
Tightening torque:
First time
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
Second time (tighten only (a) and (b))
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
RH side
(g)
(i)
(a)
(c)
(j)
(e)
(f)
(a)
(c)
(h)
(f)
(d)
(b)
ME-02703
(4) Use the ST to rotate the spring stopper in

the direction of the arrow to fasten the adjuster
pin.
ST 18258AA000 SPRING INSTALLER
(d)
(b)
(e)
ME-02715
LH side
(f)
(a)
(c)
ST
ME-02704
(d)
(b)
(e)
ME-02716
6) Install the timing belt cover. <Ref. to ME(H4SO)43, INSTALLATION, Timing Belt Cover.>
(A)
(B)
C: DISASSEMBLY
(C)
ME-02705
(A) Adjuster pin

(B) Spring stopper
(C) Spring
2) Install the cam sprocket. <Ref. to ME(H4SO)-49,

INSTALLATION, Cam Sprocket.>
4) Adjust the valve clearance. <Ref. to ME(H4SO)31, ADJUSTMENT, Valve Clearance.>
NOTE:
Intake valve rocker assembly cannot be disassembled.
1) Remove the exhaust valve rocker arm from the
rocker shaft.
NOTE:
Keep all the removed parts in order for re-installing
in their original positions.
2) Remove the nut and adjusting screw from exhaust valve rocker.
ME(H4SO)-52

MECHANICAL
D: ASSEMBLY
NOTE:
Intake valve rocker assembly cannot be disassembled.
1) Install the adjusting screw and nut to the exhaust
valve rocker.
2) Insert the exhaust valve rocker arm to rocker
shaft.
NOTE:
Valve rocker arms, and rocker shaft have identification marks. Make sure the parts with same markings are properly assembled.
2) If the oil clearance exceeds the limit, replace the

valve rocker arm or shaft, whichever shows greater
amount of wear.
Rocker arm inside diameter:
22.020 22.041 mm (0.8669 0.8678 in)
Rocker shaft diameter:
21.987 22.000 mm (0.8656 0.8661 in)
3) If the roller or valve contact surface of valve
rocker arm is worn or dented excessively, replace
the valve rocker arm.
4) Check that the valve rocker arm roller rotates
smoothly. If not, replace the valve rocker arm.
E: INSPECTION
1. INTAKE VALVE ROCKER ASSEMBLY
1) If the roller or valve contact surface of valve
rocker arm is worn or dented excessively, replace
the valve rocker assembly.
2) Check that the valve rocker arm roller rotates
smoothly. If not, replace the valve rocker assembly.
2. EXHAUST VALVE ROCKER ASSEMBLY

1) Measure the inner diameter of valve rocker arm
and outer diameter of valve rocker shaft, and confirm the difference (oil clearance) between the two
values.
Clearance between arm and shaft:
Standard:
0.020 0.054 mm (0.0008 0.0021 in)
Service limit:
0.10 mm (0.0039 in)
ME-02706
ME-00257
ME(H4SO)-53
Camshaft
MECHANICAL
19.Camshaft
12) Remove the camshaft cap.

(1) Remove the bolts (a) and (b) in alphabetical
sequence.
A: REMOVAL
NOTE:
Valve Clearance.>
REMOVAL, V-belt.>
6) Remove the timing belt cover No. 2 (LH).
7) Remove the timing belt cover No. 2 (RH).
(a)
(b)
ME-02707
(2) Equally loosen the bolts (c) through (j) all the
way in alphabetical sequence.
(j)
(h)
(d)
(f)
NOTE:
Do not damage or lose the seal rubber when removing the timing belt covers.
(e)
(c)
(g)
(i)
ME-02708
(3) Remove the bolts (k) through (p) in alphabetical sequence using ST.
ST 499497000
TORX PLUS
(n)
(p)
(l)
ME-00258
8) Remove the tensioner bracket.

(m)
(k)
(o)
ME-02709
(4) Remove the camshaft cap.

13) Remove the camshaft.
14) Remove the oil seal.
15) Remove the plug from rear side of camshaft.
ME-00259
9) Remove the camshaft position sensor support.

(LH side only)
10) Remove the oil level gauge guide. (LH side
only)
11) Remove the valve rocker assembly. <Ref. to
ME(H4SO)-51, REMOVAL, Valve Rocker Assembly.>
CAUTION:
Do not remove the oil seal unless necessary.
Do not scratch the journal surface when removing the oil seal.
ME(H4SO)-54
Camshaft
MECHANICAL
B: INSTALLATION
1) Apply a thin coat of engine oil to camshaft journals, and install the camshaft.
2) Install the camshaft cap.
(1) Apply liquid gasket to the mating surfaces of
camshaft cap.
(4) Tighten the TORX bolts (e) through (j) in alphabetical sequence using ST.
ST 499497000
TORX PLUS
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
(e)
(g)
(i)
Liquid gasket:
THREE BOND 1280B
(Part No. K0877YA018)
(h)
(j)
(f)
ME-02712
(5) Tighten the bolts (k) through (r) in alphabetical sequence.

ME-02710
NOTE:
Apply a coat of liquid gasket of 3 mm (0.12 in) in
diameter (A) along the edge (B) of camshaft cap
(C) mating surface.
Install within 5 min. after applying liquid gasket.
Tightening torque:
9.75 Nm (1.0 kgf-m, 7.2 ft-lb)
(k)
(m)
(q)
(o)
(A)
(p)
(r)
(n)
ME-02713
(6) Tighten the bolts (s) and (t) in alphabetical

sequence.
(B)
(C)
ME-00265
(2) Temporarily tighten the bolts (a) through (d)

in alphabetical sequence.
(c)
(l)
NOTE:
Use new seal washer.
Install and tighten the seal washer.
Tightening torque:
9.75 Nm (1.0 kgf-m, 7.2 ft-lb)
(a)
(s)
(b)
(d)
(t)
ME-02711
(3) Install the valve rocker assembly.

<Ref. to ME(H4SO)-51, INSTALLATION, Valve
Rocker Assembly.>
ME(H4SO)-55
ME-02714
Camshaft
MECHANICAL
3) Apply a coat of engine oil to the oil seal periphery

and oil seal lip, then install the oil seal (A) on camshaft using ST1 and ST2.
RH side
(f)
(a)
(c)
NOTE:
Use a new oil seal.
ST1 499597000 OIL SEAL GUIDE
ST2 499587500 OIL SEAL INSTALLER
(d)
ST1
(b)
(e)
ME-02715
LH side
(f)
(a)
(c)
ST2
(A)
ME-02596
4) Install the plug (A) using ST.

ST 499587700
CAMSHAFT OIL SEAL INSTALLER
(d)
(b)
(e)
ME-02716
7) Install the oil level gauge guide. (LH side only)

8) Install the camshaft position sensor support. (LH
side only)
9) Install the tensioner bracket.
(A)
ST
Tightening torque:
24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
ME-02717

6) Install the rocker cover and rocker cover gasket,
and then connect PCV hose.
NOTE:
Tighten the bolts in two stages in alphabetical
sequence as shown in figure.
Tightening torque:
First time
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
Second time (tighten only (a) and (b))
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
ME-00273
10) Install the timing belt cover No. 2 (RH).

Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
ME(H4SO)-56
Camshaft
MECHANICAL
4) Check the cam face condition, and remove the

minor faults by grinding with oil stone. Measure the
cam height H. If it exceeds the limit, replace it.
11) Install the timing belt cover No. 2 (LH).

Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
Cam height H:
Part
Constant
Unit: mm (in)
Standard
Limit
Intake
Low speed
Standard
Limit
ME-00274
12) Install the cam sprocket. <Ref. to ME(H4SO)49, INSTALLATION, Cam Sprocket.>
Belt Cover.>
C: INSPECTION
1. CAMSHAFT
High speed
Standard
Limit
Standard
Exhaust
Limit
40.075 40.175
(1.5778 1.5817)
39.975 (1.5738)
35.182 35.282
(1.3851 1.3891)
35.082 (1.3812)
40.315 40.415
(1.5872 1.5911)
40.215 (1.5833)
40.149 40.249
(1.5807 1.5846)
40.049 (1.5767)
Cam base circle diameter A:

Intake
34.00 mm (1.3386 in)
Exhaust
34.00 mm (1.3386 in)
Base circle step of adjacent intake cams (low
speed and high speed):
0.03 mm (0.001 in) or less
1) Measure the bend, and repair or replace if necessary.

Service limit:
0.025 mm (0.00098 in)
ME-00275
2) Check the journal for damage and wear. Replace if faulty.

3) Measure the outer diameter of camshaft journal
and inner diameter of cylinder head journal, and
confirm the difference (oil clearance) between the
two values. If the oil clearance exceeds standard, replace the camshaft or cylinder head as necessary.
5) Measure the thrust clearance of camshaft with

setting the dial gauge at end of camshaft. If the
thrust clearance exceeds the limit, replace the
camshaft caps and cylinder head as a set. If necessary, replace the camshaft.
Standard:
0.030 0.090 mm (0.0012 0.0035 in)
Service limit:
0.10 mm (0.0039 in)
Unit: mm (in)
Standard
Oil
clearance Limit
ME-00276
0.055 0.090 (0.0022 0.0035)

0.10 (0.0039)
Camshaft journal O.D. 31.928 31.945 (1.2570 1.2577)

Journal hole I.D.
32.000 32.018 (1.2598 1.2605)
ME(H4SO)-57
Cylinder Head
MECHANICAL
20.Cylinder Head
12) Remove the bolts (a) and (c) to remove cylinder

head.
A: REMOVAL
NOTE:
Valve Clearance.>
REMOVAL, V-belt.>
6) Remove the intake manifold. <Ref. to
FU(H4SO)-13, REMOVAL, Intake Manifold.>
7) Remove the bolt which installs the A/C compressor bracket on cylinder head.
8) Remove the valve rocker assembly. <Ref. to
ME(H4SO)-51, REMOVAL, Valve Rocker Assembly.>
9) Remove the camshaft. <Ref. to ME(H4SO)-54,
REMOVAL, Camshaft.>
10) Remove the cylinder head bolts in alphabetical
sequence as shown in the figure.
NOTE:
Leave bolts (a) and (c) engaged by three or four
threads to prevent the cylinder head from falling.
(c)
(e)
(a)
(b)
(f)
(d)
ME-02745
11) While tapping the cylinder head with a plastic

hammer, separate it from cylinder block.
(c)
(e)
(a)
(b)
(f)
(d)
ME-02745
13) Remove the cylinder head gasket.

CAUTION:
Be careful not to scratch the mating surface of
cylinder block and cylinder head.
14) Similarly, remove the right side cylinder head.
B: INSTALLATION
1) Install the cylinder head and gaskets on cylinder
block.
CAUTION:
NOTE:
Use new cylinder head gaskets.
2) Tighten the cylinder head bolts.
(1) Apply a thin coat of engine oil to washer and
bolt thread.
(2) Tighten all bolts to 29 Nm (3.0 kgf-m, 22 ftlb) in alphabetical sequence. Then tighten all
bolts to 69 Nm (7.0 kgf-m, 51 ft-lb) in alphabetical sequence.
(3) Loosen all the bolts by 180 in reverse order
of installation, and loosen again by 180 in the
same order.
(4) Tighten all bolts to 42 Nm (3.9 kgf-m, 31 ftlb) in alphabetical sequence.
(5) Tighten all bolts by 80 to 90 in alphabetical
sequence.
sequence.
CAUTION:
The tightening angle of the bolt should not exceed 45.
ME(H4SO)-58
Cylinder Head
MECHANICAL
(7) Further tighten the bolts (a) and (b) by 40

45.
CAUTION:
Make sure the total re-tightening angle of the
step (6) and (7) does not exceed 90.
(f)
(a)
C: DISASSEMBLY
1) Place the cylinder head on the ST.
ST 498267800
CYLINDER HEAD TABLE
2) Set the ST on valve spring. Compress the valve
spring and remove the valve spring retainer key.
Remove each valve and valve spring.
ST 499718000
VALVE SPRING REMOVER
NOTE:
Mark each valve to prevent confusion.
Pay careful attention not to damage the lips of intake valve oil seals and exhaust valve oil seals.
Keep all the removed parts in order for re-installing in their original positions.
(c)
(d)
(b)
(e)
ME-02746
3) Install the camshaft. <Ref. to ME(H4SO)-55, INSTALLATION, Camshaft.>

4) Install the valve rocker assembly. <Ref. to
ME(H4SO)-51, INSTALLATION, Valve Rocker Assembly.>
5) Install the A/C compressor bracket on cylinder
head.
6) Install the intake manifold.
<Ref. to FU(H4SO)-15, INSTALLATION, Intake
Manifold.>
7) Install the cam sprocket. <Ref. to ME(H4SO)-49,
INSTALLATION, Cam Sprocket.>
10) Install the rocker cover and rocker cover gasket, and then connect PCV hose.
NOTE:
Use a new gasket.
Belt Cover.>
ME(H4SO)-59
ST
ME-00280
Cylinder Head
MECHANICAL
D: ASSEMBLY
(8)
(1)
(3)
(5)
(7)
(11)
(2)
(4)
(6)
(9)
(12)
(10)
(13)
(14)
ME-02999
(1)
Valve
(6)
Retainer
(11)
Plug
(2)
(3)
Valve guide
Valve spring seat
(7)
(8)
Retainer key
Spark plug gasket
(12)
(13)
Camshaft cap
Valve rocker ASSY
(4)
(5)
Oil seal
Valve spring
(9)
(10)
Camshaft
Oil seal
(14)
Seal washer
ME(H4SO)-60
Cylinder Head
MECHANICAL
1) Installation of valve spring and valve:

(1) Place the cylinder head on the ST.
ST 498267800
CYLINDER HEAD TABLE
(2) Coat the stem of each valve with engine oil
and insert the valve into valve guide.
NOTE:
When inserting the valve into valve guide, use special care not to damage the oil seal lip.
(3) Install the valve spring and retainer.
NOTE:
Be sure to install the valve spring with its closecoiled end facing the seat on cylinder head.
(4) Set the ST on valve spring.
ST 499718000
VALVE SPRING REMOVER
E: INSPECTION
1. CYLINDER HEAD
1) Make sure that no crack or other damage do not
exists. In addition to visual inspection, inspect important areas using liquid penetrant tester.
Also make sure the gasket installing surface shows
no trace of gas and water leaks.
2) Place the cylinder head on the ST.
ST 498267800
CYLINDER HEAD TABLE
3) Measure the warping of the cylinder head surface that mates with crankcase using a straight
edge and thickness gauge.
If the warping exceeds the limit, regrind the surface
with a surface grinder.
Warping limit:
0.035 mm (0.0012 in)
ST
Grinding limit:
0.1 mm (0.004 in)
Standard height of cylinder head:
97.5 mm (3.839 in)
ME-00280
(5) Compress the valve spring and fit the valve

spring retainer key.
NOTE:
Uneven torque for the cylinder head bolts can
cause warping. When reassembling, pay special
attention to the torque so as to tighten evenly.
(A)
(B)
(B)
(B)
(A)
ST
ME-00285
ME-02719
(A) Straight edge

(A) Retainer key
(B) Thickness gauge
(B) Valve spring

(C) Retainer
(6) After installing, tap the valve spring retainers

lightly with a plastic hammer for better seating.
ME(H4SO)-61
Cylinder Head
MECHANICAL
2. VALVE SEAT
Inspect the intake and exhaust valve seats, and correct the contact surfaces with a valve seat cutter if
they are defective or when valve guides are replaced.
Service limit:
0.15 mm (0.0059 in)
Valve seat width W:

Standard:
Intake (A)
0.8 1.4 mm (0.03 0.055 in)
Exhaust (B)
1.2 1.8 mm (0.047 0.071 in)
(A)
ME-00763
Service limit:
Intake (A)
1.7 mm (0.067 in)
Exhaust (B)
2.2 mm (0.087 in)
(A) Valve guide

Y
X
(A)
(B)
ME-00289
ME-00397
2) If the clearance between valve guide and stem

exceeds the limit, replace the valve guide or valve
itself whichever shows greater amount of wear.
See the following procedure for valve guide replacement.
Valve guide inner diameter:
6.000 6.012 mm (0.2362 0.2367 in)
ME-00287
3. VALVE GUIDE
1) Check the clearance between valve guide and
stem. The clearance can be checked by measuring
respectively the outer diameter of valve stem with a
micrometer and the inner diameter of valve guide
with a caliper gauge.
Clearance between the valve guide and valve
stem:
Valve stem outer diameters:

Intake
5.950 5.965 mm (0.2343 0.2348 in)
Exhaust
5.945 5.960 mm (0.2341 0.2346 in)
(1) Place the cylinder head on ST1 with the
combustion chamber upward so that valve
guides fit the holes in ST1.
(2) Insert the ST2 into valve guide and press it
down to remove the valve guide.
ST1 498267800 CYLINDER HEAD TABLE
ST2 499767200 VALVE GUIDE REMOVER
Standard:
Intake
0.035 0.062 mm (0.0014 0.0024 in)
Exhaust
0.040 0.067 mm (0.0016 0.0026 in)
ST2
ST1
ME-00290
ME(H4SO)-62
Cylinder Head
MECHANICAL
(3) Turn the cylinder head upside down and

place the ST as shown in the figure.
Intake side
ST 499767700
VALVE GUIDE ADJUSTER
Exhaust side
ST 499767800
VALVE GUIDE ADJUSTER
(6) Check the valve guide protrusion.

Valve guide protrusion L:
Intake
20.0 21.0 mm (0.787 0.827 in)
Exhaust
16.5 17.5 mm (0.650 0.689 in)
ST
(A)
(A)
ME-00291
ME-00293
(A) Valve guide
(A) Valve guide
(4) Before installing a new valve guide, make

sure that neither scratches nor damages exist
on the inner surface of valve guide holes in cylinder head.
(5) Put a new valve guide, coated with sufficient
oil, in cylinder, and insert the ST1 into valve
guide. Press in until the valve guide upper end
is flush with the upper surface of ST2.
Intake side
ST2 499767700 VALVE GUIDE ADJUSTER
Exhaust side
ST2 499767800 VALVE GUIDE ADJUSTER
ST1
(7) Ream the inside of valve guide using ST.

Put the reamer in valve guide, and rotate the
reamer slowly clockwise while pushing it lightly.
Bring the reamer back while rotating it clockwise. After reaming, clean the valve guide to remove chips.
NOTE:
Apply engine oil to the reamer when reaming.
If the inner surface of the valve guide is torn,
slightly grind the edge of the reamer with an oil
stone.
If the inner surface of valve guide becomes lustrous and the reamer does not chip, use a new
reamer or remedy the reamer.
ST 499767400
VALVE GUIDE REAMER
ST2
ME-00292
ME-00294
(8) Recheck the contact condition between valve

and valve seat after replacing the valve guide.
ME(H4SO)-63
Cylinder Head
MECHANICAL
4. INTAKE AND EXHAUST VALVE

1) Inspect the flange and stem of valve, and replace if damaged, worn, or deformed, or if H is outside of the specif11ied limit.
H:
Intake
Standard:
0.8 1.2 mm (0.03 0.047 in)
Limit:
0.6 mm (0.024 in)
Exhaust
Standard:
1.0 1.4 mm (0.039 0.055 in)
Limit:
0.6 mm (0.024 in)
Valve overall length:
Intake
120.6 mm (4.75 in)
Exhaust
121.7 mm (4.79 in)
2) To measure the squareness of the valve spring,

stand the spring on a surface plate and measure its
deflection at the top of spring using a try square.
Free length
mm (in)
55.2 (2.173)
Tension/spring
height N (kgf, lb)/
mm (in)
Set
Lift
Squareness
235.3 270.7 (24 27.6,

52.9 60.8)/45.0 (1.772)
578.9 639.9
(59.1 65.3, 130.3 143.9)/
34.7 (1.366)
2.5, 2.4 mm (0.094 in) or less
ME-00283
6. INTAKE AND EXHAUST VALVE OIL SEAL

In the following case, remove the oil seal from the
valve guide and replace it with a new part.
When the lip is damaged.
When the spring is out of the specified position.
When readjusting the surfaces of intake valve
and valve sheet.
When replacing the intake valve guide.
1) Place the cylinder head on ST1.
2) Using the ST2, press-fit the oil seal.
ST2 498857100 VALVE OIL SEAL GUIDE
ME-00295
2) Put a small amount of grinding compound on the

seat surface, and lap the valve and seat surface.
Replace with a new valve oil seal after lapping.
NOTE:
Apply engine oil to oil seal before press-fitting.
When press-fitting the oil seal, do not use a hammer or strike in.
The intake valve oil seal and exhaust valve oil
seal can be differentiated by colors.
Color of rubber part:
Intake [Gray]
Exhaust [Green]
NOTE:
It is possible to differentiate between the intake
valve and the exhaust valve by their overall length.
ST2
5. VALVE SPRING
1) Check the valve springs for damage, free length,
and tension. Replace the valve spring if it is not
within the standard value presented in the table.
ST1
ME-00284
ME(H4SO)-64
Cylinder Block
MECHANICAL
21.Cylinder Block
12) Remove the bolts (a) and (d) to remove cylinder head.
A: REMOVAL
(f)
(d)
NOTE:
Before conducting this procedure, drain the engine
oil completely.
FU(H4SO)-13, REMOVAL, Intake Manifold.>
REMOVAL, V-belt.>
7) Remove the crank sprocket. <Ref. to
ME(H4SO)-50, REMOVAL, Crank Sprocket.>
8) Remove the generator and A/C compressor with
their brackets.
9) Remove the rocker cover.
sequence shown in the figure.
NOTE:
Leave bolts (a) and (d) engaged by three or four
threads to prevent the cylinder head from falling.
(f)
(d)
(a)
(A)
(c)
(b)
(e)
ME-02720
(A) Front side

CAUTION:
14) Similarly, remove the right side cylinder head.
15) Remove the clutch housing cover. (MT model)
16) Remove the flywheel (MT model) or drive plate
(AT model).
Using the ST, lock the crankshaft.
ST 498497100
CRANKSHAFT STOPPER
MT model
(a)
(A)
ST
(c)
(b)
(e)
ME-00297
AT model
ME-02720
(A) Front side

hammer, separate it from cylinder block.
ME-00298
17) Remove the oil separator cover.

18) Remove the water by-pass pipe for heater.
ME(H4SO)-65
Cylinder Block
MECHANICAL
19) Remove the water pump after loosening the

bolts in alphabetical sequence as shown in the figure.
(B)
(C)
(A)
(D)
(E)
(F)
ME-02463
20) Remove the bolts which install oil pump onto

cylinder block.
NOTE:
When disassembling and checking the oil pump,
loosen the relief valve plug before removing the oil
pump.
22) Remove the oil pan.

(1) Place the cylinder block to face the #2 and
#4 piston side upward.
(2) Remove the bolts which secure oil pan to
cylinder block.
(3) Insert an oil pan cutter blade between cylinder block-to-oil pan clearance and remove the
oil pan.
CAUTION:
Do not use a screwdriver or similar tool in place
of oil pan cutter.
23) Remove the oil strainer stay.
24) Remove the oil strainer.
25) Remove the baffle plate.
26) Remove the oil filter. <Ref. to LU (H4SO)-24,
REMOVAL, Engine Oil Filter.>
LU-00015
21) Remove the oil pump from cylinder block using

a flat tip screwdriver.
CAUTION:
cylinder block and oil pump.
ME-00138
ME(H4SO)-66
Cylinder Block
MECHANICAL
27) Remove the water pipe.
ME-00300
(2)
(1)
(3)
(4)
(6)
(4)
(3)
(5)
(4)
(2)
(3)
(1)
(8)
(4)
(7)
(3)
(1)
(2)
ME-02889
(1)
(2)
Service hole plug

Gasket
(4)
(5)
Piston pin
Service hole cover
(3)
Snap ring
(6)
O-ring
28) Remove the service hole cover and service

hole plugs using a hexagon wrench [14 mm].
(7)
(8)
Seal washer
Washer
29) Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove
the piston snap ring through service hole of #1 and
#2 cylinders.
ME-00140
ME-00141
ME(H4SO)-67
Cylinder Block
MECHANICAL
30) Draw out the piston pin from #1 and #2 pistons

using ST.
ST 499097700
PISTON PIN REMOVER
NOTE:
Be careful not to confuse the original combination
of piston, piston pin and cylinder.
ST
31) Similarly remove the piston pins from #3 and #4

pistons.
32) Remove the bolts which connect cylinder block
on the side of #1 and #3 cylinders (RH).
33) Loosen the bolts which connect cylinder block
on the side of #2 and #4 cylinders (LH) two or three
turns.
34) Set up the cylinder block so that #2 and #4 cylinders (LH) are on the upper side, then remove
bolts connecting the cylinder block.
35) Separate the cylinder block (RH) and (LH).
NOTE:
When separating the cylinder block, do not allow
the connecting rod to fall or damage the cylinder
block.
ME-00142
(5)
(7)
(1)
(4)
(2)
(4)
(6)
(3)
(1)
(5)
ME-02890
(1)
Cylinder block
(4)
Crankshaft bearing
(6)
Seal washer
(2)
(3)
Rear oil seal

Crankshaft
(5)
Piston
(7)
Washer
36) Remove the rear oil seal.

37) Remove the crankshaft together with connecting rod.
38) Remove the crankshaft bearings from cylinder
block using a hammer handle.
39) Draw out each piston from cylinder block using

wooden bar or hammer handle.
NOTE:
Be careful not to confuse the piston and cylinder
combination.
NOTE:
Be careful not to confuse the crankshaft bearing
combination. Press the bearing at the end opposite
to locking lip.
ME(H4SO)-68
Cylinder Block
MECHANICAL
B: INSTALLATION
(6)
(5)
(4)
(7)
(1)
(3)
(2)
(7)
(3)
(6)
(6)
ME-03021
(1)
Crankshaft bearing
(4)
Rear oil seal
(6)
Seal washer
(2)
(3)
Crankshaft
Cylinder block
(5)
O-ring
(7)
Washer
1) Remove oil on the mating surface of cylinder

block before installation. Apply a coat of engine oil
to the bearing and crankshaft journal.
2) Position the crankshaft and the O-ring on the #1
and #3 cylinder block.
3) Apply liquid gasket to the mating surface of #1
and #3 cylinder blocks (RH), and install #2 and #4
cylinder blocks (LH) to above and position them.
NOTE:
Do not allow liquid gasket to jut into O-ring grooves,
oil passages, bearing grooves, etc.
Liquid gasket:
equivalent
ME-00145
4) Apply a coat of engine oil to the washer and bolt

thread.
NOTE:
ME(H4SO)-69
Cylinder Block
MECHANICAL
5) Tighten the 10 mm cylinder block connecting

bolts on the LH side (A D) in alphabetical order.
Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
(E)
8) Further tighten the cylinder block connecting

bolts on the RH side (E J) in alphabetical sequence.
Tightening torque:
18 Nm (1.8 kgf-m, 13 ft-lb)
(J)
(A)
(G)
(D)
(I)
(H)
(F)
(B)
(C)
ME-02987

bolts on the RH side (E J) in alphabetical order.
Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
ME-02988

bolts on the LH side (A D) in alphabetical sequence.
(A), (C): Angle tightening
Tightening angle:
90
(B), (D): Torque tightening
(A)
(D)
Tightening torque:
40 Nm (4.1 kgf-m, 29.6 ft-lb)
(B)
(C)
(E)
ME-02988

(J)
(G)
Tightening torque:
18 Nm (1.8 kgf-m, 13 ft-lb)
(I)
(H)
(F)
ME-02987
10) Tighten the cylinder block connecting bolts on

the RH side (E J) in alphabetical sequence.
(E)
(J)
Tightening angle:
90
(G)
(I)
(F)
(H)
(A)
ME-02987
(D)
(B)
(C)
ME-02988
ME(H4SO)-70
Cylinder Block
MECHANICAL
11) Tighten the 8 mm and 6 mm cylinder block connecting bolts on LH side (A H) in alphabetical sequence.
Tightening torque:
(A) (G): 25 Nm (2.5 kgf-m, 18.1 ft-lb)
(H): 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
14) Position the second ring gap at 180 on the reverse side the top ring gap.
NOTE:
Assemble so that the piston ring mark R faces the
upper side of the piston.
180
(G)
(C)
(E)
(A)
180
(B)
(B)
(A)
(B)
(A)
RH
(D)
LH
ME-02721
(F)
(H)
ME-00147
15) Position the upper rail gap at (C) in the figure.
12) Apply a coat of engine oil to the oil seal periphery, then install the rear oil seal using ST1 and ST2.
(C)
NOTE:
Use a new rear oil seal.
25
25
(C)
(B)
(A)
LH
RH
ST2
ME-02722
16) Align the upper rail spin stopper (E) to the side
hole (D) on the piston.
(D)
(E)
ST1
ME-00148
(A) Rear oil seal

(B) Flywheel attaching bolt
13) Position the top ring gap at (A) or (B) in the figure.
NOTE:
Assemble so that the piston ring mark R faces the
upper side of the piston.
ME-02471
17) Position the expander gap at (F) in the figure.

180
(C)
(F)
(C)
(F)
180
RH
LH
ME-02723
ME(H4SO)-71
Cylinder Block
MECHANICAL
18) Position the lower rail gap at (G) in the figure.

120
(G)
(C)
19) Install the snap ring.

Install the snap rings in the piston holes located opposite to the service holes in cylinder block before
assembling pistons to the cylinder.
NOTE:
Use new snap rings.
#3
(C)
(G)
120
RH
LH
#1
ME-02724
NOTE:
Make sure the ring gaps do not face the same direction.
Make sure ring gaps are not within the piston
skirt area.
#4
(A)
#2
ME-00306
(A) Front side

(5)
(4)
(1)
(5)
(3)
(4)
(3)
(2)
(2)
(1)
ME-02426
(1)
Piston
(4)
Gasket
(2)
(3)
Piston pin
Snap ring
(5)
Service hole plug
ME(H4SO)-72

T: 70 (7.1, 50.6)
Cylinder Block
MECHANICAL
20) Install the piston.

#2 cylinder side upward.
(2) Using the ST1, turn the crankshaft so that
#1 and #2 connecting rods are set at bottom
dead center.
ST1 499987500 CRANKSHAFT SOCKET
(3) Apply a coat of engine oil to the pistons and
cylinders and insert pistons in their cylinders using ST2.
ST2 498747300 PISTON GUIDE
(3) Apply a coat of engine oil to piston pin, and

insert the piston pin into piston and connecting
rod through service hole.
(4) Install the snap ring.
NOTE:
Use new snap rings.
ST1
ME-00159
(5) Apply liquid gasket to the bolt threads of service plug.

ST2
ME-00157
NOTE:
Face the piston front mark towards the front of the
engine.
RH
(A)
Liquid gasket:
equivalent
ME-00160
LH
ME-02725
(A) Front mark
21) Install the piston pin.

(1) Apply a coat of engine oil to ST3.
(2) Insert ST3 into the service hole to align piston pin hole with connecting rod small end.
ST3 499017100 PISTON PIN GUIDE
ST1
ST3
ME-00158
ME(H4SO)-73
Cylinder Block
MECHANICAL
(6) Install the service hole plug and gasket.

NOTE:
Use a new gasket.
ME-00140
T2
(5)
T1
(6)
(3)
(4)
(7)
(2)
(1)
(3)
(2)
(1)
ME-02394
(1)
(2)
Piston
Piston pin
(5)
(6)
Service hole plug

Service hole cover
(3)
(4)
Snap ring
Gasket
(7)
O-ring
ME(H4SO)-74

T1: 6.4 (0.65, 4.7)
T2: 70 (7.1, 50.6)
Cylinder Block
MECHANICAL

#4 cylinder side upward. Following the same
procedures as used for #1 and #2 cylinders, install the pistons and piston pins.
22) Install the water pipe.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
27) Apply liquid gasket to the mating surfaces and

the threaded portion of bolt (A) shown in the figure
(when reusing the bolt), and then install the oil separator cover.
NOTE:
Liquid gasket:
Mating surface
THREE BOND 1217G or equivalent
Bolt (A) thread (when reusing the bolt)
equivalent
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
(A)
ME-00300
23) Install the baffle plate.

Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
24) Install the oil strainer and O-ring.
Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
25) Install the oil strainer stay.
ME-02452
NOTE:
Tighten the oil strainer stay together with the baffle
plate.
28) Install the flywheel. (MT model)

<Ref. to CL-14, INSTALLATION, Flywheel.>
To lock the crankshaft, use the ST.
ST 498497100
CRANKSHAFT STOPPER
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
26) Apply liquid gasket to the mating surfaces, and
install the oil pan.
Tightening torque:
72 Nm (7.3 kgf-m, 52.8 ft-lb)
NOTE:
Liquid gasket:
THREE BOND 1207C (Part No. 004403012) or
equivalent
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
ST
ME-00162
ME(H4SO)-75
ME-00297
Cylinder Block
MECHANICAL
29) Install the drive plate.

To lock the crankshaft, use the ST.
ST 498497100
CRANKSHAFT STOPPER
(3) Apply a coat of engine oil to the inside of oil

seal.
Tightening torque:
72 Nm (7.3 kgf-m, 52.8 ft-lb)
ME-00312
ME-00298
30) Install the housing cover.

31) Installation of oil pump:
(1) Replace the front oil seal with a new part using ST.
ST 499587100
OIL SEAL INSTALLER
(4) Install the oil pump to cylinder block. Be

careful not to damage the oil seal during installation.
NOTE:
Make sure the oil seal lip is not folded.
Align the flat surface of oil pumps inner rotor with
crankshaft before installation.
Use new O-rings and seals when installing the oil
pump.
(5) Apply liquid gasket to the three bolts thread
shown in figure. (when reusing the bolt)
Liquid gasket:
equivalent
Tightening torque:
T: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
ME-00164
(2) Apply liquid gasket to the matching surface

of oil pump.
Liquid gasket:
equivalent
T
LU-02103
(A)
ME-00165
(A) O-ring
ME(H4SO)-76
Cylinder Block
MECHANICAL
32) Install the water pump and gasket.

Tightening torque:
First: 12 Nm (1.2 kgf-m, 8.7 ft-lb)
Second: 12 Nm (1.2 kgf-m, 8.7 ft-lb)
NOTE:
When installing the water pump, tighten bolts in
two stages in alphabetical sequence as shown in
the figure.
Use a new gasket.
(B)
(C)
(A)
(D)
(E)
(F)
ME-02463
33) Install the water by-pass pipe for heater.

34) Install the oil filter.
<Ref. to LU (H4SO)-24, INSTALLATION, Engine
Oil Filter.>
35) Tighten the cylinder head bolts. <Ref. to
ME(H4SO)-58, INSTALLATION, Cylinder Head.>
36) Install the oil level gauge guide and tighten the
bolts. (LH side only)
<Ref. to ME(H4SO)-50, INSTALLATION, Crank
Sprocket.>
38) Install the cam sprocket. <Ref. to ME(H4SO)49, INSTALLATION, Cam Sprocket.>
40) Adjust the valve clearance. <Ref. to
ME(H4SO)-31, ADJUSTMENT, Valve Clearance.>
41) After assembling the rocker cover gasket to the
rocker cover, install it to the cylinder head, and then
connect it to PCV hose.
NOTE:
Belt Cover.>
<Ref. to FU(H4SO)-15, INSTALLATION, Intake
Manifold.>
45) Install the generator and A/C compressor
brackets on cylinder head.
C: DISASSEMBLY
(1)
(2)
(2)
(5)
(4)
(3)
(6)
ME-02411
(1)
(2)
Connecting rod cap

(3)
(4)
Top ring
Second ring
ME(H4SO)-77
(5)
(6)
Oil ring
Snap ring
Cylinder Block
MECHANICAL
1) Remove the connecting rod cap.

2) Remove the connecting rod bearing.
4) Remove the oil ring by hand.
NOTE:
Arrange the removed connecting rod, connecting
rod cap and bearing in order, to prevent confusion.
3) Remove the piston rings using piston ring expander.
NOTE:
Arrange the removed piston rings in proper order,
to prevent confusion.
5) Remove the snap ring.
D: ASSEMBLY
(3)
T
(1)
(1)
(2)
(4)
(5)
(6)
(8)
(7)
ME-00392
(1)
(2)

Connecting rod
(5)
(6)
Second ring
Top ring
(3)
(4)
Connecting rod cap

Oil ring
(7)
(8)
Snap ring
Side mark

T: 45 (4.6, 33.3)
1) Apply oil to the surfaces of the connecting rod

bearings.
2) Install the connecting rod bearings on connecting rods and connecting rod caps.
3) Position each connecting rod with a side mark
facing forward, and install it.
4) Install the connecting rod cap with connecting
rod nut.
Make sure the arrow on connecting rod cap faces
toward front during installation.
E: INSPECTION
NOTE:
Each connecting rod has its own mating cap.
Make sure that they are assembled correctly by
checking their matching number.
When tightening the connecting rod nuts, apply
oil on the threads.
5) Install the expander, lower rail and upper rail by
hand. Install the second ring and top ring using piston ring expander.
Warping limit:
0.025 mm (0.00098 in)
1. CYLINDER BLOCK
1) Visually check for cracks and damage. Especially, inspect the important parts using liquid penetrant tester.
2) Check the oil passages for clogging.
3) Inspect the cylinder block surface that mates
with cylinder head for warping by using a straight
edge, and correct by grinding if necessary.
Grinding limit:
0.1 mm (0.004 in)
Standard height of cylinder block:
201.0 mm (7.91 in)
ME(H4SO)-78
Cylinder Block
MECHANICAL
2. CYLINDER AND PISTON

1) The cylinder bore size is stamped on the cylinder
block front upper surface.
NOTE:
Measurement should be performed at a temperature of 20C (68F).
Standard sized pistons are classified into two
grades, A and B. These grades should be used
as guide lines in selecting a standard piston.
Standard diameter:
A: 99.505 99.515 mm (3.9175 3.9179 in)
B: 99.495 99.505 mm (3.9171 3.9175 in)
2) How to measure the inner diameter of each cylinder

Measure the inner diameter of each cylinder in both
the thrust and piston pin directions at the heights as
shown in the figure, using a cylinder bore gauge.
NOTE:
Taper:
Standard:
0.015 mm (0.0006 in)
Service limit:
0.050 mm (0.0020 in)
Out-of-roundness:
Standard:
0.010 mm (0.0004 in)
Service limit:
0.050 mm (0.0020 in)
(A)
(B)
(B)
#5
#4
(A)
#1
#2
(F)
#3
(D)
H1
(E) (C)
H2
H3
ME-00170
H4
(A) Main journal size mark

(B) Cylinder block (RH)-(LH) combination mark
(C) #1 cylinder bore size mark
(D) #2 cylinder bore size mark
(E) #3 cylinder bore size mark
ME-00171
(F) #4 cylinder bore size mark

(A) Piston pin direction
(B) Thrust direction
H1 10 mm (0.39 in)
H2 45 mm (1.77 in)
H3 80 mm (3.15 in)
H4 115 mm (4.53 in)
3) When the piston is to be replaced due to general

wear or cylinder wear, select a suitable sized piston
by measuring the piston clearance.
ME(H4SO)-79
Cylinder Block
MECHANICAL
4) How to measure the outer diameter of each cylinder:

Measure the outer diameter of each piston at the
height as shown in the figure. (Thrust direction)
NOTE:
Piston grade point H:
38.2 mm (1.504 in)
Standard:
A: 99.505 99.515 mm (3.9175 3.9179 in)
B: 99.495 99.505 mm (3.9171 3.9175 in)
0.25 mm (0.0098 in) oversize:
99.745 99.765 mm (3.9270 3.9278 in)
99.995 100.015 mm (3.9368 3.9376 in)
H
ME-00172
5) Calculate the clearance between cylinder and

piston.
(2) If the cylinder inner diameter exceeds the

limit after boring and honing, replace the cylinder block.
Cylinder inner boring limit (diameter):
To 100.005 mm (3.9372 in)
NOTE:
Immediately after reboring, the cylinder diameter
may differ from its real diameter due to temperature
rise. Thus, pay attention when measuring the cylinder diameter.
3. PISTON AND PISTON PIN

1) Check the pistons and piston pins for damage,
cracks and wear, and the piston ring grooves for
wear and damage. Replace if faulty.
2) Measure the piston-to-cylinder clearance at
each cylinder. <Ref. to ME(H4SO)-79, CYLINDER
AND PISTON, INSPECTION, Cylinder Block.>If
any of the clearances exceeds the limit value, replace the piston or bore the cylinder to enable use
of the oversize piston.
3) Make sure that the piston pin can be inserted
into the piston pin hole with fingers at 20C (68F).
Replace if faulty.
Clearance between piston hole and piston pin:
Standard:
0.004 0.008 mm (0.0002 0.0003 in)
Service limit:
0.020 mm (0.0008 in)
NOTE:
Cylinder to piston clearance at 20C (68F):
Standard:
0.010 0.010 mm (0.00039 0.00039 in)
Service limit:
0.030 mm (0.0012 in)
6) Boring and honing
(1) If any of the measured value of taper, out-ofroundness or cylinder-to-piston clearance is not
within the service 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 replace to oversize pistons.
Do not perform boring on one cylinder only.
Nor replace an oversize piston for one cylinder
only.
ME(H4SO)-80
ME-00173
ME-00174
Cylinder Block
MECHANICAL
4) Check the snap ring installation groove (A) on

the piston for burr. If necessary, remove burr from
the groove so that the piston pin can lightly move.
2) Clean the piston ring groove and piston ring.

3) Squarely place the piston ring and oil ring in cylinder, and measure the piston ring gap with a thickness gauge.
mm (in)
(A)
Top ring
Piston ring
gap
Second
ring
Oil ring rail
Standard
0.20 0.35
(0.0079 0.0138)
0.37 0.52
(0.0144 0.0203)
0.20 0.50
(0.0079 0.0197)
Limit
1.0 (0.039)
1.5 (0.059)
ME-00175
5) Check the piston pin snap ring for distortion,

cracks and wear.
4. PISTON RING
1) If the piston ring is broken, damaged or worn, or
if its tension is insufficient, or when the piston is replaced, replace the piston ring with a new part of
the same size as piston.
NOTE:
Marks that shows the installing direction are
shown on the end of top and second rings. Face
these marks upward when installing the rings to
piston.
Oil ring consists of the upper rail, expander and
lower rail. Be careful about the direction of rail
when installing the oil ring to piston.
ME-00177
4) Measure the clearance between piston ring and

piston ring groove with a thickness gauge.
NOTE:
Before measuring the clearance, clean the piston
ring groove and piston ring.
mm (in)
(A)
(B)
Clearance
between piston
ring and piston
ring groove
Top ring
Second
ring
Standard
0.040 0.080
(0.0016 0.0031)
0.030 0.070
(0.0012 0.0028)
Limit
0.15
(0.059)
(C)
(A)
(B)
(C)
ME-00178
ME-02472
(A) Upper rail

(B) Expander
(C) Lower rail
ME(H4SO)-81
Cylinder Block
MECHANICAL
5. CONNECTING ROD
1) Replace the connecting rod, if the large or small
end thrust surface is damaged.
2) Check for bend or twist using a connecting rod
aligner. Replace the connecting rod if the bend or
twist exceeds the limit.
Limit of bend or twist per 100 mm (3.94 in) in
length:
0.10 mm (0.0039 in)
(A)
4) Inspect the connecting rod bearing for scar,

peeling, seizure, melting, wear, etc.
5) Measure the oil clearance on each connecting
rod bearing using plastigauge. If there is an oil
clearance that exceeds the service limit, replace
the defective bearing with a new standard or undersized bearing as necessary. (See the table below.)
Connecting rod oil clearance:
Standard:
0.016 0.044 mm (0.00063 0.0017 in)
Service limit:
0.05 mm (0.0020 in)
Unit: mm (in)
(B)
(A)
Bearing
Bearing size
Outer diameter of
crank pin
Standard
1.492 1.501
(0.0587 0.0591)
51.984 52.000
(2.0466 2.0472)
0.03 (0.0012)
Undersize
0.05 (0.0020)
Undersize
0.25 (0.0098)
Undersize
1.510 1.513
(0.0594 0.0596)
1.520 1.523
(0.0598 0.0600)
1.620 1.623
(0.0638 0.0639)
51.954 51.970
(2.0454 2.0461)
51.934 51.950
(2.0446 2.0453)
51.734 51.750
(2.0368 2.0374)
6) Inspect the bushing at connecting rod small end,

and replace if worn or damaged. Also measure the
piston pin clearance at connecting rod small end.
(B)
ME-00179
(A) Thickness gauge
Clearance between piston pin and bushing:

Standard:
0 0.022 mm (0 0.0009 in)
Service limit:
0.030 mm (0.0012 in)
(B) Connecting rod
3) Install the connecting rod fitted with bearing to

crankshaft and measure the side clearance (thrust
clearance). Replace the connecting rod if the side
clearance exceeds the specified limit.
Connecting rod side clearance:
Standard:
0.070 0.330 mm (0.0028 0.0130 in)
Service limit:
0.4 mm (0.016 in)
ME-00181
ME-00174
ME-00180
ME(H4SO)-82
Cylinder Block
MECHANICAL
7) Replacement procedure is as follows.

(1) Remove the bushing from connecting rod
with ST and press.
(2) Press the bushing with the ST after applying
oil on the periphery of new bushing.
ST 499037100
CONNECTING ROD BUSHING REMOVER AND INSTALLER
ST
ME-00182
(3) Make two 3 mm (0.12 in) holes in the

pressed bushing by aligning with the pre-manufactured holes on the connecting rod. Then,
ream the inside of bushing.
(4) After completion of reaming, clean the bushing to remove chips.
3) Inspect the crank journal and crank pin for wear.

If they are not within the standard, replace the bearing with a suitable (undersize) one, and replace or
readjust the crankshaft if necessary. When grinding
the crank journal or crank pin, finish them to the
specified dimensions according to the undersize
bearing to be used.
Crank pin
Out-of-roundness:
0.003 mm (0.0001 in)
Cylindricality:
0.004 mm (0.0002 in)
Grinding limit:
To 51.750 mm (2.0374 in) dia.
Crank journal
Out-of-roundness:
0.005 mm (0.0002 in)
Cylindricality:
0.006 mm (0.0002 in)
Grinding limit:
To 59.758 mm (2.3527 in) dia.
6. CRANKSHAFT AND CRANKSHAFT

BEARING
1) Clean the crankshaft completely, and check it for
cracks using liquid penetrant tester. Replace if
faulty.
2) Measure the bend of crankshaft. If it exceeds the
limit, repair or replace it.
NOTE:
If a suitable V-block is not available, install #1 and
#5 crankshaft bearing on cylinder block, position
the crankshaft on these bearings, and then measure the crankshaft bend using a dial gauge.
Crankshaft bend limit:
0.035 mm (0.0014 in)
ME-00183
ME(H4SO)-83
ME-00184
Cylinder Block
MECHANICAL
Unit: mm (in)
Crank journal outer diameter
#2, #4, #5
59.992 60.008
(2.3619 2.3625)
Bearing size
1.998 2.011
(0.0787 0.0792)
2.000 2.013
(0.0787 0.0793)
1.492 1.501
(0.0587 0.0591)
Journal O.D.
59.962 59.978
(2.3607 2.3613)
59.962 59.978
(2.3607 2.3613)
51.954 51.970
(2.0454 2.0461)
2.017 2.020
(0.0794 0.0795)
59.942 59.958
(2.3599 2.3605)
2.027 2.030
(0.0798 0.0799)
2.019 2.022
(0.0795 0.0796)
59.942 59.958
(2.3599 2.3605)
2.029 2.032
(0.0799 0.0800)
1.510 1.513
(0.0594 0.0596)
51.934 51.950
(2.0446 2.0453)
1.520 1.523
(0.0598 0.0600)
Journal O.D.
59.742 59.758
(2.3520 2.3527)
59.742 59.758
(2.3520 2.3527)
51.734 51.750
(2.0368 2.0374)
Bearing size
2.127 2.130
(0.0837 0.0839)
2.129 2.132
(0.0838 0.0839)
1.620 1.623
(0.0638 0.0639)
Journal O.D.
Standard
0.03 (0.0012)
Undersize
0.05 (0.0020)
Undersize
0.25 (0.0098)
Undersize
Crank pin outer diameter
#1, #3
59.992 60.008
(2.3619 2.3625)
Bearing size
Journal O.D.
Bearing size
4) Use a thickness gauge to measure the thrust

clearance of crankshaft at center bearing. If the
clearance exceeds the limit, replace the bearing.
Crankshaft thrust clearance:
Standard:
0.030 0.115 mm (0.0012 0.0045 in)
Service limit:
0.25 mm (0.0098 in)
ME-00322
5) Inspect individual crankshaft bearings for signs

of flaking, seizure, melting and wear.
6) Measure the oil clearance on each crankshaft
bearing using plastigauge. If the measured value
exceeds the limit, replace the defective bearing
with an undersize one, and replace or readjust the
crankshaft if necessary.
Crankshaft oil clearance:
Standard:
0.010 0.030 mm (0.0004 0.0012 in)
Service limit:
0.040 mm (0.0016 in)
ME(H4SO)-84
51.984 52.000
(2.0466 2.0472)
Oil Switching Solenoid Valve

MECHANICAL
22.Oil Switching Solenoid Valve

A: REMOVAL
8) Remove the oil switching solenoid valve holder

from the cylinder head.
(A)
(C)
(B)
1. RH SIDE
(D)
(E)
ME-02726
(A) Oil switching solenoid valve

(B) Variable valve lift diagnosis oil pressure switch
(C) Oil temperature sensor
FU-00009
2) Remove the air intake chamber.

Chamber.>
bracket.
(D) Oil switching solenoid valve holder

(E) Gasket
2. LH SIDE
ME-02697
4) Disconnect the connector from the oil switching

solenoid valve.
5) Remove the oil switching solenoid valve.
6) Remove the variable valve lift diagnosis oil pressure switch.
<Ref. to FU(H4SO)-34, REMOVAL, Variable Valve
Lift Diagnosis Oil Pressure Switch.>
7) Remove the oil temperature sensor.
<Ref. to FU(H4SO)-35, REMOVAL, Oil Temperature Sensor.>
FU-00009
2) Remove the V-belts.

<Ref. to ME(H4SO)-40, REMOVAL, V-belt.>
<Ref. to ME(H4SO)-42, REMOVAL, Crank Pulley.>
4) Remove the timing belt cover.
<Ref. to ME(H4SO)-43, REMOVAL, Timing Belt
Cover.>
<Ref. to ME(H4SO)-44, REMOVAL, Timing Belt.>
6) Remove the cam sprocket.
<Ref. to ME(H4SO)-49, REMOVAL, Cam Sprocket.>
8) Disconnect the connector from the oil switching
solenoid valve.
9) Remove the oil switching solenoid valve.
10) Remove the variable valve lift diagnosis oil
pressure switch.
<Ref. to FU(H4SO)-34, REMOVAL, Variable Valve
Lift Diagnosis Oil Pressure Switch.>
ME(H4SO)-85
Oil Switching Solenoid Valve

MECHANICAL
11) Remove the oil switching solenoid valve holder

from the cylinder head.
(B)
2. LH SIDE
NOTE:
Use a new gasket.
Apply liquid gasket to the bolt threads of oil temperature sensor.
Liquid gasket:
equivalent
(D)
(C) (A)
ME-02727

(C) Oil switching solenoid valve holder
(D) Gasket
Tightening torque:
T1
8 Nm (0.8 kgf-m, 5.9 ft-lb)
T2
10 Nm (1.0 kgf-m, 7.4 ft-lb)
T3
17 Nm (1.7 kgf-m, 12.5 ft-lb)
(B)
B: INSTALLATION
T3
1. RH SIDE
NOTE:
Use a new gasket.
Apply liquid gasket to the bolt threads of oil temperature sensor.
Liquid gasket:
equivalent
Tightening torque:
T1
8 Nm (0.8 kgf-m, 5.9 ft-lb)
T2
10 Nm (1.0 kgf-m, 7.4 ft-lb)
T3
17 Nm (1.7 kgf-m, 12.5 ft-lb)
T4
18 Nm (1.8 kgf-m, 13.3 ft-lb)
T1
(D)
(C) (A)
T1
ME-03003

(C) Oil switching solenoid valve holder
(D) Gasket
(C)
(A)
T2
T4
(B)
T2
T3
(D)
(E)
ME-03002

(C) Oil temperature sensor
(D) Oil switching solenoid valve holder
(E) Gasket
ME(H4SO)-86
Intake and Exhaust Valve

MECHANICAL
23.Intake and Exhaust Valve

A: SPECIFICATION
Refer to Cylinder Head for removal and installation procedures of intake and exhaust valves. <Ref.
to ME(H4SO)-58, REMOVAL, Cylinder Head.>
<Ref. to ME(H4SO)-58, INSTALLATION, Cylinder
Head.>
ME(H4SO)-87
Piston
MECHANICAL
24.Piston
A: SPECIFICATION
Refer to Cylinder Block for removal and installation procedures of pistons. <Ref. to ME(H4SO)-65,
REMOVAL, Cylinder Block.> <Ref. to ME(H4SO)69, INSTALLATION, Cylinder Block.>
ME(H4SO)-88
Connecting Rod
MECHANICAL
25.Connecting Rod
A: SPECIFICATION
Refer to Cylinder Block for removal and installation procedures of connecting rod.
<Ref. to ME(H4SO)-65, REMOVAL, Cylinder
Block.> <Ref. to ME(H4SO)-69, INSTALLATION,
Cylinder Block.>
ME(H4SO)-89
Crankshaft
MECHANICAL
26.Crankshaft
A: SPECIFICATION
Refer to Cylinder Block for removal and installation procedures of the crankshaft. <Ref. to
ME(H4SO)-65, REMOVAL, Cylinder Block.> <Ref.
to ME(H4SO)-69, INSTALLATION, Cylinder
Block.>
ME(H4SO)-90
Engine Trouble in General

MECHANICAL
27.Engine Trouble in General

A: INSPECTION
NOTE:
RANK shown in the chart refers to the possibility of the cause of trouble in order Very often to Rarely
A Very often
B Sometimes
C Rarely
Symptoms
1. Engine does not start.
1) Starter does not turn.
Problem parts etc.

Starter
Battery
Friction
2) Initial combustion does

not occur.
Possible cause
RANK
Defective battery-to-starter harness

Defective starter switch
B
C
Defective inhibitor switch

Defective starter
C
B
Improper connection of terminal

Run-down battery
A
A
Defective charging system

Seizure of crankshaft and connecting rod bearing
B
C
Seized camshaft
Seized or stuck piston and cylinder
C
C
Starter
Defective starter
Engine control system <Ref. to EN(H4SO)(diag)-2, Basic Diagnostic Procedure.>
C
A
Fuel line
Defective fuel pump and relay

Clogged fuel line
A
C
Timing belt
Lack of or insufficient fuel

Degradation, etc.
B
B
Compression
Defective timing
Incorrect valve clearance
B
C
Loosened spark plug or defective gasket

Loosened cylinder head bolt or defective gasket
C
C
Improper valve sealing

Defective valve stem
C
C
Worn or broken valve spring

Worn or stuck piston rings, cylinder and piston
B
C
Incorrect valve timing

Improper engine oil (low viscosity)
B
B
ME(H4SO)-91

MECHANICAL
Symptoms
3) Initial combustion occurs.
Problem parts etc.
RANK
A
B
Defective throttle body gasket

B
C
Clogged fuel line

C
B
Timing belt
Degradation, etc.
Defective timing
B
B
Compression

C
C

C
C

C
B

C
B
Fuel line
4) Engine stalls after initial

combustion.
Possible cause

Intake system
Defective intake manifold gasket

B
A
Intake system
Loosened or cracked intake duct

Loosened or cracked PCV hose
B
C
Loosened or cracked vacuum hose

C
B

Dirty air cleaner element
B
C
Fuel line
Clogged fuel line

C
B
Timing belt
Degradation, etc.
Defective timing
B
B
Compression

C
C

C
C

C
B

C
B
ME(H4SO)-92

MECHANICAL
Symptoms
2. Rough idle and engine
stall
Problem parts etc.
Possible cause

Intake system
RANK
A
A

A
A

B
B
Defective PCV valve

Loosened oil filler cap
C
B

C
C
Clogged fuel line

C
B
Defective timing
C
B

B
B

B
C

B
B

A
B
Lubrication system
Incorrect oil pressure

Defective rocker cover gasket
B
C
Cooling system
Others
Overheating
Evaporative emission control system malfunction
C
A
Stuck or damaged throttle valve
Fuel line
Timing belt
Compression
ME(H4SO)-93

MECHANICAL
Symptoms
3. Low output, hesitation and
poor acceleration
Problem parts etc.
RANK
A
A

A
B

B
B
Defective PCV valve

B
B

A
B
Clogged fuel line

B
C
Defective timing
B
B

B
B

B
C

B
C

A
B
Lubrication system
Cooling system

Overheating
B
C
Others
Over-cooling
C
A
Fuel line
Timing belt
Compression
4. Surging
Possible cause

Intake system

Intake system
A
A

A
A

B
B
Defective PCV valve

B
B

B
B
Clogged fuel line

B
C
Defective timing
B
B

C
C

C
C

C
C

A
B
Cooling system
Overheating
Others
Fuel line
Timing belt
Compression
ME(H4SO)-94

MECHANICAL
Symptoms
Problem parts etc.
Possible cause
RANK
5. Engine does not return to

idle.

Intake system
A
A
6. Dieseling (Run-on)
Others
A
A
Cooling system
Others
B
B
7. After burning in exhaust

system

Intake system
9. Excessive engine oil consumption
A
C

C
B
Defective PCV valve

B
C
Defective timing
B
B

C
C

B
C

C
C
Lubrication system

A
C
Cooling system
Others
Over-cooling
C
C
Timing belt
Compression
8. Knocking
Overheating

Intake system
A
B
Timing belt
Compression
Defective timing
B
C
Cooling system

Overheating
B
A

Defective PCV valve
A
B

C
A

Loosened oil pump attaching bolts and defective gasket
A
B
Defective oil filter seal

Defective crankshaft oil seal
B
B

Loosened oil drain plug or defective gasket
B
B
Loosened oil pan fitting bolts or defective oil pan
Intake system
Compression
Lubrication system
ME(H4SO)-95

MECHANICAL
Symptoms
Problem parts etc.
Possible cause
10. Excessive fuel consump- Engine control system <Ref. to EN(H4SO)(diag)-2, Basic Diagnostic Procedure.>
tion
Intake system
Timing belt
Compression
RANK
A
A
Defective timing
B
B

C
C

B
C

C
B
Lubrication system

B
C
Cooling system
Over-cooling
ME(H4SO)-96
Engine Noise
MECHANICAL
28.Engine Noise
A: INSPECTION
Type of sound
Regular clicking sound
Heavy and dull clank
Condition
Possible cause
Sound increases as engine

speed increases.
Oil pressure is low.

Oil pressure is normal.
High-pitched clank (Spark

knock)
Clank when engine speed is

1,000 to 2,000 rpm
Knocking sound when engine

is operating under idling speed
and engine is warm
Squeaky sound
Camshaft journal wear

Worn connecting rod bearing (large end)
Damaged engine mounting
Sound is reduced when fuel
injector connector of noisy cyl-

inder is disconnected.
(NOTE*)
Sound is noticeable when
accelerating with an overload
condition.

injector connector of noisy cylinder is disconnected.
(NOTE*)
Sound is not reduced if each
fuel injector connector is disconnected in turn. (NOTE*)
Valve mechanism is defective.

Worn valve rocker
Worn camshaft
Broken valve spring
Ignition timing advanced

Accumulation of carbon inside combustion chamber
Wrong spark plug
Improper gasoline
Camshaft journal wear
Worn cylinder liner and piston ring

Broken or stuck piston ring
Worn piston pin and hole at piston end of connecting rod
Worn cam sprocket
Worn camshaft journal bore in cylinder head assembly
Insufficient generator lubrication
Rubbing sound
Gear scream when starting
engine
Sound like polishing glass with
a dry cloth
Hissing sound
Timing belt noise
Loose timing belt

Belt contacting with case/adjacent part
Valve noise
Poor contact of generator brush and rotor

Defective ignition starter switch
Worn gear and starter pinion
Loose drive belt
Defective water pump shaft
Insufficient compression
Air leakage in air intake system, hose, connection or manifold
NOTE*)
When disconnecting the fuel injector connector, the malfunction indicator light illuminates and DTC is stored in ECM memory.
Therefore, perform the Clear Memory Mode <Ref. to EN(H4SO)(diag)-44, OPERATION, Clear Memory Mode.> and Inspection
Mode <Ref. to EN(H4SO)(diag)-35, PROCEDURE, Inspection Mode.> after connecting the fuel injector connector.
ME(H4SO)-97
Engine Noise
MECHANICAL
ME(H4SO)-98
General Description
EXHAUST
A: COMPONENT
(8)
(5)
T7
(4)
(3)
(2)
(5)
(7)
(6)
(5)
(5)
(1)
(6)
T7
(11)
T3
(19)
(10)
T3
(25)
(17)
(9)
(24)
T2
(23)
T5
(12)
(13)
(14)
(21)
T1
T1
(15)
(16)
(18)
T1
(20)
T6
T1
(21)
(26)
T4
T4
T1
(22)
T1
(27)
(28)
T1
EX (H4SO)-2
EX-02133
General Description
EXHAUST
(1)
(2)
Gasket
Spring
(14)
Center exhaust pipe rear lower

cover
(25)
Front catalytic converter upper

cover
(3)
(4)
Chamber
Rear exhaust pipe
(15)
Rear catalytic converter lower

cover
(26)
Front catalytic converter lower

cover
(5)
(6)
Cushion rubber
Self-locking nut
(16)
Center exhaust pipe front lower

cover
(27)
Front exhaust pipe lower cover

RH
(7)
(8)
Gasket
Muffler
(17)
(18)
Front oxygen (A/F) sensor

Front catalytic converter
(28)
Front exhaust pipe lower cover LH
(9)
Center exhaust pipe front upper

cover
(19)
(20)
Rear oxygen sensor

Gasket

T1: 13 (1.3, 9.4)
(10)
Rear catalytic converter upper

cover
(21)
Gasket
T2: 18 (1.8, 13.0)
(22)
(23)
Front exhaust pipe

Front exhaust pipe upper cover
LH
T3: 21 (2.1, 15.2)

T4: 30 (3.1, 22.4)
(11)
Center exhaust pipe rear upper

cover
(12)
Center exhaust pipe
(13)
Rear catalytic converter
(24)

RH
B: CAUTION
points.
the battery.
EX (H4SO)-3
T5: 35 (3.6, 26.0)

T6: 40 (4.1, 29.5)
T7: 48 (4.9, 35.4)
Front Exhaust Pipe

EXHAUST
2. Front Exhaust Pipe
7) Remove the nuts which hold front exhaust pipe

onto cylinder heads.
A: REMOVAL
CAUTION:
Be careful not to pull down the front and center
exhaust pipe assembly.
FU-00009
3) Unclip the clip fastening the harness and disconnect the following connectors.
EX-02122
8) Remove the bolt which holds center exhaust

pipe to hanger bracket.
(A)
EX-02123
(B)
FU-02734


5) Separate the center exhaust pipe from rear exhaust pipe.
9) Remove the front and center exhaust pipe assembly from the vehicle.
CAUTION:
Be careful not to let the front and center exhaust pipe assembly fall off when removing as
it is quite heavy.
After removing the front and center exhaust
pipe assembly, do not apply excessive pulling
force on the rear exhaust pipe.
10) Separate the front exhaust pipe from center exhaust pipe.
EX-02121

EX-02124
11) Remove the front oxygen (A/F) sensor and rear

oxygen sensor. <Ref. to FU(H4SO)-36, REMOVAL, Front Oxygen (A/F) Sensor.> <Ref. to
FU(H4SO)-38, REMOVAL, Rear Oxygen Sensor.>
EX (H4SO)-4
Front Exhaust Pipe

EXHAUST
B: INSTALLATION
1) Install the front oxygen (A/F) sensor and rear oxygen sensor to the front exhaust pipe. <Ref. to
FU(H4SO)-36, INSTALLATION, Front Oxygen (A/
F) Sensor.> <Ref. to FU(H4SO)-38, INSTALLATION, Rear Oxygen Sensor.>
2) Install the front exhaust pipe to center exhaust
pipe.
6) Tighten the bolt which holds center exhaust pipe

to hanger bracket.
Tightening torque:
35 Nm (3.6 kgf-m, 26.0 ft-lb)
NOTE:
Use a new gasket.
Tightening torque:
40 Nm (4.1 kgf-m, 29.5 ft-lb)
EX-02123
7) Tighten the nuts which hold front exhaust pipe to

cylinder heads.
NOTE:
Use a new gasket.
Tightening torque:
30 Nm (3.1 kgf-m, 22.4 ft-lb)
EX-02124
3) Install the front and center exhaust pipe assembly to the vehicle.
4) Temporarily tighten the nuts which hold front exhaust pipe to cylinder heads.
EX-02122
EX-02122

5) Tighten the bolt which holds the center exhaust

pipe to exhaust pipe.
(A)
NOTE:
Use a new gasket.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
(B)
FU-02734

EX-02121
EX (H4SO)-5
Front Exhaust Pipe

EXHAUST
FU-00009
C: INSPECTION
leaks.
2) Check for hole or rust.
EX (H4SO)-6
Center Exhaust Pipe

EXHAUST
3. Center Exhaust Pipe

A: REMOVAL
After removing the center and front exhaust pipes
as one unit, separate them. Refer to Front Exhaust
Pipe for removal procedure. <Ref. to EX (H4SO)4, REMOVAL, Front Exhaust Pipe.>
B: INSTALLATION
Install the center exhaust pipe and front exhaust
pipe as one unit. Refer to Front Exhaust Pipe for
installation procedure. <Ref. to EX (H4SO)-5, INSTALLATION, Front Exhaust Pipe.>
C: INSPECTION
leaks.
EX (H4SO)-7
Rear Exhaust Pipe

EXHAUST
4. Rear Exhaust Pipe
B: INSTALLATION
A: REMOVAL
1) Install the rear exhaust pipe bracket to cushion

rubber.

3) Separate the rear exhaust pipe from center exhaust pipe.
EX-02126
2) Install the rear exhaust pipe to muffler.

EX-00214
4) Separate the rear exhaust pipe from muffler.

CAUTION:
Be careful not to pull down the rear exhaust
pipe.
NOTE:
Use a new gasket and self-locking nut.
When the lubricant was applied to the cushion
rubber during the removal/installation, degrease it
after reassembling.
Tightening torque:
48 Nm (4.9 kgf-m, 35.4 ft-lb)
EX-02125
5) Apply a coat of spray type lubricant to the mating

area of cushion rubber.
6) Remove the rear exhaust pipe bracket from
cushion rubber.
EX-02125
3) Install the rear exhaust pipe to center exhaust

pipe.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
EX-02126
EX-00214
C: INSPECTION
leaks.
3) Check the cushion rubber for wear or crack.
EX (H4SO)-8
Muffler
EXHAUST
5. Muffler
C: INSPECTION
A: REMOVAL

leaks.

3) Separate the muffler from rear exhaust pipe.
EX-02125

EX-02127
5) Remove the front and rear cushion rubber, and

then remove the muffler.
B: INSTALLATION
NOTE:
after reassembling.
Tightening torque:
48 Nm (4.9 kgf-m, 35.4 ft-lb)
EX-02125
EX (H4SO)-9
Muffler
EXHAUST
EX (H4SO)-10
General Description
COOLING
A: SPECIFICATION
Non-turbo model
Engine
Non-turbo
Cooling system
2 (US qt, Imp qt)
Total engine coolant capacity
Electric fan + Forced engine coolant circulation system

AT: approx. 6.5 (6.87, 5.72)
MT: approx. 6.6 (6.98, 5.81)
Type
Centrifugal impeller type

20 2 (5.3 US gal, 4.4 Imp gal)/min.
Discharge rate
Discharge
performance I
Discharge
performance II
Water pump
Discharge
performance III
Pump speed
Discharge pressure
Engine
coolant temperature
Discharge rate
Pump speed
Discharge pressure
Engine coolant
temperature
Discharge rate
Pump speed
Discharge pressure
Engine coolant
temperature
100 2 (26.4 US gal, 22.0 Imp gal)/min.

3,000 rpm 49.0 kPa (5.0 mAq)
200 2 (52.8 US gal, 44.0 Imp gal)/min.

6,000 rpm 225.4 kPa (23.0 mAq)
80C (176F)
76 mm (2.99 in)
8
Pump pulley diameter

Clearance between impeller and case
60 mm (2.36 in)
0.5 1.5 mm (0.020 0.059 in)
Type
Starts to open
Wax pellet type

80 84C (176 183F)
Fully opens
Valve lift
95C (203F)
9.0 mm (0.354 in) or more
Valve bore
Motor input
Radiator fan
35 mm (1.38 in)
120 W
Main fan
Sub fan
120 W
320 mm (12.60 in) /5 (main fan)
320 mm (12.60 in) / 7 (sub fan)
Down flow
Fan diameter / Blade

Type
Core dimensions
Width Height
Thickness
Radiator
Pressure range in which cap valve is open
Fins
Reservoir
tank
80C (176F)
80C (176F)
Impeller diameter
Number of impeller vanes
Thermostat
760 rpm 2.9 kPa (0.3 mAq)
691.5 360 16 mm
(27.22 14.17 0.63 in)
Above: 10815 kPa
(1.10.15 kg/cm2, 162 psi)
Below: 1.0 to 4.9 kPa
(0.01 to 0.05 kg/cm2, 0.1 to 0.7 psi)
Corrugated fin type
0.5 2 (0.5 US qt, 0.4 Imp qt)
Capacity
CO(H4SO)-2
General Description
COOLING
Coolant
Coolant
Water for dilution
agent
SUBARU coolant
Item number
000016218
Alternative
type
Distilled water
SOA345001

None
CO(H4SO)-3
General Description
COOLING
Turbo model
Engine
DOHC Turbo
Cooling system
2 (US qt, Imp qt)
Total engine coolant capacity

Type
Discharge
performance I
Discharge
performance II
Water pump
Discharge
performance III
Electric fan + Forced engine coolant circulation system

AT: 7.3 (7.71, 6.42)
MT: 7.4 (7.82, 6.51)
Centrifugal impeller type
Discharge rate
Pump speed
Discharge pressure
Engine coolant temperature
20 2 (5.3 US gal, 4.4 Imp gal)/min.
Discharge rate
Pump speed
Discharge pressure
100 2 (26.4 US gal, 22.0 Imp gal)/min.
Discharge rate
Pump speed
Discharge pressure
Engine coolant
temperature
200 2 (52.8 US gal, 44.0 Imp gal)/min.
760 rpm 2.9 kPa (0.3 mAq)

80C (176F)
3,000 rpm 49.0 kPa (5.0 mAq)

80C (176F)
6,000 rpm 225.4 kPa (23.0 mAq)

80C (176F)
Impeller diameter
76 mm (2.99 in)
Number of impeller vanes

Pump pulley diameter
8
60 mm (2.36 in)
Clearance between impeller and case

Type
Thermostat
0.5 1.5 mm (0.020 0.059 in)

Wax pellet type
Starts to open
Fully opens
76 80C (169 176F)

91C (196F)
Valve lift
Valve bore

35 mm (1.38 in)
Main fan
Sub fan
Motor input
Radiator fan
120 W
120 W
320 mm (12.60 in) /5 (main fan)
320 mm (12.60 in) / 7 (sub fan)
Down flow
Fan diameter / Blade

Type
Core dimensions
Width Height
Thickness
691.5 360 16 mm
(27.22 14.17 0.63 in)
Coolant filler tank side

Radiator
Pressure range in
which cap valve is
open
Above: 10815 kPa

(1.10.15 kg/cm2, 162 psi)
Below: 1.0 to 4.9 kPa
(0.01 to 0.05 kg/cm2, 0.1 to 0.7 psi)
Above only: 13714.7 kPa
(1.400.15 kgf/cm, 202.1 psi)
Corrugated fin type
Radiator side
Fins
Reservoir
tank
0.5 2 (0.5 US qt, 0.4 Imp qt)
Capacity
Coolant
Coolant
Water for dilution
agent
SUBARU coolant
Item number
000016218
Distilled water
Alternative
type
SOA345001
None
CO(H4SO)-4
General Description
COOLING
B: COMPONENT
1. WATER PUMP
Non-turbo model
(2)
(1)
T1
(3)
T1
(4)
(5)
T2
(6)
CO-00265
(1)
Water pump ASSY
(4)
Thermostat
(2)
(3)
Gasket
Heater by-pass hose
(5)
(6)
Gasket
Thermostat cover

T1: First 12 (1.2, 8.9)
Second 12 (1.2, 8.9)
T2: 12 (1.2, 8.9)
CO(H4SO)-5
General Description
COOLING
Turbo model
T1
(5)
(8)
(4)
T1
T2
T2
(3)
(7)
(6)
(2)
T3
(1)
CO-02140
(1)
(2)
Thermostat cover
Gasket
(5)
(6)
Gasket
Heater by-pass hose
(3)
(4)
Thermostat
Water pump ASSY
(7)
(8)
Coolant filler by-pass hose

Water by-pass pipe

T1: 6.4 (0.65, 4.7)
T2: First 12 (1.2, 8.9)
Second 12 (1.2, 8.9)
T3: 12 (1.2, 8.9)
CO(H4SO)-6
General Description
COOLING
2. RADIATOR AND ELECTRIC FAN

Non-turbo model
A
(8)
T5
T2
(7)
(12)
(6)
(5)
(14)
(5)
T3
(10)
(4)
(9)
T1
(11)
(3)
(23)
(2)
A
(15)
(22)
T4
(17)
T3
T1
(5)
T4
(13)
(21)
(5)
(15)
(16)
T2
(15)
(15)
B
(18)
(19)
(24)
T5
(1)
C
(15)
(15)
(20)
CO-02193
(1)
(2)
Radiator lower cushion

Radiator
(12)
(13)
Radiator sub fan motor

Radiator main fan
(22)
(23)
Radiator drain plug

Radiator cap
(3)
(4)
Radiator upper cushion

Radiator upper bracket
(14)
(15)
Radiator main fan motor

ATF hose clamp (AT model)
(24)
Radiator under cover (AT model)
(5)
(6)
Clamp
Radiator inlet hose
(16)
(17)
ATF hose A (AT model)

ATF hose B (AT model)

T1: 4.4 (0.45, 3.3)
(7)
(8)
Engine coolant reservoir tank cap

Over flow hose
(18)
(19)
ATF pipe (AT model)

ATF hose C (AT model)
T2: 7.5 (0.76, 5.5)

T3: 18 (1.8, 13.0)
(9)
(10)
Engine coolant reservoir tank

Radiator fan shroud
(20)
(21)
ATF hose D (AT model)

Radiator outlet hose
T4: 3.4 (0.35, 2.5)

T5: 4.9 (0.50, 3.6)
(11)
Radiator sub fan
CO(H4SO)-7
General Description
COOLING
Turbo model
(5)
(27)
(24)
(23)
(25)
(5)
(29)
(6)
(5)
(5)
(7)
(8)
T5
T2
(12)
(14)
T3
(10)
(4)
(3)
T1
(11)
(28)
(9)
(17)
(2)
(15)
(22)
T3
T4
T1
(5)
T4
(15)
(13)
(21)
T2
(15)
(15)
(18)
(19)
(5)
(26)
C
(15)
T5
(1)
(16)
(15)
(20)
CO-02194
CO(H4SO)-8
General Description
COOLING
(1)
(2)
Radiator lower cushion

Radiator
(13)
(14)
Radiator main fan

Radiator main fan motor
(25)
(26)
Overflow hose B
Radiator under cover (AT model)
(3)
(4)
Radiator upper cushion

Radiator upper bracket
(15)
(16)
ATF hose clamp (AT model)

ATF hose A (AT model)
(27)
(28)
Air breather hose

Radiator cap
(5)
(6)
Clamp
Radiator inlet hose
(17)
(18)
ATF hose B (AT model)

ATF pipe (AT model)
(29)
Overflow hose C
(7)
(8)
Engine coolant reservoir tank cap

Overflow hose A
(19)
(20)
ATF hose C (AT model)

ATF hose D (AT model)

T1: 4.4 (0.45, 3.3)
(9)
(10)
Engine coolant reservoir tank

Radiator fan shroud
(21)
(22)
Radiator outlet hose

Radiator drain plug
T2: 7.5 (0.76, 5.5)

T3: 18 (1.8, 13.0)
(11)
Radiator sub fan
(23)
Engine coolant filler tank
T4: 3.4 (0.35, 2.5)
(12)
Radiator sub fan motor
(24)
Engine coolant filler tank cap
T5: 4.9 (0.50, 3.6)
C: CAUTION
points.
the battery.
CO(H4SO)-9
General Description
COOLING
D: PREPARATION TOOL
1. NON-TURBO MODEL
ILLUSTRATION
TOOL NUMBER
499977100
DESCRIPTION
REMARKS
CRANK PULLEY
WRENCH
Used for stopping crank pulley when loosening

and tightening crank pulley bolts.
18231AA010
CAM SPROCKET
WRENCH (For LH)
Used for removing and installing cam sprocket

(LH).
also be used.
499207400
CAM SPROCKET
WRENCH (For RH)
Used for removing and installing cam sprocket

(RH).
ST-499977100
ST18231AA010
ST-499207400
CO(H4SO)-10
General Description
COOLING
2. TURBO MODEL
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
499977100
CRANK PULLEY
WRENCH
Used for stopping crank pulley when loosening

and tightening crank pulley bolts.
499977500
CAM SPROCKET
WRENCH

(Intake)
499207400
CAM SPROCKET
WRENCH

(Exhaust)
ST-499977100
ST-499977500
ST-499207400
CO(H4SO)-11
Radiator Fan System

COOLING
2. Radiator Fan System

A: WIRING DIAGRAM
BATTERY
SBF-1
B72
IGNITION
SWITCH
SBF-4
No.17
No.18
A/C RELAY HOLDER
A/C RELAY HOLDER
30A
FAN
RELAY 1
30A
1
31
34
32
30
28
25
27
29
MAIN FAN
MOTOR
FAN
RELAY 2
F27
FAN
MODE
RELAY
5
7
F2
10
11
F17
F27
B100
B25
18
B24
29
SUB FAN
MOTOR
1
2
F16
B136
ECM
E
B72
1 2
3 4
F2
F16
F17
1 2
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
F27
5 6
14 15 16
25 26 27
33 34 35
20
30
5 6 7
25 26 27
15 16 17
10
35
21
31
18
8
11
28
22 23 24
32 33 34 36
29
12 13 14
19
9
CO-02223
CO(H4SO)-12
Radiator Fan System

COOLING
B: INSPECTION
DETECTING CONDITION:
Engine coolant temperature is above 95C (203F).
Vehicle speed is below 19 km/h (12 MPH).
TROUBLE SYMPTOM:
Radiator main and sub fans do not rotate under the above conditions.
1
Step
CHECK OPERATION OF RADIATOR FAN.
1) Connect the test mode connector.
3) Using Subaru Select Monitor, check the
compulsory operation of radiator fan.
NOTE:
When performing the compulsory operation
check for the radiator fan using Subaru Select
Monitor, the radiator main fan and sub fan will
repeat such a operation as low speed revolution
high speed revolution OFF in this order.
Subaru Select Monitor
Refer to Compulsory Valve Operation Check
Mode for detail procedures. <Ref. to
EN(H4SO)(diag)-45, Compulsory Valve Operation Check Mode.>
3) Using Subaru Select Monitor, check the
compulsory operation of radiator fan.
NOTE:
When performing the compulsory operation
check for the radiator fan using Subaru Select
Monitor, the radiator main fan and sub fan will
repeat such a operation as low speed revolution
high speed revolution OFF in this order.
Mode for detail procedures. <Ref. to
CHECK POWER SUPPLY TO FAN RELAY 1.
2) Remove the fan relay 1 from A/C relay
holder.
3) Measure the voltage between fan relay 1
terminal and chassis ground.
Connector & terminal
(F27) No. 31 (+) Chassis ground ():
CHECK POWER SUPPLY TO FAN RELAY 1.
CHECK FUSE.
1) Remove the 30 A fuse from A/C relay
holder.
2) Check the condition of fuse.
Check
Do the radiator main and sub
fans rotate at low speed?
Yes
Go to step 2.
No
Go to step 3.
Do the radiator main and sub

fans rotate at high speed?
Radiator main fan

system is normal.
Go to step 32.
Is the voltage 10 V or more?
Go to step 4.
Go to step 5.
Go to step 8.
Go to step 7.
Is the fuse blown out?
Replace the fuse.
Go to step 6.
CO(H4SO)-13
Radiator Fan System

COOLING
10
11
12
13
14
Step
CHECK HARNESS OF 30 A FUSE TERMINAL
AND FAN RELAY 1 TERMINAL.
2) Measure the resistance between 30 A fuse
terminal and fan relay 1 terminal.
Terminals
No. 2 No. 31:
CHECK FUSE.
2) Remove the fuse No. 18.
CHECK FAN RELAY 1.
2) Measure the resistance between fan relay 1
terminals.
Terminals
No. 30 No. 31:
CHECK FAN RELAY 1.
1) Connect the battery to fan relay 1 terminals
No. 32 and No. 34.
terminals.
Terminals
No. 30 No. 31:
CHECK HARNESS BETWEEN FAN RELAY 1
TERMINAL AND MAIN FAN MOTOR CONNECTOR.
1) Disconnect the connector from the main fan
motor.
2) Measure the resistance of the harness
between fan relay 1 terminal and main fan
motor connector.
(F17) No. 1 (F27) No. 30:
CHECK THE HARNESS BETWEEN MAIN
FAN MOTOR CONNECTOR AND FAN MODE
RELAY CONNECTOR.
1) Remove the fan mode relay from A/C relay
holder.
2) Measure the resistance of harness between
main fan motor connector and fan mode relay
connector.
(F17) No. 2 (F27) No. 9:
CHECK POOR CONTACT.
Check poor contact of main fan motor connector.
CHECK MAIN FAN MOTOR.
Connect the battery positive (+) terminal to terminal No. 1, and the ground () terminal to terminal No. 2 of main fan motor.
CHECK FAN MODE RELAY.
Measure the resistance of fan mode relay.
Terminals
No. 6 No. 9:
Check
Yes
Is the resistance less than 1 ? Repair the power
supply line.
No
Repair the open
circuit of harness.
Replace the fuse.
Repair the power

supply line.
Is the resistance 1 M or
more?
Go to step 9.
Replace the fan

relay 1.
Is the resistance less than 1 ? Go to step 10.
Replace the fan

relay 1.
Repair the open

circuit of the harness between fan
relay 1 terminal
and main fan motor
connector.
Repair the open

circuit of the harness between the
main fan motor
connector and fan
mode relay connector.
Is there poor contact in main

fan motor connector?
Does the main fan rotate?
Repair the poor

Go to step 13.
contact of main fan
motor connector.
Go to step 14.
Replace the main
fan motor with a
new part.
CO(H4SO)-14
Replace the fan

mode relay.
Radiator Fan System

COOLING
15
16
17
18
19
20
21
22
23
Step
CHECK HARNESS BETWEEN FAN MODE
RELAY TERMINAL AND SUB FAN MOTOR
CONNECTOR.
1) Disconnect the connector from the sub fan
motor.
fan mode relay terminal and sub fan motor connector.
(F16) No. 1 (F27) No. 6:
CHECK SUB FAN MOTOR AND GROUND
CIRCUIT.
Measure the resistance between sub fan motor
connector and chassis ground.
(F16) No. 2 Chassis ground:
CHECK POOR CONTACT.
Check the poor contact of sub fan motor connector.
CHECK SUB FAN MOTOR.
Connect the battery positive (+) terminal to terminal No. 1, and the ground () terminal to terminal No. 2 of sub fan motor.
AND ECM.
1) Disconnect the connectors from ECM.
terminal and ECM connector.
(B136) No. 18 (F27) No. 32:
CHECK POOR CONTACT.
Check poor contact of ECM connector.
Check
Yes
No
Repair the open
mode relay terminal and sub fan
motor connector.
Repair the open

circuit of harness
between sub fan
motor connector
and chassis
ground.
Go to step 18.
Is there poor contact in sub fan Repair the poor

motor connector?
contact of sub fan
motor connector.
Does the sub fan rotate?
Go to step 19.
Replace the sub

fan motor with a
new part.
Repair the open

relay 1 terminal
and ECM.
Is there poor contact in ECM

connector?
Go to step 22.
Contact your SOA

Service Center.
NOTE:
Multiple parts may
be deteriorated.
Go to step 23.
Go to step 26.
Go to step 25.
Replace the fuse.
Go to step 24.
CHECK POWER SUPPLY TO FAN RELAY 2. Is the voltage 10 V or more?

holder.
CHECK POWER SUPPLY TO FAN RELAY 2. Is the voltage 10 V or more?
CHECK FUSE.
1) Remove the 30 A fuse from A/C relay
holder.
CO(H4SO)-15
Repair poor contact in ECM connector.
Radiator Fan System

COOLING
24
25
26
27
28
29
30
31
32
Step
CHECK HARNESS OF 30 A FUSE TERMINAL
AND FAN RELAY 2 TERMINAL.
2) Measure the resistance between 30 A fuse
terminal and fan relay 2 terminal.
Terminals
No. 4 No. 28:
CHECK FUSE.
2) Remove the fuse No. 17.
CHECK FAN RELAY 2.
holder.
3) Measure the resistance of fan relay 2.
Terminals
No. 28 No. 29:
CHECK FAN RELAY 2.
1) Connect the battery to fan relay 2 terminals
No. 25 and No. 27.
terminals.
Terminals
No. 28 No. 29:
TERMINAL AND SUB FAN MOTOR CONNECTOR.
motor.
fan relay 2 terminal and sub fan motor connector.
(F16) No. 1 (F27) No. 29:
AND ECM.
terminal and ECM connector.
(B136) No. 29 (F27) No. 27:
CHECK HARNESS BETWEEN FAN MODE
RELAY AND ECM.
Measure the resistance between fan mode
relay terminal and ECM connector.
(B136) No. 29 (F27) No. 7:
CHECK POOR CONTACT.
Check
Yes
Is the resistance less than 1 ? Repair the power
supply line.
No
Repair the open
circuit of harness.
Replace the fuse.
Repair the power

supply line.
more?
Go to step 27.
Replace the fan

relay 2.
Replace the fan

relay 2.
Repair the open

relay 2 terminal
and sub fan motor
connector.
Repair the open

relay 2 terminal
and ECM.
Repair the open

mode relay terminal and ECM.

connector?
Does the radiator main fan

rotate when the radiator main
and sub fans do not rotate at
high speed?
Go to step 21.
Contact your SOA

Service Center.
NOTE:
Multiple parts may
be deteriorated.
Go to step 33.
CO(H4SO)-16
Radiator Fan System

COOLING
33
34
35
36
Step
CHECK GROUND CIRCUIT OF FAN MODE
RELAY.
1) Remove the fan mode relay from A/C relay
holder.
2) Measure the resistance between fan mode
relay terminal and chassis ground.
CHECK POWER SUPPLY TO FAN MODE RELAY.
2) Measure the voltage between fan mode
relay terminal and chassis ground.
2) Remove the fan mode relay.
3) Measure the resistance of fan mode relay.
Terminals
(F27) No. 8 (F27) No. 9:
1) Connect the battery to terminals No. 5 and
No. 7 of fan mode relay.
2) Measure the resistance of fan mode relay.
Terminals
(F27) No. 8 (F27) No. 9:
Check
Yes
No
Repair the open
circuit of harness
between fan mode
relay and chassis
ground.
Go to step 35.
Repair the power

supply line.
more?
Go to step 36.
Replace the fan

mode relay.
Replace the fan

mode relay.
CO(H4SO)-17
Engine Coolant
COOLING
3. Engine Coolant
A: REPLACEMENT
1. DRAINING OF ENGINE COOLANT
4) Remove the drain cock to drain engine coolant
into container.
NOTE:
Remove the radiator cap so that engine coolant will
drain faster.
CO-00009
5) Install the drain cock.
2. FILLING OF ENGINE COOLANT

1) Fill cooling system conditioner into the filler neck
of the radiator (the filler neck of the coolant filler
tank on turbo models).
Cooling system protecting agent:
<Ref. to CO(H4SO)-2, SPECIFICATION, General Description.>
2) Fill engine coolant into the filler neck of the radiator (the filler neck of the coolant filler tank on turbo
models) up to the filler neck position.
Recommended engine coolant:
Coolant level:
3) Fill engine coolant into the reservoir tank up to
FULL level.
4) Close the radiator cap (on Non-turbo models) or

the coolant filler tank cap (on turbo models), start
the engine and race 5 to 6 times at less than 3,000
rpm, then stop the engine. (Complete this operation
within 40 seconds.)
5) Wait for one minute after the engine stops, then
open the radiator cap (on non-turbo models) or the
coolant filler tank cap (on turbo models). If the engine coolant level drops, add engine coolant into
6) Perform the procedures 4) and 5) again.
8) Start the engine and operate the heater at maximum hot position and the blower speed setting to
LO.
9) Run the engine at 2,000 rpm or less until radiator
fan starts and stops.
NOTE:
Be careful with the engine coolant temperature
gauge to prevent overheating.
10) Stop the engine and wait until the engine coolant temperature lowers to 30C (86F).
11) Open the radiator cap (on non-turbo models) or
the coolant filler tank cap (on turbo models). If the
engine coolant level drops, add engine coolant into
Then, pour the coolant into reservoir tank up to
FULL level.
13) Set the heater setting to maximum hot position
and the blower speed setting to LO and start the
engine. Perform racing at less than 3,000 rpm. If
the flowing sound is heard at this time, perform the
procedures from 9) again.
FULL
FULL
LOW
LOW
CO-00010
CO(H4SO)-18
Engine Coolant
COOLING
1. RELATIONSHIP OF SUBARU COOLANT

CONCENTRATION AND FREEZING TEMPERATURE
Specific gravity
of coolant
The concentration and safe operating temperature

of SUBARU coolant is shown in the diagram. Measuring the temperature and specific gravity of the
coolant will provide this information.
[Example]
If the coolant temperature is 25C (77F) and its
specific gravity is 1.054, the concentration is 35%
(point A), the safe operating temperature is 14C
(7F) (point B), and the freezing temperature is
20C (4F) (point C).
Safe operating temperature
Concentration
of coolant
1.100
1.090
60%
1.080
1.070
C
1.060
50%
(1.054)
1.050
1.040
1.030
40%
30%
Freezing
temperature
20%
1.010
1.000
25 C
(77 F)
1.020
10%
0
10 20 30 40
-40 -30 -20 -10
(-40) (-22) (-4) (14) (32) (50) (68) (86) (104)
Coolant temperature C ( F)
CO-02172
2. PROCEDURE TO ADJUST THE CONCENTRATION OF THE COOLANT

To adjust the concentration of coolant according to
temperature, find the proper fluid concentration in
the above diagram and replace the necessary
amount of coolant with an undiluted solution of
SUBARU genuine coolant (concentration 50%).
The amount of engine coolant that should be replaced can be determined using the diagram.
[Example]
Assume that the engine coolant concentration must
be increased from 25% to 40%. Find point A, where
the 25% line of engine coolant concentration intersects with the 40% curve of the necessary engine
coolant concentration, and read the scale on the
vertical axis of the graph at height A. The quantity
of coolant to be drained is 2.1 2 (2.2 US qt, 1.8 Imp
qt). Drain 2.1 2 (2.2 US qt, 1.8 Imp qt) of coolant
from the cooling system and add 2.1 2 (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.
Quantity of coolant to be
drained (US qt, Imp qt)
B: INSPECTION
Necessary Concentration
of coolant
3
(3.2,
2.6)
2
(2.1,
1.8)
1
(1.1,
0.9)
0
45%
A
35%
40%
30%
25%
20%
10% 15%
10
20
30
40
50
Concentration of coolant in
the vehicie cooling system %
Concentration of coolant in vehicie
and quantity to be drained
CO-00012
CO(H4SO)-19
Water Pump
COOLING
4. Water Pump
7) Remove the belt cover (LH) No. 2.
A: REMOVAL
1. NON-TURBO MODEL
1) Remove the radiator. <Ref. to CO(H4SO)-27,
REMOVAL, Radiator.>
2) Remove the V-belts.
<Ref. to ME(H4SO)-40, REMOVAL, V-belt.>
<Ref. to ME(H4SO)-44, TIMING BELT, REMOVAL, Timing Belt.>
4) Remove the automatic belt tension adjuster.
CO-00019
CO-00020
CO-00016
9) Disconnect the hose from water pump.

10) Remove the water pump.
5) Remove the belt idler No. 2.
CO-00017
6) Remove the cam sprocket (LH) using ST.

NOTE:
CAMSHAFT SPROCKET WRENCH (499207100)
can also be used.
ST
CO-00018
CO(H4SO)-20
CO-00021
Water Pump
COOLING
2. TURBO MODEL
9) Remove the belt cover (LH) No. 2.

REMOVAL, Radiator.>
2) Remove the V-belts. <Ref. to ME(H4DOTC)-40,
REMOVAL, V-belt.>
3) Remove the timing belt. <Ref. to ME(H4DOTC)44, REMOVAL, Timing Belt.>
4) Remove the automatic belt tension adjuster (A).
5) Remove the belt idler (B).
6) Remove the belt idler No. 2 (C).
CO-00024

(A)
(B)
(C)
CO-00023
7) Remove the camshaft position sensor. <Ref. to

FU(H4DOTC)-28, REMOVAL, Camshaft Position
Sensor.>
8) Remove the cam sprocket (LH) using ST.
ST 499977500
CAM SPROCKET WRENCH
(INTAKE)
CO-00025
11) Disconnect the hose from water pump.

CO-00021
ME-00710
ST
499207400
CAM SPROCKET WRENCH

(EXHAUST)
ME-00709
CO(H4SO)-21
Water Pump
COOLING
B: INSTALLATION
5) Install the cam sprocket (LH) using ST.

1. NON-TURBO MODEL
1) Install the water pump onto cylinder block (LH).
NOTE:
Replace with a new gasket.
When installing the water pump, tighten the bolts
in two stages in alphabetical sequence as shown in
figure.
NOTE:
CAMSHAFT SPROCKET WRENCH (499207100)
can also be used.
Tightening torque:
78 Nm (8.0 kgf-m, 57.9 ft-lb)
Tightening torque:
First:
12 Nm (1.2 kgf-m, 8.9 ft-lb)
Second:
12 Nm (1.2 kgf-m, 8.9 ft-lb)
ST
(B)
(C)
(A)
CO-00018
(D)
6) Install the belt idler No. 2.

(E)
Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
(F)
ME-02463
2) Install the hose to water pump.

Tightening torque:
24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
CO-00017
CO-00020
4) Install the belt cover No. 2 (LH).

Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
7) Install an automatic belt tension adjuster with the

tension rod held by a pin. <Ref. to ME(H4SO)-45,
Timing Belt.>
TIMING BELT, INSTALLATION, Timing Belt.>
10) Install the radiator. <Ref. to CO(H4SO)-29, INSTALLATION, Radiator.>
CO-00019
CO(H4SO)-22
Water Pump
COOLING
2. TURBO MODEL
1) Install the water pump onto cylinder block (LH).
NOTE:
Replace with a new gasket.
When installing the water pump, tighten the bolts
in two stages in alphabetical sequence as shown in
figure.
5) Install the cam sprocket (LH) using ST.

ST 499977500
CAM SPROCKET WRENCH
(INTAKE)
Tightening torque:
Tighten to 30 Nm (3.0 kgf-m, 21.8 ft-lb), and
then tighten further by 45.
Tightening torque:
First:
12 Nm (1.2 kgf-m, 8.9 ft-lb)
Second:
12 Nm (1.2 kgf-m, 8.9 ft-lb)
(B)
(C)
(A)
ME-00710
(D)
ST
(E)
499207400
(F)
CAM SPROCKET WRENCH

(EXHAUST)
Tightening torque:
ME-02463
2) Install the hose to water pump.

Tightening torque:
24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
ME-00709
CO-00025
6) Install the camshaft position sensor. <Ref. to

FU(H4DOTC)-28, INSTALLATION, Camshaft Position Sensor.>
7) Install the belt idler No. 2 (C).
8) Install the belt idler (B).
4) Install the belt cover No. 2 (LH).

Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
CO-00024
CO(H4SO)-23
Water Pump
COOLING
9) Install the automatic belt tension adjuster (A)

with the tension rod held by a pin. <Ref. to
ME(H4DOTC)-46, AUTOMATIC BELT TENSION
ADJUSTER ASSEMBLY AND BELT IDLER, INSTALLATION, Timing Belt.>
Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
(A)
(B)
(C)
CO-00023
10) Install the timing belt. <Ref. to ME(H4DOTC)47, TIMING BELT, INSTALLATION, Timing Belt.>
11) Install the V-belts. <Ref. to ME(H4DOTC)-40,
INSTALLATION, V-belt.>
C: INSPECTION
1) Check the water pump bearing for smooth rotation.
2) Check the water pump pulley for abnormalities.
3) Make sure the impeller is not deformed or damaged.
4) Inspect the clearance between impeller and
pump case.
Clearance between impeller and pump case:
Specification
0.5 1.5 mm (0.020 0.060 in)
CO-00293
5) After water pump installation, check pulley shaft

for engine coolant leaks. If leaks are noted, replace
the water pump assembly.
CO(H4SO)-24
Thermostat
COOLING
5. Thermostat
6) Remove the thermostat cover, and then remove

the gasket and thermostat.
A: REMOVAL
4) Drain engine coolant completely. <Ref. to
CO(H4SO)-18, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
(C)
CO-00009
(B)
5) Disconnect the radiator outlet hose from thermostat cover.
(A)
CO-00154
(A) Thermostat cover

(B) Gasket
(C) Thermostat
CO-00270
CO(H4SO)-25
Thermostat
COOLING
B: INSTALLATION
C: INSPECTION
1) Install a gasket to thermostat, and install the

thermostat and gasket to water pump as a unit.
Then, install the thermostat cover.
Replace the thermostat if the valve does not close

completely at an ambient temperature or if the following test shows unsatisfactory results.
Inspection method
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 measured value should
meet the specification.
NOTE:
When reinstalling the thermostat, use a new gasket.
The thermostat must be installed with the jiggle
pin facing upward.
Tightening torque:
12 Nm (1.2 kgf-m, 8.9 ft-lb)
NOTE:
Leave the thermostat in the boiling water for
more than five minutes before measuring valve lift.
Hold the thermostat with a wire or the like to
avoid contacting with container bottom.
Starting temperature to open:
Non-turbo model
80 84C (176 183F)
Turbo model
76 80C (169 176F)
(D)
Fully opens:
Non-turbo model
95C (203F)
Turbo model
91C (196F)
T
(C)
Valve lift:
(B)
(A)
(A)
CO-02153
(A) Thermostat cover

(B) Gasket
(C) Thermostat
(D) Jiggle pin
(B)
2) Connect the radiator outlet hose to thermostat

cover.
5) Fill engine coolant. <Ref. to CO(H4SO)-18,
FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
CO(H4SO)-26
CO-00033
(A) Thermometer
(B) Thermostat
Radiator
COOLING
6. Radiator
8) Disconnect the ATF cooler hoses from ATF

pipes. (AT model) Apply the cap to prevent ATF
leaks.
A: REMOVAL
1. NON-TURBO MODEL
WARNING:
The radiator is pressurized. Wait until engine
cools down before working on the radiator.
CO-02236

10) Disconnect the over flow hose.
11) Remove the reservoir tank.
FU-00009

6) Disconnect the connectors of radiator main fan
(A) and sub fan motor (B).
(A)
CO-00015
12) Disconnect the radiator inlet hose from radiator.
(B)
CO-00013
CO-02212
13) Remove the radiator upper brackets.
CO-00270
CO-00036
CO(H4SO)-27
Radiator
COOLING
14) Detach the power steering hose from the clip

on the radiator.

(A) and sub fan motor (B).
(A)
CO-00037
15) Lift the radiator up and away from vehicle.

16) Remove the radiator under cover. (AT model)
CO-00013
CO-00270
CO-00070
2. TURBO MODEL
WARNING:
2) Remove the collector cover.
(B)
9) Disconnect the ATF cooler hoses from ATF

pipes. (AT model)
Apply the cap to prevent ATF leaks.
CO-02236

FU-00009

CO-00015
CO(H4SO)-28
Radiator
COOLING
12) Disconnect the radiator inlet hose, air breather

hose and the overflow hose from radiator.
B: INSTALLATION
1. NON-TURBO MODEL
1) Attach the radiator under cover to the radiator.
(AT model)
(A)
(C)
(B)
CO-02195
(A) Radiator inlet hose

(B) Air breather hose
(C) Over flow hose
CO-00070
2) Attach the radiator lower cushions to holes on

the vehicle.
CO-00041
CO-00040
14) Disconnect the power steering hose from the

clip on the radiator.
3) Install the radiator to vehicle.

NOTE:
Make pins on the lower side of radiator be fitted into
the radiator lower cushions on body side.
4) Install the radiator upper brackets and tighten
the bolts.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
CO-00037
15) Lift the radiator up and away from vehicle.

16) Remove the radiator under cover. (AT model)
CO-00036
CO-00070
CO(H4SO)-29
Radiator
COOLING
5) Attach the power steering hose to the radiator.
11) Connect the radiator outlet hose.
CO-00037
6) Connect the radiator inlet hose.
CO-00270
12) Connect the connectors to the radiator main

fan motor (A) and sub fan motor (B).
(A)
(B)
CO-02212
CO-00013
7) Install the reservoir tank.

Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
CO-00015
8) Connect the over flow hose.

10) Connect the ATF cooler hoses. (AT model)
FU-00009

17) Check the ATF level. <Ref. to 4AT-28, INSPECTION, Automatic Transmission Fluid.>
CO-02236
CO(H4SO)-30
Radiator
COOLING
2. TURBO MODEL
1) Attach the radiator under cover to the radiator.

(AT model)
CO-00037
CO-00070
6) Connect the radiator inlet hose, air breather

hose and the overflow hose (B).
2) Attach the radiator lower cushions to holes on

the vehicle.
(A)
(C)
(B)
CO-02195

CO-00041
3) Install the radiator to vehicle.
(C) Over flow hose
NOTE:
the radiator lower cushions on body side.
4) Install the radiator upper brackets and tighten
the bolts.

Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
CO-00015

9) Connect the ATF cooler hoses. (AT model)
CO-00040
CO-02236
CO(H4SO)-31
Radiator
COOLING
C: INSPECTION
10) Connect the radiator outlet hose.
1) Remove the radiator cap (for Non-turbo model)

or the coolant filler tank cap (for turbo model), and
fill the engine coolant, and then install the tester (A)
to the installation position of cap.
Non-turbo model
(A)
CO-00270
11) Connect the connectors to the radiator main

fan motor (A) and sub fan motor (B).
CO-00042
(A)
(B)
Turbo model
CO-00013

CO-02168
2) When engine coolant leaks at/around radiator,

apply the following pressure.
Non-turbo model
157 kPa (1.6 kg/cm, 23 psi)
Turbo model
122 kPa (1.2 kg/cm, 18 psi)
FU-00009

16) Check the ATF level. <Ref. to 4AT-28, INSPECTION, Automatic Transmission Fluid.>
17) Install the collector cover.
CAUTION:
Inspection must be carried out at the side of
coolant filler tank, not at the side of radiator.
(Turbo model)
Engine should be turned off.
Wipe engine coolant from check points in advance.
Be careful to prevent engine coolant from
spurting out when removing tester.
Be careful not to deform the filler neck of radiator when installing and removing the tester.
CO(H4SO)-32
Radiator Cap
COOLING
7. Radiator Cap
A: INSPECTION
1) Attach the radiator cap to tester.
CO-00044
2) Increase pressure until the tester gauge pointer

stops. Radiator cap is functioning properly if it holds
the service limit pressure for 5 6 seconds.
Non-turbo model radiator side and turbo model
coolant filler tank side
Specified pressure:
93 123 kPa (0.95 1.25 kgf/cm2, 14 18
psi)
83 kPa (0.85 kgf/cm2, 12 psi)
Radiator side on turbo models
Specified pressure:
122 152 kPa (1.24 1.55 kgf/cm2, 18
22 psi)
112 kPa (1.14 kgf/cm2, 16 psi)
CAUTION:
Be sure to remove foreign matter and rust
from the cap in advance. Otherwise, results of
pressure test will be incorrect.
Do not confuse the cap of coolant filler tank
and cap of radiator.
CO(H4SO)-33
Radiator Main Fan and Fan Motor

COOLING
8. Radiator Main Fan and Fan

Motor
8) Remove the radiator under cover attaching

bolts. (AT model)
A: REMOVAL
1. NON-TURBO MODEL
CO-00070
9) Lift the radiator outlet hose and float the radiator

from the radiator under cover. Remove the ATF
hose from 2 places on the clip of radiator fan motor
assembly. (AT model)
FU-00009
3) Remove the radiator upper brackets. (AT model)
CO-00143
CO-00036

6) Drain approximately 1 2 (1.06 US qt, 0.88 Imp
qt) of engine coolant. <Ref. to CO(H4SO)-18,
DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
7) Disconnect the connectors of main fan motor (A)
and sub fan motor (B).

12) Disconnect the over flow hose.
CO-00015
(A)
(B)
14) Remove the mounting bolts from the radiator

fan motor assembly.
CO-00013
CO-00064
CO(H4SO)-34

COOLING
15) Disconnect the radiator inlet hose from radiator.
4) Remove the radiator upper brackets. (AT model)
CO-00036
CO-02212
16) Detach the power steering hose from the clip

on the radiator.

7) Drain approximately 1 2 (1.06 US qt, 0.88 Imp
motor connector (A) and sub fan motor connector
(B).
CO-00037
(A)
17) Lift the radiator fan motor assembly up and

away from vehicle.
(B)
CO-00013
9) Remove the radiator under cover attaching

bolts. (AT model)
CO-00065
2. TURBO MODEL
CO-00070
FU-00009
CO(H4SO)-35

COOLING
10) Lift the radiator outlet hose and float the radiator from the radiator under cover. Remove the ATF
hose from 2 places on the clip of radiator fan motor
assembly. (AT model)
14) Disconnect the radiator inlet hose and the over

flow hose.
(A)
(C)
(B)
CO-02195
CO-00143

(C) Over flow hose

15) Disconnect the power steering hose from the

clip on the radiator.
CO-00015
13) Remove the mounting bolts from radiator main

fan motor assembly.
CO-00037
16) Remove the radiator main fan motor assembly

from vehicle.
CO-00064
CO-00065
CO(H4SO)-36

COOLING
B: INSTALLATION
1. NON-TURBO MODEL
1) Install the radiator main fan motor assembly to
the radiator.
from the radiator under cover. Connect the ATF
hose to 2 locations on the clip of radiator main fan
motor assembly. (AT model)
NOTE:
the vehicle side.
CO-00037
9) Connect the radiator inlet hose.
CO-02212
CO-00143
4) Tighten the attachment bolts of the radiator under cover. (AT model)
10) Install the mounting bolts to radiator main fan

motor assembly.
Tightening torque:
4.9 Nm (0.50 kgf-m, 3.6 ft-lb)
CO-00070
5) Connect the radiator main fan motor connector

(A) and sub fan motor connector (B).
CO-00064

Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
(A)
(B)
CO-00013

CO-00015
12) Install the over flow hose.
CO(H4SO)-37

COOLING
13) Install the radiator upper brackets. (AT model)
4) Tighten the attachment bolts of the radiator under cover. (AT model)
CO-00036
CO-00070
5) Connect the radiator main fan motor connector

(A) and sub fan motor connector (B).
(A)
(B)
FU-00009

2. TURBO MODEL
1) Install the radiator main fan motor assembly to
the radiator.
from the radiator under cover. Connect the ATF
hose to 2 locations on the clip of radiator main fan
motor assembly. (AT model)
CO-00013

8) Connect the power steering hose to the clip on
the radiator.
NOTE:
the vehicle side.
CO-00037
CO-00143
CO(H4SO)-38

COOLING
9) Connect the radiator inlet hose and the overflow

hose to radiator.
(A)
12) Install the radiator upper brackets. (AT model)
(C)
(B)
CO-00036
CO-02195

(C) Over flow hose
10) Install the mounting bolts to radiator main fan

motor assembly.
Tightening torque:
4.9 Nm (0.5 kgf-m, 3.6 ft-lb)
FU-00009

CO-00064

Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
CO-00015
CO(H4SO)-39

COOLING
C: DISASSEMBLY
D: ASSEMBLY
1) Remove the clip which holds motor connector

onto the shroud.
2) Remove the nuts which secure the fan to the fan
motor.
Assemble in the reverse order of disassembly.

Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
CO-00048
CO-00047
3) Remove the bolts which hold fan motor onto

shroud.
Tightening torque:
3.4 Nm (0.35 kgf-m, 2.5 ft-lb)
CO-00048
CO(H4SO)-40
CO-00047
Radiator Sub Fan and Fan Motor

COOLING
9. Radiator Sub Fan and Fan

Motor
D: ASSEMBLY
A: REMOVAL
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
Refer to the radiator main fan and fan motor. <Ref.

to CO(H4SO)-34, REMOVAL, Radiator Main Fan
and Fan Motor.>
B: INSTALLATION
Refer to the radiator main fan and fan motor. <Ref.
to CO(H4SO)-37, INSTALLATION, Radiator Main
Fan and Fan Motor.>
C: DISASSEMBLY
1) Remove the clip which holds motor connector
onto the shroud.
2) Remove the nuts which secure the fan to the fan
motor.
CO-00050
Tightening torque:
3.4 Nm (0.35 kgf-m, 2.5 ft-lb)
CO-00049
3) Remove the bolts which hold fan motor onto

shroud.
CO-00050
CO(H4SO)-41
CO-00049
Reservoir Tank
COOLING
10.Reservoir Tank
A: REMOVAL
1) Disconnect the over flow hose which is connected to the radiator filler neck.
2) Remove the bolts which install reservoir tank
onto radiator main fan shroud.
CO-00015
B: INSTALLATION
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
CO-00015
C: INSPECTION
Make sure the engine coolant level is between
FULL and LOW.
CO(H4SO)-42
Coolant Filler Tank

COOLING
11.Coolant Filler Tank
8) Remove the coolant filler tank.
A: REMOVAL
NOTE:
Mount the coolant filler tank only to the turbo model.
WARNING:
2) Drain approximately 3.0 2 (3.2 US qt, 2.6 Imp
3) Remove the air cleaner upper cover and the air
intake duct. <Ref. to IN (H4SO)-5, REMOVAL, Air
Cleaner Case.>
5) Disconnect the engine coolant hoses from coolant filler tank.
CO-02170
B: INSTALLATION
1) Install in the reverse order of removal.
Tightening torque:
T1: 16 Nm (1.6 kgf-m, 11.8 ft-lb)
T2: 13 Nm (1.3 kgf-m, 9.6 ft-lb)
CO-02169
6) Remove the bolts and nut which install coolant

filler tank.
7) Disconnect the engine coolant hose which connects the under side of coolant filler tank.
T1
T2
CO-02171

CO(H4SO)-43
Engine Cooling System Trouble in General

COOLING
12.Engine Cooling System Trouble in General

A: INSPECTION
Trouble
Possible cause
Corrective action
a. Insufficient engine coolant
Replenish engine coolant, inspect for leakage, and

repair it if necessary.
b. Loose timing belt

c. Oil on timing belt
Repair or replace timing belt tensioner.

Replace.
d. Malfunction of thermostat
e. Malfunction of water pump
Replace.
Replace.
f. Clogged engine coolant passage
Clean.
Inspect and repair the ignition control system. <Ref. to
EN(H4SO)(diag)-2, PROCEDURE, Basic Diagnostic
Procedure.> <Ref. to EN(H4DOTC)(diag)-2, PROCEDURE, Basic Diagnostic Procedure.>
Clean, repair or replace.
g. Improper ignition timing

Overheating
h. Clogged or leaking radiator

i. Engine oil mixed in engine coolant
j. Air/fuel mixture ratio too lean
Over-cooling
Engine coolant
leaks
Strange noise
Replace the engine coolant.

Inspect and repair the fuel injection system. <Ref. to
EN(H4SO)(diag)-2, PROCEDURE, Basic Diagnostic
Procedure.> <Ref. to EN(H4DOTC)(diag)-2, PROCEDURE, Basic Diagnostic Procedure.>
k. Excessive back pressure in exhaust system

l. Insufficient clearance between piston and cylinder
Clean or replace.
Adjust or replace.
m. Slipping clutch
n. Dragging brake
Correct or replace.
Adjust.
o. Defective radiator fan
Inspect the radiator fan relay, engine coolant temperature sensor or fan motor and replace them.
a. Ambient temperature extremely low

b. Defective thermostat
Partly cover radiator front area.

Replace.
a. Loosened or damaged connecting units on hoses

b. Leakage from water pump
Correct or replace.
Replace.
c. Leakage from water pipe

d. Leakage around cylinder head gasket
Correct or replace.
Retighten cylinder head bolts or replace gasket.
e. Damaged or cracked cylinder head and cylinder

block
Correct or replace.
f. Damaged or cracked thermostat case

g. Leakage from radiator
Correct or replace.
Correct or replace.
a. Defective drive belt

b. Defective radiator fan
Replace.
Replace.
c. Defective water pump bearing

d. Defective water pump mechanical seal
Replace water pump.

Replace water pump.
CO(H4SO)-44
General Description
LUBRICATION
A: SPECIFICATION
Lubrication method
Forced lubrication
Pump type
Number of teeth
Trochoid type
9
Inner rotor
Outer rotor
10
78 10 mm (3.07 0.39 in)
Outer rotor diameter thickness
Oil pump
Tip clearance between inner and outer rotors
Specification
Limit
0.04 0.14 mm (0.0016 0.0055 in)

0.18 mm (0.0071 in)
Side clearance between inner rotor and pump case
Specification
Limit
0.02 0.07 mm (0.0008 0.0028 in)

0.12 mm (0.0047 in)
Case clearance between outer rotor and pump case
Specification
Limit
0.10 0.175 mm (0.0039 0.0069 in)

0.20 mm (0.0079 in)
600 rpm
Performance
(Oil temperature 80C (176F)
5,000 rpm
Discharge
pressure
Discharge
rate
Discharge
pressure
Discharge
rate
Oil filter
Outer diameter: 65 mm
(2.56 in)
470 cm2 (73 sq in)

160 kPa (1.63 kgf/cm2, 23.2 psi)
(2.68 in)
68 65 mm (2.68 2.56 in)
(2.56 in)
65 74.4 mm (2.56 2.93 in)

M 20 1.5
Immersed contact point type
Operating voltage wattage

Warning light operating pressure
12 V 3.4 W or less
14.7 kPa (0.15 kgf/cm2, 2.1 psi)
Non-turbo
981 kPa (10 kgf/cm2, 142 psi) or more

5.0 2 (5.4 US qt, 4.5 Imp qt)
Turbo
Non-turbo
5.0 2 (5.4 US qt, 4.5 Imp qt)

4.2 2 (4.4 US qt, 3.7 Imp qt)
Turbo
Non-turbo
4.3 2 (4.5 US qt, 3.8 Imp qt)

4.0 2 (4.2 US qt, 3.5 Imp qt)
Turbo
4.0 2 (4.2 US qt, 3.5 Imp qt)
Proof pressure
Capacity
(at overhaul)
Engine oil
When replacing engine oil and oil

filter
When replacing engine oil only
47.0 2 (49.7 US qt, 41.4 Imp qt)/min.
800 cm2 (124 sq in)
Installation bolt specifications

Type
Oil pressure
switch
294 kPa (3.0 kgf/cm2, 43 psi)
(2.68 in)
By-pass valve opening pressure
Outer diameter width
4.6 2 (4.9 US qt, 4.0 Imp qt)/min.
588 kPa (6.0 kgf/cm2, 85 psi)

Full-flow filter type
Relief valve working pressure

Filter type
Filtration area
98 kPa (1.0 kgf/cm2, 14 psi)
LU (H4SO)-2
General Description
LUBRICATION
Recommended oil:
Items having the API standard SM Energy
Conserving logo
ILSAC standard GF-4 starburst mark displayed on container top.
SAE (1)
( C) -30 -20 -15
( F) -22 -4 5
15
30
32
59
86 104
40
10W-30, 10W-40
5W-30 (2)
LU-02203
(1) SAE viscosity No. and applicable temperature

(2) Recommended
CAUTION:
It is acceptable to fill an engine with oil of another name when replacing oil, but use an API
standard specified by Subaru or one that has
SAE viscosity number.
NOTE:
Use an oil with the viscosity shown below if the vehicle is used in regions of high temperature, or in
severe environments. API standard: SM or SL
SAE viscosity No.: 30, 40, 10W-50, 20W-40, 20W50
LU (H4SO)-3
General Description
LUBRICATION
B: COMPONENT
1. NON-TURBO MODEL
(13)
T4
(16)
(15)
(14)
(12)
T2
(17)
(28)
(11)
T2
(18)
(29)
T2
T7
(10)
T2
(9)
T6
(19)
(8)
(30)
T3
(24)
(20)
(7)
(6)
T3
T3
(27)
(5)
(4)
(3)
(2)
(1)
T1
T5
(22)
(21)
(23)
(26)
(25)
T5
LU-02285
(1)
(2)
Plug
Gasket
(15)
(16)
O-ring
Oil filler cap
(28)
(29)
Seal
Rocker cover
(3)
(4)
Relief valve spring

Relief valve
(17)
(18)
O-ring
Baffle plate
(30)
O-ring
(5)
(6)
Oil seal
Oil pump case
(19)
(20)
O-ring
Oil strainer

T1: 5 (0.5, 3.6)
(7)
(8)
Inner rotor
Outer rotor
(21)
(22)

O-ring
T2: 6.4 (0.65, 4.7)

T3: 10 (1.0, 7.2)
(9)
(10)
Oil pump cover

Oil filter
(23)
(24)
Oil pan
Oil level gauge
T4: 25 (2.5, 18.1)

T5: 44 (4.5, 32.5)
(11)
(12)
O-ring
Oil pump ASSY
(25)
(26)
Drain plug
Metal gasket
(13)
(14)
Oil pressure switch

Oil filler duct
(27)
Gasket
T6: 5.4 (0.55, 4.0)

T7: <Ref. to ME(H4SO)-55, INSTALLATION, Camshaft.>
LU (H4SO)-4
General Description
LUBRICATION
2. TURBO MODEL
(17)
(16)
T6
(36)
T2
(19)
T10
(20)
(15)
(21)
(14)
T2
(29)
(30)
T4
T2
T9
(6)
T5
(13)
T2
(7)
(32)
(38)
(31)
(9)
(8)
(33)
(34)
T2
T2
(35)
(18)
(29)
(26)
(22)
(12)
T2
T2
T3
T8
(23)
(5)
(4)
(11)
(2)
T1
(3)
(1)
T7
(10)
(27)
T1
(24)
(37)
(25)
(28)
LU (H4SO)-5
T7
LU-02284
General Description
LUBRICATION
(1)
(2)
Plug
Gasket
(18)
(19)
O-ring
Oil filler duct
(35)
(36)
O-ring
O-ring
(3)
(4)
Relief valve spring

Relief valve
(20)
(21)
O-ring
Rocker cover
(37)
(38)
O-ring
Plug
(5)
(6)
Oil seal
Oil pump case
(22)
(23)
Oil strainer
Gasket
(7)
(8)
Inner rotor
Outer rotor
(24)
(25)

Oil pan
T1: 5 (0.5, 3.6)

T2: 6.4 (0.65, 4.7)
(9)
(10)
Oil pump cover

Oil filter
(26)
(27)
Oil level gauge

Metal gasket
T3: 10 (1.0, 7.2)

T4: 45 (4.6, 33.2)
(11)
Oil cooler connector
(28)
Drain plug
T5: 69 (7.0, 51)
(12)
(13)
Water by-pass pipe

Oil cooler
(29)
(30)
Gasket
Adapter (1)
T6: 25 (2.5, 18.1)

T7: 44 (4.5, 32.5)
(14)
(15)
O-ring
Oil pump ASSY
(31)
(32)
Adapter (2)
Baffle plate
T8: 54 (5.5, 40)

T9: 5.4 (0.55, 4.0)
(16)
(17)
Oil pressure switch

Oil filler cap
(33)
(34)
Seal
O-ring
C: CAUTION
points.
the battery.
LU (H4SO)-6
T10: <Ref. to ME(H4DOTC)-55,

INSTALLATION, Camshaft.>
General Description
LUBRICATION
D: PREPARATION TOOL
ILLUSTRATION
TOOL NUMBER
499977100
DESCRIPTION
CRANK PULLEY
WRENCH
REMARKS
loosening and tightening the crank pulley bolt.
18332AA000
OIL FILTER
WRENCH

18332AA010
OIL FILTER
WRENCH

499587100
OIL SEAL
INSTALLER
Used for installing oil seal into oil pump.
ST-499977100
ST18332AA000
ST18332AA010
ST-499587100
LU (H4SO)-7
Oil Pressure System

LUBRICATION
2. Oil Pressure System

A: WIRING DIAGRAM
No.14
IGNITION
SWITCH
B108
F46
BATTERY
SBF-4
SBF-1
B36
OIL PRESSURE
WARNING LIGHT
B9
i1
COMBINATION
METER
i12
B:
i10
A3
A:
14
i3
B38
28
TB
B200
TB NA
14 31
F74
NA
TB
B22
F61
E3
E2
NA : NON-TURBO MODEL
E11
TB : TURBO MODEL
OIL PRESSURE
SWITCH
A:
B:
i12
4 5 6
1 2 3
7 8 9 10 11 12 13 14
F46
i10
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B36
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B38
1
2
F74
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
F61
1 2
: TB
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
B22 : NA
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35 36 37 38 39 40 41
43
44 45
46 47
48 49 50 51 52 53 54
LU-02181
LU (H4SO)-8
Oil Pressure System

LUBRICATION
B: INSPECTION
1
Step
Check
CHECK COMBINATION METER.
Does the warning light illumi1) Turn the ignition switch to ON (engine OFF). nate?
2) Check other warning lights.
Yes
Go to step 2.
CHECK THE HARNESS CONNECTOR BEIs the voltage 10 V or more?

TWEEN THE COMBINATION METER AND
THE OIL PRESSURE SWITCH.
2) Disconnect the connector from oil pressure
switch.
4) Measure the voltage of harness between oil
pressure switch connector and chassis ground.
(E11) No. 1 (+) Chassis ground ():
Is the resistance less than 10
?
2) Remove the combination meter.
3) Measure the resistance of combination
meter.
Terminals
(i10) No. 9 (i12) No. 3:
Replace the oil

pressure switch.
LU (H4SO)-9
Replace the harness connector

between the combination meter and
the oil pressure
switch.
No
Repair or replace
the combination
meter. <Ref. to IDI3, INSPECTION,
Combination Meter
System.>
Go to step 3.
Repair or replace
the combination
meter. <Ref. to IDI3, INSPECTION,
Combination Meter
System.>
Engine Oil
LUBRICATION
3. Engine Oil
B: REPLACEMENT
A: INSPECTION
1) Open the engine oil filler cap for quick draining of

engine oil.
3) Remove the service hole clip located on the under cover.

2) Remove the oil level gauge and wipe away the
oil.
the level gauge is correctly inserted and properly
orientated.
4) Remove it again and note the reading. If the engine oil level is below L line, add oil to bring the
level up to F line.
5) After turning off the engine, wait a few minutes
for the oil to return to the oil pan before checking
the level.
6) Just after driving or while the engine is warm, engine oil level shows in the range between F line
and cutout portion. This is caused by thermal expansion of engine oil.
PM-00303
4) Rotate the service hole cover in the arrow direction.
NOTE:
To prevent overfilling of engine oil, do not add oil
above F line when the engine is cold.
(A)
(B)
(C)
(E)
PM-00304
(D)
5) Drain engine oil by loosening the engine oil drain

plug.
LU-00213
(A) Oil level gauge
NOTE:
Prepare the container for draining of engine oil.

(C) Upper level
(D) Lower level
(E) Approx. 1.0 2 (1.1 US qt, 0.9 Imp qt)
(A)
(B)
PM-00305
(A) Drain plug

(B) Oil filter
LU (H4SO)-10
Engine Oil
LUBRICATION
6) Tighten the engine oil drain plug after draining

engine oil.
NOTE:
Use a new drain plug gasket.
Tightening torque:
44 Nm (4.5 kgf-m, 32.5 ft-lb)
(A)
(B)
PM-00305
(A) Drain plug

(B) Oil filter
7) Install the service hole cover.

8) Using engine oil of proper quality and viscosity,
fill engine oil through the oil filler duct to the upper
level on level gauge. Make sure that the vehicle is
parked on a level surface when checking oil level.
Recommended oil
<Ref. to LU (H4SO)-2, SPECIFICATION, General Description.>
Engine oil capacity:
<Ref. to LU (H4SO)-2, SPECIFICATION, General Description.>
9) Close the engine oil filler cap.
10) Start the engine and warm it up for a time.
11) After the engine stops, recheck the oil level. If
necessary, add engine oil up to the upper level on
level gauge.
(A)
(B)
(C)
(E)
(D)
LU-00213
(A) Oil level gauge

(C) Upper level
(D) Lower level
(E) Approx. 1.0 2 (1.1 US qt, 0.9 Imp qt)
LU (H4SO)-11
Oil Pump
LUBRICATION
4. Oil Pump
8) Remove the crankshaft position sensor.
A: REMOVAL
LU-00046
FU-00009
2) Remove the collector cover. (Turbo model)

5) Remove the bolts which install water pipe of oil
cooler to oil pump. (Turbo model)
9) Remove the V-belts. (Non-turbo model) <Ref. to

ME(H4SO)-40, REMOVAL, V-belt.> (Turbo model)
<Ref. to ME(H4DOTC)-40, REMOVAL, V-belt.>
10) Remove the V-belt tensioner.
LU-00011
11) Remove the crank pulley using ST.

ST 499977100
CRANK PULLEY WRENCH
LU-00137
6) Remove the water pipe and hoses between oil

cooler and water pump. (Turbo model)
LU-00012
12) Remove the water pump. <Ref. to CO(H4SO)20, REMOVAL, Water Pump.>
LU-00064

REMOVAL, Radiator.>
LU-00013
LU (H4SO)-12
Oil Pump
LUBRICATION
B: INSTALLATION

Perform the following.
1) Apply liquid gasket to the mating surfaces of oil
pump.
Liquid gasket:
equivalent
LU-02111
15) Remove the bolts which install oil pump onto

cylinder block.
NOTE:
pump.
(A)
LU-00017
2) Replace O-ring (A) with a new part.

3) Apply a coat of engine oil to the inside of oil seal.
LU-00015
16) Remove the oil pump by using flat tip screwdriver.

CAUTION:
Be careful not to scratch mating surfaces of
LU-00018
4) Position the oil pump, aligning the notched area

with crankshaft, and push the oil pump straight.
CAUTION:
Be careful not to scratch the oil seal when installing oil pump on cylinder block.
5) Install the oil pump.
LU-00016
LU (H4SO)-13
Oil Pump
LUBRICATION
6) Apply liquid gasket to the three bolts thread

shown in figure. (if the bolts are reused)
Liquid gasket:
equivalent
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
C: DISASSEMBLY
Remove the screw which secures oil pump cover
and then disassemble oil pump. Inscribe alignment
marks on the inner and outer rotors so that they can
be replaced in their original positions during reassembly.
CAUTION:
Before disassembling the oil pump, remove the
relief valve.
(E)
(D)
(B)
(C)
T
LU-02103
(A)
(I)
(F)
(G)
(H)
LU-00020
(A) Oil seal

(B) Oil pump case
(C) Inner rotor
(D) Outer rotor
(E) Oil pump cover
(F) Relief valve
(G) Relief valve spring
(H) Plug
(I) Gasket
LU (H4SO)-14
Oil Pump
LUBRICATION
D: ASSEMBLY
5) Assemble the oil pump cover.
1) Assemble the front oil seal by using ST.

ST 499587100
OIL SEAL INSTALLER
Tightening torque:
T1: 5.4 Nm (0.55 kgf-m, 4.0 ft-lb)
T2: 44 Nm (4.5 kgf-m, 32.5 ft-lb)
NOTE:
Use a new front oil seal.
T1
(E)
(D)
(B)
ST
LU-00021
(C)
(A)
2) Apply a coat of engine oil to inner and outer rotors.

3) Assemble the inner and outer rotors in their original positions.
4) Assemble the oil relief valve and install relief
valve spring and plug.
(F)
(G)
(I)
(H)
T2
NOTE:
Use a new gasket.
LU-02134
(A) Oil seal

(B) Pump case
(C) Inner rotor
(D) Outer rotor
(E) Pump cover
(F) Relief valve
(G) Relief valve spring
(H) Plug
(I) Gasket
LU (H4SO)-15
Oil Pump
LUBRICATION
E: INSPECTION
3. SIDE CLEARANCE
1. TIP CLEARANCE
Measure the tip clearance of rotors. If the clearance
exceeds the limit, replace rotors as a matched set.
Tip clearance:
Specification:
0.04 0.14 mm (0.0016 0.0055 in)
Service limit:
0.18 mm (0.0071 in)
Measure the clearance between oil pump inner rotor and oil pump cover. If the clearance exceeds
the limit, replace rotor or oil pump case.
Side clearance:
Specification:
0.02 0.07 mm (0.0008 0.0028 in)
Service limit:
0.12 mm (0.0047 in)
LU-00025
LU-00023
4. OIL RELIEF VALVE
2. CASE CLEARANCE
Measure the clearance between outer rotor and oil
pump case. If the clearance exceeds the limit, replace the rotor.
Case clearance:
Specification:
0.10 0.175 mm (0.0039 0.0069 in)
Service limit:
0.20 mm (0.0079 in)
Check the valve for assembly condition and damage, and the relief valve spring for damage and deterioration. Replace the parts if defective.
Relief valve spring
Free length:
73.7 mm (2.902 in)
Installed length:
54.7 mm (2.154 in)
Load when installed:
93.1 N (9.49 kgf, 20.88 lb)
5. OIL PUMP CASE

Check the oil pump case for worn shaft hole,
clogged oil passage, worn rotor chamber, cracks
and other faults.
6. OIL SEAL
Check the oil seal lips for deformation, hardening,
wear, etc. and replace if defective.
LU-00024
LU (H4SO)-16
Oil Pan and Strainer

LUBRICATION
5. Oil Pan and Strainer
A: REMOVAL
2) Remove the front wheels.
ME-00213
FU-00009

LU-00049

wire ropes.
LU-00026

(Non-turbo model) <Ref. to IN (H4SO)-7, REMOVAL, Air Intake Duct.> <Ref. to IN (H4SO)-5, REMOVAL, Air Cleaner Case.>
7) Remove the air intake boot and air cleaner upper
cover. (Turbo model)
LU-00070
LU-00028

CAUTION:
When lifting up the vehicle, raise up wire ropes
at the same time.
14) Drain the engine oil. <Ref. to LU (H4SO)-10,
REPLACEMENT, Engine Oil.>
(Non-turbo model) <Ref. to EX (H4SO)-4, REMOVAL, Front Exhaust Pipe.>
8) Remove the intercooler. (Turbo model) <Ref. to

IN(H4DOTC)-11, REMOVAL, Intercooler.>
LU (H4SO)-17

LUBRICATION

B: INSTALLATION
CAUTION:
Before installing the oil pan, clean the mating
surface of oil pan and engine block.
1) Make sure that the seals (A) are installed securely on the buffle plate in a direction as shown in
the figure below.
(A)
ME-02650
17) Remove the bolts which install oil pan on cylinder block with the engine raised up.
18) Insert the oil pan cutter blade into the gap between cylinder block and oil pan.
CAUTION:
of oil pan cutter.
LU-00052

Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
3) Install the oil strainer onto baffle plate.
NOTE:
Replace the O-ring with a new part.
(D)
Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
4) Tighten the strainer stay together with the baffle
plate.
Tightening torque:
6.4 Nm (0.65 kgf-m, 9.7 ft-lb)
(C)
NOTE:
(B)
Liquid gasket:
equivalent
(A)
LU-02286
(A) Oil pan

(B) Oil strainer
(C) Baffle plate
(D) Cylinder block
LU-00034
LU (H4SO)-18

LUBRICATION
6) Tighten the bolt which installs oil pan to engine

block.
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
9) Install the front and center exhaust pipe. (Nonturbo model) <Ref. to EX (H4SO)-5, INSTALLATION, Front Exhaust Pipe.>
NOTE:
Use a new gasket.
(D)
CAUTION:
When lowering the vehicle, lower the lift-up device and wire ropes at the same time.
(C)
(B)
(A)
LU-00028

LU-02286
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
T2: 58 Nm (5.9 kgf-m, 42.8 ft-lb)
(A) Oil pan

(B) Oil strainer
(C) Baffle plate
(D) Cylinder block
7) Lower the engine onto front crossmember.

8) Install front cushion rubber onto front crossmember by tightening with nuts.
NOTE:
T2
T1
ME-00218
14) Install the radiator upper brackets.
Tightening torque:
85 Nm (8.7 kgf-m, 63 ft-lb)
LU-00049
(B)
(A)
(A)
(B)
ME-02651
15) Install the air intake duct and air cleaner case.
(Non-turbo model) <Ref. to IN (H4SO)-7, INSTALLATION, Air Intake Duct.> <Ref. to IN (H4SO)-5,
INSTALLATION, Air Cleaner Case.>
16) Install the intercooler. (Turbo model) <Ref. to
IN(H4DOTC)-11, INSTALLATION, Intercooler.>
LU (H4SO)-19

LUBRICATION
17) Install the air intake boot and air cleaner upper
cover. (Turbo model)
LU-00070
18) Connect the connector to the mass air flow and

intake air temperature sensor.
LU-00026
19) Install the front wheels.

FU-00009
21) Refill the engine oil. <Ref. to LU (H4SO)-10, INSPECTION, Engine Oil.>
22) Install the collector cover. (Turbo model)
C: INSPECTION
Visually check that the oil pan, oil strainer, oil
strainer stay and baffle plate are not damaged.
LU (H4SO)-20
Oil Pressure Switch

LUBRICATION
6. Oil Pressure Switch
2) Install the oil pressure switch onto engine block.
A: REMOVAL
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)

2) Remove the generator from bracket. <Ref. to SC
(H4SO)-14, REMOVAL, Generator.>
3) Disconnect the terminal from oil pressure switch.
LU-00037
3) Connect the terminal to the oil pressure switch.

LU-00036
4) Remove the oil pressure switch.
LU-00036
LU-00037
4) Install the generator to bracket. <Ref. to SC

(H4SO)-14, INSTALLATION, Generator.>
5) Install the collector cover. (Turbo model)
C: INSPECTION
B: INSTALLATION
1) Apply liquid gasket to the oil pressure switch
threads.
Check the oil pressure switch installation portion for

oil leakage and oil seepage.
Liquid gasket:
equivalent
LU-00038
LU (H4SO)-21
Engine Oil Cooler

LUBRICATION
7. Engine Oil Cooler
B: INSTALLATION
A: REMOVAL
NOTE:
The engine oil cooler is mounted to the turbo model.
NOTE:
The engine oil cooler is mounted to the turbo model.
3) Drain the engine oil.
<Ref. to LU (H4SO)-10, REPLACEMENT, Engine
Oil.>
4) Drain engine coolant.
5) Remove the water by-pass pipe between oil
cooler and water pump.
6) Remove the engine oil filter.
<Ref. to LU (H4SO)-24, REMOVAL, Engine Oil Filter.>
7) Remove the oil cooler connector and remove the
oil cooler.
8) Remove the adapters (1) and (2).
NOTE:
Use new O-rings and gasket.
2) Touch the adapter (1) knock pin (A) to the cylinder block rib (B) to install the adapter (1).
(A)
(B)
LU-00042
3) Install the adapter (2).

4) Touch the engine oil cooler stopper (A) to the
adapter (2) rib (B) to install the engine oil cooler.
(G)
(A)
(H)
T1
(B)
(H)
(C)
T4
(A)
(F)
(G)
(D)
(E)
T3
T2
LU-02273
(A) Adapter (1)

(B) Adapter connector
(C) Adapter (2)
(D) Oil cooler
(E) Oil cooler connector
(F) Plug
(G) Gasket
(H) O-ring
LU (H4SO)-22
(B)
LU-00043
Engine Oil Cooler

LUBRICATION
5) When installing the plug, apply liquid gasket to

the plug screw.
Liquid gasket:
equivalent
Tightening torque:
T1: 45 Nm (4.6 kgf-m, 33.2 ft-lb)
T2: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
T3: 54 Nm (5.5 kgf-m, 40 ft-lb)
T4: 69 Nm (7.0 kgf-m, 51 ft-lb)
(G)
(A)
(H)
T1
(B)
(H)
(C)
T4
(F)
(G)
(D)
(E)
T3
T2
LU-02273
(A) Adapter (1)

(C) Adapter (2)
(D) Oil cooler
(F) Plug
(G) Gasket
(H) O-ring
C: INSPECTION
1) Check that coolant passages are not clogged
using an air blower.
2) Check the mating surfaces of cylinder block, Oring and gasket groove, and oil filter for damage.
LU (H4SO)-23
Engine Oil Filter

LUBRICATION
8. Engine Oil Filter
B: INSTALLATION
A: REMOVAL
CAUTION:
Do not tighten excessively, or oil may leak.
1) Clean the oil filter installation surface on cylinder
block or oil cooler.
2) Obtain a new oil filter and apply a thin coat of engine oil to the seal rubber.
3) Install the oil filter turning it by hand, being careful not to damage the seal rubber.
(approx. 2/3 3/4 rotation) after the seal rubber of
the oil filter comes in contact with cylinder block or
oil cooler. When using a torque wrench, tighten to
12 Nm (1.2 kgf-m, 8.7 ft-lb).
(approx. 1 rotation) after the seal rubber of the oil
filter comes in contact with cylinder block or oil
cooler. When using a torque wrench, tighten to 14
Nm (1.4 kgf-m, 10.3 ft-lb).

2) Remove the service hole clip located on the under cover.
PM-00303
3) Rotate the service hole cover in the arrow direction.
C: INSPECTION
1) After installing the oil filter, run the engine and
make sure that no oil is leaking around seal rubber.
PM-00304
4) Remove the crank pulley using ST.

ST 18332AA000 OIL FILTER WRENCH (OUTER DIAMETER: 68 mm (2.68
in) FOR OIL FILTER)
ST 18332AA010 OIL FILTER WRENCH (OUTER DIAMETER: 65 mm (2.56
in) FOR OIL FILTER)
NOTE:
The filter element and filter case are permanently
jointed; therefore, interior cleaning is not necessary.
2) Check the engine oil level. <Ref. to LU (H4SO)10, INSPECTION, Engine Oil.>
(A)
(B)
PM-00305
(A) Drain plug

(B) Oil filter
LU (H4SO)-24
Engine Lubrication System Trouble in General

LUBRICATION
9. Engine Lubrication System Trouble in General

A: INSPECTION
Before performing diagnostics, make sure that the engine oil level is correct and no oil leakage exists.
Trouble
Possible cause
1) Oil pressure switch
failure
1. Warning light remains

on.
2) Low oil pressure
3) No oil pressure
2. Warning light does

not illuminate.
3. Warning light flickers

momentarily.
Corrective action
Cracked diaphragm or oil leakage within switch

Broken spring or seized contacts
Replace.
Replace.
Clogging of oil filter

Malfunction of oil by-pass valve in oil filter
Replace.
Clean or replace.
Malfunction of oil relief valve in oil pump

Clogged oil passage
Clean or replace.
Clean.
Excessive tip clearance and side clearance of oil

pump rotor and gear
Clogged oil strainer or broken pipe
Clean or replace.
Insufficient engine oil

Broken pipe of oil strainer
Replenish.
Replace.
Replace.
Stuck oil pump rotor

1) Malfunction of combination meter
Replace.
Replace.
2) Poor contact of switch contact points

3) Disconnection of wiring
Replace.
Repair.
1) Poor contact of terminals

2) Defective wiring harness
Repair.
Repair.
3) Low oil pressure
Check for the same

possible causes as
listed 1. 2.
LU (H4SO)-25
Engine Lubrication System Trouble in General

LUBRICATION
LU (H4SO)-26
General Description
SPEED CONTROL SYSTEMS
A: SPECIFICATION
Accelerator pedal
Stroke
At pedal pad
52 57 mm (2.05 2.24 in)
B: COMPONENT
(1)
(2)
SP-02030
(1)
Accelerator pedal ASSY
(2)
Stopper
C: CAUTION
Remove contamination including dirt and corrosion before removal or installation.
Keep the parts in order and protect them from
dust and dirt.
Before removal or installation, be sure to clarify
the failure. Avoid unnecessary removal, installation, disassembly and replacement.
points.
the battery.
SP (H4SO)-2

T: 18 (1.8, 13.0)
Accelerator Pedal
2. Accelerator Pedal
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the connector (A).
3) Remove the nut (B) securing accelerator pedal
assembly.
(A)
(B)
SP-02036
B: INSTALLATION
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
C: DISASSEMBLY
NOTE:
Accelerator pedal cannot be disassembled.
SP (H4SO)-3
Accelerator Pedal
SP (H4SO)-4
General Description
IGNITION
A: SPECIFICATION
Item
Ignition coil and ignitor
assembly
Specification
Type
Manufacturer
FH 0286
Diamond Electric
Secondary coil resistance

Manufacturer and type
11.2 k15%
NGK: FR5AP-11
Thread size (diameter, pitch, length)

Spark plug gap
Spark plug
mm
mm (in)
14, 1.25, 19
1.0 1.1 (0.039 0.043)
Electrode
Platinum
B: COMPONENT
(4)
(4)
(1)
(1)
T2
(3)
(1)
T1
(2)
(2)
(1)
T2
IG-02063
(1)
Spark plug
(3)
Ignition coil and ignitor ASSY
(2)
Spark plug cord (#1, #3)
(4)
Spark plug cord (#2, #4)
IG(H4SO)-2

T1: 6.4 (0.65, 4.7)
T2: 21 (2.1, 15.2)
General Description
IGNITION
C: CAUTION
points.
the battery.
IG(H4SO)-3
Spark Plug
IGNITION
2. Spark Plug
2. LH SIDE
A: REMOVAL
1) Remove the battery.

2) Remove the spark plug cords by pulling the boot.
(Do not pull the cord itself.)
Spark plug:
<Ref. to IG(H4SO)-2, SPECIFICATION, General Description.>
1. RH SIDE
IG-00021
3) Remove the spark plug with a spark plug socket.
FU-00009
2) Remove the air cleaner case. <Ref. to IN

(H4SO)-5, REMOVAL, Air Cleaner Case.>
3) Remove the spark plug cords by pulling the boot.
(Do not pull the cord itself.)
IG-00022
B: INSTALLATION
1. RH SIDE
Tightening torque:
21 Nm (2.1 kgf-m, 15.2 ft-lb)
IG-00017
NOTE:
The tightening torque described above should be
applied to only new spark plugs without oil on their
threads.
In case their threads are lubricated, the torque
should be reduced by approx. 1/3 of the specified
torque in order to avoid over-stressing.
2. LH SIDE
IG-00018
Tightening torque:
21 Nm (2.1 kgf-m, 15.2 ft-lb)
NOTE:
threads.
IG(H4SO)-4
Spark Plug
IGNITION
C: INSPECTION
Check the electrodes and inner and outer ceramic
insulator of plugs, noting the type of deposits and
the degree of electrode erosion.
3) Oil fouled:
Wet black deposits show oil entrance into combustion chamber through worn rings or increased
clearance between valve guides and stems.
(A)
(B)
(C)
(D)
(E)
IG-00013
IG-00010
4) Overheating:
White or light gray insulator with black or brown
spots and bluish burnt electrodes indicates engine
overheating, incorrect ignition timing, improper fuel, or loose spark plugs.
(A) Spark plug gap

(B) Carbon accumulation or wear
(C) Crack
(D) Damage
(E) Damaged gasket
1) Normal:
Brown to grayish-tan deposits and slight electrode
wear indicate correct spark plug heat range.
IG-00014
D: ADJUSTMENT
IG-00011
2) Carbon fouled:
Dry fluffy carbon deposits on insulator and electrode are mostly caused by slow speed driving in
the city, weak ignition, too rich fuel mixture, dirty air
cleaner, etc.
Clean the spark plugs using a wire brush.

Clean and remove the carbon or oxide deposits.
But do not wear away ceramic insulator at this time.
If deposits are too stubborn, replace the spark
plugs.
After cleaning the spark plugs, measure the spark
plug gap using a gap gauge.
NOTE:
Do not use a plug cleaner because the spark plugs
are applied with platinum tip.
Spark plug gap: L
1.0 1.1 mm (0.039 0.043 in)
IG-00012
IG-02035
IG(H4SO)-5
Ignition Coil and Ignitor Assembly

IGNITION
3. Ignition Coil and Ignitor

Assembly
C: INSPECTION
Check the following items using a tester. Replace if
defective.
Secondary coil resistance
A: REMOVAL
CAUTION:
If the resistance is extremely low, it indicates the presence of a short-circuit.
Ignitor is integrated with the coil. Therefore
the resistance of primary side coil cannot be
measured.
Specified resistance:
FU-00009
2) Disconnect the spark plug cords from ignition

coil and ignitor assembly.
[Secondary side]
Between (A) and (B)
11.2 k15%
Between (C) and (D)
11.2 k15%
(C)
(D)
(A)
(B)
IG-02066
IG-02064
3) Disconnect the connector (A) from ignition coil

and ignitor assembly.
4) Remove the bolt (B) which secures the ignition
coil and ignitor assembly to intake manifold.
(B)
(A)
(B)
IG-02065
B: INSTALLATION
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
CAUTION:
Connect the spark plug cords to correct positions. Failure to do so will damage the unit.
IG(H4SO)-6
Spark Plug Cord

IGNITION
4. Spark Plug Cord

A: INSPECTION
Check the following items.
Damage to cords, deformation, burning or rust
formation of terminals
Resistance value of cords
#1 cord: 7.1 12.1 k
#2 cord: 12.1 19.9 k
#3 cord: 7.7 13.0 k
#4 cord: 12.3 20.2 k
IG-00102
IG(H4SO)-7
Spark Plug Cord

IGNITION
IG(H4SO)-8
General Description
STARTING/CHARGING SYSTEMS
A: SPECIFICATION
Item
Specification
Vehicle model
Type
MT
Model
Manufacturer
M000T30471
Number of pinion teeth

Voltage
No-load
Current
characteristics
Rotating speed
Load
characteristics
9
11 V
90 A or less
More than 2,000 rpm
7.5 V
300 A
7.7 V
400 A
8.84 Nm (0.90 kgf-m, 6.5 ft-lb) or

more
More than 870 rpm
16.7 Nm (1.70 kgf-m, 12.3 ft-lb) or

more
More than 710 rpm
Voltage
Current
4V
680 A or less
3.5 V
960 A or less
Torque
17 Nm (1.73 kgf-m, 12.5 ft-lb) or

more
31 Nm (3.16 kgf-m, 22.9 ft-lb) or

more
Voltage
Current
Torque
Rotating-field three-phase type, voltage regulator built-in type, with load

response control system
Type
Model
12 V 1.0 kW
12 V 1.4 kW
Counterclockwise (when observed from pinion)
95 A or less
More than 2,500 rpm
Rotating speed
Lock
characteristics
Non-turbo
Turbo
A2TG0391
A3TG0491
Non-turbo
Mitsubishi Electric
12 V 90 A
Manufacturer
Voltage and
output
Turbo
Polarity on ground side
Generator
Direction of rotation
Armature connection
12 V 110 A
Negative
Clockwise (when observed from pulley side)
3-phase Y-type
Non-turbo
1,500 rpm 40 A or more

Turbo

Output current
Battery
M000T20171
Mitsubishi Electric
Voltage and output

Starter
AT
Reduction type
Regulated voltage
Voltage and capacity
14.1 14.8 V [20C (68F)]

12V-48AH (55D23L)
12V-52AH (75D23L)
SC (H4SO)-2
General Description
B: COMPONENT
1. STARTER
(1)
(4)
(10)
(9)
(3)
(2)
(8)
(7)
(6)
(5)
(16)
(12)
(11)
(14)
(15)
(13)
SC-00058
(1)
(2)
Front bracket
Sleeve bearing
(7)
(8)
Internal gear ASSY

Shaft ASSY
(12)
(13)
Armature
Brush holder ASSY
(3)
(4)
Lever set
Switch ASSY
(9)
(10)
Gear ASSY
Packing
(14)
(15)
Sleeve bearing
Rear cover
(5)
(6)
Stopper set
Overrunning clutch
(11)
Yoke ASSY
(16)
Rear cover set
SC (H4SO)-3
General Description
2. GENERATOR
(5)
(6)
(4)
(2)
(3)
(1)
(12)
(11)
(10)
(9)
(8)
(7)
SC-00144
(1)
(2)
Pulley
Front cover
(5)
(6)
Rotor
Bearing
(9)
(10)
Brush
Rectifier
(3)
(4)
Ball bearing
Bearing retainer
(7)
(8)
Starter coil
IC regulator with brush
(11)
(12)
Rear cover
Terminal
SC (H4SO)-4
General Description
C: CAUTION
points.
the battery.
SC (H4SO)-5
Starter
2. Starter
6) Disconnect the connector and terminal from

starter.
A: REMOVAL
SC-00006
(A) Terminal
FU-00009

3) Remove the air intake chamber. (Non-turbo
model)
Chamber.>
5) Remove the air intake chamber stay LH. (Nonturbo model)
MT model
(B) Connector
7) Remove the starter from transmission.

NOTE:
For MT model, the bolt is used in place of nut (A)
shown in the figure.
(A)
SC-00184
B: INSTALLATION
SC-00176
AT model
NOTE:
For MT model, the bolt is used in place of nut (A)
Tightening torque:
50 Nm (5.1 kgf-m, 37 ft-lb)
(A)
SC-00177
SC-00184
SC (H4SO)-6
Starter
C: DISASSEMBLY
4) Remove the bolts passing through both sides,

and the brush holder screws, then remove rear
cover and brush holder assembly.
1. STARTER ASSEMBLY
1) Loosen the nuts fastening the switch assembly
terminal M, then disconnect the connector.
(A)
(A)
(B)
SC-00062
(A) Brush holder ASSY
SC-02094
(B) Rear cover

(A) Terminal M
2) Remove the bolts fastening the switch assembly, then remove the switch assembly, plunger and
plunger spring as a unit from the starter.
5) Remove the armature and yoke assembly from

the front bracket.
(B)
NOTE:
Be careful because the pinion gap adjustment
washer may sometimes be used on the mounting
surface of the switch assembly.
(A)
(A)
(C)
SC-00063
(A) Armature
(B) Yoke ASSY
(C) Front bracket
SC-00060
6) Remove the packing A, planetary gears and

packing B.
(A) Switch ASSY

(C)
3) Remove the bolts on both sides, then remove

rear cover set.
(A)
(B)
(A)
SC-00064
(A) Packing A
(B) Planetary gear
SC-02095
(A) Rear cover set
SC (H4SO)-7
(C) Packing B
Starter
(2) Remove the ring, spacer, and clutch from

the shaft.
7) Remove the plate.
(A)
SC-00065
(A) Plate
8) Remove the front assembly and overrunning

clutch from the front bracket.
NOTE:
Check the following points before removal.
Lever direction
Internal gear assembly position
(A)
SC-00014
(A) Socket wrench

(B) Ring
(C) Shaft
(D) Stopper
(B)
(C)
(D)
SC-00066
(A) Lever
(B) Shaft ASSY
(C) Overrunning clutch
(D) Internal gear ASSY
9) Use the following procedures to remove the

overrunning clutch from the shaft assembly.
(1) Use the appropriate tool (such as the right
size of socket wrench) to lightly tap on the stopper to remove it from the ring.
SC (H4SO)-8
Starter
D: ASSEMBLY
(1) Lever direction
NOTE:
Apply grease to the following parts before assembly.
Sleeve bearing
Pinion shaft rotational portion
Shaft spline portion
Inside of reduction system
Lever fulcrum/Clutch rotational portion
1) Install the overrunning clutch to the shaft assembly.
2) Use the following procedures to install stopper to
the shaft assembly.
(1) Use the appropriate tool (such as the right
size of socket wrench) to lightly tap on the ring
to insert it into the shaft groove.
SC-00069
(2) Internal gear position
(A)
(B)
SC-00070
4) Install the plate.

SC-00067
(A)
(2) Using the ST, press the stopper into the

ring.
(A)
(B)
SC-00065
(A) Plate
SC-00068
5) Install the planetary gear.

6) Be careful of the installation position to install the
packing A and B.
(A) Ring
(B) Stopper
(B)
3) Be careful of the following to install the shaft assembly to the front bracket.
(A)
SC-00071
(A) Packing A
(B) Packing B
7) Install the armature to the yoke assembly.
SC (H4SO)-9
Starter
8) Align the yoke assembly with the groove and install it to the front bracket.
10) Align the rear cover groove with the brush holder assembly to install.
(A)
(B)
SC-00072
9) Use the following procedures to install the brush

holder to the yoke assembly.
(1) Push the brush into the brush holder, then
use the appropriate tool (such as the right size
of socket wrench) to fasten in position.
SC-00062
(A) Brush holder ASSY

(B) Rear cover
11) Install the rear cover set.
(A)
SC-02095
SC-00073
(2) Align the brush holder with the groove in the

yoke assembly, the slide to install.
(A) Rear cover set
12) Use the following procedures to install the

switch assembly to the front bracket.
(1) Insert the plunger and plunger spring into
the switch assembly.
(2) Hook the protrusion on the plunger onto the
lever end, then install to the front bracket.
(A)
SC-00074
SC-00060
(A) Switch ASSY
SC (H4SO)-10
Starter
13) Install the connector to the switch assembly terminal M.
3) Depth of segment mold

Check the depth of the segment mold.
Depth of segment mold:
0.5 mm (0.020 in)
(A)
(B)
(C)
SC-02094
(A)
(A) Terminal M
SC-00022
E: INSPECTION
(A) Depth of segment mold

(B) Segment
1. ARMATURE
1) Check the commutator for signs of seizure or
stepped wear caused by roughness of the surface.
If there is light wear, use sandpaper to repair.
2) Run-out test
Check for run-out on the commutator. If excessive,
replace it.
Commutator run-out:
Standard:
0.05 mm (0.0020 in)
Service limit:
0.10 mm (0.0039 in) or less
(C) Mold
4) Armature short-circuit test

Place the armature on the growler tester to check
for short circuits. While slowly turning the armature,
support the steel seat for the armature core. If the
circuits on the armature are shorted, the steel seat
will vibrate, causing it to move to the core. When
the steel seat has moved and vibrated, replace or
repair the armature with the shorted circuit.
(A)
(B)
SC-00023
SC-00021
(A) Steel seat

(B) Growler tester
(A) Dial gauge

(B) V-block
SC (H4SO)-11
Starter
5) Armature ground test

Use a circuit tester to touch the probe of one side to
the commutator segment, and the other probe to
the shaft. If there is no continuity, it is normal. If
there is continuity, the armature is grounded.
If grounded, replace the armature.
2) Brush movement
Check that the brush moves smoothly in the brush
holder.
3) Brush spring force
Measure the brush spring force with a spring scale.
Replace the brush holder if below the service limit.
Brush spring force:
Standard:
15.9 19.5 N (1.62 1.99 kgf, 3.57 4.38
lb) (When new)
Service limit:
2.5 N (0.25 kgf, 0.56 lb)
5. SWITCH ASSEMBLY
SC-00024
2. YOKE
Make sure that the pole is set at the predetermined
position.
3. OVERRUNNING CLUTCH
Check that there is no wear or damage to the piston
teeth. Replace if damaged. If it rotates smoothly
when rotated in the correct direction (counterclockwise) and does not return to the other direction, it is
normal.
Using a circuit tester (set in ), check that there is

continuity between terminals S and M, and between terminal S and ground.
Also check to be sure there is no continuity between terminal M and B.
Terminal / Resistance:
S M/1 or less
S Ground/1 or less
M B/1 M or more
CAUTION:
To prevent spilling of grease, do not clean the
overrunning clutch with oil.
S
M
4. BRUSH AND BRUSH HOLDER

1) Brush length
Measure the length of the brush. If it exceeds service limits, replace it.
Replace if there is wear or fissures.
SC-00075
6. SWITCH ASSEMBLY OPERATION

1) Using a lead wire, connect the terminal S of
switch assembly to positive terminal of battery, and
starter body to ground terminal of battery. The pinion should be forced endwise on shaft.
Brush length:
Standard:
12.3 mm (0.484 in)
Service limit:
7.0 mm (0.276 in)
NOTE:
With the pinion forced endwise on shaft, starter motor can sometimes rotate because current flows,
through pull-in coil, to motor. This is not a problem.
(A)
(B)
SC-00102
(A) Service limit line

(B) Brush
SC (H4SO)-12
Starter
2) Disconnect the connector from terminal M. Then

using a lead wire, connect the positive terminal of
battery and terminal M and ground terminal to starter body.
In this test set up, the pinion should return to its
original position even when it is pulled out with a
screwdriver.
(B)
SC-02096
(A) Terminal S
(B) Terminal M
7. PERFORMANCE TEST
The starter should be submitted to performance
tests whenever it has been overhauled, to assure
its satisfactory performance when installed on the
engine.
Three performance tests, no-load test, load test,
and lock test, are presented here; however, if the
load test and lock test cannot be performed, carry
out at least the no-load test.
For these performance tests, use the circuit shown
in figure.
(B)
(A)
M
+
(C)
A
SC-00077
(A) Variable resistance

(B) Starter body
(C) Magnetic switch
Rotating speed:
MT model
More than 2,500 rpm
AT model
More than 2,000 rpm
2) Load test
Apply the specified braking torque to starter. The
condition is normal if the current draw and starter
speed are within standard.
Load test (Standard):
Voltage/Load:
MT model
7.5 V/8.84 Nm (0.90 kgf-m, 6.5 ft-lb)
AT model
7.7 V/16.7 Nm (1.7 kgf-m, 12.3 ft-lb)
Current/Speed:
MT model
300 A/870 rpm or more
AT model
400 A/710 rpm or more
3) Lock test
With the starter stalled, or not rotating, measure the
torque developed and current draw when the voltage is adjusted to standard voltage.
Lock test (Standard):
12V
V
No-load test (Standard):

Voltage/Current
MT model
Max. 11 V / 95 A
AT model
Max. 11 V / 90 A
(A)
1) No-load test
With switch on, adjust the variable resistance until
the voltage is 11 V, read the value of ammeter to
measure starter speed. Compare these values with
the standard.
Voltage/Current
MT model
4 V / 680 A or less
AT model
3.5 V / 960 A or less
Torque:
MT model
17.0 Nm (1.73 kgf-m, 12.5 ft-lb) or more
AT model
31.0 Nm (3.16 kgf-m, 22.9 ft-lb) or more
SC (H4SO)-13
Generator
3. Generator
6) Remove the bolts which install the bracket to remove the generator.
A: REMOVAL
SC-00032
B: INSTALLATION
FU-00009

3) Disconnect the connector and terminal from
generator.
Non-turbo model

CAUTION:
Check and adjust the V-belt tension. <Ref. to
ME(H4SO)-41, INSPECTION, V-belt.> or <Ref. to
ME(H4DOTC)-41, INSPECTION, V-belt.>
SC-00178
SC-00032
Turbo model
C: DISASSEMBLY
1) Remove the four through-bolts.
SC-02107
4) Remove the V-belt covers. (Non-turbo model)

5) Remove the front side V-belts.
<Ref. to ME(H4SO)-40, FRONT SIDE BELT, REMOVAL, V-belt.>
SC (H4SO)-14
SC-00078
Generator
2) Use a drier to heat the rear cover (A) portion to

50C (122F).
(A)
CAUTION:
Insert the aluminum plate or wood piece into
the contact surface of the vise while support
the rotor in the vise to prevent damaging the rotor.
(A)
(B)
SC-00079
(C)
3) Insert the end of a flat tip screwdriver into the

gap between stator core and front cover. Separate
these to disassemble.
(D)
SC-00036
(A) Front cover

(B) Pulley
(C) Nut
(D) Rotor
(A)
5) Use the following procedures to remove the ball

bearings.
(1) Remove the bolt, and then detach the bearing retainer.
(A)
SC-00080
(A) Screwdriver
4) Using a vise, support the rotor and remove the

pulley bolt.
SC-00081
(2) Firmly install the appropriate tool (such as

the right size of socket wrench) to the bearing
inner race.
SC-00035
SC-00082
(3) Use the press to push the ball bearings from

the front cover.
SC (H4SO)-15
Generator
6) Using the bearing puller, remove the bearings

from the rotor.
(2) Disconnect the connection between the IC

regulator and rectifier, then remove the IC regulator.
SC-00046
7) Disconnect the connection between the rectifier

and stator coil, then remove the stator coil.
CAUTION:
Do not touch it with 180 to 270 W solder on its
terminals for more than 5 seconds consecutively, because the rectifier cannot withstand so
much heat.
SC-00085

brush.
(1) Remove the cover A.
(A)
SC-00086
(A) Cover A
SC-00083
(2) Remove the cover B.
8) Use the following procedures to remove the IC

regulator.
(1) Remove the screws which secure IC regulator to the rear cover.
(A)
SC-00087
(A) Cover B
SC-00084
(3) Disconnect the connection and remove the

brush.
SC-00088
SC (H4SO)-16
Generator

rectifier.
(1) Remove the bolts which secure the rectifier.
D: ASSEMBLY
1) Pull-out of the brush
Before assembling, push the brush into the brush
holder. Then pass a wire through the hole (dia. 1
mm (0.0394 in), Length: 4 to 5 cm (1.6 to 2.0 in) and
fasten at that position.
CAUTION:
After re-assembling, remove the wire.
(A)
SC-00089
(2) Remove the cover on the terminal B.
SC-00092
(A) Wire
SC-00090
(3) Remove the nuts of the terminal B, then remove the rectifier.
SC-00091
2) Install the ball bearings.

(1) Set the ball bearings in the front cover, then
firmly install the appropriate tool (such as the
right size of socket wrench) to the bearing outer
race.
(2) Using a press to press the ball bearings into
the specified positions.
(3) Install the bearing retainer.
3) Using a press to install the bearings (rear side)
to the rotor shaft.
4) Heat the bearing box inside the rear cover to [50
to 60 C (122 to 140 F] and push the rear bearings
into the rear cover.
CAUTION:
Do not apply grease to the rear bearings. If oil
adheres to the bearing box, completely wipe it
away.
5) After re-assembling, manually turn the pulley to
check that the rotor rotates smoothly.
SC (H4SO)-17
Generator
E: INSPECTION
2. ROTOR
1. DIODE
CAUTION:
There is the possibility of damaging the diodes
if a mega-tester (used to measure high voltages) or a similar measuring instrument is used.
Therefore, absolutely never use in this test.
1) Check the positive diode
Check the continuity between the diode lead and
positive side heat sink. If resistance is 1 or less
only in the direction from the diode lead to the heat
sink, the positive diode is normal.
(A)
(B)
1) Slip ring surface

Check that there is no dirt on the slip ring or roughness in the sliding surface. Repair the slip ring surface using a lathe or sand paper.
2) Slip ring outer diameter
Measure the slip ring outer diameter. Replace the
rotor assembly if the slip ring is worn.
Slip ring outer diameter:
Standard:
22.7 mm (0.894 in)
Tolerance limit value:
22.1 mm (0.870 in)
3) Continuity test
Using a circuit tester, check the resistance between
slip rings.
Replace the rotor assembly if the resistance is not
within the specified value.
Approximately 1.8 2.2
SC-00042
(A) Diode lead

(B) Heat sink (Positive side)
2) Check negative diode

Check the continuity between the diode lead and
negative side heat sink. If resistance is 1 or less
only in the direction from the heat sink to the diode
lead, the negative diode is normal.
SC-00044
4) Insulation test
Check the continuity between the slip ring and the
rotor core or shaft. If the resistance is 1 or less,
replace the rotor assembly because the rotor coil is
grounded.
(A)
(B)
SC-00043
(A) Diode lead

(B) Heat sink (Negative side)
SC-00045
5) Ball bearings (rear side)

Check the rear ball bearings. If there is any noise,
or the rotor does not rotate smoothly, replace.
SC (H4SO)-18
Generator
3. STATOR
4. BRUSH
1) Continuity test
Inspect the continuity between the stator coil lead
wire terminals. If the resistance is 1 M or more, replace the stator assembly because the lead wire is
damaged.
1) Measure the length of each brush. Replace the

brush if wear exceeds service limits. There is a service limit mark (A) on each brush.
5.0
(0.197)
(A)
Brush length:
Standard:
18.5 mm (0.728 in)
Service limit:
5.0 mm (0.197 in)
13.5
(0.531)
(A)
SC-00047
(A) Stator
2) Insulation test
Inspect the continuity between the stator coil stator
core and lead wire terminals. If the resistance is 1
or less, replace the stator assembly because the
stator coil is grounded.
SC-00049
2) Check that there is appropriate pressure on the

brush spring.
Use a spring pressure indicator to push the brush
into the brush holder until the leading end protrudes
2 mm (0.08 in). Then, measure the brush spring
pressure. If the pressure is 2.2 N (0.224 kgf, 7.91
oz) or less, replace the brush spring with a new
part. 4.8 6.0 N (0.489 0.612 kgf, 17.26
21.60 oz) pressure is required for the new spring.
SC-00048
SC-00093
5. BEARINGS (FRONT SIDE)

Check the front ball bearings. Replace the ball
bearings if there is resistance in the rotation, or if
there is noise.
SC (H4SO)-19
Battery
4. Battery
A: REMOVAL
1) Disconnect the positive (+) terminal after disconnecting the negative () terminal of battery.
2) Remove the flange nut from battery rod and remove battery holder.
When in contact with a metallic portion of the

vehicle, never allow metallic tools held in the
other hand to come into contact with the battery positive terminal or any hardware attached
to the terminal.
1. EXTERNAL PARTS
Check the battery case, top cover, vent plugs, and
terminal posts for dirt or cracks. 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:
SC-02099
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) Remove the battery.
3. SPECIFIC GRAVITY OF ELECTROLYTE:
B: INSTALLATION
Tightening torque:
3.4 Nm (0.35 kgf-m, 2.5 ft-lb)
1) Measure specific gravity of electrolyte using a

hydrometer and a thermometer.
Specific gravity varies with temperature of electrolyte so that it must be corrected at 20C (68F) using the following equation:
NOTE:
Clean the battery cable terminals and apply
grease to retard the formation of corrosion.
Connect the positive (+) terminal, and then connect the negative () terminal of battery.
Initial diagnosis of the electronic throttle control
is performed after the battery is installed. Therefore, start the engine after 10 seconds or more
have passed since turning the ignition switch to
ON.
S20 = St + 0.0007 (t 20)

S20: Specific gravity corrected at electrolytic
solution temperature of 20C (68F)
St: Measured specific gravity
t: Measured temperature (C)
Determine whether or not battery must be
charged, according to corrected specific
gravity.
Standard specific gravity: 1.220 1.290 [at
20C (68F)]
C: INSPECTION
WARNING:
Battery fluid is corrosive acid and has toxicity; be careful of handling the fluid.
Do not let the battery fluid contact with skin,
eyes or clothing. Especially at contact with
eyes, flush with water for 15 minutes and get
prompt medical attention.
Do not let electrolyte contact with painted
surfaces.
Batteries produce explosive gases; be careful of handling.
Keep open flames away from batteries.
When working around batteries, be sure to
protect eyes with safety glasses, etc., in case
an explosion occurs. Never lean over a battery.
Ventilate sufficiently when using or charging
batteries in enclosed space.
Before starting work, remove rings, watches
and other metallic objects.
1.28
1.26
1.24
1.22
1.20
1.18
(1)
1.16
1.14
1.12
100%
(2)
[20 C (68 F)]
75% 50%
(4)
22%
0%
(3) (%)
SC-00094
(1) Specific gravity

(2) Complete charge
(3) State of charge
(4) Specific gravity and state of charge
2) Measuring the specific gravity of the electrolytic

solution in the battery will disclose the state of
charge of the battery. The relation between specific
gravity and state of charge is as shown in the figure.
SC (H4SO)-20
Battery
D: MEASUREMENT
4. QUICK CHARGING
WARNING:
Do not bring an open flame close to the battery
while working.
Quick charging is a method that the battery is

charged in a short period of time with a relatively
large current by using a quick charger.
Since a large current flow raises electrolyte temperature, the battery is subject to damage if the large
current is used for prolonged time. For this reason,
the quick charging must be carried out within a current range that will not increase the electrolyte temperature above 40C (104F).
Also the quick charging is a temporary mean to
bring battery voltage up to some level, and battery
should be charged slowly with low current as a rule.
CAUTION:
Prior to charging, corroded terminals should
be cleaned with a brush and common caustic
soda solution.
Be careful since battery electrolytic solution
overflows while charging the battery.
Observe instructions when handling the battery charger.
Before charging the battery on the vehicle,
disconnect the battery ground terminal to prevent damage of generator diodes or other electrical units.
CAUTION:
Observe the items in 3. NORMAL CHARGING.
Never use more than 10 A when charging the
battery because it will shorten the battery life.
1. JUDGMENT OF BATTERY IN CHARGED

CONDITION
1) Specific gravity of electrolyte should be held
within the specific range from 1.250 to 1.290 for
more than one hour.
2) Voltage per battery cell should be held at a specific value in a range from 2.5 to 2.8 V for more than
one hour.
2. CHECK CONDITION OF CHARGE WITH

HYDROMETER.
Hydrometer
indicator
Green dot
State of
charge
65% or more
Corrective action
Load test
Dark dot
65% or less
Charge battery
Low
Replace the battery.*
Clear dot
electrolyte
(If cranking is difficult)
* Check electrical system before replacement.
3. NORMAL CHARGING
Charge the battery at the current value specified by
manufacturer or at approximately 1/10 of batterys
ampere-hour rating.
SC (H4SO)-21
Battery
SC (H4SO)-22
Basic Diagnostic Procedure

ENGINE (DIAGNOSTICS)
1. Basic Diagnostic Procedure

A: PROCEDURE
NOTE:
If the AT OIL TEMP warning light illuminates when the Subaru Select Monitor or general scan tool is connected, perform the following procedures.
1. Disconnect Subaru Select Monitor or general scan tool from the vehicle.
2. Repeat the ignition switch ON-OFF cycle three times.
3. Turn the ignition switch to ON.
If the malfunction indicator light turns off, the Subaru Select Monitor or general scan tool may be faulty. Connect a different Subaru Select Monitor or general scan tool, and if malfunction indicator light remains off, delete the DTC. <Ref. to EN(H4SO)(diag)-44, Clear Memory Mode.>
1
Step
Check
CHECK ENGINE START FAILURE.
Does the engine start?
1) Ask the customer when and how the trouble
occurred using the interview check list. <Ref. to
EN(H4SO)(diag)-3, CHECK, Check List for
Interview.>
Yes
Go to step 2.
CHECK ILLUMINATION OF MALFUNCTION Does the malfunction indicator Go to step 3.

INDICATOR LIGHT.
light illuminate?
CHECK INDICATION OF DTC ON DISPLAY. Is DTC displayed on the Subaru

Select Monitor or general scan
2) Connect the Subaru Select Monitor or gen- tool?
eral scan tool to data link connector.
3) Turn the ignition switch to ON, and run the
Subaru Select Monitor or general scan tool.
4) Read the DTC on Subaru Select Monitor or
general scan tool.
PERFORM DIAGNOSIS.
1) Perform the Clear Memory Mode. <Ref. to
EN(H4SO)(diag)-44, Clear Memory Mode.>
2) Perform the Inspection Mode. <Ref. to
EN(H4SO)(diag)-35, Inspection Mode.>
Repair the trouble

cause. <Ref. to
EN(H4SO)(diag)67, List of Diagnostic Trouble Code
(DTC).> Go to step
4.
Is DTC displayed on the Subaru Repair the trouble

Select Monitor or general scan cause. <Ref. to
tool?
(DTC).>
EN(H4SO)(diag)-2
No
Inspection using
Diagnostics for
Engine Start Failure. <Ref. to
EN(H4SO)(diag)53, Diagnostics for
Engine Starting
Failure.>
Inspection using
General Diagnostic Table. <Ref. to
EN(H4SO)(diag)337, INSPECTION, General
Diagnostic Table.>
Perform the diagnosis of the malfunction indicator
light circuit or the
combination meter.
<Ref. to
EN(H4SO)(diag)48, Malfunction
Indicator Light.>
Finish the diagnosis.
Check List for Interview

2. Check List for Interview

A: CHECK
1. CHECK LIST NO. 1
Check the following item when problem has occurred.
NOTE:
Use copies of this page for interviewing customers.
Customers name
Date of purchase
Engine No.
Fuel brand
Date of repair
V.I.N. No.
Odometer reading
Weather
Fine
Cloudy
Rainy
Snowy
Various/Others:
Ambient air temperature
Place
Engine temperature
km
miles
C (F)
Hot
Warm
Cool
Cold
Highway
Suburbs
Inner city
Uphill
Downhill
Rough road
Others :
Cold
Warming-up
After warming-up
Any temperature
Others :
Engine speed
Vehicle speed
rpm
MPH
Driving conditions
Not affected
At starting
While idling
At racing
While accelerating
While cruising
While decelerating
While turning (RH/LH)
Headlight
Blower
ON /
ON /
OFF
OFF
Rear defogger
Radio
ON /
ON /
OFF
OFF
A/C compressor
Radiator fan
ON /
ON /
OFF
OFF
CD/Cassette
Car phone
ON /
ON /
OFF
OFF
Front wiper
Rear wiper
ON /
ON /
OFF
OFF
Wireless device
ON /
OFF
EN(H4SO)(diag)-3

2. CHECK LIST NO. 2

Check the following item about the vehicles state when malfunction indicator light turns on.
NOTE:
a) Other warning lights or indicators turn on.
Yes /
No
Low fuel warning light

Charge indicator light
AT diagnostic indicator light
ABS warning light
Oil pressure warning light
b) Fuel level
Lack of gasoline:
Yes /
No
Indicator position of fuel gauge:
Experience of running out of fuel:
Yes /
No
c) Intentional connecting or disconnecting of harness connectors or spark plug cords:
What:
d) Intentional connecting or disconnecting of hoses:
What:
e) Installing of other parts except genuine parts:
What:
Where:
f) Occurrence of noise:
Yes /
Yes /
Yes /
Yes /
No
No
No
From where:
What kind:
g) Occurrence of smell:
Yes /
No
From where:
What kind:
h) Intrusion of water into engine compartment or passenger compartment:
Yes /
i) Troubles occurred
Engine does not start.
Engine stalls during idling.
Engine stalls while driving.
Engine speed decreases.
Engine speed does not decrease.
Rough idling
Poor acceleration
Back fire
After fire
Does not shift.
Excessive shift shock
EN(H4SO)(diag)-4
No
No
General Description
A: CAUTION
1) Airbag system wiring harness is routed near the
ECM, main relay and fuel pump relay.
CAUTION:
All airbag system wiring harnesses and connectors are yellow. Do not use the electrical
test equipment on these circuits.
Be careful not to damage the airbag system
wiring harness when servicing the ECM, TCM,
main relay and fuel pump relay.
2) Never connect the battery in reverse polarity.
The ECM will be destroyed instantly.
The fuel injector and other parts will be damaged
in just a few minutes.
3) Do not disconnect the battery terminals while the
engine is running.
A large counter electromotive force will be generated in the generator, and this voltage may damage
electronic parts such as ECM etc.
4) Before disconnecting the connectors of each
sensor and ECM, be sure to turn the ignition switch
to OFF.
5) Use a tapered pin with a diameter of less than
0.64 mm (0.025 in) when measuring the voltage or
resistance of individual sensor or all electrical control modules. Do not insert the pin more than 5 mm
(0.20 in) into the part.
6) Before removing the ECM from the located position, disconnect two cables on battery. Otherwise,
the ECM may be damaged.
CAUTION:
the wrong spec. ECM to avoid any damage on
the fuel injection system.
7) Connectors of each sensor in the engine compartment and the harness connectors on the engine side and body side are all designed to be
waterproof. Even if the connectors are waterproof,
take care not to allow water to get into them when
washing the vehicle, or when servicing the vehicle
in rainy weather.
8) Use ECM mounting stud bolts at the body side
grounding point when measuring voltage and resistance inside the passenger compartment.
9) Use the engine ground terminal or engine assembly as the grounding point to the body when
measuring the voltage and resistance in engine
compartment.
10) Every MFI-related part is a precision part. Do
not drop them.
11) Observe the following cautions when installing
a radio in MFI equipped models.
CAUTION:
The antenna must be kept as far apart as possible from control unit. (The ECM is located under the steering column, inside of the
instrument panel lower trim panel.)
The antenna feeder must be placed as far
apart as possible from the ECM and MFI harness.
Carefully adjust the antenna for correct
matching.
When mounting a large power type radio, pay
special attention to the three items above mentioned.
Incorrect installation of the radio may affect
the operation of ECM.
12) Before disconnecting the fuel hose, release the
fuel pressure. <Ref. to FU(H4SO)-44, RELEASING
OF FUEL PRESSURE, PROCEDURE, Fuel.>
13) For the model with ABS, the ABS warning light
may illuminate when performing driving test with
jacked-up or lifted-up condition, but this is not a
system malfunction. The reason for this is the
speed difference between the front and rear
wheels. After diagnosis of engine control system,
perform the ABS memory clear procedure of selfdiagnosis function.
EN(H4SO)(diag)-5
General Description
B: INSPECTION
Before performing diagnostics, check the following
item which might affect engine problems.
1. BATTERY
1) Measure the battery voltage and specific gravity
of electrolyte.
Standard voltage:
12 V
Specific gravity:
1.260 or more
2) Check the condition of the main and other fuses,
and harnesses and connectors. Also check for
proper grounding.
2. ENGINE GROUND
Make sure the engine ground terminal is properly
connected to engine.
ME-00476
C: NOTE
1. GENERAL DESCRIPTION
The on-board diagnosis (OBD) system detects
and indicates a fault in various inputs and outputs
of the complex electronic control. Malfunction indicator light in the combination meter indicates occurrence of a fault or trouble.
Further, against such a failure or sensors as may
disable the drive, the fail-safe function is provided
to ensure the minimal driveability.
The OBD system incorporated with the vehicles
within this type of engine complies with OBD-II regulations. The OBD system monitors the components and the system malfunction listed in Engine
Section which affects on emissions.
When the system decides that a malfunction occurs, malfunction indicator light illuminates. At the
same time of the malfunction indicator light illumination or blinking, a DTC and a freeze frame engine conditions are stored into on-board computer.
The OBD system stores freeze frame engine
condition data (engine load, engine coolant temperature, fuel trim, engine speed and vehicle
speed, etc.) into on-board computer first when it
detects a malfunction.
If the OBD system detects the various malfunctions including the fault of fuel trim or misfire, the
OBD system first stores freeze frame engine conditions about the fuel trim or misfire.
When the malfunction does not occur again for
three consecutive driving cycles, malfunction indicator light is turned off, but DTC remains at onboard computer.
When troubleshooting the vehicle which complies with OBD-II regulations, connect the Subaru
Select Monitor or general scan tool to the vehicle.
2. ENGINE AND EMISSION CONTROL SYSTEM

The Multipoint Fuel Injection (MFI) system is a
system that supplies the optimum air-fuel mixture
to the engine for all the various operating conditions through the use of the latest electronic technology.
With this system, the fuel which is pressurized at a
constant pressure is injected into the intake air passage of the cylinder head. The injection quantity of
fuel is controlled by an intermittent injection system, where the electro-magnetic injection valve (fuel injector) opens for a short period of time
depending on the quantity of air required for one
cycle of operation. In actual operation, the injection
quantity is determined by the duration of an electric
pulse applied to the fuel injector and this permits
simple, yet highly precise metering of the fuel.
Furthermore, all operating conditions of the engine are converted into electronic signals, and this
enables additional system features with greatly improved adaptability, making it easier to add compensation features.
The MFI system also has the following features:
Reduced emission of harmful exhaust gases
Reduction in fuel consumption
Increased engine output
Superior acceleration and deceleration
Superior startability and warm-up performance in cold weather since compensation is
made for engine coolant and intake air temperature
EN(H4SO)(diag)-6
General Description
D: PREPARATION TOOL
ILLUSTRATION
TOOL NUMBER
1B020XU0
DESCRIPTION
SUBARU SELECT
MONITOR KIT
ST1B020XU0
EN(H4SO)(diag)-7
REMARKS
Electrical Component Location

4. Electrical Component Location

A: LOCATION
1. ENGINE
Control module
(1)
(4)
(1)
(2)
Engine control module (ECM)

Malfunction indicator light
(3)
(3) (2)
EN-00155
Test mode connector
(4)
Data link connector
(2)
EN-00156
EN-00157
(3 )
EN-00158
EN(H4SO)(diag)-8
(4)
EN-00236

Sensor
(1)
(8)
(3)
(4)
(2)
(7)
(5)
(6)
EN-03846
(1)
Mass air flow and intake air temperature sensor
(4)
Throttle position sensor
(7)
(2)
(3)
Manifold absolute pressure sensor

Engine coolant temperature sensor
(5)
(6)
Knock sensor
(8)
EN(H4SO)(diag)-9

(1)
(2)
EN-03046
EN-01971
(3)
(4)
EN-03047
EN-01972
(5)
(6)
EN-03048
EN-03050
(7)
EN-03049
EN(H4SO)(diag)-10
(8)
EN-04089

(3)
(2)
(4)
(1)
EN-03847
(1)
(2)

Rear oxygen sensor
(3)
(4)
(1)
(3)
(2)
(4)
EN-00165
(1)
(2)
Fuel level sensor

Fuel temperature sensor
(3)
EN(H4SO)(diag)-11
(4)

(3)
(1)
(2)
EN-03852
EN-00168
EN(H4SO)(diag)-12
EN-03853

Solenoid valve, emission control system parts and ignition system parts
(4)
(5)
(3)
(2)
(1)
(5)
(4)
EN-03848
(1)
(3)
Ignition coil and ignitor ASSY
(2)
EGR valve
(4)
Oil switching solenoid valve
EN(H4SO)(diag)-13
(5)

pressure switch

(2)
(1)
EN-03052
EN-03053
(3)
(5)
(4)
EN-02864
EN(H4SO)(diag)-14
EN-04088

(1)
(2)
(3)
EN-03849
(1)
(2)
Canister
(3)
Drain valve
(2)
(1)
EN-02866
(3)
EN-02868
EN(H4SO)(diag)-15
EN-03055

(1)
(8)
(7)
(6)
(3)
(4)
(5)
(2)
(9)
EN-04087
(1)
(2)
Inhibitor switch
Fuel pump
(4)
(5)
Fuel pump relay

Electronic throttle control relay
(7)
(8)
Radiator sub fan relay

Fan mode relay
(3)
Main relay
(6)
Radiator main fan relay
(9)
Starter
(2)
EN-04086
EN-00178
(8)
(4) (3)
(5)
EN-03017
(9)
EN-02096
EN(H4SO)(diag)-16
(7)
(6)
EN-03678
Engine Control Module (ECM) I/O Signal

5. Engine Control Module (ECM) I/O Signal

A: ELECTRICAL SPECIFICATION
To B135
To B134
7 6 5 4 3
17 16 15 14 13 12 11
27 26 25 24 23 22 21
34 33
32 31
2 1
10 9 8
20 19 18
30 29 28
To B136
7 6 5 4 3
2 1
19 18 17 16 15 14 13 12 11 10 9 8
27 26
25 24
23 22 21 20
35 34
33 32
31 30 29 28
6 5
4 3 2 1
16 15 14 13 12 11 10 9 8 7
27 26 25 24 23 22 21 20 19 18 17
30 29 28
35 34 33 32 31
To B137
7 6 5 4 3 2 1
17 16 15 14 13 12 11 10 9 8
25 24
23 22 21 20 19 18
31 30
29 28
27 26
EN-01812
Content
Connector
No.
Terminal No.
B134
B134
Signal (V)
Note
Ignition SW ON
(engine OFF)
Engine ON (idling)
13
14
0
0
7 +7
0
Sensor output waveform
B134
B135
24
4
0
0
0
0 0.9
B135
B136
10 13
1 14
Waveform
B136
10 13
1 14
Waveform
Rear oxygen sensor

heater signal
B136
10 13
1 14
Waveform
B134
34
1.0 1.4
1.0 1.4
After engine is warmed-up.
Vehicle speed signal
B136
12
0 or 5
0 or 5
Signal
B135
26
0.3 4.5
5 and 0 are repeatedly displayed when vehicle is driven.
Shield
Ground
B135
B135
35
34
0
0
0
0
B135
18
0.3 4.6
0.3 4.6
B134
B134
12
22
0
0
7 +7
0
Shield
Starter switch
B134
B136
24
32
0
0
0
0
Cranking: 8 14
A/C switch
B136
23
B136
33
B135
27
ON: 10 13
OFF: 0
ON: 0
OFF: 10 13
10 13
ON: 12 14
OFF: 0
ON: 0
OFF: 12 14
12 14
Signal (+)
Crankshaft posi- Signal ()
tion sensor Shield
Rear oxy- Signal
gen senShield
sor
Front oxy- Signal 1
gen (A/F)
sensor
Signal 2
heater
Air flow
sensor
Intake air temperature

sensor signal
Camshaft
position
sensor
Signal (+)
Signal ()
A/C middle pressure

switch
Ignition switch
EN(H4SO)(diag)-17

Connector
No.
Terminal No.
Neutral position switch
B136
31
Test mode connector
B135
Content
Knock
sensor
Signal
Shield
Back-up power supply

Control module power
supply
Signal (V)
Note
Ignition SW ON
(engine OFF)
Engine ON (idling)
19
ON: 0
OFF: 10 13
10 13
ON: 0
OFF: 12 14
13 14
When connected: 0
B134
B134
15
25
2.5
0
2.5
0
B135
B134
5
7
10 13
10 13
12 14
12 14
Ignition switch OFF: 10 13
2
18
10 13
0
12 14
1 3.4
Waveform
Ignition
control
#1, #2
B135
B137
#3, #4
#1
B137
B137
19
8
0
10 13
1 3.4
1 14
Waveform
Waveform
Fuel injector
#2
#3
B137
B137
9
10
10 13
10 13
1 14
1 14
Waveform
Waveform
#4
B137
11
B136
13
A/C relay control
B136
1 14
ON: 0.5 or less
OFF: 12 14
ON: 0.5 or less
OFF: 12 14
Waveform
Fuel pump relay control
10 13
ON: 0.5 or less
OFF: 10 13
ON: 0.5 or less
OFF: 10 13
Radiator fan relay 1

control
B136
18
ON: 0.5 or less

OFF: 10 13
ON: 0.5 or less

OFF: 12 14
Radiator fan relay 2

control
B136
29
ON: 0.5 or less

OFF: 10 13
ON: 0.5 or less

OFF: 12 14
Model with A/C only
Starter relay control
B136
20
Self-shutoff control
B136
24
ON: 0.5 or less

OFF: 10 13
0.5 or less
ON: 0.5 or less

OFF: 12 14
0.5 or less
Malfunction indicator
light
Light ON: 1 or less

Light OFF: 10 14
B136
11
B136
22
B137
29
ON: 1 or less
OFF: 10 13
0 13
ON: 1 or less
OFF: 12 14
B134
3.4 3.8
1.4 1.8
Signal
B135
32
2.3 2.7
2.3 2.7
GND
(sensor)
B135
30
B136
28
ON: 1 or less
OFF: 10 13
ON: 1 or less
OFF: 12 14
Drain valve
B136
17
ON: 1 or less
OFF: 10 13
ON: 1 or less
OFF: 12 14
Fuel level sensor

Fuel temperature sensor signal
B135
10
0.3 4.5
0.3 4.5
B135
17
14
14
Small light switch
B135
15
ON: 0
OFF: 10 13
ON: 0
OFF: 12 14
Blower fan switch
B135
16
ON: 0
OFF: 10 13
ON: 0
OFF: 12 14
Rear defogger switch
B135
14
ON: 0
OFF: 10 13
ON: 0
OFF: 12 14
Engine speed output

Purge control solenoid
valve
Fuel tank
pressure
sensor
EN(H4SO)(diag)-18
Waveform
The valve operates when fuel

filler cap is removed and reinstalled.

Content
Connector
No.
Terminal No.
B134
Signal (V)
Note
Ignition SW ON
(engine OFF)
Engine ON (idling)
33
ON: 1 or less
OFF: 10 13
ON: 0
OFF: 12 14
B135
2.7 2.9
B135
2.35 2.55
B135
B136
16
1 or less 4 or more
1 or less 4 or
more
Main
B134
18
0.64 0.72
Fully opened: 3.96
0.64 0.72
(After engine is
warmed-up.)
Fully closed: 0.6 Fully opened:

3.96
Sub
B134
28
1.51 1.58
Fully opened: 4.17
1.51 1.58
(After engine is
warmed-up.)
Fully closed: 1.48 Fully opened:

4.17
Power
supply
B134
19
GND
(sensor)
B134
29
B137
Duty waveform
Duty waveform
Drive frequency: 500 Hz
B137
Duty waveform
Duty waveform
B136
10 13
12 14
B136
21
When ignition switch is turned

to ON: ON
Main sensor signal
B135
23
Fully closed: 0.7

Fully opened: 3.0
Fully closed: 0.7

Fully opened: 3.0
Main
power
supply
B135
21
B135
29
B135
31
Fully closed: 0.7

Fully opened: 3.0
Fully closed: 0.7

Fully opened: 3.0
Sub power
supply
B135
22
GND
(Sub sensor)
B135
30
Cruise control set light
B135
ON: 0
OFF: 10 13
ON: 0
OFF: 12 14
Main light
B135
ON: 0
OFF: 10 13
ON: 0
OFF: 12 14
25
When clutch pedal is

depressed: 0
released: 10 13

depressed: 0
released: 12 14
Power steering oil pressure switch

Front oxygen (A/F) sensor signal (+)
Front oxygen (A/F) sensor signal ()
Front oxygen (A/F) sensor shield
SSM communication
line
Electronic
throttle
control
Electronic throttle control motor (+)

Electronic throttle control motor ()
Electronic throttle control motor power supply
Electronic throttle control motor relay
Accelerator pedal
position
sensor
GND
(Main sensor)
Sub sensor signal
Clutch switch
B136
EN(H4SO)(diag)-19

Content
Connector
No.
Terminal No.
Brake switch 1
B135
20
Brake switch 2
B135
28
Cruise control command switch
When brake pedal is

depressed: 0
When brake pedal is
released: 10 13
When brake pedal is
depressed: 10 13
When brake pedal is
released: 0
When brake pedal is

depressed: 0
When brake pedal is
released: 12 14
When brake pedal is
depressed: 12 14
When brake pedal is
released: 0
When not operating:

3.5 4.5
When operating RES/
ACC: 2.5 3.5
When operating SET/
COAST: 0.5 1.5
When operating cancel: 0 0.5
ON: 0
OFF: 5
When not operating:

3.5 4.5
When operating RES/
ACC: 2.5 3.5
When operating SET/
COAST: 0.5 1.5
When operating cancel: 0 0.5
ON: 0
OFF: 5
Note
24
B135
12
B134
23
1.0 1.4
1.0 1.4
B134
31
B134
32
B137
25
Duty waveform
B137
24
B137
31
Duty waveform
B137
30
B134
30
B136
27
Signal 1
B136
B134
35
8
10 13
0 or 12 14
Signal 2
Signal 3
B134
B134
9
10
10 13
10 13
0 or 12 14
0 or 12 14
Signal 4
(Engine 1)
B134
B134
20
5
10 13
0
0 or 12 14
0
(Engine 2)
(Engine 3)
B137
B137
7
2
0
0
0
0
(Engine 4)
(Engine 5)
B137
B137
1
3
0
0
0
0
(Ignition 1)
(Ignition 2)
B137
B137
26
6
0
0
0
0
(Body)
B136
Variable valve lift diagnosis

Oil pressure switch RH
Variable valve lift diagnosis
Oil pressure switch LH
Oil switch- Signal (+)
ing soleSignal ()
noid valve
RH
Oil switch- Signal (+)
ing soleSignal ()
noid valve
LH
Blow-by leak diagnosis
signal
CAN com- Signal (+)
munication Signal ()
Ground
Engine ON (idling)
B135
Cruise control main

switch
signal
EGR solenoid valve
Signal (V)
Ignition SW ON
(engine OFF)
Pulse signal
Pulse signal
EN(H4SO)(diag)-20
When there is an open circuit

(malfunction): 10 14
Engine Condition Data

6. Engine Condition Data

Content
Engine load
Specification
Other than U5
model
17.6 35.6 (%): Idling

15.4 31.1 (%): 2,500 rpm racing
U5 model
14.4 29.2 (%): Idling

15.7 31.8 (%): 2,500 rpm racing
Measuring condition:
Gear position is in N or P range.
A/C is turned OFF.
Turn all the accessory switches to OFF.
EN(H4SO)(diag)-21
Data Link Connector

7. Data Link Connector

A: NOTE
This connector is used both for general scan tools and the Subaru Select Monitor.
CAUTION:
Do not connect any scan tools other than general scan tools and the Subaru Select Monitor, because
the circuit for the Subaru Select Monitor may be damaged.
9 10 11 12 13 14 15 16
EN-04893
Terminal No.
Content
Terminal No.
Content
1
2
Blank
Blank
9
10
Blank
Blank
3
4
Ground
Blank
11
12
Blank
Blank
5
6
Blank
CAN-H
13
14
Blank
CAN-L
7
8
Subaru Select Monitor signal

Blank
15
16
Blank
Power supply
EN(H4SO)(diag)-22
General Scan Tool

8. General Scan Tool

A: OPERATION
1. HOW TO USE GENERAL SCAN TOOL
1) Prepare a scan tool (general scan tool) required
by SAE J1978.
2) Open the cover and connect the general scan
tool to the data link connector located in the lower
portion of instrument panel (on the drivers side).
ME-00325
3) Using the general scan tool, call up DTC and

freeze frame data.
General scan tool functions consist of:
(1) MODE $01: Current powertrain diagnostic
data
(2) MODE $02: Powertrain freeze frame data
(3) MODE $03: Emission-related powertrain
DTC
(4) MODE $04: Clear/Reset emission-related
diagnostic information
(5) MODE $06: Request on-board monitoring
test results for intermittently monitored systems
test results for continuously monitored systems
(7) MODE $09: Request vehicle information
Read out the data according to repair procedures.
(For detailed operation procedure, refer to the general scan tool instruction manual.)
NOTE:
For details concerning DTC, refer to List of Diagnostic Trouble Code (DTC). <Ref. to
EN(H4SO)(diag)-67, List of Diagnostic Trouble
Code (DTC).>
EN(H4SO)(diag)-23
General Scan Tool

2. MODE $01 (CURRENT POWERTRAIN DIAGNOSTIC DATA)

Refer to data denoting the current operating condition of analog input/output, digital input/output or the powertrain system.
A list of the support data and PID (Parameter Identification) codes are shown in the following table.
PID
01
Data
Number of emission-related powertrain DTC and malfunction indicator light status and diagnosis support information
Unit of measure
03
04
Fuel system control status

Calculated engine load value
05
06

Short term fuel trim
C
%
07
Long term fuel trim
0B
0C
Intake manifold absolute pressure

Engine speed
kPa
rpm
0D
0E
Vehicle speed
Ignition timing advance
km/h
0F
10

Air flow rate from mass air flow sensor
C
g/sec
11
13
Throttle valve absolute opening angle

Check whether oxygen sensor is installed.
15
1C
Oxygen sensor output voltage and short term fuel trim associated with oxygen sensor
Supporting OBD system
24
34
A/F value and A/F sensor output voltage

A/F value and A/F current
V and %
and V
and mA
$1F
$21
Elapsed time after starting engine

Elapsed time after MIL illuminates
sec
km
$2C
$2D
Target EGR
EGR deviation
%
%
$2E
$2F
Evaporative purge
Fuel level
%
%
$30
$31
Engine speed for warm up after DTC clear

Travel distance after DTC clear
km
$32
$33
Tank pressure
Atmospheric pressure
$3C
$41
Catalytic temperature #1
Diagnostic monitor of each DC
$42
$43
ECM power voltage

Absolute load
V
%
$44
$45
A/F target lambda

Relative throttle opening angle
$46
$47
Ambient temperature
Absolute throttle opening angle 2
C
%
$49
$4A
Absolute accelerator opening angle 1

%
%
$4C
$4D
Target throttle opening angle

Engine operating time during MIL illuminates
%
min
$4E
$51
Elapsed time after DTC clear

Fuel used
min
$5A
Relative accelerator opening angle
mmHg
mmHg
NOTE:
Refer to general scan tool manufacturers instruction manual to access generic OBD-II PIDs (MODE $01).
EN(H4SO)(diag)-24
General Scan Tool

3. MODE $02 (POWERTRAIN FREEZE FRAME DATA)

Refer to data denoting the operating condition when trouble is detected by on-board diagnosis system.
PID
02
Data
DTC that caused the freeze frame data storage required by CARB
Unit of measure
03
04

05
06

C
%
07
0B
Long term fuel trim

%
kPa
0C
0D
Engine speed
Vehicle speed
rpm
km/h
0E
0F

10
11

15
1C
$1F
$2C

Target EGR
$2D
$2E
EGR deviation
Evaporative purge
%
%
$2F
$13
Fuel level
Air fuel ratio sensor
$32
$33
Tank pressure
$42
$43
ECM power voltage

Absolute load
V
%
$44
$45
A/F target lambda

$46
$47
Ambient temperature
C
%
$49
$4A

%
%
$4C
C
g/sec
%
V and %
sec
%
mmHg
mmHg
NOTE:
Refer to general scan tool manufacturers instruction manual to access freeze frame data (MODE $02).
4. MODE $03 (EMISSION-RELATED POWERTRAIN DTC)

Refer to Read Diagnostic Trouble Code (DTC) for information about data denoting emission-related powertrain DTC. <Ref. to EN(H4SO)(diag)-67, List of Diagnostic Trouble Code (DTC).>
5. MODE $04 (CLEAR/RESET EMISSION-RELATED DIAGNOSTIC INFORMATION)

Refer to the mode used to clear or reset emission-related diagnostic information (OBD-II trouble diagnostic
information).
NOTE:
Refer to general scan tool manufacturers instruction manual to clear the emission-related diagnostic information (MODE $04).
EN(H4SO)(diag)-25
General Scan Tool

6. MODE $06
Refer to the test value of troubleshooting and data of test specification on the support data bit sequence table. A list of the support data is shown in the following table.
OBDMID
TID
SID
$81
$82
$0A
$8D
A/F sensor conduction abnormal (B1S1)
$83
$84
$14
$1E
A/F sensor range abnormal (B1S1)
$85
$86
$1E
$20
A/F sensor response (B1S1)
$87
$88
$0B
$0B
Oxygen sensor circuit abnormal (B1S2)
$07
$0B
Oxygen sensor drop abnormal (B1S2)
$08
$A5
$0B
$0B
$05
$06
$10
$10
Oxygen sensor response abnormal (B1S2)
$21
$31
$89
$8A
$20
$FD
Catalyst degradation diagnosis (Bank 1)

EGR system diagnosis
$39
$93
$94
$FE
$FE
Evaporative emission control system (Cap off)

Evaporative emission control system (0.04)
$3C
$95
$96
$FE
$FE
Evaporative emission control system (0.02)
$3D
$97
$98
$FE
$FE
Evaporative emission control system (Purge flow)
$99
$9A
$24
$24
A/F sensor heater abnormal (B1S1)
$42
$9B
$9C
$14
$24
A/F sensor heater performance abnormal (B1S1)

Oxygen sensor heater abnormal (B1S2)
$A1
$9D
$0B
$24
$24
Misfire monitoring (All cylinders)
$A2
$0C
$0B
$24
$24
Misfire monitoring (#1 cylinder)
$A3
$0C
$0B
$24
$24
$A4
$0C
$0B
$24
$24
$A5
$0C
$0B
$24
$24
$0C
$24
$01
$02
$3B
$41
Test value & Test specification
7. MODE $07
Refer to the data of DTC (pending code) for troubleshooting result about emission in the first time.
8. MODE $09
Refer to data of vehicle specification (V.I.N., calibration ID, diagnosis frequency etc.).
EN(H4SO)(diag)-26

9. Subaru Select Monitor
2. READ DIAGNOSTIC TROUBLE CODE

(DTC) FOR ENGINE (NORMAL MODE)
A: OPERATION
1. HOW TO USE SUBARU SELECT MONITOR
1) Prepare the Subaru Select Monitor kit. <Ref. to
EN(H4SO)(diag)-7, PREPARATION TOOL, General Description.>
2) Connect the diagnosis cable to the Subaru Select Monitor.
link connector.
(1) Data link connector is located in the lower
portion of instrument panel (on the drivers
side).
Refer to Read Diagnostic Trouble Code (DTC) for

information about how to display a DTC. <Ref. to
EN(H4SO)(diag)-34, Read Diagnostic Trouble
Code (DTC).>

(DTC) FOR ENGINE (OBD MODE)
EN(H4SO)(diag)-34, Read Diagnostic Trouble
Code (DTC).>
ME-00325
(2) Connect the diagnosis cable to the data link

connector.
CAUTION:
Do not connect scan tools except for Subaru
Select Monitor and general scan tool.
4) Turn the ignition switch to ON (engine OFF) and
run the Subaru Select Monitor.
5) Using the Subaru Select Monitor, call up DTCs
and various data, then record them.
EN(H4SO)(diag)-27

4. READ CURRENT DATA FOR ENGINE (NORMAL MODE)

1) On the Main Menu display screen, select the {Each System Check}.
2) On the System Selection Menu display screen, select the {Engine Control System}.
3) Select the [OK] after the information of engine type has been displayed.
4) On the Engine Diagnosis display screen, select the {Current Data Display/Save}.
5) On the Display Menu screen, select the {Data Display}.
6) Using the scroll key, scroll the display screen up or down until the desired data is shown.
A list of the support data is shown in the following table.
Contents
Display
Engine load
Engine Load
Engine coolant temperature signal
Coolant Temp.
Unit of measure
%
C or F
Note (at idling)

21.0%
92C or 198F (After
warming up)
0.8%
A/F correction #1
A/F Correction #1
A/F learning #1
A/F Learning #1
Mani. Absolute Pressure
Engine speed signal
Engine Speed
Meter vehicle speed signal
Meter Vehicle Speed
Ignition timing signal
Ignition Timing
km/h or
MPH
deg
Intake air temperature signal
Intake Air Temp.
C or F
Intake air amount
Mass Air Flow
Throttle opening angle signal
Throttle Opening Angle
(Ambient air temperature)

2.8 3.2 g/s or 0.37
0.42 lb/m
2.0%
Rear oxygen sensor voltage

Battery voltage
Rear O2 Sensor
Battery Voltage
V
V
0.1 0.7 V
12 14 V
Mass air flow voltage

Injection 1 pulse width
Air Flow Sensor Voltage

Fuel Injection #1 Pulse
V
ms
1.26 V
2.82 ms
Knock sensor correction
Knocking Correction
0.0 deg
Atmospheric absolute pressure signal
Atmospheric Pressure
deg
mmHg, kPa,
inHg or psig
Intake manifold relative pressure
Mani. Relative Pressure
mmHg, kPa,
inHg or psig
Fuel tank pressure signal
Fuel Tank Pressure
mmHg, kPa,
inHg or psig
(Air intake absolute pressure atmosphere pressure)

+7.9 mmHg, +1.1 kPa,
+0.31 inHg or +0.15 psig
Fuel temperature signal

Fuel level signal
Fuel Temp.
Fuel Level
C or F
V
+20C or +68F
05V
Acceleration opening angle signal
Acceleration Opening
Angle
0.0%
Purge control solenoid duty ratio

No. of EGR steps
CPC Valve Duty Ratio

No. of EGR Step
%
STEP
0 3%
0 STEP
A/F sensor current value 1
A/F Sensor #1 Current

A/F Sensor #1 Resistance
A/F sensor output
lambda 1
mA
0.2 0.2 mA
32
1.0
Ignition timing learning

A/F correction #3
Learned Ignition Timing

A/F Correction #3
deg
%
0.3%
A/F learning #3
A/F Learning #3
0.00%
A/F sensor resistance value 1

A/F sensor output lambda 1
EN(H4SO)(diag)-28
mmHg, kPa,
inHg or psig
rpm
g/s or lb/m
0.0%
200 300 mmHg, 26.7
40 kPa, 7.8 11.8
inHg or 3.8 5.8 psig
600 800 rpm (Agree
with the tachometer indication)
0 km/h or 0 MPH (at parking)
14 16 deg
(Atmosphere pressure)

Contents
Display
Unit of measure
%
Note (at idling)
Throttle motor duty
Throttle Motor Duty
Throttle power supply voltage

Sub throttle sensor voltage
Throttle Motor Voltage

Sub Throttle Sensor
V
V
(Battery voltage)
1.52 V
Main throttle sensor voltage

Sub accelerator sensor voltage
Main Throttle Sensor

Sub Accelerator Sensor
V
V
0.66 V
0.68 V
Main accelerator sensor voltage
Main Accelerator Sensor

Memorized Cruise
Speed
V
km/h or
MPH
0.68 V
Engine oil temperature
Engine Oil Temperature
85C (After engine

warmed-up)
Oil switching solenoid valve duty R

Oil switching solenoid valve duty L
Osv Duty R
OSV Duty L
%
%
16.9%
16.9%
Oil switching solenoid valve current R

Oil switching solenoid valve current L
OSV Current R
OSV Current L
mA
mA
192 mA
192 mA
Variable valve lift lift mode

#1 cylinder roughness monitor
VVL Lift Mode

Roughness Monitor #1
1
0

0
0

AT/MT identification terminal
AT Model ID Signal
0
AT model / MT model
Test mode terminal

Neutral position switch signal
Test Mode Terminal

Neutral Position Switch
U-check
Neutral
Soft idle switch signal

Ignition switch signal
Idle Switch Signal

Ignition Switch
At idle
ON input
Power steering switch signal

Air conditioning switch signal
P/S Switch
A/C Switch
OFF input (At OFF)

OFF input (At OFF)
Starter switch signal

Rear O2 monitor
Starter Switch
Rear O2 Rich Signal
OFF input
Rich/Lean
Knocking signal
Knocking Signal
Crankshaft Position Signal
None
Provided
Camshaft position sensor signal

Rear defogger switch signal
Camshaft Position Signal

Rear Defogger Switch
Provided
OFF input (At OFF)
Blower fan switch signal

Light switch signal
Blower Fan Switch

Light Switch
OFF input (At OFF)

OFF input (At OFF)
A/C middle pressure switch signal

Air conditioner compressor relay output signal
A/C Mid Pressure Switch

A/C Compressor Signal
OFF input (At OFF)

OFF output (At OFF)
Radiator fan relay 1 signal

Radiator Fan Relay #1

OFF output (At OFF)

OFF output (At OFF)
Fuel pump relay signal

Pressure control solenoid valve signal
Fuel Pump Relay

PCV Solenoid Valve
ON output
OFF output
PCV hose assembly diagnosis signal
Blow-by Leak Diagnosis

Connector
Connect
D check request flag

Delivery mode connector
D Check Request
Delivery Mode
OFF
OFF
Drain valve signal

Variable valve lift diagnosis oil pressure switch signal 1
Vent. Solenoid Valve

Eng. Oil Press. SW 1
OFF output
ON
Variable valve lift diagnosis oil pressure switch signal 2

AT coordinate retard angle demand signal
Eng. Oil Press. SW 2

Retard Signal from AT
ON
None
AT coordinate fuel cut demand signal
Fuel Cut Signal from AT
None
Memory vehicle speed
Crankshaft position sensor signal
EN(H4SO)(diag)-29
15%
0 km/h or 0 MPH

Contents
Display
Unit of measure
Note (at idling)
AT cooperative permission signal
Torque Control Permission Signal
ON
Electronic throttle control motor relay signal

Clutch switch signal
ETC Motor Relay

Clutch Switch
ON
OFF (At OFF)
Stop light switch signal

SET/COAST switch signal
Stop Light Switch

SET/COAST Switch
OFF (At OFF)

OFF (At OFF)
RES/ACC switch signal

Brake switch signal
RESUME/ACCEL Switch
Brake Switch
OFF (At OFF)

OFF (At OFF)
Main switch signal
Main Switch
Cruise Control Cancel
Switch
OFF (At OFF)
OFF (At OFF)
Cruise control cancel switch signal
NOTE:
For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
5. READ CURRENT DATA FOR ENGINE (OBD MODE)

4) On the Engine Diagnosis display screen, select the {OBD System}.
5) On the OBD Menu display screen, select the {Current Data Display/Save}.
6) On the Display Menu screen, select the {Data Display}.
Contents
Display
Unit of measure
Note (at idling)
Number of diagnosis code
Number of DTC
Condition of malfunction indicator light

Monitoring test of misfire
MI (MIL)
Misfire monitoring
ON or OFF
Finish or incomplete
Monitoring test of fuel system

Monitoring test of comprehensive component
Fuel system monitoring

Component monitoring
Test of catalyst
Test of heated catalyst
Catalyst Diagnosis
Heated catalyst
No support
Test of evaporative emission purge control system
Evaporative purge system
Secondary air system test

Test of air conditioning system refrigerant
Secondary air system

A/C system refrigerant
No support
No support
Oxygen sensor test

Oxygen sensor heater test
Oxygen sensor
O2 Heater Diagnosis
Test of EGR system

Air fuel ratio control system for bank 1
EGR system
A/F Control #1
Normal CLOSE
Engine load data

Load
Coolant Temp.
%
C or F
23.0%
92C or 198F
Short term fuel trim by front oxygen (A/F) sensor

Long term fuel trim by front oxygen (A/F) sensor
A/F Correction Value #1

A/F Learning Value #1
%
%
0.8%
+0.0%
Engine speed signal
Engine Speed
mmHg, kPa,
inHg or psig
rpm
211 mmHg, 28.1 kPa,

8.31 inHg or 4.08 psig
700 rpm
Vehicle Speed
km/h or
MPH
0 km/h or 0 MPH
#1 Cylinder ignition timing

Ignition timing #1
Intake Air Temp.
C or F
+16.0
36C or 97F
EN(H4SO)(diag)-30

Contents
Display
Unit of measure
g/s or
lb/m
Note (at idling)
Intake air amount
Mass Air Flow
Throttle position signal

Oxygen sensor (Bank 1 Sensor 2)

Oxygen sensor #12
%
V
13%
0.7 V
Air fuel ratio correction by rear oxygen sensor

On-board diagnostic system
A/F Correction #12

OBD system
0.0%
CARBOBD2
Front oxygen (A/F) sensor (Bank 1 Sensor 1)

Oxygen sensor #11

Oxygen sensor #12
Support
Support

A/F sensor #11

A/F sensor #11
1.001
2.79 V

A/F sensor #11

A/F sensor #11
mA
1.001
0.00 mA

Travel distance after malfunction indicator light illuminating
Time Since Engine Start

Lighted MI lamp history
sec
km or miles
Target EGR
EGR deviation
Target EGR
EGR deviation
%
%
Evaporative purge
Commanded Evap
Purge
0%
Fuel level signal

Engine speed for warm up after DTC clear
Fuel Level
Number of warm-ups

Meter since DTC cleared

Fuel Tank Pressure
km or miles
mmHg, kPa,
inHg or psig
+7.9 mmHg, +1.1 kPa,

+0.31 inHg or +0.15 psig
Atomosphere Pressure
mmHg, kPa,
inHg or psig
Catalytic temperature #1
Diagnostic monitor of each drive cycle
C or F
ECM power voltage
Catalyst Temperature #1
Diagnostic monitor of
each DC
Control module voltage
13.789 V
Absolute load
Air fuel ratio target lambda
Absolute Load Value

Target Equivalence Ratio
22%
0.976

Ambient temperature
Relative Throttle Pos.

Ambient Temperature
%
C or F
2%

Absolute Throttle Pos.#2

Accelerator Pedal
Pos.#1
%
%
32%
13%
Accelerator Pedal
Pos.#2
13%

Engine operating time during MIL illuminates
Target Throt. Act. Cont.

Time while MIL lighted
%
min
0%

Fuel used
Time since DTC cleared

Type of fuel
min
GAS
Relative Accelera. Pos.
0%
2.7 g/s or 0.36 lb/m
NOTE:
EN(H4SO)(diag)-31

6. READ FREEZE FRAME DATA FOR ENGINE (OBD MODE)

5) On the OBD Menu display screen, select the {Freeze Frame Data}.
Contents
Display
Unit of measure
Freeze frame data DTC code

Freeze frame data

Fuel system for Bank 1
DTC
Normal CLOSE or initial OPEN
Engine load data

Engine load
Coolant Temp.

Short term fuel trim B1

Long term fuel trim B1
Intake manifold absolute pressure signal

Engine speed signal

Engine Speed

Vehicle Speed
Ignition Timing
Intake air amount

Mass Air Flow

Intake Air Temp.

Oxygen sensor #12

Oxygen sensor #12
A/F Correction #12

Oxygen sensor #11
A/F Correction #12

Oxygen sensor #11
%
Support
Oxygen sensor #12

Supporting OBD
Oxygen sensor #12

Supporting OBD
Support
OBD2(CARB)
Target EGR
EGR deviation
Target EGR
EGR deviation
%
%
Evaporative purge
Fuel level
Commanded Evap Purge

Fuel Level
%
%

Fuel Tank Pressure

Atmosphere Pressure
mmHg, kPa, inHg or psig

ECM power voltage

Absolute load
Control module voltage

Absolute Load Value
V
%

Relative throttle position
Target Equivalence Ratio

Relative Throttle Pos.
Ambient temperature
Ambient Temperature
Absolute Throttle Pos.#2
C or F
%

Accelerator Pedal Pos.#1

Accelerator Pedal Pos.#2
%
%

Target Throt. Act. Cont.

Front oxygen (A/F) sensor (B1S1)
%
Support
Oxygen sensor (B1S2)
Support
%
C or F
%
%
mmHg, kPa, inHg or psi
rpm
km/h or MPH
g/sec
C or F
%
V
NOTE:
EN(H4SO)(diag)-32

7. V.I.N. REGISTRATION
4) On the Engine Diagnosis display screen, select the {V.I.N. Registration}.
5) Perform the procedures shown on the display screen.
NOTE:
EN(H4SO)(diag)-33
Read Diagnostic Trouble Code (DTC)

10.Read Diagnostic Trouble

Code (DTC)
A: OPERATION
1. SUBARU SELECT MONITOR (NORMAL
MODE)
1) On the Main Menu display screen, select the
{Each System Check}.
2) On the System Selection Menu display
screen, select the {Engine Control System}.
3) Select the [OK] after the information of engine
type has been displayed.
4) On the Engine Diagnosis screen, select the
{DTC Display}.
5) On the Diagnostic Code(s) Display screen,
select the {Current Diagnostic Code(s)} or {History
Diagnostic Code(s)}.
3. GENERAL SCAN TOOL

Refer to data denoting emission-related powertrain
DTC.
Code (DTC).>
NOTE:
Refer to general scan tool manufacturers instruction manual to access powertrain DTC (MODE
$03).
NOTE:
For detailed operation procedure, refer to the
SUBARU SELECT MONITOR OPERATION
MANUAL.
Code (DTC).>
2. SUBARU SELECT MONITOR (OBD

MODE)
5) On the OBD Menu display screen, select the
Diagnostic Code(s) Display.
6) Make sure DTC is shown on the screen.
NOTE:
MANUAL.
Code (DTC).>
EN(H4SO)(diag)-34
Inspection Mode
11.Inspection Mode
A: PROCEDURE
Carry out trouble diagnosis shown in the following DTC table.
When performing trouble diagnosis which is not shown in the DTC table, refer to the Drive cycle. <Ref. to
EN(H4SO)(diag)-40, Drive Cycle.>
P0031
DTC
Item
HO2S Heater Control Circuit Low (Bank 1 Sensor 1)
Condition
P0032
P0037
HO2S Heater Control Circuit High (Bank 1 Sensor 1)

P0038
P0077

Intake Valve Control Solenoid Circuit High (Bank 1)
P0083
P0102

Mass or Volume Air Flow Circuit Low Input
P0103
P0107
Mass or Volume Air Flow Circuit High Input

Manifold Absolute Pressure/Barometric Pressure Circuit Low Input
P0108
P0112
Manifold Absolute Pressure/Barometric Pressure Circuit High Input

Intake Air Temperature Sensor 1 Circuit Low
P0113
P0117
Intake Air Temperature Sensor 1 Circuit High

Engine Coolant Temperature Circuit Low
P0118
P0122
Engine Coolant Temperature Circuit High

Throttle/Pedal Position Sensor/Switch A Circuit Low
P0123
P0131
Throttle/Pedal Position Sensor/ Switch A Circuit High

O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1)
P0132
P0137
O2 Sensor Circuit High Voltage (Bank 1 Sensor 1)

P0138
P0140

O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 2)
P0182
P0183
Fuel Temperature Sensor A Circuit Low Input

Fuel Temperature Sensor A Circuit High Input
P0197
P0198
Engine Oil Temperature Sensor Low

Engine Oil Temperature Sensor High
P0222
P0223
Throttle/Pedal Position Sensor/Switch B Circuit Low

Throttle/Pedal Position Sensor/Switch B Circuit High
P0327
P0328
Knock Sensor 1 Circuit Low (Bank 1 or Single Sensor)

Knock Sensor 1 Circuit High (Bank 1 or Single Sensor)
P0335
P0336
Crankshaft Position Sensor A Circuit

Crankshaft Position Sensor A Circuit Range/Performance
P0340
P0447
Camshaft Position Sensor A Circuit (Bank 1 or Single Sensor)

Camshaft Position Sensor A Circuit Range/Performance (Bank 1 or Single Sensor)
Evaporative Emission Control System Vent Control Circuit Open
P0448
P0452
Evaporative Emission Control System Vent Control Circuit Shorted

Evaporative Emission Control System Pressure Sensor Low Input
P0453
P0458
Evaporative Emission Control System Pressure Sensor High Input

Evaporative Emission System Purge Control Valve Circuit Low
P0462
P0463
Fuel Level Sensor A Circuit Low

Fuel Level Sensor A Circuit High
P0502
P0503
Vehicle Speed Sensor A Circuit Low Input

Vehicle Speed Sensor A Intermittent/Erratic/High
P0512
Starter Request Circuit
P0341
EN(H4SO)(diag)-35
Inspection Mode
DTC
Item
Condition
P0519
P0600
Idle Air Control System Performance

Serial Communication Link
P0604
P0605
Internal Control Module Random Access Memory (RAM) Error

Internal Control Module Read Only Memory (ROM) Error
P0607
P0638
Control Module Performance

Throttle Actuator Control Range/Performance (Bank 1)
P0691
P0692
Fan 1 Control Circuit Low

Fan 1 Control Circuit High
P0700
P0851
Transmission Control System (MIL Request)

Park/Neutral Switch Input Circuit Low
P0852
P1152
Park/Neutral Switch Input Circuit High

O2 Sensor Circuit Range/Performance (Low) (Bank 1 Sensor 1)
P1153
P1160
O2 Sensor Circuit Range/Performance (High) (Bank 1 Sensor 1)

Return Spring Failure
P1400
P1420
Fuel Tank Pressure Control Solenoid Valve Circuit Low

Fuel Tank Pressure Control Sol. Valve Circuit High
P1491
P1518
Positive Crankcase Ventilation (Blow-by) Function Problem

Starter Switch Circuit Low Input
P1560
P2101
Back-up Voltage Circuit Malfunction

Throttle Actuator Control Motor Circuit Range/Performance
P2102
P2109
Throttle Actuator Control Motor Circuit Low

Throttle/Pedal Position Sensor A Minimum Stop Performance
P2122
P2123
Throttle/Pedal Position Sensor/Switch D Circuit Low Input

Throttle/Pedal Position Sensor/Switch D Circuit High Input
P2127
P2128
Throttle/Pedal Position Sensor/Switch E Circuit Low Input

Throttle/Pedal Position Sensor/Switch E Circuit High Input
P2135
P2138
Throttle/Pedal Position Sensor/Switch A/B Voltage Correlation

Throttle/Pedal Position Sensor/Switch D/E Voltage Correlation
P2227
P2228
Barometric Pressure Circuit Range/ Performance

Barometric Pressure Circuit Low
P2229
Barometric Pressure Circuit High
EN(H4SO)(diag)-36
Inspection Mode
1. PREPARATION FOR THE INSPECTION

MODE
1) Check battery voltage is more than 12 V and fuel
remains half [20 40 2 (5.3 10.6 US gal, 4.4
8.8 Imp gal)].
2) Lift-up the vehicle using a garage jack and place
it on rigid racks, or drive the vehicle onto free rollers.
WARNING:
Before raising the vehicle, ensure parking
brakes are applied.
Do not use a pantograph jack in place of a rigid rack.
Secure a rope or wire to the front or rear towing hooks to prevent the lateral runout of front
wheels.
Do not abruptly depress/release clutch pedal
or accelerator pedal during works even when
the engine is operating at low speeds since this
may cause vehicle to jump off free rollers.
In order to prevent the vehicle from slipping
due to vibration, do not place any wooden
blocks or similar items between the rigid racks
and vehicle.
Since the rear wheels will also rotate, do not
place anything near them. Also, make sure that
nobody goes in front of the vehicle.
2. SUBARU SELECT MONITOR

1) After clearing the memory, check for any remaining unresolved trouble data. <Ref. to EN(H4SO)(diag)-44, Clear Memory Mode.>
5) Connect the test mode connector (A) at the lower portion of instrument panel (on the drivers side).
(A)
EN-00238

link connector.
side).
ME-00325
(A)

connector.
(B)
(A) Rigid rack

(B) Free rollers
EN-00041
CAUTION:
Do not connect the scan tools except for Subaru Select Monitor and general scan tool.
11) On the Engine Diagnosis display screen, select the {Dealer Check Mode Procedure}.
12) When the Perform Inspection (Dealer Check)
Mode is shown on the screen, select the [OK].
EN(H4SO)(diag)-37
Inspection Mode
13) Perform subsequent procedures as instructed

on the display screen.
If trouble still remains in the memory, the corresponding DTC appears on the display screen.
NOTE:
MANUAL.
For details concerning DTC, refer to List of Diagnostic Trouble Code (DTC).
<Ref. to EN(H4SO)(diag)-67, List of Diagnostic
Trouble Code (DTC).>
Release the parking brake.
The speed difference between front and rear
wheels may light the ABS warning light, but this
indicates no malfunctions. When engine control
diagnosis is finished, perform the ABS memory
clearance procedure of self-diagnosis system.
EN(H4SO)(diag)-38
Inspection Mode

1) After clearing the memory, check for any remaining unresolved trouble data.
<Ref. to EN(H4SO)(diag)-44, Clear Memory
Mode.>
(A )
EN-00238
4) Connect the general scan tool to its data link

connector.
9) Place the selector lever or shift lever in D range

(AT model) or 1st gear (MT model) and drive the
vehicle at 5 to 10 km/h (3 to 6 MPH).
NOTE:
For AWD model, 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
clearance procedure of self-diagnosis system.
10) Using the general scan tool, check DTC and
record the result(s).
NOTE:
For detailed operation procedures, refer to the
General Scan Tool Instruction Manual.
<Ref. to EN(H4SO)(diag)-67, List of Diagnostic
CAUTION:
Do not connect the scan tools except for Subaru Select Monitor and general scan tool.
ME-00325

NOTE:
Ensure the selector lever is placed in P range
before starting. (AT model)
Depress the clutch pedal when starting engine.
(MT model)
6) Using the selector lever or shift lever, turn the P
position switch and N position switch to ON.
7) Depress the brake pedal to turn the brake switch
ON. (AT model)
8) Keep the engine speed in 2,500 3,000 rpm
range for 40 seconds.
EN(H4SO)(diag)-39
Drive Cycle
12.Drive Cycle
A: PROCEDURE
There are 6 drive patterns of drive cycles A F for the trouble diagnosis. Performing the specified drive pattern allows to diagnose malfunctioning items listed below. After the malfunctioning items listed below are repaired, always check if they correctly resume their functions by performing the required drive pattern.
1. PREPARATION FOR DRIVE CYCLE

1) Check battery voltage is more than 12 V and fuel remains half [20 40 2 (5.3 10.6 US gal, 4.4 8.8
Imp gal)].
2) After clearing the memory, check for any remaining unresolved trouble data. <Ref. to EN(H4SO)(diag)-44,
Clear Memory Mode.>
3) Disconnect the test mode connector.
NOTE:
Except for the water temperature specified items at starting, be sure to carry out the diagnosis after the engine is warmed up.
For the DTC which has * mark on it, carry out the diagnosis twice. After finishing first diagnosis, stop the
engine, and do the second diagnosis at the same condition.
2. DRIVE CYCLE A (AFTER RUNNING 20 MINUTES AT 80 KM/H (50 MPH), IDLE THE ENGINE
FOR 1 MINUTE.)
DTC
*P0125
Item
Insufficient Coolant Temperature for Closed Loop Fuel Control
Condition
Coolant temperature at start is
less than 20C (68F).
*P0133
Coolant Thermostat (Engine Coolant Temperature Below Thermostat Regulating Temperature)

O2 Sensor Circuit Slow Response (Bank 1 Sensor 1)
*P0171
System too Lean (Bank 1)
*P0172
System too Rich (Bank 1)
*P0196
Engine Oil Temperature Sensor Circuit Range/Performance
*P0301
Cylinder 1 Misfire Detected
Diagnosis completes in drive

cycle B or C as well.
*P0302

*P0303
*P0304
*P0420
Catalyst System Efficiency Below Threshold (Bank 1)
*P0442
Evaporative Emission Control System Leak Detected (Small Leak)
*P0451
Evaporative Emission Control System Pressure Sensor
*P0456
Evaporative Emission Control System Leak Detected (Very Small Leak)
*P0457
Evaporative Emission Control System Leak Detected (Fuel Cap Loose/Off)
*P0459
P1443
Evaporative Emission Control System Purge Control Valve Circuit High

Vent Control Solenoid Valve Function Problem
*P2096
Post Catalyst Fuel Trim System Too Lean Bank 1
*P2097
Post Catalyst Fuel Trim System Too Rich Bank 1
P2103
Throttle Actuator Control Motor Circuit High
*P0128

EN(H4SO)(diag)-40





Drive Cycle
3. DRIVE CYCLE B (TEN MINUTES IDLING)

NOTE:
Drive the vehicle in more than 10 km/h (6 MPH) before diagnosis.
DTC
Item
*P0126
Insufficient Coolant Temperature for Stable Operation
*P0171
System Too Lean (Bank 1)
*P0172
System Too Rich (Bank 1)
*P0301
*P0302
*P0303
*P0304
Condition

cycle A or C as well.
*P0464
Fuel Level Sensor Circuit Intermittent
*P0483
*P0506
Fan Rationality Check

Idle Air Control System RPM Lower Than Expected
*P0507
Idle Air Control System RPM Higher Than Expected
*P2096
*P2097
P2103

4. DRIVE CYCLE C (DRIVE ACCORDING TO THE FOLLOWING DRIVE PATTERN)

(H)
(C)
96 (60)
(D)
(G)
(F)
65 (40)
(E)
(B)
(A)
0
50
150
100
(I)
EN-00195
(A)
Idle the engine for 1 minute.
(D)
(B)
Accelerate the vehicle to 96 km/h

(60 MPH) within 20 seconds.
Drive the vehicle at 96 km/h (60
MPH) for 20 seconds.
(E)
(C)
(F)
Decelerate the vehicle to 65 km/h

(40 MPH) with throttle fully
closed.
EN(H4SO)(diag)-41
(G)
Stop vehicle with the throttle fully

closed.
(H)
Vehicle speed km/h (MPH)
(I)
Sec.
Drive Cycle
DTC
P0026
Item
Intake Valve Control Solenoid Circuit Range/Performance (Bank 1)
Condition
P0028
*P0030

HO2S Heater Control Circuit (Bank 1 Sensor 1)
*P0068
P0076
Manifold Absolute Pressure/Barometric Pressure Circuit Range/Performance

Intake Valve Control Solenoid Circuit Low (Bank 1)
P0082
*P0101

Mass or Volume Air Flow Circuit Range/Performance
P0134
*P0139

*P0171
*P0172
*P0301
*P0302

cycle A or B as well.
*P0303

*P0304
*P0400
Exhaust Gas Recirculation Flow
P1492
P1493
EGR Solenoid Valve Signal #1 Circuit Malfunction (Low Input)

EGR Solenoid Valve Signal #1 Circuit Malfunction (High Input)
P1494
P1495

P1496
P1497

P1498
P1499

*P2096

*P2097

P2103



5. DRIVE CYCLE D
DRIFT DIAGNOSIS
1) Make sure that the engine coolant temperature at engine starting is less than 30C (86F).
2) Make sure that fuel remains more than 9.0 2 (2.4 US gal, 2.0 Imp gal) and the battery voltage is more than
10.9 V.
3) Make sure that the engine coolant temperature rises for more than 10C (18F) from the level of engine
starting and is also above 75C (167F).
4) Idle the engine for more than 120 seconds in the condition of step 3.
EN(H4SO)(diag)-42
Drive Cycle
STUCK DIAGNOSIS
1) Make sure that the battery voltage is more than 10.9 V.
2) Perform the Clear Memory Mode. <Ref. to EN(H4SO)(diag)-44, Clear Memory Mode.>
3) Drive the vehicle for the distance equal to the fuel of 50 2 (13.2 US gal, 11 Imp gal).
NOTE:
It is acceptable to drive the vehicle intermittently.
Do not disconnect the terminal of battery during diagnosis. (Data will be cleared when disconnecting the
battery terminals.)
DTC
P0181
Item
Condition
Fuel Temperature Sensor A Circuit Range/Performance
6. DRIVE CYCLE E
3) Drive the vehicle for the distance equal to the fuel of 30 2 (7.9 US gal, 6.6 Imp gal).
NOTE:
battery terminals.)
DTC
P0461
Item
Fuel Level Sensor A Circuit Range/Performance
Condition
7. DRIVE CYCLE F
2) Warm-up the engine until engine coolant temperature rises above 95C (203F) after starting the engine.
3) Idle the engine for more than 10 minutes in the condition of step 2.
NOTE:
Do not disconnect the terminal of battery during diagnosis. (Data will be cleared when disconnecting the battery terminals.)
DTC
P0111
Item
Intake Air Temperature Sensor 1 Circuit Range/Performance
Condition
8. DRIVE CYCLE H
2) Read the engine coolant temperature, intake air temperature and fuel temperature with ignition switch ON.
<Ref. to EN(H4SO)(diag)-28, READ CURRENT DATA FOR ENGINE (NORMAL MODE), OPERATION,
Subaru Select Monitor.>
3) Start the engine if the value in step 2) meets the following two conditions.
Condition:
|engine coolant temperature intake air temperature | 5C (41F)
|engine coolant temperature fuel temperature| 2C (36F)
NOTE:
If the value does not meet the conditions, turn the ignition switch to OFF and wait until it meets.
Start the engine in P range (AT model) or in N position (MT model).
4) Idle the engine for one minute in the condition of step 3.
DTC
*P1602
Item
Control Module Programming Error
EN(H4SO)(diag)-43
Condition
Clear Memory Mode

13.Clear Memory Mode
A: OPERATION
For clear memory procedures using the general

scan tool, refer to General Scan Tool Instruction
Manual.

MODE)
4) On the Engine Diagnosis display screen, select the {Clear Memory}.
5) When the Done and Turn Ignition Switch OFF
are shown on the display screen, turn the ignition
switch to OFF, and then close the Subaru Select
Monitor.
NOTE:
Initial diagnosis of the electronic throttle control is
performed after the memory is erased. Therefore,
start the engine after 10 seconds or more have
passed since turning the ignition switch to ON.
NOTE:
is performed after the memory is erased. Therefore, start the engine after 10 seconds or more
ON.
MANUAL.

MODE)
5) On the OBD Menu display screen, select
{DTC Clear}.
6) When the Clear Diagnostic Code? is shown on
the screen, select the [OK].
7) Turn the ignition switch to OFF and close the
Subaru Select Monitor.
NOTE:
MANUAL.
EN(H4SO)(diag)-44
Compulsory Valve Operation Check Mode

14.Compulsory Valve Operation

Check Mode
A: OPERATION
(A )
11) Select the desired compulsory actuator on the

Actuator ON/OFF Operation display screen.
12) Selecting the [NO] completes the compulsory
valve operation check mode. The display will then
return to the Actuator ON/OFF Operation
screen.
A list of the support data is shown in the following
table.
Contents
Display
Compulsory fuel pump relay operFuel Pump Relay

ation check
Compulsory radiator fan relay
Radiator Fan Relay
operation check
Compulsory air conditioning relay
A/C Compressor Relay
operation check
Compulsory purge control solenoid valve operation check
Compulsory pressure control

solenoid valve operation check
PCV Solenoid Valve
Compulsory air assist vent control

solenoid valve operation check
Vent Control Solenoid

Valve
EN-00238

link connector.
side).
NOTE:
The following parts will be displayed but not
functional.
Display
EGR Solenoid Valve
ASV Solenoid Valve
FICD Solenoid
Pressure Switching Sol.1
Turbocharger Wastegate Solenoid
AAI Solenoid Valve
Emission-bypass Valve
ME-00325

connector.
CAUTION:
9) On the Engine Diagnosis display screen, select the {System Operation Check Mode}.
10) On the System Operation Check Mode display screen, select the {Actuator ON/OFF Operation}.
Fuel Tank Sensor Control Valve

Secondary Air Combination Valve 1
Secondary Air Combination Valve 2
Secondary Air Pump Relay

MANUAL.
EN(H4SO)(diag)-45
System Operation Check Mode

15.System Operation Check

Mode
A: OPERATION
3) Connect the Subaru Select Monitor to data link
connector located in the lower portion of the instrument panel (on the drivers side).
1. FUEL PUMP CONTROL (OFF OPERATION)

CAUTION:
After carrying out the Operation Check Mode,
perform the Clear Memory Mode <Ref. to
EN(H4SO)(diag)-44, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to
EN(H4SO)(diag)-35, PROCEDURE, Inspection
Mode.>.
1) On the System Operation Check Mode display screen, select the {Fuel Pump Control}.
2) On the Fuel Pump Control display screen, select the {OFF Operation}.
3) On the Start the Engine display screen, start
the engine and select the [OK].
4) Selecting the [NO] completes the OFF Operation. The display will then return to the Fuel Pump
Control screen.
2. FUEL PUMP CONTROL (ON/OFF OPERATION)

ME-00325
CAUTION:
9) The following items are displayed on the monitor.
Display
Fuel Pump Control
Idling Ignition Timing Fixed
Idle Speed Control
Injector Control
EGR Valve Control
CAUTION:
Mode.>.
2) On the Fuel Pump Control display screen, select the {ON/OFF Operation}.
3) On the Turn Ignition Switch ON with Engine
Stalled display screen, select the [OK].
4) Selecting the [NO] completes the ON/OFF Operation. The display will then return to the Fuel
Pump Control screen.
3. IDLING IGNITION TIMING FIXED

CAUTION:
Mode.>.
1) On the System Operation Check Mode display screen, select the {Idling Ignition Timing
Fixed}.
3) Selecting the [NO] completes the Idling Ignition
Timing Fixed. The display will then return to the
System Operation Check Mode screen.
EN(H4SO)(diag)-46

4. IDLE SPEED CONTROL

CAUTION:
Mode.>.
1) On the System Operation Check Mode display screen, select the {Idle Speed Control}.
3) On the Idle Speed Control display screen, select [ ] or [ ] to change the setting value, and select the [OK].
It is possible to set by 50 rpm, ranging from 500 rpm
to 2,000 rpm. However, the actual idle speed that
can be controlled is varied by vehicle type.
4) Selecting the [NO] completes the Idling Speed
Control. The display will then return to the System
Operation Check Mode screen.
5. INJECTOR CONTROL (INJECTION STOP

MODE)
CAUTION:
Mode.>.
1) On the System Operation Check Mode display screen, select the {Injector Control}.
2) On the Injector Control display screen, select
the {Injection Stop Mode}.
3) By the desired injector number on the Injection
Stop Mode select the [OK].
5) Selecting the [NO] completes the Injection Stop
Mode. The display will then return to the Injector
Control screen.
6. INJECTOR CONTROL (INJECTION

QUANTITY CONTROL)
CAUTION:
Mode.>.
the {Injection Quantity Control}.
4) On the Injection Quantity Control display
screen, Select [ ] or [ ] to change the setting value, and select the [OK].
It is possible to set by 1%, ranging from 0 to 20%.
5) Selecting the [NO] completes the Injection
Quantity Control. The display will then return to the
Injector Control screen.
7. EGR VALVE CONTROL

CAUTION:
Mode.>.
1) On the System Operation Check Mode display screen, select the {EGR Valve Control}.
3) On the EGR Valve Control display screen, select [ ] or [ ] to change the setting value, and select the [OK].
It is possible to set by 1 STEP. However, the actual
STEP amount that can be controlled is varied by
vehicle type.
4) Selecting the [NO] completes the EGR Valve
Control. The display will then return to the System
Operation Check Mode screen.
NOTE:
MANUAL.
EN(H4SO)(diag)-47
Malfunction Indicator Light

16.Malfunction Indicator Light

A: PROCEDURE
1. Activation of malfunction indicator light. <Ref. to EN(H4SO)(diag)-49, ACTIVATION OF MALFUNCTION INDICATOR LIGHT,
Malfunction Indicator Light.>
2. Malfunction indicator light does not come on. <Ref. to EN(H4SO)(diag)-50, MALFUNCTION INDICATOR LIGHT DOES NOT
COME ON, Malfunction Indicator Light.>
3. Malfunction indicator light does not go off. <Ref. to EN(H4SO)(diag)-52, MALFUNCTION INDICATOR LIGHT DOES NOT GO
OFF, Malfunction Indicator Light.>
EN(H4SO)(diag)-48

B: ACTIVATION OF MALFUNCTION
INDICATOR LIGHT
1) When the ignition switch is turned on (engine
off), the malfunction indicator light in the combination meter illuminates.
NOTE:
If the malfunction indicator light does not illuminate,
perform diagnostics of the malfunction indicator
light circuit or the combination meter circuit. <Ref.
to EN(H4SO)(diag)-50, MALFUNCTION INDICATOR LIGHT DOES NOT COME ON, Malfunction
Indicator Light.>
(1)
EN-03060
(1) Malfunction indicator light
2) After starting the engine, the malfunction indicator light goes out. If it does not go off, either the engine or emission control system has malfunction.
(1)
(3)
(4)
(2)
(3)
(4)
(5)
(6)
EN-01679
(1) No faulty
(2) Trouble occurs
(3) ON
(4) OFF
(5) Ignition switch ON
(6) Engine start
EN(H4SO)(diag)-49

C: MALFUNCTION INDICATOR LIGHT DOES NOT COME ON

DIAGNOSIS:
The malfunction indicator light circuit is open or shorted.
TROUBLE SYMPTOM:
When the ignition switch is turned to ON (engine OFF), malfunction indicator light does not come on.
WIRING DIAGRAM:
B72
IGNITION
SWITCH
BATTERY
SBF-4
No.14
4
SBF-1
B36
i1
B9
A1
17
i3
COMBINATION METER
B38
11
A: i12
B: i10
B136 ECM
B72
1 2
3 4
i10
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
31 32
28 29 30
B38
5 6
14 15 16
25 26 27
33 34 35
B36
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
i12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
EN-03839
EN(H4SO)(diag)-50

Step
CHECK OUTPUT SIGNAL OF ECM.
2) Measure the voltage between ECM connector and chassis ground.
(B136) No. 11 (+) Chassis ground ():
CHECK POOR CONTACT.
Check for poor connection by shaking or pulling
ECM connector and harness.
CHECK ECM CONNECTOR.
Check the connection of ECM connector.
Check
Is the voltage less than 1 V?
Yes
Go to step 4.
Does the malfunction indicator Repair poor conlight illuminate?

tact in ECM connector.
Is the ECM connector correctly Replace the ECM.
connected?
<Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>
CHECK HARNESS BETWEEN COMBINATION METER AND ECM CONNECTOR.

2) Remove the combination meter. <Ref. to
IDI-10, Combination Meter.>
3) Disconnect the connector from ECM and
combination meter.
ECM and combination meter connector.
(B136) No. 11 (i12) No. 1:
CHECK POOR CONTACT.

Is there poor contact in combi- Repair the poor
Check poor contact of combination meter con- nation meter connector?
contact of combinector.
nation meter connector.
CHECK HARNESS BETWEEN COMBINAIs the voltage 10 V or more?
Replace the combination meter cirTION METER AND IGNITION SWITCH CONcuit board. <Ref. to
NECTOR.
IDI-10, Combina1) Turn the ignition switch to ON.
tion Meter.>
2) Measure the voltage between combination
meter connector and chassis ground.
(i10) No. 9 (+) Chassis ground ():
EN(H4SO)(diag)-51
No
Go to step 2.
Go to step 3.
Repair the connection of ECM connector.
Repair the harness

and connector.
NOTE:
In this case, repair
the following item:
Open circuit in
harness between
ECM and combination meter connector
Poor contact in
coupling connector
Go to step 6.
Check the following item and repair

if necessary.
NOTE:
Blown out of fuse
(No. 13)
Open or short
circuit in harness
between fuse (No.
13) and battery terminal
Poor contact in
ignition switch connector

D: MALFUNCTION INDICATOR LIGHT DOES NOT GO OFF

DIAGNOSIS:
The malfunction indicator light circuit is shorted.
TROUBLE SYMPTOM:
Although malfunction indicator light comes on when the engine runs, DTC is not shown on the Subaru Select
Monitor or general scan tool display.
WIRING DIAGRAM:
B72
IGNITION
SWITCH
BATTERY
SBF-4
No.14
4
SBF-1
B36
i1
B9
A1
17
i3
COMBINATION METER
B38
11
A: i12
B: i10
B136 ECM
B136
B72
1 2
3 4
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
31 32
28 29 30
i10
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B38
5 6
14 15 16
25 26 27
33 34 35
B36
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
i12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
EN-03839
Step
Check
Yes
Does the malfunction indicator Repair the short
light illuminate?
circuit of harness
between combination meter and
ECM connector.
EN(H4SO)(diag)-52
No
Replace the ECM.
<Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>
Diagnostics for Engine Starting Failure

17.Diagnostics for Engine Starting Failure

A: PROCEDURE
1. Check of the fuel amount.
2. Inspection of starter motor circuit. <Ref. to EN(H4SO)(diag)-54, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting
Failure.>
3. Inspection of ECM power supply and ground line. <Ref. to EN(H4SO)(diag)-57, CHECK POWER SUPPLY AND GROUND
LINE OF ENGINE CONTROL MODULE (ECM), Diagnostics for Engine Starting Failure.>
4. Inspection of ignition control system. <Ref. to EN(H4SO)(diag)-59, IGNITION CONTROL SYSTEM, Diagnostics for Engine
Starting Failure.>
5. Inspection of fuel pump circuit. <Ref. to EN(H4SO)(diag)-62, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.>
6. Inspection of fuel indicator circuit. <Ref. to EN(H4SO)(diag)-65, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting
Failure.>
EN(H4SO)(diag)-53

B: STARTER MOTOR CIRCUIT

CAUTION:
After repairing or replacing the defective part, perform the Clear Memory Mode <Ref. to EN(H4SO)(diag)-44, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO)(diag)-35, PROCEDURE, Inspection Mode.>.
WIRING DIAGRAM:
IGNITION
SWITCH
BATTERY
SBF-1
SBF-4
1
3
MT
: MT MODEL
AT
: AT MODEL
B72
INTERRUPT
RELAY
5
2
3
1
B59
TO SECURITY SYSTEM
INHIBITOR SWITCH
P
AT
MT
12
11
B225
7
T3
T7
24
27
28
26
B12
12
STARTER
INTERLOCK
RELAY(AT)
AT
STARTER INTERLOCK
RELAY (MT)
28
27
26
24
STARTER MOTOR
AT
MT
B14
MT
B225
2
1
32
20
CLUTCH SWITCH (MT)
B106
B136
ECM
B225
B106
1
2
B72
1 2
3 4
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
B59
B12
1 2 3
4 5 6
1 2 3 4
5 6 7 8
9 10 11 12
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
T7
1 2 3 4 5 6
7 8 9 10 11 12
EN-04767
EN(H4SO)(diag)-54

1
2
7
8
Step
CHECK BATTERY.
Check the battery voltage.
CHECK OPERATION OF STARTER MOTOR.
NOTE:
Check the security alarm is not sounding. (model with security alarm)
CHECK DTC.
CHECK INPUT SIGNAL FOR STARTER MOTOR.

2) Disconnect the connector from starter
motor.
3) Turn the ignition switch to ST.
4) Measure the power supply voltage between
starter motor connector terminal and engine
ground.
(B14) No. 1 (+) Engine ground ():
NOTE:
For AT model, place the select lever in P or
N range.
For MT model, depress the clutch pedal.
CHECK HARNESS BETWEEN BATTERY
AND IGNITION SWITCH CONNECTOR.
1) Disconnect the connector from ignition
switch.
ignition switch connector and chassis ground.
CHECK IGNITION SWITCH.
switch.
2) Measure the resistance between ignition
switch terminals after turning the ignition switch
to ST position.
Terminals
No. 1 No. 3:
CHECK TRANSMISSION TYPE.
CHECK INPUT VOLTAGE OF STARTER INTERLOCK RELAY.
2) Disconnect the connector from starter interlock relay.
3) Connect the connector to ignition switch.
4) Measure the input voltage between starter
interlock relay connector and chassis ground
after turning the ignition switch to ST.
Check
Yes
Go to step 2.
Does the starter motor operate?
Go to step 3.
Is DTC displayed? <Ref. to

EN(H4SO)(diag)-34, OPERATION, Read Diagnostic Trouble
Code (DTC).>
Check the appropriate DTC using

the List of Diagnostic Trouble Code
(DTC). <Ref. to
(DTC).>
Check the starter
motor. <Ref. to SC
(H4SO)-6,
Starter.>
Go to step 6.
Repair the open

circuit of harness
between ignition
switch and battery,
and check fuse
SBF No. 4 and
SBF No. 1.
No
Charge or replace
the battery.
Go to step 4.
Go to step 5.
Replace the ignition switch.
Is the transmission type AT?

Go to step 12.
Repair open or
short circuit to
ground in harness
between starter
interlock relay and
ignition switch.
NOTE:
Check
security
system
(if
equipped). <Ref. to
SL-21,
Security
System.>
EN(H4SO)(diag)-55
Go to step 8.
Go to step 9.

10
11
12
13
14
15
16
Step
Check
Yes
CHECK STARTER INTERLOCK RELAY.
1) Connect the battery to starter interlock relay
terminals No. 26 and No. 24.
2) Measure the resistance between starter
interlock relay terminals.
Terminals
No. 27 No. 28:
CHECK INPUT VOLTAGE OF INHIBITOR
Go to step 11.
SWITCH.
2) Disconnect the connector from inhibitor
switch.
3) Connect the connector to the ignition switch.
4) Measure the input voltage between inhibitor
switch connector terminal and engine ground
while turning the ignition switch to ST.
No
Replace the starter
interlock relay.
Repair open or
ground short circuit
in harness
between inhibitor
switch and starter
interlock relay.
NOTE:
Check
security
system
(if
equipped). <Ref. to
SL-21,
Security
System.>
CHECK INHIBITOR SWITCH.
Is the resistance less than 1 ? Repair open or
Replace the inhibi1) Place the select lever in P or N range.
ground short circuit tor switch. <Ref. to
2) Measure the resistance between inhibitor
in harness
4AT-47, Inhibitor
switch terminals.
between inhibitor Switch.>
switch and starter
(T3) No. 11 No. 12:
motor.
CHECK INPUT VOLTAGE OF STARTER IN- Is the voltage 10 V or more?
Go to step 13.
Repair open or
TERLOCK RELAY.
short circuit to
ground in harness
2) Disconnect the connector from starter interbetween starter
lock relay.
interlock relay and
ignition switch.
NOTE:
Check
security
system
(if
equipped). <Ref. to
SL-21,
Security
System.>
Replace the starter
interlock relay.
Terminals
No. 27 No. 28:
Repair the open
CHECK GROUND CIRCUIT OF CLUTCH
circuit of ground
SWITCH.
cable.
1) Disconnect the connector from clutch
switch.
2) Measure the resistance between the clutch
switch connector and chassis ground.
(B106) No. 1 Chassis ground:
CHECK CLUTCH SWITCH.
Replace the clutch
Measure the resistance between clutch switch
switch. <Ref. to
terminals while depressing the clutch pedal.
CL-28, Clutch
Terminals
Switch.>
No. 1 No. 2:
CHECK CLUTCH SWITCH CIRCUIT.
Is the resistance less than 1 ? Repair the ground Repair the open
1) Connect the connector to the clutch switch.
short of the harcircuit in harness
ness between
between starter
starter interlock
interlock relay and
while depressing the clutch pedal.
relay and starter
clutch switch.
motor.
EN(H4SO)(diag)-56

C: CHECK POWER SUPPLY AND GROUND LINE OF ENGINE CONTROL MODULE (ECM)
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
3
5
TO IGNITION COIL
SBF-5
6
4
1
2
IGNITION
B72
BATTERY
SWITCH
No.11
B47
SBF-4
1
B5
B27
C24
A7
B2
SBF-1
A: B134
B: B135
ECM
C: B136
D2
D3
D7
D1
A5
D: B137
35
37
52
34
36
B22
E3
B72
1 2
3 4
D: B137
B47
1
3
5
2
4
6
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
30 31
26 27
28 29
A: B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
32 33
34 35
28 29 30 31
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B22
5 6
14 15 16
25 26 27
33 34 35
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-03793
EN(H4SO)(diag)-57

Step
CHECK MAIN RELAY.
2) Remove the main relay.
3) Connect the battery to main relay terminals
No. 1 and No. 2.
4) Measure the resistance between main relay
terminals.
Terminals
No. 3 No. 5:
No. 4 No. 6:
CHECK GROUND CIRCUIT FOR ECM.
ECM and chassis ground.
CHECK INPUT VOLTAGE OF ECM.
Measure the voltage between ECM connector
and chassis ground.
CHECK INPUT VOLTAGE OF MAIN RELAY.
Measure the voltage between main relay connector and chassis ground.
1) Connect the main relay connector.
Check
?
Yes
Go to step 2.
No
Replace the main
relay.
Repair the open

circuit of harness
between ECM connector and engine
grounding terminal.
Go to step 4.
Repair the open or

of power supply
circuit.
Go to step 5.
Repair the open or

of harness of
power supply circuit.
Check ignition control system. <Ref.

to
EN(H4SO)(diag)59, IGNITION
CONTROL SYSTEM, Diagnostics
for Engine Starting
Failure.>
Repair the open or

of harness
between ECM connector and main
relay connector.
EN(H4SO)(diag)-58

D: IGNITION CONTROL SYSTEM

CAUTION:
WIRING DIAGRAM:
26
6
19
18
B137 ECM
A/F & OXYGEN

RELAY HOLDER
B100
BATTERY
F2
SBF-5
15 A
14
B225
B47
47
33
32
49
B22
E3
MAIN RELAY
3
4
1
2
E12
IGNITION COIL &

IGNITOR ASSEMBLY
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
B137
B225
B22
39
52
40
46
53
41
47
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
30 31
26 27
28 29
B47
1
3
5
2
4
6
F2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
E12
1 2 3 4
54
EN-03841
EN(H4SO)(diag)-59

Step
Check
CHECK IGNITION SYSTEM FOR SPARKS. Does spark occur at each cylin1) Remove the plug cord cap from each spark der?
plug.
2) Install a new spark plug on plug cord cap.
CAUTION:
Do not remove the spark plug from engine.
3) Contact the spark plugs thread portion to
the engine.
4) While opening the throttle valve fully, crank
the engine to check that spark occurs at each
cylinder.
CHECK POWER SUPPLY CIRCUIT FOR IG- Is the voltage 10 V or more?
NITION COIL AND IGNITOR ASSEMBLY.
2) Disconnect the connector from ignition coil
ignition coil and ignitor assembly connector and
engine ground.
(E12) No. 2 (+) Engine ground ():
Yes
No
Check fuel pump Go to step 2.
system. <Ref. to
EN(H4SO)(diag)62, FUEL PUMP
CIRCUIT, Diagnostics for Engine
Starting Failure.>
Go to step 3.
CHECK HARNESS OF IGNITION COIL AND

IGNITOR ASSEMBLY GROUND CIRCUIT.
2) Measure the resistance between the ignition coil and ignitor assembly connector and
engine ground.
(E12) No. 3 Engine ground:
CHECK IGNITION COIL AND IGNITOR ASSEMBLY.

1) Remove the spark plug cords.
2) Measure the resistance between spark plug
cord contact portions to check secondary coil.
Terminals
No. 1 No. 2:
No. 3 No. 4:
CHECK INPUT SIGNAL FOR IGNITION COIL
AND IGNITOR ASSEMBLY.
1) Connect the connector to the Ignition coil
2) Check if voltage varies synchronously with
engine speed when cranking, while monitoring
voltage between ignition coil and ignitor assembly connector and engine ground.
Is the resistance between 10

and 15 k?
Go to step 5.
Does the voltage vary more

than 10 V?
Go to step 6.
EN(H4SO)(diag)-60
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
the ignition coil and
ignitor assembly
and ignition switch
connector
Poor contact in
coupling connector
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
ignition coil and ignitor
assembly
connector and engine grounding terminal
Replace the ignition coil and ignitor
assembly. <Ref. to
IG(H4SO)-6, Ignition Coil and Ignitor
Assembly.>
Replace the ignition coil and ignitor

assembly. <Ref. to
IG(H4SO)-6, Ignition Coil and Ignitor
Assembly.>

Step
CHECK HARNESS BETWEEN ECM AND IGNITION COIL AND IGNITOR ASSEMBLY
CONNECTOR.
ECM and ignition coil and ignitor assembly connector.
(B137) No. 18 (E12) No. 1:
(B137) No. 19 (E12) No. 4:
CONNECTOR.
Measure the resistance of harness between
ECM and engine ground.
Connector & terminal:
(B137) No. 18 Engine ground:
CHECK POOR CONTACT.
Check
Yes
No
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and ignition
coil and ignitor assembly connector
Poor contact in
coupling connector
more?
Go to step 8.
Repair the ground

short circuit of harness between
ECM and ignition
coil and ignitor
assembly connector.

connector?
Check fuel pump

circuit. <Ref. to
EN(H4SO)(diag)62, FUEL PUMP
Starting Failure.>
EN(H4SO)(diag)-61

E: FUEL PUMP CIRCUIT

CAUTION:
WIRING DIAGRAM:
SBF-5
F44
B61
B72
IGNITION
SWITCH
BATTERY
SBF-4
No.11
FUEL PUMP
RELAY
2
1
3
4
SBF-1
13
B136
ECM
B46
B98
R2
FUEL PUMP
8
16
1
4
R58
R57
R15
B46
1 2
3 4
B72
1 2
3 4
R58
R57
B98
F44
1 2 3
4 5 6
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
1 2
3 4 5
6 7 8 9 10 11 12
1 2 3 4
5 6 7 8
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
31 32
28 29 30
5 6
14 15 16
25 26 27
33 34 35
EN-03842
EN(H4SO)(diag)-62

Step
Check
CHECK OPERATING SOUND OF FUEL
Does the fuel pump emit operPUMP.
ating sound?
Make sure that fuel pump is in operation for 2
seconds when turning the ignition switch to ON.
NOTE:
The fuel pump can be executed using the Subaru Select Monitor.
For procedure, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(H4SO)(diag)-45, Compulsory Valve Operation Check
Mode.>
CHECK GROUND CIRCUIT OF FUEL PUMP. Is the resistance less than 5 ?
2) Remove the fuel pump access hole lid.
4) Measure the resistance of harness connector between fuel pump and chassis ground.
(R58) No. 4 Chassis ground:
CHECK POWER SUPPLY TO FUEL PUMP. Is the voltage 10 V or more?

2) Measure the voltage of power supply circuit
between fuel pump connector and chassis
ground.
(R58) No. 1 (+) Chassis ground ():
CHECK HARNESS BETWEEN FUEL PUMP Is the resistance less than 1 ?
AND FUEL PUMP RELAY CONNECTOR.
2) Measure the resistance of harness connector between fuel pump and fuel pump relay.
(R58) No. 1 (B46) No. 4:
CHECK HARNESS BETWEEN FUEL PUMP

AND FUEL PUMP RELAY CONNECTOR.
fuel pump and fuel pump relay connector.
CHECK FUEL PUMP RELAY.
1) Disconnect the connectors from fuel pump
relay and main relay.
2) Remove the fuel pump relay and main relay
with bracket.
3) Connect the battery to fuel pump relay connector terminals No. 1 and No. 3.
4) Measure the resistance between connector
terminals of fuel pump relay.
Terminals
No. 2 No. 4:
Yes
Check the fuel
injector circuit.
<Ref. to
EN(H4SO)(diag)65, FUEL INJECTOR CIRCUIT,
Diagnostics for
Engine Starting
Failure.>
No
Go to step 2.
Go to step 3.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
fuel pump connector and chassis
grounding terminal
Poor contact in
coupling connector
Go to step 4.
Replace the fuel

pump. <Ref. to
FU(H4SO)-52,
Fuel Pump.>
Go to step 5.
more?
Go to step 6.

?
Go to step 7.
EN(H4SO)(diag)-63
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
fuel pump connector and chassis
grounding terminal
Poor contact in
coupling connector
Repair the short
circuit of harness
between fuel pump
and fuel pump
relay connector.
Replace the fuel
pump relay. <Ref.
to FU(H4SO)-42,
Fuel Pump Relay.>

Step
Check
Yes
CHECK HARNESS BETWEEN ECM AND
FUEL PUMP RELAY CONNECTOR.
ECM and fuel pump relay connector.
(B136) No. 13 (B46) No. 3:
CHECK POOR CONTACT.
Repair poor conCheck poor contact of ECM connector.
connector?
EN(H4SO)(diag)-64
No
Repair the open
circuit of harness
between ECM and
fuel pump relay
connector.
Check the fuel

injector circuit.
<Ref. to
EN(H4SO)(diag)65, FUEL INJECTOR CIRCUIT,
Diagnostics for
Engine Starting
Failure.>

F: FUEL INJECTOR CIRCUIT

CAUTION:
Check or repair only faulty parts.
After repairing or replacing the defective part, perform the Clear Memory Mode <Ref. to
EN(H4SO)(diag)-44, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO)(diag)-35, PROCEDURE, Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
6
4
BATTERY
SBF-5
14
5
3
F2
B100
2
1
B47
11
10
B22
45
44
9
43
42
48
B137 ECM
E3
E17
E6
E16
E5
E
FUEL INJECTOR
No. 1
E5
E16
E6
E17
1 2
FUEL INJECTOR
No. 2
B47
1
3
5
2
4
6
FUEL INJECTOR
No. 3
FUEL INJECTOR
No. 4
B22
F2
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
B137
35
43
48
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-03778
EN(H4SO)(diag)-65

Step
Check
CHECK OPERATION OF EACH FUEL INJEC- Does the fuel injector operate?
TOR.
While cranking the engine, check that each fuel
injector emits the operating sound. Use a
sound scope or attach a screwdriver to the
injector for this check.
CHECK POWER SUPPLY TO EACH FUEL IN- Is the voltage 10 V or more?
JECTOR.
2) Disconnect the connector from fuel injector.
fuel injector terminal and engine ground.
#1 (E5) No. 2 (+) Engine ground ():
Yes
No
Check the fuel
Go to step 2.
pressure. <Ref. to
ME(H4SO)-29,
INSPECTION,
Fuel Pressure.>
Go to step 3.

FUEL INJECTOR CONNECTOR.
ECM and fuel injector connector.
#1 (B137) No. 8 (E5) No. 1:
#2 (B137) No. 9 (E16) No. 1:
#3 (B137) No. 10 (E6) No. 1:
#4 (B137) No. 11 (E17) No. 1:

#1 (B137) No. 8 Chassis ground:
CHECK EACH FUEL INJECTOR.
2) Measure the resistance between each fuel
injector terminals.
Terminals
No. 1 No. 2:
CHECK POOR CONTACT.
more?
Go to step 5.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
main relay and fuel
injector connector
Poor contact in
main relay connector
Poor contact in
coupling connector
Poor contact in
fuel injector connector
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and fuel injector connector
Poor contact in
coupling connector
Repair the ground
ECM and fuel
injector connector.
Is the resistance between 5 and Go to step 6.

20 ?
Replace the faulty

fuel injector.

connector?
Inspection using
General Diagnostic Table <Ref. to
EN(H4SO)(diag)337, INSPECTION, General
Diagnostic Table.>
EN(H4SO)(diag)-66
List of Diagnostic Trouble Code (DTC)

18.List of Diagnostic Trouble Code (DTC)

A: LIST
DTC
Item
Note
P0026
Intake Valve Control Solenoid Circuit

Range/Performance (Bank 1)
<Ref. to EN(H4SO)(diag)-74, DTC P0026 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/PERFORMANCE (BANK 1), Diagnostic Procedure
with Diagnostic Trouble Code (DTC).>
P0028

Range/Performance (Bank 2)
P0030
HO2S Heater Control Circuit (Bank 1

Sensor 1)
P0031
HO2S Heater Control Circuit Low

(Bank 1 Sensor 1)
P0032
HO2S Heater Control Circuit High

(Bank 1 Sensor 1)
P0037

(Bank 1 Sensor 2)
<Ref. to EN(H4SO)(diag)-76, DTC P0028 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/PERFORMANCE (BANK 2), Diagnostic Procedure
<Ref. to EN(H4SO)(diag)-78, DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to EN(H4SO)(diag)-80, DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic
<Ref. to EN(H4SO)(diag)-83, DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic
<Ref. to EN(H4SO)(diag)-85, DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2), Diagnostic Procedure with Diagnostic
P0038

(Bank 1 Sensor 2)
P0068
MAP/MAF - Throttle Position Correla- <Ref. to EN(H4SO)(diag)-90, DTC P0068 MAP/MAF - THROTTLE POSItion
TION CORRELATION, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0076

Low (Bank 1)
P0077

High (Bank 1)
P0082

Low (Bank 2)
P0083

High (Bank 2)
P0101
Mass or Volume Air Flow Circuit

Range/Performance
<Ref. to EN(H4SO)(diag)-100, DTC P0101 MASS OR VOLUME AIR FLOW

CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic
P0102
Mass or Volume Air Flow Circuit Low

Input

CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0103
Mass or Volume Air Flow Circuit High

Input
P0107
P0108

CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(H4SO)(diag)-107, DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4SO)(diag)-110, DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4SO)(diag)-88, DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2), Diagnostic Procedure with Diagnostic
<Ref. to EN(H4SO)(diag)-92, DTC P0076 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4SO)(diag)-94, DTC P0077 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4SO)(diag)-96, DTC P0082 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4SO)(diag)-98, DTC P0083 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(H4SO)(diag)-67

Item
Note
P0111
DTC
Intake Air Temperature Sensor 1 Circuit Range/Performance
<Ref. to EN(H4SO)(diag)-113, DTC P0111 INTAKE AIR TEMPERATURE

SENSOR 1 CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>
P0112
P0113
P0117
Engine Coolant Temperature Circuit

Low
P0118

High
P0122
Throttle/Pedal Position Sensor/

Switch A Circuit Low

SENSOR 1 CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
SENSOR 1 CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to EN(H4SO)(diag)-120, DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(H4SO)(diag)-122, DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(H4SO)(diag)-125, DTC P0122 THROTTLE/PEDAL POSITION
SENSOR/SWITCH A CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0123

Switch A Circuit High

SENSOR/SWITCH A CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0125
Insufficient Coolant Temperature for

Closed Loop Fuel Control
<Ref. to EN(H4SO)(diag)-129, DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL, Diagnostic Procedure
P0126
Insufficient Engine Coolant Tempera- <Ref. to EN(H4SO)(diag)-131, DTC P0126 INSUFFICIENT ENGINE COOLture for Stable Operation
ANT TEMPERATURE FOR STABLE OPERATION, Diagnostic Procedure
Coolant Thermostat (Engine Coolant <Ref. to EN(H4SO)(diag)-133, DTC P0128 COOLANT THERMOSTAT
Temperature Below Thermostat Reg- (ENGINE COOLANT TEMPERATURE BELOW THERMOSTAT REGULATulating Temperature)
ING TEMPERATURE), Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0128
P0131
O2 Sensor Circuit Low Voltage (Bank

1 Sensor 1)
<Ref. to EN(H4SO)(diag)-134, DTC P0131 O2 SENSOR CIRCUIT LOW

VOLTAGE (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0132
O2 Sensor Circuit High Voltage

(Bank 1 Sensor 1)
<Ref. to EN(H4SO)(diag)-136, DTC P0132 O2 SENSOR CIRCUIT HIGH

P0133
O2 Sensor Circuit Slow Response

(Bank 1 Sensor 1)
P0134
O2 Sensor Circuit No Activity

Detected (Bank 1 Sensor 1)
P0137
O2 Sensor Circuit Low Voltage (Bank

1 Sensor 2)
P0138

(Bank 1 Sensor 2)
<Ref. to EN(H4SO)(diag)-138, DTC P0133 O2 SENSOR CIRCUIT SLOW

RESPONSE (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic
<Ref. to EN(H4SO)(diag)-140, DTC P0134 O2 SENSOR CIRCUIT NO
ACTIVITY DETECTED (BANK 1 SENSOR 1), Diagnostic Procedure with
<Ref. to EN(H4SO)(diag)-142, DTC P0137 O2 SENSOR CIRCUIT LOW
<Ref. to EN(H4SO)(diag)-145, DTC P0138 O2 SENSOR CIRCUIT HIGH
P0139

(Bank 1 Sensor 2)
<Ref. to EN(H4SO)(diag)-148, DTC P0139 O2 SENSOR CIRCUIT SLOW

RESPONSE (BANK 1 SENSOR 2), Diagnostic Procedure with Diagnostic
P0140

<Ref. to EN(H4SO)(diag)-150, DTC P0140 O2 SENSOR CIRCUIT NO

P0171
<Ref. to EN(H4SO)(diag)-152, DTC P0171 SYSTEM TOO LEAN (BANK 1),

Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(H4SO)(diag)-68

DTC
Item
Note
P0172
<Ref. to EN(H4SO)(diag)-153, DTC P0172 SYSTEM TOO RICH (BANK 1),

P0181
Fuel Temperature Sensor A Circuit

Range/Performance
<Ref. to EN(H4SO)(diag)-155, DTC P0181 FUEL TEMPERATURE SENSOR A CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with
P0182

Low Input
<Ref. to EN(H4SO)(diag)-157, DTC P0182 FUEL TEMPERATURE SENSOR A CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0183

High Input
P0196
Engine Oil Temperature Sensor Circuit Range/Performance
P0197
Engine Oil Temperature Sensor Low
<Ref. to EN(H4SO)(diag)-159, DTC P0183 FUEL TEMPERATURE SENSOR A CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4SO)(diag)-162, DTC P0196 ENGINE OIL TEMPERATURE
SENSOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with
SENSOR LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0198
Engine Oil Temperature Sensor High
P0222

Switch B Circuit Low
P0223

Switch B Circuit High
P0301
P0302
P0303
P0304
<Ref. to EN(H4SO)(diag)-173, DTC P0304 CYLINDER 4 MISFIRE

DETECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0327
Knock Sensor 1 Circuit Low (Bank 1

or Single Sensor)
<Ref. to EN(H4SO)(diag)-179, DTC P0327 KNOCK SENSOR 1 CIRCUIT

LOW (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0328
Knock Sensor 1 Circuit High (Bank 1

or Single Sensor)
P0335
P0336
P0340
Camshaft Position Sensor A Circuit

(Bank 1 or Single Sensor)
<Ref. to EN(H4SO)(diag)-181, DTC P0328 KNOCK SENSOR 1 CIRCUIT

HIGH (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4SO)(diag)-183, DTC P0335 CRANKSHAFT POSITION SENSOR A CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(H4SO)(diag)-185, DTC P0336 CRANKSHAFT POSITION SENSOR A CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with
<Ref. to EN(H4SO)(diag)-187, DTC P0340 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure
P0341

Range/Performance (Bank 1 or Single Sensor)
<Ref. to EN(H4SO)(diag)-189, DTC P0341 CAMSHAFT POSITION SENSOR A CIRCUIT RANGE/PERFORMANCE (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0400
<Ref. to EN(H4SO)(diag)-192, DTC P0400 EXHAUST GAS RECIRCULATION FLOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0420
Catalyst System Efficiency Below

Threshold (Bank 1)
<Ref. to EN(H4SO)(diag)-195, DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

SENSOR HIGH, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
SENSOR/SWITCH B CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
SENSOR/SWITCH B CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(H4SO)(diag)-69

DTC
Item
Note
P0442
<Ref. to EN(H4SO)(diag)-199, DTC P0442 EVAPORATIVE EMISSION

CONTROL SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0447
P0448
P0451
P0452
P0453

CONTROL SYSTEM VENT CONTROL CIRCUIT OPEN, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
CONTROL SYSTEM VENT CONTROL CIRCUIT SHORTED, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
CONTROL SYSTEM PRESSURE SENSOR, Diagnostic Procedure with
CONTROL SYSTEM PRESSURE SENSOR LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0456
Evaporative Emission Control System Leak Detected (Very Small

Leak)
P0457
Evaporative Emission Control Sys<Ref. to EN(H4SO)(diag)-217, DTC P0457 EVAPORATIVE EMISSION

tem Leak Detected (Fuel Cap Loose/ CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF), DiagOff)
nostic Procedure with Diagnostic Trouble Code (DTC).>
P0458
Evaporative Emission System Purge

Control Valve Circuit Low
P0459
P0461
P0462
P0463
P0464
P0483
P0502
P0503
P0506

CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK), Diagnostic
<Ref. to EN(H4SO)(diag)-220, DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT LOW, Diagnostic Procedure with
Evaporative Emission System Purge <Ref. to EN(H4SO)(diag)-222, DTC P0459 EVAPORATIVE EMISSION SYSControl Valve Circuit High
TEM PURGE CONTROL VALVE CIRCUIT HIGH, Diagnostic Procedure with
Fuel Level Sensor A Circuit Range/ <Ref. to EN(H4SO)(diag)-224, DTC P0461 FUEL LEVEL SENSOR A CIRPerformance
CUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4SO)(diag)-226, DTC P0462 FUEL LEVEL SENSOR A CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4SO)(diag)-229, DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Fuel Level Sensor Circuit Intermittent <Ref. to EN(H4SO)(diag)-232, DTC P0464 FUEL LEVEL SENSOR CIRCUIT
INTERMITTENT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(H4SO)(diag)-234, DTC P0483 FAN RATIONALITY CHECK,
Vehicle Speed Sensor A Circuit
<Ref. to EN(H4SO)(diag)-234, DTC P0502 VEHICLE SPEED SENSOR A
Low Input
CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
Vehicle Speed Sensor A Intermit<Ref. to EN(H4SO)(diag)-235, DTC P0503 VEHICLE SPEED SENSOR A
tent/Erratic/High
INTERMITTENT/ERRATIC/HIGH, Diagnostic Procedure with Diagnostic
<Ref. to EN(H4SO)(diag)-237, DTC P0506 IDLE AIR CONTROL SYSTEM
Idle Air Control System RPM Lower
Than Expected
RPM LOWER THAN EXPECTED, Diagnostic Procedure with Diagnostic
P0507
Idle Air Control System RPM Higher

Than Expected

RPM HIGHER THAN EXPECTED, Diagnostic Procedure with Diagnostic
P0512
<Ref. to EN(H4SO)(diag)-241, DTC P0512 STARTER REQUEST CIRCUIT,

EN(H4SO)(diag)-70

DTC
Item
Note
P0519

PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0600
<Ref. to EN(H4SO)(diag)-246, DTC P0600 SERIAL COMMUNICATION

LINK, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0604
Internal Control Module Random

Access Memory (RAM) Error
<Ref. to EN(H4SO)(diag)-248, DTC P0604 INTERNAL CONTROL MODULE

RANDOM ACCESS MEMORY (RAM) ERROR, Diagnostic Procedure with
P0605
Internal Control Module Read Only

Memory (ROM) Error
P0607
<Ref. to EN(H4SO)(diag)-249, DTC P0605 INTERNAL CONTROL MODULE

READ ONLY MEMORY (ROM) ERROR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4SO)(diag)-250, DTC P0607 CONTROL MODULE PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0638
<Ref. to EN(H4SO)(diag)-251, DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0691
<Ref. to EN(H4SO)(diag)-252, DTC P0691 FAN 1 CONTROL CIRCUIT

LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0692
<Ref. to EN(H4SO)(diag)-253, DTC P0692 FAN 1 CONTROL CIRCUIT

HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0700
Transmission Control System (MIL

Request)
<Ref. to EN(H4SO)(diag)-253, DTC P0700 TRANSMISSION CONTROL

SYSTEM (MIL REQUEST), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0851

(AT Model)
<Ref. to EN(H4SO)(diag)-254, DTC P0851 PARK/NEUTRAL SWITCH

INPUT CIRCUIT LOW (AT MODEL), Diagnostic Procedure with Diagnostic
Trouble Code (DTC).> or <Ref. to EN(H4SO)(diag)-256, DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT LOW (MT MODEL), Diagnostic Procedure
P0852
Park/Neutral Switch Input Circuit

High
P1152
<Ref. to EN(H4SO)(diag)-258, DTC P0852 PARK/NEUTRAL SWITCH

INPUT CIRCUIT HIGH (AT MODEL), Diagnostic Procedure with Diagnostic
Trouble Code (DTC).> or <Ref. to EN(H4SO)(diag)-261, DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH (MT MODEL), Diagnostic Procedure
<Ref. to EN(H4SO)(diag)-263, DTC P1152 O2 SENSOR CIRCUIT RANGE/
PERFORMANCE (LOW) (BANK 1 SENSOR 1), Diagnostic Procedure with
P1153
<Ref. to EN(H4SO)(diag)-265, DTC P1153 O2 SENSOR CIRCUIT RANGE/

PERFORMANCE (HIGH) (BANK 1 SENSOR 1), Diagnostic Procedure with
P1160
<Ref. to EN(H4SO)(diag)-266, DTC P1160 RETURN SPRING FAILURE,

P1400
Fuel Tank Pressure Control Solenoid

Valve Circuit Low
<Ref. to EN(H4SO)(diag)-267, DTC P1400 FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P1420
Fuel Tank Pressure Control Sol.

Valve Circuit High
<Ref. to EN(H4SO)(diag)-269, DTC P1420 FUEL TANK PRESSURE CONTROL SOL. VALVE CIRCUIT HIGH, Diagnostic Procedure with Diagnostic
P1443
Vent Control Solenoid Valve Function

Problem
P1491
P1492
<Ref. to EN(H4SO)(diag)-271, DTC P1443 VENT CONTROL SOLENOID

VALVE FUNCTION PROBLEM, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Positive Crankcase Ventilation (Blow- <Ref. to EN(H4SO)(diag)-273, DTC P1491 POSITIVE CRANKCASE VENTIby) Function Problem
LATION (BLOW-BY) FUNCTION PROBLEM, Diagnostic Procedure with
EGR Solenoid Valve Signal #1 Cir<Ref. to EN(H4SO)(diag)-274, DTC P1492 EGR SOLENOID VALVE SIGcuit Malfunction (Low Input)
NAL #1 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Procedure with
EN(H4SO)(diag)-71

DTC
Item
Note
P1493
<Ref. to EN(H4SO)(diag)-274, DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Procedure
P1494
P1495
P1496
P1497
P1498
<Ref. to EN(H4SO)(diag)-274, DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Procedure with
P1499
P1518
<Ref. to EN(H4SO)(diag)-282, DTC P1518 STARTER SWITCH CIRCUIT

LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P1560
Back-Up Voltage Circuit Malfunction
<Ref. to EN(H4SO)(diag)-285, DTC P1560 BACK-UP VOLTAGE CIRCUIT

MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P1602
<Ref. to EN(H4SO)(diag)-287, DTC P1602 CONTROL MODULE PROGRAMMING ERROR, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P2096
Post Catalyst Fuel Trim System Too

Lean Bank 1
P2097

Rich Bank 1
P2101
P2102
<Ref. to EN(H4SO)(diag)-299, DTC P2096 POST CATALYST FUEL TRIM

SYSTEM TOO LEAN BANK 1, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to EN(H4SO)(diag)-305, DTC P2097 POST CATALYST FUEL TRIM
SYSTEM TOO RICH BANK 1, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to EN(H4SO)(diag)-311, DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure
<Ref. to EN(H4SO)(diag)-317, DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P2103
<Ref. to EN(H4SO)(diag)-319, DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P2109
Throttle/Pedal Position Sensor A

Minimum Stop Performance

SENSOR A MINIMUM STOP PERFORMANCE, Diagnostic Procedure with
P2122

Switch D Circuit Low Input
P2123

Switch D Circuit High Input
P2127

Switch E Circuit Low Input

SENSOR/SWITCH D CIRCUIT LOW INPUT, Diagnostic Procedure with
SENSOR/SWITCH D CIRCUIT HIGH INPUT, Diagnostic Procedure with
SENSOR/SWITCH E CIRCUIT LOW INPUT, Diagnostic Procedure with
EN(H4SO)(diag)-72

DTC
Item
Note
P2128

Switch E Circuit High Input

SENSOR/SWITCH E CIRCUIT HIGH INPUT, Diagnostic Procedure with
P2135

Switch A/B Voltage Correlation
P2138

Switch D/E Voltage Correlation
P2227
Barometric Pressure Circuit Range/

Performance
P2228
P2229

SENSOR/SWITCH A/B VOLTAGE CORRELATION, Diagnostic Procedure
SENSOR/SWITCH D/E VOLTAGE CORRELATION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4SO)(diag)-335, DTC P2227 BAROMETRIC PRESSURE CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4SO)(diag)-335, DTC P2228 BAROMETRIC PRESSURE CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4SO)(diag)-336, DTC P2229 BAROMETRIC PRESSURE CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(H4SO)(diag)-73
Diagnostic Procedure with Diagnostic Trouble Code (DTC)

19.Diagnostic Procedure with Diagnostic Trouble Code (DTC)

A: DTC P0026 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/PERFORMANCE (BANK 1)
DTC DETECTING CONDITION:
Immediately at fault recognition
GENERAL DESCRIPTION <Ref. to GD(H4SO)-8, DTC P0026 INTAKE VALVE CONTROL SOLENOID
CIRCUIT RANGE/PERFORMANCE (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
B134 ECM
31
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
B134
21
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B22
E3
E71
VVL DIAGNOSIS
OIL PRESSURE SWITCH RH
EN-03799
EN(H4SO)(diag)-74

Step
CHECK ANY OTHER DTC ON DISPLAY.
Check
Is any other DTC displayed?

VARIABLE VALVE LIFT DIAGNOSIS OIL
more?
PRESSURE SWITCH CONNECTOR.
3) Disconnect the connectors from ECM and
variable valve lift diagnosis oil pressure switch
connector.
connector and engine ground.
Is the resistance less than 1 ?
ECM and variable valve lift diagnosis oil pressure switch connector.
(B134) No. 31 (E71) No. 1:
CHECK DTC.
1) Erase the memory. <Ref. to
2) After idling the engine, check the DTC.
Is DTC displayed?
CHECK DTC.
Is DTC displayed?
EN(H4SO)(diag)-75
Yes
No
Check DTC using Go to step 2.
List of Diagnostic
Trouble Code
(DTC). <Ref. to
(DTC).>
Go to step 3.
Repair the ground
ECM and variable
valve lift diagnosis
oil pressure switch
connector.
Replace the variable valve lift diagnosis oil pressure

switch. <Ref. to
FU(H4SO)-34,
Variable Valve Lift
Diagnosis Oil
Pressure Switch.>
Go to step 4.
Replace the oil
switching solenoid
valve. <Ref. to
ME(H4SO)-85, Oil
Switching Solenoid
Valve.> Go to step
5.
Check the oil flow
path.
Repair the open

circuit of harness
between ECM and
variable valve lift
diagnosis oil pressure switch connector.
END.
END.

B: DTC P0028 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/PERFORMANCE (BANK 2)

CIRCUIT RANGE/PERFORMANCE (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
B134 ECM
32
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
B134
22
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B22
E3
E72
VVL DIAGNOSIS
OIL PRESSURE SWITCH LH
EN-03800
EN(H4SO)(diag)-76

Step
Check

more?
connector.
connector and engine ground.
ECM and variable valve lift diagnosis oil pressure switch connector.
(B134) No. 32 (E72) No. 1:
CHECK DTC.
Is DTC displayed?
CHECK DTC.
Is DTC displayed?
EN(H4SO)(diag)-77
Yes
No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
(DTC).>
Go to step 3.
Repair the ground
ECM and variable
valve lift diagnosis
oil pressure switch
connector.
Replace the variable valve lift diagnosis oil pressure

switch. <Ref. to
FU(H4SO)-34,
Variable Valve Lift
Diagnosis Oil
Pressure Switch.>
Go to step 4.
Replace the oil
switching solenoid
valve. <Ref. to
ME(H4SO)-85, Oil
Switching Solenoid
Valve.> Go to step
5.
Check the oil flow
path.
Repair the open

circuit of harness
between ECM and
variable valve lift
diagnosis oil pressure switch connector.
end.
end.

C: DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1)

Two consecutive driving cycles with fault
GENERAL DESCRIPTION <Ref. to GD(H4SO)-11, DTC P0030 HO2S HEATER CONTROL CIRCUIT
(BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
SBF HOLDER
F34
MAIN RELAY
SBF-1
4
15
14
6
4
F100
BATTERY
SBF-5
F2
5
3
7
B61
2
1
F44
FRONT
OXYGEN
(A/F) SENSOR
6
1
3
50
51
3
4
B47
E23
A/F & OXYGEN

RELAY
E3
B22
5
3
1
B9
B8
B1
C24
C2
C3
B5
B327
A: B134 C: B136
B: B135 D: B137
36
34
35
37
52
A5
D1
D2
D3
D7
ECM
B22
E3
E
F2
B47
1
3
5
2
4
6
1 2 3 4
10 11 12 13 14
F34
5 6 7 8 9
15 16 17 18 19 20
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
A: B134
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN(H4SO)(diag)-78
1 2
8 9 10
18 19 20
28 29 30
F44
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B327
1 2 3 4
5 6 7 8
1 2 3
4
5
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
28 29
30 31
26 27
E23
3 2 1
6 5 4
EN-04768

Step
FRONT OXYGEN (A/F) SENSOR CONNECTOR.
1) Start and warm-up the engine.
front oxygen (A/F) sensor.
ECM and front oxygen (A/F) sensor connector.
(B136) No. 2 (E23) No. 4:
(B136) No. 3 (E23) No. 4:
(B135) No. 8 (E23) No. 4:
(B135) No. 9 (E23) No. 3:
CHECK HARNESS BETWEEN A/F & OXYGEN SENSOR RELAY AND FRONT OXYGEN
(A/F) SENSOR CONNECTOR.
main relay and front oxygen (A/F) sensor connector.
(B327) No. 5 (E23) No. 6:
CHECK FRONT OXYGEN (A/F) SENSOR.
Measure the resistance between front oxygen
(A/F) sensor connector terminals.
Terminals
No. 1 No. 4:
CHECK POOR CONTACT.
Check the poor contact of ECM and front oxygen (A/F) sensor connector.
Check
Yes
No
Repair the open
circuit of harness
between ECM and
front oxygen (A/F)
sensor connector.
Repair the open

circuit of harness
between ECM and
front oxygen (A/F)
sensor connector.
Repair the open

circuit of harness
between A/F &
oxygen sensor
relay and front oxygen (A/F) sensor
connector.
Replace the front

oxygen (A/F) sensor. <Ref. to
FU(H4SO)-36,
Front Oxygen (A/F)
Sensor.>
Is there poor contact in ECM or Repair the poor
Replace the front
the front oxygen (A/F) sensor contact in ECM or oxygen (A/F) senconnector?
the front oxygen
sor. <Ref. to
(A/F) sensor con- FU(H4SO)-36,
nector.
Front Oxygen (A/F)
Sensor.>
EN(H4SO)(diag)-79

D: DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1)

LOW (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
SBF HOLDER
F34
MAIN RELAY
SBF-1
4
15
14
6
4
F100
BATTERY
SBF-5
F2
5
3
7
B61
2
1
F44
FRONT
OXYGEN
(A/F) SENSOR
6
1
3
50
51
3
4
B47
E23
A/F & OXYGEN

RELAY
E3
B22
5
3
1
B9
B8
B1
C24
C2
C3
B5
B327
A: B134 C: B136
B: B135 D: B137
36
34
35
37
52
A5
D1
D2
D3
D7
ECM
B22
E3
E
F2
B47
1
3
5
2
4
6
1 2 3 4
10 11 12 13 14
F34
5 6 7 8 9
15 16 17 18 19 20
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
A: B134
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN(H4SO)(diag)-80
1 2
8 9 10
18 19 20
28 29 30
F44
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B327
1 2 3 4
5 6 7 8
1 2 3
4
5
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
28 29
30 31
26 27
E23
3 2 1
6 5 4
EN-04768

Step
Check
Yes
Are DTC P0031 and P0037 dis- Go to step 2.
played at the same time on the
Subaru Select Monitor or general scan tool?
Go to step 3.
CHECK POWER SUPPLY TO FRONT OXYGEN (A/F) SENSOR.

2) Disconnect the connector from front oxygen
(A/F) sensor.
4) Measure the voltage between front oxygen
(A/F) sensor connector and engine ground.

ECM connector and chassis ground.
CHECK CURRENT DATA.

Is the current 0.2 A or more?
2) Read the data of front oxygen (A/F) sensor
heater current using the Subaru Select Monitor
or general scan tool.
NOTE:
For detailed operation procedure, refer to
READ CURRENT DATA FOR ENGINE. <Ref.
to EN(H4SO)(diag)-27, Subaru Select Monitor.>
General scan tool
CHECK INPUT SIGNAL OF ECM.
1) Start and idle the engine.
EN(H4SO)(diag)-81
Repair the poor

contact of connector.
NOTE:
the following item:
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
ECM connector
Go to step 7.
No
Go to step 5.
Repair the power

supply line.
NOTE:
the following item:
Open circuit in
harness between
main relay and
front oxygen (A/F)
sensor connector
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and engine
ground terminal
Poor contact in
ECM connector
Poor contact in
coupling connector
Go to step 5.
Go to step 6.

Step
and chassis ground.
2) Measure the resistance between front oxygen (A/F) sensor connector terminals.
Terminals
No. 4 No. 6:
Check
Yes
Does the voltage change when Repair poor conshaking the ECM harness and tact in ECM conconnector?
nector.
No
Go to step 7.

?
Replace the front

FU(H4SO)-36,
Front Oxygen (A/F)
Sensor.>
EN(H4SO)(diag)-82
Repair the harness

and connector.
NOTE:
the following item:
Open or ground
short circuit of harness between front
oxygen (A/F) sensor and ECM connector
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
ECM connector

E: DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1)

HIGH (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
SBF HOLDER
F34
MAIN RELAY
SBF-1
4
15
14
6
4
F100
BATTERY
SBF-5
F2
5
3
7
B61
2
1
F44
FRONT
OXYGEN
(A/F) SENSOR
6
1
3
50
51
3
4
B47
E23
A/F & OXYGEN

RELAY
E3
B22
5
3
1
B9
B8
B1
C24
C2
C3
B5
B327
A: B134 C: B136
B: B135 D: B137
36
34
35
37
52
A5
D1
D2
D3
D7
ECM
B22
E3
E
F2
B47
1
3
5
2
4
6
1 2 3 4
10 11 12 13 14
F34
5 6 7 8 9
15 16 17 18 19 20
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
A: B134
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN(H4SO)(diag)-83
1 2
8 9 10
18 19 20
28 29 30
F44
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B327
1 2 3 4
5 6 7 8
1 2 3
4
5
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
28 29
30 31
26 27
E23
3 2 1
6 5 4
EN-04768

Step
CHECK FRONT OXYGEN (A/F) SENSOR
HEATER CURRENT.
2) Repair the battery short circuit of harness
between ECM and front oxygen (A/F) sensor
connector.
NOTE:
General scan tool
and chassis ground.
Check
Yes
Go to step 2.
No
Go to step 3.
Replace the ECM. END.

<Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>
Does the voltage change when Repair the battery END.

shaking the ECM harness and short circuit of harconnector?
ness between
ECM and front oxygen (A/F) sensor
connector.
EN(H4SO)(diag)-84

F: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2)

CAUTION:
WIRING DIAGRAM:
B22
F34
SBF-1
MAIN RELAY
15
14
6
4
F100
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
SBF HOLDER
BATTERY
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
SBF-5
F2
5
3
E22
B61
1
3
B47
2
4
50
53
19
REAR OXYGEN SENSOR
E22
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
C: B136
E3
A/F & OXYGEN RELAY
F34
F44
2
1
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B22
4
5
5 6
14 15 16
25 26 27
33 34 35
D: B137
B4
A29
B1
C24
C4
B5
A: B134
C: B136
F44
B327
1 2 3 4
5 6 7 8
1 2 3
4
5
ECM
D: B137
A5
D1
D2
D3
D7
B: B135
36
34
35
37
52
B327
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
B47
1
3
5
2
4
6
F2
B22
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
E3
A: B134
E
E
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
EN-04091
EN(H4SO)(diag)-85

Step
Check
Yes
CHECK CURRENT DATA.

2) Read the data of rear oxygen sensor heater
current using Subaru Select Monitor or general
scan tool.
NOTE:
General scan tool
and chassis ground.
1) Disconnect the connector from the rear oxygen sensor.
No
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and engine
ground terminal
Poor contact in
ECM connector
Poor contact in
coupling connector
Repair the connec- Go to step 3.
tor.
NOTE:
the following item:
Poor contact in
rear oxygen sensor connector
Poor contact in
rear oxygen sensor
connecting
harness connector
Poor contact in
ECM connector
Go to step 6.
Go to step 4.
nector.
Go to step 5.
Repair the battery

ECM and rear oxygen sensor connector. After repair,
replace the ECM.
<Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>
EN(H4SO)(diag)-86
Replace the ECM.

<Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>

Step
Check
CHECK POWER SUPPLY TO REAR OXYIs the voltage 10 V or more?
GEN SENSOR.
4) Measure the voltage between rear oxygen
sensor connector and engine ground or chassis
ground.
CHECK REAR OXYGEN SENSOR.

2) Measure the resistance between rear oxygen sensor connector terminals.
Terminals
No. 1 No. 2:

?
EN(H4SO)(diag)-87
Yes
Go to step 7.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
rear oxygen sensor and ECM connector
Poor contact in
Poor contact in
ECM connector
Poor contact in
coupling connector
No
Repair the power
supply line.
NOTE:
the following item:
Open circuit in
harness between
main relay and rear
oxygen
sensor
connector
Poor contact in
Poor contact in
coupling connector
Replace the rear
oxygen sensor.
<Ref. to
FU(H4SO)-38,
Rear Oxygen Sensor.>

G: DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2)

CAUTION:
WIRING DIAGRAM:
B22
F34
SBF-1
MAIN RELAY
15
14
6
4
F100
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
SBF HOLDER
BATTERY
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
SBF-5
F2
5
3
E22
B61
1
3
B47
2
4
50
53
19
REAR OXYGEN SENSOR
E22
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
C: B136
E3
A/F & OXYGEN RELAY
F34
F44
2
1
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B22
4
5
5 6
14 15 16
25 26 27
33 34 35
D: B137
B4
A29
B1
C24
C4
B5
A: B134
C: B136
F44
B327
1 2 3 4
5 6 7 8
1 2 3
4
5
ECM
D: B137
A5
D1
D2
D3
D7
B: B135
36
34
35
37
52
B327
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
B47
1
3
5
2
4
6
F2
B22
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
E3
A: B134
E
E
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
EN-04091
EN(H4SO)(diag)-88

Step
and chassis ground.
CHECK CURRENT DATA.
2) Repair the battery short circuit of harness
between ECM and rear oxygen sensor connector.
current using Subaru Select Monitor or general
scan tool.
NOTE:
General scan tool
CHECK POOR CONTACT.
Check
Yes
Go to step 2.
Is the current 7 A or more?

<Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>

connector?
EN(H4SO)(diag)-89
No
Go to step 3.
END.

H: DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION

GENERAL DESCRIPTION <Ref. to GD(H4SO)-21, DTC P0068 MAP/MAF - THROTTLE POSITION
CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
E21
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
3
2
1
1 2 3
B22
E21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
20
19
7
E3
B22
B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
19
29
6
1 2
8 9 10
18 19 20
28 29 30
B134 ECM
EN-03797
EN(H4SO)(diag)-90

Step
CHECK AIR INTAKE SYSTEM.
Check
Yes
No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
(DTC).>
Repair the air
Go to step 3.
intake system.
Are there holes, loose bolts or

disconnection of hose on air
intake system?
CHECK MANIFOLD ABSOLUTE PRESSURE Is the measured value 73.3 Go to step 4.
SENSOR.
106.6 kPa (550 800 mmHg,
1) Start the engine and warm-up engine until 21.65 31.50 inHg) when the
coolant temperature is greater than 60C
ignition is turned ON, and 20.0
(140F).
46.7 kPa (150 350 mmHg,
2) Place the select lever or shift lever in P or 5.91 13.78 inHg) during
N range.
idling?
3) Turn the A/C switch to OFF.
4) Turn all the accessory switches to OFF.
5) Read the data of intake manifold pressure
sensor signal using Subaru Select Monitor or
general scan tool.
NOTE:
General scan tool
Is the measured value less than Go to step 5.
CHECK THROTTLE OPENING ANGLE.
Read the data of throttle position signal using 5% when throttle is fully
closed?
NOTE:
General scan tool
CHECK THROTTLE OPENING ANGLE.
Is the measured value more
Replace the manithan 85% when throttle is fully fold absolute presopen?
sure sensor. <Ref.
to FU(H4SO)-27,
Manifold Absolute
Pressure Sensor.>
EN(H4SO)(diag)-91
Replace the manifold absolute pressure sensor. <Ref.

to FU(H4SO)-27,
Manifold Absolute
Pressure Sensor.>
Adjust or replace
the throttle position
sensor. <Ref. to
FU(H4SO)-26,
Throttle Position
Sensor.>
Replace the throttle position sensor.

<Ref. to
FU(H4SO)-26,
Throttle Position
Sensor.>

I:
DTC P0076 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 1)

CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B137 ECM
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
24
25
B137
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
23
24
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B22
E69
E3
1 2
1
2
E69
OIL SWITCHING SOLENOID VALVE RH
EN-03801
EN(H4SO)(diag)-92

Step
Check
Yes
CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1 ? Go to step 2.
SWITCHING SOLENOID VALVE.
oil switching solenoid valve.
3) Measure the resistance between ECM and
(B137) No. 25 (E69) No. 1:
(B137) No. 24 (E69) No. 2:
CHECK OIL SWITCHING SOLENOID VALVE. Is the resistance between 6 and

1) Remove the oil switching solenoid valve
12 ?
connector.
2) Measure the resistance between oil switching solenoid valve terminals.
Terminals
No. 1 No. 2:
EN(H4SO)(diag)-93
Repair the poor

contact of ECM
and oil switching
solenoid valve.
No
Repair the open
circuit of harness
between ECM and
oil switching solenoid valve connector.
NOTE:
the following item:
Open circuit in
harness between
ECM
and
oil
switching solenoid
valve connector
Poor contact in
coupling connector
Replace the oil
switching solenoid
valve. <Ref. to
ME(H4SO)-85, Oil
Switching Solenoid
Valve.>

J: DTC P0077 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 1)

CIRCUIT HIGH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B137 ECM
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
24
25
B137
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
23
24
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B22
E69
E3
1 2
1
2
E69
OIL SWITCHING SOLENOID VALVE RH
EN-03801
EN(H4SO)(diag)-94

Step
CHECK HARNESS BETWEEN ECM AND OIL
3) Measure the resistance between oil switching solenoid valve and engine ground.
CHECK OIL SWITCHING SOLENOID VALVE.
connector.
Terminals
No. 1 No. 2:
Check
more?
Yes
Go to step 2.
Is the resistance between 6 and Repair the poor

12 ?
contact of ECM
and oil switching
solenoid valve.
EN(H4SO)(diag)-95
No
Repair the short
circuit between
ECM and oil
switching solenoid
valve connector.
Replace the oil

switching solenoid
valve. <Ref. to
ME(H4SO)-85, Oil
Switching Solenoid
Valve.>

K: DTC P0082 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 2)

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
30
31
B137 ECM
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
27
28
E70
1 2
B22
E3
1
2
E70
OIL SWITCHING SOLENOID VALVE LH
EN-03802
EN(H4SO)(diag)-96

Step
Check
Yes
(B137) No. 31 (E70) No. 1:
(B137) No. 30 (E70) No. 2:
CHECK OIL SWITCHING SOLENOID VALVE. Is the resistance between 6 and

12 ?
connector.
Terminals
No. 1 No. 2:
EN(H4SO)(diag)-97
Repair the poor

contact of ECM
and oil switching
solenoid valve.
No
Repair the open
circuit of harness
between ECM and
oil switching solenoid valve connector.
NOTE:
the following item:
Open circuit in
harness between
ECM
and
oil
switching solenoid
valve connector
Poor contact in
coupling connector
Replace the oil
switching solenoid
valve. <Ref. to
ME(H4SO)-85, Oil
Switching Solenoid
Valve.>

L: DTC P0083 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 2)

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
30
31
B137 ECM
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
27
28
E70
1 2
B22
E3
1
2
E70
OIL SWITCHING SOLENOID VALVE LH
EN-03802
EN(H4SO)(diag)-98

Step
3) Measure the resistance between oil switching solenoid valve and engine ground.
CHECK OIL SWITCHING SOLENOID VALVE.
connector.
Terminals
No. 1 No. 2:
Check
more?
Yes
Go to step 2.

12 ?
contact of ECM
and oil switching
solenoid valve.
EN(H4SO)(diag)-99
No
Repair the short
circuit between
ECM and oil
switching solenoid
valve connector.
Replace the oil

switching solenoid
valve. <Ref. to
ME(H4SO)-85, Oil
Switching Solenoid
Valve.>

M: DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE

GENERAL DESCRIPTION <Ref. to GD(H4SO)-26, DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT
RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Poor driving performance
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
BATTERY
SBF-5
14
5
3
B100
F2
2
1
B47
MASS AIR FLOW &
INTAKE AIR
TEMPERATURE SENSOR
26
18
34
35
30
B3
E
B135 ECM
B3
1 2 3 4 5
B47
1
3
5
2
4
6
B135
F2
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
EN-03798
EN(H4SO)(diag)-100

Step
Check
EN(H4SO)(diag)-101
Yes
the List of Diagnostic Trouble
Code (DTC).
<Ref. to
(DTC).>
NOTE:
In this case, it is not
necessary to inspect DTC P0101.
No
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(H4SO)-28,
Mass Air Flow and
Intake Air Temperature Sensor.>

N: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT

LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
BATTERY
SBF-5
14
5
3
B100
F2
2
1
B47
MASS AIR FLOW &
INTAKE AIR
TEMPERATURE SENSOR
26
18
34
35
30
B3
E
B135 ECM
B3
1 2 3 4 5
B47
1
3
5
2
4
6
B135
F2
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
EN-03798
EN(H4SO)(diag)-102

Step
Check
CONNECT SUBARU SELECT MONITOR OR Is the voltage 0.2 4.7 V?
THE GENERAL SCAN TOOL, AND READ
DATA.
2) Connect the Subaru Select Monitor or general scan tool to data link connector.
3) Turn the ignition switch to ON, and the Subaru Select Monitor or general scan tool power
switch to ON.
5) Read the mass air flow sensor voltage using
NOTE:
General scan tool

and chassis ground while engine is idling.
CHECK POWER SUPPLY TO MASS AIR
FLOW SENSOR.
2) Disconnect the connector from mass air
flow sensor.
4) Measure the voltage between mass air flow
sensor connector and chassis ground.
MASS AIR FLOW SENSOR CONNECTOR.
ECM and mass air flow sensor connector.
(B135) No. 26 (B3) No. 3:
(B135) No. 34 (B3) No. 2:
(B135) No. 30 (B3) No. 5:
Is the voltage 0.2 V or more?
Yes
No
Even if the malGo to step 2.
function indicator
light illuminates,
the circuit has
returned to a normal condition at
this time. Temporary poor contact of
connector or harness may be the
cause. Repair the
harness or connector in mass air
flow sensor.
NOTE:
the following item:
Open or ground
short circuit in harness
between
mass air flow sensor and ECM connector
Poor contact in
mass air flow sensor or ECM connector
Go to step 3.
Go to step 4.
Repair the open

circuit between
mass air flow sensor and main relay.
Repair the open

circuit between
ECM and mass air
flow sensor connector.
more?
Repair the ground

short circuit
between ECM and
mass air flow sensor connector.
EN(H4SO)(diag)-103
Go to step 6.

Step
Check
Yes
CHECK POOR CONTACT.
Is there poor contact in mass air Repair the poor
Check poor contact of mass air flow sensor con- flow sensor connector?
contact of mass air
nector.
EN(H4SO)(diag)-104
No
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(H4SO)-28,
Mass Air Flow and

O: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT

HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
BATTERY
SBF-5
14
5
3
B100
F2
2
1
B47
MASS AIR FLOW &
INTAKE AIR
TEMPERATURE SENSOR
26
18
34
35
30
B3
E
B135 ECM
B3
1 2 3 4 5
B47
1
3
5
2
4
6
B135
F2
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
EN-03798
EN(H4SO)(diag)-105

Step
Check
DATA.
switch to ON.
NOTE:
General scan tool
2) Disconnect the connector from mass airflow
sensor.
ECM connector and mass air flow sensor connector.
(B3) No. 2 (B135) No. 34:
EN(H4SO)(diag)-106
Yes
Even if the malfunction indicator
light illuminates,
the circuit has
this time.
No
Go to step 2.
Repair the battery Go to step 3.

mass air flow sensor connector and
ECM connector.
Replace the mass

air flow sensor.
<Ref. to
FU(H4SO)-28,
Mass Air Flow and
Repair the open

circuit of harness
between mass air
flow sensor connector and ECM
connector.

P: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE

CIRCUIT LOW INPUT
GENERAL DESCRIPTION <Ref. to GD(H4SO)-33, DTC P0107 MANIFOLD ABSOLUTE PRESSURE/
BAROMETRIC PRESSURE CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
E21
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
3
2
1
1 2 3
B22
E21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
20
19
7
E3
B22
B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
19
29
6
1 2
8 9 10
18 19 20
28 29 30
B134 ECM
EN-03797
EN(H4SO)(diag)-107

Step
CHECK CURRENT DATA.
2) Read the data of intake manifold absolute
pressure signal using Subaru Select Monitor or
general scan tool.
NOTE:
General scan tool
CHECK POOR CONTACT.
Check the poor contact in ECM and manifold
pressure sensor connector.

and chassis ground.
Measure the voltage between ECM and chassis
ground.
CHECK INPUT SIGNAL FOR ECM (USING
SUBARU SELECT MONITOR).
Read the data of atmospheric absolute pressure signal using Subaru Select Monitor.
NOTE:
MANIFOLD ABSOLUTE PRESSURE SENSOR CONNECTOR.
2) Disconnect the connector from manifold
absolute pressure sensor.
4) Measure the voltage between manifold
absolute pressure sensor connector and
engine ground.
Check
Yes
13.3 kPa (100 mmHg, 3.94
inHg) ?
No
Go to step 2.

manifold pressure sensor concontact in ECM or
nector?
manifold pressure
sensor connector.

light illuminates,
the circuit has
this time.
Go to step 4.
Is the voltage less than 0.2 V? Go to step 6.
Go to step 5.

Repair poor conthan 13.3 kPa (100 mmHg, 3.94 tact in ECM coninHg) when shaking the ECM nector.
harness and connector?
Go to step 6.
Repair the open

circuit of harness
between ECM and
manifold absolute
pressure sensor
connector.
EN(H4SO)(diag)-108
Go to step 7.

Step
ECM and manifold absolute pressure sensor
connector.
(B134) No. 6 (E21) No. 1:
CHECK POOR CONTACT.
Check poor contact of manifold absolute pressure sensor connector.
Check
Yes
No
Repair the open
circuit of harness
between ECM and
manifold absolute
pressure sensor
connector.
Is there poor contact in manifold absolute pressure sensor

connector?

to FU(H4SO)-27,
Manifold Absolute
Pressure Sensor.>
EN(H4SO)(diag)-109
Repair the poor

contact of manifold absolute pressure sensor
connector.

Q: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE

CIRCUIT HIGH INPUT
GENERAL DESCRIPTION <Ref. to GD(H4SO)-35, DTC P0108 MANIFOLD ABSOLUTE PRESSURE/
BAROMETRIC PRESSURE CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
E21
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
3
2
1
1 2 3
B22
E21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
20
19
7
E3
B22
B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
19
29
6
1 2
8 9 10
18 19 20
28 29 30
B134 ECM
EN-03797
EN(H4SO)(diag)-110

Step
CHECK CURRENT DATA.
general scan tool.
NOTE:
General scan tool
and chassis ground.
and chassis ground.
Read the data of atmospheric absolute pressure signal using Subaru Select Monitor.
NOTE:
engine ground.
connector.
(B134) No. 29 (E21) No. 2:
Check
than 119.5 kPa (896.5 mmHg,
35.29 inHg) ?
Yes
Go to step 9.
No
Go to step 2.
Go to step 3.
Go to step 4.

Repair poor conthan 13.3 kPa (100 mmHg, 3.94 tact in ECM coninHg) when shaking the ECM nector.
Go to step 5.
Go to step 6.
Repair the open

circuit of harness
between ECM and
manifold absolute
pressure sensor
connector.
Repair the open

circuit of harness
between ECM and
manifold absolute
pressure sensor
connector.
EN(H4SO)(diag)-111

Step
connector.
(B134) No. 6 (E21) No. 1:
CHECK POOR CONTACT.
Check
Yes
No
Repair the open
circuit of harness
between ECM and
manifold absolute
pressure sensor
connector.

connector?
Repair the poor

connector.

MANIFOLD ABSOLUTE PRESSURE SENthan 119.5 kPa (896.5 mmHg,
SOR CONNECTOR.
35.29 inHg) ?
1) Turn the ignition switch to OFF and Subaru
Select Monitor or the general scan tool switch to
OFF.
switch to ON.
general scan tool.
NOTE:
General scan tool
Repair the battery

ECM and manifold
absolute pressure
sensor connector.

to FU(H4SO)-27,
Manifold Absolute
Pressure Sensor.>
to FU(H4SO)-27,
Manifold Absolute
Pressure Sensor.>
EN(H4SO)(diag)-112

R: DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/PERFORMANCE

GENERAL DESCRIPTION <Ref. to GD(H4SO)-37, DTC P0111 INTAKE AIR TEMPERATURE SENSOR
1 CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
BATTERY
SBF-5
14
5
3
B100
F2
2
1
B47
MASS AIR FLOW &
INTAKE AIR
TEMPERATURE SENSOR
26
18
34
35
30
B3
E
B135 ECM
B3
1 2 3 4 5
B47
1
3
5
2
4
6
B135
F2
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
EN-03798
EN(H4SO)(diag)-113

Step
Check
EN(H4SO)(diag)-114
Yes
Check DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
(DTC).>
NOTE:
No
Replace the intake
air temperature
sensor. <Ref. to
FU(H4SO)-28,
Mass Air Flow and

S: DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW

1 CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
BATTERY
SBF-5
14
5
3
B100
F2
2
1
B47
MASS AIR FLOW &
INTAKE AIR
TEMPERATURE SENSOR
26
18
34
35
30
B3
E
B135 ECM
B3
1 2 3 4 5
B47
1
3
5
2
4
6
B135
F2
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
EN-03798
EN(H4SO)(diag)-115

Step
CHECK CURRENT DATA.
2) Read the data of intake air temperature sensor signal using Subaru Select Monitor or general scan tool.
NOTE:
General scan tool
CHECK HARNESS BETWEEN INTAKE AIR
TEMPERATURE SENSOR AND ECM CONNECTOR.
2) Disconnect the connector from intake air
temperature sensor.
NOTE:
General scan tool
Check
Is the intake air temperature
above 120C (248F) ?

less than 40C (40F) ?
EN(H4SO)(diag)-116
Yes
Go to step 2.
No
Repair the poor
contact.
NOTE:
the following item:
Poor contact in
intake air temperature sensor
Poor contact in
ECM
Poor contact in
coupling connector
Poor contact in
joint connector
Replace the intake Repair the ground
air temperature
short circuit of harsensor. <Ref. to
ness between
FU(H4SO)-28,
intake air temperaMass Air Flow and ture sensor and
Intake Air Temper- ECM connector.
ature Sensor.>

T: DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH

1 CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
BATTERY
SBF-5
14
5
3
B100
F2
2
1
B47
MASS AIR FLOW &
INTAKE AIR
TEMPERATURE SENSOR
26
18
34
35
30
B3
E
B135 ECM
B3
1 2 3 4 5
B47
1
3
5
2
4
6
B135
F2
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
EN-03798
EN(H4SO)(diag)-117

Step
CHECK CURRENT DATA.
NOTE:
General scan tool
2) Disconnect the connector from intake air
temperature sensor.
3) Measure the voltage between intake air
temperature sensor connector and engine
ground.
2) Measure the voltage between intake air
ground.
Measure the voltage between intake air temperature sensor connector and engine ground.
Check
less than 40C (40F) ?
Yes
Go to step 2.
No
Repair the poor
contact.
NOTE:
the following item:
Poor contact in
Poor contact in
ECM
Poor contact in
coupling connector
Poor contact in
joint connector
intake air temperature sensor and
ECM connector.

ECM connector.
Go to step 5.
EN(H4SO)(diag)-118
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM connector
Poor contact in
Poor contact in
ECM
Poor contact in
coupling connector
Poor contact in
joint connector

Step
Check
CHECK HARNESS BETWEEN INTAKE AIR Is the resistance less than 5 ?
intake air temperature sensor connector and
engine ground.
EN(H4SO)(diag)-119
Yes
Replace the intake
air temperature
sensor. <Ref. to
FU(H4SO)-28,
Mass Air Flow and
No
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM connector
Poor contact in
Poor contact in
ECM
Poor contact in
coupling connector
Poor contact in
joint connector

U: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW

GENERAL DESCRIPTION <Ref. to GD(H4SO)-43, DTC P0117 ENGINE COOLANT TEMPERATURE
CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Hard to start
Erroneous idling
CAUTION:
WIRING DIAGRAM:
BATTERY
No.14
SBF-4
4
B72
IGNITION
SWITCH
i1
B9
B36
SBF-1
ECM
C:
i11
COMBINATION METER
B134
34
i10
C10
B:
11
B22
E3
E8
1
E57
ENGINE
ELECTRONIC
THROTTLE
CONTROL
B72
1 2
3 4
E8
1 2
3
C:
i11
1 2 3 4 5 6 7 8 9 10
B:
TEMPERATURE
SENSOR
B22
i10
8 9 10 11 12 13 14
1 2 3 4 5 6 7
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B134
E57
1 2 3 4 5 6
COOLANT
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
B36
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
EN-03773
EN(H4SO)(diag)-120

Step
Check
Yes
CHECK CURRENT DATA.
Is the engine coolant tempera- Go to step 2.
ture above 150C (302F) ?
2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor
NOTE:
General scan tool
No
Repair the poor
contact.
NOTE:
the following item:
Poor contact in
engine
coolant
temperature sensor
Poor contact in
ECM
Poor contact in
coupling connector
Poor contact in
joint connector
CHECK HARNESS BETWEEN ENGINE
Is the engine coolant tempera- Replace the
Repair the ground
COOLANT TEMPERATURE SENSOR AND ture less than 40C (40F) ? engine coolant
short circuit of harECM CONNECTOR.
temperature sen- ness between
sor. <Ref. to
engine coolant
FU(H4SO)-22,
temperature sencoolant temperature sensor.
Engine Coolant
sor and ECM con3) Turn the ignition switch to ON.
Temperature Sen- nector.
4) Read the data of engine coolant temperasor.>
ture sensor signal using Subaru Select Monitor
NOTE:
General scan tool
EN(H4SO)(diag)-121

V: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH

GENERAL DESCRIPTION <Ref. to GD(H4SO)-45, DTC P0118 ENGINE COOLANT TEMPERATURE
CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Hard to start
Erroneous idling
CAUTION:
WIRING DIAGRAM:
BATTERY
No.14
SBF-4
4
B72
IGNITION
SWITCH
i1
B9
B36
SBF-1
ECM
C:
i11
COMBINATION METER
B134
34
i10
C10
B:
11
B22
E3
E8
1
E57
ENGINE
ELECTRONIC
THROTTLE
CONTROL
B72
1 2
3 4
E8
1 2
3
C:
i11
1 2 3 4 5 6 7 8 9 10
B:
TEMPERATURE
SENSOR
B22
i10
8 9 10 11 12 13 14
1 2 3 4 5 6 7
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B134
E57
1 2 3 4 5 6
COOLANT
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
B36
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
EN-03773
EN(H4SO)(diag)-122

Step
Check
Yes
CHECK CURRENT DATA.
ture less than 40C (40F) ?
NOTE:
General scan tool
COOLANT TEMPERATURE SENSOR AND
ECM CONNECTOR.
3) Measure the voltage between engine coolant temperature sensor connector and engine
ground.
ECM CONNECTOR.
ground.
ECM CONNECTOR.
Measure the voltage between engine coolant
ground.
EN(H4SO)(diag)-123
No
Repair the poor
contact.
NOTE:
the following item:
Poor contact in
engine
coolant
temperature sensor
Poor contact in
ECM
Poor contact in
coupling connector
Poor contact in
joint connector
ECM and engine
coolant temperature sensor connector.

ECM and engine
Go to step 5.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and engine
coolant temperature sensor connector
Poor contact in
engine
coolant
temperature sensor connector
Poor contact in
ECM connector
Poor contact in
coupling connector
Poor contact in
joint connector

Step
Check
ECM CONNECTOR.
engine coolant temperature sensor connector
and engine ground.
EN(H4SO)(diag)-124
Yes
Replace the
engine coolant
temperature sensor. <Ref. to
FU(H4SO)-22,
Engine Coolant
Temperature Sensor.>
No
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and engine
Poor contact in
engine
coolant
Poor contact in
ECM connector
Poor contact in
coupling connector
Poor contact in
joint connector

W: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT

LOW
GENERAL DESCRIPTION <Ref. to GD(H4SO)-47, DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
B309
1 2
3 4
E57
BATTERY
ELECTRONIC THROTTLE
CONTROL RELAY
SBF-5
B309
1 2 3 4 5 6
2
1
3
4
B122
1 2 3 4
5 6 7 8
C21
C1
MAIN RELAY
D: B137
ECM
D: B137
E
C6
A18
A28
A29
D4
D5
A19
C15
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
30 31
26 27
28 29
MT
D7
A5
D1
D2
D3
A: B134
A: B134
B122
3
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
17
18
19
20
39
38
52
36
34
35
37
B22
1 2
8 9 10
18 19 20
28 29 30
E3
C: B136
5 6
14 15 16
25 26 27
33 34 35
E57
1
2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B22
ELECTRONIC THROTTLE
E
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
CONTROL
34
42
MT
: MT MODEL
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-03774
EN(H4SO)(diag)-125

Step
CHECK SENSOR OUTPUT.
2) Read the data of main throttle sensor signal
using Subaru Select Monitor.
CHECK POOR CONTACT.
Check poor contact in connector between ECM
and electronic throttle control.
ELECTRONIC THROTTLE CONTROL.
3) Disconnect the connectors from electronic
throttle control.
4) Measure the resistance between ECM connector and electronic throttle control connector.
(B134) No. 18 (E57) No. 6:
(B134) No. 19 (E57) No. 5:
Measure the resistance between ECM connector and chassis ground.
CHECK POWER SUPPLY OF ELECTRONIC
THROTTLE CONTROL.
1) Connect the ECM connector.
3) Measure the voltage between electronic
throttle control connector and engine ground.
CHECK SHORT CIRCUIT INSIDE THE ECM.
2) Measure the resistance between electronic
Check
Yes
Go to step 2.
Is there poor contact in connec- Repair the poor

tor between ECM and eleccontact.
tronic throttle control?
No
Go to step 3.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
more?
Go to step 5.
Repair the chassis

short circuit of harness.
Is the voltage 4.5 5.5 V?
Go to step 6.
Is the resistance 10 or more? Repair the poor

Repair poor concontact of electact in ECM contronic throttle connector.
trol connector.
Replace the accelerator pedal position sensor if
defective.
EN(H4SO)(diag)-126

X: DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT

HIGH
GENERAL DESCRIPTION <Ref. to GD(H4SO)-49, DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
B309
1 2
3 4
E57
BATTERY
ELECTRONIC THROTTLE
CONTROL RELAY
SBF-5
B309
1 2 3 4 5 6
2
1
3
4
B122
1 2 3 4
5 6 7 8
C21
C1
MAIN RELAY
D: B137
ECM
D: B137
E
C6
A18
A28
A29
D4
D5
A19
C15
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
30 31
26 27
28 29
MT
D7
A5
D1
D2
D3
A: B134
A: B134
B122
3
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
17
18
19
20
39
38
52
36
34
35
37
B22
1 2
8 9 10
18 19 20
28 29 30
E3
C: B136
5 6
14 15 16
25 26 27
33 34 35
E57
1
2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B22
ELECTRONIC THROTTLE
E
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
CONTROL
34
42
MT
: MT MODEL
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-03774
EN(H4SO)(diag)-127

Step
CHECK POOR CONTACT.
Check
Yes
No
Go to step 3.

Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.

throttle control.
(B134) No. 18 (E57) No. 6:
(B134) No. 29 (E57) No. 3:
CHECK SENSOR OUTPUT POWER SUPPLY.
Measure the voltage between electronic throttle
control connector and engine ground.
EN(H4SO)(diag)-128
Go to step 4.
Go to step 5.
Replace the electronic throttle control. <Ref. to

FU(H4SO)-12,
Throttle Body.>
Repair the battery

ECM connector
and electronic
throttle control
connector.

Y: DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP

FUEL CONTROL
GENERAL DESCRIPTION <Ref. to GD(H4SO)-51, DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine does not return to idle.
CAUTION:
WIRING DIAGRAM:
BATTERY
No.14
SBF-4
4
B72
IGNITION
SWITCH
i1
B9
B36
SBF-1
ECM
C:
i11
COMBINATION METER
B134
34
i10
C10
B:
11
B22
E3
E8
1
E57
ENGINE
ELECTRONIC
THROTTLE
CONTROL
B72
1 2
3 4
C:
i11
1 2 3 4 5 6 7 8 9 10
E8
E57
1 2
3
1 2 3 4 5 6
B:
COOLANT
TEMPERATURE
SENSOR
B22
i10
8 9 10 11 12 13 14
1 2 3 4 5 6 7
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
B36
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
EN-03773
EN(H4SO)(diag)-129

Step
Check
CHECK THERMOSTAT.
Does the thermostat remain

opened?
EN(H4SO)(diag)-130
Yes
Check DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
(DTC).>
NOTE:
Replace the thermostat. <Ref. to
CO(H4SO)-25,
Thermostat.>
No
Go to step 2.
Replace the
engine coolant
FU(H4SO)-22,
Engine Coolant

Z: DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR STABLE OPERATION

GENERAL DESCRIPTION <Ref. to GD(H4SO)-53, DTC P0126 INSUFFICIENT ENGINE COOLANT
TEMPERATURE FOR STABLE OPERATION, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
BATTERY
No.14
SBF-4
4
B72
IGNITION
SWITCH
i1
B9
B36
SBF-1
ECM
C:
i11
COMBINATION METER
B134
34
i10
C10
B:
11
B22
E3
E8
1
E57
ENGINE
ELECTRONIC
THROTTLE
CONTROL
B72
1 2
3 4
C:
i11
1 2 3 4 5 6 7 8 9 10
E8
E57
1 2
3
1 2 3 4 5 6
B:
COOLANT
TEMPERATURE
SENSOR
B22
i10
8 9 10 11 12 13 14
1 2 3 4 5 6 7
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
B36
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
EN-03773
EN(H4SO)(diag)-131

Step
Check
Yes
Check DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
(DTC).>
CHECK ENGINE COOLANT TEMPERATURE Does the resistance change
Repair poor conSENSOR.
when engine is cold and warm tact in ECM conMeasure the resistance between engine cool- up?
nector.
ant temperature sensor terminals when engine
is cold and warm up.
Terminals
No. 1 No. 2:
EN(H4SO)(diag)-132
No
Go to step 2.
Replace the
engine coolant
FU(H4SO)-22,
Engine Coolant

AA:DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE

BELOW THERMOSTAT REGULATING TEMPERATURE)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-55, DTC P0128 COOLANT THERMOSTAT (ENGINE
COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE), Diagnostic Trouble
Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Thermostat remains open.
CAUTION:
1
Step
CHECK VEHICLE CONDITION.
CHECK ENGINE COOLANT.
CHECK RADIATOR FAN.

2) Check radiator fan operation.
Check
Yes
Was the vehicle driven or idled In this case, it is not
with the engine partially subnecessary to
merged under water?
inspect DTC
P0128.
Check DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
(DTC).>
Are the coolant level and mix- Go to step 4.
ture ratio of engine coolant to
anti-freeze solution correct?
Does the radiator fan continuously rotate for more than 3

minutes during idling?
EN(H4SO)(diag)-133
No
Go to step 2.
Go to step 3.
Replace the
engine coolant.
<Ref. to
CO(H4SO)-18,
REPLACEMENT,
Engine Coolant.>
Repair radiator fan Replace the thercircuit. <Ref. to
mostat. <Ref. to
CO(H4SO)-34,
CO(H4SO)-25,
Radiator Main Fan Thermostat.>
and Fan Motor.>
and <Ref. to
CO(H4SO)-41,
Radiator Sub Fan
and Fan Motor.>

AB:DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)

GENERAL DESCRIPTION <Ref. to GD(H4SO)-57, DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE
CAUTION:
WIRING DIAGRAM:
SBF HOLDER
F34
MAIN RELAY
SBF-1
4
15
14
6
4
F100
BATTERY
SBF-5
F2
5
3
7
B61
2
1
F44
1
3
B47
FRONT
OXYGEN
(A/F) SENSOR
E23
A/F & OXYGEN

RELAY
3
4
51
50
E3
B22
5
3
1
B9
B8
B1
C24
C2
C3
B5
B327
A: B134 C: B136
B: B135 D: B137
36
34
35
37
52
A5
D1
D2
D3
D7
ECM
B22
E3
E
F2
B47
1
3
5
2
4
6
1 2 3 4
10 11 12 13 14
F34
5 6 7 8 9
15 16 17 18 19 20
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
A: B134
B22
5 6
14 15 16
25 26 27
33 34 35
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN(H4SO)(diag)-134
1 2
8 9 10
18 19 20
28 29 30
F44
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B327
1 2 3 4
5 6 7 8
1 2 3
4
5
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
28 29
30 31
26 27
E23
3 2 1
6 5 4
EN-04768

Step
CONNECTOR AND COUPLING CONNECTOR.
front oxygen (A/F) sensor connector.
Check
Does water enter the connector?
Yes
No
Dry the water thor- Go to step 2.
oughly.
more?
Replace the front

FU(H4SO)-36,
Front Oxygen (A/F)
Sensor.>
EN(H4SO)(diag)-135
Repair the ground

connector.

AC:DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)

GENERAL DESCRIPTION <Ref. to GD(H4SO)-59, DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE
CAUTION:
WIRING DIAGRAM:
SBF HOLDER
F34
MAIN RELAY
SBF-1
4
15
14
6
4
F100
BATTERY
SBF-5
F2
5
3
7
B61
2
1
F44
1
3
B47
FRONT
OXYGEN
(A/F) SENSOR
E23
A/F & OXYGEN

RELAY
3
4
51
50
E3
B22
5
3
1
B9
B8
B1
C24
C2
C3
B5
B327
A: B134 C: B136
B: B135 D: B137
36
34
35
37
52
A5
D1
D2
D3
D7
ECM
B22
E3
E
F2
B47
1
3
5
2
4
6
1 2 3 4
10 11 12 13 14
F34
5 6 7 8 9
15 16 17 18 19 20
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
A: B134
B22
5 6
14 15 16
25 26 27
33 34 35
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN(H4SO)(diag)-136
1 2
8 9 10
18 19 20
28 29 30
F44
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B327
1 2 3 4
5 6 7 8
1 2 3
4
5
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
28 29
30 31
26 27
E23
3 2 1
6 5 4
EN-04768

Step
Check
Does water enter the connecCONNECTOR AND COUPLING CONNECtor?
TOR.
(A/F) sensor.
3) Measure the voltage of harness between
EN(H4SO)(diag)-137
Yes
No
oughly.
Replace the front
FU(H4SO)-36,
Front Oxygen (A/F)
Sensor.>
Repair the battery

connector.

AD:DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1)

GENERAL DESCRIPTION <Ref. to GD(H4SO)-61, DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
SBF HOLDER
F34
MAIN RELAY
SBF-1
4
15
14
6
4
F100
BATTERY
SBF-5
F2
5
3
7
B61
2
1
F44
1
3
B47
FRONT
OXYGEN
(A/F) SENSOR
E23
A/F & OXYGEN

RELAY
3
4
51
50
E3
B22
5
3
1
B9
B8
B1
C24
C2
C3
B5
B327
A: B134 C: B136
B: B135 D: B137
36
34
35
37
52
A5
D1
D2
D3
D7
ECM
B22
E3
E
F2
B47
1
3
5
2
4
6
1 2 3 4
10 11 12 13 14
F34
5 6 7 8 9
15 16 17 18 19 20
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
A: B134
B22
5 6
14 15 16
25 26 27
33 34 35
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN(H4SO)(diag)-138
1 2
8 9 10
18 19 20
28 29 30
F44
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B327
1 2 3 4
5 6 7 8
1 2 3
4
5
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
28 29
30 31
26 27
E23
3 2 1
6 5 4
EN-04768

Step
Check
CHECK EXHAUST SYSTEM.

Is there any fault in exhaust
system?
NOTE:
Loose installation of front portion of exhaust
pipe onto cylinder heads
Loose connection between front exhaust pipe
and front catalytic converter
Damage of exhaust pipe resulting in a hole
EN(H4SO)(diag)-139
Yes
No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
(DTC).>
NOTE:
Repair the exhaust Replace the front
system.
FU(H4SO)-36,
Front Oxygen (A/F)
Sensor.>

AE:DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1)

GENERAL DESCRIPTION <Ref. to GD(H4SO)-64, DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY
DETECTED (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
SBF HOLDER
F34
MAIN RELAY
SBF-1
4
15
14
6
4
F100
BATTERY
SBF-5
F2
5
3
7
B61
2
1
F44
FRONT
OXYGEN
(A/F) SENSOR
6
1
3
50
51
3
4
B47
E23
A/F & OXYGEN

RELAY
E3
B22
5
3
1
B9
B8
B1
C24
C2
C3
B5
B327
A: B134 C: B136
B: B135 D: B137
36
34
35
37
52
A5
D1
D2
D3
D7
ECM
B22
E3
E
F2
B47
1
3
5
2
4
6
1 2 3 4
10 11 12 13 14
F34
5 6 7 8 9
15 16 17 18 19 20
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
A: B134
B22
5 6
14 15 16
25 26 27
33 34 35
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN(H4SO)(diag)-140
1 2
8 9 10
18 19 20
28 29 30
F44
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B327
1 2 3 4
5 6 7 8
1 2 3
4
5
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
28 29
30 31
26 27
E23
3 2 1
6 5 4
EN-04768

Step
Check
Yes
(B135) No. 8 (E23) No. 3:
(B135) No. 9 (E23) No. 1:
CHECK POOR CONTACT.
Check poor contact of ECM and the front oxygen (A/F) sensor connector.
No
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
connector
Poor contact in
coupling connector
Replace the front
the front oxygen (A/F) sensor contact in ECM or oxygen (A/F) senconnector?
the front oxygen
sor. <Ref. to
(A/F) sensor con- FU(H4SO)-36,
nector.
Front Oxygen (A/F)
Sensor.>
EN(H4SO)(diag)-141

AF:DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)

GENERAL DESCRIPTION <Ref. to GD(H4SO)-66, DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE
CAUTION:
WIRING DIAGRAM:
B22
F34
SBF HOLDER
SBF-1
MAIN RELAY
15
14
6
4
F100
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
BATTERY
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
SBF-5
F2
5
3
E22
B61
1
3
B47
2
4
50
53
19
REAR OXYGEN SENSOR
E22
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
C: B136
E3
A/F & OXYGEN RELAY
F34
F44
2
1
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B22
4
5
5 6
14 15 16
25 26 27
33 34 35
D: B137
B4
A29
B1
C24
C4
B5
A: B134
C: B136
F44
B327
1 2 3 4
5 6 7 8
1 2 3
4
5
ECM
D: B137
A5
D1
D2
D3
D7
B: B135
36
34
35
37
52
B327
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
B47
1
3
5
2
4
6
F2
B22
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
E3
A: B134
E
E
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
EN-04091
EN(H4SO)(diag)-142

3
4
Step
CHECK REAR OXYGEN SENSOR DATA.

1) Warm-up the engine until engine coolant
temperature is above 70C (158F), and keep
the engine speed at 3,000 rpm. (Max. 2 minutes)
2) Read the data of rear oxygen sensor signal
using Subaru Select Monitor or general scan
tool.
NOTE:
General scan tool
CHECK REAR OXYGEN SENSOR CONNECTOR AND COUPLING CONNECTOR.
REAR OXYGEN SENSOR CONNECTOR.
rear oxygen sensor.
ECM and rear oxygen sensor connector.
(B135) No. 4 (E22) No. 3:
(B134) No. 29 (E22) No. 4:
CHECK HARNESS BETWEEN REAR OXYGEN SENSOR AND ECM CONNECTOR.
sensor harness connector and engine ground
or chassis ground.
Check
Yes
No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
(DTC).>
NOTE:
Is the voltage 490 mV or more? Go to step 6.
Go to step 3.
Does water enter the connec- Dry the water thor- Go to step 4.
tor?
oughly.
Is the resistance 3 or more? Repair the open
Go to step 5.
circuit of harness
between ECM and
rear oxygen sensor
connector.
EN(H4SO)(diag)-143
Replace the rear

oxygen sensor.
<Ref. to
FU(H4SO)-38,
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
Poor contact in
Poor contact in
ECM connector

Step
Check
Check exhaust system parts.
system?
NOTE:
Loose installation of portions
Damage (crack, hole etc.) of parts
Looseness and improper attachment of parts
between front oxygen (A/F) sensor and rear oxygen sensor
EN(H4SO)(diag)-144
Yes
Repair or replace
faulty parts.
No
Replace the rear
oxygen sensor.
<Ref. to
FU(H4SO)-38,

AG:DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)

GENERAL DESCRIPTION <Ref. to GD(H4SO)-69, DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE
CAUTION:
WIRING DIAGRAM:
B22
F34
SBF HOLDER
SBF-1
MAIN RELAY
15
14
6
4
F100
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
BATTERY
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
SBF-5
F2
5
3
E22
B61
1
3
B47
2
4
50
53
19
REAR OXYGEN SENSOR
E22
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
C: B136
E3
A/F & OXYGEN RELAY
F34
F44
2
1
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B22
4
5
5 6
14 15 16
25 26 27
33 34 35
D: B137
B4
A29
B1
C24
C4
B5
A: B134
C: B136
F44
B327
1 2 3 4
5 6 7 8
1 2 3
4
5
ECM
D: B137
A5
D1
D2
D3
D7
B: B135
36
34
35
37
52
B327
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
B47
1
3
5
2
4
6
F2
B22
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
E3
A: B134
E
E
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
EN-04091
EN(H4SO)(diag)-145

3
4
Step

temperature is above 70C (158F), and rapidly
reduce the engine speed from 3,000 rpm.
tool.
NOTE:
General scan tool
rear oxygen sensor.
(B135) No. 4 (E22) No. 3:
(B134) No. 29 (E22) No. 4:
or chassis ground.
Check
Yes
No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
(DTC).>
NOTE:
Is the voltage 250 mV or less? Go to step 6.
Go to step 3.
tor?
oughly.
Go to step 5.
circuit of harness
between ECM and
rear oxygen sensor
connector.
EN(H4SO)(diag)-146
Replace the rear

oxygen sensor.
<Ref. to
FU(H4SO)-38,
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
Poor contact in
Poor contact in
ECM connector

Step
Check
system?
NOTE:
Loose installation of portions
EN(H4SO)(diag)-147
Yes
Repair or replace
faulty parts.
No
Replace the rear
oxygen sensor.
<Ref. to
FU(H4SO)-38,

AH:DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2)

GENERAL DESCRIPTION <Ref. to GD(H4SO)-70, DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
B22
F34
SBF HOLDER
SBF-1
MAIN RELAY
15
14
6
4
F100
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
BATTERY
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
SBF-5
F2
5
3
E22
B61
1
3
B47
2
4
50
53
19
REAR OXYGEN SENSOR
E22
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
C: B136
E3
A/F & OXYGEN RELAY
F34
F44
2
1
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B22
4
5
5 6
14 15 16
25 26 27
33 34 35
D: B137
B4
A29
B1
C24
C4
B5
A: B134
C: B136
F44
B327
1 2 3 4
5 6 7 8
1 2 3
4
5
ECM
D: B137
A5
D1
D2
D3
D7
B: B135
36
34
35
37
52
B327
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
B47
1
3
5
2
4
6
F2
B22
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
E3
A: B134
E
E
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
EN-04091
EN(H4SO)(diag)-148

Step
Check
Yes
No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
(DTC).>
NOTE:
Repair the open
circuit of harness
between ECM and
rear oxygen sensor
connector.

rear oxygen sensor.
(B135) No. 4 (E22) No. 3:
more?
Measure the resistance between rear oxygen
sensor harness connector and chassis ground.
(E22) No. 3 Chassis ground:
sensor terminals.
Terminals
No. 3 No. 4:
EN(H4SO)(diag)-149
Go to step 4.
Repair the chassis

Replace the rear

oxygen sensor.
<Ref. to
FU(H4SO)-38,
Temporary poor
contact occurs.
Check the poor

AI: DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 2)

GENERAL DESCRIPTION <Ref. to GD(H4SO)-75, DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY
CAUTION:
WIRING DIAGRAM:
B22
F34
SBF-1
MAIN RELAY
15
14
6
4
F100
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
SBF HOLDER
BATTERY
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
SBF-5
F2
5
3
E22
B61
1
3
B47
2
4
50
53
19
REAR OXYGEN SENSOR
E22
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
C: B136
E3
A/F & OXYGEN RELAY
F34
F44
2
1
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B22
4
5
5 6
14 15 16
25 26 27
33 34 35
D: B137
B4
A29
B1
C24
C4
B5
A: B134
C: B136
F44
B327
1 2 3 4
5 6 7 8
1 2 3
4
5
ECM
D: B137
A5
D1
D2
D3
D7
B: B135
36
34
35
37
52
B327
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
B47
1
3
5
2
4
6
F2
B22
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
E3
A: B134
E
E
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
EN-04091
EN(H4SO)(diag)-150

4
5
Step

tool.
NOTE:
General scan tool
tool.
NOTE:
General scan tool
rear oxygen sensor.
(B135) No. 4 (E22) No. 3:
(B134) No. 29 (E22) No. 4:
Check
Yes
No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
(DTC).>
NOTE:
Go to step 3.
Go to step 4.
tor?
oughly.
Go to step 6.
circuit of harness
between ECM and
rear oxygen sensor
connector.
EN(H4SO)(diag)-151

Step
Check
CHECK HARNESS BETWEEN REAR OXY- Is the voltage 0.2 0.5 V?
GEN SENSOR AND ECM CONNECTOR.
Yes
Replace the rear
oxygen sensor.
<Ref. to
FU(H4SO)-38,

system?
NOTE:
Looseness and improper attachment of exhaust system parts
Repair or replace
faulty parts.
No
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
Poor contact in
Poor contact in
ECM connector
Replace the rear
oxygen sensor.
<Ref. to
FU(H4SO)-38,
AJ:DTC P0171 SYSTEM TOO LEAN (BANK 1)

Refer to DTC P0172 for diagnostic procedure. <Ref. to EN(H4SO)(diag)-153, DTC P0172 SYSTEM TOO
RICH (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(H4SO)(diag)-152

AK:DTC P0172 SYSTEM TOO RICH (BANK 1)

GENERAL DESCRIPTION <Ref. to GD(H4SO)-79, DTC P0172 SYSTEM TOO RICH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
1
2
Step
Check
Are there holes or loose bolts
on exhaust system?
intake system?
CHECK FUEL PRESSURE.
Is the measured value 339.5
360.5 kPa (3.5 3.7 kgf/cm2,
WARNING:
Place NO FIRE signs near the working 49 52 psi)?
area.
Measure the fuel pressure. <Ref. to ME(H4SO)29, INSPECTION, Fuel Pressure.>
WARNING:
Release fuel pressure before removing the
fuel pressure gauge.
Yes
No
Repair the exhaust Go to step 2.
system.
Repair the air
Go to step 3.
intake system.
Go to step 4.
CHECK ENGINE COOLANT TEMPERATURE Is the engine coolant tempera- Go to step 5.

SENSOR.
1) Start the engine and warm-up completely.
NOTE:
General scan tool
EN(H4SO)(diag)-153
Repair the following item.

Fuel pressure is
too high:
Clogged fuel line
or bent hose
Fuel pressure is
too low:
Improper fuel
pump discharge
Clogged fuel line
Replace the
engine coolant
FU(H4SO)-22,
Engine Coolant

Step
CHECK THE MASS AIR FLOW AND INTAKE
AIR TEMPERATURE SENSOR.
1) Start the engine and warm-up engine until
(140F).
2) Place the select lever in N or P position.
5) Read the data of mass air flow and intake air
temperature sensor signal using Subaru Select
Monitor.
NOTE:
CHECK MASS AIR FLOW AND INTAKE AIR
TEMPERATURE SENSOR.
(140F).
2) Place the shift lever in neutral position.
5) Open the front hood.
6) Measure the ambient temperature.
Monitor or general scan tool.
NOTE:
General scan tool
Check
3.4 g/s (0.28 0.45 lb/m)?
Yes
Go to step 6.
No
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(H4SO)-28,
Mass Air Flow and
Subtract the ambient temperature from intake air temperature. Is the obtained value 10
50C (18 90F)?
Replace the ECM.

<Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>
Check the mass air

flow and intake air
FU(H4SO)-28,
Mass Air Flow and
EN(H4SO)(diag)-154

AL:DTC P0181 FUEL TEMPERATURE SENSOR A CIRCUIT RANGE/PERFORMANCE

GENERAL DESCRIPTION <Ref. to GD(H4SO)-81, DTC P0181 FUEL TEMPERATURE SENSOR A
CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
FUEL TANK
FUEL TEMPERATURE
6
5
SENSOR
R58
5
3
R57
R15
7
2
R2
17
30
B98
B135 ECM
R57
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
R58
1 2 3
4 5 6
B135
B98
1 2
3 4 5
6 7 8 9 10 11 12
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
EN-03777
EN(H4SO)(diag)-155

Step
Check
EN(H4SO)(diag)-156
Yes
Check DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
(DTC).>
NOTE:
No
Replace the fuel
EC(H4SO)-9, Fuel

AM:DTC P0182 FUEL TEMPERATURE SENSOR A CIRCUIT LOW INPUT

CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
FUEL TANK
FUEL TEMPERATURE
6
5
SENSOR
R58
5
3
R57
R15
7
2
R2
17
30
B98
B135 ECM
R57
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
R58
1 2 3
4 5 6
B135
B98
1 2
3 4 5
6 7 8 9 10 11 12
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
EN-03777
EN(H4SO)(diag)-157

Step
CHECK CURRENT DATA.
2) Read the data of fuel temperature sensor
signal using Subaru Select Monitor or general
scan tool.
NOTE:
General scan tool
CHECK CURRENT DATA.
2) Remove the access hole lid.
scan tool.
NOTE:
General scan tool
Check
Is the fuel temperature above
150C (302F) ?
Yes
Go to step 2.
No
light illuminates,
the circuit has
this time.
Is the fuel temperature less

than 40C (40F) ?
Replace the fuel

EC(H4SO)-9, Fuel
Repair the ground

short circuit of the
harness between
fuel pump and
ECM connector.
EN(H4SO)(diag)-158

AN:DTC P0183 FUEL TEMPERATURE SENSOR A CIRCUIT HIGH INPUT

CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
FUEL TANK
FUEL TEMPERATURE
6
5
SENSOR
R58
5
3
R57
R15
7
2
R2
17
30
B98
B135 ECM
R57
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
R58
1 2 3
4 5 6
B135
B98
1 2
3 4 5
6 7 8 9 10 11 12
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
EN-03777
EN(H4SO)(diag)-159

Step
CHECK CURRENT DATA.
scan tool.
NOTE:
General scan tool
CHECK HARNESS BETWEEN FUEL TEMPERATURE SENSOR AND ECM CONNECTOR.
4) Measure the voltage between fuel pump
Measure the voltage between fuel pump connector and chassis ground.
Check
Is the fuel temperature less
than 40C (40F) ?
Yes
Go to step 2.
No
Repair the poor
contact.
NOTE:
the following item:
Poor contact in
fuel pump connector
Poor contact in
ECM connector
Poor contact in
coupling connector
Poor contact in
joint connector
ECM and fuel
pump connector.

ECM and fuel
pump connector.
Go to step 5.
EN(H4SO)(diag)-160
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and fuel
pump connector
Poor contact in
fuel pump connector
Poor contact in
ECM connector
Poor contact in
coupling connector

Step
Check
CHECK HARNESS BETWEEN FUEL TEMIs the resistance less than 1 ?
PERATURE SENSOR AND ECM CONNECTOR.
fuel pump connector and ECM.
(R58) No. 5 (B135) No. 30:
EN(H4SO)(diag)-161
Yes
Replace the fuel
EC(H4SO)-9, Fuel
No
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and fuel
pump connector
Poor contact in
fuel pump connector
Poor contact in
ECM connector
Poor contact in
coupling connector
Poor contact in
joint connector

AO:DTC P0196 ENGINE OIL TEMPERATURE SENSOR CIRCUIT RANGE/PERFORMANCE

GENERAL DESCRIPTION <Ref. to GD(H4SO)-88, DTC P0196 ENGINE OIL TEMPERATURE SENSOR
TROUBLE SYMPTOM:
Hard to start
Erroneous idling
CAUTION:
WIRING DIAGRAM:
E75
1 2
OIL
TEMPERATURE
SENSOR
B22
E75
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B134
6
19
23
29
E3
1 2
8 9 10
18 19 20
28 29 30
B22
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B134 ECM
EN-04769
EN(H4SO)(diag)-162

Step
Check
EN(H4SO)(diag)-163
Yes
Check DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
(DTC).>
NOTE:
No
Replace the
engine oil temperature sensor. <Ref.
to FU(H4SO)-35,
Oil Temperature
Sensor.>

AP:DTC P0197 ENGINE OIL TEMPERATURE SENSOR LOW

LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Hard to start
Erroneous idling
CAUTION:
WIRING DIAGRAM:
E75
1 2
OIL
TEMPERATURE
SENSOR
B22
E75
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B134
6
19
23
29
E3
1 2
8 9 10
18 19 20
28 29 30
B22
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B134 ECM
EN-04769
EN(H4SO)(diag)-164

Step
CHECK HARNESS BETWEEN ENGINE OIL
engine oil temperature sensor.
engine oil temperature sensor connector and
engine ground.
CHECK POOR CONTACT.
Check poor contact of engine oil temperature
sensor connector.
Check
more?
Yes
Go to step 2.
Is there poor contact in engine Repair the poor

oil temperature sensor connec- contact.
tor?
EN(H4SO)(diag)-165
No
Repair the ground
short circuit
between ECM and
engine oil temperature sensor connector.
Replace the
engine oil temperature sensor. <Ref.
to FU(H4SO)-35,
Oil Temperature
Sensor.>

AQ:DTC P0198 ENGINE OIL TEMPERATURE SENSOR HIGH

HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Hard to start
Erroneous idling
CAUTION:
WIRING DIAGRAM:
E75
1 2
OIL
TEMPERATURE
SENSOR
B22
E75
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B134
6
19
23
29
E3
1 2
8 9 10
18 19 20
28 29 30
B22
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B134 ECM
EN-04769
EN(H4SO)(diag)-166

Step
Check
CHECK HARNESS BETWEEN ENGINE OIL Is the voltage 10 V or more?
2) Disconnect the connector from the oil temperature sensor.
3) Measure the voltage between the engine oil
ground.
2) Measure the voltage between the engine oil
ground.
Measure the voltage between the engine oil
ground.
Yes
No
Repair battery
Go to step 2.
ECM and engine
oil temperature
connector.
Go to step 3.
Repair battery
ECM and engine
oil temperature
connector.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and engine
oil
temperature
connector
Poor contact in
engine oil temperature sensor connector
Poor contact in
ECM connector
Poor contact in
coupling connector
CHECK HARNESS BETWEEN ENGINE OIL Is the resistance less than 5 ? Replace the
Repair the harness
TEMPERATURE SENSOR AND ECM CONengine oil tempera- and connector.
NECTOR.
ture sensor. <Ref. NOTE:
to FU(H4SO)-35, In this case, repair
Oil Temperature
the following item:
engine oil temperature sensor connector and
Sensor.>
Open circuit in
engine ground.
harness between
ECM and engine
oil
temperature
connector
Poor contact in
engine oil temperature sensor connector
Poor contact in
ECM connector
Poor contact in
coupling connector
Poor contact in
joint connector
EN(H4SO)(diag)-167
Go to step 4.

AR:DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT

LOW
GENERAL DESCRIPTION <Ref. to GD(H4SO)-92, DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
B309
1 2
3 4
E57
BATTERY
ELECTRONIC THROTTLE
CONTROL RELAY
SBF-5
B309
1 2 3 4 5 6
2
1
3
4
B122
1 2 3 4
5 6 7 8
C21
C1
MAIN RELAY
D: B137
ECM
D: B137
E
C6
A18
A28
A29
D4
D5
A19
C15
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
30 31
26 27
28 29
MT
D7
A5
D1
D2
D3
A: B134
A: B134
B122
3
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
17
18
19
20
39
38
52
36
34
35
37
B22
1 2
8 9 10
18 19 20
28 29 30
E3
C: B136
5 6
14 15 16
25 26 27
33 34 35
E57
1
2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B22
ELECTRONIC THROTTLE
E
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
CONTROL
34
42
MT
: MT MODEL
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-03774
EN(H4SO)(diag)-168

Step
Check
2) Read the data of sub throttle sensor signal
CHECK POOR CONTACT.
Is there poor contact?
throttle control.
(B134) No. 28 (E57) No. 4:
CHECK SENSOR POWER SUPPLY.
Yes
Go to step 2.
No
Go to step 3.
Repair the poor

contact.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
more?
Go to step 5.
Repair the chassis

Go to step 6.

trol connector.
Replace the electronic throttle control if defective.
EN(H4SO)(diag)-169

AS:DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT

HIGH
GENERAL DESCRIPTION <Ref. to GD(H4SO)-93, DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
B309
1 2
3 4
E57
BATTERY
ELECTRONIC THROTTLE
CONTROL RELAY
SBF-5
B309
1 2 3 4 5 6
2
1
3
4
B122
1 2 3 4
5 6 7 8
C21
C1
MAIN RELAY
D: B137
ECM
D: B137
E
C6
A18
A28
A29
D4
D5
A19
C15
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
30 31
26 27
28 29
MT
D7
A5
D1
D2
D3
A: B134
A: B134
B122
3
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
17
18
19
20
39
38
52
36
34
35
37
B22
1 2
8 9 10
18 19 20
28 29 30
E3
C: B136
5 6
14 15 16
25 26 27
33 34 35
E57
1
2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B22
ELECTRONIC THROTTLE
E
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
CONTROL
34
42
MT
: MT MODEL
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-03774
EN(H4SO)(diag)-170

Step
CHECK POOR CONTACT.
throttle control.
(B134) No. 28 (E57) No. 4:
Check
Yes
No
Go to step 3.

Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
Go to step 6.
Repair the battery

ECM connector
and electronic
throttle control
connector.
Go to step 7.
Repair the battery

ECM connector
and electronic
throttle control
connector.
Sensor power supply circuit may be
shorted.
more?
terminals.
(B134) No. 28 (B134) No. 19:
EN(H4SO)(diag)-171
Repair the poor

contact. Replace
the electronic
throttle control.

AT:DTC P0301 CYLINDER 1 MISFIRE DETECTED

NOTE:
For the diagnostic procedure, refer to DTC P0304. <Ref. to EN(H4SO)(diag)-173, DTC P0304 CYLINDER 4
MISFIRE DETECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AU:DTC P0302 CYLINDER 2 MISFIRE DETECTED

NOTE:
AV:DTC P0303 CYLINDER 3 MISFIRE DETECTED

NOTE:
EN(H4SO)(diag)-172

AW:DTC P0304 CYLINDER 4 MISFIRE DETECTED

Immediately at fault recognition (A misfire which could damage catalyst occurs.)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-99, DTC P0304 CYLINDER 4 MISFIRE DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
Erroneous idling
Rough driving
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
BATTERY
SBF-5
14
5
3
F2
B100
2
1
B47
11
10
B22
45
44
9
43
42
48
B137 ECM
E3
E17
E6
E16
E5
E
FUEL INJECTOR
No. 1
E5
E16
E6
E17
1 2
FUEL INJECTOR
No. 2
B47
1
3
5
2
4
6
FUEL INJECTOR
No. 3
FUEL INJECTOR
No. 4
B22
F2
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
B137
35
43
48
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-03778
EN(H4SO)(diag)-173

Step
Check

2) Measure the voltage between ECM connector and chassis ground on faulty cylinders.
#1 (B137) No. 8 (+) Chassis ground ():
#3 (B137) No. 10 (+) Chassis ground (
):
):
CHECK HARNESS BETWEEN FUEL INJECTOR AND ECM CONNECTOR.
2) Disconnect the connector from fuel injector
on faulty cylinders.
3) Measure the resistance between ECM connector and engine ground on faulty cylinders.
#1 (E5) No. 1 Engine ground:
Measure the resistance of harness connector
between ECM connector and fuel injector on
faulty cylinders.
#1 (B137) No. 8 (E5) No. 1:
#2 (B137) No. 9 (E16) No. 1:
#3 (B137) No. 10 (E6) No. 1:
#4 (B137) No. 11 (E17) No. 1:
CHECK FUEL INJECTOR.

Measure the resistance between fuel injector
terminals on faulty cylinder.
Terminals
No. 1 No. 2:
more?
Yes
No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
(DTC).>
NOTE:
necessary to inspect DTC P0301,
P0302, P0303 and
P0304.
Go to step 7.
Go to step 3.
Go to step 4.
Repair the ground

short circuit of harness between fuel
injector and ECM
connector.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
Poor contact in
coupling connector
Replace the faulty
fuel injector. <Ref.
to FU(H4SO)-30,
Fuel Injector.>

20 ?
EN(H4SO)(diag)-174

10
11
Step
CHECK POWER SUPPLY LINE.
2) Measure the voltage between fuel injector
and engine ground on faulty cylinders.
Check
CHECK HARNESS BETWEEN FUEL INJEC- Is the voltage 10 V or more?

TOR AND ECM CONNECTOR.
):
):
2) Measure the resistance between fuel injector terminals on faulty cylinder.
Terminals
No. 1 No. 2:
Yes
Repair the poor
contact of all connectors in fuel
injector circuit.
No
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
main relay and fuel
injector connector
on faulty cylinders
Poor contact in
coupling connector
Poor contact in
Poor contact in
fuel injector connector on faulty
cylinders
ECM and fuel
injector. After
repair, replace the
ECM. <Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>
Replace the faulty

fuel injector <Ref.
to FU(H4SO)-30,
Fuel Injector.> and
ECM. <Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>
CHECK INSTALLATION OF CAMSHAFT PO- Is the camshaft position sensor Tighten the camSITION SENSOR/CRANKSHAFT POSITION or crankshaft position sensor shaft position senSENSOR.
loosely installed?
sor or crankshaft
position sensor.
CHECK CRANK SPROCKET.
Is the crank sprocket rusted or Replace the crank
Remove the timing belt cover.
does it have broken teeth?
sprocket. <Ref. to
ME(H4SO)-50,
Crank Sprocket.>
Is the timing belt dislocated
Repair the installaCHECK INSTALLATION CONDITION OF
from its proper position?
tion condition of
TIMING BELT.
timing belt. <Ref. to
Turn the crankshaft using ST, and align the
ME(H4SO)-44,
alignment mark on crank sprocket with alignTiming Belt.>
ment mark on cylinder block.
ST 499987500
CRANKSHAFT
SOCKET
EN(H4SO)(diag)-175
Go to step 9.
Go to step 10.
Go to step 11.
Go to step 12.

12
13
14
Step
CHECK FUEL LEVEL.
Check
Is the fuel meter indication
higher than the Lower level?
CHECK STATUS OF MALFUNCTION INDIDoes the malfunction indicator

CATOR LIGHT.
light illuminate or blink?
1) Clear the memory using Subaru Select
Monitor. <Ref. to EN(H4SO)(diag)-44, Clear
Memory Mode.>
2) Start the engine, and drive the vehicle more
than 10 minutes.
CHECK CAUSE OF MISFIRE.
Was the cause of misfire identified when the engine is running? Ex. Disconnection of
spark plug cord.
Yes
Go to step 13.
Go to step 15.
Finish diagnostics
operation, if the
engine has no
abnormality.
15
16
CHECK MISFIRE SYMPTOM.

2) Read the DTC.
NOTE:
General scan tool
CHECK DTC ON DISPLAY.
Are DTC P0301 and P0302 dis- Go to step 22.
played?
17
Is there any fault in air intake

system?
No
Replenish the fuel
so that fuel meter
indication is higher
than the Lower
level. After filling
fuel, Go to step 13.
Go to step 14.
Repair the poor

contact of the connector.
NOTE:
the following items.
Poor contact of
the ignition coil
connector
Poor contact of
the fuel injector
connector of the
faulty cylinder
Poor contact of
ECM connector
Poor contact of
the coupling connector
Go to step 16.
Repair the air

intake system.
NOTE:
Are there air
leaks or air suction
caused by loose or
dislocated
nuts
and bolts?
Are there cracks
or any disconnection of hoses?
Does the Subaru Select Moni- Go to step 21.
Go to step 17.
tor or general scan tool display
only one DTC?
EN(H4SO)(diag)-176
Go to step 18.

18
Step
Check
Are DTC P0303 and P0304 displayed?
Is there any fault in the cylinder?
19
20
21
ONLY ONE CYLINDER.
22
GROUP OF #1 AND #2 CYLINDERS.
Are there any faults in #1 and

#2 cylinders?
23

#4 cylinders?
EN(H4SO)(diag)-177
Yes
Go to step 23.
No
Go to step 19.
Go to step 24.
Go to step 20.
Go to step 25.
Go to step 26.
Repair or replace
faulty parts.
NOTE:
Spark plug
Spark plug cord
Fuel injector
Compression ratio
Repair or replace
faulty parts.
NOTE:
Spark plug
Fuel injector
Ignition coil
Compression
ratio
If any fault are
not found, check
the
IGNITION
CONTROL SYSTEM of #1 and #2
cylinders
side.
<Ref.
to
EN(H4SO)(diag)59,
IGNITION
for Engine Starting
Failure.>
Repair or replace
faulty parts.
NOTE:
Spark plug
Fuel injector
Ignition coil
If any fault are
not found, check
the
IGNITION
CONTROL SYSTEM of #3 and #4
cylinders
side.
<Ref.
to
EN(H4SO)(diag)59,
IGNITION
for Engine Starting
Failure.>
Go to DTC P0171.
<Ref. to
EN(H4SO)(diag)152, DTC P0171
SYSTEM TOO
LEAN (BANK 1),
Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
Go to DTC P0171.
<Ref. to
SYSTEM TOO
LEAN (BANK 1),
(DTC).>
Go to DTC P0171.
<Ref. to
SYSTEM TOO
LEAN (BANK 1),
(DTC).>

24
Step
Check
#3 cylinders?
25

#4 cylinders?
26
CYLINDER AT RANDOM.
Is the engine idle rough?
EN(H4SO)(diag)-178
Yes
Repair or replace
faulty parts.
NOTE:
Spark plug
Fuel injector
Skipping timing
belt teeth
No
Go to DTC P0171.
<Ref. to
SYSTEM TOO
LEAN (BANK 1),
(DTC).>
Repair or replace Go to DTC P0171.
faulty parts.
<Ref. to
EN(H4SO)(diag)NOTE:
Check the follow- 152, DTC P0171
SYSTEM TOO
ing items.
LEAN (BANK 1),
Spark plug
Diagnostic Proce Fuel injector
Compression ra- dure with Diagnostic Trouble Code
tio
Skipping timing (DTC).>
belt teeth
Go to DTC P0171. Repair or replace
<Ref. to
faulty parts.
EN(H4SO)(diag)- NOTE:
152, DTC P0171 Check the followSYSTEM TOO
ing items.
LEAN (BANK 1), Spark plug
Diagnostic Proce- Fuel injector
dure with Diagnos- Compression ratic Trouble Code
tio
(DTC).>

AX:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR)

GENERAL DESCRIPTION <Ref. to GD(H4SO)-100, DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW
(BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Knocking occurs.
CAUTION:
WIRING DIAGRAM:
KNOCK
SENSOR
E14
1 2
E14
B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
16
E3
B22
24
15
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B134 ECM
E
EN-04770
EN(H4SO)(diag)-179

Step
Check
CHECK HARNESS BETWEEN KNOCK SEN- Is the resistance 700 k or
SOR AND ECM CONNECTOR.
more?
3) Measure the resistance between ECM harness connector and chassis ground.
No
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
knock sensor and
ECM connector
Poor contact in
knock sensor connector
Poor contact in
coupling connector
CHECK KNOCK SENSOR.
Is the resistance 700 k or
Go to step 3.
Repair the harness
1) Disconnect the connector from knock sen- more?
and connector.
sor.
NOTE:
2) Measure the resistance between knock
sensor connector terminal and engine ground.
the following item:
Terminals
Poor contact in
No. 1 Engine ground:
CHECK INSTALLATION CONDITION OF
Is the knock sensor installation Replace the knock Tighten the knock
KNOCK SENSOR.
bolt tightened securely?
sensor. <Ref. to
sensor installation
FU(H4SO)-25,
bolt securely.
Knock Sensor.>
EN(H4SO)(diag)-180
Yes
Go to step 2.

AY:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR)

GENERAL DESCRIPTION <Ref. to GD(H4SO)-102, DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH
TROUBLE SYMPTOM:
Knocking occurs.
CAUTION:
WIRING DIAGRAM:
KNOCK
SENSOR
E14
1 2
E14
B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
16
E3
B22
24
15
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B134 ECM
E
EN-04770
EN(H4SO)(diag)-181

Step
CHECK HARNESS BETWEEN KNOCK SENSOR AND ECM CONNECTOR.
CHECK KNOCK SENSOR.
1) Disconnect the connector from knock sensor.
Terminals
Check
Yes
Is the resistance less than 400 Go to step 2.
k?
No
Go to step 3.
Is the resistance less than 400 Replace the knock

k?
sensor. <Ref. to
FU(H4SO)-25,
Knock Sensor.>
Repair the ground

knock sensor connector and ECM
connector.
NOTE:
The harness between both connectors are shielded.
Remove the shield
and repair the

1) Connect the connectors to ECM and knock
sensor.
3) Measure the voltage between ECM and
chassis ground.
EN(H4SO)(diag)-182

light illuminates,
the circuit has
this time. (However, the possibility
of poor contact still
remains.)
NOTE:
the following item:
Poor contact in
Poor contact in
ECM connector
Poor contact in
coupling connector

AZ:DTC P0335 CRANKSHAFT POSITION SENSOR A CIRCUIT

GENERAL DESCRIPTION <Ref. to GD(H4SO)-104, DTC P0335 CRANKSHAFT POSITION SENSOR A
CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
Failure of engine to start
CAUTION:
WIRING DIAGRAM:
CRANKSHAFT
POSITION
SENSOR
E10
2
1
1 2
E10
B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B22
E3
15
14
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
B22
14
13
24
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B134 ECM
E
EN-03780
EN(H4SO)(diag)-183

Step
Check
CHECK HARNESS BETWEEN CRANKIs the resistance 100 k or
SHAFT POSITION SENSOR AND ECM CON- more?
NECTOR.
2) Disconnect the connector from crankshaft
position sensor.
crankshaft position sensor connector and
engine ground.
CHECK HARNESS BETWEEN CRANKSHAFT POSITION SENSOR AND ECM CONNECTOR.

engine ground.

engine ground.
CHECK CONDITION OF CRANKSHAFT POSITION SENSOR.
CHECK CRANKSHAFT POSITION SENSOR.

terminals of crankshaft position sensor.
Terminals
No. 1 No. 2:
Yes
No
Repair the harness Go to step 2.
and connector.
NOTE:
the following item:
Open circuit in
harness between
crankshaft
position sensor and
ECM connector
Poor contact in
ECM connector
Poor contact in
coupling connector
Is the resistance less than 10 Repair the ground Go to step 3.
?
crankshaft position sensor and
ECM connector.
NOTE:
The harness between both connectors
are
shielded. Repair
the ground short
circuit of harness
with shield.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
crankshaft
position sensor and
ECM connector
Poor contact in
ECM connector
Poor contact in
coupling connector
Is the crankshaft position sen- Go to step 5.
Tighten the cranksor installation bolt tightened
shaft position sensecurely?
sor installation bolt
securely.
Replace the crankIs the resistance between 1 and Repair the poor
contact of crankshaft position sen4 k?
shaft position sensor. <Ref. to
sor connector.
FU(H4SO)-23,
Crankshaft Position Sensor.>
EN(H4SO)(diag)-184

BA:DTC P0336 CRANKSHAFT POSITION SENSOR A CIRCUIT RANGE/PERFORMANCE

GENERAL DESCRIPTION <Ref. to GD(H4SO)-106, DTC P0336 CRANKSHAFT POSITION SENSOR A
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
CRANKSHAFT
POSITION
SENSOR
E10
2
1
1 2
E10
B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B22
E3
15
14
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
B22
14
13
24
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B134 ECM
E
EN-03780
EN(H4SO)(diag)-185

Step
Check
CHECK CONDITION OF CRANKSHAFT PO- Is the crankshaft position senSITION SENSOR.

sor installation bolt tightened
Turn the ignition switch to OFF.
securely?

Are crank sprocket teeth

cracked or damaged?

TIMING BELT.
alignment mark on crank sprocket with alignment mark on cylinder block.
ST 499987500
CRANKSHAFT
SOCKET

EN(H4SO)(diag)-186
Yes
No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
(DTC).>
Go to step 3.
Tighten the crankshaft position sensor installation bolt
securely.
Replace the crank Go to step 4.
sprocket. <Ref. to
ME(H4SO)-50,
Crank Sprocket.>
Repair the installa- Replace the cranktion condition of
shaft position sentiming belt. <Ref. to sor. <Ref. to
ME(H4SO)-44,
FU(H4SO)-23,
Crankshaft PosiTiming Belt.>
tion Sensor.>

BB:DTC P0340 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 1 OR SINGLE SENSOR)

GENERAL DESCRIPTION <Ref. to GD(H4SO)-108, DTC P0340 CAMSHAFT POSITION SENSOR A
CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
CAMSHAFT
POSITION
SENSOR
E15
2
1
1 2
E15
B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
13
12
E3
B22
22
12
24
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B134 ECM
E
EN-03781
EN(H4SO)(diag)-187

Step
Check
CHECK HARNESS BETWEEN CAMSHAFT Is the resistance 100 k or
POSITION SENSOR AND ECM CONNECmore?
TOR.
2) Disconnect the connector from camshaft
position sensor.
camshaft position sensor connector and engine
ground.
Yes
No
and connector.
NOTE:
the following item:
Open circuit in
harness between
camshaft position
sensor and ECM
connector
Poor contact in
ECM connector
Poor contact in
coupling connector
CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than 10 Repair the ground Go to step 3.
POSITION SENSOR AND ECM CONNEC?
short circuit of harTOR.
ness between
camshaft position
sensor and ECM
ground.
connector.
NOTE:
are
shielded. Repair
the ground short
circuit of harness
with shield.
CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than 5 ? Go to step 4.
Repair the harness
and connector.
POSITION SENSOR AND ECM CONNECTOR.
NOTE:
the following item:
ground.
Open circuit in
harness between
camshaft position
sensor and ECM
connector
Poor contact in
ECM connector
Poor contact in
coupling connector
CHECK CONDITION OF CAMSHAFT POSI- Is the camshaft position sensor Go to step 5.
Tighten the camTION SENSOR.
installation bolt tightened
securely.
Replace the camCHECK CAMSHAFT POSITION SENSOR.
contact of camshaft position sen1) Remove the camshaft position sensor.
4 k?
sor connector.
FU(H4SO)-24,
terminals of camshaft position sensor.
Camshaft Position
Terminals
Sensor.>
No. 1 No. 2:
EN(H4SO)(diag)-188

BC:DTC P0341 CAMSHAFT POSITION SENSOR A CIRCUIT RANGE/PERFORMANCE (BANK 1 OR SINGLE SENSOR)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-110, DTC P0341 CAMSHAFT POSITION SENSOR A
CIRCUIT RANGE/PERFORMANCE (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
CAMSHAFT
POSITION
SENSOR
E15
2
1
1 2
E15
B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
13
12
E3
B22
22
12
24
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B134 ECM
E
EN-03781
EN(H4SO)(diag)-189

Step
Yes
Check DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
(DTC).>
CHECK HARNESS BETWEEN CAMSHAFT Is the resistance 100 k or
Repair the harness
POSITION SENSOR AND ECM CONNECmore?
and connector.
TOR.
NOTE:
the following item:
position sensor.
Open circuit in
harness between
camshaft position
ground.
sensor and ECM
connector
Poor contact in
ECM connector
Poor contact in
coupling connector
CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than 10 Repair the ground
POSITION SENSOR AND ECM CONNEC?
short circuit of harTOR.
ness between
camshaft position
sensor and ECM
ground.
connector.
NOTE:
are
shielded. Repair
the ground short
circuit of harness
with shield.
CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than 5 ? Go to step 5.
POSITION SENSOR AND ECM CONNECTOR.
ground.
CHECK CONDITION OF CAMSHAFT POSITION SENSOR.
Check
Is the camshaft position sensor Go to step 6.

securely?
EN(H4SO)(diag)-190
No
Go to step 2.
Go to step 3.
Go to step 4.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
camshaft position
sensor and ECM
connector
Poor contact in
ECM connector
Poor contact in
coupling connector
Tighten the camshaft position sensor installation bolt
securely.

Step
CHECK CAMSHAFT POSITION SENSOR.
1) Remove the camshaft position sensor.
terminals of camshaft position sensor.
Terminals
No. 1 No. 2:
Check
Yes
4 k?
CHECK CAM SPROCKET.

Remove the timing belt cover. <Ref. to
ME(H4SO)-43, Timing Belt Cover.>

TIMING BELT.
Turn the crankshaft using ST, and align alignment mark on cam sprocket with alignment
mark on timing belt cover LH.
ST 499987500
CRANKSHAFT
SOCKET
Are cam sprocket teeth cracked Replace the cam

or damaged?
sprocket. <Ref. to
ME(H4SO)-49,
Cam Sprocket.>
Repair the installafrom its proper position?
tion condition of
ME(H4SO)-44,
Timing Belt.>

securely?
EN(H4SO)(diag)-191
No
Replace the camshaft position sensor. <Ref. to
FU(H4SO)-24,
Camshaft Position
Sensor.>
securely.
Go to step 9.

FU(H4SO)-24,
Camshaft Position
Sensor.>

BD:DTC P0400 EXHAUST GAS RECIRCULATION FLOW

GENERAL DESCRIPTION <Ref. to GD(H4SO)-112, DTC P0400 EXHAUST GAS RECIRCULATION
FLOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Movement performance problem when engine is low speed.
Erroneous idling
Movement performance problem
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
E18
6
4
BATTERY
1 2 3
4 5 6
SBF-5
7
5
3
B61
2
1
B47
F44
1
3
5
48
B22
B47
2
4
6
E3
F44
1 2 3 4
5 6 7 8
5
2
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
EGR VALVE
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
1
3
4
6
E18
B134
1 2
8 9 10
18 19 20
28 29 30
26
25
29
30
E3
9
8
10
20
B22
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B134 ECM
EN-03782
EN(H4SO)(diag)-192

Step
Check
CHECK CURRENT DATA.

2) Read data of intake manifold absolute pressure signal using Subaru Select Monitor or general scan tool.
NOTE:
General scan tool
CHECK POWER SUPPLY OF EGR SOLENOID VALVE.
1) Disconnect the connector from EGR solenoid valve.
3) Measure the voltage between EGR solenoid valve and engine ground.
CHECK EGR SOLENOID VALVE.
Measure the resistance between EGR solenoid
valve terminals.
NOTE:
Make sure there is no foreign material between
EGR solenoid valve and valve seat.
Terminals
No. 1 No. 2:
No. 3 No. 2:
No. 4 No. 5:
No. 6 No. 5:
OUTPUT SIGNAL FROM ECM.
2) Connect the connector to ECM and EGR
solenoid valve.
chassis ground.

than 53.3 kPa (400 mmHg,
15.75 inHg)?
Yes
No
Check the appro- Go to step 2.
priate DTC using
Code (DTC).
<Ref. to
(DTC).>
Make sure that the Go to step 3.
EGR valve, manifold absolute pressure sensor and
throttle body are
installed securely.
Go to step 4.
Repair the open

circuit of harness
between main
relay and EGR
solenoid valve connector.

and 30 ?
Go to step 5.
Replace the EGR

solenoid valve.
<Ref. to
FU(H4SO)-29,
EGR Valve.>
Is the voltage 0 10 V?
Repair the poor

contact portion of
ECM connector.
Go to step 6.
EN(H4SO)(diag)-193

Step
CHECK HARNESS BETWEEN EGR SOLENOID VALVE AND ECM CONNECTOR.
2) Disconnect the connector from EGR solenoid valve and ECM.
EGR solenoid valve and ECM connector.
(B134) No. 10 (E18) No. 4:
(B134) No. 9 (E18) No. 1:
(B134) No. 8 (E18) No. 3:
(B134) No. 20 (E18) No. 6:
CHECK HARNESS BETWEEN EGR SOLENOID VALVE AND ECM CONNECTOR.
EGR solenoid valve and chassis ground.
CHECK POOR CONTACT.
Check poor contact of ECM and EGR solenoid
valve connectors.
Check
Yes
No
Repair the open
circuit of harness
between ECM and
EGR solenoid
valve connector.
more?
Go to step 8.
Repair the short

circuit of harness
between main
relay and EGR

and EGR solenoid valve connectors?
Repair the poor

contact of ECM
and EGR solenoid
valve connectors.

light illuminates,
the circuit has
returned to the
specified condition
at this time.
EN(H4SO)(diag)-194

BE:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK

1)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-116, DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
Idle mixture is out of specifications.
CAUTION:
WIRING DIAGRAM:
F34
SBF HOLDER
MAIN RELAY
SBF-1
4
15
2
BATTERY
6
4
SBF-5
14
5
3
F100
F2
2
1
7
B61
E22
E23
1
3
FRONT
OXYGEN
(A/F) SENSOR
4
1
A/F & OXYGEN

RELAY
REAR
OXYGEN
SENSOR
B22
50
E3
F44
B47
4
E3
1
E3
3
4
B122
B22
51
19
53
B22
2
5
1
B : B135
A : B134
B122
B327
1 2 3 4
5 6 7 8
1 2 3
4
5
F34
2
A: B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B22
1
3
2
4
E23
B47
1
3
5
3 2 1
6 5 4
B: B135
2
4
6
C : B136
B9
B8
C2
C3
B1
B5
B4
A29
C4
C24
B327
ECM
F44
1 2 3 4
5 6 7 8
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
F2
1 2 3 4
10 11 12 13 14
B22
5 6 7 8 9
15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
C: B136
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
5 6
14 15 16
25 26 27
33 34 35
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04771
EN(H4SO)(diag)-195

Step
Check for gas leaks or air suction caused by
loose or dislocated nuts and bolts, and open
hole at exhaust pipes.
NOTE:
Check the following positions.
Between cylinder head and front exhaust
pipe
Between front exhaust pipe and front catalytic
converter
Between front catalytic converter and rear
catalytic converter
Looseness and improper attachment of front
oxygen (A/F) sensor or rear oxygen sensor
CHECK WAVEFORM DATA ON SUBARU
SELECT MONITOR (WHILE DRIVING).
1) Drive the vehicle at a constant speed of 80
112 km/h (50 70 MPH).
2) Keep the condition of step 1) for 5 minutes,
then read the waveform data in a driving condition using Subaru Select Monitor.
Check
system?
Yes
Repair or replace
the exhaust system. <Ref. to EX
(H4SO)-2, General Description.>
Are normal waveform pattern

displayed?

function indicator
light illuminates,
the circuit has
this time. Reproduce the fault and
perform the diagnosis again.
NOTE:
In this case, the
probable cause is
considered as the
temporarily poor
contact of connectors.
RrO2 SENSOR
A/F LAMBDA 1
RrO2 SENSOR
A/F LAMBDA 1
EN-04895
EN(H4SO)(diag)-196
No
Go to step 2.

Step
SELECT MONITOR (WHILE IDLING).
1) Idle the engine.
2) Under the condition of step 1), read the
waveform data using Subaru Select Monitor.
Check
Are normal waveform pattern
displayed?
Yes
Go to step 4.
No
Go to step 5.
RrO2 SENSOR
RrO2 SENSOR
EN-04896
5
6
Is the catalytic converter dam- Replace the cata- Go to step 5.

aged?
lytic converter.
<Ref. to
EC(H4SO)-3,
Front Catalytic
Converter.>
CHECK REAR OXYGEN SENSOR CONNEC- Does water enter the connec- Dry the water thor- Go to step 6.
TOR AND COUPLING CONNECTOR.
tor?
oughly.
Repair the open
circuit of harness
between ECM and
rear oxygen sensor
rear oxygen sensor.
connector.
(B135) No. 4 (E22) No. 3:
(B135) No. 29 (E22) No. 4:
CHECK CATALYTIC CONVERTER.
EN(H4SO)(diag)-197

Step
2) Measure the resistance between rear oxygen sensor connector and chassis ground.
Check
CHECK REAR OXYGEN SENSOR SHIELD. Is the resistance less than 1 ?

2) Bare the harness sensor shield on the body
side of rear oxygen sensor connector.
3) Measure the resistance between sensor
shield and chassis ground.
EN(H4SO)(diag)-198
Yes
Go to step 8.
Replace the rear

oxygen sensor.
<Ref. to
FU(H4SO)-38,
No
Repair the harness
and connector.
NOTE:
Repair the following points.
Open circuit in
harness between
Poor contact in
Poor contact in
ECM connector
Repair the open
circuit in rear oxygen sensor harness.

BF:DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-119, DTC P0442 EVAPORATIVE EMISSION CONTROL
SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Fuel odor
There is a hole of more than 1.0 mm (0.04 in) dia. in evaporation system or fuel tank.
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
B61
BATTERY
F44
SBF-5
5
3
C24
2
1
C28
R2
ECM
D29
D: B137
B98
48
B98
10
C17
C: B136
41
B47
R2
B22
E3
10
R15
R57
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B47
1
3
5
2
4
6
E4
1
PRESSURE CONTROL
SOLENOID VALVE
DRAIN VALVE
B22
R68
R69
PURGE CONTROL
SOLENOID VALVE
R68
B98
F44
R57
R69
3 4 5
1 2
6 7 8 9 10 11 12
1 2 3 4
5 6 7 8
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
E4
1 2
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
D: B137
5 6
14 15 16
25 26 27
33 34 35
EN(H4SO)(diag)-199
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
EN-04772

Step
CHECK FUEL FILLER CAP.

Is the fuel filler cap tightened
securely?
2) Check the fuel filler cap.
NOTE:
The DTC is stored in memory if fuel filler cap is
or was loose or if the cap chain was caught
while tightening.
Is the fuel filler cap SUBARU
genuine?
CHECK FUEL FILLER PIPE PACKING.
CHECK DRAIN VALVE.

3) Operate the drain valve.
NOTE:
Drain valve operation can be executed using
Subaru Select Monitor. For procedure, refer to
Compulsory Valve Operation Check Mode.
<Ref. to EN(H4SO)(diag)-45, Compulsory
Valve Operation Check Mode.>
CHECK PURGE CONTROL SOLENOID
VALVE.
Operate the purge control solenoid valve.
NOTE:
Purge control solenoid valve operation can be
executed using Subaru Select Monitor. For procedure, refer to Compulsory Valve Operation
Check Mode. <Ref. to EN(H4SO)(diag)-45,
Compulsory Valve Operation Check Mode.>
CHECK PRESSURE CONTROL SOLENOID
VALVE.
Operate the pressure control solenoid valve.
NOTE:
The pressure control solenoid valve operation
can be executed using the Subaru Select Monitor. For procedure, refer to Compulsory Valve
Operation
Check
Mode.
<Ref.
to
Check
Yes
No
priate DTC using
Code (DTC).
<Ref. to
(DTC).>
Go to step 3.
Securely install the
fuel filler cap.
Go to step 4.
Replace with a
genuine fuel filler
cap.
Go to step 5.
Is there any damage to the seal Repair or replace

between fuel filler cap and fuel the fuel filler cap
filler pipe?
and fuel filler pipe.
<Ref. to
FU(H4SO)-48,
Fuel Filler Pipe.>
Does the drain valve operate? Go to step 6.
Replace the drain
valve. <Ref. to
EC(H4SO)-17,
Drain Valve.>
Does the purge control solenoid valve operate?
Go to step 7.
Replace the purge

control solenoid
valve. <Ref. to
EC(H4SO)-7,
Purge Control
Solenoid Valve.>
Does the pressure control sole- Go to step 8.

noid valve operate?
Replace the pressure control solenoid valve. <Ref. to

EC(H4SO)-12,
Pressure Control
Solenoid Valve.>
EN(H4SO)(diag)-200

Step
CHECK EVAPORATIVE EMISSION CONTROL SYSTEM LINE.
CHECK CANISTER.
10
CHECK FUEL TANK.

Remove the fuel tank. <Ref. to FU(H4SO)-45,
Fuel Tank.>
11
CHECK ANY OTHER MECHANICAL TROUBLE IN EVAPORATIVE EMISSION CONTROL SYSTEM.
Check
Yes
Is there a hole of more than 1.0 Repair or replace
mm (0.04 in) dia. in evaporation the evaporation
line?
line. <Ref. to
FU(H4SO)-59,
Fuel Delivery,
Return and Evaporation Lines.>
Is the canister damaged or is Repair or replace
there a hole of more than 1.0
the canister. <Ref.
mm (0.04 in) dia. in it?
to EC(H4SO)-6,
Canister.>
Is the fuel tank damaged or is Repair or replace
the fuel tank. <Ref.
to FU(H4SO)-45,
Fuel Tank.>
Are there holes of more than
Repair or replace
1.0 mm (0.04 in) dia., cracks, the hoses or pipes.
clogging, disconnections or
bend of hoses or pipes in evaporative emission control system?
EN(H4SO)(diag)-201
No
Go to step 9.
Go to step 10.
Go to step 11.

BG:DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL

CIRCUIT OPEN
SYSTEM VENT CONTROL CIRCUIT OPEN, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
BATTERY
SBF-5
5
3
7
B61
F44
2
1
B98
1
2
10
6
1
R2
B47
R15
R57
R69
DRAIN
VALVE
CANISTER
R2
17
B98
B136 ECM
R69
1 2
B47
1
3
5
2
4
6
F44
1 2 3 4
5 6 7 8
R57
B98
1 2
3 4 5
6 7 8 9 10 11 12
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
EN-03785
EN(H4SO)(diag)-202

Step
chassis ground.
CHECK HARNESS BETWEEN DRAIN
VALVE AND ECM CONNECTOR.
2) Disconnect the connectors from drain valve
and ECM.
drain valve connector and chassis ground.
ECM and drain valve connector.
(B136) No. 17 (R69) No. 2:
Check
Yes
No
Go to step 2.
more?
Go to step 3.
Repair the ground

ECM and drain
valve connector.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and drain
valve connector
Poor contact in
coupling connector
Replace the drain
valve. <Ref. to
EC(H4SO)-17,
Drain Valve.>

CHECK DRAIN VALVE.
and 100 ?
Measure the resistance between drain valve
terminals.
Terminals
No. 1 No. 2:
CHECK POWER SUPPLY TO DRAIN VALVE. Is the voltage 10 V or more?
2) Measure the voltage between drain valve
and chassis ground.
EN(H4SO)(diag)-203
Go to step 5.
Repair the poor

contact of drain
valve connector.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
main relay and
drain valve
Poor contact in
coupling connector
Poor contact in

BH:DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL

CIRCUIT SHORTED
SYSTEM VENT CONTROL CIRCUIT SHORTED, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
BATTERY
SBF-5
5
3
7
B61
F44
2
1
B98
1
2
10
6
1
R2
B47
R15
R57
R69
DRAIN
VALVE
CANISTER
R2
17
B98
B136 ECM
R69
1 2
B47
1
3
5
2
4
6
F44
1 2 3 4
5 6 7 8
R57
B98
1 2
3 4 5
6 7 8 9 10 11 12
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
EN-03785
EN(H4SO)(diag)-204

Step
2) Connect the test mode connector at the
lower portion of instrument panel (on the
drivers side).
chassis ground while operating the drain valve.
NOTE:
chassis ground.
CHECK POOR CONTACT.
Check
Yes
Go to step 2.
No
light illuminates,
the circuit has
this time. In this
case, repair the
poor contact in
ECM connector.
Go to step 4.
Go to step 3.

connector?
Replace the ECM.

<Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>
short circuit of har1) Turn the ignition switch to OFF.
ness between
2) Disconnect the connector from the drain
ECM and drain
valve.
valve connector.
After repair,
replace the ECM.
chassis ground.
<Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>
CHECK DRAIN VALVE.
Is the resistance less than 1 ? Replace the drain Go to step 6.
valve and ECM.
2) Measure the resistance between drain valve
<Ref. to
terminals.
EC(H4SO)-17,
Terminals
Drain Valve.>
No. 1 No. 2:
<Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>
CHECK POOR CONTACT.
Repair poor con- Replace the ECM.
connector?
tact in ECM con<Ref. to
nector.
FU(H4SO)-40,
Engine Control
Module (ECM).>
EN(H4SO)(diag)-205

BI: DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR

SYSTEM PRESSURE SENSOR, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
FUEL TANK
PRESSURE
SENSOR
R47
14
13
12
R57
R15
R2
30
32
22
B98
B135 ECM
R47
B98
R57
B135
1 2 3
1 2
3 4 5
6 7 8 9 10 11 12
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
EN-03786
EN(H4SO)(diag)-206

Step
Check

2) Open the fuel flap.
CHECK PRESSURE VACUUM LINE.
NOTE:
Disconnection, leakage and clogging of the
vacuum hoses and pipes between fuel tank
pressure sensor and fuel tank
air ventilation hoses and pipes between fuel filler pipe and fuel tank

securely?
Is there any fault in pressure/
vacuum line?
EN(H4SO)(diag)-207
Yes
No
priate DTC using
Code (DTC).
<Ref. to
(DTC).>
Go to step 3.
fuel filler cap.
Repair or replace
the hoses and
pipes.
Replace the fuel

tank pressure sensor. <Ref. to
EC(H4SO)-11,
Fuel Tank Pressure Sensor.>

BJ:DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR LOW INPUT
SYSTEM PRESSURE SENSOR LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
FUEL TANK
PRESSURE
SENSOR
R47
14
13
12
R57
R15
R2
30
32
22
B98
B135 ECM
R47
B98
R57
B135
1 2 3
1 2
3 4 5
6 7 8 9 10 11 12
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
EN-03786
EN(H4SO)(diag)-208

Step
CHECK CURRENT DATA.
2) Remove the fuel filler cap.
3) Install the fuel filler cap.
5) Read the data of fuel tank pressure sensor
scan tool.
NOTE:
General scan tool
CHECK POWER SUPPLY TO FUEL TANK
PRESSURE SENSOR.
and chassis ground.
ground.
Read the data of fuel tank pressure sensor signal using Subaru Select Monitor.
NOTE:
COUPLING CONNECTOR IN REAR WIRING
HARNESS.
2) Remove the rear seat cushion.
3) Separate rear wiring harness and fuel tank
cord.
5) Measure the voltage between rear wiring
harness connector and chassis ground.
Check
Yes
2.8 kPa (21.0 mmHg, 0.827
inHg)?
No
light illuminates,
the circuit has
this time.
Go to step 3.
Go to step 4.
Does the measured value

Repair poor conchange when shaking the ECM tact in ECM conharness and connector?
nector.
Go to step 5.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and rear wiring harness connector
Poor contact in
coupling connector
EN(H4SO)(diag)-209
Go to step 6.

10
11
Step
Check
Yes
HARNESS.
ECM and rear wiring harness connector.
(B135) No. 30 (R15) No. 14:

HARNESS.
rear wiring harness connector and chassis
ground.
(R15) No. 14 (+) Chassis ground:
CHECK FUEL TANK CORD.
1) Disconnect the connector from fuel tank
pressure sensor.
2) Measure the resistance of fuel tank cord.
(R57) No. 12 (R47) No. 3:
Measure the resistance of fuel tank cord.
(R57) No. 14 (R47) No. 2:
fuel tank pressure sensor connector and engine
ground.
CHECK POOR CONTACT.
Check poor contact in fuel tank pressure sensor
connector.
more?
Go to step 8.
No
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
Poor contact in
coupling connector
Poor contact in
joint connector
Repair the ground
Repair the open

circuit in fuel tank
cord.
Repair the open

cord.
more?
Repair the ground

short circuit of fuel
tank cord.
Go to step 11.
Is there poor contact in fuel tank Repair the poor

pressure sensor connector?
contact in fuel tank
pressure sensor
connector.
EN(H4SO)(diag)-210
Replace the fuel

EC(H4SO)-11,

BK:DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE

SENSOR HIGH INPUT
SYSTEM PRESSURE SENSOR HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
FUEL TANK
PRESSURE
SENSOR
R47
14
13
12
R57
R15
R2
30
32
22
B98
B135 ECM
R47
B98
R57
B135
1 2 3
1 2
3 4 5
6 7 8 9 10 11 12
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
EN-03786
EN(H4SO)(diag)-211

Step
CHECK CURRENT DATA.
scan tool.
NOTE:
General scan tool
PRESSURE SENSOR.
and chassis ground.
PRESSURE SENSOR.
and chassis ground.
ground.
NOTE:
HARNESS.
cord.
Check
Yes
Is the measured value 2.8 kPa Go to step 11.
(21.0 mmHg, 0.827 inHg) or
more?
No
Go to step 2.
Go to step 3.
Go to step 4.
nector.
Replace the ECM.

<Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>
Go to step 5.

nector.
Go to step 6.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
Poor contact in
coupling connector
EN(H4SO)(diag)-212
Go to step 7.

10
11
Step
Check
Yes
HARNESS.
(B135) No. 32 (R15) No. 13:
(B135) No. 30 (R15) No. 14:

pressure sensor.
(R57) No. 13 (R47) No. 1:
(R57) No. 14 (R47) No. 2:
CHECK POOR CONTACT.
Check poor contact in fuel tank pressure sensor
connector.

pressure sensor
connector.
No
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
Poor contact in
coupling connector
Repair the open
cord.
Repair the open

cord.
Replace the fuel

EC(H4SO)-11,
Replace the fuel
Is the measured value 2.8 kPa Repair battery
FUEL TANK PRESSURE SENSOR CONNEC- (21.0 mmHg, 0.827 inHg) or
short circuit of har- tank pressure senTOR.
sor. <Ref. to
more?
ness between
ECM and fuel tank EC(H4SO)-11,
Fuel Tank Prespressure sensor
pressure sensor.
sure Sensor.>
connector.
scan tool.
NOTE:
General scan tool
EN(H4SO)(diag)-213

BL:DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK)
SYSTEM LEAK DETECTED (VERY SMALL LEAK), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Fuel odor
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
B61
BATTERY
F44
SBF-5
5
3
C24
2
1
C28
R2
ECM
D29
D: B137
B98
48
B98
10
C17
C: B136
41
B47
R2
B22
E3
10
R15
R57
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B47
1
3
5
2
4
6
E4
1
PRESSURE CONTROL
SOLENOID VALVE
DRAIN VALVE
B22
R68
R69
PURGE CONTROL
SOLENOID VALVE
R68
B98
F44
R57
R69
3 4 5
1 2
6 7 8 9 10 11 12
1 2 3 4
5 6 7 8
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
E4
1 2
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
D: B137
5 6
14 15 16
25 26 27
33 34 35
EN(H4SO)(diag)-214
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
EN-04772

Step

securely?
NOTE:
while tightening.
genuine?
CHECK DRAIN VALVE.

NOTE:
VALVE.
NOTE:
VALVE.
NOTE:
Operation
Check
Mode.
<Ref.
to
Check
Yes
No
priate DTC using
Code (DTC).
<Ref. to
(DTC).>
Go to step 3.
fuel filler cap.
Go to step 4.
Replace with a
genuine fuel filler
cap.
Go to step 5.

filler pipe?
<Ref. to
FU(H4SO)-48,
Fuel Filler Pipe.>
Replace the drain
valve. <Ref. to
EC(H4SO)-17,
Drain Valve.>
Go to step 7.
Replace the purge

control solenoid
valve. <Ref. to
EC(H4SO)-7,
Purge Control
Solenoid Valve.>

noid valve operate?

EC(H4SO)-12,
Pressure Control
Solenoid Valve.>
EN(H4SO)(diag)-215

Step
CHECK CANISTER.
10
CHECK FUEL TANK.

Fuel Tank.>
11
Check
Yes
Is there a hole of more than 0.5 Repair or replace
mm (0.020 in) dia. in evapora- the evaporation
tion line?
line. <Ref. to
FU(H4SO)-59,
Fuel Delivery,
the canister. <Ref.
to EC(H4SO)-6,
Canister.>
to FU(H4SO)-45,
Fuel Tank.>
Repair or replace
clogging, disconnections or
bend of hoses or pipes in evaporative emission control system?
EN(H4SO)(diag)-216
No
Go to step 9.
Go to step 10.
Go to step 11.

BM:DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF)
TROUBLE SYMPTOM:
Fuel odor
Fuel filler cap is loose or not installed.
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
B61
BATTERY
F44
SBF-5
5
3
C24
2
1
C28
R2
ECM
D29
D: B137
B98
48
B98
10
C17
C: B136
41
B47
R2
B22
E3
10
R15
R57
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B47
1
3
5
2
4
6
E4
1
PRESSURE CONTROL
SOLENOID VALVE
DRAIN VALVE
B22
R68
R69
PURGE CONTROL
SOLENOID VALVE
R68
B98
F44
R57
R69
3 4 5
1 2
6 7 8 9 10 11 12
1 2 3 4
5 6 7 8
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
E4
1 2
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
D: B137
5 6
14 15 16
25 26 27
33 34 35
EN(H4SO)(diag)-217
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
EN-04772

Step

securely?
NOTE:
while tightening.
genuine?
CHECK DRAIN VALVE.

NOTE:
VALVE.
NOTE:
VALVE.
NOTE:
Operation
Check
Mode.
<Ref.
to
CHECK CANISTER.
Check
Yes
No
priate DTC using
Code (DTC).
<Ref. to
(DTC).>
Go to step 3.
fuel filler cap.
Go to step 4.
Replace with a
genuine fuel filler
cap.
Go to step 5.

filler pipe?
<Ref. to
FU(H4SO)-48,
Fuel Filler Pipe.>
Replace the drain
valve. <Ref. to
EC(H4SO)-17,
Drain Valve.>
Go to step 7.
Replace the purge

control solenoid
valve. <Ref. to
EC(H4SO)-7,
Purge Control
Solenoid Valve.>

noid valve operate?

EC(H4SO)-12,
Pressure Control
Solenoid Valve.>
Is the canister damaged?
EN(H4SO)(diag)-218
Repair or replace Go to step 9.

the canister. <Ref.
to EC(H4SO)-6,
Canister.>

10
Step
CHECK FUEL TANK.
Fuel Tank.>
Check
Is the fuel tank damaged?
Yes
No
to FU(H4SO)-45,
Fuel Tank.>
Repair or replace Repair poor con0.5 mm (0.020 in) dia., cracks, the hoses or pipes. tact in ECM conclogging or disconnections of
nector.
hoses or pipes in evaporative
emission control system?
EN(H4SO)(diag)-219

BN:DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE

CIRCUIT LOW
GENERAL DESCRIPTION <Ref. to GD(H4SO)-144, DTC P0458 EVAPORATIVE EMISSION SYSTEM
PURGE CONTROL VALVE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
BATTERY
E4
SBF-5
7
5
3
B61
1 2
F44
2
1
B47
B47
1
3
5
2
4
6
F44
1 2 3 4
5 6 7 8
B137 ECM
29
B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
28 29
30 31
26 27
48
41
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
B22
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
E3
2
1
E4
PURGE CONTROL
SOLENOID VALVE
EN-03787
EN(H4SO)(diag)-220

Step
chassis ground.
CHECK HARNESS BETWEEN PURGE CONTROL SOLENOID VALVE AND ECM CONNECTOR.
2) Disconnect the connectors from purge control solenoid valve and ECM.
purge control solenoid valve connector and
engine ground.
CHECK HARNESS BETWEEN PURGE CONTROL SOLENOID VALVE AND ECM CONNECTOR.
ECM and purge control solenoid valve.
(B137) No. 29 (E4) No. 1:
Check
Yes
No
Go to step 2.
more?
Go to step 3.
Repair the ground

ECM and purge
control solenoid
valve connector.
Repair the open

circuit of harness
between ECM and
purge control solenoid valve connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and purge
control
solenoid
valve connector
Poor contact in
coupling connector
Replace the purge
control solenoid
valve. <Ref. to
EC(H4SO)-7,
Purge Control
Solenoid Valve.>

VALVE.
and 100 ?
2) Measure the resistance between purge control solenoid valve terminals.
Terminals
No. 1 No. 2:
CHECK POWER SUPPLY TO PURGE CON- Is the voltage 10 V or more?
TROL SOLENOID VALVE.
2) Measure the voltage between purge control
solenoid valve and engine ground.
EN(H4SO)(diag)-221
Go to step 5.
Repair the poor

contact of the
Repair the harness

and connector.
NOTE:
the following items.
Open circuit of
harness between
main relay and
purge control solenoid valve connector
Poor contact of
Poor contact of
the main relay connector

BO:DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE

CIRCUIT HIGH
GENERAL DESCRIPTION <Ref. to GD(H4SO)-146, DTC P0459 EVAPORATIVE EMISSION SYSTEM
PURGE CONTROL VALVE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
BATTERY
E4
SBF-5
7
5
3
B61
1 2
F44
2
1
B47
B47
1
3
5
2
4
6
F44
1 2 3 4
5 6 7 8
B137 ECM
29
B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
28 29
30 31
26 27
48
41
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
B22
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
E3
2
1
E4
PURGE CONTROL
SOLENOID VALVE
EN-03787
EN(H4SO)(diag)-222

Step
drivers side).
chassis ground while operating the purge control solenoid valve.
NOTE:
chassis ground.
CHECK POOR CONTACT.
Check
Yes
Go to step 2.
No
light illuminates,
the circuit has
this time. In this
case, repair the
poor contact in
ECM connector.
Go to step 4.
Go to step 3.

connector?
Replace the ECM.

<Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>
CHECK HARNESS BETWEEN PURGE CON- Is the voltage 10 V or more?
TROL SOLENOID VALVE AND ECM CONshort circuit of harNECTOR.
ness between
ECM and purge
2) Disconnect the connector from purge concontrol solenoid
trol solenoid valve.
valve connector.
After repair,
replace the ECM.
chassis ground.
<Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>
Is the resistance less than 1 ? Replace the purge Go to step 6.
VALVE.
control solenoid
valve <Ref. to
2) Measure the resistance between purge conEC(H4SO)-7,
trol solenoid valve terminals.
Purge Control
Terminals
Solenoid Valve.>
No. 1 No. 2:
and ECM <Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>.
CHECK POOR CONTACT.
<Ref. to
connector?
tact in ECM conFU(H4SO)-40,
nector.
Engine Control
Module (ECM).>
EN(H4SO)(diag)-223

BP:DTC P0461 FUEL LEVEL SENSOR A CIRCUIT RANGE/PERFORMANCE

GENERAL DESCRIPTION <Ref. to GD(H4SO)-148, DTC P0461 FUEL LEVEL SENSOR A CIRCUIT
CAUTION:
WIRING DIAGRAM:
BATTERY
No.14
SBF-4
4
IGNITION
B72
SWITCH
i1
B9
B36
SBF-1
COMBINATION
i10
C:
i11
METER
C1
B10
B:
10
15
12
B38
i3
R2
28
i3
11
R15
B38
R57
R58
1 2
1 2 3
4 5 6
B36
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
C:
i11
2
FUEL LEVEL
LEVEL SENSOR
FUEL SUB
R58
3
R59
E3
SENSOR
36
B22
R59
B135 ECM
B98
B98
1 2 3 4 5 6 7 8 9 10
1 2
3 4 5
6 7 8 9 10 11 12
B:
i10
8 9 10 11 12 13 14
1 2 3 4 5 6 7
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B22
B38
R57
B72
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
1 2
3 4
B135
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-03788
EN(H4SO)(diag)-224

Step
Check
EN(H4SO)(diag)-225
Yes
Check DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
(DTC).>
NOTE:
necessary to inspect this trouble.
No
Replace the fuel
level sensor <Ref.
to FU(H4SO)-54,
Fuel Level Sensor.> and fuel sub
level sensor. <Ref.
to FU(H4SO)-55,
Fuel Sub Level
Sensor.>

BQ:DTC P0462 FUEL LEVEL SENSOR A CIRCUIT LOW

CAUTION:
WIRING DIAGRAM:
BATTERY
No.14
SBF-4
4
IGNITION
B72
SWITCH
i1
B9
B36
SBF-1
COMBINATION
i10
C:
i11
METER
C1
B10
B:
10
15
12
B38
i3
R2
28
i3
11
R15
B38
R57
R58
1 2
1 2 3
4 5 6
B36
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
C:
i11
2
FUEL LEVEL
LEVEL SENSOR
FUEL SUB
R58
3
R59
E3
SENSOR
36
B22
R59
B135 ECM
B98
B98
1 2 3 4 5 6 7 8 9 10
1 2
3 4 5
6 7 8 9 10 11 12
B:
i10
8 9 10 11 12 13 14
1 2 3 4 5 6 7
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B22
B38
R57
B72
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
1 2
3 4
B135
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-03788
EN(H4SO)(diag)-226

Step
Check
Yes
CHECK SPEEDOMETER AND TACHOMEDoes the speedometer and
Go to step 2.
TER OPERATION IN COMBINATION METER. tachometer operate normally?

1) Turn the ignition switch to ON. (engine OFF)
Read the data of fuel level sensor signal using
NOTE:

2) Disconnect the fuel tank cord connector
(R57) and rear wiring harness connector (R15).
COMBINATION METER.
2) Disconnect the connector from connector
(i12) and ECM connector.
chassis ground.
COMBINATION METER.
Measure the resistance between ECM and
combination meter connector.
(B135) No. 10 (i11) No. 1:
Is the voltage less than 0.12 V Repair poor conby shaking the harness and
tact in ECM conconnector of ECM?
nector.
Is the voltage 0.12 V or more? Go to step 5.
No
Repair or replace
the combination
meter. <Ref. to IDI3, Combination
Meter System.>
Go to step 3.

light illuminates,
the circuit has
this time. A temporary poor contact of
the connector may
be the cause.
NOTE:
the following item:
Poor contact in
combination meter
connector
Poor contact in
ECM connector
Poor contact in
coupling connector
Go to step 6.
more?
Go to step 7.
Repair the ground


?
Repair or replace
the combination
Meter System.>
Repair the open

circuit between
NOTE:
the following item:
Poor contact in
coupling connector
EN(H4SO)(diag)-227

10
Step
2) Disconnect the connector from the fuel sub
level sensor.
3) Measure the resistance between fuel sub
level sensor and chassis ground.
1) Disconnect the connector from fuel pump
assembly.
2) Measure the resistance between fuel pump
assembly and chassis ground.
CHECK FUEL LEVEL SENSOR.
FU(H4SO)-52, Fuel Pump.>
2) Measure the resistance between fuel level
sensor and terminals with its float set to the full
position.
Terminals
No. 3 No. 2:
CHECK FUEL SUB LEVEL SENSOR.
1) Remove the fuel sub level sensor. <Ref. to
FU(H4SO)-55, Fuel Sub Level Sensor.>
level sensor and terminals with its float set to
the full position.
Terminals
No. 1 No. 2:
Check
more?
Yes
Go to step 8.
No
Repair the ground
tank cord.
more?
Go to step 9.
Repair the ground

tank cord.
Is the resistance between 0.5

and 2.5 ?
Go to step 10.
Replace the fuel

level sensor.

and 2.5 ?
Repair the poor

Replace the fuel
contact in harness sub level sensor.
between ECM and
combination meter
connector.
EN(H4SO)(diag)-228

BR:DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH

CAUTION:
WIRING DIAGRAM:
BATTERY
No.14
SBF-4
4
IGNITION
B72
SWITCH
i1
B9
B36
SBF-1
COMBINATION
i10
C:
i11
METER
C1
B10
B:
10
15
12
B38
i3
R2
28
i3
11
R15
B38
R57
R58
1 2
1 2 3
4 5 6
B36
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
C:
i11
2
FUEL LEVEL
LEVEL SENSOR
FUEL SUB
R58
3
R59
E3
SENSOR
36
B22
R59
B135 ECM
B98
B98
1 2 3 4 5 6 7 8 9 10
1 2
3 4 5
6 7 8 9 10 11 12
B:
i10
8 9 10 11 12 13 14
1 2 3 4 5 6 7
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B22
B38
R57
B72
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
1 2
3 4
B135
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-03788
EN(H4SO)(diag)-229

Step
Check
Yes
Go to step 2.


2) Disconnect the combination meter connector (i12) and ECM connector.
FUEL TANK CORD.
2) Disconnect the fuel tank cord connector
(R57) and rear wiring harness connector (R15).
fuel tank cord.
(B135) No. 10 (R15) No. 7:
CHECK HARNESS BETWEEN FUEL TANK Is the resistance less than 5 ? Go to step 6.
CORD AND CHASSIS GROUND.
Measure the resistance between fuel tank cord
and chassis ground.

1) Disconnect the connector from the fuel level ?
sensor.
sensor and coupling connector.
(R57) No. 11 (R58) No. 2:
EN(H4SO)(diag)-230
Go to step 7.
No
Repair or replace
the combination
Meter System.>
light illuminates,
the circuit has
the connector may
be the cause.
NOTE:
the following item:
Poor contact in
fuel pump connector
Poor contact in
coupling connector
Repair the battery
short circuit
between ECM and
combination meter
connector.
Repair the open

circuit between
ECM and fuel tank
cord.
Repair the open

circuit between fuel
tank cord and
chassis ground.
NOTE:
the following item:
Poor contact in
coupling connector
Repair the open
circuit between
coupling connector
and fuel level sensor.

10
Step
level sensor.
sensor and fuel sub level sensor.
(R58) No. 3 (R59) No. 2:
Measure the resistance between fuel level sensor and coupling connector.
(R57) No. 7 (R59) No. 1:
2) While moving the fuel level sensor float up
and down, measure resistance between fuel
level sensor terminals.
Terminals
No. 3 No. 2:
2) While moving the fuel sub level sensor float
up and down, measure resistance between fuel
sub level sensor terminals.
Terminals
No. 1 No. 2:
Check
?
Yes
Go to step 8.
No
Repair the open
level sensor and
fuel sub level sensor.

?
Go to step 9.
Is the resistance 54.5 or

more?
Replace the fuel

level sensor. <Ref.
to FU(H4SO)-54,
Fuel Level Sensor.>
Repair the open

circuit between
coupling connector
Go to step 10.
Is the resistance 41.5 or

more?
Replace the fuel

sub level sensor.
<Ref. to
FU(H4SO)-55,
Fuel Sub Level
Sensor.>
EN(H4SO)(diag)-231
Replace the combination meter.

<Ref. to IDI-10,
Combination
Meter.>

BS:DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT

GENERAL DESCRIPTION <Ref. to GD(H4SO)-154, DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
BATTERY
No.14
SBF-4
4
IGNITION
B72
SWITCH
i1
B9
B36
SBF-1
COMBINATION
i10
C:
i11
METER
C1
B10
B:
10
15
12
B38
i3
R2
28
i3
11
R15
B38
R57
R58
1 2
1 2 3
4 5 6
B36
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
C:
i11
2
FUEL LEVEL
LEVEL SENSOR
FUEL SUB
R58
3
R59
E3
SENSOR
36
B22
R59
B135 ECM
B98
B98
1 2 3 4 5 6 7 8 9 10
1 2
3 4 5
6 7 8 9 10 11 12
B:
i10
8 9 10 11 12 13 14
1 2 3 4 5 6 7
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B22
B38
R57
B72
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
1 2
3 4
B135
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-03788
EN(H4SO)(diag)-232

Step
Check

and down, make sure that the resistance
between fuel level sensor terminals changes
smoothly.
Terminals
No. 3 No. 2:
up and down, make sure that the resistance
smoothly.
Terminals
No. 1 No. 2:
Does the resistance change

smoothly?

smoothly?
EN(H4SO)(diag)-233
Yes
No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
(DTC).>
Go to step 3.
Replace the fuel
level sensor. <Ref.
to FU(H4SO)-54,
Fuel Level Sensor.>
Repair poor contact in ECM, combination meter and

coupling connectors.
Replace the fuel

sub level sensor.
<Ref. to
FU(H4SO)-55,
Fuel Sub Level
Sensor.>

BT:DTC P0483 FAN RATIONALITY CHECK

GENERAL DESCRIPTION <Ref. to GD(H4SO)-157, DTC P0483 FAN RATIONALITY CHECK, Diagnostic
Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Occurrence of noise
Overheating
CAUTION:
NOTE:
If the vehicle, with the engine idling, is placed very close to a wall or another vehicle, preventing normal cooling function, the OBD system may detect malfunction.
1
Step
Check
Yes
Code (DTC).
<Ref. to
(DTC).>
No
Check the radiator
fan and fan motor.
<Ref. to
CO(H4SO)-34,
Radiator Main Fan
and Fan Motor.>
and <Ref. to
CO(H4SO)-41,
Radiator Sub Fan
and Fan Motor.>
BU:DTC P0502 VEHICLE SPEED SENSOR A CIRCUIT LOW INPUT

NOTE:
For the diagnostic procedure, refer to DTC P0503. <Ref. to EN(H4SO)(diag)-235, DTC P0503 VEHICLE
SPEED SENSOR A INTERMITTENT/ERRATIC/HIGH, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
EN(H4SO)(diag)-234

BV:DTC P0503 VEHICLE SPEED SENSOR A INTERMITTENT/ERRATIC/HIGH

GENERAL DESCRIPTION <Ref. to GD(H4SO)-158, DTC P0502 VEHICLE SPEED SENSOR A CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-159, DTC
P0503 VEHICLE SPEED SENSOR A INTERMITTENT/ERRATIC/HIGH, Diagnostic Trouble Code (DTC)
Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
B17
IGNITION
SWITCH
BATTERY
SBF-4
1 2 3
SBF-1
1
No.17
B72
4
B72
1 2
3 4
i10
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B54
TCM
VEHICLE SPEED SENSOR
B22
21
B17
1
2
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
AT
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
MT
COMBINATION
METER
MT
: MT MODEL
AT
: AT MODEL
i10
B54
12
36
B22
18
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B36
5 6
14 15 16
25 26 27
33 34 35
12
i1
B136
E3
B36
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B136 ECM
EN-03790
EN(H4SO)(diag)-235

1
2
Step
CHECK DTC P0720 ON DISPLAY.
Check
Does the Subaru Select Monitor or general scan tool indicate
DTC P0720?
CHECK SPEEDOMETER OPERATION IN

COMBINATION METER.

COMBINATION METER CONNECTOR.
2) Disconnect the connector from the combination meter.
3) Measure resistance between ECM and
combination meter.
(B136) No. 12 (i10) No. 12:
Yes
No
Go to step 2.
Go to step 3.
Check the front
Go to step 3.
vehicle speed sensor signal circuit.
<Ref. to
4AT(D)(diag)-49,
DTC P0720 OUTPUT SPEED SENSOR CIRCUIT,
(DTC).>
Does the speedometer operate Go to step 4.
Check the speednormally?
ometer and vehicle
speed sensor.
<Ref. to IDI-12,
Speedometer.>
<Ref. to 4AT-51,
Front Vehicle
Speed Sensor.>
<Ref. to 4AT-54,
Rear Vehicle
Speed Sensor.>
<Ref. to 4AT-55,
Torque Converter
Turbine Speed
Sensor.>
Is the resistance less than 10 Repair poor con- Repair the harness
?
tact in ECM conand connector.
nector.
NOTE:
the following item:
Open circuit in
harness between
Poor contact in
ECM connector
Poor contact in
combination meter
connector
Poor contact in
coupling connector
EN(H4SO)(diag)-236

BW:DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED
GENERAL DESCRIPTION <Ref. to GD(H4SO)-160, DTC P0506 IDLE AIR CONTROL SYSTEM RPM
LOWER THAN EXPECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine is difficult to start.
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
B309
1 2
3 4
E57
BATTERY
ELECTRONIC THROTTLE
CONTROL RELAY
SBF-5
B309
1 2 3 4 5 6
2
1
3
4
B122
1 2 3 4
5 6 7 8
C21
C1
MAIN RELAY
D: B137
ECM
D: B137
E
C6
A18
A28
A29
D4
D5
A19
C15
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
30 31
26 27
28 29
MT
D7
A5
D1
D2
D3
A: B134
A: B134
B122
3
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
17
18
19
20
39
38
52
36
34
35
37
B22
1 2
8 9 10
18 19 20
28 29 30
E3
C: B136
5 6
14 15 16
25 26 27
33 34 35
E57
1
2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B22
ELECTRONIC THROTTLE
E
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
CONTROL
34
42
MT
: MT MODEL
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-03774
EN(H4SO)(diag)-237

Step
CHECK AIR CLEANER ELEMENT.

2) Check the air cleaner element.
CHECK ELECTRONIC THROTTLE CONTROL.

2) Remove the electronic throttle control.
3) Check the electronic throttle control.
Check
Yes
Code (DTC).
<Ref. to
(DTC).>
NOTE:
Is there excessive clogging on Replace the air
air cleaner element?
cleaner element.
<Ref. to IN
(H4SO)-4, Air
Cleaner Element.>
Are foreign matter found inside Remove foreign
electronic throttle control?
matter from electronic throttle control.
EN(H4SO)(diag)-238
No
Go to step 2.
Go to step 3.
Perform the diagnosis of DTC

P2101.

BX:DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED
GENERAL DESCRIPTION <Ref. to GD(H4SO)-162, DTC P0507 IDLE AIR CONTROL SYSTEM RPM
HIGHER THAN EXPECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine keeps running at higher speed than specified idle speed.
CAUTION:
WIRING DIAGRAM:
B309
1 2
3 4
E57
BATTERY
ELECTRONIC THROTTLE
CONTROL RELAY
SBF-5
B309
1 2 3 4 5 6
2
1
3
4
B122
1 2 3 4
5 6 7 8
C21
C1
MAIN RELAY
D: B137
ECM
D: B137
E
C6
A18
A28
A29
D4
D5
A19
C15
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
30 31
26 27
28 29
MT
D7
A5
D1
D2
D3
A: B134
A: B134
B122
3
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
17
18
19
20
39
38
52
36
34
35
37
B22
1 2
8 9 10
18 19 20
28 29 30
E3
C: B136
5 6
14 15 16
25 26 27
33 34 35
E57
1
2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B22
ELECTRONIC THROTTLE
E
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
CONTROL
34
42
MT
: MT MODEL
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-03774
EN(H4SO)(diag)-239

Step
Check

3) Check the following items.
Loose installation of intake manifold and
throttle body
Cracks of intake manifold gasket and throttle
body gasket
Disconnection of vacuum hoses

system?
Yes
No
priate DTC using
Code (DTC).
<Ref. to
(DTC).>
NOTE:
Repair air suction Go to step 3.
and leaks.
Perform the diagAre foreign matter found inside Remove foreign

matter from elec- nosis of DTC
tronic throttle con- P2101.
trol.
EN(H4SO)(diag)-240

BY:DTC P0512 STARTER REQUEST CIRCUIT

GENERAL DESCRIPTION <Ref. to GD(H4SO)-164, DTC P0512 STARTER REQUEST CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
CAUTION:
EN(H4SO)(diag)-241

WIRING DIAGRAM:
IGNITION
SWITCH
BATTERY
SBF-1
SBF-4
1
3
MT
: MT MODEL
AT
: AT MODEL
B72
INTERRUPT
RELAY
5
2
3
1
B59
TO SECURITY SYSTEM
INHIBITOR SWITCH
P
AT
MT
12
11
B225
7
T3
T7
24
27
28
26
B12
12
STARTER
INTERLOCK
RELAY(AT)
AT
STARTER INTERLOCK
RELAY (MT)
28
27
26
24
STARTER MOTOR
AT
MT
B14
MT
B225
2
1
32
20
CLUTCH SWITCH (MT)
B106
B136
ECM
B225
B106
1
2
B72
1 2
3 4
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
B59
B12
1 2 3
4 5 6
1 2 3 4
5 6 7 8
9 10 11 12
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
T7
1 2 3 4 5 6
7 8 9 10 11 12
EN-04767
EN(H4SO)(diag)-242

Step
Check
CHECK OPERATION OF STARTER MOTOR. Does the starter motor operTurn the ignition switch to ON.
ate?
NOTE:
Place the inhibitor switch in each position. (AT
model)
Depress or release the clutch pedal. (MT model)
EN(H4SO)(diag)-243
Yes
Repair the battery
short circuit in
starter motor circuit.
No
Check the starter
motor circuit. <Ref.
to
EN(H4SO)(diag)54, STARTER
MOTOR CIRCUIT,
Diagnostics for
Engine Starting
Failure.>

BZ:DTC P0519 IDLE AIR CONTROL SYSTEM PERFORMANCE

GENERAL DESCRIPTION <Ref. to GD(H4SO)-165, DTC P0519 IDLE AIR CONTROL SYSTEM PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
B309
1 2
3 4
E57
BATTERY
ELECTRONIC THROTTLE
CONTROL RELAY
SBF-5
B309
1 2 3 4 5 6
2
1
3
4
B122
1 2 3 4
5 6 7 8
C21
C1
MAIN RELAY
D: B137
ECM
D: B137
E
C6
A18
A28
A29
D4
D5
A19
C15
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
30 31
26 27
28 29
MT
D7
A5
D1
D2
D3
A: B134
A: B134
B122
3
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
17
18
19
20
39
38
52
36
34
35
37
B22
1 2
8 9 10
18 19 20
28 29 30
E3
C: B136
5 6
14 15 16
25 26 27
33 34 35
E57
1
2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B22
ELECTRONIC THROTTLE
E
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
CONTROL
34
42
MT
: MT MODEL
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-03774
EN(H4SO)(diag)-244

Step
Check

throttle body
body gasket

system?
Yes
No
priate DTC using
Code (DTC).
<Ref. to
(DTC).>
NOTE:
and leaks.

trol.
EN(H4SO)(diag)-245

CA:DTC P0600 SERIAL COMMUNICATION LINK

GENERAL DESCRIPTION <Ref. to GD(H4SO)-166, DTC P0600 SERIAL COMMUNICATION LINK, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
TCM
18
17
27
35
B54
B136 ECM
B54
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
EN-04773
EN(H4SO)(diag)-246

Step
TCM.
3) Disconnect the connector from TCM.
4) Measure the resistance between the ECM
and TCM connectors.
(B136) No. 27 (B54) No. 18:
(B136) No. 35 (B54) No. 17:
TCM.
TCM.
Check the resistance between ECM connectors.
(B136) No. 27 (B136) No. 35:
CHECK THE STATUS OF THE AT SYSTEM.
Diagnose the AT using the Subaru Select Monitor.
Check that trouble code 86 is displayed.
Check
Yes
No
Repair the harness
or connector.
more?
Go to step 3.
Repair the harness

or connector.
more?
Go to step 4.
Repair the harness

or connector.
Is trouble code 86 displayed?
Check the AT sys- Replace the ECM.

tem.
<Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>
EN(H4SO)(diag)-247

CB:DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY

(RAM) ERROR
GENERAL DESCRIPTION <Ref. to GD(H4SO)-167, DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
3
5
TO IGNITION COIL
SBF-5
6
4
1
2
IGNITION
B72
BATTERY
SWITCH
No.11
B47
SBF-4
1
B5
B27
C24
A7
B2
SBF-1
A: B134
B: B135
ECM
C: B136
D2
D3
D7
D1
A5
D: B137
35
37
52
34
36
B22
E3
B72
1 2
3 4
D: B137
B47
1
3
5
2
4
6
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
30 31
26 27
28 29
A: B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
24 25
20 21 22 23
26 27
32 33
34 35
28 29 30 31
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B22
5 6
14 15 16
25 26 27
33 34 35
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-03793
EN(H4SO)(diag)-248

Step
Check
Yes
No
Check the appro- Temporary poor
priate DTC using contact occurs.
Code (DTC).
<Ref. to
(DTC).>
CC:DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM)

ERROR
NOTE:
For the diagnostic procedure, refer to DTC P0607. <Ref. to EN(H4SO)(diag)-250, DTC P0607 CONTROL
MODULE PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(H4SO)(diag)-249

CD:DTC P0607 CONTROL MODULE PERFORMANCE

GENERAL DESCRIPTION <Ref. to GD(H4SO)-169, DTC P0605 INTERNAL CONTROL MODULE READ
ONLY MEMORY (ROM) ERROR, Diagnostic Trouble Code (DTC) Detecting Criteria.> and <Ref. to
GD(H4SO)-170, DTC P0607 CONTROL MODULE PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
TO IGNITION COIL
3
5
SBF-5
6
4
1
2
IGNITION
SWITCH
B72
B47
BATTERY
No.11
SBF-4
1
B5
B27
4
C24
A7
B2
SBF-1
A: B134
B: B135
C: B136
D: B137
C6
A28
A18
A19
D4
D5
A29
D3
D7
D1
D2
A5
ECM
B122
18
17
20
39
38
19
37
52
34
35
36
3
7
B73
ELECTRONIC
THROTTLE CONTROL
E57
B47
B72
1
3
5
1 2 3
4 5 6
2
4
6
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
32 33
34 35
28 29 30 31
E57
B122
1 2 3 4 5 6
1 2 3 4
5 6 7 8
5 6
14 15 16
25 26 27
33 34 35
B73
A: B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
D: B137
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
4
6
5
1
2
3
E4
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
28 29
30 31
26 27
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04100
EN(H4SO)(diag)-250

Step
2) Disconnect the connectors from the ECM
ECM and electronic throttle control connector.
(E57) No. 5 (B134) No. 19:
(E57) No. 3 (B134) No. 29:
CHECK ECM GROUND HARNESS.
and chassis ground.
Check
Yes
Go to step 2.
No
Repair the open or
of power supply
circuit.
Go to step 3.
Repair the open or

of power supply
circuit.
Repair the open

circuit of harness
between ECM and
electronic throttle
control connector.

Further tighten
the engine ground
terminal.
Poor contact in
ECM connector
Poor contact in
coupling connector
Replace the ECM.

<Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>
CE:DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE

(BANK 1)
NOTE:
For the diagnostic procedure, refer to DTC P2101. <Ref. to EN(H4SO)(diag)-311, DTC P2101 THROTTLE
ACTUATOR CONTROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(H4SO)(diag)-251

CF:DTC P0691 FAN 1 CONTROL CIRCUIT LOW

GENERAL DESCRIPTION <Ref. to GD(H4SO)-175, DTC P0691 FAN 1 CONTROL CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Radiator fan does not operate properly.
Overheating
CAUTION:
1
Step
Check
Is DTC P0691 displayed?
EN(H4SO)(diag)-252
Yes
No
Check the radiator Temporary poor
fan system. <Ref. contact occurs.
to CO(H4SO)-12,

CG:DTC P0692 FAN 1 CONTROL CIRCUIT HIGH

GENERAL DESCRIPTION <Ref. to GD(H4SO)-176, DTC P0692 FAN 1 CONTROL CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Overheating
CAUTION:
1
Step
Check
Yes
No
Check the radiator Temporary poor
fan system. <Ref. contact occurs.
to CO(H4SO)-12,
CH:DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST)

GENERAL DESCRIPTION <Ref. to GD(H4SO)-177, DTC P0700 TRANSMISSION CONTROL SYSTEM
(MIL REQUEST), Diagnostic Trouble Code (DTC) Detecting Criteria.>
NOTE:
For the diagnostic procedure, refer to AT section. <Ref. to 4AT(D)(diag)-2, PROCEDURE, Basic Diagnostic
Procedure.>
EN(H4SO)(diag)-253

CI: DTC P0851 PARK/NEUTRAL SWITCH INPUT CIRCUIT LOW (AT MODEL)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-178, DTC P0851 PARK/NEUTRAL SWITCH INPUT CIRCUIT LOW (AT MODEL), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B12
31
B136 ECM
MT
: MT MODEL
AT
: AT MODEL
1 2 3 4
5 6 7 8
9 10 11 12
T7
1 2 3 4 5 6
7 8 9 10 11 12
AT
MT
B136
B25
INHIBITOR SWITCH
T2
P
NEUTRAL
POSITION
SWITCH
B12
12
12
11
7
T3
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
T7
T2
1
B25
B25
1 2
B22
STARTER MOTOR
B22
36
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
E3
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B14
E
EN-03794
EN(H4SO)(diag)-254

Step
CHECK SELECT CABLE.
Check
Is there any fault in the select
cable?

2) Place the select lever other than N and P
range.
chassis ground.
TRANSMISSION HARNESS CONNECTOR.
transmission harness connector (T3).
CHECK TRANSMISSION HARNESS CONNECTOR.
switch.
transmission harness connector and engine
ground.
(T3) No. 12 Engine ground:
Yes
Repair or adjust
the selector cable
connection. <Ref.
to CS-25, Select
Cable.>
No
Go to step 2.
Go to step 3.
more?
Go to step 4.
Repair the ground

ECM and transmission harness connector.
more?
Replace the inhibitor switch. <Ref. to

4AT-47, Inhibitor
Switch.>
Repair the ground

transmission harness connector
and inhibitor switch
connector.
EN(H4SO)(diag)-255

CJ:DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT LOW (MT MODEL)

GENERAL DESCRIPTION <Ref. to GD(H4SO)-179, DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT
LOW (MT MODEL), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B12
31
B136 ECM
MT
: MT MODEL
AT
: AT MODEL
1 2 3 4
5 6 7 8
9 10 11 12
T7
1 2 3 4 5 6
7 8 9 10 11 12
AT
MT
B136
B25
INHIBITOR SWITCH
T2
P
NEUTRAL
POSITION
SWITCH
B12
12
12
11
7
T3
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
T7
T2
1
B25
B25
1 2
B22
STARTER MOTOR
B22
36
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
E3
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B14
E
EN-03794
EN(H4SO)(diag)-256

Step
2) Place the shift lever in neutral.
chassis ground.
1) Place the shift lever in a position other than
neutral.
chassis ground.
CHECK NEUTRAL POSITION SWITCH.
2) Disconnect the connector from the transmission harness.
4) Measure the resistance between transmission harness and connector terminals.
(T2) No. 1 No. 2:
neutral.
2) Measure the resistance between transmission harness connector terminals.
(T2) No. 1 No. 2:
NEUTRAL POSITION SWITCH CONNECTOR.
chassis ground.
(B136) No. 31 (B25) No. 2:
ground.
Check
Yes
Go to step 2.
No
Go to step 3.
Go to step 3.
Repair the short

circuit in transmission harness, or
replace the neutral
position switch.
more?
Go to step 5.
Repair the short

replace the neutral
position switch.
Repair the ground

more?
Repair the open

circuit of harness
between ECM and
transmission harness connector.
Go to step 7.
Is the resistance less than 5 ? Repair the poor

contact of transmission harness
connector.
EN(H4SO)(diag)-257
Repair the open

circuit between
and engine ground
terminal.

CK:DTC P0852 PARK/NEUTRAL SWITCH INPUT CIRCUIT HIGH (AT MODEL)

GENERAL DESCRIPTION <Ref. to GD(H4SO)-180, DTC P0852 PARK/NEUTRAL SWITCH INPUT CIRCUIT HIGH (AT MODEL), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B12
31
B136 ECM
MT
: MT MODEL
AT
: AT MODEL
1 2 3 4
5 6 7 8
9 10 11 12
T7
1 2 3 4 5 6
7 8 9 10 11 12
AT
MT
B136
B25
INHIBITOR SWITCH
T2
P
NEUTRAL
POSITION
SWITCH
B12
12
12
11
7
T3
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
T7
T2
1
B25
B25
1 2
B22
STARTER MOTOR
B22
36
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
E3
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B14
E
EN-03794
EN(H4SO)(diag)-258

Step
CHECK SELECT CABLE.
Check
cable?

chassis ground with select lever at N and P
range.
ground with select lever at other than N and
P range.
ground.
CHECK HARNESS BETWEEN ECM AND INHIBITOR SWITCH CONNECTOR.
inhibitor switch.
ECM and inhibitor switch connector.
(B136) No. 31 (T7) No. 12:
Yes
Repair or adjust
the selector cable
connection. <Ref.
to CS-25, Select
Cable.>
Go to step 3.
No
Go to step 2.
Go to step 4.
Go to step 4.

ECM and inhibitor
switch connector.
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and inhibitor
switch connector
Poor contact in
coupling connector
Poor contact of
inhibitor
switch
connector
Poor contact in
ECM connector
EN(H4SO)(diag)-259

Step
Check
CHECK INHIBITOR SWITCH GROUND LINE. Is the resistance less than 5 ?
inhibitor switch connector and engine ground.
EN(H4SO)(diag)-260
Yes
4AT-47, Inhibitor
Switch.>
No
Repair open circuit
of harness
between inhibitor
switch connector
and starter motor
ground line.
NOTE:
the following item:
Open circuit in
harness between
inhibitor
switch
connector
and
starter
motor
ground line
Poor contact in
starter motor connector
Poor contact in
starter
motor
ground
Starter motor

CL:DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH (MT MODEL)

GENERAL DESCRIPTION <Ref. to GD(H4SO)-181, DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT
HIGH (MT MODEL), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B12
31
B136 ECM
MT
: MT MODEL
AT
: AT MODEL
1 2 3 4
5 6 7 8
9 10 11 12
T7
1 2 3 4 5 6
7 8 9 10 11 12
AT
MT
B136
B25
INHIBITOR SWITCH
T2
P
NEUTRAL
POSITION
SWITCH
B12
12
12
11
7
T3
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
T7
T2
1
B25
B25
1 2
B22
STARTER MOTOR
B22
36
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
E3
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B14
E
EN-03794
EN(H4SO)(diag)-261

Step
chassis ground.
neutral.
chassis ground.
CHECK NEUTRAL SWITCH.
neutral.
(T2) No. 1 No. 2:
NEUTRAL SWITCH CONNECTOR.
1) Disconnect the connector from ECM.
(B136) No. 31 (B25) No. 2:
NEUTRAL SWITCH CONNECTOR.
ground.
Check
Yes
Go to step 2.
No
Go to step 3.
Go to step 4.
more?
Go to step 4.
Repair the open

circuit in transmission harness or
replace neutral
switch.
Repair open circuit

of harness
between ECM and

contact in transmission harness
connector.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
transmission harness
connector
and engine ground
Poor contact in
coupling connector
EN(H4SO)(diag)-262

CM:DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK 1

SENSOR 1)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-182, DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
F34
SBF HOLDER
MAIN RELAY
SBF-1
4
15
2
BATTERY
6
4
SBF-5
14
5
3
F100
F2
2
1
7
B61
E23
1
3
E22
4
FRONT
OXYGEN
(A/F) SENSOR
4
1
A/F & OXYGEN

RELAY
REAR
OXYGEN
SENSOR
50
E3
B22
F44
B47
4
E3
1
E3
3
4
B122
B22
51
19
53
B22
2
5
1
B : B135
A : B134
B122
B327
1 2 3 4
5 6 7 8
1 2 3
4
5
F34
2
A: B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B22
1
3
2
4
E23
B47
1
3
5
3 2 1
6 5 4
B: B135
2
4
6
C : B136
B9
B8
C2
C3
B1
B5
B4
A29
C4
C24
B327
ECM
F44
1 2 3 4
5 6 7 8
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
F2
1 2 3 4
10 11 12 13 14
B22
5 6 7 8 9
15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
C: B136
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
5 6
14 15 16
25 26 27
33 34 35
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04771
EN(H4SO)(diag)-263

Step
Check
Yes
Does water enter the connec- Dry the water thorCONNECTOR AND COUPLING CONNECtor?
oughly.
TOR.
(B135) No. 9 (E23) No. 1:
(B135) No. 8 (E23) No. 3:
CHECK POOR CONTACT.

Is there poor contact in front
Check poor contact of front oxygen (A/F) sensor oxygen (A/F) sensor connecconnector.
tor?
EN(H4SO)(diag)-264
No
Go to step 2.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
connector
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
ECM connector
Repair the poor
Replace the front
contact in front
oxygen (A/F) senoxygen (A/F) sensor. <Ref. to
FU(H4SO)-36,
sor connector.
Front Oxygen (A/F)
Sensor.>

CN:DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK 1

SENSOR 1)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-184, DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
F34
SBF HOLDER
MAIN RELAY
SBF-1
4
15
2
BATTERY
6
4
SBF-5
14
5
3
F100
F2
2
1
7
B61
E23
1
3
E22
4
FRONT
OXYGEN
(A/F) SENSOR
4
1
A/F & OXYGEN

RELAY
REAR
OXYGEN
SENSOR
50
E3
B22
F44
B47
4
E3
1
E3
3
4
B122
B22
51
19
53
B22
2
5
1
B : B135
A : B134
B122
B327
1 2 3 4
5 6 7 8
1 2 3
4
5
F34
2
A: B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B22
1
3
2
4
E23
B47
1
3
5
3 2 1
6 5 4
B: B135
2
4
6
C : B136
B9
B8
C2
C3
B1
B5
B4
A29
C4
C24
B327
ECM
F44
1 2 3 4
5 6 7 8
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
F2
1 2 3 4
10 11 12 13 14
B22
5 6 7 8 9
15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
C: B136
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
5 6
14 15 16
25 26 27
33 34 35
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04771
EN(H4SO)(diag)-265

Step
CHECK OUTPUT SIGNAL FOR ECM.
1) Connect the connector to ECM.
and chassis ground.

and chassis ground.

and chassis ground.
Check
Yes
No
oughly.
more?
Repair the ground Go to step 3.

connector.
more?

connector.
Go to step 5.
Repair the battery

connector. After
repair, replace the
ECM. <Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>
Go to step 6.
Replace the front

FU(H4SO)-36,
Front Oxygen (A/F)
Sensor.>
Repair the battery Repair poor conshort circuit of har- tact in ECM conness between
nector.
connector. After
repair, replace the
ECM. <Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>
CO:DTC P1160 RETURN SPRING FAILURE

NOTE:
EN(H4SO)(diag)-266

CP:DTC P1400 FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT

LOW
GENERAL DESCRIPTION <Ref. to GD(H4SO)-188, DTC P1400 FUEL TANK PRESSURE CONTROL
SOLENOID VALVE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
BATTERY
SBF-5
6
4
7
B61
F44
5
3
2
1
B47
PRESSURE
CONTROL
SOLENOID
VALVE
R68
10
R57
R15
R2
1
10
R2
B98
28
24
B98
B136
R68
1 2
B47
1
3
5
2
4
6
B98
F44
1 2
3 4 5
6 7 8 9 10 11 12
1 2 3 4
5 6 7 8
ECM
R57
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
EN-03795
EN(H4SO)(diag)-267

Step
chassis ground.
CHECK HARNESS BETWEEN PRESSURE
CONTROL SOLENOID VALVE AND ECM
CONNECTOR.
2) Disconnect the connectors from the pressure control solenoid valve and ECM.
pressure control solenoid valve connector and
chassis ground.
CONNECTOR.
ECM and pressure control solenoid valve connector.
(B136) No. 28 (R68) No. 2:
Check
Yes

?

ECM and pressure
control solenoid
valve connector.
CHECK PRESSURE CONTROL SOLENOID Is the resistance between 10

and 100 ?
VALVE.
Measure the resistance between pressure control solenoid valve terminals.
Terminals
No. 1 No. 2:
CHECK POWER SUPPLY TO THE PRESIs the voltage 10 V or more?
SURE CONTROL SOLENOID VALVE.
2) Measure the voltage between pressure control solenoid valve and chassis ground.
EN(H4SO)(diag)-268
No
Go to step 2.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and pressure
control
solenoid
valve connector
Poor contact in
coupling connector
Go to step 5.
EC(H4SO)-12,
Pressure Control
Solenoid Valve.>
Repair the poor
Repair the harness
contact in the pres- and connector.
sure control sole- NOTE:
noid valve
connector.
the following item:
Open circuit in
harness between
main relay and
pressure control
solenoid
valve
connector
Poor contact in
coupling connector
Poor contact in

CQ:DTC P1420 FUEL TANK PRESSURE CONTROL SOL. VALVE CIRCUIT HIGH
GENERAL DESCRIPTION <Ref. to GD(H4SO)-190, DTC P1420 FUEL TANK PRESSURE CONTROL
SOL. VALVE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
BATTERY
SBF-5
6
4
7
B61
F44
5
3
2
1
B47
PRESSURE
CONTROL
SOLENOID
VALVE
R68
10
R57
R15
R2
1
10
R2
B98
28
24
B98
B136
R68
1 2
B47
1
3
5
2
4
6
B98
F44
1 2
3 4 5
6 7 8 9 10 11 12
1 2 3 4
5 6 7 8
ECM
R57
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
EN-03795
EN(H4SO)(diag)-269

Step
drivers side).
chassis ground while operating the pressure
NOTE:
Operation
Check
Mode.
<Ref.
to
chassis ground.
CHECK POOR CONTACT.
Check
Yes
Go to step 2.
No
light illuminates,
the circuit has
this time. In this
case, repair the
poor contact in
ECM connector.
Go to step 4.
Go to step 3.

connector?
Replace the ECM.

<Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>
CHECK HARNESS BETWEEN PRESSURE Is the voltage 10 V or more?
short circuit of harCONNECTOR.
ness between
ECM and pressure
control solenoid
valve connector.
After repair,
replace the ECM.
chassis ground.
<Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>
CHECK PRESSURE CONTROL SOLENOID Is the resistance less than 1 ? Replace the pres- Go to step 6.
VALVE.
sure control sole1) Turn the ignition switch to OFF.
noid valve <Ref. to
2) Measure the resistance between pressure
EC(H4SO)-12,
control solenoid valve terminals.
Pressure Control
Terminals
Solenoid Valve.>
No. 1 No. 2:
and ECM <Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>.
CHECK POOR CONTACT.
connector?
nector.
FU(H4SO)-40,
Engine Control
Module (ECM).>
EN(H4SO)(diag)-270

CR:DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM

GENERAL DESCRIPTION <Ref. to GD(H4SO)-192, DTC P1443 VENT CONTROL SOLENOID VALVE
FUNCTION PROBLEM, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper fuel supply
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
BATTERY
SBF-5
5
3
7
B61
F44
2
1
B98
1
2
10
6
1
R2
B47
R15
R57
R69
DRAIN
VALVE
CANISTER
R2
17
B98
B136 ECM
R69
1 2
B47
1
3
5
2
4
6
F44
B98
R57
1 2 3 4
5 6 7 8
1 2
3 4 5
6 7 8 9 10 11 12
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
EN-03785
EN(H4SO)(diag)-271

Step
Check
CHECK VENT LINE HOSES.

Is there any fault in the vent
line?
Clogging of vent hoses between canister and
drain valve
Clogging of vent hose between drain valve
and air filter
Clogging of drain filter
CHECK DRAIN VALVE OPERATION.
Does the drain valve operate?
drivers side).
NOTE:
EN(H4SO)(diag)-272
Yes
No
Check the relevant Go to step 2.
DTC using List of
Diagnostic Trouble
Code (DTC).
<Ref. to
(DTC).>
faulty parts.
Replace the drain

valve. <Ref. to
EC(H4SO)-17,
Drain Valve.>

CS:DTC P1491 POSITIVE CRANKCASE VENTILATION (BLOW-BY) FUNCTION

PROBLEM
GENERAL DESCRIPTION <Ref. to GD(H4SO)-194, DTC P1491 POSITIVE CRANKCASE VENTILATION (BLOW-BY) FUNCTION PROBLEM, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
ECM
34
42
30
B134
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
10
B22
E3
E61
2
1
1 2
E61
PCV
DIAGNOSIS
CONNECTOR
EN-03804
EN(H4SO)(diag)-273

1
2
Step
CHECK BLOW-BY HOSE.
Check the blow-by hose condition.
CHECK HARNESS BETWEEN PCV DIAGNOSIS CONNECTOR AND ECM CONNECTOR.
2) Disconnect the connectors from the PCV
diagnosis connector and ECM.
PCV diagnosis connector and ECM connector.
(B134) No. 30 (E61) No. 2:
PCV diagnosis connector and chassis ground.
CHECK GROUND CIRCUIT OF PCV DIAGNOSIS CONNECTOR.
PCV diagnosis connector and engine ground.
CHECK PCV DIAGNOSIS CONNECTOR.
Measure the resistance between PCV diagnosis connector terminals.
Terminals
No. 1 No. 2:
Check
Yes
Is there any disconnection or
Replace or repair
crack in blow-by hose?
the blow-by hose.
more?
Go to step 4.

contact in ECM
connector and
PCV diagnosis
connector.
No
Go to step 2.
Repair the open
circuit of harness
between PCV
diagnosis connector and ECM connector.
Repair the ground

short circuit of harness between PCV
Repair the ground
circuit of PCV diagnosis connector.
Replace the PCV

diagnosis connector.
CT:DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION

(LOW INPUT)
NOTE:
For the diagnostic procedure, refer to DTC P1498. <Ref. to EN(H4SO)(diag)-276, DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Procedure with Diagnostic
CU:DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION

(HIGH INPUT)
NOTE:
For the diagnostic procedure, refer to DTC P1499. <Ref. to EN(H4SO)(diag)-279, DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Procedure with Diagnostic
CV:DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION

(LOW INPUT)
NOTE:
EN(H4SO)(diag)-274

CW:DTC P1495 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION

(HIGH INPUT)
NOTE:
CX:DTC P1496 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION

(LOW INPUT)
NOTE:
CY:DTC P1497 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION

(HIGH INPUT)
NOTE:
EN(H4SO)(diag)-275

CZ:DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION

(LOW INPUT)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-196, DTC P1492 EGR SOLENOID VALVE SIGNAL #1
CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to
GD(H4SO)-200, DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-200, DTC P1496 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Trouble Code (DTC)
Detecting Criteria.> <Ref. to GD(H4SO)-200, DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT
MALFUNCTION (LOW INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
Engine breathing
CAUTION:
EN(H4SO)(diag)-276

WIRING DIAGRAM:
MAIN RELAY
E18
6
4
BATTERY
1 2 3
4 5 6
SBF-5
7
5
3
B61
2
1
B47
F44
1
3
5
48
B22
B47
2
4
6
E3
F44
1 2 3 4
5 6 7 8
5
2
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
EGR VALVE
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
1
3
4
6
E18
B134
1 2
8 9 10
18 19 20
28 29 30
26
25
29
30
E3
9
8
10
20
B22
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B134 ECM
EN-03782
EN(H4SO)(diag)-277

Step
Check
CHECK POWER SUPPLY TO EGR SOLEIs the voltage 10 V or more?
NOID VALVE.
4) Measure the voltage between EGR solenoid valve connector and engine ground.
Yes
Go to step 2.

EGR SOLENOID VALVE CONNECTOR.
EGR solenoid valve connector.
DTC P1492; (B134) No. 10 (E18) No. 4:
DTC P1494; (B134) No. 9 (E18) No. 1:
DTC P1496; (B134) No. 8 (E18) No. 3:
DTC P1498; (B134) No. 20 (E18) No. 6:

2) Measure the resistance between ECM connector and chassis ground.
DTC P1492; (B134) No. 10 Chassis
ground:
ground:
ground:
ground:
CHECK POOR CONTACT.
Check poor contact in ECM connector and EGR
more?
Go to step 4.

connector or EGR solenoid
valve connector?
Repair the poor

contact in ECM
connector or EGR
EN(H4SO)(diag)-278
No
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
EGR
solenoid
valve and main relay connector
Poor contact in
coupling connector
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and EGR solenoid valve connector
Poor contact in
coupling connector
Repair the ground
short in harness
between ECM and
EGR solenoid
valve connector.
Replace the EGR

solenoid valve.
<Ref. to
FU(H4SO)-29,
EGR Valve.>

DA:DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION

(HIGH INPUT)
GENERAL DESCRIPTION <Ref. to GD(H4SO)-198, DTC P1493 EGR SOLENOID VALVE SIGNAL #1
CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to
GD(H4SO)-200, DTC P1495 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-200, DTC P1497 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Trouble Code (DTC)
Detecting Criteria.> <Ref. to GD(H4SO)-200, DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT
MALFUNCTION (HIGH INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
Engine breathing
CAUTION:
EN(H4SO)(diag)-279

WIRING DIAGRAM:
MAIN RELAY
E18
6
4
BATTERY
1 2 3
4 5 6
SBF-5
7
5
3
B61
2
1
B47
F44
1
3
5
48
B22
B47
2
4
6
E3
F44
1 2 3 4
5 6 7 8
5
2
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
EGR VALVE
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
1
3
4
6
E18
B134
1 2
8 9 10
18 19 20
28 29 30
26
25
29
30
E3
9
8
10
20
B22
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B134 ECM
EN-03782
EN(H4SO)(diag)-280

Step
Check

DTC P1493;
(B134) No. 10 Chassis ground ():
DTC P1495;
DTC P1497;
DTC P1499;
EN(H4SO)(diag)-281
Yes
Check DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
(DTC).>
Repair the battery
short in harness
between ECM and
EGR solenoid
valve connector.
After repair,
replace the ECM.
<Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>
No
Go to step 2.
Replace the ECM.

<Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>

DB:DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT

GENERAL DESCRIPTION <Ref. to GD(H4SO)-201, DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
CAUTION:
EN(H4SO)(diag)-282

WIRING DIAGRAM:
IGNITION
SWITCH
BATTERY
SBF-1
SBF-4
1
3
MT
: MT MODEL
AT
: AT MODEL
B72
INTERRUPT
RELAY
5
2
3
1
B59
TO SECURITY SYSTEM
INHIBITOR SWITCH
P
AT
MT
12
11
B225
7
T3
T7
24
27
28
26
B12
12
STARTER
INTERLOCK
RELAY(AT)
AT
STARTER INTERLOCK
RELAY (MT)
28
27
26
24
STARTER MOTOR
AT
MT
B14
MT
B225
2
1
32
20
CLUTCH SWITCH (MT)
B106
B136
ECM
B225
B106
1
2
B72
1 2
3 4
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
B59
B12
1 2 3
4 5 6
1 2 3 4
5 6 7 8
9 10 11 12
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
T7
1 2 3 4 5 6
7 8 9 10 11 12
EN-04767
EN(H4SO)(diag)-283

Step
Check
CHECK OPERATION OF STARTER MOTOR. Does the starter motor operate
Place the inhibitor switch in P or N range. (AT when ignition switch is turned to
model)
ST?
Depress the clutch pedal. (MT model)
EN(H4SO)(diag)-284
Yes
Repair the harness
and connector.
NOTE:
the following item:
Open or ground
short circuit of harness
between
ECM and starter
motor connector
Poor contact in
ECM connector
No
Check the starter
to
EN(H4SO)(diag)54, STARTER
MOTOR CIRCUIT,
Diagnostics for
Engine Starting
Failure.>

DC:DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION

GENERAL DESCRIPTION <Ref. to GD(H4SO)-202, DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
3
5
TO IGNITION COIL
SBF-5
6
4
1
2
IGNITION
B72
BATTERY
SWITCH
No.11
B47
SBF-4
1
B5
B27
C24
A7
B2
SBF-1
A: B134
B: B135
ECM
C: B136
D2
D3
D7
D1
A5
D: B137
35
37
52
34
36
B22
E3
B72
1 2
3 4
D: B137
B47
1
3
5
2
4
6
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
30 31
26 27
28 29
A: B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
24 25
20 21 22 23
26 27
32 33
34 35
28 29 30 31
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B22
5 6
14 15 16
25 26 27
33 34 35
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-03793
EN(H4SO)(diag)-285

Step
chassis ground.
MAIN FUSE BOX CONNECTOR.
CHECK FUSE SBF-5.
Check
Yes

?

ECM connector
and battery terminal.
Replace the fuse.
EN(H4SO)(diag)-286
No
Go to step 2.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and battery
Poor contact in
ECM connector
Poor contact in
battery terminal

DD:DTC P1602 CONTROL MODULE PROGRAMMING ERROR

GENERAL DESCRIPTION <Ref. to GD(H4SO)-203, DTC P1602 CONTROL MODULE PROGRAMMING
ERROR, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine keeps running at lower speed than specified idle speed.
Engine stalls.
CAUTION:
EN(H4SO)(diag)-287

WIRING DIAGRAM:
B309
1 2
3 4
E57
BATTERY
ELECTRONIC THROTTLE
CONTROL RELAY
SBF-5
B309
1 2 3 4 5 6
2
1
3
4
B122
1 2 3 4
5 6 7 8
C21
C1
MAIN RELAY
D: B137
ECM
D: B137
E
C6
A18
A28
A29
D4
D5
A19
C15
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
30 31
26 27
28 29
MT
D7
A5
D1
D2
D3
A: B134
A: B134
B122
3
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
17
18
19
20
39
38
52
36
34
35
37
B22
1 2
8 9 10
18 19 20
28 29 30
E3
C: B136
5 6
14 15 16
25 26 27
33 34 35
E57
1
2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B22
ELECTRONIC THROTTLE
E
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
CONTROL
34
42
MT
: MT MODEL
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-03774
EN(H4SO)(diag)-288

MAIN RELAY
6
4
BATTERY
SBF-5
14
5
3
F2
B100
2
1
B47
11
10
B22
45
44
9
43
42
48
B137 ECM
E3
E17
E6
E16
E5
E
FUEL INJECTOR
No. 1
E5
E16
E6
E17
1 2
FUEL INJECTOR
No. 2
B47
1
3
5
2
4
6
FUEL INJECTOR
No. 3
FUEL INJECTOR
No. 4
B22
F2
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
B137
35
43
48
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-03778
EN(H4SO)(diag)-289

Step
Check
CHECK ENGINE OIL.
Is the engine oil filled to the

specified amount?
Yes
No
priate DTC using
Code (DTC).
<Ref. to
(DTC).>
Go to step 3.
Replace the
engine oil. <Ref. to
LU (H4SO)-10,
REPLACEMENT,
Engine Oil.>
system.
Repair the air
Go to step 5.
intake system.

on exhaust system?
intake system?
Go to step 6.
Is the fuel pressure 339.5
360.5 kPa (3.5 3.7 kgf/cm2,
WARNING:
area.
WARNING:
SENSOR.
NOTE:
General scan tool
EN(H4SO)(diag)-290

Fuel pressure is
too high:
Clogged fuel line
or bent hose
Fuel pressure is
too low:
Improper fuel
pump discharge
Clogged fuel line
Replace the
engine coolant
FU(H4SO)-22,
Engine Coolant

Step
TEMPERATURE SENSOR.
(140F).
NOTE:
General scan tool
TEMPERATURE SENSOR.
(140F).
NOTE:
General scan tool
):
):
Check
3.4 g/s (0.28 0.45 lb/m)
Yes
Go to step 8.
No
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(H4SO)-28,
Mass Air Flow and
Subtract the ambient tempera- Go to step 9.

ture from intake air temperature. Is the obtained value 10
50C (18 90F)?
Check the mass air

flow and intake air
FU(H4SO)-28,
Mass Air Flow and
Go to step 10.
EN(H4SO)(diag)-291
Go to step 14.

10
11
12
13
Step
Check
Yes
CHECK HARNESS BETWEEN FUEL INJEC- Is the resistance 1 M or
Go to step 11.
more?
CHECK HARNESS BETWEEN FUEL INJEC- Is the resistance less than 1 ? Go to step 12.
faulty cylinders.
#1 (B137) No. 8 (E5) No. 1:
#2 (B137) No. 9 (E16) No. 1:
#3 (B137) No. 10 (E6) No. 1:
#4 (B137) No. 11 (E17) No. 1:
Terminals
No. 1 No. 2:

20 ?
EN(H4SO)(diag)-292
Repair the poor

injector circuit.
No
Repair the ground
injector and ECM
connector.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
Poor contact in
coupling connector
Replace the faulty
to FU(H4SO)-30,
Fuel Injector.>
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
main relay and fuel
injector connector
on faulty cylinders
Poor contact in
coupling connector
Poor contact in
Poor contact in
cylinders

14
15
16
17
18
19
20
Step
Check
):
):
Terminals
No. 1 No. 2:
Yes
No
ECM connector
and fuel injector.
After repair,
replace the ECM.
<Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>
Replace the faulty

fuel injector <Ref.
to FU(H4SO)-30,
Fuel Injector.> and
ECM. <Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>
loosely installed?
sor or crankshaft
position sensor.
sprocket. <Ref. to
ME(H4SO)-50,
Crank Sprocket.>
Repair the installaTIMING BELT.
tion condition of
Turn the crankshaft, and align alignment mark
on crank sprocket with alignment mark on cylinME(H4SO)-44,
der block.
Timing Belt.>
CHECK ELECTRONIC THROTTLE CONIs the resistance less than 1 ? Go to step 20.
TROL RELAY.
2) Remove the electronic throttle control relay.
No. 6 of electronic throttle control relay.
throttle control relay terminals.
Terminals
No. 2 No. 4:
Go to step 21.
CHECK POWER SUPPLY OF ELECTRONIC Is the voltage 5 V or more?
THROTTLE CONTROL RELAY.
control relay connector and chassis ground.
EN(H4SO)(diag)-293
Go to step 16.
Go to step 17.
Go to step 18.
Go to step 19.
Replace the electronic throttle control relay.
Repair the open or

of power supply
circuit.

21
22
23
24
25
26
Step
ELECTRONIC THROTTLE CONTROL RELAY.
throttle control relay connector and chassis
ground.
ground.
Measure the resistance between ECM connector and electronic throttle control relay connector.
(B136) No. 21 (B309) No. 3:
(B136) No. 1 (B309) No. 4:
1) Connect all connectors.
NOTE:
NOTE:
CHECK POOR CONTACT.
Check
Yes
Go to step 22.
No
Repair the power
supply short circuit
of harness
between ECM and
electronic throttle
control.
more?
Go to step 23.
Repair the ground

ECM and electronic throttle control relay.
Repair the open

circuit of harness
between ECM and
electronic throttle
control relay.
Go to step 25.
Go to step 27.
Go to step 26.
Go to step 27.
Repair the poor

contact.
Go to step 31.
EN(H4SO)(diag)-294

27
28
29
30
31
32
33
Step
throttle control.
(B134) No. 18 (E57) No. 6:
(B134) No. 28 (E57) No. 4:
(B134) No. 19 (E57) No. 5:
CHECK SHORT CIRCUIT IN ECM.
NOTE:
Read the data of sub throttle sensor signal
NOTE:
CHECK POOR CONTACT.
Check
Yes
No
Repair the open
circuit of harness
connector.
more?
Go to step 29.
Repair the ground

Go to step 30.
Repair poor contact in ECM connector
Is the resistance 10 or more? Go to step 31.
Go to step 34.
Go to step 34.
Go to step 39.
EN(H4SO)(diag)-295
Repair the poor

contact.

34
35
36
37
38
39
Step
throttle control.
(B134) No. 29 (E57) No. 3:
(B134) No. 18 (E57) No. 6:
(B134) No. 28 (E57) No. 4:
2) Remove the ECM.
3) Measure the resistance between ECM connectors.
(B134) No. 18 (B134) No. 19:
(B134) No. 28 (B134) No. 19:
2) Connect the connectors except for electric
throttle control relay.
NOTE:
Check
Yes
No
Repair the open
circuit of harness
connector.
Go to step 37.
Go to step 38.
Repair the battery

ECM connector
and electronic
throttle control
connector.
Repair the short
circuit of harness
between ECM connector and electronic throttle
control connector.
more?
Go to step 39.
Repair the short

circuit to sensor
power supply.
Go to step 40.
Repair the poor

contact of electronic throttle control connector.
EN(H4SO)(diag)-296

40
41
42
43
44
45
Step
NOTE:
ELECTRONIC THROTTLE CONTROL MOTOR.
throttle control.
(B137) No. 5 (E57) No. 2:
(B137) No. 4 (E57) No. 1:
CHECK ELECTRONIC THROTTLE CONTROL MOTOR HARNESS.
Measure the resistance between electronic
throttle control connector terminals.
(E57) No. 2 (E57) No. 1:
CHECK ELECTRONIC THROTTLE CONTROL GROUND CIRCUIT.
Check
Yes
Go to step 41.
No
Repair poor contact in ECM connector. Replace
the electronic
throttle control if
defective.
Repair the open

circuit of harness
connector.
Go to step 43.
Repair the power

of harness
between ECM and
electronic throttle
control.
more?
Go to step 44.
Repair the short

circuit of harness.
more?
Go to step 45.
Repair the short

circuit of harness.

?
Go to step 46.
Repair the open

circuit of harness.
EN(H4SO)(diag)-297

46
47
Step
throttle control terminals.
Terminals
No. 1 No. 2:
Move the throttle valve to the fully opened and
fully closed positions with fingers.
Check that the valve returns to the specified
position when releasing fingers.
Check
Yes
Is the resistance 50 or less? Go to step 47.
No
Replace the electronic throttle control.
Does the valve return to the

Repair poor conspecified position? Standard
tact in ECM convalue: 3 mm (0.12 in) from fully nector.
closed position
EN(H4SO)(diag)-298

DE:DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN BANK 1
GENERAL DESCRIPTION <Ref. to GD(H4SO)-205, DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN BANK 1, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
F34
SBF HOLDER
MAIN RELAY
SBF-1
4
15
2
BATTERY
6
4
SBF-5
14
5
3
F100
F2
2
1
7
B61
E22
E23
1
3
FRONT
OXYGEN
(A/F) SENSOR
4
1
A/F & OXYGEN

RELAY
REAR
OXYGEN
SENSOR
B22
50
E3
F44
B47
4
E3
1
E3
3
4
B122
B22
51
19
53
B22
2
5
1
B : B135
A : B134
B122
B327
1 2 3 4
5 6 7 8
1 2 3
4
5
F34
2
A: B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B22
1
3
2
4
E23
B47
1
3
5
3 2 1
6 5 4
B: B135
2
4
6
C : B136
B9
B8
C2
C3
B1
B5
B4
A29
C4
C24
B327
ECM
F44
1 2 3 4
5 6 7 8
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
F2
1 2 3 4
10 11 12 13 14
B22
5 6 7 8 9
15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
C: B136
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
5 6
14 15 16
25 26 27
33 34 35
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04771
EN(H4SO)(diag)-299

Step
Check
Yes
No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
(DTC).>
NOTE:
oughly.

TOR.
(B135) No. 9 (E23) No. 1:
(B135) No. 8 (E23) No. 3:

and chassis ground.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
connector
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
ECM connector
Repair the ground
connector.
more?
Go to step 5.
Go to step 6.
Repair the battery Repair poor conshort circuit of har- tact in ECM connector.
ness between
connector. After
repair, replace the
ECM. <Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>
EN(H4SO)(diag)-300
Go to step 7.

9
10
11
12
Step
and chassis ground.
and chassis ground.
Check
Yes
No
Go to step 9.
Repair the battery

connector. After
repair, replace the
ECM. <Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>
Repair the exhaust
system.
Repair the air
intake system.

on exhaust system?
intake system?
Is the measured value 339.5 Go to step 12.
360.5 kPa (3.5 3.7 kgf/cm2,
WARNING:
area.
WARNING:
CHECK ENGINE COOLANT TEMPERATURE Is the temperature 60C
SENSOR.
(140F) or more?
NOTE:
General scan tool
EN(H4SO)(diag)-301
Go to step 13.
Go to step 10.
Go to step 11.

Fuel pressure is
too high:
Clogged fuel line
or bent hose
Fuel pressure is
too low:
Improper fuel
pump discharge
Clogged fuel line
Replace the
engine coolant
FU(H4SO)-22,
Engine Coolant

13
14
15
Step
TEMPERATURE SENSOR.
(140F).
NOTE:
General scan tool
TEMPERATURE SENSOR.
(140F).
NOTE:
General scan tool
tool.
NOTE:
General scan tool
Check
3.4 g/s (0.28 0.45 lb/m)
Yes
Go to step 14.
No
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(H4SO)-28,
Mass Air Flow and

50C (18 90F)?
Check the mass air

flow and intake air
FU(H4SO)-28,
Mass Air Flow and
Go to step 16.
EN(H4SO)(diag)-302

16
17
18
19
Step
rear oxygen sensor.
(B135) No. 4 (E22) No. 3:
(B134) No. 29 (E22) No. 4:
or chassis ground.
Check
Yes
No
tor?
oughly.
Go to step 18.
circuit of harness
between ECM and
rear oxygen sensor
connector.
Replace the rear

oxygen sensor.
<Ref. to
FU(H4SO)-38,

tool.
NOTE:
General scan tool
EN(H4SO)(diag)-303
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
Poor contact in
Poor contact in
ECM connector
Go to step 16.

20
Step
Check
CHECK THE FRONT OXYGEN (A/F) SENDoes voltage keep to be 0.8 V
SOR AND REAR OXYGEN SENSOR DATA. or more for more than five min1) Warm-up the engine until engine coolant
utes?
temperature is above 70C (158F), and leave it
unattended for five minutes in idling state.
tool.
NOTE:
General scan tool
EN(H4SO)(diag)-304
Yes
No
Replace the front Go to step 17.
FU(H4SO)-36,
Front Oxygen (A/F)
Sensor.>

DF:DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH BANK 1
GENERAL DESCRIPTION <Ref. to GD(H4SO)-207, DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH BANK 1, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
F34
SBF HOLDER
MAIN RELAY
SBF-1
4
15
2
BATTERY
6
4
SBF-5
14
5
3
F100
F2
2
1
7
B61
E22
E23
1
3
FRONT
OXYGEN
(A/F) SENSOR
4
1
A/F & OXYGEN

RELAY
REAR
OXYGEN
SENSOR
B22
50
E3
F44
B47
4
E3
1
E3
3
4
B122
B22
51
19
53
B22
2
5
1
B : B135
A : B134
B122
B327
1 2 3 4
5 6 7 8
1 2 3
4
5
F34
2
A: B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B22
1
3
2
4
E23
B47
1
3
5
3 2 1
6 5 4
B: B135
2
4
6
C : B136
B9
B8
C2
C3
B1
B5
B4
A29
C4
C24
B327
ECM
F44
1 2 3 4
5 6 7 8
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
F2
1 2 3 4
10 11 12 13 14
B22
5 6 7 8 9
15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
C: B136
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
5 6
14 15 16
25 26 27
33 34 35
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04771
EN(H4SO)(diag)-305

Step
Check
Yes
No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
(DTC).>
NOTE:
oughly.

TOR.
(B135) No. 9 (E23) No. 1:
(B135) No. 8 (E23) No. 3:

and chassis ground.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
connector
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
ECM connector
Repair the ground
connector.
more?
Go to step 5.
Go to step 6.
Repair the battery Repair poor conshort circuit of har- tact in ECM connector.
ness between
connector. After
repair, replace the
ECM. <Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>
EN(H4SO)(diag)-306
Go to step 7.

9
10
11
12
Step
and chassis ground.
and chassis ground.
Check
Yes
No
Go to step 9.
Repair the battery

connector. After
repair, replace the
ECM. <Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>
Repair the exhaust
system.
Repair the air
intake system.

on exhaust system?
intake system?
Is the measured value 339.5 Go to step 12.
360.5 kPa (3.5 3.7 kgf/cm2,
WARNING:
area.
WARNING:
CHECK ENGINE COOLANT TEMPERATURE Is the temperature 60C
SENSOR.
(140F) or more?
NOTE:
General scan tool
EN(H4SO)(diag)-307
Go to step 13.
Go to step 10.
Go to step 11.

Fuel pressure is
too high:
Clogged fuel line
or bent hose
Fuel pressure is
too low:
Improper fuel
pump discharge
Clogged fuel line
Replace the
engine coolant
FU(H4SO)-22,
Engine Coolant

13
14
15
Step
TEMPERATURE SENSOR.
(140F).
NOTE:
General scan tool
TEMPERATURE SENSOR.
(140F).
NOTE:
General scan tool
tool.
NOTE:
General scan tool
Check
3.4 g/s (0.28 0.45 lb/m)
Yes
Go to step 14.
No
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(H4SO)-28,
Mass Air Flow and

50C (18 90F)?
Check the mass air

flow and intake air
FU(H4SO)-28,
Mass Air Flow and
Go to step 16.
EN(H4SO)(diag)-308

16
17
18
19
Step
rear oxygen sensor.
(B135) No. 4 (E22) No. 3:
(B134) No. 29 (E22) No. 4:
or chassis ground.
Check
Yes
No
tor?
oughly.
Go to step 18.
circuit of harness
between ECM and
rear oxygen sensor
connector.
Replace the rear

oxygen sensor.
<Ref. to
FU(H4SO)-38,

tool.
NOTE:
General scan tool
EN(H4SO)(diag)-309
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
Poor contact in
Poor contact in
ECM connector
Go to step 16.

20
Step
Check
Does voltage keep to be 0.8 V
AND REAR OXYGEN SENSOR.
or more for more than five min1) Warm-up the engine until engine coolant
utes?
tool.
NOTE:
General scan tool
EN(H4SO)(diag)-310
Yes
No
FU(H4SO)-36,
Front Oxygen (A/F)
Sensor.>

DG:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/

PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H4SO)-172, DTC P0638 THROTTLE ACTUATOR CONTROL
RANGE/PERFORMANCE (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to
GD(H4SO)-186, DTC P1160 RETURN SPRING FAILURE, Diagnostic Trouble Code (DTC) Detecting Criteria.> or <Ref. to GD(H4SO)-209, DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT
RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to GD(H4SO)-215,
DTC P2109 THROTTLE/PEDAL POSITION SENSOR A MINIMUM STOP PERFORMANCE, Diagnostic
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
EN(H4SO)(diag)-311

WIRING DIAGRAM:
B309
1 2
3 4
E57
BATTERY
ELECTRONIC THROTTLE
CONTROL RELAY
SBF-5
B309
1 2 3 4 5 6
2
1
3
4
B122
1 2 3 4
5 6 7 8
C21
C1
MAIN RELAY
D: B137
ECM
D: B137
E
C6
A18
A28
A29
D4
D5
A19
C15
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
30 31
26 27
28 29
MT
D7
A5
D1
D2
D3
A: B134
A: B134
B122
3
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
17
18
19
20
39
38
52
36
34
35
37
B22
1 2
8 9 10
18 19 20
28 29 30
E3
C: B136
5 6
14 15 16
25 26 27
33 34 35
E57
1
2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B22
ELECTRONIC THROTTLE
E
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
CONTROL
34
42
MT
: MT MODEL
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-03774
EN(H4SO)(diag)-312

Step
CHECK ELECTRONIC THROTTLE CONTROL RELAY.
Terminals
No. 2 No. 4:
ground.
ground.
2) Measure the resistance between ECM connector and electronic throttle control relay connector.
(B136) No. 21 (B309) No. 3:
(B136) No. 1 (B309) No. 4:
Check
Yes
No
Go to step 3.
Repair the open or

of power supply
circuit.
Go to step 4.
Repair the power

of harness
between ECM and
electronic throttle
control.
more?
Go to step 5.
Repair the ground

Repair the open

circuit of harness
between ECM and
electronic throttle
control relay.
Go to step 7.
Go to step 9.
Go to step 8.
Go to step 9.
EN(H4SO)(diag)-313

10
11
12
13
14
15
16
Step
CHECK POOR CONTACT.
throttle control.
(B134) No. 18 (E57) No. 6:
(B134) No. 28 (E57) No. 4:
CHECK POOR CONTACT.
throttle control.
(B134) No. 18 (E57) No. 6:
(B134) No. 28 (E57) No. 4:
Check
Yes
Repair the poor
contact.
No
Go to step 13.
Repair the open

circuit of harness
connector.
more?
Go to step 11.
Repair the ground

Go to step 12.
Go to step 16.
Go to step 16.
Go to step 21.
Repair the poor

contact.
EN(H4SO)(diag)-314
Repair the open

circuit of harness
connector.

17
18
19
20
21
22
23
Step
2) Remove the ECM.
(B134) No. 18 (B134) No. 19:
(B134) No. 28 (B134) No. 19:
Check
Yes
No
Go to step 19.
Go to step 20.
Repair the battery

ECM connector
and electronic
throttle control
connector.
Repair the short
circuit of harness
control connector.
more?
Go to step 21.
Repair the short

circuit to sensor
power supply.
Go to step 22.
Go to step 23.
Repair the poor

Repair poor contact in ECM connector. Replace
the electronic
throttle control if
defective.
Repair the open
circuit of harness
connector.

throttle control.
(B137) No. 5 (E57) No. 2:
(B137) No. 4 (E57) No. 1:
EN(H4SO)(diag)-315

24
25
26
27
28
29
Step
(E57) No. 2 (E57) No. 1:
Terminals
No. 1 No. 2:
Check
Yes
Go to step 25.
No
Repair the power
of harness
between ECM and
electronic throttle
control.
more?
Go to step 26.
Repair the short

circuit of harness.
more?
Go to step 27.
Repair the short

circuit of harness.

?
Go to step 28.
Repair the open

circuit of harness.

closed position
EN(H4SO)(diag)-316

DH:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW

MOTOR CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
B309
1 2
3 4
E57
BATTERY
ELECTRONIC THROTTLE
CONTROL RELAY
SBF-5
B309
1 2 3 4 5 6
2
1
3
4
B122
1 2 3 4
5 6 7 8
C21
C1
MAIN RELAY
D: B137
ECM
D: B137
E
C6
A18
A28
A29
D4
D5
A19
C15
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
30 31
26 27
28 29
MT
D7
A5
D1
D2
D3
A: B134
A: B134
B122
3
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
17
18
19
20
39
38
52
36
34
35
37
B22
1 2
8 9 10
18 19 20
28 29 30
E3
C: B136
5 6
14 15 16
25 26 27
33 34 35
E57
1
2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B22
ELECTRONIC THROTTLE
E
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
CONTROL
34
42
MT
: MT MODEL
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-03774
EN(H4SO)(diag)-317

Step
Terminals
No. 2 No. 4:
ground.
ground.
(B136) No. 21 (B309) No. 3:
(B136) No. 1 (B309) No. 4:
Check
Yes
No
Go to step 3.
Repair the open or

of power supply
circuit.
Go to step 4.
Repair the power

of harness
between ECM and
electronic throttle
control relay.
more?
Go to step 5.
Repair the ground

Is the resistance less than 1 ? Repair poor contact in ECM connector.
EN(H4SO)(diag)-318
Repair the open

circuit of harness
between ECM and
electronic throttle
control relay.

DI: DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH

MOTOR CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
B309
1 2
3 4
E57
BATTERY
ELECTRONIC THROTTLE
CONTROL RELAY
SBF-5
B309
1 2 3 4 5 6
2
1
3
4
B122
1 2 3 4
5 6 7 8
C21
C1
MAIN RELAY
D: B137
ECM
D: B137
E
C6
A18
A28
A29
D4
D5
A19
C15
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
30 31
26 27
28 29
MT
D7
A5
D1
D2
D3
A: B134
A: B134
B122
3
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
17
18
19
20
39
38
52
36
34
35
37
B22
1 2
8 9 10
18 19 20
28 29 30
E3
C: B136
5 6
14 15 16
25 26 27
33 34 35
E57
1
2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B22
ELECTRONIC THROTTLE
E
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
CONTROL
34
42
MT
: MT MODEL
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-03774
EN(H4SO)(diag)-319

Step
Terminals
No. 2 No. 4:
CHECK SHORT CIRCUIT OF ELECTRONIC
THROTTLE CONTROL RELAY POWER SUPPLY.
ground.
3) Measure the resistance between ECM connector and engine ground.
Check
more?
Yes
Go to step 2.
No
Go to step 3.
Repair the power

of harness
between ECM and
electronic throttle
control relay.
more?
Repair the ground

DJ:DTC P2109 THROTTLE/PEDAL POSITION SENSOR A MINIMUM STOP

PERFORMANCE
NOTE:
EN(H4SO)(diag)-320

DK:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT

LOW INPUT
GENERAL DESCRIPTION <Ref. to GD(H4SO)-217, DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B315
1 2 3 4 5 6
ACCELERATOR PEDAL
POSITION SENSOR
1 2 3 4
5 6 7 8
B122
B315
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
28 29
30 31
26 27
4
7
B30
B31
B22
B29
B23
C6
B21
A: B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B: B135
ECM
B: B135
C: B136
1 2
3
8 9 10 11 12 13
20 21 22 23
28 29 30 31
A5
D7
D2
D1
D3
D: B137
4 5 6 7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
36
52
35
34
C: B136
37
B122
A: B134
1 2
8 9 10
18 19 20
28 29 30
B22
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
E3
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-04614
EN(H4SO)(diag)-321

Step
Check
CHECK ACCELERATOR PEDAL POSITION Is the voltage 0.4 V or more?
SENSOR OUTPUT.
2) Read the data of main accelerator pedal
position sensor signal using Subaru Select
Monitor. <Ref. to EN(H4SO)(diag)-27, Subaru
Select Monitor.>
CHECK POOR CONTACT.
Check poor contact of connector between ECM
and accelerator pedal position sensor.
CHECK HARNESS BETWEEN ECM AND ACCELERATOR PEDAL POSITION SENSOR.
3) Disconnect the connectors from accelerator
pedal position sensor.
4) Measure the resistance of ECM connector
and accelerator pedal position sensor connector.
(B135) No. 21 (B315) No. 4:
(B135) No. 23 (B315) No. 6:
2) Measure the resistance between accelerator pedal position sensor connector and chassis
ground.
CHECK POWER SUPPLY OF ACCELERATOR PEDAL POSITION SENSOR.
2) Measure the voltage between accelerator
pedal position sensor connector and chassis
ground.
Yes
Go to step 2.
No
Go to step 3.
Repair the poor

contact.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
more?
Go to step 5.
EN(H4SO)(diag)-322
Repair the chassis

Replace the accel- Repair poor conerator pedal posi- tact in ECM contion sensor. <Ref. nector.
to SP (H4SO)-3,
Accelerator
Pedal.>

DL:DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT

HIGH INPUT
GENERAL DESCRIPTION <Ref. to GD(H4SO)-219, DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B315
1 2 3 4 5 6
ACCELERATOR PEDAL
POSITION SENSOR
1 2 3 4
5 6 7 8
B122
B315
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
28 29
30 31
26 27
4
7
B30
B31
B22
B29
B23
C6
B21
A: B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B: B135
ECM
B: B135
C: B136
1 2
3
8 9 10 11 12 13
20 21 22 23
28 29 30 31
A5
D7
D2
D1
D3
D: B137
4 5 6 7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
36
52
35
34
C: B136
37
B122
A: B134
1 2
8 9 10
18 19 20
28 29 30
B22
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
E3
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-04614
EN(H4SO)(diag)-323

Step
Check
Yes
CHECK ACCELERATOR PEDAL POSITION Is the voltage less than 4.8 V? Go to step 2.
SENSOR OUTPUT.
Monitor. <Ref. to EN(H4SO)(diag)-27, Subaru
Select Monitor.>
CHECK POOR CONTACT.
Repair the poor
contact.
CHECK HARNESS BETWEEN ECM AND AC- Is the resistance less than 1 ? Go to step 4.
CELERATOR PEDAL POSITION SENSOR.
4) Measure the resistance between ECM connector and accelerator pedal position sensor
connector.
(B135) No. 21 (B315) No. 4:
(B135) No. 29 (B315) No. 5:
(B135) No. 23 (B315) No. 6:
ground.
CHECK POWER SUPPLY OF ACCELERAIs the voltage 4.5 5.5 V?
Go to step 6.
TOR PEDAL POSITION SENSOR.
ground.
CHECK HARNESS BETWEEN ECM AND AC- Is the voltage less than 4.8 V? Repair poor conCELERATOR PEDAL POSITION SENSOR.
tact in ECM con1) Turn the ignition switch to OFF.
nector.
2) Connect the accelerator pedal position sensor connector.
EN(H4SO)(diag)-324
No
Go to step 3.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
Repair the short

circuit of harness
between ECM connector and accelerator pedal
position sensor
connector.
Replace the ECM if
defective. <Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>
Repair the poor
contact of accelerator pedal position
sensor connector.
defective. <Ref. to
SP (H4SO)-3,
Accelerator
Pedal.>

DM:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT

LOW INPUT
GENERAL DESCRIPTION <Ref. to GD(H4SO)-221, DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B315
1 2 3 4 5 6
ACCELERATOR PEDAL
POSITION SENSOR
1 2 3 4
5 6 7 8
B122
B315
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
28 29
30 31
26 27
4
7
B30
B31
B22
B29
B23
C6
B21
A: B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B: B135
ECM
B: B135
C: B136
1 2
3
8 9 10 11 12 13
20 21 22 23
28 29 30 31
A5
D7
D2
D1
D3
D: B137
4 5 6 7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
36
52
35
34
C: B136
37
B122
A: B134
1 2
8 9 10
18 19 20
28 29 30
B22
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
E3
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-04614
EN(H4SO)(diag)-325

Step
Check
SENSOR OUTPUT.
2) Read the data of sub accelerator pedal position sensor signal using Subaru Select Monitor.
<Ref. to EN(H4SO)(diag)-27, Subaru Select
Monitor.>
CHECK POOR CONTACT.
connector.
(B135) No. 22 (B315) No. 1:
(B135) No. 31 (B315) No. 3:
ground.
ground.
Yes
Go to step 2.
No
Go to step 3.
Repair the poor

contact.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
more?
Go to step 5.
EN(H4SO)(diag)-326
Repair the chassis

to SP (H4SO)-3,
Accelerator
Pedal.>

DN:DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT

HIGH INPUT
GENERAL DESCRIPTION <Ref. to GD(H4SO)-223, DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B315
1 2 3 4 5 6
ACCELERATOR PEDAL
POSITION SENSOR
1 2 3 4
5 6 7 8
B122
B315
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
28 29
30 31
26 27
4
7
B30
B31
B22
B29
B23
C6
B21
A: B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B: B135
ECM
B: B135
C: B136
1 2
3
8 9 10 11 12 13
20 21 22 23
28 29 30 31
A5
D7
D2
D1
D3
D: B137
4 5 6 7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
36
52
35
34
C: B136
37
B122
A: B134
1 2
8 9 10
18 19 20
28 29 30
B22
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
E3
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-04614
EN(H4SO)(diag)-327

Step
Check
Yes
SENSOR OUTPUT.
<Ref. to EN(H4SO)(diag)-27, Subaru Select
Monitor.>
CHECK POOR CONTACT.
Repair the poor
contact.
connector.
(B135) No. 22 (B315) No. 1:
(B135) No. 30 (B315) No. 2:
(B135) No. 31 (B315) No. 3:
ground.
ground.
No
Go to step 3.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
Is the voltage less than 4.5

5.5 V?
Repair the short

circuit of harness
position sensor
connector.
Replace the ECM if
defective. <Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>
Repair the poor
sensor connector.
defective. <Ref. to
SP (H4SO)-3,
Accelerator
Pedal.>
Go to step 6.
CHECK HARNESS BETWEEN ECM AND AC- Is the voltage less than 4.8 V? Repair poor conCELERATOR PEDAL POSITION SENSOR.
tact in ECM con1) Turn the ignition switch to OFF.
nector.
EN(H4SO)(diag)-328

DO:DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH A/B VOLTAGE CORRELATION

GENERAL DESCRIPTION <Ref. to GD(H4SO)-225, DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH A/B VOLTAGE CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B309
1 2
3 4
E57
BATTERY
ELECTRONIC THROTTLE
CONTROL RELAY
SBF-5
B309
1 2 3 4 5 6
2
1
3
4
B122
1 2 3 4
5 6 7 8
C21
C1
MAIN RELAY
D: B137
ECM
D: B137
E
C6
A18
A28
A29
D4
D5
A19
C15
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
30 31
26 27
28 29
MT
D7
A5
D1
D2
D3
A: B134
A: B134
B122
3
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
17
18
19
20
39
38
52
36
34
35
37
B22
1 2
8 9 10
18 19 20
28 29 30
E3
C: B136
5 6
14 15 16
25 26 27
33 34 35
E57
1
2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B22
ELECTRONIC THROTTLE
E
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
CONTROL
34
42
MT
: MT MODEL
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-03774
EN(H4SO)(diag)-329

10
Step
CHECK POOR CONTACT.
throttle control.
(B134) No. 18 (E57) No. 6:
(B134) No. 28 (E57) No. 4:
CHECK POOR CONTACT.
Check
Yes
Go to step 2.
No
Go to step 4.
Go to step 3.
Go to step 4.
Repair the poor

contact.
Go to step 14.
Repair the open

circuit of harness
connector.
more?
Go to step 6.
Repair the ground

Go to step 7.
Go to step 11.
Go to step 11.
Temporary poor
contact occurred,
but it is normal at
present.
EN(H4SO)(diag)-330
Repair the poor

contact.

11
12
13
14
15
16
Step
throttle control.
(B134) No. 18 (E57) No. 6:
(B134) No. 28 (E57) No. 4:
2) Disconnect the ECM connector.
(B134) No. 18 (B134) No. 19:
(B134) No. 28 (B134) No. 19:
CHECK ELECTRONIC THROTTLE CONTROL HARNESS.
throttle control.
(E57) No. 6 (E57) No. 4:
Check
Yes
No
Repair the open
circuit of harness
connector.
Go to step 14.
Repair the battery

ECM connector
and electronic
throttle control
connector.
Go to step 15.
Repair the short

circuit of harness
control connector.
more?
Go to step 16.
Repair the short

circuit to sensor
power supply.
more?
Repair the short

circuit of harness.
EN(H4SO)(diag)-331

DP:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D/E VOLTAGE CORRELATION

GENERAL DESCRIPTION <Ref. to GD(H4SO)-227, DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D/E VOLTAGE CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B315
1 2 3 4 5 6
ACCELERATOR PEDAL
POSITION SENSOR
1 2 3 4
5 6 7 8
B122
B315
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
28 29
30 31
26 27
4
7
B30
B31
B22
B29
B23
C6
B21
A: B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B: B135
ECM
B: B135
C: B136
1 2
3
8 9 10 11 12 13
20 21 22 23
28 29 30 31
A5
D7
D2
D1
D3
D: B137
4 5 6 7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
36
52
35
34
C: B136
37
B122
A: B134
1 2
8 9 10
18 19 20
28 29 30
B22
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
E3
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-04614
EN(H4SO)(diag)-332

Step
Check
SENSOR OUTPUT.
position sensor signal and sub accelerator
pedal position sensor signal using Subaru
Select Monitor.
NOTE:
CHECK ACCELERATOR PEDAL POSITION Is the voltage less than 4.8 V?
SENSOR OUTPUT.
Select Monitor.
NOTE:
CHECK POOR CONTACT.
Yes
Go to step 2.
No
Go to step 4.
Go to step 3.
Go to step 4.
Repair the poor

contact.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
connector.
(B135) No. 22 (B315) No. 1:
(B135) No. 30 (B315) No. 2:
(B135) No. 31 (B315) No. 3:
(B135) No. 21 (B315) No. 4:
(B135) No. 29 (B315) No. 5:
(B135) No. 23 (B315) No. 6:
CHECK HARNESS BETWEEN ECM AND AC- Is the resistance 1 M or
Go to step 6.
CELERATOR PEDAL POSITION SENSOR. more?
EN(H4SO)(diag)-333
Repair the chassis


Step
ground.
ground.
terminals of accelerator pedal position sensor.
(B315) No. 6 (B315) No. 3:
Check
Yes
No
Go to step 8.
more?
EN(H4SO)(diag)-334
Repair the poor

sensor connector.
defective. <Ref. to
SP (H4SO)-3,
Accelerator
Pedal.>
Repair the short
circuit of harness
position sensor
connector.

DQ:DTC P2227 BAROMETRIC PRESSURE CIRCUIT RANGE/PERFORMANCE

GENERAL DESCRIPTION <Ref. to GD(H4SO)-229, DTC P2227 BAROMETRIC PRESSURE CIRCUIT
CAUTION:
1
Step
Check
Yes
Check DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
(DTC).>
No
Replace the ECM.
<Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>
DR:DTC P2228 BAROMETRIC PRESSURE CIRCUIT LOW

CAUTION:
1
Step
Check
EN(H4SO)(diag)-335
Yes
Check DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
(DTC).>
NOTE:
It is not necessary
to inspect DTC
P2228.
No
Replace the ECM.
<Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>

DS:DTC P2229 BAROMETRIC PRESSURE CIRCUIT HIGH

CAUTION:
1
Step
Check
EN(H4SO)(diag)-336
Yes
Check DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
(DTC).>
NOTE:
It is not necessary
to inspect DTC
P2229.
No
Replace the ECM.
<Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>
General Diagnostic Table

20.General Diagnostic Table

A: INSPECTION
1. ENGINE
NOTE:
Malfunction of parts other than those listed is also possible. <Ref. to ME(H4SO)-91, Engine Trouble in General.>
Symptom
1. Engine stalls during idling.
Problem parts
1) Manifold absolute pressure sensor
2) Mass air flow and intake air temperature sensor
3) Ignition parts (*1)
4) Engine coolant temperature sensor (*2)
5) Crankshaft position sensor (*3)
6) Camshaft position sensor (*3)
7) Fuel injection parts (*4)
2. Rough idling

5) Air intake system (*5)
7) Electronic throttle control
10) Oxygen sensor
11) Fuel pump and fuel pump relay
12) EGR valve
3. Engine does not return to idle.
1) Engine coolant temperature sensor

2) Throttle position sensor
5) EGR valve

4. Poor acceleration
9) A/C switch and A/C cut relay
10) Engine torque control signal circuit
12) EGR valve
13) Tumble generator valve
5. Engine stalls, engine sags or hesitates at accel6) Purge control solenoid valve
eration.
10) EGR valve
EN(H4SO)(diag)-337

Symptom
6. Surging
7. Spark knock
8. After-burning in exhaust system
Problem parts
9) EGR valve
4) Knock sensor
7) EGR valve
*1: Check ignition coil and ignitor assembly and spark plug.
*2: Indicate the symptom occurring only in cold temperatures.
*3: Make sure the secure installation.
*4: Check fuel injector, fuel pressure regulator and fuel filter.
*5: Inspect air leak in air intake system.
2. AUTOMATIC TRANSMISSION
NOTE:
Check general diagnostics table with non-conformity symptom for automatic transmission. <Ref. to
4AT(D)(diag)-2, Basic Diagnostic Procedure.>
EN(H4SO)(diag)-338


A: INSPECTION
1. ENGINE
NOTE:
Malfunction of parts other than those listed is also possible. <Ref. to ME(H4SO)-91, Engine Trouble in General.>
Symptom
Problem parts
2. Rough idling

10) Oxygen sensor
12) EGR valve

5) EGR valve

12) EGR valve
5. Engine stalls, engine sags or hesitates at accel6) Purge control solenoid valve
eration.
10) EGR valve
EN(H4SO)(diag)-337

Symptom
6. Surging
7. Spark knock
8. After-burning in exhaust system
Problem parts
9) EGR valve
4) Knock sensor
7) EGR valve
*3: Make sure the secure installation.
2. AUTOMATIC TRANSMISSION
NOTE:
Check general diagnostics table with non-conformity symptom for automatic transmission. <Ref. to
4AT(D)(diag)-2, Basic Diagnostic Procedure.>
EN(H4SO)(diag)-338

GENERAL DESCRIPTION
1. List of Diagnostic Trouble Code (DTC)

A: LIST
DTC
Item
Index
P0026
<Ref. to GD(H4SO)-8, DTC P0026 INTAKE VALVE CONTROL SOLENOID

CIRCUIT RANGE/PERFORMANCE (BANK 1), Diagnostic Trouble Code
(DTC) Detecting Criteria.>
P0028
P0030
HO2S Heater Control Circuit

(Bank 1 Sensor 1)

CIRCUIT RANGE/PERFORMANCE (BANK 2), Diagnostic Trouble Code
<Ref. to GD(H4SO)-11, DTC P0030 HO2S HEATER CONTROL CIRCUIT
P0031

(Bank 1 Sensor 1)

P0032

(Bank 1 Sensor 1)
P0037

(Bank 1 Sensor 2)
P0038

(Bank 1 Sensor 2)
P0068
MAP/MAF - Throttle Position Correlation


<Ref. to GD(H4SO)-21, DTC P0068 MAP/MAF - THROTTLE POSITION
P0076
P0077
P0082

P0083

P0101

Range/Performance
P0102

Low Input
<Ref. to GD(H4SO)-26, DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
<Ref. to GD(H4SO)-29, DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0103

High Input
<Ref. to GD(H4SO)-31, DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0107
<Ref. to GD(H4SO)-33, DTC P0107 MANIFOLD ABSOLUTE PRESSURE/

BAROMETRIC PRESSURE CIRCUIT LOW INPUT, Diagnostic Trouble Code
P0108
P0111
Intake Air Temperature Sensor 1

Circuit Range/Performance
P0112

Circuit Low
<Ref. to GD(H4SO)-35, DTC P0108 MANIFOLD ABSOLUTE PRESSURE/

BAROMETRIC PRESSURE CIRCUIT HIGH INPUT, Diagnostic Trouble
<Ref. to GD(H4SO)-37, DTC P0111 INTAKE AIR TEMPERATURE SENSOR
1 CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC)
1 CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4SO)-2

GENERAL DESCRIPTION
DTC
Item
Index
P0113

Circuit High

1 CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0117

<Ref. to GD(H4SO)-43, DTC P0117 ENGINE COOLANT TEMPERATURE

<Ref. to GD(H4SO)-45, DTC P0118 ENGINE COOLANT TEMPERATURE
<Ref. to GD(H4SO)-47, DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
<Ref. to GD(H4SO)-49, DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0118
P0122
P0123

P0125
Insufficient Coolant Temperature

For Closed Loop Fuel Control
<Ref. to GD(H4SO)-51, DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL, Diagnostic Trouble Code
P0126
Insufficient Engine Coolant Temperature for Stable Operation
<Ref. to GD(H4SO)-53, DTC P0126 INSUFFICIENT ENGINE COOLANT

TEMPERATURE FOR STABLE OPERATION, Diagnostic Trouble Code
P0128
Coolant Thermostat (Engine Coolant Temperature Below Thermostat Regulating Temperature)
<Ref. to GD(H4SO)-55, DTC P0128 COOLANT THERMOSTAT (ENGINE

COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE), Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0131
O2 Sensor Circuit Low Voltage

(Bank 1 Sensor 1)
<Ref. to GD(H4SO)-57, DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE

P0132

(Bank 1 Sensor 1)
<Ref. to GD(H4SO)-59, DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE

P0133

(Bank 1 Sensor 1)
<Ref. to GD(H4SO)-61, DTC P0133 O2 SENSOR CIRCUIT SLOW

RESPONSE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0134

<Ref. to GD(H4SO)-64, DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY

P0137

(Bank 1 Sensor 2)
<Ref. to GD(H4SO)-66, DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE

P0138

(Bank 1 Sensor 2)
<Ref. to GD(H4SO)-69, DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE

P0139

(Bank 1 Sensor 2)
<Ref. to GD(H4SO)-70, DTC P0139 O2 SENSOR CIRCUIT SLOW

RESPONSE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0140

<Ref. to GD(H4SO)-75, DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY

P0171
<Ref. to GD(H4SO)-77, DTC P0171 SYSTEM TOO LEAN (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0172
<Ref. to GD(H4SO)-79, DTC P0172 SYSTEM TOO RICH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0181
<Ref. to GD(H4SO)-81, DTC P0181 FUEL TEMPERATURE SENSOR A

P0182

P0183

Engine Oil Temperature Sensor

<Ref. to GD(H4SO)-88, DTC P0196 ENGINE OIL TEMPERATURE SENSOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC)
P0196
GD(H4SO)-3

GENERAL DESCRIPTION
DTC
Item
Index
P0197

Low
<Ref. to GD(H4SO)-90, DTC P0197 ENGINE OIL TEMPERATURE SENSOR LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0198

High
<Ref. to GD(H4SO)-91, DTC P0198 ENGINE OIL TEMPERATURE SENSOR HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
<Ref. to GD(H4SO)-92, DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
P0223

<Ref. to GD(H4SO)-93, DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0301
<Ref. to GD(H4SO)-94, DTC P0301 CYLINDER 1 MISFIRE DETECTED,

Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0302
P0303
P0304

P0327
Knock Sensor 1 Circuit Low

P0222
P0328
P0335
P0336
P0340
P0341
<Ref. to GD(H4SO)-100, DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW

(BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting
Criteria.>
Knock Sensor 1 Circuit High
<Ref. to GD(H4SO)-102, DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH
(BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting
Criteria.>
Crankshaft Position Sensor A Cir- <Ref. to GD(H4SO)-104, DTC P0335 CRANKSHAFT POSITION SENSOR
cuit
A CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
Crankshaft Position Sensor A Cir- <Ref. to GD(H4SO)-106, DTC P0336 CRANKSHAFT POSITION SENSOR
cuit Range/Performance
A CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC)
Camshaft Position Sensor A Cir- <Ref. to GD(H4SO)-108, DTC P0340 CAMSHAFT POSITION SENSOR A
cuit (Bank 1 or Single Sensor)
CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC)
Camshaft Position Sensor A Cir- <Ref. to GD(H4SO)-110, DTC P0341 CAMSHAFT POSITION SENSOR A
CIRCUIT RANGE/PERFORMANCE (BANK 1 OR SINGLE SENSOR), Diag(Bank 1 or Single Sensor)
nostic Trouble Code (DTC) Detecting Criteria.>
P0400
<Ref. to GD(H4SO)-112, DTC P0400 EXHAUST GAS RECIRCULATION

FLOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
<Ref. to GD(H4SO)-116, DTC P0420 CATALYST SYSTEM EFFICIENCY
BELOW THRESHOLD (BANK 1), Diagnostic Trouble Code (DTC) Detecting
Criteria.>
P0420

Threshold (Bank 1)
P0442
<Ref. to GD(H4SO)-119, DTC P0442 EVAPORATIVE EMISSION CONTROL

SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Trouble Code
P0447

SYSTEM VENT CONTROL CIRCUIT OPEN, Diagnostic Trouble Code
P0448
P0451
P0452

SYSTEM VENT CONTROL CIRCUIT SHORTED, Diagnostic Trouble Code
SYSTEM PRESSURE SENSOR, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
SYSTEM PRESSURE SENSOR LOW INPUT, Diagnostic Trouble Code
GD(H4SO)-4

GENERAL DESCRIPTION
Item
Index
P0453
DTC

SYSTEM PRESSURE SENSOR HIGH INPUT, Diagnostic Trouble Code
P0456
Evaporative Emission Control System Leak Detected

(Very Small Leak)
Evaporative Emission Control System Leak Detected (Fuel Cap
Loose/Off)
Evaporative Emission System
Purge Control Valve Circuit Low

SYSTEM LEAK DETECTED (VERY SMALL LEAK), Diagnostic Trouble
SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF), Diagnostic Trouble
<Ref. to GD(H4SO)-144, DTC P0458 EVAPORATIVE EMISSION SYSTEM
PURGE CONTROL VALVE CIRCUIT LOW, Diagnostic Trouble Code (DTC)
<Ref. to GD(H4SO)-146, DTC P0459 EVAPORATIVE EMISSION SYSTEM
PURGE CONTROL VALVE CIRCUIT HIGH, Diagnostic Trouble Code (DTC)
<Ref. to GD(H4SO)-148, DTC P0461 FUEL LEVEL SENSOR A CIRCUIT
P0457
P0458
P0459

Purge Control Valve Circuit High
P0461
Fuel Level Sensor A Circuit

Range/Performance
P0462
P0463
P0464

P0483

<Ref. to GD(H4SO)-154, DTC P0464 FUEL LEVEL SENSOR CIRCUIT
INTERMITTENT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
<Ref. to GD(H4SO)-157, DTC P0483 FAN RATIONALITY CHECK, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0502

Low Input
<Ref. to GD(H4SO)-158, DTC P0502 VEHICLE SPEED SENSOR A CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0503
Vehicle Speed Sensor A Intermit- <Ref. to GD(H4SO)-159, DTC P0503 VEHICLE SPEED SENSOR A
tent/Erratic/High
INTERMITTENT/ERRATIC/HIGH, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
P0506
Idle Air Control System RPM

Lower Than Expected
P0507

Higher Than Expected
P0512
P0519
P0600
<Ref. to GD(H4SO)-166, DTC P0600 SERIAL COMMUNICATION LINK,

P0604

<Ref. to GD(H4SO)-167, DTC P0604 INTERNAL CONTROL MODULE

RANDOM ACCESS MEMORY (RAM) ERROR, Diagnostic Trouble Code
P0605

Memory (ROM) Error
P0607
<Ref. to GD(H4SO)-169, DTC P0605 INTERNAL CONTROL MODULE

READ ONLY MEMORY (ROM) ERROR, Diagnostic Trouble Code (DTC)
<Ref. to GD(H4SO)-170, DTC P0607 CONTROL MODULE PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0638
Throttle Actuator Control Range/

Performance (Bank 1)
<Ref. to GD(H4SO)-172, DTC P0638 THROTTLE ACTUATOR CONTROL

RANGE/PERFORMANCE (BANK 1), Diagnostic Trouble Code (DTC)
P0691
<Ref. to GD(H4SO)-175, DTC P0691 FAN 1 CONTROL CIRCUIT LOW,

<Ref. to GD(H4SO)-160, DTC P0506 IDLE AIR CONTROL SYSTEM RPM

<Ref. to GD(H4SO)-162, DTC P0507 IDLE AIR CONTROL SYSTEM RPM
<Ref. to GD(H4SO)-164, DTC P0512 STARTER REQUEST CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
<Ref. to GD(H4SO)-165, DTC P0519 IDLE AIR CONTROL SYSTEM PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4SO)-5

GENERAL DESCRIPTION
DTC
Item
Index
P0692
<Ref. to GD(H4SO)-176, DTC P0692 FAN 1 CONTROL CIRCUIT HIGH,

P0700

Request)
Low (AT Model)
<Ref. to GD(H4SO)-177, DTC P0700 TRANSMISSION CONTROL SYSTEM

<Ref. to GD(H4SO)-178, DTC P0851 PARK/NEUTRAL SWITCH INPUT
CIRCUIT LOW (AT MODEL), Diagnostic Trouble Code (DTC) Detecting Criteria.>
Neutral Switch Input Circuit Low

(MT Model)
High (AT Model)
<Ref. to GD(H4SO)-179, DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT

<Ref. to GD(H4SO)-180, DTC P0852 PARK/NEUTRAL SWITCH INPUT
CIRCUIT HIGH (AT MODEL), Diagnostic Trouble Code (DTC) Detecting Criteria.>
Neutral Switch Input Circuit High

(MT Model)
<Ref. to GD(H4SO)-181, DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT

<Ref. to GD(H4SO)-182, DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC)
<Ref. to GD(H4SO)-184, DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC)
P0851
P0851
P0852
P0852
P1152
P1153
P1160
P1400
P1420

Valve Circuit High
<Ref. to GD(H4SO)-190, DTC P1420 FUEL TANK PRESSURE CONTROL

P1443
<Ref. to GD(H4SO)-192, DTC P1443 VENT CONTROL SOLENOID VALVE

P1491
Positive Crankcase Ventilation

(Blow-by) Function Problem
<Ref. to GD(H4SO)-194, DTC P1491 POSITIVE CRANKCASE VENTILATION (BLOW-BY) FUNCTION PROBLEM, Diagnostic Trouble Code (DTC)
P1492
<Ref. to GD(H4SO)-196, DTC P1492 EGR SOLENOID VALVE SIGNAL #1

CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Trouble Code (DTC)
P1493
P1494
P1495
P1496

CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Trouble Code (DTC)
P1497

P1498

<Ref. to GD(H4SO)-186, DTC P1160 RETURN SPRING FAILURE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
<Ref. to GD(H4SO)-188, DTC P1400 FUEL TANK PRESSURE CONTROL
GD(H4SO)-6

GENERAL DESCRIPTION
DTC
Item
Index
P1499

P1518
<Ref. to GD(H4SO)-201, DTC P1518 STARTER SWITCH CIRCUIT LOW

INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P1560
<Ref. to GD(H4SO)-202, DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P1602
Control Module Programming Error <Ref. to GD(H4SO)-203, DTC P1602 CONTROL MODULE PROGRAMMING ERROR, Diagnostic Trouble Code (DTC) Detecting Criteria.>
Post Catalyst Fuel Trim System
<Ref. to GD(H4SO)-205, DTC P2096 POST CATALYST FUEL TRIM SYSToo Lean Bank 1
TEM TOO LEAN BANK 1, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P2096
P2097

Too Rich Bank 1
<Ref. to GD(H4SO)-207, DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH BANK 1, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P2101
Throttle Actuator Control Motor Cir- <Ref. to GD(H4SO)-209, DTC P2101 THROTTLE ACTUATOR CONTROL
MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code
P2102
cuit Low
P2103
cuit High
P2109

<Ref. to GD(H4SO)-215, DTC P2109 THROTTLE/PEDAL POSITION SENSOR A MINIMUM STOP PERFORMANCE, Diagnostic Trouble Code
P2122

P2123

P2127

P2128

<Ref. to GD(H4SO)-217, DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC)
<Ref. to GD(H4SO)-219, DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC)
<Ref. to GD(H4SO)-221, DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC)
<Ref. to GD(H4SO)-223, DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC)
P2135

<Ref. to GD(H4SO)-225, DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH A/B VOLTAGE CORRELATION, Diagnostic Trouble Code
P2138

<Ref. to GD(H4SO)-227, DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D/E VOLTAGE CORRELATION, Diagnostic Trouble Code
P2227
Barometric Pressure Circuit

Range/Performance
P2228
<Ref. to GD(H4SO)-229, DTC P2227 BAROMETRIC PRESSURE CIRCUIT

P2229

GD(H4SO)-7
Diagnostic Trouble Code (DTC) Detecting Criteria

GENERAL DESCRIPTION
2. Diagnostic Trouble Code (DTC) Detecting Criteria

A: DTC P0026 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/
PERFORMANCE (BANK 1)
1. OUTLINE OF DIAGNOSIS
Detect NG when having either Low NG or High NG.
A variable valve lift diagnosis oil pressure switch is installed for diagnosis. It is possible to determine whether
the intake valve is in high mode (increase the amount of lift) or in low mode (suppressing the amount of lift)
when the variable valve lift diagnosis oil pressure switch is turned ON or OFF.
NORMAL
Large
High mode
Variable valve lift diagnosis oil pressure

switch
ON
Small
Low mode
OFF
Oil switching solenoid valve duty
Intake valve
Low NG
When the variable valve lift diagnosis oil pressure switch remains OFF even though the intake valve tried to
enter high mode (oil switching solenoid valve duty is large), this is judged as a Low NG.
High NG
When the variable valve lift diagnosis oil pressure switch remains ON even though the intake valve tried to
enter low mode (oil switching solenoid valve duty is small), this is judged as a High NG.
2. COMPONENT DESCRIPTION
The variable valve lift system optimizes the intake valve lift by switching between the low lift cam and the high
lift cam according to the engine speed. The amount of intake valve lift is varied by controlling the oil switching
solenoid valve duty according to signals from the ECM.
3. ENABLE CONDITION
Secondary Parameters
Battery voltage
Enable Conditions
10.9 V
After engine starting

6 sec.
15C (59F)
Variable valve lift control
Operation
4. GENERAL DRIVING CYCLE

Perform the diagnosis continuously 6 seconds after engine start while variable valve lift is being controlled.
GD(H4SO)-8

GENERAL DESCRIPTION
5. DIAGNOSTIC METHOD
Abnormality Judgment
Judge as NG when the continuous time of meeting the following conditions is longer than the predetermined
time.
Judgment Value
Malfunction Criteria
Low NG
Duty ratio
Threshold Value
62%

switch
High NG
OFF
Duty ratio
switch
< 33%
ON
Time Needed for Diagnosis:

0.784 seconds
3.0 seconds
Low side
High side
Malfunction Indicator Light Illumination: Illuminates as soon as a malfunction occurs.

Normality Judgment
Judge as OK and clear the NG when the continuous time when the following conditions are established are
more than 3 seconds.
Judgment Value
Threshold Value
Low OK
Duty ratio
switch
High OK
62%
ON
Duty ratio
switch
< 33%
OFF
6. DTC CLEAR CONDITION

When the OK idling cycle is completed 40 times in a row
When Clear Memory is performed
7. MALFUNCTION INDICATOR LIGHT CLEAR CONDITION

When the OK driving cycle is completed 3 times in a row
8. FAIL SAFE
None
9. ECM OPERATION AT DTC SETTING

Memorize the freeze frame data. (For test mode $02)
GD(H4SO)-9

GENERAL DESCRIPTION
B: DTC P0028 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/

PERFORMANCE (BANK 2)
NOTE:
For diagnostic procedures, refer to DTC P0026. <Ref. to GD(H4SO)-8, DTC P0026 INTAKE VALVE CONTROL SOLENOID CIRCUIT RANGE/PERFORMANCE (BANK 1), Diagnostic Trouble Code (DTC) Detecting
Criteria.>
GD(H4SO)-10

GENERAL DESCRIPTION
C: DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1)

Detect functional errors of the front oxygen (A/F) sensor heater.
Judge as NG when it is determined that the front oxygen (A/F) sensor impedance is large by referring to the
engine condition such as fuel shut-off in deceleration, etc.
(1)
(2)
(3)
(4)
(5)
EN-01683
(1)
(2)
Element cover (outer)

Element cover (inner)
(3)
(4)
Sensor element
Ceramic heater
(5)
Sensor housing
3. ENABLE CONDITION
Enable Conditions
Continuous time when all of the following

conditions are met
30 seconds or more
Battery voltage
After fuel cut
> 10.9 V
20 seconds or more
Heater current
Front lambda sensor duty 35%
Operation
Experienced

Perform the diagnosis continuously after 50 seconds or more have passed since the engine started.
Judge as NG when the continuous time of meeting the malfunction criteria below becomes more than the
time needed for diagnosis (10 seconds). Judge as OK and clear NG when the continuous time of not completing the malfunction criteria below becomes more than the time needed for diagnosis (10 seconds).
Judgment Value
Front oxygen (A/F) sensor impedance
Threshold Value
> 50
Time Needed for Diagnosis: 10 seconds

Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving cycles.
GD(H4SO)-11

GENERAL DESCRIPTION


8. FAIL SAFE
Front oxygen (A/F) sensor main learning compensation: Not allowed to calculate.
Front oxygen (A/F) sensor sub learning compensation: Not allowed to calculate.
Purge control: Not allowed to purge.

GD(H4SO)-12

GENERAL DESCRIPTION
D: DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1)

Detect the open or short circuit of heater.
The heater performs duty control, and the output terminal voltage at ON is 0 V and the output terminal voltage
at OFF is the battery voltage.
Judge NG when the terminal voltage remains Low.
(A)
OFF
(B)
ON
(D)
0V
(C)
EN-01792
(A)
Battery voltage
(C)
128 milliseconds
(B)
Front oxygen (A/F) sensor heater

output voltage
(D)
Low error
3. ENABLE CONDITION
Battery voltage
Enable Conditions
10.9 V

Always perform the diagnosis continuously.
GD(H4SO)-13

GENERAL DESCRIPTION
Judge NG when the continuous time of meeting the malfunction criteria below becomes more than 1 second
(8 cycles).
Judgment Value
Output voltage level
Front oxygen (A/F) sensor heater control
duty
Threshold Value
Low
< 87.5%
Time Needed for Diagnosis: 1 second

Normality Judgment
Judge as OK and clear the NG when the malfunction criteria below are completed.
Judgment Value
Threshold Value
High


8. FAIL SAFE
Front oxygen (A/F) sensor heater control: Not allowed to apply current to the heater.
A/F main learning: Not allowed to calculate the A/F main learning compensation factor.
A/F sub learning: Not allowed to calculate the A/F sub learning compensation factor.

GD(H4SO)-14

GENERAL DESCRIPTION
E: DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1)

Judge NG when the terminal voltage remains High.
(A)
(D)
OFF
(B)
ON
0V
(C)
EN-01793
(A)
Battery voltage
(C)
128 milliseconds
(B)
Front oxygen (A/F) sensor heater

output voltage
(D)
High malfunction
3. ENABLE CONDITION
Battery voltage
Enable Conditions
10.9 V

GD(H4SO)-15

GENERAL DESCRIPTION
(8 cycles).
Judgment Value
duty
Threshold Value
High
12.5%

Normality Judgment
Judgment Value
Threshold Value
Low


8. FAIL SAFE

GD(H4SO)-16

GENERAL DESCRIPTION

Detect the rear oxygen sensor heater open or short circuit.
The rear oxygen sensor heater performs duty control, and the output terminal voltage at ON is 0 V, and the
output terminal voltage at OFF is the battery voltage.
(A)
OFF
(B)
ON
(D)
0V
(C)
EN-01792
(A)
Battery voltage
(B)
Rear oxygen sensor heater output

voltage
(C)
256 milliseconds (cycles)
3. ENABLE CONDITION
Battery voltage
Enable Conditions
> 10.9 V
Elapsed time after engine starting
1 sec.

Perform the diagnosis continuously after starting the engine.
GD(H4SO)-17
(D)
Low error

GENERAL DESCRIPTION
Judge as NG when the continuous time while meeting all of the malfunction criteria below is more than 2560
milliseconds (10 cycles).
Judgment Value
Output voltage
Rear oxygen sensor heater control duty
Threshold Value
Low
< 75%
Time Needed for Diagnosis: 2.56 seconds

Normality Judgment
Judgment Value
Output voltage
Threshold Value
High


8. FAIL SAFE
Sub feedback control: Not allowed.

GD(H4SO)-18

GENERAL DESCRIPTION

(A)
(D)
OFF
(B)
ON
0V
(C)
EN-01793
(A)
Battery voltage
(B)
Rear oxygen sensor heater output

voltage
(C)
256 milliseconds (cycles)
3. ENABLE CONDITION
Battery voltage
Enable Conditions
> 10.9 V
Elapsed time after engine starting
1 sec.

GD(H4SO)-19
(D)
High malfunction

GENERAL DESCRIPTION
Judgment Value
Output voltage
Threshold Value
High
20%

Normality Judgment
Judgment Value
Output voltage
Threshold Value
Low


8. FAIL SAFE

GD(H4SO)-20

GENERAL DESCRIPTION
H: DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION

Detect the malfunction of intake manifold pressure sensor output property. Judge NG when the intake air
pressure AD value is Low whereas it seemed to be High from the viewpoint of engine condition, or when it
is High whereas it seemed to be Low from the engine condition.
(1)
(2)
(A)
(B)
(3)
EN-01765
(1)
(2)
Connector
Terminals
(3)
O-ring
(A)
(B)
Output voltage
Absolute pressure
3. ENABLE CONDITION
Enable Conditions
75C (167F)

Perform the diagnosis continuously after idling.
GD(H4SO)-21

GENERAL DESCRIPTION
Judge NG when either Low side or High side becomes NG.
Judge as NG when the continuous time of meeting the malfunction criteria below becomes more than the
predetermined time.
Judgment Value
Threshold Value
Low side
Engine speed
Throttle position
< 2500 rpm

12
Intake air amount every 0.5 engine revs.

Output voltage
0.55 g (0.019 oz)/rev

< 1.4 V
High side
Engine speed
600 900 rpm
Throttle position
2.44
< 0.4 g (0.014 oz)/rev
Output voltage
3.4 V
Time Needed for Diagnosis: 3 seconds for low side, 7 seconds for high side
Normality Judgment
Judge as OK and clear the NG when both Low side and High side become OK.
Judge as OK when the malfunction criteria below are completed.
Judgment Value
Threshold Value
Low side
Engine speed
< 2500 rpm
Throttle position
12
0.55 g (0.019 oz)/rev
Output voltage
High side
1.4 V
Engine speed
Throttle position
600 900 rpm

2.44

Output voltage
< 0.4 g (0.014 oz)/rev

< 3.4 V


8. FAIL SAFE
Intake manifold pressure sensor process: Estimate the pressure from engine load.
ISC feedback: Not allowed to calculate the amount of feedback.

GD(H4SO)-22

GENERAL DESCRIPTION
I:
DTC P0076 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 1)
Detect the open circuit of the oil switching solenoid valve.
Judge as NG when the current is small even though the output duty is large.
2. ENABLE CONDITION
Battery voltage
Enable Conditions
10.9 V

Judge as NG when the continuous time when the following conditions are established is more than 2 seconds.
Judgment Value
Duty ratio
Control current
Threshold Value
30%
< 0.026 A

Normality Judgment
Judge as OK and clear the NG when the continuous time when the following conditions are established is
Judgment Value
| Oil switching solenoid valve target current value oil switching solenoid valve
current value |
Threshold Value
< 0.08 A
Control current
0.11 A


7. FAIL SAFE
None

GD(H4SO)-23

GENERAL DESCRIPTION
J: DTC P0077 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 1)

Detect short circuits of the oil switching solenoid valve.
Judge as a short NG when the current is large even though the output duty is small.
2. ENABLE CONDITION
Battery voltage
Enable Conditions
10.9 V

Judge as NG when the continuous time when the following conditions are established is more than 2 seconds.
Judgment Value
Duty ratio
Control current
Threshold Value
< 7%
0.465 A

Normality Judgment
Judge as OK and clear the NG when the continuous time when the following conditions are established is
Judgment Value
| Oil switching solenoid valve target current value oil switching solenoid valve
current value |
Threshold Value
< 0.08 A


7. FAIL SAFE
None

GD(H4SO)-24

GENERAL DESCRIPTION
K: DTC P0082 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 2)

NOTE:
For the diagnostic procedure, refer to DTC P0076. <Ref. to GD(H4SO)-23, DTC P0076 INTAKE VALVE
CONTROL SOLENOID CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
L: DTC P0083 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 2)

NOTE:
For the diagnostic procedure, refer to DTC P0077. <Ref. to GD(H4SO)-24, DTC P0077 INTAKE VALVE
CONTROL SOLENOID CIRCUIT HIGH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4SO)-25

GENERAL DESCRIPTION
M: DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE

Detect the malfunction of air flow sensor output property.
Judge as a low side NG when the air flow voltage indicates a small value regardless of running in a state
where the air flow voltage increases. Judge as High side NG when the air flow voltage indicates a large value
regardless of running in a state where the air flow voltage decreases. Judge air flow sensor property NG
when the Low side or High side becomes NG.
(1)
(3)
(2)
(A)
(4)
EN-01766
(1)
(2)
Air flow sensor

Intake air temperature sensor
(3)
(4)
Voltage (V)
Intake air volume (kg/s)
3. ENABLE CONDITION
Enable Conditions
75C (167F)

GD(H4SO)-26
(A)
Air

GENERAL DESCRIPTION
Judge as NG when the continuous time with the following criteria established exceeds the predetermined
time.
Judgment Value
Threshold Value
(Low side error)

Output voltage
< 1.2 V
Engine speed
Throttle opening angle
2000 rpm
13
Intake manifold pressure
53.3 kPa (400

mmHg, 15.7 inHg)
(High side error 1)

Output voltage
Engine speed
2.66 V
600 900 rpm

< 2.44
< 40.0 kPa (300
mmHg, 11.8 inHg)
(High side error 2)

Output voltage
Engine speed
1.45 V
600 900 rpm

< 2.44
< 40.0 kPa (300
mmHg, 11.8 inHg)
Fuel system diagnosis
Rich side malfunction

Low side : 3 seconds
High side: 10 seconds
Normality Judgment
Judge as OK when the criteria below are met.
Judgment Value
Threshold Value
(Low side error)

Output voltage
1.2 V
Engine speed
2000 rpm
13
53.3 kPa
(400 mmHg, 15.7 inHg)
(High side error)

Output voltage
Engine Speed
< 2.66 V
600 900 rpm

< 2.44
< 40.0 kPa
(300 mmHg, 11.8 inHg)
GD(H4SO)-27

GENERAL DESCRIPTION


8. FAIL SAFE
None

GD(H4SO)-28

GENERAL DESCRIPTION
N: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT

Detect open or short circuits of the air flow sensor.
Judge as NG if it is out of specification.
(1)
(3)
(2)
(A)
(4)
EN-01766
(1)
(2)
Air flow sensor

(3)
(4)
Voltage (V)
(A)
Air
3. ENABLE CONDITION
Enable Conditions
None

Judge as NG when the continuous time of meeting the malfunction criteria below becomes 0.5 seconds or
more. Judge as OK and clear the NG when the malfunction criteria below are not met.
Judgment Value
Output voltage
Threshold Value
0.2 V



GD(H4SO)-29

GENERAL DESCRIPTION
8. FAIL SAFE
None

GD(H4SO)-30

GENERAL DESCRIPTION
O: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT

(1)
(3)
(2)
(A)
(4)
EN-01766
(1)
(2)
Air flow sensor

(3)
(4)
Voltage (V)
(A)
Air
3. ENABLE CONDITION
Enable Conditions
None

Judge NG when the continuous time of meeting the malfunction criteria below becomes more than 0.5 seconds. Judge as OK and clear the NG when the malfunction criteria below are not met.
Judgment Value
Output voltage
Threshold Value
4.985 V



GD(H4SO)-31

GENERAL DESCRIPTION
8. FAIL SAFE
None

GD(H4SO)-32

GENERAL DESCRIPTION
P: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE

CIRCUIT LOW INPUT
Detect the open or short circuit of intake manifold pressure sensor.
(1)
(2)
(A)
(B)
(3)
EN-01765
(1)
(2)
Connector
Terminals
(3)
O-ring
(A)
(B)
Output voltage
Absolute pressure
3. ENABLE CONDITION
Enable Conditions
None

Judgment Value
Output voltage
Threshold Value
< 0.568 V



GD(H4SO)-33

GENERAL DESCRIPTION
8. FAIL SAFE

GD(H4SO)-34

GENERAL DESCRIPTION
Q: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE

CIRCUIT HIGH INPUT
(1)
(2)
(A)
(B)
(3)
EN-01765
(1)
(2)
Connector
Terminals
(3)
O-ring
(A)
(B)
Output voltage
Absolute pressure
3. ENABLE CONDITION
Enable Conditions
None

Judgment Value
Output voltage
Threshold Value
4.921 V



GD(H4SO)-35

GENERAL DESCRIPTION
8. FAIL SAFE

GD(H4SO)-36

GENERAL DESCRIPTION
R: DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/

PERFORMANCE
Detect the malfunction of intake air temperature sensor output property.
Judge as NG when the intake air temperature is not varied whereas it seemed to be varied from the viewpoint
of engine condition.
(1)
(3)
(2)
(A)
(4)
EN-01767
(1)
(2)
Air flow sensor

(3)
(4)
Resistance value ()
Intake air temperature C (F)
(A)
Air
3. ENABLE CONDITION
Enable Conditions
Coolant temp. before engine start

< 30C (86F)

> 100C (212F)
Battery voltage
Continuous time when the vehicle speed
is less than 60 km/h (37 MPH)
10.9 V
600 seconds or more

Perform the diagnosis when the vehicle speed condition is completed after starting and idling the cold engine.
GD(H4SO)-37

GENERAL DESCRIPTION
Judge as NG when the continuous time of meeting the malfunction criteria below becomes 1 seconds or
more.
Judgment Value
Threshold Value
Output voltage difference between Max.

and Min.
< 20 mV (Equivalent to
approximately 0.5C
(0.9F) near 25C)

Normality Judgment
Judge as OK and clear the NG when the malfunction criteria below are met.
Judgment Value
and Min.
Threshold Value
20 mV


8. FAIL SAFE
Intake air temperature sensor process: Intake air temperature is fixed at 20C (68F).

GD(H4SO)-38

GENERAL DESCRIPTION
S: DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW

Detect open or short circuit of the intake air temperature sensor.
(1)
(3)
(2)
(A)
(4)
EN-01767
(1)
(2)
Air flow sensor

(3)
(4)
Resistance value ()
(A)
Air
3. ENABLE CONDITION
Enable Conditions
None

more.
Judgment Value
Output voltage
Ignition switch
Threshold Value
< 0.166 V
ON

Normality Judgment
Judgment Value
Output voltage
Threshold Value
0.166 V
Ignition switch
ON
GD(H4SO)-39

GENERAL DESCRIPTION


8. FAIL SAFE

GD(H4SO)-40

GENERAL DESCRIPTION
T: DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH

(1)
(3)
(2)
(A)
(4)
EN-01767
(1)
(2)
Air flow sensor

(3)
(4)
Resistance value ()
(A)
Air
3. ENABLE CONDITION
Enable Conditions
None

more.
Judgment Value
Output voltage
Ignition switch
Threshold Value
4.716 V
ON

Normality Judgment
Judgment Value
Output voltage
Threshold Value
< 4.716 V
Ignition switch
ON
GD(H4SO)-41

GENERAL DESCRIPTION


8. FAIL SAFE

GD(H4SO)-42

GENERAL DESCRIPTION
U: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW

Detect the open or short circuit of the engine coolant temperature sensor.
(1)
(A)
(B)
(2)
EN-02917
(1)
(2)
Connector
Thermistor element
(A)
(B)
Resistance value (k)

Temperature C (F)
3. ENABLE CONDITION
Enable Conditions
None

Judgment Value
Output voltage
Threshold Value
0.166 V



GD(H4SO)-43

GENERAL DESCRIPTION
8. FAIL SAFE
Engine coolant temperature sensor process: Engine coolant temperature is fixed at 70C (158F)
ISC Feedback: Calculate target engine speed as engine coolant temperature 70C (158F).
ISC learning: Not allowed to learn.
Air conditioner control: Not allowed to turn the air conditioner to ON.
Radiator fan control: Both main and sub fan turn to ON.
Tumble generator valve control: Open the tumble generator valve.

GD(H4SO)-44

GENERAL DESCRIPTION
V: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH

(1)
(A)
(B)
(2)
EN-02917
(1)
(2)
Connector
Thermistor element
(A)
(B)

Temperature C (F)
3. ENABLE CONDITION
Enable Conditions
None

Judgment Value
Output voltage
Threshold Value
4.716 V



GD(H4SO)-45

GENERAL DESCRIPTION
8. FAIL SAFE

GD(H4SO)-46

GENERAL DESCRIPTION
W: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT

LOW
Detect the open or short circuit of throttle position sensor 1.
(3)
(4)
(1)
(2)
EN-01859
(1)
(2)
Throttle position sensor 1 signal

(3)
(4)

3. ENABLE CONDITION
Ignition switch
Enable Conditions
ON

Judgment Value
Sensor 1 input voltage
Threshold Value
0.309 V
Time Needed for Diagnosis: 24 milliseconds


When Clear Memory is performed (Only with engine stopped)

GD(H4SO)-47

GENERAL DESCRIPTION
8. FAIL SAFE
Stop the continuity to the electronic throttle control motor. (Throttle opening is fixed to 6.)

GD(H4SO)-48

GENERAL DESCRIPTION
X: DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT

HIGH
(3)
(4)
(1)
(2)
EN-01859
(1)
(2)

(3)
(4)
3. ENABLE CONDITION
Ignition switch
Enable Conditions
ON

Judgment Value
Threshold Value
4.646 V



GD(H4SO)-49

GENERAL DESCRIPTION
8. FAIL SAFE

GD(H4SO)-50

GENERAL DESCRIPTION
Y: DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP

FUEL CONTROL
Detect the malfunction of engine coolant temperature output property.
Judge as NG when the engine coolant temperature does not rise in driving conditions where it should.
(1)
(A)
(B)
(2)
EN-02917
(1)
(2)
Connector
Thermistor element
(A)
(B)

Temperature C (F)
3. ENABLE CONDITION
Engine speed
Battery voltage
Enable Conditions
500 rpm
> 10.9 V

Perform the diagnosis only once after engine starting.
Judge as NG when the malfunction criteria below are met.
Judgment Value
Threshold Value
< 20C (68F)
Timer for diagnosis after engine starting
Judgment value of
timer after engine
starting
GD(H4SO)-51

GENERAL DESCRIPTION

a. Timer stop at fuel cut mode.
b. During the driving conditions except a) above, timer counts up.
64 milliseconds + TWCNT milliseconds (at the time of 64 milliseconds)
TWCNT is defined as follows.
TWCNT = 0 (at idle switch ON)
TWCNT at idle switch OFF is shown in the following table.
0 (0)
Temperature
C (F)
8 (5)
16 (10)
24 (15)
32 (20)
20 (4)
0 ms
10 (14)
0 ms
40 (25)
48 (30)
56 (35)
117.209
32.076 ms 39.977 ms 47.879 ms 82.544 ms
154.214 ms 185.206 ms
ms
25.704 ms 33.606 ms 41.508 ms 68.520 ms 95.532 ms 125.667 ms 155.802 ms
0 (32)
10 (50)
0 ms
0 ms
17.646 ms 25.548 ms 33.450 ms 53.652 ms 73.855 ms

7.901 ms 15.802 ms 23.704 ms 37.941 ms 52.177 ms
97.120 ms
68.573 ms
120.386 ms
82.538 ms
Judgment value of timer after engine starting

t = 574 33 Ti (seconds)
Ti : The lowest engine coolant temperature after starting the engine
Time Needed for Diagnosis: Undetermined. (It is varied by the lowest engine coolant temperature and engine conditions such as vehicle speed and engine coolant temperature.)
Normality Judgment
Judgment Value
Threshold Value
20C (68F)


8. FAIL SAFE

GD(H4SO)-52

GENERAL DESCRIPTION
Z: DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR

STABLE OPERATION
Detect the malfunction of the engine coolant temperature sensor characteristics.
Memorize the engine coolant temperature and fuel temperature at the last engine stop, and use them to
judge as NG when the engine coolant temperature does not decrease when it should.
(1)
(A)
(B)
(2)
EN-02917
(1)
(2)
Connector
Thermistor element
(A)
(B)

Temperature C (F)
3. ENABLE CONDITION
Battery voltage
Refueling from the last engine stop till
the current engine start
Fuel level
Engine coolant temperature at the last
engine stop
Enable Conditions
10.9 V
None
15.0 2(3.96 US gal,
3.3 Imp gal)
75C (167F)
and
< 100C (212F)
GD(H4SO)-53

GENERAL DESCRIPTION

Perform the diagnosis only once after starting the engine.
Judge as NG if the continuous time with the following conditions established is more than 2.5 seconds.
Judgment Value
engine stop Minimum engine coolant
temperature after the engine start
Fuel temperature at the last engine stop
fuel temperature
Threshold Value
< 2.5C (4.5F)
5C (9F)
Intake air temperature fuel temperature 2.5C (4.5F)

Fuel temperature
35C (95F)
Normality Judgment
When the following conditions are established, judged as OK.
Judgment Value
Threshold Value
2.5C (4.5F)



8. FAIL SAFE
None

GD(H4SO)-54

GENERAL DESCRIPTION
AA:DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE

Detect malfunctions of the thermostat function.
Judge as NG when the engine coolant temperature is lower than the estimated engine coolant temperature
and the difference between them is large. Judge as OK when the engine coolant temperature comes to 70C
(158F), and the difference is small, before judging NG.
(8)
(2)
(2)
(7)
(6)
(5)
(4)
(9)
(1)
(3)
EN-01692
(1)
(2)
Valve
Spring
(4)
(5)
Piston
Guide
(7)
(8)
Stop ring
Wax element
(3)
Stopper
(6)
Rubber packing
(9)
Jiggle valve
3. ENABLE CONDITION
Enable Conditions
None

GD(H4SO)-55

GENERAL DESCRIPTION
more.
Judgment Value
Threshold Value
Battery voltage
Engine coolant temperature at engine
starting
10.9 V
< 55C (131F)

(Estimated measured) Engine coolant
temperature
Vehicle speed
< 75C (167F)

> 30C (54F)
Estimated coolant temperature

Estimate ambient temperature
75C (167F)
7C (19F)
30 km/h (19 MPH)
Time Needed for Diagnosis: Not fixed

Normality Judgment
Judgment Value
Battery voltage
Threshold Value
10.9 V

starting
< 55C (131F)
(Estimated measured) Engine coolant

temperature
30C (54F)
75C (167F)


8. FAIL SAFE
None

Memorize the diagnostic value and trouble standard value. (For test mode $06)
GD(H4SO)-56

GENERAL DESCRIPTION
AB:DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)

Detect the open or short circuit of sensor.
Judge as NG when the element applied voltage is out of range, or the element current is out of range.
(3)
(1)
(A)
(2)
(2)
(C)
(B)
(D)
(4)
EN-01693
(1)
(2)
Atmosphere
Exhaust gas
(A)
(B)
Electromotive force
Air fuel ratio
(3)
(4)
ZrO2
Ceramic heater
(C)
(D)
Lean
Rich
3. ENABLE CONDITION
Battery voltage
Enable Conditions
10.9 V

Judge as NG when the continuous time of meeting any one of the malfunction criteria below is more than 1
second.
Judgment Value
Input voltage
Threshold Value
< 1.8 V
Input current
< 0.005 A


GD(H4SO)-57

GENERAL DESCRIPTION

8. FAIL SAFE

GD(H4SO)-58

GENERAL DESCRIPTION
AC:DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)

Judge as NG when the element applied voltage is out of range, or the element current is out of range.
(3)
(1)
(A)
(2)
(2)
(C)
(B)
(D)
(4)
EN-01693
(1)
(2)
Atmosphere
Exhaust gas
(A)
(B)
Electromotive force
Air fuel ratio
(3)
(4)
ZrO2
Ceramic heater
(C)
(D)
Lean
Rich
3. ENABLE CONDITION
Battery voltage
Enable Conditions
10.9 V

Judge as NG when the continuous time of meeting any one of the malfunction criteria below is more than 1
second.
Judgment Value
Input voltage
Threshold Value
3.8 V
Input current
0.005 A


GD(H4SO)-59

GENERAL DESCRIPTION

8. FAIL SAFE

GD(H4SO)-60

GENERAL DESCRIPTION
AD:DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1)

Detect the slow response of front oxygen (A/F) sensor.
Front oxygen (A/F) sensor cover has some ventilation holes for exhaust gas. Clogged ventilation holes are
diagnosed.
When the holes are clogged, the A/F output variation becomes slow compared with the actual A/F variation
because oxygen which reaches the zirconia layer is insufficient. Therefore, if the sensor cover holes are
clogged, the rich to lean judgment in the ECM is delayed when the change from rich to lean occurs.
Judge as NG when the actual movement in comparison to the ECM control amount is slow.
(2)
(3)
(1)
EN-01694
(1)
Cover
(2)
Zirconia
(3)
Clogging
(3)
(1)
(A)
(2)
(2)
(C)
(B)
(D)
(4)
EN-01693
(1)
(2)
Atmosphere
Exhaust gas
(A)
(B)
Electromotive force
Air fuel ratio
(3)
(4)
ZrO2
Ceramic heater
(C)
(D)
Lean
Rich
GD(H4SO)-61

GENERAL DESCRIPTION
3. ENABLE CONDITION
Enable Conditions
All secondary parameters enable conditions
1 second or more
Battery voltage
> 10.9 V
> 75.1 kPa (563
mmHg, 22.2 inHg)
Closed loop control with main feedback

Operating
0 50

120 seconds or more

75C (167F)
Engine speed
Vehicle speed
1000 3200 rpm

10 120 km/h (6
75 MPH)
10 40 g (0.35
1.41 oz)/s
Amount of intake air

Engine load change during 0.5 engine
revs.
0.02 g (0.001 oz)/rev
Learning value of EVAP conc. during

purge
0.2
Total time of operating canister purge
20 seconds or more

Perform diagnosis only once at a constant speed of 10 to 120 km/h (6 to 75 MPH) after 120 seconds or more
have passed after the engine starting.
Calculate faf difference every 128 milliseconds, and the value difference. Calculate the diagnostic value after calculating for 210 seconds.
Judge as NG when the malfunction criteria below are met. Judge as OK and clear the NG when the malfunction criteria below are not met.
Judgment Value
parafca = td2faf/td2lmd
where,
Threshold Value
0.44
td2faf (N) = td2faf (n1) + |d2faf (n)|

td2lmd (N) = td2lmd (n1) + |d2lmd (n)|
add up to a total of 210 seconds
d2faf (n) = (faf (n) faf (n1)) (faf (n1)
faf (n2))
d2lmd (n) = (lmd (n) lmd (n1)) (lmd
(n1) lmd (n2))
faf = main feedback compensation coefficient every 128 milliseconds
lmd = output lambda every 128 milliseconds


GD(H4SO)-62

GENERAL DESCRIPTION

8. FAIL SAFE
A/F sensor sub learning compensation: Not allowed to calculate.

GD(H4SO)-63

GENERAL DESCRIPTION
AE:DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1

SENSOR 1)
Detect open circuits of the sensor.
Judge as NG when the impedance of the element is large.
(3)
(1)
(A)
(2)
(2)
(C)
(B)
(D)
(4)
EN-01693
(1)
(2)
Atmosphere
Exhaust gas
(A)
(B)
Electromotive force
Air fuel ratio
(3)
(4)
ZrO2
Ceramic heater
(C)
(D)
Lean
Rich
3. ENABLE CONDITION
Enable Conditions
None

Judge as NG when the continuous time of meeting the malfunction criteria below becomes more than 5 seconds.
Judgment Value
Battery voltage
10.9 V
Threshold Value
Time of heater duty 70%

30 sec.
500


GD(H4SO)-64

GENERAL DESCRIPTION

8. FAIL SAFE

GD(H4SO)-65

GENERAL DESCRIPTION
AF:DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)

Detect the continuity NG of oxygen sensor. If the oxygen sensor voltage reading is not within the probable
range considering the operating conditions, judge as NG.
(E)
(3)
V
(1)
(F)
(A)
(2)
(2)
(C)
(B)
(D)
EN-01696
(A)
(B)
Electromotive force
Air fuel ratio
(C)
(D)
Rich
Lean
(E)
(F)
Theoretical air fuel ratio

Comparative voltage
(1)
Atmosphere
(2)
Exhaust gas
(3)
Electromotive force
GD(H4SO)-66

GENERAL DESCRIPTION
3. ENABLE CONDITION
Used only for abnormality judgment
High side
Enable Conditions
Secondary air injection system

Not in operation
Closed loop control with the oxygen sen- In operation
sor
Misfire detection during 200 revs.
Front oxygen (A/F) sensor compensation
coefficient
Battery voltage
Low side 1
< 5 times
Not in limit value
> 10.9 V
Not in operation

sor
< 5 times
coefficient
Not in limit value
Battery voltage
> 10.9 V
10 g/second
Low side 2
Not in operation

sor
coefficient
< 5 times
Not in limit value
Battery voltage
> 10.9 V
< 10 g/second
Current continuation time of the rear oxy- 30 seconds or more

gen sensor heater
Low side 3
Not in operation

sor
coefficient
< 5 times
Not in limit value
Battery voltage
> 10.9 V
< 10 g/second
Current continuation time of the rear oxy- 30 seconds or more

gen sensor heater
Fuel cut
Experienced
Used only for normality judgment

Enable Condition
Not in operation

sor
coefficient
< 5 times
Not in limit value
Battery voltage
> 10.9 V
GD(H4SO)-67

GENERAL DESCRIPTION

After starting the engine, perform the diagnosis in series while the engine is in a constant operating condition.
Judge as NG if the continuous time when the following conditions are established exceeds the predetermined time, and judge as OK if it doesnt.
Judgment Value
Threshold Value
High side
DTC
P0138
Maximum output voltage without continuity

Low side
1200 mV
Minimum output voltage without continuity
< 30 mV
P0137
Time Needed for Diagnosis

High side: 2.5 seconds
Low side 1: 20 seconds
Low side 3: Value from Map
Map
Fuel Cut Time (Seconds)
Time Needed for Diagnosis (Seconds)
0
2
40
40
10
60


8. FAIL SAFE

GD(H4SO)-68

GENERAL DESCRIPTION
AG:DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)

NOTE:
For the detection conditions, refer to DTC P0137. <Ref. to GD(H4SO)-66, DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4SO)-69

GENERAL DESCRIPTION
AH:DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2)

Detect the slow response of the oxygen sensor.
Judge as NG if either the rich to lean response diagnosis or lean to rich response diagnosis is NG, and judge
as OK if both are OK.
[Rich lean response diagnosis]
1. Measure the response time for oxygen sensor output changes when the A/F ratio changes to rich to lean.
If the measured response time is larger than the threshold value, it is NG. If it is smaller, it is OK.
2. Judge as NG when the oxygen sensor voltage is large (rich) when recovering from a deceleration fuel cut.
[Lean rich response diagnosis]
1. Measure the response time for oxygen sensor output changes when the A/F ratio changes to lean to rich.
If the measured response time is larger than the threshold value, it is NG.
2. Judge as NG when the oxygen sensor voltage remains small when recovering from a deceleration fuel
cut.
DIAGNOSTIC METHOD
Measure the response time of the output change of the oxygen sensor when the A/F ratio changes to rich to
lean. And judge as NG when the measured response time is larger than the threshold value.
(E)
(3)
V
(1)
(F)
(A)
(2)
(2)
(C)
(B)
(D)
EN-01696
(1)
Atmosphere
(A)
Electromotive force
(D)
Lean
(2)
(3)
Exhaust gas
Electromotive force
(B)
(C)
Air fuel ratio

Rich
(E)
(F)

Comparative voltage
3. ENABLE CONDITION
Rich lean response diagnosis
Enable Condition
Battery voltage
A/F sub feedback control condition
> 10.9 V
Completed
Deceleration fuel cut time is 6 seconds or more.

After fuel cut
Experienced
2 sec.
Rear oxygen heater current calculation time

Rear oxygen heater current continuous time
60 sec.
30 sec.
Catalyst warm-up counter (U5 model)

Estimated temperature in catalyst layer (Except for U5 model)
9000 times
400C (752F)
GD(H4SO)-70

GENERAL DESCRIPTION

Perform the diagnosis only once when deceleration fuel cut occurs after rapid acceleration. (Pay attention to
the oxygen sensor voltage to decide on the timing of the deceleration.)
When the oxygen sensor output voltage changes from 0.55 V (rich) to 0.15 V (lean), calculate the minimum
response time for output change between 0.5 V and 0.2 V for the judgment criteria.
Diagnosis execution condition
0.55V
0.5V
Measure the response time.
Rear oxygen sensor (V)
0.2V
0.15V
0V
Fuel cut on deceleration

More than 6 seconds
Execute the malfunction judgment

in 2 seconds from the recovery of
fuel cut on deceleration.
EN-05052
1. Judge as NG when the judgment value is larger than the threshold value after deceleration fuel cut.
Response time (diagnosis value) > threshold value abnormal
NOTE:
Variation time of rear oxygen sensor output voltage is short during fuel shut-off in deceleration. Carry out the
NG judgment only after the fuel shut-off in deceleration. Even without deceleration fuel cut, judge as OK if the
value is below the threshold.
When the deceleration fuel cut time is more than 6 seconds, judge as NG if the following criteria are met 2
seconds after recovering from the deceleration fuel cut.
GD(H4SO)-71

GENERAL DESCRIPTION
2. Judge as NG when the oxygen sensor voltage at recovery from a deceleration fuel cut is large.
If the fuel cut time in a deceleration fuel cut is long (more than 6 s), and even after recovering from a deceleration fuel cut, the oxygen sensor voltage is high (0.55 V or more), judge as NG.
Judgment Value
Shortest time change from rich (0.5 V O2
output) to lean (0.2 V) if voltage reduces
from 0.55 V to 0.15 V.
Time at over 0.55 V
Threshold Value
> 0.491 sec.
> 2 sec.
Time Needed for Diagnosis: 1 time

Normality Judgment
1. Regardless of a deceleration fuel cut, if the response time (diagnosis value) when the oxygen sensor voltage has changed from rich to lean is shorter than the threshold value (judgment value), judge as a normal
condition.
Response time (diagnosis value) threshold value normal
2. Do not judge as a normal condition.
Judgment Value
from 0.55 V to 0.15 V.
Threshold Value
0.491 sec.


8. FAIL SAFE

10.ENABLE CONDITION
Lean rich response diagnosis
Enable Conditions
Battery voltage
A/F main feedback control condition
> 10.9 V
Completed
Deceleration fuel cut 6 seconds

After fuel cut
Experienced
2 sec.
11.GENERAL DRIVING CYCLE

GD(H4SO)-72

GENERAL DESCRIPTION
12.DIAGNOSTIC METHOD
Calculate the minimum value of 0.3 V to 0.5 V output change response time when the oxygen sensor output
voltage changes from 0.25 V (lean) to 0.55 V (rich).
Diagnosis execution
condition
Measure the response time
(diagnostic value).
0.55V
0.5V
Rear O 2 sensor (V)
0.3V
0.25V
0V
Judge NG when the voltage of

rear oxgen sensor is 0.25 V or
less for 120 seconds or more
after recovery of fuel cut on
deceleration.
>= 120s
>= 6s
Execute the malfunction judgement in 2 seconds

from recovery of fuel cut on deceleration.
EN-02210
GD(H4SO)-73

GENERAL DESCRIPTION
1. Judge as NG when the judgment value is larger than the threshold value after deceleration fuel cut.
Response time (diagnostic value) > threshold value abnormal
2. If the oxygen sensor voltage is small after recovering from a deceleration fuel cut, and remains small,
judge as NG.
Judgment Value
Shortest time change from lean
(0.3 V O2 output) to rich (0.5 V) when
voltage drops from 0.5 V to 0.25 V.
Time at less than 0.25 V
Threshold Value
> 2 sec.
> 120 sec.

Normality Judgment
1. Regardless of a deceleration fuel cut, if the response time (diagnostic value) when the oxygen sensor voltage has changed from rich to lean is shorter than the threshold value (judgment value), judge as normal.
Response time (diagnostic value) threshold value normal
2. Normality judgement is not to be performed.
Judgment Value
Shortest time change from lean
(0.3 V O2 output) to rich (0.5 V) when
voltage drops from 0.55 V to 0.25 V.
Threshold Value
2 sec.
13.DTC CLEAR CONDITION

14.MALFUNCTION INDICATOR LIGHT CLEAR CONDITION

15.FAIL SAFE
16.ECM OPERATION AT DTC SETTING

GD(H4SO)-74

GENERAL DESCRIPTION
AI: DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED

(BANK 1 SENSOR 2)
Detect abnormalities in the rear oxygen sensor output property.
When looking at the intake air amount, coolant temperature, main feedback control, deceleration fuel cut and
other operating conditions, even though the rear oxygen sensor voltage should be moving under those conditions, if the voltage is low, this is judged as a Low side NG. If the voltage is high, it is judged as a High side
NG.
When either Low side or High side is NG, judged as rear oxygen sensor property NG.
2. ENABLE CONDITION
Target output voltage of the rear oxygen
sensor
Air intake amount
Enable Conditions
75C (167F)
0.6 V
Battery voltage
10 g (0.35 oz)/seconds
or more
> 10.9 V
Closed loop with the oxygen sensor

In operation
5 times or less

coefficient
Deceleration fuel cut of 5 seconds or
more.
Not in limit value

Experienced

Perform the diagnosis only once after idling.
When one of the following conditions is established, judged as NG.
Judgment Value
Threshold Value
Maximum output voltage low side diagnosis
< 0.55 V
Minimum output voltage high side diagnosis
> 0.25 V

Normality Judgment
Judgment Value
Maximum output voltage low side diagnosis
Threshold Value
0.55 V
Minimum output voltage high side diagnosis
0.25 V
GD(H4SO)-75

GENERAL DESCRIPTION


7. FAIL SAFE

GD(H4SO)-76

GENERAL DESCRIPTION
AJ:DTC P0171 SYSTEM TOO LEAN (BANK 1)

Detect fuel system malfunction by the amount of main feedback control.
DIAGNOSTIC METHOD
Fuel system is diagnosed by comparing the target air fuel ratio calculated by ECM with the actual air fuel ratio measured by sensor.
2. ENABLE CONDITION
Lean side
Enable Conditions
A/F main learning system
In operation

75C (167F)
Value from Map 5
Intake air change during 0.5 engine revs. 0.02 g (0.001 oz)/rev
Map 5
Engine speed (rpm)
Measured value (g(oz)/rev)
Idling
NA
650
1000
1500
2000
2500
3000
3500
4000
4500
0.203
0.183
0.155
0.149
0.157
0.162
0.18
0.193
0.205
(0.0072) (0.0065) (0.0055) (0.0053) (0.0055) (0.0057) (0.0063) (0.0068) (0.0072)

Perform the diagnosis continuously at idling or at a constant speed after warming up the engine.
GD(H4SO)-77

GENERAL DESCRIPTION
Compare the diagnosed value (fsobd) with the threshold value, and if a condition where the malfunction criteria below are met continues for more than 50 seconds, judge that there is a fault in the fuel system.
Judgment Value
Threshold Value
fsobd = (sglmd tglmda) + faf + flaf

where,
sglmd = measured lambda
tglmda = target lambda
fsobdL1
See Map 4
fsobdL1 = lean side
threshold value of
fsobd
faf = main feedback compensation coefficient (every 64 milliseconds)

flaf = main feedback learning compensation coefficient
Map 4 Threshold value for fuel system malfunction criteria

Amount of air (g(oz)/s)
fsobdL1 (%)
0 (0)
40
3.2
6.4
9.6
12.8
16
19.2
(0.113) (0.226) (0.339) (0.451) (0.564) (0.677)
40
33.2
26.5
26.5
26.5
26.5
Time Needed for Diagnosis: 10 seconds 5 times

Normality Judgment
Judge as OK when the malfunction criteria below continue for 10 seconds or more.
Judgment Value
Threshold Value
< 19%


When similar driving conditions are repeated 3 times and the result is OK.
7. FAIL SAFE
None

GD(H4SO)-78

GENERAL DESCRIPTION
AK:DTC P0172 SYSTEM TOO RICH (BANK 1)

DIAGNOSTIC METHOD
2. ENABLE CONDITION
Enable Conditions

In operation
75C (168F)

Value from Map 5
Intake air change during 0.5 engine revs. 0.02 g (0.001 oz)/rev
purge
Cumulative time of canister purge after
engine start
Continuous period after canister purge
starting
< 0.1
20 seconds or more
30 seconds or more
Map 5
Engine speed (rpm)
Measured value
(g(oz)/rev)
Idling
NA
650
1000
1500
2000
2500
3000
3500
4000
4500
0.203
0.183
0.155
0.149
0.157
0.162
0.18
0.193
0.205
(0.0072) (0.0065) (0.0055) (0.0053) (0.0055) (0.0057) (0.0063) (0.0068) (0.0072)

GD(H4SO)-79

GENERAL DESCRIPTION
Judgment Value
Threshold Value

where,
fsobdR1
See Map 4
fsobdR1 = rich side

threshold value of fsobd

Map 4 Threshold value for fuel system malfunction criteria

0 (0)
fsobdR1 (%)
40
3.2
6.4
9.6
12.8
11.7
19.2
(0.113) (0.226) (0.339) (0.451) (0.413) (0.677)
40
33.2
26.5
26.5
26.5
26.5

Normality Judgment
Judge as OK when the malfunction criteria below continues for 10 seconds.
Judgment Value
Threshold Value
20%


7. FAIL SAFE
Purge control solenoid valve control: Not allowed to purge.

GD(H4SO)-80

GENERAL DESCRIPTION
AL:DTC P0181 FUEL TEMPERATURE SENSOR A CIRCUIT RANGE/

PERFORMANCE
Detect faults in the fuel temperature sensor output properties.
Diagnosis is performed in two methods; drift diagnosis and stuck diagnosis. If either is NG, judge as NG. If
both are OK, Judge as OK and clear the NG.
DRIFT DIAGNOSIS
Normally fuel temperature is lower than engine coolant temperature. When the fuel temperature becomes
higher than the engine coolant temperature, the range is considered to be shifted, and judged as NG.
(A)
(B)
EN-01700
(A)
Resistance value ()
(B)
Fuel temperature C (F)
3. ENABLE CONDITION
Enable Conditions
None

GD(H4SO)-81

GENERAL DESCRIPTION
more.
Judgment Value
Fuel level
Threshold Value
9.0 2 (2.38 US gal,
1.98 Imp gal)
20 seconds or more
Engine coolant temperature engine

coolant temperature at engine start
> 10C (18F)
Fuel temperature Engine coolant temperature

Battery voltage
10C (18F)
> 10.9 V

Normality Judgment
Judgment Value
Fuel level
Threshold Value
9.0 2 (2.38 US gal,
1.98 Imp gal)
20 seconds or more

coolant temperature at engine start
> 10C (18F)

< 10C (18F)

< 75C (167F)
Battery voltage
> 10.9 V
Stuck Diagnosis
As the engine warms up (cumulative amount of intake air after starting is large), if the fuel temperature which
should rise does not, determine as being stuck and NG.
6. ENABLE CONDITION
Enable Conditions
20 seconds or more
Battery voltage
> 10.9 V

Always perform diagnosis after 20 seconds have passed since the engine started.
GD(H4SO)-82

GENERAL DESCRIPTION
Judgment Value
Accumulated amount of intake air
Fuel temperature difference between
Max. and Min.
Threshold Value
551 kg (1215 lb)
< 2C (3.6F)
Time Needed for Diagnosis: Undetermined

Normality Judgment
Judgment Value
Threshold Value
551 kg (1215 lb)

Max. and Min.
2C (3.6F)


11.FAIL SAFE
None

GD(H4SO)-83

GENERAL DESCRIPTION
AM:DTC P0182 FUEL TEMPERATURE SENSOR A CIRCUIT LOW INPUT

Detect the open or short circuit of fuel temperature sensor.
(A)
(B)
EN-01700
(A)
Resistance value ()
(B)
3. ENABLE CONDITION
Enable Conditions
None

more.
Judgment Value
Output voltage
Threshold Value
< 0.166 V
Battery voltage
10.9 V

Normality Judgment
Judgment Value
Output voltage
Battery voltage
Threshold Value
0.166 V
10.9 V
GD(H4SO)-84

GENERAL DESCRIPTION


8. FAIL SAFE
None

GD(H4SO)-85

GENERAL DESCRIPTION
AN:DTC P0183 FUEL TEMPERATURE SENSOR A CIRCUIT HIGH INPUT

(A)
(B)
EN-01700
(A)
Resistance value ()
(B)
3. ENABLE CONDITION
Enable Conditions
None

GD(H4SO)-86

GENERAL DESCRIPTION
more.
Judgment Value
Output voltage
Battery voltage
Threshold Value
4.716 V
10.9 V

Normality Judgment
Judgment Value
Output voltage
Battery voltage
Threshold Value
< 4.716 V
10.9 V


8. FAIL SAFE
None

GD(H4SO)-87

GENERAL DESCRIPTION
AO:DTC P0196 ENGINE OIL TEMPERATURE SENSOR CIRCUIT RANGE/

PERFORMANCE
Detect for abnormal values in the oil temperature sensor output properties.
Judge as NG when the oil temperature does not rise even though the engine is running under a condition
where it should rise.
2. ENABLE CONDITION
Battery voltage
Engine speed
Enable Conditions
10.9 V
500 rpm

GD(H4SO)-88

GENERAL DESCRIPTION
When the following conditions are established, judged as NG.
Judgment Value
Threshold Value

After engine start oil temperature sensor
characteristic diagnosis timer
< 15C (59F)

Judgment value for after engine
start oil temperature sensor characteristic diagnosis timer
After engine start oil temperature sensor characteristic diagnosis timer (timer for diagnosis).
a. Timer stop at fuel cut mode
64 milliseconds + TOILCNT milliseconds (at the time of 64 milliseconds)
Where, TOILCNT is determined as follows.
TOILCNT = 0 (at idle switch ON)
For TOILCNT at Idle switch off, refer to the following table.
Temperature
C (F)
30 (22)
0 (0)
64 ms
8 (5)
73.2 ms
16 (10)
83.9 ms
24 (15)
96.3 ms
32 (20)
113.2 ms
40 (25)
133.9 ms
48 (30)
160.2 ms
56 (35)
194.6 ms
20 (4)
10 (14)
64 ms
64 ms
73.3 ms
73.4 ms
84 ms
84.2 ms
96.6 ms
96.9 ms
113.7 ms
114.5 ms
135 ms
136.4 ms
162 ms
164.4 ms
197.4 ms
201.5 ms
0 (32)
10(50)
64 ms
102.2 ms
73.5 ms
114.8 ms
84.5 ms
129.4 ms
97.4 ms
146.7 ms
115.6 ms
171.7 ms
138.5 ms
203.4 ms
168 ms
245.1 ms
207.6 ms
302.1 ms
After engine start oil temperature characteristic diagnosis timer judgment value (t).
t = 1882940 43302 Ti (t 1882940)
Ti = The lowest coolant temperature after starting the engine
Normality Judgment
Judgment Value
Threshold Value
15C (59F)


7. FAIL SAFE
Oil temperature sensor process: Engine oil temperature is fixed at 70C (158F).

GD(H4SO)-89

GENERAL DESCRIPTION
AP:DTC P0197 ENGINE OIL TEMPERATURE SENSOR LOW

Detect the open or short circuit of the oil temperature sensor.
Judge as NG when outside of the possible range.
2. ENABLE CONDITION
Enable Conditions
None

Judge as NG when the continuous time when the following conditions are established is more than 0.5 seconds. Judge as OK and clear the NG when the following conditions are not established.
Judgment Value
Output voltage
Threshold Value
0.166 V



7. FAIL SAFE

GD(H4SO)-90

GENERAL DESCRIPTION
AQ:DTC P0198 ENGINE OIL TEMPERATURE SENSOR HIGH

Detect the open or short circuit of the oil temperature sensor.
Judge as NG when outside of the judgment value.
2. ENABLE CONDITION
Enable Conditions
None

Judge as NG when the continuous time when the following conditions are established is more than 0.5 seconds. Judge as OK and clear the NG when the following conditions are not established.
Judgment Value
Output voltage
Threshold Value
4.716 V



7. FAIL SAFE

GD(H4SO)-91

GENERAL DESCRIPTION
AR:DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT LOW

(3)
(4)
(1)
(2)
EN-01859
(1)
(2)

(3)
(4)
3. ENABLE CONDITION
Ignition switch
Enable Conditions
ON

Judgment Value
Threshold Value
0.749 V



8. FAIL SAFE

GD(H4SO)-92

GENERAL DESCRIPTION
AS:DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT HIGH

(3)
(4)
(1)
(2)
EN-01859
(1)
(2)

(3)
(4)
3. ENABLE CONDITION
Ignition switch
Enable Conditions
ON

Judgment Value
Threshold Value
4.747 V



8. FAIL SAFE

GD(H4SO)-93

GENERAL DESCRIPTION

Detect the presence of misfire occurrence. (Revolution fluctuation method)
Monitoring misfire which influences exhaust deterioration (1.5 times of FTP) and catalyst damage is made
obligatory by the law. Misfire affecting these two has two patterns below.
Intermittent misfire (The same cylinder misfires in random, or different cylinders misfire in random.): FTP
1.5 times misfire
Every time misfire (The same cylinder misfires every time.): FTP 1.5 times misfire, Catalyst damage misfire
The following detecting methods are adopted for these detection.
1) Intermittent misfire: FTP 1.5 times misfire
180 Interval Difference Method (MT: 1,800 rpm or less; AT: None)
360 Interval Difference Method (whole range)
720 Interval Difference Method (3,000 rpm or more)
2) Every time misfire: FTP 1.5 times misfire, Catalyst damage misfire
360 Interval Difference Method
2. ENABLE CONDITION
Enable Conditions
All secondary parameters enable
1 second or more
conditions
Intake manifold pressure change dur- < 13.3 kPa
ing 0.5 engine revs.
(100 mmHg, 3.94 inHg)
Throttle position change during 16
milliseconds
< 21
Fuel shut-off function

Not in operation
75.0 kPa
(563 mmHg, 22.2 inHg)
9.0 2
(2.38 US gal, 1.98 Imp gal)
Fuel level
AT torque control
Evaporative system leak check
Not in operation
Not in operation
Engine speed
460 6,400 rpm

> Value from Map 3
Battery voltage
Fuel parameter determination
8V
Not extremely low volatility
GD(H4SO)-94

GENERAL DESCRIPTION
Map 3
MT (Vehicle Speed < 64 km/h (40 MPH))
rpm
kPa
(mmHg,
inHg)
650
25.6
(192,
7.56)
1000
23.1
(173,
6.82)
1500
20.0
(150,
5.91)
2000
20.0
(150,
5.91)
2500
20.0
(150,
5.91)
3000
21.6
(162,
6.38)
3500
26.4
(198,
7.80)
4000
28.0
(210,
8.27)
4500
29.5
(221,
8.71)
5000
32.4
(243,
9.57)
5500
6000
6400
36.4
39.9
44.5
(273, (299, (324,
10.75) 11.78) 13.14)
MT (Vehicle Speed 64 km/h (40 MPH))

rpm
650
1000
1500
2000
2500
3000
3500
4000
4500
5000
kPa
(mmHg,
inHg)
31.6
(237,
9.33)
31.6
(237,
9.33)
31.6
(237,
9.33)
31.1
(233,
9.19)
31.3
(235,
9.24)
33.1
(248,
9.78)
33.9
(254,
10.01)
28.8
(216,
8.51)
30.1
(226,
8.89)
33.3
(250,
9.84)
rpm
700
1000
1500
2000
2500
3000
3500
4000
4500
5000
kPa
(mmHg,
inHg)
25.6
(192,
7.56)
24.4
(183,
7.21)
22.0
(165,
6.50)
22.4
(168,
6.62)
22.8
(171,
6.73)
23.9
(179,
7.06)
29.9
(224,
8.83)
31.3
(235,
9.24)
29.9
(244,
8.83)
5500
6000
6400
40.1
44.5
36.9
(277, (301, (324,
10.90) 11.84) 13.14)
AT
5500
6000
6400
43.3
44.5
35.6
39.3
(267, (295, (325, (334,
10.51) 11.61) 12.79) 13.14)

Detect misfires from idling to high rpm.
Perform the diagnosis continuously.
When a misfire occurs, the engine speed will decreased and the crankshaft position speed will change. Calculate the interval difference value (diagnostic value) from crankshaft position speed by the following formula, and judge whether a misfire is occurring or not comparing the calculated result with judgment value.
Counting the number of misfires, if the misfire ratio is higher during 1000 rev. or 200 rev., Judge corresponding cylinders as NG.
Diagnostic value
calculation
(Calculate from
angle speed)
Misfire detection every

single ignition
(Compare diagnostic
value with judgment

value)
NG judgment (Misfire occurrence judgment required by the law) (Compare

number of misfire with judgment)
FTP 1.5 times misfire NG judgment

Catalyst damage misfire NG judgment
GD(H4SO)-95

GENERAL DESCRIPTION
As shown in the following figure, pick a cylinder as the standard and name it omg 0. And the former crankshaft position speed is named omg 1, the second former crankshaft position speed is named omg 2, the third
is named omg 3, etc.
(A)
#3
(B)
#2
#4
#1
#3
#2
#4
#1
#3
omg7
omg6
omg5
omg4
omg3
omg2
omg1
omg0
#2
EN-01774
(A)
Ignition order
(B)
Crankshaft position speed

Diagnostic value
domg 180 = (omg 1 omg 0) (omg 5 omg 1)/4
Judge as a misfire in the following cases.
domg 180 > judgment value of positive side
domg 180 judgment value of negative side
(Judgment value before 180CA)
domg180
Threshold valve (positive number)
domg180
Threshold valve (negative number)
Judged as misfire.
EN-02877
GD(H4SO)-96

GENERAL DESCRIPTION

Diagnostic value
Misfire judgment
domg 360 = (omg 1 omg 0) (omg 3 omg 2)

domg 360 > Judgment value Judge as misfire
domg360
Threshold valve
domg360
Judged as misfire.
EN-03273

Diagnostic value
Misfire judgment
domg720
Threshold valve
domg720
Judged as misfire.
EN-03274
GD(H4SO)-97

GENERAL DESCRIPTION
FTP 1.5 times misfire (Misfire occurrence level which influences exhaust gas)
Judgment Value (Judge that malfunction occurs when the misfire ratio is high in 1000 engine revs.)
Threshold Value
FTP emission diagnostic value
> 1.0 % in 1000 revs
Time Needed for Diagnosis: 1000 engine revs.

Catalyst damage misfire (Misfire occurrence level damaging catalyst)
Judgment Value (Judge that malfunction occurs when the misfire ratio is high in 200 engine revs.
(400 ignitions))
Threshold Value
Catalyst damage misfire diagnostic value
See Map 1
Map 1 Threshold value of malfunction criteria for misfire damaging catalyst

Intake air (g (oz)/rev)
Engine speed (rpm)
percentage
0.16
(0.0006)
0.28
(0.010)
0.4
(0.014)
0.52
(0.018)
0.64
(0.023)
0.76
(0.027)
0.92
(0.032)
1.1
(0.039)
1.2
(0.042)
1.3
(0.046)
700
1000
25
25
25
25
25
25
25
25
22.5
22.5
20
20
16
15.75
12
11
12
11
12
11
1500
2000
25
20
25
20
22.5
20
20
20
18.25
17
16.75
14.25
13.5
12.75
10
11
10
11
10
11
2500
3000
20
16.75
20
16.75
18.25
15.5
16.75
14.25
15.5
12.75
14.25
11
12.75
11
11
11
11
11
11
11
3500
4000
16.75
14.25
16.75
14.25
14
11
11
7.75
10
6
9
5
8.5
5
7.75
5
7.75
5
7.75
5
4500
5000
11
11
11
11
8.25
9.5
7.75
7.75
5
5
5
5
5
5
5
5
5
5
5
5
5500
6000
9
9
9
5
7.75
5
6.75
5
5
5
5
5
5
5
5
5
5
5
5
5
6400
These figures indicate the misfire rate (%) in 400 ignitions; for example, 22.5 (%) means 400 (ignition) 22.5
(%) = 90 (ignition) misfires. This value or more is judged as a misfire.


7. FAIL SAFE
None

GD(H4SO)-98

GENERAL DESCRIPTION

NOTE:
For the diagnostic procedure, refer to DTC P0301. <Ref. to GD(H4SO)-94, DTC P0301 CYLINDER 1 MISFIRE DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.>

NOTE:
AW:DTC P0304 CYLINDER 4 MISFIRE DETECTED

NOTE:
GD(H4SO)-99

GENERAL DESCRIPTION
AX:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR)

Detect the open or short circuit of knock sensor.
(1)
(4)
(5)
(2)
(A)
(3)
EN-01707
(1)
(2)
Case
Weight
(3)
Piezoelectric element
(4)
(5)
Nut
Resistance
3. ENABLE CONDITION
Enable Conditions
None

GD(H4SO)-100
(A)
To knock sensor harness

GENERAL DESCRIPTION
Judge as NG when the continuous time of meeting the malfunction criteria below becomes 1 second or more.
Judgment Value
Output voltage
Ignition switch
Threshold Value
< 0.238 V
ON

Normality Judgment
Judgment Value
Output voltage
Ignition switch
Threshold Value
0.25 V
ON


8. FAIL SAFE
None

GD(H4SO)-101

GENERAL DESCRIPTION
AY:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR)

(1)
(4)
(5)
(2)
(A)
(3)
EN-01707
(1)
(2)
Case
Weight
(3)
Piezoelectric element
(4)
(5)
Nut
Resistance
3. ENABLE CONDITION
Enable Conditions
None

GD(H4SO)-102
(A)
To knock sensor harness

GENERAL DESCRIPTION
Judgment Value
Output voltage
Ignition switch
Threshold Value
4.714 V
ON

Normality Judgment
Judgment Value
Output voltage
Ignition switch
Threshold Value
< 4.7 V
ON


8. FAIL SAFE
None

GD(H4SO)-103

GENERAL DESCRIPTION
AZ:DTC P0335 CRANKSHAFT POSITION SENSOR A CIRCUIT

Detect the open or short circuit of the crankshaft position sensor.
Judge as NG when the crank signal is not input even though the starter was turned on.
(A)
#3BTDC10 CA
#1BTDC10 CA
#2BTDC10 CA
#4BTDC10 CA
#1BTDC10 CA
(B)
30 CA 30 CA
10 CA
EN-05538
(A)
Camshaft signal
(B)
Crankshaft signal
(1)
(3)
(2)
(1)
EN-05539
(2)
Crank sprocket
3. ENABLE CONDITION
Enable Conditions
None

GD(H4SO)-104
(3)
Crankshaft half-turn

GENERAL DESCRIPTION
Judgment Value
Threshold Value
Starter switch
ON
Not detected
Battery voltage
8V

Normality Judgment
Judge as OK when the malfunction criteria below are met.
Judgment Value
Threshold Value
Input exists
Battery voltage
8V


8. FAIL SAFE
None

GD(H4SO)-105

GENERAL DESCRIPTION
BA:DTC P0336 CRANKSHAFT POSITION SENSOR A CIRCUIT RANGE/

PERFORMANCE
Detect for faults in crankshaft position sensor output properties.
Judge as NG when there is a problem in the number of crankshaft signals for every revolution.
(A)
#3BTDC10 CA
#1BTDC10 CA
#2BTDC10 CA
#4BTDC10 CA
#1BTDC10 CA
(B)
30 CA 30 CA
10 CA
Number of crankshaft signal = 30 is normal.
EN-05540
(A)
Camshaft signal
(B)
Crankshaft signal
(1)
(3)
(2)
(1)
EN-05539
(2)
Crank sprocket
3. ENABLE CONDITION
Battery voltage
Engine speed
Enable Conditions
8V
< 4000 rpm
GD(H4SO)-106
(3)
Crankshaft half-turn

GENERAL DESCRIPTION

Perform the diagnosis continuously under 4000 rpm engine speed.
Judge as NG when all the malfunction criteria below are completed more than 10 times in a row.
Judgment Value
Cylinder number identification
Threshold Value
Completed
Number of crankshaft position sensor

signal during 1 rev.
Not = 30

Normality Judgment
Judge as OK and clear the NG when all the malfunction criteria below are met.
Judgment Value
Cylinder number distinction
Threshold Value
Completed
= 30


8. FAIL SAFE
None

GD(H4SO)-107

GENERAL DESCRIPTION
BB:DTC P0340 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 1 OR

SINGLE SENSOR)
Detect the open or short circuit of the camshaft position sensor.
Judge as NG when the number of camshaft signals remains abnormal.
Number of camshaft signal = 2 is normal at two engine revolution.
(A)
#1BTDC10 CA
#2BTDC10 CA
#3BTDC10 CA
#4BTDC10 CA
#1BTDC10 CA
(B)
10 CA
30 CA 30 CA
EN-05541
(A)
Camshaft signal
(B)
Crankshaft signal
3. ENABLE CONDITION
Enable Conditions
None

GD(H4SO)-108

GENERAL DESCRIPTION
Judge as NG when the following malfunction criteria continues for 8 engine revolutions or more.
Judgment Value
Voltage
Number of camshaft sensor signals during 2 rev.
Threshold Value
8V
Not = 2
Time Needed for Diagnosis: 8 rev.

Normality Judgment
Judge as OK and clear the NG when the following criteria are established.
Judgment Value
Voltage
Number of camshaft sensor signal during 2 rev.
Threshold Value
8V
2


8. FAIL SAFE
None

GD(H4SO)-109

GENERAL DESCRIPTION
BC:DTC P0341 CAMSHAFT POSITION SENSOR A CIRCUIT RANGE/

PERFORMANCE (BANK 1 OR SINGLE SENSOR)
Detect the malfunction of camshaft position sensor output property.
Judge NG when the camshaft position signal input timing is shifted from the crankshaft position sensor signal
because of timing belt tooth chip etc.
OK
NG
OK
NG
(A)
#1BTDC10 CA
#2BTDC10 CA
#3BTDC10 CA
#4BTDC10 CA
#1BTDC10 CA
(B)
10 CA
30 CA 30 CA
EN-05542
(A)
Camshaft signal
(B)
(1)
Crankshaft signal
(4)
(3)
(1)
(5)
(2)
EN-01782
(1)
(2)
Boss
Cam sprocket
(3)
(4)
Air gap
GD(H4SO)-110
(5)
Camshaft one revolution (Engine

two revolutions)

GENERAL DESCRIPTION
3. ENABLE CONDITION
Enable Conditions

Battery voltage
Completed
8V
Engine speed
Engine operation
550 1,000 rpm

Idling
Misfire
Not detected

Always perform the diagnosis continuously at idle speed.
Judge NG when the engine speed continues 4 revolutions for the malfunction criteria below. Judge as OK
and clear the NG when the malfunction criteria below are not met.
Judgment Value
Position of camshaft position sensor signal
Threshold Value
Not between BTDC
10CA and BTDC
80CA
Time Needed for Diagnosis: 4 revs.



8. FAIL SAFE
None

GD(H4SO)-111

GENERAL DESCRIPTION
BD:DTC P0400 EXHAUST GAS RECIRCULATION FLOW

Detect EGR system malfunction.
Intake manifold pressure (negative pressure) is constant because the throttle valve is fully closed during deceleration fuel cut. At this time, when the EGR valve is opened/closed, the intake manifold pressure will
change. EGR system OK/NG is judged by the range of this change.
(7)
(1)
(6)
(5)
(2)
(4)
(3)
EN-02192
(1)
(2)
ECM
Detecting circuit
(3)
Switching circuit
(4)
(5)
CPU
EGR valve
(6)
(7)
Main relay
Battery power supply
3. ENABLE CONDITION
Enable Conditions
40 seconds or more

Engine speed
75C (167F)
1200 2,950 rpm
Intake manifold pressure (absolute pressure)

< 40.0 kPa (300 mmHg, 11.81 inHg)

5C (41F)
Throttle position
Battery voltage
< 0.25
> 10.9 V
Vehicle speed
75.0 kPa (563 mmHg, 22.17 inHg)

53 km/h (33 MPH)

Neutral switch
In operation
Over 1 second after changing from
OFF and ON to OFF.
No change for over 5 seconds.
Load (A/C, power steering, lighting, rear

defogger, heater fan and radiator fan)

During deceleration fuel cut from more than 53 km/h (approx. 33 MPH), perform diagnosis once.
Be careful of vehicle speed and engine speed. (Diagnosis will not be completed if the vehicle speed and engine speed conditions become out of specification due to deceleration.)
GD(H4SO)-112

GENERAL DESCRIPTION
Measure the pressure values as follows when the enable conditions are established, and perform diagnosis
by calculating those results.
1. Label the intake manifold pressure value as PMOF1, which is observed when enable conditions are established, and set the EGR target step to 50 steps (nearly full open).
2. Label the intake manifold pressure value as PMON, which is observed after one second has passed since
EGR target step was set to 50 steps (when the enable conditions were established), and set the EGR target
step to 0.
3. Label the intake manifold pressure value as PMOF2, which is observed after one second has passed
since EGR target step was set to 0 (after two seconds have passed since the enable conditions were established).
Judge as NG when the following conditions are established, and judge as OK when not.
PMON (PMOF1 + PMOF2) / 2< 2.48 kPa (18.63 mmHg, 0.733 inHg)
GD(H4SO)-113

GENERAL DESCRIPTION
(G)
2sec
1sec
1sec
ON
(A)
OFF
(B)
(H)
50step
(C)
(I)
(H)
(D)
(I)
PMON
(E)
PMOF2
PMOF1
(F)
EN-02168
(A)
(B)
Deceleration fuel cut

Diagnosis enable conditions
(E)
Intake manifold pressure (During

normal condition)
(G)
(H)
Start diagnosis
Open
(C)
(D)
EGR target step

EGR actual step
(F)
Diagnostic mode timer
(I)
Closed


GD(H4SO)-114

GENERAL DESCRIPTION
8. FAIL SAFE
A/F main learning = Not allowed.
Knock learning = Not allowed.
EGR control: Not allowed to operate.

GD(H4SO)-115

GENERAL DESCRIPTION
BE:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1)

Detect the deterioration of the catalyst function.
Though the front oxygen sensor output would change slowly with a new catalyst, the sensor output with a deteriorated catalyst becomes high and the inversion time is shortened.
For this reason, the catalyst diagnosis is carried out by monitoring the front oxygen sensor output and comparing it with the front oxygen (A/F) sensor output.
(1)
(2)
(A)
(3)
(B)
(3)
(C)
(D)
EN-01713
(1)
(A)
Normal
(2)
(3)
Front oxygen sensor

Catalytic converter
(B)
Deterioration
GD(H4SO)-116
(C
Output waveform from the front

oxygen (A/F) sensor
(D)
Output waveform from the front

oxygen sensor

GENERAL DESCRIPTION
3. ENABLE CONDITION
Enable Conditions
Battery voltage
> 10.9 V
> 75.1 kPa (563 mmHg, 22.2 inHg)

Catalyst warm-up counter (Map 2)
(U5 model)
70C (158F)
9000
< 5 times
Learning value of evaporation gas density

Sub feedback
0.20
Evaporative system diagnosis

Time of difference (< 0.10) between
actual and target lambda
Vehicle speed
Not in operation
1000 milliseconds or more

Engine load change every 0.5 engine
revs.
10 40 g (0.35 1.41 oz)/s

< 0.02 g (0.001 oz)/rev
Rear oxygen output change from lower

than 660 mV to higher than 660 mV
Experienced after fuel cut

Purge execution calculated time
205 sec.
5 seconds or more
Time from recovering from the fuel cut

(U5 model)
Value from Map 23
Estimated temperature inside catalyst

layer (other than U5 model)
650C (1202F)
In operation
> 70 km/h (43.5 MPH)
Map 2
Add the following value every 512 milliseconds.
Intake amount of air
(g(oz)/s)
Total value for
warm-up counter
0 (0)
3.2
6.4
9.6
12.8
16
19.2
22.4
25.6
28.8
32
35.2
(0.113) (0.226) (0.339) (0.451) (0.564) (0.677) (0.790) (0.903) (1.016) (1.129) (1.242)
15
31
46
62
77
92
Map 23
Time from recovering from the
fuel cut (ms)
Value (ms)
5000
30000
60000
180000
60000
180000
300000

Perform the diagnosis only once at a constant speed of 70 km/h (43 MPH).
GD(H4SO)-117
108
123
127
127

GENERAL DESCRIPTION
After establishing the execution conditions, calculate the front oxygen (A/F) sensor lambda deviation cumulative value per 128 milliseconds ( | (sglmdn sglmdn-1 ) |) and rear oxygen sensor output voltage deviation
cumulative value ( | (ro2sadn ro2sadn-1)|), and when the front oxygen (A/F) sensor lambda deviation cumulative value ( | (sglmdn sglmdn-1) |) becomes higher than the predetermined value, calculate the diagnostic value.
Judge as NG when the malfunction criteria below are met. Judge as OK if the criteria below are not met.
Judgment Value
Threshold Value
| (ro2sadn ro2sadn-1) | / | (sglmdn sglmdn-1) | > 15.4 (U5 model), > 18.5 (other than U5 model)
Time Needed for Diagnosis: 30 to 55 seconds



8. FAIL SAFE
None

GD(H4SO)-118

GENERAL DESCRIPTION
BF:DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK)
Check if there is a leakage in fuel system or not, and perform the function diagnosis of valve.
(5)
: (A)
: (B)
(6)
(8)
(3)
(2)
(1)
(11)
(13)
(20)
(12)
(22)
(9)
(21)
(4)
(19)
(7)
(23)
(18) (17) (16)
(15) (14)
(10)
(1)
Fuel gauge
(10)
Canister
(19)
Fuel tank
(2)
(3)
Combination meter
Fuel injector
(11)
(12)

Pressure control valve
(20)
(21)
Vent valve
Shut-off valve
(4)
(5)
Pressure regulator
Throttle body
(13)
(14)

(22)
(23)
Drain filter
(6)
(7)
Intake manifold
Fuel filter
(15)
(16)
Fuel level sensor

Fuel pump
(8)
(9)

Drain valve
(17)
(18)
Jet pump
Fuel cut valve
(A)
Fuel line
(B)
Vaporized fuel line
EN-04898
In this system diagnosis, check for leakage and valve function is conducted by changing the fuel tank pressure and monitoring the pressure change using the fuel tank pressure sensor. During 0.04-inch diagnosis,
perform in the order of mode Z mode A mode B mode C and mode D; During 0.02-inch diagnosis,
perform in the order of mode A mode B mode C mode D and mode E.
GD(H4SO)-119

GENERAL DESCRIPTION
0.04-INCH DIAGNOSIS
Mode
Z
OK
Mode
A
OK
Mode
B
OK
Mode
C
OK
Mode
D
OK
NG
Early OK
Large leakage judgement
END
Cancel
NG
Mode
Z
Extend
NG
OK
EN-02872
Mode
Mode Z
(Purge control solenoid valve opening
failure diagnosis)
Mode A
(Estimated evaporation amount)
Mode description
Perform purge control solenoid valve opening failure diagnosis
from the size of tank pressure variation from diagnosis start.
3 16 seconds
Calculate the tank pressure change amount (P1).
Mode C
(Pressure increase check,
advanced OK judgment)
Decrease the pressure in the tank to the target value by introducing the intake manifold pressure to the fuel tank.
If the tank pressure cannot be reduced, it is diagnosed as large
leak.
Wait until the tank pressure returns to the target (start level of P2
calculation). If the tank pressure does not become the value,
make advanced OK judgment.
Mode D
(Negative pressure variation measurement,
evaporation leakage diagnosis)
Calculate the tank pressure variation (P2), and obtain the diagnostic value using P1 found in Mode A.
Perform the evaporation diagnosis using the diagnostic value.
Mode B
(Sealed negative pressure,
large leakage judgment)
Diagnosis period
10 seconds
5 25 seconds
1 15 seconds
10 seconds
Mode Table for Evaporative Emission Control System Diagnosis

Mode
Mode Z
Mode A
Tank internal pressure under normal

conditions
Roughly the same as atmospheric pressure
(Same as 0 kPa (0 mmHg, 0 inHg))
Pressure is in proportion to amount of
evaporative emission.
Mode B
Negative pressure is formed due to intake

manifold negative pressure.
Mode C
Mode D
Reaches target pressure

Pressure change is small.
Diagnostic item
Purge control solenoid valve is judged to be open.
Large leak
EVAP system large leak judgement [1.0 mm (0.04 in)]
GD(H4SO)-120
DTC
P0457
P0457
None
P0442

GENERAL DESCRIPTION
0.02-inch Diagnosis
OK
Mode A
Mode B
OK
Mode C
OK
OK
Mode D
Mode E
Cancel
Early OK 2
Cancel
END
Early OK 1
Cancel
Cancel
Cancel
EN-02871
Mode
Mode Description
Diagnosis period
Mode A
(0 point compensation)
When the pressure in the tank is high, wait until it returns to 0

point (Near 0 mmHg).
0 12 seconds
Mode B
(Negative pressure introduced)
0 27 seconds
Mode C
(Negative pressure maintained)
Wait until the tank pressure returns to the target (start level of
P2 calculation).
Calculate the time it takes for the tank pressure to return to the
P2 calculation complete pressure. If the tank pressure does not
return to the P2 calculation complete pressure, make advanced
OK judgment.
Mode D
(Negative pressure change calculated)
Mode E
Calculate the amount of evaporation (P1).
(Evaporation generated amount calculated)
0 20 seconds
0 200 seconds
0 280 seconds
PCV controls the fuel tank pressure to be equal to the atmospheric air pressure. Normally, the solenoid is set
to OFF. The valve opens and closes mechanically in accordance with the pressure difference between tank
and atmospheric air, or tank and canister.
GD(H4SO)-121

GENERAL DESCRIPTION
The valve is forcibly opened by setting the solenoid to ON at the time of diagnosis.
(a)
(1)
(4)
(b)
(c)
(3)
(2)
EN-01715
(1)
Solenoid
(3)
Valve
(a)
(2)
Diaphragm
(4)
Spring
(b)
(c)
Fuel tank
Canister
Valve Operation and Air Flow

In the figure below, divided by the diaphragm, the part above X is charged with atmospheric air pressure, and
the part below X is charged with tank pressure. Also, the part above Y is charged with tank pressure, and the
part below Y is charged with canister pressure.
If the atmospheric air pressure port is A, tank pressure port is B, and canister pressure port is C, the air flows
according to pressure difference from each port as shown in the table below.
A
(a)
(b)
(c)
EN-01716
(a)
(b)
Fuel tank
Condition of pressure
Flow
A < B (solenoid OFF)

B < C (solenoid OFF)
BC
CB
Solenoid ON
B C
GD(H4SO)-122
(c)
Canister

GENERAL DESCRIPTION
When A < B (Solenoid OFF)
A
(a)
(b)
(c)
EN-01717
(a)
(b)
Fuel tank
(c)
Canister
When B < C (Solenoid OFF)
A
(a)
C
(c)
(b)
(1)
EN-01718
(1)
Valve
(a)
(b)
(c)
Fuel tank
Canister
GD(H4SO)-123

GENERAL DESCRIPTION
When Solenoid is ON
A
(a)
C
(c)
(b)
EN-01719
(a)
(b)
Fuel tank
(c)
Canister
Drain Valve
Drain valve controls the ambient air to be introduced to the canister.
EN-02293
GD(H4SO)-124

GENERAL DESCRIPTION
3. ENABLE CONDITION
0.04-inch Diagnosis
Enable Conditions
Battery voltage
10.9 V
Barometric pressure
Total time of canister purge operation
75.1 kPa (563 mmHg, 22.17 inHg)

120 seconds or more

856 seconds or more

0.08
Engine speed
Fuel tank pressure
1,050 6,000 rpm

4.00 kPa (30 mmHg, 1.18 inHg)
Intake manifold vacuum (relative pressure)

Vehicle speed
< 26.7 kPa (200 mmHg, 7.87 inHg)

32 km/h (20 MPH)
Fuel level
Closed air/fuel ratio control
9.0 51.0 (2.38 13.47 US gal, 1.98 11.22 Imp gal)

In operation
Fuel temperature
10 45C (14 113F)

10C (14F)
Pressure change per second

Minimum pressure change value every one second
Maximum pressure change value every one second
Change of fuel level
< 0.23 kPa (1.7 mmHg, 0.07 inHg)

< 0.23 kPa (1.7 mmHg, 0.07 inHg)
Air fuel ratio
< 2.5 2/128 milliseconds

(0.66 US gal/128 milliseconds, 0.55 Imp gal/128 milliseconds)
0.76 1.25
GD(H4SO)-125

GENERAL DESCRIPTION
0.02-inch Diagnosis
(At starting a diagnosis)
Enable Condition
Evap. diagnosis
Battery voltage
Incomplete
10.9 V
75.1 kPa (563 mmHg, 22.2 inHg)
Time from 0.02 inch leak, previous incomplete diagnosis
When cancelling in mode A
> 120 sec.
When cancelling in other than mode A
> 600 sec.

120 seconds or more

Fuel Temp.
120 seconds or more

10 70C (14 158F)
Fuel level
9.0 51.0 2
(2.38 13.47 US gal, 1.98 11.22 Imp gal)
< 8.0 kPa (60 mmHg, 2.36 inHg)

Fuel tank pressure
0.67 1.43 kPa

(5 10.7 mmHg, 0.20 0.42 inHg)
Vehicle speed
30 km/h (19 MPH)

In operation
Engine speed
(During diagnosis)
550 6000 rpm

Pressure change every one second
Value from Map

< 0.06 kPa (0.44 mmHg, 0.02 inHg)
Minimum pressure change value every one second

Maximum pressure change value every one second
< 0.07 kPa (0.51 mmHg, 0.02 inHg)
| Pressure change in tank every second |

Atmospheric pressure change (Mode D)
0.1 kPa (0.75 mmHg, 0.03 inHg)

0.48 0.32 kPa (3.6 2.4 mmHg, 0.14 0.09 inHg)
Atmospheric pressure change (Mode E)
0.32 0.32 kPa (2.4 2.4 mmHg, 0.09 0.09 inHg)
Map
Fuel level (2, US gal, Imp gal)
10, 2.64,
2.2
20, 5.28,
4.4
30, 7.93,
6.6
40, 10.57,
8.8
50, 13.21,
11
60, 15.85,
13.2
Change (2, US gal, Imp gal)
4.2, 1.11,
0.92
4.2, 1.11,
0.92
4.1, 1.08,
0.9
4.0, 1.06,
0.88
3.9, 1.03,
0.86
3.8, 1.0,
0.84
3.8, 1.0,
0.84

0.04-inch Diagnosis
After 856 seconds or more have passed since the engine started, perform the diagnosis only once at a
constant speed of 32 km/h (20 MPH) or more.
Pay attention to the fuel temperature and fuel level.
0.02-inch Diagnosis
After 770 seconds or more have passed since the engine started, perform the diagnosis at a constant
speed of 68 km/h (42 MPH) or more, to judge as NG or OK.
If judgment cannot be made, repeat the diagnosis.
Be careful of the remaining fuel level.
GD(H4SO)-126

GENERAL DESCRIPTION
Purge control solenoid valve stuck open fault diagnosis
DTC
P0457 Evaporative Emission Control System Leak Detected (Fuel Cap Loose/Off)
Purpose of Mode Z
When performing the leakage diagnosis of EVAP system, the purge control solenoid valve must operate normally. Therefore, mode Z is used to diagnose the purge control solenoid valve stuck open condition. Note
that if a purge control solenoid valve stuck open fault is detected, the EVAP system leakage diagnosis is cancelled.
Diagnostic method
Purge control solenoid valve functional diagnosis is performed by monitoring the tank pressure in mode Z.
Normality Judgment
Judge OK and change to Mode A when the criteria below are completed in 3 seconds after Mode Z started.
Judgment Value
(Tank pressure when Mode Z started)
(Tank pressure when Mode Z finished)
Threshold Value
0.4 kPa
(3 mmHg, 0.12 inHg)
DTC
P0457
Normal
(1)
(2)
evptez
evptezha
evptezini
(3)
0
(4)
(5)
EN-02869
(1)
Mode Z
(3)
Fuel tank pressure
(2)
3 seconds
(4)
0.4 kpa (3.0 mmHg, 0.12 inHg)
(5)
OK judgment
evptez evptezha 0.4 kPa (3.0 mmHg, 0.12 inHg)

evptezini evptezha 0.4 kPa (3.0 mmHg, 0.12 inHg)
Judge as normal when both are established.
If OK judgment cannot be made, extend Mode Z 16 seconds more, and judge as NG when all the criteria below are completed after 16 seconds.
Judgment Value
Tank pressure when Mode Z started
Threshold Value
> 0.6 kPa
(4.5 mmHg, 0.18 inHg)
1.43 kPa
(10.7 mmHg, 0.42 inHg)
Time of 2 2 or more fuel no sloshing
40 sec.
DTC
P0457
GD(H4SO)-127

GENERAL DESCRIPTION

When judgment for purge control solenoid valve stuck open NG is made, end the evaporative diagnosis.
Cancel the evaporative diagnosis when the OK/NG judgment for purge control solenoid valve stuck open
cannot be made in Mode Z.
Purge Control Solenoid Valve Open Fixation
(1)
(2)
(3)
(6)
evptez
evptezini
(4)
0
(5)
evptezha
(7)
(8)
EN-02870
(1)
Mode Z
(4)
Fuel tank pressure
(7)
No fuel sloshing for 40 seconds
(2)
(3)
Extended mode Z
16 seconds
(5)
(6)
0.87 kpa (6.5 mmHg, 0.26 inHg)

1.43 kpa (10.7 mmHg, 0.42 inHg)
(8)
NG judgment
evptezini, evptez 1.43 kPa (10.7 mmHg, 0.42 inHg)

No fuel sloshing of over 2 2 (0.53 US gal, 0.44 Imp gal) for 40 seconds or more.
Judge as normal when all are established.
GD(H4SO)-128

GENERAL DESCRIPTION
Leak Diagnosis
DTC
P0442 Evaporative Emission Control System Leak Detected (Small Leak)
Diagnostic method
The diagnostic method consists of creating a sealed vacuum in the fuel tank and then determining the
presence of leakage from the speed at which the tank internal pressure returns to atmospheric pressure.
The diagnosis is divided into the following five phases.
Mode A: (Estimated evaporation gas amount)
Calculate the tank pressure change amount (P1) when using mode A. After calculating P1, switch to mode B.
Mode B: (Negative pressure sealed)
Introduce negative pressure in the intake manifold to the tank.
Approximately 0 1.4 kPa (0 10.5 mmHg, 0 0.41 inHg)
When the pressure above (desired negative pressure) is reached, enters Mode C.
In this case, if the tank pressure does not reach the target negative pressure, judge that there is a large leakage (10 seconds or 25 seconds) in the system and terminate the evaporative emission control system diagnosis.
Judge as NG (large leak) when the criteria below are met.
Judgment Value
Time to reach target negative pressure
Threshold Value
25 sec.
Or mode B time
(Min. pressure value in tank when in
mode B) (Tank pressure when mode B
started)
10 sec.
< 0.53 kPa
(4 mmHg, 0.16 inHg)
DTC
P0457
Mode C: (Check pressure rise)

Stop the introduction of negative pressure. (Wait until the tank pressure returns to the start level of P2 calculation.)
Change to Mode D when the tank pressure returns to the start level of P2 calculation.
Judge immediate OK and change to Mode E when it does not return in spite of spending the specified time.
Tank pressure when starting calculation of P2
1.3 kPa (9.75 mmHg, 0.38
inHg)
Make advanced OK
judgment
15 seconds
Mode D: (Measure amount of negative pressure change)

Monitor the tank pressure change amount in mode D. In this case, the tank pressure increases (nears atmospheric pressure), because evaporation occurs. However, if any leakage exists, the pressure increases additionally in proportion to this leakage. The pressure variation of this tank is P2.
After calculating P2, perform a small leak diagnosis according to the items below.
When Mode D is ended
Assign tank variations measured in Mode A and Mode D; P1 and P2, to the formula below, judge small leaks
in the system. If the measured judgment value exceeds the threshold value, it is judged to be a malfunction.
GD(H4SO)-129

GENERAL DESCRIPTION
Judge as NG when the criteria below are met and judge as OK and clear NG when not met.
Judgment Value
P2 1.5 P1
Threshold Value
> Value from Map 7
P2: Tank pressure that changes every 10

seconds in mode D
P1: Tank pressure that changes every 10
seconds in mode A
* Threshold value:
Map (Remaining Fuel
vs Tank temperature)
DTC
P0442
* 1.5: Evaporation amount compensation value when below negative pressure (Amount of evaporation occurrence increases as
a vacuum condition increases.)
Map 7 Malfunction criteria limit for evaporation diagnosis

Fuel temperature vs Fuel level
10 2 (2.6 US gal, 2.2 Imp gal)
20 2 (5.3 US gal, 4.4 Imp gal)
30 2 (7.9 US gal, 6.6 Imp gal)
40 2 (10.6 US gal, 8.8 Imp gal)
50 2 (13.2 US gal, 11.0 Imp gal)
5C (41F)
15C (59F)
25C (77F)
35C (95F)
45C (113F)
0.49 kPa
(3.68 mmHg,
0.145 inHg)
0.50 kPa
(3.77 mmHg,
0.148 inHg)
0.51 kPa
(3.85 mmHg,
0.152 inHg)
0.65 kPa
(4.88 mmHg,
0.192 inHg)
0.49 kPa
(3.68 mmHg,
0.145 inHg)
0.51 kPa
(3.79 mmHg,
0.149 inHg)
0.52 kPa
(3.9 mmHg,
0.154 inHg)
0.65 kPa
(4.90 mmHg,
0.193 inHg)
0.53 kPa
(3.95 mmHg,
0.156 inHg)
0.53 kPa
(4.01 mmHg,
0.158 inHg)
0.54 kPa
(4.06 mmHg,
0.160 inHg)
0.66 kPa
(4.98 mmHg,
0.196 inHg)
0.54 kPa
(4.07 mmHg,
0.160 inHg)
0.56 kPa
(4.17 mmHg,
0.164 inHg)
0.57 kPa
(4.27 mmHg,
0.168 inHg)
0.71 kPa
(5.32 mmHg,
0.209 inHg)
0.56 kPa
(4.17 mmHg,
0.164 inHg)
0.57 kPa
(4.27 mmHg,
0.168 inHg)
0.60 kPa
(4.48 mmHg,
0.176 inHg)
0.76 kPa
(5.73 mmHg,
0.226 inHg)
0.79 kPa
(5.90 mmHg,
0.232 inHg)
0.79 kPa
(5.90 mmHg,
0.232 inHg)
0.79 kPa
(5.90 mmHg,
0.232 inHg)
0.85 kPa
(6.38 mmHg,
0.251 inHg)
0.88 kPa
(6.60 mmHg,
0.260 inHg)

Leak Diagnosis
DTC
P0456 Evaporative Emission Control System Leak Detected (very small leak)
Diagnostic method
Mode A: (0 point compensation)
When the pressure in the tank is high, wait until it returns to 0 point (Near 0 mmHg,). Shift to mode B when
returned to the 0 point. Cancel the diagnosis when 0 point does not return in the specified time.
Mode B: (Vacuum pressure introduction)
Approximately 0 2.0 kPa (0 15 mmHg, 0 0.59 inHg)
At this time, if the tank internal pressure does not reach the target vacuum pressure, cancel the diagnosis.
Mode C: (Vacuum pressure maintained)
Change to Mode D either when the tank pressure returns to the start level of P2 calculation, or when the predetermined amount of time has passed.
GD(H4SO)-130

GENERAL DESCRIPTION
Mode D: (Vacuum pressure change amount calculation)

Monitor the tank pressure in mode D, calculate (P2) the pressure change in the tank, and measure the time
(evpdset) for the tank pressure to return when calculation of P2 is completed. Shift to Mode E when the tank
pressure returns to the end level of P2 calculation. If it does not return to the P2 calculation end tank internal
pressure after the predetermined amount of time has passed, make advanced OK judgment or cancel the diagnosis.
Normality Judgment
Judgment Value
Advanced OK judgment 1
Mode D time
Tank internal pressure
Mode D time
P2
Threshold Value
30 sec.
1.8 kPa (13.4 mmHg, 0.53 inHg)
200 sec.
0.9 1.3 kPa
(7 9.6 mmHg, 0.28 0.38 inHg)
Mode E: (Evaporation occurrence amount calculation)

Calculate the change of tank pressure with the time evpdset to judge as NG/OK according to the value of P1.
(There are gray judgments.)
Judgment Value
P1
Threshold Value
< Value from Map 7
* Threshold value: Map
(Remaining fuel vs evpdset)

Time (evpdset) vs fuel level
10 2 (2.6 US gal, 2.2 Imp gal)
30 2 (7.9 US gal, 6.6 Imp gal)
50 2 (13.2 US gal, 11.0 Imp gal)
0 seconds
30 seconds
80 seconds
0 kPa
(0 mmHg,
0 inHg)
0 kPa
(0 mmHg,
0 inHg)
0 kPa
(0 mmHg,
0 inHg)
0.21 kPa
(1.6 mmHg,
0.063 inHg)
0.21 kPa
(1.6 mmHg,
0.063 inHg)
0.24 kPa
(1.8 mmHg,
0.071 inHg)
0.29 kPa
(2.2 mmHg,
0.087 inHg)
0.29 kPa
(2.2 mmHg,
0.087 inHg)
0.29 kPa
(2.2 mmHg,
0.087 inHg)
GD(H4SO)-131
100 seconds
0.29 kPa
(2.2 mmHg,
0.087 inHg)
0.29 kPa
(2.2 mmHg,
0.087 inHg)
0.29 kPa
(2.2 mmHg,
0.087 inHg)
150 seconds
0.29 kPa
(2.2 mmHg,
0.087 inHg)
0.29 kPa
(2.2 mmHg,
0.087 inHg)
0 kPa
(0 mmHg,
0 inHg)
200 seconds
0.29 kPa
(2.2 mmHg,
0.087 inHg)
0 kPa
(0 mmHg,
0 inHg)
0 kPa
(0 mmHg,
0 inHg)

GENERAL DESCRIPTION
Normality Judgment
Judgment Value
P1
Threshold Value
> Value from Map 8

0 seconds
30 seconds
80 seconds
100 seconds
150 seconds
200 seconds
10 2 (2.6 US gal, 2.2 Imp gal)
0.16 kPa
(1.2 mmHg,
0.047 inHg)
0.37 kPa
(2.8 mmHg,
0.110 inHg)
0.45 kPa
(3.4 mmHg,
0.134 inHg)
0.45 kPa
(3.4 mmHg,
0.134 inHg)
0.45 kPa
(3.4 mmHg,
0.134 inHg)
0.45 kPa
(3.4 mmHg,
0.134 inHg)
30 2 (7.9 US gal, 6.6 Imp gal)
0.16 kPa
(1.2 mmHg,
0.047 inHg)
0.37 kPa
(2.8 mmHg,
0.110 inHg)
0.45 kPa
(3.4 mmHg,
0.134 inHg)
0.45 kPa
(3.4 mmHg,
0.134 inHg)
0.45 kPa
(3.4 mmHg,
0.134 inHg)
0.45 kPa
(3.4 mmHg,
0.134 inHg)
50 2 (13.2 US gal, 11.0 Imp gal)
0.16 kPa
(1.2 mmHg,
0.047 inHg)
0.40 kPa
(3 mmHg,
0.118 inHg)
0.45 kPa
(3.4 mmHg,
0.134 inHg)
0.45 kPa
(3.4 mmHg,
0.134 inHg)
0.45 kPa
(3.4 mmHg,
0.134 inHg)
0.45 kPa
(3.4 mmHg,
0.134 inHg)
Time (evpdset) vs fuel level



8. FAIL SAFE
None

GD(H4SO)-132

GENERAL DESCRIPTION
BG:DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL

CIRCUIT OPEN
Detect open or short circuit of the drain valve.
Judge as NG when the ECM output level differs from the actual terminal level.
(19)
( 9 ) (10)
(14)
(15)
(11)
(16)
(12)
(8)
(13)
(7)
(17)
(4)
(5)
(19)
(6)
(2) (1)
(18)
(3)
EN-02294
(1)
(2)
Bobbin
Coil
(8)
(9)
Magnetic plate
Shaft
(14)
(15)
Retainer
Diaphragm
(3)
(4)
Diode
Stator core
(10)
(11)
Plate
Valve
(16)
(17)
Movable core
Spring
(5)
(6)
End plate
Body
(12)
(13)
Housing
Filter
(18)
(19)
Cover
O-ring
(7)
Yoke
3. ENABLE CONDITION
Enable Conditions
None

GD(H4SO)-133

GENERAL DESCRIPTION
Judge as NG when the continuous time of meeting all the malfunction criteria below becomes more than 2.5
seconds.
Judgment Value
Threshold Value
Ignition switch
Battery voltage
ON
10.9 V

Terminal output voltage when ECM outputs OFF signal
1 second or more
Low

Normality Judgment
Judgment Value
Ignition switch
Threshold Value
ON
Battery voltage
10.9 V
1 second or more
High


8. FAIL SAFE
Pressure control solenoid valve control: Open the pressure control solenoid valve.

GD(H4SO)-134

GENERAL DESCRIPTION
BH:DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL

CIRCUIT SHORTED
(19)
( 9 ) (10)
(14)
(15)
(11)
(16)
(12)
(8)
(13)
(7)
(17)
(4)
(5)
(19)
(6)
(2) (1)
(18)
(3)
EN-02294
(1)
(2)
Bobbin
Coil
(8)
(9)
Magnetic plate
Shaft
(14)
(15)
Retainer
Diaphragm
(3)
(4)
Diode
Stator core
(10)
(11)
Plate
Valve
(16)
(17)
Movable core
Spring
(5)
(6)
End plate
Body
(12)
(13)
Housing
Filter
(18)
(19)
Cover
O-ring
(7)
Yoke
3. ENABLE CONDITION
Enable Conditions
None

GD(H4SO)-135

GENERAL DESCRIPTION
Judge as NG when the continuous time of meeting the malfunction criteria below becomes more than 2.5
seconds.
Judgment Value
Threshold Value
Ignition switch
Battery voltage
ON
10.9 V

Terminal output voltage when ECM outputs ON signal
1 second or more
High

Normality Judgment
Judgment Value
Ignition switch
Threshold Value
ON
Battery voltage
10.9 V
1 second or more
Low


8. FAIL SAFE

GD(H4SO)-136

GENERAL DESCRIPTION
BI: DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR

Detect the tank pressure sensor output property abnormality.
If there is no variation of tank internal pressure when there should be under the operating condition, judge as
NG.
(1)
(2)
(A)
(B)
(C)
EN-03875
(1)
(2)
Connector
Terminals
(A)
(B)
Output voltage
Input voltage
(C)
To fuel tank
3. ENABLE CONDITION
Enable Conditions
60 seconds or more
Fuel level
Fuel temperature
9.0 2 (2.4 US gal, 2.0 Imp gal)

< 35C (95F)
Battery voltage
10.9 V
> 75.1 kPa
(563 mmHg, 22.2 inHg)

Be sure to check the fuel level and fuel temperature.
GD(H4SO)-137

GENERAL DESCRIPTION
Judgment Value
Threshold Value
Number of times when the difference

between the maximum value and minimum value for the fuel level every 60
seconds is 2 2 (0.53 US gal, 0.44 Imp
gal) or more (with enable conditions
established)
16 times
Maximum Minimum tank pressure

(with enable conditions established)
Maximum Minimum fuel temperature
(with enable condition completed)
< 0.05 kPa (0.375

mmHg, 0.01 inHg)
7C (12.6F)
If the maximum value minimum value for the fuel level every 60 seconds is less than 2 liters, extend 60 seconds and make judgment with the maximum and minimum values for the fuel level in 120 seconds. If a difference does not appear though the time was extended 60 seconds, extend the time (180, 240, 300 seconds)
and continue the judgment. If the maximum value minimum value for the fuel level is 2 liters or more, the
diagnosis counter counts up.
Time Needed for Diagnosis: 1 minute 16 times or more
Normality Judgment
Judgment Value
Threshold Value
0.05 kPa (0.375
mmHg, 0.01 inHg)


8. FAIL SAFE
Purge control solenoid valve control: Not allowed to purge fixed mode.

GD(H4SO)-138

GENERAL DESCRIPTION
BJ:DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE

SENSOR LOW INPUT
Detect the open or short circuit of the fuel tank pressure sensor.
(1)
(2)
(A)
(B)
(C)
EN-03875
(1)
(2)
Connector
Terminals
(A)
(B)
Output voltage
Input voltage
3. ENABLE CONDITION
Battery voltage
Enable Conditions
10.9 V

GD(H4SO)-139
(C)
To fuel tank

GENERAL DESCRIPTION
more.
Judgment Value
Fuel tank pressure
Threshold Value
7.48 kPa (56.15
mmHg, 2.21 inHg)

Normality Judgment
Judgment Value
Fuel tank pressure
Threshold Value
> 7.48 kPa (56.15
mmHg, 2.21 inHg)


8. FAIL SAFE

GD(H4SO)-140

GENERAL DESCRIPTION
BK:DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE

SENSOR HIGH INPUT
(1)
(2)
(A)
(B)
(C)
EN-03875
(1)
(2)
Connector
Terminals
(A)
(B)
Output voltage
Input voltage
3. ENABLE CONDITION
Vehicle speed
Enable Conditions
2 km/h (1 MPH)
All conditions of EVAP canister purge

Completed
0.08
Main feedback compensation coefficient

Battery voltage
0.9
10.9 V

Perform the diagnosis continually when purging.
GD(H4SO)-141
(C)
To fuel tank

GENERAL DESCRIPTION
more.
Judgment Value
Fuel tank pressure
Fuel temperature
Threshold Value
> 7.98 kPa (59.85
mmHg, 2.36 inHg)
< 35C (95F)
75.1 kPa (563
mmHg, 22.2 inHg)

Normality Judgment
Judgment Value
Fuel tank pressure
Threshold Value
7.98 kPa (59.85
mmHg, 2.36 inHg)


8. FAIL SAFE

GD(H4SO)-142

GENERAL DESCRIPTION
BL:DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED

(VERY SMALL LEAK)
NOTE:
For the detection standard, refer to DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK
DETECTED (SMALL LEAK). <Ref. to GD(H4SO)-119, DTC P0442 EVAPORATIVE EMISSION CONTROL
BM:DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED

(FUEL CAP LOOSE/OFF)
NOTE:
For the detection standard, refer to DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK
DETECTED (SMALL LEAK). <Ref. to GD(H4SO)-119, DTC P0442 EVAPORATIVE EMISSION CONTROL
GD(H4SO)-143

GENERAL DESCRIPTION
BN:DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE

CIRCUIT LOW
Detect open or short circuit of the purge control solenoid valve.
(A)
(B)
EN-01733
(A)
To canister
(B)
To intake manifold
3. ENABLE CONDITION
Ignition switch
Enable Conditions
ON
Battery voltage
10.9 V
1 second or more

Always perform the diagnosis after starting the engine.
GD(H4SO)-144

GENERAL DESCRIPTION
Judgment Value
Threshold Value
Continuous time with the following condi- 2.5 sec.

tions established:
Duty ratio of ON
< 75%
Terminal output voltage
Low

Normality Judgment
Judgment Value
Threshold Value
High


8. FAIL SAFE
None

GD(H4SO)-145

GENERAL DESCRIPTION
BO:DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE

CIRCUIT HIGH
(A)
(B)
EN-01733
(A)
To canister
(B)
To intake manifold
3. ENABLE CONDITION
Ignition switch
Enable Conditions
ON
Battery voltage
10.9 V
1 second or more

GD(H4SO)-146

GENERAL DESCRIPTION
Judgment Value
Threshold Value

tions established:
Duty ratio of ON
25%
High

Normality Judgment
Judgment Value
Threshold Value
Low


8. FAIL SAFE
None

GD(H4SO)-147

GENERAL DESCRIPTION
BP:DTC P0461 FUEL LEVEL SENSOR A CIRCUIT RANGE/PERFORMANCE

Detect malfunctions of the fuel level sensor output property.
If the fuel level does not vary in a particular driving condition / engine condition where it should, judge as NG.
Fuel level (L)
Resistance ( )
EN-01734
3. ENABLE CONDITION
Enable Conditions
None

GD(H4SO)-148

GENERAL DESCRIPTION
Judgment Value
Threshold Value

Max. Min. values of fuel level output
> 331 kg (729.9 lb)

< 2.6 2 (0.69 US gal,
0.57 Imp gal)
Battery voltage
10.9 V
5 seconds or more

Normality Judgment
Judgment Value
Threshold Value
> 331 kg (729.9 lb)
2.6 2 (0.69 US gal,

0.57 Imp gal)
Battery voltage
10.9 V
5 seconds or more


8. FAIL SAFE
None

GD(H4SO)-149

GENERAL DESCRIPTION
BQ:DTC P0462 FUEL LEVEL SENSOR A CIRCUIT LOW

Detect the open or short circuit of fuel level sensor. Judge as NG if it is out of specification.
(1)
(4)
(2)
(3)
EN-01735
(1)
(2)

Fuel level sensor
(3)
3. ENABLE CONDITION
Enable Conditions
None

GD(H4SO)-150
(4)
Detecting circuit

GENERAL DESCRIPTION
Judge as NG when the continuous time of meeting the malfunction criteria below becomes more than time
needed for diagnosis (2.5 seconds).
Judgment Value
Threshold Value
Ignition switch
Battery voltage
ON
10.9 V

Output voltage
3 seconds or more
0.035 V

Normality Judgment
Judgment Value
Threshold Value
Ignition switch
Battery voltage
ON
10.9 V

Output voltage
3 seconds or more
> 0.035 V


8. FAIL SAFE
None

GD(H4SO)-151

GENERAL DESCRIPTION
BR:DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH

(1)
(4)
(2)
(3)
EN-01735
(1)
(2)

Fuel level sensor
(3)
3. ENABLE CONDITION
Enable Condition
None

GD(H4SO)-152
(4)
Detecting circuit

GENERAL DESCRIPTION
Judge as NG when the continuous time of meeting the malfunction criteria below exceeds the time required
for diagnosis (2.5 seconds).
Judgment Value
Threshold Value
Ignition switch
Battery voltage
ON
10.9 V

Output voltage
3 seconds or more
4.911 V

Normality Judgment
Judgment Value
Threshold value
Ignition switch
Battery voltage
ON
10.9 V

Output voltage
3 seconds or more
< 4.911 V


8. FAIL SAFE
None

GD(H4SO)-153

GENERAL DESCRIPTION
BS:DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT

Detect the unstable output faults from the fuel level sensor caused by noise. Judge as NG when the max. value and cumulative value of output voltage variation of the fuel level sensor is larger than the threshold value.
2. ENABLE CONDITION
Engine speed
Threshold Value
500 rpm

Ignition switch
1 second or more
ON
Battery voltage
> 10.9 V
Idle switch
Fuel level
ON
9.0 51 2 (2.38 13.47
US gal, 1.98 11.22 Imp gal)
10 seconds or more
Vehicle speed = 0 km/h (0 MPH)

Pay attention to the fuel level.
GD(H4SO)-154

GENERAL DESCRIPTION
Calculate the Max. value (delflmax) and cumulative value (sumfl) of output voltage variation of fuel level sensor during 12.2 seconds. Judge as normal when both max. and cumulative values are not over the threshold
value. Otherwise, when either of them is over the threshold value, the diagnosis counter counts up. Judge as
NG if the counter indicated 4 counts.
Diagnosis condition
12.2S
Diagnosis timer
Malfunction
Fuel level sensor

A/D value
Normal
Amount of Fuel level
output voltage variation
Calculate the Max. value (delvflmx)

and the cumulative value (sumvfl).
6
5
4
3
2
1
Diagnosis counter
NG at 4 counts
EN-02216
GD(H4SO)-155

GENERAL DESCRIPTION
Judgment Value
Threshold Value
Total times of the condition reaching fol- 4 times

lows,
DELFLMAX 0.2 0.26 V or SUMFL
16 V
At that time, DELFLMAX: Maximum difference of sensor output for 12.2 seconds; SUMFL: Integrated value of the
sensor output deviation for 12.2 seconds
The diagnosis counter does not count up when the following conditions are completed within 12.2 seconds.
Maximum value minimum value of
change of tank pressure for 12.2 seconds
0.05 kPa (0.375

mmHg, 0.02 inHg)
Maximum value minimum value of battery voltage for 12.2 seconds
1.65 V
Time Needed for Diagnosis: 12.2 seconds 4 times

Normality Judgment
Judgment Value
DELFLMAX
Threshold Value
< 0.2 0.26 V
SUMFL
< 16 V
At that time, DELFLMAX: Maximum difference of sensor output for 12.2 seconds; SUMFL: Integrated value of the
sensor output deviation for 12.2 seconds


7. FAIL SAFE
None

GD(H4SO)-156

GENERAL DESCRIPTION
BT:DTC P0483 FAN RATIONALITY CHECK

Detect the function abnormality of the radiator fan.
Judge as NG when the engine coolant temperature slowly decreases even when the radiator fan is rotating.
2. ENABLE CONDITION
Diagnostic enable condition is established if the radiator fan changes from OFF ON when all of the conditions below are met.
When one of the conditions below is not met, the diagnostic enable condition is not established.
Enable Conditions
Engine speed
Idle switch
560 900 rpm

ON
Vehicle speed
< 2 km/h (1 MPH)
Battery voltage
10.9 V

Perform the diagnosis continuously when the radiator fan changes from OFF ON when idling.
Judge as NG when the continuous time of meeting the malfunction criteria below becomes more than 5 minutes.
Judgment Value
Threshold Value
100C (212F)
Radiator fan signal change

OFF to ON
Does not decrease
Time Needed for Diagnosis: 5 minutes

Normality Judgment
Judgment Value
Radiator fan signal change
Threshold Value
OFF to ON
Decrease


7. FAIL SAFE
None

GD(H4SO)-157

GENERAL DESCRIPTION
BU:DTC P0502 VEHICLE SPEED SENSOR A CIRCUIT LOW INPUT

Detect the open or short circuit of vehicle speed. Judge NG when low vehicle speed (0 km/h (0 MPH)) remains whereas it seemed to be in a usual driving speed.
2. ENABLE CONDITION (FOR ABNORMALITY JUDGMENT ONLY)

Engine speed
Enable Condition
< 4000 rpm
Fuel cut in decel.

Battery voltage
In operation
10.9 V

Perform the diagnosis continuously during deceleration fuel cut.
more.
Judgment Value
Vehicle speed
Threshold Value
<1

Normality Judgment
Judge as OK and clear the NG when all of the following criteria are established.
Threshold Value
Vehicle speed
Starter switch
1
OFF
Starter switch ON OFF time
3 sec.


7. FAIL SAFE
Vehicle speed sensor signal process: Vehicle speed = 10 km/h (6 MPH)
ISC control: Open loop compensation is set to specified value (1 g (0.04 oz)/s). Not allowed to calculate
ISC feed back amount.
Radiator fan control: Both main and sub fan ON

GD(H4SO)-158

GENERAL DESCRIPTION
BV:DTC P0503 VEHICLE SPEED SENSOR A INTERMITTENT/ERRATIC/HIGH

Detect the open or short circuit of vehicle speed. Judge NG when high vehicle speed (240 km/h (149 MPH)
or more) remains whereas it seemed to be in a usual driving speed.
2. ENABLE CONDITION (FOR ABNORMALITY JUDGMENT ONLY)

Engine speed
Enable Condition
< 4000 rpm
Fuel cut in decel.

Battery voltage
In operation
10.9 V

Perform the diagnosis continuously during deceleration fuel cut.
more.
Judgment Value
Vehicle speed
Threshold Value
240

Normality Judgment
Threshold Value
Vehicle speed
Starter switch
< 240
OFF
3 sec.


7. FAIL SAFE
Vehicle speed sensor signal process: Vehicle speed = 10 km/h (6 MPH)
ISC control: Open loop compensation is set to specified value (1 g (0.04 oz)/s). Not allowed to calculate
ISC feed back amount.
Radiator fan control: Both main and sub fan ON

GD(H4SO)-159

GENERAL DESCRIPTION
BW:DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED
Detect the malfunction that actual engine speed is not close to target engine speed during idling. Judge as
NG when actual engine speed is not close to target engine speed during idling.
2. ENABLE CONDITION
Enable Conditions
75C (167F)
Battery voltage
10.9 V
> 75.1 kPa (563
mmHg, 22.2 inHg)
Fuel level
9.0 2 (2.38 US gal,

1.98 Imp gal)

Feedback in ISC
10.5 sec.
In operation
Lambda value
After air condition switching ON/OFF
0.81 1.1
> 5.1 sec.
After intake manifold pressure changes

more than 4 kPa (30 mmHg, 1.2 inHg)
After neutral switch ON/OFF change
> 5.1 sec.
Vehicle speed
0 km/h (0 MPH)
> 5.1 sec.

Perform the diagnosis continuously at idling after warming up engine.
Judge as NG when the continuous time of meeting the malfunction criteria below is 10 seconds 3 times.
Judgment Value
Actual target engine speed
Threshold Value
< 100 rpm
Feedback value for ISC
Max.

Normality Judgment
Judge as OK and clear NG when the continuous time of meeting the malfunction criteria below becomes
Judgment Value
Threshold Value
100 rpm


GD(H4SO)-160

GENERAL DESCRIPTION
7. FAIL SAFE
None

GD(H4SO)-161

GENERAL DESCRIPTION
BX:DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED
2. ENABLE CONDITION
Enable Conditions
75C (167F)
Battery voltage
10.9 V
> 75.1 kPa (563
mmHg, 22.2 inHg)
Fuel level
9.0 2 (2.38 US gal,

1.98 Imp gal)

Feedback in ISC
10.5 sec.
In operation
Lambda value
After air condition switching ON/OFF
0.81 1.1
> 5.1 sec.

more than 4 kPa (30 mmHg, 1.2 inHg)
After neutral switch ON/OFF change
> 5.1 sec.
Vehicle speed
0 km/h (0 MPH)
> 5.1 sec.

Perform the diagnosis continuously at idling after warming up engine.
Judgment Value
Threshold Value
200 rpm
Min.

Normality Judgment
Judgment Value
Threshold Value
< 200 rpm


GD(H4SO)-162

GENERAL DESCRIPTION
7. FAIL SAFE
None

GD(H4SO)-163

GENERAL DESCRIPTION
BY:DTC P0512 STARTER REQUEST CIRCUIT

Detect the open or short circuit of starter SW.
Judge ON NG when the starter SW signal remains ON.
2. ENABLE CONDITION
Enable Conditions
None

Judge as ON NG when the continuous time of meeting the malfunction criteria below becomes more than 3
minutes.
Judgment Value
Threshold Value
Engine speed
Starter OFF signal
> 500 rpm

Not detected
Battery voltage
>8V

Normality Judgment
Judge ON OK and clear the NG when the malfunction criteria below are met.
Judgment Value
Starter OFF signal
Battery voltage
Threshold Value
Detected
>8V


7. FAIL SAFE
None

GD(H4SO)-164

GENERAL DESCRIPTION
BZ:DTC P0519 IDLE AIR CONTROL SYSTEM PERFORMANCE

Detect malfunctions in which the engine speed continues to rise during idling.
2. ENABLE CONDITION
Battery voltage
Enable Conditions
10.9 V
Feedback in ISC
Vehicle speed
In operation
< 4 km/h (2 MPH)
1 second or more

Perform the diagnosis continuously if the vehicle speed at less than 4 km/h (2 MPH).
Judge as NG when the continuous time of meeting the all malfunction criteria below becomes more than 2
seconds.
Judgment Value
Threshold Value
Engine speed targeted engine speed

Feedback compensation for ISC
> 2000 rpm

0
Engine speed change every 180 degree

engine revs.
5 rpm

Normality Judgment
Judgment Value
Threshold Value
< 200 rpm


7. FAIL SAFE
Fuel cut: Cuts off fuel for only #1 and #2 cylinders, or for all cylinders according to vehicle speed, engine
speed, and throttle position.

GD(H4SO)-165

GENERAL DESCRIPTION
CA:DTC P0600 SERIAL COMMUNICATION LINK

Detect malfunction of CAN communication.
Judge as NG when CAN communication is not established, CAN communication with AT is not established,
and the data from the AT is not normal.
ECM and TCM are connected by high speed CAN.
(Common Specifications)
CAN Protocol 2.0 B (Active)
Frame Format: 11 Bit ID Frame (Standard Frame)
(High speed CAN)
Conforms to ISO11898
Communication Speed: 500 kbps
3. ENABLE CONDITION
Battery voltage
Enable Conditions
10.9 V
Starter switch
Engine
OFF
run

Judge as NG when either of the following conditions is established.
Judge as OK and clear the NG when the continuous time when all of the following criteria are established is
more than the predetermined time (1 second).
Judgment Value
bus off flag or warning flag
Threshold Value
set
ID is not received from the TCM
= 500 milliseconds


7. MALFUNCTION INDICATOR CLEAR PARAMETERS

8. FAIL SAFE
None

GD(H4SO)-166

GENERAL DESCRIPTION
CB:DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY

(RAM) ERROR
Detect the malfunction of microcomputer (RAM).
When there is a problem in the main CPU normal RAM, or the sub CPU normal RAM, judge as NG. Judge
as OK when both are operating properly.
If it is possible to write data to the whole area of RAM in the initial routine, and is possible to read the same
data, it is judged as OK, and if not, NG.
2. ENABLE CONDITION
Enable Conditions
None
Diagnosis with the initial routine.

Perform the diagnosis as soon as the ignition switch is turned to ON.
Judgment Value
Threshold Value
Main CPU normal RAM abnormal

Write 5AA5A55A and then read. (Whole
area of RAM)
Or write A55A5AA5 and then read.
(Whole area of RAM)
5AA5A55A cannot be
read.
A55A5AA5 cannot be
read.
Sub CPU normal RAM abnormal

Write 5AA5 and then read. (Whole area
of RAM)
Or write A55A and then read. (Whole
area of RAM)
5AA5 cannot be read.

A55A cannot be read.

Normality Judgment
Judgment Value
Threshold Value
Main CPU normal RAM abnormal

Write 5AA5A55A and then read. (Whole
area of RAM)
5AA5A55A can be
read.
And write A55A5AA5 and then read.

(Whole area of RAM)
A55A5AA5 can be
read.
Sub CPU normal RAM abnormal

Write 5AA5 and then read. (Whole area
of RAM)
And write A55A and then read. (Whole
area of RAM)
5AA5 can be read.

A55A can be read.
GD(H4SO)-167

GENERAL DESCRIPTION


7. FAIL SAFE
None

GD(H4SO)-168

GENERAL DESCRIPTION
CC:DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM)

ERROR
Judge as NG when SUM value of ROM is outside the standard value.
2. ENABLE CONDITION
Ignition switch
Enable Conditions
ON

more.
Judgment Value
SUM value of ROM
Threshold Value
Specification



7. FAIL SAFE

GD(H4SO)-169

GENERAL DESCRIPTION
CD:DTC P0607 CONTROL MODULE PERFORMANCE

Judge as NG when either the following is completed.
When the read value of throttle position sensor 1 signal is mismatched between main CPU and sub CPU.
When the read value of accelerator pedal position sensor 1 signal is mismatched between main CPU and
sub CPU.
When the sub CPU operates abnormally.
When the communication between main CPU sub CPU is abnormal.
When the input amplifier circuit of throttle position sensor 1 is abnormal.
When the cruise control cannot be canceled correctly.
When the signal of brake SW1 and 2 is mismatched.
When the directed angle from the main CPU is abnormal.
(1)
(12)
(2)
(11)
(10)
(13)
(10)
(3)
(4)
(10)
(5)
(14)
(6)
(10)
(7)
(8)
(9)
EN-01862
(1)
(2)

Throttle position sensor 1
(6)
Accelerator pedal position sensor

2
(10)
(11)
I/F circuit
Amplifier circuit
(3)
(4)
Throttle position sensor 2

(7)
(8)
Battery
Stop light
(12)
(13)

Sub CPU
(5)

1
(9)
Brake switch
(14)
Main CPU
GD(H4SO)-170

GENERAL DESCRIPTION
3. ENABLE CONDITION
Enable Conditions
(1) Ignition switch

(2) Ignition switch
ON
ON
(3) None
(4) None
(5) Throttle opening angle

(6) Brake switch (only with cruise control) ON
(7) None
(8) Cruise control
OFF

(1) (4): Always perform the diagnosis continuously.
(5): Always perform the diagnosis continuously when idling.
(6): Perform the diagnosis when the brake pedal is depressed.
(7): Always perform the diagnosis continuously.
(8): Always perform the diagnosis continuously when the cruise control pedal is not operating.
Judgment Value
Threshold Value
(1) Difference of CPU reading value of the throttle position sensor signal
(2) Difference of CPU on read value of the accelerator pedal position sensor signal
0.0858 V
0.038 V
(3) WD pulse from sub CPU

(4) Communication between CPU
WD pulse occur
Possible to communicate
(5) | Throttle position sensor 1 opening angle (Throttle position sensor 1 opening angle after
the amplifier) 1/4 |
< 3
(6) Cruise control cancel signal at brake ON

(7) Brake switch 1, 2 signal
Cruise control cancel signal ON

SW 1 and 2 are matched

1. 250 milliseconds
2. 250 milliseconds
3. 200 milliseconds
4. 200 milliseconds
5. 24 milliseconds
6. 250 milliseconds
7. 200 milliseconds


8. FAIL SAFE

GD(H4SO)-171

GENERAL DESCRIPTION
CE:DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE

(BANK 1)
Judge as NG when the target opening angle and actual opening angle is mismatched or the current to motor
is more than specified duty for specified time continuously.
(3)
(1)
(4)
(2)
EN-01863
(1)
(2)
Motor
(3)
(4)
Drive circuit
3. ENABLE CONDITION
Ignition switch
Enable Conditions
ON
Normal operation of electric throttle control ON

Always perform the diagnosis continuously when the electric throttle control is operating.
GD(H4SO)-172

GENERAL DESCRIPTION
Judgment Value
Threshold Value
Difference between target opening angle

and actual opening angle
3.5 or less
Output duty to drive circuit
95% or less

Target opening angle and actual opening angle: 250 milliseconds (For NG) 2000 milliseconds (For OK)
Output duty to drive circuit: 2000 milliseconds
Details of Judgment Value
30
(25.0)
20
(3)
(1)
(12.0)
10
(5.0)
(3.5)
0
0
5 (6.15)
10
(9.65)
15
(14.65)
20
25 (26.65)
30
(2)
EN-03129
(1)
Difference between target opening

angle and actual opening angle ()
(2)
Target throttle opening angle ()
GD(H4SO)-173
(3)
NG area

GENERAL DESCRIPTION
Details of Judgment (The actual opening angle target opening angle is always 1000 milliseconds)
1000
(1)
500
(3)
(400)
(300)
(250)
0
0
5 (5.5) (9.0) 10
(13.0) 15
20 (22.0)
25
30
(2)
EN-01865
(1)
Judgment time (milliseconds)
(2)
Throttle position sensor 1 opening angle
(3)
NG area


8. FAIL SAFE

GD(H4SO)-174

GENERAL DESCRIPTION
CF:DTC P0691 FAN 1 CONTROL CIRCUIT LOW

Detect the open or short circuit of radiator fan circuit.
2. ENABLE CONDITION
Enable Conditions
None

seconds.
Judgment Value
Threshold Value

Engine speed
1 second or more
500 rpm
Ignition switch
Battery voltage
ON
10.9 V
Terminal voltage level when ECM outputs OFF signal
Low level

Normality Judgment
Judgment Value
Threshold Value
1 second or more
Engine speed
Ignition switch
500 rpm
ON
Battery voltage
10.9 V
High level


7. FAIL SAFE
None

GD(H4SO)-175

GENERAL DESCRIPTION
CG:DTC P0692 FAN 1 CONTROL CIRCUIT HIGH

Detect the open or short circuit of radiator fan circuit.
2. ENABLE CONDITION
Enable Conditions
None

seconds.
Judgment Value
Threshold Value

Engine speed
1 second or more
500 rpm
Ignition switch
Battery voltage
ON
10.9 V
Terminal voltage level when ECM outputs ON signal
High level

Normality Judgment
Judgment Value
Threshold Value
1 second or more
Engine speed
Ignition switch
500 rpm
ON
Battery voltage
10.9 V
Low level


7. FAIL SAFE
None

GD(H4SO)-176

GENERAL DESCRIPTION
CH:DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST)

CAN communication is established with AT and, judge as NG when there is a MIL lighting request.
2. ENABLE CONDITION
Battery voltage
Enable Conditions
10.9 V

Judge as NG when the continuous time of meeting the malfunction criteria below becomes more than predetermined amount of time (2.5 seconds).
Judge as OK and clear the NG when the following conditions are not met.
Judgment Value
MIL lighting request from TCM
Threshold Value
set



7. FAIL SAFE
None

GD(H4SO)-177

GENERAL DESCRIPTION
CI: DTC P0851 PARK/NEUTRAL SWITCH INPUT CIRCUIT LOW (AT MODEL)
Detect the open or short circuit of the neutral SW.
Judge NG when the ECM neutral terminal input differs from the reception data from TCM.
2. ENABLE CONDITION
Enable Conditions
Ignition switch
Battery voltage
ON
10.9 V

Starter switch
2 seconds or more
OFF

Perform the diagnosis continuously in 2 seconds after starting the engine.
seconds. Judge as OK and clear the NG when the malfunction criteria below are not met.
Judgment Value
Neutral switch signal when park/neutral
= OFF and any other switches = ON
on AT
Threshold Value
LOW (ON)



7. FAIL SAFE
Control of cruise control: Not allowed to control.

GD(H4SO)-178

GENERAL DESCRIPTION
CJ:DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT LOW (MT MODEL)

Judge NG when there is no change in the neutral SW even if the driving shift was applied. (There is neutral
SW ON/OFF inversion from the vehicle speed and engine speed.)
2. ENABLE CONDITION
Enable Conditions
Ignition switch
Battery voltage
ON
10.9 V

Starter switch
2 seconds or more
OFF

Judge NG when the malfunction criteria below are completed 3 time or more after the neutral SW change.
Judge as OK and clear the NG if there is change in the neutral SW.
Judgment Value
Threshold Value
Neutral switch signal (while changing

from a to b below)
LOW (ON)
Driving condition change

a) Vehicle speed = 0 km/h (0 MPH) and
engine speed 600 900 rpm
a) to b)
b) Vehicle speed 64 km/h (40 MPH)

and engine speed 1600 2550 rpm
Time Needed for Diagnosis: Monitoring 3 times



7. FAIL SAFE

GD(H4SO)-179

GENERAL DESCRIPTION
CK:DTC P0852 PARK/NEUTRAL SWITCH INPUT CIRCUIT HIGH (AT MODEL)

Judge the open or short circuit of the neutral SW.
2. ENABLE CONDITION
Enable Conditions
Ignition switch
Battery voltage
ON
10.9 V

Starter switch
2 seconds or more
OFF

Judge as NG when the continuous time until meeting the malfunction criteria below becomes 2.56 seconds.
Judge as OK and clear the NG when the malfunction criteria below are not met.
Judgment Value
= ON and any other switches = OFF
on AT
Threshold Value
HIGH (OFF)



7. FAIL SAFE

GD(H4SO)-180

GENERAL DESCRIPTION
CL:DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH (MT MODEL)

2. ENABLE CONDITION
Enable Conditions
Ignition switch
Battery voltage
ON
10.9 V

Starter switch
2 seconds or more
OFF

Judge as OK and clear the NG if there is change in the neutral SW.
Judgment Value
Threshold Value

from a to b below)
HIGH (OFF)

a) to b)
b) Vehicle speed 64 km/h (40 MPH)




7. FAIL SAFE

GD(H4SO)-181

GENERAL DESCRIPTION
CM:DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK 1

SENSOR 1)
Detect that value remains Low.
Judge as NG when lambda value is abnormal in accordance with value of front oxygen (A/F) sensor and
running conditions such as vehicle speed, amount of intake air, engine coolant temperature, sub feedback
control, etc.
value = Actual air fuel ratio/Theoretical air fuel ratio
> 1: Lean
< 1: Rich
(3)
(1)
(A)
(2)
(2)
(C)
(B)
(D)
(4)
EN-01693
(1)
Atmosphere
(A)
Electromotive force
(2)
(3)
Exhaust gas
ZrO2
(B)
(C)
Air fuel ratio

Lean
(4)
Ceramic heater
(D)
Rich
GD(H4SO)-182

GENERAL DESCRIPTION
3. ENABLE CONDITION
Enable Conditions

Battery voltage
4 seconds or more
> 10.9 V
Rear oxygen sensor sub feedback
> 75.1 kPa (563 mmHg, 22.2 inHg)

Execution
Rear oxygen sensor output voltage Feedback target voltage

Or rear oxygen sensor sub feedback compensation coefficient
0.2 V 0.1 V
On Min.
Or rear oxygen sensor sub feedback compensation coefficient

On Max.
60 seconds or more

Vehicle speed
75C (167F)
20 km/h (12 MPH)

Load change during 0.5 engine revs.
6 g (0.21 oz)/s
0.02 g (0.001 oz)/rev

0 50
0.2

Target lambda load compensation coefficient
20 seconds or more
0.03 0

Perform diagnosis continuously at a constant speed of 20 km/h (12 MPH) or more after 60 seconds have
passed since the engine started.
Judge as NG when the continuous time of meeting the malfunction criteria below becomes more than 10 seconds. Judge as OK and clear the NG when the malfunction criteria below are not met.
Judgment Value
value when rear oxygen sensor sub
feedback compensation coefficient is not
at maximum limit
Threshold Value
0.85



8. FAIL SAFE

GD(H4SO)-183

GENERAL DESCRIPTION
CN:DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK 1

SENSOR 1)
Detect that value remains High.
control, etc.
value = Actual air fuel ratio/Theoretical
air fuel ratio
> 1: Lean
< 1: Rich
(3)
(1)
(A)
(2)
(2)
(C)
(B)
(D)
(4)
EN-01693
(1)
(2)
Atmosphere
Exhaust gas
(A)
(B)
Electromotive force
Air fuel ratio
(3)
(4)
ZrO2
Ceramic heater
(C)
(D)
Lean
Rich
GD(H4SO)-184

GENERAL DESCRIPTION
3. ENABLE CONDITION
Enable Conditions

Battery voltage
4 seconds or more
> 10.9 V
> 75.1 kPa (563 mmHg, 22.2 inHg)

Execution
Rear oxygen sensor output voltage Feedback target voltage 0.2 V 0.1 V
Or rear oxygen sensor sub feedback compensation coefficient On Min.
Or rear oxygen sensor sub feedback compensation coefficient On Max.
60 seconds or more
Vehicle speed
75C (167F)
20 km/h (12 MPH)

6 g (0.21 oz)/s
0.02 g (0.001 oz)/rev

0 50
0.2

Target lambda load compensation coefficient
20 seconds or more
0.03 0

Perform diagnosis continuously at a constant vehicle speed of 20 km/h (12 MPH) or more after 60 seconds
have passed since the engine started.
Judgment Value
feedback compensation coefficient cannot be at minimum limit
Threshold Value
1.15



8. FAIL SAFE

GD(H4SO)-185

GENERAL DESCRIPTION
CO:DTC P1160 RETURN SPRING FAILURE

Judge as NG when the valve does not move to the close direction with the motor power stopped and the
valve open more than the default opening.
(1)
(8)
S S
(7)
(3)
(6)
(2)
(4)
(5)
EN-01866
(1)
(2)
Opener spring
Return spring
(4)
(5)
Full closed stopper

Throttle valve
(3)
Intermediate stopper
(6)
Gear
(7)
(8)
DC motor
Main and sub throttle sensor
3. ENABLE CONDITION
Motor continuity
Enable Conditions
OFF
OFF

Ignition switch ON OFF
Ignition switch OFF ON (Only after clearing memory)
Judgment Value
Opening variation after continuity is set
to OFF
Threshold Value
2


GD(H4SO)-186

GENERAL DESCRIPTION

8. FAIL SAFE
Throttle opening is fixed to 6.

GD(H4SO)-187

GENERAL DESCRIPTION
CP:DTC P1400 FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT

LOW
Detect the open/short circuit of pressure control solenoid valve.
Judge as NG when ECM output level is different from actual terminal level.
(1)
(A)
(2)
(3)
(4)
(B)
(C)
(5)
EN-01759
(1)
(2)
Filter
Coil
(3)
Connector terminal
(4)
(5)
Diaphragm
Valve
(A)
(B)
Shut-off valve
(C)
To fuel tank
3. ENABLE CONDITION
Ignition switch
Enable Conditions
ON
Battery voltage
10.9 V
1 second or more

needed for diagnosis (2.5 seconds). Judge as OK and clear the NG when the malfunction criteria below are
not met.
Judgment Value
Threshold Value
Low

GD(H4SO)-188

GENERAL DESCRIPTION


8. FAIL SAFE
None

GD(H4SO)-189

GENERAL DESCRIPTION
CQ:DTC P1420 FUEL TANK PRESSURE CONTROL SOL. VALVE CIRCUIT HIGH
(1)
(A)
(2)
(3)
(4)
(B)
(C)
(5)
EN-01759
(1)
(2)
Filter
Coil
(3)
Connector terminal
(4)
(5)
Diaphragm
Valve
(A)
(B)
Shut-off valve
(C)
To fuel tank
3. ENABLE CONDITION
Ignition switch
Enable Conditions
ON
Battery voltage
10.9 V
1 second or more

not met.
Judgment Value
Threshold Value
High


GD(H4SO)-190

GENERAL DESCRIPTION

8. FAIL SAFE
None

GD(H4SO)-191

GENERAL DESCRIPTION
CR:DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM

Detect the abnormal function (stuck closed) of the drain valve.
Judge as NG when fuel tank pressure is low.
(19)
( 9 ) (10)
(14)
(15)
(11)
(16)
(12)
(8)
(13)
(7)
(17)
(4)
(5)
(19)
(6)
(2) (1)
(18)
(3)
EN-02294
(1)
(2)
Bobbin
Coil
(8)
(9)
Magnetic plate
Shaft
(15)
(16)
Diaphragm
Movable core
(3)
(4)
Diode
Stator core
(10)
(11)
Plate
Valve
(17)
(18)
Spring
Cover
(5)
(6)
End plate
Body
(12)
(13)
Housing
Filter
(19)
O-ring
(7)
Yoke
(14)
Retainer
3. ENABLE CONDITION
Drain valve
Enable Conditions
Open
Battery voltage
10.9 V
75.0 kPa (563 mmHg, 22.17 inHg)
Tank pressure when starter is OFF ON
0.7 1.4 kPa (5 10.7 mmHg, 0.20 0.42 inHg)

GD(H4SO)-192

GENERAL DESCRIPTION
Judge as NG when the continuous time while meeting all of the malfunction criteria below is more than 3 seconds.
Judgment Value
Tank pressure
Threshold Value
4.0 kPa (30 mmHg, 1.18 inHg)

Normality Judgment
Judgment Value
Tank pressure
Threshold Value
> 4.0 kPa (30 mmHg, 1.18 inHg)
Cumulative time when all of the malfunc- 30 sec.

tion criteria below is completed.
Purge control solenoid valve duty ratio
Fuel temp.
Not = 0
10 45C (14 113F)
26.7 kPa (200 mmHg, 7.87 inHg)


8. FAIL SAFE

GD(H4SO)-193

GENERAL DESCRIPTION
CS:DTC P1491 POSITIVE CRANKCASE VENTILATION (BLOW-BY) FUNCTION

PROBLEM
Detect the blow-by hose release abnormality.
Judge as NG when the diagnosis terminal voltage is high.
(1)
(4)
(2)
(3)
EN-01790
(1)
(2)

Detecting circuit
(3)
(4)
PCV diagnosis connector

5V
3. ENABLE CONDITION
Enable Conditions
None

GD(H4SO)-194

GENERAL DESCRIPTION
Judge as NG when the continuous time with the following criteria established exceeds 2.5 seconds.
Judgment Value
Threshold Value
Battery voltage
Engine speed
> 10.9 V
500 rpm
Positive crankcase ventilation diagnosis

voltage
High

Normality Judgment
Judge as OK when the following conditions are established after predetermined amount of time has passed.
Judgment Value
Threshold Value
Battery voltage
Engine speed
> 10.9 V
500 rpm

voltage
Low


8. FAIL SAFE
None

GD(H4SO)-195

GENERAL DESCRIPTION
CT:DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION

(LOW INPUT)
Detects open or short circuit of EGR.
(5)
(1)
(6)
(3)
(2)
(4)
EN-02051
(1)
(2)

Computer unit (CPU)
(3)
(4)
Detecting circuit
Switch circuit
3. ENABLE CONDITION
EGR valve target position
Battery voltage
Enable Conditions
> 0 step
> 10.9 V

Perform diagnosis continuously during EGR operation.
GD(H4SO)-196
(5)
(6)
Battery voltage
Main relay

GENERAL DESCRIPTION
time.
Judgment Value
Threshold Value
Low level

Malfunction Indicator Light: Illuminates as soon as a malfunction occurs.
Normality Judgment
Judgment Value
Threshold Value
High level


8. FAIL SAFE
Knock sensor learning compensation: Not allowed to calculate.

GD(H4SO)-197

GENERAL DESCRIPTION
CU:DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION

(HIGH INPUT)
Detects open or short circuit of EGR.
(5)
(1)
(6)
(3)
(2)
(4)
EN-02051
(1)
(2)

Computer unit (CPU)
(3)
(4)
Detecting circuit
Switch circuit
3. ENABLE CONDITION
Battery voltage
EGR valve target position
Enable Conditions
> 10.9 V
> 0 step

GD(H4SO)-198
(5)
(6)
Battery voltage
Main relay

GENERAL DESCRIPTION
time.
Judgment Value
Threshold Value
High level

Normality Judgment
Judgment Value
Threshold Value
Low level


8. FAIL SAFE
Knock sensor learning compensation: Not allowed to calculate.

GD(H4SO)-199

GENERAL DESCRIPTION
CV:DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION

(LOW INPUT)
NOTE:
For the detection conditions, refer to DTC P1492. <Ref. to GD(H4SO)-196, DTC P1492 EGR SOLENOID
VALVE SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CW:DTC P1495 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION

(HIGH INPUT)
NOTE:
VALVE SIGNAL #1 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Trouble Code (DTC) Detecting
Criteria.>
CX:DTC P1496 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION

(LOW INPUT)
NOTE:
CY:DTC P1497 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION

(HIGH INPUT)
NOTE:
Criteria.>
CZ:DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION

(LOW INPUT)
NOTE:
DA:DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION

(HIGH INPUT)
NOTE:
Criteria.>
GD(H4SO)-200

GENERAL DESCRIPTION

Judge as OFF NG when the engine starts without starter ON experience.
2. ENABLE CONDITION
Enable Conditions
None

Judge as OFF NG when the malfunction criteria below are met.
Judgment Value
Threshold Value
Vehicle speed
Starter ON signal
< 1 km/h (1 MPH)

Not detected
engine speed, after engine speed of less

than 500 rpm continues for more than
0.8 seconds.
500 rpm

Normality Judgment
Judge as OFF OK and clear the NG when the malfunction criteria below are met.
Judgment Value
Starter ON
Battery voltage
Threshold Value
Experienced
>8V


7. FAIL SAFE
None

GD(H4SO)-201

GENERAL DESCRIPTION

Detect the open/short circuit of back-up power supply circuit.
Judge as NG when the backup voltage becomes smaller than the battery voltage.
2. ENABLE CONDITION
Enable Conditions
None

Judge as NG when the continuous time with the following criteria established exceeds 2.5 seconds.
Judgment Value
Threshold Value
Voltage of back-up power supply

Battery voltage
Low
10.9 V
Engine speed
500 rpm

Normality Judgment
Judgment Value
Threshold Value

Battery voltage
High
10.9 V
Engine speed
500 rpm


7. FAIL SAFE
None

GD(H4SO)-202

GENERAL DESCRIPTION

Detect the malfunction of catalytic converter initial warm-up retard angle control.
Judge as NG if the ECM is not operating properly when performing catalytic converter initial warm-up retard
angle control.
Judge as NG when judged NG in either or both diagnosis of exhaust temperature and diagnosis of idle
speed.
Diagnosis of exhaust temperature
Judge as NG if the exhaust temperature is below the specified value at 14 seconds after a cold start.
Diagnosis of idle speed
Judge as NG when actual engine speed is not close to target engine speed after stopping retard angle control.
2. ENABLE CONDITION
Enable Conditions
> 75.1 kPa (563

mmHg, 22.2 inHg)
Battery voltage
Diagnosis of cold start
> 10.9 V
Incomplete
Engine
Vehicle speed
Start
2 km/h (1 MPH)
Misfire during 200 engine revs.

Time elapsed after engine start
<5
= 14 seconds

Diagnose at cold start.
GD(H4SO)-203

GENERAL DESCRIPTION
Diagnosis of exhaust temperature
Calculate the estimated exhaust temperature when the enable conditions for judgment were established.
Judge as NG if the following conditions are established within 14 seconds after starting the engine.
Judgment Value
Threshold Value
Estimated exhaust temperature
< Value from Map 1
Map 1
Engine coolant temperature at
start C (F)
40
(40)
30
(22)
20
(4)
10
(14)
0
(32)
10
(50)
20
(68)
30
(86)
40
(104)
50
(122)
Threshold value AT model C (F)
152
(306)
135
(275)
152
(306)
135
(275)
152
(306)
135
(275)
152
(306)
135
(275)
152
(306)
135
(275)
143
(289)
135
(275)
135
(275)
134
(273)
127
(261)
129
(264)
121
(250)
126
(259)
118
(244)
119
(246)
Threshold value MT model C (F)
Time Needed for Diagnosis:14 seconds

Malfunction indicator light: Illuminates when malfunction occurs in 2 continuous driving cycles.
Normality Judgement
Judgment Value
Threshold Value
Value from Map 1
Diagnosis of idle speed

Judges NG when all of the following conditions are established, and judge as OK if they are not established.
Continuous time of (target engine RPM
engine RPM > 300)
(actual retard amount > AT
model:18CA, MT model:13CA)
Threshold Value
10000 ms
3000 ms



7. FAIL SAFE
None

GD(H4SO)-204

GENERAL DESCRIPTION
DE:DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN BANK 1
Detect the malfunction of fuel system from the amount of sub feedback control.
Judge as NG when the sub feedback learning control is being performed and when the learning value goes
to the lean side.
(E)
(3)
V
(1)
(F)
(A)
(2)
(2)
(C)
(B)
(D)
EN-01696
(1)
(2)
Atmosphere
Exhaust gas
(A)
(B)
Electromotive force
Air fuel ratio
(D)
(E)
Lean
(3)
Electromotive force
(C)
Rich
(F)
Comparative voltage
3. ENABLE CONDITION
Continuous time when the following conditions are established
Sub feedback learning execution conditions
Enable Conditions
1 second or more
Completed

Perform the diagnosis continuously at a constant speed of 50 100 km/h (31 62 MPH).
more. Judge as OK when the continuous time of not meeting the malfunction criteria below becomes 5 seconds or more.
Judgment Value
Sub feedback learning value
Threshold Value
0.02
Time Needed for Diagnosis: 5 seconds 1 time

GD(H4SO)-205

GENERAL DESCRIPTION


8. FAIL SAFE
None

GD(H4SO)-206

GENERAL DESCRIPTION
DF:DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH BANK 1
Detect the malfunction of fuel system from the amount of sub feedback control.
Judge as NG when the sub feedback learning control is being performed and when the learning value goes
to the rich side.
(E)
(3)
V
(1)
(F)
(A)
(2)
(2)
(C)
(B)
(D)
EN-01696
(1)
(2)
Atmosphere
Exhaust gas
(A)
(B)
Electromotive force
Air fuel ratio
(D)
(E)
Lean
(3)
Electromotive force
(C)
Rich
(F)
Comparative voltage
3. ENABLE CONDITION
Continuous time when the following conditions are established
Sub feedback learning execution conditions
Enable Conditions
1 second or more
Completed

Perform the diagnosis continuously at a constant speed of 50 100 km/h (31 62 MPH).
more. Judge as OK when the continuous time of not meeting the malfunction criteria below becomes 5 seconds or more.
Judgment Value
Threshold Value
0.038

GD(H4SO)-207

GENERAL DESCRIPTION


8. FAIL SAFE
None

GD(H4SO)-208

GENERAL DESCRIPTION
DG:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/

PERFORMANCE
Judge as NG when the motor current becomes too large or drive circuit is heated.
12V
12V
(1)
(6)
(2)
(3)
(7)
(4)
(2)
(5)
EN-01867
(1)
(4)
Drive circuit
(6)
(2)
(3)
Detecting circuit
Overcurrent detection circuit
(5)
Temperature detection circuit
(7)
Motor
3. ENABLE CONDITION
Under control of electronic throttle control
Enable Conditions
ON

GD(H4SO)-209

GENERAL DESCRIPTION
Judgment Value
Motor current
Drive circuit inner temperature
Threshold Value
8A
175C (347F)

500 milliseconds (For NG)
2000 milliseconds (For OK)


8. FAIL SAFE

GD(H4SO)-210

GENERAL DESCRIPTION
DH:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW

Judge as NG when the electronic throttle control power is not supplied even when ECM sets the electronic
throttle control relay to ON.
12V
12V
(1)
(4)
(2)
(5)
(3)
EN-01868
(1)
(3)
Drive circuit
(2)
Voltage detection circuit
(4)
(5)
Motor
3. ENABLE CONDITION
Electronic throttle control relay output
Enable Conditions
ON

Judgment Value
Motor power voltage
Threshold Value
5V

GD(H4SO)-211

GENERAL DESCRIPTION


8. FAIL SAFE

GD(H4SO)-212

GENERAL DESCRIPTION
DI: DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH

Judge as NG when the electronic throttle control power is supplied even when ECM sets the electronic throttle relay to OFF.
12V
12V
(1)
(4)
(2)
(5)
(3)
EN-01868
(1)
(3)
Drive circuit
(2)
Voltage detection circuit
(4)
(5)
Motor
3. ENABLE CONDITION
Electronic throttle control relay output
Enable Conditions
OFF

When ignition switch ON OFF
Judgment Value
Motor power voltage
Threshold Value
5V

GD(H4SO)-213

GENERAL DESCRIPTION


8. FAIL SAFE

GD(H4SO)-214

GENERAL DESCRIPTION
DJ:DTC P2109 THROTTLE/PEDAL POSITION SENSOR A MINIMUM STOP

PERFORMANCE
Judge as NG when all close point learning cannot conducted or abnormal value is detected.
(1)
(3)
(2)
(4)
EN-01869
(1)
(2)

Drive circuit
(3)
(4)
Motor
3. ENABLE CONDITION
Ignition switch
Enable Conditions
ON OFF
Ignition switch (only after cleaning the

memory)
OFF ON

Perform the diagnosis at all close point learning.
Judgment Value
Throttle opening angle at all close point
learning
Throttle sensor opening angle when the
ignition switch is ON Throttle minimum
stop position
Threshold Value
10.127 or more,
19.872 or less
1.683
Time Needed for Diagnosis: 8 80 milliseconds


GD(H4SO)-215

GENERAL DESCRIPTION

8. FAIL SAFE

GD(H4SO)-216

GENERAL DESCRIPTION
DK:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT

LOW INPUT
Detect the open or short circuit of accelerator pedal position sensor 1.
(4)
(1)
(2)
(3)
EN-01861
(1)
(2)

1 signal
(3)

2 signal
(4)
3. ENABLE CONDITION
Ignition switch
Enable Conditions
ON

Judgment Value
Threshold Value
0.308 V



GD(H4SO)-217

GENERAL DESCRIPTION
8. FAIL SAFE
Single malfunction: Control with normal sensor
Simultaneous failure: Throttle opening is fixed to 6.

GD(H4SO)-218

GENERAL DESCRIPTION
DL:DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT

HIGH INPUT
(4)
(1)
(2)
(3)
EN-01861
(1)
(2)

1 signal
(3)

2 signal
(4)
3. ENABLE CONDITION
Ignition switch
Enable Conditions
ON

Judgment Value
Threshold Value
4.856 V



GD(H4SO)-219

GENERAL DESCRIPTION
8. FAIL SAFE

GD(H4SO)-220

GENERAL DESCRIPTION
DM:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT

LOW INPUT
(4)
(1)
(2)
(3)
EN-01861
(1)
(2)

1 signal
(3)

2 signal
(4)
3. ENABLE CONDITION
Ignition switch
Enable Conditions
ON

Judgment Value
Threshold Value
0.308 V



GD(H4SO)-221

GENERAL DESCRIPTION
8. FAIL SAFE

GD(H4SO)-222

GENERAL DESCRIPTION
DN:DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT

HIGH INPUT
(4)
(1)
(2)
(3)
EN-01861
(1)
(2)

1 signal
(3)

2 signal
(4)
3. ENABLE CONDITION
Ignition switch
Enable Conditions
ON

Judgment Value
Threshold Value
4.865 V



GD(H4SO)-223

GENERAL DESCRIPTION
8. FAIL SAFE

GD(H4SO)-224

GENERAL DESCRIPTION
DO:DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH A/B VOLTAGE CORRELATION

Judge as NG when the signal level of throttle position sensor 1 is different from the throttle position sensor 2.
(3)
(4)
(1)
(2)
EN-01859
(1)
(2)

(3)
(4)

3. ENABLE CONDITION
Ignition switch
Enable Conditions
ON

GD(H4SO)-225

GENERAL DESCRIPTION
Judgment Value
Threshold Value
Signal difference between two sensors
4.5

12
(11.625)
(3)
10
(9.75)
8
(7.625)
(1)
6
(5.5)
(4.5)
4
0
0(2.125)(4.25)
(9.0) 10
20
30(31.625)
(2)
EN-04014
(1)
Sensor output difference ()
(2)
Throttle position sensor 1 opening angle ()
(3)
NG area
Time Needed for Diagnosis: 24 milliseconds (For NG), 24 milliseconds (For OK)


8. FAIL SAFE

GD(H4SO)-226

GENERAL DESCRIPTION
DP:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D/E VOLTAGE CORRELATION

Judge as NG when the signal level of accelerator pedal position sensor 1 is different from the accelerator
peda position sensor 2.
(4)
(1)
(2)
(3)
EN-01861
(1)
(2)

1 signal
(3)

2 signal
3. ENABLE CONDITION
Ignition switch
Battery voltage
Enable Conditions
ON
6 (V)

GD(H4SO)-227
(4)

GENERAL DESCRIPTION
Judgment Value
Threshold Value
1.465
(3.116)
(3)
(2.455)
(1.663)
(1)
(1.597)
(1.465)
0
0
(0.6)
(3.0)
(2.384)
(4.0)
(2)
EN-04015
(1)
Sensor output difference ()
(2)
Throttle position sensor 2 opening angle ()
(3)
NG area



8. FAIL SAFE

GD(H4SO)-228

GENERAL DESCRIPTION
DQ:DTC P2227 BAROMETRIC PRESSURE CIRCUIT RANGE/PERFORMANCE

Detect the malfunction of atmospheric pressure sensor output property.
Judge as NG when the atmospheric pressure sensor output is largely different from the intake manifold pressure at engine starting.
The atmospheric pressure sensor is built into the ECM.
3. ENABLE CONDITION
Engine speed
Enable Conditions
< 300 rpm
Vehicle speed
< 1 km/h (1 MPH)

Perform the diagnosis before engine starts with the ignition switch ON.
more.
Judgment Value
Threshold Value
| Atmospheric pressure Manifold pressure |
26.7 kPa (200

mmHg, 7.88 inHg)
|Intake manifold pressure at engine startup Manifold pressure |
< 1.33 kPa (10 mmHg,

2.95 inHg)

Normality Judgment
Judge as OK and clear the NG when the continuous time with the following criteria established is more than
0.3 seconds.
Judgment Value
Atmospheric pressure Manifold pressure
Threshold Value
< 26.7 kPa (200
mmHg, 7.88 inHg)


8. FAIL SAFE
Atmospheric pressure sensor process: Fix the atmospheric pressure to 101 kPa (760 mmHg, 29.8 inHg).

GD(H4SO)-229

GENERAL DESCRIPTION
DR:DTC P2228 BAROMETRIC PRESSURE CIRCUIT LOW

Detect the open/short circuit of the atmospheric pressure sensor.
3. ENABLE CONDITION
Enable Conditions
None

more.
Judgment Value
Ignition switch
Threshold Value
ON
Output voltage
< 0.118 V

Normality Judgment
Judgment Value
Ignition switch
Output voltage
Threshold Value
ON
0.118 V


8. FAIL SAFE

GD(H4SO)-230

GENERAL DESCRIPTION
DS:DTC P2229 BAROMETRIC PRESSURE CIRCUIT HIGH

Detect the open/short circuit of the atmospheric pressure sensor.
3. ENABLE CONDITION
Enable Conditions
None

more.
Judgment Value
Ignition switch
Threshold Value
ON
Output voltage
4.936 V

Normality Judgment
Judgment Value
Ignition switch
Output voltage
Threshold Value
ON
< 4.936 V


8. FAIL SAFE

GD(H4SO)-231

GENERAL DESCRIPTION
GD(H4SO)-232
General Description
A: SPECIFICATION
Fuel tank
Fuel pump
Capacity
60 2 (15.9 US gal, 13.2 Imp gal)
Locations
Type
Under rear seat

Impeller
Shutoff discharge pressure

Discharge rate
Fuel filter
450 677 kPa (4.59 6.9 kg/cm2, 65.27 98.2 psi)

145 2 (38.3 US gal, 31.9 Imp gal)/h or more
[300 kPa, 12 V (3.06 kg/cm2, 43.5 psi)]
Intank type
FU(H4DOTC)-2
General Description
B: COMPONENT
1. INTAKE MANIFOLD
T6
T2
(17)
(16)
T6
(15)
T6
T3
T6
(18)
T2
(25)
(14)
(20)
T3
(19)
T6
T2
(12)
(21)
(26)
T5
(22)
(13)
T4
(10)
T7
T7
T6
(10)
T4
(9)
(11)
(24)
(11)
T2
(8)
(7)
T2
(23)
(9)
T6
(24)
T6
T6
(5)
(4)
(2)
(6)
(14)
(7)
(3)
(1)
(8)
T2
T1
(12)
(13)
(3)
T1
(2)
T2
(3)
(2)
T1
FU-02991
FU(H4DOTC)-3
General Description
(1)
(2)
Fuel pipe ASSY

Fuel hose
(14)
(15)
Fuel injector pipe

Pressure regulator
(25)
(26)
Collector cover bracket (Front)

Collector cover bracket (Rear)
(3)
(4)
Clamp
Purge control solenoid valve 1
(16)
(17)
Pressure regulator hose

Fuel pipe protector RH
(27)
Collector cover bracket (Rear)
(5)
(6)
Vacuum hose A
Vacuum control hose
(18)
(19)
Blow-by hose stay

Intake manifold

T1: 1.25 (0.13, 0.94)
(7)
(8)
Intake manifold gasket

Guide pin
(20)
Wastegate control solenoid valve

ASSY
T2:
T3:
6.4 (0.65, 4.7)

8.25 (0.84, 6.1)
(9)
(10)
Tumble generator valve ASSY

Tumble generator valve gasket
(21)
(22)
Fuel pipe protector LH

Nipple
T4:
T5:
8.5 (0.87, 6.3)

17 (1.73, 12.5)
(11)
Tumble generator valve actuator
(23)
T6:
19 (1.9, 14.0)
(12)
(13)
Fuel injector
O-ring
(24)
Vacuum hose B
T7:
25 (2.5, 18.1)
FU(H4DOTC)-4
General Description
2. AIR INTAKE SYSTEM
T2
T1
(3)
(4)
(1)
(2)
FU-02976
(1)
(2)
Gasket
Throttle body
(3)
(4)
Manifold absolute pressure sensor Tightening torque:Nm (kgf-m, ft-lb)

O-ring
T1: 1.6 (0.16, 1.2)
T2: 8 (0.8, 5.8)
FU(H4DOTC)-5
General Description
3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS
T1
(4)
T2
T1
T1
(1)
(3)
(2)
FU-01036
(1)
(2)

Knock sensor
(3)
(4)
Camshaft position sensor LH

Camshaft position sensor RH

T1: 6.4 (0.65, 4.7)
T2: 24 (2.4, 17.4)
FU(H4DOTC)-6
General Description
4. FUEL TANK
T1
(12)
(13)
(14)
T1
(9)
(44)
(13)
C
B
(23)
(15)
(13)
(18)
(12)
(13)
(13)
(15)
(13)
(30)
(13)
T1
T1
(8)
(6)
(19)
(15)
T2
(43)
(13)
(11)
(10)
(7)
(13)
(6)
(11)
(10)
(33)
(22)
(13)
D
(42)
(13)
(34)
(13)
(13)
(13)
(36)
(21)
(39)
T4
(20)
(29)
(7)
(31)
B
(28)
(17)
T1
(32)
(35)
(13)
(20)
(21)
(40)
(27)
(16)
(25)
(24)
(20)
(5)
(21)
T3
(20) (21) (26)
(2)
(31)
T3
T2
(4)
(41)
(38)
(3)
T2
(37)
(37)
(1)
T2
T2
FU(H4DOTC)-7
T2
FU-02992
General Description
(1)
(2)
Heat shield cover

Fuel tank band
(18)
(19)
Evaporation hose C
Evaporation pipe ASSY
(35)
(36)
Vent valve gasket

Purge hose
(3)
(4)
Protector LH
Protector RH
(20)
(21)
Retainer
Quick connector
(37)
(38)
Clip
Cover bracket
(5)
(6)
Fuel tank
Canister hose A
(22)
(23)
Jet pump hose A

Fuel level sensor
(39)
(40)
Filler hose
Fuel return tube
(7)
(8)
Clamp
Fuel pump gasket
(24)
(25)
Fuel pipe ASSY

Jet pump hose B
(41)
(42)
Fuel tank band LH

Evaporation hose E
(9)
(10)
Fuel pump ASSY

Fuel cut valve gasket
(26)
(27)
Evaporation hose D
Fuel sub level sensor gasket
(43)
(44)
Evaporation hose F
Evaporation pipe
(11)
Fuel cut valve
(28)
Jet pump filter
(12)
(13)
Evaporation hose A
Clip
(29)
(30)

Protect cover
(14)
(15)
Joint pipe
Evaporation hose B
(31)
(32)
Clip
Vent valve
T2: 7.4 (0.75, 5.4)

T3: 33 (3.4, 25)
(16)
(17)
Fuel delivery tube

Clamp
(33)
(34)

Fuel tank pressure sensor hose
T4: 1.96 (0.20, 1.45)
FU(H4DOTC)-8

T1: 4.4 (0.45, 3.3)
General Description
5. FUEL LINE
(31)
(28)
(28)
(36)
(15)
(17)
(18)
(16)
(30)
(32) (34)
(19)
T1
(20)
(12)
(35)
(23)
(28)
(34)
(24)
(33)
(22)
(13) (14)
(21)
(25)
T2
T2
(27)
(26)
T3
T3
(37)
(2)
(28)
(1)
(3) (1)
(4) (37)
(5)
(11)
(8)
(10)
(6)
(7)
(1)
(9)
T3
(1)
(29)
T3
FU-02993
FU(H4DOTC)-9
General Description
(1)
(2)
Clamp
Fuel return hose A
(16)

bracket
(29)
(30)
Clip
Clamp
(3)
(4)
Fuel damper valve (Return)

Fuel return hose B
(17)
(18)
Drain hose C
Canister upper bracket
(31)

hose
(5)
(6)
Evaporation hose A
Clip
(19)
(20)
Cushion rubber
Canister lower bracket
(32)
(33)
Clamp
Retainer
(7)
(8)
Fuel delivery hose A

Fuel delivery hose B
(21)
(22)
Canister
Drain valve
(34)
(35)
Clamp
Drain pipe
(9)
(10)
Fuel damper valve bracket

Fuel damper valve (Delivery)
(23)
(24)
(36)
(37)
Canister bracket spacer

Clamp
(11)
Fuel pipe ASSY
Drain filter
tube
(12)
(13)
Evaporation hose B
Joint pipe
(25)
(26)
Drain hose A
Connector drain

T1: 25 (2.5, 18.1)
(14)
(15)
Canister hose A
(27)
(28)
Drain hose B
Clip
FU(H4DOTC)-10
T2: 23 (2.3, 16.6)

T3: 1.25 (0.13, 0.9)
General Description
6. FUEL FILLER PIPE
(10)
(9)
(8)
(11)
(15)
(1)
T2
T2
(16)
T1
(13)
(12)
(3)
(16)
T2
(5)
(16)
(2)
(3)
T2
(14)
(6)
(4)
T2
(7)
FU-02994
(1)
(2)
Fuel filler pipe ASSY

Evaporation hose holder
(8)
(9)
Filler pipe packing

Filler ring
(15)
(16)
(3)
(4)
Clip
Clamp
(10)
(11)
Filler cap
Shut valve
(5)
(6)
Evaporation hose A
Evaporation pipe
(12)
(13)
Evaporation hose B
Evaporation hose C
(7)
Evaporation pipe holder
(14)
Joint pipe
FU(H4DOTC)-11
Fuel filler pipe protector

Clamp
T1: 4.4 (0.45, 3.3)

T2: 7.5 (0.76, 5.5)
General Description
C: CAUTION

points.
the battery.
Follow all government and local regulations concerning disposal of refuse when disposing fuel.
D: PREPARATION TOOL
ILLUSTRATION
TOOL NUMBER
42099AE000
DESCRIPTION
CONNECTOR
REMOVER
ST42099AE000
FU(H4DOTC)-12
REMARKS
Removal of quick connector
Throttle Body
2. Throttle Body
B: INSTALLATION
A: REMOVAL
NOTE:
Use a new gasket.
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
FU-00009

3) Remove the intercooler. <Ref. to IN(H4DOTC)11, REMOVAL, Intercooler.>
4) Disconnect the connector from the throttle position sensor (A), and the manifold pressure sensor
(B).
(B)
(A)
FU-01073
5) Disconnect the engine coolant hoses from throttle body.
FU-01074
6) Remove the bolts which install throttle body to

the intake manifold.
FU(H4DOTC)-13
FU-01075
Intake Manifold
3. Intake Manifold
(2) Disconnect the power steering switch connector.
A: REMOVAL
2) Release the fuel pressure. <Ref. to
FU(H4DOTC)-49, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.>
FU-00017

steering pipe bracket to the intake manifold.
NOTE:
FU-00009
filler cap.
8) Drain the coolant about 3.0 2 (3.2 US qt, 2.6
Imp qt).
ME-00036
(4) Remove the bolts which install power steering pump bracket.
FU-00016
9) Remove the air cleaner upper cover and air intake boot. <Ref. to IN(H4DOTC)-8, REMOVAL, Air
Cleaner Case.>
<Ref. to CO(H4SO)-43, REMOVAL, Coolant Filler
Tank.>
(1) Remove the front side of the V-belts. <Ref.
to ME(H4DOTC)-40, REMOVAL, V-belt.>
FU-00019
(5) Remove the reservoir tank from the bracket

by pulling it upward.
FU-02572
FU(H4DOTC)-14
Intake Manifold

side wheel apron.
17) Disconnect the pressure hose from the intake

duct.
FU-00024
FU-00021
14) Disconnect the emission hose (A) and the connector (B) from the PCV hose assembly.
(A)
18) Disconnect the engine harness connectors

from the bulk head harness connector.
(B)
FU-01032
15) Disconnect the engine coolant hose from throttle body.
ME-03008

coolant temperature sensor (A), oil pressure switch
(B) and crankshaft position sensor (C).
(A)
(B)
(C)
FU-01074
FU-00027
16) Disconnect the brake booster hose.
FU-02817
FU-02751
FU(H4DOTC)-15
Intake Manifold
LH side
(A)
FU-01310
FU-02818
22) Disconnect the connector from ignition coil.

RH side
24) Using the ST, disconnect the fuel hose from

each fuel pipe. <Ref. to FU(H4DOTC)-64, REMOVAL, Fuel Delivery, Return and Evaporation Lines.>
CAUTION:
or cloth.
(A)
FU-01307
LH side
ST
(B)
(C)
FU-02752

(B) Return hose
(C) Evaporation hose
FU-01308
25) Remove the bolts which hold intake manifold

onto the cylinder heads.
23) Disconnect the engine harness fixed by clip (A)

from the bracket.
RH side
(A)
FU-02753

FU-01309
FU(H4DOTC)-16
Intake Manifold
B: INSTALLATION
1) Install the intake manifold onto cylinder heads.
5) Connect the connectors to camshaft position

sensor.
NOTE:
Use a new gasket.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
FU-02818
6) Connect the connector to the ignition coil.

RH side
FU-02753
2) Connect the fuel delivery hose, return hose, and

evaporation hose.
FU-01307
LH side
FU-02754
3) Connect the connector to the engine coolant

temperature sensor (A), oil pressure switch (B) and
crankshaft position sensor (C).
(A)
FU-01308
(B)
(C)
FU-00027
4) Connect the connector to the knock sensor.
FU-02751
FU(H4DOTC)-17
Intake Manifold
7) Connect the engine harness with clip (A) to the

bracket.
RH side
10) Connect the engine coolant hoses to throttle

body.
(A)
FU-01074
FU-01309
LH side
11) Connect the emission hose (A) and the connector (B) to the PCV hose assembly.
(A)
(A)
FU-01032
FU-01310
8) Connect the engine harness connectors to bulkhead harness connectors.
(B)
12) Connect the pressure hose to the intake duct.
FU-00024
ME-03008
9) Connect the brake booster vacuum hose.

(1) Install the reservoir tank to the bracket.
FU-02817
FU(H4DOTC)-18
FU-02572
Intake Manifold
(2) Connect the connector to the power steering

pump switch.
FU-02737
FU-00017
(3) Install the power steering pump, and tighten

the bolts.
Tightening torque:
22 Nm (2.2 kgf-m, 15.9 ft-lb)
19) Install the passengers side front side sill cover.

20) Install the glove box. <Ref. to EI-36, INSTALLATION, Glove Box.>
25) Fill engine coolant.
C: DISASSEMBLY
FU-00019
(4) Install the power steering pipe bracket onto

the right side intake manifold.
FU-02755
ME-00036
(5) Install the front side V-belts. <Ref. to

ME(H4DOTC)-40, INSTALLATION, V-belt.>
14) Install the coolant filler tank.
<Ref. to CO(H4SO)-43, INSTALLATION, Coolant
Filler Tank.>
15) Install the intercooler. <Ref. to IN(H4DOTC)11, INSTALLATION, Intercooler.>
16) Install the air cleaner element.
17) Install the air cleaner upper cover and air intake
duct as a unit. <Ref. to IN(H4DOTC)-8, INSTALLATION, Air Cleaner Case.>
FU(H4DOTC)-19
FU-02756
Intake Manifold
3) Remove the engine ground terminal from the intake manifold.
FU-02757
FU-01041
7) Disconnect the connector from tumble generator

valve actuator.
FU-01042
4) Disconnect the connector from the throttle position sensor (A), and the manifold pressure sensor
(B).
FU-00616

valve sensor.
(B)
(A)
FU-01073
5) Remove the throttle body from intake manifold.
FU-00617
9) Remove the purge control solenoid valve. <Ref.

to EC (H4DOTC)-8, REMOVAL, Purge Control Solenoid Valve.>
10) Remove the two bolts which hold fuel pipes on
the left side of intake manifold.
FU-01075
FU-02758
FU(H4DOTC)-20
Intake Manifold

LH side
12) Remove the fuel injector.
FU-00048
FU-00044
13) Remove the harness bracket which holds the

engine harness onto intake manifold.
FU-00618
RH side
FU-02759
14) Remove the engine harness from intake manifold.

15) Loosen the clamp which holds the front LH side
fuel hose to injector pipe to remove the pipe from
clamp.
FU-00046
FU-02760
16) Loosen the clamp which holds the RH side fuel

hose to injector pipe to remove the pipe from
clamp.
FU-00619
FU-01051
FU(H4DOTC)-21
Intake Manifold
17) Remove the bolts which install fuel pipes on intake manifold.
D: ASSEMBLY
NOTE:
Use a new gasket.
1) Install the tumble generator valve assembly onto
intake manifold.
Tightening torque:
8.25 Nm (0.84 kgf-m, 6.1 ft-lb)
FU-01052
18) Remove the fuel pipe assembly and pressure

regulator from intake manifold.
19) Remove the intake duct from intake manifold.
FU-00053
2) Install the air intake duct to the intake manifold.

Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
FU-01076
20) Remove the tumble generator assembly from

intake manifold.
FU-01076
3) Install the fuel pipe assembly and pressure regulator to intake manifold.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
FU-00053
FU-01052
4) Install the fuel injector pipe LH.
FU(H4DOTC)-22
Intake Manifold
5) Connect the fuel hose LH to the injector pipe,

and tighten the clamp screw.
10) Tighten the bolts which secure fuel injector pipe

Tightening torque:
1.25 Nm (0.13 kgf-m, 0.94 ft-lb)
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
LH side
FU-02760
FU-00044
6) Install the fuel injector pipe RH.

7) Connect the fuel hose RH to the injector pipe,
and tighten the clamp screw.
Tightening torque:
1.25 Nm (0.13 kgf-m, 0.94 ft-lb)
FU-00618
RH side
FU-01051
8) Install the engine harness onto intake manifold.

9) Install the harness bracket which holds the engine harness onto intake manifold.
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
FU-00046
FU-02759
FU-00619
FU(H4DOTC)-23
Intake Manifold
11) Tighten the two bolts which install the fuel pipe
on the left side of intake manifold.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
16) Install the throttle body to intake manifold.

NOTE:
Use a new gasket.
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
FU-02758
12) Install the purge control solenoid valve. <Ref.

to EC (H4DOTC)-8, INSTALLATION, Purge Control Solenoid Valve.>
13) Connect the connector to the tumble generator
valve sensor.
FU-01075
17) Connect the connector to the throttle position

sensor (A), and the manifold pressure sensor (B).
(B)
(A)
FU-01073
FU-00617
14) Connect the connector to the tumble generator

valve actuator.
FU-00616
15) Connect the connector to the fuel injector.
FU-02757
FU(H4DOTC)-24
Intake Manifold
18) Install the engine ground terminal to the intake

manifold.
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
E: INSPECTION
Make sure that the fuel pipe and fuel hose are not
cracked and those connections are tight.
FU-01041
FU-01042
19) Install the fuel pipe protector RH.

Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
FU-02755
20) Install the fuel pipe protector LH.

Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
FU-02756
FU(H4DOTC)-25
Engine Coolant Temperature Sensor


Sensor
A: REMOVAL
FU-00009

4) Drain the engine coolant. <Ref. to CO(H4SO)18, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
5) Disconnect the connectors from the engine coolant temperature sensor.
FU-00055
6) Remove the engine coolant temperature sensor.
B: INSTALLATION
NOTE:
Use a new gasket.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
FU(H4DOTC)-26
Crankshaft Position Sensor

5. Crankshaft Position Sensor
B: INSTALLATION
A: REMOVAL
Tightening torque:
T: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
FU-00009

3) Remove the bolt which installs crankshaft position sensor to cylinder block.
FU-00056
4) Remove the crankshaft position sensor, and

then disconnect the connector from it.
FU-00057
FU(H4DOTC)-27
FU-00058
Knock Sensor
7. Knock Sensor
B: INSTALLATION
A: REMOVAL
1) Install the knock sensor to the cylinder block.
Tightening torque:
24 Nm (2.4 kgf-m, 17.4 ft-lb)
NOTE:
The portion of the knock sensor cord that is pulled
out must be positioned at a 60 angle relative to the
engine rear.
(A)
FU-00009

60
FU-02727
(A) Front side
FU-02751
5) Remove the knock sensor from the cylinder

block.
FU-02751
3) Install the intercooler.

<Ref. to IN(H4DOTC)-11, INSTALLATION, Intercooler.>
FU-02726
FU-00009
FU(H4DOTC)-29
Mass Air Flow and Intake Air Temperature Sensor

8. Mass Air Flow and Intake Air

Temperature Sensor
A: REMOVAL
FU-00009

3) Remove the mass air flow and intake air temperature sensor.
FU-00067
B: INSTALLATION
Tightening torque:
1.0 Nm (0.1 kgf-m, 0.7 ft-lb)
FU(H4DOTC)-30
Manifold Absolute Pressure Sensor

9. Manifold Absolute Pressure

Sensor
A: REMOVAL
FU-00009

3) Disconnect the connector from manifold absolute pressure sensor.
FU-01077
4) Remove the manifold absolute pressure sensor

from throttle body.
B: INSTALLATION
NOTE:
Use new O-rings.
Tightening torque:
1.6 Nm (0.16 kgf-m, 1.2 ft-lb)
FU(H4DOTC)-31
Fuel Injector
10.Fuel Injector

steering pipe bracket to the intake manifold.
A: REMOVAL
NOTE:
1. RH SIDE
ME-00036
(4) Remove the bolts which install power steering pump bracket.
FU-00009
filler cap.
5) Remove the air cleaner upper cover and air intake boot. <Ref. to IN(H4DOTC)-8, REMOVAL, Air
Cleaner Case.>
<Ref. to CO(H4SO)-43, REMOVAL, Coolant Filler
Tank.>
(1) Remove the front side of the V-belts. <Ref.
to ME(H4DOTC)-40, REMOVAL, V-belt.>
(2) Disconnect the power steering switch connector.
FU-00019

by pulling it upward.
FU-02572

side wheel apron.
FU-00017
FU-00021
FU(H4DOTC)-32
Fuel Injector

injector pipe.
FU-02755
FU-00048
2. LH SIDE
FU-02757
11) Remove the bolt which holds the injector pipe

to the intake manifold.
FU-00009
FU-00046
filler cap.
<Ref. to FU(H4DOTC)-14, REMOVAL, Intake Manifold.>
FU-02756
FU-00619
FU(H4DOTC)-33
Fuel Injector
8) Remove the two bolts which hold fuel pipes on

the left side of intake manifold.
B: INSTALLATION
1. RH SIDE
NOTE:
Use new O-rings and insulators.
FU-02758

(B)
(A)
FU-02314
(A) Insulator
(B) Fuel injector
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
FU-00044
FU-00046
FU-00618
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)

injector pipe.
FU-00619
FU(H4DOTC)-34
Fuel Injector
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
FU-00044
FU-02755
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
2. LH SIDE
NOTE:
Use new O-rings and insulators.
(B)
FU-00618
(A)
FU-02314
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
(A) Insulator
(B) Fuel injector
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
FU-02756
FU-02758
FU(H4DOTC)-35
Tumble Generator Valve Assembly

11.Tumble Generator Valve

Assembly
9) Remove the tumble generator valve body from

intake manifold.
A: REMOVAL
FU-00053
B: INSTALLATION
NOTE:
Use a new gasket.
FU-00009
filler cap.
valve sensor.
Tightening torque:
8.25 Nm (0.84 kgf-m, 6.1 ft-lb)
FU-00053
FU-00617

valve actuator.
FU-00616
8) Remove the fuel injector.

<Ref. to FU(H4DOTC)-32, REMOVAL, Fuel Injector.>
FU(H4DOTC)-36
Tumble Generator Valve Actuator


Actuator
A: REMOVAL
1. RH SIDE
FU-00009
filler cap.
5) Remove the secondary air pump. <Ref. to EC
(H4DOTC)-9, REMOVAL, Secondary Air Pump.>
valve actuator.
7) Remove the tumble generator valve actuator.
FU-00009
filler cap.
valve actuator.
7) Remove the tumble generator valve actuator.
FU-00622
B: INSTALLATION
1. RH SIDE
2. LH SIDE
FU-00621
2. LH SIDE
FU(H4DOTC)-37
Tumble Generator Valve Position Sensor


Position Sensor
A: SPECIFICATION
The tumble generator valve position sensor cannot
be adjusted when installed, so it should not be removed from the tumble generator valve assembly.
Refer to Tumble Generator Valve Assembly for
removal and installation procedure. <Ref. to
FU(H4DOTC)-36, REMOVAL, Tumble Generator
Valve Assembly.> <Ref. to FU(H4DOTC)-36, INSTALLATION, Tumble Generator Valve Assembly.>
FU(H4DOTC)-38
Wastegate Control Solenoid Valve

14.Wastegate Control Solenoid

Valve
6) Disconnect pressure hose (D) from the wastegate control solenoid valve.
A: REMOVAL
(D)
FU-02998
7) Remove the wastegate control solenoid valve

from the bracket.
FU-00009
2) Remove the engine harness connector (A) from

bracket.
3) Disconnect the connector (B) from wastegate
4) Remove the front oxygen (A/F) sensor connector (C) from the bracket.
B: INSTALLATION
Tightening torque:
6.5 Nm (0.66 kgf-m, 4.8 ft-lb)
FU-02997
(A)
(B)
(C)
FU-02996
5) Remove the bracket from vehicle body.
FU-02997
FU(H4DOTC)-39

15.Front Oxygen (A/F) Sensor

A: REMOVAL
8) Apply spray-type lubricant to the threaded portion of front oxygen (A/F) sensor, and leave it for
one minute or more.
9) Remove the front oxygen (A/F) sensor.
CAUTION:
When removing the oxygen (A/F) sensor, wait
until exhaust pipe cools, otherwise it will damage the exhaust pipe.
FU-00009
3) Disconnect the connector from front oxygen (A/

F) sensor.
FU-00080
B: INSTALLATION
1) Before installing front oxygen (A/F) sensor, apply the anti-seize compound only to the threaded
portion of front oxygen (A/F) sensor. This facilitates
the next removal.
FU-02995
4) Disconnect the engine harness fixed by clip (A)

from the bracket (B).
equivalent
CAUTION:
Never apply anti-seize compound to the protector of front oxygen (A/F) sensor.
2) Install the front oxygen (A/F) sensor.
Tightening torque:
30 Nm (3.1 kgf-m, 22.1 ft-lb)
(B)
(A)
FU-00078
5) Remove the front right side wheel.

FU-00080
FU-00783
FU(H4DOTC)-40

3) Install the service hole cover.
FU-00783

5) Install the front right side wheel.
Tightening torque:
100 Nm (10.2 kgf-m, 73.8 ft-lb)
6) Connect the engine harness to the bracket (B)
using the clip (A).
(B)
(A)
FU-00078
7) Connect the connector of front oxygen (A/F)

sensor.
FU-02995
FU-00009
FU(H4DOTC)-41
Rear Oxygen Sensor

16.Rear Oxygen Sensor
7) Remove the rear oxygen sensor.
A: REMOVAL
CAUTION:
When removing the oxygen (A/F) sensor, wait
until exhaust pipe cools, because it can damage the exhaust pipe.

FU-00009

4) Disconnect the connector from the rear oxygen
sensor.
FU-00081
5) Remove the clip by pulling out from the upper

side of crossmember.
FU-00082
6) Apply spray-type lubricant to the threaded portion of rear oxygen sensor, and leave it for one
minute or more.
FU(H4DOTC)-42
FU-00371
Rear Oxygen Sensor

B: INSTALLATION
3) Connect the rear oxygen sensor connector.
1) Before installing rear oxygen sensor, apply the

anti-seize compound only to the threaded portion of
rear oxygen sensor. This facilitates the next removal.
equivalent
CAUTION:
Never apply anti-seize compound to the protector of rear oxygen sensor.
2) Install the rear oxygen sensor.
FU-00081
4) Connect the clip to the crossmember.
Tightening torque:
21 Nm (2.1 kgf-m, 15.2 ft-lb)
FU-00082
FU-00371

AT model
FU-00009
FU-01311
MT model
FU-01312
FU(H4DOTC)-43
Engine Control Module (ECM)

17.Engine Control Module (ECM)
B: INSTALLATION
A: REMOVAL
NOTE:
When replacing the ECM, be careful not to use the
wrong spec. ECM to avoid any damage on the fuel
injection system.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
FU-00009
2) Remove the lower inner trim of passengers

side.
<Ref. to EI-43, REMOVAL, Lower Inner Trim.>
3) Detach the floor mat of passengers seat.
FU-01029
5) Remove the nuts (A) which hold ECM to bracket.

6) Remove the clip (B) from the bracket.
(A)
(A)
(B)
FU-00316
7) Disconnect the ECM connectors, and take out

the ECM.
FU(H4DOTC)-44
Main Relay
18.Main Relay
A: REMOVAL
FU-00009

4) Disconnect the connectors from main relay.
FU-02736
5) Remove the main relay from the mounting

bracket.
B: INSTALLATION
FU(H4DOTC)-45
Fuel Pump Relay

19.Fuel Pump Relay

A: REMOVAL
FU-00009

FU-02737
5) Remove the fuel pump relay from the mounting

bracket.
B: INSTALLATION
FU(H4DOTC)-46
Electronic Throttle Control Relay

20.Electronic Throttle Control

Relay
A: REMOVAL
FU-00009

4) Disconnect the connector from electric throttle
control relay.
FU-02738
5) Remove the electronic throttle control relay from

the mounting bracket.
B: INSTALLATION
FU(H4DOTC)-47
Fuel Pump Control Unit

21.Fuel Pump Control Unit

A: REMOVAL
FU-00009
2) Remove the rear quarter trim. <Ref. to EI-44,

REMOVAL, Rear Quarter Trim.>
3) Disconnect the connector from fuel pump control
unit.
4) Remove the fuel pump control unit.
FU-00088
B: INSTALLATION
FU(H4DOTC)-48
Fuel
22.Fuel
5) Set a container under the vehicle and remove

the drain plug from fuel tank to drain fuel from fuel
tank.
A: PROCEDURE
1. RELEASING OF FUEL PRESSURE
WARNING:
CAUTION:
2) Remove the side sill cover on the passengers
side.
FU-02704
6) Tighten the fuel drain plugs.

NOTE:
Use a new gasket.
Tightening torque:
26 Nm (2.65 kgf-m, 19.2 ft-lb)
FU-02737
4) Start the engine and run it until it stalls.

5) After the engine stalls, crank it for five more seconds.
2. DRAINING FUEL
WARNING:
CAUTION:
FU-00009
filler cap.
FU(H4DOTC)-49
Fuel Tank
23.Fuel Tank
10) Loosen the clamp and disconnect the fuel filler

hose (A) and evaporation hose (B) from the fuel filler pipe.
A: REMOVAL
WARNING:
CAUTION:
<Ref. to FU(H4DOTC)-49, DRAINING FUEL,
PROCEDURE, Fuel.>
4) Remove the rear seat.
5) Disconnect the connector (A) of fuel tank cord to
the rear harness.
6) Push the grommet (B) which holds the fuel tank
cord on the floor panel into under the body.
(B)
(A)
(B)
FU-02372
(B)
(A)
FU-02373
(B)
11) Move the clips, and disconnect the quick connector. <Ref. to FU(H4DOTC)-64, REMOVAL, Fuel
Delivery, Return and Evaporation Lines.>
12) Disconnect the fuel hoses.
FU-02739
7) Remove the rear crossmember. <Ref. to RS-16,

REMOVAL, Rear Crossmember.>
8) Remove the canisters. <Ref. to EC (H4DOTC)7, REMOVAL, Canister.>
FU-02564
FU(H4DOTC)-50
Fuel Tank
13) Support the fuel tank with transmission jack, remove the bolts from bands and dismount the fuel
tank from the vehicle.
WARNING:
Fuel may remain undrained in the side of the
fuel tank without the drain plug. Be careful not
to lose balance and drop the fuel tank when removing it, as this remaining fuel may offset the
weight balance of the tank.
4) Insert the evaporation hose (B) into the lower

end of evaporation pipe, and secure the clamps
and clips.
(B)
(A)
(B)
FU-02372
CAUTION:
Do not allow clips to touch hose (A) and rear
suspension crossmember.
(A)
FU-00411
B: INSTALLATION
1) Support the fuel tank with transmission jack and
push the fuel tank harness into access hole with
grommet.
2) Set the fuel tank and temporarily tighten the
bolts of fuel tank bands.
WARNING:
FU-02424
5) Connect the fuel hoses, and hold them with clips

and quick connector. <Ref. to FU(H4DOTC)-65,
INSTALLATION, Fuel Delivery, Return and Evaporation Lines.>
FU-00411
3) Insert the fuel filler hose (A) approx. 35 to 40 mm

(1.38 to 1.57 in) over the lower end of fuel filler pipe
and tighten the clamp.
FU-02564
6) Connect the connector to pressure control solenoid valve.

7) Install the canister. <Ref. to EC (H4DOTC)-7,
INSTALLATION, Canister.>
FU(H4DOTC)-51
Fuel Tank
8) Tighten the band mounting bolts.

Tightening torque:
33 Nm (3.4 kgf-m, 25 ft-lb)
FU-00411
9) Install the rear crossmember. <Ref. to RS-16,

INSTALLATION, Rear Crossmember.>
10) Connect the connector (A) to the fuel tank cord
and plug the service hole with grommet (B).
(A)
(B)
FU-02739
11) Set the rear seat and floor mats.

FU-02737
13) Install the passengers side front side sill cover.

14) Install the glove box. <Ref. to EI-36, INSTALLATION, Glove Box.>
C: INSPECTION
1) Check that there are no cracks, holes, or other
damage on the fuel tank.
2) Make sure that the fuel pipe and fuel hose are
not cracked and those connections are tight.
FU(H4DOTC)-52
Fuel Filler Pipe

24.Fuel Filler Pipe
9) Disconnect the evaporation hose from the clip of

fuel filler pipe.
A: REMOVAL
WARNING:
CAUTION:
FU-00098
10) Disconnect the evaporation hose from the pipe.
FU-00009
filler cap.
4) Remove the screws which secure packing.
FU-00325
11) Remove the bolts which hold fuel filler pipe

bracket on the body.
FU-00095
5) Remove the rear wheel RH.

7) Drain fuel from fuel tank. <Ref. to FU(H4DOTC)49, DRAINING FUEL, PROCEDURE, Fuel.>
8) Remove the fuel filler pipe protector.
FU-00326
12) Loosen the clamp and separate the fuel filler

hose (A) from the fuel filler pipe.
13) Loosen the clip and disconnect the evaporation
hose (B).
(B)
FU-00786
(A)
FU-00327
14) Remove the fuel filler pipe to the underside of

the vehicle.
FU(H4DOTC)-53
Fuel Filler Pipe

15) Remove the evaporation pipe together with clip

from the body.
5) Connect the evaporation hose to the pipe.
FU-00325
FU-00328
B: INSTALLATION
1) Open the fuel filler flap lid.
2) Set the fuel saucer (A) with rubber packing (C),
and insert the fuel filler pipe into hole from the inner
side of apron.
3) Align the holes in fuel filler pipe neck and set the
cup (B), and tighten the screws.
NOTE:
If the edges of rubber packing are folded toward the
inside, straighten it with a screwdriver.
6) Connect the fuel filler hose (A) to the pipe with an

overlap of 35 to 40 mm (1.38 to 1.57 in).
L = 37.52.5 mm (1.4760.098 in)
7) Connect the evaporation hose (B) to the pipe
with an overlap of 25 to 30 mm (0.98 to 1.18 in).
L = 27.52.5 mm (1.0830.098 in)
CAUTION:
Do not allow clips to touch evaporation hose
(B) and rear suspension crossmember.
(B)
(A)
(B)
(A)
(C)
FU-00327
FU-00103
(2)
(1)
4) Install the evaporation pipe.
(3)
L/2
L
FU-00104
FU-00328
(1) Hose
(2) Clip
(3) Pipe
FU(H4DOTC)-54
Fuel Filler Pipe

8) Tighten the bolts which hold fuel filler pipe bracket on the body.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
C: DISASSEMBLY
1) Move the clamp and disconnect the evaporation
hose from the joint pipe.
FU-00329
FU-00326
9) Fasten the evaporation hoses to the clip of fuel

filler pipe.
2) Remove the bolts which install the joint pipe to

the fuel filler pipe.
FU-00330
FU-00098
10) Install the fuel filler pipe protector.
3) Disconnect the evaporation hose from fuel filler

pipe.
FU-00331
FU-00786

12) Install the rear wheel RH.
Tightening torque:
100 Nm (10.2 kgf-m, 73.8 ft-lb)

<Ref. to EC (H4DOTC)-20, REMOVAL, Shut
Valve.>
FU-00009
FU(H4DOTC)-55
Fuel Filler Pipe

D: ASSEMBLY
1) Install the shut valve to the fuel filler pipe. <Ref.
to EC (H4DOTC)-20, INSTALLATION, Shut
Valve.>
2) Connect the evaporation hose to the fuel filler
pipe.
FU-00331
3) Connect the evaporation hose to the evaporation pipe.
FU-00329
4) Install the evaporation pipe to the fuel filler pipe.
FU-00330
FU(H4DOTC)-56
Fuel Pump
25.Fuel Pump
A: REMOVAL
WARNING:
CAUTION:
NOTE:
Fuel pump assembly consists of fuel pump, fuel filter and fuel level sensor.
FU-02363
10) Disconnect the quick connector and then disconnect the fuel delivery hose and return hose.
<Ref. to FU(H4DOTC)-64, REMOVAL, Fuel Delivery, Return and Evaporation Lines.>
11) Move the clips, and disconnect the jet pump
hose (A).
FU-00009
filler cap.
(A)
FU-02364
12) Remove the nuts which install fuel pump assembly onto fuel tank.
FU-02566
13) Remove the fuel pump assembly from the fuel

tank.
FU-00105
FU(H4DOTC)-57
Fuel Pump
B: INSTALLATION
Tighten the nuts in alphabetical sequence shown
in the figure to the specified torque.
NOTE:
Use a new gasket and retainer.
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
(C)
(A)
(E)
(G)
(H)
(F)
(B)
(D)
FU-02567
C: INSPECTION
Connect the lead harness to the connector terminal
of fuel pump, and apply the battery power supply to
check whether the pump operates.
CAUTION:
Wipe off fuel completely.
Keep the battery as far apart from fuel pump
as possible.
Turn the battery supply ON and OFF on the
battery side.
Do not run the fuel pump for a long time under non-load condition.
3 2 1
6 5 4
FU-00332
FU(H4DOTC)-58
Fuel Level Sensor

26.Fuel Level Sensor

A: REMOVAL
WARNING:
CAUTION:
NOTE:
The fuel level sensor is built in fuel pump assembly.
<Ref. to FU(H4DOTC)-57, REMOVAL, Fuel
Pump.>
2) Disconnect the connector from fuel pump bracket.
FU-01065
3) Remove the fuel temperature sensor (A).

4) Remove the bolt (B) which installs the fuel level
sensor on the mounting bracket.
(B)
(A)
FU-02745
B: INSTALLATION
NOTE:
Use a new gasket.
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
FU(H4DOTC)-59

9) Remove the bolts which install fuel sub level

sensor on fuel tank.
A: REMOVAL
WARNING:
CAUTION:
FU-00115
10) Remove the fuel sub level sensor.
FU-00009

FU-00116
B: INSTALLATION
Tighten the nuts to the specified torque in the order as shown in the figure.
NOTE:
Use a new gasket.
FU-00113
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
7) Disconnect the connector from the fuel sub level

sensor.
8) Disconnect the fuel jet pump hose.
3
1
5
6
2
4
FU-01145
FU-00114
FU(H4DOTC)-60
Fuel Filter
28.Fuel Filter
A: REMOVAL
WARNING:
CAUTION:
NOTE:
The fuel filter is assembled in fuel pump assembly.
Pump.>
2) Separate the fuel pump and fuel filter.
(A)
(B)
FU-01064
(A) Fuel filter

(B) Fuel pump
B: INSTALLATION
CAUTION:
C: INSPECTION
1) Check the inside of fuel filter for dirt and water
sediment.
2) If it is clogged, or if the replacement interval has
been reached, replace it.
FU(H4DOTC)-61
Fuel Cut Valve

29.Fuel Cut Valve
B: INSTALLATION
A: REMOVAL

CAUTION:
or cloth.
1) Remove the fuel tank.
Tank.>
NOTE:
Use a new gasket.
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
FU-02748
FU-00334
3) Loosen the clip and disconnect the evaporation

hose from the fuel cut valve.
FU-02747
4) Remove the bolts which install the fuel cut valve.
FU(H4DOTC)-62
Fuel Damper Valve

30.Fuel Damper Valve

A: REMOVAL
CAUTION:
or cloth.
2) Remove the fuel damper valve from the fuel delivery line (A) and the fuel return line (B).
(B)
(A)
FU-02761
B: INSTALLATION
CAUTION:
Tightening torque:
1.25 Nm (0.13 kgf-m, 0.94 ft-lb)
FU(H4DOTC)-63

31.Fuel Delivery, Return and Evaporation Lines

A: REMOVAL
WARNING:
CAUTION:
2) Release the fuel pressure. <Ref. to FU(H4DOTC)-49, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.>
3) Open the fuel filler flap lid, and remove the fuel filler cap.
4) Remove the floor mat. <Ref. to EI-48, REMOVAL, Floor Mat.>
5) Disconnect the fuel delivery pipes and hoses, and then disconnect the fuel return pipes and hoses, evaporation pipes and hoses.
FU-02426
6) In the engine room, remove the fuel delivery

hose (A), return hose (B) and evaporation hose (C).
delivery line and return line by pushing the ST in
the direction of the arrow.
CAUTION:
or cloth.
(A)
ST
(B)
(C)
FU-02418
FU(H4DOTC)-64


8) Disconnect the quick connector on the fuel line.
(1) Clean the pipe and connector, if they are
covered with dust.
(2) To prevent from damaging or entering foreign matter, wrap the pipes and connectors with
plastic bag etc.
B: INSTALLATION
1) Connect the quick connector to the fuel delivery
line.
CAUTION:
Replace the retainer other than in the engine
room with a new part.
Make sure there are no damage or dust on
connections. If necessary, clean seal surface of
pipe.
NOTE:
Use a new retainer.
(A)
FU-01333
(B)
(3) Hold the connector (A) and push the retainer

(B) down.
(4) Pull out the connector (A) from the retainer
(B).
FU-00125
(A) Seal surface

(B) Pipe
(B)
(A)
(C)
(1) Set the new retainer (B) to connector (A).

(2) Push the pipe into the connector completely.
(A)
(B)
FU-00124
(A) Connector
(C)
(B) Retainer
(C) Pipe
FU-00126
(A) Connector
(B) Retainer
(C) Pipe
FU(H4DOTC)-65

CAUTION:
Pull the connector to ensure it is connected
securely.
Make sure the two retainer pawls are engaged in their mating positions in the connector.
Be sure to inspect hoses and their connections for any leakage of fuel.
3) Connect the evaporation hose to the pipe with

L = 17.52.5 mm (0.6890.098 in)
(2)
(1)
(3)
L/2
L
FU-00129
(A)
(1) Hose
(B)
(2) Clip
(3) Pipe
(C)
FU-00127
C: INSPECTION
(A) Connector
(B) Retainer
(C) Pipe
2) Connect the fuel delivery hose and return hose

to the pipe with an overlap of 20 to 25 mm (0.79 to
0.98 in).
Type A: When the amount of inserting is specified.
Type B: When the amount to be inserted is not
specified.
1) Make sure that there are no cracks on the fuel

pipes and fuel hoses.
2) Make sure the fuel pipe and fuel hose connections are tightened firmly.
2: 2.51.5 mm (0.0980.059 in)

L: 22.52.5 mm (0.8860.098 in)
CAUTION:
Be sure to inspect hoses and their connections
for any leakage of fuel.
(3)
(4)
(5)
(1)
L
(2)
FU-00128
(1) Type A
(2) Type B
(3) Pipe
(4) Clamp
(5) Hose
FU(H4DOTC)-66

32.Fuel System Trouble in General

A: INSPECTION
Corrective action
1. Insufficient fuel supply to injector

1)
Fuel pump does not operate.
Inspect contact, especially ground, and tighten it
securely.
Defective terminal contact
2)
Trouble in electromagnetic or electronic circuit parts

Decline of fuel pump function
Replace the faulty part.

Replace the fuel pump.
3)
4)
Clogged fuel filter

Clogged or bent fuel pipe or hose
Replace the fuel filter.

Clean, correct or replace fuel pipe or hose.
5)
Air is mixed in fuel system
Inspect or retighten each connection part.
6)
7)
Clogged or bent air breather tube or pipe

Damaged diaphragm of pressure regulator
Clean, correct or replace the air breather tube or pipe.

Replace.
2. Leakage or blow out of fuel

1)
Loose joints of the fuel pipe
Retighten.
2)
3)
Cracked fuel pipe, hose and fuel tank

Defective welding part on the fuel tank
Replace.
Replace.
4)
Defective drain packing of the fuel tank
5)
Clogged or bent air breather tube or air vent tube
Replace.
Clean, correct or replace the air breather tube or air vent
tube.
3. Gasoline smell inside of compartment

1)
Loose joints at air breather tube, air vent tube and fuel filler
pipe
Retighten.
2)
3)
Problem in tightening of the fuel saucer packing air

Fuel pump trouble
Correct or replace the packing.

Replace.
4. Defective fuel meter indicator

1)
Defective operation of fuel level sensor
Replace.
2)
Defective operation of fuel meter
5. Noise
1)
Replace.
Large operation noise or vibration of fuel pump
Replace.
NOTE:
When the vehicle is left unattended for an extended period of time, water may accumulate in the fuel tank.
Fill fuel fully to prevent the problem.
In snow-covered areas, mountainous areas, skiing areas, etc. where ambient temperatures drop below
0C (32F) throughout the winter season, use an water removing agent in the fuel system to prevent freezing
fuel system and accumulating water.
When water is accumulated in fuel filter, fill the water removing agent in the fuel tank.
Before using water removing agent, follow the cautions noted on the bottle.
FU(H4DOTC)-67

FU(H4DOTC)-68
General Description
A: COMPONENT
1. SECONDARY AIR PUMP
T
EC-02183
(1)
Secondary air pump

T: 5 (0.5, 3.7)
EC (H4DOTC)-2
General Description
2. SECONDARY AIR COMBINATION VALVE

T2
3
8
5
6
T1
9
T1
T2
3
T1
T2
T2
EC-02184
(1)
(2)
Gasket
Secondary air combination valve
LH
(3)
Gasket
(4)
Pipe LH
(5)
(6)
Air duct
Clamp
(7)
Secondary air combination valve

RH
(8)
Pipe RH
EC (H4DOTC)-3
(9)
Gasket

T1: 9 (0.9, 6.6)
T2: 19 (1.9, 13.7)
General Description
B: CAUTION
points.
the battery.
C: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
18353AA000
DESCRIPTION
CLAMP PLIERS
ST18353AA000
EC (H4DOTC)-4
REMARKS
Used for removing and installing the PCV
hose.
This is a general tool made by the French
company CAILLAU. (code) 54.0.000.205
To make this easier to obtain in the same way as
genuine Subaru parts, it has been provided with
a tool number as an ST.
Front Catalytic Converter

2. Front Catalytic Converter

A: REMOVAL
1) Remove the center exhaust pipe. <Ref. to
EX(H4DOTC)-8, REMOVAL, Center Exhaust
Pipe.>
2) Disconnect the front catalytic converter (A) from
the rear catalytic converter (B).
(A)
(B)
EC-00076
B: INSTALLATION
NOTE:
Use a new gasket.
C: INSPECTION
leaks.
EC (H4DOTC)-5
Rear Catalytic Converter

3. Rear Catalytic Converter

A: REMOVAL
1) Remove the center exhaust pipe.
<Ref. to EX(H4DOTC)-8, REMOVAL, Center Exhaust Pipe.>
2) Disconnect the rear catalytic converter (B) from
the front catalytic converter (A).
(A)
(B)
EC-00076
B: INSTALLATION
NOTE:
Use a new gasket.
C: INSPECTION
leaks.
EC (H4DOTC)-6
Canister
4. Canister
B: INSTALLATION
A: REMOVAL
NOTE:
Replace the retainer of quick connector with a
new part.

Tightening torque:
23 Nm (2.3 kgf-m, 17 ft-lb)
FU-00009

4) Disconnect the connector (A) from drain valve.
5) Disconnect the evaporation hoses (B) and (C)
from the canister.
EC-02073
C: INSPECTION
Make sure the canister and canister hoses are not
cracked or loose.
(C)
(A)
(B)
EC-02072
6) Disconnect the quick connector (A) from the

canister.
7) Disconnect the drain hose (B) from the canister.
(B)
(A)
EC-02114
8) Remove the canister from the body.
EC-02073
EC (H4DOTC)-7
Purge Control Solenoid Valve

5. Purge Control Solenoid Valve
B: INSTALLATION
A: REMOVAL
Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)
(B)
(A)
FU-00009
2) Disconnect the connector and hoses from purge

3) Loosen the bolt and remove the purge control
solenoid valve from the intake manifold.
EC-02181
(A) Purge control solenoid valve 1

(B) Purge control solenoid valve 2
NOTE:
Connect the evaporation hose as shown in the figure.
(B)
(B)
(A)
EC-02181
(c)

(a)
(A)
(c)
(b)
EC-02182

(a) To intake duct
(b) To intake manifold
(c) To splitter and then to fuel pipe
C: INSPECTION
EC (H4DOTC)-8
Secondary Air Pump

6. Secondary Air Pump

A: REMOVAL
FU-00009
2) Disconnect the connector (A) from secondary air

pump.
3) Disconnect the hose (B) from secondary air
pump.
4) Remove the bolt (C) which secures the secondary air pump to the body.
B
C
EC-02137
B: INSTALLATION
Tightening torque:
5 Nm (0.5 kgf-m, 3.7 ft-lb)
T
EC-02138
C: INSPECTION
EC (H4DOTC)-9
Secondary Air Combi Valve

7. Secondary Air Combi Valve

A: REMOVAL
2. SECONDARY AIR COMBINATION

VALVE RH

VALVE LH
FU-00009
FU-00009

3) Disconnect the connector from the secondary air
combination valve LH.
4) Disconnect the air duct.
5) Disconnect the pipe LH.
6) Remove the secondary air combination valve
LH.
C

LH. <Ref. to EC (H4DOTC)-10, SECONDARY AIR
COMBINATION VALVE LH, REMOVAL, Secondary Air Combi Valve.>
FU(H4DOTC)-14, REMOVAL, Intake Manifold.>
5) Disconnect the connector from the secondary air
combination valve RH.
6) Disconnect the pipe RH.
RH.
C
B
D
E
A
D
F
EC-02185
EC-02140
(A) Secondary air combination valve LH

(B) Clamp
(C) Air duct
(D) Gasket
(E) Pipe LH
(F) Gasket
(A) Secondary air combination valve RH

(B) Clamp
(C) Air duct
(D) Gasket
(E) Pipe RH
EC (H4DOTC)-10
Secondary Air Combi Valve

B: INSTALLATION
C: INSPECTION

VALVE LH
Check the air duct and pipe for looseness.

NOTE:
Use a new gasket.
Tightening torque:
T1: 9 Nm (0.9 kgf-m, 6.6 ft-lb)
T2: 19 Nm (1.9 kgf-m, 13.7 ft-lb)
C
D *
T2
T1
E
T2
T2
F *
EC-02186
(A) Secondary air combination valve LH

(B) Clamp
(C) Air duct
(D) Gasket
(E) Pipe LH
(F) Gasket

VALVE RH
NOTE:
Use a new gasket.
Tightening torque:
T1: 9 Nm (0.9 kgf-m, 6.6 ft-lb)
T2: 19 Nm (1.9 kgf-m, 13.7 ft-lb)
C
B
T2
D *
E
T1
EC-02142
(A) Secondary air combination valve RH

(B) Clamp
(C) Air duct
(D) Gasket
(E) Pipe RH
EC (H4DOTC)-11
Fuel Level Sensor

8. Fuel Level Sensor

A: REMOVAL
Refer to the FU (H4DOTC) section for removal procedure. <Ref. to FU(H4DOTC)-59, REMOVAL,
Fuel Level Sensor.>
B: INSTALLATION
Refer to the FU (H4DOTC) section for installation
procedure. <Ref. to FU(H4DOTC)-59, INSTALLATION, Fuel Level Sensor.>
EC (H4DOTC)-12
Fuel Temperature Sensor

9. Fuel Temperature Sensor

A: REMOVAL
Level Sensor for removal procedure. <Ref. to
FU(H4DOTC)-59, REMOVAL, Fuel Level Sensor.>
B: INSTALLATION
Level Sensor for installation procedure. <Ref. to
FU(H4DOTC)-59, INSTALLATION, Fuel Level
Sensor.>
EC (H4DOTC)-13


A: REMOVAL
Refer to the FU (H4DOTC) section for removal procedure. <Ref. to FU(H4DOTC)-60, REMOVAL,
Fuel Sub Level Sensor.>
B: INSTALLATION
Refer to the FU (H4DOTC) section for installation
procedure. <Ref. to FU(H4DOTC)-60, INSTALLATION, Fuel Sub Level Sensor.>
EC (H4DOTC)-14
Fuel Tank Pressure Sensor

11.Fuel Tank Pressure Sensor

A: REMOVAL
6) Disconnect the pressure hose from the fuel tank

pressure sensor.
WARNING:
CAUTION:
1) Remove the fuel tank. <Ref. to FU(H4DOTC)50, REMOVAL, Fuel Tank.>
EC-02146
B: INSTALLATION
Tightening torque:
7.4 Nm (0.75 kgf-m, 5.4 ft-lb)
T
EC-02143
3) Disconnect the connector from the fuel pressure

sensor.
4) Remove the clip which holds the fuel pipe to the
fuel tank.
EC-02160
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
T
T
EC-02144
5) Remove the bolt and nut which secures the fuel

tank pressure sensor to the bracket.
EC-02147
C: INSPECTION
EC-02145
EC (H4DOTC)-15

12.Pressure Control Solenoid

Valve
7) Disconnect the two evaporation hoses from the

pressure control solenoid valve.
A: REMOVAL
EC-00056
8) Remove the pressure control solenoid valve

from the bracket.
FU-00009

5) Remove the bolt which installs the pressure control solenoid valve holding bracket to the body.
EC-00057
9) Disconnect the hose from the pressure control

solenoid valve.
EC-02078

EC-00058
EC-00055
EC (H4DOTC)-16

B: INSTALLATION
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
EC-02078
C: INSPECTION
EC (H4DOTC)-17
Drain Filter
13.Drain Filter
A: SPECIFICATION
The drain filter is embedded in the canister and
therefore cannot be disassembled.
EC (H4DOTC)-18
Vent Valve
14.Vent Valve
B: INSTALLATION
A: REMOVAL
WARNING:
CAUTION:
1) Remove the fuel tank. <Ref. to FU(H4DOTC)50, REMOVAL, Fuel Tank.>
NOTE:
Use a new gasket.
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
T
(A)
EC-00038
(A) Gasket
EC-02143
3) Remove the clip and disconnect the hose from

the vent valve.
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
T
T
EC-02147
EC-02148
4) Remove the nut and then remove the vent valve.
C: INSPECTION
EC-02149
EC (H4DOTC)-19
Shut Valve
15.Shut Valve
A: REMOVAL
WARNING:
CAUTION:
1) Remove the fuel filler pipe.
<Ref. to FU(H4DOTC)-53, REMOVAL, Fuel Filler
Pipe.>
2) Disconnect the evaporation hose from shut
valve.
EC-00041
EC-00050
B: INSTALLATION
Tightening torque:
4.5 Nm (0.46 kgf-m, 3.3 ft-lb)
EC-00050
C: INSPECTION
EC (H4DOTC)-20
Drain Valve
16.Drain Valve
C: INSPECTION
A: REMOVAL
1) Make sure that all hoses are properly connected.

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

FU-00009

5) Disengage the clip, then remove the drain valve
from the canister.
(A)
(A)
(B)
EC-00266
(A) Clip
(B) Drain valve
B: INSTALLATION
NOTE:
Use a new clip.
(A)
(A)
(B)
EC-00266
(A) Clip
(B) Drain valve
EC (H4DOTC)-21
PCV Hose Assembly

17.PCV Hose Assembly

A: REMOVAL
CAUTION:
Do not remove if the PCV hose, diagnostics
connector and PCV valve are not damaged.
2) Fit the depression in the ST with the protrusion
on the clamp to unlock.
3) Remove the PCV hose assembly.
LU-00242
B: INSTALLATION
NOTE:
Use a new clamp.
1) Install the PCV hose assembly, then lock by fitting the ST on the clamp protrusion.
LU-00243

<Ref. to FU(H4DOTC)-17, INSTALLATION, Intake
Manifold.>
EC (H4DOTC)-22
General Description
INTAKE (INDUCTION)
A: COMPONENT
1. AIR CLEANER
T4
(1)
(2)
T1
(3)
T3
(12)
(8)
T3
T1
(14)
T1
(13)
(11)
(6)
T1
(12)
T2
(7)
(4)
(6)
(10)
(5)
(9)
IN-00001
(1)
Mass air flow and intake air

temperature sensor
(7)
Air cleaner lower case
(14)
Cushion rubber
Air intake duct
Cushion
(2)
Air cleaner upper cover
(8)
(9)
(3)
(4)
Air cleaner element

Spacer
(10)
(11)
Resonator chamber ASSY

Cushion rubber
T1: 7.5 (0.76, 5.5)

T2: 33 (3.4, 24.6)
(5)
(6)
Bushing
Clip
(12)
(13)
Clamp
Air intake boot
T3: 2.5 (0.25, 1.8)

T4: 1.0 (0.1, 0.7)
IN(H4DOTC)-2
General Description
INTAKE (INDUCTION)
2. INTAKE DUCT
(4)
T2
(3)
(5)
(1)
(2)
T1
(7)
(7)
(6)
IN-00190
(1)
(2)
Clamp
PCV hose ASSY
(5)
(6)
Air by-pass hose C

Intake duct
(3)
(4)
Air by-pass hose A

Air by-pass hose B
(7)
Clamp
IN(H4DOTC)-3

T1: 19 (1.9, 13.7)
T2: 3 (0.3, 2.2)
General Description
INTAKE (INDUCTION)
3. INTERCOOLER
T3
(1)
(2)
(12)
(4)
T2
(5)
T2
(4)
T1
T3
(7)
(6)
(7)
(3)
(10)
T3
(11)
(8)
(7)
T3
(9)
(10)
(11)
(10)
(11)
T3
IN-02200
(1)
(2)
Intercooler
Intercooler bracket RH
(7)
(8)
O-ring
Clamp
(3)
(4)
Intercooler bracket LH
Clamp
(9)
(10)
Air by-pass hose A

Intercooler duct
(5)
(6)
Air intake duct

Air by-pass valve
(11)
(12)
Clamp
PCV pipe
IN(H4DOTC)-4

T1: 3 (0.3, 2.2)
T2: 6.3 (0.64, 4.6)
T3: 16 (1.6, 11.6)
General Description
INTAKE (INDUCTION)
4. TURBOCHARGER
T2
(1)
T5
(3)
T4
(3)
(3)
(4)
(3)
(3)
(8)
(9)
T3
(3)
T1
(7)
(10)
(3)
(6)
(12)
(5)
(11)
(10)
(2)
T3
IN-02203
(1)
(2)
Oil inlet pipe A

Turbocharger bracket LH
(7)
(8)
Engine coolant hose

Gasket
(3)
(4)
Metal gasket
Turbocharger
(9)
(10)
Oil outlet pipe

Clip
T2: 16 (1.6, 11.6)

T3: 33 (3.4, 24.6)
(5)
(6)
Water pipe
Clamp
(11)
(12)
Oil outlet hose

Turbocharger bracket RH
T4: 29 (3.0, 21.7)

T5: 4.9 (0.50, 3.6)
IN(H4DOTC)-5

T1: 4.4 (0.45, 3.3)
General Description
INTAKE (INDUCTION)
B: CAUTION
points.
the battery.
IN(H4DOTC)-6
Air Cleaner Element

INTAKE (INDUCTION)
2. Air Cleaner Element

A: REMOVAL
1) Remove the clip (A) from the air cleaner upper
cover.
(A)
IN-02199
B: INSTALLATION
NOTE:
Before installing the air cleaner upper cover, align
the protrusion with the hole of air cleaner lower
case, and then secure the upper cover and lower
case.
IN-00008
C: INSPECTION
Replace if excessively damaged or dirty.
IN(H4DOTC)-7
Air Cleaner Case

INTAKE (INDUCTION)
3. Air Cleaner Case
B: INSTALLATION
A: REMOVAL
Tightening torque:
33 Nm (3.4 kgf-m, 24.6 ft-lb)
FU-00009
2) Disconnect the connector from mass air flow and

intake air temperature sensor.
IN-00007
NOTE:
Before installing the air cleaner upper cover, align
the protrusion with the hole of air cleaner lower
case, and then secure the upper cover and lower
case.
IN-00005
3) Loosen the clamps (A) which connect the air intake boot and the intake duct.
4) Remove the clip (B) from air cleaner upper cover.
IN-00008
C: INSPECTION
Replace if excessively damaged or dirty.
(B)
(A)
IN-00006
5) Remove the air cleaner upper cover.

IN-00007
IN(H4DOTC)-8
Air Intake Duct

INTAKE (INDUCTION)
4. Air Intake Duct

A: REMOVAL
Remove the bolts which install the air intake duct
on the front side of body.
IN-00009
B: INSTALLATION
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
IN-00009
C: INSPECTION
2) Inspect that no foreign objects in the air intake
duct.
IN(H4DOTC)-9
Intake Duct
INTAKE (INDUCTION)
5. Intake Duct
A: REMOVAL
FU-00009

4) Remove the sensor, engine harness and fuel
pipe attached to the intake manifold. <Ref. to
FU(H4DOTC)-19, DISASSEMBLY, Intake Manifold.>
5) Remove the intake duct from intake manifold.
IN-00250
B: INSTALLATION
Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)
IN-00250
IN(H4DOTC)-10
Intercooler
INTAKE (INDUCTION)
6. Intercooler
6) Loosen the clamps (B) which connect the throttle

body and intercooler.
A: REMOVAL
(A)

2) Disconnect the PCV hose from PCV pipe.
(B)
IN-02140
7) Separate the intercooler duct from turbocharger.

8) Remove the intercooler from throttle body.
IN-02139
3) Remove the air by-pass valve from intercooler.
B: INSTALLATION
Tightening torque:
16 Nm (1.6 kgf-m, 11.6 ft-lb)
IN-00167
4) Remove the bolts which secure the intercooler to

the bracket.
IN-00014
IN-00014
IN-00169
IN-00169
5) Loosen the clamps (A) which connect the turbocharger and intercooler duct.
IN(H4DOTC)-11
Intercooler
INTAKE (INDUCTION)
C: DISASSEMBLY
D: ASSEMBLY

NOTE:
Be careful not to pinch the O-ring.
Tightening torque:
16 Nm (1.6 kgf-m, 11.6 ft-lb)
IN-00167
2) Remove the intercooler ducts from intercooler.
IN-00167
IN-00018
3) Separate the duct.

IN-00018
IN-00027
IN(H4DOTC)-12
Turbocharger
INTAKE (INDUCTION)
7. Turbocharger
8) Loosen the clamp which secures turbocharger to

intake duct.
A: REMOVAL
IN-00074
9) Disconnect the engine coolant hoses from pipe,

and remove the turbocharger bracket RH.
FU-00009

4) Remove the center exhaust pipe. <Ref. to
EX(H4DOTC)-8, REMOVAL, Center Exhaust
Pipe.>
6) Separate the turbocharger joint pipe from turbocharger.
IN-02201
10) Remove the oil inlet pipe from turbocharger.

(A)
(B)
(B)
IN-00019
(B)
7) Disconnect the engine coolant hose which is

connected to coolant filler tank.
IN-02204
(A) Oil inlet pipe

(B) Metal gasket
IN-00174
IN-00022
IN(H4DOTC)-13
Turbocharger
INTAKE (INDUCTION)
11) Disconnect the oil outlet hose from pipe.
3) Install the oil inlet pipe to turbocharger.

NOTE:
Use a new gasket.
Tightening torque:
T1: 16 Nm (1.6 kgf-m, 11.6 ft-lb)
T2: 29 Nm (3.0 kgf-m, 21.7 ft-lb)
T3: 4.9 Nm (0.50 kgf-m, 3.6 ft-lb)
T1
T1
(A)
T3
IN-00024
(B)
12) Take out the turbocharger from engine compartment.
T2
(B)
B: INSTALLATION
(B)
1) Connect the oil outlet hose to outlet pipe.

IN-02208
(A) Oil inlet pipe

(B) Metal gasket
4) Install the turbocharger bracket RH and connect

the engine coolant hoses to the pipe.
IN-00024
Tightening torque:
33 Nm (3.4 kgf-m, 24.6 ft-lb)
2) Install the turbocharger to intake duct.

Tightening torque:
3 Nm (0.3 kgf-m, 2.2 ft-lb)
IN-02201
5) Install the joint pipe to turbocharger.

NOTE:
Use a new gasket.
IN-00074
Tightening torque:
35 Nm (3.6 kgf-m, 25.8 ft-lb)
IN-00019
IN(H4DOTC)-14
Turbocharger
INTAKE (INDUCTION)
6) Connect the engine coolant hose which is connected to the coolant filler tank.
IN-00174

8) Install the center exhaust pipe. <Ref. to
EX(H4DOTC)-9, INSTALLATION, Center Exhaust
Pipe.>
IN(H4DOTC)-15
Air By-pass Valve

INTAKE (INDUCTION)
8. Air By-pass Valve

A: REMOVAL
IN-00167
3) Disconnect the air by-pass hoses from air valve.
B: INSTALLATION
NOTE:
Be careful not to pinch the O-ring.
Tightening torque:
16 Nm (1.6 kgf-m, 11.6 ft-lb)
IN-00167
IN(H4DOTC)-16
Resonator Chamber
INTAKE (INDUCTION)
9. Resonator Chamber
B: INSTALLATION
A: REMOVAL

3) Remove the air intake duct. <Ref. to
IN(H4DOTC)-9, REMOVAL, Air Intake Duct.>
<Ref. to IN(H4DOTC)-8, REMOVAL, Air Cleaner
Case.>
5) Remove the resonator chamber mounting bolt
on the right of engine compartment.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
IN-00026
IN-00025
6) Remove the front tire RH, and lift-up the vehicle.

7) Remove the front mudguard RH.
8) Remove the resonator chamber from the inside
front fender.
IN-00025
C: INSPECTION
Check for cracks or loose connection. Check that
no foreign objects are mixed in the resonator chamber.
IN-00026
IN(H4DOTC)-17
Resonator Chamber
INTAKE (INDUCTION)
IN(H4DOTC)-18
General Description
MECHANICAL
A: SPECIFICATION
Model
2.5 L
Horizontally opposed, liquid cooled, 4-cylinder,
4-stroke gasoline engine
Cylinder arrangement
Bore Stroke
mm (in)
cm3 (cu in)
Piston displacement
Compression ratio
Compression pressure (at 350 rpm)
Number of piston rings
Open
Intake valve timing
Close
Engine
Exhaust valve timing

Valve clearance
Belt driven, double overhead camshaft, 4-valve/cylinder

99.5 79.0 (3.92 3.11)
2,457 (149.94)
8.4
kPa (kgf/cm2, psi)
981 1,177 (10 12, 142 171)

Pressure ring: 2, Oil ring: 1
Max.retard
5 ATDC
Min. advance
Max.retard
35 BTDC
65 ABDC
Min. advance
25 ABDC
55 BBDC
Open
Close
Intake
mm (in)
Exhaust
mm (in)
No Load
Idle speed
[At neutral position on MT,
or P or N range on AT]
rpm
A/C ON
5 ATDC
0.200.02 (0.00790.0008)
0.350.02 (0.01380.0008)
MT: 700100
AT: 700100
A/C refrigerant pressure is
MT: 725100
low
AT: 750100
A/C refrigerant pressure is
MT: 800100
high
AT: 825100
1324
Ignition order
Ignition timing
MT
Model
BTDC/rpm
AT
Model
1710/700
1710/700
NOTE:
OS: Oversize US: Undersize
Belt
tension
adjuster
Protrusion of adjuster rod
5.2 6.2 mm (0.204 0.244 in)
Spacer O.D.
17.955 17.975 mm (0.7069 0.7077 in)
Tensioner bushing I.D.

Belt
tensioner
Clearance between spacer and

bushing
Side clearance of spacer
Standard
18.0 18.08 mm (0.7087 0.7118 in)

0.025 0.125 mm (0.0010 0.0049 in)
Limit
Standard
0.175 mm (0.069 in)

0.2 0.55 mm (0.0079 0.0217 in)
Limit
ME(H4DOTC)-2
0.81 mm (0.0319 in)
General Description
MECHANICAL
Bend limit
0.020 mm (0.0079 in)

Standard
Limit
0.068 0.116 mm (0.0027 0.0046 in)

0.14 mm (0.0055 in)
Intake
Standard
Limit
46.55 46.65 mm (1.833 1.837 in)

46.45 mm (1.829 in)
Exhaust
Standard
Limit
46.75 46.85 mm (1.841 1.844 in)

46.65 mm (1.837 in)
Standard
Front
Center rear
Thrust clearance
Camshaft
Cam lobe height
Camshaft journal O.D.
Standard
Limit
Oil clearance
Cylinder
head
37.946 37.963 mm (1.4939 1.4946 in)

29.946 29.963 mm (1.1790 1.1796 in)
0.037 0.072 mm (0.0015 0.0028 in)
0.10 mm (0.0039 in)

(Mating surface with cylinder block)
Grinding limit
0.035 mm (0.0014 in)

0.3 mm (0.012 in)
Standard height
Seating angle
Valve seat
Valve guide
127.5 mm (5.02 in)

90
Intake
Standard
Limit
0.6 1.4 mm (0.024 0.055 in)

1.7 mm (0.067 in)
Exhaust
Standard
Limit
1.2 1.8 mm (0.047 0.071 in)

2.2 mm (0.087 in)
Contacting width
Inside diameter
Protrusion above head
6.000 6.012 mm (0.2362 0.2367 in)

15.8 16.2 mm (0.622 0.638 in)
Intake
Standard
Limit
1.0 1.4 mm (0.039 0.055 in)

0.8 mm (0.031 in)
Exhaust
Standard
Limit
1.3 1.7 mm (0.051 0.067 in)

0.8 mm (0.031 in)
Intake
Exhaust
5.955 5.970 mm (0.2344 0.2350 in)

5.945 5.960 mm (0.2341 0.2346 in)
Intake
Exhaust
0.030 0.057 mm (0.0012 0.0022 in)

0.040 0.067 mm (0.0016 0.0026 in)
Head edge thickness
Valve
Stem outer diameter
Valve stem gap
Standard
Limit
Overall length
Intake
0.15 mm (0.0059 in)

104.4 mm (4.110 in)
Exhaust
104.65 mm (4.120 in)

47.32 mm (1.863 in)
Free length
Squareness
Valve
spring
Set
Tension/spring height
Lift
Outer diameter
Valve lifter
Inner diameter (cylinder head)

Valve lifter clearance
Standard
2.5, 2.1 mm (0.083 in) or less

205 235 N (20.9 24.0 kgf, 46.1 52.8 lb)/
36.0 mm (1.417 in)
426 490 N (43.4 50.0 kgf, 95.8 110 lb)/
26.50 mm (1.043 in)
34.959 34.975 mm (1.3763 1.3770 in)
34.994 35.016 mm (1.3777 1.3786 in)
0.019 0.057 mm (0.0007 0.0022 in)
Limit
ME(H4DOTC)-3
0.100 mm (0.0039 in)
General Description
MECHANICAL
(Mating surface with cylinder head)
Grinding limit
0.025 mm (0.0098 in)

0.1 mm (0.004 in)
Standard height
Cylinder inner diameter
Cylinder
block
Standard
Taper
Out-of-roundness
Piston clearance
201.0 mm (7.91 in)

99.505 99.515 mm (3.9175 3.9179 in)
B
Standard
99.495 99.505 mm (3.9171 3.9175 in)

0.015 mm (0.0006 in)
Limit
Standard
0.050 mm (0.0020 in)

0.010 mm (0.0004 in)
Limit
Standard
0.050 mm (0.0020 in)

0.010 0.010 mm (0.0004 0.0004 in)
Limit
Cylinder inner boring limit (diameter)

Standard
Piston
Piston pin
99.495 99.505 mm (3.9171 3.9175 in)

99.745 99.765 mm (3.9270 3.9278 in)
0.50 mm (0.0197 in) OS

Standard
Standard clearance between piston
and piston pin
Limit
99.995 100.015 mm (3.9368 3.9376 in)

0.004 0.008 mm (0.0002 0.0003 in)
Top ring
Ring closed gap
Piston ring
Second
ring
Oil ring
Top ring
Ring groove gap
Second
ring
Bend or twist per 100 mm (3.94 in) in

length
Side clearance of large end
Oil clearance
Bearing of
large end
Bushing of
small end
100.005 mm (3.9372 in)

99.505 99.515 mm (3.9175 3.9179 in)
B
0.25 mm (0.0098 in) OS
Outer diameter
Standard
0.020 mm (0.0008 in)

Piston pin must be fitted into position with thumb at 20C
(68F).
0.20 0.25 mm (0.0079 0.0098 in)
Limit
Standard
1.0 mm (0.039 in)

0.37 0.52 mm (0.015 0.020 in)
Limit
Standard
1.0 mm (0.039 in)

0.20 0.50 mm (0.0079 0.0197 in)
Limit
Standard
1.5 mm (0.059 in)

0.040 0.080 mm (0.0016 0.0031 in)
Limit
Standard
0.15 mm (0.0059 in)

0.030 0.070 mm (0.0012 0.0028 in)
Degree of fit
Connecting
rod
0.030 mm (0.0012 in)
Thickness at center portion
Clearance between piston pin and

bushing
Limit
0.15 mm (0.0059 in)
Limit
0.10 mm (0.0039 in)
Standard
0.070 0.330 mm (0.0028 0.0130 in)
Limit
Standard
0.4 mm (0.016 in)

0.017 0.045 mm (0.0007 0.0018 in)
Limit
Standard
0.05 mm (0.0020 in)

1.490 1.502 mm (0.0587 0.0591 in)
0.03 mm
(0.0012 in)
US
1.504 1.512 mm (0.0592 0.0595 in)
0.05 mm
(0.0020 in)
US
1.514 1.522 mm (0.0596 0.0599 in)
0.25 mm
(0.0098 in)
US
Standard
Limit
ME(H4DOTC)-4
1.614 1.622 mm (0.0635 0.0639 in)

0 0.022 mm (0 0.0009 in)
0.030 mm (0.0012 in)
General Description
MECHANICAL
Bending limit
Crank pin
Crank journal
0.035 mm (0.0014 in)

Out-of-roundness
Cylindricality
Out-of-roundness
To 51.750 mm (2.0374 in)

0.005 mm (0.0002 in)
Cylindricality
0.006 mm (0.0002 in)

To 59.758 mm (2.3527 in)
Standard
0.03 mm
(0.0012 in)
US
0.05 mm
(0.0020 in)
US
0.25 mm
(0.0098 in)
US
Crankshaft
Standard
0.03 mm
(0.0012 in)
US
0.05 mm
(0.0020 in)
US
0.25 mm
(0.0098 in)
US
51.984 52.000 mm (2.0466 2.0472 in)

51.954 51.970 mm (2.0454 2.0461 in)
51.934 51.950 mm (2.0447 2.0453 in)
51.734 51.750 mm (2.0368 2.0374 in)

59.992 60.008 mm (2.3619 2.3625 in)
59.962 59.978 mm (2.3607 2.3613 in)
59.942 59.958 mm (2.3599 2.3605 in)
59.742 59.758 mm (2.3520 2.3527 in)
Thrust clearance
Standard
Limit
0.030 0.115 mm (0.0012 0.0045 in)

0.25 mm (0.0098 in)
Oil clearance
Standard
Limit
0.010 0.030 mm (0.0004 0.0012 in)

0.040 mm (0.0016 in)
Standard
0.03 mm
(0.0012 in)
US
0.05 mm
(0.0020 in)
US
0.25 mm
(0.0098 in)
US
1.998 2.011 mm (0.0787 0.0792 in)
#1, #3
Main
bearing
0.003 mm (0.0001 in)

0.004 mm (0.0002 in)
Thickness of main
bearing
#2, #4, #5
Standard
0.03 mm
(0.0012 in)
US
0.05 mm
(0.0020 in)
US
0.25 mm
(0.0098 in)
US
ME(H4DOTC)-5
2.017 2.020 mm (0.0794 0.0795 in)
2.027 2.030 mm (0.0798 0.0799 in)
2.127 2.130 mm (0.0837 0.0839 in)

2.000 2.013 mm (0.0787 0.0793 in)
2.019 2.022 mm (0.0795 0.0796 in)
2.029 2.032 mm (0.0799 0.0800 in)
2.129 2.132 mm (0.0838 0.0839 in)
General Description
MECHANICAL
B: COMPONENT
1. TIMING BELT
(2)
(1)
(2)
T2
T7
(3)
T1
(2)
(4)
T7
(19)
T8
(9)
(12)
(5)
T1
T3
(6)
T5
(7)
T1
(8)
T3
T4
T8
T1
T5
(14)
T1
T5
T4
(2)
(10)
(14)
T7
(19)
T4
(17)
(11)
(13)
T5
T1
(15)
(16)
T6
(18)
T1
ME-03010
(1)
(2)
Timing belt cover No. 2 (RH)

Timing belt guide (MT model)
(10)
(11)
Intake cam sprocket (LH)

Exhaust cam sprocket (LH)
(3)
(4)
Crank sprocket
Timing belt cover No. 2 (LH)
(12)
(13)
Timing belt
Belt idler No. 2
T2: 9.75 (1.0, 7.2)

T3: 24.5 (2.5, 18.1)
(5)
(6)
Tensioner bracket
Automatic belt tension adjuster
ASSY
(14)
(15)
Belt idler
Timing belt cover (LH)
Front belt cover
Timing belt cover (RH)
T4: 39 (4.0, 28.9)

INSTALLATION, Cam
Sprocket.>
Crank pulley
O-ring
(7)
Belt idler
(16)
(17)
(8)
(9)
Exhaust cam sprocket (RH)

Intake cam sprocket (RH)
(18)
(19)

T1: 5 (0.5, 3.6)

T7: 6.4 (0.65, 4.7)
T8: 3.4 (0.35, 2.5)
ME(H4DOTC)-6
General Description
MECHANICAL
2. CYLINDER HEAD AND CAMSHAFT

(1)
T7
T2
(2)
(6)
T6
T5
T2
(8)
(28)
(32)
T6
(9)
(31)
T2
T5
(29)
(13)
(4)
(7)
T3
(14)
(5)
(10)
(12)
(3)
T1
(30)
(11)
T2
(15)
(9)
(23)
(8)
(24)
T2
(25)
(16)
(32)
(14)
(6)
T6
T4
(19)
T5
(27)
(26)
(21)
T6
(31)
(28)
(12)
(17)
(20)
(30)
(18)
(11)
T5
T3
(22)
T1
T7
T7
ME-03011
ME(H4DOTC)-7
General Description
MECHANICAL
(1)
(2)
Rocker cover (RH)

Rocker cover gasket (RH)
(17)
(18)
Exhaust camshaft (LH)

Camshaft cap (Front LH)
(32)
Union screw without filter (Without

protrusion)
(3)
(4)
Camshaft cap (Front RH)

Intake camshaft cap (Rear RH)
(19)
(20)
Intake camshaft cap (Rear LH)

Exhaust camshaft cap (Rear LH)
(5)
(6)
Intake camshaft (RH)

Oil flow control solenoid valve
(21)
(22)
Rocker cover gasket (LH)

Rocker cover (LH)
(7)
(8)
Exhaust camshaft cap (Rear RH)

Gasket
(23)
(24)
Oil filler cap

Gasket
T2: 8 (0.8, 5.9)
(9)
(10)
Oil return cover

Exhaust camshaft (RH)
(25)
(26)
Oil filler duct

O-ring
T3: 9.75 (1.0, 7.2)

T4: 6.4 (0.65, 4.7)

INSTALLATION, Cylinder
Head.>
(11)
Cylinder head bolt
(27)
Oil pipe (LH)
T5: 20 (2.0, 14.5)
(12)
(13)
Oil seal
Cylinder head (RH)
(28)
(29)
Gasket
Oil pipe (RH)
(14)
(15)
Cylinder head gasket

Cylinder head (LH)
(30)
(31)
(16)
Intake camshaft (LH)
Stud bolt
Union screw with filter (With protrusion)
T6: 29 (3.0, 21.4)

ME(H4DOTC)-8
General Description
MECHANICAL
3. CYLINDER HEAD AND VALVE ASSEMBLY
(11)
(1)
(4)
(5)
(6)
(7)
(8)
(9)
(3)
(2)
(11)
(4)
(5)
(6)
(7)
(8)
(9)
(12)
(4)
(10)
(6)
(12)
(7)
(8)
(4)
(9)
(10)
(6)
(7)
(8)
(9)
ME-02583
(1)
(2)
Exhaust valve
Intake valve
(5)
(6)

Valve spring
(9)
(10)
Valve lifter
(3)
(4)
Cylinder head
Valve spring seat
(7)
(8)
Retainer
Retainer key
(11)
(12)
Intake valve guide

Exhaust valve guide
ME(H4DOTC)-9
General Description
MECHANICAL
4. CYLINDER BLOCK
(7)
T2
T2
T6
T2
T8
(32)
T2
T10
(1)
T5
(6)
(10)
(8)
T4
(33)
(2)
(3)
T2
(5)
(4)
(10)
T2
(9)
(4)
(29)
T6
(10)
(3)
(11)
(30)
(15)
(14)
(10)
T4
(31)
(18)
T2
(3)
T13
T12
(33)
T6
(32) (12)
(28)
(31)
(15)
(10)
(4)
(16)
T4
(19)
T2
T2
(26)
(30)
(17)
T3
(20)
T2
T7
(24)
T2
T5
(13)
(27)
T11
(18)
T1
(21)
(23)
(22)
T9
(25)
ME-03012
ME(H4DOTC)-10
General Description
MECHANICAL
(1)
(2)
Oil pressure switch

Cylinder block (RH)
(18)
(19)
Connector
Oil strainer
(3)
(4)
Service hole plug

Gasket
(20)
(21)
Gasket
Oil pan
T2: 6.4 (0.65, 4.7)

T3: 10 (1.0, 7.2)
(5)
(6)
Oil separator cover

Water by-pass pipe
(22)
(23)
Drain plug
Metal gasket
(7)
(8)
Oil pump
Front oil seal
(24)
(25)

Oil filter
T4: 25 (2.5, 18.1)

INSTALLATION, Cylinder
Block.>
(9)
(10)
Rear oil seal

O-ring
(26)
(27)
Gasket
Water pump hose
(11)
Service hole cover
(28)
Plug
T6: 70 (7.1, 50.6)

T7: First 12 (1.2, 8.7)
Second 12 (1.2, 8.7)
(12)
(13)
Cylinder block (LH)

Water pump
(29)
(30)
Seal
Gasket
T8: 16 (1.6, 11.6)

T9: 44 (4.5, 33)
(14)
(15)
Baffle plate
Adapter
(31)
(32)
O-ring
Washer
T10: 25 (2.5, 18.1)

T11: 54 (5.3, 39)
(16)
(17)
Oil cooler
Water by-pass pipe
(33)
Seal washer
T12: 45 (4.6, 33)

T13: 69 (7.0, 50.9)
ME(H4DOTC)-11

T1: 5 (0.5, 3.6)
General Description
MECHANICAL
5. CRANKSHAFT AND PISTON

(1)
T2
(5)
(4)
(6)
T2
(2)
(10)
(9)
(3)
(12)
(7)
(13)
(10)
(8)
T1
(11)
(15)
(13)
(14)
(14)
(11)
T1
(13)
(8)
(16)
(10)
(13)
(7)
(6)
(5)
(12)
(10)
(9)
(19)
(18)
(17)
(18)
(17)
ME-02467
(1)
(2)
Flywheel (MT model)

Ball bearing (MT model)
(9)
(10)
Piston pin
Snap ring
(17)
(18)

(3)
(4)
Reinforcement (AT model)

Drive plate (AT model)
(11)
(12)
Connecting rod bolt

Connecting rod
(19)
Crankshaft bearing #5
(5)
(6)
Top ring
Second ring
(13)
(14)

Connecting rod cap

T1: 52 (5.3, 38.4)
(7)
(8)
Oil ring
Piston
(15)
(16)
Crankshaft
Woodruff key
ME(H4DOTC)-12
T2: 72 (7.3, 52.8)
General Description
MECHANICAL
6. ENGINE MOUNTING
T2
(3)
T2
(3)
T1
(2)
(2)
(1)
T1
T3
T3
ME-00706
(1)
(2)
Heat shield cover

Front cushion rubber
(3)
Front engine mounting bracket

T1: 35 (3.6, 25.8)
T2: 42 (4.3, 30.9)
T3: 85 (8.7, 62.7)
ME(H4DOTC)-13
General Description
MECHANICAL
C: CAUTION
points.
Before disconnecting electrical connectors of
sensors or units, be sure to disconnect the ground
cable from battery.
All parts should be thoroughly cleaned, paying
special attention to engine oil passages, pistons
and bearings.
Rotating parts and sliding parts such as piston,
bearing and gear should be coated with oil prior to
assembly.
Be careful not to let oil, grease or coolant contact
the timing belt, clutch disc and flywheel.
All removed parts, if to be reused, should be reinstalled in the original positions and directions.
Bolts, nuts and washers should be replaced with
new parts as required.
Even if necessary inspections have been made
in advance, proceed with assembly work while
making rechecks.
Remove or install the engine in an area where
chain hoists, lifting devices, etc. are available for
ready use.
Be sure not to damage coated surfaces of body
panels with tools or stain seats and windows with
coolant or oil. Place a cover over fender, as required, for protection.
Prior to starting work, prepare the following:
Service tools, clean cloth, containers to catch coolant and oil, wire ropes, chain hoist, transmission
jacks, etc.
Lift-up or lower the vehicle when necessary.
Make sure to support the correct positions.
ME(H4DOTC)-14
General Description
MECHANICAL
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
498267600
CYLINDER HEAD
TABLE
Used for replacing valve guides.

498457000
ENGINE STAND
ADAPTER RH

(499817100).
498457100
ENGINE STAND
ADAPTER LH

(499817100).
498497100
CRANKSHAFT
STOPPER
Used for removing and installing the flywheel

and the drive plate.
ST-498267600
ST-498457000
ST-498457100
ST-498497100
ME(H4DOTC)-15
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
498747300
PISTON GUIDE
Used for installing piston in cylinder.

(2.5 L model)
498857100
VALVE OIL SEAL

GUIDE
Used for press-fitting of intake and exhaust valve

guide oil seals.
499017100
PISTON PIN GUIDE
Used for installing piston pin, piston and

connecting rod.
499037100
CONNECTING ROD
BUSHING
REMOVER AND
INSTALLER
Used for removing and installing connecting rod

bushing.
499097700
PISTON PIN
REMOVER ASSY
Used for removing piston pin.
ST-498747300
ST-498857100
ST-499017100
ST-499037100
ST-499097700
ME(H4DOTC)-16
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
499207400
CAM SPROCKET
WRENCH

(Exhaust side)
499977500
CAM SPROCKET
WRENCH

(Intake side)
499587200
CRANKSHAFT OIL
SEAL INSTALLER

GUIDE (499597100).
499597100
CRANKSHAFT OIL
SEAL GUIDE

499718000
VALVE SPRING
REMOVER
ST-499207400
ST-499977500
ST-499587200
ST-499597100
ST-499718000
ME(H4DOTC)-17
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
18251AA020
VALVE GUIDE
ADJUSTER
Used for installing intake and exhaust valve

guides.
499767200
VALVE GUIDE
REMOVER
Used for removing valve guides.
499767400
VALVE GUIDE
REAMER
Used for reaming valve guides.
499817100
ENGINE STAND
Stand used for engine disassembly and

assembly.
ADAPTER RH (498457000) & LH (498457100).
499977100
CRANK PULLEY
WRENCH

loosening/tightening crank pulley bolt.
ST18251AA020
ST-499767200
ST-499767400
ST-499817100
ST-499977100
ME(H4DOTC)-18
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
499987500
DESCRIPTION
REMARKS
CRANKSHAFT
SOCKET
Used for rotating crankshaft.
18332AA000
OIL FILTER
WRENCH

18332AA010
OIL FILTER
WRENCH

499587100
OIL SEAL
INSTALLER
Used for installing oil pump oil seal.
499587600
OIL SEAL
INSTALLER
Used for installing camshaft oil seal for DOHC

engine.
ST-499987500
ST18332AA000
ST18332AA010
ST-499587100
ST-499587600
ME(H4DOTC)-19
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
499597200
OIL SEAL GUIDE
Used for installing camshaft oil seal for DOHC

engine.
Used together with OIL SEAL INSTALLER
(499587600).
498277200
STOPPER SET
Used for installing automatic transmission

assembly to engine.
1B020XU0
SUBARU SELECT
MONITOR KIT
CONNECTOR
REMOVER
Used for removing the quick connector in engine

compartment.
ST-499597200
ST-498277200
ST1B020XU0
42099AE000
ST42099AE000
2. GENERAL TOOL
Compression gauge
TOOL NAME
REMARKS
Used for measuring compression.
Vacuum gauge
Oil pressure gauge
Used for measuring negative pressure.

Fuel pressure gauge

Timing light
Used for measuring fuel pressure.

Used for measuring ignition timing.
ME(H4DOTC)-20
General Description
MECHANICAL
E: PROCEDURE
It is possible to conduct the following service procedures 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.
V-belt
Timing belt
Camshaft
Cylinder head
ME(H4DOTC)-21
Compression
MECHANICAL
2. Compression
A: INSPECTION
CAUTION:
1) After warming-up the engine, turn the ignition
switch to OFF.
2) Make sure that the battery is fully charged.
4) Remove all the spark plugs.
<Ref. to IG(H4DOTC)-4, REMOVAL, Spark Plug.>
5) Fully open the throttle valve.
6) Check the starter motor for satisfactory performance and operation.
7) Hold the compression gauge tightly against the
spark plug hole.
NOTE:
The screw of a screw-in type compression gauge
should be less than 18 mm (0.71 in) in length.
8) Crank the engine by means of the starter motor,
and read the maximum value on the gauge when
the pointer is steady.
ME-03009
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 12 kgf/cm2, 142
171 psi)
Service limit:
882 kPa (9.0 kgf/cm2, 128 psi)
Difference between cylinders:
49 kPa (0.5 kgf/cm2, 7 psi), or less
ME(H4DOTC)-22
Idle Speed
MECHANICAL
3. Idle Speed
A: INSPECTION
1) Before checking the idle speed, check the following item:
clogging, ignition timing is correct, spark plugs
are in good condition, and hoses are connected
properly.
not illuminate.
OFF.
link connector.
12) Check the idle speed when loaded. (Turn the

air conditioning switch to ON and operate the
compressor for at least one minute before measurement.)
Idle speed [A/C ON and gears in neutral]:
When A/C refrigerant pressure is low.
MT: 725100 rpm
AT: 750100 rpm
When A/C refrigerant pressure is low.
MT: 800100 rpm
AT: 825100 rpm
NOTE:
Idle speed cannot be adjusted manually, because
the idle speed is automatically adjusted. If the prescribed idle speed cannot be maintained, refer to
the General On-board Diagnosis Table under Engine Control System. <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.>
ME-00325
Menu.
10) Start the engine, and read the engine idle
speed.
11) Check the idle speed when no-loaded. (Headlight, heater fan, rear defroster, radiator fan, A/C,
etc. are OFF.)
Idle speed [No load and gears in neutral]:
700100 rpm
ME(H4DOTC)-23
Ignition Timing
MECHANICAL
4. Ignition Timing
2. METHOD WITH TIMING LIGHT
A: INSPECTION
CAUTION:
1. METHOD WITH SUBARU SELECT MONITOR

following item:
not illuminate.
OFF.
link connector.

following item:
(2) Make sure that the malfunction indicator
light does not illuminate.
2) Warm-up the engine.
OFF.
6) Remove the air cleaner cover and element.
7) Connect the timing light to the power wire of #1
ignition coil.
8) Connect the connectors of air cleaner cover, element, and the mass air flow and intake air temperature sensor.
9) Start the engine, turn the timing light to the crank
pulley, and check the ignition timing by means of
crank pulley indicator.
1710/700
system. Refer to Engine Control System. <Ref. to
EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.>
ME-00325
Menu.
10) Start the engine and check the ignition timing at
idle speed.
1710/700
system. Refer to Engine Control System. <Ref. to
EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.>
ME(H4DOTC)-24
Intake Manifold Vacuum

MECHANICAL
5. Intake Manifold Vacuum

A: INSPECTION
3) Disconnect the brake vacuum hose from the
brake vacuum hose, and then install the vacuum
gauge.
4) Keep the engine at idle speed and read the vacuum gauge indication.
By observing the gauge needle movement, internal
condition of the engine can be diagnosed as described below.
ME-00008
Vacuum pressure (at idling, A/C OFF ):

60.0 kPa (450 mmHg, 17.72 inHg) or less
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
tendency becomes more evident as engine temperature rises.
Leakage around intake manifold gasket, or disconnected or

damaged vacuum hose
2. Needle intermittently drops to position lower than normal

position.
Leakage around cylinder
3. Needle drops suddenly and intermittently from normal

position.
4. When engine speed is gradually increased, needle begins to
vibrate rapidly at certain speed, and then vibration increases as
engine speed increases.
Sticky valve
5. Needle vibrates above and below normal position in narrow

range.
Defective ignition system or throttle chamber idle adjustment
Weak or broken valve springs
ME(H4DOTC)-25
Engine Oil Pressure

MECHANICAL
6. Engine Oil Pressure

A: INSPECTION
2) Remove the oil pressure switch. <Ref. to LU
(H4SO)-21, REMOVAL, Oil Pressure Switch.>
3) Connect the oil pressure gauge hose to cylinder
block.
FU-00009
5) Start the engine, and measure the oil pressure.
ME-00009
Oil pressure:
98 kPa (1.0 kgf/cm2, 14 psi) or more at 600
rpm
294 kPa (3.0 kgf/cm2, 43 psi) or more at 5,000
rpm
CAUTION:
If the oil pressure is out of standard values,
check the oil pump, oil filter and lubrication
line. <Ref. to LU (H4SO)-25, INSPECTION, Engine Lubrication System Trouble in General.>
If the oil pressure warning light is turned on
and oil pressure is in the specified range, check
the oil pressure switch. <Ref. to LU (H4SO)-25,
INSPECTION, Engine Lubrication System Trouble in General.>
NOTE:
The specified data is based on an engine oil temperature of 80C (176F).
6) After measuring the oil pressure, install the oil
pressure switch. <Ref. to LU (H4SO)-21, INSTALLATION, Oil Pressure Switch.>
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
ME(H4DOTC)-26
Fuel Pressure
MECHANICAL
7. Fuel Pressure
6) Connect the pressure regulator vacuum hose

and measure the fuel pressure.
A: INSPECTION
CAUTION:
Before removing the fuel pressure gauge, release the fuel pressure.
NOTE:
If out of specification, check or replace the pressure
regulator and pressure regulator vacuum hose.
2) Disconnect the fuel delivery hose from fuel
damper, and connect fuel pressure gauge.
Fuel pressure:
Standard:
230 260 kPa (2.35 2.65 kgf/cm2, 33
38 psi)
NOTE:
The fuel pressure gauge registers 10 to 20 kPa (0.1
to 0.2 kgf/cm2, 1 to 3 psi) higher than standard values during high-altitude operations.
ME-00790
3) Connect the connector of fuel pump relay.
FU-02334

5) After warming up, disconnect the pressure regulator vacuum hose from the intake manifold, and
measure the fuel pressure.
Fuel pressure:
Standard:
284 314 kPa (2.9 3.2 kgf/cm2, 41 46
psi)
ME(H4DOTC)-27
Valve Clearance
MECHANICAL
8. Valve Clearance
(2) Remove the bolt which holds the engine

harness bracket on the body.
A: INSPECTION
NOTE:
Inspection and adjustment of valve clearance
should be performed while engine is cold.
ME-02685
FU-00009

4) Remove the air intake duct. <Ref. to
IN(H4DOTC)-9, REMOVAL, Air Intake Duct.>
5) Remove a bolt which secures timing belt cover
(RH).
8) Loosen the remaining bolts which secure timing
belt cover (RH), then remove the timing belt cover.
(1) Remove the air cleaner case. <Ref. to
IN(H4DOTC)-8, REMOVAL, Air Cleaner
Case.>
(2) Disconnect the connector of ignition coil.
(3) Remove the ignition coil.
(4) Place a suitable container under the vehicle.
(RH).
cover (RH).
(1) Disconnect the battery cable, and then remove the battery and battery carrier.
(3) Remove the secondary air pump. <Ref. to

EC (H4DOTC)-9, REMOVAL, Secondary Air
Pump.>
(4) Disconnect the connector of ignition coil.
(5) Remove the ignition coil.
(6) Place a suitable container under the vehicle.
(LH).
cover (LH).
12) Turn the crank pulley clockwise until arrow
mark on the camshaft sprocket is set to position
NOTE:
Turn the crankshaft using socket wrench.
ME-00733
13) Measure the #1 cylinder intake valve and #3

cylinder exhaust valve clearance by using thickness gauge (A).
NOTE:
Insert a thickness gauge in a direction as horizontal as possible with respect to the valve lifter.
Lift-up the vehicle and measure the exhaust
valve clearance.
ME-00013
ME(H4DOTC)-28
Valve Clearance
MECHANICAL
Valve clearance:
Intake
0.200.02 mm (0.00790.0008 in)
Exhaust
0.350.02 mm (0.01380.0008 in)
If the measured value is not within specification,
take notes of the value in order to adjust the valve
clearance later on.
(3) Set the arrow mark on cam sprocket to the

position shown in the figure, and measure the
#1 cylinder exhaust valve and #4 cylinder intake
valve clearances.
(A)
ME-00736

ME-00019
14) If necessary, adjust the valve clearance. <Ref.

to ME(H4DOTC)-30, ADJUSTMENT, Valve Clearance.>
15) Further turn the crank pulley clockwise.
Using the same procedures described previously,
then measure valve clearances again.
#2 cylinder exhaust valve and #3 cylinder intake
valve clearances.
Tightening torque:
33 Nm (3.4 kgf-m, 25 ft-lb)
ME-00023
ME-00734

#2 cylinder intake valve and #4 cylinder exhaust
valve clearances.
ME-00735
ME(H4DOTC)-29
Valve Clearance
MECHANICAL
B: ADJUSTMENT
Part No.
Thickness mm (in)
NOTE:
Adjustment of valve clearance should be performed while engine is cold.
1) Measure all the valve clearances. <Ref. to
ME(H4DOTC)-28, INSPECTION, Valve Clearance.>
13228 AB172
13228 AB182
4.75 (0.1870)
4.76 (0.1874)
13228 AB192
13228 AB202
4.77 (0.1878)
4.78 (0.1882)
13228 AB212
13228 AB222
4.79 (0.1886)
4.80 (0.1890)
NOTE:
Record each valve clearance after measurement.
13228 AB232
13228 AB242
4.81 (0.1894)
4.82 (0.1898)
13228 AB252
13228 AB262
4.83 (0.1902)
4.84 (0.1906)
13228 AB272
13228 AB282
4.85 (0.1909)
4.86 (0.1913)
13228 AB292
13228 AB302
4.87 (0.1917)
4.88 (0.1921)
13228 AB312
13228 AB322
4.89 (0.1925)
4.90 (0.1929)
13228 AB332
13228 AB342
4.91 (0.1933)
4.92 (0.1937)
13228 AB352
13228 AB362
4.93 (0.1941)
4.94 (0.1945)
13228 AB372
13228 AB382
4.95 (0.1949)
4.96 (0.1953)
13228 AB392
13228 AB402
4.97 (0.1957)
4.98 (0.1961)
13228 AB412
13228 AB422
4.99 (0.1965)
5.00 (0.1969)
13228 AB432
13228 AB442
5.01 (0.1972)
5.02 (0.1976)
13228 AB452
13228 AB462
5.03 (0.1980)
5.04 (0.1984)
13228 AB472
13228 AB482
5.05 (0.1988)
5.06 (0.1992)
13228 AB492
13228 AB502
5.07 (0.1996)
5.08 (0.2000)
13228 AB512
13228 AB522
5.09 (0.2004)
5.10 (0.2008)
Intake valve: S = (V + T) 0.20

Exhaust valve: S = (V + T) 0.35
13228 AB532
13228 AB542
5.11 (0.2012)
5.12 (0.2016)
S: Required thickness of valve lifter

V: Measured valve clearance
T: Used valve lifter thickness
13228 AB552
13228 AB562
5.13 (0.2020)
5.14 (0.2024)
13228 AB572
13228 AB582
5.15 (0.2028)
5.16 (0.2031)
13228 AB592
13228 AB602
5.17 (0.2035)
5.18 (0.2039)
13228 AB612
13228 AB622
5.19 (0.2043)
5.20 (0.2047)
13228 AB632
13228 AB642
5.21 (0.2051)
5.22 (0.2055)
13228 AB652
5.23 (0.2059)
13228 AB662
5.24 (0.2063)
ME-00024
2) Remove the camshaft. <Ref. to ME(H4DOTC)54, REMOVAL, Camshaft.>

3) Remove the valve lifter.
4) Measure the thickness of valve lifter using micrometer.
ME-00025
5) Select a valve lifter of suitable thickness from the

following table using the measured valve clearance
and valve lifter thickness.
Unit: (mm)
Part No.
Thickness mm (in)
13228 AB102
13228 AB112
4.68 (0.1843)
4.69 (0.1846)
13228 AB122
13228 AB132
4.70 (0.1850)
4.71 (0.1854)
13228 AB142
13228 AB152
4.72 (0.1858)
4.73 (0.1862)
13228 AB162
4.74 (0.1866)
ME(H4DOTC)-30
Valve Clearance
MECHANICAL
Part No.
Thickness mm (in)
13228 AB672
13228 AB682
5.25 (0.2067)
5.26 (0.2071)
13228 AB692
13228 AB702
5.27 (0.2075)
4.38 (0.1724)
13228 AB712
13228 AB722
4.40 (0.1732)
4.42 (0.1740)
13228 AB732
13228 AB742
4.44 (0.1748)
4.46 (0.1756)
13228 AB752
13228 AB762
4.48 (0.1764)
4.50 (0.1771)
13228 AB772
13228 AB782
4.52 (0.1780)
4.54 (0.1787)
13228 AB792
13228 AB802
4.56 (0.1795)
4.58 (0.1803)
13228 AB812
13228 AB822
4.60 (0.1811)
4.62 (0.1819)
13228 AB832
13228 AB842
4.64 (0.1827)
4.66 (0.1835)
13228 AB852
13228 AB862
5.29 (0.2083)
5.31 (0.2091)
13228 AB872
13228 AB882
5.33 (0.2098)
5.35 (0.2106)
13228 AB892
13228 AB902
5.37 (0.2114)
5.39 (0.2122)
13228 AB912
13228 AB922
5.41 (0.2123)
5.43 (0.2138)
13228 AB932
13228 AB942
5.45 (0.2146)
5.47 (0.2154)
13228 AB952
13228 AB962
5.49 (0.2161)
5.51 (0.2169)
13228 AB972
13228 AB982
5.53 (0.2177)
5.55 (0.2185)
13228 AB992
13228 AC002
5.57 (0.2193)
5.59 (0.2201)
13228 AC012
13228 AC022
5.61 (0.2209)
5.63 (0.2217)
13228 AC032
5.65 (0.2224)
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.
ME(H4DOTC)-31
Engine Assembly
MECHANICAL
9. Engine Assembly
A: REMOVAL
2) Open the front hood fully and support with the
front food stay.
4) Collect the refrigerant from A/C system. <Ref. to
AC-19, Refrigerant Recovery Procedure.>
5) Release the fuel pressure. <Ref. to FU(H4SO)44, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.>
ME-03008
(2) Engine ground terminal
ME-00028
FU-00009
7) Open the fuel filler flap lid, and remove the filler
cap.
8) Remove the air cleaner case and air intake boot.
Case.>
10) Remove the radiator from the vehicle. <Ref. to
CO(H4SO)-27, REMOVAL, Radiator.>
11) Remove the coolant filler tank. <Ref. to
CO(H4SO)-43, REMOVAL, Coolant Filler Tank.>
12) Remove the secondary air pump. <Ref. to EC
(H4DOTC)-9, INSPECTION, Secondary Air
Pump.>
13) Disconnect the A/C pressure hoses from A/C
compressor.
(3) Right and left engine ground cables
FU-00131
FU-00132
ME-02686

15) Disconnect the following connectors and cables.
ME(H4DOTC)-32
Engine Assembly
MECHANICAL
(4) Generator connector, terminal and A/C

compressor connector
(2) Remove the power steering pipe from the

fuel pip protector RH along with the bracket.
(B)
(A)
ME-00036
ME-00030
(3) Remove the power steering pump.
(A) A/C compressor connector

(B) Generator connector and terminal
ME-00037

by pulling it upwards.
FU-00878
16) Disconnect the following hoses.

ME-02674

side wheel apron.
ME-02687

(1) Remove the front side V-belt. <Ref. to
ME(H4DOTC)-40, FRONT SIDE BELT, REMOVAL, V-belt.>
ME-00039

ME(H4DOTC)-33
Engine Assembly
MECHANICAL

24) Using the ST to remove the fuel hose from

each fuel pipe. <Ref. to FU(H4DOTC)-64, REMOVAL, Fuel Delivery, Return and Evaporation Lines.>
CAUTION:
or cloth.
(A)
ME-00040

ST
(B)
(C)
FU-02418

(B) Return hose
(C) Evaporation hose
ME-02688

wire ropes.
22) Separate the torque converter clutch from drive

plate. (AT model)
(1) Lower the vehicle.
(3) Remove the bolts which hold torque converter clutch to drive plate.
(4) Remove other bolts while rotating the crankshaft using socket wrench.
ME-00047
26) Support the transmission with a garage jack.

CAUTION:
Be sure to always perform this work, in order to
prevent the transmission from lowering for its
own weight.
ME-00044

(A)
(B)
ME-00215
MT-00069
(A) Transmission
(B) Garage jack
ME(H4DOTC)-34
Engine Assembly
MECHANICAL
CAUTION:
Before removing the engine away from transmission, check to be sure no work has been
overlooked.
27) Separation of engine and transmission.
(1) Remove the starter. <Ref. to SC (H4SO)-6,
REMOVAL, Starter.>
(2) Set the ST to torque converter clutch case.
(AT model)
ST 498277200
STOPPER SET
NOTE:
4) Tighten the bolts which hold upper side of transmission to engine.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
ME-00050
ST

ME-00049
(3) Remove the bolts which hold upper side of

ME-00047
6) Remove the garage jack.

ME-00050
28) Remove the engine from vehicle.

(1) Slightly raise the engine.
(2) Raise the transmission with garage jack.
(3) Move the engine horizontally until main
shaft is withdrawn from clutch cover.
(4) Slowly move the engine away from engine
compartment.
NOTE:
29) Remove the front cushion rubbers.
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 37 ft-lb)
T2: 58 Nm (5.9 kgf-m, 43 ft-lb)
T1
T2
MT-00085
B: INSTALLATION
8) Remove the ST from converter case. (AT model)
1) Install the front cushion rubbers.

Tightening torque:
35 Nm (3.6 kgf-m, 25.8 ft-lb)
2) Apply a small amount of grease to splines of
mainshaft. (MT model)
3) Position the engine in engine compartment and
connect the engine to the transmission.
NOTE:
Be careful not to drop the ST into the converter
case when removing the ST.
ST 498277200
STOPPER SET
9) Install the starter. <Ref. to SC (H4SO)-6, INSTALLATION, Starter.>
ME(H4DOTC)-35
Engine Assembly
MECHANICAL
10) Install the torque converter clutch to drive plate.

(AT model)
(1) Tighten the bolts which hold torque converter clutch to drive plate.
(2) Tighten other bolts while rotating the crankshaft using socket wrench.
(3) Install the power steering pipes onto the fuel

pipe protector RH.
NOTE:
Be careful not to drop bolts into the torque converter clutch housing.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
ME-00036
(4) Install the front side V-belt and adjust it.

<Ref. to ME(H4DOTC)-40, FRONT SIDE
BELT, INSTALLATION, V-belt.>
13) Tighten the nuts and bolts which hold lower
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
ME-00044
(3) Install the service hole plug.

(1) Install the reservoir tank to the bracket.
ME-00040
14) Tighten the nuts which install the front cushion

rubber onto crossmember.
ME-02674
(2) Install the power steering pump.
Tightening torque:
85 Nm (8.7 kgf-m, 62.7 ft-lb)
NOTE:
Tightening torque:
20.1 Nm (2.05 kgf-m, 14.8 ft-lb)
(B)
ME-00037
ME(H4DOTC)-36
(A)
(A)
(B)
ME-02689
Engine Assembly
MECHANICAL
15) Install the center exhaust pipe.

<Ref. to EX(H4DOTC)-9, INSTALLATION, Center
Exhaust Pipe.>
17) Connect the following hoses.
(1) Fuel delivery hose, return hose and evaporation hose
18) Connect the following connectors and terminals.
(1) Engine ground terminal
19) Install the air intake system.
(1) Install
the
intercooler.
<Ref.
to
(2) Install the air cleaner case and air intake
boot. <Ref. to IN(H4DOTC)-8, INSTALLATION,
Air Cleaner Case.>
20) Install the A/C pressure hoses.
27) Charge the A/C system with refrigerant.

<Ref. to AC-20, PROCEDURE, Refrigerant Charging Procedure.>
29) Remove the front hood stay, and close the front
hood.
C: INSPECTION
1) Check that the pipes and hoses are correctly installed.
2) Check that the engine coolant and ATF are at
specified levels. (AT model)
3) Start the engine and check for exhaust gas, engine coolant, leaks of fuel, etc. Also check for noise
and vibrations.
NOTE:
Use new O-rings.
Tightening torque:
15 Nm (1.5 kgf-m, 10.8 ft-lb)
ME-02686

23) Install the coolant filler tank.
<Ref. to CO(H4SO)-43, INSTALLATION, Coolant
Filler Tank.>
24) Install the secondary air pump. <Ref. to EC
(H4DOTC)-9, INSTALLATION, Secondary Air
Pump.>
25) Install the battery in the vehicle, and connect
cables.
26) Refill engine coolant.
ME(H4DOTC)-37
Engine Mounting
MECHANICAL
10.Engine Mounting
A: REMOVAL
1) Remove the engine unit. <Ref. to ME(H4DOTC)32, REMOVAL, Engine Assembly.>
2) Remove the engine mounting from engine assembly.
B: INSTALLATION
Tightening torque:
Engine mounting:
35 Nm (3.6 kgf-m, 25.8 ft-lb)
C: INSPECTION
Make sure that no crack or other damage do not exists.
ME(H4DOTC)-38

MECHANICAL
11.Preparation for Overhaul

A: PROCEDURE
1) After removing the engine from body, secure it to
ST in the following procedure.
RH
LH
ST3 499817100 ENGINE STAND
ST2
ST1
ST3
ME-00057
2) In this section the procedures described under

each index are all connected and stated in order.
The procedure for overhauling of the engine will be
completed 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 previously in order to do that particular procedure.
ME(H4DOTC)-39
V-belt
MECHANICAL
12.V-belt
B: INSTALLATION
A: REMOVAL
CAUTION:
Wipe off any oil and water on the belt and pulley.
NOTE:
1. FRONT SIDE BELT

1) Install the front side belt (C), and tighten the slider bolt so as to obtain the specified belt tension.
<Ref. to ME(H4DOTC)-41, INSPECTION, V-belt.>
1. FRONT SIDE BELT

4) Remove the front side belt (C).
(B)
(C)
Tightening torque:
Lock bolt through bolt:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
Slider bolt
8 Nm (0.8 kgf-m, 5.5 ft-lb)
(B)
(A)
(C)
ME-00059
2. REAR SIDE BELT

(A)

ME-00059
2. REAR SIDE BELT

2) Install a rear side belt, and tighten the slider bolt
(B) so as to obtain the specified belt tension.
<Ref. to ME(H4DOTC)-41, INSPECTION, V-belt.>
(B)
(A)
ME-00060

4) Remove the belt tensioner.
Tightening torque:
Lock nut (A)
22.6 Nm (2.3 kgf-m, 16.6 ft-lb)
(B)
(A)
ME-00060
ME-00061
ME(H4DOTC)-40
V-belt
MECHANICAL
C: INSPECTION
Belt tension (without belt tension gauge):
1) Replace the belts, if crack, fraying or wear is

found.
2) Check the V-belt tension and adjust it if necessary by changing generator installing position and/
or idler pulley installing position.
(A)
7 9 mm (0.276 0.354 in)
At inspection
9 11 mm (0.354 0.433 in)
Belt tension (with belt tension gauge):
(B)
7.5 8.5 mm (0.295 0.335 in)
At inspection
9.0 10.0 mm (0.354 0.394 in)
(A)
640 780 N (65 80 kgf, 144 175 lb)
At inspection:
490 640 N (50 65 kgf, 110 144 lb)
(B)
650 750 N (66 76 kgf, 146 169 lb)
At inspection
350 450 N (36 46 kgf, 78 101 lb)
98 N (10 kgf, 22 lb)

P/S
GEN
(A) (B)
A/C
I/P
(A)
C/P
P/S
A/C
GEN
ME-00062
(B)
(A) Front side belt

(B) Rear side belt
C/P Crank pulley
GEN Generator
I/P
C/P
PM-00154
(A) Front side belt

(B) Rear side belt

I/P Idler pulley
C/P Crank pulley

GEN Generator
A/C A/C compressor pulley
I/P Idler pulley
ME(H4DOTC)-41
Crank Pulley
MECHANICAL
13.Crank Pulley
3) Check that the tightening angle of the clamp pulley bolt is a minimum of 65. Perform the following
procedure when less than 65.
A: REMOVAL
NOTE:
REMOVAL, V-belt.>
2) Remove the crank pulley bolt. To lock the crankshaft, use ST.
ST 499977100
CRANK PULLEY WRENCH
ST
ME-00063
B: INSTALLATION
2) Install the pulley bolt.
ST 499977100
CRANK PULLEY WRENCH
(1) Clean the crank pulley thread using compressed air.
and thread.
(4) Tighten the crank pulley bolts.
Tightening torque:
180 Nm (18.3 kgf-m, 132.7 ft-lb)
CAUTION:
If the tightening angle of crank pulley bolt is
less than 65, the bolt is damaged. In this case,
the bolt must be replaced.
(1) Replace the crank pulley bolts and clean
them.
Crank pulley bolt:
Part No. 12369AA011
and thread.
(5) Tighten the crank pulley bolts 65 to 75.
NOTE:
Conduct the tightening procedures by confirming
the turning angle of crank pulley bolt referring to the
gauge indicated on timing belt cover.
ME-00061

C: INSPECTION
1) Check the V-belt is not worn or otherwise damaged.
2) Check the tension of the belt. <Ref. to
ME(H4DOTC)-41, INSPECTION, V-belt.>
ST
ME-00063
ME(H4DOTC)-42
Timing Belt Cover

MECHANICAL
14.Timing Belt Cover

A: REMOVAL
NOTE:
REMOVAL, V-belt.>
<Ref. to ME(H4DOTC)-42, REMOVAL, Crank Pulley.>
3) Remove the timing belt cover (LH) (A).
4) Remove the timing belt cover (RH) (B).
5) Remove the front timing belt cover (C).
(B)
(A)
(C)
ME-00064
B: INSTALLATION
1) Install the front timing belt cover (C).
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
2) Install the timing belt cover (RH) (B).
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
3) Install the timing belt cover (LH) (A).
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
(B)
(A)
(C)
ME-00064
4) Install the crank pulley. <Ref. to ME(H4DOTC)42, INSTALLATION, Crank Pulley.>

C: INSPECTION
Make sure the cover is not damaged.
ME(H4DOTC)-43
Timing Belt
MECHANICAL
15.Timing Belt
A: REMOVAL
NOTE:
when replacing a single part. For operation procedures, refer to Timing Belt of the PM section.
<Ref. to PM-12, Timing Belt.>
1. TIMING BELT
ME-00729

REMOVAL, V-belt.>
2) Remove
the crank
pulley.
<Ref. to
ME(H4DOTC)-42, REMOVAL, Crank Pulley.>
<Ref. to ME(H4DOTC)-43, REMOVAL, Timing Belt
Cover.>
ME-00065
ME-00727
ME-00728
ME(H4DOTC)-44
Timing Belt
MECHANICAL
5) If the alignment mark or arrow mark (which indicates the direction of rotation) on timing belt fade
away, put new marks before removing the timing
belt as shown in procedures below.
(1) Turn the crankshaft using ST, and align the
alignment marks on crank sprocket, intake cam
sprocket (LH), exhaust cam sprocket (LH), intake cam sprocket (RH) and exhaust cam
sprocket (RH) with notches of timing belt cover
and cylinder block.
ST 499987500
CRANKSHAFT SOCKET
Z1: 54.5-teeth length

Z2: 51-teeth length
Z3: 28-teeth length
Z1
Z3
Z2
Z3
ME-00072
6) Remove the belt idler (A).

(C)
(B)
ST
ME-00069
(2) Using white paint, put alignment and/or arrow marks on timing belts in relation to the cam
sprockets.
(A)
ME-03015

CAUTION:
After the timing belt has been removed, never
rotate the intake and exhaust sprocket. If the
cam sprocket is rotated, the intake and exhaust
valve heads strike together and valve stems are
bent.
ME-00070

1) Remove the belt idler (B) and (C).
(C)
(B)
ME-00071
(A)
ME-03015
ME(H4DOTC)-45
Timing Belt
MECHANICAL
2) Remove the belt idler No. 2.
(2) Slowly move the adjuster rod down with a

pressure of more than 294 N (30 kgf, 66 lb) until
the adjuster rod is aligned with the stopper pin
hole in the cylinder.
ME-00075

ME-00077
(3) With a 2 mm (0.08 in) dia. stopper pin or a 2

mm (0.08 in) (nominal) dia. hex bar wrench inserted into the stopper pin hole in the cylinder,
secure the adjuster rod.
ME-00076
B: INSTALLATION
1) Preparation for installation of automatic belt tension adjuster assembly.
CAUTION:
N (1,000 kgf, 2,205 lb).
Press the adjuster rod as far as the end surface of the cylinder. Do not press the adjuster
rod into cylinder. Doing so may damage the cylinder.
Do not release the press pressure until stopper pin is completely inserted.
(1) Attach the automatic belt tension adjuster
assembly to vertical pressing tool.
ME(H4DOTC)-46
ME-00078
Timing Belt
MECHANICAL
2) Install the automatic belt tension adjuster assembly.

Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
2) Align the mark (A) on crank sprocket with the

mark on oil pump cover at cylinder block.
(A)
ME-00081
ME-00079
3) Align single line mark (A) on the exhaust cam

sprocket (RH) with notch (B) on timing belt cover.
3) Install the belt idler No. 2.

(A)
Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
(B)
ME-00082
ME-00075
4) Align single line mark (A) on the intake cam

sprocket (RH) with notch (B) on timing belt cover.
(Ensure double lines (C) on intake and exhaust
camshaft sprockets are aligned.)
4) Install the belt idlers.
(B)
Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
(A)
(C)
ME-00083
ME-00080
5) Align the single line mark (A) on exhaust cam

sprocket (LH) with notch (B) on timing belt cover by
turning the sprocket counterclockwise (as viewed
from front of engine).
2. TIMING BELT
1) Preparation for installation of automatic belt tension adjuster assembly. <Ref. to ME(H4DOTC)-46,
Timing Belt.>
(B)
(A)
ME-00084
ME(H4DOTC)-47
Timing Belt
MECHANICAL
6) Align the single line mark (A) on intake cam

sprocket (LH) with notch (B) on timing belt cover by
turning the sprocket clockwise (as viewed from
front of engine). (Make sure the double line marks
(C) on intake and exhaust cam sprockets are
aligned.)
(B)
(A)
(C)
ME-00085
When the camshafts are rotated to install the

timing belts, #2 intake and #4 exhaust cam of
camshafts (LH) are held to push their corresponding valves down. (Under this condition,
these valves are held lifted.) Right-side camshafts are held so that their cams do not push
valves down.
Camshafts (LH) must be rotated from the zero-lift position to the position where the timing
belt is to be installed with the smallest possible
angle, in order to prevent mutual interference of
intake and exhaust valve heads.
Do not allow the camshafts to rotate in the direction shown in the upper figure. Doing this
may cause both the intake and exhaust valves
to lift simultaneously, resulting in mutual interference of valve heads.
7) Make sure that the cam and crank sprockets are

positioned properly.
CAUTION:
Intake and exhaust camshafts for this DOHC
engine can be independently rotated with the
timing belts removed. As can be seen from the
figure, if the intake and exhaust valves are lifted
simultaneously, the valve heads will interfere
with each other, resulting in bent valves.
(A)
NG
N
G
OK
OK
(A)
(B)
(A)
(A)
(A)
(B)
ME-03022
(A) Direction of rotation

(B) Timing belt installation position
(B)
ME-00086
(A) Intake camshaft

(B) Exhaust camshaft
When the timing belts are not installed, four

camshafts are held at the zero-lift position,
where all cams on camshafts do not push the
intake and exhaust valves down. (Under this
condition, all valves remain unlifted.)
ME(H4DOTC)-48
Timing Belt
MECHANICAL
8) Installation of timing belt:

Align the alignment mark on the timing belt with
marks on the sprockets in the alphabetical order
shown in the figure. While aligning marks, position
the timing belt properly.
CAUTION:
Disengagement of more than three timing
belt teeth may result in interference between
the valve and piston.
Make sure that the direction of belt rotation is
correct.
(1)
(2)
(4)
(3)
(5)
(D)
(6)
(B)
(A)
RH-IN
LH-IN
RH-EX
LH-EX
(E)
(7)
(C)
(1)
Arrow mark
(4)
Length of 54.5-teeth
(2)
(3)
Timing belt
Length of 28-teeth
(5)
(6)
Length of 51-teeth
Length of 28-teeth
(7)
ME-00089
Install it in the end
9) Install the belt idlers.
11) Install the timing belt guide. (MT model)
Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
NOTE:
Clean the timing belt cover screw holes before
installing bolts.
Apply liquid gasket to the bolt threads. (Cam
sprocket side only)
NOTE:
Make sure that the marks on the timing belt and
sprockets are aligned.
Liquid gasket
or the equivalent
(1) Temporarily tighten the bolts mounting the
timing belt guide.
(2) Check and adjust the clearance between
timing belt and timing belt guide.
ME-00090
10) After ensuring that the marks on the timing belt

and sprockets are aligned, remove the stopper pin
from tensioner adjuster.
ME(H4DOTC)-49
Timing Belt
MECHANICAL
(3) Tighten the bolts mounting the timing belt

guide.
Clearance:
1.00.5 mm (0.0390.020 in)
Tightening torque:
9.75 Nm (1.0 kgf-m, 7.2 ft-lb)
ME-00091
ME-00095
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
ME-00730
ME-00727
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
ME-00731
ME-00728
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
ME-00732
ME-00729
ME(H4DOTC)-50
Timing Belt
MECHANICAL

<Ref. to ME(H4DOTC)-43, INSTALLATION, Timing Belt Cover.>
<Ref. to ME(H4DOTC)-42, INSTALLATION, Crank
Pulley.>
C: INSPECTION
1. TIMING BELT
1) Check the timing belt teeth for breaks, cracks or
wear. If any fault is found, replace the belt.
2) Check the condition of the backside of belt. If
cracks are found, replace the belt.
CAUTION:
Be careful not to let oil, grease or engine
coolant contact the belt. Remove quickly and
thoroughly if this happens.
Do not bend the belt sharply.
Bending diameter: h
3) If the adjuster rod is not stiff and moves freely

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 cylinder. Repeat this operation
two to three times.
(2) With the adjuster rod extended all the way
up, apply a pressure of 294 N (30 kgf, 66 lb) to
it to inspect the stiffness of the adjuster rod.
(3) If the adjuster rod is not stiff and compresses, replace the automatic belt tension adjuster
assembly with a new part.
CAUTION:
N (1,000 kgf, 2,205 lb).
Press the adjuster rod to the end surface of
the cylinder. Do not press the adjuster rod into
cylinder. Doing so may damage the cylinder.
4) Measure the rod protrusion amount H from the
body edge. If it is not within specifications, replace
with new part.
Amount of rod protrusion: H
5.2 6.2 mm (0.204 0.244 in)
H
ME-00099
2. AUTOMATIC BELT TENSION ADJUSTER

1) Visually check the oil seals for leaks, and rod
ends for uneven wear and scratches. If necessary,
replace the automatic belt tension adjuster assembly.
NOTE:
Slight traces of oil at rods oil seal does not indicate
a problem.
2) Check that the adjuster rod does not move when
a pressure of 294 N (30 kgf, 66 lb) is applied to it.
This is to check the adjuster rod stiffness.
ME-00100
3. BELT TENSION PULLEY

1) Check the mating surfaces of timing belt and
contact point of adjuster rod for uneven wear or
scratches. Replace the automatic belt tension adjuster assembly if faulty.
2) Check the belt tension pulley for smooth rotation. Replace if noise or excessive play occurs.
3) Check the belt tension pulley for grease leakage.
4. BELT IDLER
1) Check the belt idler for smooth rotation. Replace
if noise or excessive play occurs.
2) Check the outer contacting surfaces of idler pulley for abnormal wear and scratches.
3) Check the belt idler for grease leakage.
ME(H4DOTC)-51
Cam Sprocket
MECHANICAL
16.Cam Sprocket
B: INSTALLATION
A: REMOVAL
1) Fasten the cam sprocket and install to the cam

shaft using ST.
NOTE:
REMOVAL, V-belt.>
Cover.>
<Ref. to ME(H4DOTC)-44, REMOVAL, Timing
Belt.>
5) Fasten the cam sprocket and remove from the
cam shaft using ST.
ST 499207400
CAM SPROCKET WRENCH
NOTE:
Do not confuse left and right side cam sprockets
during installation.
ST 499207400
CAM SPROCKET WRENCH
Tightening torque:
ME-00709
ST
499977500
CAM SPROCKET WRENCH
Tightening torque:
ME-00709
ST
499977500
CAM SPROCKET WRENCH
ME-00710
ME-00710
2) Install the timing belt. <Ref. to ME(H4DOTC)-46,

Pulley.>
C: INSPECTION
1) Check the sprocket teeth for uneven wear or
scratches.
2) Make sure there is no free play between sprocket and key.
ME(H4DOTC)-52
Crank Sprocket
MECHANICAL
17.Crank Sprocket
C: INSPECTION
A: REMOVAL
1) Check the sprocket teeth for uneven wear or

scratches.
2) Make sure there is no free play between sprocket and key.
3) Check the protrusion of crank sprocket used for
sensor for damage and contamination of foreign
matter.
NOTE:
REMOVAL, V-belt.>
Cover.>
Belt.>
ME-00103
B: INSTALLATION
ME-00103
2) Install the timing belt.

<Ref. to ME(H4DOTC)-46, INSTALLATION, Timing Belt.>
4) Install the crank pulley. <Ref. to ME(H4DOTC)42, INSTALLATION, Crank Pulley.>
ME(H4DOTC)-53
Camshaft
MECHANICAL
18.Camshaft
9) Remove the timing belt cover No. 2 (RH).
A: REMOVAL
NOTE:
when replacing a single part. Refer to Valve Clearance for preparation. <Ref. to ME(H4DOTC)-28,
INSPECTION, Valve Clearance.>
REMOVAL, V-belt.>
2) Remove
the crank
pulley.
<Ref. to
ME(H4DOTC)-42, REMOVAL, Crank Pulley.>
Cover.>
4) Remove the timing belt. <Ref. to ME(H4DOTC)44, REMOVAL, Timing Belt.>
5) Remove the cam sprocket. <Ref. to
ME(H4DOTC)-52, REMOVAL, Cam Sprocket.>
6) Disconnect the oil flow control solenoid valve assembly connector.
ME-00107
10) Remove the oil level gauge guide. (LH side)

11) Remove the rocker cover and gasket.
12) Remove the oil pipe.
(B)
(A)
ME-02738
(A) Union screw with filter (With protrusion)

(B) Union screw without filter (Without protrusion)
ME-00770
13) Loosen the oil flow control solenoid valve assembly and intake camshaft cap bolts equally, a little at a time in alphabetical sequence shown in the
figure.
(A)
(B)
ME-00105
ME-00106
ME(H4DOTC)-54
(E)
(C)
(F)
(D)
ME-00771
Camshaft
MECHANICAL
14) Loosen the exhaust camshaft cap bolts equally, a little at a time in alphabetical sequence shown
in the figure.
Camshaft RH must be rotated when set at the

position shown in the figure.
Intake camshaft LH: Rotate 80 clockwise.
Exhaust camshaft LH: Rotate 45 clockwise.
A
(a)
(A)
(B)
77.5
(b)
11
(E)
(C)
(F)
(D)
ME-00772
15) Remove the oil flow control solenoid valve assembly, intake camshaft cap and camshaft.
16) Remove the exhaust camshaft caps and camshaft.
B
(b)
11
NOTE:
Arrange camshaft caps in order so that they can be
installed in their original positions.
17) Similarly, remove the camshafts (RH) and related parts.
77.5
(a)
B: INSTALLATION
1) Camshaft installation:
Apply engine oil to the cylinder head at camshaft
bearing installation location before installing the
camshaft. Install the camshaft so that each valve is
close to or in contact with base circle of the cam.
NOTE:
Set the cam shaft to the position shown in the figure. It is necessary to rotate the cam shaft (LH)
slightly when installing the timing belt.
ME-00111
A Cylinder head (LH)

B Cylinder head (RH)
(a) Intake camshaft
(b) Exhaust camshaft
2) Camshaft cap and oil flow control solenoid valve

assembly installation:
(1) Apply small amount of liquid gasket to the
mating surface of cap.
NOTE:
Do not apply liquid gasket excessively. Applying
excessively may cause excess gasket to come out
and flow toward oil seal, resulting in oil leak.
Liquid gasket:
equivalent
ME-00773
(2) Apply a thin coat of engine oil to cap bearing

surface, and install the cap to the camshaft.
ME(H4DOTC)-55
Camshaft
MECHANICAL
(3) Gradually tighten the camshaft cap and oil

control valve assembly in at least two stages in
alphabetical sequence shown in the figure, and
then tighten to specified torque.
Tightening torque:
T1: 9.75 Nm (1.0 kgf-m, 7.2 ft-lb)
T2: 20 Nm (2.0 kgf-m, 14.5 ft-lb)
(G)
(L)
(C)
T2
(A)
(B)
NOTE:
Use a new gasket.
(2) Apply liquid gasket to the specified point of
the cylinder head. Apply extra amount of liquid
gasket around plugs 5 mm (0.2 in) or more.
Liquid gasket:
equivalent
T1
(E)
(F)
4) Rocker cover installation:

(1) Install the gasket on rocker cover. Install the
peripheral gasket and ignition coil unit gasket.
(K)
T2
(J)
T1
(H)
(D)
(I)
ME-02379
(4) After tightening the camshaft cap, ensure

the camshaft rotates only slightly while holding
it at base circle.
3) Apply a coat of engine oil to the oil seal periphery
and oil seal lip, then install the oil seal on camshaft
using ST1 and ST2.
NOTE:
Use a new oil seal.
ME-02737
ST1
ST2
ME-00116
(3) Install the rocker cover on cylinder head.

Ensure the gasket is properly positioned during
installation.
(4) Temporarily tighten the rocker cover tightening bolts in alphabetical sequence shown in
the figure, and then tighten to specified torque
in alphabetical sequence.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
(C),(K)
(H)
(E)
(B),(J)
(A),(I)
(G)
(D),(L)
ME(H4DOTC)-56
(F)
ME-00777
Camshaft
MECHANICAL
5) Install the oil pipe.
9) Install the timing belt cover No. 2 (RH).
NOTE:
Make sure not to mix up the union screws with filter
and without filter as their installation positions are
different.
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
Tightening torque:
29 Nm (3.0 kgf-m, 21.4 ft-lb)
(B)
ME-00107
10) Install the timing belt cover No. 2 (LH).

(A)
ME-02738
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
(A) Union screw with filter (With protrusion)

(B) Union screw without filter (Without protrusion)
6) Connect the oil flow control solenoid valve connector.
ME-00106
ME-00770
7) Similarly, install the parts on right-hand side.

Tightening torque:
24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
11) Install the cam sprocket.

<Ref. to ME(H4DOTC)-52, INSTALLATION, Cam
Sprocket.>
12) Install the timing belt. <Ref. to ME(H4DOTC)46, INSTALLATION, Timing Belt.>
Pulley.>
ME-00105
ME(H4DOTC)-57
Camshaft
MECHANICAL
C: INSPECTION
1) Measure the bend, and repair or replace if necessary.
Service limit:
0.020 mm (0.0008 in)
(6) Measure the widest point of the plastigauge

on each journal. If the oil clearance exceeds the
limit, replace the camshaft. If necessary, replace the camshaft caps and cylinder head as a
set.
Standard:
0.037 0.072 mm (0.0015 0.0028 in)
Service limit:
0.10 mm (0.0039 in)
ME-00118
2) Check the journal for damage and wear. Replace if faulty.

3) Check the cutout portion used for camshaft sensor for damage. Replace if faulty.
4) Measure the outside diameter of camshaft journal. If the journal diameter is not within the standard, check the oil clearance.
Front
Standard
Camshaft journal
Center, rear
37.946 37.963 mm
(1.4939 1.4946 in)
29.946 29.963 mm
(1.1790 1.1796 in)
5) Measurement of the camshaft journal oil clearance:

(1) Clean the bearing caps and camshaft journals.
(2) Place the camshafts on cylinder head.
(Without installing the valve lifter.)
(3) Place a plastigauge across each camshaft
journals.
(4) Gradually tighten the cap in at least two
stages in alphabetical sequence shown in the
figure, and then tighten to specified torque. Do
not turn the camshaft.
ME-00119
(7) Completely remove the plastigauge.

6) Check the cam face condition; remove the minor
faults by grinding with oil stone. Measure the cam
height H. Replace if it exceeds the limit.
Cam height H:
Standard:
Intake
46.55 46.65 mm (1.833 1.837 in)
Exhaust
46.75 46.85 mm (1.841 1.844 in)
Service limit:
Intake
46.45 mm (1.829 in)
Exhaust
46.65 mm (1.837 in)
Cam base circle diameter A:
37.0 mm (1.457 in)
Tightening torque:
T1: 9.75 Nm (1.0 kgf-m, 7.2 ft-lb)
T2: 20 Nm (2.0 kgf-m, 14.5 ft-lb)
(A)
T2
(E)
(C)
(F)
(D)
T1
(B)
ME-00774
(5) Remove the bearing caps.
ME(H4DOTC)-58
ME-00120
Camshaft
MECHANICAL
7) Measure the thrust clearance of camshaft with

setting the dial gauge at end of camshaft. If the
thrust clearance exceeds the limit, replace the caps
and cylinder head as a set. If necessary replace the
camshaft.
Standard:
0.068 0.116 mm (0.0027 0.0046 in)
Service limit:
0.14 mm (0.0055 in)
ME-00121
ME(H4DOTC)-59
Cylinder Head
MECHANICAL
19.Cylinder Head

hammer, separate it from cylinder block. Remove
the bolts (A) and (D) to remove cylinder head.
A: REMOVAL
NOTE:
when replacing a single part. Refer to Valve Clearance for preparation. <Ref. to ME(H4DOTC)-28,
INSPECTION, Valve Clearance.>
REMOVAL, V-belt.>
Cover.>
Belt.>
<Ref. to ME(H4DOTC)-52, REMOVAL, Cam
Sprocket.>
7) Remove the bolt which installs the A/C compressor bracket on cylinder head.
8) Remove the camshaft. <Ref. to ME(H4DOTC)54, REMOVAL, Camshaft.>
sequence shown in the figure.
Leave the bolts (A) and (D) engaged by three or
four threads to prevent the cylinder head from falling.
(D)
(F)
(A)
(B)
(E)
(C)
ME-00122
(D)
(F)
(A)
(B)
(E)
(C)
ME-00122

CAUTION:
12) Similarly, remove the cylinder head (RH).
B: INSTALLATION
1) Install the cylinder head and gaskets on cylinder
block.
CAUTION:
NOTE:
Use new cylinder head gaskets.
2) Tighten the cylinder head bolts.
(1) Apply a thin coat of engine oil to washer and
bolt thread.
(4) Loosen all the bolts by 180 in the reverse
order of tightening, and loosen again by 180.
sequence.
sequence.
CAUTION:
Do not tighten the bolts more than 45.
(8) Further tighten the bolts (A) and (B) by 40 to
45.
ME(H4DOTC)-60
Cylinder Head
MECHANICAL
CAUTION:
Make sure that the total re-tightening angle of
the previous steps (7) and (8) does not exceed
90.
(C)
(E)
(A)
(B)
(F)
(D)
ME-00123
C: DISASSEMBLY
1) Remove the valve lifter.
2) Compress the valve spring and remove the
valve spring retainer key. Remove each valve and
valve spring.
ST2 499718000 VALVE SPRING REMOVER
NOTE:
Mark each valve to prevent confusion.
Pay careful attention not to damage the lips of intake valve oil seals and exhaust valve oil seals.
Keep all the removed parts in order for re-installing in their original positions.
3) Install the camshaft. <Ref. to ME(H4DOTC)-55,

4) Install the A/C compressor bracket on cylinder
head.
Manifold.>
Sprocket.>
Pulley.>
ME(H4DOTC)-61
ST2
ST1
ME-00124
Cylinder Head
MECHANICAL
D: ASSEMBLY
(11)
(1)
(4)
(5)
(6)
(7)
(8)
(9)
(3)
(2)
(11)
(4)
(5)
(6)
(7)
(8)
(9)
(12)
(4)
(10)
(6)
(12)
(7)
(8)
(4)
(9)
(10)
(6)
(7)
(8)
(9)
ME-02583
(1)
Exhaust valve
(5)
(9)
Valve lifter
(2)
(3)
Intake valve
Cylinder head
(6)
(7)
Valve spring
Retainer
(10)
(11)

Intake valve guide
(4)
Valve spring seat
(8)
Retainer key
(12)
Exhaust valve guide
1) Installation of valve spring and valve:

(1) Coat the stem of each valve with engine oil
and insert the valve into valve guide.
NOTE:
When inserting the valve into valve guide, use special care not to damage the oil seal lip.
(2) Set the cylinder head on ST1.
(3) Install the valve spring and retainer using
ST2.
ST2 499718000 VALVE SPRING REMOVER
ME(H4DOTC)-62
Cylinder Head
MECHANICAL
NOTE:
Be sure to install the valve spring with its closecoiled end facing the seat on cylinder head.
ST2
2. VALVE SEAT
Inspect the intake and exhaust valve seats, and
correct the contact surfaces with a valve seat cutter
if they are defective or when valve guides are replaced.
Valve seat width: W
Intake
Standard:
0.6 1.4 mm (0.024 0.055 in)
Service limit:
1.7 mm (0.067 in)
ST1
ME-00124
(4) Compress the valve spring and install the

retainer key.
(5) After installing, tap the valve spring retainers
lightly with a wooden hammer for better seating.
2) Apply oil to the surfaces of the valve lifter.
3) Install the valve lifter.
Exhaust
Standard:
1.2 1.8 mm (0.047 0.071 in)
Service limit:
2.2 mm (0.087 in)
E: INSPECTION
1. CYLINDER HEAD
1) Visually check for cracks and damage. Use liquid penetrant tester on the important sections to
check for fissures.
2) Measure the warping of the cylinder head surface that mates with crankcase using a straight
edge (A) and thickness gauge (B).
If the warping exceeds 0.035 mm (0.0014 in), regrind the surface with a surface grinder.
Warping limit:
0.035 mm (0.0014 in)
Grinding limit:
0.3 mm (0.012 in)
ME-00127
3. VALVE GUIDE
1) Check the clearance between valve guide and
stem. The clearance can be checked by measuring
respectively the outer diameter of valve stem with a
micrometer and the inner diameter of valve guide
with a caliper gauge.
Clearance between the valve guide and valve
stem:
Standard height of cylinder head:

127.5 mm (5.02 in)
NOTE:
Uneven torque for the cylinder head bolts can
cause warping. When reinstalling, pay special attention to the torque so as to tighten evenly.
Standard:
Intake
0.030 0.057 mm (0.0012 0.0022 in)
Exhaust
0.040 0.067 mm (0.0016 0.0026 in)
Service limit:
0.15 mm (0.0059 in)
(A)
(B)
ME-00126
ME(H4DOTC)-63
Cylinder Head
MECHANICAL
2) If the clearance between valve guide and valve

stem exceeds the limit, replace the valve guide or
valve itself whichever shows greater amount of
wear. See the following procedure for valve guide
replacement.
Valve guide inner diameter:
6.000 6.012 mm (0.2362 0.2367 in)
Valve stem outer diameters:
Intake
5.955 5.970 mm (0.2344 0.2350 in)
Exhaust
5.945 5.960 mm (0.2341 0.2346 in)
(1) Place the cylinder head on ST1 with the
combustion chamber upward so that valve
guides fit the holes in ST1.
(2) Insert the ST2 into valve guide and press it
down to remove the valve guide.
ST2
ST1
ME-00128
(3) Turn the cylinder head upside down and

place the ST as shown in the figure.
ST 18251AA020 VALVE GUIDE ADJUSTER
ST
(5) Put a new valve guide, coated with sufficient

oil, in the cylinder head, and insert the ST1 into
valve guide. Press in until the valve guide upper
end is flush with the upper surface of ST2.
ST2 18251AA020 VALVE GUIDE ADJUSTER
ST1
ST2
ME-00130
(6) Check the valve guide protrusion.

Valve guide protrusion: L
15.8 16.2 mm (0.622 0.638 in)
(7) Insert the ST in valve guide, and rotate the
ST slowly clockwise while pushing it lightly.
Bring the ST back while rotating it clockwise.
(Reaming Work)
(8) After reaming, clean the valve guide to remove chips.
ST 499767400
VALVE GUIDE REAMER
NOTE:
Apply engine oil to the ST when reaming.
If the inner surface of valve guide is damaged,
the edge of ST should be slightly ground with oil
stone.
If the inner surface of valve guide becomes lustrous and the ST does not chip, use a new ST or
remedy the ST.
(9) Recheck the contact condition between
valve face and valve seat after replacing the
valve guide.
ME-00757
(4) Before installing a new valve guide, make

sure that neither scratches nor damages exist
on the inner surface of valve guide holes in cylinder head.
ME(H4DOTC)-64
Cylinder Head
MECHANICAL
4. INTAKE AND EXHAUST VALVE
5. VALVE SPRING
1) Inspect the flange and stem of valve, and replace if damaged, worn, or deformed. If H is less
than the specified limit, replace with a new valve.
1) Check the valve springs for damage, free length,

and spring constant. Replace the valve spring if it is
not within standard values presented in the table.
2) To measure the squareness of the valve spring,
stand the spring on a surface plate and measure its
deflection at the top of spring using a try square.
H:
Intake (A)
Standard:
1.0 1.4 mm (0.039 0.055 in)
Service limit:
0.8 mm (0.031 in)
Valve spring
47.32 mm (1.863 in)
Free length
Set
Exhaust (B)
Standard:
1.3 1.7 mm (0.057 0.067 in)
Service limit:
0.8 mm (0.031 in)
Tension/spring
height
Lift
Squareness
205 235 N (20.9 24.0 kgf,

46.1 52.8 lb) /36.0 mm (1.417
in)
426 490 N
(43.4 50.0 kgf, 95.8 110 lb)
/26.50 mm (1.041 in)
2.5, 2.1 mm (0.083 in) or less
(A)
ME-00132
(B)
ME-00758
2) Put a small amount of grinding compound on the

seat surface, and lap the valve and valve seat. Install a new valve oil seal after lapping.
NOTE:
It is possible to differentiate between the intake
valve and the exhaust valve by their overall length.
Valve overall length:
Intake (A)
104.4 mm (4.110 in)
Exhaust (B)
104.65 mm (4.120 in)
ME(H4DOTC)-65
Cylinder Head
MECHANICAL
6. INTAKE AND EXHAUST VALVE OIL

SEAL
3) Measure the inner diameter of valve lifter mating

surface on cylinder head.
1) For the following, replace the oil seal with a new

part.
See the procedure 2) and subsequent for replacement procedures.
When the lip is damaged.
When the spring is out of the specified position.
When readjusting the surfaces of intake valve
and valve sheet.
When replacing the intake valve guide.
2) Place the cylinder head on ST1.
3) Using the ST2, press-fit the oil seal.
ST2 498857100 VALVE OIL SEAL GUIDE
Inner diameter:
34.994 35.016 mm (1.3777 1.3786 in)
NOTE:
Apply engine oil to oil seal before press-fitting.
When press-fitting the oil seal, do not use a hammer or strike in.
The intake valve oil seal and exhaust valve oil
seal can be differentiated by colors.
ME-00135
NOTE:
If difference between outer diameter of valve lifter
and inner diameter of valve lifter mating part is over
the limit, replace the cylinder head.
Standard:
0.019 0.057 mm (0.0007 0.0022 in)
Service limit:
0.100 mm (0.0039 in)
Color of rubber part:

Intake [Gray]
Exhaust [Green]
ST2
ME-00133
7. VALVE LIFTER
1) Check the valve lifter visually.
2) Measure the outer diameter of valve lifter.
Outer diameter:
34.959 34.975 mm (1.3763 1.3770 in)
ME-00134
ME(H4DOTC)-66
Cylinder Block
MECHANICAL
20.Cylinder Block
12) Remove the drive plate. (AT model)

Lock the crankshaft using ST.
ST 498497100
CRANKSHAFT STOPPER
A: REMOVAL
NOTE:
Before conducting this procedure, drain the engine
oil completely.
REMOVAL, V-belt.>
Cover.>
Belt.>
<Ref. to ME(H4DOTC)-52, REMOVAL, Cam
Sprocket.>
<Ref. to ME(H4DOTC)-53, REMOVAL, Crank
Sprocket.>
8) Remove the generator and A/C compressor with
their brackets.
9) Remove the cylinder head.
<Ref. to ME(H4DOTC)-60, REMOVAL, Cylinder
Head.>
10) Remove the clutch disc and cover. <Ref. to CL12, REMOVAL, Clutch Disc and Cover.>
11) Remove the flywheel. (MT model)
<Ref. to CL-14, REMOVAL, Flywheel.>
ST 498497100
CRANKSHAFT STOPPER
ST
ME-00136
13) Remove the oil separator cover.

14) Remove the water by-pass pipe for heater.
15) Remove the oil filter. <Ref. to LU (H4SO)-24,
REMOVAL, Engine Oil Filter.>
16) Remove the oil cooler.
(G)
(A)
(H)
(B)
(H)
(C)
(F)
(G)
(D)
(E)
ME-02739
(A) Adapter (1)

(C) Adapter (2)
(D) Oil cooler
ST
ME-00778

(F) Plug
(G) Gasket
(H) O-ring
ME(H4DOTC)-67
Cylinder Block
MECHANICAL
18) Remove the oil pump from cylinder block.

NOTE:
pump.
Remove the oil pump from cylinder block using a
flat tip screwdriver.
CAUTION:
19) Removal of oil pan:

(1) Turn the cylinder block with #2 and #4 piston
sides facing upward.
(2) Remove the bolts which secure oil pan to
cylinder block.
(3) Insert an oil pan cutter blade between cylinder block-to-oil pan clearance and remove the
oil pan.
CAUTION:
of oil pan cutter.
20) Remove the oil strainer stay.
23) Remove the water pipe.
ME-00138
(2)
(1)
(3)
(4)
(6)
(4)
(3)
(5)
(4)
(2)
(3)
(1)
(8)
(4)
(7)
(3)
(1)
(2)
ME-02889
(1)
Service hole plug
(4)
Piston pin
(7)
Seal washer
(2)
(3)
Gasket
Snap ring
(5)
(6)
Service hole cover

O-ring
(8)
Washer
ME(H4DOTC)-68
Cylinder Block
MECHANICAL
24) Remove the service hole cover and service

hole plugs using a hexagon wrench [14 mm].
ME-00140
25) Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove
the piston snap ring by inserted the radio pincers
into the service hole of #1 and #2 cylinders.
ME-00141
26) Draw out the piston pin from #1 and #2 pistons

using ST.
ST 499097700
PISTON PIN REMOVER
NOTE:
Be careful not to confuse the original combination
of piston, piston pin and cylinder.
ST
ME-00142
27) Similarly remove the piston pins from #3 and #4

pistons.
28) Remove the bolts which connect cylinder block
on the side of #1 and #3 cylinders.
29) Loosen the bolts which connect cylinder block
on the side of #2 and #4 cylinders two or three
turns.
30) Set up the cylinder block so that #2 and #4 cylinders are on the upper side, then remove bolts
connecting the cylinder block.
ME(H4DOTC)-69
Cylinder Block
MECHANICAL
31) Separate the cylinder block (LH) and (RH).

NOTE:
When separating the cylinder block, do not allow
the connecting rod to fall or damage the cylinder
block.
(5)
(7)
(1)
(4)
(2)
(4)
(6)
(3)
(1)
(5)
ME-02890
(1)
(2)
Cylinder block
Rear oil seal
(4)
(5)
Crankshaft bearing
Piston
(3)
Crankshaft
(6)
Seal washer
32) Remove the rear oil seal.

33) Remove the crankshaft together with connecting rod.
34) Remove the crankshaft bearings from cylinder
block using a hammer handle.
NOTE:
Do not confuse the combination of crankshaft bearings. Press the bearing at the end opposite to locking lip.
35) Remove each piston from cylinder block using
wooden bar or hammer handle.
NOTE:
Be careful not to confuse the piston and cylinder
combination.
ME(H4DOTC)-70
(7)
Washer
Cylinder Block
MECHANICAL
B: INSTALLATION
(6)
(5)
(4)
(7)
(1)
(3)
(2)
(7)
(3)
(6)
(6)
ME-03021
(1)
Crankshaft bearing
(4)
Rear oil seal
(2)
(3)
Crankshaft
Cylinder block
(5)
(6)
O-ring
Seal washer
1) Remove oil on the mating surface of cylinder

block before installation. Apply a coat of engine oil
to the bearing and crankshaft journal.
2) Position the crankshaft and the O-ring on the #1
and #3 cylinder block.
(7)
Washer
3) Apply liquid gasket to the mating surface of #1

and #3 cylinder blocks, and position #2 and #4 cylinder blocks.
Liquid gasket:
equivalent
NOTE:
Do not allow liquid gasket to jut into O-ring grooves,
oil passages, bearing grooves, etc.
ME-00145
4) Apply a coat of engine oil to the washer and bolt

thread.
NOTE:
ME(H4DOTC)-71
Cylinder Block
MECHANICAL

bolts on the LH side (A D) in alphabetical order.
Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)

bolts on the RH side (E J) in alphabetical sequence.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
(A)
(E)
(D)
(J)
(G)
(B)
(C)
(I)
ME-00779

bolts on the RH side (E J) in alphabetical order.
Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
(E)
ME-00780

(A), (C): Angle tightening
Tightening angle:
90
(B), (D): Torque tightening
(J)
(G)
(I)
(H)
(F)
Tightening torque:
40 Nm (4.1 kgf-m, 29.6 ft-lb)
(H)
(F)
(A)
ME-00780

(D)
(B)
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
(C)
ME-00779
10) Tighten the cylinder block connecting bolts on

the RH side (E J) in alphabetical sequence.
(A)
Tightening angle:
90
(D)
(B)
(E)
(C)
ME-00779
(J)
(G)
(I)
(H)
(F)
ME-00780
ME(H4DOTC)-72
Cylinder Block
MECHANICAL
11) Tighten the 8 mm and 6 mm cylinder block connecting bolts on LH side (A H) in alphabetical sequence.
15) Position the upper rail gap at (C) in the figure.
Tightening torque:
(A) (G): 25 Nm (2.5 kgf-m, 18.1 ft-lb)
(H): 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
(C)
25
(G)
(C)
(E)
(A)
(B)
ME-02470
16) Align the upper rail spin stopper (E) to the side
hole (D) on the piston.
(D)
(D)
(E)
(F)
(H)
ME-00147
12) Apply a coat of engine oil to the oil seal periphery, then install the rear oil seal using ST1 and ST2.
NOTE:
Use a new rear oil seal.
ST1 499597100 CRANKSHAFT OIL SEAL
GUIDE
ST2 499587200 CRANKSHAFT OIL SEAL INSTALLER
(B)
ME-02471
17) Position the expander gap at (F) in the figure.
(A)
ST2
25
(F)
ST1
ME-00784
ME-00148
18) Position the lower rail gap at (G) in the figure.
(A) Rear oil seal

(B) Flywheel attaching bolt
(G)
13) Position the top ring gap at (A) or (B) in the figure.
14) Position the second ring gap at 180 on the reverse side the top ring gap.
35
180
ME-00785
(A)
NOTE:
Make sure the ring gaps do not face the same direction.
Make sure ring gaps are not within the piston
skirt area.
(B)
ME-00781
ME(H4DOTC)-73
Cylinder Block
MECHANICAL

Install the snap rings in the piston holes located opposite to the service holes in cylinder block before
positioning pistons to the cylinder.
NOTE:
Use new snap rings.
#3
#1
#4
(A)
#2
ME-00154
(A) Front side

(5)
(4)
(1)
(5)
(3)
(4)
(3)
(2)
(2)
(1)
ME-02426
(1)
Piston
(4)
Gasket
(2)
(3)
Piston pin
Snap ring
(5)
Service hole plug
20) Installing piston:

#2 cylinder side upward.
(2) Using the ST1, turn the crankshaft so that
#1 and #2 connecting rods are set at bottom
dead center.
ST1 499987500 CRANKSHAFT SOCKET

T: 70 (7.1, 51.4)
(3) Apply a coat of engine oil to the pistons and

cylinders and insert pistons in their cylinders using ST2.
ST2 498747300 PISTON GUIDE
ST1
ST2
ME-00157
ME(H4DOTC)-74
Cylinder Block
MECHANICAL
NOTE:
Face the piston front mark towards the front of the
engine.
(5) Apply liquid gasket around the service hole

plug.
Liquid gasket:
equivalent
(A)
ME-00786
(A) Front mark

ME-00160
21) Installing piston pin:

(1) Apply a coat of engine oil to ST3.
(2) Insert ST3 into the service hole to align the
piston pin hole and the connecting rod small
end.
ST3 499017100 PISTON PIN GUIDE
ST1
ST3
ME-00158
(3) Apply a coat of engine oil to piston pin, and

insert the piston pin into piston and connecting
rod through service hole.
(4) Using radio pincers, install the snap ring.
NOTE:
Use new snap rings.
ME-00159
ME(H4DOTC)-75
Cylinder Block
MECHANICAL
(6) Install the service hole plug and gasket.

NOTE:
Use a new gasket.
ME-00140
T2
(5)
T1
(6)
(3)
(4)
(7)
(2)
(1)
(3)
(2)
(1)
ME-02394
(1)
(2)
Piston
Piston pin
(5)
(6)
Service hole plug

Service hole cover
(3)
(4)
Snap ring
Gasket
(7)
O-ring

#4 cylinder side upward. Following the same
procedures as used for #1 and #2 cylinders, install the pistons and piston pins.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)

T1: 6.4 (0.65, 4.7)
T2: 70 (7.1, 51.4)
24) Install the oil strainer and O-ring.

Tightening torque:
10 Nm (1.0 kgf-m, 7 ft-lb)
25) Install the oil strainer stay.
NOTE:
Tighten the oil strainer stay together with the baffle
plate.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
ME(H4DOTC)-76
Cylinder Block
MECHANICAL

NOTE:
28) Install the flywheel. (MT model) <Ref. to CL-14,

INSTALLATION, Flywheel.>
ST 498497100
CRANKSHAFT STOPPER
Liquid gasket:
equivalent
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
ST
ME-00778
29) Install the drive plate. (AT model)

ST 498497100
CRANKSHAFT STOPPER
Tightening torque:
72 Nm (7.3 kgf-m, 53.1 ft-lb)
ME-00162
27) Apply liquid gasket to the mating surfaces and

the threaded portion of bolt (A) shown in the figure
(when reusing the bolt), and then install the oil separator cover.
NOTE:
Liquid gasket:
Mating surface
THREE BOND 1217G or equivalent
Bolt (A) thread (when reusing the bolt)
equivalent
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
ST
ME-00136
30) Install the clutch disc and cover. <Ref. to CL12, INSTALLATION, Clutch Disc and Cover.>
31) Installation of oil pump:
(1) Install a new oil seal using ST.
ST 499587100
OIL SEAL INSTALLER
NOTE:
Use a new front oil seal.
(A)
ME-02452
ME-00164
ME(H4DOTC)-77
Cylinder Block
MECHANICAL
(2) Apply liquid gasket to the matching surface

of oil pump.
Liquid gasket:
equivalent
(5) When reusing three bolts shown in the figure, apply liquid gasket to the bolt threads.
Liquid gasket:
equivalent
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
(A)
ME-00165
(A) O-ring
T
LU-02103
(3) Apply a coat of engine oil to the inside of oil

seal.
32) Install the service hole plug and gasket.

Tightening torque:
First: 12 Nm (1.2 kgf-m, 8.7 ft-lb)
Second: 12 Nm (1.2 kgf-m, 8.7 ft-lb)
NOTE:
When installing the water pump, tighten bolts in
two stages in alphabetical sequence as shown in
the figure.
Use a new gasket.
(B)
(C)
ME-00312
(A)
(4) Install the oil pump to cylinder block. Be

careful not to damage the oil seal during installation.
NOTE:
Align the flat surface of oil pumps inner rotor with
crankshaft before installation.
Use new O-rings and seals when installing the oil
pump.
(D)
(E)
(F)
CO-02121
33) Install the water by-pass pipe for heater.
ME(H4DOTC)-78
Cylinder Block
MECHANICAL
34) Install the oil cooler.

Sprocket.>
Sprocket.>
Pulley.>
Manifold.>
47) Install the generator and A/C compressor
brackets on cylinder head.
Tightening torque:
T1: 45 Nm (4.6 kgf-m, 33 ft-lb)
T2: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
T3: 54 Nm (5.3 kgf-m, 39 ft-lb)
(G)
(A)
(H)
T1
(B)
(H)
(C)
(F)
(G)
(D)
(E)
T2
T3
ME-02983
(A) Adapter (1)

(C) Adapter (2)
(D) Oil cooler
(F) Plug
(G) Gasket
(H) O-ring
35) Install the oil filter. <Ref. to LU (H4SO)-24, INSTALLATION, Engine Oil Filter.>
36) Install the water by-pass pipe between oil cooler and water pump.
NOTE:
Use new O-rings.
38) Install the cylinder head.
<Ref. to ME(H4DOTC)-60, INSTALLATION, Cylinder Head.>
39) Install the oil level gauge guide and tighten the
attaching bolt (left side).
40) Install the rocker cover and rocker cover gasket.
NOTE:
Use a new gasket.
ME(H4DOTC)-79
Cylinder Block
MECHANICAL
C: DISASSEMBLY
(1)
(2)
(2)
(5)
(4)
(3)
(6)
ME-02741
(1)
(2)
Connecting rod cap

(3)
(4)
Top ring
Second ring
1) Remove the connecting rod cap.

2) Remove the connecting rod bearing.
(5)
(6)
Oil ring
Snap ring
4) Remove the oil ring by hand.
NOTE:
Arrange the removed connecting rod, connecting
rod cap and bearing in order to prevent confusion.
3) Remove the piston rings using piston ring expander.
NOTE:
Arrange the removed piston rings in proper order to
prevent confusion.
D: ASSEMBLY
T
(3)
(1)
(1)
(2)
(4)
(5)
(8)
(6)
(7)
ME-02985
(1)
(5)
Second ring
(2)
(3)
Connecting rod
Connecting rod cap
(6)
(7)
Top ring
Snap ring
(4)
Oil ring
(8)
Side mark
ME(H4DOTC)-80

T: 52 (5.3, 38.4)
Cylinder Block
MECHANICAL
1) Apply oil to the surface of the connecting rod

bearings, and install the connecting rod bearings
on connecting rods and connecting rod caps.
2) Install the connecting rod on crankshaft.
3) Position each connecting rod with the marking
side facing forward.
4) Tighten the connecting rod cap with the connecting rod bolt. Make sure the arrow on connecting rod
cap faces the front during installation.
Tightening torque:
52 Nm (5.3 kgf-m, 38.4 ft-lb)
NOTE:
Each connecting rod has its own mating cap.
Make sure that they are assembled correctly by
checking their matching number.
When tightening the connecting rod nuts, apply
oil on the threads.
5) Install the oil ring upper rail, expander and lower
rail by hand.
6) Install the second ring and top ring using piston
ring expander.
E: INSPECTION
1. CYLINDER BLOCK
1) Visually check for cracks and damage. Use liquid penetrant tester on the important sections to
check for fissures.
2) Check the oil passages for clogging.
3) Inspect the crankcase surface that mates with
cylinder head for warping by using a straight edge,
and correct by grinding if necessary.
Warping limit:
0.025 mm (0.00098 in)
Grinding limit:
0.1 mm (0.004 in)
Standard height of cylinder block:
201.0 mm (7.91 in)
ME(H4DOTC)-81
Cylinder Block
MECHANICAL
2. CYLINDER AND PISTON

1) The cylinder bore size is stamped on the cylinder
block front upper surface.
NOTE:
Standard sized pistons are classified into two
grades, A and B. These grades should be used
as guide lines in selecting a standard piston.
Standard diameter:
A: 99.505 99.515 mm (3.9175 3.9179 in)
B: 99.495 99.505 mm (3.9171 3.9175 in)
NOTE:
Taper:
Standard:
0.015 mm (0.0006 in)
Service limit:
0.050 mm (0.0020 in)
Out-of-roundness:
Standard:
0.010 mm (0.0004 in)
Service limit:
0.050 mm (0.0020 in)
(A)
H1
#4
(B)
(A)
#5
H2
#1
(F)
#3
#2
(B)
(D)
H3
H4
(E) (C)
ME-00170
ME-00171
(A) Main journal size mark

(B) Cylinder block (RH) (LH) combination mark
(C) #1 cylinder bore size mark
(D) #2 cylinder bore size mark
(E) #3 cylinder bore size mark
(A) Piston pin direction

(B) Thrust direction
H1: 10 mm (0.39 in)
H2: 45 mm (1.77 in)
H3: 80 mm (3.15 in)
(F) #4 cylinder bore size mark
H4: 115 mm (4.53 in)
2) How to measure the inner diameter of each cylinder:

Measure the inner diameter of each cylinder in both
the thrust and piston pin directions at the heights as
shown in the figure, using a cylinder bore gauge.
3) When the 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 as shown in the figure. (Thrust direction)
ME(H4DOTC)-82
Cylinder Block
MECHANICAL
NOTE:
Piston grade point H:
38.2 mm (1.50 in)
Piston outer diameter:
Standard:
A: 99.505 99.515 mm (3.9175 3.9179
in)
B: 99.495 99.505 mm (3.9171 3.9175
in)
99.745 99.765 mm (3.9270 3.9278 in)
99.995 100.015 mm (3.9368 3.9376 in)
H
ME-00172
5) Calculate the clearance between cylinder and

piston.
NOTE:
(2) If the cylinder inner diameter exceeds the

limit after boring and honing, replace the cylinder block.
NOTE:
Immediately after reboring, the cylinder diameter
may differ from its real diameter due to temperature
rise. Thus, pay attention to this when measuring
the cylinder diameter.
Cylinder inner boring limit (diameter):
100.005 mm (3.9372 in)
3. PISTON AND PISTON PIN

1) Check the piston and piston pin for breaks,
cracks or wear. Replace if faulty.
2) Check the piston ring groove for wear and damage. Replace if faulty.
3) Measure the piston-to-cylinder clearance at
each cylinder. <Ref. to ME(H4DOTC)-82, CYLINDER AND PISTON, INSPECTION, Cylinder
Block.> If any of the clearances exceeds the limit,
replace the piston or bore the cylinder to use an
oversize piston.
4) Make sure that the piston pin can be inserted
into the piston pin hole with a thumb at 20C (68F).
Replace if faulty.
Standard clearance between piston pin and
hole in piston:
Standard:
0.004 0.008 mm (0.0002 0.0003 in)
Service limit:
0.020 mm (0.0008 in)
Cylinder to piston clearance at 20C (68F):

Standard:
0.010 0.010 mm (0.0004 0.0004 in)
Service limit:
0.030 mm (0.0012 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.
ME-00173
CAUTION:
When any of the cylinders needs reboring, all
other cylinders must be bored at the same time,
and replace to oversize pistons.
Do not perform boring on one cylinder only.
Nor replace an oversize piston for one cylinder
only.
ME-00174
ME(H4DOTC)-83
Cylinder Block
MECHANICAL
5) Check the snap ring installation groove (A) on

the piston for burr. If necessary, remove burr from
the groove so that the piston pin can lightly move.
2) Squarely place the piston ring and oil ring in cylinder using the piston, and measure the piston ring
gap with a thickness gauge.
Unit: mm (in)
Top ring
(A)
Piston
ring gap
Second
ring
Oil ring
rail
Standard
0.20 0.25
(0.0079 0.0098)
0.37 0.52
(0.015 0.020)
0.20 0.50
(0.0079 0.0197)
Limit
1.0 (0.039)
1.0 (0.039)
1.5 (0.059)
ME-00175
6) Check the piston pin snap ring for distortion,

cracks and wear.
4. PISTON RING
1) If the piston ring is broken, damaged or worn, or
if its tension is insufficient, or when the piston is replaced, replace the piston ring with a new part of
the same size as piston.
NOTE:
Marks that shows the installing direction are
shown on the end of top and second rings. Face
these marks upward when installing the rings to
piston.
Oil ring consists of the upper rail, expander and
lower rail. When installing the oil ring on piston, be
careful of each rails direction.
ME-00177
3) Fit the piston ring straight into the piston ring

groove, then measure the clearance between piston ring and piston ring groove with a thickness
gauge.
NOTE:
Before measuring the clearance, clean the piston
ring groove and piston ring.
Unit: mm (in)
(A)
(B)
(C)
Clearance
between piston ring and
piston ring
groove
Top ring
Second
ring
Standard
0.040 0.080
(0.0016
0.0031)
0.030 0.070
(0.0012
0.0028)
Limit
0.15 (0.0059)
0.15 (0.0059)
(A)
(B)
(C)
ME-00178
ME-02472
(A) Upper rail

(B) Expander
(C) Lower rail
ME(H4DOTC)-84
Cylinder Block
MECHANICAL
5. CONNECTING ROD
1) Replace the connecting rod, if the large or small
end thrust surface is damaged.
2) Check for bend or twist using a connecting rod
aligner. Replace the connecting rod if the bend or
twist exceeds the limit.
Limit of bend or twist per 100 mm (3.94 in) in
length:
0.10 mm (0.0039 in)
(A)
4) Inspect the connecting rod bearing for scar,

peeling, seizure, melting, wear, etc.
5) Measure the oil clearance on each connecting
rod bearing using plastigauge. If any oil clearance
is not within specification, replace the defective
bearing with a new part of standard size or undersize as necessary. (See the table below.)
Connecting rod oil clearance:
Standard:
0.017 0.045 mm (0.0007 0.0018 in)
Service limit:
0.05 mm (0.0020 in)
Unit: mm (in)
(B)
Bearing
Standard
0.03
(0.0012)
undersize
0.05
(0.0020)
undersize
0.25
(0.0098)
undersize
(A)
(B)
ME-00179
(A) Thickness gauge

(B) Connecting rod
3) Install the connecting rod fitted with bearing to

the crankshaft and measure the side clearance
(thrust clearance) using a thickness gauge. Replace the connecting rod if the side clearance exceeds the specified limit.
Connecting rod side clearance:
Standard:
0.070 0.330 mm (0.0028 0.0130 in)
Service limit:
0.4 mm (0.016 in)
ME-00180
ME(H4DOTC)-85
Bearing size
(Thickness at
center)
1.490 1.502
(0.0587 0.0591)
51.984 52.000
(2.0466 2.0472)
1.504 1.512
(0.0592 0.0595)
51.954 51.970
(2.0454 2.0461)
1.514 1.522
(0.0596 0.0599)
51.934 51.950
(2.0447 2.0453)
1.614 1.622
(0.0635 0.0639)
51.734 51.750
(2.0368 2.0374)
Outer diameter of
crank pin
Cylinder Block
MECHANICAL
6) Inspect the bushing at connecting rod small end,

and replace with a new part if worn or damaged.
7) Measure the piston pin clearance at connecting
rod small end. Replace it with a new part if the limit
has been exceeded.
Clearance between piston pin and bushing:
Standard:
0 0.022 mm (0 0.0009 in)
Service limit:
0.030 mm (0.0012 in)
(4) After completion of reaming, clean the bushing to remove chips.
6. CRANKSHAFT AND CRANKSHAFT

BEARING
1) Clean the crankshaft completely, and check for
cracks by means of red lead check etc. If faulty, replace with new a new crankshaft.
2) Measure the bend of crankshaft. If it exceeds the
limit, correct or replace it.
NOTE:
If a suitable V-block is not available, use only a #1
and #5 crankshaft bearings on cylinder block, and
position the crankshaft on cylinder block. Then,
measure the crankshaft bend using a dial gauge.
Crankshaft bend limit:
0.035 mm (0.0014 in)
ME-00181
ME-00183
ME-00174
8) The replacement procedure for the connecting

rod small end bushing is as follows.
(1) Remove the bushing from connecting rod
with ST and press.
(2) Press the bushing with the ST after applying
oil on the periphery of new bushing.
ST 499037100
CONNECTING ROD BUSHING REMOVER AND INSTALLER
ST
ME-00182
(3) Make two 3 mm (0.12 in) holes in the

pressed bushing according to the pre-manufactured holes on the connecting rod to ream the
inside of bushing.
ME(H4DOTC)-86
Cylinder Block
MECHANICAL
3) Inspect the crank journal and crank pin for wear.

If they are not within the specification, replace the
bearing with a suitable (undersize) one, and replace or grind to correct the crankshaft as necessary. When grinding the crank journal or crank pin,
finish them to the specified dimensions according
to the undersize bearing to be used.
Crank journal:
Out-of-roundness:
0.005 mm (0.0002 in)
Cylindricality:
0.006 mm (0.0002 in)
Grinding limit:
To 59.758 mm (2.3527 in) dia.
Crank pin:
Out-of-roundness:
0.003 mm (0.0001 in)
Cylindricality:
0.004 mm (0.0002 in)
Grinding limit:
To 51.750 mm (2.0374 in) dia.
ME-00184
Unit: mm (in)
#1, #3
#2, #4, #5
Standard
0.03 (0.0012)
undersize
0.05 (0.0020)
undersize
0.25 (0.0098)
undersize
Journal O.D.
59.992 60.008
(2.3619 2.3625)
59.992 60.008
(2.3619 2.3625)
51.984 52.000
(2.0466 2.0472)
Bearing size
(Thickness at
center)
1.998 2.011
(0.0787 0.0792)
2.000 2.013
(0.0787 0.0793)
1.490 1.502
(0.0587 0.0591)
Journal O.D.
59.962 59.978
(2.3607 2.3613)
59.962 59.978
(2.3607 2.3613)
51.954 51.970
(2.0454 2.0461)
Bearing size
(Thickness at
center)
2.017 2.020
(0.0794 0.0795)
2.019 2.022
(0.0795 0.0796)
1.504 1.512
(0.0592 0.0595)
Journal O.D.
59.942 59.958
(2.3599 2.3605)
59.942 59.958
(2.3599 2.3605)
51.934 51.950
(2.0447 2.0453)
Bearing size
(Thickness at
center)
2.027 2.030
(0.0798 0.0799)
2.029 2.032
(0.0799 0.0800)
1.514 1.522
(0.0596 0.0599)
Journal O.D.
59.742 59.758
(2.3520 2.3527)
59.742 59.758
(2.3520 2.3527)
51.734 51.750
(2.0368 2.0374)
Bearing size
(Thickness at
center)
2.127 2.130
(0.0837 0.0839)
2.129 2.132
(0.0838 0.0839)
1.614 1.622
(0.0635 0.0639)
ME(H4DOTC)-87
Cylinder Block
MECHANICAL
4) Use a thickness gauge to measure the thrust

clearance of crankshaft at center bearing. If the
clearance exceeds the limit, replace the bearing.
Crankshaft thrust clearance:
Standard:
0.030 0.115 mm (0.0012 0.0045 in)
Service limit:
0.25 mm (0.0098 in)
ME-00313
5) Inspect individual crankshaft bearings for signs

of flaking, seizure, melting and wear.
6) Measure the oil clearance on each crankshaft
bearing using plastigauge. If the measured value
exceeds the limit, replace the defective bearing
with an undersize one, and replace or readjust the
crankshaft if necessary.
Crankshaft oil clearance:
Standard:
0.010 0.030 mm (0.0004 0.0012 in)
Service limit:
0.040 mm (0.0016 in)
ME(H4DOTC)-88
Intake and Exhaust Valve

MECHANICAL
21.Intake and Exhaust Valve

A: SPECIFICATION
Refer to 19. Cylinder Head for work relating to the
intake and the exhaust valves.
Head.> <Ref. to ME(H4DOTC)-60, INSTALLATION, Cylinder Head.>
ME(H4DOTC)-89
Piston
MECHANICAL
22.Piston
A: SPECIFICATION
Refer to 20. Cylinder Block for work relating to the
piston.
Block.> <Ref. to ME(H4DOTC)-71, INSTALLATION, Cylinder Block.>
ME(H4DOTC)-90
Connecting Rod
MECHANICAL
23.Connecting Rod
A: SPECIFICATION
connecting rods.
ME(H4DOTC)-91
Crankshaft
MECHANICAL
24.Crankshaft
A: SPECIFICATION
crankshaft.
ME(H4DOTC)-92

MECHANICAL
25.Engine Trouble in General

A: INSPECTION
NOTE:
RANK shown in the chart refers to the possibility of the cause of trouble in order Very often to Rarely
A Very often
B Sometimes
C Rarely
Symptoms
1. Engine does not start.
1) Starter does not turn.
Problem parts etc.

Starter
Battery
Excessive friction
2) Initial combustion does

not occur.
Possible cause
RANK
Defective battery-to-starter harness

Defective starter switch
B
C
Defective inhibitor switch or neutral switch

Defective starter
C
B
Improper connection of terminal

Run-down battery
A
A
Defective charging system

Seizure of crankshaft and connecting rod bearing
B
C
Seized camshaft
Seized or stuck piston and cylinder
C
C
Starter
Defective starter
Engine control system <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.>
C
A
Fuel line

Clogged fuel line
A
C
Timing belt

Degradation, etc.
B
B
Compression
Defective timing
B
C

Loosened cylinder head bolt or defective head gasket
C
C

C
C

B
C

B
B
ME(H4DOTC)-93

MECHANICAL
Symptoms
3) Initial combustion occurs.
Problem parts etc.
RANK
A
B

B
C
Clogged fuel line

C
B
Timing belt
Degradation, etc.
Defective timing
B
B
Compression

C
C

C
C

C
B

C
B
Fuel line
4) Engine stalls after initial

combustion.
Possible cause

Intake system

B
A
Intake system

B
C

C
B

B
C
Fuel line
Clogged fuel line

C
B
Timing belt
Degradation, etc.
Defective timing
B
B
Compression

C
C

C
C

C
B

C
B
ME(H4DOTC)-94

MECHANICAL
Symptoms
2. Rough idle and engine
stall
Problem parts etc.
Possible cause

Intake system
RANK
A
A

A
A

B
B
Defective PCV valve

C
B

C
C
Clogged fuel line

C
B
Defective timing
C
B

B
B

B
C

B
B

A
B
Lubrication system

B
C
Cooling system
Others
Overheating
C
A

Accelerator cable out of adjustment
B
C
Fuel line
Timing belt
Compression
ME(H4DOTC)-95

MECHANICAL
Symptoms
3. Low output, hesitation and
poor acceleration
Problem parts etc.
RANK
A
A

A
B

B
B
Defective PCV valve

B
B

A
B
Clogged fuel line

B
C
Defective timing
B
B

B
B

B
C

B
C

A
B
Lubrication system
Cooling system

Overheating
B
C
Others
Over-cooling
C
A
Fuel line
Timing belt
Compression
4. Surging
Possible cause

Intake system

Intake system
A
A

A
A

B
B
Defective PCV valve

B
B

B
B
Clogged fuel line

B
C
Defective timing
B
B

C
C

C
C

C
C

A
B
Cooling system
Overheating
Others
Fuel line
Timing belt
Compression
ME(H4DOTC)-96

MECHANICAL
Symptoms
5. Engine does not return to
idle.
6. Dieseling (Run-on)
7. After burning in exhaust

system
Problem parts etc.
Others
A
B

Accelerator cable out of adjustment

Cooling system
Overheating
A
B
Others
B
A
Intake system

C
C

Defective PCV valve
B
B

Defective timing
C
B

B
C

C
B

C
C

C
A

Over-cooling
C
C
Compression
Lubrication system
Cooling system
9. Excessive engine oil

consumption
RANK
A
A
Timing belt
8. Knocking
Possible cause

Intake system
Others
C
A
Intake system
Timing belt

Defective timing
B
B
Compression

C
B
Cooling system
Intake system
Overheating
A
A
Defective PCV valve

B
C
Compression

A
A
Lubrication system
Loosened oil pump attaching bolts and defective

gasket
Defective oil filter o-ring
B
B
Defective crankshaft oil seal

B
B
Loosened oil drain plug or defective gasket

Loosened oil pan fitting bolts or defective oil pan
B
B
ME(H4DOTC)-97

MECHANICAL
Symptoms
10. Excessive fuel
consumption
Problem parts etc.
Possible cause
RANK

Intake system
A
A
Timing belt
Compression
Defective timing
B
B

C
C

B
C

C
B
Lubrication system

B
C
Cooling system
Over-cooling
ME(H4DOTC)-98
Engine Noise
MECHANICAL
26.Engine Noise
A: INSPECTION
Type of sound
Regular clicking sound
Condition
Sound increases as engine
speed increases.
Oil pressure is low.
Heavy and dull clank

Oil pressure is normal.
High-pitched clank
Sound is noticeable when

accelerating with an overload
condition.
Clank when engine speed is

1,000 to 2,000 rpm

injector connector of noisy
cylinder is disconnected.
(NOTE*)
Knocking sound when engine

is operating under idling speed
and engine is warm
Squeaky sound

injector connector of noisy
cylinder is disconnected.
(NOTE*)
Sound is not reduced if each
fuel injector connector is
disconnected in turn. (NOTE*)
Possible cause
Valve mechanism is defective.

Incorrect valve clearance adjustment
Worn camshaft
Broken valve spring
Worn camshaft main bearing
Loosened flywheel mounting bolt
Damaged engine mounting
Ignition timing advanced

Accumulation of carbon inside combustion chamber
Wrong heat-durability spark plug
Improper octane value gasoline
Worn camshaft main bearing
Worn cylinder liner and piston ring

Broken or stuck piston ring
Worn piston pin and hole at piston end of connecting rod
Unusually worn valve lifter
Worn cam sprocket
Worn camshaft journal bore in cylinder head assembly
Insufficient generator lubrication
Rubbing sound
Gear scream when starting
engine
Sound like polishing glass with
a dry cloth
Hissing sound
Timing belt noise
Loose timing belt

Belt contacting with case/adjacent part
Valve noise
Poor contact of generator brush and rotor

Defective ignition starter switch
Worn gear and starter pinion
Loose drive belt
Defective water pump shaft
Insufficient compression
Air leakage in air intake system, hose, connection or manifold
NOTE*)
When disconnecting the fuel injector connector, the malfunction indicator light illuminates and DTC is stored in ECM memory.
Therefore, perform the Clear Memory Mode and Inspection Mode after connecting the fuel injector connector. <Ref. to
EN(H4DOTC)(diag)-50, OPERATION, Clear Memory Mode.> <Ref. to EN(H4DOTC)(diag)-38, PROCEDURE, Inspection
Mode.>
ME(H4DOTC)-99
Engine Noise
MECHANICAL
ME(H4DOTC)-100
General Description
EXHAUST
A: COMPONENT
1. FRONT EXHAUST PIPE
(16)
T2
T3
(1)
T1
(2)
T3
(17)
(3)
(15)
T1
A
(14)
(11)
T5
T4
(4)
(5)
(12)
(6)
(18)
(20)
(7)
(13)
T2
T2
T3
(8)
(10)
(7)
(9)
(19)
T3
T4
T1
T1
EX(H4DOTC)-2
EX-02155
General Description
EXHAUST
(1)
(2)
Gasket
Exhaust manifold upper cover
(RH)
(10)
(11)
Front exhaust pipe lower cover

Gasket
(3)
Exhaust manifold (RH)
(12)
(13)
Exhaust manifold inner cover (LH)

Exhaust manifold outer cover (LH) Tightening torque: Nm (kgf-m, ft-lb)
(4)
Exhaust manifold lower cover

(RH)
(14)
(15)
Gasket
Turbocharger joint pipe
T1: 7.5 (0.8, 5.5)

T2: 19 (1.9, 14.0)
(5)
(6)

Front exhaust pipe upper insulator
(RH)
(16)
(17)
Gasket
T3: 35 (3.6, 26.0)

T4: 40 (4.0, 28.9)
(18)
(19)
Exhaust manifold (LH)

Front exhaust pipe lower insulator
(LH)
T5: <Ref. to FU(H4DOTC)-40,

INSTALLATION, Front Oxygen
(A/F) Sensor.>
(7)
Gasket
(8)
Front exhaust pipe
(9)
Front exhaust pipe lower insulator

(RH)
EX(H4DOTC)-3
(20)
Front exhaust pipe upper insulator

(LH)
General Description
EXHAUST
2. CENTER AND REAR EXHAUST PIPE, AND MUFFLER

(5)
(23)
(22)
T5
(21)
(4)
(20)
(16)
(17)
(19)
(23)
(18)
T5
(4)
(15)
(13)
T6
A
(11)
(9)
T4
A
(8)
(1)
(7)
(3)
T2
(14)
T4
T3
(2)
(10)
T4
T1
(12)
T1
T4
T1
(6)
EX-02137
(1)
(2)
Gasket
(12)
Lower rear catalytic converter

cover
(22)
(23)
(3)
(4)
Center exhaust pipe (Front)

Self-locking nut
(13)
(14)
Rear oxygen sensor

(5)
(6)
Muffler cutter
Bracket
(15)
(16)
Gasket
Rear exhaust pipe
T1: 13 (1.3, 9.6)

T2: 18 (1.8, 13.0)
(7)
(8)
Gasket
Center exhaust pipe (Rear)
(17)
(18)
Chamber
Cushion
T3: 30 (3.1, 22.4)

T4: 35 (3.6, 26.0)
(9)
(10)
Center pipe upper cover (Rear)

Center pipe lower cover (Rear)
(19)
(20)
Spring
Bolt
(11)
Upper rear catalytic converter

cover
(21)
Gasket
T5: 48 (4.9, 35.4)

T6: <Ref. to FU(H4DOTC)-43,
INSTALLATION, Rear Oxygen
Sensor.>
EX(H4DOTC)-4
Muffler
Cushion
General Description
EXHAUST
B: CAUTION
Be careful not to burn your hands, because each
part on the vehicle is hot after running.
points.
battery.
EX(H4DOTC)-5
Front Exhaust Pipe

EXHAUST
2. Front Exhaust Pipe

A: REMOVAL
8) While holding the front exhaust pipe assembly

with one hand, remove the nuts which hold the front
exhaust pipe assembly to cylinder head exhaust
port.
EX-00004
FU-00009

4) Remove the front oxygen (A/F) sensor. <Ref. to
FU(H4DOTC)-40, REMOVAL, Front Oxygen (A/F)
Sensor.>
6) Remove the exhaust manifold lower cover (RH)
and the exhaust manifold cover (LH).
EX-00005
9) Remove the front exhaust pipe assembly.

10) Remove the covers from exhaust manifold and
front exhaust pipe.
11) Separate the front exhaust pipe from exhaust
manifolds.
EX-00246
7) Remove the nuts which hold front exhaust pipe

assembly onto turbocharger joint pipe.
EX-00245
EX(H4DOTC)-6
Front Exhaust Pipe

EXHAUST
B: INSTALLATION
NOTE:
Use a new gasket.
1) Install the front exhaust pipe and the exhaust
manifold.
6) Install the exhaust manifold lower cover (RH)

and the exhaust manifold cover (LH).
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
Tightening torque:
35 Nm (3.6 kgf-m, 26.0 ft-lb)
EX-00246
EX-00245
2) Install the front exhaust pipe cover.
7) Install the front oxygen (A/F) sensor. <Ref. to

FU(H4DOTC)-40, INSTALLATION, Front Oxygen
(A/F) Sensor.>
9) Connect the ground cable to battery.
Tightening torque:
7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
3) Install the exhaust manifold upper cover (RH).
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
4) Install the front exhaust pipe assembly.
Tightening torque:
35 Nm (3.6 kgf-m, 26.0 ft-lb)
5) Connect the exhaust manifold (RH) to turbocharger joint pipe.
FU-00009
Tightening torque:
T1: 35 Nm (3.6 kgf-m, 26.0 ft-lb)
T2: 40 Nm (4.0 kgf-m, 28.9 ft-lb)
T2
T1
EX-00070
T2
T2
EX-00071
EX(H4DOTC)-7
Center Exhaust Pipe

EXHAUST
3. Center Exhaust Pipe
11) Remove the bolts which install the upper side

of turbocharger upper cover, and remove it.
A: REMOVAL
5) Remove the intercooler bracket.
EX-00011
12) Separate the center exhaust pipe from turbocharger.
EX-00007

8) Remove the bolts which install the lower side of
turbocharger upper cover.
CAUTION:
Be careful, the turbocharger and exhaust pipe
are hot.
EX-00012

14) Disconnect the connector from rear oxygen
sensor.
EX-00009
FU-00081

10) Remove the turbocharger upper cover.
15) Vertically draw out clip from crossmember.
EX-00010
EX(H4DOTC)-8
FU-00082
Center Exhaust Pipe

EXHAUST
16) Separate the center exhaust pipe from rear exhaust pipe.
EX-02081

pipe bracket to transmission.
B: INSTALLATION
NOTE:
Use a new gasket.
1) Install the center exhaust pipe and temporarily
tighten the bolt which holds center exhaust pipe to
hanger bracket.
2) Temporarily tighten the bolt which holds the center pipe to transmission.
3) Connect the center exhaust pipe to turbocharger.
Tightening torque:
35 Nm (3.6 kgf-m, 26.0 ft-lb)
EX-00012
EX-00014
18) Remove the intercooler bracket.

pipe to hanger bracket.
4) Install the center exhaust pipe to rear exhaust

pipe.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
CAUTION:
Be careful not to pull down the center exhaust
pipe.
EX-02081
5) Connect the connector to rear oxygen sensor.

EX-00043
FU-00081
EX-00016
EX(H4DOTC)-9
Center Exhaust Pipe

EXHAUST
6) Secure clip on the crossmember.
11) Position the turbocharger lower cover, and

tighten the bolts which install the upper side of lower cover.
Tightening torque:
7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
FU-00082

bracket to transmission.
Tightening torque:
30 Nm (3.1 kgf-m, 22.4 ft-lb)
EX-00011
12) Position the turbocharger upper cover, and

tighten the bolts which install the upper side of upper cover.
Tightening torque:
7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
EX-00014

to hanger bracket.
Tightening torque:
35 Nm (3.6 kgf-m, 26.0 ft-lb)
EX-00017

14) Tighten the bolts which install the under side of
turbocharger upper cover.
Tightening torque:
7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
EX-00043
9) Tighten the bolts which hold the intercooler

bracket.
Tightening torque:
35 Nm (3.6 kgf-m, 26.0 ft-lb)
EX-00009
EX(H4DOTC)-10
Center Exhaust Pipe

EXHAUST
15) Install the universal joint.

(1) Align the bolt hole on the long yoke side of
universal joint with the cutout at the serrated
section of shaft end, and then insert the universal joint.
(2) Align the bolt hole on the short yoke side of
universal joint with the cutout on the serrated
section of gearbox assembly. Lower the universal joint completely.
(3) Temporarily tighten the bolt of short yoke
side. Raise the universal joint to make sure the
bolt is properly passing through the cutout at
the serrated section.
(4) Tighten the long yoke side bolt, and also
tighten the short yoke side bolt.
Tightening torque:
24 Nm (2.4 kgf-m, 17.4 ft-lb)
CAUTION:
Make sure the universal joint bolts are tightened through the shaft serration notches.
Excessively large tightening torque of universal joint bolts may lead to heavy steering
wheel operation.
Standard clearance between gearbox and DOJ:
EX-00008

18) Install the intercooler bracket.
EX-00007
19) Install the intercooler. <Ref. to IN(H4DOTC)11, INSTALLATION, Intercooler.>

20) Align the center of the roll connector. <Ref. to
AB-20, ADJUSTMENT, Roll Connector.>
EX(H4DOTC)-11
Joint Pipe
EXHAUST
4. Joint Pipe
B: INSTALLATION
A: REMOVAL

NOTE:
Use a new gasket.
Tightening torque:
T: 35 Nm (3.6 kgf-m, 26.0 ft-lb)
T
FU-00009

4) Remove the front oxygen (A/F) sensor. <Ref. to
FU(H4DOTC)-40, REMOVAL, Front Oxygen (A/F)
Sensor.>
6) Remove the exhaust manifold lower cover (RH).
EX-00247
7) Remove the nuts which hold the front exhaust

manifold to joint pipe.
EX-00018

9) Remove
the
turbocharger.
<Ref.
to
IN(H4DOTC)-13, REMOVAL, Turbocharger.>
10) Take off the joint pipe in the upward direction.
EX(H4DOTC)-12
EX-00019
Rear Exhaust Pipe

EXHAUST
5. Rear Exhaust Pipe
7) Remove the rear exhaust pipe from cushion rubber.
A: REMOVAL
EX-02126
FU-00009

4) Separate the rear exhaust pipe from center exhaust pipe.
CAUTION:
Be careful, exhaust pipe is hot.
EX-02132
5) Separate the rear exhaust pipe from muffler.

CAUTION:
Be careful not to pull down the rear exhaust
pipe.
EX-00020

EX(H4DOTC)-13
Rear Exhaust Pipe

EXHAUST
B: INSTALLATION
5) Connect the ground cable to battery.
NOTE:
after reassembling.
1) Install the rear exhaust pipe to cushion rubber.
FU-00009
C: INSPECTION
leaks.
EX-02126
2) Install the rear exhaust pipe to muffler.

Tightening torque:
48 Nm (4.9 kgf-m, 35.4 ft-lb)
EX-00020
3) Install the rear exhaust pipe to center exhaust

pipe.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
EX-02132
EX(H4DOTC)-14
Muffler
EXHAUST
6. Muffler
B: INSTALLATION
A: REMOVAL

3) Separate the muffler from rear exhaust pipe.
NOTE:
after reassembling.
CAUTION:
Be careful, exhaust pipe is hot.
Tightening torque:
48 Nm (4.9 kgf-m, 35.4 ft-lb)
EX-00020

5) Remove the cushion rubber, and detach the
muffler.
CAUTION:
Be careful not to drop the muffler during removal.
EX-00020
C: INSPECTION
leaks.
EX-00022
EX(H4DOTC)-15
Muffler
EXHAUST
EX(H4DOTC)-16
General Description
COOLING
A: SPECIFICATION
Specifications for the turbo model are included in
the CO (H4SO) section. <Ref. to CO(H4SO)-2,
General Description.>
CO(H4DOTC)-2
General Description
LUBRICATION
A: SPECIFICATION
the LU (H4SO) section. <Ref. to LU (H4SO)-2,
LU(H4DOTC)-2
General Description
A: SPECIFICATION
Specifications for the turbo model are the same as
in the SP (H4SO) section. <Ref. to SP (H4SO)-2,
SP(H4DOTC)-2
General Description
IGNITION
A: SPECIFICATION
Item
Specification
Type
Ignition system
Ignition coil
FK0186
Independent ignition coil
Manufacturer
Manufacturer and type
Diamond Electric
NGK: ILFR6B
Thread diameter, pitch,

length
Spark plug
mm
Spark plug gap

Electrode
mm (in)
14, 1.25, 26.5

0.7 0.8 (0.028 0.031)
Iridium
B: COMPONENT
T2
T1
(2)
(1)
T1
(1)
(2)
T2
IG-00001
(1)
Spark plug
(2)
Ignition coil

T1: 21 (2.1, 15.2)
T2: 16 (1.6, 11.7)
IG(H4DOTC)-2
General Description
IGNITION
C: CAUTION
points.
the battery.
IG(H4DOTC)-3
Spark Plug
IGNITION
2. Spark Plug
A: REMOVAL
Spark plug:
<Ref. to IG(H4DOTC)-2, SPECIFICATION,
1. RH SIDE
IG-00004
2. LH SIDE
1) Disconnect the ground cable from battery and
remove the battery and battery carrier.
FU-00009

Case.>
FU-00009

3) Remove the secondary air pump.
<Ref. to EC (H4DOTC)-9, REMOVAL, Secondary
Air Pump.>
FU-01307
5) Remove the ignition coil.
FU-01308
5) Remove the ignition coil.
IG-00003
IG-00008
IG(H4DOTC)-4
Spark Plug
IGNITION
C: INSPECTION
Check the electrodes and inner and outer ceramic
insulator of plugs, noting the type of deposits and
the degree of electrode erosion.
(A)
(B)
(C)
IG-00009
B: INSTALLATION
(D)
(E)
1. RH SIDE
IG-00010
(A) Spark plug gap
Tightening torque:
Spark plug
21 Nm (2.1 kgf-m, 15.2 ft-lb)
Ignition coil
16 Nm (1.6 kgf-m, 11.7 ft-lb)
(B) Carbon accumulation or wear

(C) Crack
(D) Damage
(E) Damaged gasket
NOTE:
threads.
1) Normal:
Brown to grayish-tan deposits and slight electrode
wear indicate correct spark plug heat range.
2. LH SIDE
Tightening torque:
Spark plug
21 Nm (2.1 kgf-m, 15.2 ft-lb)
Ignition coil
16 Nm (1.6 kgf-m, 11.7 ft-lb)
IG-00011
NOTE:
threads.
2) Carbon fouled:
Dry fluffy carbon deposits on insulator and electrode are mostly caused by slow speed driving in
the city, weak ignition, too rich fuel mixture, dirty air
cleaner, etc.
IG-00012
IG(H4DOTC)-5
Spark Plug
IGNITION
3) Oil fouled:
Wet black deposits show oil entrance into combustion chamber through worn rings or increased
clearance between valve guides and stems.
IG-00013
4) Overheating:
White or light gray insulator with black or brown
spots and bluish burnt electrodes indicate engine
overheating, incorrect ignition timing, improper fuel, or loose spark plugs.
IG-00014
D: ADJUSTMENT
Clean the spark plugs using a wire brush.
Clean and remove the carbon or oxide deposits.
But do not wear away ceramic insulator at this time.
If deposits are too stubborn, replace the spark
plugs.
After cleaning the spark plugs, measure the spark
plug gap using a gap gauge.
NOTE:
Do not use a plug cleaner because the spark plugs
are applied with iridium tip.
Spark plug gap: L
0.7 0.8 mm (0.028 0.031 in)
IG-00091
IG(H4DOTC)-6
Ignition Coil
IGNITION
3. Ignition Coil
A: REMOVAL
Direct ignition type has been adopted. Refer to
Spark Plug, REMOVAL for removal procedures.
<Ref. to IG(H4DOTC)-4, REMOVAL, Spark Plug.>
B: INSTALLATION
Tightening torque:
16 Nm (1.6 kgf-m, 11.7 ft-lb)
C: INSPECTION
For inspection procedures, refer to Diagnostics for
Engine Start Failure. <Ref. to EN(H4DOTC)(diag)64, IGNITION CONTROL SYSTEM, Diagnostics
for Engine Starting Failure.>
IG(H4DOTC)-7
Ignition Coil
IGNITION
IG(H4DOTC)-8
General Description
A: SPECIFICATION
the SC (H4SO) section. <Ref. to SC (H4SO)-2,
SC(H4DOTC)-2


A: PROCEDURE
NOTE:
If the malfunction indicator light illuminates when Subaru Select Monitor or general scan tool is connected,
perform the following procedures.
1. Disconnect Subaru Select Monitor or general scan tool from the vehicle.
If the malfunction indicator light turns off, the Subaru Select Monitor or general scan tool may be faulty. Connect a different Subaru Select Monitor or general scan tool, and if malfunction indicator light remains off, delete the DTC. <Ref. to EN(H4DOTC)(diag)-50, Clear Memory Mode.>
1
Step
Check
CHECK ENGINE START FAILURE.
EN(H4DOTC)(diag)-3, CHECK, Check List for
Interview.>
CHECK ILLUMINATION OF MALFUNCTION Does the malfunction indicator

INDICATOR LIGHT.
light illuminate?
CHECK INDICATION OF DTC ON THE DISPLAY.

4) Read the DTC on Subaru Select Monitor or
general scan tool.
PERFORM DIAGNOSIS.
EN(H4DOTC)(diag)-50, Clear Memory Mode.>
EN(H4DOTC)(diag)-38, Inspection Mode.>
Is DTC displayed on the Subaru

tool?
Is DTC displayed on the Subaru

tool?
EN(H4DOTC)(diag)-2
Yes
Go to step 2.
No
Inspection using
Diagnostics for
Engine Start Failure. <Ref. to
EN(H4DOTC)(diag
)-58, Diagnostics
for Engine Starting
Failure.>
Go to step 3.
Inspection using
General Diagnostic Table. <Ref. to
EN(H4DOTC)(diag
)-400, General
Diagnostic Table.>
Repair the trouble Perform the diagcause. <Ref. to
nosis of the malEN(H4DOTC)(diag function indicator
)-70, List of Diag- light circuit or the
nostic Trouble
combination meter.
Code (DTC).> Go <Ref. to
to step 4.
EN(H4DOTC)(diag
)-54, Malfunction
Indicator Light.>
Repair the trouble Finish the diagnocause. <Ref. to
sis.
EN(H4DOTC)(diag
)-70, List of Diagnostic Trouble
Code (DTC).>


A: CHECK
1. CHECK LIST NO. 1
Check the following item when problem has occurred.
NOTE:
Customers name
Date of purchase
Engine No.
Fuel brand
Date of repair
V.I.N.
Odometer reading
Weather
Fine
Cloudy
Rainy
Snowy
Various/Others:
Place
Engine temperature
km
miles
C (F)
Hot
Warm
Cool
Cold
Highway
Suburbs
Inner city
Uphill
Downhill
Rough road
Others :
Cold
Warming-up
After warming-up
Any temperature
Others :
Engine speed
Vehicle speed
rpm
MPH
Driving conditions
Not affected
At starting
While idling
At racing
While accelerating
While cruising
While decelerating
While turning (RH/LH)
Headlight
Blower
ON /
ON /
OFF
OFF
Rear defogger
Radio
ON /
ON /
OFF
OFF
A/C compressor
Radiator fan
ON /
ON /
OFF
OFF
CD/Cassette
Car phone
ON /
ON /
OFF
OFF
Front wiper
Rear wiper
ON /
ON /
OFF
OFF
Wireless device
ON /
OFF
EN(H4DOTC)(diag)-3

2. CHECK LIST NO. 2

Check the following item about the vehicles state when malfunction indicator light turns on.
NOTE:
a) Other warning lights or indicators turn on.
Yes /
No

AT diagnostic indicator light
ABS warning light
b) Fuel level
Lack of gasoline:
Yes /
No
Indicator position of fuel gauge:
Experienced running out of fuel:
Yes /
No
c) Intentional connecting or disconnecting of harness connectors or spark plug cords:
What:
d) Intentional connecting or disconnecting of hoses:
What:
e) Installing of other parts except genuine parts:
What:
Where:
Yes /
Yes /
Yes /
Yes /
No
No
No
From where:
What kind:
g) Occurrence of smell:
Yes /
No
From where:
What kind:
h) Intrusion of water into engine compartment or passenger compartment:
Yes /
i) Troubles occurred
Engine stalls during idling.
Engine stalls while driving.
Engine speed decreases.
Engine speed does not decrease.
Rough idling
Poor acceleration
Back fire
After fire
Does not shift.
EN(H4DOTC)(diag)-4
No
No
General Description
A: CAUTION
1) Airbag system wiring harness is routed near the
ECM, main relay and fuel pump relay.
CAUTION:
All airbag system wiring harness and connectors are all colored yellow. Do not use the
electrical test equipment on these circuits.
wiring harness when servicing the ECM, TCM,
main relay and fuel pump relay.
The ECM will be destroyed instantly.
The fuel injector and other parts will be damaged.
engine is running.
electronic parts such as ECM etc.
sensor and ECM, be sure to turn the ignition switch
to OFF.
5) Poor contact has been identified as a primary
cause of this problem. Measure the voltage or resistance of individual sensor or all electrical control
modules using 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) into the part.
6) Remove the ECM from the located position after
disconnecting two cables on battery.
Otherwise, the ECM may be damaged.
CAUTION:
the wrong spec. ECM to avoid damaging the
fuel injection system.
7) Connectors of each sensor in the engine compartment and the harness connectors on the engine side and body side are all designed to be
waterproof. Even if the connectors are waterproof,
take care not to allow water to get into them when
washing the vehicle, or when servicing the vehicle
in rainy weather.
8) Use ECM mounting stud bolts as the body head
grounding point when measuring voltage and resistance in the passenger compartment.
9) Use the engine ground terminal or engine assembly as the grounding point to chassis when
measuring the voltage and resistance in engine
compartment.
10) Every MFI-related part is a precision part. Do
not drop them.
11) Observe the following cautions when installing
a radio in MFI equipped models.
CAUTION:
The antenna must be kept as far apart as possible from control unit. (The ECM is located under the steering column, inside of instrument
panel lower trim panel.)
The antenna feeder must be placed as far
apart as possible from the ECM and MFI harness.
Carefully adjust the antenna for correct
matching.
When mounting a large power type radio, pay
special attention to the three items mentioned
above.
Incorrect installation of the radio may affect
the operation of ECM.
12) Release fuel pressure before disconnecting the
fuel hose. <Ref. to FU(H4DOTC)-49, RELEASING
OF FUEL PRESSURE, PROCEDURE, Fuel.>
13) For the model with ABS, the ABS warning light
may illuminate when performing driving test with
jacked-up or lifted-up condition, but this is not a
system malfunction. The reason for this is the
speed difference between the front and rear
wheels. After diagnosis of engine control system,
perform the ABS memory clear procedure of selfdiagnosis function.
B: INSPECTION
Before performing diagnostics, check the following
item which might affect engine problems.
1. BATTERY
1) Measure the battery voltage and specific gravity
of electrolyte.
Standard voltage:
12 V
Specific gravity:
1.260 or more
2) Check the condition of the main and other fuses,
and harnesses and connectors. Also check for
proper grounding.
2. ENGINE GROUND
Make sure the engine ground terminal is properly
connected to the engine.
EN(H4DOTC)(diag)-5
ME-00476
General Description
C: NOTE
2. ENGINE AND EMISSION CONTROL SYSTEM
The on-board diagnosis (OBD) system detects
and indicates a fault in various inputs and outputs
of the complex electronic control. Malfunction indicator light in the combination meter indicates occurrence of a fault or trouble.
Further, against such a failure or sensors as may
disable the drive, the fail-safe function is provided
to ensure the minimal drive ability.
The OBD system incorporated with the vehicles
within this type of engine complies with OBD-II regulations. The OBD system monitors the components and the system malfunction listed in Engine
Section which affects on emissions.
When the system decides that a malfunction occurs, malfunction indicator light illuminates. At the
same time of the malfunction indicator light illumination or blinking, a DTC and a freeze frame engine conditions are stored into on-board computer.
The OBD system stores freeze frame engine
condition data (engine load, engine coolant temperature, fuel trim, engine speed and vehicle
speed, etc.) into on-board computer first when it
detects a malfunction.
If the OBD system detects the various malfunctions including the fault of fuel trim or misfire, the
OBD system first stores freeze frame engine conditions about the fuel trim or misfire.
When the malfunction does not occur again for
three consecutive driving cycles, malfunction indicator light is turned off, but DTC remains at onboard computer.
When troubleshooting the vehicle which complies with OBD-II regulations, connect the Subaru
Select Monitor or general scan tool to the vehicle.
The Multipoint Fuel Injection (MFI) system is a

system that supplies the optimum air-fuel mixture
to the engine for all the various operating conditions through the use of the latest electronic technology.
With this system fuel, which is pressurized at a constant pressure, is injected into the intake air passage of the cylinder head. The injection quantity of
fuel is controlled by an intermittent injection system
where the electro-magnetic injection valve (fuel injector) opens only for a short period of time, depending on the quantity of air required for one cycle
of operation. In actual operation, the injection quantity is determined by the duration of an electric
pulse applied to the fuel injector and this permits
simple, yet highly precise metering of the fuel.
Furthermore, all operating conditions of the engine are converted into electronic signals, and this
enables additional system features with greatly improved adaptability, making it easier to add compensation features.
The MFI system also has the following features:
Reduced emission of harmful exhaust gases.
Reduction in fuel consumption.
Increased engine output.
Superior acceleration and deceleration.
Superior start ability and warm-up performance in cold weather since compensation is
made for coolant and intake air temperature.
EN(H4DOTC)(diag)-6
General Description
D: PREPARATION TOOL
ILLUSTRATION
TOOL NUMBER
1B020XU0
TOOL NAME
SUBARU SELECT
MONITOR KIT
REMARKS
CRANKSHAFT
SOCKET
Used for rotating the crankshaft.
ST1B020XU0
499987500
ST-499987500
EN(H4DOTC)(diag)-7


A: LOCATION
1. ENGINE
Control module
(1)
(4)
(1)
(2)

(3)
(3) (2)
EN-00155
Test mode connector
(4)
Data link connector
(2)
EN-00156
EN-00157
(3 )
EN-00158
EN(H4DOTC)(diag)-8
(4)
EN-00236

Sensor
(8)
(5)
(2)
(7)
(1)
(3)
(6)
(9)
(4)
(5)
(8)
EN-03854
(1)
(2)

(3)
(4)
(5)
Knock sensor
(8)
Tumble generator valve position

sensor
(6)
(7)

Mass air flow and intake air temperature sensor
(9)
Secondary air pressure sensor
EN(H4DOTC)(diag)-9

(3)
(2)
(1)
EN-00295
EN-02009
(5)
(4)
EN-00297
EN-01798
(6)
(7)
EN-00299
(8)
EN-00300
(9)
EN-00301
EN(H4DOTC)(diag)-10
EN-03855

(1)
(2)
(3)
(4)
EN-03863
(1)
(2)

(3)
Rear oxygen sensor
(4)
(1)
(2)
EN-00303
EN-03858
(3)
(4)
EN-03859
EN(H4DOTC)(diag)-11
EN-03860

(1)
(3)
(2)
(4)
EN-00165
(1)
(2)
Fuel level sensor

(3)
(4)
(3)
(1)
(2)
EN-03852
EN-00168
EN(H4DOTC)(diag)-12
EN-03853

Solenoid valve, actuator, emission control system parts and ignition system parts
(1)
(7) (8)
(3)
(5)
(4)
(9) (2)
(6)
(4)
(5)
(3)
EN-04779
(1)
(2)
Wastegate control solenoid valve

(5)
(6)

Secondary air pump
(8)

switching valve (LH)
(3)
(4)
Ignition coil
Tumble generator valve actuator
(7)

switching valve (RH)
(9)
EN(H4DOTC)(diag)-13

(1)
(9)
(2)
EN-04780
EN-04111
(4)
(3)
EN-01805
EN-01806
(5)
(6)
EN-02011
(7)
(8)
EN-03857
EN(H4DOTC)(diag)-14
EN-04112

(1)
(2)
(3)
EN-03861
(1)
(2)
Canister
(3)
Drain valve
(2)
(1)
EN-02866
(3)
EN-02868
EN(H4DOTC)(diag)-15
EN-03015

(1)
(8) (7)
(6)
(3)
(4)
(5)
(2)
(9)
EN-04113
(1)
(2)
Inhibitor switch
Fuel pump
(4)
(5)
Fuel pump relay

(7)
(8)
Radiator sub fan relay

Fan mode relay
(3)
Main relay
(6)
Radiator main fan relay
(9)
Starter
(2)
EN-00178
EN-03862
(8)
(4) (3)
(5)
EN-03017
(9)
EN-02096
EN(H4DOTC)(diag)-16
(7)
(6)
EN-03678

2. TRANSMISSION
Solenoid valve and switch (MT vehicles)
EN-00192
(1)
EN(H4DOTC)(diag)-17

5. Engine Control Module (ECM) I/O Signal

To B135
To B134
7 6 5 4 3
17 16 15 14 13 12 11
27 26 25 24 23 22 21
34 33
32 31
2 1
10 9 8
20 19 18
30 29 28
To B137
To B136
7 6 5 4 3
2 1
19 18 17 16 15 14 13 12 11 10 9 8
27 26
25 24
23 22 21 20
35 34
33 32
31 30 29 28
6 5
4 3 2 1
16 15 14 13 12 11 10 9 8 7
27 26 25 24 23 22 21 20 19 18 17
30 29 28
35 34 33 32 31
7 6 5 4 3 2 1
17 16 15 14 13 12 11 10 9 8
25 24
23 22 21 20 19 18
31 30
29 28
27 26
EN-01812
Contents
Connector
No.
Terminal
No.
Signal (V)
Ignition SW ON
(engine OFF)
Engine ON (idling)
Note
Crankshaft
position
sensor
Signal (+)
Signal ()
B134
B134
13
14
0
0
7 +7
0
Shield
Signal
B134
B135
24
4
0
0
0
0 0.9
Rear oxygen
sensor
Shield
GND
(sensor)
Signal 1
B135
B135
30
B136
0 1.0
Signal 2
B136
0 1.0
Front
oxygen (A/F)
sensor
heater
Rear oxygen sensor heater

signal
Engine cool- Signal
ant tempera- GND
ture sensor
(sensor)
B136
0 1.0
B134
34
1.0 1.4
1.0 1.4
B134
29
B136
13
0 or 5
0 or 5
5 and 0 are repeatedly

displayed when vehicle is
driven.
B135
B135
26
35
0.3 4.5
0
B135
34
B135
18
0.3 4.6
0.3 4.6
Signal
B134
26
Fully closed: 3.8 4.9

Fully open: 0.2 0.9
Power supply
GND
(sensor)
B134
19
B134
29
Air flow sensor
Signal
Shield
GND
signal
Tumble generator valve
position sensor RH
EN(H4DOTC)(diag)-18

Signal (V)
Connector
No.
Terminal
No.
Signal
B134
16
Power supply
B134
19
Fully closed: 3.8 4.9

Fully open: 0.2 0.9
5
5
GND
(sensor)
B134
29
B137
22
0 or 10 13
0 or 12 14
B137
23
0 or 10 13
0 or 12 14
B137
12
0 or 10 13
0 or 12 14
B137
13
0 or 10 13
0 or 12 14
Wastegate control solenoid

valve
B137
27
0 or 10 13
0 or 12 14
Starter switch
B136
32
B136
24
Ignition switch
B135
19
0
ON: 12 14
OFF: 0
12 14
Cranking: 8 14
A/C switch
0
ON: 10 13
OFF: 0
10 13
ON: 12 14
OFF: 0
13 14
When connected: 0
Contents
Tumble generator valve

position sensor LH
Tumble generator valve RH

(open)
Tumble generator valve RH
(close)
Tumble generator valve LH
(open)
Tumble generator valve LH
(close)
Ignition SW ON
(engine OFF)
Engine ON (idling)
Note
B135
27
ON: 10 13
OFF: 0
10 13
Signal
Shield
B134
B134
15
25
2.8
0
2.8
0
Back-up power supply
B135
10 13
12 14
Ignition switch OFF:

10 13
Control module power supply
B134
B135
7
2
10 13
10 13
12 14
12 14
Sensor power supply

#1
B134
B137
19
18
5
0
5
12 14
Waveform
#2
#3
B137
B137
19
20
0
0
12 14
12 14
Waveform
Waveform
#4
#1
B137
B137
21
8
0
10 13
12 14
1 14
Waveform
Waveform
#2
#3
B137
B137
9
10
10 13
10 13
1 14
1 14
Waveform
Waveform
#4
Signal 1
B137
B136
11
12
10 13
0 or 5
1 14
0 or 5
Waveform
Signal 2
B135
33
B136
Radiator fan relay 1 control
B136
18
12 14
ON: 0.5 or less
OFF: 12 14
ON: 0.5 or less
OFF: 12 14
A/C relay control
10 13
ON: 0.5 or less
OFF: 10 13
ON: 0.5 or less
OFF: 10 13
Radiator fan relay 2 control
B136
29
ON: 0.5 or less

OFF: 10 13
ON: 0.5 or less

OFF: 12 14
Model with A/C only
B136
11
Light ON: 1 or less

Light OFF: 10 14
Engine speed output
B136
22
B137
29
ON: 1 or less
OFF: 10 13
0 13 or more
ON: 1 or less
OFF: 12 14
B136
31
Test mode connector

Knock
sensor
Ignition
control
Fuel injector
Fuel pump
control unit
EN(H4DOTC)(diag)-19
Waveform

Contents
2
Signal
Manifold
absolute
pressure
sensor
Connector
No.
Terminal
No.
B136
B134
Signal (V)
Ignition SW ON
(engine OFF)
Engine ON (idling)
ON: 1 or less
OFF: 10 13
1.7 2.4
ON: 1 or less
OFF: 12 14
1.1 1.6
B134
19
Note
Power supply
GND
(sensor)
Signal
B134
29
B135
32
2.3 2.7
2.3 2.7
Power supply
B135
22
B135
30
B136
28
ON: 1 or less
OFF: 10 13
ON: 1 or less
OFF: 12 14
Drain valve
B136
17
ON: 1 or less
OFF: 10 13
ON: 1 or less
OFF: 12 14
Fuel level sensor

Fuel temperature sensor signal
B135
10
0.12 4.75
0.12 4.75
B135
17
2.5 3.8
2.5 3.8
Blow-by leak diagnosis signal
B134
30
Small light switch
B135
15
ON: 0
OFF: 10 13
ON: 0
OFF: 12 14
Blower fan switch
B135
16
ON: 0
OFF: 10 13
ON: 0
OFF: 12 14
B135
14
ON: 0
OFF: 10 13
B134
33
10 13
ON: 0
OFF: 12 14
ON: 0
OFF: 12 14
B135
2.8 3.2
2.8 3.2
B135
2.4 2.7
2.4 2.7

shield
B135
SSM/GST communication
line
B136
16
1 4
1 4
Ground (engine 4)
Ground (ignition system 1)
B137
B137
1
26
0
0
0
0
Ground (ignition system 2)

Ground (engine 3)
B137
B137
6
2
0
0
0
0
Ground (engine 1)
Ground (engine 5)
B134
B137
5
3
0
0
0
0
Ground (engine 2)
(LH)
B137
B134
21
0 0.9
0
ON: 0
OFF: 4.7 5.3
B134
11
0 0.9
Fuel tank
pressure
sensor
GND
(sensor)
Pressure control solenoid
valve
Power steering oil pressure

switch
signal (+)
signal ()

(RH)
ON: 0
OFF: 4.7 5.3
EN(H4DOTC)(diag)-20
The valve operates when

fuel filler cap is removed
and reinstalled.
Ambient temperature:
25C (77F)
At the time of open circuit
(fault): 5


Connector
No.
Terminal
No.
Main
B134
Sub
Contents
Signal (V)
Note
Ignition SW ON
(engine OFF)
Engine ON (idling)
18
0.64 0.72
Fully opened: 3.96
0.64 0.72
(After engine is
warmed-up.)
Fully closed: 0.6

Fully opened: 3.96
B134
28
1.51 1.58
Fully opened: 4.17
1.51 1.58
(After engine is
warmed-up.)
Fully closed: 1.48

Fully opened: 4.17
B134
19
B134
29
B137
Duty waveform
Duty waveform
Electronic throttle control

motor ()
B137
Duty waveform
Duty waveform

motor power supply
B136
10 13
12 14

motor relay
B136
21
ON: 10 13
OFF: 0
0
ON: 12 14
OFF: 0
0
ON: 10 13
OFF: 0
ON: 12 14
OFF: 0
0
Fully closed: 1
Fully opened: 3.5
0
Fully closed: 1
Fully opened: 3.5
Electronic
throttle
control
Power supply
Ground
(sensor)
motor (+)
Oil flow control solenoid

(LH)
Signal (+)
B137
15
Signal ()
B137
14
Oil flow control solenoid

(RH)
Signal (+)
B137
17
Signal ()
Main sensor
signal
B137
16
B135
23
Main power
supply
B135
21
GND
(main sensor)
B135
29
B135
31
Fully closed: 1
Fully opened: 3.5
Fully closed: 1
Fully opened: 3.5
B135
22
B135
30
Main light
B135
ON: 0
OFF: 10 13
ON: 0
OFF: 12 14
Cruise control set light
B135
ON: 0
OFF: 10 13
ON: 0
OFF: 12 14

depressed: 0
released: 10 13
When clutch pedal

is depressed: 0
When clutch pedal
is released: 12
14
ON: 10 13
OFF: 0
When brake pedal is
depressed: 0
When brake pedal is
released: 10 13
ON: 12 14
OFF: 0
When brake pedal is
depressed: 0
When brake pedal is
released: 12 14
Accelerator
pedal position sensor
Sub sensor
signal
Sub power
supply
Ground
(Sub sensor)
Clutch switch
B136
25
SET/COAST switch
B135
24
Brake switch 1
B135
20
EN(H4DOTC)(diag)-21

Contents
Connector
No.
Terminal
No.
Signal (V)
Ignition SW ON
(engine OFF)
Engine ON (idling)
When brake pedal is When brake pedal is

depressed: 10 13 depressed: 12 14
When brake pedal is When brake pedal is
released: 0
released: 0
ON: 10 13
ON: 12 14
OFF: 0
OFF: 0
Note
Brake switch 2
B135
28
Main switch
B135
12
CAN commu- Signal (+)

nication
Signal ()
B136
B136
27
35
Secondary
air piping
pressure
sensor
B134
27
1.7 2.4
1.1 1.6
B134
19
B134
29
Secondary air combination

valve relay 1
B136
30
ON: 0
OFF: 10 13
ON: 0
OFF: 12 14
Secondary air combination

valve relay 2
B136
19
ON: 0
OFF: 10 13
ON: 0
OFF: 12 14
B136
ON: 0
OFF: 10 13
ON: 0
OFF: 12 14
Signal
Power
supply
GND
(sensor)
Secondary air pump relay
Pulse signal
Pulse signal
EN(H4DOTC)(diag)-22
Engine Condition Data

6. Engine Condition Data

Content
Specification
17.6 35.64 (%): Idling
13.2 26.73 (%): 2,500 rpm racing
Engine load
Measuring condition:
Gear position is in neutral.
Turn the A/C off.
Turn all the accessory switches to OFF.
EN(H4DOTC)(diag)-23
Data Link Connector

7. Data Link Connector

A: NOTE
This connector is used for the general scan tool and the Subaru Select Monitor.
CAUTION:
Do not connect any scan tools other than general scan tools and the Subaru Select Monitor, because
the circuit for the Subaru Select Monitor may be damaged.
9 10 11 12 13 14 15 16
EN-04893
Terminal No.
Content
Terminal No.
Content
1
2
Empty
Empty
9
10
Empty
Empty
3
4
Empty
Ground
11
12
Empty
Empty
5
6
Ground
CAN (+)
13
14
Empty
CAN ()
7
8
Subaru select monitor/General scan tool signal

Empty
15
16
Empty
Power supply
EN(H4DOTC)(diag)-24
General Scan Tool

8. General Scan Tool

A: OPERATION
1. HOW TO USE GENERAL SCAN TOOL
1) Prepare a scan tool (general scan tool) required
by SAE J1978.
2) Open the cover and connect the general scan
tool to the data link connector located in the lower
portion of instrument panel (on the drivers side).
EN-00334
3) Using the general scan tool, call up DTC and

freeze frame data.
General scan tool functions consist of:
(1) MODE $01: Current power train diagnostic
data
(2) MODE $02: Powertrain freeze frame data
(3) MODE $03: Emission-related powertrain
DTC
(4) MODE $04: Clear/Reset emission-related
diagnostic information
test results for intermittently monitored systems
test results for continuously monitored systems
(7) MODE $09: Request vehicle information
Read data according to repair procedures. (For detailed operation procedure, refer to the general
scan tool instruction manual.)
NOTE:
EN(H4DOTC)(diag)-70, List of Diagnostic Trouble
Code (DTC).>
EN(H4DOTC)(diag)-25
General Scan Tool

2. MODE $01 (CURRENT POWERTRAIN DIAGNOSTIC DATA)

Refer to data denoting the current operating condition of analog input/output, digital input/output or the powertrain system.
PID
03
Data
Number of emission-related powertrain DTC and malfunction indicator light status and diagnosis support information
04
05

%
C
06
07

Long term fuel trim
%
%
0B
0C

Engine speed
0D
0E
Vehicle speed
km/h
0F
10

C
g/sec
11
12

Secondary air control status
13
15
Check whether oxygen sensor is installed.

1C
1F

21
24

A/F value and A/F sensor output voltage
2E
2F
Evaporative purge
Fuel level
%
%
30
31
Number of warm ups after DTC clear

km
32
33
Fuel tank pressure

34
3C
A/F value and A/F sensor current

Catalytic temperature#1
41
42

ECM power voltage
43
44
Absolute load
A/F target lambda
45
46

Ambient temperature
%
C
47
49

%
%
4A
4C

%
%
4D
4E
Engine operating time during malfunction indicator illuminates

51
5A
Fuel used
01
Unit of measure
mmHg
rpm
V and %
sec
km
and V
mmHg
mmHg
and mA
C
min
min
NOTE:
Refer to general scan tool manufacturers instruction manual to access generic OBD-II PIDs (MODE $01).
EN(H4DOTC)(diag)-26
General Scan Tool

3. MODE $02 (POWERTRAIN FREEZE FRAME DATA)

Refer to data denoting the operating condition when trouble is detected by on-board diagnosis system.
PID
02
Data
DTC that caused CARB required freeze frame data storage
Unit of measure
03
04

05
06

C
%
07
0B
Long term fuel trim

0C
0D
Engine speed
Vehicle speed
0E
0F

10
11

12
13
Secondary air control status

Air fuel ratio sensor
15
1C
Oxygen sensor output voltage and oxygen sensor short term fuel trim
1F
2E

Evaporative purge
2F
32
Fuel level
Fuel tank pressure
%
mmHg
33
42
ECM power voltage
mmHg
V
43
44
Absolute load
A/F target lambda
45
46

Ambient temperature
%
C
47
49

%
%
4A
4C

%
%
%
mmHg
rpm
km/h
C
g/sec
%
V and %
sec
%
NOTE:
Refer to general scan tool manufacturers instruction manual to access freeze frame data (MODE $02).
4. MODE $03 (EMISSION-RELATED POWERTRAIN DTC)

Refer to Read Diagnostic Trouble Code (DTC) for information about data denoting emission-related powertrain DTC. <Ref. to EN(H4DOTC)(diag)-37, Read Diagnostic Trouble Code (DTC).>
5. MODE $04 (CLEAR/RESET EMISSION-RELATED DIAGNOSTIC INFORMATION)

Refer to the mode used to clear or reset emission-related diagnostic information (OBD-II trouble diagnostic
information).
NOTE:
Refer to general scan tool manufacturers instruction manual to clear the emission-related diagnostic information (MODE $04).
EN(H4DOTC)(diag)-27
General Scan Tool

6. MODE $06
Refer to the test value of troubleshooting and data of test specification on the support data bit sequence table. A list of the support data is shown in the following table.
OBDMID
TID
SID
$81
$82
$0A
$8D
$83
$84
$14
$1E
$85
$86
$1E
$20
$87
$88
$0B
$0B
$07
$0B
$08
$A5
$0B
$0B
$05
$06
$10
$10
Oxygen Sensor Response Abnormal (Bank 1 Sensor 2)
$21
$39
$89
$93
$20
$FE
Catalyst Degradation Diagnosis (Bank 1)

Evaporative Emission Control System Leak Detected (Cap off)
$3B
$94
$95
$FE
$FE
Evaporative Emission Control System (0.04 inch leak)
$3C
$96
$97
$FE
$FE
Evaporative Emission Control System (0.02 inch leak)
$3D
$98
$99
$FE
$24
$41
$9A
$9B
$24
$14
$42
$9C
$9D
$24
$24
Oxygen Sensor Heater Abnormal (Bank 1 Sensor 1)
$A1
$0B
$0C
$24
$24
Misfire Monitoring (All cylinders)
$A2
$0B
$0C
$24
$24
Misfire Monitoring (#1 cylinder)
$A3
$0B
$0C
$24
$24
$A4
$0B
$0C
$24
$24
$A5
$0B
$0C
$24
$24
$E1
$A6
$FE
Purge Control Solenoid Valve 2 Stock Closed
$01
$02
Diagnostic item
A/F Sensor Conduction Abnormal (Bank 1 Sensor 1)
A/F Sensor Range Abnormal (Bank 1 Sensor 1)

A/F Sensor Response Abnormal (Bank 1 Sensor 1)
Oxygen Sensor Circuit Abnormal (Bank 1 Sensor 2)
Oxygen Sensor Drop Abnormal (Bank 1 Sensor 2)
Evaporative Emission Control System Leak Detected (purge flow)

A/F Sensor Heater Abnormal (Bank 1 Sensor 1)
A/F Sensor Heater Characteristics Abnormal (Bank 1 Sensor 1)
7. MODE $07
Refer to the data of DTC (pending code) for troubleshooting result about emission in the first time.
8. MODE $09
Refer to the data of vehicle specification (V.I.N., calibration ID, etc.).
EN(H4DOTC)(diag)-28


A: OPERATION
1. HOW TO USE SUBARU SELECT MONITOR
EN(H4DOTC)(diag)-7, PREPARATION TOOL,
link connector.
side).
EN-00334

connector.
CAUTION:
Do not connect any scan tools except the Subaru Select Monitor or the general scan tool.
5) Using the Subaru Select Monitor, call up DTC
and data, then record them.

(DTC) FOR ENGINE (NORMAL MODE)
EN(H4DOTC)(diag)-37, Read Diagnostic Trouble
Code (DTC).>

(DTC) FOR ENGINE (OBD MODE)
EN(H4DOTC)(diag)-37, Read Diagnostic Trouble
Code (DTC).>
EN(H4DOTC)(diag)-29

4. READ CURRENT DATA FOR ENGINE (NORMAL MODE)

1) On the Main Menu display screen, select {Each System Check}.
2) On the System Selection Menu display screen, select {Engine Control System}.
4) On the Engine Diagnosis display screen, select {Current Data Display/Save}.
5) On the Data Display Menu screen, select {Data Display}.
Content
Display
Engine load
Engine Load
Coolant Temp.
A/F correction #1
A/F learning #1
A/F Correction #1
A/F Learning #1
Engine speed signal
Engine Speed
Meter vehicle speed signal
Meter Vehicle Speed
Ignition Timing

Intake Air Temp.

Mass Air Flow
Throttle opening angle signal

Rear oxygen sensor voltage
Unit of
measure
Note (at idling)
%
C or F
21.0%
80 100C or 176 212F
%
%
10 +10%
15 +15%
mmHg, kPa, 220 275 mmHg, 29.5 37 kPa,

inHg or psig
8.7 10 inHg or 4.2 5.3 psig
rpm
km/h or
MPH
deg
700 rpm (Agree with the

tachometer indication)
0 km/h or 0 MPH (at parking)
+17.0 deg
C or F
g/s or lb/m
20 50C or 68 122F
3.6 g/s or 0.48 lb/m

Rear O2 Sensor
%
V
3.0 3.2%
0 1.0 V
Battery voltage
Mass air flow voltage
Battery Voltage
Air Flow Sensor Voltage
V
V
12 15 V
1.0 1.7 V
Injection 1 pulse width
Fuel Injection #1 Pulse
1.2 2.2 ms
Mani. Relative Pressure
ms
mmHg, kPa,
inHg or psig
mmHg, kPa,
inHg or psig
(Air intake absolute pressure

atmosphere pressure)
Ignition timing learning value

Acceleration opening angle signal
Learned Ignition Timing

Accel. Opening Angle
deg
%
0 deg
0.0%
Fuel temperature signal

Fuel level signal
Fuel Temp.
Fuel Level
C or F
V
+21C or 70F
05V
Primary supercharged pressure control signal

Purge control solenoid duty ratio
Primary Control
%
%
0.0%
0 25%
Tumble generator valve RH opening signal

Tumble generator valve LH opening signal
TGV Position Sensor R

TGV Position Sensor L
V
V
0.44 V
0.48 V
Fuel pump duty ratio

AVCS advance angle amount RH
Fuel Pump Duty

VVT Adv. Ang. Amount R
%
deg
33%
0 deg
AVCS advance angle amount LH

Oil flow control solenoid valve duty RH (AVCS)
VVT Adv. Ang. Amount L

OCV Duty R
deg
%
0 deg
9.4%
Oil flow control solenoid valve duty LH (AVCS)

Oil flow control solenoid valve current RH
OCV Duty L
OCV Current R
%
mA
9.4%
40 100 mA
Oil flow control solenoid valve current LH

A/F sensor current value 1
OCV Current L
A/F Sensor #1 Current
mA
mA
40 100 mA
20 20 mA
A/F sensor resistance value 1

A/F sensor output lambda 1
A/F Sensor #1 Resistance

A/F Sensor #1
27 35
1.00
A/F correction 3
A/F learning 3
A/F Correction #3
A/F Learning #3
%
%
0.00%
0.00%
EN(H4DOTC)(diag)-30

Content
Display
Unit of
measure
%
Note (at idling)
Throttle motor duty
Throttle Motor Duty
Throttle motor voltage

Sub throttle sensor voltage
Throttle Motor Voltage

Sub-throttle Sensor
V
V
12 15 V
1.52 V
Main throttle sensor voltage

Sub accelerator sensor voltage
Main-throttle Sensor
Sub-accelerator Sensor
V
V
0.66 V
0.68 V
Main accelerator sensor voltage
Main-accelerator Sensor
Secondary air supply piping pressure
V
mmHg, kPa,
inHg or psig
0.66 V
765 mmHg, 102 kPa,
Secondary airflow signal
Secondary airflow amount
0.00 g/s or 0.00 lb/m
Memory vehicle speed
Memory Vehicle Speed
g/s or lb/m
km/h or
MPH
Odd Meter
Estimated Cumulative
Driving Distance
km

0
0

0
0
Knock sensor correction
Knock Correction
Fuel Tank Pressure
0.0 deg
+8.8 mmHg, +1.2 kPa,
+0.4 inHg or 0.2 psig
ON/OFF
Secondary air supply piping pressure signal
10%
0 km/h or 0 MPH
AT/MT identification terminal
AT Vehicle ID Signal
deg
mmHg, kPa,
inHg or psig
Test mode terminal

Test Mode Signal

U-check
OFF

Neutral position switch signal

OFF
Neutral
Soft idle switch signal

Ignition switch signal
Soft Idle Switch Signal

Ignition Switch
Idling
ON input
Power steering switch signal

Air conditioning switch signal
P/S Switch
A/C Switch
OFF input (At OFF)

OFF input (At OFF)
Starter switch signal

Rear oxygen monitor
Starter Switch
Rear O2 Rich Signal
OFF input
Rich/Lean
Knocking signal
Knock Signal
Crankshaft Position Sig.
None
Provided
Camshaft position sensor signal

Rear defogger switch signal
Camshaft Position Sig.

Rear Defogger SW
Provided
OFF input (At OFF)
Blower fan switch signal

Light switch signal
Blower Fan SW
Light Switch
OFF input (At OFF)

OFF input (At OFF)
A/C middle pressure switch signal

Air conditioner compressor relay output signal
A/C Mid Pressure Switch

A/C Compressor Signal
OFF input (At OFF)

OFF output (At OFF)


OFF output (At OFF)

OFF output (At OFF)
PCV hose assembly diagnosis signal

Pressure control solenoid valve signal
Blow-by Leak Connector

PCV Solenoid
Connected
OFF output (At OFF)
Tumble generator valve output signal

Tumble generator valve drive signal
TGV Output
TGV Drive
None
Opening direction
Drain valve signal

Purge control solenoid valve 2 signal
Vent Control Solenoid

CPC Solenoid 2
OFF output (At OFF)

OFF (At OFF)
AT coordinate retard angle demand signal

AT coordinate fuel cut demand signal
Retard Signal from AT

Fuel Cut Signal from AT
None
None
EN(H4DOTC)(diag)-31

Content
Display
Unit of
measure
Note (at idling)
Vehicle dynamics control (VDC) torque down

prohibition output
Ban of Torque Down
Allow
Vehicle dynamics control (VDC) torque down

demand
VDC torque down demand
None
Torque control permission signal
AT Cooperative Control
Request Signal
Allow
ETC motor relay signal

Clutch switch signal
ETC Motor Relay

Clutch Switch
ON
OFF (At OFF)

SET/COAST switch signal
Stop Light Switch

SET/COAST Switch
OFF (At OFF)

OFF (At OFF)
RES/ACC switch signal
RESUME/ACCEL Switch
OFF (At OFF)
Brake switch signal

Main switch signal
Brake Switch
Main Switch
OFF (At OFF)

OFF (At OFF)
Secondary air combination valve relay 2 signal
Secondary Air
Combination Valve Relay 2
OFF (At OFF)
OFF (At OFF)
Secondary air pump relay signal
OFF (At OFF)
Cruise control cancel switch signal
Secondary Air Pump Relay

Secondary Air
Combination Valve Relay 1
CC Cancel SW
OFF (At OFF)
Malfunction indicator light signal
MIL Lit Flag
OFF (when light is OFF)
Secondary air combination valve relay 1 signal
NOTE:
EN(H4DOTC)(diag)-32

5. READ CURRENT DATA FOR ENGINE (OBD MODE)

4) On the Engine Diagnosis display screen, select {OBD System}.
5) On the OBD Menu screen, select {Current Data Display/Save}.
6) On the Data Display Menu screen, select {Data Display}.
Content
Display
Unit of
measure
Note (at idling)
Number of diagnosis code

Condition of malfunction indicator light
Number of Diag. Code:

MI (MIL)
ON or OFF
Monitoring test of misfire

Monitoring test of fuel system
Misfire Monitoring
Fuel system monitoring
Monitoring test of comprehensive component

Test of catalyst
Component monitoring
Catalyst Diagnosis
Test of heating-type catalyst
Heated catalyst
Evaporative purge system
no support
Test of Secondary air system

Test of air conditioning system refrigerant

A/C system refrigerant
no support
Oxygen sensor test

Oxygen sensor heater test
Oxygen sensor
O2 Heater Diagnosis
Test of EGR system

EGR system
Fuel System for Bank 1
no support
CLOSE NORMAL
Engine load data

Calculated load valve

Coolant Temp.
%
C or F
21.0%
+91C or 196F


%
%
+0.8%
+3.9%
mmHg, kPa,
inHg or psig
233 mmHg, 31 kPa,

Engine speed signal
Engine Speed
700 rpm
Vehicle Speed
rpm
km/h or
MPH
0 km/h or 0 MPH
C or F
g/s or lb/m
54C or 129F
2.8 g/s or 0.37 lb/m
Test of evaporative emission purge control system
#1 Cylinder ignition timing
Ignition timing adv.#1

Intake air amount
Intake Air Temp.

Mass Air Flow


13%
Stop
Oxygen sensor #12

Air fuel ratio correction by rear oxygen sensor
Oxygen Sensor #12

Short term fuel trim #12
V
%
0.1 0.7 V
+0.0%

Oxygen sensor #11
OBD System
Oxygen Sensor #11
CARB-OBD2
Support
Rear oxygen sensor output signal

A/F lambda signal
Oxygen Sensor #12

A/F sensor #11
Support
1.001
A/F sensor output signal

A/F lambda signal #11
A/F sensor #11

A/F sensor #11
2.805 V
0.999
A/F sensor current #11

A/F sensor #11

Elapsed Time After
Starting Engine
mA
sec
0.02 mA
EN(H4DOTC)(diag)-33
+16.5

Content
Display
Unit of
measure
Note (at idling)
km or miles
Elapsed Time After MIL

Illuminates
Evaporative purge
Fuel level signal
Evaporative purge
Fuel level
%
%
0%
Number of warm ups after DTC clear
Number Of Warm Ups

After DTC Clear
Travel distance after

DTC clear
km or miles
Fuel Tank Pressure
+8.8 mmHg, +1.2 kPa,

+0.4 inHg or 0.2 psig
Catalyzer temperature #1
Catalyzer temperature
#1
mmHg, kPa,
inHg or psig
mmHg, kPa,
inHg or psig
C or F
Diagnostic monitor of
each DC
ECM power voltage

Absolute load
ECM power voltage

Absolute load
V
%
13.789 V
22%

A/F target lambda

0.976
2%
Ambient temperature
Ambient temperature
Absolute throttle opening
angle 2
Absolute accelerator
opening angle 1
C or F
%
Absolute accelerator
opening angle 2
Target throttle opening

angle
Engine operating time during malfunction indicator illuminates
Engine operating time

during MIL illuminates
Elapsed time after DTC
clear
Fuel used

Fuel used
Relative accelerator
opening angle
32%
13%
13%
0%
min
min
GAS
0%
NOTE:
EN(H4DOTC)(diag)-34

6. READ FREEZE FRAME DATA FOR ENGINE (OBD MODE)

5) On the Menu screen, select {Freeze Frame Data}.
Content
Display
Unit of measure
DTC of freeze frame data

Freeze frame data

Fuel system for Bank 1
DTC
Close normal or open initial
Oxygen sensor #12

Short term fuel trim by oxygen (A/F) sensor (Bank 1)
Oxygen sensor #12

V
%
Engine load data

Engine load
Coolant Temp.
Short term fuel trim by front oxygen (A/F) sensor (Bank 1)

Long term fuel trim by front oxygen (A/F) sensor (Bank 1)


Engine speed signal

Engine Speed

Ignition timing #1
Vehicle Speed
Ignition timing adv. #1

Intake Air Temp.

Mass Air Flow


Oxygen sensor #11

Oxygen sensor #12
Oxygen sensor #11

Oxygen sensor #12

OBD System
Elapsed Time After Starting Engine
Evaporative purge
Fuel level signal
Evaporative purge
Fuel level

Tank pressure
ECM power voltage

Absolute load
ECM power voltage

Absolute load
V
%

A/F target lambda

Ambient temperature
Ambient temperature


%
%
%
C or F
%
%
rpm
km/h or MPH
C or F
g/s
%
Support
Support
sec
%
%
C or F
%
NOTE:
EN(H4DOTC)(diag)-35

7. V.I.N. REGISTRATION
1) On the Main Menu display screen, select the {Each System Check} and press the [YES] key.
2) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES]
key.
3) Press the [YES] key after the information of engine type has been displayed.
4) On the Engine Diagnosis display screen, select the {V.I.N. Registration} and press the [YES] key.
5) Perform the procedures shown on the display screen.
NOTE:
EN(H4DOTC)(diag)-36

10.Read Diagnostic Trouble

Code (DTC)
A: OPERATION
MODE)
1) On the Main Menu display screen, select
screen, select {Engine Control System}.
4) On the Engine Diagnosis screen, select {DTC
Display}.
select {Current Diagnostic Code(s)} or {History Diagnostic Code(s)}.

Refer to the data denoting emission-related powertrain DTC.
Code (DTC).>
NOTE:
Refer to the general scan tool manufacturers operation manual to access powertrain DTC (MODE
$03).
NOTE:
MANUAL.
Code (DTC).>

MODE)
5) On the OBD Menu display screen, select {Diagnostic Code(s) Display}.
6) Make sure DTC is shown on the screen.
NOTE:
MANUAL.
Code (DTC).>
EN(H4DOTC)(diag)-37
Inspection Mode
11.Inspection Mode
A: PROCEDURE
Perform the diagnosis shown in the following DTC table.
When performing the diagnosis not listed in List of Diagnostic Trouble Code (DTC), refer the item on the
drive cycle. <Ref. to EN(H4DOTC)(diag)-44, Drive Cycle.>
DTC
P0011
Item
Intake Camshaft Position-Timing Over- Advanced or System Performance (Bank 1)
P0016
P0018
Crankshaft Position - Camshaft Position Correlation (Bank 1)

Crankshaft Position - Camshaft Position Correlation (Bank 2)
P0021
P0031
A Camshaft Position-Timing Over- Advanced or System Performance (Bank 2)

P0032
P0037

P0038
P0102

Mass or Volume Air Flow Circuit Low Input
P0103
P0107
Mass or Volume Air Flow Circuit High Input

P0108
P0112

P0113
P0117

P0118
P0122

Throttle/Pedal Position Sensor / Switch A Circuit Low Input
P0123
P0131
Throttle/Pedal Position Sensor/ Switch A Circuit High

P0132
P0137

P0138
P0140

P0182
P0183

P0222
P0223
Throttle/Pedal Position Sensor/Switch B Circuit Low

Throttle/Pedal Position Sensor/Switch B Circuit High
P0230
P0245
Fuel Pump Primary Circuit

Turbo/Super Charger Wastegate Solenoid A Low
P0327
P0328
Knock Sensor 1 Circuit Low Input (Bank 1 or Single Sensor)

Knock Sensor 1 Circuit High (Bank 1 or Single Sensor)
P0335
P0336

P0340
P0345
Camshaft Position Sensor A Circuit (Bank 1 or Single Sensor)

Camshaft Position Sensor A Circuit (Bank 2)
P0413
P0416
Secondary Air Injection System Switching Valve A Circuit Open

Secondary Air Injection System Switching Valve B Circuit Open
P0418
P0447
Secondary Air Injection System Control A Circuit Open

P0448
P0452

P0453
P0458

Evaporative Emission System Purge Control Valve Circuit Low
P0462
EN(H4DOTC)(diag)-38
Condition
Inspection Mode
DTC
Item
Condition
P0463
P0502

Vehicle Speed Sensor A Circuit Low Input
P0503
P0512

P0513
P0519
Incorrect Immobilizer Key

P0600
P0604

Internal Control Module Random Access Memory (RAM) Error
P0605
P0607
Internal Control Module Read Only Memory (ROM) Error

P0638
P0691

P0700
P0851
Transmission Control System (MIL Request)

P0852
P1152

P1153
P1160

P1400
P1410

Secondary Air Injection System Switching Valve Stuck Open
P1420
P1491
Fuel Tank Pressure Control Sol. Valve Circuit High

Positive Crankcase Ventilation (Blowby) Function Problem
P1518
P1560

P1570
P1571
Antenna
Reference Code Incompatibility
P1572
P1574
Egi-Immobilizer Communications (Except Antenna Circuit)

Key Communication Failure
P1576
P1577
EGI Control Module EEPROM

IMM Control Module EEPROM
P2006
P2007
Intake Manifold Runner Control Stuck Closed (Bank 1)

Intake Manifold Runner Control Stuck Closed (Bank 2)
P2008
P2009
Tumble Generator Valve Signal 1 Circuit Malfunction (Open)

Tumble Generator Valve Signal 1 Circuit Malfunction (Short)
P2011
P2012
Tumble Generator Valve Signal 2 Circuit Malfunction (Open)

Tumble Generator Valve Signal 2 Circuit Malfunction (Short)
P2016
P2017
Tumble Generator Valve Position Sensor 1 Circuit Low

Tumble Generator Valve Position Sensor 1 Circuit High
P2021
P2022
Tumble Generator Valve Position Sensor 2 Circuit Low

Tumble Generator Valve Position Sensor 2 Circuit High
P2088
P2089
OCV Solenoid Valve Signal A Circuit Open (Bank 1)

OCV Solenoid Valve Signal A Circuit Short (Bank 1)
P2092
P2093
OCV Solenoid Valve Signal A Circuit Open (Bank 2)

OCV Solenoid Valve Signal A Circuit Short (Bank 2)
P2101
P2102

P2109
P2122
Throttle/Pedal Position Sensor A Minimum Stop Performance

Throttle/Pedal Position Sensor/Switch D Circuit Low Input
P2123
Throttle/Pedal Position Sensor/Switch D Circuit High Input
P2127
Throttle/Pedal Position Sensor/Switch E Circuit Low Input
EN(H4DOTC)(diag)-39
Inspection Mode
DTC
Item
Condition
P2128
P2135
Throttle/Pedal Position Sensor/Switch E Circuit High Input

Throttle/Pedal Position Sensor/Switch A/B Voltage Correlation
P2138
P2419
Throttle/Pedal Position Sensor/Switch D/E Voltage Correlation

Evaporative Emissions System Purge Control Valve Circuit Low
P2420
P2431
Evaporative Emission Control System Purge Control Valve Circuit High

Secondary Air Injection System Air Flow /Pressure Sensor Circuit Range/Performance
P2432
P2433
Secondary Air Injection System Air Flow /Pressure Sensor Circuit Low
Secondary Air Injection System Air Flow /Pressure Sensor Circuit High
P2444
Secondary Air Injection System Pump Stuck On
EN(H4DOTC)(diag)-40
Inspection Mode
1. PREPARATION FOR THE INSPECTION

MODE
1) Check battery voltage is more than 12 V and fuel
remains half [20 40 2 (5.3 10.6 US gal, 4.4
8.8 Imp gal)].
2) Lift-up the vehicle using a garage jack and place
it on rigid racks, or drive the vehicle onto free rollers.
WARNING:
Before raising the vehicle, ensure parking
brakes are applied.
Do not use a pantograph jack in place of a rigid rack.
Secure a rope or wire to the front or rear towing hooks to prevent the lateral runout of front
wheels.
Do not abruptly depress/release clutch pedal
or accelerator pedal during works even when
the engine is operating at low speeds since this
may cause vehicle to jump off free rollers.
In order to prevent the vehicle from slipping
due to vibration, do not place any wooden
blocks or similar items between the rigid racks
and vehicle.
Since the rear wheels will also rotate, do not
place anything near them. Also, make sure that
nobody goes in front of the vehicle.

4) Connect the test mode connector (A) located at
the lower portion of instrument panel (on the drivers side).
(A)
EN-00333
(A) Test mode connector

EN-00334
(A)
(B)
(A) Rigid rack

(B) Free rollers
EN-00041
CAUTION:
10) On the Engine Diagnosis display screen, select {D Check}.
11) When the Perform D Check? is shown on the
screen, select the [OK].
EN(H4DOTC)(diag)-41
Inspection Mode
12) Perform subsequent procedures as instructed

on the display screen.
If trouble still remains in the memory, the corresponding DTC appears on the display screen.
NOTE:
MANUAL.
<Ref. to EN(H4DOTC)(diag)-70, List of Diagnostic Trouble Code (DTC).>
Release the parking brake.
does not indicate a malfunction. When engine
control diagnosis is finished, perform the ABS
memory clearance procedure of the self-diagnosis system. <Ref. to ABS(diag)-26, Clear Memory Mode.>

(A)
EN-00333
3) Connect the general scan tool to data link connector located in the lower portion of the instrument
panel (on the drivers side).
CAUTION:
EN-00334

NOTE:
Make sure the select lever is placed in the P position before starting. (AT model)
Depress the clutch pedal when starting engine.
(MT model)
5) Using the select lever or shift lever, turn the P
position switch and N position switch on.
6) Depress the brake pedal to turn the brake switch
ON. (AT model)
7) Keep the engine speed in 2,500 3,000 rpm
range for 40 seconds.
EN(H4DOTC)(diag)-42
Inspection Mode
8) Place the selector lever or shift lever in D range

(AT model) or 1st gear (MT model) and drive the
vehicle at 5 to 10 km/h (3 to 6 MPH).
NOTE:
For AWD model, 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
clearance procedure of the self-diagnosis system.
<Ref. to ABS(diag)-26, Clear Memory Mode.>
9) Using the general scan tool, check DTC and
record the result(s).
NOTE:
<Ref. to EN(H4DOTC)(diag)-70, List of Diagnostic
EN(H4DOTC)(diag)-43
Drive Cycle
12.Drive Cycle
A: PROCEDURE
For the troubleshooting, there are seven driving patterns of drive cycles A to G. Driving in the specified pattern allows to diagnose malfunctioning items listed below. After the repair of the following trouble items, be
sure to drive the vehicle with the specified drive patterns to check whether the function is resumed correctly.
1. PREPARATION FOR DRIVE CYCLE

1) Check battery voltage is more than 12 V and fuel remains half [20 40 2 (5.3 10.6 US gal, 4.4 8.8
Imp gal)].
2) Disconnect the test mode connector.
NOTE:
Except for the water temperature specified items at starting, be sure to carry out the diagnosis after the engine is warmed up.
Perform the diagnosis twice if the DTC marked with *. After completing the first diagnosis, stop the engine
and perform second diagnosis in same condition.
EN(H4DOTC)(diag)-44
Drive Cycle
2. DRIVE CYCLE A DRIVE THE VEHICLE WITH 80 KM/H (50 MPH) FOR 20 MINUTES, AND
THEN IDLE THE ENGINE FOR A MINUTE.
DTC
Item
Condition
at engine start is 20C (68F)
or less.
*P0125
Insufficient Coolant Temperature for Closed Loop Fuel Control
*P0128

Coolant Thermostat (Coolant Temperature Below Thermostat Regulating Temperature) at engine start is 55C
(131F) or less.
*P0133
*P0171
*P0172

P0301

P0302
P0303
P0304
*P0420
Catalyst System Efficiency Below Threshold (Bank 1)
P0441
CPC 2 Solenoid Characteristic (Closed)
*P0442
*P0451
*P0456
Evaporative emission control system (0.02 inch leak)
*P0457
Evaporative Emission Control System Leak Detected (Fuel Cap Loose/Off)


Coolant temperature at start

is less than 25C (77F).

P0459
Evaporative Emission System Purge Control Valve Circuit High
P0692
P1443

*P2096

*P2097

P2103

EN(H4DOTC)(diag)-45
Drive Cycle
3. DRIVE CYCLE B (10 MINUTES IDLING)

NOTE:
Drive the vehicle in more than 10 km/h (6 MPH) before diagnosis.
DTC
Item
*P0126
Insufficient Coolant Temperature for Stable Operation
*P0171
*P0172
P0301
P0302
P0303
P0304
Condition

*P0464
*P0483
*P0506

Idle Air Control System RPM Lower Than Expected
*P0507
Idle Air Control System RPM Higher Than Expected
*P2096
*P2097

P2103

EN(H4DOTC)(diag)-46

Drive Cycle
4. DRIVE CYCLE C (DRIVE ACCORDING TO THE FOLLOWING DRIVE PATTERN)

(H)
(C)
97 (60)
(D)
64 (40)
(G)
(F)
(E)
(B)
(A)
0
50
100
150
(I)
EN-00842
(A)
(B)
(C)
Idle the engine for more than 10

seconds.
(D)

(F)
(E)
Decelerate the vehicle to 64 km/h

(40 MPH) with throttle fully closed.
(G)
(H)
Stop the vehicle with throttle fully

closed.
(I)
(sec.)

DTC
*P0030
P0068
*P0101
P0134
*P0139
Item
HO2S Heater Control Circuit (Bank 1 Sensor 1)
Mass or Volume Air Flow Circuit Range/Performance
*P0171
*P0172
*P0244
P0246
Turbo/Supercharger Wastegate Solenoid A Range/Performance

Turbo/Super Charger Wastegate Solenoid A High
*P0301
*P0302
*P0303
*P0304
P2004
P2005
Intake Manifold Runner Control Stuck Open (Bank 1)

Intake Manifold Runner Control Stuck Open (Bank 2)
*P2096
Post Catalyst Fuel Trim System Too Lean (Bank 1)
*P2097
Post Catalyst Fuel Trim System Too Rich (Bank 1)
P2103
EN(H4DOTC)(diag)-47
Condition



Drive Cycle
5. DRIVE CYCLE D
Drift Diagnosis
2) Make sure that fuel remains more than 10 2 (2.6 US gal, 2.2 Imp gal) and the battery voltage is more than
10.9 V.
3) Make sure that the engine coolant temperature rises for more than 10C (18F) from the level of engine
starting and is also above 75C (167F).
4) Idle the engine for more than 120 seconds in the condition of step 3.
Stuck Diagnosis
2) Perform the Clear Memory Mode. <Ref. to EN(H4DOTC)(diag)-50, Clear Memory Mode.>
3) Drive for approximately 50 2 (13.2 US gal, 11 Imp gal) of fuel.
NOTE:
battery terminals.)
DTC
P0181
Item
Condition
6. DRIVE CYCLE E
1) Make sure that the battery voltage is 10.9 V or more.
3) Drive for approximately 30 2 (7.9 US gal, 6.6 Imp gal) of fuel.
NOTE:
battery terminals.)
DTC
P0461
Item
Fuel Level Sensor Circuit Range/Performance
Condition
7. DRIVE CYCLE F
2) Warm-up the engine until engine coolant temperature rises above 95C (203F) after starting the engine.
3) Idle the engine for more than 10 minutes in the condition of step 2.
NOTE:
Do not disconnect the terminal of battery during diagnosis. (Data will be cleared when disconnecting the battery terminals.)
DTC
P0111
Item
Intake Air Temperature Circuit Range/Performance
EN(H4DOTC)(diag)-48
Condition
Drive Cycle
8. DRIVE CYCLE G
1) Remove the battery negative terminal, and reconnect after 10 seconds have passed.
2) Start the engine and warm-up engine until coolant temperature is 80C (176F).
NOTE:
Do not let engine coolant temperature drop below 5C (41F).
NOTE:
Do not let engine coolant temperature drop below 5C (41F).
DTC
Item
Condition
P0410
*
P0411
Secondary Air Injection System

Secondary Air Injection System Incorrect Flow Detected
P0414
P0417
Secondary Air Injection System Switching Valve A Circuit Shorted

Secondary Air Injection System Switching Valve B Circuit Shorted
P1418
Secondary Air Injection System Control A Circuit Shorted

Secondary Air Injection System Switching Valve Stuck Open (Bank 1)
*P2442
Secondary Air Injection System Switching Valve Stuck Closed (Bank 1)

Secondary Air Injection System Switching Valve Stuck Open (Bank 2)
*P2443
Secondary Air Injection System Switching Valve Stuck Closed (Bank 2)
*P2440
*P2441
9. DRIVE CYCLE H
2) Read the engine coolant temperature, intake air temperature and fuel temperature with ignition switch ON.
<Ref. to EN(H4DOTC)(diag)-30, READ CURRENT DATA FOR ENGINE (NORMAL MODE), OPERATION,
3) Start the engine if the value in step 2) meets the following two conditions.
Condition:
|engine coolant temperature intake air temperature | 5C (41F)
|engine coolant temperature fuel temperature| 2C (36F)
NOTE:
If the value does not meet the conditions, turn the ignition switch to OFF and wait until it meets.
Start the engine in P range (AT model) or in N position (MT model).
4) Idle the engine for one minute in the condition of step 3.
DTC
*P1602
Item
ECM error (cold start)
Condition
EN(H4DOTC)(diag)-49
Clear Memory Mode

A: OPERATION
For procedures clearing memory using the general

scan tool, refer to the general scan tool operation
manual.

MODE)
4) On the Engine Diagnosis display screen, select {Clear Memory}.
5) When the Done is shown on the display
screen, turn the ignition switch to OFF and then
close the Subaru Select Monitor.
NOTE:
Initial diagnosis of the electronic throttle control is
performed after the memory is erased. Therefore,
start the engine after 10 seconds or more have
passed since turning the ignition switch to ON.
NOTE:
ON.
MANUAL.

MODE)
5) On the OBD Menu display screen, select
{DTC Clear}.
6) When the Perform Diagnostic Code(s) Clear?
is shown on the screen, select the [OK].
7) Turn the ignition switch to OFF and then close
the Subaru Select Monitor.
NOTE:
ON.
MANUAL.
EN(H4DOTC)(diag)-50
Compulsory Valve Operation Check Mode

14.Compulsory Valve Operation

Check Mode
A: PROCEDURE
12) Selecting the [NO] completes the compulsory

operation check mode. The display will then return
to the Actuator ON/OFF Operation screen.
A list of the support data is shown in the following
table.
Contents
Display
Compulsory fuel pump relay operation

check
Compulsory radiator fan relay operation
check
Compulsory air conditioning relay operation check
Compulsory purge control solenoid 1
valve operation check
CPC Solenoid 2
Compulsory pressure control solenoid

PCV Solenoid
EN-00333

Radiator Fan
Relay
A/C Compressor
Relay
CPC Solenoid
Compulsory purge control solenoid 2

Compulsory drain valve operation

check
Compulsory wastegate control solenoid valve operation check
(A)
Fuel Pump
Secondary air combination valve 1

compulsory operation check
Secondary air combination valve 2
compulsory operation check
Secondary air pump relay compulsory
operation check
Vent. Control
Solenoid
Wastegate control solenoid
Secondary Air
Combination
Valve 1
Secondary Air
Combination
Valve 2
Secondary air
pump relay
NOTE:
The following parts will be displayed but not
functional because they are not installed on the
vehicle.
EN-00334
CAUTION:
9) On the Engine Diagnosis display screen, select {System Operation Check Mode}.
10) On the System Operation Check Mode display screen, select {Actuator ON/OFF Operation}.
11) Select the desired compulsory actuator on the
Actuator ON/OFF Operation display screen and
select the [OK].
Display
EGR Solenoid
ASV Solenoid
FICD Solenoid
AAI Solenoid
Exhaust Bypass Valve Control Permit Flag

MANUAL.
EN(H4DOTC)(diag)-51

15.System Operation Check

Mode
A: OPERATION
1. FUEL PUMP CONTROL (OFF OPERATION)

CAUTION:
EN(H4DOTC)(diag)-50,
OPERATION, Clear
Memory Mode.> and Inspection Mode <Ref. to
EN(H4DOTC)(diag)-38, PROCEDURE, Inspection Mode.>.
2) On the Fuel Pump Control display screen, select the {OFF Operation}.
4) Select the [NO] completes the OFF Operation.
The display will then return to the Fuel Pump Control screen.
2. FUEL PUMP CONTROL (ON/OFF OPERATION)

ME-00325
CAUTION:
9) The following items are displayed on the monitor.
Display
Fuel Pump Control
Idling Ignition Timing Fixed
Idle Speed Control
Injector Control
CAUTION:
OPERATION, Clear
2) On the Fuel Pump Control display screen, select
the {ON/OFF Operation}.
3) On the Turn Ignition Switch ON with Engine
Stalled display screen, select the [OK].
4) Selecting the [NO] completes the ON/OFF Operation. The display will then return to the Fuel
Pump Control screen.
3. IDLING IGNITION TIMING FIXED

CAUTION:
OPERATION, Clear
1) On the System Operation Check Mode display screen, select the {Idling Ignition Timing
Fixed}.
3) Selecting the [NO] completes the Idling Ignition
Timing Fixed. The display will then return to the
System Operation Check Mode screen.
EN(H4DOTC)(diag)-52

4. IDLE SPEED CONTROL

CAUTION:
EN(H4DOTC)(diag)-50, OPERATION,
Clear
1) On the System Operation Check Mode display screen, select the {Idle Speed Control}.
3) On the Idle Speed Control display screen, select [ ] or [ ] to change the setting value.
It is possible to set by 50 rpm, ranging from 500 rpm
to 2,000 rpm. However, the actual idle speed that
can be controlled is varied by vehicle type.
4) Select the [NO] completes the Idling Speed Control. The display will then return to the System Operation Check Mode screen.
5. INJECTOR CONTROL (INJECTION STOP

MODE)
CAUTION:
EN(H4DOTC)(diag)-50, OPERATION,
Clear
the {Injection Stop Mode}.
3) Select the desired injector number on the Injection Stop Mode.
5) Select the [NO] completes the Injection Stop
Mode. The display will then return to the Injector
Control screen.
6. INJECTOR CONTROL (INJECTION

QUANTITY CONTROL)
CAUTION:
OPERATION, Clear
the {Injection Quantity Control}.
the engine and select the [YES] key.
4) On the Injection Quantity Control display
screen, select [ ] or [ ] to change the setting value, and select the [OK].
It is possible to set by 1%, ranging from 0 to 20%.
5) Select the [NO] completes the Injection Quantity
Control. The display will then return to the Injector
Control screen.
NOTE:
MANUAL.
EN(H4DOTC)(diag)-53

16.Malfunction Indicator Light

A: PROCEDURE
1. Activation of malfunction indicator light. <Ref. to EN(H4DOTC)(diag)-54, ACTIVATION OF MALFUNCTION INDICATOR LIGHT,
Malfunction Indicator Light.>
2. Check that the malfunction indicator light does not come on. <Ref. to EN(H4DOTC)(diag)-55, MALFUNCTION INDICATOR
LIGHT DOES NOT COME ON, Malfunction Indicator Light.>
3. Check that the malfunction indicator light does not go off. <Ref. to EN(H4DOTC)(diag)-57, MALFUNCTION INDICATOR LIGHT
DOES NOT GO OFF, Malfunction Indicator Light.>
B: ACTIVATION OF MALFUNCTION
INDICATOR LIGHT
1) When the ignition switch is turned to ON (engine
off), the malfunction indicator light in the combination meter come on.
NOTE:
If the malfunction indicator light does not illuminate,
perform diagnostics of the malfunction indicator
light circuit or the combination meter circuit. <Ref.
to EN(H4DOTC)(diag)-55, MALFUNCTION INDICATOR LIGHT DOES NOT COME ON, Malfunction Indicator Light.>
2) After starting the engine, the malfunction indicator light goes out. If it does not, either the engine or
the emission control system has a problem.
(1)
(3)
(4)
(2)
(3)
(4)
(5)
(6)
EN-01679
(1) No faulty
(2) Trouble occurs
(3) ON
(4) OFF
(6) Engine start
(1)
EN-00157
(1) Malfunction indicator light
EN(H4DOTC)(diag)-54

C: MALFUNCTION INDICATOR LIGHT DOES NOT COME ON

DIAGNOSIS:
The malfunction indicator light circuit is open or shorted.
TROUBLE SYMPTOM:
When the ignition switch is turned to ON (engine OFF), the malfunction indicator light does not come on.
WIRING DIAGRAM:
B72
IGNITION
SWITCH
BATTERY
SBF-4
No.14
SBF-1
B36
i1
B9
A1
COMBINATION
METER
B:
i10
i3
17
i12
B38
11
A:
ECM
B136
i10
B72
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
1 2
3 4
B:
B36
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
A:
i12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
EN-03843
EN(H4DOTC)(diag)-55

Step
Check
CHECK POOR CONTACT.
Does the malfunction indicator
light come on when shaking or
pulling the ECM connector and
harness?
CHECK ECM CONNECTOR.
Is the ECM connector correctly
connected?
Yes
Go to step 4.
No
Go to step 2.
Go to step 3.
Replace the ECM.

<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>

combination meter.
(B136) No. 11 (i12) No. 1:
CHECK POOR CONTACT.

Is there poor contact in combi- Repair the poor
Check poor contact of combination meter con- nation meter connector?
contact of combinector.
nation meter connector.
CHECK HARNESS BETWEEN COMBINAIs the voltage 10 V or more?
Replace the comTION METER AND IGNITION SWITCH CONbination meter cirNECTOR.
cuit board. <Ref. to
IDI-10, Combina2) Measure the voltage between combination
tion Meter.>
EN(H4DOTC)(diag)-56
Repair the connection of ECM connector.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
Poor contact in
coupling connector
Go to step 6.
Check the following item and repair

if necessary.
NOTE:
Blown out of fuse
(No. 14)
Open or short
circuit of harness
between fuse (No.
14) and battery terminal
Poor contact in
ignition switch connector

D: MALFUNCTION INDICATOR LIGHT DOES NOT GO OFF

DIAGNOSIS:
The malfunction indicator light circuit is shorted.
TROUBLE SYMPTOM:
Although malfunction indicator light comes on when the engine runs, DTC is not shown on the Subaru Select
Monitor or general scan tool display.
WIRING DIAGRAM:
B72
IGNITION
SWITCH
BATTERY
SBF-4
No.14
SBF-1
B36
i1
B9
A1
COMBINATION
METER
B:
i10
i3
17
i12
B38
11
A:
ECM
B136
i10
B72
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
1 2
3 4
B:
A:
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B38
B36
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
i12
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
EN-03843
Step
Check
Yes
Does the malfunction indicator Repair the short
light illuminate?
circuit of harness
ECM connector.
EN(H4DOTC)(diag)-57
No
Replace the ECM.
<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>

17.Diagnostics for Engine Starting Failure

A: PROCEDURE
1. Check for fuel amount.
2. Inspection of starter motor circuit. <Ref. to EN(H4DOTC)(diag)-59, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting Failure.>
3. Inspection of ECM power supply and ground line. <Ref. to EN(H4DOTC)(diag)-62, CHECK POWER SUPPLY AND GROUND
LINE OF ENGINE CONTROL MODULE (ECM), Diagnostics for Engine Starting Failure.>
4. Inspection of ignition control system. <Ref. to EN(H4DOTC)(diag)-64, IGNITION CONTROL SYSTEM, Diagnostics for Engine
Starting Failure.>
5. Inspection of fuel pump circuit. <Ref. to EN(H4DOTC)(diag)-67, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.>
6. Inspection of fuel injector circuit. <Ref. to EN(H4DOTC)(diag)-68, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting
Failure.>
EN(H4DOTC)(diag)-58

B: STARTER MOTOR CIRCUIT

CAUTION:
EN(H4DOTC)(diag)-50, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to
WIRING DIAGRAM:
IGNITION SWITCH
BATTERY
SBF-4
SBF-1
1
3
B72
INTERRUPT
RELAY
5
2
3
1
*1
: AT MODEL
*2
: MT MODEL
B59
TO SECURITY SYSTEM
INHIBITOR SWITCH
*2
B12
12
12
11
7
T3
T7
*1
STARTER INTERLOCK
RELAY (MT)
28
27
26
24
STARTER MOTOR
2
B14
B225
32
CLUTCH SWITCH (MT)
2
1
B106
B136
B106
B72
1
2
1 2
3 4
B225
1
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
ECM
B59
T7
B12
1 2 3
4
5
1 2 3 4 5 6
7 8 9 10 11 12
1 2 3 4
5 6 7 8
9 10 11 12
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
EN-04781
EN(H4DOTC)(diag)-59

1
2
3
7
8
Step
Check
CHECK BATTERY.
Check the battery voltage.
CHECK OPERATION OF STARTER MOTOR. Does the starter motor operate?
CHECK DTC.
Is DTC displayed? <Ref. to
OPERATION, Read Diagnostic
CHECK INPUT SIGNAL FOR STARTER MOTOR.

2) Disconnect the connector from starter
motor.
3) Turn the ignition switch to ST.
starter motor connector terminal and engine
ground.
NOTE:
For AT model, place the select lever in P or
N range.
AND IGNITION SWITCH CONNECTOR.
switch.
ignition switch connector and chassis ground.
switch.
2) Measure the resistance between ignition
switch terminals after turning the ignition switch
to ST.
Terminals
No. 1 No. 3:
Check the type of the transmission.
CHECK INHIBITOR SWITCH INPUT VOLTAGE.
switch.
3) Connect the connector to the ignition switch.
4) Measure the input voltage between inhibitor
switch connector terminal and engine ground
while turning the ignition switch to ST.
Yes
Go to step 2.
Go to step 3.
No
Charge or replace
the battery.
Go to step 4.

the List of Diagnostic Trouble Code
(DTC). <Ref. to
EN(H4DOTC)(diag
Code (DTC).>
Check the starter
motor. <Ref. to SC
(H4SO)-6,
Starter.>
Go to step 6.
Repair the open

circuit of harness
between ignition
switch and battery,
and check fuse
SBF No. 4 and
SBF No. 1.
Go to step 5.
Replace the ignition switch.
Go to step 8.
Go to step 12.
Go to step 9.
Repair open or
of harness
between inhibitor
switch and ignition
switch.
NOTE:
Check security
system (if
equipped). <Ref. to
SL-21, Security
System.>
EN(H4DOTC)(diag)-60

10
11
12
13
14
Step
Check
Yes
1) Place the select lever in P or N range.
2) Measure the resistance between inhibitor
switch terminals.
(T3) No. 11 No. 12:
CHECK INPUT VOLTAGE OF STARTER IN- Is the voltage 10 V or more?
Go to step 11.
TERLOCK RELAY.
2) Disconnect the connector from starter interlock relay.
Terminals
No. 27 No. 28:
CHECK GROUND CIRCUIT OF CLUTCH
SWITCH.
1) Disconnect the connector from clutch
switch.
2) Measure the resistance between the clutch
switch connector and chassis ground.
Measure the resistance between clutch switch
terminals while depressing the clutch pedal.
Terminals
No. 1 No. 2:
1) Connect the connector to the clutch switch.
while depressing the clutch pedal.
No
4AT-47, Inhibitor
Switch.>
Repair open or
short circuit to
ground in harness
between starter
interlock relay and
ignition switch.
NOTE:
Check security
system (if
equipped). <Ref. to
SL-21, Security
System.>
Replace the starter
interlock relay.
Repair the open

circuit of ground
cable.
Replace the clutch

switch. <Ref. to
CL-28, Clutch
Switch.>
Is the resistance less than 1 ? Repair the ground

short of the harness between
starter interlock
relay and starter
motor.
Repair the open

circuit in harness
between starter
interlock relay and
clutch switch.
EN(H4DOTC)(diag)-61

C: CHECK POWER SUPPLY AND GROUND LINE OF ENGINE CONTROL

MODULE (ECM)
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
4
6
SBF-5
7
5
3
B61
2
1
B72
No.11
B47
F44
IGNITION
SWITCH
SBF-4
SBF-1
C23
A7
B2
B5
B19
A : B134
B : B135 ECM
C : B136
C15
MT
A5
D2
D1
D7
D3
D : B137
E
B72
B47
1
3
5
1 2
3 4
2
4
6
A : B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
36
35
34
54
37
B22
E3
F44
1 2 3
5 6 7
MT : MT MODEL
D : B137
4
8
B22
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
C : B136
B : B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
24 25
26 27
20 21 22 23
28 29 30 31
32 33
34 35
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
EN(H4DOTC)(diag)-62
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04782

Step
CHECK MAIN RELAY.
2) Remove the main relay.
3) Connect the battery to main relay terminals
No. 1 and No. 2.
4) Measure the resistance between main relay
terminals.
Terminals
No. 3 No. 5:
No. 4 No. 6:
and chassis ground.
CHECK INPUT VOLTAGE OF MAIN RELAY.
Measure the voltage between main relay connector and chassis ground.
1) Connect the main relay connector.
Check
?
Yes
Go to step 2.
No
Replace the main
relay.
Repair the open

circuit of harness
between ECM connector and engine
grounding terminal.
Go to step 4.
Repair the open or

of power supply
circuit.
Go to step 5.
Repair the open or

of harness of
Check ignition control system. <Ref.

to
EN(H4DOTC)(diag
)-64, IGNITION
for Engine Starting
Failure.>
Repair the open or

of harness
between ECM connector and main
relay connector.
EN(H4DOTC)(diag)-63

D: IGNITION CONTROL SYSTEM

CAUTION:
WIRING DIAGRAM:
26
21
20
ECM
19
18
B137
IGNITION
SWITCH
SBF-1
No.11
SBF-4
1
4
B72
53
16
15
14
13
49
B22
E3
E34
3
E33
E32
E31
E
IGNITION
COIL No. 1
E31
B72
E32
E33
E34
1
2
3
1 2
3 4
IGNITION
COIL No. 2
IGNITION
COIL No. 3
B137
B22
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
IGNITION
COIL No. 4
41
47
54
EN-04783
EN(H4DOTC)(diag)-64

Step
CHECK SPARK PLUG CONDITION.
1) Remove the spark plug. <Ref. to
IG(H4DOTC)-4, REMOVAL, Spark Plug.>
2) Check the spark plug condition. <Ref. to
IG(H4DOTC)-5, INSPECTION, Spark Plug.>
CHECK IGNITION SYSTEM FOR SPARKS.
1) Connect the spark plug to ignition coil.
FU(H4DOTC)-49, RELEASING OF FUEL
3) Contact the spark plugs thread portion to
the engine.
4) While opening the throttle valve fully, crank
the engine to check that spark occurs at each
cylinder.
CHECK POWER SUPPLY CIRCUIT FOR IGNITION COIL AND IGNITOR ASSEMBLY.
ignition coil and ignitor assembly connector and
engine ground.
CHECK HARNESS OF IGNITION COIL AND
IGNITOR ASSEMBLY GROUND CIRCUIT.
2) Measure the resistance between the ignition coil and ignitor assembly connector and the
ECM.
(E31) No. 2 (B137) No. 6, 26:
(E32) No. 2 (B137) No. 6, 26:
(E33) No. 2 (B137) No. 6, 26:
(E34) No. 2 (B137) No. 6, 26:
CONNECTOR.
ECM and ignition coil and ignitor assembly connector.
(B137) No. 21 (E34) No. 1:
(B137) No. 20 (E33) No. 1:
(B137) No. 19 (E32) No. 1:
(B137) No. 18 (E31) No. 1:
Check
Yes
Is the spark plug condition sta- Go to step 2.
tus OK?
No
Replace the spark
plug.
Does spark occur at each cylin- Check fuel pump Go to step 3.

der?
system. <Ref. to
EN(H4DOTC)(diag
)-67, FUEL PUMP
Starting Failure.>
Go to step 4.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
the ignition coil and
ignitor assembly
and ignition switch
connector
Poor contact in
coupling connector
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and ignition
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and ignition
Poor contact in
coupling connector
EN(H4DOTC)(diag)-65

Step
CONNECTOR.
ECM and engine ground.
CHECK POOR CONTACT.
Check
more?
Yes
Go to step 7.
No
Repair the ground
ECM and ignition
coil and ignitor
assembly connector.

connector?
Check fuel pump

circuit. <Ref. to
EN(H4DOTC)(diag
)-67, FUEL PUMP
Starting Failure.>
EN(H4DOTC)(diag)-66

E: FUEL PUMP CIRCUIT

CAUTION:
WIRING DIAGRAM:
BATTERY
SBF-5
7
2
1
4
3
B61
FUEL PUMP
RELAY
IGNITION SWITCH
SBF-4
No.11
B46
7
8
21
B99
R3
SBF-1
1
B72
3
2
5
R122
F44
C12
B33
ECM
FUEL PUMP
CONTROL UNIT
B : B135
R122
6
4
C : B136
6
12
R15
1
4
R57
FUEL
PUMP
F44
1 2 3 4
5 6 7 8
B72
1 2
3 4
B : B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
R58
B99
B46
1 2
3 4
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
R58
R122
1 2 3
4 5 6
R57
1 2
3 4 5
6 7 8 9 10 11 12
C : B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
Step
Check
CHECK OPERATING SOUND OF FUEL
Does the fuel pump emit operPUMP.
ating sound?
Make sure that the fuel pump operates for 2
seconds when turning the ignition switch to ON.
NOTE:
Fuel pump operation check can also be executed using Subaru Select Monitor.
For procedure, refer to Compulsory Valve Operation
Check
Mode.
<Ref.
to
EN(H4DOTC)(diag)-51, Compulsory Valve Operation Check Mode.>
EN(H4DOTC)(diag)-67
EN-04784
Yes
Check the fuel
injector circuit.
<Ref. to
EN(H4DOTC)(diag
)-68, FUEL INJECTOR CIRCUIT,
Diagnostics for
Engine Starting
Failure.>
No
Display the DTC.
<Ref. to
EN(H4DOTC)(diag
)-37, OPERATION, Read Diagnostic Trouble
Code (DTC).>

F: FUEL INJECTOR CIRCUIT

CAUTION:
Check or repair only faulty parts.
WIRING DIAGRAM:
MAIN RELAY
6
4
B61
BATTERY
F44
SBF-5
5
3
2
1
B47
45
11
10
44
43
48
42
B137 ECM
B22
E3
2
1
E17
2
1
E6
2
1
E16
2
1
E5
#1
#2
#3
#4
FUEL INJECTOR
E5
E6
E16
E17
1 2
B47
1
3
5
2
4
6
F44
B137
B22
1 2 3 4
5 6 7 8
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
26 27
28 29
30 31
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04785
EN(H4DOTC)(diag)-68

Step
Check
CHECK OPERATION OF EACH FUEL INJEC- Does the fuel injector emit
TOR.
operating sound?
While cranking the engine, check each fuel
injector emits operating sound. Use a sound
scope or attach a screwdriver to the injector for
this check.
CHECK POWER SUPPLY TO EACH FUEL IN- Is the voltage 10 V or more?
JECTOR.
fuel injector terminal and engine ground.
Yes
No
Check the fuel
Go to step 2.
pressure. <Ref. to
ME(H4DOTC)-27,
INSPECTION,
Fuel Pressure.>
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
main relay and fuel
injector connector
Poor contact in
Poor contact in
coupling connector
Poor contact in
fuel injector connector
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
(B137) No. 8 (E5) No. 1:
harness between
(B137) No. 9 (E16) No. 1:
ECM and fuel in(B137) No. 10 (E6) No. 1:
jector connector
(B137) No. 11 (E17) No. 1:
Poor contact in
coupling connector
Is the resistance less than 1 ? Repair the ground Go to step 5.
short circuit of harMeasure the resistance of harness between
ness between
ECM and fuel
injector connector.
CHECK EACH FUEL INJECTOR.
Is the resistance between 5 Go to step 6.
Replace the faulty
20 ?
fuel injector.
2) Measure the resistance between each fuel
injector terminals.
Terminals
No. 1 No. 2:
CHECK POOR CONTACT.
Repair poor con- Inspection using
tact in ECM conGeneral DiagnosCheck poor contact of ECM connector.
connector?
nector.
tic Table <Ref. to
EN(H4DOTC)(diag
)-400, INSPECTION, General
Diagnostic Table.>
EN(H4DOTC)(diag)-69
Go to step 3.


A: LIST
DTC
Item
Note
P0011
Intake Camshaft Position - Timing

Over-Advanced or System
<Ref. to EN(H4DOTC)(diag)-78, DTC P0011 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE
(BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0016
Crankshaft Position - Camshaft

Position Correlation (Bank 1)
P0018

P0021
Intake Camshaft Position - Timing

Over-Advanced or System Performance (Bank 2)
(Bank 1 Sensor 1)
<Ref. to EN(H4DOTC)(diag)-79, DTC P0016 CRANKSHAFT POSITION CAMSHAFT POSITION CORRELATION (BANK 1), Diagnostic Procedure
<Ref. to EN(H4DOTC)(diag)-80, DTC P0018 CRANKSHAFT POSITION CAMSHAFT POSITION CORRELATION (BANK 2), Diagnostic Procedure
<Ref. to EN(H4DOTC)(diag)-81, DTC P0021 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE
<Ref. to EN(H4DOTC)(diag)-82, DTC P0030 HO2S HEATER CONTROL
CIRCUIT (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic
CIRCUIT LOW (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0030
P0031

(Bank 1 Sensor 1)
P0032

(Bank 1 Sensor 1)

CIRCUIT HIGH (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0037

(Bank 1 Sensor 2)

CIRCUIT LOW (BANK 1 SENSOR 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0038

(Bank 1 Sensor 2)
P0068
MAP/MAF - Throttle Position

Correlation
P0101

Range/Performance
P0102
Mass or Volume Air Flow Circuit Low

Input

CIRCUIT HIGH (BANK 1 SENSOR 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-94, DTC P0068 MAP/MAF - THROTTLE
POSITION CORRELATION, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-96, DTC P0101 MASS OR VOLUME AIR
FLOW CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with
FLOW CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0103
Mass or Volume Air Flow Circuit High

Input

FLOW CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0107
Manifold Absolute Pressure/

Barometric Pressure Circuit Low Input
<Ref. to EN(H4DOTC)(diag)-103, DTC P0107 MANIFOLD ABSOLUTE

PRESSURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0108

<Ref. to EN(H4DOTC)(diag)-105, DTC P0108 MANIFOLD ABSOLUTE
Barometric Pressure Circuit High Input PRESSURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-107, DTC P0111 INTAKE AIR TEMPERACircuit Range/Performance
TURE SENSOR 1 CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-109, DTC P0112 INTAKE AIR TEMPERACircuit Low
TURE SENSOR 1 CIRCUIT LOW, Diagnostic Procedure with Diagnostic
P0111
P0112
EN(H4DOTC)(diag)-70

DTC
Item
Note
P0113

Circuit High
<Ref. to EN(H4DOTC)(diag)-111, DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH, Diagnostic Procedure with Diagnostic
P0117

Low
P0118

High
P0122
Throttle/Pedal Position Sensor/Switch

A Circuit Low
P0123

A Circuit High
P0125
Insufficient Coolant Temperature for

Closed Loop Fuel Control
<Ref. to EN(H4DOTC)(diag)-114, DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-116, DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-119, DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT LOW, Diagnostic Procedure with
<Ref. to EN(H4DOTC)(diag)-121, DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT HIGH, Diagnostic Procedure with
<Ref. to EN(H4DOTC)(diag)-123, DTC P0125 INSUFFICIENT COOLANT
TEMPERATURE FOR CLOSED LOOP FUEL CONTROL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0126
Insufficient Engine Coolant

Temperature for Stable Operation
<Ref. to EN(H4DOTC)(diag)-125, DTC P0126 INSUFFICIENT ENGINE

COOLANT TEMPERATURE FOR STABLE OPERATION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0128
Coolant Thermostat (Engine Coolant

Temperature Below Thermostat
Regulating Temperature)
P0131

(Bank 1 Sensor 1)
P0132

(Bank 1 Sensor 1)
<Ref. to EN(H4DOTC)(diag)-127, DTC P0128 COOLANT THERMOSTAT

(ENGINE COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-128, DTC P0131 O2 SENSOR CIRCUIT
LOW VOLTAGE (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
HIGH VOLTAGE (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0133

(Bank 1 Sensor 1)

SLOW RESPONSE (BANK 1 SENSOR 1), Diagnostic Procedure with
P0134
O2 Sensor Circuit No Activity Detected

(Bank 1 Sensor 1)
<Ref. to EN(H4DOTC)(diag)-134, DTC P0134 O2 SENSOR CIRCUIT NO

P0137

(Bank 1 Sensor 2)
P0138

(Bank 1 Sensor 2)
P0139

(Bank 1 Sensor 2)
P0140
O2 Sensor Circuit No Activity Detected

(Bank 1 Sensor 2)

LOW VOLTAGE (BANK 1 SENSOR 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
HIGH VOLTAGE (BANK 1 SENSOR 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
SLOW RESPONSE (BANK 1 SENSOR 2), Diagnostic Procedure with
<Ref. to EN(H4DOTC)(diag)-144, DTC P0140 O2 SENSOR CIRCUIT NO
P0171
P0172
P0181

Range/Performance
<Ref. to EN(H4DOTC)(diag)-146, DTC P0171 SYSTEM TOO LEAN

<Ref. to EN(H4DOTC)(diag)-147, DTC P0172 SYSTEM TOO RICH
<Ref. to EN(H4DOTC)(diag)-149, DTC P0181 FUEL TEMPERATURE
SENSOR A CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure
EN(H4DOTC)(diag)-71

DTC
Item
Note
P0182

Low Input

SENSOR A CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic
P0183

High Input
P0222

B Circuit Low
P0223

B Circuit High
P0230
P0244
Turbo/Super Charger Wastegate

Solenoid A Range/Performance
P0245

Solenoid A Low
P0246

Solenoid A High

SENSOR A CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-156, DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT LOW, Diagnostic Procedure with
<Ref. to EN(H4DOTC)(diag)-158, DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT HIGH, Diagnostic Procedure with
<Ref. to EN(H4DOTC)(diag)-161, DTC P0230 FUEL PUMP PRIMARY
CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-164, DTC P0244 TURBO/SUPER
CHARGER WASTEGATE SOLENOID A RANGE/PERFORMANCE,
CHARGER WASTEGATE SOLENOID A LOW, Diagnostic Procedure
CHARGER WASTEGATE SOLENOID A HIGH, Diagnostic Procedure
P0301
P0302
P0303
P0304
P0327

P0328

P0335
P0336

Range/Performance
P0340

<Ref. to EN(H4DOTC)(diag)-182, DTC P0340 CAMSHAFT POSITION

SENSOR A CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0345

(Bank 2)
<Ref. to EN(H4DOTC)(diag)-184, DTC P0345 CAMSHAFT POSITION

SENSOR A CIRCUIT (BANK 2), Diagnostic Procedure with Diagnostic
P0410
P0411
Secondary Air Injection System Incorrect Flow Detected
<Ref. to EN(H4DOTC)(diag)-186, DTC P0410 SECONDARY AIR INJECTION SYSTEM, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(H4DOTC)(diag)-190, DTC P0411 SECONDARY AIR INJECTION SYSTEM INCORRECT FLOW DETECTED, Diagnostic Procedure
<Ref. to EN(H4DOTC)(diag)-169, DTC P0301 CYLINDER 1 MISFIRE

<Ref. to EN(H4DOTC)(diag)-174, DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with
<Ref. to EN(H4DOTC)(diag)-176, DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with
<Ref. to EN(H4DOTC)(diag)-178, DTC P0335 CRANKSHAFT POSITION
SENSOR A CIRCUIT, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-180, DTC P0336 CRANKSHAFT POSITION
SENSOR A CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure
EN(H4DOTC)(diag)-72

DTC
Item
Note
P0413

Switching Valve A Circuit Open
<Ref. to EN(H4DOTC)(diag)-193, DTC P0413 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE A CIRCUIT OPEN, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0414

Switching Valve A Circuit Shorted
P0416

Switching Valve B Circuit Open
P0417

Switching Valve B Circuit Shorted
P0418

Control A Circuit Open
P0420

Threshold (Bank 1)
<Ref. to EN(H4DOTC)(diag)-196, DTC P0414 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE A CIRCUIT SHORTED, Diagnostic
<Ref. to EN(H4DOTC)(diag)-199, DTC P0416 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE B CIRCUIT OPEN, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-202, DTC P0417 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE B CIRCUIT SHORTED, Diagnostic
<Ref. to EN(H4DOTC)(diag)-205, DTC P0418 SECONDARY AIR INJECTION SYSTEM CONTROL A CIRCUIT OPEN, Diagnostic Procedure
<Ref. to EN(H4DOTC)(diag)-208, DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1), Diagnostic Procedure with
P0441

Incorrect Purge Flow
<Ref. to EN(H4DOTC)(diag)-212, DTC P0441 EVAPORATIVE EMISSION

SYSTEM INCORRECT PURGE FLOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0442
Evaporative Emission Control System

Leak Detected (Small Leak)

CONTROL SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0447

Vent Control Circuit Open
P0448

Vent Control Circuit Shorted
P0451

Pressure Sensor
P0452

Pressure Sensor Low Input

CONTROL SYSTEM VENT CONTROL CIRCUIT OPEN, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
CONTROL SYSTEM VENT CONTROL CIRCUIT SHORTED, Diagnostic
CONTROL SYSTEM PRESSURE SENSOR, Diagnostic Procedure with
CONTROL SYSTEM PRESSURE SENSOR LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0453

Pressure Sensor High Input

CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0456

Leak Detected (Very Small Leak)

CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK), Diagnostic
P0457

Leak Detected (Fuel Cap Loose/Off)
P0458

Control Valve Circuit Low
P0459

Control Valve Circuit High
P0461
Fuel Level Sensor A Circuit Range/

Performance

CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
SYSTEM PURGE CONTROL VALVE CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-239, DTC P0461 FUEL LEVEL SENSOR A
CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0462

CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
EN(H4DOTC)(diag)-73

DTC
Item
Note
P0463

CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0464
P0483
<Ref. to EN(H4DOTC)(diag)-247, DTC P0464 FUEL LEVEL SENSOR

CIRCUIT INTERMITTENT, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-249, DTC P0483 FAN RATIONALITY
CHECK, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0502
Vehicle Speed Sensor A Circuit Low

Input
P0503
P0506
P0507
P0512
P0513
P0519
P0600
P0604
P0605
P0607
P0638
P0691
P0692
P0700
P0851
P0851
P0852
<Ref. to EN(H4DOTC)(diag)-250, DTC P0502 VEHICLE SPEED SENSOR

A CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
Vehicle Speed Sensor A Intermittent/ <Ref. to EN(H4DOTC)(diag)-252, DTC P0503 VEHICLE SPEED SENSOR
Erratic/High
A INTERMITTENT/ERRATIC/HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Idle Air Control System RPM Lower
<Ref. to EN(H4DOTC)(diag)-254, DTC P0506 IDLE AIR CONTROL SYSThan Expected
TEM RPM LOWER THAN EXPECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Idle Air Control System RPM Higher
<Ref. to EN(H4DOTC)(diag)-256, DTC P0507 IDLE AIR CONTROL SYSThan Expected
TEM RPM HIGHER THAN EXPECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-258, DTC P0512 STARTER REQUEST CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to IM(diag)-17, DTC P0513 INCORRECT IMMOBILIZER KEY, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-260, DTC P0519 IDLE AIR CONTROL SYSTEM PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-262, DTC P0600 SERIAL COMMUNICATION
LINK, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-264, DTC P0604 INTERNAL CONTROL
MODULE RANDOM ACCESS MEMORY (RAM) ERROR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-265, DTC P0605 INTERNAL CONTROL
Memory (ROM) Error
MODULE READ ONLY MEMORY (ROM) ERROR, Diagnostic Procedure
<Ref. to EN(H4DOTC)(diag)-266, DTC P0607 CONTROL MODULE PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Throttle Actuator Control Range/Per<Ref. to EN(H4DOTC)(diag)-268, DTC P0638 THROTTLE ACTUATOR
formance (Bank 1)
CONTROL RANGE/PERFORMANCE (BANK 1), Diagnostic Procedure
<Ref. to EN(H4DOTC)(diag)-268, DTC P0691 FAN 1 CONTROL CIRCUIT
LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-268, DTC P0692 FAN 1 CONTROL CIRCUIT
HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-268, DTC P0700 TRANSMISSION CONRequest)
TROL SYSTEM (MIL REQUEST), Diagnostic Procedure with Diagnostic
<Ref. to EN(H4DOTC)(diag)-269, DTC P0851 PARK/NEUTRAL SWITCH
(AT Model)
INPUT CIRCUIT LOW (AT MODEL), Diagnostic Procedure with Diagnostic
<Ref. to EN(H4DOTC)(diag)-271, DTC P0851 NEUTRAL SWITCH INPUT
(MT Model)
CIRCUIT LOW (MT MODEL), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Park/Neutral Switch Input Circuit High
(AT Model)
<Ref. to EN(H4DOTC)(diag)-273, DTC P0852 PARK/NEUTRAL SWITCH

INPUT CIRCUIT HIGH (AT MODEL), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(H4DOTC)(diag)-74

DTC
Item
Note
P0852

(MT Model)
<Ref. to EN(H4DOTC)(diag)-276, DTC P0852 NEUTRAL SWITCH INPUT

CIRCUIT HIGH (MT MODEL), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P1152
O2 Sensor Circuit Range/Performance

(Low) (Bank 1 Sensor 1)
P1153
O2 Sensor Circuit Range/Performance

(High) (Bank 1 Sensor 1)
P1160
P1400
Fuel Tank Pressure Control Solenoid

Valve Circuit Low
P1410

Switching Valve Stuck Open
P1418

Control A Circuit Shorted
P1420
Fuel Tank Pressure Control Sol. Valve

Circuit High

RANGE/PERFORMANCE (LOW) (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
RANGE/PERFORMANCE (HIGH) (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-281, DTC P1160 RETURN SPRING FAILURE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-282, DTC P1400 FUEL TANK PRESSURE
CONTROL SOLENOID VALVE CIRCUIT LOW, Diagnostic Procedure with
<Ref. to EN(H4DOTC)(diag)-284, DTC P1410 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK OPEN, Diagnostic Procedure
<Ref. to EN(H4DOTC)(diag)-287, DTC P1418 SECONDARY AIR INJECTION SYSTEM CONTROL A CIRCUIT SHORTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-290, DTC P1420 FUEL TANK PRESSURE
CONTROL SOL. VALVE CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P1443
Vent Control Solenoid Valve Function

Problem
<Ref. to EN(H4DOTC)(diag)-292, DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P1491

<Ref. to EN(H4DOTC)(diag)-294, DTC P1491 POSITIVE CRANKCASE

VENTILATION (BLOW-BY) FUNCTION PROBLEM, Diagnostic Procedure
P1518
P1560
Back-up Voltage Circuit Malfunction
P1570
Antenna
P1571
<Ref. to EN(H4DOTC)(diag)-296, DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(H4DOTC)(diag)-298, DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to IM(diag)-19, DTC P1570 ANTENNA, Diagnostic Procedure with
<Ref. to IM(diag)-13, DTC P1571 REFERENCE CODE INCOMPATIBILITY, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P1572
IMM Circuit Failure

(Except Antenna Circuit)
P1574
P1576
<Ref. to IM(diag)-17, DTC P1576 EGI CONTROL MODULE EEPROM,

P1577
<Ref. to IM(diag)-18, DTC P1577 IMM CONTROL MODULE EEPROM,

P1602
<Ref. to EN(H4DOTC)(diag)-300, DTC P1602 CONTROL MODULE PROGRAMMING ERROR, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P2004
Intake Manifold Runner Control Stuck

Open (Bank 1)
<Ref. to EN(H4DOTC)(diag)-310, DTC P2004 INTAKE MANIFOLD RUNNER CONTROL STUCK OPEN (BANK 1), Diagnostic Procedure with
<Ref. to IM(diag)-14, DTC P1572 IMM CIRCUIT FAILURE (EXCEPT

ANTENNA CIRCUIT), Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to IM(diag)-16, DTC P1574 KEY COMMUNICATION FAILURE,
EN(H4DOTC)(diag)-75

DTC
Item
Note
P2005

Open (Bank 2)
<Ref. to EN(H4DOTC)(diag)-311, DTC P2005 INTAKE MANIFOLD RUNNER CONTROL STUCK OPEN (BANK 2), Diagnostic Procedure with
P2006

Closed (Bank 1)
P2007

Closed (Bank 2)
P2008
Intake Manifold Runner Control Circuit

/ Open (Bank 1)
P2009

Low (Bank 1)
P2011

/ Open (Bank 2)
<Ref. to EN(H4DOTC)(diag)-311, DTC P2006 INTAKE MANIFOLD RUNNER CONTROL STUCK CLOSED (BANK 1), Diagnostic Procedure with
<Ref. to EN(H4DOTC)(diag)-312, DTC P2007 INTAKE MANIFOLD RUNNER CONTROL STUCK CLOSED (BANK 2), Diagnostic Procedure with
<Ref. to EN(H4DOTC)(diag)-313, DTC P2008 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT / OPEN (BANK 1), Diagnostic Procedure with
<Ref. to EN(H4DOTC)(diag)-315, DTC P2009 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW (BANK 1), Diagnostic Procedure with
<Ref. to EN(H4DOTC)(diag)-317, DTC P2011 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT / OPEN (BANK 2), Diagnostic Procedure with
P2012

Low (Bank 2)
<Ref. to EN(H4DOTC)(diag)-319, DTC P2012 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW (BANK 2), Diagnostic Procedure with
P2016
Intake Manifold Runner Position

Sensor / Switch Circuit Low
(Bank 1)
<Ref. to EN(H4DOTC)(diag)-321, DTC P2016 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT LOW (BANK 1), Diagnostic
P2017

Sensor / Switch Circuit High
(Bank 1)
(Bank 2)
(Bank 2)
OCV Solenoid Valve Signal A Circuit
Open (Bank 1)
<Ref. to EN(H4DOTC)(diag)-324, DTC P2017 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT HIGH (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-326, DTC P2021 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT LOW (BANK 2), Diagnostic
<Ref. to EN(H4DOTC)(diag)-329, DTC P2022 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT HIGH (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-331, DTC P2088 OCV SOLENOID VALVE
SIGNAL A CIRCUIT OPEN (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P2089

Short (Bank 1)

SIGNAL A CIRCUIT SHORT (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P2092

Open (Bank 2)

SIGNAL A CIRCUIT OPEN (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P2093
Intake Camshaft Position Actuator

Control Circuit High (Bank 2)
P2096

Lean Bank 1
P2097

Rich Bank 1
P2101
Throttle Actuator Control Motor Circuit

Range/Performance
<Ref. to EN(H4DOTC)(diag)-337, DTC P2093 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-339, DTC P2096 POST CATALYST FUEL
TRIM SYSTEM TOO LEAN BANK 1, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-345, DTC P2097 POST CATALYST FUEL
TRIM SYSTEM TOO RICH BANK 1, Diagnostic Procedure with Diagnostic
<Ref. to EN(H4DOTC)(diag)-351, DTC P2101 THROTTLE ACTUATOR
CONTROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P2102

Low
P2021
P2022
P2088

CONTROL MOTOR CIRCUIT LOW, Diagnostic Procedure with Diagnostic
EN(H4DOTC)(diag)-76

Item
Note
P2103
DTC

High

CONTROL MOTOR CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P2109

P2122

D Circuit Low Input
P2123

D Circuit High Input
P2127

E Circuit Low Input
P2128

E Circuit High Input
<Ref. to EN(H4DOTC)(diag)-360, DTC P2109 THROTTLE/PEDAL POSITION SENSOR A MINIMUM STOP PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-361, DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT LOW INPUT, Diagnostic Procedure
<Ref. to EN(H4DOTC)(diag)-363, DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-365, DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT LOW INPUT, Diagnostic Procedure
<Ref. to EN(H4DOTC)(diag)-367, DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P2135

A/B Voltage Correlation
<Ref. to EN(H4DOTC)(diag)-369, DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH A/B VOLTAGE CORRELATION, Diagnostic
P2138

D/E Voltage Correlation
<Ref. to EN(H4DOTC)(diag)-373, DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D/E VOLTAGE CORRELATION, Diagnostic
P2419

Switching Valve Control Circuit Low
P2420

Switching Valve Control Circuit High
P2431
Secondary Air Injection System Air

Flow /Pressure Sensor Circuit Range/
Performance

SYSTEM SWITCHING VALVE CONTROL CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
SYSTEM SWITCHING VALVE CONTROL CIRCUIT HIGH, Diagnostic
<Ref. to EN(H4DOTC)(diag)-380, DTC P2431 SECONDARY AIR INJECTION SYSTEM AIR FLOW/PRESSURE SENSOR CIRCUIT RANGE/
PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P2432

Flow /Pressure Sensor Circuit Low
P2433

Flow /Pressure Sensor Circuit High
P2440
P2441
P2442
<Ref. to EN(H4DOTC)(diag)-383, DTC P2432 SECONDARY AIR INJECTION SYSTEM AIR FLOW/PRESSURE SENSOR CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-386, DTC P2433 SECONDARY AIR INJECTION SYSTEM AIR FLOW /PRESSURE SENSOR CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-389, DTC P2440 SECONDARY AIR INJECSwitching Valve Stuck Open (Bank 1) TION SYSTEM SWITCHING VALVE STUCK OPEN (BANK 1), Diagnostic
<Ref. to EN(H4DOTC)(diag)-392, DTC P2441 SECONDARY AIR INJECSwitching Valve Stuck Closed (Bank 1) TION SYSTEM SWITCHING VALVE STUCK CLOSED (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-393, DTC P2442 SECONDARY AIR INJECSwitching Valve Stuck Open
TION SYSTEM SWITCHING VALVE STUCK OPEN (BANK 2), Diagnostic
(Bank 2)
P2443

<Ref. to EN(H4DOTC)(diag)-396, DTC P2443 SECONDARY AIR INJECSwitching Valve Stuck Closed (Bank 2) TION SYSTEM SWITCHING VALVE STUCK CLOSED (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P2444
Secondary Air Injection System Pump

Stuck On
<Ref. to EN(H4DOTC)(diag)-397, DTC P2444 SECONDARY AIR INJECTION SYSTEM PUMP STUCK ON, Diagnostic Procedure with Diagnostic
EN(H4DOTC)(diag)-77


A: DTC P0011 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR
SYSTEM PERFORMANCE (BANK 1)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-9, DTC P0011 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
Improper idling
CAUTION:
1
Step
CHECK CURRENT DATA.

1) Start the engine and let it idle.
2) Using the Subaru Select Monitor or general
scan tool, inspect the AVCS advance angle
amount and oil flow control solenoid valve duty
output.
NOTE:
For detailed operation procedures, refer to
to EN(H4DOTC)(diag)-29, Subaru Select Monitor.>
General scan tool
Check
Yes
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
Is AVCS advance approxiCheck the followmately 0 degrees, and the oil
ing item and repair
flow control solenoid valve duty or replace if necesoutput approx. 10%?
sary.
Oil pipe (clog)
Oil flow control
solenoid valve
(clogged or dirty oil
passages, spring
settings)
Intake camshaft
(dirt, damage of
camshaft)
Timing belt
(matching of timing
mark)
EN(H4DOTC)(diag)-78
No
Go to step 2.
A temporary malfunction. Perform

the following, and
clean the oil routing. Replace the
engine oil and idle
the engine for 5
minutes, and then
replace the oil filter
and engine oil.

B: DTC P0016 CRANKSHAFT POSITION - CAMSHAFT POSITION

CORRELATION (BANK 1)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-12, DTC P0016 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
Improper idling
CAUTION:
1
Step
CHECK CURRENT DATA.

output.
NOTE:
General scan tool
Check
Yes
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
ing item and repair
sary.
Oil pipe (clog)
Oil flow control
solenoid valve
passages, spring
settings)
Intake camshaft
(dirt, damage of
camshaft)
Timing belt
(matching of timing
mark)
EN(H4DOTC)(diag)-79
No
Go to step 2.

the following, and
engine oil and idle
the engine for 5
minutes, and then
and engine oil.

C: DTC P0018 CRANKSHAFT POSITION - CAMSHAFT POSITION

CORRELATION (BANK 2)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-12, DTC P0018 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
Improper idling
CAUTION:
1
Step
CHECK CURRENT DATA.

output.
NOTE:
General scan tool
Check
Yes
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
ing item and repair
sary.
Oil pipe (clog)
Oil flow control
solenoid valve
passages, spring
settings)
Intake camshaft
(dirt, damage of
camshaft)
Timing belt
(matching of timing
mark)
EN(H4DOTC)(diag)-80
No
Go to step 2.

the following, and
engine oil and idle
the engine for 5
minutes, and then
and engine oil.

D: DTC P0021 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-12, DTC P0021 INTAKE CAMSHAFT POSITION TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
Improper idling
CAUTION:
1
Step
CHECK CURRENT DATA.

output.
NOTE:
General scan tool
Check
Yes
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
ing item and repair
sary.
Oil pipe (clog)
Oil flow control
solenoid valve
passages, spring
settings)
Intake camshaft
(dirt, damage of
camshaft)
Timing belt
(matching of timing
mark)
EN(H4DOTC)(diag)-81
No
Go to step 2.

the following, and
engine oil and idle
the engine for 5
minutes, and then
and engine oil.

E: DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1)

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-13, DTC P0030 HO2S HEATER CONTROL CIRCUIT
CAUTION:
WIRING DIAGRAM:
F2
1 2 3 4
10 11 12 13 14
BATTERY
MAIN RELAY
5 6 7 8 9
15 16 17 18 19 20
SBF-5
6
4
14
B262
B100
5
3
1
3
5
2
4
6
1 2 3 4
5 6 7 8
1
3
FRONT OXYGEN
(A/F) SENSOR
A: B134
1 2
8 9 10
18 19 20
28 29 30
B262
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
B122
B1
B9
B8
C2
C3
1
5
C: B136
A: B134
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B: B135
ECM
5 6
14 15 16
25 26 27
33 34 35
C: B136
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
26 27
28 29
30 31
A5
D2
D1
D: B137
D7
D3
36
B22
35
34
B47
54
37
2
1
2
4
B122
B47
F2
B22
E3
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
E
EN-04786
EN(H4DOTC)(diag)-82

Step
1) Start and warm-up the engine.
front oxygen (A/F) sensor.
(B136) No. 2 (B262) No. 2:
(B136) No. 3 (B262) No. 2:
(B135) No. 8 (B262) No. 3:
(B135) No. 9 (B262) No. 4:
main relay and front oxygen (A/F) sensor connector.
(B47) No. 4 (B262) No. 1:
Measure the resistance between front oxygen
(A/F) sensor connector terminals.
Terminals
No. 1 No. 2:
CHECK POOR CONTACT.
Check the poor contact of ECM and front oxygen (A/F) sensor connector.
Check
Yes
No
Repair the open
circuit of harness
between ECM and
front oxygen (A/F)
sensor connector.
Repair the open

circuit of harness
between ECM and
front oxygen (A/F)
sensor connector.
Repair the open

circuit of harness
between ECM and
front oxygen (A/F)
sensor connector.
Replace the front

FU(H4SO)-36,
Front Oxygen (A/F)
Sensor.>
Is there poor contact in the
Repair poor con- Replace the front
ECM or front oxygen (A/F) sen- tact of the ECM or oxygen (A/F) sensor connector?
front oxygen (A/F) sor. <Ref. to
sensor.
FU(H4SO)-36,
Front Oxygen (A/F)
Sensor.>
EN(H4DOTC)(diag)-83


CAUTION:
WIRING DIAGRAM:
F2
1 2 3 4
10 11 12 13 14
BATTERY
MAIN RELAY
5 6 7 8 9
15 16 17 18 19 20
SBF-5
6
4
14
B262
B100
5
3
1
3
5
2
4
6
1 2 3 4
5 6 7 8
1
3
FRONT OXYGEN
(A/F) SENSOR
A: B134
1 2
8 9 10
18 19 20
28 29 30
B262
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
B122
B1
B9
B8
C2
C3
1
5
C: B136
A: B134
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B: B135
ECM
5 6
14 15 16
25 26 27
33 34 35
C: B136
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
26 27
28 29
30 31
A5
D2
D1
D: B137
D7
D3
36
B22
35
34
B47
54
37
2
1
2
4
B122
B47
F2
B22
E3
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
E
EN-04786
EN(H4DOTC)(diag)-84

Step
Check
CHECK POWER SUPPLY TO FRONT OXY- Is the voltage 10 V or more?
GEN (A/F) SENSOR.
(A/F) sensor.
4) Measure the voltage between front oxygen
(A/F) sensor connector and engine ground.
Yes
Go to step 2.

CHECK CURRENT DATA.

NOTE:
General scan tool
(B136 No. 3 (+) Chassis ground ():
and chassis ground.
Repair the poor

NOTE:
the following item:
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
ECM connector
Go to step 6.
Does the voltage change when Repair poor conshaking the harness and contact in ECM connector of the ECM while moni- nector.
toring the value with a voltage
meter?
EN(H4DOTC)(diag)-85
No
Repair the power
supply line.
NOTE:
the following item:
Open circuit of
harness between
main relay and
front oxygen (A/F)
sensor connector
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground cable
Poor contact in
ECM connector
Poor contact in
coupling connector
Go to step 4.
Go to step 5.
Go to step 6.

Step
Check
?
2) Measure the resistance between front oxygen (A/F) sensor connector terminals.
Terminals
No. 1 No. 2:
EN(H4DOTC)(diag)-86
Yes
Repair the harness
and connector.
NOTE:
the following item:
Open or ground
short circuit of harness between front
oxygen (A/F) sensor and ECM connector
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
ECM connector
No
Replace the front
FU(H4SO)-36,
Front Oxygen (A/F)
Sensor.>


CAUTION:
WIRING DIAGRAM:
F2
1 2 3 4
10 11 12 13 14
BATTERY
MAIN RELAY
5 6 7 8 9
15 16 17 18 19 20
SBF-5
6
4
14
B262
B100
5
3
1
3
5
2
4
6
1 2 3 4
5 6 7 8
1
3
FRONT OXYGEN
(A/F) SENSOR
A: B134
1 2
8 9 10
18 19 20
28 29 30
B262
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
B122
B1
B9
B8
C2
C3
1
5
C: B136
A: B134
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B: B135
ECM
5 6
14 15 16
25 26 27
33 34 35
C: B136
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
26 27
28 29
30 31
A5
D2
D1
D: B137
D7
D3
36
B22
35
34
B47
54
37
2
1
2
4
B122
B47
F2
B22
E3
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
E
EN-04786
EN(H4DOTC)(diag)-87

Step
HEATER CURRENT.
2) Repair the short to power supply in the harness between ECM and front oxygen (A/F) sensor connector.
NOTE:
General scan tool
and chassis ground.
Check
Yes
Go to step 3.

<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
Does the voltage change when

shaking the harness and connector of the ECM while monitoring the value with a voltage
meter?
Repair the short to END.

power supply in the
harness between
connector.
EN(H4DOTC)(diag)-88
No
Go to step 2.

H: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2)

CAUTION:
WIRING DIAGRAM:
B18
BATTERY
MAIN RELAY
1 2
6
4
14
A: B134
1 2
8 9 10
18 19 20
28 29 30
1
3
B18
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B : B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
B122
2
5
C : B136
B1
B30
C4
B4
A:
B134
B:
B135
C:
B136
D:
B137
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
26 27
28 29
30 31
A5
D2
D1
5 6
14 15 16
25 26 27
33 34 35
D : B137
ECM
D7
D3
F2
1 2 3 4
10 11 12 13 14
36
B22
35
34
B47
1 2 3 4
5 6 7 8
F2
REAR OXYGEN
SENSOR
54
37
2
1
3 4
2
4
6
B100
5
3
B122
B47
1
3
5
E3
5 6 7 8 9
15 16 17 18 19 20
E
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
E
EN-04787
EN(H4DOTC)(diag)-89

Step
Check
Yes
CHECK CURRENT DATA.

current using the Subaru Select Monitor or general scan tool.
NOTE:
General scan tool
and chassis ground.
Does the voltage change when

shaking the harness and connector of the ECM while monitoring the value with a voltage
meter?
EN(H4DOTC)(diag)-90
No
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and engine
ground cable
Poor contact in
ECM connector
Poor contact in
coupling connector
tor.
NOTE:
the following item:
Poor contact in
Poor contact in
rear oxygen sensor connecting
harness connector
Poor contact in
ECM connector
Go to step 6.
Go to step 4.
Go to step 5.
Replace the ECM.

<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
Repair the short to

power supply in the
harness between
ECM and rear oxygen sensor connector. After repair,
replace the ECM.
<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>

Step
Check
CHECK POWER SUPPLY TO REAR OXYIs the voltage 10 V or more?
GEN SENSOR.
sensor connector and engine ground or chassis
ground.

2) Measure the resistance between the rear
oxygen sensor connector terminals.
Terminals
No. 1 No. 2:
Yes
Go to step 7.
Is the resistance less than 30 ? Repair the harness

and connector.
NOTE:
the following item:
Open circuit of
harness between
the rear oxygen
sensor and ECM
connector
Poor contact in
Poor contact in
ECM connector
Poor contact in
coupling connector
EN(H4DOTC)(diag)-91
No
Repair the power
supply line.
NOTE:
the following item:
Open circuit of
harness between
main relay and rear
oxygen
sensor
connector
Poor contact in
Poor contact in
coupling connector
Replace the rear
oxygen sensor.
<Ref. to
FU(H4DOTC)-42,

I:
DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2)

CAUTION:
WIRING DIAGRAM:
B18
BATTERY
MAIN RELAY
1 2
6
4
14
A: B134
1 2
8 9 10
18 19 20
28 29 30
1
3
B18
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B : B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
B122
2
5
C : B136
B1
B30
C4
B4
A:
B134
B:
B135
C:
B136
D:
B137
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
26 27
28 29
30 31
A5
D2
D1
5 6
14 15 16
25 26 27
33 34 35
D : B137
ECM
D7
D3
F2
1 2 3 4
10 11 12 13 14
36
B22
35
34
B47
1 2 3 4
5 6 7 8
F2
REAR OXYGEN
SENSOR
54
37
2
1
3 4
2
4
6
B100
5
3
B122
B47
1
3
5
E3
5 6 7 8 9
15 16 17 18 19 20
E
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
E
EN-04787
EN(H4DOTC)(diag)-92

Step
CHECK CURRENT DATA.
1) Repair the short to power supply in the harness between ECM and rear oxygen sensor
connector.
current using the Subaru Select Monitor or general scan tool.
NOTE:
General scan tool
CHECK POOR CONTACT.
Check
Yes
Go to step 2.
Is the current 7 A or more?

<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>

connector?
EN(H4DOTC)(diag)-93
No
Go to step 3.
END.

J: DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-23, DTC P0068 MAP/MAF - THROTTLE POSITION
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
THROTTLE BODY
2
3
1
MANIFOLD ABSOLUTE
PRESSURE SENSOR
E21
19
20
7
E3
29
19
6
B22
B134 ECM
E21
1 2 3
B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04788
EN(H4DOTC)(diag)-94

Step
Check
CHECK IDLE SWITCH SIGNAL.
Does the LED of {Idle Switch
Signal} come on?
2) Operate the LED operation mode for engine
NOTE:
LED OPERATION MODE FOR ENGINE.
<Ref. to EN(H4DOTC)(diag)-29, Subaru Select
Monitor.>
CHECK CONDITION OF MANIFOLD ABSOLUTE PRESSURE SENSOR.
Is the manifold absolute pressure sensor installation bolt

tightened securely?
CHECK CONDITION OF THROTTLE BODY.
Is the throttle body installation

EN(H4DOTC)(diag)-95
Yes
Go to step 2.
No
Check the throttle
position sensor circuit. <Ref. to
EN(H4DOTC)(diag
)-369, DTC P2135
THROTTLE/
PEDAL POSITION SENSOR/
SWITCH A/B
VOLTAGE CORRELATION, Diagnostic Procedure
with Diagnostic
Trouble Code
(DTC).>
NOTE:
Check the relative Go to step 3.
DTC. List of Diagnostic Trouble
Code (DTC) <Ref.
to
EN(H4DOTC)(diag
Code (DTC).>
NOTE:
Go to step 4.
Securely tighten
the manifold absolute pressure sensor installation
bolt.
Replace the mani- Tighten the throttle
fold absolute pres- body installation
sure sensor. <Ref. bolt securely.
to FU(H4DOTC)31, Manifold Absolute Pressure Sensor.>

K: DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/

PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-25, DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
BATTERY
SBF-5
7
5
3
B61
F44
2
1
B47
MASS AIR FLOW &
INTAKE AIR
TEMPERATURE SENSOR
2
34
3
26
18
5
35
30
B3
E
B135
B3
1 2 3 4 5
B47
1
3
5
2
4
6
ECM
B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
F44
1 2 3 4
5 6 7 8
EN-03809
EN(H4DOTC)(diag)-96

Step
Check
EN(H4DOTC)(diag)-97
Yes
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
NOTE:
No
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(H4DOTC)-30,
Mass Air Flow and

L: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-28, DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
BATTERY
SBF-5
7
5
3
B61
F44
2
1
B47
MASS AIR FLOW &
INTAKE AIR
TEMPERATURE SENSOR
2
34
3
26
18
5
35
30
B3
E
B135
B3
1 2 3 4 5
B47
1
3
5
2
4
6
ECM
B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
F44
1 2 3 4
5 6 7 8
EN-03809
EN(H4DOTC)(diag)-98

Step
Check
DATA.
NOTE:
General scan tool

and chassis ground while engine is idling.
CHECK POWER SUPPLY TO MASS AIR
FLOW SENSOR.
2) Disconnect the connector from mass air
flow sensor.
ECM and mass air flow sensor connector.
(B135) No. 26 (B3) No. 3:
(B135) No. 34 (B3) No. 2:
(B135) No. 30 (B3) No. 5:
Yes
No
function indicator
light illuminates,
the circuit has
this time. Temporary poor contact of
connector or harness may be the
cause. Repair the
harness or connector in mass air
flow sensor.
NOTE:
the following item:
Open or ground
short circuit in harness between
mass air flow sensor and ECM connector
Poor contact in
mass air flow sensor or ECM connector
Go to step 3.
Repair the poor
contact in ECM
connector.
Go to step 4.
Repair the open

circuit between
mass air flow sensor and main relay.
Repair the open

circuit between
ECM and mass air
more?
Repair the ground

short circuit
between ECM and
mass air flow sensor connector.
EN(H4DOTC)(diag)-99
Go to step 6.

Step
Check
Yes
CHECK POOR CONTACT.
Is there poor contact in mass air Repair the poor
Check poor contact of mass air flow sensor con- flow sensor connector?
contact of mass air
nector.
EN(H4DOTC)(diag)-100
No
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(H4DOTC)-30,
Mass Air Flow and

M: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-30, DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
BATTERY
SBF-5
7
5
3
B61
F44
2
1
B47
MASS AIR FLOW &
INTAKE AIR
TEMPERATURE SENSOR
2
34
3
26
18
5
35
30
B3
E
B135
B3
1 2 3 4 5
B47
1
3
5
2
4
6
ECM
B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
F44
1 2 3 4
5 6 7 8
EN-03809

Step
Check
DATA.
NOTE:
General scan tool
2) Disconnect the connector from mass airflow
sensor.
ECM connector and mass air flow sensor connector.
(B3) No. 2 (B135) No. 34:
Yes
light illuminates,
the circuit has
this time.
No
Go to step 2.
Repair the short

Go to step 3.
circuit to power
supply in the harness between the
mass air flow sensor connector and
ECM connector.
Replace the mass

air flow sensor.
<Ref. to
FU(H4DOTC)-30,
Mass Air Flow and
Repair the open

circuit of harness
between mass air
flow sensor connector and ECM
connector.

N: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE

CIRCUIT LOW INPUT
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-32, DTC P0107 MANIFOLD ABSOLUTE PRESSURE/
BAROMETRIC PRESSURE CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
THROTTLE BODY
2
3
1
MANIFOLD ABSOLUTE
PRESSURE SENSOR
E21
19
20
7
E3
29
19
6
B22
B134 ECM
E21
1 2 3
B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04788

Step
and chassis ground.
ground.
engine ground.
connector.
(B134) No. 29 (E21) No. 2:
manifold absolute pressure sensor connector
and engine ground.
CHECK POOR CONTACT.
Check
Yes
Go to step 2.
No
Repair the poor
contact in ECM
connector.
Repair the poor

contact in ECM
connector.
Go to step 4.
Repair the open

circuit of harness
between ECM and
manifold absolute
pressure sensor
connector.
Repair the open

circuit of harness
between ECM and
manifold absolute
pressure sensor
connector.
more?
Go to step 6.
Repair ground
ECM and manifold
absolute pressure
sensor connector.

connector?
Repair the poor

connector.


O: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE

CIRCUIT HIGH INPUT
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-34, DTC P0108 MANIFOLD ABSOLUTE PRESSURE/
BAROMETRIC PRESSURE CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
THROTTLE BODY
2
3
1
MANIFOLD ABSOLUTE
PRESSURE SENSOR
E21
19
20
7
E3
29
19
6
B22
B134 ECM
E21
1 2 3
B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04788

Step
and chassis ground.
and chassis ground.
engine ground.
connector.
(B134) No. 6 (E21) No. 1:
connector.
(B134) No. 29 (E21) No. 2:
CHECK POOR CONTACT.
Check
Yes
Go to step 2.
No
Repair the poor
contact in ECM
connector.
Go to step 3.
Repair the poor

contact in ECM
connector.
Go to step 4.
Repair the open

circuit of harness
between ECM and
manifold absolute
pressure sensor
connector.
Repair the open

circuit of harness
between ECM and
manifold absolute
pressure sensor
connector.
Repair the open

circuit of harness
between ECM and
manifold absolute
pressure sensor
connector.

connector?

Repair the poor

connector.

P: DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/

PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-36, DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
BATTERY
SBF-5
7
5
3
B61
F44
2
1
B47
MASS AIR FLOW &
INTAKE AIR
TEMPERATURE SENSOR
2
34
3
26
18
5
35
30
B3
E
B135
B3
1 2 3 4 5
B47
1
3
5
2
4
6
ECM
B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
F44
1 2 3 4
5 6 7 8
EN-03809

Step
CHECK ENGINE COOLANT TEMPERATURE.

2) Measure the engine coolant temperature
using the Subaru Select Monitor or general
scan tool.
NOTE:
General scan tool
Check
Yes
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
NOTE:
Is the engine coolant tempera- Replace the mass
ture 75 95C (167 203F) air flow and intake
?
air temperature
sensor. <Ref. to
FU(H4DOTC)-30,
Mass Air Flow and
No
Go to step 2.
Check DTC P0125

using List of Diagnostic Trouble
Code (DTC). <Ref.
to
EN(H4DOTC)(diag
Code (DTC).>

Q: DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-38, DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
BATTERY
SBF-5
7
5
3
B61
F44
2
1
B47
MASS AIR FLOW &
INTAKE AIR
TEMPERATURE SENSOR
2
34
3
26
18
5
35
30
B3
E
B135
B3
1 2 3 4 5
B47
1
3
5
2
4
6
ECM
B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
F44
1 2 3 4
5 6 7 8
EN-03809

Step
CHECK CURRENT DATA.
NOTE:
General scan tool
CHECK HARNESS BETWEEN MASS AIR
FLOW AND INTAKE AIR TEMPERATURE
SENSOR AND THE ECM CONNECTOR.
2) Disconnect the connector from the mass air
flow and intake air temperature sensor.
NOTE:
General scan tool
Check
Is the temperature 55C
(131F) or more?
Yes
Go to step 2.
No
Repair the poor
contact.
NOTE:
the following item:
Poor contact of
mass air flow and
Poor contact in
ECM
Poor contact in
joint connector
Is the temperature less than

36C (33F)?
Replace the mass

air flow and intake
air temperature
sensor. <Ref. to
FU(H4DOTC)-30,
Mass Air Flow and
Repair the ground

harness between
the mass air flow
and intake air temperature sensor
and ECM connector.

R: DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-40, DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
BATTERY
SBF-5
7
5
3
B61
F44
2
1
B47
MASS AIR FLOW &
INTAKE AIR
TEMPERATURE SENSOR
2
34
3
26
18
5
35
30
B3
E
B135
B3
1 2 3 4 5
B47
1
3
5
2
4
6
ECM
B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
F44
1 2 3 4
5 6 7 8
EN-03809

Step
CHECK CURRENT DATA.
NOTE:
General scan tool
2) Disconnect the connector from the mass air
flow and intake air temperature sensor.
3) Measure the voltage between the mass air
flow and intake air temperature sensor connectors and engine ground.
2) Measure the voltage between connectors of
mass air flow and intake air temperature sensor
and engine ground.
Measure the voltage between the mass air flow
and intake air temperature sensor, manifold
absolute pressure sensor connector, and
engine ground.
Check
36C (33F)?
Yes
Go to step 2.
Repair the short

Go to step 3.
circuit to power
mass air flow and
ECM connector.
Repair the short

Go to step 4.
circuit to power
mass air flow and
ECM connector.
Go to step 5.
No
Repair the poor
contact.
NOTE:
the following item:
Poor contact of
mass air flow and
Poor contact in
ECM
Poor contact in
joint connector
Repair the harness

and connector.
NOTE:
the following item:
Open circuit between mass air
flow and intake air
temperature sensor and ECM connector.
Poor contact of
mass air flow and
Poor contact in
ECM
Poor contact in
joint connector

Step
Check
mass air flow and intake air temperature sensor
and engine ground.
Yes
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(H4DOTC)-30,
Mass Air Flow and
No
Repair the harness
and connector.
NOTE:
the following item:
Open circuit between mass air
flow and intake air
temperature sensor and ECM connector.
Poor contact of
mass air flow and
Poor contact in
ECM
Poor contact in
joint connector

S: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-42, DTC P0117 ENGINE COOLANT TEMPERATURE
TROUBLE SYMPTOM:
Hard to start
Improper idling
CAUTION:
WIRING DIAGRAM:
E8
ENGINE
COOLANT
TEMPERATURE
SENSOR
2
1
1 2
3
E8
B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
8
19
E3
B22
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
34
29
48
36
B134 ECM
EN-04789

Step
Check
CHECK CURRENT DATA.
(248F) or more?
NOTE:
General scan tool
Is the temperature 40C (
COOLANT TEMPERATURE SENSOR AND 40F) or more?
ECM CONNECTOR.
NOTE:
General scan tool
Yes
Go to step 2.
No
Repair the poor
contact.
NOTE:
the following item:
Poor contact in
engine coolant
temperature sensor
Poor contact in
ECM
Poor contact in
coupling connector
Poor contact in
joint connector
Replace the
Repair the ground
engine coolant
short circuit of hartemperature sen- ness between
sor. <Ref. to
engine coolant
FU(H4DOTC)-26, temperature senEngine Coolant
sor and ECM conTemperature Sen- nector.
sor.>

T: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-44, DTC P0118 ENGINE COOLANT TEMPERATURE
TROUBLE SYMPTOM:
Hard to start
Improper idling
CAUTION:
WIRING DIAGRAM:
E8
ENGINE
COOLANT
TEMPERATURE
SENSOR
2
1
1 2
3
E8
B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
8
19
E3
B22
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
34
29
48
36
B134 ECM
EN-04789

Step
Check
CHECK CURRENT DATA.
40C (40F)?
NOTE:
General scan tool
Yes
Go to step 2.

ECM CONNECTOR.
ground.
ECM CONNECTOR.
ground.
ECM CONNECTOR.
Measure the voltage between engine coolant
ground.
Repair the short

circuit to power
supply in the harness between
ECM and engine
No
Repair the poor
contact.
NOTE:
the following item:
Poor contact in
engine coolant
temperature sensor
Poor contact in
ECM
Poor contact in
coupling connector
Poor contact in
joint connector
Go to step 3.
Repair the short

circuit to power
supply in the harness between
ECM and engine
Go to step 4.
Go to step 5.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and engine
Poor contact in
engine coolant
Poor contact in
ECM connector
Poor contact in
coupling connector
Poor contact in
joint connector

Step
Check
ECM CONNECTOR.
engine coolant temperature sensor connector
and engine ground.
Yes
Replace the
engine coolant
FU(H4DOTC)-26,
Engine Coolant
No
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and engine
Poor contact in
engine coolant
Poor contact in
ECM connector
Poor contact in
coupling connector
Poor contact in
joint connector

U: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT

LOW
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-46, DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
ELECTRONIC THROTTLE
CONTROL RELAY
B309
B309
BATTERY
SBF-5
2
1
3
4
1 2
3 4
8
7
MAIN RELAY
B61
F44
B20
B122
1
5
9
13
2
6
10
14
3
7
11
15
1 2 3 4
5 6 7 8
4
8
12
16
C1
C21
B47
E57
1 2 3 4 5 6
A: B134
C: B136
D: B137
ECM
D2
C6
A5
A28
A18
A29
A19
D4
D5
D7
D3
F44
1 2 3
5 6 7
3
7
4
8
2
4
6
B122
A: B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
1 2
8 9 10
18 19 20
28 29 30
19
20
54
37
39
38
B22
B47
1
3
5
E3
C: B136
36
B20
35
16
15
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
E1
D: B137
B22
E3
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
E
E57
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
4
6
3
5
1
2
B22
ELECTRONIC
THROTTLE
CONTROL
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04790

Step
2) Measure the voltage between ECM connector and terminal.
(B134) No. 28 (+) (B134) No. 29 ():
3) Check the voltage change while shaking the
ECM harness and connector, engine harness
connector, and electronic throttle control connector harness.
CHECK POOR CONTACT.
throttle control.
(B134) No. 19 (E57) No. 5:
THROTTLE CONTROL.
4) Check the voltage change by shaking the
harness and connector of ECM, and engine
harness connector, while monitoring the value
with voltage meter.
Check
Yes
Go to step 2.

No
Go to step 3.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
more?
Go to step 5.
Repair the chassis

Go to step 6.

trol connector.
defective.

V: DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT

HIGH
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-48, DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
ELECTRONIC THROTTLE
CONTROL RELAY
B309
B309
BATTERY
SBF-5
2
1
3
4
1 2
3 4
8
7
MAIN RELAY
B61
F44
B20
B122
1
5
9
13
2
6
10
14
3
7
11
15
1 2 3 4
5 6 7 8
4
8
12
16
C1
C21
B47
E57
1 2 3 4 5 6
A: B134
C: B136
D: B137
ECM
D2
C6
A5
A28
A18
A29
A19
D4
D5
D7
D3
F44
1 2 3
5 6 7
3
7
4
8
2
4
6
B122
A: B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
1 2
8 9 10
18 19 20
28 29 30
19
20
54
37
39
38
B22
B47
1
3
5
E3
C: B136
36
B20
35
16
15
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
E1
D: B137
B22
E3
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
E
E57
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
4
6
3
5
1
2
B22
ELECTRONIC
THROTTLE
CONTROL
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04790

Step
CHECK POOR CONTACT.
Check
Yes
No
Go to step 3.

Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.

throttle control.
(B134) No. 18 (E57) No. 6:
(B134) No. 29 (E57) No. 3:
CHECK SENSOR OUTPUT POWER SUPPLY.
Go to step 4.
Go to step 5.
Replace the electronic throttle control. <Ref. to

FU(H4DOTC)-13,
Throttle Body.>
Repair the short

circuit to power
ECM connector
and electronic
throttle control
connector.

W: DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP

FUEL CONTROL
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-50, DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
E8
ENGINE
COOLANT
TEMPERATURE
SENSOR
2
1
1 2
3
E8
B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
8
19
E3
B22
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
34
29
48
36
B134 ECM
EN-04789

Step
CHECK ENGINE COOLING SYSTEM.

NOTE:
Thermostat open stuck
Coolant level
Engine coolant freeze
Tire diameter
Check
Yes
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
NOTE:
Is there any fault in engine cool- Replace the thering system?
mostat. <Ref. to
CO(H4SO)-25,
Thermostat.>
No
Go to step 2.
Replace the
engine coolant
FU(H4DOTC)-26,
Engine Coolant

X: DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR

STABLE OPERATION
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-52, DTC P0126 INSUFFICIENT ENGINE COOLANT
TEMPERATURE FOR STABLE OPERATION, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
E8
ENGINE
COOLANT
TEMPERATURE
SENSOR
2
1
1 2
3
E8
B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
8
19
E3
B22
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
34
29
48
36
B134 ECM
EN-04789

Step
Check
Yes
No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4DOTC)(diag
Code (DTC).>
CHECK ENGINE COOLANT TEMPERATURE Is there a change in resistance Repair the poor
Replace the
SENSOR.
between the cold condition and contact in ECM.
engine coolant
Measure the resistance between the engine
after warm up?
temperature sencoolant temperature sensor terminals when the
sor. <Ref. to
engine coolant is cold and after warm-up.
FU(H4SO)-22,
Terminals
Engine Coolant
No. 1 No. 2:

Y: DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-54, DTC P0128 COOLANT THERMOSTAT (ENGINE
COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE), Diagnostic Trouble
TROUBLE SYMPTOM:
Thermostat remains open.
CAUTION:
1
Step
CHECK VEHICLE.
CHECK ENGINE COOLANT.
CHECK RADIATOR FAN.

2) Check radiator fan operation.
Check
Yes
Was the vehicle driven or idled In this case, it is not
with the engine partially subnecessary to
merged under water?
inspect DTC
P0128.
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
Are the coolant level and mix- Go to step 4.
ture ratio of engine coolant to
anti-freeze solution correct?
Does the radiator fan continuously rotate for more than 3

minutes during idling?
No
Go to step 2.
Go to step 3.
Replace the
engine coolant.
<Ref. to
CO(H4SO)-18,
REPLACEMENT,
Engine Coolant.>
Repair radiator fan Replace the thercircuit. <Ref. to
mostat. <Ref. to
CO(H4SO)-34,
CO(H4SO)-25,
Radiator Main Fan Thermostat.>
and Fan Motor.>
and <Ref. to
CO(H4SO)-41,
Radiator Sub Fan
and Fan Motor.>.

Z: DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-56, DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
F2
1 2 3 4
10 11 12 13 14
BATTERY
MAIN RELAY
5 6 7 8 9
15 16 17 18 19 20
SBF-5
6
4
14
B262
B100
5
3
1
3
5
2
4
6
1 2 3 4
5 6 7 8
1
3
FRONT OXYGEN
(A/F) SENSOR
A: B134
1 2
8 9 10
18 19 20
28 29 30
B262
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
B122
B1
B9
B8
C2
C3
1
5
C: B136
A: B134
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B: B135
ECM
5 6
14 15 16
25 26 27
33 34 35
C: B136
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
26 27
28 29
30 31
A5
D2
D1
D: B137
D7
D3
36
B22
35
34
B47
54
37
2
1
2
4
B122
B47
F2
B22
E3
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
E
EN-04786

Step
Check
Yes
No
oughly.
more?
Replace the front

FU(H4SO)-36,
Front Oxygen (A/F)
Sensor.>
Repair the ground

connector.

AA:DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-58, DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
F2
1 2 3 4
10 11 12 13 14
BATTERY
MAIN RELAY
5 6 7 8 9
15 16 17 18 19 20
SBF-5
6
4
14
B262
B100
5
3
1
3
5
2
4
6
1 2 3 4
5 6 7 8
1
3
FRONT OXYGEN
(A/F) SENSOR
A: B134
1 2
8 9 10
18 19 20
28 29 30
B262
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
B122
B1
B9
B8
C2
C3
1
5
C: B136
A: B134
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B: B135
ECM
5 6
14 15 16
25 26 27
33 34 35
C: B136
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
26 27
28 29
30 31
A5
D2
D1
D: B137
D7
D3
36
B22
35
34
B47
54
37
2
1
2
4
B122
B47
F2
B22
E3
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
E
EN-04786

Step
Check
TOR.
(A/F) sensor.
Yes
No
oughly.
Replace the front
FU(H4SO)-36,
Front Oxygen (A/F)
Sensor.>
Repair the short to

power supply in the
harness between
connector.

AB:DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1)

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-60, DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
F2
1 2 3 4
10 11 12 13 14
BATTERY
MAIN RELAY
5 6 7 8 9
15 16 17 18 19 20
SBF-5
6
4
14
B262
B100
5
3
1
3
5
2
4
6
1 2 3 4
5 6 7 8
1
3
FRONT OXYGEN
(A/F) SENSOR
A: B134
1 2
8 9 10
18 19 20
28 29 30
B262
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
B122
B1
B9
B8
C2
C3
1
5
C: B136
A: B134
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B: B135
ECM
5 6
14 15 16
25 26 27
33 34 35
C: B136
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
26 27
28 29
30 31
A5
D2
D1
D: B137
D7
D3
36
B22
35
34
B47
54
37
2
1
2
4
B122
B47
F2
B22
E3
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
E
EN-04786

Step
Check

system?
NOTE:
Loose installation of front portion of exhaust
pipe onto cylinder heads
Loose connection between front exhaust pipe
and front catalytic converter
Damage of exhaust pipe resulting in a hole
Yes
No
priate DTC using
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
NOTE:
Repair the exhaust Replace the front
system.
FU(H4SO)-36,
Front Oxygen (A/F)
Sensor.>

AC:DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1

SENSOR 1)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-63, DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY
CAUTION:
WIRING DIAGRAM:
F2
1 2 3 4
10 11 12 13 14
BATTERY
MAIN RELAY
5 6 7 8 9
15 16 17 18 19 20
SBF-5
6
4
14
B262
B100
1
3
5
2
4
6
1 2 3 4
5 6 7 8
1
3
FRONT OXYGEN
(A/F) SENSOR
A: B134
1 2
8 9 10
18 19 20
28 29 30
B262
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
B122
B1
B9
B8
C2
C3
1
5
C: B136
A: B134
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B: B135
ECM
5 6
14 15 16
25 26 27
33 34 35
C: B136
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
26 27
28 29
30 31
A5
D2
D1
D: B137
D7
D3
36
B22
35
34
B47
54
37
2
1
2
4
B122
B47
F2
5
3
B22
E3
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
E
EN-04786

Step
Check
(B135) No. 8 (B262) No. 3:
(B135) No. 9 (B262) No. 4:
Yes
Replace the front
FU(H4SO)-36,
Front Oxygen (A/F)
Sensor.>
No
Repair the open
circuit of harness
between ECM and
front oxygen (A/F)
sensor connector.

AD:DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-65, DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
B18
BATTERY
MAIN RELAY
1 2
6
4
14
A: B134
1 2
8 9 10
18 19 20
28 29 30
1
3
B18
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B : B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
B122
2
5
C : B136
B1
B30
C4
B4
A:
B134
B:
B135
C:
B136
D:
B137
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
26 27
28 29
30 31
A5
D2
D1
5 6
14 15 16
25 26 27
33 34 35
D : B137
ECM
D7
D3
F2
1 2 3 4
10 11 12 13 14
36
B22
35
34
B47
1 2 3 4
5 6 7 8
F2
REAR OXYGEN
SENSOR
54
37
2
1
3 4
2
4
6
B100
5
3
B122
B47
1
3
5
E3
5 6 7 8 9
15 16 17 18 19 20
E
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
E
EN-04787

3
4
Step

tool.
NOTE:
For MT vehicles, depress the clutch pedal.
General scan tool
rear oxygen sensor.
(B135) No. 4 (B18) No. 3:
(B135) No. 30 (B18) No. 4:
Check
Yes
No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4DOTC)(diag
Code (DTC).>
NOTE:
Go to step 3.
tor?
oughly.
Go to step 5.
circuit of harness
between ECM and
rear oxygen sensor
connector.
Replace the rear

oxygen sensor.
<Ref. to
FU(H4DOTC)-42,
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
Poor contact in
Poor contact in
ECM connector

Step
Check
system?
NOTE:
Yes
Repair or replace
faulty parts.
No
Replace the rear
oxygen sensor.
<Ref. to
FU(H4DOTC)-42,

AE:DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-67, DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
B18
BATTERY
MAIN RELAY
1 2
6
4
14
A: B134
1 2
8 9 10
18 19 20
28 29 30
1
3
B18
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B : B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
B122
2
5
C : B136
B1
B30
C4
B4
A:
B134
B:
B135
C:
B136
D:
B137
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
26 27
28 29
30 31
A5
D2
D1
5 6
14 15 16
25 26 27
33 34 35
D : B137
ECM
D7
D3
F2
1 2 3 4
10 11 12 13 14
36
B22
35
34
B47
1 2 3 4
5 6 7 8
F2
REAR OXYGEN
SENSOR
54
37
2
1
3 4
2
4
6
B100
5
3
B122
B47
1
3
5
E3
5 6 7 8 9
15 16 17 18 19 20
E
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
E
EN-04787

3
4
Step

tool.
NOTE:
General scan tool
rear oxygen sensor.
(B135) No. 4 (B18) No. 3:
(B135) No. 30 (B18) No. 4:
Check
Yes
No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4DOTC)(diag
Code (DTC).>
NOTE:
Go to step 3.
tor?
oughly.
Go to step 5.
circuit of harness
between ECM and
rear oxygen sensor
connector.
Replace the rear

oxygen sensor.
<Ref. to
FU(H4DOTC)-42,
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
Poor contact in
Poor contact in
ECM connector

Step
Check
system?
NOTE:
Yes
Repair or replace
faulty parts.
No
Replace the rear
oxygen sensor.
<Ref. to
FU(H4DOTC)-42,

AF:DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2)

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-68, DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
B18
BATTERY
MAIN RELAY
1 2
6
4
14
A: B134
1 2
8 9 10
18 19 20
28 29 30
1
3
B18
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B : B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
B122
2
5
C : B136
B1
B30
C4
B4
A:
B134
B:
B135
C:
B136
D:
B137
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
26 27
28 29
30 31
A5
D2
D1
5 6
14 15 16
25 26 27
33 34 35
D : B137
ECM
D7
D3
F2
1 2 3 4
10 11 12 13 14
36
B22
35
34
B47
1 2 3 4
5 6 7 8
F2
REAR OXYGEN
SENSOR
54
37
2
1
3 4
2
4
6
B100
5
3
B122
B47
1
3
5
E3
5 6 7 8 9
15 16 17 18 19 20
E
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
E
EN-04787

Step
Check
Yes
No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4DOTC)(diag
Code (DTC).>
NOTE:
Repair the harness
and connector.
NOTE:
rear oxygen sensor.
the following item:
Open circuit in
harness between
rear oxygen sen(B135) No. 4 (B18) No. 3:
sor and ECM connector
Go to step 4.
Repair the chassis
more?
harness between
the rear oxygen
sensor and ECM
connector.
Is the resistance less than 1 ? Replace the rear Repair the poor
oxygen sensor.
contact in rear oxysensor terminals.
<Ref. to
gen sensor conTerminals
FU(H4DOTC)-42, nector.
No. 3 No. 4:

AG:DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1

SENSOR 2)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-73, DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY
CAUTION:
WIRING DIAGRAM:
B18
BATTERY
MAIN RELAY
1 2
6
4
14
A: B134
1 2
8 9 10
18 19 20
28 29 30
1
3
B18
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B : B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
B122
2
5
C : B136
B1
B30
C4
B4
A:
B134
B:
B135
C:
B136
D:
B137
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
26 27
28 29
30 31
A5
D2
D1
5 6
14 15 16
25 26 27
33 34 35
D : B137
ECM
F2
1 2 3 4
10 11 12 13 14
36
B22
35
34
B47
1 2 3 4
5 6 7 8
F2
REAR OXYGEN
SENSOR
D7
D3
2
1
54
37
5
3
3 4
2
4
6
B100
B122
B47
1
3
5
E3
5 6 7 8 9
15 16 17 18 19 20
E
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
E
EN-04787

4
5
Step

tool.
NOTE:
General scan tool
tool.
NOTE:
General scan tool
rear oxygen sensor.
(B135) No. 4 (B18) No. 3:
(B135) No. 30 (B18) No. 4:
Check
Yes
No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4DOTC)(diag
Code (DTC).>
NOTE:
Go to step 3.
Go to step 4.
tor?
oughly.
Go to step 6.
circuit of harness
between ECM and
rear oxygen sensor
connector.

Step
Check
CHECK HARNESS BETWEEN REAR OXY- Is the voltage 0.2 0.5 V?
GEN SENSOR AND ECM CONNECTOR.
Yes
Replace the rear
oxygen sensor.
<Ref. to
FU(H4DOTC)-42,

system?
NOTE:
Repair or replace
faulty parts.
No
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
Poor contact in
Poor contact in
ECM connector
Replace the rear
oxygen sensor.
<Ref. to
FU(H4DOTC)-42,
AH:DTC P0171 SYSTEM TOO LEAN (BANK 1)

NOTE:
For the diagnostic procedure, refer to DTC P0172. <Ref. to EN(H4DOTC)(diag)-147, DTC P0172 SYSTEM
TOO RICH (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

AI: DTC P0172 SYSTEM TOO RICH (BANK 1)

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-75, DTC P0171 SYSTEM TOO LEAN (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> and <Ref. to GD(H4DOTC)-78, DTC P0172 SYSTEM TOO
RICH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
1
2
Step
Check
on exhaust system?
intake system?
Is the measured value 284
314 kPa (2.9 3.2 kgf/cm2, 41
WARNING:
Place NO FIRE signs near the working 46 psi)?
area.
Measure the fuel pressure while disconnecting
pressure regulator vacuum hose from intake
manifold. <Ref. to ME(H4DOTC)-27, INSPECTION, Fuel Pressure.>
WARNING:
NOTE:
If fuel pressure does not increase, squeeze the
fuel return hose 2 to 3 times, then measure fuel
pressure again.
Is the measured value 230
After connecting the pressure regulator vacuum 260 kPa (2.35 2.65 kgf/cm2,
33 38 psi)?
hose, measure fuel pressure. <Ref. to
ME(H4DOTC)-27, INSPECTION, Fuel Pressure.>
WARNING:
NOTE:
If fuel pressure does not increase, squeeze
the fuel return hose 2 to 3 times, then measure
fuel pressure again.
If the measured value at this step is out of
specification, check or replace pressure regulator and pressure regulator vacuum hose.
Yes
No
system.
Repair the air
Go to step 3.
intake system.
Go to step 4.

Fuel pressure is
too high:
Clogged fuel
return line or bent
hose
Fuel pressure is
too low:
Improper fuel
pump discharge
Clogged fuel
supply line
Go to step 5.

Fuel pressure is
too high:
Faulty pressure
regulator
Clogged fuel
return line or bent
hose
Fuel pressure is
too low:
Faulty pressure
regulator
Improper fuel
pump discharge
Clogged fuel
supply line

Step
CHECK ENGINE COOLANT TEMPERATURE
SENSOR.
NOTE:
General scan tool
TEMPERATURE SENSOR.
(140F).
NOTE:
General scan tool
TEMPERATURE SENSOR.
(140F).
NOTE:
General scan tool
Check
Yes
ture 60C (140F) or more?
No
Replace the
engine coolant
FU(H4DOTC)-26,
Engine Coolant

4.7 g/s (0.36 0.62 lb/m)?
Go to step 7.
Replace the mass

air flow and intake
air temperature
sensor. <Ref. to
FU(H4DOTC)-30,
Mass Air Flow and
Subtract the ambient temperature from intake air temperature. Is the obtained value 10
50C (18 90F)?
Replace the ECM.

<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
Check the mass air

flow and intake air
FU(H4DOTC)-30,
Mass Air Flow and

AJ:DTC P0181 FUEL TEMPERATURE SENSOR A CIRCUIT RANGE/

PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-81, DTC P0181 FUEL TEMPERATURE SENSOR A
CAUTION:
WIRING DIAGRAM:
FUEL TANK
6
5
FUEL TEMPERATURE
SENSOR
R58
3
2
R57
R15
7
2
R2
B98
36
B22
A5
B17
B30
E3
A: B134
ECM
B: B135
A: B134
R58
1 2 3
4 5 6
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B98
B: B135
B22
R57
1 2
3 4 5
6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
41
47
54
EN-04791

Step
Check
Yes
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
NOTE:
No
Replace the fuel
temperature sensor. <Ref. to EC
(H4DOTC)-13,
Fuel Temperature
Sensor.>

AK:DTC P0182 FUEL TEMPERATURE SENSOR A CIRCUIT LOW INPUT

CAUTION:
WIRING DIAGRAM:
FUEL TANK
6
5
FUEL TEMPERATURE
SENSOR
R58
3
2
R57
R15
7
2
R2
B98
36
B22
A5
B17
B30
E3
A: B134
ECM
B: B135
A: B134
R58
1 2 3
4 5 6
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B98
B: B135
B22
R57
1 2
3 4 5
6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
41
47
54
EN-04791

Step
CHECK CURRENT DATA.
2) Read the data of the fuel temperature sensor signal using the Subaru Select Monitor or
general scan tool.
NOTE:
General scan tool
general scan tool operation manual.
CHECK CURRENT DATA.
5) Read data of the fuel temperature sensor
signal using the Subaru Select Monitor or general scan tool.
NOTE:
General scan tool
Check
(302F) or more?
Yes
Go to step 2.
No
light illuminates,
the circuit has
this time.

40C (40F)?
Replace the fuel

(H4DOTC)-13,
Fuel Temperature
Sensor.>
Repair ground
pump and ECM
connector.

AL:DTC P0183 FUEL TEMPERATURE SENSOR A CIRCUIT HIGH INPUT

CAUTION:
WIRING DIAGRAM:
FUEL TANK
6
5
FUEL TEMPERATURE
SENSOR
R58
3
2
R57
R15
7
2
R2
B98
36
B22
A5
B17
B30
E3
A: B134
ECM
B: B135
A: B134
R58
1 2 3
4 5 6
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B98
B: B135
B22
R57
1 2
3 4 5
6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
41
47
54
EN-04791

Step
CHECK CURRENT DATA.
2) Read the data of the fuel temperature sensor signal using the Subaru Select Monitor or
general scan tool.
NOTE:
General scan tool
Measure the voltage between fuel pump connector and chassis ground.
Check
40C (40F)?
Yes
Go to step 2.
Repair the short

circuit to power
ECM and fuel
pump connector.
Repair the short

circuit to power
ECM and fuel
pump connector.
Go to step 4.
Go to step 5.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and fuel
pump connector
Poor contact in
fuel pump connector
Poor contact in
ECM connector
Poor contact in
coupling connector
No
Repair the poor
contact.
NOTE:
the following item:
Poor contact in
fuel pump connector
Poor contact in
ECM connector
Poor contact in
coupling connector
Poor contact in
joint connector
Go to step 3.

Step
Check
CHECK HARNESS BETWEEN FUEL TEMIs the resistance less than 1 ?
PERATURE SENSOR AND ECM CONNECTOR.
fuel pump connector and ECM.
(R58) No. 5 (B135) No. 30:
Yes
Replace the fuel
(H4DOTC)-13,
Fuel Temperature
Sensor.>
No
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and fuel
pump connector
Poor contact in
fuel pump connector
Poor contact in
ECM connector
Poor contact in
coupling connector
Poor contact in
joint connector

AM:DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT

LOW
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-88, DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
ELECTRONIC THROTTLE
CONTROL RELAY
B309
B309
BATTERY
SBF-5
2
1
3
4
1 2
3 4
8
7
MAIN RELAY
B61
F44
B20
B122
1
5
9
13
2
6
10
14
3
7
11
15
1 2 3 4
5 6 7 8
4
8
12
16
C1
C21
B47
E57
1 2 3 4 5 6
A: B134
C: B136
D: B137
ECM
D2
C6
A5
A28
A18
A29
A19
D4
D5
D7
D3
F44
1 2 3
5 6 7
3
7
4
8
2
4
6
B122
A: B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
1 2
8 9 10
18 19 20
28 29 30
19
20
54
37
39
38
B22
B47
1
3
5
E3
C: B136
36
B20
35
16
15
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
E1
D: B137
B22
E3
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
E
E57
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
4
6
3
5
1
2
B22
ELECTRONIC
THROTTLE
CONTROL
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04790

Step
Check
2) Measure the voltage between ECM connector and terminal.
(B134) No. 28 (+) (B134) No. 29 ():
CHECK POOR CONTACT.
throttle control.
(B134) No. 19 (E57) No. 5:
with voltage meter.
Yes
Go to step 2.
No
Go to step 3.
Repair the poor

contact.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
more?
Go to step 5.
Repair the chassis

Go to step 6.

Repair poor concontact of electact in ECM contronic throttle con- nectot.
trol connector.

AN:DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT

HIGH
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-90, DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
ELECTRONIC THROTTLE
CONTROL RELAY
B309
B309
BATTERY
SBF-5
2
1
3
4
1 2
3 4
8
7
MAIN RELAY
B61
F44
B20
B122
1
5
9
13
2
6
10
14
3
7
11
15
1 2 3 4
5 6 7 8
4
8
12
16
C1
C21
B47
E57
1 2 3 4 5 6
A: B134
C: B136
D: B137
ECM
D2
C6
A5
A28
A18
A29
A19
D4
D5
D7
D3
F44
1 2 3
5 6 7
3
7
4
8
2
4
6
B122
A: B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
1 2
8 9 10
18 19 20
28 29 30
19
20
54
37
39
38
B22
B47
1
3
5
E3
C: B136
36
B20
35
16
15
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
E1
D: B137
B22
E3
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
E
E57
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
4
6
3
5
1
2
B22
ELECTRONIC
THROTTLE
CONTROL
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04790

Step
CHECK POOR CONTACT.
throttle control.
(B134) No. 28 (E57) No. 4:
(B134) No. 29 (E57) No. 3:
with voltage meter.
with voltage meter.
Check
Yes
No
Go to step 3.

Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
Go to step 6.
Repair the short

circuit to power
ECM connector
and electronic
throttle control
connector.
Go to step 7.
Repair the short

circuit to power
ECM connector
and electronic
throttle control
connector.

Step
Check
more?
terminals.
(B134) No. 28 (B134) No. 19:
Yes
Repair the poor
contact. Replace
the electronic
throttle control if
defective.
No
Sensor power supply circuit may be
shorted.

AO:DTC P0230 FUEL PUMP PRIMARY CIRCUIT

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-92, DTC P0230 FUEL PUMP PRIMARY CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
BATTERY
SBF-5
7
2
1
4
3
B61
FUEL PUMP
RELAY
IGNITION SWITCH
SBF-4
No.11
B46
7
8
21
B99
R3
SBF-1
1
B72
3
2
5
R122
F44
C12
B33
ECM
FUEL PUMP
CONTROL UNIT
B : B135
R122
6
4
C : B136
6
12
R15
1
4
R57
FUEL
PUMP
F44
1 2 3 4
5 6 7 8
B72
1 2
3 4
B : B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
R58
B99
B46
1 2
3 4
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
R58
R122
1 2 3
4 5 6
R57
1 2
3 4 5
6 7 8 9 10 11 12
C : B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
EN-04784

Step
Check
CHECK POWER SUPPLY CIRCUIT TO FUEL Is the voltage 10 V or more?
PUMP CONTROL UNIT.
control unit.
control unit and chassis ground.
Yes
Go to step 2.
CHECK GROUND CIRCUIT OF FUEL PUMP Is the resistance less than 5 ? Go to step 3.
CONTROL UNIT.
fuel pump control unit and chassis ground.

CONTROL UNIT AND FUEL PUMP CONNECTOR.
fuel pump control unit and fuel pump connector.
(R122) No. 4 (R58) No. 4:
(R122) No. 6 (R58) No. 1:
CONTROL UNIT AND FUEL PUMP CONNECTOR.
CONTROL UNIT AND ECM CONNECTOR.
fuel pump control unit and ECM connector.
(R122) No. 2 (B136) No. 12:
(R122) No. 5 (B135) No. 33:
more?
No
Repair the power
supply circuit.
NOTE:
the following item:
Open or ground
pump relay and
fuel pump control
unit
Poor contact of
fuel pump control
unit connector
Poor contact of
fuel pump relay
connector
Repair the harness
and connector.
NOTE:
the following item:
Open circuit between fuel pump
control unit and
chassis ground
Poor contact of
fuel pump control
unit connector
Repair the open
pump control unit
and fuel pump.
Go to step 5.
Repair the ground

short circuit
between fuel pump
control unit and
fuel pump.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit between fuel pump
control unit and
ECM
Poor contact of
fuel pump control
unit and ECM connector

Step
CONTROL UNIT AND ECM CONNECTOR.
CHECK POOR CONTACT.
Check poor contact of ECM and fuel pump control unit connector.
Check
more?
Yes
Go to step 7.
Is there poor contact of ECM

Repair poor conand fuel pump control unit contact in ECM and
nector?
fuel pump control
unit.
CHECK EXPERIENCE OF RUNNING OUT OF Has the vehicle experienced
Finish the diagnoFUEL.
running out of fuel?
sis.
NOTE:
DTC may be recorded as a result
of fuel pump idling
while running out
of fuel.
No
Repair the ground
short circuit
between fuel pump
control unit and
ECM.
Go to step 8.
Replace the fuel

pump control unit.
<Ref. to
FU(H4DOTC)-48,
Fuel Pump Control
Unit.>

AP:DTC P0244 TURBO/SUPER CHARGER WASTEGATE SOLENOID A

RANGE/PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-94, DTC P0244 TURBO/SUPER CHARGER WASTEGATE SOLENOID A RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
BATTERY
SBF-5
F44
5
3
B61
1 2 3 4
5 6 7 8
F44
2
1
B47
B47
1
3
5
B137
2
4
6
ECM
B137
27
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
B127
1 2
2
1
B127
WASTEGATE CONTROL
SOLENOID VALVE
EN-03813

Step
Check
Yes
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
NOTE:
No
Replace the wastegate control solenoid valve. <Ref. to
FU(H4DOTC)-39,
Wastegate Control
Solenoid Valve.>

AQ:DTC P0245 TURBO/SUPER CHARGER WASTEGATE SOLENOID A LOW

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-96, DTC P0245 TURBO/SUPER CHARGER WASTEGATE SOLENOID A LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
BATTERY
SBF-5
F44
5
3
B61
1 2 3 4
5 6 7 8
F44
2
1
B47
B47
1
3
5
B137
2
4
6
ECM
B137
27
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
B127
1 2
2
1
B127
WASTEGATE CONTROL
SOLENOID VALVE
EN-03813

Step
chassis ground.
Check
Yes
No
function indicator
light illuminates,
the circuit has
this time.
CHECK HARNESS BETWEEN WASTEGATE Is the resistance less than 10 ? Repair ground
Go to step 3.
short circuit of harCONNECTOR.
ness between
ECM and waste2) Disconnect the connectors from wastegate
gate control solecontrol solenoid valve and ECM.
noid valve
connector.
wastegate control solenoid valve connector and
engine ground.
CHECK HARNESS BETWEEN WASTEGATE Is the resistance less than 1 ? Go to step 4.
Repair open circuit
of harness
CONNECTOR.
between ECM and
wastegate control
wastegate control solenoid valve of harness
solenoid valve conconnector and ECM.
nector.
NOTE:
(B137) No. 27 (B127) No. 1:
the following item:
Open circuit of
harness between
ECM and wastegate control solenoid
valve
connector
CHECK WASTEGATE CONTROL SOLEIs the resistance between 30 Go to step 5.
Replace the wasteNOID VALVE.
34 ?
gate control sole1) Remove the wastegate control solenoid
noid valve. <Ref. to
valve.
FU(H4DOTC)-39,
2) Measure the resistance between wastegate
Wastegate Control
Solenoid Valve.>
Terminals
No. 1 No. 2:
CHECK POWER SUPPLY TO WASTEGATE Is the voltage 10 V or more?
Repair poor con- Repair the harCONTROL SOLENOID VALVE.
tact in wastegate nesss and connec1) Turn the ignition switch to ON.
control solenoid
tor.
2) Measure the voltage between wastegate
valve connector.
NOTE:
control solenoid valve and engine ground.
the following item:
Open circuit of
harness between
main relay and
wastegate control
solenoid valve connector
Poor contact in

AR:DTC P0246 TURBO/SUPER CHARGER WASTEGATE SOLENOID A HIGH

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-98, DTC P0246 TURBO/SUPER CHARGER WASTEGATE SOLENOID A HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
BATTERY
SBF-5
F44
5
3
B61
1 2 3 4
5 6 7 8
F44
2
1
B47
B47
1
3
5
B137
2
4
6
ECM
B137
27
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
B127
1 2
2
1
B127
WASTEGATE CONTROL
SOLENOID VALVE
EN-03813

Step
chassis ground.
CHECK POOR CONTACT.
Check
Yes
Go to step 3.
No
Go to step 2.

connector?
Replace the ECM.

<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
Go to step 4.
CHECK HARNESS BETWEEN WASTEGATE Is the voltage 10 V or more?

CONNECTOR.
2) Disconnect the connector from wastegate
chassis ground.
Repair the short

circuit to power
ECM and wastegate control solenoid valve
connector. After
repair, replace the
ECM. <Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
CHECK WASTEGATE CONTROL SOLEIs the resistance less than 1 ? Replace the wasteNOID VALVE.
gate control sole1) Turn the ignition switch to OFF.
noid valve and
2) Measure the resistance between wastegate
ECM. <Ref. to
FU(H4DOTC)-39,
Terminals
Wastegate Control
No. 1 No. 2:
Solenoid Valve.>
<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
CHECK POOR CONTACT.
connector?
Go to step 5.
Replace the ECM.

<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
AS:DTC P0301 CYLINDER 1 MISFIRE DETECTED

NOTE:
For the diagnostic procedure, refer to DTC P0304. <Ref. to EN(H4DOTC)(diag)-170, DTC P0304 CYLINDER 4 MISFIRE DETECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

NOTE:

NOTE:


Immediately at fault recognition (A misfire which could damage catalyst occurs.)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-105, DTC P0304 CYLINDER 4 MISFIRE DETECTED,
TROUBLE SYMPTOM:
Engine stalls.
Improper idling
Rough driving
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
B61
BATTERY
F44
SBF-5
5
3
2
1
B47
45
11
10
44
43
48
42
B137 ECM
B22
E3
2
1
E17
2
1
E6
2
1
E16
2
1
E5
#1
#2
#3
#4
FUEL INJECTOR
E5
E6
E16
E17
1 2
B47
1
3
5
2
4
6
F44
B137
B22
1 2 3 4
5 6 7 8
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04785

Step
Check

faulty cylinders.
#1 (B137) No. 8 (E5) No. 1:
#2 (B137) No. 9 (E16) No. 1:
#3 (B137) No. 10 (E6) No. 1:
#4 (B137) No. 11 (E17) No. 1:

Terminals
No. 1 No. 2:
more?
Yes
No
priate DTC using
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
Go to step 7.
Go to step 3.
Go to step 4.
Repair the ground

injector and ECM
connector.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
Poor contact in
coupling connector
Replace the faulty
to FU(H4DOTC)32, Fuel Injector.>

20 ?

10
11
Step
Check

Terminals
No. 1 No. 2:
Yes
Repair the poor
injector circuit.
Repair the short

circuit to power
ECM connector
and fuel injector.
After repair,
replace the ECM.
<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
Replace the faulty

fuel injector and
ECM. <Ref. to
FU(H4DOTC)-32,
Fuel Injector.>
<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
loosely installed?
sor or crankshaft
position sensor.
CHECK CRANKSHAFT SPROCKET.
sprocket. <Ref. to
ME(H4DOTC)-53,
Crank Sprocket.>
tion condition of
TIMING BELT.
the timing belt.
alignment mark on crank sprocket with align<Ref. to
ment mark on cylinder block.
ME(H4DOTC)-44,
ST 499987500
CRANKSHAFT
Timing Belt.>
SOCKET
No
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
main relay and fuel
injector connector
on faulty cylinders
Poor contact in
coupling connector
Poor contact in
Poor contact in
cylinders
Go to step 8.
Go to step 9.
Go to step 10.
Go to step 11.
Go to step 12.

12
13
Step
CHECK FUEL LEVEL.
Check
Is the fuel meter indication
higher than the Lower level?
Yes
Go to step 13.
CHECK STATUS OF MALFUNCTION INDIDoes the malfunction indicator

CATOR LIGHT.
light illuminate or blink?
1) Clear the memory using Subaru Select
Monitor.
<Ref. to EN(H4DOTC)(diag)-50, Clear Memory
Mode.>
2) Start the engine, and drive the vehicle more
than 10 minutes.
CHECK CAUSE OF MISFIRE.
Has the cause of misfire diagnosed when the engine is running?
Go to step 15.
15

system?
16
CHECK CYLINDER.
Is there any fault in the cylinder?
Repair the air

intake system.
NOTE:
Are there air
leaks or air suction
caused by loose or
dislocated
nuts
and bolts?
Are there cracks
or any disconnection of hoses?
Repair or replace
faulty parts.
NOTE:
Spark plug
Fuel injector
Compression
14
Finish diagnostics
operation, if the
engine has no
abnormality.
No
Replenish the fuel
so that fuel meter
indication is higher
than the Lower
level. After refueling, Go to step 13.
Go to step 14.
Repair the poor

contact.
NOTE:
the following item:
Poor contact of
ignition coil connector
Poor contact in
cylinders
Poor contact in
ECM connector
Poor contact in
coupling connector
Go to step 16.
Go to DTC P0171
and P0172. <Ref.
to
EN(H4DOTC)(diag
)-146, DTC P0171
SYSTEM TOO
LEAN (BANK 1),
(DTC).>

AW:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE

SENSOR)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-106, DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW
TROUBLE SYMPTOM:
Knocking occurs.
CAUTION:
WIRING DIAGRAM:
E14
KNOCK SENSOR
E14
1 2
B20
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
E3
13
19
E1
B22
B20
B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B22
29
25
15
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
B134 ECM
E
EN-04792

Step
Check
CHECK HARNESS BETWEEN KNOCK SEN- Is the resistance 700 k or
SOR AND ECM CONNECTOR.
more?
3) Measure the resistance between ECM harness connector and chassis ground.
No
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
knock sensor and
ECM connector
Poor contact in
Poor contact in
coupling connector
CHECK KNOCK SENSOR.
Is the resistance 700 k or
Go to step 3.
Repair the harness
1) Disconnect the connector from knock sen- more?
and connector.
sor.
NOTE:
the following item:
Terminals
Poor contact in
Poor contact in
coupling connector
Is the knock sensor installation Replace the knock Tighten the knock
KNOCK SENSOR.
sensor. <Ref. to
sensor installation
FU(H4DOTC)-29, bolt securely.
Knock Sensor.>
Yes
Go to step 2.

AX:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE

SENSOR)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-108, DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH
TROUBLE SYMPTOM:
Knocking occurs.
CAUTION:
WIRING DIAGRAM:
E14
KNOCK SENSOR
E14
1 2
B20
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
E3
13
19
E1
B22
B20
B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B22
29
25
15
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
B134 ECM
E
EN-04792

Step
CHECK HARNESS BETWEEN KNOCK SENSOR AND ECM CONNECTOR.
CHECK KNOCK SENSOR.
1) Disconnect the connector from knock sensor.
Terminals
Check
Yes
Is the resistance less than 400 Go to step 2.
k?
No
Go to step 3.
Is the resistance less than 400 Replace the knock

k?
sensor. <Ref. to
FU(H4DOTC)-29,
Knock Sensor.>
Repair the ground

knock sensor connector and ECM
connector.
NOTE:
The harness between both connectors are
shielded. Remove
the shield and repair the short circuit of harness.

1) Connect the connectors to ECM and knock
sensor.
chassis ground.

light illuminates,
the circuit has
remains.)
NOTE:
the following item:
Poor contact in
Poor contact in
ECM connector
Poor contact in
coupling connector

AY:DTC P0335 CRANKSHAFT POSITION SENSOR A CIRCUIT

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-110, DTC P0335 CRANKSHAFT POSITION SENSOR
A CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
2
1
CRANKSHAFT
POSITION
SENSOR
E10
E10
1 2
E1
8
7
B20
B20
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
14
13
24
1 2
8 9 10
18 19 20
28 29 30
B134 ECM
EN-04793

Step
Check
CHECK HARNESS BETWEEN CRANKIs the resistance 100 k or
SHAFT POSITION SENSOR AND ECM CON- more?
NECTOR.
2) Disconnect the connector from crankshaft
position sensor.
engine ground.

engine ground.

engine ground.
CHECK CONDITION OF CRANKSHAFT POSITION SENSOR.
CHECK CRANKSHAFT POSITION SENSOR.

terminals of crankshaft position sensor.
Terminals
No. 1 No. 2:
Yes
No
and connector.
NOTE:
the following item:
Open circuit in
harness between
crankshaft
position sensor and
ECM connector
Poor contact in
ECM connector
Poor contact in
coupling connector
Go to step 3.
Repair the ground
more?
crankshaft position sensor and
ECM connector.
NOTE:
The harness between both connectors are
shielded. Remove
the shield and repair the ground
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
crankshaft
position sensor and
ECM connector
Poor contact in
ECM connector
Poor contact in
coupling connector
Is the crankshaft position sen- Go to step 5.
Tighten the cranksor installation bolt tightened
securely.
Replace the crankIs the resistance between 1 Repair the poor
contact of crankshaft position sen4 k?
sor connector.
FU(H4DOTC)-27,
Crankshaft Position Sensor.>

AZ:DTC P0336 CRANKSHAFT POSITION SENSOR A CIRCUIT RANGE/

PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-112, DTC P0336 CRANKSHAFT POSITION SENSOR
A CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
2
1
CRANKSHAFT
POSITION
SENSOR
E10
E10
1 2
E1
8
7
B20
B20
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
14
13
24
1 2
8 9 10
18 19 20
28 29 30
B134 ECM
EN-04793

Step
Check
CHECK CONDITION OF CRANKSHAFT PO- Is the crankshaft position senSITION SENSOR.

sor installation bolt tightened
securely?

Remove the front belt cover.
Are crank sprocket teeth

cracked or damaged?

TIMING BELT.
alignment mark on crank sprocket with alignment mark on cylinder block.
ST 499987500
CRANKSHAFT
SOCKET

Yes
No
priate DTC using
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
Go to step 3.
Tighten the crankshaft position sensor installation bolt
securely.
Replace the crank Go to step 4.
sprocket. <Ref. to
ME(H4DOTC)-53,
Crank Sprocket.>
Repair the installa- Replace the cranktion condition of
shaft position senthe timing belt.
sor. <Ref. to
<Ref. to
FU(H4DOTC)-27,
ME(H4DOTC)-44, Crankshaft Position Sensor.>
Timing Belt.>

BA:DTC P0340 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 1 OR

SINGLE SENSOR)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-114, DTC P0340 CAMSHAFT POSITION SENSOR
A CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
BATTERY
SBF-5
5
3
7
B61
F44
2
1
2
3
2
3
CAMSHAFT
POSITION
SENSOR RH
CAMSHAFT
POSITION
SENSOR LH
B47
E35
E36
E1
1
2
21
B20
11
48
17
B22
22
E3
B134
ECM
E35
E36
1 2 3
B47
1
3
5
2
4
6
F44
1 2 3 4
5 6 7 8
B20
1
5
9
13
2
6
10
14
3
7
11
15
B134
4
8
12
16
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04794

Step
CHECK POWER SUPPLY OF CAMSHAFT
POSITION SENSOR.
position sensor.
3) Measure the voltage between camshaft
position sensor and engine ground.
POSITION SENSOR.
CHECK HARNESS BETWEEN CAMSHAFT
POSITION SENSOR AND ECM.
3) Measure the resistance between camshaft
position sensor and ECM.
(E36) No. 2 (B134) No. 11:
(E35) No. 3 (B134) No. 22:
Measure the resistance between camshaft
Check
Yes
No
Repair the short
Go to step 2.
circuit to power
supply between
the main relay connector and camshaft position
sensor connector.
Go to step 3.
more?
Repair the open or

between main
relay connector
and camshaft position sensor connector.
Repair the open
circuit between
camshaft position
sensor and ECM.
Go to step 5.
Repair the ground

short between the
camshaft position
sensor and ECM.

securely?

securely.
Go to step 7.

Check the waveform of the camshaft position
sensor. <Ref. to EN(H4DOTC)(diag)-18,
Engine Control Module (ECM) I/O Signal.>
Is there any abnormality in

waveform?
CHECK POOR CONTACT.


connector?

FU(H4DOTC)-28,
Camshaft Position
Sensor.>
nector.
FU(H4DOTC)-44,
Engine Control
Module (ECM).>

BB:DTC P0345 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 2)

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-115, DTC P0345 CAMSHAFT POSITION SENSOR
A CIRCUIT (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
6
4
BATTERY
SBF-5
5
3
7
B61
F44
2
1
2
3
2
3
CAMSHAFT
POSITION
SENSOR RH
CAMSHAFT
POSITION
SENSOR LH
B47
E35
E36
E1
1
2
21
B20
11
48
17
B22
22
E3
B134
ECM
E35
E36
1 2 3
B47
1
3
5
2
4
6
F44
1 2 3 4
5 6 7 8
B20
1
5
9
13
2
6
10
14
3
7
11
15
B134
4
8
12
16
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04794

Step
POSITION SENSOR.
position sensor.
POSITION SENSOR.
3) Measure the resistance between camshaft
position sensor and ECM.
(E35) No. 2 (B134) No. 21:
(E35) No. 3 (B134) No. 22:
Measure the resistance between camshaft
Check
Yes
No
Repair the short
Go to step 2.
circuit to power
supply between
the main relay connector and camshaft position
sensor connector.
Go to step 3.
more?
Repair the open or

between main
relay connector
and camshaft position sensor connector.
Repair the open
circuit between
camshaft position
sensor and ECM.
Go to step 5.
Repair the ground

short between the
camshaft position
sensor and ECM.

securely?

securely.
Go to step 7.

Check the waveform of the camshaft position
sensor. <Ref. to EN(H4DOTC)(diag)-18,
Engine Control Module (ECM) I/O Signal.>
Is there any abnormality in

waveform?
CHECK POOR CONTACT.


connector?

FU(H4DOTC)-28,
Camshaft Position
Sensor.>
nector.
FU(H4DOTC)-44,
Engine Control
Module (ECM).>

BC:DTC P0410 SECONDARY AIR INJECTION SYSTEM

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-116, DTC P0410 SECONDARY AIR INJECTION SYSTEM, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:

WIRING DIAGRAM:
MAIN RELAY
6
4
5
3
B47
F44
B100
SBF-1
15
SECONDARY
AIR COMBINATION
VALVE RELAY 2
BATTERY
SBF-5
B61
2
1
F2
1
10A
20
21
12
22
13
24
60A
F9
SECONDARY
F27
AIR COMBINATION
VALVE RELAY 1
F2
B100
10
11
4
5
3
6
12
14
F27
46
47
19
20
5
SECONDARY AIR PUMP
2
1
20
F2
16
E3
B22
F11
C8
C30
C19
A29
A27
1
2
E40
A19
B100
E41
SECONDARY
AIR PUMP RELAY
F9
ECM
A: B134
C: B136
SECONDARY
SECONDARY
AIR COMBINATION VALVE LH
AIR COMBINATION
(WITH BUILT-IN PRESSURE SENSOR) VALVE RH
F11
E40
1 2
B47
1
3
5
2
4
6
E41
F44
1 2 3
4 5 6
1 2 3 4
5 6 7 8
F9
B22
1
3
4
5
6
A: B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
F2
2
7 8 9
10
11
13
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
F27
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
12
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
5 6 7 10 15 16 17 20 25 26 29 30
35
8
11
18
21
27
31
9 12 13 14 19 22 23 24 28 32 33 34 36
EN-04795

Step
CHECK SECONDARY AIR PUMP OPERATION.
3) Perform operation check for the secondary
air pump using the Subaru Select Monitor.
NOTE:
Mode for more operation procedure. <Ref. to
CHECK DUCT BETWEEN SECONDARY AIR
PUMP AND COMBINATION VALVE.
Inspection of the duct between the secondary
air pump and combination valve.
CHECK POWER SUPPLY TO SECONDARY
AIR PUMP.
In the condition of step 1, measure the voltage
between the secondary air pump and the chassis ground.
CHECK HARNESS BETWEEN SECONDARY
AIR PUMP RELAY AND SECONDARY AIR
PUMP CONNECTOR.
2) Disconnect the connector from the secondary air pump relay and secondary air pump.
3) Measure resistance between the secondary
air pump relay and secondary air pump connector terminal.
(F9) No. 5 (F11) No. 2 :
CHECK SECONDARY AIR PUMP RELAY.
2) Remove the secondary air pump relay from
the relay box.
3) Connect the battery to the secondary air
pump relay terminals No. 3 and No. 6.
4) Measure the resistance between secondary
air pump relay terminals.
Terminals
No. 4 No. 5
CHECK SECONDARY AIR PUMP RELAY
POWER SOURCE.
2) Measure the voltage between the secondary air pump relay connector and chassis
ground.
Check
Does the secondary air pump
operate?
Yes
Go to step 2.
Is there damage or disconnec- Replace or contion of the duct?

nect the duct.
Replace the secondary air pump.
No
Go to step 3.
Temporary poor
contact occurs.
Check the poor
Go to step 4.
Repair the open

circuit between
secondary air
pump relay and
secondary air
pump connector
terminal.
Replace the secondary air pump

relay.
Repair the open or

of power supply
circuit.
Go to step 7.

Step
SECONDARY AIR PUMP RELAY CONNECTOR.
2) Disconnect the connector of ECM.
between the ECM and secondary air pump
relay connector terminal.
(B136) No. 8 (F9) No. 6:
Check
Yes
Is the resistance less than 1 ? Replace the ECM.
<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
No
Repair open circuit
of the harness
between the ECM
and secondary air
pump relay connector terminal.

BD:DTC P0411 SECONDARY AIR INJECTION SYSTEM INCORRECT FLOW

DETECTED
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-125, DTC P0411 SECONDARY AIR INJECTION SYSTEM INCORRECT FLOW DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:

WIRING DIAGRAM:
MAIN RELAY
6
4
5
3
B47
F44
B100
SBF-1
15
SECONDARY
AIR COMBINATION
VALVE RELAY 2
BATTERY
SBF-5
B61
2
1
F2
1
10A
20
21
12
22
13
24
60A
F9
SECONDARY
F27
AIR COMBINATION
VALVE RELAY 1
F2
B100
10
11
4
5
3
6
12
14
F27
46
47
19
20
5
SECONDARY AIR PUMP
2
1
20
F2
16
E3
B22
F11
C8
C30
C19
A29
A27
1
2
E40
A19
B100
E41
SECONDARY
AIR PUMP RELAY
F9
ECM
A: B134
C: B136
SECONDARY
SECONDARY
AIR COMBINATION
F11
E40
1 2
B47
1
3
5
2
4
6
E41
F44
1 2 3
4 5 6
1 2 3 4
5 6 7 8
F9
B22
1
3
4
5
6
A: B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
F2
2
7 8 9
10
11
13
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
F27
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
12
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
5 6 7 10 15 16 17 20 25 26 29 30
35
8
11
18
21
27
31
9 12 13 14 19 22 23 24 28 32 33 34 36
EN-04795

Step
CHECK SECONDARY AIR COMBINATION
VALVE.
Inspection of the pipe between the secondary
air combination valve and cylinder head.
VALVE.
Race the engine at 2000 RPM and check
whether an exhaust leak can be heard.
Check
Yes
Is there damage or disconnec- Replace the pipe
tion of the pipe?
between the secondary air combination valve and
cylinder head.
Is there an exhaust leaking
Replace the pipe
sound?
between the secondary air combination valve and
cylinder head.
No
Go to step 2.
Repair the poor

contact in ECM
connector.

BE:DTC P0413 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE A

CIRCUIT OPEN
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-126, DTC P0413 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE A CIRCUIT OPEN, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:

WIRING DIAGRAM:
MAIN RELAY
6
4
5
3
B47
F44
B100
SBF-1
15
SECONDARY
AIR COMBINATION
VALVE RELAY 2
BATTERY
SBF-5
B61
2
1
F2
1
10A
20
21
12
22
13
24
60A
F9
SECONDARY
F27
AIR COMBINATION
VALVE RELAY 1
F2
B100
10
11
4
5
3
6
12
14
F27
46
47
19
20
5
SECONDARY AIR PUMP
2
1
20
F2
16
E3
B22
F11
C8
C30
C19
A29
A27
1
2
E40
A19
B100
E41
SECONDARY
AIR PUMP RELAY
F9
ECM
A: B134
C: B136
SECONDARY
SECONDARY
AIR COMBINATION
F11
E40
1 2
B47
1
3
5
2
4
6
E41
F44
1 2 3
4 5 6
1 2 3 4
5 6 7 8
F9
B22
1
3
4
5
6
A: B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
F2
2
7 8 9
10
11
13
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
F27
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
12
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
5 6 7 10 15 16 17 20 25 26 29 30
35
8
11
18
21
27
31
9 12 13 14 19 22 23 24 28 32 33 34 36
EN-04795

Step
Check
SECONDARY AIR COMBINATION VALVE
RELAY 1.
2) Disconnect the connector from the ECM
and secondary air combination valve relay 1.
between the ECM and secondary air combination valve relay 1 terminal.
(B136) No. 30 (F27) No. 14:
more?
RELAY 1.
Yes
Go to step 2.
No
Repair open circuit
of the harness
between the ECM
and secondary air
combination valve
relay 1 terminal.
Temporary poor
contact occurs.
Check the poor
Repair open circuit

of the harness
between the ECM
and secondary air
combination valve
relay 1 terminal.

BF:DTC P0414 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE A

CIRCUIT SHORTED
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-127, DTC P0414 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE A CIRCUIT SHORTED, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:

WIRING DIAGRAM:
MAIN RELAY
6
4
5
3
B47
F44
B100
SBF-1
15
SECONDARY
AIR COMBINATION
VALVE RELAY 2
BATTERY
SBF-5
B61
2
1
F2
1
10A
20
21
12
22
13
24
60A
F9
SECONDARY
F27
AIR COMBINATION
VALVE RELAY 1
F2
B100
10
11
4
5
3
6
12
14
F27
46
47
19
20
5
SECONDARY AIR PUMP
2
1
20
F2
16
E3
B22
F11
C8
C30
C19
A29
A27
1
2
E40
A19
B100
E41
SECONDARY
AIR PUMP RELAY
F9
ECM
A: B134
C: B136
SECONDARY
SECONDARY
AIR COMBINATION
F11
E40
1 2
B47
1
3
5
2
4
6
E41
F44
1 2 3
4 5 6
1 2 3 4
5 6 7 8
F9
B22
1
3
4
5
6
A: B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
F2
2
7 8 9
10
11
13
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
F27
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
12
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
5 6 7 10 15 16 17 20 25 26 29 30
35
8
11
18
21
27
31
9 12 13 14 19 22 23 24 28 32 33 34 36
EN-04795

Step
Check
RELAY 1.
(B136) No. 30 (F27) No. 14:
RELAY 1.
ground.
Yes
Go to step 2.
No
Repair open circuit
of the harness
between the ECM
and secondary air
combination valve
relay 1 terminal.
Repair the short

circuit to the power
ECM and secondary air combination
valve relay 1 terminal.
Temporary poor
contact occurs.
Check the poor

BG:DTC P0416 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE B

CIRCUIT OPEN
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-128, DTC P0416 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE B CIRCUIT OPEN, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:

WIRING DIAGRAM:
MAIN RELAY
6
4
5
3
B47
F44
B100
SBF-1
15
SECONDARY
AIR COMBINATION
VALVE RELAY 2
BATTERY
SBF-5
B61
2
1
F2
1
10A
20
21
12
22
13
24
60A
F9
SECONDARY
F27
AIR COMBINATION
VALVE RELAY 1
F2
B100
10
11
4
5
3
6
12
14
F27
46
47
19
20
5
SECONDARY AIR PUMP
2
1
20
F2
16
E3
B22
F11
C8
C30
C19
A29
A27
1
2
E40
A19
B100
E41
SECONDARY
AIR PUMP RELAY
F9
ECM
A: B134
C: B136
SECONDARY
SECONDARY
AIR COMBINATION
F11
E40
1 2
B47
1
3
5
2
4
6
E41
F44
1 2 3
4 5 6
1 2 3 4
5 6 7 8
F9
B22
1
3
4
5
6
A: B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
F2
2
7 8 9
10
11
13
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
F27
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
12
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
5 6 7 10 15 16 17 20 25 26 29 30
35
8
11
18
21
27
31
9 12 13 14 19 22 23 24 28 32 33 34 36
EN-04795

Step
Check
RELAY 2.
(B136) No. 19 (F27) No. 24:
more?
RELAY 2.
Yes
Go to step 2.
No
Repair open circuit
of the harness
between the ECM
and secondary air
combination valve
relay 2 terminal.
Temporary poor
contact occurs.
Check the poor
Repair open circuit

of the harness
between the ECM
and secondary air
combination valve
relay 2 terminal.

BH:DTC P0417 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE B

CIRCUIT SHORTED
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-128, DTC P0417 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE B CIRCUIT SHORTED, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:

WIRING DIAGRAM:
MAIN RELAY
6
4
5
3
B47
F44
B100
SBF-1
15
SECONDARY
AIR COMBINATION
VALVE RELAY 2
BATTERY
SBF-5
B61
2
1
F2
1
10A
20
21
12
22
13
24
60A
F9
SECONDARY
F27
AIR COMBINATION
VALVE RELAY 1
F2
B100
10
11
4
5
3
6
12
14
F27
46
47
19
20
5
SECONDARY AIR PUMP
2
1
20
F2
16
E3
B22
F11
C8
C30
C19
A29
A27
1
2
E40
A19
B100
E41
SECONDARY
AIR PUMP RELAY
F9
ECM
A: B134
C: B136
SECONDARY
SECONDARY
AIR COMBINATION
F11
E40
1 2
B47
1
3
5
2
4
6
E41
F44
1 2 3
4 5 6
1 2 3 4
5 6 7 8
F9
B22
1
3
4
5
6
A: B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
F2
2
7 8 9
10
11
13
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
F27
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
12
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
5 6 7 10 15 16 17 20 25 26 29 30
35
8
11
18
21
27
31
9 12 13 14 19 22 23 24 28 32 33 34 36
EN-04795

Step
Check
RELAY 2.
(B136) No. 19 (F27) No. 24:
RELAY 2.
ground.
Yes
Go to step 2.
No
Repair open circuit
of the harness
between the ECM
and secondary air
combination valve
relay 2 terminal.
Repair the short

valve relay 2 terminal.
Temporary poor
contact occurs.
Check the poor

BI: DTC P0418 SECONDARY AIR INJECTION SYSTEM CONTROL A CIRCUIT

OPEN
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-129, DTC P0418 SECONDARY AIR INJECTION SYSTEM CONTROL A CIRCUIT OPEN, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:

WIRING DIAGRAM:
MAIN RELAY
6
4
5
3
B47
F44
B100
SBF-1
15
SECONDARY
AIR COMBINATION
VALVE RELAY 2
BATTERY
SBF-5
B61
2
1
F2
1
10A
20
21
12
22
13
24
60A
F9
SECONDARY
F27
AIR COMBINATION
VALVE RELAY 1
F2
B100
10
11
4
5
3
6
12
14
F27
46
47
19
20
5
SECONDARY AIR PUMP
2
1
20
F2
16
E3
B22
F11
C8
C30
C19
A29
A27
1
2
E40
A19
B100
E41
SECONDARY
AIR PUMP RELAY
F9
ECM
A: B134
C: B136
SECONDARY
SECONDARY
AIR COMBINATION
F11
E40
1 2
B47
1
3
5
2
4
6
E41
F44
1 2 3
4 5 6
1 2 3 4
5 6 7 8
F9
B22
1
3
4
5
6
A: B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
F2
2
7 8 9
10
11
13
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
F27
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
12
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
5 6 7 10 15 16 17 20 25 26 29 30
35
8
11
18
21
27
31
9 12 13 14 19 22 23 24 28 32 33 34 36
EN-04795

Step
SECONDARY AIR PUMP RELAY.
and secondary air pump relay.
relay terminal.
(B136) No. 8 (F9) No. 6:
Check
Yes
more?
Temporary poor
contact occurs.
Check the poor
No
Repair open circuit
of the harness
between the ECM
and secondary air
pump relay terminal.
Repair ground
short of the harness between the
ECM and secondary air pump relay
terminal.

BJ:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1)

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-130, DTC P0420 CATALYST SYSTEM EFFICIENCY
BELOW THRESHOLD (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
Idle mixture is out of specifications.
CAUTION:
WIRING DIAGRAM:
BATTERY
MAIN RELAY
SBF-5
6
4
14
F2
B100
5
3
FRONT OXYGEN
(A/F) SENSOR
REAR OXYGEN
SENSOR
B47
1
2
B262
2
4
1
B18
3
4
2
1
1
2
5
B : B135
B47
B18
1
3
1
3
5
2
4
B:
B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
24 25
26 27
20 21 22 23
28 29 30 31
32 33
34 35
B122
2
4
6
1 2 3 4
5 6 7 8
C:
C : B136
B8
B9
C2
C3
B1
B4
B30
C4
B122
ECM
B262
2
4
1
3
F2
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
EN-03818

Step
Check for gas leaks or air suction caused by
loose or dislocated nuts and bolts, and open
hole at exhaust pipes.
NOTE:
Check the following positions.
Between cylinder head and front exhaust
pipe
Between front exhaust pipe and front catalytic
converter
Between front catalytic converter and rear
catalytic converter
SELECT MONITOR (WHILE DRIVING).
1) Drive the vehicle at a constant speed of 80
112 km/h (50 70 MPH).
2) Keep the condition of step 1) for 5 minutes,
then read the waveform data in a driving condition using Subaru Select Monitor.
RrO2 SENSOR
A/F LAMBDA 1
Check
system?
Yes
Repair or replace
the exhaust system. <Ref. to
EX(H4DOTC)-2,
No
Go to step 2.
Is normal waveform pattern dis- Even if the mulGo to step 3.

played?
function indicator
light illuminates,
the circuit has
this time.Reproduce the failure,
and then perform
the diagnosis
again.
NOTE:
In this case, temporary poor contact of connector
may be the cause.
RrO2 SENSOR
A/F LAMBDA 1
EN-04895

Step
SELECT MONITOR (WHILE IDLING).
1) Idle the engine.
2) Under the condition of step 1), read the
waveform data using Subaru Select Monitor.
Check
Yes
Is normal waveform pattern dis- Go to step 4.
played?
No
Go to step 5.
RrO2 SENSOR
RrO2 SENSOR
EN-04896
5
6
CHECK CATALYTIC CONVERTER.
Is the catalytic converter dam- Replace the cata- Go to step 5.

aged?
lytic converter.
<Ref. to EC
(H4DOTC)-5,
Front Catalytic
Converter.>
CHECK REAR OXYGEN SENSOR CONNEC- Does water enter the connec- Dry the water thor- Go to step 6.
TOR AND COUPLING CONNECTOR.
tor?
oughly.
Repair the open
circuit of harness
between ECM and
rear oxygen sensor
rear oxygen sensor.
connector.
(B135) No. 4 (B18) No. 3:
(B135) No. 30 (B18) No. 4:

Step
Check
CHECK REAR OXYGEN SENSOR SHIELD. Is the resistance less than 1 ?

2) Bare the harness sensor shield on the body
side of rear oxygen sensor connector.
3) Measure the resistance between sensor
shield and chassis ground.
Yes
Go to step 8.
Replace the rear

oxygen sensor.
<Ref. to
FU(H4DOTC)-42,
No
Repair the harness
and connector.
NOTE:
Repair the following points.
Open circuit in
the harness between rear oxygen
sensor and ECM
connector
Poor contact in
Poor contact in
ECM connector
Repair the open
circuit in rear oxygen sensor harness.

BK:DTC P0441 EVAPORATIVE EMISSION SYSTEM INCORRECT PURGE FLOW

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-131, DTC P0441 EVAPORATIVE EMISSION SYSTEM INCORRECT PURGE FLOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
1
Step

VALVE 2 PURGE LINE.

VALVE 2.
3) Using the Subaru Select Monitor, operate
the purge control solenoid valve 2.
NOTE:
The purge control solenoid valve 2 can be operated using Subaru Select Monitor. Regarding
the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to
Check
Yes
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
Are there any clogged, crushed Repair or replace
or bent lines in the purge con- the purge control
trol solenoid valve 2 purge line? solenoid valve 2
purge line.
Does the purge control soleRepair the poor
noid valve 2 operate?
contact in ECM
connector.
No
Go to step 2.
Go to step 3.
Replace the purge

control solenoid
valve 2. <Ref. to
EC (H4DOTC)-8,
Purge Control
Solenoid Valve.>


(SMALL LEAK)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-132, DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Fuel odor
CAUTION:
WIRING DIAGRAM:
BATTERY
MAIN RELAY
SBF-5
7
6
4
B61
F44
5
3
2
1
C : B136
ECM
B47
C7
D29
C28
C17
D : B137
10
B98
B22
50
41
48
R2
E3
R15
R57
E52
R68
R69
F44
1 2 3 4
5 6 7 8
B47
1
3
5
2
4
6
B98
R57
1 2
3 4 5
6 7 8 9 10 11 12
C:
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
PRESSURE
CONTROL
SOLENOID VALVE
D:
5 6
14 15 16
25 26 27
33 34 35
PURGE CONTROL
PURGE CONTROL
SOLENOID VALVE 1 SOLENOID VALVE 2
B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
28 29
30 31
26 27
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
1 2
E52
DRAIN VALVE
E4
E4
R68
2
R69
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04796

Step
CHECK DRAIN VALVE.

NOTE:
The drain valve can be operated using Subaru
Select Monitor. Regarding the procedures, refer to Compulsory Valve Operation Check
Mode. <Ref. to EN(H4DOTC)(diag)-51, Compulsory Valve Operation Check Mode.>
VALVE.
NOTE:
executed using Subaru Select Monitor. Regarding the procedures, refer to Compulsory Valve
Operation
Check
Mode.
<Ref.
to
VALVE.
NOTE:
can be executed using the Subaru Select Monitor. Regarding the procedures, refer to Compulsory Valve Operation Check Mode. <Ref. to
Yes
No
priate DTC using
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
Go to step 3.
Tighten fuel filler
cap securely.

securely?
NOTE:
while tightening.
Is a genuine fuel filler cap being Go to step 4.
used?
Check
Replace with a
genuine fuel filler
cap.
Go to step 5.

filler pipe?
<Ref. to
FU(H4DOTC)-53,
Fuel Filler Pipe.>
Replace the drain
valve. <Ref. to EC
(H4DOTC)-21,
Drain Valve.>
Go to step 7.
Replace the purge

control solenoid
valve. <Ref. to EC
(H4DOTC)-8,
Purge Control
Solenoid Valve.>

noid valve operate?

EC (H4DOTC)-16,
Pressure Control
Solenoid Valve.>

Step
CHECK CANISTER.
10
CHECK FUEL TANK.

Remove the fuel tank. <Ref. to FU(H4DOTC)50, Fuel Tank.>
11
Check
Yes
Are there any holes of more
Repair or replace
than 1.0 mm (0.04 in) dia. in the the evaporation
evaporation line?
line. <Ref. to
FU(H4DOTC)-64,
Fuel Delivery,
the canister. <Ref.
to EC (H4DOTC)7, Canister.>
there any hole of more than 1.0 the fuel tank. <Ref.
to FU(H4DOTC)50, Fuel Tank.>
Is there any hole of more than Repair or replace
1.0 mm (0.04 in) dia., crack,
the hoses or pipes.
clogging, or disconnections,
bend, misconnection of hoses
or pipes in evaporative emission control system?
No
Go to step 9.
Go to step 10.
Go to step 11.
Repair the poor

contact in ECM
connector.

BM:DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL

CIRCUIT OPEN
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-148, DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT OPEN, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
BATTERY
MAIN RELAY
SBF-5
6
4
7
B61
F44
5
3
1
B98
2
1
9
R2
R15
1
2
DRAIN
VALVE
R57
CANISTER
R69
B47
R57
R15
R2
17
B98
B136
ECM
R69
F44
1 2
1 2 3 4
5 6 7 8
B47
1
3
5
2
4
6
B98
R57
3 4 5
1 2
6 7 8 9 10 11 12
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
EN-04797

Step
chassis ground.
CHECK POOR CONTACT.
Check
Yes
Go to step 2.
No
Go to step 3.

connector?

light illuminates,
the circuit has
remains.)
NOTE:
the following item:
Poor contact in
drain valve connector
Poor contact in
ECM connector
Poor contact in
coupling connector
Repair the ground
ECM and drain
valve connector.

Go to step 4.
more?
2) Disconnect the connectors from drain valve
and ECM.
drain valve connector and chassis ground.
ECM and drain valve connector.
(B136) No. 17 (R69) No. 2:
CHECK DRAIN VALVE.

Measure the resistance between drain valve
terminals.
Terminals
No. 1 No. 2:

100 ?
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and drain
valve connector
Poor contact in
coupling connector
Replace the drain
valve. <Ref. to EC
(H4DOTC)-21,
Drain Valve.>

Step
Check
CHECK POWER SUPPLY TO DRAIN VALVE. Is the voltage 10 V or more?
2) Measure the voltage between drain valve
and chassis ground.
Yes
Repair the poor
contact of drain
valve connector.
No
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
main relay and
drain valve
Poor contact in
coupling connector
Poor contact in

BN:DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL

CIRCUIT SHORTED
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-150, DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT SHORTED, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
BATTERY
MAIN RELAY
SBF-5
6
4
7
B61
F44
5
3
1
B98
2
1
9
R2
R15
1
2
DRAIN
VALVE
R57
CANISTER
R69
B47
R57
R15
R2
17
B98
B136
ECM
R69
F44
1 2
1 2 3 4
5 6 7 8
B47
1
3
5
2
4
6
B98
R57
3 4 5
1 2
6 7 8 9 10 11 12
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
EN-04797

Step
drivers side).
chassis ground while operating the drain valve.
NOTE:
Subaru Select Monitor. Regarding the procedures, refer to Compulsory Valve Operation
Check Mode. <Ref. to EN(H4DOTC)(diag)-51,
chassis ground.
CHECK POOR CONTACT.

2) Disconnect the connector from the drain
valve.
chassis ground.
Check
Yes
Go to step 2.
No
light illuminates,
the circuit has
this time. In this
case, repair the
poor contact in
ECM connector.
Go to step 4.
Go to step 3.

connector?
Replace the ECM.

<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
Go to step 5.
Repair the short

ECM and drain
valve connector.
After repair,
replace the ECM.
<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
CHECK DRAIN VALVE.
Is the resistance less than 1 ? Replace the drain
valve <Ref. to EC
2) Measure the resistance between drain valve
(H4DOTC)-21,
terminals.
Drain Valve.> and
Terminals
ECM <Ref. to
No. 1 No. 2:
FU(H4DOTC)-44,
Engine Control
Module (ECM).>.
CHECK POOR CONTACT.
connector?
Go to step 6.
Replace the ECM.

<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>

BO:DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE

SENSOR
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-152, DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
FUEL TANK
PRESSURE
SENSOR
R47
11
10
R57
R15
R2
30
32
22
B98
B135 ECM
R47
B135
1 2 3
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
B98
R57
3 4 5
1 2
6 7 8 9 10 11 12
EN-04798

Step
Check

2) Open the fuel flap.
CHECK PRESSURE VACUUM LINE.
NOTE:
vacuum hoses and pipes between fuel tank
pressure sensor and fuel tank
air ventilation hoses and pipes between the fuel
filler pipe and fuel tank

securely?
Is there a fault in the pressure
vacuum line?
Yes
No
priate DTC using
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
Go to step 3.
Tighten fuel filler
cap securely.
Repair or replace
the hoses and
pipes.
Replace the fuel

tank pressure sensor. <Ref. to EC
(H4DOTC)-15,

BP:DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE

SENSOR LOW INPUT
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-154, DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
FUEL TANK
PRESSURE
SENSOR
R47
11
10
R57
R15
R2
30
32
22
B98
B135 ECM
R47
B135
1 2 3
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
B98
R57
3 4 5
1 2
6 7 8 9 10 11 12
EN-04798

Step
CHECK CURRENT DATA.
5) Read the data of the fuel tank pressure sensor signal using Subaru Select Monitor or general scan tool.
NOTE:
General scan tool
PRESSURE SENSOR.
and chassis ground.
ground.
NOTE:
HARNESS.
cord.
Check
Yes
2.8 kPa (21.0 mmHg, 0.827
inHg)?
No
light illuminates,
the circuit has
this time.
Repair the poor

contact in ECM
connector.
Go to step 3.
Go to step 4.

nector.
Go to step 5.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
Poor contact in
coupling connector
Go to step 6.

10
11
Step
Check
Yes
HARNESS.
(B135) No. 32 (R15) No. 10:

HARNESS.
rear wiring harness connector and chassis
ground.
pressure sensor.
(R57) No. 8 (R47) No. 3:
(R57) No. 10 (R47) No. 1:
fuel tank pressure sensor connector and engine
ground.
CHECK POOR CONTACT.
Check for poor contact in the fuel tank pressure
sensor connector.
more?
Go to step 8.
No
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
Poor contact in
coupling connector
Poor contact in
joint connector
Repair the ground
Repair the open

cord.
Repair the open

cord.
more?
Repair the ground

tank cord.
Go to step 11.

pressure sensor
connector.
Replace the fuel

(H4DOTC)-15,

BQ:DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE

SENSOR HIGH INPUT
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-156, DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
FUEL TANK
PRESSURE
SENSOR
R47
11
10
R57
R15
R2
30
32
22
B98
B135 ECM
R47
B135
1 2 3
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
B98
R57
3 4 5
1 2
6 7 8 9 10 11 12
EN-04798

Step
CHECK CURRENT DATA.
NOTE:
General scan tool
PRESSURE SENSOR.
and chassis ground.
PRESSURE SENSOR.
and chassis ground.
ground.
NOTE:
HARNESS.
cord.
Check
Yes
Is the measured value 2.8 kPa Go to step 11.
(21.0 mmHg, 0.827 inHg) or
more?
No
Go to step 2.
Go to step 3.
Go to step 4.
Repair poor conDoes the measured value

change when shaking the ECM tact in ECM conharness and connector?
nector.
Replace the ECM.

<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
Go to step 5.
Is the measured value 2.8 kPa Repair poor con(21.0 mmHg, 0.827 inHg) or tact in ECM conmore when shaking the ECM nector.
Go to step 6.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
Poor contact in
coupling connector
Go to step 7.

10
11
Step
Check
Yes
HARNESS.
(B135) No. 32 (R15) No. 10:
(B135) No. 30 (R15) No. 11:

pressure sensor.
(R57) No. 10 (R47) No. 1:
(R57) No. 11 (R47) No. 2:
CHECK POOR CONTACT.
Check for poor contact in fuel tank pressure
sensor connector.

pressure sensor
connector.
No
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
Poor contact in
coupling connector
Repair the open
cord.
Repair the open

cord.
Replace the fuel

(H4DOTC)-15,
Is the measured value 2.8 kPa Repair the short
Replace the fuel
FUEL TANK PRESSURE SENSOR CONNEC- (21.0 mmHg, 0.827 inHg) or
circuit to power
tank pressure senTOR.
more?
supply in the har- sor. <Ref. to EC
ness between the (H4DOTC)-15,
ECM and fuel tank Fuel Tank Prespressure sensor.
pressure sensor
sure Sensor.>
connector.
NOTE:
General scan tool

BR:DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED

(VERY SMALL LEAK)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-157, DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Fuel odor
CAUTION:
WIRING DIAGRAM:
BATTERY
MAIN RELAY
SBF-5
7
6
4
B61
F44
5
3
2
1
C : B136
ECM
B47
C7
D29
C28
C17
D : B137
10
B98
B22
50
41
48
R2
E3
R15
R57
E52
R68
R69
F44
1 2 3 4
5 6 7 8
B47
1
3
5
2
4
6
B98
R57
1 2
3 4 5
6 7 8 9 10 11 12
C:
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
PRESSURE
CONTROL
SOLENOID VALVE
D:
5 6
14 15 16
25 26 27
33 34 35
PURGE CONTROL
PURGE CONTROL
B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
28 29
30 31
26 27
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
1 2
E52
DRAIN VALVE
E4
E4
R68
2
R69
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04796

Step
CHECK DRAIN VALVE.

NOTE:
VALVE.
NOTE:
Operation Check Mode. <Ref. to
VALVE.
NOTE:
Yes
No
priate DTC using
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
Go to step 3.
Tighten fuel filler
cap securely.

securely?
NOTE:
while tightening.
used?
Check
Replace with a
genuine fuel filler
cap.
Go to step 5.

filler pipe?
<Ref. to
FU(H4DOTC)-53,
Fuel Filler Pipe.>
Replace the drain
valve. <Ref. to EC
(H4DOTC)-21,
Drain Valve.>
Go to step 7.
Replace the purge

control solenoid
valve. <Ref. to EC
(H4DOTC)-8,
Purge Control
Solenoid Valve.>

noid valve operate?

EC (H4DOTC)-16,
Pressure Control
Solenoid Valve.>

Step
CHECK CANISTER.
10
CHECK FUEL TANK.

11
Check
Are there any holes of more
than 0.5 mm (0.020 in) dia. in
the evaporation line?
Yes
Repair or replace
the evaporation
line. <Ref. to
FU(H4DOTC)-64,
Fuel Delivery,
the canister. <Ref.
there any hole of more than 0.5 the fuel tank. <Ref.
Is there any hole of more than Repair or replace
0.5 mm (0.020 in) dia., crack, the hoses or pipes.
bend, misconnection of hoses
or pipes in evaporative emission control system?
No
Go to step 9.
Go to step 10.
Go to step 11.
Repair the poor

contact in ECM
connector.

BS:DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-157, DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF), Diagnostic Trouble Code (DTC) Detecting
Criteria.>
TROUBLE SYMPTOM:
Fuel odor
Fuel filler cap is loose or not installed.
CAUTION:
WIRING DIAGRAM:
BATTERY
MAIN RELAY
SBF-5
7
6
4
B61
F44
5
3
2
1
C : B136
ECM
B47
C7
D29
C28
C17
D : B137
10
B98
B22
50
41
48
R2
E3
R15
R57
E52
R68
R69
F44
1 2 3 4
5 6 7 8
B47
1
3
5
2
4
6
B98
R57
1 2
3 4 5
6 7 8 9 10 11 12
C:
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
PRESSURE
CONTROL
SOLENOID VALVE
D:
5 6
14 15 16
25 26 27
33 34 35
PURGE CONTROL
PURGE CONTROL
B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
28 29
30 31
26 27
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
1 2
E52
DRAIN VALVE
E4
E4
R68
2
R69
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04796

Step
CHECK DRAIN VALVE.

NOTE:
VALVE.
NOTE:
Operation Check Mode. <Ref. to
VALVE.
NOTE:
Yes
No
priate DTC using
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
Go to step 3.
Tighten fuel filler
cap securely.

securely?
NOTE:
while tightening.
used?
Check
Replace with a
genuine fuel filler
cap.
Go to step 5.

filler pipe?
<Ref. to
FU(H4DOTC)-53,
Fuel Filler Pipe.>
Replace the drain
valve. <Ref. to EC
(H4DOTC)-21,
Drain Valve.>
Go to step 7.
Replace the purge

control solenoid
valve. <Ref. to EC
(H4DOTC)-8,
Purge Control
Solenoid Valve.>

noid valve operate?

EC (H4DOTC)-16,
Pressure Control
Solenoid Valve.>

Step
CHECK CANISTER.
Check
Is the canister damaged?
CHECK FUEL TANK.

10
Yes
Repair or replace
the canister. <Ref.
Is the fuel tank damaged?
Repair or replace
Repair or replace
misconnection of hoses or
pipes in evaporative emission
control system?
No
Go to step 9.
Go to step 10.
Repair the poor

contact in ECM
connector.

BT:DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE

CIRCUIT LOW
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-158, DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
F44
6
4
BATTERY
1 2 3 4
5 6 7 8
SBF-5
7
5
3
B61
F44
2
1
B47
B47
ECM
2
4
6
29
B137
1
3
5
B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
48
41
B22
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
E3
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
E4
1
2
E4
1 2
E
PURGE CONTROL
SOLENOID VALVE 1
EN-04799

Step
chassis ground.
Check
Yes
light illuminates,
the circuit has
this time.
Go to step 3.
CHECK HARNESS BETWEEN PURGE CON- Is the resistance 1 M or

TROL SOLENOID VALVE AND ECM CONmore?
NECTOR.
2) Disconnect the connectors from purge control solenoid valve and ECM.
purge control solenoid valve connector and
engine ground.
CHECK HARNESS BETWEEN PURGE CON- Is the resistance less than 1 ? Go to step 4.
TROL SOLENOID VALVE AND ECM CONNECTOR.
ECM and purge control solenoid valve.
(B137) No. 29 (E4) No. 2:

VALVE.
100 ?
2) Measure the resistance between purge control solenoid valve terminals.
Terminals
No. 1 No. 2:
TROL SOLENOID VALVE.
solenoid valve and engine ground.
Go to step 5.
Repair the poor

contact in purge
control solenoid
valve connector.
No
Go to step 2.
Repair the ground

ECM and purge
control solenoid
valve connector.
Repair the open

circuit of harness
between ECM and
NOTE:
the following item:
Open circuit in
harness between
ECM and purge
control
solenoid
valve connector
Poor contact in
coupling connector
Replace the purge
control solenoid
valve. <Ref. to EC
(H4DOTC)-8,
Purge Control
Solenoid Valve.>
Repair the harness
and connector.
NOTE:
Open circuit of
harness between
main relay and
purge control solenoid valve connector
Poor contact in
coupling connector
Poor contact in

BU:DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE

CIRCUIT HIGH
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-160, DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
F44
6
4
BATTERY
1 2 3 4
5 6 7 8
SBF-5
7
5
3
B61
F44
2
1
B47
B47
ECM
2
4
6
29
B137
1
3
5
B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
48
41
B22
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
E3
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
E4
1
2
E4
1 2
E
PURGE CONTROL
SOLENOID VALVE 1
EN-04799

Step
drivers side).
chassis ground while operating the purge control solenoid valve.
NOTE:
chassis ground.
CHECK POOR CONTACT.
Check
Yes
Go to step 2.
No
light illuminates,
the circuit has
this time. In this
case, repair the
poor contact in
ECM connector.
Go to step 4.
Go to step 3.

connector?
Replace the ECM.

<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
Go to step 5.

TROL SOLENOID VALVE AND ECM CONNECTOR.
2) Disconnect the connector from purge control solenoid valve.
chassis ground.
Repair the short

circuit to power
ECM and purge
control solenoid
valve connector.
After repair,
replace the ECM.
<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
Is the resistance less than 1 ? Replace the purge
VALVE.
control solenoid
valve and ECM.
2) Measure the resistance between purge con<Ref. to EC
(H4DOTC)-8,
Terminals
Purge Control
No. 1 No. 2:
Solenoid Valve.>
<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
CHECK POOR CONTACT.
Repair poor contact in ECM conCheck poor contact of ECM connector.
connector?
nector.
Go to step 6.
Replace the ECM.

<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>

BV:DTC P0461 FUEL LEVEL SENSOR A CIRCUIT RANGE/PERFORMANCE

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-162, DTC P0461 FUEL LEVEL SENSOR A CIRCUIT
CAUTION:
WIRING DIAGRAM:
BATTERY
No.14
SBF-4
4
SBF-1
B36
IGNITION SWITCH
i1
B9
B72
COMBINATION
METER
B:
i10
C:
i11
C1
B10
FUEL
GAUGE
16
28
i3
B38
B135
10
ECM
E
36
B98
6
12
B22
E3
R2
E
5
R15
R57
1
2
3
2
E
R59
FUEL
LEVEL SENSOR
FUEL SUB
LEVEL SENSOR
B72
1 2
3 4
i11
B135
1 2 3 4 5 6 7 8 9 10
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
C:
B98
R59
R58
R58
R57
1 2 3
4 5 6
3 4 5
1 2
6 7 8 9 10 11 12
B22
B36
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
i10
B38
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
B:
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04800

Step
Check
Yes
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
NOTE:
No
Replace the fuel
level sensor and
fuel sub level sensor. <Ref. to
FU(H4DOTC)-59,
Fuel Level Sensor.> <Ref. to
FU(H4DOTC)-60,
Fuel Sub Level
Sensor.>

BW:DTC P0462 FUEL LEVEL SENSOR A CIRCUIT LOW

CAUTION:
WIRING DIAGRAM:
BATTERY
No.14
SBF-4
4
SBF-1
B36
IGNITION SWITCH
i1
B9
B72
COMBINATION
METER
B:
i10
C:
i11
C1
B10
FUEL
GAUGE
16
28
i3
B38
B135
10
ECM
E
36
B98
6
12
B22
E3
R2
E
5
R15
R57
1
2
3
2
E
R59
FUEL
LEVEL SENSOR
FUEL SUB
LEVEL SENSOR
B72
1 2
3 4
i11
B135
1 2 3 4 5 6 7 8 9 10
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
C:
B98
R59
R58
R58
R57
1 2 3
4 5 6
3 4 5
1 2
6 7 8 9 10 11 12
B22
B36
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
i10
B38
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
B:
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04800

Step
Check
Yes
Go to step 2.

Read the data of fuel level sensor signal using
NOTE:

2) Separate fuel tank cord connector (R57)
and rear wiring harness connector (R15).
COMBINATION METER.
2) Disconnect the connector from connector
(i11), (i12) and ECM connector.
chassis ground.
COMBINATION METER.
combination meter connector.
(B135) No. 10 (i11) No. 1:
nector.
No
Repair or replace
the combination
Meter.>
Go to step 3.

light illuminates,
the circuit has
the connector may
be the cause.
NOTE:
the following item:
Poor contact in
combination meter
connector
Poor contact in
ECM connector
Poor contact in
coupling connector
Go to step 6.
more?
Go to step 7.
Repair the ground


?
Repair or replace
the combination
Meter.>
Repair the open

circuit between
NOTE:
the following item:
Poor contact in
coupling connector

10
Step
level sensor.
level sensor and chassis ground.
assembly.
2) Measure the resistance between fuel pump
assembly and chassis ground.
FU(H4DOTC)-57, Fuel Pump.>
sensor and terminals with its float set to the full
position.
Terminals
No. 2 No. 3:
FU(H4DOTC)-60, Fuel Sub Level Sensor.>
level sensor and terminals with its float set to
the full position.
Terminals
No. 1 No. 2:
Check
more?
Yes
Go to step 8.
No
Repair the ground
tank cord.
more?
Go to step 9.
Repair the ground

tank cord.

2.5 ?
Go to step 10.
Replace the fuel

level sensor.

2.5 ?
Repair the poor

Replace the fuel
contact in harness sub level sensor.
between ECM and
combination meter
connector.

BX:DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH

CAUTION:
WIRING DIAGRAM:
BATTERY
No.14
SBF-4
4
SBF-1
B36
IGNITION SWITCH
i1
B9
B72
COMBINATION
METER
B:
i10
C:
i11
C1
B10
FUEL
GAUGE
16
28
i3
B38
B135
10
ECM
E
36
B98
6
12
B22
E3
R2
E
5
R15
R57
1
2
3
2
E
R59
FUEL
LEVEL SENSOR
FUEL SUB
LEVEL SENSOR
B72
1 2
3 4
i11
B135
1 2 3 4 5 6 7 8 9 10
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
C:
B98
R59
R58
R58
R57
1 2 3
4 5 6
3 4 5
1 2
6 7 8 9 10 11 12
B22
B36
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
i10
B38
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
B:
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04800

Step
Check
Yes
Go to step 2.


2) Disconnect the combination meter connector (i11) and ECM connector.
FUEL TANK CORD.
2) Separate fuel tank cord connector (R57)
and rear wiring harness connector (R15).
fuel tank cord.
(B135) No. 10 (R15) No. 5:
CHECK HARNESS BETWEEN FUEL TANK Is the resistance less than 5 ? Go to step 6.
CORD AND CHASSIS GROUND.
Measure the resistance between fuel tank cord
and chassis ground.

1) Disconnect the connector from the fuel level ?
sensor.
sensor and coupling connector.
(R57) No. 7 (R58) No. 2:
Go to step 7.
No
Repair or replace
the combination
Meter.>
light illuminates,
the circuit has
the connector may
be the cause.
NOTE:
the following item:
Poor contact in
fuel pump connector
Poor contact in
coupling connector
Repair the short
circuit to power
supply between
the ECM and combination meter
connector.
Repair the open

circuit between
ECM and fuel tank
cord.
Repair the open

tank cord and
chassis ground.
NOTE:
the following item:
Poor contact in
coupling connector
Repair the open
circuit between
coupling connector

10
Step
level sensor.
sensor and fuel sub level sensor.
(R58) No. 3 (R59) No. 2:
Measure the resistance between the fuel sub
level sensor and coupling connector.
(R57) No. 5 (R59) No. 1:
and down, measure resistance between fuel
level sensor terminals.
Terminals
No. 2 No. 3:
up and down, measure resistance between fuel
sub level sensor terminals.
Terminals
No. 1 No. 2:
Check
Yes
No
Repair the open
level sensor and
fuel sub level sensor.
Repair the open

circuit between the
coupling connector
and fuel sub level
sensor.
Go to step 10.
Is the resistance 53 or more? Replace the fuel

level sensor. <Ref.
to FU(H4DOTC)59, Fuel Level Sensor.>
Is the resistance 45 or more? Replace the fuel

sub level sensor.
<Ref. to
FU(H4DOTC)-60,
Fuel Sub Level
Sensor.>

<Ref. to IDI-10,
Combination
Meter.>

BY:DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-168, DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
BATTERY
No.14
SBF-4
4
SBF-1
B36
IGNITION SWITCH
i1
B9
B72
COMBINATION
METER
B:
i10
C:
i11
C1
B10
FUEL
GAUGE
16
28
i3
B38
B135
10
ECM
E
36
B98
6
12
B22
E3
R2
E
5
R15
R57
1
2
3
2
E
R59
FUEL
LEVEL SENSOR
FUEL SUB
LEVEL SENSOR
B72
1 2
3 4
i11
B135
1 2 3 4 5 6 7 8 9 10
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
C:
B98
R59
R58
R58
R57
1 2 3
4 5 6
3 4 5
1 2
6 7 8 9 10 11 12
B22
B36
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
i10
B38
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
B:
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04800

Step
Check

and down, make sure that the resistance
smoothly.
Terminals
No. 3 No. 2:
up and down, make sure that the resistance
smoothly.
Terminals
No. 1 No. 2:

gradually?

gradually?
Yes
No
priate DTC using
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
Go to step 3.
Replace the fuel
level sensor. <Ref.
to FU(H4DOTC)59, Fuel Level Sensor.>
Repair poor contact in ECM, combination meter and

coupling connectors.
Replace the fuel

sub level sensor.
<Ref. to
FU(H4DOTC)-60,
Fuel Sub Level
Sensor.>

BZ:DTC P0483 FAN RATIONALITY CHECK

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-171, DTC P0483 FAN RATIONALITY CHECK, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Occurrence of noise
Overheating
CAUTION:
NOTE:
If the vehicle, with the engine idling, is placed very close to a wall or another vehicle, preventing normal cooling function, the OBD system may detect malfunction.
1
Step
Check
Yes
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
No
Check radiator fan,
fan motor and thermostat and if thermostat is stuck,
replace thermostat. <Ref. to
CO(H4SO)-34,
Radiator Main Fan
and Fan Motor.>
<Ref. to
CO(H4SO)-41,
Radiator Sub Fan
and Fan Motor.>

CA:DTC P0502 VEHICLE SPEED SENSOR A CIRCUIT LOW INPUT

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-172, DTC P0502 VEHICLE SPEED SENSOR A CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
B36
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
BATTERY
No.5
i10
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
10
IGNITION
RELAY
B225
B17
1 2
3 4
B54
TCM
B136
MT
: MT MODEL
1
2
: AT MODEL
B54
B17
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
AT
AT
21
VEHICLE SPEED
SENSOR
B22
MT
COMBINATION
METER
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
i10
B22
36
18
12
2
34
42
E3
B36
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
B225
13
i1
B136
ECM
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
RELAY BLOCK (BLACK)
EN-04801

Step
CHECK HARNESS BETWEEN VEHICLE
SPEED SENSOR AND ECM CONNECTOR.
2) Disconnect the connector from vehicle
speed sensor and ECM.
vehicle speed sensor connector and chassis
ground.
CHECK POOR CONTACT.
Check poor contact in vehicle speed sensor
connector.
Check
more?
Yes
Go to step 2.
Is there poor contact in vehicle Repair the poor

speed sensor connector?
contact in vehicle
speed sensor connector.
No
Repair ground
vehicle speed sensor and ECM connector.
Replace the vehicle speed sensor.

<Ref. to 5MT-37,
Vehicle Speed
Sensor.>

CB:DTC P0503 VEHICLE SPEED SENSOR A INTERMITTENT/ERRATIC/HIGH

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-173, DTC P0503 VEHICLE SPEED SENSOR A INTERMITTENT/ERRATIC/HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
B36
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
BATTERY
No.5
i10
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
10
IGNITION
RELAY
B225
B17
1 2
3 4
B54
TCM
B136
MT
: MT MODEL
1
2
: AT MODEL
B54
B17
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
AT
AT
21
VEHICLE SPEED
SENSOR
B22
MT
COMBINATION
METER
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
i10
B22
36
18
12
2
34
42
E3
B36
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
B225
13
i1
B136
ECM
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
RELAY BLOCK (BLACK)
EN-04801

Step
CHECK SPEEDOMETER OPERATION IN
COMBINATION METER.
Check
Yes
Does the speedometer operate Go to step 2.
normally?

COMBINATION METER CONNECTOR.
3) Measure resistance between ECM and
combination meter.
(B136) No. 13 (i10) No. 12:
No
Check the speedometer. <Ref. to
IDI-12, Speedometer.>
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
Poor contact in
ECM connector
Poor contact in
combination meter
connector
Poor contact in
coupling connector

CC:DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-174, DTC P0506 IDLE AIR CONTROL SYSTEM RPM
TROUBLE SYMPTOM:
Hard to start the engine.
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
ELECTRONIC THROTTLE
CONTROL RELAY
B309
B309
BATTERY
SBF-5
2
1
3
4
1 2
3 4
8
7
MAIN RELAY
B61
F44
B20
B122
1
5
9
13
2
6
10
14
3
7
11
15
1 2 3 4
5 6 7 8
4
8
12
16
C1
C21
B47
E57
1 2 3 4 5 6
A: B134
C: B136
D: B137
ECM
D2
C6
A5
A28
A18
A29
A19
D4
D5
D7
D3
F44
1 2 3
5 6 7
3
7
1
3
5
4
8
2
4
6
B122
A: B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
1 2
8 9 10
18 19 20
28 29 30
19
20
54
37
39
38
B22
B47
E3
C: B136
36
B20
35
16
15
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
E1
D: B137
B22
E3
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
26 27
28 29
30 31
E
E57
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
4
6
3
5
1
2
B22
ELECTRONIC
THROTTLE
CONTROL
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04790

Step
CHECK AIR CLEANER ELEMENT.

2) Check the air cleaner element.

Check
Yes
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
NOTE:
Is the air cleaner element
Replace the air
excessively clogged?
cleaner element.
<Ref. to
IN(H4DOTC)-8, Air
Cleaner Case.>
Are foreign matter found inside Remove foreign
matter from electronic throttle control.
No
Go to step 2.
Go to step 3.
Perform the diagnosis of DTC

P2101.

CD:DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-176, DTC P0507 IDLE AIR CONTROL SYSTEM RPM
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
ELECTRONIC THROTTLE
CONTROL RELAY
B309
B309
BATTERY
SBF-5
2
1
3
4
1 2
3 4
8
7
MAIN RELAY
B61
F44
B20
B122
1
5
9
13
2
6
10
14
3
7
11
15
1 2 3 4
5 6 7 8
4
8
12
16
C1
C21
B47
E57
1 2 3 4 5 6
A: B134
C: B136
D: B137
ECM
D2
C6
A5
A28
A18
A29
A19
D4
D5
D7
D3
F44
1 2 3
5 6 7
3
7
4
8
2
4
6
B122
A: B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
1 2
8 9 10
18 19 20
28 29 30
19
20
54
37
39
38
B22
B47
1
3
5
E3
C: B136
36
B20
35
16
15
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
E1
D: B137
B22
E3
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
26 27
28 29
30 31
E
E57
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
4
6
3
5
1
2
B22
ELECTRONIC
THROTTLE
CONTROL
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04790

Step
Check

throttle body
body gasket

system?
Yes
No
priate DTC using
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
NOTE:
and leaks.

trol.

CE:DTC P0512 STARTER REQUEST CIRCUIT

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-178, DTC P0512 STARTER REQUEST CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
IGNITION SWITCH
BATTERY
SBF-4
SBF-1
1
3
B72
INTERRUPT
RELAY
5
2
3
1
*1
: AT MODEL
*2
: MT MODEL
B59
TO SECURITY SYSTEM
INHIBITOR SWITCH
*2
B12
12
12
11
7
T3
T7
*1
STARTER INTERLOCK
RELAY (MT)
28
27
26
24
STARTER MOTOR
2
B14
B225
32
CLUTCH SWITCH (MT)
2
1
B106
B136
B106
1
2
B225
B72
1 2
3 4
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
ECM
B59
T7
B12
1 2 3
4
5
1 2 3 4 5 6
7 8 9 10 11 12
1 2 3 4
5 6 7 8
9 10 11 12
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
EN-04781

Step
Check
Yes
CHECK OPERATION OF STARTER MOTOR. Does the starter motor operate Repair the short
when ignition switch is turned circuit to power
ON?
supply in the
starter motor circuit. After repair,
replace the ECM.
<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
No
Check the starter
to
EN(H4DOTC)(diag
)-59, STARTER
MOTOR CIRCUIT,
Diagnostics for
Engine Starting
Failure.>

CF:DTC P0519 IDLE AIR CONTROL SYSTEM PERFORMANCE

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-180, DTC P0519 IDLE AIR CONTROL SYSTEM PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Fuel is cut according to fail-safe function.
CAUTION:
WIRING DIAGRAM:
ELECTRONIC THROTTLE
CONTROL RELAY
B309
B309
BATTERY
SBF-5
2
1
3
4
1 2
3 4
8
7
MAIN RELAY
B61
F44
B20
B122
1
5
9
13
2
6
10
14
3
7
11
15
1 2 3 4
5 6 7 8
4
8
12
16
C1
C21
B47
E57
1 2 3 4 5 6
A: B134
C: B136
D: B137
ECM
D2
C6
A5
A28
A18
A29
A19
D4
D5
D7
D3
F44
1 2 3
5 6 7
3
7
4
8
2
4
6
B122
A: B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
1 2
8 9 10
18 19 20
28 29 30
19
20
54
37
39
38
B22
B47
1
3
5
E3
C: B136
36
B20
35
16
15
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
E1
D: B137
B22
E3
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
26 27
28 29
30 31
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
4
6
3
5
1
2
B22
ELECTRONIC
E57 THROTTLE
CONTROL
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04790

Step
Check

throttle body
body gasket

system?
Yes
No
priate DTC using
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
NOTE:
and leaks.

trol.

CG:DTC P0600 SERIAL COMMUNICATION LINK

CAUTION:
EN(H4DOTC)(diag)-38, Inspection Mode.>.
WIRING DIAGRAM:
B54
35
27
TWISTED PAIR LINE
17
18
TCM
B136
B54
ECM
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
EN-04802

Step
TCM.
4) Measure the resistance between ECM,
TCM connectors.
(B136) No. 35 (B54) No. 17:
(B136) No. 27 (B54) No. 18:
TCM.
TCM.
Check the resistance between ECM connectors.
(B136) No. 35 (B136) No. 27:
CHECK THE STATUS OF THE AT SYSTEM.
Diagnose the AT using the Subaru Select Monitor.
Check
Is the resistance 1 or less?
Yes
Go to step 2.
No
Repair the harness
and connector.
more?
Go to step 3.
Repair the harness

and connector.
more?
Go to step 4.
Repair the harness

and connector.
Check the AT sys- Replace the ECM.

tem.
<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>

CH:DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY

(RAM) ERROR
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-182, DTC P0604 INTERNAL CONTROL MODULE
RANDOM ACCESS MEMORY (RAM) ERROR, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:

WIRING DIAGRAM:
MAIN RELAY
4
6
SBF-5
7
5
3
B61
2
1
B72
No.11
B47
F44
IGNITION
SWITCH
SBF-4
SBF-1
C23
A7
B2
B5
B19
A : B134
B : B135 ECM
C : B136
C15
MT
A5
D2
D1
D7
D3
D : B137
E
B72
B47
1
3
5
1 2
3 4
2
4
6
A : B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
36
35
34
54
37
B22
E3
F44
1 2 3
5 6 7
MT : MT MODEL
D : B137
4
8
B22
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
B : B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
24 25
26 27
20 21 22 23
28 29 30 31
32 33
34 35
Step
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
C : B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04782
Check
Yes
No
Is DTC P0604 displayed on the Replace the ECM. Temporary poor
contact occurs.
Subaru Select Monitor or gen- <Ref. to
eral scan tool?
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
CI: DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM)
ERROR
NOTE:
For the diagnostic procedure, refer to DTC P0607. <Ref. to EN(H4DOTC)(diag)-266, DTC P0607 CONTROL
MODULE PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

CJ:DTC P0607 CONTROL MODULE PERFORMANCE

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-184, DTC P0607 CONTROL MODULE PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
4
6
B61
F44
5
3
SBF-5
7
B72
1
2
IGNITION
SWITCH
BATTERY
No.11
SBF-4
1
4
B5
B19
C: B136
ECM
D: B137
C6
A29
A19
A28
A18
B: B135
A5
D2
D1
D7
D3
A: B134
D4
D5
C23
A7
B2
B47
SBF-1
7
3
B122
19
20
39
38
36
35
34
54
37
B22
16
15
E3
B20
E57
B47
B72
1 2
3 4
1
3
5
2
4
6
A: B134
B20
E57
1 2 3 4 5 6
1
5
9
13
2
6
10
14
3
7
11
15
3
5
4
6
1
2
E1
ELECTRONIC THROTTLE
CONTROL
F44
B122
1 2 3 4
5 6 7 8
4
8
12
16
B: B135
1 2 3
5 6 7
B22
4
8
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
D: B137
C: B136
34
42
35
43
48
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
32 33
34 35
28 29 30 31
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
28 29
30 31
26 27
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04803

Step
2) Disconnect the connectors from the ECM
ECM and electronic throttle control connector.
(E57) No. 5 (B134) No. 19:
(E57) No. 3 (B134) No. 29:
CHECK ECM GROUND HARNESS.
and chassis ground.
Check
Yes
Go to step 2.
No
Repair the open or
of power supply
circuit.
Go to step 3.
Repair the open or

of power supply
circuit.
Repair the open

circuit of harness
between ECM and
electronic throttle
control connector.

Further tighten
the engine ground
terminal.
Poor contact in
ECM connector
Poor contact in
coupling connector
Replace the ECM.

<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>

CK:DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE

(BANK 1)
NOTE:
For the diagnostic procedure, refer to DTC P2101. <Ref. to EN(H4DOTC)(diag)-351, DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
CL:DTC P0691 FAN 1 CONTROL CIRCUIT LOW

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-189, DTC P0691 FAN 1 CONTROL CIRCUIT LOW,
TROUBLE SYMPTOM:
Overheating
CAUTION:
1
Step
Check
Yes
No
Is DTC P0691 displayed on the Inspect the radiator Temporary poor
Subaru Select Monitor?
fan relay. <Ref. to contact occurs.
CO(H4SO)-12,
CM:DTC P0692 FAN 1 CONTROL CIRCUIT HIGH

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-190, DTC P0692 FAN 1 CONTROL CIRCUIT HIGH,
TROUBLE SYMPTOM:
Overheating
CAUTION:
1
Step
Check
Yes
No
Is DTC P0692 displayed on the Inspect the radiator Temporary poor
Subaru Select Monitor?
fan relay. <Ref. to contact occurs.
CO(H4SO)-12,
CN:DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST)

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-191, DTC P0700 TRANSMISSION CONTROL SYSTEM
NOTE:
For the diagnostic procedure, refer to AT section. <Ref. to 4AT(D)(diag)-2, PROCEDURE, Basic Diagnostic
Procedure.>

CO:DTC P0851 PARK/NEUTRAL SWITCH INPUT CIRCUIT LOW (AT MODEL)

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-192, DTC P0851 PARK/NEUTRAL SWITCH INPUT
CIRCUIT LOW (AT MODEL), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
B128
B136 ECM
31
1 2
3 4
B12
1 2 3 4
5 6 7 8
9 10 11 12
B128
AT
MT
T7
T12
1 2 3 4 5 6
7 8 9 10 11 12
T9
INHIBITOR SWITCH
T2
NEUTRAL
POSITION
SWITCH
12
T12
11
1 2
T3
T7
T2
B12
12
T12
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
T9
B128
5 6
14 15 16
25 26 27
33 34 35
STARTER MOTOR
M
B14
EN-04804

Step
CHECK SELECT CABLE.
Check
cable?

2) Place the select lever other than N and P
range.
chassis ground.
CHECK TRANSMISSION HARNESS CONNECTOR.
switch.
ground.
Yes
No
Repair or adjust
Go to step 2.
the selector cable.
<Ref. to CS-25,
Select Cable.>
function indicator
light illuminates,
the circuit has
this time.
more?
Go to step 4.
Repair the ground

more?

4AT-47, Inhibitor
Switch.>
Repair the ground

and inhibitor switch
connector.

CP:DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT LOW (MT MODEL)

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-193, DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
B128
B136 ECM
31
1 2
3 4
B12
1 2 3 4
5 6 7 8
9 10 11 12
B128
AT
MT
T7
T12
1 2 3 4 5 6
7 8 9 10 11 12
T9
INHIBITOR SWITCH
T2
NEUTRAL
POSITION
SWITCH
12
T12
11
1 2
T3
T7
T2
B12
12
T12
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
T9
B128
5 6
14 15 16
25 26 27
33 34 35
STARTER MOTOR
M
B14
EN-04804

Step
2) Place the shift lever in a position except for
neutral.
chassis ground.
chassis ground.
2) Disconnect the connector from the transmission harness.
3) Place the shift lever in a position except for
neutral.
4) Measure the resistance between transmission harness and connector terminals.
(T9) No. 1 No. 3:
chassis ground.
(B136) No. 31 (B128) No. 1:
Measure the resistance of the harness between
the ECM and transmission harness connector.
(B128) No. 3 (B136) No. 6:
Check
Yes
Go to step 2.
No
Go to step 4.
Repair the poor

contact in ECM
connector.
Go to step 3.
more?
Go to step 4.
Repair the short

replace the neutral
position switch.
Repair the short

replace the neutral
position switch.
Repair the ground
more?
Go to step 6.
Repair the open

circuit of harness
between ECM and

contact of transmission harness
connector.
Repair the open

circuit between the
and ECM.

CQ:DTC P0852 PARK/NEUTRAL SWITCH INPUT CIRCUIT HIGH (AT MODEL)

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-194, DTC P0852 PARK/NEUTRAL SWITCH INPUT
CIRCUIT HIGH (AT MODEL), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
B128
B136 ECM
31
1 2
3 4
B12
1 2 3 4
5 6 7 8
9 10 11 12
B128
AT
MT
T7
T12
1 2 3 4 5 6
7 8 9 10 11 12
T9
INHIBITOR SWITCH
T2
NEUTRAL
POSITION
SWITCH
12
T12
11
1 2
T3
T7
T2
B12
12
T12
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
T9
B128
5 6
14 15 16
25 26 27
33 34 35
STARTER MOTOR
M
B14
EN-04804

Step
CHECK SELECT CABLE.
Check
cable?

chassis ground with select lever at N and P
range.
ground with select lever at other than N and
P range.
ground.
Yes
No
Repair or adjust
Go to step 2.
the selector cable.
<Ref. to CS-26,
INSPECTION,
Select Cable.>
Go to step 3.
Go to step 4.
Repair the poor

contact in ECM
connector.
Go to step 5.
Repair the short

Go to step 5.
ECM and inhibitor
switch connector.
CHECK HARNESS BETWEEN ECM AND IN- Is the resistance less than 1 ? Go to step 6.
Repair the harness
HIBITOR SWITCH CONNECTOR.
and connector.
NOTE:
inhibitor switch.
the following item:
Open circuit in
ECM and inhibitor switch connector.
harness between
ECM and inhibitor
(B136) No. 31 (T7) No. 12:
switch connector
Poor contact in
coupling connector
Poor contact of
inhibitor
switch
connector
Poor contact in
ECM connector

Step
Check
CHECK INHIBITOR SWITCH GROUND LINE. Is the resistance less than 5 ?
inhibitor switch connector and engine ground.
Yes
4AT-47, Inhibitor
Switch.>
No
Repair open circuit
of harness
between inhibitor
switch connector
and starter motor
ground line.
NOTE:
the following item:
Open circuit in
harness between
inhibitor switch
connector and
starter motor
ground line
Poor contact in
starter motor connector
Poor contact in
starter motor
ground
Starter motor

CR:DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH (MT MODEL)

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-195, DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
B128
B136 ECM
31
1 2
3 4
B12
1 2 3 4
5 6 7 8
9 10 11 12
B128
AT
MT
T7
T12
1 2 3 4 5 6
7 8 9 10 11 12
T9
INHIBITOR SWITCH
T2
NEUTRAL
POSITION
SWITCH
12
T12
11
1 2
T3
T7
T2
B12
12
T12
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
T9
B128
5 6
14 15 16
25 26 27
33 34 35
STARTER MOTOR
M
B14
EN-04804

Step
2) Place the shift lever except in neutral position.
chassis ground.
chassis ground.
chassis ground.
Check
Yes
Go to step 2.
No
Go to step 4.
Repair the poor

contact in ECM
connector.
Go to step 3.
Repair the short

Go to step 4.
circuit to power
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
ECM and neutral switch connector.
harness between
ECM and trans(B136) No. 31 (B128) No. 1:
mission harness
connector
Poor contact in
Poor contact in
ECM connector
Repair the open
CHECK NEUTRAL POSITION SWITCH
circuit in the neuGROUND LINE.
tral position switch
ground line.
the ECM and transmission harness connector.
(B128) No. 3 (B136) No. 6:
Replace the neu1) Place the shift lever in neutral position.
contact of transtral position switch.
2) Measure the resistance between transmismission harness
sion harness connector socket terminals.
connector.
Terminals
No. 1 No. 3:

CS:DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK 1

SENSOR 1)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-196, DTC P1152 O2 SENSOR CIRCUIT RANGE/
PERFORMANCE (LOW) (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
F2
1 2 3 4
10 11 12 13 14
BATTERY
MAIN RELAY
5 6 7 8 9
15 16 17 18 19 20
SBF-5
6
4
14
B262
B100
1
3
5
2
4
6
1 2 3 4
5 6 7 8
1
3
FRONT OXYGEN
(A/F) SENSOR
A: B134
1 2
8 9 10
18 19 20
28 29 30
B262
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
B122
B1
B9
B8
C2
C3
1
5
C: B136
A: B134
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B: B135
ECM
5 6
14 15 16
25 26 27
33 34 35
C: B136
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
26 27
28 29
30 31
A5
D2
D1
D: B137
D7
D3
36
B22
35
34
B47
54
37
2
1
2
4
B122
B47
F2
5
3
B22
E3
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
E
EN-04786

Step
Check
Yes
Does water enter the connec- Dry the water thorCONNECTOR AND COUPLING CONNECtor?
oughly.
TOR.
(B135) No. 9 (B262) No. 4:
(B135) No. 8 (B262) No. 3:
CHECK POOR CONTACT.

Check poor contact of front oxygen (A/F) sensor oxygen (A/F) sensor connecconnector.
tor?
No
Go to step 2.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
connector
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
ECM connector
Repair the poor
Replace the front
contact in front
oxygen (A/F) senoxygen (A/F) sensor. <Ref. to
FU(H4SO)-36,
sor connector.
Front Oxygen (A/F)
Sensor.>

CT:DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK 1

SENSOR 1)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-198, DTC P1153 O2 SENSOR CIRCUIT RANGE/
PERFORMANCE (HIGH) (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
F2
1 2 3 4
10 11 12 13 14
BATTERY
MAIN RELAY
5 6 7 8 9
15 16 17 18 19 20
SBF-5
6
4
14
B262
B100
1
3
5
2
4
6
1 2 3 4
5 6 7 8
1
3
FRONT OXYGEN
(A/F) SENSOR
A: B134
1 2
8 9 10
18 19 20
28 29 30
B262
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
B122
B1
B9
B8
C2
C3
1
5
C: B136
A: B134
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B: B135
ECM
5 6
14 15 16
25 26 27
33 34 35
C: B136
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
26 27
28 29
30 31
A5
D2
D1
D: B137
D7
D3
36
B22
35
34
B47
54
37
2
1
2
4
B122
B47
F2
5
3
B22
E3
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
E
EN-04786

Step
and chassis ground.

and chassis ground.

and chassis ground.
Check
Yes
No
oughly.
more?
Go to step 3.
Repair the ground

connector.
more?
Go to step 4.
Repair the ground

connector.
Go to step 5.
Go to step 6.
Repair the short to

power supply in the
harness between
connector. After
repair, replace the
ECM. <Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
Replace the front

FU(H4SO)-36,
Front Oxygen (A/F)
Sensor.>
Repair the short to Repair poor conpower supply in the tact in ECM conharness between nector.
connector. After
repair, replace the
ECM. <Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
CU:DTC P1160 RETURN SPRING FAILURE

NOTE:

CV:DTC P1400 FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT

LOW
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-202, DTC P1400 FUEL TANK PRESSURE CONTROL
CAUTION:
WIRING DIAGRAM:
BATTERY
MAIN RELAY
SBF-5
7
6
4
B61
F44
5
3
B47
PRESSURE
CONTROL
SOLENOID
VALVE
2
1
R68
R57
R15
10
R2
28
B98
B136
ECM
R68
1 2
B47
1
3
5
2
4
6
B98
R57
3 4 5
1 2
6 7 8 9 10 11 12
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
F44
1 2 3 4
5 6 7 8
EN-04805

Step
chassis ground.
CONNECTOR.
2) Disconnect the connectors from the pressure control solenoid valve and ECM.
pressure control solenoid valve connector and
chassis ground.
CONNECTOR.
ECM and pressure control solenoid valve connector.
(B136) No. 28 (R68) No. 2:
Check
Yes
No
Repair the poor
Go to step 2.
contct in ECM connector.
more?
Go to step 3.
Repair the ground

ECM and pressure
control solenoid
valve connector.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and pressure
control solenoid
valve connector
Poor contact in
coupling connector
Replace the presCHECK PRESSURE CONTROL SOLENOID Is the resistance between 10 Go to step 5.
100 ?
sure control soleVALVE.
noid valve. <Ref. to
Measure the resistance between pressure conEC (H4DOTC)-16,
Terminals
Pressure Control
Solenoid Valve.>
No. 1 No. 2:
CHECK POWER SUPPLY TO THE PRESIs the voltage 10 V or more?
Repair the poor
Repair the harness
SURE CONTROL SOLENOID VALVE.
contact of pressure and connector.
control solenoid
NOTE:
2) Measure the voltage between pressure convalve connector.
trol solenoid valve and chassis ground.
the following item:
Open circuit in
harness between
main relay and
pressure control
solenoid valve
connector
Poor contact in
coupling connector
Poor contact in

CW:DTC P1410 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE

STUCK OPEN
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-204, DTC P1410 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK OPEN, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:

WIRING DIAGRAM:
MAIN RELAY
6
4
5
3
B47
F44
B100
SBF-1
15
SECONDARY
AIR COMBINATION
VALVE RELAY 2
BATTERY
SBF-5
B61
2
1
F2
1
10A
20
21
12
22
13
24
60A
F9
SECONDARY
F27
AIR COMBINATION
VALVE RELAY 1
F2
B100
10
11
4
5
3
6
12
14
F27
46
47
19
20
5
SECONDARY AIR PUMP
2
1
20
F2
16
E3
B22
F11
C8
C30
C19
A29
A27
1
2
E40
A19
B100
E41
SECONDARY
AIR PUMP RELAY
F9
ECM
A: B134
C: B136
SECONDARY
SECONDARY
AIR COMBINATION
F11
E40
1 2
B47
1
3
5
2
4
6
E41
F44
1 2 3
4 5 6
1 2 3 4
5 6 7 8
F9
B22
1
3
4
5
6
A: B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
F2
2
7 8 9
10
11
13
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
F27
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
12
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
5 6 7 10 15 16 17 20 25 26 29 30
35
8
11
18
21
27
31
9 12 13 14 19 22 23 24 28 32 33 34 36
EN-04795

Step
Check
Are there air leaks from the pipe
VALVE.
connections?
1) Remove the secondary air combination
valve.
<Ref. to EC (H4DOTC)-10, Secondary Air
Combi Valve.>
2) Blow in air from the secondary air combination valve air inlet, and check whether there are
leaks at the pipe connections.
Yes
Replace the secondary air combination valve on the
side with the air
leak. <Ref. to EC
(H4DOTC)-10,
Secondary Air
Combi Valve.>
No
Temporary poor
contact occurs.
Check the poor

CX:DTC P1418 SECONDARY AIR INJECTION SYSTEM CONTROL A CIRCUIT

SHORTED
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-205, DTC P1418 SECONDARY AIR INJECTION SYSTEM CONTROL A CIRCUIT SHORTED, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:

WIRING DIAGRAM:
MAIN RELAY
6
4
5
3
B47
F44
B100
SBF-1
15
SECONDARY
AIR COMBINATION
VALVE RELAY 2
BATTERY
SBF-5
B61
2
1
F2
1
10A
20
21
12
22
13
24
60A
F9
SECONDARY
F27
AIR COMBINATION
VALVE RELAY 1
F2
B100
10
11
4
5
3
6
12
14
F27
46
47
19
20
5
SECONDARY AIR PUMP
2
1
20
F2
16
E3
B22
F11
C8
C30
C19
A29
A27
1
2
E40
A19
B100
E41
SECONDARY
AIR PUMP RELAY
F9
ECM
A: B134
C: B136
SECONDARY
SECONDARY
AIR COMBINATION
F11
E40
1 2
B47
1
3
5
2
4
6
E41
F44
1 2 3
4 5 6
1 2 3 4
5 6 7 8
F9
B22
1
3
4
5
6
A: B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
F2
2
7 8 9
10
11
13
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
F27
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
12
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
5 6 7 10 15 16 17 20 25 26 29 30
35
8
11
18
21
27
31
9 12 13 14 19 22 23 24 28 32 33 34 36
EN-04795

Step
Check
and secondary air pump relay.
relay terminal.
(B136) No. 8 (F9) No. 6:
ground.
Yes
Go to step 2.
No
Repair open circuit
of the harness
between the ECM
and secondary air
pump relay terminal.
Repair the short

circuit to power
ECM and secondary air pump relay
terminal.
Temporary poor
contact occurs.
Check the poor

CY:DTC P1420 FUEL TANK PRESSURE CONTROL SOL. VALVE CIRCUIT HIGH
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-206, DTC P1420 FUEL TANK PRESSURE CONTROL
CAUTION:
WIRING DIAGRAM:
BATTERY
MAIN RELAY
SBF-5
7
6
4
B61
F44
5
3
B47
PRESSURE
CONTROL
SOLENOID
VALVE
2
1
R68
R57
R15
10
R2
28
B98
B136
ECM
R68
1 2
B47
1
3
5
2
4
6
B98
R57
3 4 5
1 2
6 7 8 9 10 11 12
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
F44
1 2 3 4
5 6 7 8
EN-04805

Step
drivers side).
chassis ground while operating the pressure
NOTE:
chassis ground.
CHECK POOR CONTACT.
Check
Does the voltage change
between 0 10 V?
Yes
Go to step 2.
No
light illuminates,
the circuit has
this time. In this
case, repair the
poor contact in
ECM connector.
Go to step 4.
Go to step 3.

connector?
Replace the ECM.

<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
Go to step 5.
CHECK HARNESS BETWEEN PRESSURE Is the voltage 10 V or more?

CONNECTOR.
chassis ground.

VALVE.
2) Measure the resistance between pressure
Terminals
No. 1 No. 2:
CHECK POOR CONTACT.

Repair the short

circuit to power
ECM and pressure
control solenoid
valve connector.
After repair,
replace the ECM.
<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
Is the resistance less than 1 ? Replace the purge
control solenoid
valve <Ref. to EC
(H4DOTC)-16,
Pressure Control
Solenoid
Valve.>and ECM
<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
Repair poor conconnector?
Go to step 6.
Replace the ECM.

<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>

CZ:DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-208, DTC P1443 VENT CONTROL SOLENOID
VALVE FUNCTION PROBLEM, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper fuel supply
CAUTION:
WIRING DIAGRAM:
BATTERY
MAIN RELAY
SBF-5
6
4
7
B61
F44
5
3
1
B98
2
1
9
R2
R15
1
2
DRAIN
VALVE
R57
CANISTER
R69
B47
R57
R15
R2
17
B98
B136
ECM
R69
F44
1 2
1 2 3 4
5 6 7 8
B47
1
3
5
2
4
6
B98
R57
3 4 5
1 2
6 7 8 9 10 11 12
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
EN-04797

Step
Check
CHECK DRAIN VALVE OPERATION.

Does the drain valve operate?
drivers side).
NOTE:
Yes
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
Repair the poor
contact in ECM
connector.
No
Go to step 2.
Replace the drain

valve. <Ref. to EC
(H4DOTC)-21,
Drain Valve.>

DA:DTC P1491 POSITIVE CRANKCASE VENTILATION (BLOW-BY) FUNCTION

PROBLEM
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-210, DTC P1491 POSITIVE CRANKCASE VENTILATION (BLOW-BY) FUNCTION PROBLEM, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
B134
1 2
8 9 10
18 19 20
28 29 30
ECM
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
30
B134
E61
1 2
B22
4
B22
E3
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
2
1
48
36
E61
PCV
DIAGNOSIS
CONNECTOR
EN-04806

1
2
Step
CHECK BLOW-BY HOSE.
Check the condition of the blow-by hose.
2) Disconnect the connectors from the PCV
diagnosis connector and ECM.
PCV diagnosis connector and ECM connector.
(B134) No. 30 (E61) No. 2:
PCV diagnosis connector and chassis ground.
CHECK GROUND CIRCUIT OF PCV DIAGNOSIS CONNECTOR.
PCV diagnosis connector and engine ground.
CHECK PCV DIAGNOSIS CONNECTOR.
Measure the resistance between PCV diagnosis connector terminals.
Terminals
No. 1 No. 2:
Check
Yes
Is there any disconnection or
Replace or repair
crack in blow-by hose?
the blow-by hose.
more?
Go to step 4.
No
Go to step 2.
Repair the open
circuit of harness
between PCV
Repair the ground

short circuit of harness between PCV
Repair the ground
circuit of PCV diagnosis connector.
Is the resistance less than 1 ? Repair poor con- Replace the PCV
tact of the ECM
diagnosis connecand PCV diagnosis tor.
connector.


GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-212, DTC P1518 STARTER SWITCH CIRCUIT LOW
TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
IGNITION SWITCH
BATTERY
SBF-4
SBF-1
1
3
B72
INTERRUPT
RELAY
5
2
3
1
*1
: AT MODEL
*2
: MT MODEL
B59
TO SECURITY SYSTEM
INHIBITOR SWITCH
*2
B12
12
12
11
7
T3
T7
*1
STARTER INTERLOCK
RELAY (MT)
28
27
26
24
STARTER MOTOR
2
B14
B225
32
CLUTCH SWITCH (MT)
2
1
B106
B136
B106
1
2
B225
B72
1 2
3 4
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
ECM
B59
T7
B12
1 2 3
4
5
1 2 3 4 5 6
7 8 9 10 11 12
1 2 3 4
5 6 7 8
9 10 11 12
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
EN-04781

Step
Check
Yes
CHECK OPERATION OF STARTER MOTOR. Does the starter motor operate Repair the harness
when ignition switch is turned to and connector.
START?
NOTE:
the following item:
Open or ground
ECM and starter
motor connector
Poor contact in
ECM connector
No
Check the starter
to
EN(H4DOTC)(diag
)-59, STARTER
MOTOR CIRCUIT,
Diagnostics for
Engine Starting
Failure.>


GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-213, DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
4
6
SBF-5
7
5
3
B61
2
1
B72
No.11
B47
F44
IGNITION
SWITCH
SBF-4
SBF-1
C23
A7
B2
B5
B19
A : B134
B : B135 ECM
C : B136
C15
MT
A5
D2
D1
D7
D3
D : B137
E
B72
B47
1
3
5
1 2
3 4
2
4
6
A : B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
36
35
34
54
37
B22
E3
F44
1 2 3
5 6 7
MT : MT MODEL
D : B137
4
8
B22
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
B : B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
24 25
26 27
20 21 22 23
28 29 30 31
32 33
34 35
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
C : B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04782

Step
Check
chassis ground.
MAIN FUSE BOX CONNECTOR.
CHECK FUSE SBF-5.
Yes
No
Go to step 2.

ECM connector
and battery terminal.
Replace the fuse.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and battery
Poor contact in
ECM connector
Poor contact in
battery terminal


GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-215, DTC P1602 CONTROL MODULE PROGRAMMING ERROR, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Engine keeps running at lower speed than specified idle speed.
Engine stalls.
CAUTION:

WIRING DIAGRAM:
MAIN RELAY
6
4
B61
BATTERY
F44
SBF-5
5
3
2
1
B47
45
11
10
44
43
48
42
B137 ECM
B22
E3
2
1
E17
2
1
E6
2
1
E16
2
1
E5
#1
#2
#3
#4
FUEL INJECTOR
E5
E6
E16
E17
1 2
B47
1
3
5
2
4
6
F44
B137
B22
1 2 3 4
5 6 7 8
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
26 27
28 29
30 31
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04785

ELECTRONIC THROTTLE
CONTROL RELAY
B309
B309
BATTERY
SBF-5
2
1
3
4
1 2
3 4
8
7
MAIN RELAY
B61
F44
B20
B122
1
5
9
13
2
6
10
14
3
7
11
15
1 2 3 4
5 6 7 8
4
8
12
16
C1
C21
B47
E57
1 2 3 4 5 6
A: B134
C: B136
D: B137
ECM
D2
C6
A5
A28
A18
A29
A19
D4
D5
D7
D3
F44
1 2 3
5 6 7
3
7
1
3
5
4
8
2
4
6
B122
A: B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
1 2
8 9 10
18 19 20
28 29 30
19
20
54
37
39
38
B22
B47
E3
C: B136
36
B20
35
16
15
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
E1
5 6
14 15 16
25 26 27
33 34 35
D: B137
B22
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
26 27
28 29
30 31
E3
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
4
6
3
5
1
2
B22
ELECTRONIC
E57 THROTTLE
CONTROL
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04790
Step
Check
CHECK ENGINE OIL.
Is the engine oil filled to the

specified amount?

on exhaust system?
Yes
No
priate DTC using
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
Go to step 3.
Replace the
engine oil. <Ref. to
LU (H4SO)-10,
REPLACEMENT,
Engine Oil.>
system.

Step
Check
Yes
Are there holes, loose bolts or Repair the air
intake system.
intake system?
Go to step 6.
Is the fuel pressure 339.5
360.5 kPa (3.5 3.7 kgf/cm2,
WARNING:
area.
Measure the fuel pressure. <Ref. to
WARNING:
SENSOR.
ture 60C (140F) or more?
NOTE:
General scan tool
CHECK MASS AIR FLOW AND INTAKE AIR Is the measured value 2.1
Go to step 8.
TEMPERATURE SENSOR.
3.4 g/s (0.28 0.45 lb/m)?
(140F).
NOTE:
General scan tool
No
Go to step 5.

Fuel pressure is
too high:
Clogged fuel line
or bent hose
Fuel pressure is
too low:
Improper fuel
pump discharge
Clogged fuel line
Replace the
engine coolant
FU(H4DOTC)-26,
Engine Coolant
Replace the mass

air flow and intake
air temperature
sensor. <Ref. to
FU(H4DOTC)-30,
Mass Air Flow and

10
11
12
Step
TEMPERATURE SENSOR.
(140F).
NOTE:
General scan tool
faulty cylinders.
#1 (B137) No. 8 (E5) No. 1:
#2 (B137) No. 9 (E16) No. 1:
#3 (B137) No. 10 (E6) No. 1:
#4 (B137) No. 11 (E17) No. 1:
Terminals
No. 1 No. 2:
Check
Yes
50C (18 90F)?
No
Check the mass air
flow and intake air
FU(H4DOTC)-30,
Mass Air Flow and
Go to step 14.
Go to step 10.
more?
Go to step 11.
Repair the ground

injector and ECM
connector.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
Poor contact in
coupling connector
Replace the faulty

20 ?

13
14
15
16
17
18
Step
Check

Terminals
No. 1 No. 2:
Yes
Repair the poor
injector circuit.
Repair the short

circuit to power
ECM connector
and fuel injector.
After repair,
replace the ECM.
<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
Replace the faulty

fuel injector <Ref.
and ECM. <Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
loosely installed?
sor or crankshaft
position sensor.
sprocket. <Ref. to
ME(H4DOTC)-53,
Crank Sprocket.>
tion condition of
TIMING BELT.
the timing belt.
Turn the crankshaft, and align alignment mark
<Ref. to
on crank sprocket with alignment mark on cylinder block.
ME(H4DOTC)-44,
Timing Belt.>
No
Repair the harness
and connector.
NOTE:
the following item:
Open circuit in
harness between
main relay and fuel
injector connector
on faulty cylinders
Poor contact in
coupling connector
Poor contact in
Poor contact in
cylinders
Go to step 15.
Go to step 16.
Go to step 17.
Go to step 18.
Go to step 19.

19
20
21
22
23
24
Step
Terminals
No. 2 No. 4:
ground.
ground.
(B136) No. 21 (B309) No. 3:
(B136) No. 1 (B309) No. 4:
NOTE:
Check
Yes
No
Go to step 21.
Repair the open or

of power supply
circuit.
Go to step 22.
Repair the power

of harness
between ECM and
electronic throttle
control.
more?
Go to step 23.
Repair the ground

Repair the open

circuit of harness
between ECM and
electronic throttle
control relay.
Go to step 27.
Go to step 25.

25
26
27
28
29
30
31
Step
NOTE:
CHECK POOR CONTACT.
throttle control.
(B134) No. 18 (E57) No. 6:
(B134) No. 28 (E57) No. 4:
(B134) No. 19 (E57) No. 5:
NOTE:
Check
Yes
Go to step 26.
No
Go to step 27.
Repair the poor

contact.
Go to step 31.
Repair the open

circuit of harness
connector.
more?
Go to step 29.
Repair the ground

Go to step 30.
Go to step 34.

32
33
34
35
36
37
38
Step
NOTE:
CHECK POOR CONTACT.
throttle control.
(B134) No. 29 (E57) No. 3:
(B134) No. 18 (E57) No. 6:
(B134) No. 28 (E57) No. 4:
Check
Yes
No
Go to step 34.
Go to step 39.
Repair the poor

contact.
Repair the open

circuit of harness
connector.
Repair the short

circuit to power
ECM connector
and electronic
throttle control
connector.
Repair the short
circuit of harness
control connector.

more?
2) Remove the ECM.
(B134) No. 18 (B134) No. 19:
(B134) No. 28 (B134) No. 19:
Go to step 37.
Go to step 38.
Go to step 39.
Repair the short

circuit to sensor
power supply.

39
40
41
42
43
44
Step
NOTE:
NOTE:
throttle control.
(B137) No. 5 (E57) No. 2:
(B137) No. 4 (E57) No. 1:
(E57) No. 2 (E57) No. 1:
Check
Yes
Go to step 40.
No
Repair the poor
Go to step 41.
Repair the poor

Repair the open

circuit of harness
connector.
Go to step 43.
Repair the power

of harness
between ECM and
electronic throttle
control.
more?
Go to step 44.
Repair the short

circuit of harness.
more?
Go to step 45.
Repair the short

circuit of harness.

45
46
47
Step
Terminals
No. 1 No. 2:
Check
?
Yes
Go to step 46.
No
Repair the open
circuit of harness.

closed position
DE:DTC P2004 INTAKE MANIFOLD RUNNER CONTROL STUCK OPEN (BANK 1)

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-217, DTC P2004 INTAKE MANIFOLD RUNNER CONTROL STUCK OPEN (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
1
Step
Check
Yes
No
priate DTC using
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
CHECK TUMBLE GENERATOR VALVE RH. Does the tumble generator
Replace the tum- Clean the tumble
1) Remove the tumble generator valve assem- valve move smoothly? (No dirt ble generator valve generator valve.
bly.
or foreign matter is clogged)
assembly. <Ref. to
2) Check the tumble generator valve body.
FU(H4DOTC)-36,
Tumble Generator
Valve Assembly.>

DF:DTC P2005 INTAKE MANIFOLD RUNNER CONTROL STUCK OPEN (BANK 2)

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-218, DTC P2005 INTAKE MANIFOLD RUNNER CONTROL STUCK OPEN (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
1
Step
Check
Yes
No
priate DTC using
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
CHECK TUMBLE GENERATOR VALVE LH. Does the tumble generator
bly.
assembly. <Ref. to
FU(H4DOTC)-36,
Tumble Generator
Valve Assembly.>
DG:DTC P2006 INTAKE MANIFOLD RUNNER CONTROL STUCK CLOSED

(BANK 1)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-219, DTC P2006 INTAKE MANIFOLD RUNNER CONTROL STUCK CLOSED (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
1
Step
Check
Yes
No
priate DTC using
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
CHECK TUMBLE GENERATOR VALVE RH. Does the tumble generator
bly.
assembly. <Ref. to
FU(H4DOTC)-36,
Tumble Generator
Valve Assembly.>

DH:DTC P2007 INTAKE MANIFOLD RUNNER CONTROL STUCK CLOSED

(BANK 2)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-220, DTC P2007 INTAKE MANIFOLD RUNNER CONTROL STUCK CLOSED (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
1
Step
Check
Yes
No
priate DTC using
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
CHECK TUMBLE GENERATOR VALVE LH. Does the tumble generator
bly.
assembly. <Ref. to
FU(H4DOTC)-36,
Tumble Generator
Valve Assembly.>

DI: DTC P2008 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT / OPEN (BANK 1)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-221, DTC P2008 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT / OPEN (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
TUMBLE GENERATOR
VALVE ACTUATOR RH
E55
21
32
E3
23
22
B22
B137 ECM
E55
B137
B22
1 2
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04807

Step
Check
Yes
TUMBLE GENERATOR VALVE ACTUATOR
CONNECTOR.
2) Disconnect the connector from tumble generator valve and ECM connector.
3) Measure the resistance between tumble
generator valve actuator and ECM connector.
(E55) No. 1 (B137) No. 22:
(E55) No. 2 (B137) No. 23:
CHECK POOR CONTACT.

Check poor contact in tumble generator valve
actuator connector.
Is there poor contact in tumble Repair the poor

generator valve actuator concontact of tumble
generator valve
nector?
actuator connector.
No
Repair the open
circuit between
ECM and tumble
generator valve
connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and tumble
generator valve
actuator connector
Poor contact in
coupling connector
Replace the tumble generator valve
actuator. <Ref. to
FU(H4DOTC)-37,
Tumble Generator
Valve Actuator.>

DJ:DTC P2009 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW (BANK 1)

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-223, DTC P2009 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
TUMBLE GENERATOR
VALVE ACTUATOR RH
E55
21
32
E3
23
22
B22
B137 ECM
E55
B137
B22
1 2
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04807

Step
Check
CONNECTOR.
2) Disconnect the connector from tumble generator valve connector.
3) Measure the voltage between tumble generator valve actuator and chassis ground.
Yes
actuator. <Ref. to
FU(H4DOTC)-37,
Tumble Generator
Valve Actuator.>
No
Repair the short
circuit to power
supply between
the ECM and tumble generator valve
actuator.

DK:DTC P2011 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT / OPEN

(BANK 2)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-225, DTC P2011 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT / OPEN (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
TUMBLE GENERATOR
VALVE ACTUATOR LH
E51
22
33
E3
13
12
B22
B137 ECM
E51
B137
B22
1 2
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04808

Step
Check
Yes
CONNECTOR.
2) Disconnect the connector from tumble generator valve and ECM connector.
3) Measure the resistance between tumble
generator valve actuator and ECM connector.
(E51) No. 1 (B137) No. 12:
(E51) No. 2 (B137) No. 13:
CHECK POOR CONTACT.

Check poor contact in tumble generator valve
actuator connector.
Is there poor contact in tumble Repair the poor

generator valve actuator concontact of tumble
generator valve
nector?
actuator connector.
No
Repair the open
circuit between
ECM and tumble
generator valve
connector.
NOTE:
the following item:
Open circuit of
harness between
ECM and tumble
generator
valve
actuator connector
Poor contact in
coupling connector
actuator. <Ref. to
FU(H4DOTC)-37,
Tumble Generator
Valve Actuator.>

DL:DTC P2012 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW (BANK 2)

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-227, DTC P2012 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
TUMBLE GENERATOR
VALVE ACTUATOR LH
E51
22
33
E3
13
12
B22
B137 ECM
E51
B137
B22
1 2
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04808

Step
Check
CONNECTOR.
2) Disconnect the connector from tumble generator valve connector.
3) Measure the voltage between tumble generator valve actuator and chassis ground.
Yes
actuator. <Ref. to
FU(H4DOTC)-37,
Tumble Generator
Valve Actuator.>
No
Repair the short
circuit to power
supply between
the ECM and tumble generator valve
actuator.

DM:DTC P2016 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH

CIRCUIT LOW (BANK 1)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-229, DTC P2016 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
E54
TUMBLE GENERATOR
VALVE POSITION SENSOR RH
1
3
2
1 2 3
E54
B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
20
10
19
E3
1 2
8 9 10
18 19 20
28 29 30
B22
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
19
26
29
48
36
B134 ECM
EN-04809

Step
Check
Yes
CHECK CURRENT DATA.
2) Read the data of tumble generator valve
NOTE:
General scan tool

Go to step 3.
and chassis ground.
and chassis ground.
Go to step 5.
TUMBLE GENERATOR VALVE POSITION
SENSOR CONNECTOR.
2) Disconnect the connector from tumble generator valve position sensor.
4) Measure the voltage between the tumble
generator valve position sensor connector and
engine ground.
No
light illuminates,
the circuit has
the connector may
be the cause.
NOTE:
the following item:
Poor contact of
tumble generator
valve position sensor connector
Poor contact in
ECM connector
Poor contact in
coupling connector
Repair the poor
contact in ECM
connector.
Repair the poor

contact in ECM
connector.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit of
harness between
tumble generator
valve position sensor and ECM connector
Poor contact of
tumble generator
Poor contact in
ECM connector
Poor contact in
coupling connector
Poor contact in
joint connector

Step
Check
Yes
SENSOR CONNECTOR.
ECM connector and tumble generator valve
position sensor connector.
(B134) No. 26 (E54) No. 3:

SENSOR CONNECTOR.
the tumble generator valve position sensor connector and engine ground.
CHECK POOR CONTACT.
Check for poor contact in the tumble generator
valve position sensor connector.
more?
Go to step 7.
Is there poor contact in the tum- Repair poor conble generator valve position
tact of the tumble
sensor connector?
generator valve
position sensor
connector.
No
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
tumble generator
Poor contact in
ECM connector
Poor contact of
tumble generator
Poor contact in
coupling connector
Repair the ground
harness between
the tumble generator valve position
sensor and ECM
connector.
position sensor.
<Ref. to
FU(H4DOTC)-38,
Tumble Generator
Valve Position
Sensor.>

DN:DTC P2017 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH

CIRCUIT HIGH (BANK 1)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-231, DTC P2017 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT HIGH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
E54
TUMBLE GENERATOR
VALVE POSITION SENSOR RH
1
3
2
1 2 3
E54
B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
20
10
19
E3
1 2
8 9 10
18 19 20
28 29 30
B22
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
19
26
29
48
36
B134 ECM
EN-04809

Step
Check
CHECK CURRENT DATA.
NOTE:
General scan tool
No
light illuminates,
the circuit has
the connector may
be the cause.
NOTE:
the following item:
Poor contact of
tumble generator
Poor contact in
ECM connector
Poor contact in
coupling connector
CHECK HARNESS BETWEEN TUMBLE
Repair the harness
GENERATOR VALVE POSITION SENSOR
and connector.
CONNECTOR AND ECM CONNECTOR.
NOTE:
2) Disconnect the connector from tumble genthe following item:
erator valve position sensor.
Open circuit of
harness between
between the tumble generator valve position
tumble generator
sensor connector and engine ground.
valve position senConnector & terminal
sor and ECM con(E54) No. 2 Engine ground:
nector
Poor contact in
coupling connector
Poor contact in
joint connector
Repair the short
Replace the tumGENERATOR VALVE POSITION SENSOR
circuit to power
ble generator valve
supply in the har- position sensor.
ness between the <Ref. to
tumble generator FU(H4DOTC)-38,
valve position sen- Tumble Generator
engine ground.
sor and ECM con- Valve Position
nector. After repair, Sensor.>
replace the ECM.
<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
Yes
Go to step 2.

DO:DTC P2021 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-233, DTC P2021 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT LOW (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
E50
TUMBLE GENERATOR
VALVE POSITION SENSOR LH
1
3
2
1 2 3
E50
B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
20
11
19
E3
B22
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
19
16
29
48
36
B134 ECM
EN-04810

Step
Check
Yes
CHECK CURRENT DATA.
NOTE:
General scan tool

Go to step 3.
and chassis ground.
and chassis ground.
Go to step 5.
SENSOR CONNECTOR.
2) Disconnect the connector from tumble generator valve position sensor.
engine ground.
No
light illuminates,
the circuit has
the connector may
be the cause.
NOTE:
the following item:
Poor contact of
tumble generator
Poor contact in
ECM connector
Poor contact in
coupling connector
Repair the poor
contact in ECM
connector.
Repair the poor

contact iin ECM
connector.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit of
harness between
tumble generator
Poor contact of
tumble generator
Poor contact in
ECM connector
Poor contact in
coupling connector
Poor contact in
joint connector

Step
Check
Yes
SENSOR CONNECTOR.
ECM connector and tumble generator valve
position sensor connector.
(B134) No. 16 (E50) No. 3:

SENSOR CONNECTOR.
the tumble generator valve position sensor connector and engine ground.
CHECK POOR CONTACT.
Check for poor contact in the tumble generator
valve position sensor connector.
more?
Go to step 7.
Is there poor contact in the tum- Repair poor conble generator valve position
tact of the tumble
sensor connector?
generator valve
position sensor
connector.
No
Repair the harness
and connector.
NOTE:
the following item:
Open circuit of
harness between
tumble generator
Poor contact in
ECM connector
Poor contact of
tumble generator
Poor contact in
coupling connector
Repair the ground
harness between
the tumble generator valve position
sensor and ECM
connector.
position sensor.
<Ref. to
FU(H4DOTC)-38,
Tumble Generator
Valve Position
Sensor.>

DP:DTC P2022 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-235, DTC P2022 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT HIGH (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
E50
TUMBLE GENERATOR
VALVE POSITION SENSOR LH
1
3
2
1 2 3
E50
B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
20
11
19
E3
B22
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
19
16
29
48
36
B134 ECM
EN-04810

Step
Check
CHECK CURRENT DATA.
NOTE:
General scan tool
No
light illuminates,
the circuit has
the connector may
be the cause.
NOTE:
the following item:
Poor contact of
tumble generator
Poor contact in
ECM connector
Poor contact in
coupling connector
Repair the harness
GENERATOR VALVE POSITION SENSOR
and connector.
NOTE:
2) Disconnect the connector from tumble genthe following item:
erator valve position sensor.
Open circuit of
harness between
between the tumble generator valve position
tumble generator
sensor connector and engine ground.
valve position senConnector & terminal
sor and ECM con(E50) No. 2 Engine ground:
nector
Poor contact in
coupling connector
Poor contact in
joint connector
CHECK HARNESS BETWEEN ECM CONIs the voltage 4.9 V or more?
Repair the short
Replace the tumNECTOR AND TUMBLE GENERATOR
circuit to power
ble generator valve
VALVE POSITION SENSOR.
supply in the har- position sensor.
ness between the <Ref. to
tumble generator FU(H4DOTC)-38,
valve position sen- Tumble Generator
engine ground.
sor and ECM con- Valve Position
nector. After repair, Sensor.>
replace the ECM.
<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
Yes
Go to step 2.

DQ:DTC P2088 OCV SOLENOID VALVE SIGNAL A CIRCUIT OPEN (BANK 1)

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-237, DTC P2088 OCV SOLENOID VALVE SIGNAL A
CIRCUIT OPEN (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
B137 ECM
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
16
17
B137
24
23
B22
E38
E3
1 2
B22
1
2
E38
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
OIL FLOW CONTROL SOLENOID VALVE RH
EN-04811

Step
Check
Yes
FLOW CONTROL SOLENOID VALVE.
oil flow control solenoid valve.
(B137) No. 17 (E38) No. 1:
(B137) No. 16 (E38) No. 2:

Measure the resistance between ECM and oil
flow control solenoid valve.
CHECK OIL FLOW CONTROL SOLENOID
VALVE.
1) Remove the oil flow control solenoid valve
connector.
2) Measure the resistance between oil flow
Terminals
No. 1 No. 2:
more?
Go to step 3.
Is the resistance between 6 Repair the poor

12 ?
contact of ECM
and oil flow control
solenoid valve.
No
Repair the open
circuit of harness
between ECM and
oil flow control
NOTE:
the following item:
Open circuit of
harness between
ECM and oil flow
control
solenoid
valve connector
Poor contact of
Repair the short
circuit between
ECM and oil flow
control solenoid
valve connector.
Replace the oil

flow control solenoid valve. <Ref. to
ME(H4DOTC)-54,
Camshaft.>

DR:DTC P2089 OCV SOLENOID VALVE SIGNAL A CIRCUIT SHORT (BANK 1)

CIRCUIT SHORT (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
B137 ECM
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
16
17
B137
24
23
B22
E38
E3
1 2
B22
1
2
E38
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
OIL FLOW CONTROL SOLENOID VALVE RH
EN-04811

Step
Check
Yes
(B137) No. 17 (E38) No. 1:
(B137) No. 16 (E38) No. 2:

VALVE.
connector.
Terminals
No. 1 No. 2:
more?
Go to step 3.

12 ?
contact of ECM
solenoid valve.
No
Repair the open
circuit of harness
between ECM and
oil flow control
NOTE:
the following item:
Open circuit of
harness between
ECM and oil flow
control
solenoid
valve connector
Poor contact of
Repair the short
circuit between
ECM and oil flow
control solenoid
valve connector.
Replace the oil

ME(H4DOTC)-54,
Camshaft.>

DS:DTC P2092 OCV SOLENOID VALVE SIGNAL A CIRCUIT OPEN (BANK 2)

TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
B137 ECM
14
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
B22
E37
E3
1 2
28
27
15
B137
B22
1
2
E37
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
OIL FLOW CONTROL SOLENOID VALVE LH
EN-04812

Step
Check
Yes
(B137) No. 15 (E37) No. 1:
(B137) No. 14 (E37) No. 2:

Measure the resistance between ECM and oil
flow control solenoid valve.
VALVE.
connector.
Terminals
No. 1 No. 2:
more?
Go to step 3.

12 ?
contact of ECM
solenoid valve.
No
Repair the open
circuit of harness
between ECM and
oil flow control
NOTE:
the following item:
Open circuit of
harness between
ECM and oil flow
control
solenoid
valve connector
Poor contact of
Repair the short
circuit between
ECM and oil flow
control solenoid
valve connector.
Replace the oil

ME(H4DOTC)-54,
Camshaft.>

DT:DTC P2093 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT

HIGH (BANK 2)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-243, DTC P2093 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
B137 ECM
14
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
B22
E37
E3
1 2
28
27
15
B137
B22
1
2
E37
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
OIL FLOW CONTROL SOLENOID VALVE LH
EN-04812

Step
Check
Yes
(B137) No. 15 (E37) No. 1:
(B137) No. 14 (E37) No. 2:

VALVE.
connector.
Terminals
No. 1 No. 2:
more?
Go to step 3.

12 ?
contact of ECM
solenoid valve.
No
Repair the open
circuit of harness
between ECM and
oil flow control
NOTE:
the following item:
Open circuit of
harness between
ECM and oil flow
control
solenoid
valve connector
Poor contact of
Repair the short
circuit between
ECM and oil flow
control solenoid
valve connector.
Replace the oil

ME(H4DOTC)-54,
Camshaft.>

DU:DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN BANK 1
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-245, DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN BANK 1, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
BATTERY
MAIN RELAY
SBF-5
6
4
14
F2
B100
5
3
FRONT OXYGEN
(A/F) SENSOR
REAR OXYGEN
SENSOR
B47
1
2
B262
2
4
1
B18
3
4
2
1
1
2
5
B : B135
B47
B18
1
3
1
3
5
2
4
B:
B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
B122
2
4
6
1 2 3 4
5 6 7 8
C:
C : B136
B8
B9
C2
C3
B1
B4
B30
C4
B122
ECM
B262
2
4
1
3
F2
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
EN-03818

Step
Check
Yes
No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4DOTC)(diag
Code (DTC).>
NOTE:
oughly.

TOR.
(B135) No. 8 (B262) No. 3:
(B135) No. 9 (B262) No. 4:

and chassis ground.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
connector
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
ECM connector
Repair the ground
connector.
more?
Go to step 5.
Go to step 6.
connector. After
repair, replace the
ECM. <Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
Go to step 7.

9
10
11
12
Step
and chassis ground.
and chassis ground.
Check
Yes
No
Go to step 9.
Repair the short to

power supply in the
harness between
connector. After
repair, replace the
ECM. <Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
Repair the exhaust
system.
Repair the air
intake system.

on exhaust system?
intake system?
Is the measured value 284 Go to step 12.
314 kPa (2.9 3.2 kgf/cm2, 41
WARNING:
area.
WARNING:
NOTE:
pressure again.
33 38 psi)?
WARNING:
NOTE:
pressure again.
Go to step 10.
Go to step 11.

Fuel pressure is
too high:
Clogged fuel
return line or bent
hose
Fuel pressure is
too low:
Improper fuel
pump discharge
Clogged fuel
supply line

Fuel pressure is
too high:
Faulty pressure
regulator
Clogged fuel
return line or bent
hose
Fuel pressure is
too low:
Faulty pressure
regulator
Improper fuel
pump discharge
Clogged fuel
supply line

13
14
15
Step
SENSOR.
NOTE:
General scan tool
TEMPERATURE SENSOR.
(140F).
NOTE:
General scan tool
TEMPERATURE SENSOR.
(140F).
NOTE:
General scan tool
Check
(140F) or more?
Yes
Go to step 14.
No
Replace the
engine coolant
FU(H4DOTC)-26,
Engine Coolant

4.7 g/s (0.36 0.62 lb/m)?
Go to step 15.
Replace the mass

air flow and intake
air temperature
sensor. <Ref. to
FU(H4DOTC)-30,
Mass Air Flow and

50C (18 90F)?
Check the mass air

flow and intake air
FU(H4DOTC)-30,
Mass Air Flow and

16
17
18
19
Step
tool.
NOTE:
General scan tool
rear oxygen sensor.
(B135) No. 4 (B18) No. 3:
(B135) No. 30 (B18) No. 4:
or chassis ground.
Check
Yes
No
Go to step 17.
tor?
oughly.
Go to step 19.
circuit of harness
between ECM and
rear oxygen sensor
connector.
Replace the rear

oxygen sensor.
<Ref. to
FU(H4DOTC)-42,
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
the harness between rear oxygen
sensor and ECM
connector
Poor contact in
Poor contact in
ECM connector

20
21
Step
tool.
NOTE:
General scan tool
tool.
NOTE:
General scan tool
Check
Yes
No
Go to step 17.
Does voltage keep to be 0.8 V Replace the front Go to step 18.

or more for more than five min- oxygen (A/F) senutes?
sor. <Ref. to
FU(H4DOTC)-40,
Front Oxygen (A/F)
Sensor.>

DV:DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH BANK 1
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-247, DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH BANK 1, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:
WIRING DIAGRAM:
BATTERY
MAIN RELAY
SBF-5
6
4
14
F2
B100
5
3
FRONT OXYGEN
(A/F) SENSOR
REAR OXYGEN
SENSOR
B47
1
2
B262
2
4
1
B18
3
4
2
1
1
2
5
B : B135
B47
B18
1
3
1
3
5
2
4
B:
B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
B122
2
4
6
1 2 3 4
5 6 7 8
C:
C : B136
B8
B9
C2
C3
B1
B4
B30
C4
B122
ECM
B262
2
4
1
3
F2
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
EN-03818

Step
Check
Yes
No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4DOTC)(diag
Code (DTC).>
NOTE:
oughly.

TOR.
(B135) No. 8 (B262) No. 3:
(B135) No. 9 (B262) No. 4:

and chassis ground.
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
connector
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
ECM connector
Repair the ground
connector.
more?
Go to step 5.
Go to step 6.
connector. After
repair, replace the
ECM. <Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
Go to step 7.

9
10
11
12
Step
and chassis ground.
and chassis ground.
Check
Yes
No
Go to step 9.
Repair the short to

power supply in the
harness between
connector. After
repair, replace the
ECM. <Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
Repair the exhaust
system.
Repair the air
intake system.

on exhaust system?
intake system?
314 kPa (2.9 3.2 kgf/cm2, 41
WARNING:
area.
WARNING:
NOTE:
pressure again.
33 38 psi)?
WARNING:
NOTE:
pressure again.
Go to step 10.
Go to step 11.

Fuel pressure is
too high:
Clogged fuel
return line or bent
hose
Fuel pressure is
too low:
Improper fuel
pump discharge
Clogged fuel
supply line

Fuel pressure is
too high:
Faulty pressure
regulator
Clogged fuel
return line or bent
hose
Fuel pressure is
too low:
Faulty pressure
regulator
Improper fuel
pump discharge
Clogged fuel
supply line

13
14
15
Step
SENSOR.
NOTE:
General scan tool
TEMPERATURE SENSOR.
(140F).
NOTE:
General scan tool
TEMPERATURE SENSOR.
(140F).
NOTE:
General scan tool
Check
(140F) or more?
Yes
Go to step 14.
No
Replace the
engine coolant
FU(H4DOTC)-26,
Engine Coolant

4.7 g/s (0.36 0.62 lb/m)
Go to step 15.
Replace the mass

air flow and intake
air temperature
sensor. <Ref. to
FU(H4DOTC)-30,
Mass Air Flow and

50C (18 90F)?
Check the mass air

flow and intake air
FU(H4DOTC)-30,
Mass Air Flow and

16
17
18
19
Step
tool.
NOTE:
General scan tool
rear oxygen sensor.
(B135) No. 4 (B18) No. 3:
(B135) No. 30 (B18) No. 4:
or chassis ground.
Check
Yes
No
Go to step 17.
tor?
oughly.
Go to step 19.
circuit of harness
between ECM and
rear oxygen sensor
connector.
Replace the rear

oxygen sensor.
<Ref. to
FU(H4DOTC)-42,
Repair the harness

and connector.
NOTE:
the following item:
Open circuit in
harness between
Poor contact in
Poor contact in
ECM connector

20
21
Step
tool.
NOTE:
General scan tool
tool.
NOTE:
General scan tool
Check
Yes
No
Go to step 17.
Does voltage keep to be 0.8 V Replace the front Go to step 18.

or more for more than five min- oxygen (A/F) senutes?
sor. <Ref. to
FU(H4DOTC)-40,
Front Oxygen (A/F)
Sensor.>

DW:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/

PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-186, DTC P0638 THROTTLE ACTUATOR CONTROL
RANGE/PERFORMANCE (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.> <Ref. to
GD(H4DOTC)-200, DTC P1160 RETURN SPRING FAILURE, Diagnostic Trouble Code (DTC) Detecting
Criteria.> or <Ref. to GD(H4DOTC)-249, DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
ELECTRONIC THROTTLE
CONTROL RELAY
B309
B309
BATTERY
SBF-5
2
1
3
4
1 2
3 4
8
7
MAIN RELAY
B61
F44
B20
B122
1
5
9
13
2
6
10
14
3
7
11
15
1 2 3 4
5 6 7 8
4
8
12
16
C1
C21
B47
E57
1 2 3 4 5 6
A: B134
C: B136
D: B137
ECM
D2
C6
A5
A28
A18
A29
A19
D4
D5
D7
D3
F44
1 2 3
5 6 7
3
7
4
8
2
4
6
B122
A: B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
1 2
8 9 10
18 19 20
28 29 30
19
20
54
37
39
38
B22
B47
1
3
5
E3
C: B136
36
B20
35
16
15
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
E1
D: B137
B22
E3
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
E
E57
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
4
6
3
5
1
2
B22
ELECTRONIC
THROTTLE
CONTROL
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04790

Step
Terminals
No. 2 No. 4:
Measure the voltage between the electronic
throttle control relay connector and engine
ground.
3) Measure the voltage between the electronic
ground.
ground.
2) Measure the resistance between ECM connector and electronic throttle control relay connector.
(B136) No. 21 (B309) No. 3:
(B136) No. 1 (B309) No. 4:
3) Measure the voltage between ECM connector terminals.
(B134) No. 18 (+) (B134) No. 29 ():
Check
Yes
No
Go to step 3.
Repair the open or

of power supply
circuit.
Go to step 4.
Repair the power

of harness
between ECM and
electronic throttle
control.
more?
Go to step 5.
Repair the ground

Repair the open

circuit of harness
between ECM and
electronic throttle
control relay.
Go to step 9.
Go to step 7.

10
11
12
13
Step
(B134) No. 28 (+) (B134) No. 29 ():
CHECK POOR CONTACT.
throttle control.
(B134) No. 19 (E57) No. 5:
harness and connector of ECM and engine harness connector while monitoring the value with
voltage meter.
Check
Yes
Go to step 8.
No
Go to step 9.
Repair the poor

contact.
Go to step 13.
Repair the open

circuit of harness
connector.
more?
Go to step 11.
Repair the ground

Go to step 12.
Is the voltage 4.63 V?
Go to step 16.
Go to step 14.

14
15
16
17
18
19
20
Step
CHECK POOR CONTACT.
throttle control.
(B134) No. 18 (E57) No. 6:
(B134) No. 28 (E57) No. 4:
(B134) No. 29 (E57) No. 3:
voltage meter.
voltage meter.
2) Remove the ECM.
(B134) No. 18 (B134) No. 29:
(B134) No. 28 (B134) No. 29:
Check
Is the voltage 4.73 V?
Yes
Go to step 15.
No
Go to step 16.
Repair the poor

contact.
Go to step 21.
Repair the open

circuit of harness
connector.
Go to step 19.
Repair the short

circuit to power
ECM connector
and electronic
throttle control
connector.
Go to step 20.
Repair the short

circuit of harness
control connector.
more?
Go to step 21.
Repair the short

circuit to sensor
power supply.

21
22
23
24
25
26
27
Step
Check

throttle control.
(B137) No. 4 (E57) No. 1:
(B137) No. 5 (E57) No. 2:
(E57) No. 2 (E57) No. 1:
Measure the resistance between ECM connector and engine ground.
Yes
Go to step 22.
Go to step 23.
No
Repair the poor
Repair the poor
Repair the open
circuit of harness
connector.
Go to step 25.
Repair the power

of harness
between ECM and
electronic throttle
control.
more?
Go to step 26.
Repair the short

circuit of harness.
more?
Go to step 27.
Repair the short

circuit of harness.

?
Go to step 28.
Repair the open

circuit of harness.

28
29
Step
Terminals
No. 1 No. 2:
Check
Yes
No

closed position

DX:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW

TROUBLE SYMPTOM:
Improper idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
ELECTRONIC THROTTLE
CONTROL RELAY
B309
B309
BATTERY
SBF-5
2
1
3
4
1 2
3 4
8
7
MAIN RELAY
B61
F44
B20
B122
1
5
9
13
2
6
10
14
3
7
11
15
1 2 3 4
5 6 7 8
4
8
12
16
C1
C21
B47
E57
1 2 3 4 5 6
A: B134
C: B136
D: B137
ECM
D2
C6
A5
A28
A18
A29
A19
D4
D5
D7
D3
F44
1 2 3
5 6 7
3
7
1
3
5
4
8
2
4
6
B122
A: B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
1 2
8 9 10
18 19 20
28 29 30
19
20
54
37
39
38
B22
B47
E3
C: B136
36
B20
35
16
15
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
E1
D: B137
B22
E3
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
4
6
3
5
1
2
B22
ELECTRONIC
E57 THROTTLE
CONTROL
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04790

Step
Terminals
(B309) No. 2 (B309) No. 4:
Measure the voltage between the electronic
ground.
ground.
ground.
(B136) No. 21 (B309) No. 3:
(B136) No. 1 (B309) No. 4:
Check
Yes
No
Go to step 3.
Repair the open or

of power supply
circuit.
Go to step 4.
Repair the power

of harness
between ECM and
electronic throttle
control relay.
more?
Go to step 5.
Repair the ground

Repair the open

circuit of harness
between ECM and
electronic throttle
control relay.

DY:DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH

CAUTION:
WIRING DIAGRAM:
ELECTRONIC THROTTLE
CONTROL RELAY
B309
B309
BATTERY
SBF-5
2
1
3
4
1 2
3 4
8
7
MAIN RELAY
B61
F44
B20
B122
1
5
9
13
2
6
10
14
3
7
11
15
1 2 3 4
5 6 7 8
4
8
12
16
C1
C21
B47
E57
1 2 3 4 5 6
A: B134
C: B136
D: B137
ECM
D2
C6
A5
A28
A18
A29
A19
D4
D5
D7
D3
F44
1 2 3
5 6 7
3
7
4
8
2
4
6
B122
A: B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
1 2
8 9 10
18 19 20
28 29 30
19
20
54
37
39
38
B22
B47
1
3
5
E3
C: B136
36
B20
35
16
15
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
E1
D: B137
B22
E3
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
26 27
28 29
30 31
E
E57
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
4
6
3
5
1
2
B22
ELECTRONIC
THROTTLE
CONTROL
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04790

Step
Terminals
No. 2 No. 4:
CHECK SHORT CIRCUIT OF ELECTRONIC
THROTTLE CONTROL RELAY POWER SUPPLY.
ground.
3) Measure the resistance between ECM connector and engine ground.
Check
more?
Yes
Go to step 2.
No
Go to step 3.
Repair the power

of harness
between ECM and
electronic throttle
control relay.
more?
Repair the ground

DZ:DTC P2109 THROTTLE/PEDAL POSITION SENSOR A MINIMUM STOP

PERFORMANCE
NOTE:

EA:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT

LOW INPUT
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-257, DTC P2122 THROTTLE/PEDAL POSITION
SENSOR/SWITCH D CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
B315
1 2 3 4 5 6
ACCELERATOR PEDAL
POSITION SENSOR
B122
B315
1 2 3 4
5 6 7 8
A: B134
B122
B30
B31
B22
B29
B23
B21
1 2
8 9 10
18 19 20
28 29 30
ECM
A: B134
B: B135
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
A5
C: B136
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
B22
34
42
36
C6
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
E3
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
E
EN-04813

Step
Check
SENSOR OUTPUT.
Monitor. <Ref. to EN(H4DOTC)(diag)-29, Subaru Select Monitor.>
CHECK POOR CONTACT.
4) Measure the resistance of ECM connector
and accelerator pedal position sensor connector.
(B135) No. 21 (B315) No. 4:
(B135) No. 23 (B315) No. 6:
ground.
ground.
Yes
Go to step 2.
No
Go to step 3.
Repair the poor

contact.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
more?
Go to step 5.
Repair the chassis

to SP (H4SO)-3,
Accelerator
Pedal.>

EB:DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT

HIGH INPUT
SENSOR/SWITCH D CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
B315
1 2 3 4 5 6
ACCELERATOR PEDAL
POSITION SENSOR
B122
B315
1 2 3 4
5 6 7 8
A: B134
B122
B30
B31
B22
B29
B23
B21
1 2
8 9 10
18 19 20
28 29 30
ECM
A: B134
B: B135
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
A5
C: B136
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
B22
34
42
36
C6
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
E3
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
E
EN-04813

Step
Check
Yes
SENSOR OUTPUT.
Monitor. <Ref. to EN(H4DOTC)(diag)-29, Subaru Select Monitor.>
CHECK POOR CONTACT.
Repair the poor
contact.
connector.
(B135) No. 21 (B315) No. 4:
(B135) No. 29 (B315) No. 5:
(B135) No. 23 (B315) No. 6:
ground.
ground.
No
Go to step 3.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
Is the voltage 4.5 5.5 V or

more?
Repair the short

circuit of harness
position sensor
connector.
Go to step 6.
Is the voltage less than 4.8 V? Repair poor contact in ECM connector.
Repair the poor

sensor connector.
defective. <Ref. to
SP (H4SO)-3,
Accelerator
Pedal.>

EC:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT

LOW INPUT
SENSOR/SWITCH E CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
B315
1 2 3 4 5 6
ACCELERATOR PEDAL
POSITION SENSOR
B122
B315
1 2 3 4
5 6 7 8
A: B134
B122
B30
B31
B22
B29
B23
B21
1 2
8 9 10
18 19 20
28 29 30
ECM
A: B134
B: B135
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
A5
C: B136
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
B22
34
42
36
C6
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
E3
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
E
EN-04813

Step
Check
SENSOR OUTPUT.
Monitor.>
CHECK POOR CONTACT.
connector.
(B135) No. 22 (B315) No. 1:
(B135) No. 31 (B315) No. 3:
CHECK HARNESS BETWEEN ECM CONNECTOR AND ACCELERATOR PEDAL POSITION SENSOR.
ground.
ground.
Yes
Go to step 2.
No
Go to step 3.
Repair the poor

contact.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
more?
Go to step 5.
Repair the chassis

to SP (H4SO)-3,
Accelerator
Pedal.>

ED:DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT

HIGH INPUT
SENSOR/SWITCH E CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
B315
1 2 3 4 5 6
ACCELERATOR PEDAL
POSITION SENSOR
B122
B315
1 2 3 4
5 6 7 8
A: B134
B122
B30
B31
B22
B29
B23
B21
1 2
8 9 10
18 19 20
28 29 30
ECM
A: B134
B: B135
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
A5
C: B136
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
B22
34
42
36
C6
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
E3
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
E
EN-04813

Step
Check
Yes
SENSOR OUTPUT.
Monitor.>
CHECK POOR CONTACT.
Repair the poor
contact.
connector.
(B135) No. 22 (B315) No. 1:
(B135) No. 30 (B315) No. 2:
(B135) No. 31 (B315) No. 3:
ground.
ground.
No
Go to step 3.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
Repair the short

circuit of harness
position sensor
connector.
Go to step 6.
Is the voltage less than 4.8 V? Repair poor contact in ECM connector.
Repair the poor

sensor connector.
defective. <Ref. to
SP (H4SO)-3,
Accelerator
Pedal.>

EE:DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH A/B

VOLTAGE CORRELATION
SENSOR/SWITCH A/B VOLTAGE CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
ELECTRONIC THROTTLE
CONTROL RELAY
B309
B309
BATTERY
SBF-5
2
1
3
4
1 2
3 4
8
7
MAIN RELAY
B61
F44
B20
B122
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
C1
C21
B47
1 2 3 4
5 6 7 8
E57
1 2 3 4 5 6
A: B134
C: B136
D: B137
ECM
D2
C6
A5
A28
A18
A29
A19
D4
D5
D7
D3
F44
1 2 3
5 6 7
3
7
4
8
2
4
6
B122
A: B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
1 2
8 9 10
18 19 20
28 29 30
19
20
54
37
39
38
B22
B47
1
3
5
E3
C: B136
36
B20
35
16
15
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
E1
D: B137
B22
E3
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
26 27
28 29
30 31
E
E57
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
4
6
3
5
1
2
B22
ELECTRONIC
THROTTLE
CONTROL
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
EN-04790

Step
(B134) No. 18 (+) (B134) No. 29 ():
(B134) No. 28 (+) (B134) No. 29 ():
CHECK POOR CONTACT.
throttle control.
(B134) No. 19 (E57) No. 5:
voltage meter.
Check
Yes
Go to step 2.
No
Go to step 4.
Go to step 3.
Go to step 4.
Repair the poor

contact.
Go to step 14.
Repair the open

circuit of harness
connector.
more?
Go to step 6.
Repair the ground

Go to step 7.

10
11
12
13
Step
Check
Is the voltage less than 4.63 V?
Is the voltage less than 4.73 V?
CHECK POOR CONTACT.
Yes
Go to step 9.
No
Go to step 11.
Go to step 10.
Go to step 11.
Repair the poor

contact.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.

throttle control.
(B134) No. 18 (E57) No. 6:
(B134) No. 28 (E57) No. 4:
(B134) No. 29 (E57) No. 3:
Go to step 14.
voltage meter.
Repair the short

circuit to power
ECM connector
and electronic
throttle control
connector.

14
15
16
Step
voltage meter.
(B134) No. 18 (B134) No. 29:
(B134) No. 28 (B134) No. 29:
CHECK ELECTRONIC THROTTLE CONTROL HARNESS.
throttle control.
(E57) No. 6 (E57) No. 4:
Check
Yes
Go to step 15.
No
Repair the short
circuit of harness
control connector.
more?
Go to step 16.
Repair the short

circuit to sensor
power supply.
more?
Repair the short

circuit of harness.

EF:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D/E

VOLTAGE CORRELATION
SENSOR/SWITCH D/E VOLTAGE CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
B315
1 2 3 4 5 6
ACCELERATOR PEDAL
POSITION SENSOR
B122
B315
1 2 3 4
5 6 7 8
A: B134
B122
B30
B31
B22
B29
B23
B21
1 2
8 9 10
18 19 20
28 29 30
ECM
A: B134
B: B135
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
A5
C: B136
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
B22
34
42
36
C6
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
E3
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
E
EN-04813

Step
Check
SENSOR OUTPUT.
Select Monitor.
NOTE:
CHECK ACCELERATOR PEDAL POSITION Is the voltage less than 4.8 V?
SENSOR OUTPUT.
Select Monitor.
NOTE:
CHECK POOR CONTACT.
Yes
Go to step 2.
No
Go to step 4.
Go to step 3.
Go to step 4.
Repair the poor

contact.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
connector.
(B135) No. 22 (B315) No. 1:
(B135) No. 30 (B315) No. 2:
(B135) No. 31 (B315) No. 3:
(B135) No. 21 (B315) No. 4:
(B135) No. 29 (B315) No. 5:
(B135) No. 23 (B315) No. 6:
CHECK HARNESS BETWEEN ECM AND AC- Is the resistance 1 M or
Go to step 6.
CELERATOR PEDAL POSITION SENSOR. more?
Repair the chassis


Step
ground.
ground.
terminals of accelerator pedal position sensor.
(B315) No. 6 (B315) No. 3:
Check
Yes
No
Go to step 8.
more?
Repair the poor

sensor connector.
defective. <Ref. to
SP (H4SO)-3,
Accelerator
Pedal.>
Repair the short
circuit of harness
position sensor
connector.

EG:DTC P2419 EVAPORATIVE EMISSION SYSTEM SWITCHING VALVE

CONTROL CIRCUIT LOW
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-269, DTC P2419 EVAPORATIVE EMISSION SYSTEM SWITCHING VALVE CONTROL CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
F44
6
4
BATTERY
1 2 3 4
5 6 7 8
SBF-5
7
5
3
B61
F44
2
1
B47
B47
ECM
2
4
6
B136
1
3
5
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
48
50
B22
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
E3
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
E52
1
2
E52
1 2
E
PURGE CONTROL
SOLENOID VALVE 2
EN-04814

Step
chassis ground.
Check
Yes
light illuminates,
the circuit has
this time.
Go to step 3.
CHECK HARNESS BETWEEN PURGE CON- Is the resistance 1 M or

TROL SOLENOID VALVE 2 AND ECM CON- more?
NECTOR.
2) Disconnect the connectors from purge control solenoid valve 2 and ECM.
purge control solenoid valve 2 connector and
engine ground.
CHECK HARNESS BETWEEN PURGE CON- Is the resistance less than 1 ? Go to step 4.
TROL SOLENOID VALVE 2 AND ECM CONNECTOR.
ECM and purge control solenoid valve 2.
(B136) No. 7 (E52) No. 2:

VALVE 2.
100 ?
1) Remove the purge control solenoid valve 2.
2) Measure the resistance between purge control solenoid valve 2 terminals.
Terminals
No. 1 No. 2:
TROL SOLENOID VALVE 2.
solenoid valve 2 and engine ground.
Go to step 5.
Repair the poor

contact of purge
control solenoid
valve 2 connector.
No
Go to step 2.
Repair the ground

ECM and purge
control solenoid
valve 2 connector.
Repair the open

circuit of harness
between ECM and
purge control solenoid valve 2 connector.
NOTE:
the following item:
Open circuit in
harness between
ECM and purge
control
solenoid
valve 2 connector
Poor contact in
coupling connector
Replace the purge
control solenoid
valve 2. <Ref. to
EC (H4DOTC)-8,
Purge Control
Solenoid Valve.>
Repair the open
circuit of harness
between main
relay and purge
control solenoid
valve 2 connector.

EH:DTC P2420 EVAPORATIVE EMISSION SYSTEM SWITCHING VALVE

CONTROL CIRCUIT HIGH
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-270, DTC P2420 EVAPORATIVE EMISSION SYSTEM SWITCHING VALVE CONTROL CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
TROUBLE SYMPTOM:
Improper idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
F44
6
4
BATTERY
1 2 3 4
5 6 7 8
SBF-5
7
5
3
B61
F44
2
1
B47
B47
ECM
2
4
6
B136
1
3
5
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
48
50
B22
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
E3
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
E52
1
2
E52
1 2
E
PURGE CONTROL
SOLENOID VALVE 2
EN-04814

Step
Check
TROL SOLENOID VALVE 2 AND ECM CONNECTOR.
2) Disconnect the connectors from purge control solenoid valve 2 and ECM.
chassis ground.
VALVE 2.
2) Measure the resistance between purge control solenoid valve 2 terminals.
Terminals
No. 1 No. 2:
Yes
No
Repair the short
Go to step 2.
circuit to power
ECM and purge
control solenoid
valve 2 connector.
Replace the purge Repair the poor

control solenoid
contact in ECM
connector.
valve 2. <Ref. to
EC (H4DOTC)-8,
Purge Control
Solenoid Valve.>

EI: DTC P2431 SECONDARY AIR INJECTION SYSTEM AIR FLOW/PRESSURE

SENSOR CIRCUIT RANGE/PERFORMANCE
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-271, DTC P2431 SECONDARY AIR INJECTION SYSTEM AIR FLOW /PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code
CAUTION:

WIRING DIAGRAM:
MAIN RELAY
6
4
5
3
B47
F44
B100
SBF-1
15
SECONDARY
AIR COMBINATION
VALVE RELAY 2
BATTERY
SBF-5
B61
2
1
F2
1
10A
20
21
12
22
13
24
60A
F9
SECONDARY
F27
AIR COMBINATION
VALVE RELAY 1
F2
B100
10
11
4
5
3
6
12
14
F27
46
47
19
20
5
SECONDARY AIR PUMP
2
1
20
F2
16
E3
B22
F11
C8
C30
C19
A29
A27
1
2
E40
A19
B100
E41
SECONDARY
AIR PUMP RELAY
F9
ECM
A: B134
C: B136
SECONDARY
SECONDARY
AIR COMBINATION
F11
E40
1 2
B47
1
3
5
2
4
6
E41
F44
1 2 3
4 5 6
1 2 3 4
5 6 7 8
F9
B22
1
3
4
5
6
A: B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
F2
2
7 8 9
10
11
13
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
F27
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
12
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
5 6 7 10 15 16 17 20 25 26 29 30
35
8
11
18
21
27
31
9 12 13 14 19 22 23 24 28 32 33 34 36
EN-04795

1
2
Step
CHECK CURRENT DATA.
1) Turn the ignition switch to ON (engine OFF).
2) Using the Subaru Select Monitor, read secondary air piping pressure, intake manifold
absolute pressure and atmospheric pressure
data, and compare with the actual atmospheric
pressure.
NOTE:
Check
Yes
Check the relative
DTC.
Is the difference with the actual Replace the secatmospheric pressure
ondary air combi200 mmHg (27 kPa, 8 inHg or nation valve (LH).
3.9 psig) or more?
<Ref. to EC
(H4DOTC)-10,
Secondary Air
Combi Valve.>
NOTE:
The secondary air
pressure sensor is
a one piece combined part with the
secondary air combination valve
(LH).
No
Go to step 2.
Temporary poor
contact occurs.
Check the poor

EJ:DTC P2432 SECONDARY AIR INJECTION SYSTEM AIR FLOW/PRESSURE

SENSOR CIRCUIT LOW
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-272, DTC P2432 SECONDARY AIR INJECTION SYSTEM AIR FLOW /PRESSURE SENSOR CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:

WIRING DIAGRAM:
MAIN RELAY
6
4
5
3
B47
F44
B100
SBF-1
15
SECONDARY
AIR COMBINATION
VALVE RELAY 2
BATTERY
SBF-5
B61
2
1
F2
1
10A
20
21
12
22
13
24
60A
F9
SECONDARY
F27
AIR COMBINATION
VALVE RELAY 1
F2
B100
10
11
4
5
3
6
12
14
F27
46
47
19
20
5
SECONDARY AIR PUMP
2
1
20
F2
16
E3
B22
F11
C8
C30
C19
A29
A27
1
2
E40
A19
B100
E41
SECONDARY
AIR PUMP RELAY
F9
ECM
A: B134
C: B136
SECONDARY
SECONDARY
AIR COMBINATION
F11
E40
1 2
B47
1
3
5
2
4
6
E41
F44
1 2 3
4 5 6
1 2 3 4
5 6 7 8
F9
B22
1
3
4
5
6
A: B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
F2
2
7 8 9
10
11
13
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
F27
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
12
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
5 6 7 10 15 16 17 20 25 26 29 30
35
8
11
18
21
27
31
9 12 13 14 19 22 23 24 28 32 33 34 36
EN-04795

Step
Check
LH CONNECTOR.
and secondary air combination valve LH.
between the ECM and secondary air combination valve relay LH connector terminal.
(B134) No. 27 (E41) No. 2:
(B134) No. 19 (E41) No. 1:
(B134) No. 29 (E41) No. 3:
more?
LH CONNECTOR.
Yes
Go to step 2.
No
Repair open circuit
of the harness
between the ECM
and secondary air
combination valve
relay LH connector terminal.
Temporary poor
contact occurs.
Check the poor
Repair the ground

short of the harness between the
valve relay LH connector terminal.

EK:DTC P2433 SECONDARY AIR INJECTION SYSTEM AIR FLOW /PRESSURE

SENSOR CIRCUIT HIGH
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-273, DTC P2433 SECONDARY AIR INJECTION SYSTEM AIR FLOW /PRESSURE SENSOR CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:

WIRING DIAGRAM:
MAIN RELAY
6
4
5
3
B47
F44
B100
SBF-1
15
SECONDARY
AIR COMBINATION
VALVE RELAY 2
BATTERY
SBF-5
B61
2
1
F2
1
10A
20
21
12
22
13
24
60A
F9
SECONDARY
F27
AIR COMBINATION
VALVE RELAY 1
F2
B100
10
11
4
5
3
6
12
14
F27
46
47
19
20
5
SECONDARY AIR PUMP
2
1
20
F2
16
E3
B22
F11
C8
C30
C19
A29
A27
1
2
E40
A19
B100
E41
SECONDARY
AIR PUMP RELAY
F9
ECM
A: B134
C: B136
SECONDARY
SECONDARY
AIR COMBINATION
F11
E40
1 2
B47
1
3
5
2
4
6
E41
F44
1 2 3
4 5 6
1 2 3 4
5 6 7 8
F9
B22
1
3
4
5
6
A: B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
F2
2
7 8 9
10
11
13
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
F27
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
12
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
5 6 7 10 15 16 17 20 25 26 29 30
35
8
11
18
21
27
31
9 12 13 14 19 22 23 24 28 32 33 34 36
EN-04795

Step
Check
LH CONNECTOR.
and secondary air combination valve LH.
between the ECM and secondary air combination valve relay LH connector terminal.
(B134) No. 27 (E41) No. 2:
(B134) No. 19 (E41) No. 1:
(B134) No. 29 (E41) No. 3:
LH CONNECTOR.
ground.
Yes
Go to step 2.
No
Repair open circuit
of the harness
between the ECM
and secondary air
combination valve
relay LH connector terminal.
Repair the short

circuit to power
valve LH connector
terminal.
Temporary poor
contact occurs.
Check the poor

EL:DTC P2440 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE

STUCK OPEN (BANK 1)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-274, DTC P2440 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK OPEN (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:

WIRING DIAGRAM:
MAIN RELAY
6
4
5
3
B47
F44
B100
SBF-1
15
SECONDARY
AIR COMBINATION
VALVE RELAY 2
BATTERY
SBF-5
B61
2
1
F2
1
10A
20
21
12
22
13
24
60A
F9
SECONDARY
F27
AIR COMBINATION
VALVE RELAY 1
F2
B100
10
11
4
5
3
6
12
14
F27
46
47
19
20
5
SECONDARY AIR PUMP
2
1
20
F2
16
E3
B22
F11
C8
C30
C19
A29
A27
1
2
E40
A19
B100
E41
SECONDARY
AIR PUMP RELAY
F9
ECM
A: B134
C: B136
SECONDARY
SECONDARY
AIR COMBINATION
F11
E40
1 2
B47
1
3
5
2
4
6
E41
F44
1 2 3
4 5 6
1 2 3 4
5 6 7 8
F9
B22
1
3
4
5
6
A: B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
F2
2
7 8 9
10
11
13
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
F27
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
12
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
5 6 7 10 15 16 17 20 25 26 29 30
35
8
11
18
21
27
31
9 12 13 14 19 22 23 24 28 32 33 34 36
EN-04795

Step
VALVE OPERATION.
air combination valve using the Subaru Select
Monitor.
NOTE:
Mode for more operation procedure.
<Ref. to EN(H4DOTC)(diag)-51, Compulsory
PUMP AND SECONDARY AIR COMBINATION VALVE.
air pump and secondary air combination valve.
CHECK PIPE BETWEEN SECONDARY AIR
COMBINATION VALVE AND CYLINDER
HEAD.
AIR COMBINATION VALVE.
between the secondary air combination valve
and the chassis ground.
AIR COMBINATION VALVE RELAY AND
CONNECTOR TERMINAL.
2) Disconnect the connector from the secondary air combination valve relay and secondary
air combination valve.
air combination valve relay and secondary air
combination valve connector terminal.
(F27) No. 11 (E40) No. 2:
VALVE RELAY.
the relay box.
combination valve relay terminals No. 12 and
No. 14.
4) Measure the resistance between the secondary air combination valve relay terminals.
Terminals
No. 10 No. 11:
Check
Yes
Does the secondary air combi- Go to step 2.
nation valve operate properly?
No
Go to step 4.

nect the duct.
Go to step 3.
Is there damage or disconnec- Replace or contion of the pipe?

nect the pipe.
Temporary poor
contact occurs.
Check the poor
Go to step 5.
Replace the secondary air combination valve.
Repair the open

circuit between the
secondary air combination valve relay
and secondary air
combination valve
connector terminal.
Replace the secondary air combination valve relay.

Step
Check
VALVE RELAY POWER SOURCE.
2) Measure the voltage between the secondary air combination valve relay connector and
chassis ground.
RELAY CONNECTOR.
between the ECM and secondary air combination valve relay connector terminal.
(B136) No. 30 (F27) No. 14:
Yes
Go to step 8.
No
Repair the open or
of power supply
circuit.
Replace the ECM.

<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
Repair open circuit

of the harness
between the ECM
and secondary air
EM:DTC P2441 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE

STUCK CLOSED (BANK 1)
NOTE:
For the diagnostic procedure, refer to DTC P2440. <Ref. to EN(H4DOTC)(diag)-389, DTC P2440 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK OPEN (BANK 1), Diagnostic Procedure with

EN:DTC P2442 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE

STUCK OPEN (BANK 2)
GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-274, DTC P2442 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK OPEN (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:

WIRING DIAGRAM:
MAIN RELAY
6
4
5
3
B47
F44
B100
SBF-1
15
SECONDARY
AIR COMBINATION
VALVE RELAY 2
BATTERY
SBF-5
B61
2
1
F2
1
10A
20
21
12
22
13
24
60A
F9
SECONDARY
F27
AIR COMBINATION
VALVE RELAY 1
F2
B100
10
11
4
5
3
6
12
14
F27
46
47
19
20
5
SECONDARY AIR PUMP
2
1
20
F2
16
E3
B22
F11
C8
C30
C19
A29
A27
1
2
E40
A19
B100
E41
SECONDARY
AIR PUMP RELAY
F9
ECM
A: B134
C: B136
SECONDARY
SECONDARY
AIR COMBINATION
F11
E40
1 2
B47
1
3
5
2
4
6
E41
F44
1 2 3
4 5 6
1 2 3 4
5 6 7 8
F9
B22
1
3
4
5
6
A: B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
F2
2
7 8 9
10
11
13
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
F27
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
12
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
5 6 7 10 15 16 17 20 25 26 29 30
35
8
11
18
21
27
31
9 12 13 14 19 22 23 24 28 32 33 34 36
EN-04795

Step
VALVE OPERATION.
air combination valve using the Subaru Select
Monitor.
NOTE:
Mode for more operation procedure.
<Ref. to EN(H4DOTC)(diag)-51, Compulsory
PUMP AND SECONDARY AIR COMBINATION VALVE.
air pump and secondary air combination valve.
CHECK PIPE BETWEEN SECONDARY AIR
COMBINATION VALVE AND CYLINDER
HEAD.
AIR COMBINATION VALVE.
between the secondary air combination valve
and the chassis ground.
AIR COMBINATION VALVE RELAY AND
CONNECTOR TERMINAL.
2) Disconnect the connector from the secondary air combination valve relay and secondary
air combination valve.
air combination valve relay and secondary air
combination valve connector terminal.
(F27) No. 21 (E41) No. 6:
VALVE RELAY.
the relay box.
combination valve relay terminals No. 22 and
No. 24.
4) Measure the resistance between the secondary air combination valve relay terminals.
Terminals
No. 20 No. 21:
Check
Yes
Does the secondary air combi- Go to step 2.
nation valve operate properly?
No
Go to step 4.

nect the duct.
Go to step 3.
Is there damage or disconnec- Replace or contion of the pipe?

nect the pipe.
Temporary poor
contact occurs.
Check the poor
Go to step 5.
Replace the secondary air combination valve.
Repair the open

circuit between the
secondary air combination valve relay
and secondary air
combination valve
connector terminal.
Replace the secondary air combination valve relay.

Step
Check
VALVE RELAY POWER SOURCE.
2) Measure the voltage between the secondary air combination valve relay connector and
chassis ground.
RELAY CONNECTOR.
between the ECM and secondary air combination valve relay connector terminal.
(B136) No. 19 (F27) No. 24:
Yes
Go to step 8.
No
Repair the open or
of power supply
circuit.
Replace the ECM.

<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
Repair open circuit

of the harness
between the ECM
and secondary air
EO:DTC P2443 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE

NOTE:
For the diagnostic procedure, refer to DTC P2442. <Ref. to EN(H4DOTC)(diag)-393, DTC P2442 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK OPEN (BANK 2), Diagnostic Procedure with

EP:DTC P2444 SECONDARY AIR INJECTION SYSTEM PUMP STUCK ON

GENERAL DESCRIPTION <Ref. to GD(H4DOTC)-275, DTC P2444 SECONDARY AIR INJECTION SYSTEM PUMP STUCK ON, Diagnostic Trouble Code (DTC) Detecting Criteria.>
CAUTION:

WIRING DIAGRAM:
MAIN RELAY
6
4
5
3
B47
F44
B100
SBF-1
15
SECONDARY
AIR COMBINATION
VALVE RELAY 2
BATTERY
SBF-5
B61
2
1
F2
1
10A
20
21
12
22
13
24
60A
F9
SECONDARY
F27
AIR COMBINATION
VALVE RELAY 1
F2
B100
10
11
4
5
3
6
12
14
F27
46
47
19
20
5
SECONDARY AIR PUMP
2
1
20
F2
16
E3
B22
F11
C8
C30
C19
A29
A27
1
2
E40
A19
B100
E41
SECONDARY
AIR PUMP RELAY
F9
ECM
A: B134
C: B136
SECONDARY
SECONDARY
AIR COMBINATION
F11
E40
1 2
B47
1
3
5
2
4
6
E41
F44
1 2 3
4 5 6
1 2 3 4
5 6 7 8
F9
B22
1
3
4
5
6
A: B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
F2
2
7 8 9
10
11
13
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
F27
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
12
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
5 6 7 10 15 16 17 20 25 26 29 30
35
8
11
18
21
27
31
9 12 13 14 19 22 23 24 28 32 33 34 36
EN-04795

Step
CHECK SECONDARY AIR PIPING PRESSURE.
2) Using the Subaru Select Monitor, read secondary air piping pressure data, and compare
with the actual atmospheric pressure.
NOTE:
Check
Is the difference with the actual
atmospheric pressure
50 mmHg (6.7 kPa, 2.0 inHg or
0.97 psig) or more?
CHECK POWER SUPPLY TO SECONDARY Is the voltage 10 V or more?

AIR PUMP.
2) Measure the voltage between the secondary air pump and chassis ground.
CHECK SECONDARY AIR PUMP RELAY.
more?
the relay box.
3) Measure the resistance between the secondary air pump relay terminals.
Terminals
No. 4 No. 5:
Yes
No
Replace the sec- Go to step 2.
ondary air combination valve (LH).
<Ref. to EC
(H4DOTC)-10,
Secondary Air
Combi Valve.>
NOTE:
The secondary air
pressure sensor is
a one piece combined part with the
secondary air combination valve
(LH).
Go to step 3.
Temporary poor
contact occurs.
Check the poor
Repair the short

circuit to power
secondary air
pump relay and
secondary air
pump connector
terminal.
Replace the secondary air pump

relay.


A: INSPECTION
1. ENGINE
NOTE:
Malfunction of parts other than those listed is also possible. <Ref. to ME(H4DOTC)-93, Engine Trouble in
General.>
Symptom
Problem parts

10) Oxygen sensor
2. Rough idling
5. Engine stalls, hesitates, or sputters at acceleration.
6. Surging

4) Mass air flow sensor
6) Purge control solenoid valve

Symptom
Problem parts
7. Spark knock

4) Knock sensor
8. After-burn in exhaust system

*3: Ensure the secure installation.


GENERAL DESCRIPTION

A: LIST
DTC
Item
Note
P0011
Intake Camshaft Position Timing Over-Advanced or System Performance (Bank 1)
<Ref. to GD(H4DOTC)-9, DTC P0011 INTAKE CAMSHAFT POSITION - TIMING

OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1), Diagnostic Trouble
P0016

P0018

P0021
Intake Camshaft Position Timing Over-Advanced or

System Performance (Bank 2)
(Bank 1 Sensor 1)
(Bank 1 Sensor 1)
<Ref. to GD(H4DOTC)-12, DTC P0016 CRANKSHAFT POSITION - CAMSHAFT

POSITION CORRELATION (BANK 1), Diagnostic Trouble Code (DTC) Detecting
Criteria.>
<Ref. to GD(H4DOTC)-12, DTC P0018 CRANKSHAFT POSITION - CAMSHAFT
POSITION CORRELATION (BANK 2), Diagnostic Trouble Code (DTC) Detecting
Criteria.>
<Ref. to GD(H4DOTC)-12, DTC P0021 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 2), Diagnostic
<Ref. to GD(H4DOTC)-13, DTC P0030 HO2S HEATER CONTROL CIRCUIT
P0032

High (Bank 1 Sensor 1)

P0037

(Bank 1 Sensor 2)

P0038

High (Bank 1 Sensor 2)
Range/Performance
Low Input

<Ref. to GD(H4DOTC)-23, DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION, Diagnostic Trouble Code (DTC) Detecting Criteria.>
<Ref. to GD(H4DOTC)-25, DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT
LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0103

High Input

HIGH INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0107

Input
<Ref. to GD(H4DOTC)-32, DTC P0107 MANIFOLD ABSOLUTE PRESSURE/

BAROMETRIC PRESSURE CIRCUIT LOW INPUT, Diagnostic Trouble Code
P0108

Input
Circuit Low
Circuit High
<Ref. to GD(H4DOTC)-34, DTC P0108 MANIFOLD ABSOLUTE PRESSURE/

BAROMETRIC PRESSURE CIRCUIT HIGH INPUT, Diagnostic Trouble Code
<Ref. to GD(H4DOTC)-36, DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1
CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
P0117
Engine Coolant Temperature

Circuit Low
<Ref. to GD(H4DOTC)-42, DTC P0117 ENGINE COOLANT TEMPERATURE

P0118
Engine Coolant Temperature

Circuit High
<Ref. to GD(H4DOTC)-44, DTC P0118 ENGINE COOLANT TEMPERATURE

P0122

<Ref. to GD(H4DOTC)-46, DTC P0122 THROTTLE/PEDAL POSITION SENSOR/

SWITCH A CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
SWITCH A CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0030
P0031
P0068
P0101
P0102
P0111
P0112
P0113
P0123
GD(H4DOTC)-2

GENERAL DESCRIPTION
DTC
Item
Note
P0125
Insufficient Coolant Temperature

for Closed Loop Fuel Control
P0126
Insufficient Engine Coolant

<Ref. to GD(H4DOTC)-52, DTC P0126 INSUFFICIENT ENGINE COOLANT
Temperature for Stable Operation TEMPERATURE FOR STABLE OPERATION, Diagnostic Trouble Code (DTC)
Coolant Thermostat (Engine
<Ref. to GD(H4DOTC)-54, DTC P0128 COOLANT THERMOSTAT (ENGINE
Coolant Temperature Below
COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERAThermostat Regulating
TURE), Diagnostic Trouble Code (DTC) Detecting Criteria.>
Temperature)
P0128
P0131
P0140

P0171
P0172
P0181
Fuel Temperature Sensor A

P0182

Circuit Low Input
Circuit High Input
<Ref. to GD(H4DOTC)-56, DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE

<Ref. to GD(H4DOTC)-58, DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE
<Ref. to GD(H4DOTC)-60, DTC P0133 O2 SENSOR CIRCUIT SLOW
RESPONSE (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC) Detecting
Criteria.>
<Ref. to GD(H4DOTC)-63, DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY
<Ref. to GD(H4DOTC)-65, DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE
<Ref. to GD(H4DOTC)-67, DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE
<Ref. to GD(H4DOTC)-68, DTC P0139 O2 SENSOR CIRCUIT SLOW
RESPONSE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting
Criteria.>
<Ref. to GD(H4DOTC)-73, DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY
<Ref. to GD(H4DOTC)-75, DTC P0171 SYSTEM TOO LEAN (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
<Ref. to GD(H4DOTC)-78, DTC P0172 SYSTEM TOO RICH (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
<Ref. to GD(H4DOTC)-81, DTC P0181 FUEL TEMPERATURE SENSOR A
Criteria.>
P0222


SWITCH B CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0223


SWITCH B CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0230
P0132
P0133

(Bank 1 Sensor 1)
(Bank 1 Sensor 1)
O2 Sensor Circuit Slow
Response (Bank 1 Sensor 1)
<Ref. to GD(H4DOTC)-50, DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL, Diagnostic Trouble Code (DTC)
P0134

P0137

(Bank 1 Sensor 2)
(Bank 1 Sensor 2)
O2 Sensor Circuit Slow
Response (Bank 1 Sensor 2)
P0138
P0139
P0183
P0244
P0245
P0246
P0301
<Ref. to GD(H4DOTC)-92, DTC P0230 FUEL PUMP PRIMARY CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
Turbo/Super Charger Wastegate <Ref. to GD(H4DOTC)-94, DTC P0244 TURBO/SUPER CHARGER WASTESolenoid A Range/Performance GATE SOLENOID A RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC)

Solenoid A Low
Solenoid A High
<Ref. to GD(H4DOTC)-96, DTC P0245 TURBO/SUPER CHARGER WASTEGATE SOLENOID A LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
<Ref. to GD(H4DOTC)-98, DTC P0246 TURBO/SUPER CHARGER WASTEGATE SOLENOID A HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
<Ref. to GD(H4DOTC)-100, DTC P0301 CYLINDER 1 MISFIRE DETECTED,
GD(H4DOTC)-3

GENERAL DESCRIPTION
DTC
Item
Note
P0302

P0303
P0304
P0327

P0328


<Ref. to GD(H4DOTC)-106, DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW
<Ref. to GD(H4DOTC)-108, DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH
P0335
Crankshaft Position Sensor A

Circuit
Crankshaft Position Sensor A
P0336
P0340
Camshaft Position Sensor A

Circuit (Bank 1 or Single Sensor)
P0345
Camshaft Position Sensor A

Circuit (Bank 2)
P0410
<Ref. to GD(H4DOTC)-110, DTC P0335 CRANKSHAFT POSITION SENSOR A

CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
<Ref. to GD(H4DOTC)-112, DTC P0336 CRANKSHAFT POSITION SENSOR A
Criteria.>
<Ref. to GD(H4DOTC)-114, DTC P0340 CAMSHAFT POSITION SENSOR A
CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC)
<Ref. to GD(H4DOTC)-115, DTC P0345 CAMSHAFT POSITION SENSOR A
CIRCUIT (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
<Ref. to GD(H4DOTC)-116, DTC P0410 SECONDARY AIR INJECTION SYSTEM, Diagnostic Trouble Code (DTC) Detecting Criteria.>
<Ref. to GD(H4DOTC)-125, DTC P0411 SECONDARY AIR INJECTION SYSTEM INCORRECT FLOW DETECTED, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
<Ref. to GD(H4DOTC)-126, DTC P0413 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE A CIRCUIT OPEN, Diagnostic Trouble Code (DTC)
P0411

Incorrect Flow Detected
P0413

Switching Valve A Circuit Open
P0414

Switching Valve A Circuit
Shorted
<Ref. to GD(H4DOTC)-127, DTC P0414 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE A CIRCUIT SHORTED, Diagnostic Trouble Code
P0416

Switching Valve B Circuit Open
<Ref. to GD(H4DOTC)-128, DTC P0416 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE B CIRCUIT OPEN, Diagnostic Trouble Code (DTC)
P0417

Switching Valve B Circuit
Shorted
Control A Circuit Open
P0420

Threshold (Bank 1)
P0441

Incorrect Purge Flow
Evaporative Emission Control
System Leak Detected (Small
Leak)
System Vent Control Circuit
Open
<Ref. to GD(H4DOTC)-128, DTC P0417 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE B CIRCUIT SHORTED, Diagnostic Trouble Code
<Ref. to GD(H4DOTC)-129, DTC P0418 SECONDARY AIR INJECTION SYSTEM CONTROL A CIRCUIT OPEN, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
<Ref. to GD(H4DOTC)-130, DTC P0420 CATALYST SYSTEM EFFICIENCY
BELOW THRESHOLD (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
<Ref. to GD(H4DOTC)-131, DTC P0441 EVAPORATIVE EMISSION SYSTEM
INCORRECT PURGE FLOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
<Ref. to GD(H4DOTC)-132, DTC P0442 EVAPORATIVE EMISSION CONTROL
SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Trouble Code (DTC)
SYSTEM VENT CONTROL CIRCUIT OPEN, Diagnostic Trouble Code (DTC)

System Vent Control Circuit
Shorted

SYSTEM VENT CONTROL CIRCUIT SHORTED, Diagnostic Trouble Code (DTC)
P0418
P0442
P0447
P0448
GD(H4DOTC)-4

GENERAL DESCRIPTION
DTC
Item
Note
P0451

System Pressure Sensor

SYSTEM PRESSURE SENSOR, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0452

System Pressure Sensor Low
Input
System Pressure Sensor High
Input
System Leak Detected
(Very Small Leak)
System Leak Detected
(Fuel Cap Loose/Off)
Purge Control Valve Circuit Low

SYSTEM PRESSURE SENSOR LOW INPUT, Diagnostic Trouble Code (DTC)
SYSTEM PRESSURE SENSOR HIGH INPUT, Diagnostic Trouble Code (DTC)
SYSTEM LEAK DETECTED (VERY SMALL LEAK), Diagnostic Trouble Code
SYSTEM LEAK DETECTED (FUEL CAP LOOSE/OFF), Diagnostic Trouble Code
PURGE CONTROL VALVE CIRCUIT LOW, Diagnostic Trouble Code (DTC)
P0459

Purge Control Valve Circuit High

PURGE CONTROL VALVE CIRCUIT HIGH, Diagnostic Trouble Code (DTC)
P0461

Range/Performance
<Ref. to GD(H4DOTC)-162, DTC P0461 FUEL LEVEL SENSOR A CIRCUIT

P0462
Fuel Level Sensor A Circuit Low <Ref. to GD(H4DOTC)-164, DTC P0462 FUEL LEVEL SENSOR A CIRCUIT
<Ref. to GD(H4DOTC)-166, DTC P0463 FUEL LEVEL SENSOR A CIRCUIT
High
Fuel Level Sensor Circuit Inter<Ref. to GD(H4DOTC)-168, DTC P0464 FUEL LEVEL SENSOR CIRCUIT
mittent
INTERMITTENT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
<Ref. to GD(H4DOTC)-171, DTC P0483 FAN RATIONALITY CHECK, Diagnostic
P0453
P0456
P0457
P0458
P0463
P0464
P0483
P0502

Low Input
<Ref. to GD(H4DOTC)-172, DTC P0502 VEHICLE SPEED SENSOR A CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0503
<Ref. to GD(H4DOTC)-173, DTC P0503 VEHICLE SPEED SENSOR A INTERMITTENT/ERRATIC/HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0506
P0512

Lower Than Expected
Higher Than Expected
P0513
<Ref. to GD(H4DOTC)-174, DTC P0506 IDLE AIR CONTROL SYSTEM RPM

<Ref. to GD(H4DOTC)-176, DTC P0507 IDLE AIR CONTROL SYSTEM RPM
<Ref. to GD(H4DOTC)-178, DTC P0512 STARTER REQUEST CIRCUIT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
<Ref. to GD(H4DOTC)-179, DTC P0513 INCORRECT IMMOBILIZER KEY, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0519
<Ref. to GD(H4DOTC)-180, DTC P0519 IDLE AIR CONTROL SYSTEM PERFORMANCE, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0600
<Ref. to GD(H4DOTC)-181, DTC P0600 SERIAL COMMUNICATION LINK, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0604

<Ref. to GD(H4DOTC)-182, DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR, Diagnostic Trouble Code (DTC)
P0605
Internal Control Module Read

Only Memory (ROM) Error
<Ref. to GD(H4DOTC)-183, DTC P0605 INTERNAL CONTROL MODULE READ

ONLY MEMORY (ROM) ERROR, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0607
<Ref. to GD(H4DOTC)-184, DTC P0607 CONTROL MODULE PERFORMANCE,

P0507
GD(H4DOTC)-5

GENERAL DESCRIPTION
DTC
Item
Note
P0638
Throttle Actuator Control Range/

<Ref. to GD(H4DOTC)-186, DTC P0638 THROTTLE ACTUATOR CONTROL

RANGE/PERFORMANCE (BANK 1), Diagnostic Trouble Code (DTC) Detecting
Criteria.>
P0691
<Ref. to GD(H4DOTC)-189, DTC P0691 FAN 1 CONTROL CIRCUIT LOW, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0692
<Ref. to GD(H4DOTC)-190, DTC P0692 FAN 1 CONTROL CIRCUIT HIGH, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0700
Transmission Control System

(MIL Request)
Low (AT Model)
(MT Model)
<Ref. to GD(H4DOTC)-191, DTC P0700 TRANSMISSION CONTROL SYSTEM

<Ref. to GD(H4DOTC)-192, DTC P0851 PARK/NEUTRAL SWITCH INPUT CIRCUIT LOW (AT MODEL), Diagnostic Trouble Code (DTC) Detecting Criteria.>
<Ref. to GD(H4DOTC)-193, DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT
P0852

High (AT Model)
<Ref. to GD(H4DOTC)-194, DTC P0852 PARK/NEUTRAL SWITCH INPUT CIRCUIT HIGH (AT MODEL), Diagnostic Trouble Code (DTC) Detecting Criteria.>
P0852

(MT Model)
<Ref. to GD(H4DOTC)-195, DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT

P1152
O2 Sensor Circuit Range/

Performance (Low)
(Bank 1 Sensor 1)
<Ref. to GD(H4DOTC)-196, DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC)
P1153
O2 Sensor Circuit Range/

Performance (High)
(Bank 1 Sensor 1)
<Ref. to GD(H4DOTC)-198, DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK 1 SENSOR 1), Diagnostic Trouble Code (DTC)
P1160
<Ref. to GD(H4DOTC)-200, DTC P1160 RETURN SPRING FAILURE, Diagnostic

P1400
Fuel Tank Pressure Control

Solenoid Valve Circuit Low
<Ref. to GD(H4DOTC)-202, DTC P1400 FUEL TANK PRESSURE CONTROL

P1410

P1418

Control A Circuit Shorted
P1420

Valve Circuit High
Vent Control Solenoid Valve
Function Problem
<Ref. to GD(H4DOTC)-204, DTC P1410 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK OPEN, Diagnostic Trouble Code (DTC) Detecting Criteria.>
<Ref. to GD(H4DOTC)-205, DTC P1418 SECONDARY AIR INJECTION SYSTEM CONTROL A CIRCUIT SHORTED, Diagnostic Trouble Code (DTC)
<Ref. to GD(H4DOTC)-206, DTC P1420 FUEL TANK PRESSURE CONTROL
<Ref. to GD(H4DOTC)-208, DTC P1443 VENT CONTROL SOLENOID VALVE
P0851
P0851
P1443
P1491

<Ref. to GD(H4DOTC)-210, DTC P1491 POSITIVE CRANKCASE VENTILATION

(BLOW-BY) FUNCTION PROBLEM, Diagnostic Trouble Code (DTC) Detecting
Criteria.>
<Ref. to GD(H4DOTC)-212, DTC P1518 STARTER SWITCH CIRCUIT LOW
P1518
P1560
Back-up Voltage Circuit

Malfunction
<Ref. to GD(H4DOTC)-213, DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P1570
Antenna
<Ref. to GD(H4DOTC)-214, DTC P1570 ANTENNA, Diagnostic Trouble Code

P1571
P1572
P1574
IMM Circuit Failure

(Except Antenna Circuit)
<Ref. to GD(H4DOTC)-214, DTC P1571 REFERENCE CODE INCOMPATIBILITY, Diagnostic Trouble Code (DTC) Detecting Criteria.>
<Ref. to GD(H4DOTC)-214, DTC P1572 IMM CIRCUIT FAILURE (EXCEPT
ANTENNA CIRCUIT), Diagnostic Trouble Code (DTC) Detecting Criteria.>
<Ref. to GD(H4DOTC)-214, DTC P1574 KEY COMMUNICATION FAILURE,
P1576
<Ref. to GD(H4DOTC)-214, DTC P1576 EGI CONTROL MODULE EEPROM,

GD(H4DOTC)-6

GENERAL DESCRIPTION
DTC
Item
Note
P1577
<Ref. to GD(H4DOTC)-214, DTC P1577 IMM CONTROL MODULE EEPROM,

P1602
Control Module Programming

Error
Intake Manifold Runner Control
Stuck Open (Bank 1)
<Ref. to GD(H4DOTC)-215, DTC P1602 CONTROL MODULE PROGRAMMING

ERROR, Diagnostic Trouble Code (DTC) Detecting Criteria.>
<Ref. to GD(H4DOTC)-217, DTC P2004 INTAKE MANIFOLD RUNNER CONTROL STUCK OPEN (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
P2005

Stuck Open (Bank 2)
<Ref. to GD(H4DOTC)-218, DTC P2005 INTAKE MANIFOLD RUNNER CONTROL STUCK OPEN (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
P2006

Stuck Closed (Bank 1)
<Ref. to GD(H4DOTC)-219, DTC P2006 INTAKE MANIFOLD RUNNER CONTROL STUCK CLOSED (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
P2007

Stuck Closed (Bank 2)
<Ref. to GD(H4DOTC)-220, DTC P2007 INTAKE MANIFOLD RUNNER CONTROL STUCK CLOSED (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
P2008

Circuit / Open (Bank 1)
P2009

Circuit Low (Bank 1)
P2011

Circuit / Open (Bank 2)
P2012

Circuit Low (Bank 2)
<Ref. to GD(H4DOTC)-221, DTC P2008 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT / OPEN (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
<Ref. to GD(H4DOTC)-223, DTC P2009 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
<Ref. to GD(H4DOTC)-225, DTC P2011 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT / OPEN (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
<Ref. to GD(H4DOTC)-227, DTC P2012 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW (BANK 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
P2016

(Bank 1)
<Ref. to GD(H4DOTC)-229, DTC P2016 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT LOW (BANK 1), Diagnostic Trouble Code
P2017

(Bank 1)
<Ref. to GD(H4DOTC)-231, DTC P2017 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT HIGH (BANK 1), Diagnostic Trouble Code
P2021

(Bank 2)
(Bank 2)
OCV Solenoid Valve Signal A
Circuit Open (Bank 1)
Circuit Short (Bank 1)
<Ref. to GD(H4DOTC)-233, DTC P2021 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT LOW (BANK 2), Diagnostic Trouble Code
<Ref. to GD(H4DOTC)-235, DTC P2022 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH CIRCUIT HIGH (BANK 2), Diagnostic Trouble Code
<Ref. to GD(H4DOTC)-237, DTC P2088 OCV SOLENOID VALVE SIGNAL A
CIRCUIT SHORT (BANK 1), Diagnostic Trouble Code (DTC) Detecting Criteria.>
P2092

Circuit Open (Bank 2)

P2093
Intake Camshaft Position Actuator Control Circuit High (Bank 2)
<Ref. to GD(H4DOTC)-243, DTC P2093 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2), Diagnostic Trouble Code (DTC)
P2096

Too Lean Bank 1
<Ref. to GD(H4DOTC)-245, DTC P2096 POST CATALYST FUEL TRIM SYSTEM

TOO LEAN BANK 1, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P2097

Too Rich Bank 1
<Ref. to GD(H4DOTC)-247, DTC P2097 POST CATALYST FUEL TRIM SYSTEM

TOO RICH BANK 1, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P2101
Throttle Actuator Control Motor


MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Trouble Code (DTC)
P2004
P2022
P2088
P2089
GD(H4DOTC)-7

GENERAL DESCRIPTION
DTC
Item
Note
P2102

Circuit Low

P2103

Circuit High
Throttle/Pedal Position Sensor
A Minimum Stop Performance

<Ref. to GD(H4DOTC)-255, DTC P2109 THROTTLE/PEDAL POSITION SENSOR A MINIMUM STOP PERFORMANCE, Diagnostic Trouble Code (DTC)
P2122

<Ref. to GD(H4DOTC)-257, DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P2123

<Ref. to GD(H4DOTC)-259, DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC)
P2127

<Ref. to GD(H4DOTC)-261, DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT LOW INPUT, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P2128

P2135

Switching Valve Control Circuit
Low
<Ref. to GD(H4DOTC)-263, DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT HIGH INPUT, Diagnostic Trouble Code (DTC)
<Ref. to GD(H4DOTC)-265, DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH A/B VOLTAGE CORRELATION, Diagnostic Trouble Code (DTC)
<Ref. to GD(H4DOTC)-267, DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D/E VOLTAGE CORRELATION, Diagnostic Trouble Code
SWITCHING VALVE CONTROL CIRCUIT LOW, Diagnostic Trouble Code (DTC)
P2420

Switching Valve Control Circuit
High

SWITCHING VALVE CONTROL CIRCUIT HIGH, Diagnostic Trouble Code (DTC)
P2431

Air Flow /Pressure Sensor Circuit
Range/Performance
<Ref. to GD(H4DOTC)-271, DTC P2431 SECONDARY AIR INJECTION SYSTEM AIR FLOW /PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE,
P2432

Low
High
(Bank 1)
Switching Valve Stuck Closed
(Bank 1)
<Ref. to GD(H4DOTC)-272, DTC P2432 SECONDARY AIR INJECTION SYSTEM AIR FLOW /PRESSURE SENSOR CIRCUIT LOW, Diagnostic Trouble Code
<Ref. to GD(H4DOTC)-273, DTC P2433 SECONDARY AIR INJECTION SYSTEM AIR FLOW /PRESSURE SENSOR CIRCUIT HIGH, Diagnostic Trouble
<Ref. to GD(H4DOTC)-274, DTC P2440 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK OPEN (BANK 1), Diagnostic Trouble Code
<Ref. to GD(H4DOTC)-274, DTC P2441 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK CLOSED (BANK 1), Diagnostic Trouble Code
P2442

(Bank 2)
<Ref. to GD(H4DOTC)-274, DTC P2442 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK OPEN (BANK 2), Diagnostic Trouble Code
P2443

Switching Valve Stuck Closed
(Bank 2)
<Ref. to GD(H4DOTC)-274, DTC P2443 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE STUCK CLOSED (BANK 2), Diagnostic Trouble Code
P2444

Pump Stuck On
<Ref. to GD(H4DOTC)-275, DTC P2444 SECONDARY AIR INJECTION SYSTEM PUMP STUCK ON, Diagnostic Trouble Code (DTC) Detecting Criteria.>
P2109
P2138
P2419
P2433
P2440
P2441
GD(H4DOTC)-8

GENERAL DESCRIPTION
2. Diagnostic Trouble Code (DTC) Detecting Criteria

A: DTC P0011 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR
Detect the malfunction of AVCS system.
There are two types of diagnosis: Crankshaft cam timing diagnosis, and slow response diagnosis. Either of
these is performed according to the status of the engine while running.
(3)
(1)
(5)
(2)
(4)
EN-01852
(1)
AVCS timing controller
(2)
(3)
Vane
(4)
(5)

Oil pressure
(A)
Air
GD(H4DOTC)-9

GENERAL DESCRIPTION
3. ENABLE CONDITION
1. Crankshaft Timing Diagnosis
Enable Conditions
Battery voltage
10.9 V
> 60C (140F)
Target timing advance

Engine speed
= 0CA
500 rpm
AVCS
Uncontrolled
2. Slow Response Diagnosis

Enable Conditions
All secondary parameters are executable.

Battery voltage
1 second or more

Amount of AVCS target timing advance
> 60C (140F)

0CA
Engine speed
AVCS
1300 rpm
Controlled
Target timing advance change amount
< 1.07CA
10.9 V

Perform the diagnosis continuously after starting engine and while AVCS is not operating.
Perform the diagnosis continuously after starting engine and while AVCS is operating.
Judge as NG when the timing advance is outside the normal range. Judge as OK when it within the normal
range.
Judge as NG when all the following conditions are established and the continuous time is more than 20 seconds. Judge as OK and clear the NG when the following conditions are not established and the continuous
time is more than one second.
Judgment Value
Basic timing advance
Threshold Value
< 13CA
or
> 25CA

GD(H4DOTC)-10

GENERAL DESCRIPTION

During AVCS control, calculate AVCS deviation separately for positive/negative, and when the calculated
value per the set time (30 seconds) is large, this is judged as NG.
When all of the following conditions are established, judged as OK.
Judgment Value
AVCS target position
AVCS positive deviation integrated value
Threshold Value
0CA
< 8000CA (R bank)
< 8000CA (L bank)
or
AVCS negative deviation integrated
value
< 8000CA (R bank)

< 8000CA (L bank)

Malfunction Indicator Light Illumination: Illuminates when malfunction occurs in 2 continuous driving
cycles.
Normality Judgment
Judges OK when all of the following conditions are established, and clears the NG.
Judgment Value
AVCS target position
AVCS positive deviation integrated value
Threshold Value
0CA
8000CA (R bank)
8000CA (L bank)
or
AVCS negative deviation integrated
value
8000CA (R bank)
8000CA (L bank)


8. FAIL SAFE
Make the oil flow control solenoid valve drive duty a predetermined value.

GD(H4DOTC)-11

GENERAL DESCRIPTION
B: DTC P0016 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION

(BANK 1)
NOTE:
For the diagnostic procedure, refer to DTC P0011. <Ref. to GD(H4DOTC)-9, DTC P0011 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1), Diagnostic
C: DTC P0018 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION

(BANK 2)
NOTE:
D: DTC P0021 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR

NOTE:
GD(H4DOTC)-12

GENERAL DESCRIPTION
E: DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1)

Detect functional errors of the front oxygen (A/F) sensor heater.
Judge as NG when it is determined that the front oxygen (A/F) sensor impedance is large by referring to the
engine condition such as fuel shut-off in deceleration, etc.
(4)
(2)
(1)
(3)
EN-01763
(1) Protection tube

(2) Gasket
(3) Sensor housing
(4) Ceramic heater
3. ENABLE CONDITION
Enable Conditions
Time needed for all secondary parameters to be in enable conditions

Battery voltage
30 seconds or more
After fuel cut

duty 35%
Heater current
10 seconds or more
Experienced
> 10.9 V
ON

GD(H4DOTC)-13

GENERAL DESCRIPTION
Judge as NG when the continuous time of meeting the malfunction criteria below becomes more than 10 seconds. Judge as OK and clear NG when the continuous time of not completing the malfunction criteria below
becomes more than 10 seconds.
Judgment Value
Threshold Value
> 50



8. FAIL SAFE
Front oxygen sensor (A/F) sensor main learning compensation: Not allowed to calculate.
Correction when re-starting at high temperature: Normally minimum value 0.3 0.

GD(H4DOTC)-14

GENERAL DESCRIPTION

(A)
OFF
(B)
ON
(D)
0V
(C)
EN-01792
(A) Battery voltage

(B) Front oxygen (A/F) sensor heater output voltage
(C) 128 milliseconds
(D) Low error
3. ENABLE CONDITION
Battery voltage
Enable Conditions
10.9 V

GD(H4DOTC)-15

GENERAL DESCRIPTION
(8 cycles).
Judgment Value
duty
Threshold Value
Low
< 87.5%

Normality Judgment
Judgment Value
Threshold Value
High


8. FAIL SAFE
Front oxygen (A/F) sensor activation judgment: Front oxygen (A/F) sensor full activation is not complete,
or front oxygen (A/F) sensor half activation is not complete.
Compensation when starting the engine at high temperature: Make the MIN value to be 0.3 0, normally.

GD(H4DOTC)-16

GENERAL DESCRIPTION

(A)
(D)
OFF
(B)
ON
0V
(C)
EN-01793
(A) Battery voltage

(B) Front oxygen (A/F) sensor heater output voltage
(C) 128 milliseconds
(D) High malfunction
3. ENABLE CONDITION
Battery voltage
Enable Conditions
10.9 V

GD(H4DOTC)-17

GENERAL DESCRIPTION
(8 cycles).
Judgment Value
duty
Threshold Value
High
12.5%

Normality Judgment
Judgment Value
Threshold Value
Low


8. FAIL SAFE

GD(H4DOTC)-18

GENERAL DESCRIPTION
H: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2)

(A)
OFF
(B)
ON
(D)
0V
(C)
EN-01792
(A) Battery voltage

(B) Rear oxygen sensor heater output voltage
(C) 256 milliseconds (cycles)
(D) Low error
3. ENABLE CONDITION
Battery voltage
Enable Conditions
> 10.9 V

GD(H4DOTC)-19

GENERAL DESCRIPTION
Judgment Value
Threshold Value
Low
< 75%

Normality Judgment
Judgment Value
Threshold Value
High


8. FAIL SAFE
Sub feedback control: Not allowed

GD(H4DOTC)-20

GENERAL DESCRIPTION
I:
DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2)
(A)
(D)
OFF
(B)
ON
0V
(C)
EN-01793
(A) Battery voltage

(B) Rear oxygen sensor heater output voltage
(C) 256 milliseconds (cycles)
(D) High malfunction
3. ENABLE CONDITION
Battery voltage
Enable Conditions
> 10.9 V

GD(H4DOTC)-21

GENERAL DESCRIPTION
Judgment Value
Threshold Value
High
25%

Normality Judgment
Judgment Value
Threshold Value
Low


8. FAIL SAFE
Sub feedback control: Not allowed

GD(H4DOTC)-22

GENERAL DESCRIPTION
J: DTC P0068 MAP/MAF - THROTTLE POSITION CORRELATION

Detect the malfunction of intake manifold pressure sensor output property. Judge NG when the intake air
pressure AD value is Low whereas it seemed to be High from the viewpoint of engine condition, or when it
is High whereas it seemed to be Low from the engine condition.
(1)
(2)
(A)
(B)
(3)
EN-01765
(1) Connector
(2) Terminal
(A) Output voltage

(B) Absolute pressure
(3) O-ring
3. ENABLE CONDITION
Enable Conditions
70C (158F)

GD(H4DOTC)-23

GENERAL DESCRIPTION
Judge NG when either Low side or High side becomes NG.
more.
Judgment Value
Threshold Value
Low side
Engine speed
Throttle position
< 2500 rpm

10

Output voltage
> 1.356 g/rev

< 1.0 V
High side
Engine speed
600 900 rpm
Throttle position
< 1.3
< 0.4 g/rev
Output voltage
2.36 V

Normality Judgment
Judge as OK and clear the NG when both Low side and High side become OK.
Judge as OK when the malfunction criteria below are completed.
Judgment Value
Threshold Value
Low side
Engine speed
< 2500 rpm
Throttle position
Output voltage
10
1.0 V
High side
Engine speed
600 900 rpm
Throttle position
Output voltage
< 1.3
< 2.36 V


8. FAIL SAFE
Heavy fuel judgment: Not allowed to carry out the heavy judgment.
Fuel cut control: Not allowed to cut the over pressure charged fuel.

GD(H4DOTC)-24

GENERAL DESCRIPTION
K: DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE

Detect the malfunction of air flow sensor output property.
Judge as a low side NG when the air flow voltage indicates a small value regardless of running in a state
where the air flow voltage increases. Judge as a high side NG when the air flow voltage indicates a large value regardless of running in a state where the air flow voltage decreases. Judge air flow sensor property NG
when the Low side or High side becomes NG.
(1)
(3)
(2)
(A)
(4)
EN-01766
(1) Air flow sensor

(2) Intake air temperature sensor
(A) Air
(3) Voltage (V)

(4) Intake air volume (kg/s)
3. ENABLE CONDITION
Enable Conditions
70C (158F)

GD(H4DOTC)-25

GENERAL DESCRIPTION
time.
Judgment Value
Threshold Value
(Low side error)

Output voltage
< 1.5 V
Engine speed
2500 rpm
15
53.3 kPa (400 mmHg,

15.7 inHg)
(High side error 1)

Output voltage
Engine speed
1.95 V
600 900 rpm

< 4.1
< 52.7 kPa (395 mmHg,
15.6 inHg)
(High side error 2)

Output voltage
Engine speed
1.7 V
600 900 rpm

< 4.1
< 52.7 kPa (395 mmHg,
15.6 inHg)
Fuel system diagnosis
Rich side fault

Low side: 3 seconds
High side: 10 seconds
Normality Judgment
Judgment Value
Threshold Value
(Low side error)

Output voltage
1.5 V
Engine speed
2500 rpm
15
53.3 kPa (400 mmHg,

15.7 inHg)
(High side error)

Output voltage
Engine speed
< 1.95 V
600 900 rpm

< 4.1
< 52.7 kPa (395 mmHg,
15.6 inHg)

GD(H4DOTC)-26

GENERAL DESCRIPTION

8. FAIL SAFE
Air flow meter: Engine load is normally calculated by manifold pressure and engine speed; however, calculated only by manifold pressure.
EVAP conc. learning (fuel): Not allowed to learn.
Knock compensation:
Knock compensation final advance/delay angle value = knock compensation value + whole learning
compensation value + portional learning compensation value
When normal: Knock compensation value = Fixed at 0CA
Failure: Knock compensation value Fixed at 0CA. (When knock: Max. 12CA retard)
Whole learning compensation coefficient update not allowed.
Portional learning zone compensation value calculation not allowed.
ISC control: Open loop compensation is set to (1 g/s). Stop calculation of throttle sensor temperature compensation. (Hold the previous value.)

GD(H4DOTC)-27

GENERAL DESCRIPTION
L: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT

(1)
(3)
(2)
(A)
(4)
EN-01766
(1) Air flow sensor

(A) Air
(3) Voltage (V)

3. ENABLE CONDITION
Enable Conditions
None

Judgment Value
Output voltage
Threshold Value
0.2 V



GD(H4DOTC)-28

GENERAL DESCRIPTION
8. FAIL SAFE
Knock compensation:
When normal: Knock compensation value = Fixed at 0CA.

GD(H4DOTC)-29

GENERAL DESCRIPTION
M: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT

(1)
(3)
(2)
(A)
(4)
EN-01766
(1) Air flow sensor

(A) Air
(3) Voltage (V)

3. ENABLE CONDITION
Enable Conditions
None

Judge as NG when the continuous time of the following base value is higher than 0.5 seconds. Judge as OK
and clear the NG when the malfunction criteria below are not met.
Judgment Value
Output voltage
Threshold Value
4.985 V



GD(H4DOTC)-30

GENERAL DESCRIPTION
8. FAIL SAFE
Knock compensation:

GD(H4DOTC)-31

GENERAL DESCRIPTION
N: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE

CIRCUIT LOW INPUT
(1)
(2)
(A)
(B)
(3)
EN-01765
(1) Connector
(2) Terminal
(A) Output voltage

(3) O-ring
3. ENABLE CONDITION
Battery voltage
Enable Conditions
10.9 V

Judgment Value
Output voltage
Threshold Value
< 0.568 V



GD(H4DOTC)-32

GENERAL DESCRIPTION
8. FAIL SAFE

GD(H4DOTC)-33

GENERAL DESCRIPTION
O: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE

CIRCUIT HIGH INPUT
(1)
(2)
(A)
(B)
(3)
EN-01765
(1) Connector
(2) Terminal
(A) Output voltage

(3) O-ring
3. ENABLE CONDITION
Battery voltage
Enable Conditions
10.9 V

Judgment Value
Output voltage
Threshold Value
4.93 V



GD(H4DOTC)-34

GENERAL DESCRIPTION
8. FAIL SAFE

GD(H4DOTC)-35

GENERAL DESCRIPTION
P: DTC P0111 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT RANGE/

PERFORMANCE
Detect the malfunction of intake air temperature sensor output property.
Judge as NG when the intake air temperature is not varied whereas it seemed to be varied from the viewpoint
of engine condition.
(1)
(3)
(2)
(A)
(4)
EN-01767
(1) Air flow sensor

(A) Air
(3) Resistance value ()

(4) Intake air temperature C (F)
3. ENABLE CONDITION
Enable Conditions
Coolant temp. before engine start

< 30C (86F)

> 95C (203F)
Battery voltage
Continuous time when the vehicle speed
is less than 50 km/h (31 MPH)
10.9 V
600 seconds or more

Perform the diagnosis when the vehicle speed condition is completed after idling from starting the cooled engine.
GD(H4DOTC)-36

GENERAL DESCRIPTION
Judgment Value
Threshold Value

and Min.
< 20 mV (Equivalent to
approximately 0.5C
(33F) near 25C)

Normality Judgment
Judgment Value
and Min.
Threshold Value
20 mV


8. FAIL SAFE

GD(H4DOTC)-37

GENERAL DESCRIPTION
Q: DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW

(1)
(3)
(2)
(A)
(4)
EN-01767
(1) Air flow sensor

(A) Air

3. ENABLE CONDITION
Enable Conditions
None

GD(H4DOTC)-38

GENERAL DESCRIPTION
more.
Judgment Value
Output voltage
Ignition switch
Threshold Value
< 0.165 V
ON

Normality Judgment
Judgment Value
Output voltage
Ignition switch
Threshold Value
0.165 V
ON


8. FAIL SAFE

GD(H4DOTC)-39

GENERAL DESCRIPTION
R: DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH

(1)
(3)
(2)
(A)
(4)
EN-01767
(1) Air flow sensor

(A) Air

3. ENABLE CONDITION
Enable Conditions
None

GD(H4DOTC)-40

GENERAL DESCRIPTION
more.
Judgment Value
Output voltage
Ignition switch
Threshold Value
4.72 V
ON

Normality Judgment
Judgment Value
Output voltage
Ignition switch
Threshold Value
0.23 V
ON


8. FAIL SAFE

GD(H4DOTC)-41

GENERAL DESCRIPTION
S: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW

(1)
(A)
(B)
(2)
EN-01690
(1) Connector
(2) Thermistor element
(A) Resistance value (k)

(B) Temperature C (F)
3. ENABLE CONDITION
Enable Conditions
None

Judgment Value
Output voltage
Threshold Value
< 0.165 V



GD(H4DOTC)-42

GENERAL DESCRIPTION
8. FAIL SAFE
Heavy fuel judgment control: Not allowed to carry out the heavy judgment.
Radiator fan control: Both main and sub fan are in High driving.
High water temperature expansion compensation coefficient: Normally, mass expands with high water
temperature and other conditions, but this ignores water temperature conditions and expands when other
conditions are established.
AVCS Control: Oil flow control solenoid valve drive output duty = 0 %.

GD(H4DOTC)-43

GENERAL DESCRIPTION
T: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH

(1)
(A)
(B)
(2)
EN-01690
(1) Connector

3. ENABLE CONDITION
Enable Conditions
None

Judgment Value
Output voltage
Threshold Value
4.72 V



GD(H4DOTC)-44

GENERAL DESCRIPTION
8. FAIL SAFE

GD(H4DOTC)-45

GENERAL DESCRIPTION
U: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT

LOW
(3)
(4)
(1)
(2)
EN-01859
(1) Throttle position sensor 1 signal

(3) Throttle position sensor
(4) Engine control module (ECM)
3. ENABLE CONDITION
Ignition switch
Enable Conditions
ON

Judgment Value
Threshold Value
0.224 V



GD(H4DOTC)-46

GENERAL DESCRIPTION
8. FAIL SAFE

GD(H4DOTC)-47

GENERAL DESCRIPTION
V: DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT

HIGH
(3)
(4)
(1)
(2)
EN-01859

3. ENABLE CONDITION
Ignition switch
Enable Conditions
ON

Judgment Value
Threshold Value
4.851 V



GD(H4DOTC)-48

GENERAL DESCRIPTION
8. FAIL SAFE

GD(H4DOTC)-49

GENERAL DESCRIPTION
W: DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP

FUEL CONTROL
Detect the malfunction of engine coolant temperature output property.
Judge as NG when the engine coolant temperature does not rise in driving conditions where it should.
(1)
(A)
(B)
(2)
EN-01690
(1) Connector

3. ENABLE CONDITION
Engine speed
Battery voltage
Enable Conditions
500 rpm
> 10.9 V

Perform the diagnosis only once after engine starting.
Judgment Value
Threshold Value
< 20C (68F)
Judgment value of
timer after engine
starting
GD(H4DOTC)-50

GENERAL DESCRIPTION

a. Timer stop at fuel cut mode
64 milliseconds + TWCNT milliseconds (at the time of 64 milliseconds)
TWCNT is defined as follows.
TWCNT = 0 (at idle switch ON)
TWCNT show on the following table at idle switch OFF.
Temperature
C (F)
20 (4)
0 (0)
0 ms
8 (4.97)
37.14 ms
16 (9.94)
74.27 ms
24 (14.9)
111.41 ms
32 (19.9)
126.66 ms
40 (24.9)
141.91 ms
48 (29.8)
163.59 ms
56 (34.8)
185.26 ms
10 (14)
0 (32)
0 ms
0 ms
27.39 ms
17.65 ms
54.78 ms
35.29 ms
82.17 ms
52.94 ms
99.65 ms
72.64 ms
117.13 ms
92.34 ms
135.96 ms
108.34 ms
154.80 ms
124.33 ms
10 (50)
20 (68)
0 ms
0 ms
7.90 ms
7.90 ms
15.80 ms
15.80 ms
23.70 ms
23.70 ms
45.63 ms
45.63 ms
67.56 ms
67.56 ms
80.71 ms
80.71 ms
93.87 ms
93.87 ms
Judgment value of timer after engine starting

t = 451.1 25.9 Ti
Ti = The lowest engine coolant temperature after starting the engine
Time Needed for Diagnosis: To be determined. (It is varied by the Min. engine coolant temperature and engine conditions such as vehicle speed and engine coolant temperature.)
Normality Judgment
Judgment Value
Threshold Value
20C (68F)


8. FAIL SAFE

GD(H4DOTC)-51

GENERAL DESCRIPTION
X: DTC P0126 INSUFFICIENT ENGINE COOLANT TEMPERATURE FOR STABLE OPERATION

Detect the malfunction of the engine coolant temperature sensor characteristics.
Memorize the engine coolant temperature and fuel temperature at the last engine stop, and use them to
judge as NG when the engine coolant temperature does not decrease when it should.
(1)
(A)
(B)
(2)
EN-02917
(1)
(2)
Connector
Thermistor element
(A)
(B)

Temperature C (F)
3. ENABLE CONDITION
Battery voltage
Refueling from the last engine stop till
the current engine start
Fuel level
engine stop
Enable Conditions
10.9 V
None
15 2 (3.96 US gal,
3.3 Imp gal)
70C (158F)
and
< 95C (203F)

Perform the diagnosis only once after starting the engine.
GD(H4DOTC)-52

GENERAL DESCRIPTION
Judgment Value
Threshold Value

< 2.5C (4.5F)
Fuel temperature at the last engine stop

fuel temperature
5C (9F)
Intake air temperature fuel temperature

Fuel temperature
< 2.5C (4.5F)

< 35C (95F)
Normality Judgment
When the following conditions are established, it is OK.
Judgment Value
Threshold Value
2.5C (4.5F)



8. FAIL SAFE
None

GD(H4DOTC)-53

GENERAL DESCRIPTION
Y: DTC P0128 COOLANT THERMOSTAT (ENGINE COOLANT TEMPERATURE

Detect malfunctions of the thermostat function.
Judge as NG when the engine coolant temperature is lower than the estimated engine coolant temperature
and the difference between them is large. Judge as OK when the engine coolant temperature becomes to
75C (167F), and the difference is small, before judging NG.
(8)
(2)
(2)
(7)
(6)
(5)
(4)
(9)
(1)
(3)
EN-01692
(1) Valve
(2) Spring
(6) Rubber packing

(7) Stop ring
(3) Stopper
(4) Piston
(8) Wax element

(9) Jiggle valve
(5) Guide
3. ENABLE CONDITION
Enable Conditions
None

GD(H4DOTC)-54

GENERAL DESCRIPTION
more.
Judgment Value
Threshold Value
Battery voltage
10.9 V
7C (19.4F)

starting
Estimated coolant temperature
< 55C (131F)

(Estimated - Measured) Engine coolant
temperature
Vehicle speed
< 70C (158F)

> 30C (54F)
70C (158F)
30 km/h

Normality Judgment
Judgment Value
Battery voltage
Threshold Value
10.9 V

Thermostat malfunction diagnosis
7C (19.4F)
Incomplete

starting
< 55C (131F)
(Estimated - Measured) Engine coolant

temperature
30C (54F)
70C (158F)


8. FAIL SAFE
None

GD(H4DOTC)-55

GENERAL DESCRIPTION
Z: DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)

Judge as NG when the element impressed voltage is out of range, or the element current is out of range.
(3)
(1)
(A)
(2)
(2)
(C)
(B)
(D)
(4)
EN-01693
(1) Atmosphere
(2) Exhaust gas
(A) Electromotive force

(B) Air fuel ratio
(3) ZrO2
(4) Ceramic heater
(C) Lean
(D) Rich
3. ENABLE CONDITION
Voltage
Enable Conditions
10.9 V

Judge as NG when the continuous time of meeting any malfunction criteria below is more than 1 second.
Judgment Value
Input voltage
< 1.8 V
Threshold Value
Input current
< 0.01 A



GD(H4DOTC)-56

GENERAL DESCRIPTION
8. FAIL SAFE

GD(H4DOTC)-57

GENERAL DESCRIPTION
AA:DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)

Judge as NG when the element impressed voltage is out of range, or the element current is out of range.
(3)
(1)
(A)
(2)
(2)
(C)
(B)
(D)
(4)
EN-01693
(1) Atmosphere
(2) Exhaust gas

(B) Air fuel ratio
(3) ZrO2
(4) Ceramic heater
(C) Lean
(D) Rich
3. ENABLE CONDITION
Voltage
Enable Conditions
10.9 V

Judge as NG when the continuous time of meeting any malfunction criteria below is more than 1 second.
Judgment Value
Input voltage
3.8 V
Threshold Value
Input current
0.01 A



GD(H4DOTC)-58

GENERAL DESCRIPTION
8. FAIL SAFE

GD(H4DOTC)-59

GENERAL DESCRIPTION
AB:DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1)

Detect the slow response of front oxygen (A/F) sensor.
Front oxygen (A/F) sensor cover has some ventilation holes for exhaust gas. Clogged ventilation holes are
diagnosed.
When the holes are clogged, the A/F output variation becomes slow comparing with the actual A/F variation
because oxygen which reaches the zirconia layer is insufficient. Therefore, if the sensor cover holes are
clogged, the rich to lean judgment in the ECM is delayed when the change from rich to lean occurs.
Judge as NG when the actual movement in comparison to the ECM control amount is slow.
(2)
(3)
(1)
EN-01694
(1) Cover
(2) Zirconia
(3) Clogging
GD(H4DOTC)-60

GENERAL DESCRIPTION
(3)
(1)
(A)
(2)
(2)
(C)
(B)
(D)
(4)
EN-01693
(1) Atmosphere
(2) Exhaust gas

(3) ZrO2
(B) Air fuel ratio

(C) Lean
(4) Ceramic heater
(D) Rich
3. ENABLE CONDITION
Enable Conditions
1 second or more
Battery voltage
> 10.9 V
> 75.0 kPa (563 mmHg,
22.2 inHg)
Closed loop control with main feedback

Operating
0 50

120 seconds or more

70C (158F)
Engine speed
Vehicle speed
1000 3200 rpm

10 120 km/h (6.21
74.6 MPH)
10 31 g/s

Engine load change during 0.5 engine
revs.
purge
0.02 g/rev
0.2
20 seconds or more

Perform diagnosis only once, at a constant speed of 10 120 km/h (6.21 74.6 MPH) in 120 seconds or
more after warming up the engine.
GD(H4DOTC)-61

GENERAL DESCRIPTION
Calculate faf difference every 128 milliseconds, and the value difference. Calculate the diagnosis value after calculating 1640 times (210 seconds).
Judge as NG when the malfunction criteria below are completed. Judge as OK and clear the NG when the
malfunction criteria below are not met.
Judgment Value
Threshold Value
0.392
parafca = td2faf/td2lmd
where,
td2faf (N) = td2faf (n1) + |d2faf (n)|
td2lmd (N) = td2lmd (n1) + |d2lmd (n)|
add up for a total of 210 seconds
d2faf (n) = (faf (n) faf (n1)) (faf (n1) faf (n2))
d2lmd (n) = (lmd (n) lmd (n1)) (lmd (n1) lmd (n2))
faf = main feedback compensation coefficient every
128 milliseconds
lmd = output lambda every 128 milliseconds



8. FAIL SAFE

GD(H4DOTC)-62

GENERAL DESCRIPTION
AC:DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1

SENSOR 1)
Detect open circuits of the sensor.
Judge as NG when the impedance of the element is large.
(3)
(1)
(A)
(2)
(2)
(C)
(B)
(D)
(4)
EN-01693
(1) Atmosphere
(2) Exhaust gas

(B) Air fuel ratio
(3) ZrO2
(4) Ceramic heater
(C) Lean
(D) Rich
3. ENABLE CONDITION
Enable Conditions
None

Judgment Value
Voltage
Threshold Value
10.9 V
Time after engine starting

50 sec.
Cumulative amount of the front lambda
28000%
sensor heater control duty every 128 milliseconds.
500

GD(H4DOTC)-63

GENERAL DESCRIPTION


8. FAIL SAFE

GD(H4DOTC)-64

GENERAL DESCRIPTION
AD:DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)

Detect the continuity NG of oxygen sensor. If the oxygen sensor voltage reading is not within the probable
range considering the operating conditions, judge as NG.
(E)
(3)
V
(1)
(F)
(A)
(2)
(2)
(C)
(B)
(D)
EN-01696
(A)
(B)
Electromotive force
Air fuel ratio
(C)
(D)
Rich
Lean
(E)
(F)

Comparative voltage
(1)
Atmosphere
(2)
Exhaust gas
(3)
Electromotive force
GD(H4DOTC)-65

GENERAL DESCRIPTION
3. ENABLE CONDITION
Used only for abnormality judgment
Enable Conditions
High side
Closed loop control with the oxygen sensor
Not in operation
In operation

coefficient
< 5 times
Not in limit value
Battery voltage
Low side 1
> 10.9 V

Not in operation
In operation

coefficient
Battery voltage
< 5 times
Not in limit value
> 10.9 V

Low side 2
10 g (0.35 oz)/second

Not in operation
In operation

coefficient
< 5 times
Not in limit value
Battery voltage
> 10.9 V
< 10 g (0.35 oz)/second
Current continuation time of the rear oxygen

sensor heater
25 seconds or more
Low side 3
Not in operation

In operation
< 5 times

coefficient
Not in limit value
Battery voltage
> 10.9 V
< 10 g (0.35 oz)/second
Current continuation time of the rear oxygen

sensor heater
Fuel cut
25 seconds or more
Experienced
Used only for normality judgment

Enable Condition
Not in operation

In operation
< 5 times

coefficient
Battery voltage
Not in limit value

> 10.9 V

After starting the engine, perform the diagnosis in series while the engine is in a constant operating condition.
GD(H4DOTC)-66

GENERAL DESCRIPTION
Judge as NG if the continuous time when the following conditions are established exceeds the predetermined time, and judge as OK if it doesnt.
Judgment Value
Threshold Value
DTC
High side
Maximum output voltage without continuity 1200 mV
P0138
Low side
Minimum output voltage without continuity
P0137
< 30 mV

High side: 2.5 seconds
Low side 3: Refer to the Map.
Map

(Seconds)
40
2
10
40
60
Fuel Cut Time (Seconds)


8. FAIL SAFE

AE:DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)

NOTE:
For the detection conditions, refer to DTC P0137. <Ref. to GD(H4DOTC)-65, DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4DOTC)-67

GENERAL DESCRIPTION
AF:DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2)

Detect the slow response of the oxygen sensor.
Judge as NG if either the rich to lean response diagnosis or lean to rich response diagnosis is NG, and judge
as OK if both are OK.
[Rich lean diagnosis response]
1. Measure the response time for oxygen sensor output changes when the A/F ratio changes to rich to lean.
If the measured response time is larger than the threshold value, it is NG. If it is smaller, it is OK.
2. Judge as NG when the oxygen sensor voltage is large (rich) when recovering from a deceleration fuel cut.
[Lean rich diagnosis response]
1. Measure the response time for oxygen sensor output changes when the A/F ratio changes to lean to rich.
If the measured response time is larger than the threshold value, it is NG.
2. Judge as NG when the oxygen sensor voltage remains small when recovering from a deceleration fuel
cut.
DIAGNOSTIC METHOD
Measure the response time of the output change of the oxygen sensor when the A/F ratio changes to rich to
lean. And Judge as NG when the measured response time is larger than the threshold value.
(E)
(3)
V
(1)
(F)
(A)
(2)
(2)
(C)
(B)
(D)
EN-01696
(1)
Atmosphere
(A)
Electromotive force
(D)
Lean
(2)
(3)
Exhaust gas
Electromotive force
(B)
(C)
Air fuel ratio

Rich
(E)
(F)

Comparative voltage
3. ENABLE CONDITION
Rich lean diagnosis response
Enable Condition
Battery voltage
A/F sub feedback control condition
> 10.9 V
Complete
Deceleration fuel cut time is 5 seconds or more.

After fuel cut
Experienced
2 sec.
Rear oxygen heater current calculation time

Rear oxygen heater current continuous time
60 sec.
30 sec.
Estimated catalyst layer temperature
400 C (752F)
GD(H4DOTC)-68

GENERAL DESCRIPTION

When the oxygen sensor output voltage changes from 0.55 V (rich) to 0.15 V (lean), calculate the minimum
response time for output change between 0.5 V and 0.2 V for the judgment criteria.
Diagnosis execution condition
0.55V
0.5V
Measure the response time.
Rear oxygen sensor (V)
0.2V
0.15V
0V

More than 6 seconds
Execute the malfunction judgment

in 2 seconds from the recovery of
fuel cut on deceleration.
EN-05052
1) Judge as NG when the judgment value is larger than the threshold value after deceleration fuel cut.
NOTE:
Variation time of rear oxygen sensor output voltage is short during fuel shut-off in deceleration. Carry out the
NG judgment only after the fuel shut-off in deceleration. Even without deceleration fuel cut, judge as OK if the
value is below the threshold.
When the deceleration fuel cut time is more than 6 seconds, judge as NG if the following criteria are met 2
seconds after recovering from the deceleration fuel cut.
GD(H4DOTC)-69

GENERAL DESCRIPTION
2) Judge as NG when the oxygen sensor voltage at recovery from a deceleration fuel cut is large.
If the fuel cut time in a deceleration fuel cut is long (more than 6 s), and even after recovering from a deceleration fuel cut, the oxygen sensor voltage is high (0.55 V or more), judge as NG.
Judgment Value
from 0.55 V to 0.15 V.
Time at over 0.55 V
Threshold Value
> 0.837 seconds
> 2 seconds

Normality Judgment
1) Regardless of a deceleration fuel cut, if the response time (diagnostic value) when the oxygen sensor voltage has changed from rich to lean is shorter than the threshold value (judgment value), judge as a normal
condition.
2) Normality judgement is not to be performed.
Judgment Value
from 0.55 V to 0.15 V.
Threshold Value
0.837 sec.


8. FAIL SAFE

10.ENABLE CONDITION
Lean rich response diagnosis
Enable Conditions
Battery voltage
A/F main feedback control condition
> 10.9 V
Completed
Deceleration fuel cut 5 seconds

After fuel cut
Experienced
2 sec.
Current calculation time of the rear oxygen sensor heater
60 sec.
Current continuation time of the rear oxy- 30 sec.

gen sensor heater
GD(H4DOTC)-70

GENERAL DESCRIPTION
11.GENERAL DRIVING CYCLE

the oxygen sensor voltage for the timing of the deceleration.)
12.DIAGNOSTIC METHOD
Calculate the minimum value of 0.3 V to 0.5 V output change response time as judgment value, when the oxygen sensor output voltage changes from 0.25 V (lean) to 0.55 V (rich).
Diagnosis execution
condition
Measure the response time
(diagnostic value).
0.55V
0.5V
Rear O 2 sensor (V)
0.3V
0.25V
0V
Judge NG when the voltage of

rear oxgen sensor is 0.25 V or
less for 120 seconds or more
after recovery of fuel cut on
deceleration.
>= 120s
>= 6s
Execute the malfunction judgement in 2 seconds

from recovery of fuel cut on deceleration.
EN-02210
GD(H4DOTC)-71

GENERAL DESCRIPTION
1) Judge as NG when the judgment value is larger than the threshold value after deceleration fuel cut.
2) If the oxygen sensor voltage is small after recovering from a deceleration fuel cut, and remains small,
judge as NG.
Judgment Value
Shortest time change from lean (0.3 V
O2 output) to rich (0.5 V) when voltage
drops from 0.5 V to 0.25 V.
Time at less than 0.25 V
Threshold Value
> 2 seconds
> 120 seconds

Normality Judgment
1) Regardless of a deceleration fuel cut, if the response time (diagnostic value) when the oxygen sensor voltage has changed from rich to lean is shorter than the threshold value (judgment value), judge as a normal
condition.
2) Do not judge as a normal condition.
Judgment Value
Shortest time change from lean (0.3 V
O2 output) to rich (0.5 V) when voltage
drops from 0.55 V to 0.25 V.
Threshold Value
2 sec.
13.DTC CLEAR CONDITION


15.FAIL SAFE

GD(H4DOTC)-72

GENERAL DESCRIPTION
AG:DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 2)

Detect abnormalities in the rear oxygen sensor output property.
By referring to the intake air amount, engine coolant temperature, main feedback control, deceleration fuel
cut and other operating conditions, if the rear oxygen sensor voltage should be moving under those conditions but is showing a low voltage, this is judged as a Low side NG. If the voltage is high, it is judged as a High
side NG.
When either Low side or High side is NG, this is judged as an rear oxygen sensor property NG.
2. ENABLE CONDITION
Target output voltage of rear oxygen
sensor
Air intake amount
Enable Conditions
70C (158F)
0.6 V
Battery voltage
10 g (0.35 oz)/seconds
or more
> 10.9 V
Closed loop with the oxygen sensor

In operation
5 times or less

coefficient
Deceleration fuel cut of 5 seconds or
more
Not in limit value

Experienced

Perform the diagnosis only once after engine warm-up.
When the following conditions are established, it is NG.
Judgment Value
Maximum output voltage, low side
Minimum output voltage, high side
Threshold Value
< 550 mV
> 250 mV

Normality Judgment
When the following conditions are established, it is OK.
Judgment Value
Maximum output voltage, low side
Threshold Value
550 mV
Minimum output voltage, high side
250 mV

GD(H4DOTC)-73

GENERAL DESCRIPTION

7. FAIL SAFE
None

GD(H4DOTC)-74

GENERAL DESCRIPTION
AH:DTC P0171 SYSTEM TOO LEAN (BANK 1)

FUEL SYSTEM DIAGNOSIS
:A
:B
(3)
(1)
(4)
(2)
(5)
(24)
(6)
(23)
(22)
(7)
(21)
(13)
(9)
(12)
(20)
(19)
(18) (17)(16) (15) (14)
(11)
(10)
(1) Purge control solenoid valve
(14) Fuel temperature sensor
(2) Purge valve

(3) Pressure regulator
(15) Fuel level sensor

(16) Fuel pump
(4) Throttle body

(5) Fuel filter
(17) Jet pump

(18) Fuel cut valve
(6) Intake manifold

(19) Fuel sub level sensor

(20) Fuel tank
(8) Canister
(9) Pressure control solenoid valve
(21) Fuel tank pressure sensor

(22) Fuel gauge
(10) Drain valve

(11) Drain filter
(12) Shut-off valve
(13) Vent valve
(8)
EN-03873
(23) Combination meter

(24) Fuel injector
(A) Fuel line
(B) Vaporized fuel line
Diagnostic Method
GD(H4DOTC)-75

GENERAL DESCRIPTION
2. ENABLE CONDITION
Enable Conditions

In operation
70C (158F)
Engine load
Value from Map 5
Intake air change during 0.5 engine revs. 0.02 g/rev
Map 5
engine speed (rpm)
idling
Nonturbo
800
1200
1600
2000
2400
2800
3200
3600
4000
4400
0.228
0.22
0.22
0.22
0.228
0.23
0.234
0.242
0.250
0.250
(0.008) (0.0078) (0.0078) (0.0078) (0.008) 0.0081 (0.0083) (0.0085) (0.0088) (0.0088)

Judgment Value
Threshold Value
fsobdL1
where,
See Map 4
fsobdL1 = lean side
threshold value of
fsobd
Map 4
Threshold value for fuel system malfunction criteria
fsobdL1 (%)
40
2.4
4.7
7
9.4
11.7
14.1
(0.085) (0.166) (0.247) (0.332) (0.413) (0.497)
40
36.9
32.0
27.0
26.5
26.5

Normality Judgment
Judge as OK when the malfunction criteria below are completed for 10 seconds or more.
Judgment Value
Threshold Value
< 19%


GD(H4DOTC)-76

GENERAL DESCRIPTION
7. FAIL SAFE

GD(H4DOTC)-77

GENERAL DESCRIPTION
AI: DTC P0172 SYSTEM TOO RICH (BANK 1)

FUEL SYSTEM DIAGNOSIS
:A
:B
(3)
(1)
(4)
(2)
(5)
(24)
(6)
(23)
(22)
(7)
(21)
(13)
(9)
(12)
(20)
(19)
(18) (17)(16) (15) (14)
(11)
(10)
(2) Purge valve


(16) Fuel pump
(4) Throttle body

(5) Fuel filter
(17) Jet pump

(18) Fuel cut valve
(6) Intake manifold


(20) Fuel tank
(8) Canister

(22) Fuel gauge
(10) Drain valve

(11) Drain filter
(12) Shut-off valve
(13) Vent valve
(8)
EN-03873

(24) Fuel injector
(A) Fuel line
Diagnostic Method
Fuel system is diagnosed by comparing the target air fuel ratio calculated by ECM with the actual air fuel ratio
measured by sensor.
GD(H4DOTC)-78

GENERAL DESCRIPTION
2. ENABLE CONDITION
Enable Conditions

In operation
70C (158F)
Engine load
Value from Map 5
Intake air change during 0.5 engine revs. 0.02 g/rev
purge
0.1
Cumulative time of canister purge after

engine start
Continuous period after canister purge
starting
20 seconds or more
30 seconds or more
Map 5
Engine speed (rpm)
idling
Nonturbo
800
1200
1600
2000
2400
0.228
0.22
0.22
0.22
0.228
(0.008) (0.0078) (0.0078) (0.0078) (0.008)
2800
3200
3600
4000
4400
0.23
0.234
0.242
0.250
0.250
0.0081 (0.0083) (0.0085) (0.0088) (0.0088)

Judgment Value
Threshold Value

where,
faf = Main feedback compensation coefficient
(Per 64 milliseconds)
Map 4
fsobdR1
See Map 4
fsobdR1 = rich side
threshold value of
fsobd
Threshold value for fuel system malfunction criteria

fsobdR1 (%)
0
40
2.4(0.085)
40
4.7(0.166)
36.9
7(0.247)
32.0
9.4(0.332)
27.0
11.7(0.413) 14.1(0.497)
27.0
27.0

Normality Judgment
Judge as OK when the malfunction criteria below continues for 10 seconds.
Judgment Value
Threshold Value
20%

GD(H4DOTC)-79

GENERAL DESCRIPTION

7. FAIL SAFE

GD(H4DOTC)-80

GENERAL DESCRIPTION
AJ:DTC P0181 FUEL TEMPERATURE SENSOR A CIRCUIT RANGE/

PERFORMANCE
Detect faults in the fuel temperature sensor output properties.
Diagnosis is performed in two methods; drift diagnosis and stuck diagnosis. If either is NG, judge as NG. If
both are OK, Judge as OK and clear the NG.
DRIFT DIAGNOSIS
Normally fuel temperature is lower than engine coolant temperature. When the fuel temperature becomes
higher than the engine coolant temperature, the range is considered to be shifted, and judged as NG.
(A)
(B)
EN-01700
(A) Resistance value ()

3. ENABLE CONDITION
Enable Conditions
None

GD(H4DOTC)-81

GENERAL DESCRIPTION
more.
Judgment Value
Fuel level
Threshold Value
9 2 (2.38 US gal,
1.98 Imp gal)
20 seconds or more

coolant temperature at engine starting
> 10C (18F)

Battery voltage
10C (18F)
> 10.9 V

Normality Judgment
Judgment Value
Fuel level
Threshold Value
9 2 (2.38 US gal,
1.98 Imp gal)
20 seconds or more

coolant temperature at engine starting
> 10C (18F)

Battery voltage
< 10C (18F)
< 70C (158F)
> 10.9 V
Stuck Diagnosis
As the engine warms up (cumulative amount of intake air after starting is large), if the fuel temperature which
should rise does not, determine as being stuck and NG.
6. ENABLE CONDITION
Enable Conditions
20 seconds or more
Battery voltage
> 10.9 V

Always perform diagnosis continuously after 20 seconds or more have passed since the engine started.
GD(H4DOTC)-82

GENERAL DESCRIPTION
Judgment Value
Max. and Min.
Threshold Value
550 kg (1212.8 lb)
< 3C (5.4F)

Normality Judgment
Judgment Value
Threshold Value
550 kg (1212.8 lb)

Max. and Min.
3C (5.4F)


11.FAIL SAFE
None

GD(H4DOTC)-83

GENERAL DESCRIPTION
AK:DTC P0182 FUEL TEMPERATURE SENSOR A CIRCUIT LOW INPUT

(A)
(B)
EN-01700

3. ENABLE CONDITION
Enable Conditions
None

more.
Judgment Value
Output voltage
Battery voltage
Threshold Value
< 0.1646 V
10.9 V

Normality Judgment
Judgment Value
Output voltage
Threshold Value
0.1646 V
Battery voltage
10.9 V
GD(H4DOTC)-84

GENERAL DESCRIPTION


8. FAIL SAFE
None

GD(H4DOTC)-85

GENERAL DESCRIPTION
AL:DTC P0183 FUEL TEMPERATURE SENSOR A CIRCUIT HIGH INPUT

(A)
(B)
EN-01700

3. ENABLE CONDITION
Enable Conditions
None

more.
Judgment Value
Output voltage
Battery voltage
Threshold Value
4.72 V
10.9 V

Normality Judgment
Judgment Value
Output voltage
Threshold Value
< 4.72 V
Battery voltage
10.9 V
GD(H4DOTC)-86

GENERAL DESCRIPTION


8. FAIL SAFE
None

GD(H4DOTC)-87

GENERAL DESCRIPTION
AM:DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT

LOW
(3)
(4)
(1)
(2)
EN-01859

3. ENABLE CONDITION
Ignition switch
Enable Conditions
ON

Judgment Value
Threshold Value
> 0.224 V



GD(H4DOTC)-88

GENERAL DESCRIPTION
8. FAIL SAFE

GD(H4DOTC)-89

GENERAL DESCRIPTION
AN:DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT

HIGH
(3)
(4)
(1)
(2)
EN-01859

3. ENABLE CONDITION
Ignition switch
Enable Conditions
ON

Judgment Value
Threshold Value
< 4.851 V



GD(H4DOTC)-90

GENERAL DESCRIPTION
8. FAIL SAFE

GD(H4DOTC)-91

GENERAL DESCRIPTION
AO:DTC P0230 FUEL PUMP PRIMARY CIRCUIT

Detect the malfunction of fuel pump control unit.
Judge as NG when the NG signal is sent through a diagnostic line coming from the fuel pump control unit.
Fuel pump control unit detects the open or short circuit malfunction for each line, and then sends NG signals
if one of them is found NG.
+B
FP+
FPC
(3)
(2)
(1)
DI
(4)
FP-
E
EN-01771

(2) Fuel pump control unit
(3) Fuel pump
(4) Battery
3. ENABLE CONDITION
Enable Conditions
None

GD(H4DOTC)-92

GENERAL DESCRIPTION
more.
Judgment Value
Threshold Value
Battery voltage
8V
30 seconds or more
Fuel pump control

Fuel pump control unit output diagnosis
signal
ON
Low
Fuel level
10 2 (2.64 US gal,
2.2 Imp gal)

Normality Judgment
Judgment Value
Battery voltage
Threshold Value
8V

Fuel pump control
30 seconds or more
ON
Fuel pump control unit output diagnosis

signal
High


8. FAIL SAFE
OFF setting may be needed depending on the NG portion.

GD(H4DOTC)-93

GENERAL DESCRIPTION
AP:DTC P0244 TURBO/SUPER CHARGER WASTEGATE SOLENOID A

RANGE/PERFORMANCE
Detect the malfunction of wastegate control solenoid valve function.
Judge NG when becoming high wastegate pressure.
(1)
EN-01772
(1) Coil
3. ENABLE CONDITION
Enable Conditions
None

GD(H4DOTC)-94

GENERAL DESCRIPTION
Judgment Value
Threshold Value
Map 10
Map 10
Atmosphere pressure
(kPa (mmHg, inHg))
NG pressure (kPa (mmHg, inHg))
OK pressure (kPa (mmHg, inHg))
58.7
(440, 17.3)
67.2
(504, 19.8)
75.7
(568, 22.4)
84.2
(632, 24.9)
92.8
(696, 27.4)
101.3
(760, 29.9)
142.4
156.2
170.2
184.1
198.0
207.9
(1068, 42.1) (1172, 46.1) (1277, 50.3) (1381, 54.4) (1485, 58.5) (1560, 61.4)
120.0 (900,
113.8
147.8
161.7
175.6
185.6
35.4)
(1004, 33.6) (1109, 43.7) (1213, 47.8) (1317, 51.9) (1392, 54.8)

Normality Judgment
Judgment Value
Threshold Value
< Map 10


8. FAIL SAFE
None

GD(H4DOTC)-95

GENERAL DESCRIPTION
AQ:DTC P0245 TURBO/SUPER CHARGER WASTEGATE SOLENOID A LOW

Detect the open or short circuit of wastegate control solenoid valve.
Judge NG when the terminal output voltage remains Low during outputting the duty signal.
(1)
EN-01772
(1) Coil
3. ENABLE CONDITION
Battery voltage
Enable Conditions
> 10.9 V
1 second or more

GD(H4DOTC)-96

GENERAL DESCRIPTION
Judge NG when the continuous time of meeting the malfunction criteria below becomes more than 655 milliseconds.
Judgment Value
Terminal output
Duty ratio for turbocharged pressure
control
Threshold Value
Low
< 75%

Normality Judgment
Judgment Value
Threshold Value
High


8. FAIL SAFE
None

GD(H4DOTC)-97

GENERAL DESCRIPTION
AR:DTC P0246 TURBO/SUPER CHARGER WASTEGATE SOLENOID A HIGH

Detect the open or short circuit of wastegate control solenoid valve.
Judge NG when the terminal output voltage remains High during outputting the duty signal.
(1)
EN-01772
(1) Coil
3. ENABLE CONDITION
Battery voltage
Enable Conditions
> 10.9 V
1 second or more

GD(H4DOTC)-98

GENERAL DESCRIPTION
Judge NG when the continuous time of meeting the malfunction criteria below becomes more than 655 milliseconds.
Judgment Value
Terminal output
Duty ratio for turbocharged pressure
control
Threshold Value
High
> 25%

Normality Judgment
Judgment Value
Threshold Value
Low


8. FAIL SAFE
None

GD(H4DOTC)-99

GENERAL DESCRIPTION
AS:DTC P0301 CYLINDER 1 MISFIRE DETECTED

Detect the presence of misfire occurrence. (Revolution fluctuation method)
Monitoring misfire which influences exhaust deterioration (1.5 times of FTP) and catalyst damage is made
obligatory by the law. Misfire affecting these two has two patterns below.
Intermittent misfire (The same cylinder misfires in random, or different cylinders misfire in random.): FTP
1.5 times misfire
Every time misfire (The same cylinder misfires every time.): FTP 1.5 times misfire, Catalyst damage misfire
The following detecting methods are adopted for these detection.
1) Intermittent misfire: FTP 1.5 times misfire
180 Interval Difference Method (MT: 1,800 rpm or less; AT: None)
360 Interval Difference Method (whole range)
720 Interval Difference Method (3,000 rpm or more)
2) Misfire every time: FTP 1.5 times misfire, Catalyst damage misfire
2. ENABLE CONDITION
Time for keep completing all secondary parameters
Enable Conditions
1 second or more
Intake manifold pressure change during 0.5 engine revs.
< 13.3 kPa (100 mmHg, 3.93 inHg (MT model))

< 13.3 kPa (100 mmHg, 3.93 inHg (AT model))
Engine speed change

Throttle position change during 16 milliseconds
< 1,000 rpm/32 milliseconds

< 14

Atmosphere pressure
Not in operation
75.0 kPa (563 mmHg, 22.2 inHg)
Fuel level
Evaporative system leak check
9 2 (2.38 US gal, 1.98 Imp gal)

Not in operation
Engine speed
500 6500 rpm

> Value of map 3 or more
Battery voltage
8V
Map 3
MT model
Vehicle Speed < 64.4 km/h (40 MPH)
rpm
700
1000
1500
2000
2500
3000
3500
4000
4500
5000
5500
6000
6500
6700
kPa
(mmHg,
inHg)
25.1
(188,
7.40)
24.8
(186,
7.32)
23.3
(175,
6.89)
24.7
(185,
7.30)
24.0
(180,
7.09)
25.6
(192,
7.56)
28.8
(216,
8.51)
30.0
(225,
8.86)
31.6
(237,
9.33)
32.5
(244,
9.60)
37.1
(278,
10.96)
41.9
(314,
12.4)
36.9
352,
10.90)
51.1
(383,
15.1)
Vehicle Speed 64.4 km/h (40 MPH)

rpm
kPa
(mmHg,
inHg)
700
25.1
(188,
7.40)
1000
24.8
(186,
7.32)
1500
23.3
(175,
6.89)
2000
24.7
(185,
7.30)
2500
24.0
(180,
7.09)
3000
25.6
(192,
7.56)
3500
28.8
(216,
8.51)
4000
30.0
(225,
8.86)
4500
31.6
(237,
9.33)
5000
32.5
(244,
9.60)
5500
37.1
(278,
10.96)
6000
41.9
(314,
12.4)
6500
36.9
352,
10.90)
6700
51.1
(383,
15.1)
rpm
700
1000
1500
2000
2500
3000
3500
4000
4500
5000
5500
6000
6500
6700
kPa
(mmHg,
inHg)
26.3
(197,
7.76)
24.7
(185,
7.28)
23.6
(177,
6.97)
26.7
(200,
7.89)
27.3
(205,
8.07)
26.1
(196,
7.72)
29.5
(221.5,
8.72)
31.3
(235,
9.25)
AT model
GD(H4DOTC)-100
32.7
34.1
38.2
(245.5, (256, (286.5,
9.67) 10.08) 11.28)
44.0
(330,
13.0)
49.5
53.3
(371.5, (400,
14.63) 15.74)

GENERAL DESCRIPTION

If conditions are met, detect misfire from idling to high rotation.
Perform the diagnosis continuously.
(A)
(B)
(C)
EN-01773
(A) Engine control module (ECM)

(B) Diagnosis circuit
(C) Crankshaft position sensor
When a misfire occurs, the engine speed will decreased and the crankshaft position speed will change. Calculate the interval difference value (diagnostic value) from crankshaft position speed by the following formula, and judge whether a misfire is occurring or not comparing the calculated result with judgment value.
Counting the number of misfires, if the misfire ratio is higher during 1000 rev. or 200 rev., Judge corresponding cylinders as NG.
Diagnostic value calculation Misfire detection every single ignition
(Calculate from angle
(Compare diagnostic value with
speed)
judgment value)
180 Interval Method
360 Interval Method
720 Interval Method
NG judgment (Misfire occurrence judgment

required by the law)
(Compare number of misfire with judgment)
FTP 1.5 times misfire NG judgment
Catalyst damage misfire NG judgment
GD(H4DOTC)-101

GENERAL DESCRIPTION
As shown in the following figure, pick a cylinder as the standard and name it omg 0. And the former crankshaft position speed is named omg 1, the second former crankshaft position speed is named omg 2, the third
is named omg 3, etc.
(A)
#3
(B)
#2
#4
#1
#3
#2
#4
#1
#3
omg7
omg6
omg5
omg4
omg3
omg2
omg1
omg0
#2
EN-01774
(A) Ignition order

(B) Crankshaft position speed

Diagnostic value domg 180 = (omg 1 omg 0) (omg 7 omg 1)/6
Judge as a misfire in the following cases.
domg 180 > judgment value of positive side
domg 180 judgment value of negative side
(Judgment value before 180CA)
domg180
(A)
domg180
(B)
(C)
EN-01775
(A) Threshold value (judgment value of the positive

side)
(B) Threshold value (judgment value of the negative side)
(C) Judged as a misfire
GD(H4DOTC)-102

GENERAL DESCRIPTION

Diagnostic value
Misfire judgment

domg360
(A)
domg360
(B)
EN-01776
(A) Threshold value

(B) Judged as a misfire

Diagnostic value
Misfire judgment
domg720
(A)
domg720
(B)
EN-01777
(A) Threshold value

(B) Judged as a misfire
GD(H4DOTC)-103

GENERAL DESCRIPTION
FTP 1.5 times misfire (Misfire occurrence level which influences exhaust gas)
Judgment Value (Judge that malfunction occurs when the misfire ratio is high in 1000 engine revs.)
Threshold Value
FTP emission diagnostic value
> 1.0 % in 1000 revs.

Catalyst damage misfire (Misfire occurrence level damaging catalyst)
Judgment Value (Judge that malfunction occurs when the misfire ratio is high in 200 engine revs.
(400 ignitions))
Threshold Value
Catalyst damage misfire judgment value
See Map 1
Map 1 Fault criteria threshold for misfire which would result in catalyst damage
AIR INTAKE (g/gev.)
ENGINE SPEED (rpm)
%
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
1000
37.0
32.0
28.5
26.0
23.0
21.3
1500
35.0
29.5
25.5
22.5
21.3
21.3
21.3
21.3
18.0
2000
32.0
22.5
22.5
18.3
14.5
10.8
10.0
9.0
8.0
5.0
2500
29.0
21.8
14.3
11.3
9.8
9.0
8.5
8.0
7.5
5.0
3000
27.0
21.8
14.5
3500
24.5
18.5
10.8
9.8
9.0
9.0
8.0
7.5
7.0
5.0
6.8
5.8
5.5
5.0
5.0
5.0
5.0
4000
15.3
10.0
6.8
5.5
5.0
5.0
5.0
5.0
5.0
4500
5000
13.8
8.5
6.3
5.0
5.0
5.0
5.0
5.0
13.8
8.5
5.8
5.0
5.0
5.0
5.0
5.0
5500
13.5
8.3
5.5
5.0
5.0
5.0
5.0
5.0
6000
13.0
8.0
5.3
5.0
5.0
5.0
5.0
5.0
6500
12.5
7.5
5.0
5.0
5.0
5.0
5.0
6700
12.3
7.3
5.0
5.0
5.0
5.0
5.0
EN-02282
These figures indicate the misfire rate (%) in 400 ignitions; for example, 22.5 (%) means 400 (ignition) 22.5
(%) = 90 (ignition) misfires. This value or more is judged as a misfire.


When a similar driving cycle is established 3 times in a row
GD(H4DOTC)-104

GENERAL DESCRIPTION
7. FAIL SAFE
None


NOTE:
For the diagnostic procedure, refer to DTC P0301. <Ref. to GD(H4DOTC)-100, DTC P0301 CYLINDER 1
MISFIRE DETECTED, Diagnostic Trouble Code (DTC) Detecting Criteria.>

NOTE:

NOTE:
GD(H4DOTC)-105

GENERAL DESCRIPTION
AW:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE

SENSOR)
(1)
(4)
(5)
(2)
(A)
(3)
EN-01707
(1) Case
(2) Weight
(A) To knock sensor harness
(3) Piezoelectric element

(4) Nut
(5) Resistance
3. ENABLE CONDITION
Enable Conditions
None

GD(H4DOTC)-106

GENERAL DESCRIPTION
Judgment Value
Output voltage
Ignition switch
Threshold Value
< 0.238 V
ON

Normality Judgment
Judgment Value
Output voltage
Ignition switch
Threshold Value
0.238 V
ON


8. FAIL SAFE
Knock compensation:
Knock compensation final advance/delay angle value = knock compensation value + whole learning compensation value + portional learning compensation value
Failure: Knock compensation value = 5CA. (5CA retard)

GD(H4DOTC)-107

GENERAL DESCRIPTION
AX:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE

SENSOR)
(1)
(4)
(5)
(2)
(A)
(3)
EN-01707
(1) Case
(2) Weight
(A) To knock sensor harness
(3) Piezoelectric element

(4) Nut
(5) Resistance
3. ENABLE CONDITION
Enable Conditions
None

GD(H4DOTC)-108

GENERAL DESCRIPTION
Judgment Value
Output voltage
Ignition switch
Threshold Value
4.714 V
ON

Normality Judgment
Judgment Value
Output voltage
Ignition switch
Threshold Value
< 4.714 V
ON


8. FAIL SAFE
Knock compensation:
Knock compensation final advance/delay angle value = knock compensation value + whole learning compensation value + portional learning compensation value
Failure: Knock compensation value = 5CA. (5CA retard)

GD(H4DOTC)-109

GENERAL DESCRIPTION
AY:DTC P0335 CRANKSHAFT POSITION SENSOR A CIRCUIT

Detect the open or short circuit of the crankshaft position sensor.
Judge as NG when the crank signal is not input even though the starter was turned on.
50 CA
50 CA
50 CA
50 CA
50 CA
(A)
50 CA
(B)
#3BTDC10 CA
#1BTDC10 CA
#2BTDC10 CA
#4BTDC10 CA
#1BTDC10 CA
(C)
10 C
30 C 30 C
EN-03269
(A) Camshaft signal (RH)

(B) Camshaft signal (LH)
(C) Crankshaft signal
(1)
(3)
(2)
EN-01780
(1) Crankshaft position sensor

(2) Crank sprocket
(3) Crankshaft half-turn
3. ENABLE CONDITION
Enable Conditions
None
GD(H4DOTC)-110

GENERAL DESCRIPTION

Judgment Value
Starter switch
Threshold Value
ON

Battery voltage
Not detected
8V

Normality Judgment
Judge as OK when the continuous time while meeting the malfunction criteria below is 3 seconds or more.
Judgment Value
Battery voltage
Threshold Value
Input exists
8V


8. FAIL SAFE
None

GD(H4DOTC)-111

GENERAL DESCRIPTION
AZ:DTC P0336 CRANKSHAFT POSITION SENSOR A CIRCUIT RANGE/

PERFORMANCE
Detect for faults in crankshaft position sensor output properties.
Judge as NG when there is a problem in the number of crankshaft signals for every revolution.
50 CA
50 CA
50 CA
50 CA
50 CA
(A)
50 CA
(B)
#3BTDC10 CA
#1BTDC10 CA
#2BTDC10 CA
#4BTDC10 CA
#1BTDC10 CA
(C)
Number of crankshaft signal = 30 is normal.

10 C
30 C 30 C
EN-03270

(1)
(3)
(2)
EN-01780
(1) Crankshaft position sensor

(2) Crank sprocket
(3) Crankshaft half-turn
GD(H4DOTC)-112

GENERAL DESCRIPTION
3. ENABLE CONDITION
Battery voltage
Engine speed
Enable Conditions
8V
< 3000 rpm

Perform the diagnosis continuously under 3000 rpm engine speed.
Judge as NG when all the malfunction criteria below are completed more than 10 times in a row.
Judgment Value
Threshold Value
Completed

Not = 30

Normality Judgment
Judgment Value
Cylinder number distinction
Threshold Value
Completed

= 30


8. FAIL SAFE
None

GD(H4DOTC)-113

GENERAL DESCRIPTION
BA:DTC P0340 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 1 OR

SINGLE SENSOR)
Detect the open or short circuit of the camshaft position sensor.
Judge as NG when the number of camshaft signals remains abnormal.

(D) Number of camshaft position signals = When
normal, there will be 3 cam signals for every 2
engine revolutions.
3. ENABLE CONDITION
Voltage
Enable Conditions
8V

GD(H4DOTC)-114

GENERAL DESCRIPTION
When normal, there should be 3 cam signals per 2 engine revolutions. If a condition where it is not 3 times
continues, It is judged as NG.
When the engine speed is over 100 rpm, if the following conditions are established it is judged as NG. Judge
as OK and clear the NG when the following criteria are not established.
Judgment Value
Number of camshaft sensor signals during 2 revs.
Threshold Value
Not = 3
Engine speed
600 rpm

Normality Judgment
Judge as OK and clear the NG when the following criteria are established.
Judgment Value
Threshold Value
Number of camshaft angle sensor signals during 2 revs. 3


8. FAIL SAFE
Ignition timing whole learning compensation:
Enter the initial value (whole learning compensation factor = 0.5, Variable amount of whole learning
compensation factor = 0.25) to the whole learning compensation factor and variable amount of whole
learning compensation factor when IG OFF, and then make the whole learning incomplete.
learning compensation factor when making a normality judgment from abnormality judgment, and then
make the whole learning incomplete.
Ignition timing partial learning compensation:
Enter the initial value (0CA) to the compensation value of partial learning zone with IG OFF.
Enter the initial value (0CA) to the compensation value of the partial learning zone when making a normality judgment abnormality judgment.
AVCS control:
Maximum timing retard learning is not complete or maximum timing retard learning completion is not experienced.
ISC feedback compensation: Do not perform the AVCS actual timing advance compensation.
Make the OCV driving Duty to be the given value (9.36%).

BB:DTC P0345 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 2)

NOTE:
For diagnostic procedure, refer to DTC P0340. <Ref. to GD(H4DOTC)-114, DTC P0340 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Trouble Code (DTC) Detecting
Criteria.>
GD(H4DOTC)-115

GENERAL DESCRIPTION
BC:DTC P0410 SECONDARY AIR INJECTION SYSTEM

Detect NG of the secondary air supply pipe pressure, secondary air supply pipe pressure pulse, and secondary air piping flow.
2. ENABLE CONDITION
Enable Conditions
4.4C (39.92F)
Battery voltage
Atmosphere pressure
7V
563 mmHg
Engine
In operation
Pump supply pressure check

2 g (0.07 oz)/sec.
Secondary air pump

Combination valve
Pulse check with one combination valve

closed
Diagnosable range
In operation
One bank is open.
(Except when both
banks are open.)
1 (Refer to Map10)
After fuel cut

Pulse check with both combination
valves closed
Engine load
500 milliseconds
After fuel cut

Pressure check when switching combination valve
500 milliseconds
0.2 g (0.007 oz)/rev
2 g (0.07 oz)/sec.
and
20 g (0.7 oz)/sec.
Engine speed
After fuel cut
< 4000 rpm

500 milliseconds

Perform diagnosis while secondary pump is operating
GD(H4DOTC)-116

GENERAL DESCRIPTION
Measure secondary air supply pipe pressure, secondary air supply pipe pressure pulse, and secondary air
piping flow.
Perform the functional diagnosis of the system by checking the increased pressure value when the secondary air pump is ON in relation to the pressure value when the pump is OFF.
Pulse check with one combination valve closed
When the right combination valve is closed, perform diagnosis of the left combination valve for stuck closed
by supply piping pressure pulse.
When the left combination valve is closed, perform diagnosis of the right combination valve for stuck closed
by supply piping pressure pulse.
Pulse check with both combination valves closed
When both left and right combination valves are closed, perform the diagnosis of both left and right combination valves for stuck opened by supply pipe pressure pulse. Determine which valve is stuck opened by
comparing secondary air flow rate with right combination valve closed and secondary air flow rate with left
combination valve closed.
When the right combination valve is switched from closed position to open position, perform the diagnosis of
the right combination valve for the stuck closed by change of the supply pipe pressure.
When the left combination valve is switched from open position to closed position, perform the diagnosis of
the left combination valve for the stuck closed by change of the supply pipe pressure.
Check for excessive air flow
Perform the diagnosis of the secondary air system for air flow error by the secondary air flow rate with the
right combination valve closed and secondary air flow rate with the left combination valve closed.
GD(H4DOTC)-117

GENERAL DESCRIPTION
(14)
(1)
(15)
(2)
(14)
(3)
(15)
(16)
(4)
(17)
(16)
(17)
(17)
(16)
(5)
(16)
(17)
(17)
(17)
PORL
POR
(6)
POL
Pas
(7)
(8)
(9)
(10)
(11)
(12)
(13)
EN-05053
(1)
IG
(2)
(3)
Ne
Secondary air pump drive condition
(4)
E-COMB valve (Right) condition
(5)
(6)
E-COMB valve (Left) condition

Secondary air supply piping pressure (psi)
(7)
Diagnosis execution conditions
(8)
Atmospheric pressure before secondary air control (Pas) measurement
(12)

(judgment)
(13)
Flow amount check (judgment)
(9)
Right bank shut off pressure

(POR) measurement
(14)
(15)
ON
OFF
(10)
Both bank shut off pressure

(PORL) measurement
(16)
(17)
Open
Close
(11)
Left bank shut off pressure (POL)

measurement
GD(H4DOTC)-118

GENERAL DESCRIPTION
Judgment Value
When the secondary air pump is switched from OFF to ON, the pump supply pressure should increase.
Judge as NG when the pressure does not increase.
If the following conditions are met, judge as NG. If the following conditions are not met, judge as OK, and
clear the NG.
Malfunction
Criteria
Secondary air supply pipe pressure
(after atmospheric pressure compensation)
Threshold
Value
< 1 kPa (7 mmHg, 0.3 inHg)
DTC
P0410
Pulse check with one combination valve closed

Calculate the voltage pulse of the pump supply piping pressure when the right combination valve is closed
and left combination valve is open. The integrated value should be large because the left combination valve
is open and there are pulses of the pump supply piping pressure. If the value is small, diagnose the left combination valve as stuck closed.
clear the NG.
Malfunction
Criteria
Integrated value of pulse when the right
combination valve is closed
Threshold
Value
< Value of Map 1
DTC
P2443
Calculate the voltage pulse of the pump supply piping pressure when the left combination valve is closed and
right combination valve is open. The integrated value should be large because the right combination valve is
open and there are pulses of the pump supply piping pressure. If the value is small, diagnose the right combination valve as stuck closed.
clear the NG.
Malfunction
Criteria
Integrated value of pulse when the left
combination valve is closed
Threshold
Value
< Value of Map 2
DTC
P2441
Pulse check with both combination valves closed

Calculate the voltage pulse of the pump supply piping pressure when both left and right combination valves
are closed. The integrated value should be small because both combination valves are closed and there are
no pulse of supply piping pressure. If the integrated value is large, diagnose either of left of right combination
valves as stuck open.
Determine which valve is stuck opened by comparing secondary air flow rate with right combination valve
closed and secondary air flow rate with left combination valve closed. The flow rate of combination valve that
is stuck open will be high.
clear the NG.
Malfunction
Criteria
Threshold
Value
Integrated value of pulse when both left

and right combination valves are closed
> Value of Map 3
Flow rate when the right bank is closed

(value of Map 4)
Flow rate when the left bank

is closed (value of Map 5)
Integrated value of pulse when both left

and right combination valves are closed
Flow rate when the left bank is closed
(value of Map 5)
> Map 3
DTC
P2440
P2442
> Flow rate when the right bank

is closed (value of Map 4)
GD(H4DOTC)-119

GENERAL DESCRIPTION

When the left combination valve is switched from open position to closed position, the supply pipe pressure
should change. If the value change little, diagnose the left combination valve as stuck closed.
clear the NG.
Malfunction
Criteria
Changed value when the left combination valve is switched
Threshold
Value
< Value of Map 6
DTC
P2443
When the right combination valve is switched from closed position to open position, the supply pipe pressure
should change. If the value change little, diagnose the right combination valve as stuck closed.
clear the NG.
Malfunction
Criteria
Changed value when the right combination valve is switched
Threshold
Value
< Value of Map 7
DTC
P2441
Check for excessive air flow

If the secondary air flow rate when the right combination valve is closed, or the secondary air flow rate when
the left combination valve is closed becomes too large, diagnose as secondary air system air flow error.
Malfunction
Criteria
Flow rate when the right bank is closed
(value of Map 4)
or
Flow rate when the left bank is closed
(value of Map 4)
Threshold
Value
> Map 8
DTC
P0411
> Map 9
Voltage when PORL is measured voltage when POR is measured
4V
Voltage when PORL is measured voltage when POL is measured
4V
PORL: Both bank shut off pressure

POR: Right bank shut off pressure
POL: Left bank shut off pressure
GD(H4DOTC)-120

GENERAL DESCRIPTION
Map 1
Engine speed (rpm)
Amount of intake air (g (oz)/s)
1000
1500
2000
2100
4000
15 (0.53)
20 (0.71)
2
2
2
2
2
2
1.04
1.04
1.04
1.04
25 (0.88)
30 (1.06)
2
1.04
2
2
2
1.6
1.04
1.04
1.04
1.04
35 (1.23)
1.04
1.8
1.3
1.04
1.04
(V)
1000
1500
2000
2100
4000
Map 2
Engine speed (rpm)
15 (0.53)
1.04
1.04
20 (0.71)
25 (0.88)
2
2
2
2
2
2
1.04
1.04
1.04
1.04
30 (1.06)
35 (1.23)
1.04
1.04
1.04
1.04
1.04
1.04
1.04
1.04
1.04
1.04
(V)
Map 3
Intake air (g (oz)/rev)
Threshold value (V)
0.1
(0.004
)
0.3
(0.011
)
0.35
(0.012
)
1
(0.04)
12
12
GD(H4DOTC)-121

GENERAL DESCRIPTION
Map 4
Secondary
air pressure
in the pipe
when both
comb. valve
is closing
kPa (mmHg,
inHg)
Secondary
air pressure
in the pipe
when LH
comb. valve
is closing
kPa (mmHg,
inHg)
69.3
(520, 20.47)
74.7
(560, 22.06)
69.3 74.7 80.0 85.3 90.7 96.0 101.3 106.7 112.0 117.3 122.7 128.0 133.3 138.7 144.0 149.3
(520, (560, (600, (640, (680, (720, (760, (800, (840, (880, (920, (960, (1000, (1040, (1080, (1120,
20.47) 22.06) 23.63) 25.19) 26.79) 28.35) 29.92) 31.51) 33.08) 34.64) 36.24) 37.80) 39.37) 40.96) 42.53) 44.09)
200
400
600
800
1000
1200
1400
1600
1800
2000
2200
2400
2400
2400
2400
200
200
400
600
800
1000
1200
1400
1600
1800
2000
2200
2400
2400
2400
80.0
400
(600, 23.63)
200
200
400
600
800
1000
1200
1400
1600
1800
2000
2200
2400
2400
85.3
600
(640, 25.19)
400
200
200
400
600
800
1000
1200
1400
1600
1800
2000
2200
2400
90.7
(680, 26.79)
96.0
(720, 28.35)
101.3
(760, 29.92)
106.7
(800, 31.51)
600
400
200
200
400
600
800
1000
1200
1400
1600
1800
2000
2200
1000 800
600
400
200
200
400
600
800
1000
1200
1400
1600
1800
2000
1200 1000 800
600
400
200
200
400
600
800
1000
1200
1400
1600
1800
1400 1200 1000 800
600
400
200
200
400
600
800
1000
1200
1400
1600
112.0
1600 1400 1200 1000 800
(840, 33.08)
600
400
200
200
400
600
800
1000
1200
1400
117.3
1800 1600 1400 1200 1000 800
(880, 34.64)
600
400
200
200
400
600
800
1000
1200
2000 1800 1600 1400 1200 1000 800
600
400
200
200
400
600
800
1000
2200 2000 1800 1600 1400 1200 1000 800
600
400
200
200
400
600
800
2400 2200 2000 1800 1600 1400 1200 1000 800
600
400
200
200
400
600
2400 2400 2200 2000 1800 1600 1400 1200 1000 800
600
400
200
200
400
144.0
(1080,
42.53)
2400 2400 2400 2200 2000 1800 1600 1400 1200 1000 800
600
400
200
200
149.3
(1120,
44.09)
2400 2400 2400 2400 2200 2000 1800 1600 1400 1200 1000 800
600
400
200
122.7
(920, 36.24)
128.0
(960, 37.80)
133.3
(1000,
39.37)
138.7
(1040,
40.96)
800
(L/min)
GD(H4DOTC)-122

GENERAL DESCRIPTION
Map 5
Secondary
air pressure
in the pipe
when both
comb. valve
is closing
kPa (mmHg,
inHg)
Secondary
air pressure
in the pipe
when RH
comb. valve
is closing
kPa (mmHg,
inHg)
69.3
(520, 20.47)
74.7
(560, 22.06)
69.3 74.7 80.0 85.3 90.7 96.0 101.3 106.7 112.0 117.3 122.7 128.0 133.3 138.7 144.0 149.3
(520, (560, (600, (640, (680, (720, (760, (800, (840, (880, (920, (960, (1000, (1040, (1080, (1120,
20.47) 22.06) 23.63) 25.19) 26.79) 28.35) 29.92) 31.51) 33.08) 34.64) 36.24) 37.80) 39.37) 40.96) 42.53) 44.09)
200
400
600
800
1000
1200
1400
1600
1800
2000
2200
2400
2400
2400
2400
200
200
400
600
800
1000
1200
1400
1600
1800
2000
2200
2400
2400
2400
80.0
400
(600, 23.63)
200
200
400
600
800
1000
1200
1400
1600
1800
2000
2200
2400
2400
85.3
600
(640, 25.19)
400
200
200
400
600
800
1000
1200
1400
1600
1800
2000
2200
2400
90.7
(680, 26.79)
96.0
(720, 28.35)
101.3
(760, 29.92)
106.7
(800, 31.51)
600
400
200
200
400
600
800
1000
1200
1400
1600
1800
2000
2200
1000 800
600
400
200
200
400
600
800
1000
1200
1400
1600
1800
2000
1200 1000 800
600
400
200
200
400
600
800
1000
1200
1400
1600
1800
1400 1200 1000 800
600
400
200
200
400
600
800
1000
1200
1400
1600
112.0
1600 1400 1200 1000 800
(840, 33.08)
600
400
200
200
400
600
800
1000
1200
1400
117.3
1800 1600 1400 1200 1000 800
(880, 34.64)
600
400
200
200
400
600
800
1000
1200
2000 1800 1600 1400 1200 1000 800
600
400
200
200
400
600
800
1000
2200 2000 1800 1600 1400 1200 1000 800
600
400
200
200
400
600
800
2400 2200 2000 1800 1600 1400 1200 1000 800
600
400
200
200
400
600
2400 2400 2200 2000 1800 1600 1400 1200 1000 800
600
400
200
200
400
144.0
(1080,
42.53)
2400 2400 2400 2200 2000 1800 1600 1400 1200 1000 800
600
400
200
200
149.3
(1120,
44.09)
2400 2400 2400 2400 2200 2000 1800 1600 1400 1200 1000 800
600
400
200
122.7
(920, 36.24)
128.0
(960, 37.80)
133.3
(1000,
39.37)
138.7
(1040,
40.96)
800
(L/min)
GD(H4DOTC)-123

GENERAL DESCRIPTION
Map 6
Amount of intake air when LH comb.
valve switches (g (oz)/s)
Battery voltage when LH comb. valve
switches (V)
11
10
(0.35)
12.5
(0.441)
15
(0.53)
17.5
(0.617)
20
(0.71)
0.05
0.05
0.04
0.03
0.03
12
13
0.05
0.05
0.05
0.05
0.05
0.05
0.05
0.05
0.04
0.05
14
0.05
0.05
0.05
0.05
0.05
(V)
10
(0.35)
12.5
(0.441)
15
(0.53)
17.5
(0.617)
20
(0.71)
11
12
0.05
0.05
0.05
0.05
0.04
0.05
0.03
0.05
0.03
0.04
13
14
0.05
0.05
0.05
0.05
0.05
0.05
0.05
0.05
0.05
0.05
Map 7
Amount of intake air when RH comb.
valve switches (g (oz)/s)
Battery voltage when RH comb. valve
switches (V)
(V)
Map 8
Amount of intake air when POR is measuring (g (oz)/s)
Battery voltage when POR measuring
(V)
2
(0.07)
4
(0.14)
6
(0.21)
8
(0.28)
10
(0.35)
12
(0.42)
14
(0.49)
16
(0.56)
18
(0.63)
10.5
11.5
290
330
290
330
290
330
290
330
290
330
290
330
290
330
290
330
290
330
12.5
13.5
370
420
370
420
370
420
370
420
370
420
370
420
370
420
370
420
370
420
14.5
15.5
470
520
470
520
470
520
470
520
470
520
470
520
470
520
470
520
470
520
(L/min)
Map 9
Amount of intake air when POL is measuring (g (oz)/s)
Battery voltage when POL measuring
(V)
10.5
2
(0.07)
4
(0.14)
6
(0.21)
8
(0.28)
10
(0.35)
12
(0.42)
14
(0.49)
16
(0.56)
18
(0.63)
290
290
290
290
290
290
290
290
290
11.5
12.5
330
370
330
370
330
370
330
370
330
370
330
370
330
370
330
370
330
370
13.5
14.5
420
470
420
470
420
470
420
470
420
470
420
470
420
470
420
470
420
470
15.5
520
520
520
520
520
520
520
520
520
(L/min)
GD(H4DOTC)-124

GENERAL DESCRIPTION
Map 10
Engine speed (rpm)
10
(0.35)
15
(0.53)
35
(1.23)
50
(1.76)
500
1000
0
0
1
1
1
1
0
0
4000
5000
0
0
1
0
1
0
0
0



7. FAIL SAFE
None

BD:DTC P0411 SECONDARY AIR INJECTION SYSTEM INCORRECT FLOW DETECTED

NOTE:
For the diagnostic procedure, refer to DTC P0410. <Ref. to GD(H4DOTC)-116, DTC P0410 SECONDARY
AIR INJECTION SYSTEM, Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4DOTC)-125

GENERAL DESCRIPTION
BE:DTC P0413 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE A

CIRCUIT OPEN
2. ENABLE CONDITION
Enable Conditions
None

When the continuous time with following conditions being established exceeds 2.5 seconds, it is judged as
NG.
Judgment Value
Battery voltage
Threshold Value
10.9 V
Ignition
ON
Low

Normality Judgment
Judge as OK when the following conditions are established, and clear the NG.
Judgment Value
Battery voltage
Threshold Value
10.9 V
Ignition
ON
High


7. FAIL SAFE
None

GD(H4DOTC)-126

GENERAL DESCRIPTION
BF:DTC P0414 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE A

CIRCUIT SHORTED
2. ENABLE CONDITION
Enable Conditions
None

NG.
Judgment Value
Battery voltage
Threshold Value
10.9 V
Ignition
ON
High

Normality Judgment
Judgment Value
Battery voltage
Threshold Value
10.9 V
Ignition
ON
Low


7. FAIL SAFE
None

GD(H4DOTC)-127

GENERAL DESCRIPTION
BG:DTC P0416 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE B

CIRCUIT OPEN
NOTE:
AIR INJECTION SYSTEM SWITCHING VALVE A CIRCUIT OPEN, Diagnostic Trouble Code (DTC) Detecting Criteria.>
BH:DTC P0417 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE B

CIRCUIT SHORTED
NOTE:
AIR INJECTION SYSTEM SWITCHING VALVE A CIRCUIT SHORTED, Diagnostic Trouble Code (DTC)
GD(H4DOTC)-128

GENERAL DESCRIPTION
BI: DTC P0418 SECONDARY AIR INJECTION SYSTEM CONTROL A CIRCUIT

OPEN
2. ENABLE CONDITION
Enable Conditions
None

NG.
Judgment Value
Battery voltage
Threshold Value
10.9 V
Ignition
ON
Low

Normality Judgment
Judgment Value
Battery voltage
Threshold Value
10.9 V
Ignition
ON
High


7. FAIL SAFE
None

GD(H4DOTC)-129

GENERAL DESCRIPTION
BJ:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1)

Detect the deterioration of the catalyst function.
Though the rear oxygen sensor output would change slowly with a new catalyst, the sensor output with a deteriorated catalyst becomes high and the inversion time is shortened.
For this reason, the catalyst diagnosis is carried out by monitoring the rear oxygen sensor output and comparing it with the front oxygen A/F sensor output.
(1)
(2)
(A)
(3)
(B)
(3)
(C)
(D)
EN-01713
(1) Front oxygen (A/F) sensor
(A) Normal
(2) Rear oxygen sensor

(3) Catalytic converter
(B) Deterioration
(C) Output waveform from the front oxygen (A/F)
sensor
(D) Output waveform from the front oxygen sensor
3. ENABLE CONDITION
Enable Conditions
Battery voltage
> 10.9 V
Atmosphere pressure
> 75.0 kPa (563 mmHg, 22.2 inHg)

70C (158F)

< 5 times
< 0.20
Sub feedback
Evaporative system diagnosis
In operation
Not in operation
Time of difference (< 0.10) between actual and target lambda

Vehicle speed
1000 milliseconds or more

70 km/h (47 MPH)

Engine load change every 0.5 engine revs.
12 40 g/s
< 0.02 g/rev
Rear oxygen output change from lower than to higher than 600 mV
Experienced after fuel cut

235 sec.
Accumulative time of canister purge operation after engine starting

Estimated catalyst layer temperature
19.9 sec.
580C (1076F)
GD(H4DOTC)-130

GENERAL DESCRIPTION

After warm-up, perform the diagnosis only once at a constant 75 km/h (47 MPH).
After the execution criterias are established, calculate the output fluctuation value of front oxygen (A/F) sensor and output fluctuation value of rear oxygen sensor. Calculate the diagnosis value when the front oxygen
(A/F) sensor output fluctuation value is more than specified value. A/F response properties and diagnosis
values are parameters for the judgment value.
Judge as NG when the malfunction criteria below are met. Judge as OK if the criteria below are not met.
Judgment Value
Accumulated variation of rear oxygen
sensor output voltage per 32 milliseconds divided by lambda accumulated
variation of the front oxygen (A/F) sensor
per 32 milliseconds
Threshold Value
12.6
Time Needed for Diagnosis: 33 55 seconds



8. FAIL SAFE
None

BK:DTC P0441 EVAPORATIVE EMISSION SYSTEM INCORRECT PURGE FLOW

NOTE:
For the diagnostic procedure, refer to DTC P0442. <Ref. to GD(H4DOTC)-132, DTC P0442 EVAPORATIVE
EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4DOTC)-131

GENERAL DESCRIPTION

(SMALL LEAK)
Check if there is a leakage in fuel system or not, and perform the function diagnosis of valve.
:A
:B
(3)
(1)
(4)
(2)
(5)
(24)
(6)
(23)
(22)
(7)
(21)
(13)
(9)
(8)
(12)
(20)
(19)
(18) (17)(16) (15) (14)
(11)
(10)
EN-04899
(2) Purge control solenoid valve 2


(16) Fuel pump
(4) Throttle body

(5) Fuel filter
(17) Jet pump

(18) Fuel cut valve
(6) Intake manifold


(20) Fuel tank
(8) Canister

(22) Fuel gauge
(10) Drain valve

(11) Drain filter
(12) Shut-off valve
(13) Vent valve

(24) Fuel injector
(A) Fuel line
In this system diagnosis, check for leakage and valve function is conducted by changing the fuel tank pressure and monitoring the pressure change using the fuel tank pressure sensor. When in 0.04 inch diagnosis,
perform in the order of mode Z mode A mode B mode C and mode D; When in 0.02 inch diagnosis,
perform in the order of mode A mode B mode C mode D and mode E.
GD(H4DOTC)-132

GENERAL DESCRIPTION
0.04-INCH DIAGNOSIS
Mode
Z
OK
Mode
A
OK
Mode
B
OK
Mode
C
OK
Mode
D
OK
NG
Early OK
CPC2
clogging
diagnosis
Large leakage judgement
NG
END
Cancel
NG
Mode
Z
Extend
NG
OK
EN-04900
Mode
Mode Z
(Purge control solenoid valve opening failure
diagnosis)
Mode A
(Estimated evaporation amount)
Mode Description
Diagnosis Period
Perform purge control solenoid valve opening failure diagnosis

from the size of tank pressure variation from diagnosis start.
3 16 seconds
Calculate the tank pressure change amount (P1).
10 seconds
Mode B
(Sealed negative pressure, large leakage
judgment)
If the tank pressure cannot be reduced, it is diagnosed as
large leak.
5 25 seconds
Mode C
(Pressure increase check, advanced OK
judgment)
P2 calculation). If the tank pressure does not become the
value, make advanced OK judgment.
1 15 seconds
Mode D
(Negative pressure variation measurement,
evaporation leakage diagnosis)
Calculate the tank pressure variation (P2), and obtain the

diagnostic value using P1 found in Mode A.
Perform the evaporation diagnosis using the diagnostic value.
10 seconds
Blockage diagnosis of purge control

solenoid 2
Depending on the amount of change in tank inner pressure

during and after mode C end, perform blockage diagnosis of
purge control solenoid 2.
GD(H4DOTC)-133
3 seconds

GENERAL DESCRIPTION
Mode Table for Evaporative Emission Control System Diagnosis

Tank internal pressure under normal conditions
Mode
Diagnostic item
DTC
Roughly the same as atmospheric

Purge control solenoid valve is judged to
pressure (Same as 0 kPa (0 mmHg, 0 inHg)) be open.
Mode Z
Pressure is in proportion to amount of evaporative emission.

Negative pressure is formed due to intake
Large leak
manifold negative pressure.
Reaches target pressure
Mode A
Mode B
Mode C
Mode D
P0457
None
EVAP system large leak determination.

[1.0 mm (0.04 in)]
Pressure change is small.
P0457
P0442
0.02-inch Diagnosis
Mode A
OK
Mode B
OK
Mode C
OK
OK
Mode D
Mode E
Cancel
Early OK 2
Cancel
END
Early OK 1
Cancel
Cancel
Cancel
EN-02871
Mode
Mode A
(0 point compensation)
Mode B
(Negative pressure introduced)
Mode Description
When the pressure in the tank is high, wait until it returns to 0
point (Near 0 mmHg).
Decrease the pressure in the tank to the target value by
introducing the intake manifold pressure to the fuel tank.
Mode C
(Negative pressure maintained)
P2 calculation).
0 20 seconds
Mode D
(Negative pressure change calculated)
Calculate the time it takes for the tank pressure to return to the
P2 calculation complete pressure. If the tank pressure does
not return to the P2 calculation complete pressure, make
advanced OK judgment.
0 200 seconds
Calculate the amount of evaporation (P1).
0 280 seconds
Mode E
(Evaporation generated amount calculated)
GD(H4DOTC)-134
Diagnosis Period
0 12 seconds
0 27 seconds

GENERAL DESCRIPTION
PCV controls the fuel tank pressure to be equal to the atmospheric air pressure. Normally, the solenoid is set
to OFF. And the valve opens and closes mechanically in accordance with the pressure difference between
tank and atmospheric air, or tank and canister.
The valve is forcibly opened by setting the solenoid to ON at the time of diagnosis.
(a)
(1)
(4)
(b)
(c)
(3)
(2)
EN-01715
(1)
(2)
Solenoid
Diaphragm
(3)
(4)
Valve
Spring
GD(H4DOTC)-135
(a)
(b)
Atmosphere pressure
Fuel tank
(c)
Canister

GENERAL DESCRIPTION
Valve Operation and Air Flow

In the figure below, divided by the diaphragm, the part above X is charged with atmospheric air pressure, and
the part below X is charged with tank pressure. Also, the part above Y is charged with tank pressure, and the
part below Y is charged with canister pressure.
If the atmospheric air pressure port is A, tank pressure port is B, and canister pressure port is C, the air flows
according to pressure difference from each port as shown in the table below.
A
(a)
(b)
(c)
EN-01716
(a)
Atmosphere pressure
(b)
Fuel tank
Condition of pressure
Flow
A < B (solenoid OFF)

B < C (solenoid OFF)
BC
CB
Solenoid ON
B C
(c)
Canister
When A < B (Solenoid OFF)
A
(a)
(b)
(c)
EN-01717
(a)
Atmosphere pressure
(b)
Fuel tank
GD(H4DOTC)-136
(c)
Canister

GENERAL DESCRIPTION
When B < C (Solenoid OFF)
A
(a)
C
(c)
(b)
(1)
EN-01718
(1)
Valve
(a)
Atmosphere pressure
(b)
(c)
Fuel tank
Canister
When Solenoid is ON
A
(a)
C
(c)
(b)
EN-01719
(a)
Atmosphere pressure
(b)
Fuel tank
GD(H4DOTC)-137
(c)
Canister

GENERAL DESCRIPTION
Drain valve
Drain valve controls the ambient air to be introduced to the canister.
EN-02293
3. ENABLE CONDITION
0.04-inch Diagnosis
Enable Conditions
Battery voltage
Barometric pressure
10.9 V
75.0 kPa (563 mmHg, 22.2 inHg)

120 seconds or more

856 seconds or more

Engine speed
0.04
1050 6500 rpm
Fuel tank pressure

1.4 kPa (10.7 mmHg, 0.42 inHg)

< 13.3 kPa (100 mmHg, 3.94 inHg)
Vehicle speed
Fuel level
32 km/h (19.9 MPH)

9 51 2
(2.38 13.47 US gal, 1.98 11.22 Imp gal)

Fuel temperature
In operation
10 45C (14 113F)

Pressure change per second
10C (14F)
< 0.23 kPa (1.7 mmHg, 0.07 inHg)
Minimum pressure change value every one sec- < 0.23 kPa (1.7 mmHg, 0.07 inHg)
ond Maximum pressure change value every
one second
Air fuel ratio
< 2.5 2/128 milliseconds

(0.66 US gal/128 milliseconds, 0.55 Imp gal/128 milliseconds)
0.76 1.25
GD(H4DOTC)-138

GENERAL DESCRIPTION
0.02-inch Diagnosis
(At starting a diagnosis)
Enable Condition
Evap. diagnosis
Battery voltage
Incomplete
10.9 V
Atmosphere pressure
Time since last incomplete diagnosis event of
0.02-inch leakage
When cancelling in mode A
75.0 kPa (563 mmHg, 22.2 inHg)
> 120 seconds
When cancelling in other than mode A

> 600 seconds

120 seconds or more

Fuel temperature
770 seconds or more

10 70C (14 158F)
Fuel level
9 51 2
(2.38 13.47 US gal, 1.98 11.22 Imp gal)
< 13.3 kPa (100 mmHg, 3.93 inHg)

Fuel tank pressure
0.67 1.43 kPa

(5 10.7 mmHg, 0.20 0.42 inHg)
Vehicle speed
68 km/h (42 MPH)

In operation
Engine speed
(During diagnosis)
550 6000 rpm

Pressure change every one second
Value from Map

< 0.06 kPa (0.44 mmHg, 0.02 inHg)
Minimum pressure change value every one sec- < 0.07 kPa (0.51 mmHg, 0.02 inHg)
ond Maximum pressure change value every
one second
| Pressure change in tank every second |
Atmospheric pressure change (Mode D)
Atmospheric pressure change (Mode E)
0.1 kPa (0.75 mmHg, 0.03 inHg)

0.47 0.32 kPa (3.5 2.4 mmHg, 0.14 0.09
inHg)
0.32 0.32 kPa (2.4 2.4 mmHg, 0.09 0.09
inHg)
Map
Fuel level (2, US gal, Imp gal)
10, 2.64,
2.2
20, 5.28,
4.4
30, 7.93,
6.6
40, 10.57,
8.8
50, 13.21,
11
60, 15.85,
13.2
Change (2, US gal, Imp gal)
4.2, 1.11,
0.92
4.2, 1.11,
0.92
4.1, 1.08,
0.9
4.0, 1.06,
0.88
3.9, 1.03,
0.86
3.8, 1.0,
0.84
3.8, 1.0,
0.84

0.04-inch Diagnosis
Perform the diagnosis only once in 856 seconds or more after starting the engine, at a constant speed of
32 km/h (19.9 MPH) or more.
Pay attention to the fuel temperature and fuel level.
0.02-inch Diagnosis
Perform the diagnosis after 770 seconds or more after starting the engine, at a constant engine speed of
68 km/h (42 MPH) or higher, to judge as NG or OK.
If judgment cannot be made, repeat the diagnosis.
Be careful of the remaining fuel level.
GD(H4DOTC)-139

GENERAL DESCRIPTION
Purge control solenoid valve stuck open fault diagnosis
DTC
Purpose of Mode Z
When performing the leakage diagnosis of EVAP system, the purge control solenoid valve must operate normally. Therefore, mode Z is used to diagnose the purge control solenoid valve stuck open condition. Note
that if a purge control solenoid valve stuck open fault is detected, the EVAP system leakage diagnosis is cancelled.
Diagnostic Method
Purge control solenoid valve functional diagnosis is performed by monitoring the tank pressure in mode Z.
Normality Judgment
Judge OK and change to Mode A when the criteria below are completed in 3 seconds after Mode Z started.
Judgment Value
Threshold Value
0.4 kPa (3 mmHg,
0.12 inHg)
DTC
P0457
Normal
(1)
(2)
evptez
evptezha
evptezini
(3)
0
(4)
(5)
EN-02869
(1)
Mode Z
(3)
Fuel tank pressure
(2)
3 seconds
(4)
0.4 kPa (3.0 mmHg, 0.12 inHg)

Judge as normal when both calculations are established.
GD(H4DOTC)-140
(5)
OK judgment

GENERAL DESCRIPTION
If OK judgment cannot be made, extend Mode Z 16 seconds more, and judge as NG when all the criteria below are completed after 16 seconds.
Judgment Value
Threshold Value
> 0.6 kPa (4.5 mmHg,
0.18 inHg)
Tank pressure when Mode Z started
1.43 kPa (10.7 mmHg,

0.42 inHg)
2 2 or more fuel must remain in a static

(not sloshing) condition for more than:
40 sec.
DTC
P0457

When judgment for purge control solenoid valve stuck open NG is made, end the evaporative diagnosis.
Cancel the evaporative diagnosis when the OK/NG judgment for purge control solenoid valve stuck open
cannot be made in Mode Z.
GD(H4DOTC)-141

GENERAL DESCRIPTION
Purge Control Solenoid Valve Open Fixation
(1)
(2)
(3)
(6)
evptez
evptezini
(4)
0
(5)
evptezha
(7)
(8)
EN-02870
(1)
(2)
Mode Z
Extended mode Z
(4)
(5)
Fuel tank pressure

0.87 kPa (6.5 mmHg, 0.26 inHg)
(3)
16 seconds
(6)
1.43 kPa (10.7 mmHg, 0.42 inHg)
(7)
(8)
No fuel sloshing for 40 seconds

NG judgment
evptezini, evptez 1.43 kPa (10.7 mmHg, 0.42 inHg)

No fuel sloshing of over 2 2 (0.53 US gal, 0.44 Imp gal) for 40 seconds or more.
Judge as normal when all are established.
Leak Diagnosis
DTC
P0442 CPC Solenoid Function (Blocked)
P0442 Evaporative Emission Control System Leak Detected (Small Leak)
GD(H4DOTC)-142

GENERAL DESCRIPTION
Diagnostic method
Mode A: (Estimated evaporation gas amount)
Calculate the tank pressure change amount (P1) when using mode A. After calculating P1, switch to mode B.
Mode B: (Negative pressure sealed)
Approximately 0 1.4 kPa (0 10.5 mmHg, 0 0.41 inHg)
In this case, if the tank pressure does not reach the target negative pressure, judge that there is a large leakage (10 seconds or 25 seconds) in the system and terminate the evaporative emission control system diagnosis.
Judge as NG (large leak) when the criteria below are met.
Judgment Value
Threshold Value
Time to reach target negative pressure

Or mode B time
25 sec.
10 sec.
DTC
P0457
(Min. pressure value in tank when in mode > 0.5 kPa

B) (Tank pressure when mode B started) (4 mmHg, 0.16 inHg)
Mode C: (Check pressure rise)

Change to Mode D when the tank pressure returns to the start level of P2 calculation.
Judge immediate OK and perform the blockage diagnosis of purge control solenoid 2 when it does not return
in spite of spending the specified time.
Tank pressure when starting
calculation of P2
1.3 kPa
(9.75 mmHg, 0.38 inHg)
Time for advanced OK

judgment
15 seconds
Mode D: (Measure amount of negative pressure change)

Monitor the tank pressure change amount when using mode D. In this case, the tank pressure increases
(nears atmospheric pressure), because evaporation occurs. However, if any leakage exists, the pressure increases additionally in proportion to this leakage. The pressure variation of this tank is P2.
After calculating P2, perform a small leak diagnosis according to the items below.
When Mode D is ended
Assign tank variations measured in Mode A and Mode D; P1 and P2, to the formula below, judge small leaks
in the system. If the measured judgment value exceeds the threshold value, it is judged to be a malfunction.
Purge control solenoid valve 2 blockage diagnosis
Perform the purge control solenoid valve 2 blockage diagnosis according to the gap value of tank pressure
from the end of mode C to afterwards.
Tank pressure change after mode C
completion.
Threshold Value
DTC
3 seconds
< 0.115 kPa (0.86 mmHg, 0.034 inHg)
P0441
GD(H4DOTC)-143

GENERAL DESCRIPTION
Judge as NG when the criteria below are met and judge as OK and clear NG when not met.
Judgment Value
P2 1.5 P1
Threshold Value
> Value from Map 7
P2: Tank pressure that changes every

16 seconds in mode D
P1: Tank pressure that changes every
16 seconds in mode A
* Threshold value:
Map (Remaining Fuel
vs Tank temperature)
DTC
P0442
* 1.5: Evaporation amount compensation value when below negative pressure (Amount of evaporation occurrence increases as
a vacuum condition increases.)

Fuel temperature vs Fuel level
5C (41F)
15C (59F)
25C (77F)
35C (95F)
45C (113F)
0.49 kPa
(3.68 mmHg,
0.14 inHg)
0.49 kPa (3.68
mmHg, 0.14
inHg)
0.50 kPa (3.77
mmHg, 0.15
inHg)
0.51 kPa (3.85
mmHg, 0.15
inHg)
0.49 kPa
(3.68 mmHg,
0.14 inHg)
0.49 kPa (3.68
mmHg, 0.14
inHg)
0.51 kPa (3.79
mmHg, 0.15
inHg)
0.52 kPa
(3.9 mmHg,
0.15 inHg)
0.53 kPa (3.95

mmHg, 0.16
inHg)
0.53 kPa
(3.95 mmHg,
0.16 inHg)
0.53 kPa
(4.01 mmHg,
0.16 inHg)
0.54 kPa (4.06
mmHg, 0.16
inHg)
0.54 kPa
(4.07 mmHg,
0.16 inHg)
0.54 kPa
(4.07 mmHg,
0.16 inHg)
0.56 kPa
(4.17 mmHg,
0.16 inHg)
0.57 kPa (4.27
mmHg, 0.17
inHg)
0.56 kPa
(4.17 mmHg,
0.16 inHg)
0.56 kPa
(4.17 mmHg,
0.16 inHg)
0.57 kPa
(4.27 mmHg,
0.17 inHg)
0.60 kPa (4.48
mmHg, 0.18
inHg)
40 2 (10.57 US gal, 8.8 Imp gal)
0.65 kPa
(4.88 mmHg,
0.19 inHg)
0.65 kPa
(4.9 mmHg,
0.19 inHg)
0.66 kPa
(4.98 mmHg,
0.20 inHg)
0.71 kPa
(5.32 mmHg,
0.21 inHg)
0.76 kPa
(5.73 mmHg,
0.23 inHg)
50 2 (13.21 US gal, 11.0 Imp gal)
0.794 kPa
(5.96 mmHg,
0.235 inHg)
0.794 kPa
(5.96 mmHg,
0.235 inHg)
0.794 kPa
(5.96 mmHg,
0.235 inHg)
0.85 kPa
(6.38 mmHg,
0.25 inHg)
0.88 kPa
(6.6 mmHg,
0.26 inHg)
60 2 (15.85 US gal, 13.2 Imp gal)
0.794 kPa
(5.96 mmHg,
0.235 inHg)
0.794 kPa
(5.96 mmHg,
0.235 inHg)
0.794 kPa
(5.96 mmHg,
0.235 inHg)
0.85 kPa
(6.38 mmHg,
0.25 inHg)
0.88 kPa
(6.6 mmHg,
0.26 inHg)
0 2 (0 US gal, 0 Imp gal)
10 2 (2.64 US gal, 2.2 Imp gal)
20 2 (5.28 US gal, 4.4 Imp gal)
30 2 (7.93 US gal, 6.6 Imp gal)

GD(H4DOTC)-144

GENERAL DESCRIPTION
Leak Diagnosis
DTC
P0456 Evaporative Emission Control System Leak Detected (very small leak)
Diagnostic method
Mode A: (0 point compensation)
When the pressure in the tank is high, wait until it returns to 0 point (Near 0 mmHg,). Shift to mode B when
returned to the 0 point. Cancel the diagnosis when 0 point does not return in the specified time.
Mode B: (Negative pressure introduced)
Approximately 0 2.0 kPa (0 15 mmHg, 0 0.59 inHg)
When the tank internal pressure does not reach the target vacuum pressure, the diagnosis is cancelled.
Mode C: (Negative pressure maintained)
Change to Mode D either when the tank pressure returns to the start level of P2 calculation, or when the predetermined amount of time has passed.
Mode D: (Calculate the amount of negative pressure change)
Monitor the tank pressure in mode D, calculate (P2) the pressure change in the tank, and measure the time
(evpdset) for the tank pressure to return when calculation of P2 is completed. Shift to Mode E when the tank
pressure returns to the end level of P2 calculation. If it does not return to the P2 calculation end tank internal
pressure after the predetermined amount of time has passed, make advanced OK judgment or cancel the diagnosis.
Normality Judgment
Judgment Value
Mode D time
Tank internal pressure
Mode D time
P2
Threshold Value
30 sec.
1.8 kPa (13.4 mmHg, 0.53 inHg)
200 sec.
0.9 1.3 kPa (7 9.6 mmHg,
0.28 0.38 inHg)
Mode E: (Evaporation occurrence amount calculation)

Calculate the change of tank pressure with the time evpdset to judge as NG/OK according to the value of P1.
(ambiguous determination acceptable).
GD(H4DOTC)-145

GENERAL DESCRIPTION
Judgment Value
P1
Threshold Value
< Value from Map 7

Time (evpdset) vs Fuel level
0 seconds
30 seconds
80 seconds
100 seconds
150 seconds
200 seconds
0 kPa
(0 mmHg,
0 inHg)
0.21 kPa
(1.6 mmHg,
0.06 inHg)
0.29 kPa
(2.2 mmHg,
0.09 inHg)
0.29 kPa
(2.2 mmHg,
0.09 inHg)
0.29 kPa
(2.2 mmHg,
0.09 inHg)
0.29 kPa
(2.2 mmHg,
0.09 inHg)
10 2 (2.64 US gal, 2.2 Imp gal)
0 kPa
(0 mmHg,
0 inHg)
0.21 kPa
(1.6 mmHg,
0.06 inHg)
0.29 kPa
(2.2 mmHg,
0.09 inHg)
0.29 kPa
(2.2 mmHg,
0.09 inHg)
0.29 kPa
(2.2 mmHg,
0.09 inHg)
0.29 kPa
(2.2 mmHg,
0.09 inHg)
0 kPa
(0 mmHg,
0 inHg)
0 kPa
(0 mmHg,
0 inHg)
0 kPa
(0 mmHg,
0 inHg)
0 kPa
(0 mmHg,
0 inHg)
0.21 kPa
(1.6 mmHg,
0.06 inHg)
0.24 kPa
(1.8 mmHg,
0.07 inHg)
0.24 kPa
(1.8 mmHg,
0.07 inHg)
0.24 kPa
(1.8 mmHg,
0.07 inHg)
0.29 kPa
(2.2 mmHg,
0.09 inHg)
0.29 kPa
(2.2 mmHg,
0.09 inHg)
0.29 kPa
(2.2 mmHg,
0.09 inHg)
0.29 kPa
(2.2 mmHg,
0.09 inHg)
0.29 kPa
(2.2 mmHg,
0.09 inHg)
0.29 kPa
(2.2 mmHg,
0.09 inHg)
0.29 kPa
(2.2 mmHg,
0.09 inHg)
0.29 kPa
(2.2 mmHg,
0.09 inHg)
0.29 kPa
(2.2 mmHg,
0.09 inHg)
0 kPa
(0 mmHg,
0 inHg)
0 kPa
(0 mmHg,
0 inHg)
0 kPa
(0 mmHg,
0 inHg)
0 kPa
(0 mmHg,
0 inHg)
0 kPa
(0 mmHg,
0 inHg)
0 kPa
(0 mmHg,
0 inHg)
0 kPa
(0 mmHg,
0 inHg)
0 kPa
(0 mmHg,
0 inHg)
0.24 kPa
(1.8 mmHg,
0.07 inHg)
0.29 kPa
(2.2 mmHg,
0.09 inHg)
0.29 kPa
(2.2 mmHg,
0.09 inHg)
0 kPa
(0 mmHg,
0 inHg)
0 kPa
(0 mmHg,
0 inHg)
30 2 (7.93 US gal, 6.6 Imp gal)
50 2 (13.21 US gal, 11.0 Imp gal)
60 2 (15.85 US gal, 13.2 Imp gal)
70 2 (18.49 US gal, 15.4 Imp gal)
80 2 (21.14 US gal, 17.6 Imp gal)
Normality Judgment
Judgment Value
P1
Threshold Value
> Value from Map 8
GD(H4DOTC)-146

GENERAL DESCRIPTION
Map 8 Fault criteria limit for Evaporative emission control system diagnosis
Time (evpdset) vs Fuel level
10 2 (2.64 US gal, 2.2 Imp gal)
30 2 (7.93 US gal, 6.6 Imp gal)
50 2 (13.21 US gal, 11.0 Imp gal)
60 2 (15.85 US gal, 13.2 Imp gal)
70 2 (18.49 US gal, 15.4 Imp gal)
80 2 (21.14 US gal, 17.6 Imp gal)
0 seconds
30 seconds
80 seconds
100 seconds
150 seconds
200 seconds
0.16 kPa
(1.2 mmHg,
0.05 inHg)
0.37 kPa
(2.8 mmHg,
0.11 inHg)
0.45 kPa
(3.4 mmHg,
0.13 inHg)
0.45 kPa
(3.4 mmHg,
0.13 inHg)
0.45 kPa
(3.4 mmHg,
0.13 inHg)
0.45 kPa
(3.4 mmHg,
0.13 inHg)
0.16 kPa
(1.2 mmHg,
0.05 inHg)
0.16 kPa
(1.2 mmHg,
0.05 inHg)
0.16 kPa
(1.2 mmHg,
0.05 inHg)
0.16 kPa
(1.2 mmHg,
0.05 inHg)
0.16 kPa
(1.2 mmHg,
0.05 inHg)
0.37 kPa
(2.8 mmHg,
0.11 inHg)
0.37 kPa
(2.8 mmHg,
0.11 inHg)
0.40 kPa
(3.0 mmHg,
0.12 inHg)
0.40 kPa
(3.0 mmHg,
0.12 inHg)
0.40 kPa
(3.0 mmHg,
0.12 inHg)
0.45 kPa
(3.4 mmHg,
0.13 inHg)
0.45 kPa
(3.4 mmHg,
0.13 inHg)
0.45 kPa
(3.4 mmHg,
0.13 inHg)
0.45 kPa
(3.4 mmHg,
0.13 inHg)
0.45 kPa
(3.4 mmHg,
0.13 inHg)
0.45 kPa
(3.4 mmHg,
0.13 inHg)
0.45 kPa
(3.4 mmHg,
0.13 inHg)
0.45 kPa
(3.4 mmHg,
0.13 inHg)
0.45 kPa
(3.4 mmHg,
0.13 inHg)
0.45 kPa
(3.4 mmHg,
0.13 inHg)
0.45 kPa
(3.4 mmHg,
0.13 inHg)
0.45 kPa
(3.4 mmHg,
0.13 inHg)
0.45 kPa
(3.4 mmHg,
0.13 inHg)
0.45 kPa
(3.4 mmHg,
0.13 inHg)
0.45 kPa
(3.4 mmHg,
0.13 inHg)
0.45 kPa
(3.4 mmHg,
0.13 inHg)
0.45 kPa
(3.4 mmHg,
0.13 inHg)
0.45 kPa
(3.4 mmHg,
0.13 inHg)
0.45 kPa
(3.4 mmHg,
0.13 inHg)
0.45 kPa
(3.4 mmHg,
0.13 inHg)
0.16 kPa
(1.2 mmHg,
0.05 inHg)
0.40 kPa
(3.0 mmHg,
0.12 inHg)
0.45 kPa
(3.4 mmHg,
0.13 inHg)
0.45 kPa
(3.4 mmHg,
0.13 inHg)
0.45 kPa
(3.4 mmHg,
0.13 inHg)
0.45 kPa
(3.4 mmHg,
0.13 inHg)



8. FAIL SAFE
None

GD(H4DOTC)-147

GENERAL DESCRIPTION
BM:DTC P0447 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL

CIRCUIT OPEN
(1)
(2)
(3)
(4)
(5)
(6)
(10)
(7)
(9)
(8)
EN-01730
(1) Magnetic plate

(2) Yoke
(6) Valve
(7) Plate
(3) Packing
(4) Spring
(8) Retainer
(9) Movable core
(5) Valve seat
(10) Bobbin
3. ENABLE CONDITION
Enable Conditions
None

GD(H4DOTC)-148

GENERAL DESCRIPTION
seconds.
Judgment Value
Threshold Value
Ignition switch
Battery voltage
ON
10.9 V

1 second or more
Low

Normality Judgment
Judgment Value
Ignition switch
Threshold Value
ON
Battery voltage
10.9 V
1 second or more
High


8. FAIL SAFE

GD(H4DOTC)-149

GENERAL DESCRIPTION
BN:DTC P0448 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL

CIRCUIT SHORTED
(1)
(2)
(3)
(4)
(5)
(6)
(10)
(7)
(9)
(8)
EN-01730
(1) Magnetic plate

(2) Yoke
(6) Valve
(7) Plate
(3) Packing
(4) Spring
(8) Retainer
(9) Movable core
(5) Valve seat
(10) Bobbin
3. ENABLE CONDITION
Enable Conditions
None

GD(H4DOTC)-150

GENERAL DESCRIPTION
seconds.
Judgment Value
Threshold Value
Ignition switch
Battery voltage
ON
10.9 V

1 second or more
High

Normality Judgment
Judgment Value
Ignition switch
Threshold Value
ON
Battery voltage
10.9 V
1 second or more
Low


8. FAIL SAFE

GD(H4DOTC)-151

GENERAL DESCRIPTION
BO:DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE

SENSOR
Detect the tank pressure sensor output property abnormality.
Judge NG when there is no pressure variation, which should exist in the tank, considering the engine status.
(1)
(2)
(A)
(B)
(C)
EN-03875
(1) Connector
(2) Terminal
(A) Output voltage

(B) Input voltage
(C) To fuel tank
3. ENABLE CONDITION
Enable Conditions

Fuel level
60 seconds or more
9 2 (2.38 US gal,
1.98 Imp gal)
Fuel temperature
Battery voltage
< 35C (95F)

10.9 V
> 75.0 kPa (563

mmHg, 22.2 inHg)
Purge control solenoid valve ON/OFF
Experienced

Be sure to check the fuel level and fuel temperature.
GD(H4DOTC)-152

GENERAL DESCRIPTION
Judgment Value
Threshold Value
Number of times that the difference between

the Max. fuel level and Min. fuel level every
60 seconds is 2 2 (0.53 US gal, 0.44 Imp gal)
or more (with enable condition completed)
Maximum Minimum tank pressure (with
enable condition completed)
Maximum Minimum fuel temperature (with
enable condition completed)
16 times
< 0.05 kPa (0.375 mmHg,

0.01 inHg)
7C (12.6F)
If the maximum value minimum value for the fuel level is less than 2 2 every 60 seconds, extend 60 seconds more and make judgment with the maximum and minimum values for the fuel level in 120 seconds. If
a difference does not appear though the time was extended 60 seconds, extend the time (180, 240, 300 seconds) and continue the judgment. If the maximum value minimum value for the fuel level is 5 liters or more,
the diagnosis counter counts up.
Time Needed for Diagnosis: 1 minute 16 times or more
Normality Judgment
Judgment Value
Threshold Value
0.05 kPa (0.375
mmHg, 0.01 inHg)


8. FAIL SAFE

GD(H4DOTC)-153

GENERAL DESCRIPTION
BP:DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE

SENSOR LOW INPUT
(1)
(2)
(A)
(B)
(C)
EN-03875
(1) Connector
(2) Terminal
(A) Output voltage

(B) Input voltage
(C) To fuel tank
3. ENABLE CONDITION (USED WITH HIGH SIDE NORMAL/ABNORMALITY JUDGMENT

ONLY)
Battery voltage
Enable Condition
10.9 V

GD(H4DOTC)-154

GENERAL DESCRIPTION
more.
Judgment Value
Fuel tank pressure
Threshold Value
< 6.82 kPa (56.15 mmHg,
2.01 inHg)

Normality Judgment
Judgment Value
Threshold Value
Fuel tank pressure
6.82 kPa (56.15 mmHg,

2.01 inHg)
Feedback lambda coefficient
0.9


8. FAIL SAFE

GD(H4DOTC)-155

GENERAL DESCRIPTION
BQ:DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE

SENSOR HIGH INPUT
(1)
(2)
(A)
(B)
(C)
EN-03875
(1) Connector
(2) Terminal
(A) Output voltage

(B) Input voltage
(C) To fuel tank
3. ENABLE CONDITION
Enable Conditions
Vehicle speed
All conditions of EVAP canister purge
2 km/h (1.24 MPH)

Complete

Main feedback compensation coefficient
0.08
Battery voltage
10.9 V
0.9

Perform the diagnosis continually when purging.
GD(H4DOTC)-156

GENERAL DESCRIPTION
more.
Judgment Value
Fuel tank pressure
Fuel temperature
Threshold Value
7.98 kPa (59.85 mmHg,
2.36 inHg)
< 35C (95F)
75.0 kPa (563 mmHg,
22.2 inHg)

Normality Judgment
Judgment Value
Fuel tank pressure
Threshold Value
< 7.98 kPa (59.85 mmHg,
2.36 inHg)


8. FAIL SAFE

BR:DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED

(VERY SMALL LEAK)
NOTE:
For the detection conditions, refer to DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK
DETECTED (SMALL LEAK). <Ref. to GD(H4DOTC)-132, DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Trouble Code (DTC) Detecting Criteria.>
BS:DTC P0457 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED

NOTE:
For the detection conditions, refer to DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK
DETECTED (SMALL LEAK). <Ref. to GD(H4DOTC)-132, DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK), Diagnostic Trouble Code (DTC) Detecting Criteria.>
GD(H4DOTC)-157

GENERAL DESCRIPTION
BT:DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE

CIRCUIT LOW
(A)
(B)
EN-01733
(A) To canister
3. ENABLE CONDITION
Enable Conditions
Ignition switch
Battery voltage
ON
10.9 V
1 second or more

GD(H4DOTC)-158

GENERAL DESCRIPTION
Judgment Value
Threshold Value

tions established:
Duty ratio of ON
< 75%
Low

Normality Judgment
Judgment Value
Threshold Value
High


8. FAIL SAFE
None

GD(H4DOTC)-159

GENERAL DESCRIPTION
BU:DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE

CIRCUIT HIGH
(A)
(B)
EN-01733
(A) To canister
3. ENABLE CONDITION
Enable Conditions
Ignition switch
Battery voltage
ON
10.9 V
1 second or more

GD(H4DOTC)-160

GENERAL DESCRIPTION
Judgment Value
Threshold Value

tions established:
Duty ratio of ON
25%
High

Normality Judgment
Judgment Value
Threshold Value
Low


8. FAIL SAFE
None

GD(H4DOTC)-161

GENERAL DESCRIPTION
BV:DTC P0461 FUEL LEVEL SENSOR A CIRCUIT RANGE/PERFORMANCE

Detect malfunctions of the fuel level sensor output property.
If the fuel level does not vary in a particular driving condition / engine condition where it should, judge as NG.
(A)
(B)
EN-02167
(A) Fuel level (L)

(B) Resistance ()
3. ENABLE CONDITION
Enable Conditions
None

GD(H4DOTC)-162

GENERAL DESCRIPTION
Judgment Value
Threshold Value

> 331 kg (729.8 lb)

< 2.6 2 (0.69 US gal,
0.57 Imp gal)
Battery voltage
10.9 V
10 seconds or more

Normality Judgment
Judgment Value
Threshold Value
> 331 kg (729.8 lb)
2.6 2 (0.69 US gal,

0.57 Imp gal)
Battery voltage
10.9 V
10 seconds or more


8. FAIL SAFE
None

GD(H4DOTC)-163

GENERAL DESCRIPTION
BW:DTC P0462 FUEL LEVEL SENSOR A CIRCUIT LOW

(1)
(4)
(2)
(3)
EN-01735

(4) Detecting circuit
3. ENABLE CONDITION
Enable Conditions
None

GD(H4DOTC)-164

GENERAL DESCRIPTION
needed for diagnosis (2.5 seconds).
Judgment Value
Threshold Value
Ignition switch
Battery voltage
ON
10.9 V

Output voltage
3 seconds or more
< 0.035 V

Normality Judgment
Judgment Value
Threshold Value
Ignition switch
Battery voltage
ON
10.9 V

Output voltage
3 seconds or more
0.035 V


8. FAIL SAFE
None

GD(H4DOTC)-165

GENERAL DESCRIPTION
BX:DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH

Detect the open or short circuit of fuel level sensor.
(1)
(4)
(2)
(3)
EN-01735

3. ENABLE CONDITION
Enable Conditions
None

GD(H4DOTC)-166

GENERAL DESCRIPTION
Judge as NG when the continuous time of meeting the malfunction criteria below exceeds the time required
for diagnosis (10 seconds).
Judgment Value
Threshold Value
Ignition switch
Battery voltage
ON
10.9 V

Output voltage
3 seconds or more
4.911 V

Normality Judgment
Judgment Value
Threshold Value
Ignition switch
Battery voltage
ON
10.9 V

Output voltage
3 seconds or more
< 4.911 V


8. FAIL SAFE
None

GD(H4DOTC)-167

GENERAL DESCRIPTION
BY:DTC P0464 FUEL LEVEL SENSOR CIRCUIT INTERMITTENT

Detect the unstable output faults from the fuel level sensor caused by noise. Judge as NG when the max. value and cumulative value of output voltage variation of the fuel level sensor is larger than the threshold value.
2. ENABLE CONDITION
Engine speed
Threshold Value
500 rpm

Ignition switch
1 second or more
ON
Battery voltage
> 10.9 V
Idle switch
Fuel level
ON
9 51 2 (2.38 13.47 US gal,
1.98 11.22 Imp gal)
10 seconds or more
Vehicle speed = 0 km/h (0 MPH)

Pay attention to the fuel level.
GD(H4DOTC)-168

GENERAL DESCRIPTION
Calculate the Max. value (delflmax) and cumulative value (sumfl) of output voltage variation of fuel level sensor during 12.8 seconds. Judge it normal when both max. and cumulative values are not over the threshold
value. Otherwise, when either of them is over the threshold value, the diagnosis counter counts up. Judge as
NG if the counter indicated 4 counts.
(A)
(J)
(B)
(F)
(C)
(G)
(D)
(H)
(E)
(I)
EN-01736
(A) Diagnosis condition

(B) Diagnosis period
(C) Fuel level sensor A/D value
(D) Fuel level output voltage
(E) Diagnosis counter
(F) Malfunction
(G) Normal
(H) The values of DVFLMAX and SUMVFL are
regarded as maximum.
(I) NG 4 at counts
(J) 12.8 seconds
GD(H4DOTC)-169

GENERAL DESCRIPTION
Judgment Value
Total times of the condition reaching follows,
DELFLMAX 0.228 V or SUMFL 21.8
V
DELFLMAX is Max. deviation of sensor
output during 12.8 seconds
SUMFL: Integrated value of sensor output deviation in 12.8 seconds
Threshold Value
4 times
The diagnosis counter does not count up when the following conditions are completed within 12.8 seconds.
Maximum value minimum value of
change of tank pressure for 12.8 seconds
0.05 kPa (0.375 mmHg,

0.01 inHg)
Maximum value minimum value of battery voltage for 12.8 seconds
0.465 V
Time required for diagnosis: 12.8 seconds 4 times

Normality Judgment
Judgment Value
DELFLMAX
Threshold Value
< 0.228 V
SUMFL
DELFLMAX is Max. deviation of sensor
output during 12.8 seconds
SUMFL: Integrated value of sensor output deviation in 12.8 seconds
< 21.8 V


7. FAIL SAFE
None

GD(H4DOTC)-170

GENERAL DESCRIPTION
BZ:DTC P0483 FAN RATIONALITY CHECK

Detect the function abnormality of the radiator fan.
Judge as NG when the engine coolant temperature slowly decreases even when the radiator fan is rotating.
2. ENABLE CONDITION
Diagnostic enable condition is established if the radiator fan changes from OFF ON when all of the conditions below are met.
When one of the conditions below is not met, the diagnostic enable condition is not established.
Enable Conditions
Engine speed
Idle switch
550 950 rpm

ON
Vehicle speed
0 km/h (0 MPH)
Battery voltage
10.9 V

Judge as NG when the continuous time of meeting the malfunction criteria below becomes more than 5 minutes.
Judgment Value
Threshold Value
95C (203F)
Radiator fan
OFF ON
Does not decrease
Time Needed for Diagnosis: 5 minutes

Normality Judgment
Judgment Value
Radiator fan
Threshold Value
OFF ON
Decreases


7. FAIL SAFE
None

GD(H4DOTC)-171

GENERAL DESCRIPTION
CA:DTC P0502 VEHICLE SPEED SENSOR A CIRCUIT LOW INPUT

Detect the open or short circuit of vehicle speed. Judge NG when low vehicle speed (0 km/h (0 MPH)) remains whereas it seemed to be in a usual driving speed.
2. ENABLE CONDITION
Engine speed
Enable Conditions
< 4000 rpm
Fuel cut in decel.

Battery voltage
In operation
10.9 V

Perform diagnosis continually during a deceleration fuel cut, at less than 4000 rpm.
more.
Judgment Value
Vehicle speed
Threshold Value
<1

Normality Judgment
Vehicle speed
Threshold Value
1
Starter switch
OFF
3 sec.


7. FAIL SAFE
Accelerator sensor signal process: Not allowed fully closed point learning. (Hold previous value)
Vehicle speed sensor signal process: Vehicle speed = 10 km/h (6.21 MPH)
Fuel cut control: Not allowed vehicle speed 0 km/h (0 MPH) fuel cut. Normally the high vehicle speed fuel
cut performs on and of vehicle speed condition and engine speed, but perform the fuel cut only on engine
speed condition (4,800 rpm or more).
ISC control: Open loop compensation is set to (1 g/s). Not allowed ISC feedback volume calculation.
Air conditioner control: Not allowed air conditioner cut at accelerating.
Gear ratio judgment: Control as fixed in sixth gear

GD(H4DOTC)-172

GENERAL DESCRIPTION
CB:DTC P0503 VEHICLE SPEED SENSOR A INTERMITTENT/ERRATIC/HIGH

Detect the open or short circuit of vehicle speed. Judge NG when high vehicle speed (300 km/h (186.4 MPH)
or more) remains whereas it seemed to be in a usual driving speed.
2. ENABLE CONDITION
Engine speed
Enable Conditions
< 4000 rpm
Fuel cut in decel.

Battery voltage
In operation
10.9 V

Perform diagnosis continually during a deceleration fuel cut, at less than 4000 rpm.
more.
Judgment Value
Vehicle speed
Threshold Value
300

Normality Judgment
Threshold Value
Vehicle speed
Starter switch
< 300 km/h (186.4 MPH)

OFF
3 sec.


7. FAIL SAFE
Accelerator sensor signal process: Not allowed fully closed point learning. (Hold previous value)
Vehicle speed sensor signal process: Vehicle speed = 10 km/h (6.21 MPH)
Fuel cut control: Not allowed vehicle speed 0 km/h (0 MPH) fuel cut. Normally the high vehicle speed fuel
cut performs on and of vehicle speed condition and engine speed, but perform the fuel cut only on engine
speed condition (4,800 rpm or more).
ISC control: Open loop compensation is set to (1 g/s). Not allowed ISC feedback volume calculation.
Air conditioner control: Not allowed air conditioner cut at accelerating.
Gear ratio judgment: Control as fixed in sixth gear

GD(H4DOTC)-173

GENERAL DESCRIPTION
CC:DTC P0506 IDLE AIR CONTROL SYSTEM RPM LOWER THAN EXPECTED
2. ENABLE CONDITION
Enable Conditions
70C (158F)
Battery voltage
10.9 V
> 75.0 kPa (563 mmHg,
22.2 inHg)
Fuel level
9 2 (2.38 US gal,
1.98 Imp gal)

Feedback in ISC
10 seconds or more
In operation
Lambda value
After air condition switching ON-OFF,
OFF-ON
0.90 1.1
5 seconds or more

more than 4 kPa (30 mmHg, 1.2 inHg).
> 5 sec.
After neutral switch ON-OFF change

Vehicle speed
> 5 sec.
0 km/h (0 MPH)

After 10 seconds from engine starting, perform diagnosis continuously at idling after warming up.
Judgment Value
Actual Target engine speed
Threshold Value
< 100 rpm
Max.

Normality Judgment
Judgment Value
Threshold Value
100 rpm


GD(H4DOTC)-174

GENERAL DESCRIPTION
7. FAIL SAFE
Judgment of heavy fuel: Not allowed to make the judgment of heavy fuel.
Knock compensation:

GD(H4DOTC)-175

GENERAL DESCRIPTION
CD:DTC P0507 IDLE AIR CONTROL SYSTEM RPM HIGHER THAN EXPECTED
2. ENABLE CONDITION
Enable Conditions
70C (158F)
Battery voltage
10.9 V
> 75.0 kPa (563 mmHg,
22.2 inHg)
Fuel level
9 2 (2.38 US gal,
1.98 Imp gal)

Feedback in ISC
10 seconds or more
In operation
Lambda value
After air condition switching ON-OFF,
OFF-ON
0.90 1.1
5 seconds or more

more than 4 kPa (30 mmHg, 1.2 inHg).
> 5 sec.
After neutral switch ON-OFF change

Vehicle speed
> 5 sec.
0 km/h (0 MPH)

After 10 seconds from engine starting, perform diagnosis continuously at idling after warming up.
Judgment Value
Threshold Value
200 rpm
Min.

Normality Judgment
Judgment Value
Threshold Value
< 200 rpm


GD(H4DOTC)-176

GENERAL DESCRIPTION
7. FAIL SAFE
Judgment of heavy fuel: Not allowed to make the judgment of heavy fuel.
Knock compensation:

GD(H4DOTC)-177

GENERAL DESCRIPTION
CE:DTC P0512 STARTER REQUEST CIRCUIT

Judge ON NG when the starter SW signal remains ON.
Judge OFF NG when the engine starts without starter experience.
2. ENABLE CONDITION
Enable Conditions
None

Judge as ON NG when the continuous time of meeting the malfunction criteria below becomes more than 3
minutes.
Judgment Value
Threshold Value
Engine speed
Starter OFF signal
> 500 rpm

Not detected
Battery voltage
>8V

Normality Judgment
Judge ON OK and clear the NG when the malfunction criteria below are met.
Judgment Value
Starter switch
Battery voltage
Threshold Value
OFF
>8V


7. FAIL SAFE
None

GD(H4DOTC)-178

GENERAL DESCRIPTION
CF:DTC P0513 INCORRECT IMMOBILIZER KEY

DTC
Item
OUTLINE OF DIAGNOSIS
P0513
P1570

Antenna
Incorrect immobilizer key (Use of unregistered key in IMMCM)

Faulty antenna
P1571
P1572

IMM Circuit Failure (Except
Antenna Circuit)
Reference code incompatibility between IMMCM and ECM

Communication failure between IMMCM and ECM
P1574
Failure of IMMCM to verify key (transponder) ID code or transponder failure
P1576
P1577

ECM malfunctioning
IMMCM malfunctioning
2. ENABLE CONDITION
When starting the engine.

Perform the diagnosis only after starting the engine.
Judge as NG when the conditions of the diagnosis outline above are established.
GD(H4DOTC)-179

GENERAL DESCRIPTION
CG:DTC P0519 IDLE AIR CONTROL SYSTEM PERFORMANCE

Detect the malfunction that engine speed increases more than that in normal condition during idling.
2. ENABLE CONDITION
Battery voltage
Enable Conditions
10.9 V
Feedback in ISC
Vehicle speed
In operation
< 4 km/h (2.49 MPH)
1 second or more

Perform the diagnosis continuously if the vehicle speed at less than 4 km/h (2.49 MPH).
Judge as NG when the continuous time of meeting the all malfunction criteria below becomes more than 2
seconds.
Judgment Value
Threshold Value

1500 rpm
0%
Engine speed change every 180 degree

engine revs.
5 rpm

Normality Judgment
Judgment Value
Threshold Value
< 200 rpm


7. FAIL SAFE
Fuel cut: Cuts off fuel for only #1 and #2 cylinders, or for all cylinders according to vehicle speed, engine
speed, and throttle position.

GD(H4DOTC)-180

GENERAL DESCRIPTION
CH:DTC P0600 SERIAL COMMUNICATION LINK

Detect malfunction of CAN communication.
Judge as NG when CAN communication is not established, CAN communication with AT is not established,
and the data from the AT is not normal.
ECM and TCM are connected by high speed CAN.
(Common Specifications)
CAN Protocol 2.0 B (Active)
Frame Format: 11 Bit ID Frame (Standard Frame)
(High speed CAN)
Conforms to ISO11898
Communication Speed: 500 kbps
3. ENABLE CONDITION
Enable Conditions
Battery voltage
Starter switch
10.9 V
OFF
Engine
run

Judge as NG when either of the following conditions is established.
Judge as OK and clear the NG when the continuous time when all of the following criteria are established is
more than the predetermined time (1 second).
Judgment Value
bus off flag or warning flag
ID is not received from the TCM
Threshold Value
set
= 500 milliseconds



8. FAIL SAFE
None

GD(H4DOTC)-181

GENERAL DESCRIPTION
CI: DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY

(RAM) ERROR
Detect the malfunction of microcomputer (RAM).
Zero clear all normal RAM areas with the initial routine, and judge as NG when the sum of all added RAM after clearing is other than zero.
2. ENABLE CONDITION
Ignition switch
Enable Conditions
OFF ON
Diagnosis with the initial routine.

Perform the diagnosis as soon as the ignition switch is turned to ON.
Judge as NG when the criteria below are met and judge as OK when not met, and clear the NG.
Judgment Value
Sum of RAM data after data clear
Threshold Value
Cannot be read.



7. FAIL SAFE
None

GD(H4DOTC)-182

GENERAL DESCRIPTION
CJ:DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM)

ERROR
Judge as NG when SUM value of ROM is outside the standard value.
2. ENABLE CONDITION
Ignition switch
Enable Conditions
ON

more.
Judgment Value
SUM value of ROM
Threshold Value
Specification



7. FAIL SAFE

GD(H4DOTC)-183

GENERAL DESCRIPTION
CK:DTC P0607 CONTROL MODULE PERFORMANCE

Judge as NG when either the following is completed.
When the read value of throttle position sensor 1 signal is mismatched between main CPU and sub CPU.
When the read value of accelerator pedal position sensor 1 signal is mismatched between main CPU and
sub CPU.
When the sub CPU operates abnormally.
When the communication between main CPU sub CPU is abnormal.
When the input amplifier circuit of throttle position sensor 1 is abnormal.
When the cruise control cannot be canceled correctly.
When the signal of brake SW1 and 2 is mismatched.
When the directed angle from the main CPU is abnormal.
(1)
(12)
(2)
(11)
(10)
(13)
(10)
(3)
(4)
(5)
(10)
(14)
(6)
(10)
(7)
(8)
(9)

(2) Throttle position sensor 1
(8) Stop light

(9) Brake switch
(3) Throttle position sensor 2

(4) Accelerator pedal position sensor
(10) I/F circuit

(11) Amplifier circuit
(5) Accelerator pedal position sensor 1

(6) Accelerator pedal position sensor 2

(13) Sub CPU
(7) Battery
(14) Main CPU
GD(H4DOTC)-184
EN-01862

GENERAL DESCRIPTION
3. ENABLE CONDITION
Enable Conditions
(1) Ignition switch

(2) Ignition switch
ON
ON
(3) None
(4) None
(5) Throttle opening angle

(6) Brake switch (only with cruise control) ON
(7) None

(1) (4): Always perform the diagnosis continuously.
(5): Always perform the diagnosis continuously when idling.
(6): Perform the diagnosis when the brake pedal is depressed.
(7): Always perform the diagnosis continuously.
Judgment Value
Threshold Value
1. Difference of CPU on reading value of

throttle position sensor signal
2. Difference of CPU on read value of accelerator pedal position sensor signal
3. WD pulse from sub CPU
Within 0.858 V
4. Communication between CPU

5. Difference of signal on connection of
amplifier
6. Cruise control cancel signal at brake ON
Possible to communicate
Within X 43
7. Brake switch 1, 2 signal
SW 1 and 2 are matched
Within 0.042 V
WD pulse occur
Cruise control cancel signal ON

1. 250 milliseconds
2. 250 milliseconds
3. 200 milliseconds
4. 200 milliseconds
5. 24 milliseconds
6. 250 milliseconds
7. 200 milliseconds


8. FAIL SAFE

GD(H4DOTC)-185

GENERAL DESCRIPTION
CL:DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE

(BANK 1)
Judge as NG when the target opening angle and actual opening angle is mismatched or the current to motor
is more than specified duty for specified time continuously.
(3)
(1)
(4)
(2)
EN-01863
(1) Motor
(4) Drive circuit
3. ENABLE CONDITION
Ignition switch
Normal operation of electric throttle control
Enable Conditions
ON
ON

Always perform the diagnosis continuously when the electric throttle control is operating.
GD(H4DOTC)-186

GENERAL DESCRIPTION
Judgment Value
Threshold Value
Difference between target opening angle

and actual opening angle
3.5 or less
Output duty to drive circuit
95% or less

Target opening angle and actual opening angle: 250 milliseconds (For NG) 2000 milliseconds (For OK)
Output duty to drive circuit: 2000 milliseconds
30
(25.0)
20
(3)
(1)
(12.0)
10
(5.0)
(3.5)
0
0
5 (6.15)
10
(9.65)
15
(14.65)
20
25 (26.65)
30
(2)
EN-01864
(1) Difference between target opening angle and

actual opening angle ()
(2) Target throttle opening angle ()
(3) NG area
GD(H4DOTC)-187

GENERAL DESCRIPTION
Details of Judgment (The actual opening angle target opening angle is always 1000 milliseconds)
1000
(1)
500
(3)
(400)
(300)
(250)
0
0
5 (5.5) (9.0) 10
(13.0) 15
20 (22.0)
25
30
(2)
EN-01865
(1) Judgment time (milliseconds)

(2) Throttle position sensor 1 opening angle
(3) NG area


8. FAIL SAFE

GD(H4DOTC)-188

GENERAL DESCRIPTION
CM:DTC P0691 FAN 1 CONTROL CIRCUIT LOW

Detect the open/short circuit of radiator fan circuit.
2. ENABLE CONDITION
Enable Conditions
None

seconds.
Judgment Value
Threshold Value

Engine speed
1 second or more
500 rpm
Ignition switch
Battery voltage
ON
10.9 V
Low level

Normality Judgment
Judgment Value
Threshold Value
1 second or more
Engine speed
Ignition switch
500 rpm
ON
Battery voltage
10.9 V
High level


7. FAIL SAFE
None

GD(H4DOTC)-189

GENERAL DESCRIPTION
CN:DTC P0692 FAN 1 CONTROL CIRCUIT HIGH

Detect the open/short circuit of radiator fan circuit.
2. ENABLE CONDITION
Enable Conditions
None

seconds.
Judgment Value
Threshold Value

Engine speed
1 second or more
500 rpm
Ignition switch
Battery voltage
ON
10.9 V
High level

Normality Judgment
Judgment Value
Threshold Value
1 second or more
Engine speed
Ignition switch
500 rpm
ON
Battery voltage
10.9 V
Low level


7. FAIL SAFE
None

GD(H4DOTC)-190

GENERAL DESCRIPTION
CO:DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST)

CAN communication is established with AT and, judge as NG when there is a MIL lighting request.
2. ENABLE CONDITION
Battery voltage
Enable Conditions
10.9 V

Judge as NG when the continuous time of meeting the malfunction criteria below becomes longer than the
predetermined amount of time (2.5 seconds).
Judge as OK and clear the NG when the following conditions are not met.
Judgment Value
MIL lighting request from TCM
Threshold Value
set



7. FAIL SAFE
None

GD(H4DOTC)-191

GENERAL DESCRIPTION
CP:DTC P0851 PARK/NEUTRAL SWITCH INPUT CIRCUIT LOW (AT MODEL)

2. ENABLE CONDITION
Enable Conditions
Ignition switch
Battery voltage
ON
10.9 V

Starter switch
2 seconds or more
OFF

Judge as NG when the continuous time until meeting the malfunction criteria below becomes more than 6.5
seconds. Judge as OK and clear the NG when the malfunction criteria below are not met.
Judgment Value
= OFF and any other switches = ON
on AT
Threshold Value
LOW (ON)



7. FAIL SAFE
None

GD(H4DOTC)-192

GENERAL DESCRIPTION
CQ:DTC P0851 NEUTRAL SWITCH INPUT CIRCUIT LOW (MT MODEL)

2. ENABLE CONDITION
Enable Conditions
Ignition switch
Battery voltage
ON
10.9 V

Starter switch
2 seconds or more
OFF

And clear NG if there is change in the neutral SW.
Judgment Value
Threshold Value

from a to b below)
Low continues

a) to b)
b) Vehicle speed 64 km/h (39.8 MPH)




7. FAIL SAFE
Cruise control: Not allowed to command cruise control.

GD(H4DOTC)-193

GENERAL DESCRIPTION
CR:DTC P0852 PARK/NEUTRAL SWITCH INPUT CIRCUIT HIGH (AT MODEL)

2. ENABLE CONDITION
Enable Conditions
Ignition switch
Battery voltage
ON
10.9 V

Starter switch
2 seconds or more
OFF

Judge as NG when the continuous time of meeting the malfunction criteria below becomes 6.5 seconds.
Judge as OK and clear the NG when the malfunction criteria below are not met.
Judgment Value
= ON and any other switches = OFF
on AT
Threshold Value
HIGH (OFF)



7. FAIL SAFE
None

GD(H4DOTC)-194

GENERAL DESCRIPTION
CS:DTC P0852 NEUTRAL SWITCH INPUT CIRCUIT HIGH (MT MODEL)

2. ENABLE CONDITION
Enable Conditions
Ignition switch
Battery voltage
ON
10.9 V

Starter switch
2 seconds or more
OFF

And clear NG if there is change in the neutral SW.
Judgment Value
Threshold Value

from a to b below)
High continues

a) to b)
b) Vehicle speed 64 km/h (39.8 MPH)




7. FAIL SAFE
None

GD(H4DOTC)-195

GENERAL DESCRIPTION
CT:DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK 1

SENSOR 1)
Detect that value remains Low.
control, etc.
air fuel ratio
> 1: Lean
< 1: Rich
(3)
(1)
(A)
(2)
(2)
(C)
(B)
(D)
(4)
EN-01693
(1) Atmosphere
(2) Exhaust gas

(B) Air fuel ratio
(3) ZrO2
(4) Ceramic heater
(C) Lean
(D) Rich
GD(H4DOTC)-196

GENERAL DESCRIPTION
3. ENABLE CONDITION
Enable Conditions
4 seconds or more
Battery voltage
Atmosphere pressure
> 10.9 V
> 75.0 kPa (563 mmHg, 22.2 inHg)

Rear oxygen sensor output voltage Feedback
target voltage
Execution
0.2 V 0.1 V
or
Rear oxygen sensor sub feedback compensation coefficient
or
On Min.

On Max.
60 seconds or more

Vehicle speed
70C (158F)
20 km/h (12.4 MPH)

6 g/s
0.01 g/rev

0 50
0.2
20 seconds or more

Perform diagnosis continuously at a constant speed of 20 km/h (12 MPH) or more, from 60 seconds after
starting the engine.
Judgment Value
feedback compensation coefficient is not
at maximum limit
Threshold Value
0.85



8. FAIL SAFE

GD(H4DOTC)-197

GENERAL DESCRIPTION
CU:DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK 1

SENSOR 1)
Detect that value remains High.
control, etc.
air fuel ratio
> 1: Lean
< 1: Rich
(3)
(1)
(A)
(2)
(2)
(C)
(B)
(D)
(4)
EN-01693
(1) Atmosphere
(2) Exhaust gas

(B) Air fuel ratio
(3) ZrO2
(4) Ceramic heater
(C) Lean
(D) Rich
GD(H4DOTC)-198

GENERAL DESCRIPTION
3. ENABLE CONDITION
Enable Conditions
4 seconds or more
Battery voltage
> 10.9 V
> 75.0 kPa (563 mmHg,
22.2 inHg)
Execution

Rear oxygen sensor output voltage Feedback
target voltage
or
0.2 V 0.1 V
On Min.
or
60 seconds or more

Vehicle speed
70C (158F)
20 km/h (12.4 MPH)

6 g/s
0.02 g/rev

0 50
0.2
20 seconds or more
On Max.

Perform diagnosis continuously at a constant vehicle speed of 20 km/h (12 MPH) or more, from 60 seconds
after starting the engine.
Judgment Value
feedback compensation coefficient cannot be at minimum limit
Threshold Value
1.15



8. FAIL SAFE

GD(H4DOTC)-199

GENERAL DESCRIPTION
CV:DTC P1160 RETURN SPRING FAILURE

Judge as NG when the valve does not move to the close direction with the motor power stopped and the
valve open more than the default opening.
(1)
(8)
S S
(7)
(3)
(6)
(2)
(4)
(5)
EN-01866
(1) Opener spring

(2) Return spring
(5) Throttle valve

(6) Gear
(3) Intermediate stopper

(4) Full closed stopper
(7) DC motor
(8) Main and sub throttle sensor
3. ENABLE CONDITION
Enable Conditions
OFF
Motor continuity
OFF

Ignition switch ON OFF
more.
Judgment Value
Opening variation after continuity is set
to OFF
Threshold Value
< 2

GD(H4DOTC)-200

GENERAL DESCRIPTION


8. FAIL SAFE

GD(H4DOTC)-201

GENERAL DESCRIPTION
CW:DTC P1400 FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT

LOW
(1)
(A)
(2)
(3)
(4)
(B)
(C)
(5)
EN-01759
(1) Filter
(2) Coil
(A) Atmospheric pressure

(B) Shut-off valve
(3) Connector terminal

(4) Diaphragm
(C) To fuel tank
(5) Valve
3. ENABLE CONDITION
Ignition switch
Enable Conditions
ON
Battery voltage
10.9 V
1 second or more

not met.
Judgment Value
Threshold Value
Low

GD(H4DOTC)-202

GENERAL DESCRIPTION


8. FAIL SAFE
None

GD(H4DOTC)-203

GENERAL DESCRIPTION
CX:DTC P1410 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE

STUCK OPEN
Continually detects for a combination solenoid valve and lead valve stuck open condition.
Calculate the integrated value of secondary air supply piping pressure sensor output voltage maximum/minimum values and output voltage deviation for a constant time period after engine start, and if the difference
between the maximum/minimum is large and the integrated value is also large, judge as NG.
2. ENABLE CONDITION
Engine speed
Enable Conditions
< 500 rpm
9 seconds or more
After secondary air injection system stop 9 seconds or more

2 g (0.07 oz)/seconds or more
and
Less than 400 g (14.11 oz)/seconds
Battery voltage
10.9 V

Perform diagnosis continuously after engine start with the secondary air pump stopped and with a high air
flow amount.
When the solenoid and lead valves of the combination valve both are open and malfunctioning, a pulse will
appear in the secondary air supply piping pressure sensor output. This pulse is tracked by the following
method to detect the problem.
Calculate the maximum and minimum values of the secondary air supply piping pressure sensor output voltage, and integrated value (sum) of the output voltage deviation for kCOTIM seconds. The difference between
the maximum/minimum values is compared with the threshold value, and the sum is also compared with the
threshold value. If both exceed the threshold, the NG counter is counted up, and when the counter becomes
kCOCOT times, an NG judgment is made. If neither exceed the threshold, or only one exceeds the threshold,
it is judged as being normal.
Judgment Value
Pipe inner pressure difference between Max. and Min.
Threshold Value
0.048 V
Cumulative pipe inner pressure change per 4 milliseconds

Amount of atmospheric pressure change
24 V
< 4 mmHg



7. FAIL SAFE
None

GD(H4DOTC)-204

GENERAL DESCRIPTION
CY:DTC P1418 SECONDARY AIR INJECTION SYSTEM CONTROL A CIRCUIT

SHORTED
2. ENABLE CONDITION
Enable Conditions
None

NG.
Judgment Value
Battery voltage
Threshold Value
10.9 V
Ignition
ON
High

Normality Judgment
Judgment Value
Battery voltage
Threshold Value
10.9 V
Ignition
ON
Low


7. FAIL SAFE
None

GD(H4DOTC)-205

GENERAL DESCRIPTION
CZ:DTC P1420 FUEL TANK PRESSURE CONTROL SOL. VALVE CIRCUIT HIGH
(1)
(A)
(2)
(3)
(4)
(B)
(C)
(5)
EN-01759
(1) Filter
(2) Coil
(A) Atmospheric pressure

(B) Shut-off valve
(3) Connector terminal

(4) Diaphragm
(C) To fuel tank
(5) Valve
3. ENABLE CONDITION
Ignition switch
Enable Conditions
ON
Battery voltage
10.9 V
1 second or more

GD(H4DOTC)-206

GENERAL DESCRIPTION
not met.
Judgment Value
Threshold Value
High



8. FAIL SAFE
None

GD(H4DOTC)-207

GENERAL DESCRIPTION
DA:DTC P1443 VENT CONTROL SOLENOID VALVE FUNCTION PROBLEM

Detect the abnormal function (stuck closed) of the drain valve.
Judge as NG when fuel tank pressure is low.
(19)
( 9 ) (10)
(14)
(15)
(11)
(16)
(12)
(8)
(13)
(7)
(17)
(4)
(5)
(19)
(6)
(2) (1)
(18)
(3)
EN-02294
(1)
(2)
Bobbin
Coil
(8)
(9)
Magnetic plate
Shaft
(14)
(15)
Retainer
Diaphragm
(3)
(4)
Diode
Stator core
(10)
(11)
Plate
Valve
(16)
(17)
Movable core
Spring
(5)
(6)
End plate
Body
(12)
(13)
Housing
Filter
(18)
(19)
Cover
O-ring
(7)
Yoke
3. ENABLE CONDITION
Drain valve
Enable Conditions
Open
Battery voltage
10.9 V
75.0 kPa (563 mmHg, 22.2 inHg)
Tank pressure when starter is OFF ON 0.67 1.43 kPa

(5 10.7 mmHg, 0.20 0.42 inHg)

GD(H4DOTC)-208

GENERAL DESCRIPTION
Judgment Value
Tank pressure
Threshold Value
4.0 kPa
(30 mmHg, 1.18 inHg)

Normality Judgment
Judgment Value
Tank pressure
Threshold Value
> 4.0 kPa
(30 mmHg, 1.18 inHg)
Cumulative time when all of the malfunc- 30 sec.

tion criteria below is completed.
Purge control solenoid valve duty ratio
Not = 0
Fuel temperature
10 45C
(14 113F)
26.7 kPa
(200 mmHg, 7.87 inHg)


8. FAIL SAFE

GD(H4DOTC)-209

GENERAL DESCRIPTION
DB:DTC P1491 POSITIVE CRANKCASE VENTILATION (BLOW-BY) FUNCTION

PROBLEM
Detect the blow-by hose release abnormality.
Judge as NG when the diagnosis terminal voltage is high.
(1)
(4)
(2)
(3)
EN-01790

(3) PCV diagnosis connector
(4) 5 V
3. ENABLE CONDITION
Enable Conditions
None

GD(H4DOTC)-210

GENERAL DESCRIPTION
seconds.
Judgment Value
Threshold Value
Battery voltage
voltage
> 10.9 V
High
Engine speed
500 rpm

Normality Judgment
Judgment Value
Battery voltage
voltage
Engine speed
Threshold Value
> 10.9 V
Low
500 rpm


8. FAIL SAFE
None

GD(H4DOTC)-211

GENERAL DESCRIPTION
DC:DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT

Judge as OFF NG when the engine starts without starter ON experience.
2. ENABLE CONDITION
Enable Conditions
None

Judge as OFF NG when the following conditions are established.
Judgment Value
Threshold Value
Vehicle speed
Starter ON signal
< 1 km/h (0.62 MPH)

Not detected
Engine speed in 0.8 seconds or more for

which the condition that engine speed is
less than 500 rpm continues
500 rpm

Normality Judgment
Judge as OFF OK and clear the NG when the malfunction criteria below are met.
Judgment Value
Threshold Value
Starter ON
Starter ON diagnosis
Experienced
Not diagnosed
Battery voltage
>8V


7. FAIL SAFE
None

GD(H4DOTC)-212

GENERAL DESCRIPTION
DD:DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION

Detect the open/short circuit of back-up power supply circuit.
Judge as NG when the backup voltage becomes smaller than the battery voltage.
2. ENABLE CONDITION
Enable Conditions
None

seconds.
Judgment Value
Battery voltage
Threshold Value
< Battery voltage 0.7
10.9 V

Normality Judgment
Judgment Value
Threshold Value
Battery voltage 0.7
Battery voltage
10.9 V


7. FAIL SAFE
None

GD(H4DOTC)-213

GENERAL DESCRIPTION
DE:DTC P1570 ANTENNA

NOTE:
For the detection standard, refer to DTC P0513 INCORRECT IMMOBILIZER KEY. <Ref. to GD(H4DOTC)179, DTC P0513 INCORRECT IMMOBILIZER KEY, Diagnostic Trouble Code (DTC) Detecting Criteria.>
DF:DTC P1571 REFERENCE CODE INCOMPATIBILITY

NOTE:
DG:DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT)

NOTE:
DH:DTC P1574 KEY COMMUNICATION FAILURE

NOTE:
DI: DTC P1576 EGI CONTROL MODULE EEPROM

NOTE:
DJ:DTC P1577 IMM CONTROL MODULE EEPROM

NOTE:
GD(H4DOTC)-214

GENERAL DESCRIPTION
DK:DTC P1602 CONTROL MODULE PROGRAMMING ERROR

Detect the malfunction of catalytic converter initial warm-up retard angle control.
Judge as NG if the ECM is not operating properly when performing catalytic converter initial warm-up retard
angle control.
Judge as NG when either the exhaust temperature diagnosis or the idle speed diagnosis becomes NG.
Exhaust temperature diagnosis
Judge as NG if the exhaust temperature is below the specified value at 14 seconds after a cold start.
Idle speed diagnosis
Judge as NG when actual engine speed is not close to the target engine speed after stopping the retard angle
control.
2. ENABLE CONDITION
Enable Conditions
> 75.1 kPa (563 mmHg,

22.2 inHg)
Battery voltage
Cold start diagnosis
> 10.9 V
Incomplete
Engine
Vehicle speed
Run
2 km/h (1 MPH)
Misfire in 200 engine revs.

Time elapsed after engine start
<5
14 seconds

Perform diagnosis during cold start.
GD(H4DOTC)-215

GENERAL DESCRIPTION
Exhaust temperature diagnosis
When the diagnostic execution conditions are established, calculate the estimated exhaust temperature.
Judge as NG if the following conditions are established within 14 seconds after starting the engine.
Judgment Value
Threshold Value
< Value from Map 1
Map 1
Coolant temperature at
engine start
40C
(40F)
30C
(22F)
20C
(4F)
10C
(14F)
0C
(32F)
10C
(50F)
20C
(68F)
30C
(86F)
40C
50C
(104F) (122F)
Threshold Value
200C
(392F)
200C
200C
200C
200C
200C
180C
180C
180C
180C
(392F) (392F) (392F) (392F) (392F) (356F) (356F) (356F) (356F)

Normality Judgment
Judgment Value
Threshold Value
Value from Map 1
Idle speed diagnosis

Judge as NG when all the following conditions are established and judge as OK when not met.
Threshold Value
Continuous time of (target engine RPM

engine RPM > 100)
10000 milliseconds
(actual retard amount > 5CA)
3000 milliseconds



7. FAIL SAFE
None

GD(H4DOTC)-216

GENERAL DESCRIPTION
DL:DTC P2004 INTAKE MANIFOLD RUNNER CONTROL STUCK OPEN (BANK 1)

Detect the malfunction of tumble generator valve motor function.
Judge open fixing malfunction when the opening degree is large even after finishing the tumble generator
valve closing driving.
2. ENABLE CONDITION
Enable Conditions
Battery voltage
10.9 V
0C (32F)
0C (32F)

Judgment Value
Tumble generator valve opening
Tumble generator valve close signal
output
Threshold Value
67.4
2.2 seconds or more

Normality Judgment
Judgment Value
Threshold Value
< 67.4

output
2.2 seconds or more


7. FAIL SAFE
For tumble generator valve all closing points learning, not allowed to update to closing side.
For tumble generator valve all opening points learning, not allowed to update to opening side.
Tumble generator valve control
Output the open signal.

GD(H4DOTC)-217

GENERAL DESCRIPTION
DM:DTC P2005 INTAKE MANIFOLD RUNNER CONTROL STUCK OPEN (BANK 2)

Judge open fixing malfunction when the opening degree is large even after finishing the tumble generator
valve closing driving.
2. ENABLE CONDITION
Enable Conditions
Battery voltage
10.9 V
0C (32F)
0C (32F)

Judgment Value
output
Threshold Value
67.4
2.2 seconds or more

Normality Judgment
Judgment Value
Threshold Value
< 67.4

output
2.2 seconds or more


7. FAIL SAFE
Output the open signal.

GD(H4DOTC)-218

GENERAL DESCRIPTION
DN:DTC P2006 INTAKE MANIFOLD RUNNER CONTROL STUCK CLOSED

(BANK 1)
Judge close fixing malfunction when the opening degree is small even after finishing the tumble generator
valve open driving.
2. ENABLE CONDITION
Enable Conditions
Battery voltage
10.9 V
0C (32F)
0C (32F)

Judgment Value
Tumble generator valve open signal
output
Threshold Value
< 67.4
2.2 seconds or more

Normality Judgment
Judgment Value
Threshold Value
67.4

output
2.2 seconds or more


7. FAIL SAFE
Output the close signal.

GD(H4DOTC)-219

GENERAL DESCRIPTION
DO:DTC P2007 INTAKE MANIFOLD RUNNER CONTROL STUCK CLOSED

(BANK 2)
Judge close fixing malfunction when the opening degree is small even after finishing the tumble generator
valve open driving.
2. ENABLE CONDITION
Enable Conditions
Battery voltage
10.9 V
0C (32F)
0C

Judgment Value
output
Threshold Value
< 67.4
2.2 seconds or more

Normality Judgment
Judgment Value
Threshold Value
67.4

output
2.2 seconds or more


7. FAIL SAFE
Output the close signal.

GD(H4DOTC)-220

GENERAL DESCRIPTION
DP:DTC P2008 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT / OPEN

(BANK 1)
Detect the open or short circuit of tumble generator valve motor.
Judge NG when the open signal is sent from IC after tumble generator valve driving IC diagnosis.
(1)
(3)
(2)
E
EN-01789

(2) Tumble generator valve
(3) Battery
3. ENABLE CONDITION
Battery voltage
Enable Conditions
10.9 V
ECM output signal
Before signal change

from ON OFF
20 milliseconds or
more
Tumble generator valve ON signal output

time

At the main IC, check the sent signal at each timing which occurs just before the tumble generator valve output is set to ON OFF, and judge open NG when the open NG signal is sent 1 second in a row.
Judge OK and clear the NG when the OK signal is sent.
Judgment Value
Open NG signal input
Overcurrent NG signal input
Threshold Value
Low
High

GD(H4DOTC)-221

GENERAL DESCRIPTION


8. FAIL SAFE
Tumble generator valve control: Not allowed to move tumble generator valve.

GD(H4DOTC)-222

GENERAL DESCRIPTION
DQ:DTC P2009 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW (BANK 1)

Judge NG when the overcurrent signal is sent from IC after tumble generator valve driving IC diagnosis.
(1)
(3)
(2)
E
EN-01789

(3) Battery
3. ENABLE CONDITION
Battery voltage
Enable Conditions
10.9 V
ECM output signal

from ON OFF
20 milliseconds or
more

time

GD(H4DOTC)-223

GENERAL DESCRIPTION
At the main IC, check the sent signal at each timing which occurs just before the tumble generator valve output is set to ON OFF, and judge overcurrent NG when the overcurrent NG signal is sent 1 second in a row.
Judgment Value
Threshold Value
High
Low



8. FAIL SAFE

GD(H4DOTC)-224

GENERAL DESCRIPTION
DR:DTC P2011 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT / OPEN

(BANK 2)
Judge NG when the open signal is sent from IC after tumble generator valve driving IC diagnosis.
(1)
(3)
(2)
E
EN-01789

(3) Battery
3. ENABLE CONDITION
Battery voltage
Enable Conditions
10.9 V
ECM output signal

from ON OFF
20 milliseconds or
more

time

At the main IC, check the sent signal at each timing which occurs just before the tumble generator valve output is set to ON OFF, and judge open NG when the open NG signal is sent 1 second in a row. Judge OK
and clear the NG when the OK signal is sent.
Judgment Value
Threshold Value
Low
High

GD(H4DOTC)-225

GENERAL DESCRIPTION


8. FAIL SAFE

GD(H4DOTC)-226

GENERAL DESCRIPTION
DS:DTC P2012 INTAKE MANIFOLD RUNNER CONTROL CIRCUIT LOW (BANK 2)

Judge NG when the overcurrent signal is sent from IC after tumble generator valve driving IC diagnosis.
(1)
(3)
(2)
E
EN-01789

(3) Battery
3. ENABLE CONDITION
Battery voltage
Enable Conditions
10.9 V
ECM output signal

from ON OFF
20 milliseconds or
more

time

At the main IC, check the sent signal at each timing which occurs just before the tumble generator valve output is set to ON OFF, and judge overcurrent NG when the overcurrent NG signal is sent 1 second in a row.
Judgment Value
Threshold Value
High
Low

GD(H4DOTC)-227

GENERAL DESCRIPTION


8. FAIL SAFE

GD(H4DOTC)-228

GENERAL DESCRIPTION
DT:DTC P2016 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH

Detect open or short circuit of tumble generator valve position sensor.
(3)
(4)
(1)
(2)
EN-01768
(1) Rotor
(2) Return spring
(3) Voltage (V)
(4) Tumble generator valve opening ()
3. ENABLE CONDITION
Enable Conditions
None

Judgment Value
Output voltage
Threshold Value
< 0.167 V


GD(H4DOTC)-229

GENERAL DESCRIPTION

8. FAIL SAFE

GD(H4DOTC)-230

GENERAL DESCRIPTION
DU:DTC P2017 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH

(3)
(4)
(1)
(2)
EN-01768
(1) Rotor
(2) Return spring
(3) Voltage (V)
(4) Throttle valve opening angle ()
3. ENABLE CONDITION
Enable Conditions
None

Judgment Value
Output voltage
Threshold Value
4.843 V


GD(H4DOTC)-231

GENERAL DESCRIPTION

8. FAIL SAFE

GD(H4DOTC)-232

GENERAL DESCRIPTION
DV:DTC P2021 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH

(3)
(4)
(1)
(2)
EN-01768
(1) Rotor
(2) Return spring
(3) Voltage (V)
3. ENABLE CONDITION
Enable Conditions
None

Judgment Value
Output voltage
Threshold Value
< 0.167 V


GD(H4DOTC)-233

GENERAL DESCRIPTION

8. FAIL SAFE

GD(H4DOTC)-234

GENERAL DESCRIPTION
DW:DTC P2022 INTAKE MANIFOLD RUNNER POSITION SENSOR / SWITCH

(3)
(4)
(1)
(2)
EN-01768
(1) Rotor
(2) Return spring
(3) Voltage (V)
3. ENABLE CONDITION
Enable Conditions
None

Judgment Value
Output voltage
Threshold Value
4.843 V


GD(H4DOTC)-235

GENERAL DESCRIPTION

8. FAIL SAFE

GD(H4DOTC)-236

GENERAL DESCRIPTION
DX:DTC P2088 OCV SOLENOID VALVE SIGNAL A CIRCUIT OPEN (BANK 1)

Detect open or short circuit of the oil flow control valve solenoid.
Judge open NG when the current flow is small whereas duty signal is large, and judge short NG when the current flow is large whereas duty signal is small.
2. ENABLE CONDITION
Battery voltage
Enable Conditions
10.9 V

more.
Judgment Value
Threshold Value
Oil flow control solenoid valve control

duty
99.61%
Oil control solenoid valve control present

current
< 0.306 A

Normality Judgment
2 seconds.
Judgment Value
Target current value of the oil flow control
solenoid valve
Threshold Value
0.14%
|Target current value of the oil flow con 0.08 A

trol solenoid valve Oil flow control solenoid valve control current value |


GD(H4DOTC)-237

GENERAL DESCRIPTION
7. FAIL SAFE
learning compensation factor when making a normality judgment abnormality judgment, and then make
the whole learning incomplete.
Enter the initial value (0CA) to the compensation value of partial learning zone when making a normality judgment abnormality judgment.
AVCS control:
Make the oil flow control solenoid valve drive duty a predetermined value (9.36%).

GD(H4DOTC)-238

GENERAL DESCRIPTION
DY:DTC P2089 OCV SOLENOID VALVE SIGNAL A CIRCUIT SHORT (BANK 1)

2. ENABLE CONDITION
Battery voltage
Enable Conditions
10.9 V

more.
Judgment Value
Threshold Value

duty
< 0.39%

current
0.306 A

Normality Judgment
2 seconds.
Judgment Value
solenoid valve Oil flow control solenoid
valve control current value
Threshold Value
< 0.08 A


GD(H4DOTC)-239

GENERAL DESCRIPTION
7. FAIL SAFE
learning compensation factor when making a normality judgment abnormality judgment, and then
AVCS control:

GD(H4DOTC)-240

GENERAL DESCRIPTION
DZ:DTC P2092 OCV SOLENOID VALVE SIGNAL A CIRCUIT OPEN (BANK 2)

2. ENABLE CONDITION
Battery voltage
Enable Conditions
10.9 V

more.
Judgment Value
Threshold Value

duty
99.61%

current
< 0.306 A

Normality Judgment
2 seconds.
Judgment Value
solenoid valve
Threshold Value
0.14%

0.08 A


GD(H4DOTC)-241

GENERAL DESCRIPTION
7. FAIL SAFE
AVCS control:

GD(H4DOTC)-242

GENERAL DESCRIPTION
EA:DTC P2093 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT

HIGH (BANK 2)
2. ENABLE CONDITION
Battery voltage
Enable Conditions
10.9 V

more.
Judgment Value
Threshold Value

duty
< 0.39%

current
0.306 A

Normality Judgment
2 seconds.
Judgment Value
Threshold Value
< 0.08 A


GD(H4DOTC)-243

GENERAL DESCRIPTION
7. FAIL SAFE
AVCS control:

GD(H4DOTC)-244

GENERAL DESCRIPTION
EB:DTC P2096 POST CATALYST FUEL TRIM SYSTEM TOO LEAN BANK 1
Detect abnormalities in the fuel system by determining whether the sub feedback compensation amount is
shifting to rich or lean. If the sub feedback compensation amount from engine start to ignition off is shifting
to rich or lean, there is insufficient compensation. If it is insufficient, change the sub feedback compensation guard value, shift judgment line, and increment the guard operation counter (temporary NG counter).
When the guard operation counter (temporary NG counter) exceeds the set value, and the sub feedback
compensation is shifting to rich or lean, it is judged as NG.
(E)
(3)
V
(1)
(F)
(A)
(2)
(2)
(C)
(B)
(D)
EN-01696
(1) Atmosphere
(2) Exhaust gas

(B) Air fuel ratio
(3) Electromotive force
(C) Rich
(D) Lean
(E) Theoretical air fuel ratio
(F) Comparative voltage
3. ENABLE CONDITION
Enable Conditions
Continuous time when the following conditions

are established
1 second or more
Conditions for carrying out the sub feedback

learning
Complete

Perform the diagnosis continuously at a constant speed of approx. 75 km/h (47 MPH) or higher.
GD(H4DOTC)-245

GENERAL DESCRIPTION
Judge as NG when the continuous time when the following conditions are established is more than 5 seconds. Judge as OK and clear the NG when the following conditions are not established for a continuous time
of 5 seconds or more.
Judgment Value
Threshold Value
< 0.018



8. FAIL SAFE
None

GD(H4DOTC)-246

GENERAL DESCRIPTION
EC:DTC P2097 POST CATALYST FUEL TRIM SYSTEM TOO RICH BANK 1
Detect abnormalities in the fuel system by determining whether the sub feedback compensation amount is
shifting to rich or lean. If the sub feedback compensation amount from engine start to ignition off is shifting
to rich or lean, there is insufficient compensation. If it is insufficient, change the sub feedback compensation guard value, shift judgment line, and increment the guard operation counter (temporary NG counter).
When the guard operation counter (temporary NG counter) exceeds the set value, and the sub feedback
compensation is shifting to rich or lean, it is judged as NG.
(E)
(3)
V
(1)
(F)
(A)
(2)
(2)
(C)
(B)
(D)
EN-01696
(1) Atmosphere
(2) Exhaust gas

(B) Air fuel ratio
(3) Electromotive force
(C) Rich
(D) Lean
(E) Theoretical air fuel ratio
(F) Comparative voltage
3. ENABLE CONDITION
Enable Conditions
Continuous time when the following conditions

are established
1 second or more
Conditions for carrying out the sub feedback

learning
Complete

Perform the diagnosis continuously at a constant speed of approx. 75 km/h (47 MPH) or higher.
GD(H4DOTC)-247

GENERAL DESCRIPTION
Judge as NG when the continuous time when the following conditions are established is more than 5 seconds. Judge as OK and clear the NG when the following conditions are not established for a continuous time
of 5 seconds or more.
Judgment Value
Threshold Value

Count of limits moving to rich
0.018
4 times
Ratio of time for oxygen sensor upper or

lower to time or rich time/lean tim
9 (AT model)
5.7 (MT model)



8. FAIL SAFE
None

GD(H4DOTC)-248

GENERAL DESCRIPTION
ED:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/

PERFORMANCE
Judge as NG when the motor current becomes too large or drive circuit is heated.
12V
12V
(1)
(6)
(2)
(3)
(7)
(4)
(2)
(5)
EN-01867
(5) Temperature detection circuit

(3) Overcurrent detection circuit
(6) Electronic throttle control relay

(7) Motor
(4) Drive circuit
3. ENABLE CONDITION
Under control of electronic throttle control
Ignition switch
Enable Conditions
ON
ON

GD(H4DOTC)-249

GENERAL DESCRIPTION
Judgment Value
Motor current
Drive circuit inner temperature
Threshold Value
8A
175C (347F)



8. FAIL SAFE

GD(H4DOTC)-250

GENERAL DESCRIPTION
EE:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW

Judge as NG when the electronic throttle control power is not supplied even when ECM sets the electric throttle control relay to ON.
12V
12V
(1)
(4)
(2)
(5)
(3)
EN-01868

(2) Voltage detection circuit
(3) Drive circuit
(5) Motor
3. ENABLE CONDITION
electronic throttle control relay output
Battery voltage
Enable Conditions
ON
6V

GD(H4DOTC)-251

GENERAL DESCRIPTION
more.
Judgment Value
Motor power voltage
Threshold Value
5V



8. FAIL SAFE

GD(H4DOTC)-252

GENERAL DESCRIPTION
EF:DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH

Judge as NG when the electronic throttle control power is supplied even when ECM sets the electric throttle
control relay to OFF.
12V
12V
(1)
(4)
(2)
(5)
(3)
EN-01868

(2) Voltage detection circuit
(3) Drive circuit
(5) Motor
3. ENABLE CONDITION
electronic throttle control relay output
Battery voltage
Enable Conditions
OFF
6V

When ignition switch ON OFF
GD(H4DOTC)-253

GENERAL DESCRIPTION
Judgment Value
Motor power voltage
Threshold Value
5V



8. FAIL SAFE

GD(H4DOTC)-254

GENERAL DESCRIPTION
EG:DTC P2109 THROTTLE/PEDAL POSITION SENSOR A MINIMUM STOP

PERFORMANCE
Judge as NG when fully close point learning cannot conducted or outside the standard value.
(1)
(3)
(2)
(4)
EN-01869

(2) Drive circuit
(3) Motor
3. ENABLE CONDITION
Ignition switch
Ignition switch (only after cleaning the
memory)
Enable Conditions
ON OFF
OFF ON

Perform the diagnosis at full closed point learning.
Judgment Value
Threshold Value
Throttle sensor opening angle at all

close point learning
10.127 or more,
19.872 or less
Throttle opening angle when the ignition

switch is ON Throttle minimum stop
position
1.683
Time Needed for Diagnosis: 8 80 milliseconds

GD(H4DOTC)-255

GENERAL DESCRIPTION


8. FAIL SAFE

GD(H4DOTC)-256

GENERAL DESCRIPTION
EH:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT

LOW INPUT
(4)
(1)
(2)
(3)
EN-01861

(2) Accelerator pedal position sensor 1 signal
3. ENABLE CONDITION
Ignition switch
Enable Conditions
ON

Judgment Value
Threshold Value
0.219 V



GD(H4DOTC)-257

GENERAL DESCRIPTION
8. FAIL SAFE

GD(H4DOTC)-258

GENERAL DESCRIPTION
EI: DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT

HIGH INPUT
(4)
(1)
(2)
(3)
EN-01861

3. ENABLE CONDITION
Ignition switch
Enable Conditions
ON

Judgment Value
Threshold Value
4.781 V



GD(H4DOTC)-259

GENERAL DESCRIPTION
8. FAIL SAFE

GD(H4DOTC)-260

GENERAL DESCRIPTION
EJ:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT

LOW INPUT
(4)
(1)
(2)
(3)
EN-01861

3. ENABLE CONDITION
Ignition switch
Enable Conditions
ON

Judgment Value
Threshold Value
0.219 V



GD(H4DOTC)-261

GENERAL DESCRIPTION
8. FAIL SAFE

GD(H4DOTC)-262

GENERAL DESCRIPTION
EK:DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT

HIGH INPUT
(4)
(1)
(2)
(3)
EN-01861

3. ENABLE CONDITION
Ignition switch
Enable Conditions
ON

Judgment Value
Threshold Value
4.781 V



GD(H4DOTC)-263

GENERAL DESCRIPTION
8. FAIL SAFE

GD(H4DOTC)-264

GENERAL DESCRIPTION
EL:DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH A/B

VOLTAGE CORRELATION
Judge as NG when the signal level of accelerator pedal position sensor 1 is different from the throttle position
sensor 2.
(3)
(4)
(1)
(2)
EN-01859

3. ENABLE CONDITION
Ignition switch
Enable Conditions
ON

GD(H4DOTC)-265

GENERAL DESCRIPTION
Judgment Value
Threshold Value
4.25

12
(11.75)
(3)
10
(9.75)
8
(7.625)
(1)
6
(5.5)
(4.5)
4
0
0(2.125)(4.25)
(9.0) 10
20
30(31.625)
(2)
EN-04083
(1) Sensor output difference ()

(2) Throttle position sensor 1 opening angle ()
(3) NG area



8. FAIL SAFE
Stop the continuity to ETC motor. (Throttle opening is fixed to 6.)

GD(H4DOTC)-266

GENERAL DESCRIPTION
EM:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D/E

VOLTAGE CORRELATION
Judge as NG when the signal level of throttle position sensor 1 is different from the throttle position sensor 2.
(4)
(1)
(2)
(3)
EN-01861

3. ENABLE CONDITION
Ignition switch
Enable Conditions
ON

GD(H4DOTC)-267

GENERAL DESCRIPTION
Judgment Value
Threshold Value
0.77
(3)
(3.027)
3
(2.367)
(1)
2
(1.575)
(1.113)
1
(0.77)
0
0
(0.6)
1 (1.2)
(2)
EN-04084
(1) Sensor output difference

(2) Accelerator pedal position sensor 2 opening angle ()
(3) NG area



8. FAIL SAFE

GD(H4DOTC)-268

GENERAL DESCRIPTION
EN:DTC P2419 EVAPORATIVE EMISSION SYSTEM SWITCHING VALVE

CONTROL CIRCUIT LOW
Detect open or short circuit of the purge control solenoid valve 2.
2. ENABLE CONDITION
Enable Conditions
None

seconds.
Judgment Value
Threshold Value
Ignition switch
Battery voltage
ON
10.9 V

Terminal output voltage when ECM outputs
OFF signal
1 second or more
Low

Normality Judgment
Judgment Value
Threshold Value
Ignition switch
Battery voltage
ON
10.9 V

OFF signal
1 second or more
High


7. FAIL SAFE
None

GD(H4DOTC)-269

GENERAL DESCRIPTION
EO:DTC P2420 EVAPORATIVE EMISSION SYSTEM SWITCHING VALVE

CONTROL CIRCUIT HIGH
Detect open or short circuit of the purge control solenoid valve 2.
2. ENABLE CONDITION
Enable Conditions
None

seconds.
Judgment Value
Threshold Value
Ignition switch
Battery voltage
ON
10.9 V

ON signal
1 second or more
High

Normality Judgment
Judgment Value
Threshold Value
Ignition switch
Battery voltage
ON
10.9 V

ON signal
1 second or more
Low


7. FAIL SAFE
None

GD(H4DOTC)-270

GENERAL DESCRIPTION
EP:DTC P2431 SECONDARY AIR INJECTION SYSTEM AIR FLOW /PRESSURE

SENSOR CIRCUIT RANGE/PERFORMANCE
Detect malfunction in the secondary air pressure sensor output properties.
Judge as NG when the secondary air pressure sensor output is largely different from the intake manifold
pressure at engine start.
2. ENABLE CONDITION
Engine speed at startup
Vehicle speed
Enable Conditions
< 300 rpm
< 1 km/h

Perform the diagnosis with the ignition switch ON.
Judgment Value
Threshold Value
|Secondary air supply piping pressure

Intake manifold pressure |
200 mmHg
|Intake manifold pressure at engine startup Intake manifold pressure |
< 10 mmHg

Normality Judgment
Judge as OK and clear the NG when the continuous time when the following conditions are established are
more than 0.26 seconds.
Judgment Value
|Secondary air supply piping pressure
Intake manifold pressure |
Threshold Value
< 200 mmHg


7. FAIL SAFE
None

GD(H4DOTC)-271

GENERAL DESCRIPTION
EQ:DTC P2432 SECONDARY AIR INJECTION SYSTEM AIR FLOW /PRESSURE

SENSOR CIRCUIT LOW
2. ENABLE CONDITION
Enable Conditions
None

Judgment Value
Ignition switch
Threshold Value
ON
Output voltage
< 0.568 V

Normality Judgment
Judgment Value
Ignition switch
Output voltage
Threshold Value
ON
0.568 V


7. FAIL SAFE
None

GD(H4DOTC)-272

GENERAL DESCRIPTION
ER:DTC P2433 SECONDARY AIR INJECTION SYSTEM AIR FLOW /PRESSURE

SENSOR CIRCUIT HIGH
2. ENABLE CONDITION
Enable Conditions
None

Judgment Value
Ignition switch
Threshold Value
ON
Output voltage
4.921 V

Normality Judgment
Judgment Value
Ignition switch
Output voltage
Threshold Value
ON
< 4.921 V


7. FAIL SAFE
None

GD(H4DOTC)-273

GENERAL DESCRIPTION
ES:DTC P2440 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE

STUCK OPEN (BANK 1)
NOTE:
ET:DTC P2441 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE

NOTE:
EU:DTC P2442 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE

STUCK OPEN (BANK 2)
NOTE:
EV:DTC P2443 SECONDARY AIR INJECTION SYSTEM SWITCHING VALVE

NOTE:
GD(H4DOTC)-274

GENERAL DESCRIPTION
EW:DTC P2444 SECONDARY AIR INJECTION SYSTEM PUMP STUCK ON

Detect functional errors (continually ON) of the secondary air pump.
When the secondary air supply piping pressure is high in comparison to the atmospheric pressure, it is
judged as NG.
2. ENABLE CONDITION
Enable Conditions
None

When the secondary air pump is OFF, the secondary air supply pipe pressure should be atmospheric pressure. If it is higher than atmospheric pressure, judge as NG.
Judge as NG if the continuous time with all of the following conditions established is more than 5 seconds.
Threshold Value

Battery voltage
4.4C (39.92F)
10.9 V
After secondary air injection system operation

Battery voltage
0.6 seconds or more

7V
Engine
75.0 kPa (563 mmHg, 22.15 inHg)

In operation
After secondary air injection system stop

Secondary air supply piping pressure (Absolute pressure)
3 seconds or more
> Value from Map 22
Map 22
Atmospheric pressure (kPa (mmHg, inHg))
Unit:
(kPa (mmHg, inHg))
69.3
(520,
20.47)
78.0 (585,
23.03)
79.3 (595,
23.42)
74.6
(560,
22.03)
84.0 (630,
24.80)
85.4 (641,
25.22)
80.0
(600,
23.63)
90.0 (675,
26.58)
91.6 (687,
27.05)
85.3
(640,
25.19)
96.0 (720,
28.35)
97.7 (733,
28.86)
90.6
(680,
26.76)
102.0 (765,
30.13)
103.7 (778,
30.63)
96.0
(720,
28.35)
108.0 (810,
31.90)
109.8 (824,
32.43)
101.3
(760,
29.92)
114.0 (855,
33.67)
116.0 (870,
34.26)
106.6
(800,
31.48)
120.0 (900,
35.44)
122.1 (916,
16.28)
12.5
80.8 (606,
23.86)
86.9 (652,
25.67)
93.2 (699,
27.53)
99.3 (745,
29.33)
105.6 (792,
31.19)
111.7 (838,
32.99)
118.0 (885,
34.85)
124.2 (932,
36.68)
13.5
82.1 (616,
24.25)
88.4 (663,
26.11)
94.8 (711,
28.0)
101.0 (758,
29.83)
107.3 (805,
31.69)
113.7 (853,
33.58)
120.0 (900,
35.44)
126.2 (947,
37.27)
14.5
83.4 (626,
24.63)
84.8 (636,
25.05)
89.8 (674,
26.52)
89.8 (685,
26.52)
96.2 (722,
28.41)
97.8 (734,
28.89)
102.8 (771,
30.36)
104.4 (783,
30.83)
109.2 (819,
32.25)
110.9 (832,
32.75)
115.6 (867,
34.14)
117.4 (881,
34.67)
122.0 (915,
36.03)
124.0 (930,
36.62)
128.4 (963,
37.92)
130.5 (979,
38.54)
Battery voltage (V)
10.5
11.5
15.5

GD(H4DOTC)-275

GENERAL DESCRIPTION
Normality Judgment
Judge as OK if the continuous time with all of the following conditions established is more than 5 seconds,
and clear the NG.
Judgment Value
Threshold Value

Battery voltage
4.4C (39.92F)
10.9 V
After secondary air injection system

operation
Battery voltage
0.6 seconds or more
75.0 kPa (563 mmHg,

22.15 inHg)
7V
Engine
In operation
Secondary air supply piping pressure
(Absolute pressure)
Value from Map 22


7. FAIL SAFE
None

GD(H4DOTC)-276
General Description
CONTROL SYSTEMS
A: SPECIFICATION
Item
Specification
Swing torque of rod against lever
N (kgf, lb)
3.7 (0.38, 0.84) or less
B: COMPONENT
1. AT SELECT LEVER
(11)
(14)
(15)
(16)
(12)
(1)
(17)
(13)
(18)
(3)
(28)
(18)
(40)
(23)
(2)
(26)
(24)
(25)
(20)
(7)
(21)
(19)
(22)
(4)
T3
T1
(28)
(27)
(29)
(9)
(5)
(6)
(30)
(31)
(32)
(28)
(8)
(33)
(10)
(36)
(34)
(35)
T4
(37)
(39)
T4
(38)
T2
CS-00711
CS-2
General Description
CONTROL SYSTEMS
(1)
(2)
Grip
Indicator cover
(17)
(18)
Bracket
Bushing
(32)
(33)
Grommet
Packing
(3)
(4)
Cover
Blind
(19)
(20)
Lock plate B
Bushing
(34)
(35)
Spacer
Washer
(5)
(6)
Cushion
Button
(21)
(22)
Bushing
Lock plate A
(36)
(37)
Snap pin
Select cable
(7)
(8)
Cushion
P range switch
(23)
(24)
Bushing
Lock plate C
(38)
(39)
Adjusting nut B
Adjusting nut A
(9)
(10)
Spring
Guide plate
(25)
(26)
Shift lock solenoid

Clamp
(40)
Cover
(11)
Detent arm
(27)
Indicator bulb
(12)
(13)
Detent spring
Tube
(28)
(29)
Clip
Select lever arm
T1: 2.0 (0.2, 1.4)

T2: 7.5 (0.76, 5.5)
(14)
(15)
Selector lever COMPL

Spring pin
(30)
(31)
Bushing COMPL
Base plate
T3: 13 (1.3, 9.4)

T4: 18 (1.8, 13.0)
(16)
Bushing
CS-3
General Description
CONTROL SYSTEMS
2. MT GEAR SHIFT LEVER

(1)
(27)
(2)
(3)
T1
(16)
(26)
(17)
(19)
(28)
(19)
(24)
T1
(28)
(26)
(18) (26)
T1
T3
(4)
(6)
(28)
(7)
(19)
(28)
(7)
(8)
(9)
(5)
(12)
(10)
(11)
(13)
(14)
(20)
(15)
(25)
(21)
T2
T2
(23)
(22)
(26)
T2
CS-00679
(1)
(2)
Gear shift knob

Console boot
(12)
(13)
Spring pin
Bushing B
(23)
(24)
Cushion rubber
Boss
(3)
(4)
Clamp
Boot and insulator ASSY
(14)
(15)
O-ring
Boot
(25)
(26)
Bushing
Self-locking nut
(5)
(6)
Plate ASSY
Lever
(16)
(17)
Spring pin
Joint
(27)
(28)
Front cover
Bushing
(7)
(8)
Bushing
Lock wire
(18)
(19)
Rod
Spacer
(9)
(10)
Snap ring
Bushing
(20)
(21)
Bracket
Washer
T1: 12 (1.2, 8.9)

T2: 18 (1.8, 13.3)
(11)
O-ring
(22)
Stay
T3: 7.5 (0.76, 5.5)
CS-4
General Description
CONTROL SYSTEMS
C: CAUTION
Use SUBARU genuine fluid, grease etc. or
equivalent. Do not mix fluid, grease, etc. of different
grades or manufacturers.
points.
Apply grease onto sliding or revolving surfaces
before installation.
Before installing O-rings or snap rings, apply sufficient amount of grease to avoid damage and deformation.
Before securing a part on a vise, set cushioning
material such as wood blocks, aluminum plate, or
shop cloth between the part and the vise.
Before disconnecting electrical connectors, be
sure to disconnect the negative terminal from battery.
CS-5

CONTROL SYSTEMS

A: LOCATION
(4)
(7)
(2)
(3)
(1)
(6)
(5)
CS-00509
(1)
(2)
Inhibitor switch
Body integrated unit
(3)
Stop light switch
(4)
(5)
Key warning switch

Shift lock solenoid
CS-6
(6)
(7)
P range switch
Key lock solenoid

CONTROL SYSTEMS
(2)
(1)
CS-00006
CS-00083
(6)
(3 )
(5)
CS-00084
(4)
(7)
CS-00008
CS-7
CS-00085
AT Shift Lock Control System

CONTROL SYSTEMS
3. AT Shift Lock Control System

To B280
To B281
10 9
16 15 14 13 12 11 10 9
20 19 18 17 16 15 14 13 12 11
CS-00086
Contents
To Connector No.
Terminal No.
Input/Output signal
B280
Measured value and measuring conditions

9 16 V
Ignition power supply

B281
B281
19
10
10 15 V when ignition switch is at ON or START.

10 15 V when ignition switch is at ACC or ON.
Inhibitor switch (P range)
B281
Stop light switch
B281
P range switch
B281
Shift lock solenoid signal
B280
Key warning switch signal
B281
20
9 16 V when key is inserted.

0 V when key is removed.
Key lock solenoid signal
B280
Pulse is output when switching key lock between locked

and unlocked.
0 V at other conditions than above.
Ground
Ground
B280
B280
4
13
CS-8
0 V when select lever is in P range.

9 16 V when select lever is in other ranges than P
range.
9 16 V when stop light switch is ON.
0 V when stop light switch is OFF.
0 V when select lever is in P range.
9 16 V when select lever is in other ranges than P
range.
8.5 16 V when shift lock is released.
0 V when shift lock is operating.

CONTROL SYSTEMS
B: WIRING DIAGRAM
OFF ACC ON
CS-00012
(1)
Ignition switch
(4)
(7)
Shift lock solenoid
(2)
(3)
Stop light switch

Key warning switch
(5)
(6)
Inhibitor switch
Key lock solenoid
(8)
(9)
P range switch
Battery
CS-9

CONTROL SYSTEMS
C: INSPECTION
1. SHIFT LOCK OPERATION
1
Step
CHECK SHIFT LOCK.
2) Move the select lever to P range.
CHECK SHIFT LOCK.
CHECK KEY INTERLOCK.
CHECK KEY INTERLOCK.
Check
While brake pedal is not
depressed, can the select lever
move from P range to other
ranges?
Yes
No
Inspect SELECT Go to step 2.
LEVER CANNOT
BE SHIFT
LOCKED. <Ref. to
CS-15, SELECT
LEVER CANNOT
BE SHIFT
LOCKED,
INSPECTION, AT
Shift Lock Control
System.>
While brake pedal is
Go to step 3.
Inspect SELECT
depressed, can select lever
LEVER CANNOT
move from P range to other
BE SHIFTED.
ranges?
<Ref. to CS-13,
SELECT LEVER
CANNOT BE
SHIFTED,
INSPECTION, AT
Shift Lock Control
System.>
Is the ignition switch turned to Inspect KEY
Go to step 4.
the LOCK position when the INTERLOCK
select lever is set to other than DOES NOT BE
P range?
LOCK OR
UNLOCK. <Ref.
to CS-18, KEY
INTERLOCK
DOES NOT LOCK
OR RELEASE,
INSPECTION, AT
Shift Lock Control
System.>
Is the ignition switch turned to AT shift lock control Inspect KEY
the LOCK position when the system is normal. INTERLOCK
select lever is set to the P
DOES NOT BE
range?
LOCK OR
UNLOCK. <Ref.
to CS-18, KEY
INTERLOCK
DOES NOT LOCK
OR RELEASE,
INSPECTION, AT
Shift Lock Control
System.>
CS-10

CONTROL SYSTEMS
2. BODY INTEGRATED UNIT POWER SUPPLY AND GROUND CIRCUIT

WIRING DIAGRAM:
IGNITION
SWITCH
OFF ACC ON
B33
FBS-4
FBS-1
1 2 3 4
5 6 7 8
ACC
FBS-6
IG
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
No.3
No.4
No.18
B280
BATTERY
B281
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
A13
A4
A2
B10
B19
B33
JOINT
CONNECTOR
A: B280
BODY INTEGRATED UNIT
B: B281
CS-00662
CS-11

CONTROL SYSTEMS
Step
CHECK FUSE.
Remove the fuses No. 3, 4 and 18.
Check
Are the fuses No. 3, 4 and 18
blown?
Yes
No
Replace the fuses Go to step 2.
No. 3, 4 and 18. If
the replaced fuse
No. 3, 4 or 18
blows easily, repair
the short circuit of
harness between
the fuse and body
integrated unit.
CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 ? Go to step 3.
Repair the open
BODY INTEGRATED UNIT AND CHASSIS
circuit of harness
GROUND.
between the body
integrated unit and
2) Measure the harness resistance between
chassis ground.
the body integrated unit and chassis ground.
CHECK BATTERY POWER SUPPLY.
Go to step 4.
Repair the open
circuit harness
2) Check the voltage between body integrated
between battery
unit and chassis ground.
and body inteConnector & terminal
grated unit, and
poor contact in
connector.
CHECK IGNITION POWER SUPPLY CIRIs the voltage 9 V or more?
Go to step 5.
Repair the open
CUIT.
circuit harness
1) Turn the ignition switch to ACC.
between battery
2) Check the voltage between body integrated
and body inteunit and chassis ground.
grated unit, and
poor contact in
connector.
Go to step 6.
Repair the open
CUIT.
circuit harness
between battery
2) Measure the voltage between body inteand body integrated unit and chassis ground.
grated unit, and
poor contact in
connector.
CHECK POOR CONTACT.
Is there poor contact in the con- Repair the poor
Replace the body
nector?
contact.
integrated unit.
CS-12

CONTROL SYSTEMS
3. SELECT LEVER CANNOT BE SHIFTED

WIRING DIAGRAM:
SBF-1
FBS-2
B65
1 2
3 4
BATTERY
No.16
B112
1 2 3 4
STOP LIGHT SWITCH

B117
B65
1
2
3 4 5 6
B9
2
3
A: B280
B: B281 (GRAY)
B: B281
A9
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
DIODE
3
4
A: B280 (BLUE)
B112
SHIFT LOCK SOLENOID
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
4
5
B117
E
CS-00663
CS-13

CONTROL SYSTEMS
1
2
Step
CHECK STOP LIGHT SWITCH.
Depress the brake pedal.
CHECK HARNESS BETWEEN STOP LIGHT
SWITCH AND BODY INTEGRATED UNIT.
2) Disconnect the connectors of body integrated unit and stop light switch.
stop light switch and body integrated unit.
(B65) No. 3 (B281) No. 9:
CHECK HARNESS BETWEEN STOP LIGHT
SWITCH AND BODY INTEGRATED UNIT.
stop light switch and chassis ground.
CHECK HARNESS BETWEEN BODY INTEGRATED UNIT AND SHIFT LOCK SOLENOID.
1) Disconnect the connector of shift lock solenoid.
body integrated unit and the shift lock solenoid.
(B117) No. 4 (B280) No. 9:
shift lock solenoid and chassis ground.
CHECK HARNESS BETWEEN SHIFT LOCK
SOLENOID AND CHASSIS GROUND.
CHECK SHIFT LOCK SOLENOID.
Measure the resistance of the shift lock solenoid connector terminals.
Terminals
No. 4 No. 5:
Connect the battery to connector terminal of
shift lock solenoid, and operate the solenoid.
Terminals
No. 4 (+) No. 5 ():
CHECK POOR CONTACT.
Check
Yes
Does the stop light illuminate? Go to step 2.
more?
Repair the open

circuit of harness
between the body
integrated unit and
stop light switch.
No
Check the stop
light system.
Go to step 3.
Is the resistance less than 1 ? Repair the short

Go to step 4.
circuit of harness
between the body
integrated unit and
stop light switch.
more?
Repair the open

Go to step 5.
circuit of harness
between body integrated unit and
shift lock solenoid.
Is the resistance less than 1 ? Repair the short

Go to step 6.
circuit of harness
between the body
integrated unit and
more?
Repair open circuit Go to step 7.

of harness
between shift lock
solenoid and chassis ground.

and 40 ?
Go to step 8.
Replace the shift

lock solenoid.
Is the shift lock solenoid operat- Go to step 9.

ing properly?
Replace the shift

lock solenoid.

nector?
contact.
Replace the body

integrated unit.
CS-14

CONTROL SYSTEMS
4. SELECT LEVER CANNOT BE SHIFT LOCKED

WIRING DIAGRAM:
FBS-1
B65
FBS-2
1 2
3 4
FBS-4
BATTERY
IGNITION
SWITCH
B112
OFF ACC ON
1 2 3 4
No.16
B
ACC
IG
B117
INHIBITOR SWITCH
STOP LIGHT SWITCH
T3
B12
B65
B12
1 2 3 4
5 6 7 8
9 10 11 12
B9
T7
1
2
3 4 5 6
2
3
A: B280
B: B281
A: B280
A9
B19
B5
No.18
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
DIODE
3
4
B112
B: B281
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
SHIFT LOCK SOLENOID

4
B117
CS-00664
CS-15

CONTROL SYSTEMS
8
9
Step
Check
Combination meter indicator
1) Turn the ignition switch to ON. (engine OFF) light and select lever P, R,
2) Move the select lever from P to 1 range. N, 3, 2 and 1 are correctly
matched?
CUIT.
2) Measure the voltage between body integrated unit and chassis ground.
CHECK HARNESS BETWEEN THE INHIBI- Is the resistance less than 1 ?
TOR SWITCH AND THE BODY INTEGRATED
UNIT.
2) Disconnect the transmission harness and
body integrated unit connector.
the body integrated unit and chassis ground.
CHECK HARNESS BETWEEN THE INHIBI- Is the resistance 1 M or
TOR SWITCH AND THE BODY INTEGRATED more?
UNIT.
body integrated unit and inhibitor switch.
(B12) No. 3 (B281) No. 5:
CHECK HARNESS BETWEEN INHIBITOR
SWITCH AND CHASSIS GROUND.
Measure the harness resistance between the
body integrated unit and chassis ground.
more?
(T3) No. 3 No. 4:
CHECK OUTPUT SIGNAL OF BODY INTEGRATED UNIT.
Does the stop light illuminate?
CHECK HARNESS BETWEEN STOP LIGHT Is the voltage 9 V or more?
SWITCH AND AT SHIFT LOCK CONTROL
MODULE.
1) Depress the brake pedal.
CS-16
Yes
Go to step 2.
No
Adjust inhibitor
switch and select
cable.
Go to step 3.
Repair the open

circuit harness
between battery
and body integrated unit, and
poor contact in
connector.
Go to step 4.
Repair the short

circuit of harness
between the body
integrated unit and
transmission connector.
Repair the open

Go to step 5.
wire of harness
between the body
integrated unit and
Go to step 6.
Repair the open

circuit of harness
between the body
integrated unit and
chassis ground.
Repair or replace
inhibitor switch.
Go to step 7.
Go to step 8.
Go to step 16.
Go to step 9.
Check the stop

light system.
Repair the open or
short circuit of harness between the
body integrated
unit and stop light
switch.
Go to step 10.

CONTROL SYSTEMS
10
11
12
13
14
15
16
Step
2) Disconnect the shift lock solenoid and body
integrated unit connector.
body integrated unit and the shift lock solenoid.
(B280) No. 9 (B117) No. 4:
Measure the resistance of the shift lock solenoid connector terminals.
Terminals
No. 4 No. 5:
Connect the battery to connector terminal of
shift lock solenoid, and operate the solenoid.
Terminals
No. 4 (+) No. 5 ():
CHECK OUTPUT SIGNAL FOR AT SHIFT
LOCK CONTROL MODULE.
CHECK POOR CONTACT.
Check
more?
Yes
No
Repair the open
Go to step 11.
circuit of harness

?
Go to step 12.
Repair the short

circuit of harness
between the body
integrated unit and
Repair open circuit

of harness
between shift lock

and 40 ?
Go to step 14.
Replace the shift

lock solenoid.
Is the shift lock solenoid operat- Go to step 15.

ing properly?
Replace the shift

lock solenoid.
Replace the body

integrated unit.
Go to step 16.

nector?
contact.
CS-17
Replace the body

integrated unit.

CONTROL SYSTEMS
5. KEY INTERLOCK DOES NOT LOCK OR RELEASE

WIRING DIAGRAM:
SBF-2
B73
SBF-1
No.6
1
2
3 4 5 6
BATTERY
B117
1
2
3 4 5 6
B194
KEY WARNING SWITCH
F44
B61
4
1 2
1
2
A:
B280
A3
B20
KEY LOCK SOLENOID
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
6
A: B280
B73
B: B281
B: B281
B6
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
NA
"P" RANGE SWITCH
TB
B194
F44
B195
1 2 3 4
5 6 7 8
2
NA
6
B117
TB
CS-00665
CS-18

CONTROL SYSTEMS
Step
AND KEY WARNING SWITCH.
1) Disconnect the connector of key warning
switch.
key warning switch and chassis ground.
CHECK KEY WARNING SWITCH.
Measure the resistance between connector terminals of key warning switch.
Terminals
No. 1 No. 2:
1) Remove the key.
terminals of key warning switch.
Terminals
No. 1 No. 2:
CHECK HARNESS BETWEEN AT SHIFT
LOCK CONTROL MODULE AND KEY
WARNING SWITCH.
1) Disconnect the body integrated unit connector.
CHECK HARNESS BETWEEN BODY INTEGRATED UNIT AND KEY LOCK SOLENOID.
1) Disconnect the connector key lock solenoid.
body integrated unit and the key lock solenoid.
(B73) No. 5 (B280) No. 3:
CHECK HARNESS BETWEEN BODY INTEGRATED UNIT AND KEY LOCK SOLENOID.
Measure the harness resistance between the
body integrated unit and chassis ground.
CHECK HARNESS BETWEEN KEY LOCK
key lock solenoid and chassis ground.
CHECK KEY LOCK SOLENOID.
Measure the resistance of key lock solenoid
connector terminals.
Terminals
No. 1 No. 2:
CHECK HARNESS BETWEEN P RANGE
Measure the resistance of harness between P
range switch and chassis ground.
Check
Yes
Go to step 2.
No
Repair the open or
short circuit of harness between battery and key
warning switch.
more?
Replace the key

warning switch.
Go to step 3.
more?
Go to step 4.
Replace the key

warning switch.
Go to step 5.
Repair the open

circuit of harness
between body integrated unit and key
warning switch.
more?
Repair the open

Go to step 6.
circuit of harness
lock solenoid.
Repair the short of

the harness
lock solenoid.

?
Repair open circuit

or the poor contact
of the harness
between key lock
Replace the key
lock solenoid.
Go to step 8.

8 ?
CS-19
Repair the short

circuit of harness
between P range
switch and body
integrated unit.

CONTROL SYSTEMS
10
11
12
13
14
15
Step
CHECK HARNESS BETWEEN AT SHIFT
LOCK CONTROL MODULE AND P RANGE
SWITCH.
1) Disconnect the connector of P range
switch.
body integrated unit and P range switch.
(B117) No. 2 (B281) No. 6:
CHECK HARNESS BETWEEN P RANGE
Measure the resistance of harness between P
range switch and chassis ground.
CHECK P RANGE SWITCH.
2) Measure the resistance between P range
switch connector terminals.
Terminals
No. 2 No. 6:
Terminals
No. 2 No. 6:
CHECK OUTPUT SIGNAL OF BODY INTEGRATED UNIT.
1) Disconnect all connectors.
5) Measure the voltage between body integrated unit connector and chassis ground.
CHECK POOR CONTACT.
Check
more?
Yes
No
Repair the open
Go to step 11.
circuit of harness
between body integrated unit and P
range switch.
more?
Repair the open

Go to step 12.
circuit of harness
between P range
switch and chassis
ground.
Replace the P
range switch.
more?
Go to step 14.
Replace the P
range switch.
Is the voltage 7.5 16 V?
Go to step 15.
Replace the body

integrated unit.
Is there poor contact of the con- Repair the poor

nector?
contact.
CS-20
Replace the body

integrated unit.
Select Lever
CONTROL SYSTEMS
4. Select Lever
B: INSTALLATION
A: REMOVAL
1) Mount the select lever onto the vehicle body.

2) Tighten the four bolts at the prescribed torque,
then connect the connector.

3) Set the select lever to N range.
5) Remove the rear exhaust pipe and muffler.
Non-turbo model
<Ref. to EX (H4SO)-8, REMOVAL, Rear Exhaust
Pipe.> <Ref. to EX (H4SO)-9, REMOVAL, Muffler.>
Turbo model
<Ref. to EX(H4DOTC)-13, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-15, REMOVAL, Muffler.>
6) Disconnect the cable from range select lever
and then remove the cable bracket.
(B)
(A)
CS-00017
(A) Adjusting nut

(B) Cable bracket

8) Remove the console box. <Ref. to EI-38, REMOVAL, Console Box.>
9) Disconnect the connectors, and then remove the
four bolts to take out the select lever assembly from
vehicle body.
CS-00018
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
CS-00019
3) Install the console box. <Ref. to EI-36, INSTALLATION, Glove Box.>

7) Insert the thread portion of the other inner cable
and into connector hole of the select lever, and fix
the other outer cable end to bracket.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
8) Adjust the select cable position. <Ref. to CS-27,
ADJUSTMENT, Select Cable.>
9) After completion of fitting, make sure that the select lever operates smoothly all across the operating range.
10) Install the rear exhaust pipe and muffler.
Non-turbo model
<Ref. to EX (H4SO)-8, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX (H4SO)-9, INSTALLATION, Muffler.>
Turbo model
<Ref. to EX(H4DOTC)-14, INSTALLATION, Rear
Exhaust Pipe.> <Ref. to EX(H4DOTC)-15, INSTALLATION, Muffler.>
11) Inspect the following items. If the following inspection reveals problems, adjust the select cable
and inhibitor switch. <Ref. to CS-27, ADJUSTMENT, Select Cable.> <Ref. to 4AT-47, ADJUSTMENT, Inhibitor Switch.>
(1) Engine starts when the select lever is in P
and N range, but not in other range.
(2) Back-up light illuminates when the select lever is in the R range, but not in other range.
(3) Select lever and indicator positions are
matched.
CS-21
Select Lever
CONTROL SYSTEMS
C: DISASSEMBLY
1) Remove the packing.
2) Remove the grip.
3) Remove the indicator light, and then remove the
indicator cover.
7) Remove the clamp and remove the shift lock solenoid.
NOTE:
Be careful not to damage the indicator light during
removal.
(B)
(A)
(A)
(B)
CS-00106
(A) Clamp
(C)
(B) Shift lock solenoid
8) Remove the bolts which secure the lock plate B.

CS-00020
(A) Grip
(B) Indicator cover
(C) Indicator light
4) Remove the blind.

5) Remove the cover.
CS-00353
9) Remove the lock plates A, B, and C and the

bushing.
(A)
(B)
(C)
(C)
(B)
(C)
(A)
CS-00105
(A) Clip
(B) Cover
(D)
6) Remove the clips and then remove the guide

plate.
(A) Lock plate A

(B) Lock plate B
(C) Bushing
(D) Lock plate C
(B)
(A)
(A)
CS-00712
(A) Clip
(B) Guide plate
CS-22
CS-00368
Select Lever
CONTROL SYSTEMS
13) Remove the select lever arm and then remove

the select lever COMPL from the plate.
10) Remove the cushion plate.
(B)
(C)
(A)
CS-00093
CS-00109
11) Remove the P range switch.

(A) Select lever arm
(B) Selector lever COMPL
(C) Plate
(A)
14) Remove the detent spring and remove the detent arm.
(A)
CS-00708
(A) P range switch
12) Remove the grommet and then extract the

spring pin.
(B)
CS-00110
(A)
(A) Detent arm

(B) Detent spring
15) Remove the select lever COMPL bushing from

bracket.
(B)
CS-00027
(A) Spring pin

(B) Select lever arm
CS-00111
CS-23
Select Lever
CONTROL SYSTEMS
16) Remove the bracket from select lever COMPL.
D: ASSEMBLY
1) Clean all the parts before assembly.
2) Apply grease [KOPR-KOTE (Part No.
003603001) or equivalent] to each part. <Ref. to
CS-2, AT SELECT LEVER, COMPONENT, General Description.>
CS-00112
17) Remove the bushing from the bracket.
CAUTION:
Apply grease [SUNCALL GLO-244] to the axle
of lock plate.
3) Assemble in the reverse order of disassembly.
4) After completion of fitting, transfer the select lever to the 1 range from P range, then check
whether the select indicator and select lever match,
and whether the pointer and position mark match
and check the operating force.
E: INSPECTION
CS-00113
1) Inspect the removed parts by comparing with

new parts for deformation, damage and wear. Repair or replace if defective.
2) Confirm the select lever COMPL operating condition before assembling. Normal if it operates
smoothly.
CS-24
Select Cable
CONTROL SYSTEMS
5. Select Cable
8) Disconnect the select cable from range select lever and then remove the cable bracket.
A: REMOVAL
3) Prior to removal, set the lever to N range.
Non-turbo model
Pipe.>
Turbo model
<Ref. to EX(H4DOTC)-6, REMOVAL, Front Exhaust Pipe.>
6) Remove the snap pin from the range select lever.
(B)
(B) Cable bracket
9) Remove the select cable from plate assembly.
(B)
(C) (E)
CS-00036
(A) Select lever

(B) Snap pin
(C) Select cable
(D) Clamp
(E) Washer
7) Remove the plate assembly from the transmission case.
(A)
(C)
(B)
CS-00038
(A) Adjusting nut
(A)
(D)
(A)
CS-00037
(A) Select cable

(B) Plate ASSY
(C) Clamp
CS-25
Select Cable
CONTROL SYSTEMS
B: INSTALLATION
C: INSPECTION
1) Install the select cable to plate assembly.
Check the removed cable and replace if damaged,

rusty or having problems.
1) Check the cable for smooth operation.
2) Check the inner cable for damage and rust.
3) Check the outer cable for damage, bends and
cracks.
4) Check the boot for damage, cracks and deterioration.
5) Move the select lever from P to 1 range. In
each range, check that the contact of the detent is
felt. If the detentes is not felt or the position pointer
is improperly aligned, adjust the cable.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
2) Install the select cable to the range select lever.
3) Install the plate assembly to the transmission.
Tightening torque:
T: 24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
(A)
T
(B)
CS-00039
(A) Select cable

(B) Plate ASSY
4) Install the washer and snap pin to range select

lever.
(A)
(D)
(B)
(C) (E)
CS-00036
(A) Select lever

(B) Snap pin
(C) Select cable
(D) Clamp
(E) Washer
5) Move the select lever to the N range, then adjust the select cable position. <Ref. to CS-27, ADJUSTMENT, Select Cable.>
6) Install the front and center exhaust pipe.
Non-turbo model
Turbo model
<Ref. to EX(H4DOTC)-7, INSTALLATION, Front
Exhaust Pipe.>
CS-26
Select Cable
CONTROL SYSTEMS
D: ADJUSTMENT
7) Set a spanner wrench to adjusting nut B so that

it does not rotate, and then tighten the adjusting nut
A.

5) Loosen the adjusting nuts on both sides.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
(B)
(B)
(A)
(A)
CS-00042
CS-00040
(A) Adjusting nut A
(A) Adjusting nut A

(B) Adjusting nut B
(B) Adjusting nut B
6) Turn the adjusting nut B until it lightly touches

the connector.
8) After completion of fitting, make sure that the select lever operates smoothly all across the operating range.
(B)
(C)
(A)
(F)
(D)
(E)
CS-00041
(A) Front side

(B) Select lever
(C) Connector
(D) Adjusting nut B
(E) Contact point
(F) Adjusting nut A
CS-27
AT Shift Lock Solenoid and P Range Switch

CONTROL SYSTEMS
6. AT Shift Lock Solenoid and

P Range Switch
10) Remove the cover.
A: REMOVAL
(A)

3) Disconnect the connector.
4) Remove the grip.
5) Remove the indicator valve from the indicator
cover.
(B)
CS-00105
(A) Clip
(B) Cover
11) Remove the clamp and remove the shift lock

solenoid.
CS-00043
(B)
6) Remove the indicator cover.
(A)
(A) Clamp
(B) Shift lock solenoid
B: INSTALLATION
CS-00095
7) Remove the blind.

8) Remove the cushion.
9) Remove the P range switch.
(A)
CS-00709
(A) P range switch
CS-28
CS-00106
AT Shift Lock Solenoid and P Range Switch

CONTROL SYSTEMS
C: INSPECTION
1
Step
Measure the resistance of shift lock solenoid
Terminals
No. 4 No. 5:
Connect the battery to shift lock solenoid connector terminal, and then operate the solenoid.
Terminals
No. 4 (+) No. 5 ():
Check
and 40 ?
Yes
Go to step 2.
No
Replace the shift
lock solenoid and
P range switch
assembly.
Does the shift lock solenoid

operate normally?
Go to step 3.
Replace the shift

lock solenoid and
P range switch
assembly.
Replace the P
range switch.
more?
Replace the P
range switch.
CS-29
Normal operation
Body Integrated Unit

CONTROL SYSTEMS
7. Body Integrated Unit

A: REMOVAL
2) Remove the lower cover.
3) Remove the knee bolster.
CS-00097
4) Disconnect the connector from body integrated

unit.
5) Remove the body integrated unit.
CS-00098
B: INSTALLATION
CS-30
MT Gear Shift Lever

CONTROL SYSTEMS
8. MT Gear Shift Lever
10) Remove the stay from transmission bracket.
A: REMOVAL
2) Remove the gear shift knob.
5) Remove the clamp.
(A)
(B)
CS-00050
(A) Stay
(B) Transmission bracket
11) Remove the rod from joint.
(A)
CS-00099
6) Remove the bushing and insulator assembly.
(B)
CS-00051
(A) Stay
(B) Rod
12) Remove the cushion rubber from vehicle body.
CS-00100
7) Remove the plate COMPL from vehicle body.

(A)
(B)
CS-00052
(A) Stay
CS-00101

Non-turbo model
Turbo model
CS-31
(B) Cushion rubber
MT Gear Shift Lever

CONTROL SYSTEMS
13) Remove the spring pin, and then extract the

joint.
5) Insert the spring pin.

(A)
(A)
(B)
(B)
CS-00053
CS-00053
(A) Joint
(A) Joint
(B) Spring pin
(B) Spring pin
6) Mount the cushion rubber on the body.

15) Remove the lever COMPL.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
(A)
(B)
CS-00054
CS-00052
B: INSTALLATION
1) Install the joint to the transmission and secure
with spring pin.
2) Insert the lever COMPL from room side.
NOTE:
After inserting the rod and stay, temporarily put
them onto transmission mount.
(A) Stay
(B) Cushion rubber
7) Connect the rod to the joint.

Tightening torque:
12 Nm (1.2 kgf-m, 8.9 ft-lb)
(A)
(B)
CS-00051
CS-00054
(A) Stay
(B) Rod

4) Install the joint to the shifter arm.
8) Connect the stay to the transmission bracket.
CS-32
MT Gear Shift Lever

CONTROL SYSTEMS
C: DISASSEMBLY
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
1) Remove the lock wires.
(A)
(A)
(B)
CS-00050
CS-00316
(A) Stay
(A) Lock wire
(B) Transmission bracket

Non-turbo model
Turbo model
11) Install the plate COMPL to body.
2) Remove the rod from lever.
(B)
(A)
(C)
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
CS-00317
(A) Rod
(B) Lever
(C) Stay
3) Separate the rod and inner boot.

4) Remove the snap ring from the stay.
CS-00101
12) Install the boot and insulator assembly to vehicle in the proper direction.
(A)
CS-00318
(A) Snap ring
CS-00100
13) Install the clamp.

14) Install the console box. <Ref. to EI-38, INSTALLATION, Console Box.>
CS-33
MT Gear Shift Lever

CONTROL SYSTEMS
8) Remove the boss from the joint.
5) Separate the gear shift lever and the stay.
CS-00319
CS-00322
6) Remove the boot, bushing and snap ring from

gear shift lever.
(A)
(B)
(A)
(C)
D: ASSEMBLY
NOTE:
Clean all the parts before assembly.
Apply grease [KOPR-KOTE (Part No.
003603001) or equivalent] to each part.
1) Mount the bushing and cushion rubber to the
stay.
(A)
CS-00320
(B)
(A) O-ring
(B) Bushing
(C) Snap ring
7) Remove the spring pin, and then remove the

bushing and snap ring.
CS-00061
(A) Bushing
(B) Cushion rubber
2) Install the bushing and spacer to boss.

(A)
(B)
(B)
(A)
CS-00060
(A) Spring pin

(B) Bushing
(A)
(A) Bushing
(B) Spacer
CS-34
CS-00238
MT Gear Shift Lever

CONTROL SYSTEMS
3) Using new self-locking nuts, install the boss to

the joint.
6) Apply sufficient grease into boss, and then install

the gear shift lever to the stay.
Tightening torque:
12 Nm (1.2 kgf-m, 8.9 ft-lb)
CS-00319
7) Install the washer and snap ring.

CS-00322
4) Install the snap ring to gear shift lever and install

the bushing.
NOTE:
Apply grease to the bushing.
(A)
CS-00318
(A) Snap ring

(B)
8) Insert the gear shift lever and rod into boot hole.
9) Install the rod.
(A)
CS-00060
5) Apply grease to the bushing and O-ring, and

then install to gear shift lever.
(A)
(B)
(A)
Tightening torque:
12 Nm (1.2 kgf-m, 8.8 ft-lb)
(B)
(C)
(A)
(C)
CS-00320
(A) Rod
(A) O-ring
(B) Bushing
(B) Lever
(C) Stay
(C) Snap ring
CS-35
CS-00317
MT Gear Shift Lever

CONTROL SYSTEMS
E: INSPECTION
10) Install a new lock wire.
1) Check the parts (bushing, cushion rubber, spacer, boot, stay and rod, etc.) for deformation, damage and wear. If necessary, repair or replace faulty
parts. Compare the removed parts with new parts
to judge if there are damages or not.
(A)
(C)
CS-00316
(F)
(A)
(A) Rod
NOTE:
Install the lock wire to the stay groove.
Bend the extra wire to the same direction of lock
wire winding.
(A)
(C)
(A)
(C)
(D)
(A)
(A)
B
(B)
(B)
(B)
(E)
CS-00323
(C)
(A) Bushing
(B) Cushion rubber
(C) Spacer
(D) Boot
(E) Stay
(F) Rod
(B)
B-B
CS-00240
(A) Inner boot

(B) Lock wire
2) Check the swing torque of rod linked with the

gear shift lever.
If the torque exceeds the specifications, replace the
bushing or retighten nuts.
Swing torque:
Less than 3.7 N (0.38 kgf, 0.84 lb)
(C) Stay
(B)
(A)
CS-00116
(A) Pivot
(B) Swing torque
CS-36

CONTROL SYSTEMS
9. General Diagnostic Table

A: INSPECTION
Symptoms
Shift lock does not function.
Shift lock cannot be released.
Key interlock does not function.
Key interlock cannot be released.
Starter does not run.
Back-up light does not illuminate.

Gear can be shifted from N to R during driving.
Problem parts
Stop light switch
Shift lock solenoid
Stop light switch

Shift lock solenoid
Inhibitor switch
Key warning switch
P range switch
Key lock solenoid
Key warning switch

P range switch
Key lock solenoid
Inhibitor switch
Select cable
Starter circuit
Inhibitor switch
Select cable
Back-up light circuit
Shift lock solenoid

TCM
CS-37

CONTROL SYSTEMS
CS-38
General Description
5. PLANETARY GEAR AND PLATE
A: SPECIFICATION
Model
1. TORQUE CONVERTER CLUTCH
Number of front
sun gear teeth
Model
Type
Stall torque ratio
Nominal diameter
Stall speed (at sea
level)
One-way clutch
Non-turbo
Turbo
Symmetric, 3 element, single stage, 2
phase torque converter
2.05 2.35
246 mm (9.69 in)
2,200 2,700
2,700 3,200
rpm
rpm
Sprague type one-way clutch
2. OIL PUMP
Type
Driving method
Number of teeth
Parachoid constant-displacement
pump
Driven by engine
Inner rotor
9
Outer rotor
10
3. TRANSMISSION CONTROL ELEMENT

Type
Multi-plate clutch
Multi-plate brake
One-way clutch
(sprague type)
4-forward, 1-reverse, double-row planetary gears

3 sets
2 sets
1st
2nd
3rd
1.545
1.000
4th
Rev.
0.694
2.272
21
75
42
17
Number of rear
internal gear teeth
Number of high
clutch drive plates
Number of low
clutch drive plates
Number of reverse
clutch drive plates
Number of drive
plates for the 2-4
brake
Number of drive
plates for low &
reverse brake
75
4
7
2
6. SELECTOR POSITION
P (Park)
Gear ratio
2.785
Turbo
33
Number of front
pinion teeth
Number of front
internal gear teeth
Number of rear
sun gear teeth
Number of rear
pinion teeth
1 sets
4. TRANSMISSION GEAR RATIO
Non-Turbo
R (Reverse)
N (Neutral)
D (Drive)
Transmission is in neutral, output member

is immovable, engine start is possible
Transmission is in reverse.
Transmission is in neutral and engine
start is possible
Automatic gear change
1st gear 2nd gear 3rd gear
4th gear
3 (3rd)
Automatic gear change

1st gear 2nd gear 3rd gear
4th gear
2 (2nd)
2nd gear is locked.

(Deceleration is possible. 2nd gear
3rd gear 4th gear)
1 (1st)
Control method
4AT-2
1st gear is locked.

(Deceleration is possible. 1st gear 2nd
gear Third gear 4th gear)
Wire cable type
General Description
7. HYDRAULIC CONTROL AND LUBRICATION
Model
Electronic/hydraulic control
[4 forward gear changes
made by electronic signals
of vehicle speed and accelerator opening]
Type
Recommended
materials
Fluid
9. TRANSFER
Alternative
Fluid capacity
Lubrication system
Oil
Transfer
type
SUBARU ATF HP
IDEMITSU: ATF HP
Castrol: Transmax J
Pennzoil Quaker State: Pennzoil ATF-J
9.3 9.62 (9.8 10.1 US
qt, 8.2 8.4 Imp qt)
Forced feed lubrication with
oil pump
Inhibitor switch
Transmission harness
Turbo
Multi-plate transfer (MP-T)
Number of
transfer
clutch
drives &
driven
plates
Control
method
Variable
torque distribution (VTD)
Electronic, hydraulic type
Lubricant
Same automatic transmission fluid as used in

the automatic transmission
Reduction
gear ratio
1.000 (53/53)
10.FINAL REDUCTION GEAR
Automatic transmission fluid

(see above)
8. COOLING AND HARNESS

Cooling system
Non-turbo
Front final reduction gear

ratio
Non-turbo
Turbo
4.444 (40/9)
4.111 (37/9)
Liquid-cooler incorporated in
radiator
12 poles
20 poles
11.RECOMMENDED GEAR OIL
( C)
( F)
(1)
(2)
(3)
GL-5
(4)
-30 -26 -15 -5 0
-22 -15 5 23 32
Lubrication oil
15
59
25 30
77 86
90
85W
80W
75W -90
MT-00001
(1) Item
(2) Front differential gear oil
Front differential oil capacity
(3) API classification

1.1 1.32 (1.2 1.4 US qt, 1.0 1.1 Imp qt)
4AT-3
General Description
B: COMPONENT
1. TORQUE CONVERTER CLUTCH AND CASE
(1)
(2)
(3)
(15)
(4)
T2
T2
(5)
(16)
(6)
(7)
(14)
(8)
T1
T2
T2
(13)
T3
(12)
(9)
(10)
(11)
AT-00002
(1)
(2)
Pitching stopper bracket

O-ring
(9)
(10)
Input shaft
O-ring
(16)
Converter case
(3)
(4)
Differential oil level gauge

Stay
(11)
(12)
Torque converter clutch ASSY

Differential gear oil drain plug

T1: 18 (1.8, 13.0)
(5)
(6)
Seal pipe
Oil pump shaft
(13)
(14)
Gasket
Oil seal
(7)
(8)
Clip
Rubber seal
(15)
Clip (Turbo model)
T2: 41 (4.2, 30.4)

T3: 70 (7.2, 51.7) (Copper gasket)
4AT-4
44 (4.5, 32.5) (Aluminum gasket)
General Description
2. OIL PUMP
AT-03659
(1)
(2)
Oil pump rotor

Oil pump cover
(11)
(12)
Gasket
O-ring
(21)
(3)
(4)
Seal ring
Thrust needle bearing
(13)
(14)
Test plug
Stud bolt

T1: 7 (0.7, 5.1)
(5)
(6)
Drive pinion shaft

Roller bearing
(15)
(16)
O-ring
O-ring
T2: 13 (1.3, 9.4)

T3: 18 (1.8, 13.0)
(7)
(8)
Drive pinion shim

Oil pump housing
(17)
(18)
Oil seal retainer

Oil seal
T4: 25 (2.5, 18.1)

T5: 40 (4.1, 29.5)
(9)
(10)
Nipple
Air breather hose
(19)
(20)
O-ring
Drive pinion collar
T6: 42 (4.3, 31)

T7: 116 (11.8, 85)
4AT-5
Lock nut
General Description
3. TRANSMISSION CASE AND CONTROL DEVICE
(1)
(34)
(2)
(39)
T1
T4
(33)
T10
T8
(37)
(36)
(31)
(3)
(5)
(6)
(4)
(32)
(35)
(7)
(38)
(30)
(9)
(29)
(26)
(28)
T8
T3
(27)
(8)
(25)
(16)
T8
(13)
(14)
T3
(24)
(23) (22)
T5
(10)
T7
(21)
T6
T7
(15)
(19)
T2
(20)
(18)
T8
(17)
(11)
(12)
T9
AT-03373
4AT-6
General Description
(1)
(2)
ATF level gauge

Oil charge pipe
(18)
(19)
Gasket
Oil pan
(35)
(36)
Nipple
Air breather hose
(3)
(4)
O-ring
Straight pin
(20)
(21)
Magnet
Stud bolt (short)
(37)
(38)
Transmission case
Plate ASSY
(5)
(6)
Return spring
Shaft
(22)
(23)
Stud bolt (long)

Parking rod
(39)
Washer
(7)
(8)
Parking pawl
Parking support
(24)
(25)
Manual plate
Spring pin

T1: 3.4 (0.35, 2.6)
(9)
(10)
Transfer clutch seal

Gasket
(26)
(27)
Detention spring
Ball
T2: 5 (0.5, 3.6)

T3: 6 (0.6, 4.4)
(11)
Inlet pipe
(28)
Spring
T4: 12 (1.2, 8.7)
(12)
(13)
Union screw
O-ring
(29)
(30)
Gasket
Outlet pipe
T5: 13 (1.3, 10)

T6: 14 (1.4, 10)
(14)
(15)
Test plug
Oil filter
(31)
(32)
Union screw
Oil seal
T7: 18 (1.8, 13)

T8: 25 (2.5, 18.1)
(16)
(17)
Oil filter stud bolt

Drain plug (ATF)
(33)
(34)
Range select lever

Inhibitor switch ASSY
4AT-7
T9: 40 (4.1, 29.5)

T10: 45 (4.6, 33.2)
General Description
4. CONTROL VALVE AND HARNESS ROUTING
(2)
(1)
T1
(6)
(7)
(4)
(8)
(5)
(9)
(3)
T1
T1
(10)
T2
AT-01322
(1)
(2)
Stay
Transmission harness ASSY
(6)
(7)
O-ring
Front vehicle speed sensor
(3)
(4)
O-ring
O-ring
(8)
(9)
O-ring
Rear vehicle speed sensor
(5)
Torque converter turbine speed

sensor
(10)
Control valve body
4AT-8

T1: 7 (0.7, 5.1)
T2: 8 (0.8, 5.8)
General Description
5. HIGH CLUTCH AND REVERSE CLUTCH
AT-00006
(1)
(2)
High clutch drum

Lip seal
(8)
(9)
Spring retainer
Clutch cover
(15)
(16)
Dish plate
Driven plate
(3)
(4)
D-ring
Reverse clutch piston
(10)
(11)
Snap ring
Driven plate
(17)
(18)
Drive plate
Retaining plate
(5)
(6)
D-ring
D-ring
(12)
(13)
Drive plate
Retaining plate
(19)
(20)
Snap ring
(7)
High clutch piston
(14)
Snap ring
(21)
High clutch hub
4AT-9
General Description
6. PLANETARY GEAR AND 2-4 BRAKE

(5)
(4)
(3)
(2)
(13)
(1)
(12)
(11)
(10)
(9)
(8)
(7)
(6)
(19)
(18)
(16)
(17)
(16)
(17)
(16)
(15)
(14)
(24)
(26)
(23)
(25)
(22)
(21)
(20)
AT-00007
(1)
(2)

Front sun gear
(10)
(11)
Washer
(19)
(20)
Snap ring
2-4 spring retainer
(3)
(4)

Snap ring
(12)
(13)
Rear internal gear

Washer
(21)
(22)
2-4 brake piston

D-ring
(5)
(6)
Front planetary carrier

(14)
(15)
Snap ring
Retaining plate
(23)
(24)
D-ring
2-4 brake piston retainer
(7)
(8)
Rear sun gear

(16)
(17)
Drive plate
Driven plate
(25)
(26)
2-4 brake seal

Leaf spring
(9)
Rear planetary carrier
(18)
Pressure rear plate
4AT-10
General Description
7. LOW CLUTCH AND LOW & REVERSE BREAK

(10) (11)
(9)
(8)
(7)
(5)
(6)
(4)
(3)
(3)
(4)
(2)
(1)
(16)
(15)
(14)
(13)
(12)
(21)
(23)
(22)
(20)
(19)
(18)
(30)
(17)
(29)
(28)
(27)
(28)
(27)
(24)
(25)
(26)
AT-01278
(1)
(2)
Snap ring
Retaining plate
(13)
(14)
Needle bearing
Snap ring
(25)
(26)
Retaining plate
Leaf spring
(3)
(4)
Drive plate
Driven plate
(15)
(16)
One-way clutch
Snap ring
(27)
(28)
Drive plate
Driven plate
(5)
(6)
Dish plate
Snap ring
(17)
(18)

Seal ring
(29)
(30)
Dish plate
Low & reverse brake piston
(7)
(8)
Cover
Spring retainer
(19)
(20)
Needle bearing
One-way clutch inner race
(9)
(10)
D-ring
Low clutch piston
(21)
(22)
Socket bolt
Spring retainer
(11)
(12)
D-ring
Low clutch drum
(23)
(24)
Return spring
Snap ring
4AT-11
T: 25 (2.5, 18.1)
General Description
8. REDUCTION GEAR
MP-T MODEL
(4)
(3)
(2)
(1)
(11)
(10)
(8)
(8)
(9)
(8)
(7)
(6)
(5)
AT-02740
(1)
(2)
Seal ring
Ball bearing
(6)
(7)
Snap ring
Ball bearing
(11)
(3)
(4)
Reduction drive gear

Reduction drive shaft
(8)
(9)
Snap ring
Reduction driven gear

T: 100 (10.2, 73.8)
(5)
Drive pinion shaft
(10)
Washer
4AT-12
Lock nut
General Description
VTD MODEL
(7)
(4)
(3)
(11)
(6)
(2)
(10)
(5)
(4)
(9)
(3)
(8)
(23)
(1)
(22)
(21)
(19)
(20)
(19)
(17)
(18)
(16)
(15)
(14)
(13)
(12)
(32)
(31)
(29)
(30)
(27)
(27)
(28)
(25)
(26)
(27)
(24)
AT-02203
(1)
(2)
Ball bearing
Reduction drive gear
(13)
(14)
Rear drive shaft

Ball bearing
(25)
(26)
Snap ring
Ball bearing
(3)
(4)
Washer
Needle bearing
(15)
(16)
Multi-plate clutch (LSD) hub

Ball bearing
(27)
(28)
Snap ring
Reduction driven gear
(5)
(6)
Pinion gear
Carrier
(17)
(18)
Revolution gear
Driven plate (Thick)
(29)
(30)
Lock washer
Lock nut
(7)
(8)
Planetary pinion shaft

Snap ring
(19)
(20)
Drive plate
Driven plate (Thin)
(31)
(32)
Gasket
Extension case
(9)
(10)
Seal ring
(21)
(22)

Pressure plate
(11)
(12)
Intermediate shaft
Thrust washer
(23)
(24)
Rear drive shaft shim

Drive pinion shaft
4AT-13
T: 100 (10.2, 73.8)
General Description
9. DIFFERENTIAL GEAR
(12)
(1)
(13)
(2)
(11)
(3)
(12)
(11)
(4)
(13)
(5)
T2
(10)
T1
T1
(10)
(6)
(9)
(7)
(8)
(7)
(8)
(6)
(9)
AT-00011
(1)
(2)
Hypoid driven gear

Pinion shaft
(7)
(8)
Oil seal
O-ring
(13)
(3)
(4)
Differential case (RH)

Straight pin
(9)
(10)
Differential side retainer

Lock plate

T1: 25 (2.5, 18.1)
(5)
(6)
Differential case (LH)

Taper roller bearing
(11)
(12)
Washer
Differential bevel pinion
4AT-14
Differential bevel gear
T2: 62 (6.3, 45.6)
General Description
10.TRANSFER AND EXTENSION CASE

MP-T MODEL
(6)
(7)
(5)
(6)
(5)
(14)
(4)
(3)
(1)
(2)
(13)
(12)
(20)
T2
(11)
(19)
(18)
(10)
(9)
(8)
(21)
(15)
T1
(22)
T2
(23)
(17)
(16)
AT-00012
(1)
(2)

Needle bearing
(10)
(11)
Return spring
Transfer clutch piston
(20)
(21)
Dust cover
Test plug
(3)
(4)
Snap ring
Pressure plate
(12)
(13)
Rear drive shaft

Ball bearing
(22)
(23)
O-ring
Clip (Turbo model)
(5)
(6)
Drive plate
Driven plate
(14)
(15)
Seal ring
Gasket
(7)
(8)
Pressure plate
Snap ring
(16)
(17)
Transfer clutch pipe

Extension case
(9)
Transfer clutch piston

Seal
(18)
(19)
Transmission hanger
Oil seal
4AT-15
T1: 13 (1.3, 9.4)

T2: 25 (2.5, 18.1)
General Description
VTD MODEL
(5)
(4)
(2)
(3)
(2)
(1)
T1
(20)
(19)
T3
(12)
(18)
(17)
(16)
(9)
T2
(15)
(21)
(14)
(11)
(10)
(13)
(8)
(7)
(6)
AT-03359
(1)
(2)

Drive plate
(10)
Multi-plate clutch (LSD) piston

ASSY
(18)
(19)
Dust cover
O-ring
(3)
(4)
Driven plate (Thin)

(11)
(12)
O-ring
Gasket
(20)
(21)

Clip (Turbo model)
(5)
(6)
Retaining plate
Snap ring
(13)
(14)
Multi-plate clutch (LSD) pipe

Extension case
(7)
(8)
Spring retainer
Plate
(15)
(16)
O-ring
Test plug
T1: 7 (0.7, 5.1)

T2: 13 (1.3, 9.4)
(9)
O-ring
(17)
Oil seal
T3: 25 (2.5, 18.1)
4AT-16
General Description
11.TRANSMISSION MOUNTING
(2)
T2
T2
T4
(1)
(3)
T3
T5
(4)
T1
T5
AT-03696
(1)
(2)
Pitching stopper
Rear cushion rubber
(3)
Transmission rear crossmember
(4)
Stopper

T1: 35 (3.6, 26)
T2: 39 (4.0, 29)
T3: 50 (5.1, 37)
T4: 58 (5.9, 43)
T5: 70 (7.1, 51)
4AT-17
General Description
C: CAUTION
Wear work clothing, including a cap, protective
goggles and protective shoes during operation.
Do not place the oil pan with its inner side facing
up until it is installed, to prevent intrusion of foreign
matter into the valve body.
When disassembling the case and other light alloy parts, use a plastic hammer to separate the
case. Do not pry apart with screwdrivers or other
tools.
Be careful not to burn yourself, because each
Use SUBARU genuine gear oil, grease etc. or
equivalent. Do not mix fluid, grease, etc. with that of
another grade or from other manufacturers.

points.
Apply gear oil or ATF onto sliding or revolving
surfaces before installation.
Replace deformed or damaged snap rings with
new parts.
Before installing O-rings or oil seals, apply sufficient amount of ATF fluid to avoid damage and deformation.
Be careful not to incorrectly install or fail to install
O-rings, snap rings and other such parts.
Before securing a part on a vise, place a cushioning material such as wood blocks, aluminum
plates, or shop cloth between the part and the vise.
Avoid damaging the mating surface of the case.
Before applying sealant, completely remove the
old sealant.
When disassembling the AT, be sure to use nylon gloves and paper towels. Do not use cloth
gloves or waste cloth.
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
498575400
OIL PRESSURE
GAUGE ASSY
498897200
OIL PRESSURE
GAUGE ADAPTER
Used at the oil pump housing when measuring

reverse clutch pressure and line pressure.
ST-498575400
ST-498897200
4AT-18
General Description
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
498897700
OIL PRESSURE
ADAPTER SET
Used for measuring the transfer clutch pressure.
498545400
OIL FILTER
WRENCH
Used for removing and installing the ATF filter.
498277200
STOPPER SET
Used for removing and installing the automatic

transmission assembly.
ENGINE SUPPORT
ASSY
Used for supporting the engine.
PULLER ASSY
Used for removing the extension case roller

bearing.
Used for removing the extension oil seal.
Used for removing the front differential side
retainer bearing outer race.
retainer oil seal.
ST-498897700
ST-498545400
ST-498277200
41099AC000
ST41099AC000
398527700
ST-398527700
4AT-19
General Description
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
498057300
INSTALLER
Used for installing the extension oil seal.
498077000
REMOVER
Used for removing the differential taper roller

bearing.
499247400
INSTALLER
Used for installing the transfer outer snap ring.

Used with GUIDE (499257300).
499257300
SNAP RING
OUTER GUIDE
Used for installing the transfer outer snap ring.

Used with the INSTALLER (499247400).
WRENCH COMPL
RETAINER
Used for removing and installing the differential side retainer.

WRENCH ASSEMBLY (499787000) can also
be used.
ST-498057300
ST-498077000
ST-499247400
ST-499257300
18630AA010
ST18630AA010
4AT-20
General Description
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
398437700
DRIFT
Used for installing the torque converter case oil

seal.
398487700
INSTALLER
Used for installing the front differential taper

roller bearing.
398673600
COMPRESSOR
Used for removing and installing the clutch

spring.
498255400
PLATE
Used for measuring the backlash of hypoid gear.
399893600
PLIERS
Used for removing and installing the clutch

spring.
ST-398437700
ST-398487700
ST-398673600
ST-498255400
ST-399893600
4AT-21
General Description
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
498247001
MAGNET BASE
Used for measuring the gear backlash.

Used with the DIAL GAUGE (498247100).
498247100
DIAL GAUGE
Used for measuring the gear backlash.

Used with the MAGNET BASE (498247001).
498517000
REPLACER
Used for removing the front roller bearing.
398623600
SEAT
Used for removing the spring of the transfer

clutch piston.
DRIVE SHAFT
REMOVER
Used for removing the axle shaft.
ST-498247001
ST-498247100
ST-498517000
ST-398623600
28399SA000
ST28399SA000
4AT-22
General Description
ILLUSTRATION
TOOL NUMBER
28399SA010
DESCRIPTION
REMARKS
OIL SEAL PROTEC- Used for installing the axle shaft.

TOR
ST28399SA010
499267300
STOPPER PIN
Used for installing the inhibitor switch.
499787700
WRENCH
Used for removing and installing the drive pinion

lock nut.
499787500
ADAPTER

lock nut.
398643600
GAUGE
Used for measuring the total end play, extension

end play and drive pinion height.
ST-499267300
ST-499787700
ST-499787500
ST-398643600
4AT-23
General Description
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
498627100
SEAT
Used for holding the low clutch piston retainer

spring when installing snap ring.
499577000
GAUGE
Used for measuring the mating surface of the

transmission to the end face of the reduction
gear.
499737000
PULLER
Used for removing the reduction driven gear

assembly.
499737100
PULLER SET
Used for removing the reduction drive gear

assembly.
498077600
REMOVER
Used for removing the ball bearing.
ST-498627100
ST-499577000
ST-499737000
ST-499737100
ST-498077600
4AT-24
General Description
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
498937110
HOLDER

lock nut.
498677100
COMPRESSOR
Used for installing the 2-4 brake snap ring.
498437000
HIGH CLUTCH PISTON GUIDE
Used for installing the high clutch piston.
498437100
LOW CLUTCH PISTON GUIDE
Used for installing the low clutch piston.
899580100
INSTALLER
Used for press-fitting the ball bearing of the

transfer clutch.
ST-498937110
ST-498677100
ST-498437000
ST-498437100
ST-899580100
4AT-25
General Description
ILLUSTRATION
TOOL NUMBER
18675AA000
DESCRIPTION
REMARKS
DIFFERENTIAL
SIDE OIL SEAL
INSTALLER
Used for installing the differential side retainer oil

seal.
398497701
SEAT
Used for installing the needle bearing.
899524100
PULLER SET
Used for bolt only.

Used with 499737100 PULLEY SET.
Used with 499737000 PULLER.
(1) Puller
(2) Cap
398744300
PISTON GUIDE
Used for measuring the contact surface of the

transmission mating surface to the multi-plate
clutch end face.
For VTD model.
1B020XU0
SUBARU SELECT
MONITOR KIT
Used for troubleshooting for the electrical system.
ST18675AA000
ST-398497701
ST-899524100
ST-398744300
ST1B020XU0
4AT-26
General Description
2. GENERAL TOOL
TOOL NAME
Depth gauge
Thickness gauge
REMARKS
Micrometer
Used for measuring the transmission end play.

Used for measuring clearance of the clutch, brake and oil
pump.
Used for measuring thickness of the drive pinion.
Spring balance
Circuit tester
Used for measuring the starting torque of the drive pinion.

Used for measuring resistance and voltage.
TORX T70
Used for installing and removing the differential gear oil drain
plug.
Used for measuring each piston stroke.
Push/pull gauge
4AT-27
Automatic Transmission Fluid

2. Automatic Transmission Fluid

A: INSPECTION
NOTE:
The level of ATF varies with fluid temperature. Pay
attention to the ATF temperature when checking
ATF level.
1) Raise the ATF temperature by driving a distance
of 5 to 10 km (3 to 6 miles). Idle the engine to raise
ATF temperature to 70 80C (158 176F) on
the Subaru Select Monitor. <Ref. to 4AT(D)(diag)14, READ CURRENT DATA, OPERATION, Subaru Select Monitor.>
2) Make sure the vehicle is level.
3) After slowly selecting all positions (P, R, N, D, 3,
2, 1), set the select lever in the P range. Idle the
engine for 1-2 minutes, and measure the ATF level.
B: REPLACEMENT
2) Drain the ATF completely.
CAUTION:
After running the engine or after idling for a
long time, the ATF is hot. Be careful not to burn
yourself.
3) Replace the gasket with new one, and then tighten the drain plug (ATF).
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
(A)
(B)
(B)
L
F
HOT
(A)
AT-01332
(C)
COLD
L
(A) Oil pan

(B) Drain plug (ATF)
(B)

5) Pour ATF from the oil charge pipe.
(C)
AT-00674
Recommended fluid:
SUBARU ATF HP
(A) ATF level gauge

(B) Upper level
(C) Lower level
4) Make sure that ATF level is between the upper

level and lower level on the HOT side.
If the ATF level is below the lower level, check for
leaks in the transmission. If there are leaks, it is
necessary to replace the gasket, oil seals, plugs, or
repair other parts.
5) If the ATF level is below the mid level between
upper and lower marks, add the recommended
ATF until the fluid level is above mid level.
CAUTION:
Be careful not to exceed the upper level.
Adding ATF up to the upper level when the
transmission is cold will overfill the ATF. Do not
fill beyond the upper level as overfilling can
cause problems.
6) Check the ATF level after raising ATF temperature to 70 80C (158 176F) by running the
vehicle or by idling the engine again.
Substitute fluid:
IDEMITSU: ATF HP
Castrol: Transmax J
Capacity:
Fill with the same amount of ATF that was
drained from drain plug hole.
Capacity when transmission is overhauled:
9.3 9.62 (9.8 10.1 US qt, 8.2 8.4 Imp
qt)
6) Bleed the air of control valve.
<Ref. to 4AT-59, Air Bleeding of Control Valve.>
7) Check the level and leaks of ATF.
4AT-28

C: CONDITION CHECK
NOTE:
When replacing ATF, check the inside condition of the transmission body by inspecting the drained ATF.
Fluid condition
Large amount of metallic pieces are
found.

Excessive wear of the internal of the transmission body.
Corrective action
Replace ATF and check if AT operates
correctly.
Thick and varnish-form fluid.
Burned clutch and etc.
Replace ATF and check AT itself and

vehicle for faulty.
Clouded fluid or bubbles are found in

fluid.
Water mixed in fluid.
Replace ATF and check the water entering point.
4AT-29
Differential Gear Oil

3. Differential Gear Oil
3) Replace the gasket with a new one and tighten

the differential oil drain plug using the TORX BIT
T70.
A: INSPECTION
2) Remove the oil level gauge and wipe it clean.
3) Reinsert the level gauge all the way. Make sure
the level gauge is inserted correctly and in the
proper orientation.
4) Pull out the level gauge, and check the oil level.
If the differential gear oil level is below L line, add
oil to bring the level up to F line.
5) To prevent overfilling the differential gear oil, do
not fill oil above the F line.
Tightening torque:
Copper gasket
70 Nm (7.2 kgf-m, 51.7 ft-lb)
Aluminum gasket
44 Nm (4.5 kgf-m, 32.5 ft-lb)
(A)
(B)
(A)
AT-02204
(B)
L
(A) Oil pan

(B) Differential gear oil drain plug

5) Pour differential gear oil from the gauge hole into
the differential.
AT-00017
(A) Upper level

(B) Lower level
Recommended gear oil:
B: REPLACEMENT
2) Remove the differential gear oil drain plug using
TORX BIT T70, and drain the differential gear oil
completely.
CAUTION:
Immediately after the vehicle has been running, the differential gear oil is very hot. Be
careful not to burn yourself.
Be careful not to spill differential gear oil on
the exhaust pipe to prevent it from emitting
smoke or causing a fire. If differential gear oil is
spilled on the exhaust pipe, wipe it off completely.
<Ref. to 4AT-3, SPECIFICATION, General Description.>

Gear oil capacity:
1.1 1.32 (1.2 1.4 US qt, 1.0 1.1 Imp qt)
6) Check the level of differential gear oil.
<Ref. to 4AT-30, INSPECTION, Differential Gear
Oil.>
4AT-30
Road Test
4. Road Test
3) Check the ATF temperature using the Subaru

Select Monitor.
A: INSPECTION
1. GENERAL PRECAUTION
Road tests should be conducted to properly diagnose the condition of automatic transmission.
NOTE:
When performing the test, do not exceed the posted speed limit.
2. D RANGE SHIFT FUNCTION

Check shifting between 1st 2nd 3rd
4th while driving on normal city streets.
3. D RANGE SHIFT SHOCK

Check the shock level when shifting up during normal driving.
4. KICK-DOWN FUNCTION
Check kick-down for each gear. Check the shock
level during kick-down at the same time.
5. ENGINE BRAKE OPERATION

Drive in 4th gear of D range [50 60 km/h (31
37 MPH)], and shift down to D 3rd range to
check the engine brake in 3rd gear.
Drive in 3rd gear of 3 range [40 50 km/h (25
31 MPH)], and shift down from 3rd to 2nd
range to check the engine brake in 2nd gear.
Drive in 2nd gear of 2nd range [20 30 km/h (12
19 MPH)], and shift down from 2nd to 1st
range to check the 1st gear engine brake.
6. LOCK-UP FUNCTION
Check that rpm does not change sharply when
the axle pedal is lightly depressed while driving in
D range on flat roads at 60 km/h (37 MPH).
Check slip lock-up with following procedure.
Subaru Select Monitor is required for judgment.
Before starting the check, make sure that no DTC
is displayed using the Subaru Select Monitor. If
there is a DTC, perform the corrective action according to the DTC. Recheck to see that the DTC
has been cleared, then start the slip lock-up check.
1) The check is to be performed on a flat and
straight road or on a free roller.
NOTE:
Make sure that the ATF temperature is between
50 100C (122 212F).
If the temperature is low, warm-up the ATF by
running the vehicle.
4) Start the engine, so that the lock-up duty can be
read on the data display of the Subaru Select Monitor.
5) Drive the vehicle at a constant speed of 35 40
km/h (22 25 MPH).
6) Read the lock-up duty while vehicle is running.
Specification:
25 45%
NOTE:
The reading may be slightly lower on a free roller.
Slip lock-up control is not operating when the
lock-up duty is less than 5%, or when the lock-up
duty goes down immediately after starting to rise. In
these cases, improper ATF or deterioration of the
ATF may be the cause. Check the amount of ATF
or replace the fluid, then recheck.
7. P RANGE OPERATION
Stop the vehicle on an uphill grade of 5% or more
and shift to the P range. Check that the vehicle
does not move when the parking brake is released.
8. NOISE AND VIBRATION

Check for noise and vibration while driving and during shifting.
9. CLIMBING CONTROL FUNCTION

Check that the gear remains in 3rd when going
uphill.
Check that the gear remains in 3rd when applying the brakes while going downhill.
10.TRANSFER CLUTCH
Check for tight corner braking phenomenon when
the vehicle is moved forward with the steering fully
turned.
11.OIL LEAKS
After the driving test, inspect for oil leaks.
NOTE:
Slip lock-up will not operate when the vehicle is
lifted up off of its wheels, since there is no surface
resistance.
Even when checking on the free roller, the driving resistance will be slightly inadequate. It will be
easier to check if the foot brake is stepped on lightly
while performing the judgement.
2) Connect the Subaru Select Monitor.
4AT-31
Stall Test
5. Stall Test
10) When the engine speed stabilizes, quickly

record the engine speed and release accelerator
pedal.
11) Shift the select lever to N range, and cool
down the engine by idling it for more than one
minute.
12) If the stall speed in 2 range is higher than
specifications, low clutch and 2-4 brake maybe slipping. To identify this, conduct the same test as
above in R range.
13) Perform the stall tests with the select lever in
D range.
A: INSPECTION
NOTE:
The stall test is extremely important in diagnosing
the condition of an automatic transmission and engine. It should be conducted to measure the engine
stall speeds in the R and 2 ranges.
Purposes of the stall test:
Operational check of the automatic transmission
clutch
Operational check of the torque converter clutch
Engine performance check
1) Check that the throttle valve fully opens.
2) Check that the engine oil level is correct.
3) Check that the coolant level is correct.
4) Check that the ATF level is correct.
5) Check that the differential gear oil level is correct.
6) Increase the ATF temperature to 70 to 80C
(158 to 176F) by idling the engine for approximately 30 minutes (with select lever set to N or P).
7) Place wheel chocks at the front and rear of all
wheels and engage the parking brake.
8) Move the manual linkage to ensure it operates
properly, and shift the select lever to the 2 range.
9) While forcibly depressing the foot brake pedal,
gradually depress the accelerator pedal until the
engine operates at full throttle.
NOTE:
Do not continue the stall test for more than 5 seconds at a time (from closed throttle, fully open throttle to stall speed reading). Failure to follow this
instruction will cause the engine oil and ATF to deteriorate and the clutch and brake to be adversely
affected.
Be sure to cool down the engine for at least one
minute after each stall test with the select lever set
in the P or N range and with the idle speed lower
than 1,200 rpm.
If the stall speed is higher than the specified
range, attempt to finish the stall test in as short a
time as possible, in order to prevent the automatic
transmission from sustaining damage.
Stall speed (at sea level):
Non-turbo model
2,200 2,700 rpm
Turbo model
2,700 3,200 rpm
P
R
N
D
3
2
1
(A)
(B)
AT-00449
(A) Brake pedal

(B) Accelerator pedal
Stall speed (at sea level)
Below specified value
Range
2, R
Over specified value
Cause
Throttle valve is not fully open
Engine malfunction
One-way clutch of the torque converter is slipping
Line pressure too low
Low clutch slipping
One-way clutch malfunctioning
Reverse clutch slipping
Low & reverse brake slipping

Low clutch slipping
2-4 brake slipping
4AT-32
Time Lag Test

6. Time Lag Test

A: INSPECTION
NOTE:
When the select lever is shifted while the engine is
idling, there will be a certain time elapse or lag before shock is felt. This is used for checking the condition of the low clutch, reverse clutch, low &
reverse brake and one-way clutch.
Perform the test at normal operation fluid temperature of 70 80C (158 176F).
Be sure to allow a one minute interval between
tests.
Make three measurements and take the average
value.
1) Fully apply the parking brake.
Check the idle speed (A/C OFF).
3) Shift the select lever from N to D range.
Using a stop watch, measure the time which takes
from shifting the lever until the shock is felt.
Time lag: Less than 1.2 seconds
If N D time lag is longer than specified:
Low clutch worn
One-way clutch not operating properly
D-ring worn
4) In the same manner, measure the time lag of N
R.
Time lag: Less than 1.5 seconds
If N R time lag is longer than specified:
Reverse clutch worn
Low & reverse brake worn
D-ring worn
4AT-33
Line Pressure Test

7. Line Pressure Test

A: MEASUREMENT
NOTE:
If the clutch or brake shows a signs of slipping or
shift feel is not correct, check the line pressure.
Excessive shock during up-shift or if shifting
takes place at a higher point than for normal conditions, this may be due to the line pressure being too
high.
Slippage or inability to operate the vehicle may,
in most cases, be due to insufficient oil pressure for
the operation of clutch, brake or control valve.
1) Line pressure measurement (under no load):
(1) Before measuring line pressure, jack-up all
the wheels.
(2) Maintain the ATF temperature at approx. 70
80C (158 176F) during measurement.
(ATF will reach the temperature above after
idling the engine for approx. 30 minutes with the
select lever in N or P.)
2) Line pressure measurement (under heavy load):
(1) Before measuring line pressure, apply both
the foot and parking brakes with all wheels
chocked (Same as for stall test conditions).
(2) Measure the line pressure when the select
lever is in R and 2 with engine under stall
conditions.
(3) Measure the line pressure within 5 seconds
after shifting the select lever to each position. (If
the line pressure needs to be measured again,
allow the engine to idle and cool it down for
more than 1 minute.)
(4) Maintain the ATF temperature at approx. 70
80C (158 176F) during measurement.
(ATF will reach the above temperature after
idling the engine for approx. 30 minutes with the
select lever in N or P.)
3) Temporarily attach the ST to a suitable place in

the drivers compartment, remove the blind plug located in front of the toe board and pass the hose of
the ST to the engine compartment.
ST 498575400
OIL PRESSURE GAUGE
ASSY
(B)
(A)
(C)
AT-00019
(A) Pressure gauge hose

(B) Hole in toe board (blank cap hole)
(C) Brake pedal
4) Remove the test plug and install the ST instead.

ST 498897200
OIL PRESSURE GAUGE
ADAPTER
(A)
AT-00020
(A) Test plug
5) Connect the ST1 with ST2.

ST1 498897200 OIL PRESSURE GAUGE
ADAPTER
ST2 498575400 OIL PRESSURE GAUGE
ASSY
4AT-34
Line Pressure Test

6) Open/close the throttle valve, and check for

changes in duty ratio using the Subaru Select Monitor.
Standard line pressure
Range position
Line pressure duty

ratio (%)
25 35
100
(Full open)
15 25
100
(Full open)
35 43
0
(Fully
closed)
Throttle
Line pressure
position (%) kPa (kg/cm2, psi)
1,000 1,300
(10.2 13.3,
145 189)
1,500 1,850
(15.3 18.9,
217 268)
500 800
(5.1 8.2,
73 116)
4AT-35
Transfer Clutch Pressure Test

8. Transfer Clutch Pressure

Test
A: INSPECTION
Check the transfer clutch pressure in accordance
with the following procedures, in the same manner
as with line pressure. <Ref. to 4AT-34, Line Pressure Test.>
ST 498897700
OIL PRESSURE ADAPTER
SET
ST 498575400
OIL PRESSURE GAUGE
ASSY
NOTE:
Before setting in FWD mode test, install the spare
fuse on FWD mode switch. (Only models with MPT)
(A)
AT-00021
(A) Test plug
NOTE:
If no oil pressure is produced or if it does not
change in AWD mode, the transfer duty solenoid or
the control valve body may be malfunctioning.
If oil pressure is produced in FWD mode, there is
the same problem as the AWD mode. (Only models
with MP-T)
Range position
ON
Duty ratio
(%)
Throttle position
(%)
95
Fully opened (100)
60
Adjust ON Duty ratio to

60%.
5
5
2 (Hold switch ON)
N or P
Standard transfer clutch pressure kPa (kg/cm2,

psi)
AWD mode
FWD mode
Fully closed (0)
1,000 1,200
(10.2 12.2,
145 174)
500 700
(5.1 7.1,
73 102)
0 (0, 0)
Fully closed (0)
4AT-36
Automatic Transmission Assembly

9. Automatic Transmission Assembly

A: REMOVAL
2) Open the front hood and support with the hood
stay.
model)
Chamber.>
5) Remove the intercooler. (Turbo model)
<Ref. to IN(H4DOTC)-11, REMOVAL, Intercooler.>
6) Remove the air cleaner case stay. (Non-turbo
model)
10) Separate the torque converter clutch assembly

from drive plate.
CAUTION:
Be careful not to damage attachment bolts.
Be careful not to drop bolts into the converter
case.
(1) Remove the V-belt covers.
(3) Remove the bolts which hold torque converter clutch assembly to drive plate.
(4) Remove all the bolts by gradually rotating
the crank sprocket to the same direction as the
engine rotates.
AT-00102
11) Install the ST to the converter case.

ST 498277200
STOPPER SET
AT-00101
7) Disconnect the following connectors.

(1) Transmission harness connectors
ST
AT-00804
12) Remove the ATF level gauge.
AT-00089
NOTE:
Plug the opening to prevent entry of foreign particles into transmission fluid.
(2) Transmission ground terminal

8) Remove the starter.
<Ref. to SC (H4SO)-6, REMOVAL, Starter.>
AT-00680
AT-00023
13) Remove the throttle body.

<Ref. to FU(H4SO)-12, REMOVAL, Throttle
Body.>
14) Remove the pitching stopper bracket.
4AT-37

15) Set the ST.

ST 41099AC000 ENGINE SUPPORT ASSY
22) Disconnect the ATF cooler hoses from the

pipes of transmission side, and remove the ATF
level gauge guide.
ST
AT-02167
16) Remove the bolts which hold right upper side of

AT-00683
23) Remove the propeller shaft.

<Ref. to DS-12, REMOVAL, Propeller Shaft.>
24) Remove the shift select cable.
<Ref. to CS-25, REMOVAL, Select Cable.>
25) Disconnect the stabilizer link from the transverse link.
AT-00106

19) Remove the front, center and rear exhaust
pipes and the muffler. (Non-turbo model)
Pipe.> <Ref. to EX (H4SO)-8, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX (H4SO)-9, REMOVAL,
Muffler.>
20) Remove the center and rear exhaust pipes and
the muffler. (Turbo model)
<Ref. to EX(H4DOTC)-8, REMOVAL, Center Exhaust Pipe.> <Ref. to EX(H4DOTC)-13, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)15, REMOVAL, Muffler.>
21) Remove the drain plug (ATF) to drain ATF.
AT-00107
26) Remove the bolt securing ball joint of the transverse link to housing.
(A)
AT-00115
(B)
AT-01332
(A) Oil pan

4AT-38

27) Pull out the front drive shaft from the transmission.
(1) Face the letters AT on the ST to the transmission side.
ST 28399SA000 DRIVE SHAFT REMOVER

(A)
AT-00108
30) Place a transmission jack below the transmission.

AT-00461
(A) Letters AT
(2) Insert the ST between the transmission and

front drive shaft.
NOTE:
Make sure that the support plates of transmission
jack do not touch the oil pan.
31) Remove the transmission rear crossmember
from the vehicle.
NOTE:
Set the protrusion of the ST to the torque converter
clutch housing.
AT-03697
32) While lowering the transmission jack gradually,

fully retract the engine support, and then tilt the engine rearward.
33) Remove the transmission.
NOTE:
Remove the transmission and torque converter as
a single unit from engine.
(A)
ST
(B)
AT-00444
(A) Protrusion of the ST

(B) Converter case
AT-00109
(3) Hold the joint portion (AARi) of the front

drive shaft by hand and extract the housing
from the transmission by pressing it outside.
28) Remove the bolts which secure the housing
cover.
34) Remove the rear cushion rubber from transmission.
4AT-39

B: INSTALLATION
1) Replace the differential side oil seal with a new
one. <Ref. to 4AT-46, REPLACEMENT, Differential Side Retainer Oil Seal.>
2) Install the rear cushion rubber to the transmission.
6) Remove the transmission jack.

7) Tighten the bolts and nuts which hold lower side
of transmission to engine.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
Tightening torque:
39 Nm (4.0 kgf-m, 29 ft-lb)
3) Install the ST to the converter case.
ST 498277200
STOPPER SET
AT-00108
8) Tighten the bolt of the housing cover.

9) Lower the lift.
10) Connect the engine and transmission.
(1) Remove the ST from converter case.
ST
AT-00103
4) Install the transmission onto the engine.

(1) Lift-up the transmission gradually using
transmission jack.
NOTE:
When removing the ST, be careful not to drop it into
converter case.
ST 498277200
STOPPER SET
(2) Tighten the bolts which hold the right upper
side of the transmission to engine.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
AT-00109
(2) Insert the stud bolt on the engine side into

the transmission bolt hole.
(3) While lowering the transmission jack gradually, turn the screw of engine support, and then
tilt the engine forward to join them together.
5) Install the transmission rear crossmember.
Tightening torque:
T1: 35 Nm (3.6 kgf-m, 26 ft-lb)
T2: 70 Nm (7.1 kgf-m, 51 ft-lb)
T1
T2
T2
AT-03698
4AT-40
AT-00106

11) Install the torque converter clutch assembly to

the drive plate.
CAUTION:
Be careful not to damage attachment bolts.
Be careful not to drop bolts into the converter
case.
(1) Tighten the bolts which hold torque converter clutch assembly to the drive plate.
(2) Tighten all the bolts by gradually rotating the
crank sprocket to the same direction as the engine rotates.
15) Install the throttle body.

<Ref. to FU(H4SO)-12, INSTALLATION, Throttle
Body.>
16) Attach the pitching stopper.
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 37 ft-lb)
T2: 58 Nm (5.9 kgf-m, 43 ft-lb)
T2
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
T1
AT-00025

18) Replace the circlip of the front drive shaft with a
new one.
19) Apply grease to the oil seal lip.
20) Install the ST to side retainer.
ST 28399SA010 OIL SEAL PROTECTOR
AT-00102
(3) Fit the plug to service hole.

12) Install the starter.
<Ref. to SC (H4SO)-6, INSTALLATION, Starter.>
13) Remove the ST.
ST
AT-00110
ST
AT-02167
14) Install the pitching stopper bracket.

Tightening torque:
41 Nm (4.2 kgf-m, 30.4 ft-lb)
21) Align the spline portion of front drive shaft with

the serration of the differential bevel gear to insert,
and remove the ST.
22) Insert the front drive shaft into transmission securely by pressing the front housing.
AT-00111
23) Connect the ball joint to the front housing.
4AT-41

24) Tighten the attachment bolts.
31) Install the front and center exhaust pipe. (Nonturbo model)
32) Install the center exhaust pipe. (Turbo model)
Exhaust Pipe.>
34) Lower the lift.
35) Install the ATF level gauge.
Tightening torque:
49 Nm (5.0 kgf-m, 36 ft-lb)
AT-00115
25) Attach the stabilizer link to the transverse link.

Tightening torque:
45 Nm (4.6 kgf-m, 33.2 ft-lb)
AT-00693

(1) Transmission harness connectors
(2) Transmission ground terminal
37) Install the air cleaner case stay. (Non-turbo
model)
AT-00107
26) Install the shift select cable onto select lever.

<Ref. to CS-26, INSTALLATION, Select Cable.>
27) Connect the ATF cooler hoses to the pipe.
AT-00450
28) Install the ATF level gauge guide.

29) Install the propeller shaft.
<Ref. to DS-13, INSTALLATION, Propeller Shaft.>
30) Install the rear exhaust pipe and muffler assembly.
(Non-turbo model)
(Turbo model)
Tightening torque:
16 Nm (1.6 kgf-m, 11.6 ft-lb)
38) Install the air intake chamber. (Non-turbo model)
Chamber.>
39) Install the intercooler. (Turbo model)
41) Pour ATF from the oil charge pipe. <Ref. to
4AT-28, Automatic Transmission Fluid.>
42) Check the ATF level. <Ref. to 4AT-28, Automatic Transmission Fluid.>
44) Check the select lever operation.
<Ref. to 4AT-47, INSPECTION, Inhibitor Switch.>
45) Execute the learning control promotion.
<Ref. to 4AT(D)(diag)-15, FACILITATION OF
LEARNING CONTROL, OPERATION, Subaru Select Monitor.>
46) Perform the road test.
<Ref. to 4AT-31, Road Test.>
4AT-42
Transmission Mounting System

10.Transmission Mounting System
6) Remove the transmission rear crossmember.
A: REMOVAL
1. PITCHING STOPPER
model)
Chamber.>
AT-03697
7) Remove the rear cushion rubber.
B: INSTALLATION
1. PITCHING STOPPER
1) Attach the pitching stopper.
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 37 ft-lb)
T2: 58 Nm (5.9 kgf-m, 43 ft-lb)
T2
AT-00023
2. TRANSMISSION REAR CROSSMEMBER

AND REAR CUSHION RUBBER
2) Jack-up the vehicle and support it with rigid
racks.
3) Remove the front, center, rear exhaust pipes
and muffler. (Non-turbo model)
Muffler.>
4) Remove the center and rear exhaust pipe and
muffler. (Turbo model)
5) Set the transmission jack under transmission.
T1
AT-00025

Chamber.>
NOTE:
Make sure that the support plate of transmission
jack does not touch the oil pan.
4AT-43


1) Install the rear cushion rubber.
Tightening torque:
39 Nm (4.0 kgf-m, 29 ft-lb)
Tightening torque:
T1: 35 Nm (3.6 kgf-m, 26 ft-lb)
T2: 70 Nm (7.1 kgf-m, 51 ft-lb)
T1
T2
T2
AT-03698

4) Install the front, center and rear exhaust pipes,
and the muffler. (Non-turbo model)
<Ref. to EX (H4SO)-5, INSTALLATION, Front Exhaust Pipe.> <Ref. to EX (H4SO)-8, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX (H4SO)-9,
INSTALLATION, Muffler.>
5) Install the center, rear exhaust pipes and the
Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, INSTALLATION, Rear Exhaust Pipe.> <Ref. to
EX(H4DOTC)-15, INSTALLATION, Muffler.>
C: INSPECTION
Perform the following inspection procedures and
repair or replace defective parts.
1. PITCHING STOPPER
Make sure that the pitching stopper is not bent or
damaged. Check that there are no cracks, hardening or damage on rubber parts.

Make sure that the cross member is not bent or
damaged. Check the cushion rubber for cracks,
hardening or damage.
4AT-44
Extension Case Oil Seal

11.Extension Case Oil Seal

A: INSPECTION
Make sure that the ATF is not leaking from the
transmission and propeller shaft joint. If there is
leakage, replace the oil sea and check the propeller
shaft. <Ref. to 4AT-45, REPLACEMENT, Extension Case Oil Seal.>
B: REPLACEMENT
1) Clean the transmission exterior.
NOTE:
Tighten the drain plug (ATF) after draining the ATF.

(Non-turbo model)
(Turbo model)
9) Pour in ATF. <Ref. to 4AT-28, Automatic Transmission Fluid.>
10) Bleed the air of control valve. <Ref. to 4AT-59,
Air Bleeding of Control Valve.>
11) Check the level and leaks of the ATF. <Ref. to
4AT-28, Automatic Transmission Fluid.>
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
(A)
(B)
AT-01332
(A) Oil pan


(Non-turbo model)
(Turbo model)
4) Remove the propeller shaft. <Ref. to DS-12, REMOVAL, Propeller Shaft.>
5) Using the ST, remove the oil seal.
ST 398527700
PULLER ASSY
6) Using the ST, install the oil seal.
ST 498057300
INSTALLER
7) Install the propeller shaft. <Ref. to DS-13, INSTALLATION, Propeller Shaft.>
4AT-45
Differential Side Retainer Oil Seal

12.Differential Side Retainer Oil

Seal
A: INSPECTION
7) Using the ST, install the differential side retainer

oil seal by lightly tapping with a hammer.
ST 18675AA000 DIFFERENTIAL SIDE OIL
SEAL INSTALLER
Check for leakage of gear oil from differential side

retainer oil seal part. If there is oil leakage, replace
the oil seal and check the drive shaft.
ST
B: REPLACEMENT
2) Remove the front exhaust pipe and center exhaust pipe.
(Non-turbo model)
Pipe.>
(Turbo model)
3) Remove the differential gear oil drain plug, and
drain the differential gear oil.
(A)
(B)
AT-00029
8) Apply oil to the oil seal lips.

9) Install the front drive shaft using the ST. <Ref. to
DS-30, INSTALLATION, Front Drive Shaft.>
10) Install the front exhaust pipe and the center exhaust pipe.
(Non-turbo model)
(Turbo model)
Exhaust Pipe.>
12) Pour differential gear oil into the gauge hole.
Recommended gear oil:
<Ref. to 4AT-3, SPECIFICATION, General Description.>
AT-02204
(A) Oil pan

(B) Differential gear oil drain plug
4) Replace the gasket with a new one and tighten

the differential oil drain plug.
Gear oil capacity:

1.1 1.32 (1.3 1.4 US qt, 1.0 1.1 Imp qt)
13) Check the gear oil level. <Ref. to 4AT-30, INSPECTION, Differential Gear Oil.>
Tightening torque:
Copper gasket
70 Nm (7.2 kgf-m, 51.7 ft-lb)
Aluminum gasket
44 Nm (4.5 kgf-m, 32.5 ft-lb)
5) Separate the front drive shaft from the transmission. <Ref. to DS-29, REMOVAL, Front Drive
Shaft.>
6) Remove the differential side retainer oil seal using a screw driver wrapped with vinyl tape etc.
4AT-46
Inhibitor Switch
13.Inhibitor Switch
A: INSPECTION
When the driving condition or starter motor operation is improper, first check the shift linkage for improper operation. If the shift linkage is functioning
properly, check the inhibitor switch.
1) Disconnect the inhibitor switch connector.
2) Check continuity in inhibitor switch circuits with
the select lever moved to each position.
3) Check if there is continuity at equal points when

the select lever is turned 1.5 to the R and D
ranges from the N range.
If there is continuity in only one direction or in other
points, adjust the inhibitor switch. <Ref. to 4AT-47,
ADJUSTMENT, Inhibitor Switch.>
P
R
NOTE:
Also check that there is no continuity in ignition
circuit when the select lever is in the R, D, 3,
2 and 1 ranges.
If the inhibitor switch does not operate, check for
poor contact of the connector on transmission side.
Range
P
Pin No.
43
R
N
42
41
D
3
48
47
2
1
46
45
P/N
R
12 11
10 9
Signal sent to TCM
Ignition circuit
Back-up light circuit
(A)
N
D
3
2
1
(C) (A)
(B)
(C) (A)
AT-00452
(A) Continuity does not exist.

(B) Continuity exists.
(C) 1.5
4) Repeat the above checks for the other ranges. If

there are abnormalities, adjust the select cable.
<Ref. to CS-27, ADJUSTMENT, Select Cable.>
B: ADJUSTMENT
1) Shift the select lever to N range.
2) Loosen the three inhibitor switch assembly securing bolts.
3) Insert the ST as vertical as possible into the
holes in the inhibitor switch lever and switch body.
ST 499267300
STOPPER PIN
( 4 ) (3 ) (2 ) (1 )
ST
( 8 ) (7 ) (6 ) (5 )
(12) (11) (10) (9 )
AT-00030
(A) Inhibitor switch connector

AT-00032
4) Tighten the three inhibitor switch assembly securing bolts.

Tightening torque:
3.4 Nm (0.35 kgf-m, 2.6 ft-lb)
5) Repeat the inspections of the inhibitor switch. If
the inhibitor switch is determined to be faulty, replace it. <Ref. to 4AT-47, INSPECTION, Inhibitor
Switch.>
4AT-47
Inhibitor Switch
C: REMOVAL
2) Move the select lever to N.
3) Remove the air intake chamber (non-turbo model).
Chamber.>
4) Remove the inter cooler (Turbo model).
5) Disconnect the inhibitor switch connector.
10) Remove the plate assembly from the transmission case.
(A)
(B)
AT-00035
(A)
(A) Select cable

(B) Plate ASSY
11) Remove the bolt.
(A)
AT-00033
6) Remove the inhibitor switch connector from the

stay.
(Non-turbo model)
Pipe.>
(Turbo model)
9) Remove the snap pin and washer from the range
select lever.
AT-00036
(A) Inhibitor switch ASSY
12) Move the range select lever to the parking position (left side).
(A)
(A)
AT-00037
(B)
(A) Range select lever
(C) (D)
AT-00034

(B) Snap pin
(C) Select cable
(D) Washer
4AT-48
Inhibitor Switch
13) Remove the inhibitor switch assembly from the

transmission.
(A)
4) Using the ST, tighten the bolts of the inhibitor

switch.
ST 499267300
STOPPER PIN
Tightening torque:
3.4 Nm (0.36 kgf-m, 2.6 ft-lb)
ST
(A)
AT-00038
(B)
14) Disconnect the inhibitor switch harness connector from the inhibitor switch.
AT-00039

(B) Range select lever
D: INSTALLATION
1) Connect the inhibitor switch harness connector
to the inhibitor switch.
2) Install the inhibitor switch assembly to the transmission case.
5) Install the select cable to the range select lever.

6) Install the plate assembly to the transmission.
Tightening torque:
T: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
(A)
(A)
AT-00038
(B)
AT-00040

(A) Select cable
(B) Plate ASSY
3) Move the range select lever to the neutral position.
7) Install the washer and snap pin to the range select lever.
(A)
(B)
(C) (D)
AT-00034

(B) Snap pin
(C) Select cable
(D) Washer
4AT-49
Inhibitor Switch

Exhaust Pipe.>
11) Install the inhibitor switch connector to the stay.
12) Connect the inhibitor switch connector.
(A)
AT-00033

Chamber.>
15) Inspect the inhibitor switch. <Ref. to 4AT-47,
INSPECTION, Inhibitor Switch.>
4AT-50
Front Vehicle Speed Sensor

14.Front Vehicle Speed Sensor

A: REMOVAL
model)
Chamber.>
5) Disconnect the transmission connector.
11) Remove the front, center and rear exhaust

pipes and the muffler. (Non-turbo model)
Muffler.>
12) Remove the center and rear exhaust pipes and
the muffler. (Turbo model)
13) Remove the propeller shaft. <Ref. to DS-12,
REMOVAL, Propeller Shaft.>
14) Place the transmission jack under the transmission.
NOTE:
Make sure that the support plate of transmission
jack does not touch the oil pan.
bolt.
(A)
AT-00042
(A) Transmission connector
6) Remove the pitching stopper. <Ref. to 4AT-43,

REMOVAL, Transmission Mounting System.>
7) Remove the transmission connector from stay.
NOTE:
Tighten the drain plug (ATF) after draining the ATF.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
AT-00043
16) Lower the transmission jack.

NOTE:
Do not separate the transmission jack and transmission.
17) Remove the ATF cooler inlet and outlet pipes.
NOTE:
When removing the outlet pipe, do not lose the ball
and spring used with retaining screw.
18) Remove the front vehicle speed sensor and
torque converter turbine speed sensor.
(A)
(B)
(A)
(B)
AT-01332
(A) Oil pan

(C) Differential gear oil drain plug
AT-00044
(A) Front vehicle speed sensor

(B) Torque converter turbine speed sensor
4AT-51

19) Disconnect the connector from the rear vehicle

speed sensor.
(A)
B: INSTALLATION
1) Pass the transmission harness
through the hole in transmission case.
assembly
AT-01338
AT-00048
(A) Rear vehicle speed sensor

21) Disconnect the control valve connector and the
grounding cable.
2) Connect the control valve connector and the

grounding cable.
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
(A)
(A)
(B)
(B)
AT-00050
AT-00050
(A) Transmission ground cable

(B) Control valve connector
(A) Transmission ground cable

(B) Control valve connector
22) Remove the transmission harness assembly.
3) Apply proper amount of liquid gasket to the entire oil pan mating surface.
Liquid gasket:
Three bond 1217B (Part No. K0877YA020) or
equivalent
AT-02742
4AT-52

4) Fill the 3 holes aside from the bolt holes in the

transmission case, with liquid gasket.
Liquid gasket:
equivalent
AT-01339
5) Install the oil pan by equally tightening the bolts.

Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
6) Install the front vehicle speed sensor and torque
converter turbine speed sensor.
Tightening torque:
7 Nm (0.7 kgf-m, 5.1 ft-lb)
7) Connect the connector to the rear vehicle speed
sensor.
8) Install the ATF cooler inlet and outlet pipes.
12) Install the center, rear exhaust pipes and the

Exhaust Pipe.> <Ref. to EX(H4DOTC)-14, INSTALLATION, Rear Exhaust Pipe.> <Ref. to
EX(H4DOTC)-15, INSTALLATION, Muffler.>
14) Install the transmission connector to the stay.
15) Attach the pitching stopper. <Ref. to 4AT-43,
INSTALLATION, Transmission Mounting System.>
Chamber.>
18) Pour in ATF.
<Ref. to 4AT-28, Automatic Transmission Fluid.>
19) Bleed the air of control valve.
<Ref. to 4AT-59, Air Bleeding of Control Valve.>
20) Check the level and leaks of the ATF.
<Ref. to 4AT-28, Automatic Transmission Fluid.>
21) Execute the learning control promotion.
<Ref. to 4AT(D)(diag)-15, FACILITATION OF
LEARNING CONTROL, OPERATION, Subaru Select Monitor.>
NOTE:
Use a new copper washer.
Tightening torque:
T1: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
T2: 40 Nm (4.1 kgf-m, 29.5 ft-lb)
T3: 45 Nm (4.6 kgf-m, 33.2 ft-lb)
T2
T3
T1
AT-03072
9) Install the transmission rear crossmember bolt.

Tightening torque:
70 Nm (7.1 kgf-m, 51 ft-lb)
and the muffler. (Non-turbo model)
<Ref. to EX (H4SO)-5, INSTALLATION, Front Exhaust Pipe.> <Ref. to EX (H4SO)-8, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX (H4SO)-9,
INSTALLATION, Muffler.>
4AT-53
Rear Vehicle Speed Sensor

15.Rear Vehicle Speed Sensor

A: REMOVAL
4) Disconnect the connector from the rear vehicle
speed sensor.
(A)
AT-01338
5) Remove the rear vehicle speed sensor.
AT-01341
B: INSTALLATION
NOTE:
Replace O-ring with a new one.
Tightening torque:
7 Nm (0.7 kgf-m, 5.1 ft-lb)
4AT-54
Torque Converter Turbine Speed Sensor

16.Torque Converter Turbine

Speed Sensor
A: REMOVAL
When removing the torque converter turbine speed
sensor, refer to Front Vehicle Speed Sensor.
<Ref. to 4AT-51, REMOVAL, Front Vehicle Speed
Sensor.>
B: INSTALLATION
When installing the torque converter turbine speed
sensor, refer to Front Vehicle Speed Sensor.
<Ref. to 4AT-52, INSTALLATION, Front Vehicle
Speed Sensor.>
4AT-55
Control Valve Body

17.Control Valve Body
10) Completely remove the remaining liquid gasket

on the transmission case and oil pan.
11) Remove the control valve connector.
A: REMOVAL
5) Remove the drain plug (ATF) and gasket to drain
ATF.
CAUTION:
The ATF will be extremely hot after driving. Be
careful not to receive burns.
AT-00058
12) Remove the ATF cooler pipe.
AT-02928
6) Replace the gasket with new one, and then tighten the drain plug (ATF).
AT-00059
13) Remove the control valve body.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
NOTE:
Be careful not to allow foreign matter such as dust
or dirt to enter the oil pan.
NOTE:
The control valve body is replaced as an assembly
only, because it is a non-disassembly part.
AT-01717
AT-02929
8) Remove the magnet.
AT-02743
9) Clean the magnet.
4AT-56
Control Valve Body

B: INSTALLATION
1) Check the control valve body for dust and other
foreign matter.
2) Temporarily assembly the control valve body to
transmission then install the oil cooler pipe.
5) Attach the magnet at the specified position of the

oil pan.
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
AT-02743
6) Apply proper amount of liquid gasket to the entire oil pan mating surface.
AT-00059
Liquid gasket:
equivalent
3) Tighten the bolts equally.

Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
(A)
(2)
(2)
(2)
(2)
(1)
(2)
(2)
(2)
(2)
(2)
AT-02742
(1)
(2)
7) Fill the 3 holes aside from the bolt holes in the

transmission case, with liquid gasket.
(2)
AT-01718
(A) Transmission ground
Liquid gasket:
equivalent
Bolt length mm (in)

(1) 35 (1.38)
(2) 30 (1.18)
4) Connect the control valve connector.
AT-01339
8) Install the oil pan by equally tightening the bolts.

Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
AT-00058
4AT-57
Control Valve Body

9) Fill ATF from the oil charge pipe.

Recommended fluid:
SUBARU ATF HP
Substitute fluid:
IDEMITSU: ATF HP
Castrol: Transmax J
Capacity:
Fill with the same amount of fluid that was
drained from the drain plug hole.
10) Bleed the air of control valve body. <Ref. to
4AT-59, Air Bleeding of Control Valve.>
11) Check the ATF level. <Ref. to 4AT-28, Automatic Transmission Fluid.>
12) Execute the learning control promotion. <Ref.
to 4AT(D)(diag)-15, FACILITATION OF LEARNING CONTROL, OPERATION, Subaru Select
Monitor.>
C: INSPECTION
Make sure there are no holes, bending damage or
other foreign materials on each parts.
4AT-58
Air Bleeding of Control Valve

18.Air Bleeding of Control Valve

A: PROCEDURE
24) Move the select lever to the P range, and then

finish the air bleed.
1) Operate the vehicle with the select lever moved

to P range and parking brake applied.
2) Connect the Subaru Select Monitor to the vehicle.
3) Make sure there is no trouble code using the
4) Using the Subaru Select Monitor, check that the
ATF temperature is less than 60C (140F). <Ref.
to 4AT(D)(diag)-14, READ CURRENT DATA, OPERATION, Subaru Select Monitor.>
5) Close the Subaru Select Monitor.
7) Move the select lever to R range.
8) Depress the brake pedal fully until the air bleeding is completed.
9) Turn the ignition switch ON.
10) Move the select lever to P range, and then
wait for more than 3 seconds.
11) Move the select lever to R range, and then
12) Move the select lever to N range, and then
13) Move the select lever to D range, and then
14) Move the select lever to N range, and then
15) Slowly depress the accelerator pedal fully
open.
16) Slowly release the accelerator pedal to full
close.
18) Shift the select lever to D range.
19) Run the Subaru Select Monitor.
20) Select {Each System Check} in the Main Menu
of the Subaru Select Monitor.
21) On the System Selection Menu display screen,
select Transmission. Air bleed of the control valve
will start in the transmission. At this time, the AT oil
temperature warning light in the combination meter
start blinking at 2 Hz. When the AT oil temperature
warning light does not blink, repeat the procedures
from step 4).
22) Air bleed of the control valve is finished when
the AT oil temperature warning light in the combination meter changes from blinking at 2 Hz to 0.5
Hz.
NOTE:
If the AT oil temperature warning light changes
from blinking at 2 Hz to 4 Hz during the air bleed,
repeat the procedure from step 4).
23) Move the select lever to the N range, and then
turn the ignition switch OFF.
4AT-59
ATF Filter
19.ATF Filter
A: REMOVAL
NOTE:
The ATF filter is maintenance free.
2) Using the ST, remove the ATF filter.
ST 498545400
OIL FILTER WRENCH
(A)
ST
AT-00091
(A) ATF filter
B: INSTALLATION
1) Apply a thin coat of ATF to the oil seal part of
new ATF filter.
2) Install the ATF filter. Turn it by hand, being careful not to damage oil seal.
3) Tighten the ATF filter using ST.
Calculate the ATF filter tightening torque using following formula.
T2 = L2/(L1 + L2) T1
T1: 14 Nm (1.4 kgf-m, 10.1 ft-lb)
L1: ST length 78 mm (3.07 in)
Example:
mm (in)
100 (3.94)
Tightening torque
Nm (kgf-m, ft-lb)
7.7 (0.79, 5.7)
150 (5.91)
200 (7.87)
9.0 (0.92, 6.7)

9.8 (1.0, 7.2)
NOTE:
Align the ST with the torque wrench while tightening the ATF filter.
ST 498545400
OIL FILTER WRENCH
4) Fill ATF.
5) Inspect the level of ATF. <Ref. to 4AT-28, Automatic Transmission Fluid.>
C: INSPECTION
Replace the part if any damage is found in the inspection.
Check for rust, holes, ATF leaks or other damage.
4AT-60
Transmission Control Module (TCM)

20.Transmission Control Module (TCM)
B: INSTALLATION
A: REMOVAL
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
2) Connect the connector to TCM.
1) Install the TCM.

2) Remove the lower cover and then disconnect
the connector.
3) Remove the knee bolster.
(A)
AT-03374
(A) Transmission control module (TCM)

CS-00097

4) Execute the learning control promotion. <Ref. to
4AT(D)(diag)-15, FACILITATION OF LEARNING
CONTROL, OPERATION, Subaru Select Monitor.>
(A)
AT-03374
(A) Transmission control module (TCM)
5) Remove the TCM.
4AT-61
ATF Cooler Pipe and Hose

21.ATF Cooler Pipe and Hose
8) Disconnect the ATF cooler pipe from frame.
A: REMOVAL
2) Remove the battery and washer tank.
5) Disconnect the ATF cooler hose from the radiator. (Turbo model)<Ref. to CO(H4SO)-28, TURBO
MODEL, REMOVAL, Radiator.>
6) Disconnect the ATF cooler hose from the radiator. (Non-turbo model)
NOTE:
Do not use a screwdriver or other pointed tools.
If it is hard to remove the hose, wrap the hose
with cloth to prevent from damaging it, and while
turning with pliers, pull straight out by hand.
AT-00456

NOTE:
When separating the outlet pipe, do not lose the
ball and spring used with retaining screw.
AT-00455
(A)
7) Disconnect the ATF cooler hoses from the pipes.

NOTE:
Do not use a screwdriver or other pointed tools.
If it is hard to remove the hose, wrap the hose
with cloth to prevent from damaging it, and while
turning with pliers, pull straight out by hand.
(B)
(A) ATF cooler inlet pipe

(B) ATF cooler outlet pipe
AT-00450
4AT-62
AT-01526

B: INSTALLATION
1) Install the ATF cooler inlet and outlet pipes with
the new washer.
Tightening torque:
T1: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
T2: 40 Nm (4.1 kgf-m, 29.5 ft-lb)
T3: 45 Nm (4.6 kgf-m, 33.2 ft-lb)
3) Connect the ATF cooler hose to the pipe on the

transmission side.
NOTE:
Install so that the hose is not folded over, excessively bent or twisted.
Insert the hose to the specified position.
T2
AT-00450
T3
T1
AT-03072
2) Install the ATF cooler pipe to frame.

radiator side. (Non-turbo model)
NOTE:
Install so that the hose is not folded over, excessively bent or twisted.
Insert the hose to the specified position.
AT-00455
AT-00456

radiator side. (Turbo model)<Ref. to CO(H4SO)31, TURBO MODEL, INSTALLATION, Radiator.>
7) Install the battery and washer tank.
8) Fill ATF. <Ref. to 4AT-28, Automatic Transmission Fluid.>
NOTE:
Make sure there are no ATF leaks in joints between
the transmission, radiator, pipes, and hoses.
4AT-63

C: INSPECTION
Repair or replace any faulty hoses, pipes, clamps,
and washers found in the inspection below.
1) Check for ATF leaks in joints between the transmission, radiator, pipes, and hoses.
2) Check the clamp for deformation.
3) Lightly bend the hose and check for cracks in the
surface and other damage.
4) Pinch the hose with your fingers and check for
poor elasticity. Also check for poor elasticity in the
parts where the clamp was installed by pressing
with your fingernail.
5) Check for peeling, cracks, and deformation at
the tip of the hose.
4AT-64
Air Breather Hose

22.Air Breather Hose
B: INSTALLATION
A: REMOVAL
1) Install the air breather hose.

Non-turbo model

model)
Chamber.>
3) Disconnect the air breather hose.
Non-turbo model
AT-00099
(A) Air breather hose (Transmission case)

(B) Air breather hose (Oil pump housing)
Turbo model
AT-00099

Turbo model
AT-00098

AT-00098


Chamber.>
C: INSPECTION
Make sure the hose is not cracked or clogged.
4AT-65
Oil Charge Pipe

23.Oil Charge Pipe

A: REMOVAL
model)
Chamber.>
3) Remove the oil charge pipe, and then remove
the O-ring from the flange side.
(A)
(B)
AT-01528
(A) ATF level gauge

(B) Oil charge pipe
B: INSTALLATION
1) Install the oil charge pipe with a new O-ring.
Tightening torque:
41 Nm (4.2 kgf-m, 30.4 ft-lb)
(A)
(B)
AT-01528
(A) ATF level gauge

(B) Oil charge pipe

Chamber.>
C: INSPECTION
Make sure the oil charge pipe is not deformed or
damaged.
4AT-66
Torque Converter Clutch Assembly

24.Torque Converter Clutch Assembly

A: REMOVAL
1) Remove the transmission assembly from vehicle
body. <Ref. to 4AT-37, REMOVAL, Automatic
2) Pull out the torque converter assembly and oil
pump shaft horizontally.
B: INSTALLATION
1) Install the clip to the converter case.
2) Install the oil pump shaft to the torque converter
clutch assembly, and then make sure the clip is secured on the groove.
3) Insert the input shaft while rotating it lightly by
hand, and then check the amount of protrusion.
Normal protrusion A:
50 55 mm (1.97 2.17 in)
NOTE:
Do not scratch the inner surface of the bushing in
oil pump shaft.
A
AT-00291
AT-00113
3) Remove the input shaft.

NOTE:
When the torque converter clutch assembly is removed, the input shaft will also come off.
4) While holding the torque converter clutch assembly by hand, carefully install it to the torque
converter case. Take care not to damage the bushing. Do not allow the oil pump shaft bushing to
touch the starter shaft part of the oil pump cover inappropriately.
5) Turn the oil pump shaft lightly by hand to engage
the spline securely, and then check the converter
case and torque converter clutch assembly dimension A.
Dimension A:
2.7 2.9 mm (0.106 0.114 in)
(A)
AT-00114
4) Remove the clip from torque converter clutch assembly.

AT-00311
(A) Dimension A
6) Install the transmission assembly to the vehicle.

<Ref. to 4AT-40, INSTALLATION, Automatic
C: INSPECTION
Make sure the ring gear and protrusion of the
torque converter clutch end are not deformed or
damaged.
4AT-67
Extension Case
25.Extension Case
B: INSTALLATION
A: REMOVAL
1) Apply vaseline to the selected thrust needle

bearing, and install to the reduction drive gear end
surface. <Ref. to 4AT-76, ADJUSTMENT, Transfer
Clutch.>
1) Remove the transmission assembly.

<Ref. to 4AT-37, REMOVAL, Automatic Transmission Assembly.>
2) Remove the rear vehicle speed sensor.
(A)
NOTE:
Install the thrust needle bearing in the correct direction.
2) Install a new gasket.
3) Install the extension case to transmission case.
4) Tighten bolts to secure the extension case.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
AT-01338
3) Separate the transmission case and extension

case section.
AT-00118
5) Install the rear vehicle speed sensor.

Tightening torque:
7 Nm (0.7 kgf-m, 5.1 ft-lb)
(A)
AT-00118
AT-01338
6) Install the transmission assembly.

4AT-68
Extension Case
C: DISASSEMBLY
2. VTD MODEL
1. MP-T MODEL
1) Take out the transfer clutch assembly by lightly
tapping the end of rear drive shaft with a plastic
hammer.
1) Extract the circlip with ST1, ST2 and ST3 and

the press.
ST1 398673600 COMPRESSOR
ST2 498627100 SEAT
ST3 398663600 PLIERS
NOTE:
Be careful not to damage the oil seal of the extension.
ST1
ST2
ST3
(A)
AT-00121
(B)
2) Remove the test plug.

(A)
AT-00119
(A) Extension case

(B) Transfer clutch assembly
2) Remove the transfer clutch pipe without bending

the pipe.
(A)
(B)
AT-00122
(A) Test plug
(B)
(B) Extension case
3) Remove the clutch piston using compressed air.

AT-00120
(A) Extension case

(B) Transfer clutch pipe
3) Remove the dust cover from extension case.

4) Remove the oil seal from the extension case.
AT-00123
4AT-69
Extension Case
4) Remove the transfer clutch pipe without bending

the pipe.
2. VTD MODEL
1) Press-fit the new oil seal using ST and the press.
ST 498057300
INSTALLER
2) Press-fit the dust cover.
3) Install the transfer clutch pipe to the extension
case without bending the pipe.
AT-00124
5) Remove the dust cover from extension case.

D: ASSEMBLY
AT-00124
1. MP-T MODEL
4) Install the test plug.
1) Press-fit the new oil seal using ST and the press.

ST 498057300
INSTALLER
2) Press-fit the dust cover.
3) Install the transfer clutch pipe to the extension
case without bending the pipe.
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
(A)
(A)
(B)
(B)
AT-00122
(A) Test plug

(B) Extension case
AT-00120
(A) Extension case
5) Insert the multi-plate clutch, drive plate, driven

plate and spring retainer.
(B) Transfer clutch pipe
4) Install the transfer clutch assembly to the case.

NOTE:
Be careful not to damage the seal ring.
Press-fit the transfer clutch assembly to bottom
of bearing shoulder completely.
(A)
(B)
(A)
AT-00126
(A) Spring retainer

(B) Multi-plate clutch (LSD) piston ASSY
(B)
AT-00125
(A) Transfer clutch assembly

(B) Extension case
4AT-70
Extension Case
6) Install the circlip using ST1, ST2 and ST3.

ST2 498627100 SEAT
ST1
ST2
ST3
AT-00121
E: INSPECTION
Use an air compressor to check that the transfer
pipe and extension case routes are not clogged
and are not leaking.
Inspect the extension end play, and adjust it to
be within the standard value. <Ref. to 4AT-76, ADJUSTMENT, Transfer Clutch.>
(Model with MP-T)
<Ref. to 4AT-76, MP-T MODEL, ADJUSTMENT,
Transfer Clutch.>
(Model with VDC)
<Ref. to 4AT-76, VTD MODEL, ADJUSTMENT,
Transfer Clutch.>
4AT-71
Transfer Clutch
26.Transfer Clutch
C: DISASSEMBLY
A: REMOVAL
1) Remove the seal ring.

2) Remove the extension case, and take out the
transfer clutch assembly. <Ref. to 4AT-68, REMOVAL, Extension Case.> <Ref. to 4AT-69, DISASSEMBLY, Extension Case.>
B: INSTALLATION
1) Select the thrust needle bearing. <Ref. to 4AT76, ADJUSTMENT, Transfer Clutch.>
2) Install the transfer clutch assembly to the case.
AT-00127
(A) Seal ring

(B) Rear drive shaft
2) Remove the ball bearing using the ST and the

press.
ST 498077600
REMOVER
(A)
(B)
AT-00125

(B) Extension case
3) Tighten the bolts to secure the case.
AT-00128
3) Use a flat tip screwdriver to remove the snap

ring, and then take out the pressure plate, retaining
plate, drive plate and driven plate.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
AT-00118

4AT-72
AT-00129
(A) Snap ring

Transfer Clutch
4) Using the ST1, ST2 and ST3, remove the snap

ring, then take out the return spring and transfer
clutch piston seal.
ST3 398623600 SEAT
ST1
2) Install the return spring to transfer clutch piston.
(A)
ST2
(A)
ST3
(B)
AT-00133
(A) Return spring

(B)
3) Install the transfer clutch piston seal.
AT-00130
(A) Snap ring

(B) Transfer clutch piston seal
5) Use an air compressor to blow compressed air

from the rear drive shaft to remove the transfer
clutch piston.
(B)
(A)
AT-00134
(A) Transfer clutch piston seal

4) Attach the ST to the rear drive shaft.

ST 499257300
SNAP RING OUTER GUIDE
AT-00131
ST
D: ASSEMBLY
1) Install the transfer clutch piston.
(A)
AT-00135
(A) Rear drive shaft

(A)
(B)
AT-00132
(A) Transfer clutch piston

4AT-73
Transfer Clutch
5) Install the snap ring to the ST.

ST 499257300
SNAP RING OUTER GUIDE
(A)
8) Use an air compressor to apply compressed air

to see if the assembled parts move smoothly.
ST
(B)
AT-00139
AT-00136
(A) Snap ring

(B) Transfer clutch
6) Install the snap ring to the rear drive shaft using

ST1 and ST2.
ST1 499257300 SNAP RING OUTER GUIDE
ST2 499247400 INSTALLER
9) Check clearance between the snap ring and

pressure plate. <Ref. to 4AT-75, INSPECTION,
Transfer Clutch.>
10) Press-fit new ball bearing using ST.
ST 899580100
INSTALLER
ST
ST2
(A)
(A)
ST1
AT-00140
(B)
(A) Ball bearing

AT-00137
11) Apply vaseline to a new seal ring and attach to

the seal ring groove of the rear drive shaft.
(A) Snap ring

(B) Transfer clutch
7) Install the drive plate, driven plate, pressure

plate, retaining plate and snap ring.
NOTE:
While installing the seal ring, not to stretch the seal
ring excessively.
(A)
(B)
(A)
AT-00138
(A) Seal ring
(A) Snap ring
4AT-74
AT-00141
Transfer Clutch
12) Install the transfer clutch assembly while taking

care not to damage the seal ring.
Limit thickness:
1.6 mm (0.063 in)
(A)
(B)
AT-00125
AT-00142
Retaining plate
(B) Extension case
E: INSPECTION
Inspect the drive plate surface for wear and damage.
Make sure the snap ring is not worn and the return spring has no permanent distortion, damage,
or deformation.
Inspect the D-ring for damage.
be within the standard value.
MP-T MODEL<Ref. to 4AT-76, MP-T MODEL, ADJUSTMENT, Transfer Clutch.>
VTD MODEL<Ref. to 4AT-76, VTD MODEL, ADJUSTMENT, Transfer Clutch.>
1) Check clearance between the snap ring and
pressure plate.
2) Before measuring clearance, place same thickness shims on both sides to prevent the pressure
plate from tilting.
3) If the clearance exceeds the service limits, replace the driven plate and select and adjust the retaining plate to be within the initial standard value.
Part No.
31593AA151
Thickness mm (in)
3.3 (0.130)
31593AA161
31593AA171
3.7 (0.146)
4.1 (0.161)
31593AA181
4.5 (0.177)
4) Check for tight corner braking phenomenon

when the vehicle is moved forward with the steering fully turned. If tight corner braking occurs, perform the following procedures.
(1) With the steering wheel held at fully turned
position, drive the vehicle in D range and with
vehicle speed at approx. 5 km/h (3 MPH) in
both clockwise and counterclockwise directions
for approx. ten times each, while repeating acceleration and braking intermittently.
(2) If the tight corner braking phenomenon still
persists, drive the vehicle again in a circle for
several laps.
Initial standard:
0.7 1.1 mm (0.028 0.043 in)
4AT-75
Transfer Clutch
F: ADJUSTMENT
2. VTD MODEL
1. MP-T MODEL
1) Insert the rear drive shaft into the reduction drive

gear and center differential assembly.
1) Measure the distance A from the end of ST to

the rear drive shaft using ST.
ST 398643600
GAUGE
(A)
ST
(B)

(B) Center differential carrier
A
AT-01029
2) Measure the distance B from the transmission

case end to the end of ST using ST1 and ST2.
ST1 398643600 GAUGE
ST2 499577000 GAUGE
ST2
AT-00145
2) Using the ST, measure the distance L from the

end of the ST to the rear drive shaft ball bearing
outer ring contact surface.
ST 398643600
GAUGE
ST1
ST1
AT-01030
AT-01031
3) Calculation formula:
T = A B + 35.4 mm
[T = A B + 1.3937 in]
T: Thrust needle bearing thickness
A: Distance from the end of the ST to end of rear
drive shaft
B: Distance from the end of the transmission case
to the end of the ST
A Measured value
3) Measure the distance B from the transmission

case mating surface to the end surface of the ST
using the ST.
ST 398643600
GAUGE
ST

Part No.
Thickness mm (in)
806536020
806535030
3.8 (0.150)
4.0 (0.157)
806535040
806535050
4.2 (0.165)
4.4 (0.173)
806535060
806535070
4.6 (0.181)
4.8 (0.189)
806535090
5.0 (0.197)
B
AT-01032
B Measured value
4AT-76
Transfer Clutch
Calculate T:
When the clearance is 0.05 mm (0.0020 in), select
up to four adjusting shims from the table, according
to the clearance value.
When clearance is 0.05 mm (0.0020 in)
T = A B + 0.40 mm
[T = A B + 0.0157 in]
When clearance is 0.25 mm (0.0098 in)
T = A B + 0.20 mm
[T = A B + 0.0079 in]
T: Shim clearance
A: Distance from the end of extension case to the
rear drive shaft ball bearing outer ring contact surface
B: Distance from the end of the transmission case
to the end of the ST
T: Shim thickness
0.05 0.25 mm (0.0020 0.0098 in)
Adjustment shim
Part No.
33281AA001
Thickness mm (in)
0.2 (0.008)
33281AA011
0.5 (0.020)
4AT-77
Multi-plate Clutch
27.Multi-plate Clutch
3) Using the ST, measure the height B from the

transmission case mating surface to end of ST.
ST 398744300
PISTON GUIDE
A: REMOVAL
Remove the multi-plate clutch following the same
instructions as for the extension case. <Ref. to
4AT-68, REMOVAL, Extension Case.>
B: INSTALLATION
Install the multi-plate clutch following the same instructions as for the extension case. <Ref. to 4AT68, INSTALLATION, Extension Case.>
ST
C: INSPECTION
Inspect the drive plate facing for wear and damage.
Make sure the snap ring is not worn and the return spring has no permanent distortion, damage,
or deformation.
Inspect the D-ring for damage.
Measure the clearance of the multi-plate clutch
and check if it does not exceed the limit thickness.
<Ref. to 4AT-78, ADJUSTMENT, Multi-plate
Clutch.>
D: ADJUSTMENT
1) Install the drive plate and driven plate to the center differential carrier.
2) Measure the distance A from the end of ST to
the multi plate clutch piston using ST.
ST 398643600
GAUGE
AT-01033
B Measured value
T = A B + 0.45 mm
[T = A B + 0.0177 in]
Initial standard:
0.2 0.6 mm (0.008 0.024 in)
Limit thickness:
1.6 mm (0.063 in)
If the clearance exceeds the limit thickness, replace the plate set (drive and driven plate). Select a
multi-plate clutch piston driven plate that will bring
clearance within the default standard value.
ST1
AT-01031
A Measured value
4AT-78
Driven plate
Part No.
Thickness mm (in)
31589AA041
31589AA050
1.6 (0.063)
2.0 (0.079)
31589AA060
31589AA070
2.4 (0.094)
2.8 (0.110)
Rear Drive Shaft

28.Rear Drive Shaft
2) Using a press, remove the front and rear side

ball bearings and clutch hub.
A: REMOVAL
2) Remove the rear wheel speed sensor, and separate the extension case from transmission case.
<Ref. to 4AT-68, REMOVAL, Extension Case.>
3) Pull out the rear driveshaft from center differential assembly.
(B)
(A)
(C)
AT-00151
(A)
(A) Rear ball bearing

(C) Clutch hub
D: ASSEMBLY
(B)
NOTE:
Use new ball bearings and revolution gear.
Make sure the clutch hub is facing the correct direction.
AT-00145

(B)
4) Remove the drive plate and driven plate.
B: INSTALLATION
1) Select the shim. <Ref. to 4AT-76, VTD MODEL,
ADJUSTMENT, Transfer Clutch.>
2) Install drive plate and driven plate.
3) Insert the rear driveshaft into the center differential assembly.
4) Join the transmission case and the extension
case, and then install the rear vehicle speed sensor. <Ref. to 4AT-68, INSTALLATION, Extension
Case.>
(A)
(C)
(D)
AT-00152
(A) Front side

(B) Clutch hub
(C) Rear side
(D) Revolution gear
C: DISASSEMBLY
E: INSPECTION
1) Using a press, remove the revolution gear.
Make sure there are no holes, cutting damage or

within the standard value. <Ref. to 4AT-76, VTD
MODEL, ADJUSTMENT, Transfer Clutch.>
(A)
AT-00149
(A) Revolution gear
4AT-79
Reduction Driven Gear

29.Reduction Driven Gear
5) Lift the crimped section, and then remove the

lock nut.
A: REMOVAL
1. MP-T MODEL
3) Set the select lever to P range.
4) Lift the crimped section, and then remove the
lock nut.
(B)
(A)
AT-00155
6) Using the ST1 and ST2, extract the reduction

driven gear.
ST1 499737000 PULLER
ST2 899524100 PULLER SET
7) Pull out the center differential assembly. <Ref.
to 4AT-84, REMOVAL, Center Differential Carrier.>
B: INSTALLATION
1. MP-T MODEL
2) Using a plastic hammer, install the reduction
driven gear assembly and the new washer, and
tighten the new lock nut.
AT-02212
(A) Reduction driven gear

(B) Reduction drive gear
5) Using the ST1 and ST2, extract the reduction

driven gear assembly.
Tightening torque:
100 Nm (10.2 kgf-m, 73.8 ft-lb)
(B)
(A)
(B)
ST2
ST1
AT-02212
(A) Reduction driven gear assembly

(B) Reduction drive gear assembly
(A)
AT-00154
(A) Reduction driven gear assembly

(B) Reduction drive gear assembly
2. VTD MODEL
3) Remove the rear drive shaft. <Ref. to 4AT-79,
REMOVAL, Rear Drive Shaft.>
3) After tightening, stake the lock nut securely.

Case.>
4AT-80

2. VTD MODEL
2) Use a plastic hammer to install reduction driven
gear assembly.
3) Use a plastic hammer to install the center differential.
4) Install new self-locking nut and washer.
2) Remove the ball bearing from reduction driven

gear using ST.
ST 498077600
REMOVER
(A)
ST
Tightening torque:
100 Nm (10.2 kgf-m, 73.8 ft-lb)
AT-00157
(A) Ball bearing
D: ASSEMBLY
1) Install the new ball bearing to reduction driven
gear using press.
AT-00155
5) After tightening, stake the lock nut securely.

6) Insert the rear driveshaft assembly. <Ref. to
4AT-79, INSTALLATION, Rear Drive Shaft.>
Case.>
(A)
AT-00158
(A) Ball bearing
C: DISASSEMBLY
1) Remove the snap ring from reduction driven
gear.
2) Install the snap ring to reduction driven gear.
(A)
(A)
AT-00156
AT-00156
(A) Snap ring

(A) Snap ring
E: INSPECTION
Make sure the ball bearing and gear is not deformed or damaged.
4AT-81
Reduction Drive Gear

30.Reduction Drive Gear
C: DISASSEMBLY
A: REMOVAL
1) Take out the seal ring.

3) Remove the reduction driven gear. <Ref. to 4AT80, REMOVAL, Reduction Driven Gear.>
4) Using the ST, extract the reduction drive gear
assembly.
(A)
(B)
AT-00161
(A) Seal ring

(B) Reduction drive shaft
(A)
2) Remove the ball bearing using ST.

ST 498077600
REMOVER
ST1
(A)
ST
ST2
AT-00159
(B)
(A) Reduction drive gear assembly
B: INSTALLATION
AT-00162
1) Install the reduction drive gear assembly.
(A) Ball bearing
NOTE:
Press-fit it to the bottom of bearing shoulder completely.
(B) Reduction drive gear
3) Apply vaseline to the outer surface of seal ring

and shaft groove.
(A)
(A)
AT-02213
AT-00163
(A) Reduction drive gear assembly
(A) Reduction drive gear
2) Install the reduction driven gear. <Ref. to 4AT80, INSTALLATION, Reduction Driven Gear.>
Case.>
4AT-82

D: ASSEMBLY
1) Press-fit the reduction drive gear to shaft.
2) Press-fit the new ball bearing into reduction drive
gear.
3) Apply vaseline to the outer surface of new seal
ring and shaft groove.
4) Install the seal ring.
(A)
(B)
AT-00161
(A) Seal ring

(B) Reduction drive shaft
E: INSPECTION
Rotate the bearing by hand, make sure it rotates
smoothly.
Make sure there are no holes, bending damage
or other foreign materials on each parts.
the standard value. <Ref. to 4AT-76, ADJUSTMENT, Transfer Clutch.>
4AT-83
Center Differential Carrier

31.Center Differential Carrier
C: DISASSEMBLY
A: REMOVAL

3) Extract the rear drive shaft. <Ref. to 4AT-79,
REMOVAL, Rear Drive Shaft.>
4) Using the special tools, pull out the center differential carrier assembly.
(A)
AT-00166
(A) Seal ring
2) Using a press and ST, remove the ball bearing.

ST 498077600
REMOVER
ST1
ST2
AT-00164
5) Pull out the shim(s) from transmission case.

AT-00167
B: INSTALLATION
1) Install the center differential assembly with shim.
3) Remove the snap ring, and pull out the shaft

from center differential assembly.
NOTE:
Press-fit it to the bottom of bearing shoulder completely.
(A)
(B)
AT-00168
(A) Snap ring

(B) Shaft
AT-00165
2) Insert the rear driveshaft assembly. <Ref. to

4AT-79, INSTALLATION, Rear Drive Shaft.>
Case.>
4AT-84
Center Differential Carrier

4) Remove the thrust washers, pinion gears and

washers from center differential assembly.
(A)
AT-00169
(A) Pinion gear
5) Pull out the intermediate shaft and thrust bearing.
D: ASSEMBLY
1) Install the thrust washer onto intermediate shaft.
2) Install the thrust bearing onto intermediate shaft.
3) Install the pinion gears and washers.
4) Insert the shaft into the center differential assembly.
6) Using a press, install a new ball bearing into the
center differential assembly.
ST 498077000
REMOVER
(A)
ST
(B)
AT-00170
(A) Plate
7) Apply vaseline onto the seal ring outer surface

and shaft grooves.
8) Install a new seal ring.
E: INSPECTION
Make sure there are no holes, cutting damage or
within the standard value. <Ref. to 4AT-76, VTD
MODEL, ADJUSTMENT, Transfer Clutch.>
4AT-85
Parking Pawl
32.Parking Pawl
A: REMOVAL
3) Remove the reduction drive gear. <Ref. to 4AT82, REMOVAL, Reduction Drive Gear.>
4) Remove the parking pawl, return spring and
shaft.
(A)
(B)
AT-02214
(A) Return spring

(B) Parking pawl
B: INSTALLATION
1) Install the parking pawl, return spring and shaft.
(A)
(B)
AT-02214
(A) Return spring

(B) Parking pawl
2) Install the reduction drive gear. <Ref. to 4AT-82,

INSTALLATION, Reduction Drive Gear.>
3) Install the rear vehicle speed sensor and extension case. <Ref. to 4AT-68, INSTALLATION, Extension Case.>
C: INSPECTION
Check the tab of parking pawl on reduction gear for
wear or other damage.
4AT-86
Converter Case
33.Converter Case
9) Remove the converter case alignment bolt, and

then separate the transmission case and converter
case by lightly tapping with a plastic hammer.
A: REMOVAL
2) Pull out the torque converter clutch assembly.
<Ref. to 4AT-67, REMOVAL, Torque Converter
Clutch Assembly.>
NOTE:
Be careful not to damage the oil seal and bushing in the converter case with the oil pump cover.
Do not loosen the rubber seal.
AT-00175
10) Remove the seal pipe.

AT-00114
4) Lift-up the lever on the rear side of transmission

harness connector, and then disconnect it from the
stay.
5) Disconnect the inhibitor switch connector from
the stay.
(B)
(A)
AT-00176
(A) Seal pipe
11) Remove the differential assembly. <Ref. to

4AT-101, REMOVAL, Front Differential Assembly.>
12) Remove the oil seal from converter case.
AT-01351
B: INSTALLATION
(A) Transmission harness ASSY

(B) Inhibitor switch harness
6) Remove the air breather hose. <Ref. to 4AT-65,

REMOVAL, Air Breather Hose.>
7) Remove the oil charge pipe. <Ref. to 4AT-66,
REMOVAL, Oil Charge Pipe.>
<Ref. to 4AT-62, REMOVAL, ATF Cooler Pipe and
Hose.>
1) Check the appearance of each component and

clean them.
2) Press-fit the new oil seal to converter case using
ST.
ST 398437700
DRIFT
AT-00177
4AT-87
Converter Case
3) Install the differential assembly to the case.

<Ref. to 4AT-101, INSTALLATION, Front Differential Assembly.>
4) Install the right and left side retainers. <Ref. to
4AT-105, ADJUSTMENT, Front Differential Assembly.>
5) Install new seal pipe to converter case.
8) Install the converter case assembly without

damaging bushing and oil seal.
Tightening torque:
41 Nm (4.2 kgf-m, 30.4 ft-lb)
AT-00175
9) Insert the inhibitor switch connector and transmission connector to the stay.
10) Install the air breather hose. <Ref. to 4AT-65,
INSTALLATION, Air Breather Hose.>
11) Install the ATF cooler pipe. <Ref. to 4AT-63, INSTALLATION, ATF Cooler Pipe and Hose.>
12) Install the oil charge pipe along with the O-ring.
<Ref. to 4AT-66, INSTALLATION, Oil Charge
Pipe.>
AT-00176
(A) Seal pipe
6) Install new rubber pipe to converter case.

(A)
50 55 mm (1.97 2.17 in)
AT-00178
A
(A) Rubber seal
7) Apply proper amount of liquid gasket to the entire matching surface of converter case.
Liquid gasket:
Three bond 1215 (Part No. 004403007) or
equivalent
AT-00291
14) Install the torque converter clutch assembly.

<Ref. to 4AT-67, INSTALLATION, Torque Converter Clutch Assembly.>
15) Install the transmission assembly to the vehicle. <Ref. to 4AT-40, INSTALLATION, Automatic
(B)
C: INSPECTION
(A)
AT-00179
Measure the backlash, and then adjust it within

standard values. <Ref. to 4AT-98, ADJUSTMENT,
Drive Pinion Shaft Assembly.>
(A) Three bond 1215

(B) Rubber seal
4AT-88
Oil Pump Housing

34.Oil Pump Housing
13) Place two wooden blocks on the workbench,

and stand the transmission case with the rear end
facing down.
A: REMOVAL
Clutch Assembly.>
NOTE:
Be careful not to scratch the rear mating surface
of transmission case.
Check the height of the wooden blocks to avoid
damaging the parking rod protruding from the mating surface, and the drive pinion.
55mm
(2.17in)
AT-00181
AT-00114

stay.
the stay.
Hose.>
8) Separate the converter case and transmission
case. <Ref. to 4AT-87, REMOVAL, Converter
Case.>
case section. <Ref. to 4AT-68, REMOVAL, Extension Case.>
11) Remove the reduction driven gear. <Ref. to
4AT-80, REMOVAL, Reduction Driven Gear.>
12) Loosen the oil pump housing mounting bolts.
14) Remove the oil pump housing and adjusting

thrust washer.
(A)
AT-00182
(A) Oil pump housing
B: INSTALLATION
1) Secure the oil pump housing with two nuts and a
bolt.
Tightening torque:
42 Nm (4.3 kgf-m, 31 ft-lb)
(A)
AT-01035
AT-01034
(A) Oil pump housing
4AT-89
Oil Pump Housing

2) Install the converter case to the transmission

case. <Ref. to 4AT-67, INSTALLATION, Torque
Converter Clutch Assembly.>
case. <Ref. to 4AT-68, INSTALLATION, Extension
Case.>
6) Insert the inhibitor switch and transmission connector to the stay.
(B)
C: DISASSEMBLY
1. OIL PUMP COVER
1) Remove the four seal rings.
(A)
(A)
AT-00189
(A) Seal ring
2) Remove the installation bolt. Then remove the

cover by lightly tapping the end of starter shaft.
(B)
(A)
AT-01351

Pipe.>
AT-00190
(A) Oil pump cover

(B) Oil pump housing
3) Remove the oil pump inner and outer rotors.
50 55 mm (1.97 2.17 in)
(B)
(A)
A
AT-01036
AT-00291
(A) Oil pump rotor inner rotor

4AT-90
(B) Oil pump outer rotor
Oil Pump Housing

D: ASSEMBLY
2. OIL SEAL RETAINER

1) Remove the oil seal retainer.
1. OIL PUMP COVER

1) Install the oil pump rotor assembly to oil pump
housing.
(B)
(B)
(A)
(A)
AT-00183
(A) Oil seal retainer

(B) Drive pinion shaft
AT-01036
(A) Oil pump rotor inner rotor

(B) Oil pump outer rotor
2) Remove the O-ring.
2) Align both pivots with the pivot holes of the cover, and then install the oil pump cover while being
careful not to apply excessive force to the pivots.
(A)
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
(B)
(A)
AT-03361
(A) O-ring
3) Remove the oil seal from the oil seal retainer.

(A)
AT-00190
(A) Oil pump cover

(B) Oil pump housing
3) After assembling, turn the oil pump shaft to

check for smooth rotation of rotor.
(B)
AT-03360
(A) Oil seal

(B) Oil seal retainer
4AT-91
Oil Pump Housing

4) Install the oil seal retainer and new seal rings.

After installing, adjust the tooth contact with the
drive pinion backlash. <Ref. to 4AT-93, ADJUSTMENT, Oil Pump Housing.>
3) Install the oil seal being careful not to damage oil

seal lip, and secure it using three bolts.
Tightening torque:
7 Nm (0.7 kgf-m, 5.1 ft-lb)
NOTE:
There are two types of seals. They are identified by
color. Install at the proper positions by referring to
the figure.
(B)
(A)
(B)
(A)
AT-00183
(A) Oil seal retainer

AT-01307
E: INSPECTION
(A) Seal ring (Black)

(B) Seal ring (Brown)
2. OIL SEAL RETAINER

1) Install two new oil seals to the oil seal retainer in
the proper direction using the ST.
ST 499247300
INSTALLER
(A)
1) Check the seal ring and oil seal for breaks and
damage.
2) Check other parts for dents or faults.
3) Oil pump rotor assembly selection
(1) Tip clearance
Install the oil pump inner rotor and outer rotor to
the oil pump. With rotor gears facing each other, measure the crest-to-crest clearance.
Tip clearance:
0.02 0.15 mm (0.0008 0.0059 in)
(A)
(C)
(B)
AT-03360
(B)
(A) Oil seal

(B) Oil seal retainer
AT-01038
2) Apply ATF to a new O-ring and then install it to

the oil seal retainer.
(A) Thickness gauge

(B) Oil pump rotor inner rotor
(C) Oil pump outer rotor
(A)
AT-03361
(A) O-ring
4AT-92
Oil Pump Housing

(2) Side clearance

Set a depth gauge to the oil pump housing, then
measure the oil pump housing-to-oil pump rotor
clearance.
2) Measure the distance from the oil pump housing

mating surface to the end surface of the ST using
the ST.
ST 398643600
GAUGE
Side clearance:
0.02 0.04 mm (0.0008 0.0016 in)
ST
(A)
(C)
(B)
AT-00195
3) Calculation of total end play

Select the suitable thrust needle bearing from the
table below so that clearance C will be within 0.25
to 0.55 mm (0.0098 to 0.0217 in).
C = (L + G) 2
AT-01039
(A) Depth gauge

(B) Oil pump rotor inner rotor
(C) Oil pump outer rotor
(3) If the depth and side clearance are out of

specification, replace the oil pump rotor assembly.
L
G
Oil pump rotor assembly

Thickness mm (in)
Part No.
15008AA060
15008AA070
11.37 11.38 (0.4476 0.4480)

11.38 11.39 (0.4480 0.4484)
15008AA080
11.39 11.40 (0.4484 0.4488)
Clearance between concave section of high

clutch and end of clutch drum support
Distance from the transmission case mating
surface to concave portion of high clutch
Gasket thickness [0.28 mm (0.0110 in)]
Height from the oil pump housing mating surface to the upper surface of the cover for the oil
pump having the thrust needle bearing.
G
Inspect the total end play, and adjust it to be

within the standard value. <Ref. to 4AT-93, ADJUSTMENT, Oil Pump Housing.>
L
F: ADJUSTMENT
1) Measure the distance L from the end of ST to
the high clutch drum concave section using the ST.
ST 398643600
GAUGE
AT-00196

ST
Part No.
806528050
Thickness mm (in)
4.1 (0.161)
806528060
806528070
4.3 (0.169)
4.5 (0.177)
806528080
806528090
4.7 (0.185)
4.9 (0.193)
806528100
5.1 (0.201)
AT-00194
4) After completing the end play adjustment, insert

the bearing race in the high clutch race. Apply vaseline to install the thrust needle bearing to oil
pump cover.
4AT-93
Oil Pump Housing

5) After correctly installing the new gasket to the

case mating surface, carefully install the oil pump
housing assembly. Be careful to avoid hitting the
drive pinion against the inside of case.
6) Install both parts with dowel pins aligned. Make
sure there is no clearance at the mating surface.
4AT-94
Drive Pinion Shaft Assembly

35.Drive Pinion Shaft Assembly
B: INSTALLATION
A: REMOVAL
1) Assemble the drive pinion assembly to the oil

pump housing.

Clutch Assembly.>
NOTE:
Be careful not to bend the shim.
Be careful not to press-fit the pinion into housing
bore.
Tightening torque:
40 Nm (4.1 kgf-m, 29.5 ft-lb)
AT-00114
AT-01252

stay.
the stay.
6) Disconnect the air breather hose. <Ref. to 4AT65, REMOVAL, Air Breather Hose.>
Hose.>
9) Separate the converter case and transmission
case. <Ref. to 4AT-87, REMOVAL, Converter
Case.>
case section. <Ref. to 4AT-68, REMOVAL, Extension Case.>
12) Remove the reduction driven gear. <Ref. to
4AT-80, REMOVAL, Reduction Driven Gear.>
13) Remove the drive pinion shaft mounting bolt
and remove the drive shaft assembly from oil pump
housing.
2) Join the converter case with the transmission

case. <Ref. to 4AT-87, INSTALLATION, Converter
Case.>
case. <Ref. to 4AT-68, INSTALLATION, Extension
Case.>
7) Install the air breather hose. <Ref. to 4AT-65, INSTALLATION, Air Breather Hose.>
8) Install the ATF cooler inlet and outlet pipes.
<Ref. to 4AT-63, INSTALLATION, ATF Cooler Pipe
and Hose.>
50 55 mm (1.97 2.17 in)
AT-00291
AT-01252
4AT-95


4) Separate the front roller bearing from the drive

pinion shaft using a press and the ST.
ST 498517000
REPLACER
(A)
C: DISASSEMBLY
ST
1) Lift the crimped part of the locknut, and then remove the lock nut while holding the rear spline part
of the drive pinion shaft using ST1 and ST2. Pull
out the drive pinion collar.
ST1 498937110 HOLDER
ST2 499787700 WRENCH
ST3 499787500 ADAPTER
AT-00199
(A) Front roller bearing
D: ASSEMBLY
1) Measure the dimension A of drive pinion shaft.
ST 398643600
GAUGE
ST3
ST2
ST1
AT-00197

3) Separate the roller bearing and outer race from
the drive pinion shaft using a press.
A
AT-00200
2) Using a press, press-fit the new roller bearing

into the specified position.
(A)
NOTE:
If excessive force is applied to roller bearing, the
roller bearing will not turn easily.
(A)
AT-00198
(A) Outer race

(B)
AT-00201
(A) Drive pinion shaft

(B) Roller bearing
3) After fitting a new O-ring to the drive pinion shaft,

attach the drive pinion collar to the drive pinion
shaft.
4) Install the lock washer to drive pinion shaft in the
proper direction.
4AT-96

5) Tighten the new lock nuts using ST1, ST2 and

ST3.
Calculate the lock washer and lock nut specifications using following formula.
T2 = L2/(L1 + L2) T1
T1: 116 Nm (11.8 kgf-m, 85.3 ft-lb)
L1: ST2 length 0.072 m (2.83 in)
Example:
m (in)
Tightening torque
Nm ( kgf-m, ft-lb)
0.4 (15.75)
0.45 (17.72)
98 (10.0, 72.3)
100 (10.2, 73.5)
0.5 (19.69)
0.55 (21.65)
101 (10.3, 74.6)

102 (10.4, 75.4)
ST1
ST2
ST3
498937110
499787700
499787500
Holder
WRENCH
Adapter
6) Measure the starting torque of the bearing. Make

sure the starting torque is within the specified
range. If the torque is not within specified range, replace the roller bearing.
Starting torque:
MP-T model
7.6 38.1 N (0.776 3.88 kgf, 1.7 8.6 lb)
VTD model
6.8 47.5 N (0.69 4.84 kgf, 1.52 10.67
lb)
AT-00203
NOTE:
Attach ST2 to torque wrench as straight as possible.
7) Crimp the locknut in 2 locations.

8) Measure dimension B of drive pinion shaft
ST 398643600
GAUGE
ST3
ST2
L1 [m (in)]
L2 [m (in)]
B
ST1
AT-00204
AT-00202
9) Calculate the thickness t (mm) of the drive pinion shim.

t = 6.50.0625 (B A)
10) Select three or less shims from following table.
Drive pinion shim
Part No.
31451AA050
Thickness mm (in)
0.150 (0.0059)
31451AA060
31451AA070
0.175 (0.0069)
0.200 (0.0079)
31451AA080
31451AA090
0.225 (0.0089)
0.250 (0.0098)
31451AA100
0.275 (0.0108)
E: INSPECTION
Make sure that all component parts are free of
scratches, holes and other faults.
Adjust the tooth alignment. <Ref. to 4AT-98, ADJUSTMENT, Drive Pinion Shaft Assembly.>
4AT-97

F: ADJUSTMENT
1) Remove the liquid gasket from the mating surface completely.
2) Install the oil pump housing assembly to the converter case, and secure them by tightening the four
bolts evenly.
Correct tooth contact

Check item: Tooth contact surface is slightly
shifted toward the toe side under a no-load condition. (When driving, it moves towards the heel
side.)
(A)
NOTE:
Use an old gasket or aluminum washer to prevent
damaging the mating surface of the housing.
Tightening torque:
41 Nm (4.2 kgf-m, 30.4 ft-lb)
(B)
MT-01401
(A) Toe side

(B) Heel side
Face contact
Checking item: Backlash is too large.
Contact pattern
AT-00205
3) Rotate the drive pinion a few times using ST1

and ST2.
ST1 498937110 Holder
ST2
ST1
AT-00208
Corrective action: Increase thickness of drive pinion height adjusting washer in order to bring the
drive pinion shaft closer to the hypoid driven gear.
AT-00206
4) Adjust the drive pinion and hypoid driven gear

backlash. <Ref. to 4AT-105, ADJUSTMENT, Front
Differential Assembly.>
5) Apply red lead evenly to the surfaces of three or
four teeth on hypoid driven gear. Rotate the drive
pinion back and forward several times. Remove the
oil pump housing, and check the teeth contact pattern.
If the teeth contact is inappropriate, adjust the
backlash or thickness of the shim. <Ref. to 4AT105, ADJUSTMENT, Front Differential Assembly.>
4AT-98
AT-00212

Flank contact
Inspection item: Backlash is too small.
Contact pattern
Toe contact (inside contact)

Inspection item: Contact area is too small.
Contact pattern
AT-00209
AT-00210
Corrective action: Reduce the thickness of pinion

height adjusting washer according to the procedure
to move the drive pinion shaft away from the hypoid
driven gear.

for moving the drive pinion shaft away from the hypoid driven gear.
AT-00213
AT-00213
4AT-99

Heel contact (outside end contact)

Inspection item: Contact area is too small.
Contact pattern
6) If tooth contact is correct, mark the differential

side retainer position and loosen it. After fitting a
new O-ring and oil seal, screw in the differential
side retainer to the marked position. Tighten the
lock plate with specified torque.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
(A)
AT-00211
Corrective action: Increase thickness of drive pinion height adjusting washer in order to bring the
drive pinion shaft closer to the hypoid driven gear.
AT-00214
(A) Lock plate
AT-00212
4AT-100
Front Differential Assembly

36.Front Differential Assembly
B: INSTALLATION
A: REMOVAL
1) Install the differential assembly to the torque

converter clutch case.

Clutch Assembly.>
NOTE:
Do not damage the inside of the torque converter
clutch case (particularly the mating surface of the
differential side retainer).
(A)
AT-00215
(A) Differential ASSY

AT-00114

stay.
5) Disconnect the inhibitor switch from the stay.
Hose.>
8) Separate the converter case from the transmission case. <Ref. to 4AT-87, REMOVAL, Converter
Case.>
9) Remove the seal pipe.
10) Remove the differential side retainers using
ST.
NOTE:
Hold the differential case assembly by hand to
avoid damaging the retainer mounting hole of the
converter case.
ST 18630AA010 WRENCH COMPL RETAINER
2) Install the O-ring to the left and right side differential side retainer.
3) Using the ST, install the side retainer. <Ref. to
4AT-101, INSTALLATION, Front Differential Assembly.>
NOTE:
WRENCH ASSEMBLY (499787000) can also be
used.
4) Adjust the backlash of the front differential. <Ref.
to 4AT-105, ADJUSTMENT, Front Differential Assembly.>
5) Install the lock plate.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
(A)
NOTE:
used.
11) Remove the differential assembly while being
careful not to damage the attachment part of retainer.
AT-00214
(A) Lock plate
4AT-101

6) Install new seal pipe to converter case.
C: DISASSEMBLY
1. DIFFERENTIAL CASE ASSEMBLY
1) Remove the taper roller bearing using the ST
and a press.
ST 498077000
REMOVER
AT-00176
(A) Seal pipe
7) Install the converter case to the transmission

case. <Ref. to 4AT-87, INSTALLATION, Converter
Case.>
AT-00216
(B)
(A)
2) Secure the case in a vise and remove the hypoid

driven gear tightening bolts. Then separate the hypoid driven gear into the differential case (RH) and
the differential case (LH).
(A)
AT-01351
(B)

(C)
Pipe.>
50 55 mm (1.97 2.17 in)
AT-00217
(A) Hypoid driven gear

(B) Differential case (RH)
(C) Differential case (LH)
3) Pull out the straight pin and pinion shaft, and

then remove the differential bevel gear, washer and
differential bevel pinion.
(A)
AT-00291

4AT-102
(A) Differential case (RH)
AT-00218

2. DIFFERENTIAL SIDE RETAINER

NOTE:
After adjusting the drive pinion backlash and tooth
contact, remove and install the oil seal and O-ring.
4) Attach two claws to the outer race, and set the

ST to the differential side retainer.
ST 398527700
PULLER ASSY
AT-00222
(A) Shaft
AT-00219
(B) Claw

5) Restore the removed claws to original position,
and install the pin and split pin.
6) Hold the shaft of ST to avoid removing from differential side retainer, and then remove the bearing
outer race.
ST 398527700
PULLER ASSY
NOTE:
Replace the bearing inner and outer races as a single unit.
AT-00220
3) Remove the split pin, and then remove the claw.

ST 398527700
PULLER ASSY
AT-00223
(A) Shaft
(B) Differential side retainer
AT-00221
(A) Claw
(B) Split pin
(C) Pin
4AT-103

D: ASSEMBLY
1. DIFFERENTIAL CASE ASSEMBLY
1) Install the washer, differential bevel gear and differential bevel pinion in the differential case (RH).
Insert the pinion shaft.
2) Attach the straight pin in the reverse direction.
5) Measurement of backlash (Selection of washer)

(1) Install the SUBARU genuine axle shaft to
differential case.
Part No. 38415AA070Axle shaft
(2) Measure the gear backlash using ST1 and
ST2, and then insert ST2 from the access window of the case.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
NOTE:
Measure the backlash by placing the differential
bevel pinion tooth against two differential bevel
gear teeth.
Fix the differential bevel pinion gear in place with
a screwdriver or similar tool when measuring.
(A)
Standard:
0.13 0.18 mm (0.0051 0.0071 in)
AT-00218
(A) Differential case (RH)

ST1
3) Install the washer and differential bevel gear to

differential case (LH). Put the differential case (RH)
on the case, and then assemble the two cases.
4) Install the hypoid driven gear and secure by
tightening the bolt.
Tightening torque:
62 Nm (6.3 kgf-m, 45.6 ft-lb)
ST2
AT-00224
(3) If the backlash is out of specification, select

a washer from the table below.
(A)
Washer
(B)
(C)
AT-00217
(A) Hypoid driven gear

(B) Differential case (RH)
Part No.
Thickness mm (in)
803038021
803038022
0.95 (0.037)
1.00 (0.039)
803038023
1.05 (0.041)
6) Using the ST, install the taper roller bearing.

ST 398487700
INSTALLER
(C) Differential case (LH)
AT-00225
(A) Taper roller bearing
4AT-104

2. DIFFERENTIAL SIDE RETAINER
F: ADJUSTMENT
1) Install the bearing outer race to the differential

side retainer.
2) Install a new oil seal using the ST and a plastic
hammer.
ST 18675AA000 DIFFERENTIAL OIL SEAL INSTALLER
1) Using the ST, screw-in the differential side retainer until light contact is felt.
ST
NOTE:
Screw-in the RH side slightly deeper than the LH
side.
used.
ST
AT-00226
3) Install a new O-ring.

AT-00227
2) Remove the oil pump housing.

3) Remove the liquid gasket from the mating surface completely.
4) Install the oil pump housing assembly to the converter case, and secure them by tightening the four
bolts evenly.
NOTE:
Use an old gasket or aluminum washer to prevent
damaging the mating surface of the housing.
AT-00219
E: INSPECTION
Check each component for scratches, damage
or other faults.
Measure the backlash, and then adjust it to be
within specification.
<Ref. to 4AT-105, ADJUSTMENT, Front Differential Assembly.>
Tightening torque:
41 Nm (4.2 kgf-m, 30.4 ft-lb)
AT-00205
4AT-105

5) Rotate the drive pinion a few times using ST1

and ST2.
NOTE:
Turning the differential side retainer by one notch
changes the backlash about 0.05 mm (0.0020 in).
0.05 mm
(0.0020 in)
ST2
ST1
AT-00230
AT-00206
6) Tighten the differential side retainer LH until contact is felt while rotating the shaft. Then loosen the
differential side retainer RH. Keep tightening the
differential side retainer LH, and loosening the retainer RH until the pinion shaft no longer turns. This
is the zero state.
8) Turn the drive pinion a few times with ST1 and

check to see if the backlash is within the specified
value, using ST2, ST3, ST4 and ST5.
ST2 498247001 MAGNET BASE
ST3 498247100 DIAL GAUGE
ST5 498255400 PLATE
Backlash:
0.13 0.18 mm (0.0051 0.0071 in)
ST1
ST4
(A)
ST5
AT-00229
(A) Differential side retainer

ST2
7) After the zero state is established, back off the

differential side retainer LH 3 notches and secure it
with the lock plate. Then back off the differential
side retainer RH and retighten until it stops. Rotate
the drive pinion 2 or 3 times. Tighten the differential
side retainer RH 1-3/4 notches further. This sets
the preload. Finally, secure the differential side retainer with the lock plate.
ST3
AT-00231
9) Adjust the teeth contact of the front differential

and drive shaft. <Ref. to 4AT-98, ADJUSTMENT,
Drive Pinion Shaft Assembly.>
(A)
AT-00214
(A) Lock plate
4AT-106
AT Main Case
37.AT Main Case
12) Take out the high clutch hub and thrust needle
bearing.
A: REMOVAL
(A)

Clutch Assembly.>
(B)
AT-00233
(A) High clutch hub

(B) Thrust needle bearing
13) Take out the front sun gear and thrust needle
bearing.
(A)
AT-00114

stay.
the stay.
6) Disconnect the air breather hose.
Hose.>
9) Separate the converter case from the transmission case. <Ref. to 4AT-87, REMOVAL, Converter
Case.>
10) Remove the oil pump housing.
<Ref. to 4AT-89, REMOVAL, Oil Pump Housing.>
11) Take out the high clutch and reverse clutch assembly and thrust needle bearing.
(B)
AT-00251
(A) Front sun gear

14) Pull out the leaf spring of the 2-4 brake while
taking care not to bend the spring.
NOTE:
Remove it while pressing down on the lower leaf
spring.
(A)
(A)
(B)
(B)
AT-00252
AT-00232
(A) Leaf spring

(B) Retaining plate
(A) High clutch and reverse clutch ASSY

4AT-107
AT Main Case
15) Remove the snap ring and thrust needle bearing.

(A)
(A)
(B)
(B)
AT-00285
AT-00253
(A) Snap ring

(A) Snap ring
(B) 2-4 brake piston
20) Take out the 2-4 brake spring retainer.

16) Take out the retaining plate of the 2-4 brake,
drive plate and driven plate.
AT-00286
AT-00254
17) Take out the thrust needle bearing, planetary

gear assembly and low clutch assembly.
21) Remove the 2-4 brake piston and 2-4 brake

piston retainer while taking care not to damage
them.
(A)
(B)
AT-00287
AT-00255
(A) 2-4 brake piston

(B) 2-4 brake piston retainer
18) Remove the 2-4 brake seal.
AT-00284
4AT-108
AT Main Case
22) Pull out the low & reverse brake leaf spring
without bending it.
26) Remove the spring retainer.
(A)
AT-00302
AT-00293
27) Take out the return spring.
(A) Leaf spring

(A)
AT-00301
28) Apply compressed air.

AT-00294
(A) Snap ring
24) Take out the low & reverse brake retaining

plate, drive plate, driven plate and dish plate.
AT-00297
29) Take out the low & reverse brake piston.
AT-00295
25) Turn the transmission case upside down, and

then take out the socket bolts while holding the
one-way clutch inner race by hand.
AT-00300
AT-00296
4AT-109
AT Main Case
B: INSTALLATION
1) Apply ATF to the lips and install the low & reverse piston.
NOTE:
Do not let the lip seal be damaged.
6) Place the front side of transmission body up.

7) Install the thrust needle bearing.
8) Place the dish plate, driven plate, drive plate and
retaining plate neatly in this order on surface table.
9) Set the micro gauge to clutch, and read its scale.
NOTE:
The value, which is read in the gauge at this time, is
zero point.
10) Scale and record the weight Z of a flat board
which will be put on retaining plate.
NOTE:
Use a stiff board which does not bend against
load as a flat board to be put on retaining plate.
Use a flat board of its weight less than 8.5 kg
(18.7 lb).
11) Put the flat board on retaining plate.
AT-00300
2) Install the return spring.
AT-01720
AT-00301
12) Using the following formula, read the push/pull

gage, and calculate N.
N = 8.5 kg (18.7 lb) Z
N: Value indicated on push/pull gauge
8.5 kg (18.7 lb) : Load applied to clutch plate
Z: Flat board weight
3) Install the spring retainer.
AT-00302
4) Install the one-way clutch inner race.

5) Tighten the socket head bolts evenly from the
rear side of transmission case.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
AT-00296
4AT-110
AT Main Case
13) Press the center of retaining plate by applying a

force of N using push/pull gauge, and then measure and record the height A. Measure at three locations or more spaced by equal distances and
take the average value.
15) Apply compressed air intermittently to check for

operation.
NOTE:
If measuring in three locations, measure every
120. If in four locations, measure every 90.
AT-00297
16) Measure the clearance.

(1) Place same thickness shims on both sides
to prevent plate from tilting, then measure and
record the clearance B.
B
(D)
(B)
(C)
AT-01722
(A)
AT-01721
(A) Dish plate

(B) Driven plate
(C) Drive plate
(D) Retaining plate
14) Installation of the low & reverse brake:

Install the dish plate, driven plate, drive plate and
retaining plate, and then secure them with a snap
ring.
NOTE:
Pay attention to the orientation of the dish plate.
(A)
AT-00294
(A) Snap ring
4AT-111
AT Main Case
(2) Piston stroke calculation

Calculate with A and B dimensions recorded
before. If the calculated value exceeds the service limit, replace the drive plate with a new one
and select and adjust the retaining plate to be
within the default specification values.
T=A+B
T: Piston stroke
A: Amount of drive plate compression
B: Clearance between retaining plate and snap
ring
18) Install the 2-4 brake piston and 2-4 brake retainer by aligning the hole of the 2-4 brake retainer
with the hole on the transmission case.
(A)
(B)
Turbo model
Initial standard:
2.7 3.2 mm (0.106 0.126 in)
Limit thickness:
3.9 mm (0.153 in)
AT-00287

Non-turbo model
Initial standard:
2.15 2.65 mm (0.085 0.104 in)
Limit thickness:
2.95 mm (0.116 in)
19) Install 2-4 brake piston spring retainer to the

transmission case.
Retaining plate
Part No.
31667AA320
Thickness mm (in)
4.1 (0.161)
31667AA330
31667AA340
4.4 (0.173)
4.7 (0.185)
31667AA350
31667AA360
5.0 (0.197)
5.3 (0.209)
31667AA370
31667AA380
5.6 (0.220)
5.9 (0.232)
AT-00286
17) Install the leaf spring of the low & reverse

brake.
20) Position the snap ring in the transmission. Using ST, press the snap ring into the specified location.
ST 498677100
COMPRESSOR
ST
(A)
AT-00289
AT-00293
(A) Leaf spring
4AT-112
AT Main Case
21) Install the planetary gear and low clutch assembly to the transmission case.
NOTE:
Install carefully while rotating the low clutch and
planetary gear assembly slowly, paying special attention not to damage the seal ring.
(6) Press the center of retaining plate by applying a force of N using push/pull gauge, and then
measure and record the height A. Measure at
three locations or more spaced by equal distances and take the average value.
NOTE:
120. If measuring in four locations, measure every
90.
AT-00255
22) Measure the amount of drive plate compression and record that value. (Non-turbo model)
(1) Place the dish plate, driven plate, drive plate
and retaining plate neatly in this order on surface table.
(2) Set the micro gauge to clutch, and read its
scale.
(C)
(B)
NOTE:
zero point.
(3) Scale and record the weight Z of a flat
board which will be put on retaining plate.
(A)
NOTE:
(22.5 lb).
(4) Put the flat board on retaining plate.
AT-01725
(A) Drive plate

(B) Driven plate
(C) Retaining plate
23) Install the pressure rear plate, 2-4 brake drive

plate, driven plate, retaining plate and snap ring.
AT-01720
(5) Using the following formula, read the push/

pull gage, and calculate N.
N = 10.2 kg (22.5 lb) Z
4AT-113
AT-00254
AT Main Case
24) Install a new 2-4 brake seal to transmission

case.
Initial standard:
1.7 2.1 mm (0.067 0.083 in)
Limit thickness:
2.3 mm (0.091 in)
Retaining plate
AT-00284
25) After all 2-4 brake component parts have been

installed, blow in air intermittently and confirm the
operation of brake.
Part No.
31567AA991
Thickness mm (in)
5.6 (0.220)
31567AB001
31567AB011
5.8 (0.228)
6.0 (0.236)
31567AB021
31567AB031
6.2 (0.244)
6.4 (0.252)
31567AB041
6.6 (0.260)
27) Measure the clearance between the retaining

plate and snap ring. (Turbo model)
If the clearance exceeds the service limits, replace
the driven plate and select and adjust the retaining
plate so that the clearance is within default standard values.
Initial standard:
0.8 1.2 mm (0.031 0.047 in)
Limit thickness:
1.5 mm (0.059 in)
AT-00290
26) Check the piston stroke. (Non-turbo model)

(1) Measure the clearance B between the retaining plate and snap ring.
B
AT-00292
Part No.
AT-01724

before. If the service limits from the calculation
formula are exceeded, replace the drive plate
and select and adjust the retaining plate to be
with in standard values.
T=A+B
T: Piston stroke
ring
4AT-114
Retaining plate
Thickness mm (in)
31567AA991
31567AB001
5.6 (0.220)
5.8 (0.228)
31567AB011
31567AB021
6.0 (0.236)
6.2 (0.244)
31567AB031
31567AB041
6.4 (0.252)
6.6 (0.260)
AT Main Case
28) Be careful not to mistake the location of the leaf

spring to be installed.
(A)
31) Apply vaseline, then attach the thrust needle

bearing to the high clutch hub. Install the high
clutch hub by correctly engaging the splines of the
front planetary carrier.
32) Install the thrust needle bearing in the correct
direction.
(B)
AT-00252
(A) Leaf spring

(B) Retaining plate
AT-00234

direction.
(A) High clutch hub

(C) Upside
(C)
(A)
(E)
(D) Downside
(E) Outside
(D)
33) Install the high clutch assembly and reverse

clutch assembly.
(B)
(A)
AT-02217
(A) Snap ring

(C) Upside
(D) Downside
(E) Outside
AT-00235
30) Install the front sun gear and the thrust needle
bearing.
(A)
(C)
(E)
(D)
34) Adjust the total end play. <Ref. to 4AT-93, ADJUSTMENT, Oil Pump Housing.>
(B)
AT-02218
(A) Front sun gear

(C) Upside
(D) Downside
(E) Outside
4AT-115
AT Main Case

direction.
(A)
50 55 mm (1.97 2.17 in)
(C)
(B)

(E)
(D)
AT-00312

AT-00291

(C) Upside
(D) Downside
(E) Outside
36) Install the converter case assembly to the

transmission case assembly. <Ref. to 4AT-87, INSTALLATION, Converter Case.>
37) Insert the inhibitor switch and transmission
connector to the stay.
(B)

C: DISASSEMBLY
1) Remove the snap ring, and then take out the retaining plate, drive plate and driven plate.
(A)
(A)
AT-01351
(A) Transmission harness

AT-00236

Pipe.>
(A) Snap ring
2) Remove the snap ring, and then take out the retaining plate, drive plate and driven plate.
(A)
AT-00237
(A) Snap ring
4AT-116
AT Main Case
3) Using the ST1 and ST2, remove the snap ring.

ST2 498627100 SEAT
2. PLANETARY GEAR AND LOW CLUTCH

1) Remove the snap ring from low clutch drum.
ST1
(A)
(A)
ST2
(B)
AT-00259
AT-00238
(A) Snap ring

(B) Low clutch drum
(A) Snap ring
4) Take out the clutch cover, spring retainer, high

clutch piston and reverse clutch piston.
(A)
2) Take out the front planetary carrier.
(B)
(A)
(C)
(B)
AT-00260
AT-00239
(A) Front planetary carrier

(B) Low clutch drum
(A) Reverse clutch piston

(B) Clutch cover
(C) Return spring
3) Take out the rear sun gear.
5) Remove the D-ring and lip seal from the high

(A)
(A)
(B)
AT-00261
(B)
(A) Rear sun gear

(B) Rear planetary carrier
AT-00240
(A) High clutch piston

(B) Reverse clutch piston
4AT-117
AT Main Case
4) Take out the rear planetary carrier, washer and

thrust needle bearing.
(A)
7) Compress the spring retainer of the low & reverse brake, and remove the snap ring from low
clutch drum using ST1 and ST2.
ST1 498627100 SEAT
ST2
ST1
(B)
AT-00262
(B)
(A)
(A) Rear planetary carrier

(B) Low clutch drum
AT-00265
5) Take out the rear internal gear.
(A) Snap ring

(B) Low clutch drum
(A)
8) Remove the one-way clutch. <Ref. to 4AT-107,

REMOVAL, AT Main Case.>
9) Install the one-way clutch inner race to the low
clutch drum, and then apply compressed air to remove the low clutch piston.
(B)
(A)
(B)
AT-00263
(A) Rear internal gear

(B) Low clutch drum
6) Remove the snap ring from low clutch drum.

(A)
AT-00266
(A) Apply compressed air.

(B) One-way clutch inner race
10) Remove the one-way clutch inner race.

11) Remove the one-way clutch after taking out the
snap ring.
(B)
AT-00264
(A)
(C)
(A) Snap ring

(B) Low clutch drum
(B)
AT-00267
(A) Snap ring

(B) Plate
(C) One-way clutch
4AT-118
AT Main Case
12) Remove the needle bearing after taking out the

snap ring.
(B)
5. ONE-WAY CLUTCH OUTER RACE

1) Remove the one-way clutch after taking out the
snap ring.
(A)
(A)
(C)
(B)
AT-00268
AT-00267
(A) Needle bearing

(B) Snap ring
(A) Snap ring

(B) Plate
3. 2-4 BRAKE
(C) One-way clutch
Separate the 2-4 brake piston and piston retainer.

2) Remove the needle bearing after taking out the
snap ring.
(B)
(A)
(B)
(A)
AT-00288

AT-00268
(A) Needle bearing
4. ONE-WAY CLUTCH INNER RACE

(B) Snap ring
D: ASSEMBLY
(A)
1) Install the new D-ring and lip seal to the high

2) Install the high clutch piston to the reverse clutch
piston.
(B)
(A)
AT-00298
(A) One-way clutch inner race

(B) Seal ring
(B)
2) Remove the needle bearing using ST.

ST 398527700
PULLER ASSY
AT-00240
(A) High clutch piston

(B) Reverse clutch piston
4AT-119
AT Main Case
3) Install the reverse clutch assembly to the high

clutch drum. Align the groove on reverse clutch piston with the groove on high clutch drum during installation.
7) Install the snap ring using ST1 and ST2.

ST2 498627100 SEAT
ST3 498437000 HIGH CLUTCH PISTON
GAUGE
(A)
ST1
ST3
(B)
ST2
AT-00241
AT-00244
(A) Reverse clutch piston

(B) High clutch drum
4) Install the spring retainer to the high clutch piston.

(A)
8) Measure the amount of drive plate compression

and record that value.
scale.
NOTE:
zero point.
NOTE:
Use a flat board weighing less than 25.5 kg (56.2
lb).
(B)
AT-00242
(A) Return spring

(B) High clutch drum
5) Attach the ST to the high clutch piston.

ST 498437000
HIGH CLUTCH PISTON
GUIDE
ST
AT-01720
AT-00243
6) Install the cover to the high clutch piston without

bending the high clutch piston seal.
4AT-120

N = 25.5 kg (56.2 lb) Z
AT Main Case

operation.
NOTE:
90.
AT-00246
12) Check the piston stroke. (Non-turbo model)

(1) Measure the clearance B between the retaining plate and snap ring. (High clutch)
(A)
(C)
(B)
(A)
AT-01726
(A) Thickness gauge

before. If the service limits from the calculation
formula are exceeded, replace the drive plate
and select and adjust the retaining plate to within default standard values.
T=A+B
T: Piston stroke
ring
AT-01725
(A) Drive plate

(B) Driven plate
(C) Retaining plate
9) Install the thickest driven plate to piston side,

and then install the driven plate, drive plate, retaining plate to high clutch drum.
Initial standard:
2.0 2.3mm (0.079 0.091 in)
Limit thickness:
2.6 mm (0.102 in)
High clutch retaining plate
AT-00245
10) Install the snap ring to high clutch drum.
4AT-121
Part No.
31567AA710
Thickness mm (in)
4.7 (0.185)
31567AA720
31567AA730
4.8 (0.189)
4.9 (0.193)
31567AA740
31567AA670
5.0 (0.197)
5.1 (0.201)
31567AA680
31567AA690
5.2 (0.205)
5.3 (0.209)
31567AA700
5.4 (0.213)
AT Main Case
13) Measure the clearance between the high clutch

retaining plate and snap ring. (Turbo model)
At this time, do not press down the retaining plate.
Initial standard:
0.8 1.1 mm (0.031 0.043 in)
Limit thickness:
1.5 mm (0.059 in)
(A)
AT-01720

N = 15.3 kg (33.7 lb) Z
AT-00249
(A) Thickness gauge
If the clearance exceeds the service limits, replace

the drive plate, then select and adjust the retaining
plate so that the clearance is within default standard values.
Retaining plate
Part No.
31567AA710
Thickness mm (in)
4.7 (0.185)
31567AA720
31567AA730
4.8 (0.189)
4.9 (0.193)
31567AA740
31567AA670
5.0 (0.197)
5.1 (0.201)
31567AA680
31567AA690
5.2 (0.205)
5.3 (0.209)
31567AA700
5.4 (0.213)
NOTE:
90.
14) Measure the amount of drive plate compression and record that value.
scale.
(B)
NOTE:
zero point.
NOTE:
(33.7 lb).
4AT-122
(C)
(A)
AT-01727
(A) Drive plate

(B) Driven plate
(C) Retaining plate
AT Main Case
15) Install the driven plate, drive plate, retaining

plate and snap ring.
Initial standard:
1.1 1.4mm (0.043 0.055 in)
Limit thickness:
1.6 mm (0.063 in)
Reverse clutch retaining plate
AT-00247

operation.
Part No.
31567AA910
Thickness mm (in)
4.0 (0.157)
31567AA920
31567AA930
4.2 (0.165)
4.4 (0.173)
31567AA940
31567AA950
4.6 (0.181)
4.8 (0.189)
31567AA960
5.0 (0.197)
31567AA970
31567AA980
5.2 (0.205)
5.4 (0.213)

1) Apply ATF to a new D-ring and install it to low
clutch piston.
2) Install the low clutch piston to low clutch drum.
(A)
AT-00248
17) Check the piston stroke.

(1) Measure the clearance B between the retaining plate and snap ring. (Reverse clutch)
At this time, do not press down the retaining
plate.
(B)
AT-00269
(A)
(A) Low clutch piston
(B) Low clutch drum
3) Install the spring retainer to low clutch piston.

(A)
AT-01728
(A) Thickness gauge

before. If the calculated value exceeds the service limit, replace the drive plate with a new one
and adjust it within the initial specification.
T=A+B
T: Piston stroke
ring
4AT-123
(B)
AT-00270
(A) Spring retainer

(B) Low clutch drum
AT Main Case
4) Attach the ST to the low clutch drum.

ST 498437100
LOW CLUTCH PISTON
GUIDE
(2) Set the one-way clutch inner race, and apply

compressed air for checking.
(A)
ST
(B)
AT-00274
AT-00271
5) Using ST1 and ST2, set the cover on the piston

and press against it, and attach the snap ring. At
this time, be careful not to bend the cover seal.
ST1 498627100 SEAT
ST3 498437100 LOW CLUTCH PISTON
GUIDE
(A) Apply compressed air.

(B) Low clutch drum
8) Check the low clutch clearance.

(1) Place same thickness shims on both sides
to prevent plate from tilting.
(2) Check the clearance between retaining
plate and low clutch operation.
Initial standard:
0.7 1.1 mm (0.028 0.043 in)
ST2
ST3
Limit thickness:
1.6 mm (0.063 in)
ST1
(A)
AT-00272
6) Install the dish plate, driven plate, drive plate and

retaining plate, and then secure them with a snap
ring.
(B)
(A)
AT-00283
(C)
(A) Thickness gauge

(B) Low clutch drum
(D)
If the clearance exceeds the service limits, replace the drive plate, then select and adjust the
retaining plate so that the clearance is within
default standard values.
(B)
AT-00273
Part No.
(A) Snap ring

(B) Low clutch drum
(C) Dish plate
(D) Low clutch piston side
7) Check the low clutch for operation.

(1) Remove the one-way clutch. <Ref. to 4AT107, REMOVAL, AT Main Case.>
4AT-124
Retaining plate
Thickness mm (in)
31567AB050
31567AB060
3.8 (0.150)
4.0 (0.157)
31567AB070
31567AB080
4.2 (0.165)
4.4 (0.173)
31567AB090
4.6 (0.181)
AT Main Case
9) Install the washer to the rear internal gear.
12) Install the washer by aligning the protrusion of

the washer with the hole of the rear planetary carrier.
(B)
(A)
(A)
(B)
AT-00275
AT-00278
(B) Washer
(A) Washer
10) Install the rear internal gear.
13) Install the rear planetary carrier to the low

clutch drum.
(A)
(A)
(B)
AT-00276
(B)

(B) Low clutch drum
AT-00262

direction.
(A) Rear planetary carrier

(B) Low clutch drum

direction.
(A)
(B)
AT-00277
(A) Thrust needle bearing

(B) Low clutch drum
AT-00279
4AT-125
AT Main Case
15) Install the rear sun gear in the correct direction.
18) Install the snap ring to the low clutch drum.
(A)
(A)
(B)
(B)
AT-00261
AT-00281
(A) Rear sun gear
(A) Snap ring
(B) Front planetary carrier

direction.
19) Install the needle bearing, and then secure with

the snap ring.
(B)
(A)
(A)
(C)
(D)
(B)
AT-00280
AT-00268
(A) Thrust needle bearing
(A) Needle bearing
(B) Front planetary carrier

(C) Rear sun, gear side
(B) Snap ring
(D) Front planetary, carrier side
17) Install the front planetary carrier to the low

clutch drum.
(A)
20) Install the one-way clutch, and then secure with

the snap ring.
21) Set the one-way clutch inner race to the D
clutch drum. Make sure that the forward clutch is
free in the clockwise direction and locked in the
counterclockwise direction, as viewed from the
front of the vehicle.
(A)
(B)
(B)
AT-00260
(A) Front planetary carrier

(B) Low clutch drum
AT-00282
(A) Lock
(B) Free
4AT-126
AT Main Case
3. 2-4 BRAKE
5. ONE-WAY CLUTCH OUTER RACE
1) Apply ATF to D-ring and install it to 2-4 brake piston.

2) Install 2-4 brake piston to 2-4 brake piston retainer.
1) Install the needle bearing, and then secure with

the snap ring.
(B)
(A)
(B)
(A)
AT-00268
(A) Needle bearing

(B) Snap ring
AT-00288

4. ONE-WAY CLUTCH INNER RACE

1) Install the needle bearing to inner race using ST
and a press.
ST 398497701
SEAT
2) Install the one-way clutch, and then secure with

the snap ring.
3) Set the one-way clutch inner race to the low
clutch drum. Make sure that the forward clutch is
free in the clockwise direction and locked in the
counterclockwise direction, as viewed from the
front of the vehicle.
ST
(A)
(B)
AT-00299
2) Apply vaseline to the groove of inner race and to

the new seal ring.
3) Install two seal rings to the one-way clutch inner
race.
(A)
(B)
AT-00298
(A) One-way clutch inner race

(B) Seal ring
4AT-127
AT-00282
(A) Lock
(B) Free
AT Main Case
E: INSPECTION
Drive plate surface wear and damage
Driven plate discoloration (burned color)
Snap ring wear, return spring setting and breakage, and snap ring retainer deformation
Lip seal and D-ring damage
Piston and drum check ball operation
Adjust the total end play. <Ref. to 4AT-93, ADJUSTMENT, Oil Pump Housing.>

Snap ring wear, return spring setting and breakage, and spring retainer deformation
Piston check ball operation
Inspect the total end play, and adjust it to be within the standard value. <Ref. to 4AT-93, ADJUSTMENT, Oil Pump Housing.>
3. 2-4 BRAKE
Snap ring wear and spring retainer deformation
4. ONE-WAY CLUTCH
Check that the snap ring is not damaged and the
seal ring is not deformed.
5. LOW & REVERSE BRAKE

Check the following:
Snap ring wear and spring retainer deformation
4AT-128
Transmission Control Device

38.Transmission Control Device

A: REMOVAL
Clutch Assembly.>
stay.
5) Disconnect the air breather hose. <Ref. to 4AT65, REMOVAL, Air Breather Hose.>
the stay.
7) Wrap vinyl tape around the nipple attached to
the air breather hose.
8) Remove the pitching stopper bracket.
9) Remove the inhibitor switch.
12) Remove the bolts securing the range select lever, then remove the range select lever, manual
plate and parking rod.
NOTE:
Be careful not to damage the lips of press-fitted oil
seal in the case.
(A)
(C)
(B)
(D)
AT-02225
(A) Bolt
(C) Manual plate
(D) Parking rod
13) Remove the detention spring.
AT-00304
10) Remove the control valve body assembly.

<Ref. to 4AT-56, REMOVAL, Control Valve Body.>
11) Pull out the manual plate spring pin.
AT-00307
B: INSTALLATION
1) Install the detention spring to the transmission
case.
Tightening torque:
6 Nm (0.6 kgf-m, 4.4 ft-lb)
AT-02224
AT-00307
4AT-129
Transmission Control Device

2) Insert the range select lever, and then tighten

the bolt.
Tightening torque:
6 Nm (0.6 kgf-m, 4.4 ft-lb)
(B)
(A)
AT-01351
(A) Transmission harness

AT-00308
3) Insert the manual plate and parking rod.

(A)
(C)
50 55 mm (1.97 2.17 in)
(D)
(B)
AT-02225
(A) Bolt
(C) Manual plate
(D) Parking rod
AT-00291
4) Insert the spring pin to the manual plate.

(A)
(C)
(B)
(D)
C: INSPECTION
Make sure that the manual lever and detention
spring are not worn or otherwise damaged.
AT-02225
5) Install the oil pan and the control valve assembly. <Ref. to 4AT-57, INSTALLATION, Control
Valve Body.>
6) Turn over the transmission case to its original
position.
7) Install the pitching stopper bracket.
Tightening torque:
41 Nm (4.2 kgf-m, 30.4 ft-lb)
8) Install and adjust the inhibitor switch. <Ref. to
4AT-47, Inhibitor Switch.>
4AT-130

AUTOMATIC TRANSMISSION (DIAGNOSTICS)

A: PROCEDURE
1
2
3
Step
CHECK PRE-INSPECTION.
4AT(D)(diag)-4, Check List for Interview.>
2) Before performing diagnosis, inspect the following items which may influence AT problems.
General Inspection <Ref. to 4AT(D)(diag)-5,
INSPECTION, General Description.>
Disconnection of harness connector
Visual check for harness damage
Oil leakage
Stall speed test <Ref. to 4AT-32, Stall Test.>
Line pressure test <Ref. to 4AT-34, Line Pressure Test.>
Transfer clutch pressure test <Ref. to 4AT-36,
Transfer Clutch Pressure Test.>
Time lag test <Ref. to 4AT-33, Time Lag
Test.>
Road test <Ref. to 4AT-31, Road Test.>
Inhibitor switch <Ref. to 4AT-47, Inhibitor
Switch.>
CHECK AT OIL TEMP WARNING LIGHT.
Turn the ignition switch to ON.
2) Repair the AT OIL TEMP warning light circuit or power supply and ground line circuit.
<Ref. to 4AT(D)(diag)-20, AT OIL TEMP Warning Light Display.>
CHECK INDICATION OF DTC.
Display the DTC.
NOTE:
If the communication function of Subaru Select
Monitor cannot be executed normally, check
the communication circuit. <Ref. to 4AT(D)(diag)-25, COMMUNICATION FOR INITIALIZING
IMPOSSIBLE, Diagnostic Procedure for Subaru Select Monitor Communication.>
PERFORM GENERAL DIAGNOSTICS.
1) Inspect using Diagnostic Procedure without Diagnostic Trouble Code (DTC). <Ref. to
4AT(D)(diag)-87, Diagnostic Procedure without
2) Inspect using General Diagnostic Table.
<Ref. to 4AT(D)(diag)-90, General Diagnostic
Table.>
3) Perform the Clear Memory Mode.
4AT(D)(diag)-18, Inspection Mode.>
5) Display the DTC.
Check
Yes
Is the unit that is thought to
Go to step 2.
influence the AT problem working properly?
No
Repair or replace
each item.
Does the AT OIL TEMP warning light illuminate?

Is the AT OIL TEMP warning
light flashing?
Go to step 4.
Go to step 3.
Go to step 4.
Go to step 5.
Is DTC displayed?
Go to step 6.
NOTE:
Record all DTC.
Go to step 5.
Is DTC displayed?
Go to step 6.
4AT(D)(diag)-2

Step
Check
PERFORM DIAGNOSIS.
Is DTC displayed?
1) Inspect using the Diagnostic Procedure
with Diagnostic Trouble Code (DTC). <Ref. to
4AT(D)(diag)-31, Diagnostic Procedure with
NOTE:
For DTC table, refer to List of Diagnostic Trouble Code (DTC). <Ref. to 4AT(D)(diag)-29, List
of Diagnostic Trouble Code (DTC).>
2) Repair the trouble cause.
4AT(D)(diag)-18, Inspection Mode.>
5) Display the DTC.
4AT(D)(diag)-3
Yes
No
Inspect using the Finish the diagnoDiagnostic Proce- sis.
dure with Diagnostic Trouble Code
(DTC). <Ref. to
4AT(D)(diag)-31,
(DTC).>


A: CHECK
Check the following items when a problem has occurred.
NOTE:
Customers name
Date of purchase
Date of repair
Transmission model
Odometer reading
Transmission
km (miles)
Frequency
Weather
(
Place
(
Vehicle speed
AT OIL TEMP warning light (AT diagnostic indicator light)
Select lever position
Driving condition
Symptoms
V.I.N.
Continuous
Intermittent (
times a day)
Fine
Cloudy
Rainy
Snowy
Others
)
Highland
Suburbs
Inner city
Uphill
Others
)
Hot
Warm
Cool
Cold
Rough road
km/h (MPH)
Blinks continuously
P
Does not blink

D
Not affected
When revving at a standstill
While decelerating
No up-shift
At starting
While accelerating
While turning ( R/
While idling
While cruising
L)
No down-shift
No kick down
Vehicle does not move (
Lock-up malfunction
Any position
Noise or vibration
Shift shock or slip
Select lever does not move

Others
)
4AT(D)(diag)-4
Particular position)
General Description
3. ATF LEVEL
A: CAUTION
Check that the ATF level is at the specified amount.

2. MEASUREMENT
When measuring the 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 a pin of more
than 0.65 mm (0.026 in) diameter.
B: INSPECTION
(A)
(B)
L O
L O
CAUTION:
The airbag system wiring harnesses and connectors are colored yellow. Do not use an electric test equipment to check these circuits.
wiring harness when performing TCM diagnostics or servicing.
OF
OF
The airbag system wiring harness is routed near

the TCM.
(A)
(B)
HOT
COLD
1. SUPPLEMENTAL RESTRAINT SYSTEM

AIRBAG
AT-00316
(A) Upper level

(B) Lower level
4. FRONT DIFFERENTIAL OIL LEVEL

Check the front differential oil level is the specified
amount. <Ref. to 4AT-30, INSPECTION, Differential Gear Oil.>
1. BATTERY
F
Measure the battery voltage and specific gravity of

the electrolyte.
L
Standard voltage: 12 V or more
(A)
(B)
Specific gravity: 1.260 or more
2. TRANSMISSION GROUND
Check that the ground terminal bolt is tightened securely.
Chassis side
AT-00317
(A) Upper level

(B) Lower level
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
5. OPERATION OF SELECT LEVER

Check there is no noise, dragging or contact pattern in each select lever range.
WARNING:
Stop the engine while checking operation of the
select lever.
AT-00315
R
N
D
3
2
1
AT-00413
4AT(D)(diag)-5
General Description
C: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
1B020XU0
DESCRIPTION
SUBARU SELECT
MONITOR KIT
REMARKS
Troubleshooting the electrical system.
ST1B020XU0
2. GENERAL TOOL
TOOL NAME
Circuit tester
Oscilloscope
REMARKS
Used for measuring resistance, voltage and current.
Used for measuring the sensor.
4AT(D)(diag)-6


A: LOCATION
1. CONTROL MODULE
(2)
(1)
(3)
(4)
AT-00414
(1)
(2)
AT OIL TEMP warning light (AT

diagnostic indicator light)
(3)
Transmission control module

(TCM)
(4)
Data link connector
(1)
(2)
AT-00323
AT-00415
(4)
(3)
AT-03375
4AT(D)(diag)-7
AT-00417

2. SENSOR
(2)
(4)
(5)
(1)
(3)
AT-03376
(1)
(3)
(2)
Inhibitor switch
(4)

sensor
MODEL WITH MP-T
(1)
(5)
ATF temperature sensor
(3)
(2)
AT-04301
AT-03379
WITH VTD MODEL

(1)
(3)
(4)
AT-03378
4AT(D)(diag)-8
AT-03380

(5)
AT-03381
3. SOLENOID
(7)
(1)
(6)
(2)
(3)
(5)
(4)
AT-00379
(1)
(2)
Line pressure linear solenoid

High clutch duty solenoid
(3)
2-4 brake duty solenoid
(4)
(5)
(2) (3)
(4)
(7) (6)
(5)
Low & reverse duty solenoid

Low clutch duty solenoid
(1)
AT-00380
4AT(D)(diag)-9
(6)
(7)
Transfer duty solenoid

Lock-up duty solenoid
Transmission Control Module (TCM) I/O Signal

5. Transmission Control Module (TCM) I/O Signal

TO
TO
B55
7 6 5 4 3
2 1
19 18 17 16 15 14 13 12 11 10 9 8
27 26
25 24
23 22 21 20
35 34
33 32
31 30 29 28
6
16 15
27 26
35 34
B54
5
4 3 2 1
14 13 12 11 10 9 8 7
25 24 23 22 21 20 19 18 17
33 32 31
30 29 28
AT-03716
Contents
Backup power supply
Check with ignition switch ON.

Measured terminal (Connector &
Measuring conTerminal No.)
dition
Positive terminal Ground terminal
(B55) No. 25
(B55) No. 26
Chassis ground
(B55) No. 27
ACC power supply
(B55) No. 12
Chassis ground
(B55) No. 1
(B55) No. 2
Chassis ground
Ignition switch
OFF
Ignition switch
ACC
Ignition switch
ON (engine
OFF)
4AT(D)(diag)-10
Voltage (V)
Resistance ()
10 13
10 13
10 13

Contents

Terminal No.)
Positive terminal
P range switch
R range switch
N range switch
Inhibitor switch
D range switch
3 range switch
2 range switch
1 range switch
Brake switch
ATF temperature sensor ground
(B54) No. 14
(B54) No. 13
(B54) No. 11
(B54) No. 10
(B54) No. 8
(B54) No. 7
(B54) No. 19
(B54) No. 20
(B54) No. 23
(B54) No. 12
Ground terminal
Chassis ground
Chassis ground
Chassis ground
Chassis ground
Chassis ground
Chassis ground
Chassis ground
Chassis ground
(B54) No. 12
Chassis ground
(B54) No. 26
(B54) No. 15
Rear vehicle speed sensor ground
(B54) No. 15
Chassis ground
Measuring condition
Voltage (V)
Selector lever in
P range
Less than 1
Selector lever in
any other than
P range
Selector lever in
R range
8 or more
Less than 1
Selector lever in
any other than
R range
8 or more
Selector lever in
N range
Less than 1
Selector lever in
any other than
N range
8 or more
Selector lever in
D range
Less than 1
Selector lever in
any other than
D range
8 or more
Selector lever in
3 range
Less than 1
Selector lever in
any other than
3 range
8 or more
Selector lever in
2 range
Less than 1
Selector lever in
any other than
2 range
8 or more
Selector lever in
1 range
Less than 1
Selector lever in
any other than
1 range
8 or more
When brake
pedal is
depressed.
When brake
pedal is
released.
ATF temperature 20C (68F)
ATF temperature 80C
(176F)
Vehicle stopped
Vehicle speed at
least 20 km/h
(12 MPH)
4AT(D)(diag)-11
Resistance ()
10.5 or more
Less than 1
3.5 4.3
2.5 k 7 k
1.0 2.2
300 800
Less than 1
0
More than 2 (AC
range)
Less than 1

Contents

Terminal No.)
Positive terminal
Ground terminal
Measuring condition
Voltage (V)
Vehicle stopped
0
More than 1 (AC
range)
450 650
(B54) No. 27
(B54) No. 16
Vehicle speed at
least 20 km/h
(12 MPH)
Front vehicle speed sensor ground
(B54) No. 16
Chassis ground
Engine idling
after warm-up
(D range)
Engine idling
after warm-up
(N range)

sensor
(B54) No. 1

sensor ground
(B54) No. 2
Chassis ground
Vehicle speed output signal
(B54) No. 21
Chassis ground
Engine speed signal
(B55) No. 11
Chassis ground

ground
Lock-up solenoid
Transfer duty solenoid (Model with

MP-T)
(B54) No. 4
(B54) No. 3
(B54) No. 6
(B54) No. 5
(B54) No. 2
(B54) No. 3
0
450 650
More than 1 (AC
range)
Vehicle speed at
least 10 km/h (6
MPH)
Ignition switch
ON (engine
OFF)
Less than 1
4 or more
1.1 5.1
Chassis ground
Less than 1
Chassis ground
When lock up
occurs.
When lock up is
released.
4.0 6.0
Less than 1
10.5 or more
2.0 4.5
Less than 1
Less than 1
2.0 4.5
2.0 3.0
Transfer duty solenoid (Model with

VTD)
Chassis ground
P or N range
Throttle fully
opened
Less than 1
(B54) No. 5
(B55) No. 4
Chassis ground
P or N range
2nd or 4th gear
5.0 or more
Less than 1
4AT(D)(diag)-12
Ignition switch
ON (engine
OFF)
R range throttle fully open
after engine
warm-up.
Chassis ground
Less than 1
Ignition switch More than 5 (AC

ON (engine ON)
range)
Ignition switch
ON (engine
OFF)
R range throt3.7 7.7
tle fully closed
after engine
warm-up.
With fuse
installed to FWD
switch
With fuse
removed from
FWD switch (1st
gear)
Resistance ()
5.0 or more
2.0 4.5
2.0 4.5

Contents

Terminal No.)
Positive terminal
Ground terminal
(B55) No. 6
Chassis ground
(B55) No. 7
Chassis ground
(B55) No. 5
Chassis ground
FWD switch (Model with MP-T)
(B55) No. 10
Chassis ground
AWD indicator light
ATF temperature warning
ABS, E/G ECM communication signal (+)

ABS, E/G ECM communication signal ()
Combination meter
System ground
Range lock signal
Data link signal (Subaru Select

Monitor)
(B55) No. 13
(B55) No. 15
Chassis ground
Chassis ground
(B54) No. 18
Chassis ground
(B54) No. 17
Chassis ground
(B54) No. 22
Chassis ground
(B55) No. 20
Chassis ground
(B55) No. 21
(B55) No. 22
Chassis ground
Chassis ground
(B55) No. 23
Chassis ground
(B55) No. 3
(B55) No. 8
Chassis ground
Measuring condition
Voltage (V)
3rd or 4th gear
Less than 1
P or N range
1st or 2nd gear
5.0 or more
Less than 1
P or N range
Except 1 range
5.0 or more
5.0 or more
1 range
Fuse removed
2.5 5.0
10.5 or more
Fuse installed
Less than 1
Ignition switch
ON (engine
OFF)
Ignition switch
ON (engine ON)
2.0 4.5
2.0 4.5
2.0 4.5
Less than 1
9 or more
When light is
ON
Less than 1
When light is
OFF
9 or more
Ignition switch
ON
Resistance ()
Pulse signal
Pulse signal
Ignition switch
ON
Pulse signal
Less than 1
D range vehicle speed

0 km/h
(0 MPH)
10.5 or more
D range vehicle speed

20 km/h
(12 MPH)
Less than 1
Chassis ground
4AT(D)(diag)-13
7 18


A: OPERATION
(DTC)
1) Prepare the Subaru Select Monitor kit.
link connector.
side).

screen, select the {Transmission Control System}.
7) Select the [OK] after the information of transmission type is displayed.
8) On the Transmission Diagnosis screen, select
{DTC Display}.
NOTE:
For details concerning the operation procedure,
refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
For details concerning the diagnostic trouble
codes (DTC), refer to the List of DTC. <Ref. to
4AT(D)(diag)-29, List of Diagnostic Trouble Code
(DTC).>
2. READ CURRENT DATA
CC-00134

connector.

4) On the Transmission Diagnosis display
screen, select the {Current Data Display & Save}.
screen, select the {Data Display}.
6) Using the scroll key, scroll the display screen up
or down until the desired data is shown.
NOTE:
Do not connect scan tools except for Subaru Select
Monitor.
Contents
Display
Unit of measure
Battery voltage
Rear vehicle speed sensor signal
Battery Voltage
Rear Wheel Speed
V
km/h or MPH
Front vehicle speed sensor signal

Engine speed signal
Front Wheel Speed

Engine Speed
km/h or MPH
rpm
ATF temperature
Gear position
ATF Temp.
Gear Position
Line pressure control duty ratio

Lock up clutch duty ratio
Line Pressure Duty Ratio

Lock Up Duty Ratio
%
%
Transfer clutch duty ratio

Torque converter turbine speed signal
Transfer Duty Ratio

Turbine Revolution Speed
%
rpm
2-4 brake duty ratio

Low clutch duty ratio
Brake Clutch Duty Ratio

L/C Duty
%
%
High clutch duty ratio

Low & reverse brake duty ratio
H/C Duty
L&R/B Duty
%
%
Accelerator position
ATF temperature light
Accel. Opening Angle

ATF Temperature Lamp
%
ON or OFF

Parking range signal
Stop Light Switch Signal

P Range Signal
ON or OFF
ON or OFF
Neutral range signal

Reverse range signal
N Range Signal
R Range Signal
ON or OFF
ON or OFF
4AT(D)(diag)-14
C or F

Contents
Display
Unit of measure
Drive range signal

3rd range signal
D Range Signal
3rd Range Signal
ON or OFF
ON or OFF
2nd range signal

1st range signal
2nd Range Signal

1st Range Signal
ON or OFF
ON or OFF
AT diagnosis light output signal

FWD switch signal
Diagnosis Lamp
FWD SW
ON or OFF
ON or OFF
Shift lock solenoid signal

Cruise control signal
Shift Lock Solenoid

Cruise Control Signal
ON or OFF
ON or OFF
NOTE:
For details concerning the operation procedure, refer to the SUBARU SELECT MONITOR OPERATION
MANUAL.
3. CLEAR MEMORY MODE

screen, select the {Clear Memory}.
5) When Done and Turn ignition switch OFF are
shown on the display screen, turn the ignition
switch to OFF and then close the Subaru Select
Monitor.
NOTE:
If {Clear Memory 2} is selected and performed,
DTC and learned control memory are cleared. If
Clear Memory 2 is performed, execute the advance
operation of learning control. <Ref. to 4AT(D)(diag)-15, FACILITATION OF LEARNING CONTROL, OPERATION, Subaru Select Monitor.>
4. FACILITATION OF LEARNING CONTROL

NOTE:
When the following services are performed, or
when the shifting shock is occurred in total check
with vehicle driving, perform the learning with following procedures.
Replacement of TCM
Replacement of transmission assembly
Replacement of clutches
Replacement of control valve body
When {Clear Memory 2} is performed;
1) Shift the select lever to P range, and apply the
parking brake.
link connector, and then turn the ignition switch to
ON.
4) Perform {Clear Memory 2} using the Subaru Select Monitor. <Ref. to 4AT(D)(diag)-15, CLEAR
MEMORY MODE, OPERATION, Subaru Select
Monitor.>
5) Using the Subaru Select Monitor, check that
there is no DTC displayed. <Ref. to 4AT(D)(diag)14, READ DIAGNOSTIC TROUBLE CODE (DTC),
OPERATION, Subaru Select Monitor.>
6) Warm-up the engine until the ATF temperature
displayed on the Subaru Select Monitor reaches 60
90C (140 194F). <Ref. to 4AT(D)(diag)-14,
READ CURRENT DATA, OPERATION, Subaru
Select Monitor.>
7) Shift the select lever to R range.
8) Turn all switches including headlight, air conditioner, seat heater, rear defogger and etc. OFF.
9) Turn the ignition switch to OFF, and wait more
than 30 seconds with the accessory OFF.
10) When Communication Failed! is displayed on
Subaru Select Monitor, press the brake pedal fully
until the learning control promotion is completed.
12) Check that the Subaru Select Monitor is returned to normal operation.
13) Shift the select lever to P range, and then wait
for more than 3 seconds.
14) Shift the select lever to R range, and then wait
15) Shift the select lever to N range, and then wait
16) Shift the select lever to D range, and then wait
17) Shift the select lever to N range, and then wait
18) Slowly depress the accelerator pedal to full
throttle.
19) Slowly release the accelerator pedal completely.
20) Start the engine, and idle it.
4AT(D)(diag)-15

22) Start learning control promotion. At this time,

the AT OIL TEMP warning light in the combination
meter will start blinking at 2 Hz. When the AT OIL
TEMP warning light does not blink, turn the ignition
switch to OFF and repeat the procedures from step
4). When the AT OIL TEMP warning light which
blinking at 2 Hz changes to blink at 0.5 Hz, learning
control promotion is completed.
NOTE:
When blinking of AT OIL TEMP warning light
changes from 2 Hz to 4 Hz during learning control
promotion, repeat the procedure from step 4).
23) Shift the select lever to N range, and then turn
the ignition switch to OFF.
24) Shift the select lever to P range to complete
the learning control promotion.
4AT(D)(diag)-16

7. Read Diagnostic Trouble

Code (DTC)
A: OPERATION
Refer to Subaru Select Monitor for information on
how to display a DTC. <Ref. to 4AT(D)(diag)-14,
NOTE:
DTC can not be read through AT OIL TEMP warning light.
4AT(D)(diag)-17
Inspection Mode
8. Inspection Mode
A: PROCEDURE
WARNING:
Observe the traffic law when driving on public
roads.
Shift the select lever to D range, and then drive
the vehicle at 60 km/h (37 MPH) for at least 10 seconds.
4AT(D)(diag)-18
Clear Memory Mode

9. Clear Memory Mode

A: OPERATION
Refer to Subaru Select Monitor for information
about how to clear a DTC.
<Ref. to 4AT(D)(diag)-15, CLEAR MEMORY
MODE, OPERATION, Subaru Select Monitor.>
4AT(D)(diag)-19
AT OIL TEMP Warning Light Display

10.AT OIL TEMP Warning Light Display

A: OPERATION
When any on-board diagnostics item is malfunctioning, AT OIL TEMP warning light blinks from the time malfunction is detected after starting the engine until ignition switch is turned to OFF. The malfunctioning part or
unit can be determined by a DTC during the on-board diagnostics operation. Problems which occurred previously can also be identified through the memory function. If the AT OIL TEMP warning light does not show
a problem (although a problem is occurring), the problem can be determined by checking the performance
characteristics of each sensor using Subaru Select Monitor. Indicator light signal patterns are as shown in the
figure.
(1)
ON
OFF
(2)
ON
(3)
OFF
(4)
(5)
ON
(3)
OFF
(6)
(7)
ON
(3)
OFF
(8)
AT-01281
(1)
Ignition switch (Engine OFF)
(4)
Abnormal (Trouble occurs)
(7)
Normal (ATF temperature is high)
(2)
(3)
Normal
2 seconds
(5)
(6)
0.25 seconds
Blink
(8)
ATF temperature is high
B: INSPECTION
DIAGNOSIS:
The AT OIL TEMP warning light circuit is open or shorted.
TROUBLE SYMPTOM:
When the ignition switch is turned ON (engine OFF), AT OIL TEMP warning light does not illuminate.
When the on-board diagnostics is performed, the AT OIL TEMP warning light remains illuminated.
4AT(D)(diag)-20

WIRING DIAGRAM:
BATTERY
B108
F46
SBF-4
B36
SBF-1
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
IGNITION
SWITCH
B38
No.14
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
i12
5
B36
1 2 3
4 5 6
7 8 9 10 11 12 13 14
ATF TEMP. WARNING LIGHT
B9
i1
B55
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
COMBINATION METER
A:
i12
B:
i10
A2
i10
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
i3
B38
15
F46
B55
1
2
TCM
AT-03717
Step
CHECK FUSE (NO. 14).
Remove the fuse (No. 14).
Check
Yes
No
Is the fuse (No. 14) blown out? Replace the fuse Go to step 2.
(No. 14). If the
replaced fuse (No.
14) is blown out
easily, repair the
harness between
fuse (No. 14) and
the combination
meter.
4AT(D)(diag)-21

Step
CHECK HARNESS CONNECTOR BETWEEN
COMBINATION METER AND IGNITION
SWITCH.
2) Disconnect the connector (B55) from TCM.
4) Short between the combination meter connector and chassis ground.
CAUTION:
When shorting, be sure to short through the
fuse.
CHECK OPEN CIRCUIT OF HARNESS.
3) Measure the resistance between the combination meter connector and TCM connector.
(B55) No. 15 (i12) No. 2:
Measure the resistance between combination
(i12) No. 2 Chassis ground:
CHECK INPUT SIGNAL FOR TCM.
1) Connect all the connectors.
3) Measure the voltage between TCM connector and chassis ground.
CHECK POOR CONTACT.
Check
Yes
Go to step 3.
No
Repair open or
short circuit of harness between the
combination meter
and battery.
Does the warning light illuminate?
Go to step 4.
Check the combination meter.
Repair the open

circuit of harness
between TCM and
combination meter,
and the poor contact of the connector.
more?
Go to step 6.
Go to step 7.
Repair the short

circuit of harness
between TCM and
combination meter
connector.
Replace the TCM.
<Ref. to 4AT-61,
Transmission Control Module
(TCM).>
Is there poor contact of the AT Repair the poor

OIL TEMP warning light circuit? contact.
4AT(D)(diag)-22
Check the power

supply and ground
circuit. <Ref. to
4AT(D)(diag)-23,
CHECK POWER
SUPPLY AND
GROUND CIRCUIT, AT OIL
TEMP Warning
Light Display.>

C: CHECK POWER SUPPLY AND GROUND CIRCUIT

WIRING DIAGRAM:
BATTERY
F45
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
SBF-1
SBF-5
B40
E
SBF-4
No.4
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B40
16
12
B11
IGNITION
SWITCH
F45
DATA
LINK
CONNECTOR
4
No.11
B62
3 4
8
6 7
9 10
11 12
14 15
13
16
17 18
19 20
1
27
26
25
B55
B55
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
32 33
34 35
28 29 30 31
TCM
21
20
20
23
19
22
ECM
B136
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B11
T4
5 6
14 15 16
25 26 27
33 34 35
TRANSMISSION
AT-03706
Step
CHECK BATTERY TERMINAL.
CHECK POWER SUPPLY OF TCM.
Check
Yes
Is there poor contact at the bat- Repair or tighten
tery terminal?
the battery terminal.
Go to step 4.
4AT(D)(diag)-23
No
Go to step 2.
Go to step 3.

Step
CHECK FUSE (NO. 4).
2) Remove the fuse (No. 4).
Check
Is the fuse (No. 4) blown out?
Yes
Replace the fuse
(No. 4). If the
replaced fuse (No.
4) has blown out
easily, repair short
circuit of harness
between fuse (No.
4) and TCM.
Go to step 6.
CHECK IGNITION POWER SUPPLY CIRIs the voltage 10 13 V?

CUIT.
2) Measure the ignition power supply voltage
between TCM connector and chassis ground.
Is the fuse (No. 11) blown out? Replace the fuse
(No. 11). If the
replaced fuse (No.
11) has blown out
easily, repair short
circuit of harness
between fuse (No.
11) and TCM.
TCM AND TRANSMISSION.
2) Disconnect the connectors from TCM and
transmission.
TCM and transmission connector.
(B55) No. 22 (B11) No. 19:
(B55) No. 23 (B11) No. 19:
(B55) No. 20 (B11) No. 20:
(B55) No. 21 (B11) No. 20:
TRANSMISSION AND TRANSMISSION
GROUND.
transmission and transmission ground.
(T4) No. 19 Transmission ground:
CHECK POOR CONTACT OF CONNECIs there poor contact in TCM
Repair the connecTORS.
power supply, ground and data tor.
link connector?
4AT(D)(diag)-24
No
Repair the open
circuit of harness
between fuse (No.
4) and TCM, or
fuse (No. 4) and
battery, and poor
Go to step 5.
Repair the open

circuit of harness
between fuse (No.
4) and TCM, or
fuse (No. 4) and
battery, and poor
Repair the open
circuit of harness
between TCM and
transmission harness connector,
and poor contact of
connector.
Repair the open

circuit of the harness between
transmission and
transmission
ground.
Replace the TCM.

<Ref. to 4AT-61,
(TCM).>
Diagnostic Procedure for Subaru Select Monitor Communication

11.Diagnostic Procedure for Subaru Select Monitor Communication

A: COMMUNICATION FOR INITIALIZING IMPOSSIBLE
NOTE:
If the AT OIL TEMP warning light turns on when the Subaru Select Monitor or general scan tool is connected,
perform the following procedures.
1. Disconnect the Subaru Select Monitor or general scan tool from the vehicle.
If the AT OIL TEMP warning light turns off, the Subaru Select Monitor or general scan tool may be faulty.
Connect a different Subaru Select Monitor or general scan tool, and if AT OIL TEMP warning light remains
off, delete the DTC.
DIAGNOSIS:
Defective harness connector
TROUBLE SYMPTOM:
Subaru Select Monitor communication failure
WIRING DIAGRAM:
BATTERY
F45
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
SBF-1
SBF-5
B40
E
SBF-4
No.4
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B40
16
12
B11
IGNITION
SWITCH
F45
DATA
LINK
CONNECTOR
4
No.11
B62
3 4
8
6 7
9 10
11 12
14 15
13
16
17 18
19 20
1
1
B55
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
TCM
B136
21
20
20
19
23
ECM
22
27
26
25
B55
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B11
T4
5 6
14 15 16
25 26 27
33 34 35
TRANSMISSION
AT-03706
4AT(D)(diag)-25

4
5
Step
Check
CHECK INSTALLATION OF TCM CONNEC- Is the TCM connector conTOR.
nected correctly?
CHECK SUBARU SELECT MONITOR POW- Is the voltage 10 V or more?
ER SUPPLY CIRCUIT.
Measure the voltage between data link connector and chassis ground.
CHECK SUBARU SELECT MONITOR
GROUND CIRCUIT.
the data link connector and ECM or the chassis
ground.
(B40) No. 5 (B136) No. 6:
(B40) No. 6 (B136) No. 6:
CHECK ENGINE GROUND CIRCUIT.
Check the engine ground circuit.
CHECK COMMUNICATION OF SUBARU SELECT MONITOR.
3) Using the Subaru Select Monitor, check
whether communication to the transmission
system can be executed normally.
2) Disconnect the TCM connector.
3) Check whether communication to the
engine, ABS, VDC and airbag system can be
executed normally.
2) Connect the TCM connector.
3) Disconnect the ABS, VDC and airbag connector.
CAUTION:
Observe the safety precautions before disconnecting the airbag connectors. <Ref. to
AB(diag)-4, CAUTION, General Description.>
4) Check whether communication to transmission system can be executed normally.
EACH CONTROL MODULE AND DATA LINK
CONNECTOR.
2) Disconnect the following TCM connectors.
3) Check whether communication to ECM can
be executed normally.
Yes
Go to step 2.
Go to step 3.
No
Connect the TCM
connector
securely.
Repair harness
connector between
the battery and
data link connector, and poor contact of the
connector.
Repair the open
circuit of harness
between data link
connector and
chassis ground or
ECM, and poor
Is the engine ground circuit nor- Go to step 5.

mal?
Is the name of the system dis- Go to step 11.
played on Subaru Select Monitor?
Repair ground circuit of ECM.

Go to step 6.

Go to step 9.
Is the name of the system dis- Inspect the ABS,

played on Subaru Select Moni- VDC and airbag
tor?
module.
Go to step 8.

Inspect the ECM.
4AT(D)(diag)-26

Step
EACH CONTROL MODULE AND DATA LINK
CONNECTOR.
3) Measure the resistance between data link
CHECK OUTPUT SIGNAL OF TCM.
2) Measure the voltage between data link connector and chassis ground.
TCM AND DATA LINK CONNECTOR.
Measure the resistance between TCM connector and data link connector.
(B55) No. 8 (B40) No. 7:
CHECK FOR IMPROPER CONNECTION OF
Check
more?
13
CHECK POOR CONTACT OF CONNECTORS.
14
Is there poor contact in control Repair the poor

module power supply and data contact.
link connector?
Go to step 16.
CHECK POWER SUPPLY OF TCM.

CHECK FUSE (NO. 4).
10
11
12
15
16
Yes
Go to step 10.
No
Check harness
and connector
between each control module and
data link connector.
Check harness
Go to step 11.
and connector
Repair the harness
and connector
between TCM and
Is the transmission harness
connector connected to bulkhead harness connector correctly?
CHECK IGNITION POWER SUPPLY CIRCUIT.
4AT(D)(diag)-27
Go to step 13.
Replace the fuse

(No. 4). If the
replaced fuse (No.
4) has blown out
easily, repair the
short circuit of harness between fuse
(No. 4) and TCM.
Go to step 18.
Connect the bulkhead harness connector to

Go to step 14.
Go to step 15.
Repair the open

circuit of harness
between fuse (No.
4) and TCM, or
fuse (No. 4) and
battery, and poor
Go to step 17.

17
18
19
20
Step
Check
Yes
Is the fuse (No. 11) blown out? Replace the fuse
(No. 11). If the
replaced fuse (No.
11) has blown out
easily, repair the
short circuit of harness between fuse
(No. 11) and TCM.
transmission.
(B55) No. 22 (B11) No. 19:
(B55) No. 23 (B11) No. 19:
(B55) No. 20 (B11) No. 20:
(B55) No. 21 (B11) No. 20:
TRANSMISSION AND TRANSMISSION
GROUND.
transmission and transmission ground.
CHECK POOR CONTACT OF CONNECIs there poor contact in TCM
Repair the connecTORS.
power supply, ground and data tor.
link connector?
4AT(D)(diag)-28
No
Repair the open
circuit of harness
between fuse (No.
11) and TCM, or
fuse (No. 11) and
battery, and poor
Repair the open
circuit of harness
between TCM and
transmission harness connector,
and poor contact of
connector.
Repair the open

transmission and
transmission
ground.
Replace the TCM.

<Ref. to 4AT-61,
(TCM).>


A: LIST
DTC
Item
Diagnosis content
P0705
Transmission Range
Sensor Circuit (PRNDL
Input)
Inhibitor switch malfunction, open

or short circuit
P0712
Transmission Fluid Temperature Sensor Circuit

Low Input
ATF temperature sensor is faulty

or input signal circuit is open.
P0713
Transmission Fluid Temperature Sensor Circuit

High Input
ATF temperature sensor is faulty

or input signal circuit is shorted.
P0715
Input/Turbine Speed
Sensor Circuit

sensor malfunction, open or
shorted input signal circuit
P0719
Torque Converter/Brake
Brake switch malfunction, open

input signal circuit
P0720
Output Speed Sensor

Circuit
Front vehicle speed sensor malfunction, open or shorted input

signal circuit
P0724
Torque Converter/Brake
Brake switch malfunction, shorted

input signal circuit
P0725
Engine Speed Input Circuit
Open or shorted engine speed

output signal circuit
P0731
Gear 1 Incorrect Ratio
P0732
P0733
P0734
Reference
<Ref. to 4AT(D)(diag)-31, DTC P0705 TRANSMISSION RANGE SENSOR CIRCUIT (PRNDL
INPUT), Diagnostic Procedure with Diagnostic
<Ref. to 4AT(D)(diag)-39, DTC P0712 TRANSMISSION FLUID TEMPERATURE SENSOR
CIRCUIT LOW INPUT, Diagnostic Procedure
<Ref. to 4AT(D)(diag)-42, DTC P0713 TRANSMISSION FLUID TEMPERATURE SENSOR
CIRCUIT HIGH INPUT, Diagnostic Procedure
<Ref. to 4AT(D)(diag)-45, DTC P0715 INPUT/
TURBINE SPEED SENSOR CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to 4AT(D)(diag)-47, DTC P0719
TORQUE CONVERTER/BRAKE SWITCH B
CIRCUIT LOW, Diagnostic Procedure with
<Ref. to 4AT(D)(diag)-49, DTC P0720 OUTPUT SPEED SENSOR CIRCUIT, Diagnostic
Procedure with Diagnostic Trouble Code
(DTC).>
Vehicle sensor, torque converter

turbine speed sensor or control
valve malfunction
valve malfunction

TORQUE CONVERTER/BRAKE SWITCH B
CIRCUIT HIGH, Diagnostic Procedure with
<Ref. to 4AT(D)(diag)-54, DTC P0725 ENGINE
SPEED INPUT CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to 4AT(D)(diag)-56, DTC P0731 GEAR 1
INCORRECT RATIO, Diagnostic Procedure

valve malfunction


valve malfunction

P0736
Reverse Incorrect Ratio

valve malfunction
P0741
Torque Converter Clutch

Circuit Performance or
Stuck Off
Lock-up clutch is faulty or valve is

stuck.
4AT(D)(diag)-29

REVERSE INCORRECT RATIO, Diagnostic
(DTC).>
TORQUE CONVERTER CLUTCH CIRCUIT
PERFORMANCE OR STUCK OFF, Diagnostic
(DTC).>

DTC
Item
Diagnosis content
Reference
TORQUE CONVERTER CLUTCH CIRCUIT
ELECTRICAL, Diagnostic Procedure with
<Ref. to 4AT(D)(diag)-62, DTC P0748 PRESSURE CONTROL SOLENOID A ELECTRICAL, Diagnostic Procedure with Diagnostic
P0743
Torque Converter Clutch

Circuit Electrical
Lock-up solenoid is faulty or output signal circuit is open or

shorted.
P0748
Pressure Control Solenoid A Electrical
Line pressure linear solenoid is

faulty or output signal circuit is
open or shorted.
P0753
Shift Solenoid A Electrical
Low clutch duty solenoid is faulty

or output signal circuit is open or
shorted.
<Ref. to 4AT(D)(diag)-64, DTC P0753 SHIFT

SOLENOID A ELECTRICAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0758
Shift Solenoid B Electrical
2-4 brake duty solenoid is faulty

shorted.

SOLENOID B ELECTRICAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0763
Shift Solenoid C Electrical
P0768
Shift Solenoid D Electrical
P0801
Reverse Inhibit Control

Circuit
P1706
AT Vehicle Speed Sensor Circuit Malfunction

(rear wheel)
Rear vehicle speed sensor is

faulty or input signal circuit is
open or shorted.
P1707
AT AWD Solenoid Valve

Circuit Malfunction
Transfer duty solenoid is faulty or

output signal circuit is open or
shorted.
P1718
CAN Communication
Circuit
CAN communication circuit is

open or shorted.
High clutch duty solenoid is faulty

shorted.
Low & reverse clutch duty solenoid is faulty or output signal circuit is open or shorted.

SOLENOID C ELECTRICAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
SOLENOID D ELECTRICAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Shift lock solenoid is faulty or outREVERSE INHIBIT CONTROL CIRCUIT, Diagput signal circuit is open or
nostic Procedure with Diagnostic Trouble Code
shorted.
(DTC).>
4AT(D)(diag)-30
<Ref. to 4AT(D)(diag)-78, DTC P1706 AT VEHICLE SPEED SENSOR CIRCUIT MALFUNCTION (REAR WHEEL), Diagnostic Procedure
<Ref. to 4AT(D)(diag)-81, DTC P1707 AT AWD
SOLENOID VALVE MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to 4AT(D)(diag)-84, DTC P1718 CAN
COMMUNICATION CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>


A: DTC P0705 TRANSMISSION RANGE SENSOR CIRCUIT (PRNDL INPUT)
Inhibitor switch is faulty.
The inhibitor input signal circuit is shorted.
More than 2 range signal is input.
No D range signal is input when select lever is moved from the N to the 3 range.
TROUBLE SYMPTOM:
Shift characteristics are erroneous.
Engine brake does not come into effect when the select lever is shifted to 3 range.
The range position of the select lever and the AT select lever position indicator in the combination meter
do not match.
WIRING DIAGRAM:
B12
22
1 2 3 4
5 6 7 8
9 10 11 12
TCM
19
11
10
14
13
B54
T7
1 2 3 4 5 6
7 8 9 10 11 12
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
E
i10
i3
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
T7
B54
14
11
10
T3
B38
B12
P
R
COMBINATION METER
N
i10
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
D
3
2
1
INHIBITOR SWITCH
AT-03672
4AT(D)(diag)-31

4
5
7
8
10
11
12
13
14
15
16
17
18
19
20
Step
Check
When the P range is selected,
Connect the Subaru Select Monitor to data link does the LED illuminate?
connector, and then check the LED display
screen.
CHECK INDICATOR LIGHT.
Does the combination meter
P range indicator light illuminate?
When the R range is selected,
does the P range LED light
up?
CHECK R RANGE SWITCH.
When the R range is selected,
does the LED illuminate?
R range indicator light illuminate?
CHECK R RANGE SWITCH.
When the N range is selected,
does the R range LED light
up?
CHECK N RANGE SWITCH.
When the N range is selected,
N range indicator light illuminate?
CHECK N RANGE SWITCH.
When the D range is selected,
does the N range LED light
up?
CHECK D RANGE SWITCH.
When the D range is selected,
D range indicator light illuminate?
CHECK D RANGE SWITCH.
When the 3 range is selected,
does the D range LED light
up?
CHECK 3 RANGE SWITCH.
Does the combination meter 3
range indicator light illuminate?
does the 3 range LED light
up?
up?
4AT(D)(diag)-32
Yes
Go to step 2.
No
Go to step 22.
Go to step 3.
Go to step 26.
Go to step 27.
Go to step 4.
Go to step 5.
Go to step 28.
Go to step 6.
Go to step 31.
Go to step 32.
Go to step 7.
Go to step 8.
Go to step 33.
Go to step 9.
Go to step 36.
Go to step 37.
Go to step 10.
Go to step 11.
Go to step 38.
Go to step 12.
Go to step 41.
Go to step 42.
Go to step 13.
Go to step 14.
Go to step 43.
Go to step 15.
Go to step 46.
Go to step 47.
Go to step 16.
Go to step 17.
Go to step 48.
Go to step 18.
Go to step 51.
Go to step 52.
Go to step 19.
Go to step 20.
Go to step 53.
Go to step 21.
Go to step 56.

21
22
23
24
25
26
Step
Check
Yes
When the 2 range is selected, Go to step 57.
up?

INHIBITOR SWITCH AND CHASSIS
GROUND.
switch.
inhibitor switch and chassis ground.
(T7) No. 5 Chassis ground:
TCM AND COMBINATION METER.
combination meter.
TCM and combination meter.
(B54) No. 22 (i10) No. 14:
TCM AND INHIBITOR SWITCH.
2) Disconnect the connector from TCM and
inhibitor switch.
between TCM and inhibitor switch connector.
(B54) No. 14 (T7) No. 9:
2) Connect the connector to TCM and inhibitor
switch.
4) Shift the select lever to P range.
5) Measure the voltage between TCM and
chassis ground.
1) Shift the select lever to any range other than
P.
chassis ground.
No
Even if the AT OIL
TEMP warning
light is blinking, the
circuit has returned
to normal condition
at this time. A temporary poor contact of connector or
harness may be
the cause. Repair
the poor contact of
harness.
Repair the open
circuit of harness
between inhibitor
switch and chassis
ground, and poor
Repair open circuit

of harness
between TCM connector and combination meter, and
poor contact in
connector.
Repair the open

circuit of harness
between TCM and
inhibitor switch
connector, and
poor contact of the
connector.
Go to step 26.
Go to step 59.
Go to step 59.
Replace the TCM.

<Ref. to 4AT-61,
(TCM).>
4AT(D)(diag)-33

27
28
29
30
31
32
33
Step
CHECK P RANGE INDICATOR LIGHT
BULB.
3) Remove the P range indicator light bulb
from the combination meter.
2) Disconnect the connectors from TCM, inhibitor switch and combination meter.
inhibitor switch.
(B54) No. 13 (T7) No. 8:
switch.
4) Move the select lever to R range.
chassis ground.
1) Position the select lever to any other than
R range.
chassis ground.
CHECK R RANGE INDICATOR LIGHT
BULB.
3) Remove the R range indicator light bulb
from combination meter.
Check
Is the P range indicator light
bulb OK?
Yes
Go to step 59.
No
Replace the P
range indicator
light bulb. <Ref. to
more?
Go to step 29.
Repair ground
short circuit in P
range circuit.
Repair the open

circuit of harness
between TCM and
inhibitor switch
connector, and
poor contact of the
connector.
Go to step 31.
Go to step 59.
Go to step 59.
Replace the TCM.

<Ref. to 4AT-61,
(TCM).>
Is the R range indicator light

bulb OK?
Go to step 59.
Replace the R
range indicator
more?
Go to step 34.
Repair ground
short circuit in R
range circuit.
4AT(D)(diag)-34

34
35
36
37
38
39
40
Step
inhibitor switch.
(B54) No. 11 (T7) No. 10:
switch.
4) Move the select lever to N range.
chassis ground.
1) Move the select lever to any other than N
range.
chassis ground.
CHECK N RANGE INDICATOR LIGHT
BULB.
3) Remove the N range indicator light bulb
from the combination meter.
inhibitor switch.
(B54) No. 10 (T7) No. 3:
switch.
4) Move the select lever to the D range.
chassis ground.
Check
Yes
No
Repair the open
circuit of harness
between TCM and
inhibitor switch
connector, and
poor contact of the
connector.
Go to step 36.
Go to step 59.
Go to step 59.
Replace the TCM.

<Ref. to 4AT-61,
(TCM).>
Is the N range indicator light

bulb OK?
Go to step 59.
Replace the N
range indicator
more?
Go to step 39.
Repair the ground

short circuit in N
range circuit.
Repair the open

circuit of harness
between TCM and
inhibitor switch
connector, and
poor contact of the
connector.
Go to step 59.
4AT(D)(diag)-35
Go to step 41.

41
42
43
44
45
46
47
Step
1) Move the select lever to any other than D
range.
chassis ground.
CHECK D RANGE INDICATOR LIGHT
BULB.
3) Remove the D range indicator light bulb
inhibitor switch.
(B54) No. 8 (T7) No. 11:
switch.
4) Move the select lever to the 3 range.
chassis ground.
1) Move the select lever out of the 3 range.
chassis ground.
CHECK 3 RANGE INDICATOR LIGHT
BULB.
3) Remove the 3 range indicator light bulb
Check
Yes
Go to step 59.
No
Replace the TCM.
<Ref. to 4AT-61,
(TCM).>
Is the D range indicator light

bulb OK?
Go to step 59.
Replace the D
range indicator
more?
Go to step 44.
Repair ground
short circuit in D
range circuit.
Repair the open

circuit of harness
between TCM and
inhibitor switch
connector, and
poor contact of the
connector.
Go to step 46.
Go to step 59.
Go to step 59.
Replace the TCM.

<Ref. to 4AT-61,
(TCM).>
Is the 3 range indicator light

bulb OK?
Go to step 59.
Replace the 3
range indicator
4AT(D)(diag)-36

48
49
50
51
52
53
54
Step
inhibitor switch.
(B54) No. 7 (T7) No. 4:
switch.
chassis ground.
chassis ground.
BULB.
inhibitor switch.
(B54) No. 19 (T7) No. 6:
Check
more?
Yes
Go to step 49.
No
Repair ground
short circuit in 3
range circuit.
Repair the open

circuit of harness
between TCM and
inhibitor switch
connector, and
poor contact of the
connector.
Go to step 51.
Go to step 59.
Go to step 59.
Replace the TCM.

<Ref. to 4AT-61,
(TCM).>

bulb OK?
Go to step 59.
Replace the 2
range indicator
more?
Go to step 54.
Repair ground
short circuit in 2
range circuit.
4AT(D)(diag)-37
Repair the open

circuit of harness
between TCM and
inhibitor switch
connector, and
poor contact of the
connector.

59
Step
switch.
chassis ground.
chassis ground.
BULB.
CHECK POOR CONTACT.
60
55
56
57
58
Check
Yes
Go to step 56.
No
Go to step 59.
Go to step 59.
Replace the TCM.

<Ref. to 4AT-61,
(TCM).>

bulb OK?
Go to step 59.
Replace the 1
range indicator
more?
Go to step 59.
Repair ground
short circuit in 1
range circuit.

inhibitor switch circuit?
Is the inhibitor switch in the normal position?
Repair the poor

contact.
Replace the TCM.
<Ref. to 4AT-61,
(TCM).>
Go to step 60.
4AT(D)(diag)-38
Adjust inhibitor
switch and select
cable. <Ref. to
4AT-47, Inhibitor
Switch.> <Ref. to
CS-25, Select
Cable.>

B: DTC P0712 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT LOW

INPUT
Input signal circuit to ATF temperature sensor is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
AT11
1 2
3 4
B54
TCM
23
12
B11
3 4
8
6 7
9 10
11 12
14 15
13
16
17 18
19 20
1
T4
15
11
B11
T4
ATF TEMPERATURE
SENSOR
4 3
8
7
12 11
15
16
20 19
AT11
2 1
6
5
10 9
13
14
18 17
B54
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
TRANSMISSION
AT-03673
Step
Check
Yes
TCM AND ATF TEMPERATURE SENSOR.
(B54) No. 23 No. 11:
4AT(D)(diag)-39
No
Repair the open
circuit of harness
between TCM and

Step
(B54) No. 12 (B11) No. 15:
CHECK ATF TEMPERATURE SENSOR.
2) Connect the connectors to transmission and
TCM.
3) Turn the ignition switch to ON and start
engine.
4) Warm-up the transmission until the ATF
temperature reaches to 80C (176F).
NOTE:
If the ambient temperature is below 0C (32F),
drive the vehicle until the ATF reaches its operating temperature.
5) Disconnect the connector from transmission.
6) Measure the resistance between transmission connector terminals.
(T4) No. 11 No. 15:
2) Measure the resistance between transmission connector terminals.
(T4) No. 11 No. 15:
CHECK INPUT SIGNAL FOR TCM USING
SUBARU SELECT MONITOR.
1) Connect the connector to transmission.
2) Connect the Subaru Select Monitor to the
4) Read the data of ATF temperature using
CHECK POOR CONTACT.
Check
Yes
No
Repair the open
circuit of harness
between TCM and

800 ?
Go to step 4.
Go to step 7.
Does the resistance value

Go to step 5.
increase while the ATF temperature decreases?
Go to step 7.
Does the ATF temperature

gradually decrease?
Is there poor contact in ATF

temperature sensor circuit?
4AT(D)(diag)-40
Even if the AT OIL Go to step 6.

TEMP warning
to normal condition
harness may be
the cause. Repair
the harness and
poor contact of
ATF temperature
sensor and transmission connector.
Repair the poor
Replace the TCM.
contact.
<Ref. to 4AT-61,
(TCM).>

10
Step
TRANSMISSION AND ATF TEMPERATURE
SENSOR.
3) Remove the transmission connector from
bracket.
4) Lift up the vehicle and place it on rigid racks.
NOTE:
Raise all wheels off the floor.
5) Drain the automatic transmission fluid.
CAUTION:
Do not drain ATF until it cools down.
6) Remove the oil pan, and disconnect the
connector from ATF temperature sensor connector.
ATF temperature sensor and transmission connector.
8) Measure the resistance between transmission connector and transmission ground.
(T4) No. 11 (AT11) No. 1:
SENSOR.
ATF temperature sensor and transmission connector.
(T4) No. 15 (AT11) No. 3:
SENSOR.
transmission connector and transmission
ground.
SENSOR.
ground.
Check
Yes
No
Repair the open
circuit of harness
between ATF temperature sensor
and transmission
connector.
Repair the open

circuit of harness
and transmission
connector.
more?
Go to step 10.
Repair the short

circuit of harness
and transmission
connector.
more?
Replace the control valve body.

<Ref. to 4AT-56,
Control Valve
Body.>
Repair the short

circuit of harness
and transmission
connector.
4AT(D)(diag)-41

C: DTC P0713 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT HIGH

INPUT
Input signal circuit to ATF temperature sensor is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
AT11
1 2
3 4
B54
TCM
23
12
B11
3 4
8
6 7
9 10
11 12
14 15
13
16
17 18
19 20
1
T4
15
11
B11
T4
ATF TEMPERATURE
SENSOR
4 3
8
7
12 11
15
16
20 19
AT11
2 1
6
5
10 9
13
14
18 17
B54
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
TRANSMISSION
AT-03673
Step
Check
CHECK HARNESS CONNECTOR BETWEEN Is the resistance 500 or
more?
3) Measure the resistance between TCM connector terminals.
(B54) No. 23 No. 12:
4AT(D)(diag)-42
Yes
Go to step 2.
No
Go to step 4.

Step
TCM connector and chassis ground.
CHECK HARNESS.
Measure the resistance between TCM connector terminals while shaking the harness.
(B54) No. 23 No. 12:
Measure the resistance between transmission
(T4) No. 11 No. 15:
CHECK TRANSMISSION HARNESS.

CAUTION:
4) Disconnect the harness connector from
control valve.
5) Measure the resistance between transmission connector and transmission ground.
CHECK TRANSMISSION HARNESS.
connector and transmission ground.
Check
more?
Yes
Go to step 3.
No
Go to step 4.
Does the resistance change?
Go to step 4.
more?
Go to step 5.
Replace the TCM.

<Ref. to 4AT-61,
(TCM).>
Repair the short
circuit of harness
between TCM and
transmission harness.
more?
Go to step 6.
Is the resistance 500 or

more?

TEMP warning
to normal condition
at this time. A temporary short circuit
of connector or
harness may be
the cause. Repair
the harness or
connector.
Go to step 8.
Replace the transmission harness.
more?
more?
4AT(D)(diag)-43
Go to step 9.
Repair the short

circuit of harness
between TCM and
transmission harness.
Replace the transmission harness.

Step
Check
Is the resistance 500 or
Measure the resistance between control valve more?
Terminals
No. 1 No. 3:
4AT(D)(diag)-44
Yes
Even if the AT OIL
TEMP warning
to normal condition
at this time. A temporary short circuit
of connector or
harness may be
the cause. Repair
the harness or
connector.
No
<Ref. to 4AT-56,
Control Valve
Body.>

D: DTC P0715 INPUT/TURBINE SPEED SENSOR CIRCUIT

Input signal circuit of TCM is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B11
B54
3 4
8
6 7
9 10
11 12
14 15
13
16
17 18
19 20
1
TCM
1
2
B54
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
5
10
B11
T4
TORQUE
CONVERTER
TURBINE SPEED
SENSOR
AT-03675
Step
Check
CHECK TORQUE CONVERTER TURBINE
SPEED SENSOR.
650 ?
3) Measure the resistance between transmission connector receptacles terminals.
(T4) No. 5 No. 10:
4AT(D)(diag)-45
Yes
Go to step 2.
No
Replace the torque
converter turbine
speed sensor.
<Ref. to 4AT-55,
Torque Converter
Turbine Speed
Sensor.>

Step
Check
Yes
between TCM connector and transmission connector.
(B54) No. 1 (B11) No. 5:
TCM connector and transmission connector.
(B54) No. 2 (B11) No. 10:
more?
Go to step 5.
more?
Go to step 6.
No
Repair the open
circuit of harness
between TCM and
Repair the open

circuit of harness
between TCM and
transmission connector, and poor
Repair the short
circuit of harness
between TCM and
Repair the short

TCM and transmission connector,
and poor contact of
connector.
Is the revolution value same as Even if the AT OIL Go to step 7.
the tachometer reading shown TEMP warning
on the combination meter?
to normal condition
harness may be
the cause. Repair
the harness or
connector in TCM
and transmission.

1) Connect the connectors to TCM and transmission.
3) Turn the ignition switch to ON and the Subaru Select Monitor power switch ON.
5) Shift the select lever to P or N range.
6) Read the data of turbine speed using Subaru Select Monitor.
Compare the tachometer with Subaru Select
Monitor indications.
CHECK POOR CONTACT.
Is there poor contact in torque Repair the poor
converter turbine speed sensor contact.
circuit?
4AT(D)(diag)-46
Replace the TCM.

<Ref. to 4AT-61,
(TCM).>

E: DTC P0719 TORQUE CONVERTER/BRAKE SWITCH B CIRCUIT LOW

Stop light switch malfunction, open input signal circuit
TROUBLE SYMPTOM:
Gear is not shifted down when climbing a hill.
WIRING DIAGRAM:
BATTERY
B65
SBF-1
1 2
3 4
SBF-2
B54
5 6
14 15 16
25 26 27
33 34 35
No.16
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
STOP LIGHT SWITCH
B65
20
TO STOP LIGHT
B54
TCM
AT-03676
Step
CHECK OPERATION OF BRAKE LIGHT.

Check
Yes
No
Is the fuse (No. 16) blown out? Replace the fuse Go to step 2.
(No. 16). If the
replaced fuse (No.
16) is blown out
easily, repair the
harness between
fuse (No. 16) and
stop light switch.
Does the brake light illuminate? Go to step 3.
Check the brake
light circuit.
4AT(D)(diag)-47

Step
CHECK INPUT SIGNAL FROM TCM.
2) Measure the voltage of the harness
between TCM and stop light switch.
TCM AND STOP LIGHT SWITCH.
2) Disconnect the connectors from the TCM
and stop light switch.
the TCM and stop light switch.
(B54) No. 20 (B65) No. 3:
TCM and chassis ground.
CHECK POOR CONTACT.
Check
Yes
No
Go to step 4.
Repair the open

TCM and the stop
light switch.
more?
Go to step 6.
Repair the short

TCM and the stop
light switch.
Is there poor contact in input

signal circuit of the stop light
switch?
Repair the poor

contact.
Replace the TCM.

<Ref. to 4AT-61,
(TCM).>
4AT(D)(diag)-48

F: DTC P0720 OUTPUT SPEED SENSOR CIRCUIT

The vehicle speed signal is abnormal.
The circuit in combination meter is faulty.
The harness connector between TCM and vehicle speed sensor is shorted or open.
TROUBLE SYMPTOM:
Erroneous idling.
Engine stalls.
Driving performance is poor.
WIRING DIAGRAM:
B11
TCM
3 4
8
6 7
9 10
11 12
14 15
13
16
17 18
19 20
1
27
16
21
B54
T4
18
4 3
8
7
12 11
15
16
20 19
B36
2 1
6
5
10 9
13
14
18 17
i10
i1
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
14
18
B11
T4
B36
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
12
B54
SPEEDOMETER
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
COMBINATION
METER
i10
5 6
14 15 16
25 26 27
33 34 35
FRONT VEHICLE
SPEED SENSOR
AT-03677
4AT(D)(diag)-49

Step
Check
Yes
transmission.
(B54) No. 27 (B11) No. 14:
(B54) No. 16 (B11) No. 18:
more?
Go to step 4.
more?
Go to step 5.
CHECK FRONT VEHICLE SPEED SENSOR. Is the resistance between 450

Measure the resistance between transmission 650 ?
connector receptacles terminals.
(T4) No. 14 No. 18:
4AT(D)(diag)-50
Go to step 6.
No
Repair the open
circuit of harness
between TCM and
Repair the open

circuit of harness
between TCM and
transmission connector, and poor
Repair the short
circuit of harness
between TCM and
Repair the short
TCM and transmission connector,
and poor contact of
connector.
Replace the front
vehicle speed sensor. <Ref. to 4AT51, Front Vehicle
Speed Sensor.>

Step
NOTE:
4) Turn the ignition switch to ON and the Subaru Select Monitor power switch ON.
6) Read the data of vehicle speed using Subaru Select Monitor.
Compare the speedometer with Subaru
Select Monitor indications.
Vehicle speed is indicated in km/h or MPH
7) Slowly increase the vehicle speed to 60 km/
h (37 MPH).
NOTE:
does not indicate a malfunction. When AT control diagnosis is finished, perform the ABS diagnostics clear memory. <Ref. to ABS(diag)-26,
Clear Memory Mode.>
CHECK POOR CONTACT.
Check
Yes
No
Does the speedometer indica- Even if the AT OIL Go to step 7.
tion increase as the Subaru
TEMP warning
Select Monitor data increases? light is blinking, the
to normal condition
harness may be
the cause. Repair
the harness in of
front vehicle speed
sensor circuit.

vehicle speed sensor circuit?
4AT(D)(diag)-51
Repair the poor

contact.
Replace the TCM.

<Ref. to 4AT-61,
(TCM).>

G: DTC P0724 TORQUE CONVERTER/BRAKE SWITCH B CIRCUIT HIGH

Stop light switch malfunction, open input signal circuit
TROUBLE SYMPTOM:
Gear is not shifted down when climbing a hill.
WIRING DIAGRAM:
BATTERY
B65
SBF-1
1 2
3 4
SBF-2
B54
5 6
14 15 16
25 26 27
33 34 35
No.16
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
STOP LIGHT SWITCH
B65
20
TO STOP LIGHT
B54
TCM
AT-03676
1
2
Step
CHECK OPERATION OF BRAKE LIGHT.
CHECK INPUT SIGNAL FROM TCM.
2) Measure the voltage of the harness
between TCM and stop light switch.
Check
The brake light illuminates.
Yes
Go to step 2.
Go to step 5.
4AT(D)(diag)-52
No
Check the brake
light circuit.
Go to step 3.

Step
2) Disconnect the connector from stop light
switch.
stop light switch connectors.
(B65) No. 2 No. 3:
CHECK POOR CONTACT.
Check
more?
Yes
Go to step 4.
No
Replace the stop
light switch. <Ref.
to BR-50, Stop
Light Switch.>
Go to step 5.
Repair the short

circuit of harness
between TCM and
stop light switch.
Is there poor contact in input

signal circuit of the stop light
switch?
Repair the poor

contact.
Replace the TCM.

<Ref. to 4AT-61,
(TCM).>
4AT(D)(diag)-53

H: DTC P0725 ENGINE SPEED INPUT CIRCUIT

Engine speed input signal circuit is open or shorted.
TROUBLE SYMPTOM:
No lock-up occurs. (After engine is warmed-up)
AT OIL TEMP warning light remains on when the vehicle speed is 0.
WIRING DIAGRAM:
B55
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
24 25
26 27
20 21 22 23
28 29 30 31
32 33
34 35
B55
11
TCM
B136
5 6
14 15 16
25 26 27
33 34 35
22
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B136
ECM
AT-03678
Step
Check
Yes
TCM AND ECM.
ECM.
TCM and ECM.
(B55) No. 11 (B136) No. 22:
4AT(D)(diag)-54
No
Repair the open
circuit of harness
between TCM and
ECM connector.

Step
TCM AND ECM.
1) Connect the connectors to TCM and ECM.
3) Start the engine, and run the Subaru Select
Monitor.
4) Run the engine at idle.
5) Read the data of engine speed using Subaru Select Monitor.
Display shows engine speed signal value
sent from ECM.
CHECK POOR CONTACT.
CONFIRM DTC P0725.

Replace the ECM with a new part.
Check
more?
Is the revolution value almost

same as the tachometer reading shown on the combination
meter?
Yes
Go to step 3.
Even if the AT OIL

TEMP warning
to normal condition
harness may be
the cause. Repair
the harness or
connector in the
TCM and ECM.
Is there poor contact in engine Repair the poor
speed signal circuit?
contact.
Does the DTC appear again,
Replace the TCM.
after the memory has been
<Ref. to 4AT-61,
Transmission Concleared?
trol Module
(TCM).>
4AT(D)(diag)-55
No
Repair the short
circuit of harness
between TCM and
ECM connector.
Go to step 4.
Go to step 5.
Replace the ECM.
<Ref. to
FU(H4SO)-40,
Engine Control
Module (ECM).>

I:
DTC P0731 GEAR 1 INCORRECT RATIO
NOTE:
Refer to DTC P0736 for diagnostic procedure. <Ref. to 4AT(D)(diag)-57, DTC P0736 REVERSE INCORRECT RATIO, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
J: DTC P0732 GEAR 2 INCORRECT RATIO

NOTE:
K: DTC P0733 GEAR 3 INCORRECT RATIO

NOTE:
L: DTC P0734 GEAR 4 INCORRECT RATIO

NOTE:
4AT(D)(diag)-56

M: DTC P0736 REVERSE INCORRECT RATIO

Vehicle sensor, torque converter turbine speed sensor or control valve malfunction
TROUBLE SYMPTOM:
Shift point is too high or too low.
Tight corner braking phenomenon occurs.
Gear is not shifted to reverse.
Gear position is held by fail safe function.
1
Step
CHECK ACCELERATOR PEDAL POSITION
SENSOR.
3) Read the value of accelerator pedal position
sensor on Subaru Select Monitor display.
CHECK FRONT VEHICLE SPEED SENSOR.
1) Lift up the vehicle and support with rigid
racks.
3) Shift the select lever to D range and slowly
increase vehicle speed.
NOTE:
indicates no malfunction. When AT control diagnosis is finished, perform the ABS clear
memory of on-board diagnostics system. <Ref.
to ABS(diag)-26, Clear Memory Mode.>
SPEED SENSOR.
1) Move the select lever to P or N range.
2) Idle the engine.
Check
Does the value of accelerator
pedal position sensor change
from 0% to 100% smoothly
when throttle is operated from
fully closed to fully open?
Yes
Go to step 2.
No
Check the accelerator pedal position
sensor circuit.
Does the vehicle speed disGo to step 3.

played by Subaru Select Monitor roughly correspond with
vehicle speed indicated by the
combination meter?
Check the front

vehicle speed sensor circuit.
Does the value of torque converter turbine speed sensor displayed by Subaru Select
Monitor roughly correspond
with the value of tachometer in
combination meter?
Check the torque

converter turbine
speed sensor circuit.
4AT(D)(diag)-57
There are malfunctions in TCM, TCM

connector poor
contact, or transmission assembly
mechanical malfunction.

N: DTC P0741 TORQUE CONVERTER CLUTCH CIRCUIT PERFORMANCE OR

STUCK OFF
Lock up clutch malfunction
Sticky valve
TROUBLE SYMPTOM:
No lock-up occurs.
1
Step
Check
CHECK LOCK-UP DUTY SOLENOID CIRIs there any trouble?
CUIT.
Diagnose according to DTC P0743 procedure.
CHECK INHIBITOR SWITCH CIRCUIT.
Is there any trouble?
Diagnose according to DTC P0705 procedure.
CHECK STOP LIGHT SWITCH CIRCUIT.
Diagnose according to DTC P0719 and P0724
procedures.
CHECK ATF TEMPERATURE SENSOR CIRCUIT.
Diagnose according to DTC P0712 AND P0713
procedure.
CHECK ACCELERATOR PEDAL POSITION
SENSOR.
3) Read the value of accelerator pedal position
sensor on Subaru Select Monitor display.
SPEED SENSOR.
1) Move the select lever to P or N range.
2) Idle the engine.
CHECK ENGINE SPEED SIGNAL.
Idle the engine.
Yes
Repair or replace
the lock up duty
solenoid circuit.
Repair or replace
the inhibitor switch
circuit.
Repair or replace
the stop light
switch circuit.
Repair or replace
the ATF temperature sensor circuit.
Does the value of accelerator

pedal position sensor change
from 0% to 100% smoothly
when throttle is operated from
fully closed to fully open?
Go to step 6.
Does the value of turbine speed

displayed by Subaru Select
Monitor almost correspond with
the value of the tachometer?
Does the value of turbine speed
displayed by Subaru Select
Monitor almost correspond with
the value of tachometer?
Go to step 7.
4AT(D)(diag)-58
No
Go to step 2.
Go to step 3.
Go to step 4.
Go to step 5.
Check the accelerator pedal position

sensor circuit.
Check the torque

converter turbine
speed sensor circuit.
There is transmis- Check the engine
speed signal cirsion assembly
cuit.
mechanical malfunction.

O: DTC P0743 TORQUE CONVERTER CLUTCH CIRCUIT ELECTRICAL

Output signal circuit of lock-up duty solenoid is open or shorted.
TROUBLE SYMPTOM:
No lock-up occurs. (After engine is warmed-up)
WIRING DIAGRAM:
AT12
1 2 3
4 5 6
TCM
B11
B54
3 4
8
6 7
9 10
11 12
14 15
13
16
17 18
19 20
1
12
B11
T4
T4
4 3
8
7
12 11
15
16
20 19
2 1
6
5
10 9
13
14
18 17
AT12
B54
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
LOCK-UP
DUTY
SOLENOID
5 6
14 15 16
25 26 27
33 34 35
TRANSMISSION
AT-03679
Step
Check
4AT(D)(diag)-59
Yes
No
Perform the diag- Go to step 2.
nosis according to
DTC.

Step
transmission.
(B54) No. 6 (B11) No. 12:
Measure the resistance of the harness connector between TCM connector and chassis
ground.
CHECK LOCK-UP DUTY SOLENOID.
(T4) No. 12 No. 19:
CHECK OUTPUT SIGNAL FROM TCM USING SUBARU SELECT MONITOR.
NOTE:
Monitor.
5) Start the engine and warm-up the engine
until the ATF temperature exceeds 80C
(176F).
NOTE:
6) Read the data of lock-up duty solenoid
using the Subaru Select Monitor.
Lock-up duty solenoid is indicated in %.
7) Shift the select lever to D, and slowly
increase vehicle speed to 60 km/h (37 MPH).
NOTE:
Clear Memory Mode.>
Check
Yes
No
Repair the open
circuit of harness
between TCM and
more?
Go to step 4.
Repair the short

circuit of harness
between TCM and

4.5 ?
Go to step 5.
Go to step 8.
Is the measured value 95%?
Go to step 6.
Go to step 7.
4AT(D)(diag)-60

Step
Return the engine to idling speed, shift the
select lever to N range and read the data.
Check
Yes
No
TEMP warning
to normal condition
harness may be
the cause. Repair
the harness or
connector in TCM
and transmission.
Is there poor contact in lock-up Repair the poor
Replace the TCM.
duty solenoid circuit?
contact.
<Ref. to 4AT-61,
(TCM).>
Is the resistance between 2.0 Go to step 9.
Replace the con 4.5 ?
trol valve body.
<Ref. to 4AT-56,
Control Valve
Body.>
CHECK POOR CONTACT.
CHECK LOCK-UP DUTY SOLENOID (IN

TRANSMISSION).
1) Disconnect the transmission connector.
CAUTION:
connector from lock-up duty solenoid.
4) Measure the resistance between lock-up
duty solenoid and transmission ground.
(AT12) No. 4 Transmission ground:
CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 ?
LOCK-UP DUTY SOLENOID AND TRANSMISSION.
lock-up duty solenoid and transmission connector.
(T4) No. 12 (AT12) No. 4:
CHECK HARNESS CONNECTOR BETWEEN Is the resistance 1 M or
LOCK-UP DUTY SOLENOID AND TRANSmore?
MISSION.
ground.
10
4AT(D)(diag)-61
Go to step 10.
Repair the open

circuit of harness
between TCM and
Even if the AT OIL

TEMP warning
to normal condition
harness may be
the cause. Repair
the harness or
connector in lockup duty solenoid
and transmission.
Repair the short

circuit of harness
between lock-up
duty solenoid and

P: DTC P0748 PRESSURE CONTROL SOLENOID A ELECTRICAL

Output signal circuit of line pressure linear solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
TCM
4
3
B54
1
2
B11
2
4
T4
AT11
LINE
PRESSURE
LINEAR
SOLENOID
TRANSMISSION
AT11
1 2
3 4
B11
3 4
8
6 7
9 10
11 12
14 15
13
16
17 18
19 20
1
T4
4 3
8
7
12 11
15
16
20 19
B54
2 1
6
5
10 9
13
14
18 17
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
AT-03680
Step
2) Disconnect the connector from transmission
and TCM.
(B54) No. 3 (B11) No. 2:
(B54) No. 4 (B11) No. 1:
TCM AND CHASSIS GROUND.
CHECK LINE PRESSURE LINEAR SOLENOID.
(T4) No. 1 No. 2:
Check
Yes
No
Repair the open
circuit of harness
between TCM and
more?
Repair the short

circuit of harness
between TCM and
Go to step 3.

6 ?
4AT(D)(diag)-62
Go to step 5.

Step
CHECK POOR CONTACT.
Check
Is there poor contact in line
pressure linear solenoid circuit?
Yes
Repair the poor
contact.
CHECK LINE PRESSURE LINEAR SOLENOID (IN TRANSMISSION).

bracket.
CAUTION:
connector from line pressure linear solenoid.
4) Measure the resistance between line pressure linear solenoid connector and transmission ground.
(AT11) No. 2 No. 4:
TRANSMISSION AND LINE PRESSURE LINEAR SOLENOID.
line pressure linear solenoid and transmission
connector.
(T4) No. 1 (AT11) No. 2:
(T4) No. 2 (AT11) No. 4:
TRANSMISSION AND LINE PRESSURE LINEAR SOLENOID.
ground.

8 ?
No
Replace the TCM.
<Ref. to 4AT-61,
(TCM).>
<Ref. to 4AT-56,
Control Valve
Body.>
Repair the open

circuit of harness
between line pressure linear solenoid and
more?
Repair the short

circuit of harness
between line pressure linear solenoid and
4AT(D)(diag)-63
Even if the AT OIL

TEMP warning
to normal condition
harness may be
the cause. Repair
the harness or
connector in line
pressure linear
solenoid and transmission.

Q: DTC P0753 SHIFT SOLENOID A ELECTRICAL

Output signal circuit of low clutch duty solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
AT12
1 2 3
4 5 6
TCM
B11
B55
3 4
8
6 7
9 10
11 12
14 15
13
16
17 18
19 20
1
B11
T4
T4
4 3
8
7
12 11
15
16
20 19
2 1
6
5
10 9
13
14
18 17
AT12
B55
LOCK-UP
DUTY
SOLENOID
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
TRANSMISSION
AT-03681
Step
Check
Yes
transmission.
(B55) No. 7 (B11) No. 4:
4AT(D)(diag)-64
No
Repair the open
circuit of harness
between TCM and

Step
TCM connector and transmission ground.
CHECK LOW CLUTCH DUTY SOLENOID.
(T4) No. 4 No. 20:
Monitor.
temperature reaches approximately 80C
(176F).
NOTE:
If the ambient temperature falls below 0C
(32F), drive the vehicle until the ATF reaches
its operating temperature.
5) Stop the engine and turn the ignition switch
to ON. (engine OFF)
6) Shift the select lever to P or N range.
7) Read the data of low clutch duty solenoid
Low clutch duty solenoid is indicated in %.
3) Read the data of low clutch duty solenoid.
CHECK POOR CONTACT.
Check
more?
Yes
Go to step 3.
No
Repair the short
circuit of harness
between TCM and

4.5 ?
Go to step 5.
Go to step 4.
Go to step 5.
Go to step 7.

TEMP warning
to normal condition
harness may be
the cause. Repair
the harness or
connector in transmission.
Repair the poor
Replace the TCM.
contact.
<Ref. to 4AT-61,
(TCM).>
Is there poor contact in low

clutch duty solenoid circuit?
4AT(D)(diag)-65

Step
CHECK LOW CLUTCH DUTY SOLENOID (IN
TRANSMISSION).
bracket.
CAUTION:
connector from low clutch duty solenoid.
4) Measure the resistance between low clutch
duty solenoid connector and transmission
ground.
TRANSMISSION AND LOW CLUTCH DUTY
SOLENOID.
Measure the resistance of harness between low
clutch duty solenoid and transmission connector.
(T4) No. 4 (AT12) No. 2:
TRANSMISSION AND LOW CLUTCH DUTY
SOLENOID.
ground.
Check
4.5 ?
Yes
Go to step 8.
No
<Ref. to 4AT-56,
Control Valve
Body.>
Repair the open

circuit of harness
between low clutch
duty solenoid and
more?
Repair the short

circuit of harness
between low clutch
duty solenoid and
4AT(D)(diag)-66
Even if the AT OIL

TEMP warning
to normal condition
harness may be
the cause. Repair
the harness or
connector of the
low clutch duty

R: DTC P0758 SHIFT SOLENOID B ELECTRICAL

Output signal circuit of 2-4 brake duty solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
TCM
B55
B11
T4
AT12
2-4 BRAKE
DUTY
SOLENOID
TRANSMISSION
AT12
1 2 3
4 5 6
T4
B11
3 4
8
6 7
9 10
11 12
14 15
13
16
17 18
19 20
1
4 3
8
7
12 11
15
16
20 19
2 1
6
5
10 9
13
14
18 17
B55
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
AT-03682
Step
transmission.
(B55) No. 4 (B11) No. 3:
TCM connector and transmission ground.
CHECK 2-4 BRAKE DUTY SOLENOID.
(T4) No. 3 No. 20:
Check
Yes
No
Repair the open
circuit of harness
between TCM and
more?
Go to step 3.
Repair the short

circuit of harness
between TCM and

4.5 ?
Go to step 4.
Go to step 7.
4AT(D)(diag)-67

Step
Check
CHECK OUTPUT SIGNAL FROM TCM USIs the measured value 100%?
ING SUBARU SELECT MONITOR.
Monitor.
(176F).
NOTE:
to ON. (engine OFF)
6) Shift the select lever to N range.
7) While depressing the accelerator pedal,
read the data of 2-4 brake duty solenoid using
2-4 brake duty solenoid is indicated in %.
Shift the select lever to 2 range.
CHECK POOR CONTACT.
Is there poor contact in 2-4

brake duty solenoid circuit?
CHECK 2-4 BRAKE DUTY SOLENOID (IN

TRANSMISSION).
4.5 ?
bracket.
CAUTION:
connector from 2-4 brake duty solenoid.
2-4 brake duty solenoid connector and transmission ground.
4AT(D)(diag)-68
Yes
Go to step 5.
No
Go to step 6.

TEMP warning
to normal condition
harness may be
the cause. Repair
the harness or
connector in TCM
and transmission.
Repair the poor
Replace the TCM.
contact.
<Ref. to 4AT-61,
(TCM).>
Go to step 8.
<Ref. to 4AT-56,
Control Valve
Body.>

Step
Check
2-4 BRAKE DUTY SOLENOID AND TRANSMISSION.
Measure the resistance of harness between 2-4
brake duty solenoid and transmission connector.
(T4) No. 3 (AT12) No. 6:
2-4 BRAKE DUTY SOLENOID AND TRANS- more?
MISSION.
ground.
4AT(D)(diag)-69
Yes
Go to step 9.
No
Repair the open
circuit of harness
between 2-4 brake
duty solenoid and
Even if the AT OIL

TEMP warning
to normal condition
harness may be
the cause. Repair
the harness or
connector in 2-4
brake duty solenoid and transmission.
Repair the short

circuit of harness
between 2-4 brake
duty solenoid and

S: DTC P0763 SHIFT SOLENOID C ELECTRICAL

Output signal circuit of high clutch duty solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
AT12
1 2 3
4 5 6
TCM
B11
B55
3 4
8
6 7
9 10
11 12
14 15
13
16
17 18
19 20
1
B11
T4
T4
4 3
8
7
12 11
15
16
20 19
2 1
6
5
10 9
13
14
18 17
AT12
B55
HIGH
CLUTCH
DUTY
SOLENOID
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
32 33
34 35
28 29 30 31
TRANSMISSION
AT-03683
Step
Check
Yes
transmission.
(B55) No. 6 (B11) No. 7:
4AT(D)(diag)-70
No
Repair the open
circuit of harness
between TCM and

Step
Measure the resistance of the harness connector between TCM connector and chassis
ground.
CHECK HIGH CLUTCH DUTY SOLENOID.
(T4) No. 7 No. 20:
NOTE:
Monitor.
5) Start the engine and warm-up the engine
until the ATF temperature exceeds 80C
(176F).
NOTE:
6) Read the data of high clutch duty solenoid
High clutch duty solenoid is indicated in %.
7) Shift the select lever to D, and slowly
increase vehicle speed to measure at 3rd or
4th.
NOTE:
Clear Memory Mode.>
Return the engine to idling speed and shift the
select lever to N range.
NOTE:
does not indicate a malfunction. When AT control diagnosis is finished, perform the ABS diagnostics clear memory mode. <Ref. to
ABS(diag)-26, Clear Memory Mode.>
Check
more?
Yes
Go to step 3.
No
Repair the short
circuit of harness
between TCM and

4.5 ?
Go to step 4.
Go to step 7.
Go to step 5.
Go to step 6.

TEMP warning
to normal condition
harness may be
the cause. Repair
the harness or
connector in TCM
and transmission.
4AT(D)(diag)-71

Step
CHECK POOR CONTACT.
Check
Is there poor contact in high
clutch duty solenoid circuit?
Yes
Repair the poor
contact.
CHECK HIGH CLUTCH DUTY SOLENOID (IN

TRANSMISSION).
bracket.
CAUTION:
connector from high clutch duty solenoid.
4) Measure the resistance between high clutch
ground.
HIGH CLUTCH DUTY SOLENOID AND
TRANSMISSION.
high clutch duty solenoid and transmission connector.
(T4) No. 7 (AT12) No. 3:
HIGH CLUTCH DUTY SOLENOID AND
TRANSMISSION.
ground.

4.5 ?
Go to step 8.
No
Replace the TCM.
<Ref. to 4AT-61,
(TCM).>
<Ref. to 4AT-56,
Control Valve
Body.>
Repair the open

circuit of harness
between TCM and
more?
Repair the short

circuit of harness
between high
clutch duty solenoid and transmission connector.
4AT(D)(diag)-72
Even if the AT OIL

TEMP warning
to normal condition
harness may be
the cause. Repair
the harness or
connector in high
clutch duty solenoid and transmission.

T: DTC P0768 SHIFT SOLENOID D ELECTRICAL

The output signal circuit of low & reverse duty solenoid is open or shorted.
TROUBLE SYMPTOM:
Gear is not changed.
WIRING DIAGRAM:
TCM
B55
B11
T4
AT12
LOW &
REVERSE
BRAKE
DUTY
SOLENOID
TRANSMISSION
AT12
1 2 3
4 5 6
T4
B11
3 4
8
6 7
9 10
11 12
14 15
13
16
17 18
19 20
1
4 3
8
7
12 11
15
16
20 19
2 1
6
5
10 9
13
14
18 17
B55
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
32 33
34 35
28 29 30 31
AT-03684
Step
2) Disconnect the connector from transmission
and TCM.
(B55) No. 5 (B11) No. 6:
TCM AND CHASSIS GROUND.
CHECK LOW & REVERSE BRAKE DUTY SOLENOID.
(T4) No. 6 No. 20:
Check
Yes
No
Repair the open
circuit of harness
between TCM and
more?
Go to step 3.
Repair the short

circuit of harness
between TCM and

4.5 ?
Go to step 4.
Go to step 7.
4AT(D)(diag)-73

Step
Check
Monitor.
(176F).
NOTE:
to ON. (engine OFF)
6) Move the select lever to N.
7) Read the data of low & reverse brake duty
solenoid using Subaru Select Monitor.
Low & reverse brake duty solenoid is indicated in %.
1) Lift up the vehicle and support with rigid
racks.
NOTE:
2) Shift the select lever to 1 range. Slowly
increase the vehicle speed up to 15 km/h (9
MPH), and then return the accelerator pedal.
NOTE:
does not indicate a malfunction. When AT control diagnosis is finished, perform the ABS diagnostics clear memory procedure. <Ref. to
ABS(diag)-26, Clear Memory Mode.>
3) Read the data of the low & reverse duty
solenoid.
CHECK POOR CONTACT.
Is there poor contact in the low
& reverse duty solenoid circuit?
CHECK LOW & REVERSE BRAKE DUTY SO- Is the resistance between 2.0
LENOID (IN TRANSMISSION).
4.5 ?
bracket.
CAUTION:
connector from low & reverse brake duty solenoid.
4) Measure the resistance between low &
reverse brake duty solenoid connector and
transmission ground.
4AT(D)(diag)-74
Yes
Go to step 5.
No
Go to step 6.

TEMP warning
to normal condition
harness may be
the cause. Repair
the harness or
connector in TCM
and transmission.
Repair the poor

contact.
Go to step 8.
Replace the TCM.

<Ref. to 4AT-61,
(TCM).>
<Ref. to 4AT-56,
Control Valve
Body.>

Step
Check
TRANSMISSION AND LOW & REVERSE
BRAKE DUTY SOLENOID.
Measure the resistance of harness between low
& reverse duty solenoid and transmission connector.
(T4) No. 6 (AT12) No. 1:
TRANSMISSION AND LOW & REVERSE
more?
BRAKE DUTY SOLENOID.
ground.
4AT(D)(diag)-75
Yes
Go to step 9.
No
Repair open circuit
of harness
between low &
reverse brake duty
solenoid and transmission connector.
Even if the AT OIL

TEMP warning
to normal condition
harness may be
the cause. Repair
harness or connector in low &
reverse brake duty
Repair the short

low & reverse
brake duty solenoid and the transmission connector.

U: DTC P0801 REVERSE INHIBIT CONTROL CIRCUIT

Shift lock solenoid malfunction, open or short reverse inhibitor control circuit
TROUBLE SYMPTOM:
Gear is shifted from N range to P range during driving at 20 km/h (12 MPH) or more.
Gear cannot be shifted from N range to R range.
WIRING DIAGRAM:
B117
2
1
3 4 5 6
B55
TCM
B55
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
TO BODY INTEGRATED UNIT
SHIFT LOCK
SOLENOID
B117
4
5
AT-03685
Step
Check
Yes
TCM AND SHIFT LOCK SOLENOID.
TCM and shift lock solenoid connector.
(B55) No. 3 (B117) No. 4:
4AT(D)(diag)-76
No
Repair the open
circuit of harness
between TCM and
shift lock solenoid
connector.

Step
TCM AND SHIFT LOCK SOLENOID.
SOLENOID AND CHASSIS GROUND TERMINAL.
Measure the resistance of shift lock solenoid
terminals.
(B117) No. 5 No. 4:
Check
more?
Yes
Go to step 3.
No
Repair the short
circuit of harness
between TCM and
shift lock solenoid
connector.
Repair the open

circuit of harness
between chassis
ground and shift
lock solenoid connector.

18 ?
Replace the shift

lock solenoid.
<Ref. to CS-28, AT
Shift Lock Solenoid
and P Range
Switch.>
Go to step 7.

chassis ground.
NOTE:
3) Shift the select lever to D range and slowly
increase vehicle speed to 20 km/h (12 MPH).
NOTE:
Clear Memory Mode.>
chassis ground.
CHECK POOR CONTACT.
reverse inhibitor control circuit?
4AT(D)(diag)-77
Go to step 6.

TEMP warning
to normal condition
harness may be
the cause. Repair
the harness or
connector in the
reverse inhibitor
control circuit.
Repair the poor

contact.
Replace the TCM.

<Ref. to 4AT-61,
(TCM).>

V: DTC P1706 AT VEHICLE SPEED SENSOR CIRCUIT MALFUNCTION (REAR

WHEEL)
TROUBLE SYMPTOM:
No lock up or tight corner braking.
WIRING DIAGRAM:
SBF-1
BATTERY
SBF-4
B54
No.11
15
26
IGNITION
SWITCH
TCM
9
17
13
B11
3
1
2
T4
AT13
REAR VEHICLE
SPEED SENSOR
AT13
B11
1 2 3
3 4
8
6 7
5
9 10
11 12
14 15
13
16
17 18
19 20
1
B54
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
AT-03686
4AT(D)(diag)-78

Step
Check
Yes
Go to step 2.
CUIT.
2) Disconnect the connector from rear vehicle
speed sensor.
between rear vehicle speed sensor connector
and transmission ground.
(AT13) No. 3 (+) Transmission ground
():
(B54) No. 15 (AT13) No. 1:
(B54) No. 26 (AT13) No. 2:
NOTE:
3) Start the engine and set vehicle in 20 km/h
(12 MPH) condition.
NOTE:
Clear Memory Mode.>
4) Measure the AC voltage between TCM connector terminals.
(B54) No. 26 (+) No. 15 ():
No
Check harness
between rear vehicle speed sensor
and battery for
open circuit, short
or poor contact.
Repair the harness
if required.
Repair the open

circuit or poor contact of the connector in harness
between TCM and
rear vehicle speed
sensor connector.
Repair the open
circuit or poor contact of the connector in harness
between TCM and
rear vehicle speed
sensor connector.
Repair the short
circuit of harness
between TCM and
rear vehicle speed
sensor connector.
more?
Go to step 5.
more?
Go to step 6.
Repair the short

circuit of harness
between TCM and
rear vehicle speed
sensor connector.
Is the voltage approx. 2 V or

more?
Go to step 7.
Replace the rear

vehicle speed sensor. <Ref. to 4AT54, Rear Vehicle
Speed Sensor.>
4AT(D)(diag)-79

Step
CHECK POOR CONTACT.
Check
Is there poor contact in rear
vehicle speed sensor circuit?
4AT(D)(diag)-80
Yes
Repair the poor
contact.
No
Replace the TCM.
<Ref. to 4AT-61,
(TCM).>

W: DTC P1707 AT AWD SOLENOID VALVE MALFUNCTION

Output signal circuit of transfer duty solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
AT12
1 2 3
4 5 6
TCM
B54
B11
3 4
8
6 7
9 10
11 12
14 15
13
16
17 18
19 20
1
B11
T4
T4
4 3
8
7
12 11
15
16
20 19
2 1
6
5
10 9
13
14
18 17
AT12
B54
TRANSFER
DUTY
SOLENOID
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
TRANSMISSION
AT-03687
Step
Check
Yes
transmission.
(B54) No. 5 (B11) No. 8:
4AT(D)(diag)-81
No
Repair the open
circuit of harness
between TCM and

Step
between TCM and chassis ground.
CHECK TRANSFER DUTY SOLENOID.
connector and transmission terminals.
(T4) No. 8 No. 20:
3) Turn the ignition switch to ON (engine OFF),
and run the Subaru Select Monitor.
4) Shift the select lever to the N range, and
fully close the throttle pedal. (Vehicle speed is 0
km/h (0 MPH))
5) Read the data of transfer duty solenoid
Transfer duty solenoid is indicated in %.
2) Read the data of transfer duty solenoid
Transfer duty solenoid is indicated in %.
Check
more?
Yes
Go to step 3.
No
Repair the short
circuit of harness
between TCM and

4.5 ?
Go to step 4.
Go to step 7.
Go to step 5.
Go to step 8.
Is the measured value approxi- Even if the AT OIL Go to step 6.

mately 18 to 35%?
TEMP warning
to normal condition
harness may be
the cause. Repair
the harness or
connector in TCM
and transmission.
CHECK POOR CONTACT.
Is there poor contact in transfer Repair the poor
Replace the TCM.
duty solenoid circuit?
contact.
<Ref. to 4AT-61,
(TCM).>
CHECK TRANSFER DUTY SOLENOID (IN
Replace the conTRANSMISSION).
4.5 ?
trol valve body.
<Ref. to 4AT-56,
Control Valve
NOTE:
Body.>
CAUTION:
3) Remove the extension case, and disconnect the connector from transfer duty solenoid.
4) Measure the resistance between transfer
ground.
4AT(D)(diag)-82

Step
Check
TRANSFER DUTY SOLENOID AND TRANSMISSION.
transfer duty solenoid and transmission connector.
(T4) No. 8 (AT12) No. 5:
TRANSFER DUTY SOLENOID AND TRANS- more?
MISSION.
ground.
4AT(D)(diag)-83
Yes
Go to step 9.
No
Repair the open
circuit of harness
between transfer
duty solenoid and
Even if the AT OIL

TEMP warning
light turns on, the
to normal condition
harness may be
the cause. Repair
the harness or
poor contact in the
transfer duty solenoid and transmission.
Repair short circuit of the harness

between the transfer duty solenoid
and transmission
connector.

X: DTC P1718 CAN COMMUNICATION CIRCUIT

WIRING DIAGRAM:
Model without VDC
B301
B136 ECM
B40
1 2 3 4 5 6 7 8
26
11
27
35
ABSCM
9 10 11 12 13 14 15 16
B54
B136
1 2 3 4
5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30
31 32 33 34 35
TWISTED PAIR LINE
B301
B54
TCM
14
18
17
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
B40
DATA
LINK
CONNECTOR
AT-03707
4AT(D)(diag)-84

Model with VDC
81
83
14
B310
VDC
CONTROL
MODULE
11
B301
ABS
CONTROL
MODULE
26
ECM
27
35
B136
B54
18
17
TWISTED PAIR LINE
DATA LINK
CONNECTOR
TCM
9 10 11 12 13 14 15 16
12 13 14 15
1 2 3 4 5 6 7 8 8 10 11
16 17 18 19 20 21 22 23 24 25 26
B310
1
B54
B301
B40
1 2 3 4 5 6 7 8
B40
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
2
4
6
8
14
16
18
20
22
24
26
28
12
10
11
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
71
73
77
79 80 81 82 83
75
68
56 57 58 59 60 61 62 63 64 65 66
70
72
74
76
78
67
69
AT-04226
Step
Check
Yes
TCM AND VDCCM OR ABSCM&H/U.
2) Disconnect the connector from TCM, ECM,
VDCCM or ABSCM&H/U.
between TCM, VDCM or ABSCM&H/U connector.
Model with VDC
(B54) No. 17 (B310) No. 81:
Model without VDC
(B54) No. 17 (B301) No. 11:
4AT(D)(diag)-85
No
Repair open circuit
of the harness
between the TCM
and the VDCCM,
or the poor contact
in the connector.

Step
TCM AND VDCCM OR ABSCM&H/U.
TCM and VDCCM or ABSCM&H/U connector.
Model with VDC
(B54) No. 18 (B310) No. 83:
Model without VDC
(B54) No. 18 (B301) No. 26:
TCM AND ECM.
ECM.
TCM and ECM connector.
(B54) No. 17 (B136) No. 35:
TCM AND ECM.
TCM and ECM connector.
(B54) No. 18 (B136) No. 27:
TCM, ECM AND VDCCM OR ABSCM&H/U.
Check
Yes
No
Repair open circuit
of the harness
between the TCM
and the VDCCM,
or the poor contact
in the connector.
Repair open circuit

of the harness
between the TCM
and the ECM, or
the poor contact in
the connector.
Repair open circuit

of the harness
between the TCM
and the ECM, or
the poor contact in
the connector.
Repair the short
TCM, ECM and
VDCCM or
ABSCM&H/U.
more?
4AT(D)(diag)-86
It is possible that
the TCM, ECM,
VDCCM or
ABSCM&H/U are
defected (replace
and recheck).
Diagnostic Procedure without Diagnostic Trouble Code (DTC)

14.Diagnostic Procedure without Diagnostic Trouble Code (DTC)

A: CHECK FWD SWITCH
DIAGNOSIS:
LED does not come on even if FWD switch is ON.
FWD signal circuit is open or shorted.
WIRING DIAGRAM:
i11
BATTERY
SBF-4
1 2 3 4 5 6 7 8 9 10
SBF-1
F2
IGNITION
SWITCH
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
B36
COMBINATION METER
FWD SWITCH
No.14
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
i10
AWD
36
35
B: i10
B9
C4
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
F27
C: i11
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
i1
B38
F2
B55
i3
B36
B100
13
10
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
F27
B55
TCM
5 6 7 10 15 16 17 20 25 26 27 30
35
8
11
18
21
28
31
9 12 13 14 19 22 23 24 29 32 33 34 36
AT-03689
Step
Check
Yes
No
CHECK FWD SWITCH.
When the fuse is inserted to
Go to step CHECK Go to step 2.
Connect the Subaru Select Monitor to data link FWD switch, does the LED illu- SYMPTOM
connector, and then check the LED screen.
minate?
RELATED DIAGNOSTIC. <Ref. to
4AT(D)(diag)-90,
INSPECTION,
General Diagnostic Table.>
4AT(D)(diag)-87

Step
CHECK AWD INDICATOR LIGHT.
2) Disconnect the ECM and TCM connector.
4) Short between the combination meter connector and chassis ground.
CAUTION:
When shorting, be sure to short through the
fuse.
TCM AND FWD SWITCH.
2) Disconnect the connector from the TCM
and FWD switches.
TCM and FWD switch connector.
(B55) No. 10 (F27) No. 36:
FWD SWITCH AND CHASSIS GROUND.
FWD switch and chassis ground.
TCM AND FWD SWITCH.
between TCM and body to make sure that circuit does not short.
2) Connect the connector to TCM and FWD
switch.
4) Measure the signal voltage for TCM while
installing the fuse to FWD switch connector.
Measure the signal voltage for TCM with the
fuse removed from FWD switch connector.
combination meter.
between TCM and the combination meter connector.
(B55) No. 13 (i11) No. 4:
Check
Does the AWD indicator light
illuminate?
Yes
Go to step 3.
No
<Ref. to IDI-10,
Combination
Meter.>
Repair the open

circuit of harness
between TCM and
FWD switch connectors.
Repair the open

circuit of harness
between FWD
switch connector
and chassis
ground.
Repair the short
circuit of harness
between TCM and
FWD switch connectors.
more?
Go to step 6.
Go to step 7.
4AT(D)(diag)-88
Go to step 11.
Replace the TCM.

<Ref. to 4AT-61,
(TCM).>
Repair the open
circuit of harness
between TCM and
combination meter,
and the poor contact of the connector.

10
11
12
Step
Measure the resistance of the harness connector between TCM and chassis ground to make
sure that circuit is not shorted.
2) Connect the connector to TCM and combination meter.
4) Measure the signal voltage for TCM while
installing and removing the fuse to FWD switch
connector.
Measure the signal voltage for TCM with the
fuse removed from FWD switch connector.
CHECK POOR CONTACT.
Check
more?
Yes
Go to step 10.
No
Repair short circuit of harness
between TCM and
combination meter
connector.
Go to step 11.
Go to step 12.
Is there poor contact in FWD

switch circuit?
4AT(D)(diag)-89
Repair the poor

contact.
Replace the TCM.

<Ref. to 4AT-61,
(TCM).>
Replace the TCM.
<Ref. to 4AT-61,
(TCM).>


A: INSPECTION
Symptoms
Problem parts
Starter does not operate when select lever is in P or N

range. Starter rotates when select lever is in R, D, 3 or 2
range.
Abnormal noise when select lever is in P or N.
Inhibitor switch
Select cable
Select lever
Starter motor and harness
Strainer
Oil pump
Drive plate
ATF level too high or too low
Strainer
ATF level too high or too low
Hissing noise occurs during standing start.

Noise occurs while driving in D1.
Engine stalls while shifting from 1 range to another.
Vehicle moves when select lever is in N range.
Final gear
Planetary gear
Reduction gear
Differential gear oil level too high or too low
Final gear
Low & reverse brake
Reduction gear
Final gear
Low & reverse brake
Planetary gear
Reduction gear
Control valve
Lock-up damper
Engine performance
Input shaft
Select cable
Inhibitor switch
TCM
Low clutch
Shock occurs when select lever is shifted from N to D range.

Line pressure duty solenoid
Low clutch
TCM
Harness
Control valve
ATF deterioration
Excessive time lag occurs when select lever is shifted from N

to D range.
Control valve
Low clutch
Seal ring
Front gasket of transmission case
Shock occurs when the select lever is moved from N to R

range.

TCM
Harness
Control valve
ATF deterioration
4AT(D)(diag)-90

Symptoms
Problem parts
Excessive time lag occurs when the select lever is moved from
N to R range.
Vehicle does not start in any shift range. (Engine stalls)
Parking brake mechanism

Planetary gear
Vehicle does not start in any shift range. (Engine operates)
Vehicle does not start in R range only. (Engine operates)
Vehicle does not start in R range only. (Engine stalls)

Vehicle does not start in only when in the D, 3 range.
(Engine operates)
Control valve
Low & reverse clutch
Reverse clutch
Seal ring
Strainer
Control valve
Drive pinion
Hypoid gear
Axle shaft
Differential gear
Oil pump
Input shaft
Output shaft
Planetary gear
Drive plate
ATF level is too low
Select cable
Select lever
Control valve
Reverse clutch
Low clutch
2-4 brake
Planetary gear
Parking brake mechanism
Low clutch
One-way clutch
Vehicle does not start in only in the D, 3 or 2 range.

(Engine operates)
Low clutch
Vehicle does not start in only in the D, 3 or 2 range.

(Engine stalls)
Reverse clutch
Vehicle does not start in R range only. (Engine operates)
Acceleration during standing start is poor. (High rpm stall)
Control valve
Control valve
Low clutch
Reverse clutch
ATF level is too low
ATF deterioration
Acceleration during standing start is poor. (Low rpm stall)
Oil pump
Torque converter one-way clutch
Engine performance
Acceleration is poor when select lever is in the D, 3 or 2

range. (Normal rpm stall)
TCM
Control valve
High clutch
2-4 brake
Planetary gear
Acceleration is poor when select lever is in R range. (Normal

rpm stall)
Control valve
High clutch
2-4 brake
Planetary gear
4AT(D)(diag)-91

Symptoms
Problem parts
No shift occurs from 1st to 2nd gear.
No shift occurs from 2nd to 3rd gear.
No shift occurs from 3rd to 4th gear.
Engine brake does not come into effect when the select lever is
shifted to 3 range.
TCM
Control valve
2-4 brake
TCM
Control valve
High clutch
TCM
Control valve
2-4 brake
Inhibitor switch
TCM
Control valve
Engine brake is not effected when the select lever is in 3 or 2

range.
Control valve
Engine brake does not come into effect when the select lever is
shifted to 1 range.
Control valve
Low & reverse brake
Shift characteristics are erroneous.
No lock-up occurs.
Parking brake does not function.

Shift lever cannot be moved or is hard to move from P range.
ATF spurts out.
Differential oil spurts out.
Differential oil level changes excessively.
Odor is produced from ATF supply pipe.
Shock occurs when shifting from 1st to 2nd gear.
Inhibitor switch
TCM
Control valve
Ground
TCM
Control valve
Lock-up facing
Engine speed signal
Select cable
Select lever
Parking mechanism
ATF level too high
Differential gear oil level too high
Seal pipe
Double oil seal
High clutch
2-4 brake
Reverse clutch
Lock-up facing
ATF deterioration
TCM
Torque converter turbine speed sensor
Control valve
2-4 brake
ATF deterioration
Engine performance
4AT(D)(diag)-92

Symptoms
Problem parts
TCM
Control valve
2-4 brake
TCM
Control valve
High clutch
2-4 brake
ATF deterioration
Engine performance
Slippage occurs when shifting from 2nd to 3rd gear.
TCM
Control valve
High clutch
2-4 brake
Shock occurs when shifting from 3rd to 4th gear.
TCM
Control valve
2-4 brake
ATF deterioration
Engine performance
TCM
Control valve
2-4 brake
TCM
Control valve
2-4 brake
ATF deterioration
Slippage occurs when shifting from 1st to 2nd gear.
Shock occurs when shifting from 2nd to 3rd gear.
Slippage occurs when shifting from 3rd to 4th gear.
Shock occurs when select lever is shifted from the 3 range to

the 2 range.
4AT(D)(diag)-93

Symptoms
Problem parts
Shock occurs when select lever is shifted from the 2 range to

the 1 range.
Shock occurs when accelerator pedal is released from medium

speed.
Vibration occurs during straight-forward operation.
Vibration occurs during turns. (Tight corner braking phenomenon)
Front wheel slippage occurs during standing starts.
It is not set in FWD mode.
Select lever is hard to move.

Select lever is excessively hard to move. (Unreasonable resistance)
Select lever slips out of selected shift position during acceleration or while driving on rough terrain.
TCM
Control valve
ATF deterioration
Low & reverse brake duty solenoid
TCM
Control valve
Lock-up damper
Engine performance
TCM
Lock-up duty solenoid
Lock-up facing
Lock-up damper
TCM
Transfer clutch
Transfer valve
ATF deterioration
Harness
TCM
FWD switch
Control valve
Transfer clutch
Transfer valve
Transfer pipe
TCM
FWD switch
Transfer clutch
Transfer valve
Select cable
Select lever
Detent spring
Manual plate
Detent spring
Manual plate
Select cable
Select lever
Detent spring
Manual plate
4AT(D)(diag)-94
General Description
MANUAL TRANSMISSION AND DIFFERENTIAL
A: SPECIFICATION
1. MANUAL TRANSMISSION AND DIFFERENTIAL
Model
Type
Non-turbo
Turbo
5-forward speeds with synchromesh and 1-reverse
Transmission gear ratio
Front reduction
gear
Rear reduction
gear
Front differential
Center differential
1st
2nd
2.062
3.454
1.947
3rd
4th
1.448
1.088
1.366
0.972
5th
Rev.
0.780
0.738
3.333
Final
Type of gear
Gear ratio
Transfer
Type of gear
Gear ratio
Final
Type of gear
Gear ratio
Hypoid
4.111
4.444
Helical
1.000
Hypoid
4.111
Type and number of gear

Type and number of gear
4.444
Straight bevel gear (Bevel pinion: 2, Bevel gear: 2)

Straight bevel gear (Bevel pinion: 2, Bevel gear: 2 and viscous coupling)
Transmission gear oil

Transmission gear oil capacity
GL-5
3.5 2 (3.7 US qt, 3.1 Imp qt)
2. TRANSMISSION GEAR OIL
3. TRANSMISSION CASE ASSEMBLY
Recommended oil
Drive pinion shim adjustment
( C)
( F)
(1)
(2)
(3)
GL-5
(4)
-30 -26 -15 -5 0
-22 -15 5 23 32
Hypoid gear backlash:

0.13 0.18 mm (0.0051 0.0071 in)
15
59
25 30
77 86
90
Part No.
32295AA031
85W
80W
75W -90

Thickness
mm (in)
0.250
(0.0098)
32295AA041
0.175
(0.0069)
32295AA081
0.275
(0.0108)
32295AA051
0.200
(0.0079)
32295AA091
0.300
(0.0118)
32295AA061
0.225
(0.0089)
32295AA101
0.500
(0.0197)
MT-00001
(1) Item
(2) Transmission gear oil
Drive pinion shim

Thickness
Part No.
mm (in)
0.150
32295AA071
(0.0059)
Selection of main shaft rear plate

Main shaft rear plate
Dimension A mm (in)
Part No.
4.00 4.13
(0.1575 0.1626)
3.87 3.99
(0.1524 0.1571)
5MT-2
Mark
32294AA041
32294AA051
General Description
4. DRIVE PINION ASSEMBLY
6. SHIFTER FORK AND ROD
Preload adjustment of thrust bearing
Select a suitable shifter fork so that both the coupling sleeve and reverse driven gear are positioned
in the center of their synchromesh mechanisms.
Starting torque:
0.3 0.8 Nm (0.03 0.08 kgf-m, 0.2 0.6 ft-lb)
Rod end clearance

A: 3rd-4th 5th
0.5 1.3 mm (0.020 0.051 in)
B: 1st-2nd 3rd-4th
0.4 1.4 mm (0.016 0.055 in)
Adjusting washer No. 1

Part No.
Thickness mm (in)
803025051
803025052
3.925 (0.1545)
3.950 (0.1555)
803025053
803025054
3.975 (0.1565)
4.000 (0.1575)
803025055
803025056
4.025 (0.1585)
4.050 (0.1594)
803025057
4.075 (0.1604)
1st-2nd shifter fork

Part No.
Thickness mm (in)
803025059
803025054
3.850 (0.1516)
4.000 (0.1575)
803025058
4.150 (0.1634)
Adjustment of reverse idler gear position

Reverse idler gear to transmission case (LH)
wall clearance
6.0 7.5 mm (0.236 0.295 in)
Part No.
Mark
32804AA060
32804AA070
No mark
32804AA080
Part No.
5. REVERSE IDLER GEAR
Reverse shifter lever

Mark
Part No.
32810AA061
32810AA071
No mark
32810AA101
Mark
Remarks
32812AA201
7
8
Further from case wall

Standard
32812AA211
No mark
32820AA090
Closer to the case wall
32812AA221
After installing a suitable reverse shifter lever, adjust the clearance using washers.
Reverse idler gear to transmission case wall
clearance
0 0.5 mm (0 0.020 in)
Washer (20.5 26 t)
803020151
803020154
Thickness
mm (in)
1.9 (0.075)
803020152
803020153
1.1 (0.043)
1.5 (0.059)
803020155
2.3 (0.091)
Part No.
Remarks
Approaches 4th gear

by 0.2 mm (0.008 in).
Standard
Approaches 3rd gear
by 0.2 mm (0.008 in)
5th shifter fork (non-turbo) / Indentifying paint (pink)

Part No.
Thickness
mm (in)
0.4 (0.016)
Approaches 2nd gear

by 0.2 mm (0.008 in)
3rd-4th shifter fork

Mark
32820AA070
32820AA080
Part No.
Remarks
Approaches 1st gear
by 0.2 mm (0.008 in).
Standard
5MT-3
Remarks
Approaches 5th gear
by 0.2 mm (0.008 in).
Standard
Moves away from 5th
gear by 0.2 mm (0.008
in).
5th shifter fork (turbo) / Indentifying paint (blue)

Part No.
Mark
32812AA231
32812AA241
No mark
32812AA251
Remarks
Approaches 5th gear
by 0.2 mm (0.008 in).
Standard
Moves away from 5th
gear by 0.2 mm (0.008
in).
General Description
7. TRANSFER CASE
Thrust washer (50 61 t)
Neutral position adjustment

Adjusting shim
Part No.
803050074
Thickness mm (in)
1.20 (0.0472)
Part No.
32190AA000
Thickness mm (in)
0.15 (0.0059)
803050075
803050076
1.25 (0.0492)
1.30 (0.0512)
32190AA010
0.30 (0.0118)
803050077
803050078
1.35 (0.0531)
1.40 (0.0551)
803050079
1.45 (0.0571)
Reverse accent shaft

Part No.
Mark
32188AA130
32188AA140
32188AA150
Thrust washer to center differential side clearance:

0.15 0.35 mm (0.0059 0.0138 in)
Remarks
Neutral position is
closer to 1st.
Standard
Thrust washer
Neutral position is
closer to reverse gear.
Reverse check plate adjustment

Part No.
Reverse check plate

Mark Angle
32189AA000
28
32189AA010
31
33189AA020
34
32189AA030
37
32189AA040
40
Remarks
Arm stops closer to

5th gear.
Arm stops closer to
5th gear.
Arm stops in the center.
Arm stops closer to
reverse gear.
Part No.
803036050
Thickness mm (in)
0.9 (0.035)
803036054
803036051
1.0 (0.039)
1.1 (0.043)
803036055
803036052
1.2 (0.047)
1.3 (0.051)
803036056
803036053
1.4 (0.055)
1.5 (0.059)
803036057
803036058
1.6 (0.063)
1.7 (0.067)
9. FRONT DIFFERENTIAL
Bevel gear to pinion backlash:
0.13 0.18 mm (0.0051 0.0071 in)
Arm stops closer to

reverse gear.
Washer (38.1 50 t)
8. EXTENSION ASSEMBLY
Part No.
Tapered roller bearing preload (amount of standard protrusion):

0.2 0.3 mm (0.0008 0.012 in)
803038021
NOTE:
Make sure to set between the preload range.
803038022
Thickness
mm (in)
0.925
0.950
(0.0364
0.0374)
0.975
1.000
(0.0384
0.0394)
Part No.
803038023
Thickness
mm (in)
1.025
1.050
(0.0404
0.0413)
Part No.
803050060
Thickness mm (in)
0.50 (0.0197)
803050061
803050062
0.55 (0.0217)
0.60 (0.0236)
803050063
803050064
0.65 (0.0256)
0.70 (0.0276)
803050065
803050066
0.75 (0.0295)
0.80 (0.0315)
803050067
803050068
0.85 (0.0335)
0.90 (0.0354)
805030041
805030042
1.53 (0.0602)
1.65 (0.0650)
803050069
803050070
0.95 (0.0374)
1.00 (0.0394)
805030043
1.77 (0.0697)
803050071
803050072
1.05 (0.0413)
1.10 (0.0433)
803050073
1.15 (0.0453)
10.TRANSFER DRIVE GEAR

Snap ring (Outer-30) to ball bearing inner race
clearance:
0.01 0.15 mm (0.0004 0.0059 in)
Snap ring (Outer-30)
Part No.
Thickness mm (in)
5MT-4
General Description
B: COMPONENT
1. TRANSMISSION CASE
(11)
(13)
(10)
(12)
(9)
(8)
(7)
(6)
(5)
(4)
(1)
(2)
(3)
MT-01395
(1)
(2)
Transmission case ASSY

Gasket
(7)
(8)
Speedometer shaft
Snap ring (Outer)
(13)
(3)
(4)
Drain plug
Snap ring (Outer)
(9)
(10)
Oil seal
Clamp

T: 44 (4.5, 32.5) (Aluminum gasket)
(5)
(6)
Speedometer driven gear

Washer
(11)
(12)
Pitching stopper bracket

Oil level gauge (Non-turbo model)
5MT-5
Oil level gauge (Turbo model)
70 (7.1, 51.6) (Copper gasket)
General Description
TRANSMISSION CASE TIGHTENING TORQUE

Tightening torque: Nm
(kgf-m, ft-lb)
Bolt No.
Bolt size
<5> <15>
8 mm
25 (2.5, 18.1)
<1> <4>
<16>, <17>
10 mm
39 (4.0, 28.9)
MT-00003
5MT-6
General Description
2. DRIVE PINION ASSEMBLY

(4) (5)
(3)
(2)
(1)
(17)
(16)
(15)
(11)
(37)
(8)
(36)
(7)
(35)
(14)
(13)
(12)
(10)
(28)
(9)
(6)
T3
(27)
(26)
T1
(25)
(24)
(23)
(22)
(34)
(21)
(20)
(19)
(18)
(29)
(32)
(31)
(29)
(30)
T2
(33)
MT-01409
5MT-7
General Description
(1)
(2)
Drive pinion shaft

Roller bearing
(15)
(16)
1st-2nd synchronizer hub

Insert key
(29)
(30)
Washer
Thrust bearing
(3)
(4)
Washer
Thrust bearing
(17)
(18)
Reverse driven gear

Outer baulk ring
(31)
(32)
Differential bevel gear sleeve

Washer
(5)
(6)
Needle bearing
Driven shaft
(19)
(20)
Synchro cone
Inner baulk ring
(33)
(34)
Lock washer
Lock nut
(7)
(8)
Key
Woodruff key
(21)
(22)
2nd driven gear

2nd driven gear bushing
(35)
(36)
Inner baulk ring

Synchro cone
(9)
(10)
Drive pinion collar

Needle bearing
(23)
(24)
3rd-4th driven gear

Driven pinion shim
(37)
Outer baulk ring
(11)
Snap ring/outer (Non-turbo model)
(25)
Roller bearing
(12)
(13)
Washer (Non-turbo model)

Sub-gear (Non-turbo model)
(26)
(27)
5th driven gear

Lock washer
T1: 30 (3.1, 22.1)

T2: 120 (12.2, 88.5)
(14)
1st driven gear
(28)
Lock nut
T3: 260 (26.5, 192)
3. MAIN SHAFT ASSEMBLY (SINGLE-RANGE)
(3)
(1)
(17)
(2)
(16)
(15)
(13)
(11)
(14)
(12)
(10)
(9)
(5)
(8)
(7)
(6)
(18)
(4)
(29)
(28)
(26)
(27)
(25)
(33)
(24)
(32)
(23)
(31)
(22)
(19)
(20)
(30)
(21)
MT-01510
5MT-8
General Description
(1)
(2)
Oil seal
Needle bearing
(15)
(16)
Needle bearing
4th gear thrust washer
(24)
(25)
5th drive gear

5th baulk ring
(3)
(4)
Transmission main shaft

Needle bearing
(17)
(18)
(26)
(27)
Baulk lever
5th hub & sleeve No. 2
(5)
(6)
3rd drive gear

Inner baulk ring
Ball bearing (Non-turbo model)

Taper roller bearing (Turbo
model)
(19)
(28)
(29)
Lock washer
Lock nut
(7)
(8)
3rd synchro cone

Outer baulk ring
5th needle bearing race (Turbo

model)
(20)
(30)
(31)
Straight pin
Reverse idler gear shaft
(9)
(10)
3rd-4th coupling sleeve

3rd-4th synchronizer hub
5th gear thrust washer (Nonturbo model)
(32)
(33)
Reverse idler gear

Washer
(11)
3rd-4th shifting insert key
(12)
(13)
4th baulk ring

4th drive gear
(14)
4th needle bearing race
(21)
5th needle bearing race (Nonturbo model)
(22)
(23)
Needle bearing
Main shaft rear plate
5MT-9

T: 120 (12.2, 88.5)
General Description
4. SHIFTER FORK AND SHIFTER ROD

(1)
(2)
(8)
(7)
(4)
(6)
(5)
T
(3)
(12)
(18)
(9)
(10)
(10)
(7)
(6)
(5)
(17)
(16)
(8)
(10)
(11)
(3)
(6)
(15)
(5)
(14)
(8)
(7)
(3)
(13)
MT-00007
(1)
(2)
Shifter arm
5th shifter fork
(8)
(9)
Ball
3rd-4th fork rod
(15)
(16)
Spring
Snap ring (Outer)
(3)
(4)
Straight pin
Reverse fork rod
(10)
(11)
Interlock plunger
1st-2nd fork rod
(17)
(18)
Reverse fork rod arm

(5)
(6)
Checking ball plug

Gasket
(12)
(13)

(7)
Checking ball spring
(14)
Ball
T: 20 (2.0, 14.5)
5MT-10
General Description
5. TRANSFER CASE AND EXTENSION

(5)
(4)
T3
(7)
T2
(3)
(6)
(2)
(8)
T3
(20)
(1)
T1
(21)
(23)
(22)
T5
T5
(12)
(14)
(9)
(17)
(10)
(19)
(11)
(15)
T1
(13)
(16)
(35)
(18)
(34)
T6
(36)
T3
(26) (27)
(25)
(24)
(31)
T6
(30)
(37)
(29)
(33)
(32)
(28)
T4
MT-01254
5MT-11
General Description
(1)
(2)
Oil guide
Gasket
(16)
(17)
Return spring
O-ring
(31)
(32)
Transfer drive gear

Ball bearing
(3)
(4)
Transfer case
Ball
(18)
(19)
Adjusting select shim

Reverse check sleeve
(33)
(34)
Extension case
Oil seal
(5)
(6)
Reverse accent spring

Gasket
(20)
(21)
Gasket
(35)
(36)
Dust cover
Shift bracket
(7)
(8)
Plug
Oil seal
(22)
(23)
Gasket
Back-up light switch
(37)
Snap ring
(9)
(10)
Snap ring (Inner)

Reverse check plate
(24)
(25)
Roller bearing
Transfer driven gear

T1: 6.4 (0.65, 4.7)
(11)
Reverse check spring
(26)
Roller bearing
T2: 9.75 (1.0, 7.2)
(12)
(13)
Reverse return spring

Reverse check cam
(27)
(28)
Adjusting washer
Ball bearing
T3: 24.5 (2.5, 18.1)

T4: 26 (2.7, 20)
(14)
(15)

Return spring cap
(29)
(30)
Center differential
Adjusting washer
T5: 32.3 (3.3, 23.8)

T6: 40 (4.1, 30)
5MT-12
General Description
6. FRONT DIFFERENTIAL
(7)
(5)
(1)
(6)
(5)
(2)
(8)
(7)
(3)
(4)
T2
(8)
(11)
(10)
(10)
(12)
(9)
(12)
(13)
(11)
T1
T1
(13)
MT-01365
(1)
(2)
Drive pinion shaft

Hypoid driven gear
(7)
(8)
Differential bevel pinion

Roller bearing
(13)
(3)
(4)
Pinion shaft
Straight pin
(9)
(10)
Differential case
Oil seal

T1: 25 (2.5, 18.1)
(5)
(6)
Washer
Differential bevel gear
(11)
(12)
Differential side retainer

O-ring
5MT-13
Retainer lock plate
T2: 62 (6.3, 45.6)
General Description
7. TRANSMISSION MOUNTING
(4)
(6)
(3)
(5)
T3
(2)
T2
T4
T1
(1)
(7)
(8)
(3)
(2)
(9)
(7)
T1
(10)
T4
T4
T5
MT-00448
(1)
(2)
Pitching stopper
Spacer
(7)
(8)
Cushion D
Center crossmember
(3)
(4)
Cushion C
Front plate
(9)
(10)
Rear plate
Front crossmember
(5)
(6)
Rear cushion rubber

Rear crossmember

T1: 35 (3.6, 26)
T2: 50 (5.1, 36.9)
T3: 58 (5.9, 43)
T4: 70 (7.1, 51)
T5: 140 (14.3, 103)
5MT-14
General Description
C: CAUTION
When disassembling the case and other light alloy parts, use a plastic hammer to force it apart. Do
not pry apart with screwdrivers or other tools.
Use SUBARU genuine gear oil, grease or the
equivalent. Do not mix gear oil, grease, etc. with
those of different grades or from other manufacturers.
points.
Apply gear oil onto sliding or revolving surfaces
Replace deformed or damaged snap rings with
new parts.
Before installing O-rings or oil seals, apply sufficient amount of gear oil to avoid damage and deformation.
Be careful not to incorrectly install or fail to install
O-rings, snap rings and other such parts.
Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate,
or shop cloth between the part and the vise.
Before applying liquid gasket, completely remove the liquid gasket.
5MT-15
General Description
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
399411700
ACCENT BALL
INSTALLER
Used for installing reverse shifter rail arm.
899524100
PULLER SET
Used for removing and installing the roller bearing (Differential).

(1) Puller
(2) Cap
399780104
WEIGHT
Used for measuring preload on the roller bearing.
498077000
REMOVER
Used for removing the roller bearing of the drive

pinion shaft.
ST-399411700
ST-899524100
ST-399780104
ST-498077000
5MT-16
General Description
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
498077300
CENTER DIFFERENTIAL BEARING

REMOVER
Used for removing the center differential cover

ball bearing.
498147000
DEPTH GAUGE
Used for adjusting the main shaft axial end play.
498247001
MAGNET BASE
Used for measuring backlash between the

side gear and pinion, and the hypoid gear.
Used together with DIAL GAUGE
(498247100).
498247100
DIAL GAUGE
Used for measuring backlash between the

side gear and pinion, and the hypoid gear.
Used together with MAGNET BASE
(498247001).
498427400
STOPPER
Used for securing the drive pinion shaft assembly and the driven gear assembly when removing
the drive pinion shaft assembly lock nut.
ST-498077300
ST-498147000
ST-498247001
ST-498247100
ST-498247400
5MT-17
General Description
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
498787100
MAIN SHAFT
STOPPER
Used for removing and installing the lock nut of

the transmission main shaft.
498937000
TRANSMISSION
HOLDER
Used for removing and installing the lock nut of

the transmission main shaft.
499277100
BUSHING 1-2
INSTALLER
Used for installing the 1st driven gear thrust

plate and the 1st-2nd driven gear bushing.
Used for installing the roller bearing outer race
to the differential case.
499277200
INSTALLER
Used for press-fitting the 2nd driven gear, roller

bearings and the 5th driven gear onto the driven
shaft.
499757002
INSTALLER
Used for installing the snap ring (OUT 25), and

ball bearing (25 26 17).
Used for installing the bearing cone of the
transfer driven gear (extension core side).
ST-498787100
ST-498937000
ST-499277100
ST-499277200
ST-499757002
5MT-18
General Description
ILLUSTRATION
TOOL NUMBER
18630AA010
DESCRIPTION
REMARKS
WRENCH COMPL
RETAINER
Used for removing and installing the differential side retainer.

WRENCH ASSEMBLY (499787000) can also
be used.
499827000
PRESS
Used for installing the speedometer oil seal

when attaching the speedometer cable to the
transmission.
499857000
5TH DRIVEN GEAR

REMOVER
Used for removing the 5th driven gear.
499877000
RACE 4-5
INSTALLER
Used for installing the 4th needle bearing race

and ball bearing onto the transmission main
shaft.
Used together with REMOVER (899714110).
499917500
DRIVE PINION
GAUGE ASSY
Used for adjusting the drive pinion shim.
ST18630AA010
ST-499827000
ST-499857000
ST-499877000
ST-499917500
5MT-19
General Description
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
499927100
HANDLE
Used for fitting the transmission main shaft.
499937100
TRANSMISSION
STAND
Used for disassembling and assembling the

transmission.
499987003
SOCKET WRENCH
(35)
Used for removing and installing the driven pinion lock nut and main shaft lock nut.
499987300
SOCKET WRENCH
(50)
Used for removing and installing the driven gear

assembly lock nut.
899714110
REMOVER
Used for fixing the transmission main shaft, drive

pinion, rear drive shaft.
ST-499927100
ST-499937100
ST-499987003
ST-499987300
ST-899714110
5MT-20
General Description
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
899864100
REMOVER
Used for removing transmission main shaft and

drive pinion parts.
899884100
HOLDER
Used for tightening the lock nut on the sleeve.
899904100
REMOVER
Used for removing and installing the straight pin.
899988608
SOCKET WRENCH
(27)

lock nut.
398497701
ADAPTER
Used for installing roller bearing onto the differential case.

Used together with INSTALLER (499277100).
ST-899864100
ST-899884100
ST-899904100
ST-899988608
ST-398497701
5MT-21
General Description
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
499587000
INSTALLER
Used for installing the driven gears to the driven

shaft.
899824100
PRESS
Used for installing the speedometer shaft oil

seal.
499987100
SOCKET WRENCH
(35)

lock nut.
899984103
SOCKET WRENCH
(35)

lock nut.
498057300
INSTALLER
Used for installing the extension oil seal.
ST-499587000
ST-899824100
ST-499987100
ST-899984103
ST-498057300
5MT-22
General Description
ILLUSTRATION
TOOL NUMBER
498255400
DESCRIPTION
REMARKS
PLATE
Used for measuring backlash.
41099AA010
ENGINE SUPPORT
BRACKET
41099AA020
ENGINE SUPPORT
398527700
PULLER ASSY
Used for removing the extension case roller

bearing.
retainer bearing outer race.
retainer oil seal.
398643600
GAUGE
Used for measuring the total end play, extension

end play and drive pinion height.
ST-498255400
ST41099AA010
ST41099AA020
ST-398527700
ST-398643600
5MT-23
General Description
ILLUSTRATION
TOOL NUMBER
398177700
DESCRIPTION
REMARKS
INSTALLER
Used for installing the bearing cone of transfer

driven gear (transfer case side).
Used for installing the ball bearing of the transfer drive gear.
28399SA000
FRONT DRIVE
SHAFT REMOVER
Used for removing the front drive shaft. (common

for the MT model, and the AT model)
28399SA010
FRONT DRIVE
SHAFT OIL SEAL
PROTECTOR
Used for protecting the oil seal from damage

when inserting the front drive shaft.
18675AA000
DIFFERENTIAL
SIDE OIL SEAL
INSTALLER

seal.
ST-398177700
ST28399SA000
ST28399SA010
ST18675AA000
2. GENERAL TOOL
TOOL NAME
Circuit tester
REMARKS
5MT-24
Transmission Gear Oil

2. Transmission Gear Oil
B: REPLACEMENT
A: INSPECTION
1) Pull out the oil level gauge.

3) Drain transmission gear oil completely.

2) Turn the ignition switch to OFF, and wait until the
engine cools.
3) Remove the oil level gauge and wipe it clean.
the level gauge is correctly inserted and in the
proper direction.
5) Pull out the oil level gauge again and check the
oil level. If it is below the lower level, add oil through
the oil level gauge hole to bring the level up to the
upper level.
CAUTION:
Immediately after the engine has been running, the transmission gear oil is hot. Be careful
not to burn yourself.
Be careful not to spill the transmission gear
oil on exhaust pipe, to prevent emitting smoke
or causing a fire. If differential gear oil is spilled
on the exhaust pipe, wipe it off completely.
4) Use a new gasket, and tighten the transmission
gear oil drain plug.
Tightening torque:
44 Nm (4.5 kgf-m, 32.5 ft-lb) (Aluminum gasket)
70 Nm (7.1 kgf-m, 51.6 ft-lb) (Copper gasket)
(A)
(B)
(C)
PM-00030
(A) Oil level gauge
(B)
(B) Upper level

(C) Lower level
(A)
MT-00061
(A) Drain plug

(B) Gasket

6) Pour the gear oil into the gauge hole.
RECOMMENDED GEAR OIL
Use GL-5 or the equivalent.
Gear oil capacity
3.5 2 (3.7 US qt, 3.1 Imp qt)
7) Measure the transmission gear oil level to check
that it is within specifications.
CAUTION:
When inserting the level gauge into the transmission, align the protrusion on the top part of
the level gauge with the notch in the gauge
hole.
5MT-25
Manual Transmission Assembly

3. Manual Transmission Assembly
Turbo model
A: REMOVAL
2) Open the front hood fully, and support with stay.
4) Drain transmission gear oil completely.
<Ref. to 5MT-25, REPLACEMENT, Transmission
Gear Oil.>
(Non-turbo model) <Ref. to IN (H4SO)-6, REMOVAL, Air Intake Chamber.>
6) Remove the air cleaner case. (Non-turbo model)
MT-00064
(3) Vehicle speed sensor connector
MT-00065
ME-00062

8) Disconnect the following connectors and transmission cables.
(1) Neutral position switch connector
(2) Back-up light switch connector
Non-turbo model
9) Remove the starter. <Ref. to SC (H4SO)-6, REMOVAL, Starter.>

10) Remove the operating cylinder from transmission, and suspend on a wire.
(A)
CL-00253
(B)
MT-00104
(A) Neutral position switch connector

(B) Back-up light switch connector
MT-00069
5MT-26

12) Set the ST.

ST 41099AA010 ENGINE SUPPORT BRACKET
ST 41099AA020 ENGINE SUPPORT
19) Remove the gear shift rod and the stay from the
transmission.
(1) Disconnect the stay from the transmission.
(2) Remove the gear shift rod from the transmission.
ST
(A)
(B)
(B)
MT-00070
MT-00075
13) Remove the bolts which hold upper side of

(A) Stay
(B) Gear shift rod
20) Separate the stabilizer link from the transverse

link.
21) Remove the bolt securing the ball joint of the
transverse link to the housing, then separate the
transvers link and the housing.
MT-00073

15) Remove the center exhaust pipe. (Turbo model) <Ref. to EX(H4DOTC)-8, REMOVAL, Center
Exhaust Pipe.>
CAUTION:
When removing the exhaust pipes, be careful
each exhaust pipe does not drop out.
17) Remove the hanger bracket from the right side
of transmission.
FS-00026
22) Using the ST, remove the front drive shaft from
the transmission side.
NOTE:
Face letters MT on the handle of the ST to the
transmission side.
(A)
MT-00074
AT-00461
18) Remove the propeller shaft. <Ref. to DS-12,

REMOVAL, Propeller Shaft.>
5MT-27
(A) Letter MT

Keep an angle so that the protrusion of the ST

touches the transmission case during the operation.
ST 28399SA000 FRONT DRIVE SHAFT REMOVER

from the vehicle.
MT-00079
27) Remove the transmission.

ST
MT-00080
23) Hold the transmission side joint (AARi) of front

drive shaft by hand and extract the housing from
the transmission by pressing it outside so as not to
stretch the boot on the AARi side.
NOTE:
Move the transmission jack towards the rear until
main shaft is withdrawn from the clutch cover.
28) Separate the transmission assembly from the
rear cushion rubber.
B: INSTALLATION
1) Replace the differential side retainer oil seal with
a new part. <Ref. to 5MT-34, REPLACEMENT, Differential Side Retainer Oil Seal.>
NOTE:
Be sure to replace the differential side retainer oil
seal after the removing the front drive shaft.
2) Install the rear cushion rubber to the transmission assembly.
MT-00077
25) Place the transmission jack under the transmission.

CAUTION:
Always support the transmission case with a
transmission jack.
Tightening torque:
35 Nm (3.57 kgf-m, 25.8 ft-lb)
3) Install the transmission onto the engine.
(1) Gradually raise the transmission with the
transmission jack.
(2) Engage at the spline section.
NOTE:
Be careful not to hit the main shaft against the
clutch cover.
Tightening torque:
T1: 70 Nm (7.1 kgf-m, 51 ft-lb)
T2: 140 Nm (14.3 kgf-m, 103 ft-lb)
T1
T1
MT-00078
T2
T2
MT-00081
5) Take out the transmission jack.
5MT-28

6) Tighten the nuts and bolts which holds the lower

side of the transmission to the engine.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)

Tightening torque:
T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
T2: 58 Nm (5.9 kgf-m, 43 ft-lb)
T1
T2
MT-00077
MT-00085
7) Connect the engine and transmission.

(1) Install the starter.
<Ref. to SC (H4SO)-6, INSTALLATION, Starter.>
(2) Tighten the bolts which holds the upper side
of the transmission to the engine.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)

11) Install the front drive shaft into the transmission. <Ref. to DS-30, INSTALLATION, Front Drive
Shaft.>
ST 28399SA010 FRONT DRIVE SHAFT OIL
SEAL PROTECTOR
12) Insert the ball joints of the lower arm into the
housing, then tighten the installing bolts.
Tightening torque:
49 Nm (5.0 kgf-m, 36 ft-lb)
(B)
MT-00073
(A)
8) Remove the ST.
MT-00086
ST
(A) Transverse link

(B) Ball joint
13) Attach the stabilizer link to the transverse link.

Tightening torque:
45 Nm (4.6 kgf-m, 33.2 ft-lb)
MT-00070
MT-00076
5MT-29

14) Attach the gear shift rod and stay.

(1) Attach the gear shift rod to the transmission.
Tightening torque:
12 Nm (1.2 kgf-m, 8.9 ft-lb)
21) Install the operating cylinder.

Tightening torque:
37 Nm (3.8 kgf-m, 27.5 ft-lb)
(A)
(B)
(B)
CL-00253
MT-00089

(1) Transmission ground cable
(A) Stay
(B) Gear shift rod
(2) Attach the stay to the transmission.

Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
16) Install the hanger bracket on the right side of
the transmission.
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
(2) Vehicle speed sensor connector
(3) Neutral position switch connector
(4) Back-up light switch connector
23) Install the air cleaner case stay.
24) Install the air intake chamber. <Ref. to IN
25) Install the intercooler. (Turbo model) <Ref. to
26) Pour transmission gear oil through the gauge
hole. <Ref. to 5MT-25, REPLACEMENT, Transmission Gear Oil.>
MT-00074

18) Install the front exhaust pipe and the center exhaust pipe. (Non-turbo model)
Exhaust Pipe.>
5MT-30

4. Transmission Mounting System
7) Remove the rear crossmember.
A: REMOVAL
1. PITCHING STOPPER
2) Remove the air intake duct and cleaner case.
3) Remove the air intake duct. (Non-turbo model)
model) <Ref. to IN (H4SO)-6, REMOVAL, Air Intake Chamber.>
MT-00079
8) Remove the rear cushion rubber.
B: INSTALLATION
1. PITCHING STOPPER
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
T2: 58 Nm (5.9 kgf-m, 43 ft-lb)
T1
MT-00069
T2
2. CROSSMEMBER AND CUSHION RUBBER

racks.
(Non-turbo model)
Pipe.>
<Ref. to EX (H4SO)-7, REMOVAL, Center Exhaust
Pipe.>
4) Remove the center exhaust pipe. (Turbo model)
6) Set the transmission jack under the transmission
body.
MT-00085
2) Install the air intake duct and air intake chamber.

(Non-turbo model)
Chamber.>
CAUTION:
Always support the transmission case with a
transmission jack.
5MT-31


1) Install the rear cushion rubber.
Tightening torque:
35 Nm (3.6 kgf-m, 26 ft-lb)
2) Install the rear crossmember.
Tightening torque:
T1: 70 Nm (7.1 kgf-m, 51 ft-lb)
T2: 140 Nm (14.3 kgf-m, 103 ft-lb)
T1
T1
T2
T2
MT-00081

Exhaust Pipe.>
C: INSPECTION
Perform the following inspection procedures, and
repair or replace faulty parts.
1. PITCHING STOPPER
Make sure that the pitching stopper is not bent or
damaged. Check that the rubber is not stiff,
cracked or otherwise damaged.

Make sure that the crossmember is not bent or
damaged. Check that the cushion rubber is not stiff,
cracked, or otherwise damaged.
5MT-32
Oil Seal
5. Oil Seal
7) Using the ST, install the oil seal.

ST 498057300
INSTALLER
A: INSPECTION
Check the oil seals for leaks. If leading, replace
with a new oil seal.
B: REPLACEMENT
2) Drain gear oil completely.
3) Tighten the drain plug after draining gear oil and
replacing with a new gasket.
Tightening torque:
MT-00099

10) Pour in gear oil and check the oil level. <Ref. to
5MT-25, REPLACEMENT, Transmission Gear
Oil.>
MT-00097

ST 398527700
PULLER ASSY
(A)
ST
MT-00098
(A) Oil seal
5MT-33
Differential Side Retainer Oil Seal

6. Differential Side Retainer Oil

Seal
A: INSPECTION
Check for leakage of gear oil from the differential
side retainer oil seal. If there is an oil leak, replace
the oil seal.
7) Using the ST, install the differential side retainer

oil seal by lightly tapping with a hammer.
SEAL INSTALLER
NOTE:
Apply oil to the oil seal lips.
B: REPLACEMENT
ST

2) Drain the differential gear oil from the differential
oil drain plug.
MT-00103
(A)
MT-01221
(A) Drain plug
3) Replace the gasket with a new part and tighten

the differential oil drain plug.
8) Install the front drive shaft. <Ref. to DS-30, INSTALLATION, Front Drive Shaft.>
9) Install the front and center exhaust pipe. (Nonturbo model) <Ref. to EX (H4SO)-5, INSTALLATION, Front Exhaust Pipe.>
11) Pour gear oil through the gauge hole. <Ref. to
5MT-25, REPLACEMENT, Transmission Gear
Oil.>
Tightening torque:
(A)
MT-01221
(A) Drain plug

5) Separate the front drive shaft from the transmission. <Ref. to DS-29, REMOVAL, Front Drive
Shaft.>
6) Remove the differential side retainer oil seal using a screw driver wrapped with vinyl tape etc.
5MT-34
Switches and Harness

7. Switches and Harness
6) Remove the back-up light switch and neutral position switch with the harness.
A: REMOVAL
1. BACK-UP LIGHT SWITCH AND NEUTRAL POSITION SWITCH
(A)

4) Disconnect the connector back-up light switch
and neutral position switch.
Non-turbo model
(B)
MT-00106

B: INSTALLATION
(A)
1. BACK-UP LIGHT SWITCH AND NEUTRAL POSITION SWITCH

1) Install the back-up light switch and neutral position switch with the harness.
(B)
Tightening torque:
32.3 Nm (3.3 kgf-m, 23.8 ft-lb)
MT-00104
(A)
Turbo model
(B)
MT-00106
(A) Neutral position switch (Brown)

(B) Back-up light switch (Gray)
MT-00105
2) Connect the connectors of back-up light switch

and neutral position switch.
Chamber.>
5MT-35
Switches and Harness

C: INSPECTION
1. BACK-UP LIGHT SWITCH
Check the back-up light switch. <Ref. to LI-6, INSPECTION, Back-up Light System.>
2. NEUTRAL POSITION SWITCH

2) Disconnect the connector of neutral position
switch.
3) Measure the resistance between neutral position switch terminals.
Non-turbo model:
Gear shift position
Neutral position
Other positions
Terminal No.
1 and 2
Specified resistance
Less than 1
Over 1 M
Turbo model:
Gear shift position
Terminal No.
Neutral position
Other positions
1 and 3
Less than 1
Over 1 M
Non-turbo model
2 1
MT-00110
Turbo model
2 1
4 3
MT-00111
4) Replace faulty parts.
5MT-36
Vehicle Speed Sensor

8. Vehicle Speed Sensor

A: REMOVAL
3) Remove the front, center, rear exhaust pipes
and muffler.
4) Disconnect the connector from vehicle speed
sensor.
5) Turn and remove the vehicle speed sensor.
MT-00113
B: INSTALLATION
NOTE:
Discard the old vehicle speed sensor after removal, use a new sensor for the installation.
Make sure that there is no foreign matter on the
sensor mounting.
Align the tip end of the key with the key groove
on the end of speedometer shaft during installation.
1) Hand tighten the vehicle speed sensor.
2) Tighten the vehicle speed sensor using suitable
tools.
Tightening torque:
5.9 Nm (0.6 kgf-m, 4.3 ft-lb)
3) Connect the connector to the vehicle speed sensor.
and the muffler.
C: INSPECTION
Inspect the vehicle speed sensor.
<Ref. to IDI-5, CHECK VEHICLE SPEED SENSOR, INSPECTION, Combination Meter System.>
5MT-37

9. Preparation for Overhaul

A: PROCEDURE
1) Clean oil, grease, dirt and dust from the transmission.
2) Remove the drain plug to drain oil.
3) Using a new gasket, and install the drain plug.
Tightening torque:
MT-00097
4) Attach the transmission to ST.

ST 499937100
TRANSMISSION STAND
ST
MT-00115
5) Apply oil to rotating parts before assembly.

6) All disassembled parts, if to be reused, should
be reinstalled in the original positions and directions.
7) Gaskets, lock washers and lock nuts must be replaced with new parts.
8) Use liquid gasket to the specified areas to prevent leakage.
5MT-38
Transfer Case and Extension Case Assembly

10.Transfer Case and Extension

Case Assembly
2) Remove the bearing outer race from the extension case.

(B)
A: REMOVAL
from the vehicle. <Ref. to 5MT-26, REMOVAL,
Manual Transmission Assembly.>
2) Remove the back-up light switch and neutral position switch. <Ref. to 5MT-35, REMOVAL, Switches and Harness.>
3) Remove the transfer case together with the extension case assembly.
(A)
MT-00119
(A) Bearing outer race

(B) Extension case
3) While pressing the bearing outer race horizontally, rotate the driven shaft for ten turns.
4) Measure the height W between transfer case
and taper roller bearing on the transfer driven gear.
MT-00116
4) Remove the shifter arm.

5) Remove the extension case assembly.
W
MT-00120
5) Measure the depth X.

NOTE:
Measure with the bearing outer race mounted and
the thrust washer removed.
MT-00117
B: INSTALLATION
1) Install the center differential and transfer driven
gear into the transfer case.
MT-00121
MT-00118
6) Calculate the tight t using following equation. t

= X W + (0.2 0.3 mm) (0.008 0.012 in)
7) Select the washer with the nearest value in the
following table.
Tapered roller bearing preload (amount of standard protrusion):
0.2 0.3 mm (0.008 0.012 in)
5MT-39

NOTE:
Make sure to set between the preload range.
11) Measure the depth T between extension case

and transfer drive gear.
ST 398643600
GAUGE

Part No.
803050060
Thickness mm (in)
0.50 (0.0197)
803050061
803050062
0.55 (0.0217)
0.60 (0.0236)
803050063
803050064
0.65 (0.0256)
0.70 (0.0276)
803050065
803050066
0.75 (0.0295)
0.80 (0.0315)
803050067
803050068
0.85 (0.0335)
0.90 (0.0354)
803050069
803050070
0.95 (0.0374)
1.00 (0.0394)
803050071
803050072
1.05 (0.0413)
1.10 (0.0433)
803050073
803050074
1.15 (0.0453)
1.20 (0.0472)
803050075
803050076
1.25 (0.0492)
1.30 (0.0512)
803050077
803050078
1.35 (0.0531)
1.40 (0.0551)
803050079
1.45 (0.0571)
ST
MT-00123
NOTE:
ST thickness [15 mm (0.59 in)]
12) Calculate the space U using the following
equation: U = S + T 30 mm (1.18 in) [Thickness of
ST]
13) Select a suitable washer in the following table.
Standard clearance
0.15 0.35 mm (0.0059 0.0138 in)
Part No.
8) Fit the thrust washers on the transfer drive shaft.

9) Install the bearing outer race into the extension
case.
10) Measure the depth S between transfer case
and center differential.
ST 398643600
GAUGE
ST
Thrust washer
Thickness mm (in)
803036050
803036054
0.9 (0.035)
1.0 (0.039)
803036051
803036055
1.1 (0.043)
1.2 (0.047)
803036052
803036056
1.3 (0.051)
1.4 (0.055)
803036053
803036057
1.5 (0.059)
1.6 (0.063)
803036058
1.7 (0.067)
14) Fit the thrust washer onto the center differential.

15) Apply a proper amount of liquid gasket to the
transfer case mating surface.
Liquid gasket
equivalent
MT-00122
MT-00124
5MT-40

16) Install the extension assembly into the transfer

case.
19) Install the extension case assembly along with

the transfer case to the transmission case.
Tightening torque:
40 Nm (4.1 kgf-m, 30 ft-lb)
Tightening torque:
24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
MT-00117
17) Attach the shifter arm to transfer case.
MT-00116
C: DISASSEMBLY
1. TRANSFER CASE
1) Remove the reverse check assembly. <Ref. to
5MT-48, REMOVAL, Reverse Check Sleeve.>
2) Remove the oil guide.
MT-00126
18) Hang the shifter arm on 3rd-4th fork rod.

(A)
MT-00129
2. EXTENSION CASE
1) Remove the transfer drive gear assembly. <Ref.
to 5MT-43, REMOVAL, Transfer Drive Gear.>
2) Remove the shift bracket.
(B)
MT-00127
(A) Shifter arm

(B) 3rd-4th fork rod
MT-00130

<Ref. to 5MT-33, REPLACEMENT, Oil Seal.>
5MT-41

D: ASSEMBLY
1. EXTENSION CASE
1) Press-fit the new oil seal to the extension case
using ST. <Ref. to 5MT-33, REPLACEMENT, Oil
Seal.>
2) Install the shift bracket to extension case.
Tightening torque:
24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
MT-00130
3) Install the transfer drive gear to the extension

case. <Ref. to 5MT-43, INSTALLATION, Transfer
Drive Gear.>
2. TRANSFER CASE
1) Install the oil guide to the transfer case.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
MT-00129
2) Install the reverse check sleeve assembly to the

transfer case. <Ref. to 5MT-48, INSTALLATION,
Reverse Check Sleeve.>
5MT-42
Transfer Drive Gear

11.Transfer Drive Gear
C: DISASSEMBLY
A: REMOVAL

3) Remove the transfer case together with the extension case assembly. <Ref. to 5MT-39, REMOVAL, Transfer Case and Extension Case
Assembly.>
5) Remove the transfer driven gear.
6) Remove the transfer drive gear.
MT-00135
2) Remove the ball bearing.
MT-00136
D: ASSEMBLY
MT-00133
1) Set the ST against the inner race of the bearing,

and install the drive shaft.
ST 398177700
INSTALLER
B: INSTALLATION
1) Attach the transfer drive gear.
CAUTION:
Do not apply a load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
Tightening torque:
26 Nm (2.7 kgf-m, 20 ft-lb)
ST
MT-00133
2) Install the transfer driven gear.

3) Install the extension case assembly.
4) Install the transfer case and the extension case
assembly. <Ref. to 5MT-39, INSTALLATION,
Transfer Case and Extension Case Assembly.>
5) Install the back-up light switch and the neutral
position switch. <Ref. to 5MT-35, INSTALLATION,
Switches and Harness.>
6) Install the manual transmission assembly to the
vehicle. <Ref. to 5MT-28, INSTALLATION, Manual
MT-00137
2) Install the snap ring on the transfer drive shaft.

3) Inspect the clearance between the snap ring and
the ball bearing. <Ref. to 5MT-44, INSPECTION,
Transfer Drive Gear.>
5MT-43
Transfer Drive Gear

E: INSPECTION
1) Bearing
Replace the bearings in the following cases.
In case of broken or rusty bearings
In case of worn or damaged bearings
In the case that the bearing fails to turn smoothly
or makes an abnormal noise when turned, even after gear oil lubrication.
2) Drive gear
Replace the drive gear in following case.
If the drive gear tooth surface and shaft are excessively broken or damaged.
3) Measure the clearance between snap ring and
inner race of ball bearing with a thickness gauge.
Clearance:
0.01 0.15 mm (0.0004 0.0059 in)
MT-00138
If the measured value is not within the specification,

select a suitable snap ring from the table below and
replace.
Part No.
Snap ring (Outer-30)

Thickness mm (in)
805030041
1.53 (0.0602)
805030042
805030043
1.65 (0.0650)
1.77 (0.0697)
5MT-44
Transfer Driven Gear

12.Transfer Driven Gear
B: INSTALLATION
A: REMOVAL
1) Install the bearing outer races to extension case

and transfer case.

Assembly.>
5) Remove the transfer driven gear.
(C)
(A)
(B)
(D)
MT-00141
MT-00118
6) Remove bearing outer races from the extension

case and transfer case.
(A) Bearing outer race (Extension case side)

(B) Bearing outer race (Transfer case side)
(C) Extension case
(D) Transfer case
(A)
2) Install the transfer driven gear.
(B)
MT-00118
MT-00140
(A) Bearing outer race

(Extension case side)
(B) Bearing outer race
(Transfer case side)
3) Install the transfer case and the extension case

assembly. <Ref. to 5MT-39, INSTALLATION,
Transfer Case and Extension Case Assembly.>
4) Install the back-up light switch and the neutral
position switch. <Ref. to 5MT-35, INSTALLATION,
5MT-45

C: DISASSEMBLY
D: ASSEMBLY
1) Using the ST, remove the roller bearing (extension case side).
ST 498077000
REMOVER
1) Using the ST, install the roller bearing (extension

case side).
ST2 899864100 REMOVER
CAUTION:
ST
(A)
ST2
MT-00143
(A)
(A) Roller bearing
2) Using ST1 and ST2, remove the roller bearing

(transfer case side).
ST1
MT-00145
(A) Roller bearing
2) Using ST, install the roller bearing (transfer case

side).
ST 499757002
INSTALLER
ST2
(A)
ST1
CAUTION:
ST
MT-00144
(A)
(A) Roller bearing
MT-00146
(A) Roller bearing
E: INSPECTION
1) Bearing
2) Driven gear
Replace the driven gear in the following cases.
If the driven gear tooth surface and shaft are excessively broken or damaged.
5MT-46
Center Differential
13.Center Differential
D: ASSEMBLY
A: REMOVAL
Install the ball bearing into the center differential

assembly.

Assembly.>
3) Remove the extension case assembly. <Ref. to
5MT-39, REMOVAL, Transfer Case and Extension
Case Assembly.>
4) Remove the transfer driven gear. <Ref. to 5MT45, REMOVAL, Transfer Driven Gear.>
5) Remove the center differential.
CAUTION:
(A)
MT-00148
B: INSTALLATION
1) Install the center differential into transfer case.
2) Install the transfer driven gear. <Ref. to 5MT-45,
INSTALLATION, Transfer Driven Gear.>
3) Install the extension case assembly. <Ref. to
5MT-39, INSTALLATION, Transfer Case and Extension Case Assembly.>
4) Install the transfer case together with the extension case assembly. <Ref. to 5MT-39, INSTALLATION, Transfer Case and Extension Case
Assembly.>
5) Install the back-up light switch and neutral position switch. <Ref. to 5MT-35, INSTALLATION,
(A) Ball bearing
E: INSPECTION
1) Bearing
When the bearing has other problems.
2) Center differential
Replace the center differential assembly in the following case.
C: DISASSEMBLY
1) Remove the ball bearing using ST.
NOTE:
Do not reuse the ball bearing.
ST 498077300
CENTER DIFFERENTIAL
BEARING REMOVER
ST
MT-00147
2) Aside from the ball bearings, the center differential is a non-disassemby part and must not be disassembled.
5MT-47
Reverse Check Sleeve

14.Reverse Check Sleeve
2) Install the reverse check ball, reverse accent

spring, gasket and plug to transfer case.
A: REMOVAL
Assembly.>
3) Remove the shifter arm.
4) Remove the plug, gasket, reverse accent spring,
and reverse check ball.
Tightening torque:
9.75 Nm (1.0 kgf-m, 7.2 ft-lb)
MT-00149
MT-00149
5) Remove the reverse check sleeve.
3) Attach the shifter arm to the transfer case assembly.

Assembly.>
MT-00150
B: INSTALLATION
1) Install the reverse check sleeve.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
MT-00150
5MT-48

C: DISASSEMBLY
D: ASSEMBLY
1) Cover the reverse check sleeve with a rag, and

remove the snap ring using a screwdriver.
1) Install the return spring (1st-2nd), return spring

cap, reverse accent shaft, check cam, return spring
and check spring to the reverse check sleeve.
NOTE:
If deformed or worn, replace with a new snap ring.
(A)
NOTE:
Be sure to position the bent section of reverse
check spring to fit in the groove of the check cam.
(A)
(C)
(B)
(E)
(D)
(G)
(F)
MT-00153
(A) Snap ring
MT-00154
2) Remove the reverse check plate, reverse check

spring, reverse check cam, return spring (5th-Rev),
reverse accent shaft, return spring cap and return
spring (1st-2nd).
(A) Reverse check plate

(B) Reverse check spring
(C) Return spring (5th-Rev)
(D) Reverse check cam
(E) Reverse accent shaft
(A)
(F) Return spring cap

(G) Return spring (1st-2nd)
(C)
(B)
(E)
(D)
2) Hook the bent section of reverse check spring

over reverse check plate.
3) Rotate the cam so that the protrusion of the reverse check cam comes to the opening of the plate.
4) With cam held in that position, install the plate
onto the reverse check sleeve and hold in place
with the snap ring.
5) Position the new O-ring in the groove of sleeve.
(G)
(F)
MT-00154
(A) Reverse check plate

(B) Reverse check spring
(C) Return spring (5th-Rev)
(D) Reverse check cam
(E) Reverse accent shaft
(F) Return spring cap
(G) Return spring (1st-2nd)

NOTE:
For the reverse check sleeve, make sure only to
use an undamaged O-ring with no scratches on it.
Be careful not to damage the adjusting shim between reverse check sleeve assembly and the
case.
5MT-49

E: INSPECTION
Make sure the cutout of the reverse accent shaft
is aligned with the opening in the reverse check
sleeve.
Turn the cam by hand to check for smooth rotation.
Move the cam and shaft all the way toward the
plate, and make sure it releases.
If the cam does not return properly, replace the reverse check spring. If the shaft does not return,
check for scratches on the inner surface of sleeve.
If the sleeve is in good order, replace the spring.
If it is not possible to adjust the clearance with

only shims, replace the reverse accent shaft and
re-adjust.
Adjusting shim
Part No.
32190AA000
Thickness mm (in)
0.15 (0.0059)
32190AA010
0.30 (0.0118)
Part No.
(D)
(C)

Mark
Remarks
32188AA130
Neutral position is closer to 1st

gear.
32188AA140
Standard
32188AA150
Neutral position is closer to

reverse gear.
2. REVERSE CHECK PLATE ADJUSTMENT

1) Shift the shifter arm to 5th and then to reverse
to see if the reverse check mechanism operates
properly.
2) Also check to see if the arm returns to neutral
when released from the reverse position. If the arm
does not return properly, replace the reverse check
plate.
(A)
(B)
MT-00156
(A) Snap ring

(B) Reverse check plate
(C) Checking spring
(D) Check cam
Select a suitable reverse accent shaft and reverse check plate. <Ref. to 5MT-50, ADJUSTMENT, Reverse Check Sleeve.>
Part No.
32189AA000
Reverse check plate

(A):
Angle
Remarks
No.
Arm stops closer to
0
28
5th gear.
Arm stops closer to
1
31
5th gear.
F: ADJUSTMENT
32189AA010
1. NEUTRAL POSITION ADJUSTMENT
32189AA020
34
Arm stops in the center.
32189AA030
37
Arm stops closer to

reverse gear.
32189AA040
40
Arm stops closer to

reverse gear.
1) Shift the gear into 3rd gear position.

2) Because of the return spring, until the arm contacts the stopper the shifter arm will feel lighter
moving towards 1st/2nd gear and heavier towards
the reverse gear.
3) Make adjustment so that the heavy stroke (reverse side) is a little heavier than the lighter stroke
(1st/2nd side).
4) To adjust, remove the bolts holding the reverse
check sleeve assembly to the case, and move the
sleeve assembly outward, then place an adjustment shim (0 to 1 ea.) between the sleeve assembly and the case to adjust the clearance.
5) Be careful not to damage the O-ring when placing shims.
NOTE:
When the shim is removed, the neutral position
will move closer to reverse; when the shim is added, the neutral position will move closer to 1st gear.
5MT-50
(A)
MT-00157
Transmission Case
15.Transmission Case
7) Remove the drive pinion shaft assembly from

the left side of the transmission case and remove
the main shaft assembly.
A: REMOVAL
2) Remove the clutch release lever. <Ref. to CL15, REMOVAL, Release Bearing and Lever.>
Assembly.>
4) Remove the bearing mounting bolts.
NOTE:
Use a hammer handle, etc. to remove if too tight.
(A)
(B)
MT-00161
(A) Air assist injector solenoid valve

(B) Drive pinion shaft ASSY
8) Remove the differential assembly.

NOTE:
Do not confuse the right and left roller bearing
outer races.
Be careful not to damage the oil seal of retainer.
MT-01514
5) Remove the main shaft rear plate.

(A)
MT-00162
MT-01515
(A) Main shaft rear plate
6) Separate the transmission case into the right

and left cases by loosening the coupling bolts and
nuts.
MT-00160
5MT-51
Transmission Case
B: INSTALLATION
7) Tighten the bearing mounting bolts.
1) Wipe off grease, oil and dust on the mating surfaces of transmission cases with a cleaning solution.
2) Install the front differential assembly.
3) Install the main shaft assembly.
Install the transmission case knock pin into the
knock pin hole of needle bearing.
4) Install the drive pinion shaft assembly.
Install the transmission case knock pin into the roller bearing knock pin hole.
5) Apply liquid gasket, and then join the right side
and left side of the case together.
Tightening torque:
30 Nm (3.1 kgf-m, 22.1 ft-lb)
Liquid gasket
equivalent
6) Tighten the bolt together with the bracket and
the clip, as shown in the figure.
8) Perform backlash adjustment of the hypoid gear

and preload measurement of the roller bearing.
NOTE:
Insert the 10 mm bolts from the bottom and tighten the nuts at the top.
Put the cases together so that the drive pinion
shim and input shaft holder shims are not caught in
between.
Check that the speedometer gear is engaged.
Tightening torque:
8 mm bolt
25 Nm (2.5 kgf-m, 18.1 ft-lb)
10 mm bolt
39 Nm (4.0 kgf-m, 28.9 ft-lb)
(5)
MT-01516
(17)
(7)
(11)
(13)
(1)
(3)
(2)
(15)
(4)
(14)
(10) (6)
(8)
(12)
NOTE:
Support the drive pinion assembly with the ST.
ST 498427100
STOPPER
ST
(16)
(9)
MT-01514
MT-00172
9) Place the transmission with the left side of case

facing downward, and put ST1 on bearing cup.
10) Screw the retainer assembly from the bottom
into left case using ST2. Fit the ST3 on transmission main shaft. Shift the gear into 4th or 5th, and
turn the shaft several times. Screw in the retainer
while rotating the ST3 until a slight resistance is felt
on ST2.
This is the contact point of the hypoid gear and the
drive pinion shaft. Repeat the above sequence several times to ensure the contact point.
ST1 399780104 WEIGHT
ST2 18630AA010 WRENCH COMPL RETAINER
ST3 499927100 HANDLE
ST1
ST2
ST3
MT-00175
5MT-52
Transmission Case
11) With the O-ring on the upper side removed, remove the retainer weight and screw, and stop at a
point where a slight resistance is felt.
NOTE:
At this point, the backlash between the hypoid gear
and drive pinion shaft is zero.
ST
17) After checking the tooth contact of the hypoid

gears, remove the lock plate. Then loosen the retainer until the O-ring groove appears. Fit the Oring into the groove and then tighten the retainer up
to its original position before it was loosened.
Install the lock plate.
NOTE:
When loosening the retainer, record the turns it
took before the retainer was loosened.
Perform this for both upper and lower retainers.
Tightening torque:
T: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
MT-00176
12) Loosen the retainer on the lower side by 3

notches of the lock plate, and turn the retainer on
the upper side by the same amount in order to obtain the backlash.
13) Rotate the retainer of the upper side additionally by 1 notch in order to apply preload on taper roller bearing.
14) Temporarily attach both the upper and lower
lock plates, and put marks both the holder and lock
plate for later readjustment.
NOTE:
If it is hard to attach the lock plate, attach with the
front and back reversed.
15) Turn the transmission main shaft several times
while tapping around the retainer lightly with plastic
hammer.
16) Inspect and adjust backlash and tooth contact
of the hypoid gear. <Ref. to 5MT-70, INSPECTION,
Front Differential Assembly.>
T
MT-00177
18) Select the main shaft rear plate. <Ref. to 5MT58, ADJUSTMENT, Main Shaft Assembly for Single-range.>
19) Install the clutch release lever and bearing.
<Ref. to CL-15, INSTALLATION, Release Bearing
and Lever.>
Assembly.>
C: INSPECTION
Check the transmission case for cracks, damage,
or oil leaks.
5MT-53
Main Shaft Assembly for Single-range

16.Main Shaft Assembly for Single-range

A: REMOVAL
Assembly.>
3) Remove the transmission case. <Ref. to 5MT39, REMOVAL, Transfer Case and Extension Case
Assembly.>
4) Remove the drive pinion shaft assembly. <Ref.
to 5MT-59, REMOVAL, Drive Pinion Shaft Assembly.>
5) Remove the main shaft assembly.
C: DISASSEMBLY
1) Apply vinyl tape around the main shaft splines to
protect the oil seal from damage. Then pull out the
oil seal and needle bearing by hand.
2) Remove the lock nut from transmission main
shaft assembly.
NOTE:
Straighten the crimp before taking off lock nut.
ST1 498937000 TRANSMISSION HOLDER
ST2 499987003 SOCKET WRENCH (35)
B: INSTALLATION
1) Wrap the clutch splined section with vinyl tape to
prevent damage to the oil seal.
2) Apply UNILUBE #2 (or equivalent) to the sealing
lip of the oil seal.
3) Install the needle bearing and new oil seal onto
the front of the transmission main shaft assembly.
4) Attach the needle bearing outer race knock pin
hole into the transmission case knock pin.
ST2
ST1
MT-01517
3) Remove the 5th hub & sleeve No. 2, baulk lever,

5th baulk ring, 5th drive gear and 5th needle bearing from the transmission main shaft assembly.
(C)
(B)
(A)
NOTE:
Align the end face of the seal with surface (A) when
installing the oil seal.
MT-01518
(A) 5th hub & sleeve No. 2

(B) 5th baulk ring
(C) 5th drive gear
(A)
MT-00185
5) Install the drive pinion assembly. <Ref. to 5MT59, INSTALLATION, Drive Pinion Shaft Assembly.>
6) Install the transmission case. <Ref. to 5MT-52,
INSTALLATION, Transmission Case.>
Assembly.>
5MT-54

4) Using ST1 and ST2, remove the rest of parts.
D: ASSEMBLY
NOTE:
If necessary, use the new sleeve gear & hub assembly, when replacing the sleeve or hub assembly. Do not attempt to disassemble as they must
engage at a specified point. If they have to be disassembled, mark the engaging point beforehand.
1) Assemble individual sleeve and hub assemblies.

NOTE:
Position the open ends of the spring 120 apart.
(A)
(A)
(B)
ST1
(C)
(D)
ST2
MT-01523
(A) 3rd-4th hub ASSY

(B) 3rd gear side
(C) 5th hub & sleeve No. 2
(D) 5th gear side
MT-00190
(A) Press
2) Install the 3rd drive gear, outer baulk ring, synchro cone, inner baulk ring, sleeve and hub assembly for the 3rd needle bearing, on the transmission
main shaft.
5MT-55

NOTE:
Align the convex portion of baulk ring with the shifting insert.
4) Install the baulk ring, needle bearing, 4th drive

gear and 4th gear thrust washer to the transmission
main shaft.
(E)
NOTE:
Align the baulk ring and gear & hub assembly
with key convex portion.
Make sure the thrust washer is oriented in the
correct direction.
(A)
(D)
(A)
(B)
(C)
(F)
MT-00200
(A) 3rd needle bearing

(B) 3rd drive gear
(C) Inner baulk ring
(B)
(D) Synchro cone

(E) Outer baulk ring
MT-01407
(A) Groove
(F) Sleeve & hub ASSY
(B) Face this surface to 4th gear side.
3) Install the 4th needle bearing race onto transmission main shaft using ST1, ST2 and press.
CAUTION:
ST2 499877000 RACE 4-5 INSTALLER
ST2
5) Press-fit the ball bearing into the rear section of

transmission main shaft using ST1, ST2 and a
press.
CAUTION:
(A)
ST2
ST1
ST1
MT-00192
(A) 4th needle bearing race
MT-00194
5MT-56

6) Using the ST1 and ST2, install the 5th gear

thrust washer and 5th needle bearing race onto the
rear section of transmission main shaft.
Attach with the narrowed side of the baulk lever

on the 5th hub side.
(A) (B) (C)
CAUTION:
(D)
(E)
NOTE:
Make sure the thrust washer is oriented in the correct direction.
(F)
MT-01511
(A) Needle bearing

(B) 5th drive gear
(C) Baulk ring
(A)
(D) 5th hub & sleeve No. 2

(E) Lock washer
(F) Lock nut
MT-00195
(A)
(A) Face this surface to the 5th gear side.
(B)
7) Install rest of the parts to the rear section of the

transmission main shaft.
NOTE:
Align the convex portion of the baulk ring between the baulk lever.
MT-01522
(A) Baulk lever

(B) 5th hub
8) Tighten the lock nuts to the specified torque using ST1 and ST2.
9) Crimp lock nuts in two locations after tightening.
ST1 499987003 SOCKET WRENCH
ST2 498937000 TRANSMISSION HOLDER
Tightening torque:
120 Nm (12.2 kgf-m, 88.5 ft-lb)
5MT-57

E: INSPECTION
F: ADJUSTMENT
Disassembled parts should be washed clean first

and then inspected carefully.
1) Bearing
If the ball bearing, outer race or inner race is
damaged or rusted
2) Bushing (each gear)
Replace the bushing in following cases.
When the sliding surface is damaged or abnormally worn.
When the inner wall is excessively worn.
3) Gear
Replace the gear with new part if its tooth surfaces are broken, damaged or excessively worn.
Correct or replace if the cone that contacts the
baulk ring is rough or damaged.
Correct or replace if the inner surface or end face
is damaged.
4) Baulk ring
Replace the baulk ring in following cases.
When the inner surface and end face are damaged.
When the baulk ring inner surface is excessively
or partially worn down.
When the contact surface of the synchronizer
ring insert is scored or excessively worn down.
5) Shifting insert key
Replace the insert key if deformed, excessively
worn or abnormal in any way.
Selection of main shaft rear plate:

Using the ST, measure the protrusion amount (A)
of ball bearing from transmission main case surface, and select a suitable plate in the following table.
NOTE:
Before measuring, tap the end of main shaft with a
plastic hammer lightly in order to make the clearance zero between the main case surface and
moving flange of bearing.
ST 498147000
DEPTH GAUGE
MT-00208
6) Oil seal
Replace the oil seal if the lip is deformed, hardened, worn or abnormal in any way.
7) O-ring
Replace the O-ring if the sealing face is deformed,
hardened, damaged, worn or abnormal in any way.
8) Gearshift mechanism
Repair or replace the gearshift mechanism if excessively worn, bent or abnormal in any way.
5MT-58
Dimension (A)
mm (in)
4.00 4.13
(0.1575
0.1626)
3.87 3.99
(0.1524
0.1571)
Part No.
Mark
32294AA041
32294AA051
(A)
MT-00209

17.Drive Pinion Shaft Assembly
4) Inspection and adjustment of ST:
A: REMOVAL
NOTE:
Loosen the two bolts and adjust so that the scale
indicates 0.5 correctly when the plate end and the
scale end are on the same level.
Tighten the two bolts.
ST 499917500
DRIVE PINION GAUGE
ASSY

Assembly.>
3) Remove the transmission case. <Ref. to 5MT51, REMOVAL, Transmission Case.>
4) Remove the drive pinion shaft assembly.
(A)
NOTE:
Use a hammer handle, etc. to remove if too tight.
(A)
(B)
(B)
ST
MT-00242
(A) Plate
(B) Scale
MT-00161
(A) Air assist injector solenoid valve

(B) Drive pinion shaft ASSY
B: INSTALLATION
1) Remove the differential assembly.
2) Alignment marks/numbers on hypoid gear set:
The upper number on the drive pinion is a match
(A) for combining it with hypoid drive gear. The lower number is for shim adjustment (B). If no lower
number is shown, the value is zero. The number on
hypoid driven gear indicates a number for mating
with the drive pinion.
5) Position the ST by inserting the knock pin of ST

into the knock hole of transmission case.
ST 499917500
DRIVE PINION GAUGE
ASSY
6) Slide the drive pinion gauge scale with finger tip
and read the value at the point where it matches
with the end face of drive pinion.
ST 499917500
DRIVE PINION GAUGE
ASSY
ST
(A)
(A)
MT-00243
(A) Adjust the clearance to zero without shim.

+0
.1
(A)
7) The thickness of shim shall be determined by

adding the value indicated on drive pinion to the
value indicated on the ST. (Add if the number on
drive pinion is prefixed by +, and subtract if the
number is prefixed by .)
ST 499917500
DRIVE PINION GAUGE
ASSY
(B)
MT-00241
(A) Alignment number

(B) Number for shim adjustment
3) Place the drive pinion shaft assembly on transmission main case RH without shim and tighten the
bearing mounting bolts.
5MT-59

8) Select one to three shims in the following table

for the value determined as described above, and
take the shim(s) which thickness is closest to the
said value.
Drive pinion shim
Part No.
32295AA031
Thickness mm (in)
0.150 (0.0059)
32295AA041
32295AA051
0.175 (0.0069)
0.200 (0.0079)
32295AA061
32295AA071
0.225 (0.0089)
0.250 (0.0098)
32295AA081
32295AA091
0.275 (0.0108)
0.300 (0.0118)
32295AA101
0.500 (0.0197)
C: DISASSEMBLY
NOTE:
Attach a cloth to the end of driven shaft (on the frictional side of thrust needle bearing) to prevent
damage during disassembly or reassembly.
1) Unlock the crimping of lock nut. Remove the lock
nut with ST1, ST2 and ST3.
ST2 498427100 STOPPER
ST1
ST2
9) Install the differential assembly. <Ref. to 5MT67, INSTALLATION, Front Differential Assembly.>
10) Set the transmission main shaft assembly and
drive pinion assembly in position. (So there is no
clearance between the two when moved all the way
to the front). Inspect the suitable 1st2nd, 3rd4th
and 5th shifter fork so that the coupling sleeve and
reverse driven gear are positioned in the center of
their synchronizing mechanisms. <Ref. to 5MT-64,
INSPECTION, Drive Pinion Shaft Assembly.>
Assembly.>
ST3
MT-00244
2) Draw out the drive pinion from driven shaft.

Remove the differential bevel gear sleeve, adjusting washer No. 1, adjusting washer No. 2, thrust
bearing, needle bearing and drive pinion collar.
(F)
(E)
(G)
(H)
(A)
(B)
(D)
(C)
MT-00245
(A) Differential bevel gear sleeve

(B) Adjusting washer No.1 (25 37.5 t)
(C) Thrust bearing (25 37.5 3)
(D) Adjusting washer No. 2 (25 37.5 4)
(E) Needle bearing (25 30 20)
(F) Drive pinion collar
(G) Needle bearing (30 37 23)
(H) Thrust bearing (33 50 3)
5MT-60

3) Remove the roller bearing and washer using ST

and a press.
NOTE:
Do not reuse the roller bearing.
ST 498077000
REMOVER
7) Remove the roller bearing, 3rd-4th driven gear

using ST1 and ST2.
ST1
ST2
ST
MT-00249
MT-00246
4) Unlock the crimping of lock nut. Remove the lock

nut using ST1 and ST2.
ST2
8) Remove the key.

9) Remove the 2nd driven gear, inner baulk ring,
synchro cone and outer baulk ring.
(D)
(A)
ST1
(B)
(C)
MT-01329
(A) 2nd driven gear

MT-00247
(B) Inner baulk ring

(C) Synchro cone
5) Remove the 5th driven gear using ST.

ST 499857000
5TH DRIVEN GEAR REMOVER
(D) Outer baulk ring
10) Remove the 1st driven gear, inner baulk ring,

synchro cone, outer baulk ring, 2nd driven gear
bushing, gear & hub using ST1 and ST2.
(A)
ST
(D)
MT-00248
6) Remove the woodruff key.

(C)
(A) 1st driven gear

(C) Synchro cone
5MT-61
(B)
MT-00992

NOTE:
If necessary, use the new gear & hub assembly,
when replacing the gear or hub assembly. Do not
attempt to disassemble as they must engage at a
specific point. If they have to be disassembled,
mark the engaging point beforehand.
3) Install the 1st driven gear, inner baulk ring, synchro cone, outer baulk ring, gear & hub assembly
onto driven shaft.
(A)
(D)
ST1
(C)
(B)
MT-00992
(A) 1st driven gear
ST2

(C) Synchro cone
MT-00251
11) Remove the sub gear for 1st driven gear. (Nonturbo model)
D: ASSEMBLY
1) Install the sleeve and gear & hub assembly by
matching alignment marks.
NOTE:
Use the new gear and hub assembly, if the gear &
hub have been replaced.
(B)
(A)
NOTE:
Take care to install the gear & hub assembly in
proper direction.
Align the baulk ring and gear & hub assembly
with key convex portion.
4) Install the 2nd driven gear bushing onto driven
shaft using ST1, ST2 and a press.
CAUTION:
NOTE:
Attach a cloth to the end of driven shaft to prevent damage.
When press fitting, align the oil holes of shaft and
bush.
(C)
(D)
MT-00252
(A) 1st gear side

(B) 2nd gear side
ST1
(C) Flush surface

(D) Stepped surface
ST2
2) Install the washer, snap ring and sub gear onto

1st driven gear.
MT-00253
5MT-62

5) Install the 2nd driven gear, inner baulk ring, synchro cone and outer baulk ring, and insert them
onto driven shaft.
(D)
8) Position the woodruff key in groove of the rear of

driven shaft. Install the 5th driven gear onto driven
shaft using ST and a press.
CAUTION:
ST 499277200
INSTALLER
(A)
ST
(B)
(C)
MT-01329
(A) 2nd driven gear

(C) Synchro cone
MT-00257
6) After installing key on driven shaft, install the

3rd-4th driven gear using ST and a press.
CAUTION:
9) Install the lock washer. Install the lock nut and

tighten to the specified torque using ST.
ST 499987300
SOCKET WRENCH (50)
Tightening torque:
260 Nm (26.5 kgf-m, 192 ft-lb)
ST
NOTE:
Align the convex portion of baulk ring with insert.
ST 499277200
INSTALLER
ST
MT-00258
MT-00255
7) Install a set of roller bearings onto the driven

shaft using ST and a press.
NOTE:
Crimp the locknut in 2 locations.
Using spring balancer, check that starting torque
of roller bearing is 0.1 to 1.5 N (0.01 to 0.15 kgf,
0.02 to 0.33 ft).
CAUTION:
ST 499277200
INSTALLER
MT-00259
ST
MT-00256
5MT-63

10) Install the roller bearing onto drive pinion.

NOTE:
When installing the roller bearing, note its directions (front and rear) because the knock pin hole of
outer race is offset.
NOTE:
Be careful to install the spacer in the proper direction.
(A) (B)
(A)
(C) (D) (E) (F) (G) (H)

MT-00263
(A) Driven shaft
(B)
MT-00260

(C) Drive pinion collar
(A) Roller bearing
(D) Needle bearing (25 30 20)

(E) Adjusting washer No. 2 (25 36 4)
(B) Knock pin hole
11) Install the washer using ST1, ST2 and a press.

NOTE:
Replace lock nut with new parts.
Crimp the locknut in 4 locations.
ST1 499277100 BUSHING 1-2 INSTALLER
(F) Thrust bearing (25 37.5 3)

(G) Adjusting washer No. 1 (25 36 t)
(H) Differential bevel gear sleeve
E: INSPECTION
ST2
ST1
(A)
MT-00261
(A) Washer
12) Install the thrust bearing and needle bearing.

Install the driven shaft assembly.
Disassembled parts should be washed clean first

and then inspected carefully.
1) Bearing
If the ball bearing, outer race or inner race is
damaged or rusted
The roller bearing on the rear side of the drive
pinion shaft should be checked for smooth rotation
before the drive pinion assembly is disassembled.
In this case, because a preload is working on the
bearing, its rotation feels like it is slightly dragging
unlike other bearings.
(A)
(B)
MT-00262
MT-00264
13) Install the drive pinion collar, needle bearing,

adjusting washer No. 2, thrust bearing, adjusting
washer No. 1 and differential bevel gear sleeve in
this order.
(A) Drive pinion shaft

(B) Roller bearing
5MT-64

2) Bushing (each gear)

Replace the bushing in following cases.
When the sliding surface is damaged or abnormally worn.
When the inner wall is excessively worn.
3) Gear
Replace gears with new part if its tooth surfaces
are broken, damaged or excessively worn.
Correct or replace if the contact with the baulk
ring cone is rough or damaged.
Correct or replace if the inner surface or end face
is damaged.
4) Baulk ring
Replace the ring in following cases.
When the inner surface and end face are damaged.
When the ring inner surface is excessively or
partially worn down.
If the gap between the end faces of the ring and
the gear splined part is excessively small when the
ring is pressed against the cone.
F: ADJUSTMENT
1. THRUST BEARING PRELOAD
1) Select adjusting washer No. 1 to adjust the dimension (H) to zero through a visual check. Position washer (18.3 30 4) and lock washer (18
30 2) and install lock nut (18 13.5).
Clearance (A):
0.5 1.0 mm (0.020 0.040 in)
(H)
(A)
MT-00267
2) Using the ST1, ST2 and ST3, tighten the lock nut
to the specified torque.
ST2 498427100 STOPPER
MT-00265
When the contact surface of the synchronizer

ring insert is damaged or excessively worn down.
5) Shifting insert key
Replace the insert if deformed, excessively worn or
abnormal in any way.
Tightening torque:
120 Nm (12.2 kgf-m, 88.5 ft-lb)
ST1
ST2
ST3
MT-00268
MT-00208
6) Oil seal
Replace the oil seal if the lip is deformed, hardened, worn or abnormal in any way.
7) O-ring
Replace the O-ring if the sealing face is deformed,
hardened, damaged, worn or abnormal in any way.
5MT-65

3) After removing the ST2, measure the starting

torque using torque driver.
Starting torque:
0.3 0.8 Nm (0.03 0.08 kgf-m, 0.2 0.6 ftlb)
5) If specified starting torque range cannot be obtained, use a No. 1 adjusting washer and a suitable
No. 2 adjusting washer which is selected from the
following table. Repeat steps 1) through 4) to adjust
starting torque.
ST1
ST3
(A)
(B)
MT-00270
(A) Adjusting washer No. 1

MT-00269
(B) Adjusting washer No. 2
4) If the starting torque is not within the specified

limit, select new adjusting washer No. 1 and recheck starting torque.
Starting torque
Low
Dimension H
Small
Washer No. 2
Select thicker one.
High
Large
Select thinner one.

Part No.
803025059
Thickness mm (in)
3.850 (0.1516)
803025054
803025058
4.000 (0.1575)
4.150 (0.1634)
(A)
(B)
MT-00270
(A) Adjusting washer No. 1
6) Recheck that the starting torque is within the

specified range, then crimp the lock nut at four positions.
(B) Adjusting washer No. 2

Part No.
Thickness mm (in)
803025051
803025052
3.925 (0.1545)
3.950 (0.1555)
803025053
803025054
3.975 (0.1565)
4.000 (0.1575)
803025055
803025056
4.025 (0.1585)
4.050 (0.1594)
803025057
4.075 (0.1604)
5MT-66
Reverse Idler Gear

20.Reverse Idler Gear
B: INSTALLATION
A: REMOVAL
1) Install the reverse shifter lever, reverse idler

gear and reverse idler gear shaft, and secure them
with the straight pin.

2) Remove the back-up light switch and the neutral
position switch. <Ref. to 5MT-35, REMOVAL,
Assembly.>
4) Remove the transmission case. <Ref. to 5MT59, REMOVAL, Drive Pinion Shaft Assembly.>
<Ref. to 5MT-54, REMOVAL, Main Shaft Assembly
for Single-range.>
7) Remove the differential assembly. <Ref. to 5MT67, REMOVAL, Front Differential Assembly.>
8) Remove the shifter forks and rods. <Ref. to 5MT77, REMOVAL, Shifter Fork and Rod.>
9) Pull out the straight pin, and remove the reverse
idler gear shaft, reverse idler gear and washer.
(B)
(A)
(C)
(D)
MT-00303
(A) Straight pin

(B) Reverse idler gear shaft
(C) Reverse idler gear
(D) Washer
10) Remove the reverse shifter lever.
NOTE:
Be sure to install the reverse idler shaft from rear
side.
(A)
(B)
(D)
(C)
MT-00304
(A) Reverse shifter lever

(B) Reverse idler gear
(C) Reverse idler gear shaft
(D) Straight pin
2) Check and adjust clearance between the reverse idler gear and the transmission case wall surface. <Ref. to 5MT-76, INSPECTION, Reverse
Idler Gear.> <Ref. to 5MT-76, ADJUSTMENT, Reverse Idler Gear.>
3) Install the shifter forks and rods. <Ref. to 5MT77, INSTALLATION, Shifter Fork and Rod.>
<Ref. to 5MT-54, INSTALLATION, Main Shaft Assembly for Single-range.>
6) Install the drive pinion shaft assembly. <Ref. to
5MT-59, INSTALLATION, Drive Pinion Shaft Assembly.>
Assembly.>
5MT-75
Reverse Idler Gear

C: INSPECTION
D: ADJUSTMENT
1) Move the reverse shifter rod toward the reverse

side. Check and adjust clearance between the reverse idler gear and the timing case wall surface.
If out of specification, select an appropriate reverse
shifter lever and adjust.
1) Select the appropriate reverse shifter lever from

the table below, and adjust until the gap between
the reverse idler gear and transmission case wall is
within specification.
Clearance A:
6.0 7.5 mm (0.236 0.295 in)
Clearance A:
6.0 7.5 mm (0.236 0.295 in)
A
A
MT-00305
MT-00305
2) After installing a suitable reverse shifter lever,

shift into neutral. Check and adjust clearance between the reverse idler gear and the timing case
wall surface.
If out of specification, select the appropriate washer
and adjust.
Clearance:
0 0.5 mm (0 0.020 in)

Part No.
32820AA070
Mark
7
Remarks
Far from case wall
32820AA080
32820AA090
8
9
Standard
Closer to case wall
2) Select the appropriate washer from the table below, and adjust until the gap between the reverse
idler gear and transmission case wall is within
specification.
Clearance:
0 0.5 mm (0 0.020 in)
MT-00306
3) Check the reverse idler gear and shaft for damage. Replace if damaged.
MT-00306
Washer
5MT-76
Part No.
803020151
Thickness mm (in)
0.4 (0.016)
803020152
803020153
1.1 (0.043)
1.5 (0.059)
803020154
803020155
1.9 (0.075)
2.3 (0.091)
Shifter Fork and Rod

21.Shifter Fork and Rod
NOTE:
When removing the rod, keep other rods in neutral.
A: REMOVAL
2) Remove the back-up light switch and the neutral
position switch. <Ref. to 5MT-35, REMOVAL,
Assembly.>
4) Remove the transmission case. <Ref. to 5MT51, REMOVAL, Transmission Case.>
<Ref. to 5MT-54, REMOVAL, Main Shaft Assembly
for Single-range.>
7) Remove the differential assembly. <Ref. to 5MT67, REMOVAL, Front Differential Assembly.>
8) Drive out the straight pin by tapping with the ST,
and pull out the 5th shifter fork.
ST 398791700
STRAIGHT PIN REMOVER
(C)
(A)
(B)
MT-00994
(A) Straight pin

(B) 3rd-4th fork rod
(C) Shifter fork
11) Drive out the straight pin, and pull out the 1st2nd fork rod and shifter fork.
12) Remove the snap ring (outer), and pull out the
reverse shifter rod arm and reverse fork rod. Then
take out the ball, spring and interlock plunger from
the rod.
And then remove the rod.
NOTE:
When pulling out the reverse shifter rod arm, be
careful not to let the ball pop out of arm.
13) Remove the reverse shifter lever.
B: INSTALLATION
(B)
(A)
MT-00309
(A) Straight pin

(B) 5th shifter fork
9) Remove the plugs, springs and check balls.

10) Drive out the straight pin, and pull out the 3rd4th fork rod and shifter fork.
1) Apply grease to the plunger.

ST 399411700
ACCENT BALL INSTALLER
2) Install the reverse arm fork spring, ball and interlock plunger to the reverse fork rod arm. Insert the
reverse fork rod into the hole of the reverse fork rod
arm, and hold it with snap ring (outer) using ST.
3) Position the ball, spring and new gasket in the
reverse shifter rod hole on the left side of transmission case, and tighten the checking ball plug.
4) Install the 1st-2nd fork rod into 1st-2nd shifter
fork through the hole on the rear of transmission
case.
5) Align the holes in the rod and the fork, and drive
the new straight pin into these holes using the ST.
NOTE:
Set other rods to neutral.
Make sure the interlock plunger is on the 3rd-4th
fork rod side.
ST 398791700
6) Apply grease to the plunger.
7) Attach the interlock plunger on 3rd-4th fork rod.
8) Attach the 3rd-4th fork rod into 3rd-4th shifter
fork through the hole on the rear of transmission
case.
5MT-77

9) Align the holes in the rod and the fork, and drive
the new straight pin into these holes.
NOTE:
Set the reverse fork rod to neutral.
Make sure the interlock plunger (before installation) is on the reverse fork rod side.
ST 398791700
10) Install the 5th shifter fork onto the rear of reverse fork rod. Align the holes in the two parts and
drive new straight pin into the specified place.
ST 398791700
C: INSPECTION
1) Check the shift shaft and shift rod for damage.
Replace if damaged.
2) Gearshift mechanism
Repair or replace the gearshift mechanism if excessively worn, bent or abnormal in any way.
3) Inspect the clearance between 1st, 2nd driven
gear and reverse driven gear. If any clearance is
not within specifications, replace the shifter fork as
required.
Clearance (a) and (b):
9.5 mm (0.374 in)
(B)
(A)
(a)
(b)
(B)
(A)
(C)
(C)
MT-00311
MT-01398
(A) 5th shifter fork

(B) Reverse fork rod
(A) 1st driven gear

(B) Reverse driven gear
(C) Straight pin
11) Position the balls, checking ball springs and

new gaskets into 3rd-4th fork rods and 1st-2nd fork
rod holes, and install plugs.
<Ref. to 5MT-54, INSTALLATION, Main Shaft Assembly for Single-range.>
14) Install the drive pinion shaft assembly. <Ref. to
5MT-59, INSTALLATION, Drive Pinion Shaft Assembly.>
Assembly.>
5MT-78
(C) 2nd driven gear

Part No.
Mark
32804AA060
32804AA070
No mark
32804AA080
Remarks
0.2 mm on 1st gear
Near (0.008 in)
Standard
0.2 mm on 2nd gear
Near (0.008 in)

4) Inspect the clearance between the 3rd, 4th drive

gear and the coupling sleeve. If any clearance is
not within specifications, replace the shifter fork as
required.
Clearance (a):
9.3 mm (0.366 in)
(A)
(a)
(B)
Clearance (a) and (b):

7.3 mm (0.287 in)
(a)
(B)
(A)
(b)
(C)
MT-01512
(A) 5th drive gear

(B) Coupling sleeve
MT-00940
5th shifter fork (Non-turbo)
(A) 3rd drive gear

(B) Coupling sleeve
(C) 4th drive gear
Part No.

Mark
32810AA061
32810AA071
No mark
32810AA101
Remarks
Part No.
Mark
32812AA201
32812AA211
No mark
32812AA221
Remarks
Approaches 5th gear
by 0.2 mm (0.008 in).
Standard
Moves away from 5th
gear by 0.2 mm
(0.008 in).
0.2 mm on 4th gear

Near (0.008 in)
5th shifter fork (Turbo)
Standard
0.2 mm on 3rd gear
Near (0.008 in)
5) Inspect the clearance between 5th drive gear

and coupling sleeve. If any clearance is not within
specifications, replace the shifter fork as required.
Part No.
Mark
32812AA231
32812AA241
No mark
32812AA251
Remarks
Approaches 5th gear
by 0.2 mm (0.008 in).
Standard
Moves away from 5th
gear by 0.2 mm
(0.008 in).
6) Inspect the rod end clearances (A) and (B). If

any clearance is not within specifications, replace
the rod or fork as required.
Clearance (B):
1st-2nd 3rd-4th
0.4 1.4 mm (0.016 0.055 in)
Clearance (A):
3rd-4th 5th
0.5 1.3 mm (0.020 0.051 in)
(B)
(A)
MT-00379
5MT-79


A: INSPECTION
1. MANUAL TRANSMISSION
Symptoms
1. The gears are not mating well.
NOTE:
The cause for difficulty in shifting gears
can be classified into two kinds: One is a
abnormal gear shift system and the other
is abnormal transmission. However, if the
operation is heavy and engagement of the
gears is difficult, problem with clutch disengagement may also be responsible.
Check whether the clutch is correctly
functioning, before checking the gear shift
system and transmission.
Possible cause
(a) Worn, damaged or burred chamfer at
internal spline of sleeve and reverse
driven gear
(b) Worn, damaged or burred chamfer of
gear spline
(c) Worn or scratched bushings
2. Gear slip-out
Gear slips out when coasting on rough
road.
Gear slips out during acceleration.
(a) Abnormal pitching stopper adjustment Adjust.

(b) Loose engine mounting bolts
Tighten or replace.
3. Unusual noise comes from transmission.

NOTE:
If a noise is heard when the vehicle is
parked with its engine idling and if a noise
ceases when the clutch is disengaged, it
may be considered that the noise is coming from the transmission.
(d) Incorrect contact or wear between

synchronizer ring and gear cone
Corrective action
Replace.
Replace.
Replace.
Correct or replace.
(c) Worn fork shifter, broken shifter fork

rail spring
Replace.
(d) Worn or damaged ball bearing

(e) Excessive clearance between splines
of synchronizer hub and synchronizer
sleeve
(f) Synchronizer hub tooth step wear
Replace.
Replace.
(g) Worn 1st driven gear and driven shaft

(h) Worn 2nd driven gear and 2nd bushing
(i) Worn reverse idler gear and bushing
Replace.
Replace.
Replace.
Replace.
(a) Insufficient or improper lubrication

Lubricate with specified oil or replace.
(b) Worn or damaged gears and bearings Replace.
NOTE:
If the trouble is only wear of the gear teeth
surfaces, only a high whirring noise will
occur at high speeds, but if any part is broken, rhythmical clicking sounds will be
heard even at low speeds.
5MT-80

2. DIFFERENTIAL
Symptoms
1. Broken differential (case, gear, bearing, etc.)
NOTE:
Noise will occur, and eventually the differential will not be able to operate due to
broken pieces obstructing the gear revolution.
2. Differential and hypoid gear noises

Problems in the differential and hypoid
gear always appear as noise problems.
Therefore, the generation of noise is the
first indication of a problem. However,
noises from the engine, muffler, tire,
exhaust gas, bearing, body, etc. are easily mistaken for the differential noise. Pay
special attention to the hypoid gear noise
because it is easily confused with other
gear noises. There are the following four
kinds of noises.
Gear noise when driving: If noise
increases as the vehicle speed
increases, it may be due to insufficient
gear oil, incorrect gear engagement,
damaged gears, etc.
Gear noise when coasting: Damaged
gears due to misadjusted bearings and
incorrect shim adjustment.
Bearing noise when driving or coasting:
Cracked, broken or damaged bearings
Noise mainly when turning: Noise from
differential side gear, differential pinion or
differential pinion shaft, etc.
Possible cause
(a) Insufficient or improper oil
(b) Use of vehicle under severe conditions such as excessive load and
improper use of the clutch
(c) Improper adjustment of taper roller
bearing
(d) Improper adjustment of the drive pinion and the hypoid driven gear
Corrective action
Disassemble the differential and replace
broken components. At the same time
check other components for any trouble,
and replace if necessary.
Readjust the preload and backlash of the
bearing, and the contact surface of gear.
Adjust.
Adjust.
(e) Excessive backlash of a vehicle under

severe operating conditions due to worn
differential side gear, washer or differential pinion.
(f) Loose hypoid driven gear clamping
bolts
(a) Insufficient oil
Add recommended oil to the specified

level. Do not use vehicle under severe
operating conditions.
(b) Improper adjustment of hypoid driven

gear and drive pinion
Check the tooth contact.
(c) Worn teeth of hypoid driven gear and

drive pinion
(d) Loose roller bearing
Replace as a set.
Readjust the bearing preload.
Readjust the backlash of the hypoid
driven gear to drive pinion, and check the
tooth contact.
(e) Distorted hypoid driven gear or differential case

(f) Worn washer and differential pinion
shaft
Replace.
5MT-81
Tighten.
Lubricate.
Replace.

5MT-82
General Description
CLUTCH SYSTEM
A: SPECIFICATION
Model
Clutch
cover
Non-turbo
Type
Diaphragm set load
Push type
kgf (lbf)
Facing material
Clutch
disc
O.D. I.D.
thickness
mm (in)
Flywheel side
Pressure plate side
Spline outer diameter

Clutch release lever ratio
Release bearing
Full stroke
Clutch
pedal
Free play
Clutch
disc
Depth of rivet
head
Limit of runout
Turbo
580 (1,276)
mm (in)
25.2 (0.992), (Number of teeth: 24)

1.6
1.6
Grease-packed self-aligning
130 135 (5.12 5.32)
mm (in)
mm (in)
Standard
mm (in)
4.35 11.1 (0.17 0.44)

Flywheel side: 1.35 1.95 (0.053 0.077)
Clutch cover side: 1.65 2.25 (0.065 0.089)
Limit of
sinking
mm (in)
800 (1,760)
Woven (Non asbestos)

230 155 3.2
(9.06 6.10 0.126)
225 150 3.5
(8.86 5.9 0.138)
230 155 3.5
(9.06 6.10 0.138)
0.3 (0.012)
0.7 (0.028) at R = 107.5 (4.23)
CL-2
0.7 (0.028) at R = 110.0 (4.33)
General Description
CLUTCH SYSTEM
B: COMPONENT
1. CLUTCH ASSEMBLY
NON-TURBO MODEL
(1)
(4)
(2)
(5)
(3)
(6)
T1
T2
(5)
T1
(7)
(8)
(9)
CL-00496
(1)
Release lever dust cover
(6)
Release bearing
(2)
(3)
Lever spring
Pivot
(7)
(8)
Clutch cover
Clutch disc
(4)
(5)
Release lever
Clip
(9)
Flywheel
CL-3

T1: 16 (1.6, 11.6)
T2: 72 (7.3, 52.8)
General Description
CLUTCH SYSTEM
TURBO MODEL
(1)
(2)
(4)
(5)
T1
T2
(3)
T1
(6)
(7)
(8)
CL-00498
(1)
Release lever dust cover
(5)
Release bearing
(2)
(3)
Lever spring
Pivot
(6)
(7)
Clutch cover
Clutch disc
(4)
Release lever
(8)
Flywheel
CL-4

T1: 16 (1.6, 11.6)
T2: 72 (7.3, 52.8)
General Description
CLUTCH SYSTEM
2. CLUTCH PIPE AND HOSE (NON-TURBO MODEL)
(10)
(7)
(8)
(9)
T3
T2
T4
T3
(6)
(3)
(4)
(5)
T5
(2)
(1)
T1
CL-00374
(1)
(2)
Operating cylinder
Washer
(6)
(7)
Clutch pipe
Master cylinder ASSY
(3)
(4)
Clutch hose
Bracket
(8)
(9)
Clevis pin
Snap pin
T2: 15 (1.5, 10.8)

T3: 18 (1.8, 13.0)
(5)
Clip
(10)
Lever
T4: 25 (2.5, 18.1)

T5: 37 (3.8, 27.5)
CL-5

T1: 7.8 (0.8, 5.8)
General Description
CLUTCH SYSTEM
3. CLUTCH PIPE AND HOSE (TURBO MODEL)
(8)
(9)
(7)
(10)
T2
T3
T4
T3
(6)
(3)
(4)
(5)
T5
(2)
(1)
T1
CL-00411
(1)
(2)
Operating cylinder
Washer
(6)
(7)
Clutch pipe
Master cylinder ASSY
(3)
(4)
Clutch hose
Bracket
(8)
(9)
Clevis pin
Snap pin
T2: 15 (1.5, 10.8)

T3: 18 (1.8, 13.0)
(5)
Clip
(10)
Lever
T4: 25 (2.5, 18.1)

T5: 37 (3.8, 27.5)
CL-6

T1: 7.8 (0.8, 5.8)
General Description
CLUTCH SYSTEM
4. MASTER CYLINDER
Non-turbo model
(1)
(12)
T1
(11)
(2)
(10)
(3)
(9)
(4)
(8)
(5)
(7)
(6)
T2
CL-00005
(1)
Reservoir cap
(7)
Gasket
(2)
(3)
Reservoir tank
Oil seal
(8)
(9)
Return spring
Piston
(4)
(5)
Straight pin
Master cylinder
(10)
(11)
Push rod
Piston stop ring
(6)
Clutch damper
(12)
Cylinder boot
CL-7
T1: 10 (1.0, 7)
T2: 46.6 (4.75, 34.4)
General Description
CLUTCH SYSTEM
Turbo model
(12)
(1)
T1
(11)
(2)
(10)
(3)
(4)
(9)
(8)
(5)
(7)
(6)
T2
CL-00109
(1)
(2)
Reservoir cap
Reservoir tank
(7)
(8)
Gasket
Return spring
(3)
(4)
Oil seal
Straight pin
(9)
(10)
Piston
Push rod
(5)
(6)
Master cylinder
Clutch damper
(11)
(12)
Piston stop ring

Cylinder boot

T1: 10 (1.0, 7.2)
T2: 46.6 (4.75, 34.4)
CL-8
General Description
CLUTCH SYSTEM
5. OPERATING CYLINDER
T
(7)
(3)
(2)
(1)
(5)
(6)
(4)
CL-00491
(1)
(2)
Push rod
Boot
(5)
(6)
Piston spring
Operating cylinder
(3)
(4)
Piston (Non-turbo model)

Piston (Turbo model)
(7)
Bleeder screw
CL-9

T: 7.8 (0.8, 5.8)
General Description
CLUTCH SYSTEM
6. CLUTCH PEDAL
(7)
(3)
(26)
(11)
(25)
T2
(4)
T1
T2
(2)
(24)
T2
(23)
(11)
T1
(22)
T1
(20)
(1)
(21)
(27)
(2)
T1
(19) (18)
(14)
(1)
(13) (14)
(4)
(8)
(2)
(7)
(2)
(17)
(16)
(15)
(7)
(12) (11)
(5)
(1)
(6)
(9)
(10)
CL-00088
(1)
(2)
Stopper
Bushing
(12)
(13)
Clutch clevis pin

Assist rod A
(22)
(23)
Clutch switch
Stop light switch
(3)
(4)
Spring pin
Snap pin
(14)
(15)
Clip
Assist spring
(24)
(25)
Pedal bracket
Clutch master cylinder bracket
(5)
(6)
Brake pedal pad

Brake pedal
(16)
(17)
Assist bushing
Assist rod B
(26)
(27)
Lever
Clutch switch (Clutch start)
(7)
(8)
Clevis pin
Brake pedal spring
(18)
(19)
Spring S
Rod S
(9)
(10)
Clutch pedal pad

Clutch pedal
(20)
(21)
Bushing S
Clip
(11)
Bushing C
CL-10
T1: 8 (0.8, 5.8)

T2: 18 (1.8, 13.0)
General Description
CLUTCH SYSTEM
C: CAUTION
sure to clarify the problem. Avoid unnecessary removal, installation, disassembly and replacement.

points.
Before installing O-rings or snap rings, apply sufficient amount of fluid to avoid damage and deformation.
Keep fluids away from the vehicle body. If any
fluid contacts the vehicle body, immediately flush
the area with water.
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
498497100
CRANKSHAFT
STOPPER
Used for stopping rotation of the flywheel when

loosening/tightening bolts, etc.
499747100
CLUTCH DISC
GUIDE
Used when installing the clutch disc to the

flywheel.
ST-498497100
ST-499747100
2. GENERAL TOOL
TOOL NAME
REMARKS
Circuit tester
Dial gauge
Used for measuring resistance, voltage and ampere.

Used for measuring clutch disc run-out.
Depth gauge
Used for measuring clutch disc wear.
CL-11
Clutch Disc and Cover

CLUTCH SYSTEM
2. Clutch Disc and Cover
2) Install the clutch cover to the flywheel, and tighten the bolts to the specified torque.
A: REMOVAL
1) Remove the transmission assembly from the vehicle body. <Ref. to 5MT-26, REMOVAL, Manual
2) Attach the ST on the flywheel.
ST 499747100
CRANKSHAFT STOPPER
(A)
NOTE:
When installing the clutch cover to the flywheel,
position the clutch cover in order to make the gap
between inbalance marks (
paint mark) of flywheel and clutch cover 120 or more. (The inbalance marks show the residual inbalance direction.)
Note the front and rear of the clutch disc when installing.
Tighten the clutch cover installing bolts gradually. Each bolt should be tightened to the specified
torque in a crisscross order.
Tightening torque:
16 Nm (1.6 kgf-m, 11.6 ft-lb)
ST
CL-00011
(A) Clutch cover
3) Remove the clutch cover and clutch disc.

NOTE:
Take care not to allow oil to touch the clutch disc
face.
Do not disassemble the clutch cover or clutch
disc.
Be sure to mark alignment marks on the flywheel
and clutch cover before removing the clutch cover.
(A)
(3)
B: INSTALLATION
1) Insert the ST into the clutch disc and attach to
the flywheel by inserting the ST end into pilot bearing.
(1)
(5)
(6)
NOTE:
When installing the clutch disc, be careful to attach
in the correct direction.
ST 499747100
CLUTCH DISC GUIDE
(2)
(4)
ST
CL-00013
(A) Unbalance mark (paint)
3) Remove the ST.

ST 499747100
CLUTCH DISC GUIDE
4) Install the transmission assembly. <Ref. to 5MT28, INSTALLATION, Manual Transmission Assembly.>
ST
(A)
C: INSPECTION
1. CLUTCH DISC
CL-00012
(A) Flywheel side
1) Facing wear
Measure the depth of the rivet head from the surface of facing. Replace if the facings are worn locally or worn down to less than the specified value.
Depth of rivet head:
Limit of sinking
0.3 mm (0.012 in)
CL-12
Clutch Disc and Cover

CLUTCH SYSTEM
NOTE:
Do not wash the clutch disc with any cleaning fluid.
5) Replace parts that have problems such as worn

splines, loose rivets and torsion spring failure.
CL-00017
CL-00014
2) Hardened facing
Correct by using emery paper, or replace.
3) Oil soakage on facing
Replace the clutch disc and inspect transmission
front oil seal, transmission case mating surface, engine rear oil seal and other points for oil leakage.
(A) Spline
(B) Rivet
(C) Torsion spring
2. CLUTCH COVER
NOTE:
Visually check the following items without disassembling, and replace or repair if there is a problem.
1) Loose thrust rivet
2) Damaged or worn bearing contact area at the
center of diaphragm spring
(A)
(B)
(A)
CL-00015
(A) Clutch facing
4) Facing runout
If runout exceeds the specified value at the outer
circumference of facing, repair or replace.
ST 499747100
CLUTCH DISC GUIDE
Limit of runout:
Non-turbo model
0.7 mm (0.028 in) at R = 107.5 mm (4.23 in)
2.0 L Turbo model
0.7 mm (0.028 in) at R = 110 mm (4.33 in)
ST
CL-00016
CL-13
CL-00018
(A) Thrust rivet

(B) Diaphragm spring
Flywheel
CLUTCH SYSTEM
3. Flywheel
2) Tighten the flywheel attaching bolts to the specified torque.
A: REMOVAL
1) Remove the transmission assembly. <Ref. to
5MT-26, REMOVAL, Manual Transmission Assembly.>
2) Remove the clutch cover and clutch disc. <Ref.
to CL-12, REMOVAL, Clutch Disc and Cover.>
3) Using the ST, remove the flywheel.
ST 498497100
CRANKSHAFT STOPPER
NOTE:
Tighten the flywheel attachment bolts gradually.
Each bolt should be tightened to the specified
torque in crisscross order.
Tightening torque:
72 Nm (7.3 kgf-m, 52.8 ft-lb)
(5)
(1)
(7)
(3)
(4)
(8)
(2)
(6)
CL-00021
(A)
ST
CL-00019
(A) Flywheel
B: INSTALLATION
1) Install the flywheel and ST.
ST 498497100
CRANKSHAFT STOPPER
3) Install the clutch disc and cover. <Ref. to CL-12,

INSTALLATION, Clutch Disc and Cover.>
4) Install the transmission assembly. <Ref. to 5MT28, INSTALLATION, Manual Transmission Assembly.>
C: INSPECTION
CAUTION:
Since this bearing is grease-sealed and is a
non-lubrication type, do not wash with gasoline
or any solvents.
1) Damage of facing and ring gear
If there is a problem, replace the flywheel.
(B)
ST
CL-00020
(A)
CL-00022
(A) Flywheel
(B) Ring gear
2) Smoothness of rotation
Rotate the ball bearing while applying pressure in
thrust direction.
3) If noise or excessive play is noted, replace the
flywheel.
CL-14
Release Bearing and Lever

CLUTCH SYSTEM
4. Release Bearing and Lever
B: INSTALLATION
A: REMOVAL
1) Lubricate the following points with the specified

grease prior to assembly.
Contact surface of release lever and pivot
Contact surface of release lever and bearing
Transmission main shaft spline (Use grease containing molybdenum disulphide.)
Contact surface of release lever and operating
cylinder
2) While pushing the release lever against the pivot
and twisting left and right, fit the spring onto the
stepped portion of pivot. Apply grease (KOPRKOTE: Part No. 003603001) to the contact point of
the release lever and the operating cylinder.
3) Confirm that the lever spring is securely fitted by
observing it through the main case hole.

body.
<Ref. to 5MT-26, REMOVAL, Manual Transmission Assembly.>
2) Remove the two clips from the release lever and
remove the release bearing. (Non-turbo model)
3) Remove the release bearing from release lever.
(Turbo model)
CAUTION:
Be careful not to deform the clips.
4) Remove the release lever dust cover.
(A)
(A)
(B)
CL-00023
(A) Release lever
CL-00026
(B) Release lever dust cover
(A) Release lever
5) Remove the lever spring from release lever pivot

with a screwdriver, by accessing it through the
clutch housing release lever hole. Then remove the
release lever.
4) Install the release bearing and fasten it with two

clips. (Non-turbo model)
5) Install the release bearing. (Turbo model)
6) Install the release lever dust cover.
(B)
(A)
(A)
(B)
CL-00024
CL-00023
(A) Release lever

(A) Release lever
(B) Screwdriver
(B) Release lever dust cover
7) Check the bearing for smooth movement by operating the release lever.
8) Install the transmission assembly.
<Ref. to 5MT-28, INSTALLATION, Manual Transmission Assembly.>
CL-15
Release Bearing and Lever

CLUTCH SYSTEM
C: INSPECTION
2. RELEASE LEVER
1. RELEASE BEARING
Check the pivot portion of the lever and the contact

area with the release bearing case for wear.
CAUTION:
Since this bearing is grease-sealed and is a
non-lubrication type, do not wash with gasoline
or any other solvent when servicing the clutch.
1) Check the bearing for smooth movement by applying force to the bearing in radial direction.
Radial direction stroke:
1.6 mm (0.063 in)
(A)
(B)
(C)
CL-00034
(A) Release lever

(B) Pivot
(C) Release bearing
(A)
CL-00032
(A) Bearing case
2) While applying force to the bearing in the direction of rotation, check the bearing for smooth rotation.
(A)
CL-00160
(A) Bearing case
3) Check wear and damage of the bearing case

surface in contact with the lever.
CL-16
Operating Cylinder
CLUTCH SYSTEM
5. Operating Cylinder
B: INSTALLATION
A: REMOVAL
1) Apply grease (KOPR-KOTE: Part No.

003603001) to the contact point of the release lever
and the operating cylinder.

3) Remove the clutch hose from operating cylinder.
Tightening torque:
T1: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
T2: 37 Nm (3.8 kgf-m, 27.5 ft-lb)
NOTE:
Cover the hose joint to prevent the clutch fluid from
flowing out.
T2
T1
(A)
T2
CL-00254
NOTE:
Be sure to install the clutch hose with the mark
side facing upward.
Be careful not to twist the clutch hose during installation.
(B)
CL-00252
(A) Clutch hose

(B) Operating cylinder
(C)
4) Remove the operating cylinder from the transmission.
(A)
(B)
CL-00041
(A) Mark
(B) Clutch hose
(C) Operating cylinder
CL-00253
3) After bleeding air from the operating cylinder,

ensure that the clutch operates properly.
<Ref. to CL-23, Clutch Fluid Air Bleeding.>
CL-17
Operating Cylinder
CLUTCH SYSTEM
C: DISASSEMBLY
D: ASSEMBLY
1) Remove the boot and push rod.
NOTE:
When assembling, apply operating oil on all parts
while performing work.
Recommended brake fluid
FMVSS No. 116, new DOT3 or DOT4 brake fluid
1) Attach the piston spring onto the piston.
NOTE:
The illustration below is for a non-turbo model.
CL-00457
2) Blow in compressed air from the clutch hose attachment hole.

NOTE:
To prevent the piston from shooting out, face the
piston hole towards the ground, and place a wooden block to prevent damage.
CL-00459
2) Insert the piston into the operating cylinder.

3) Attach the boot to the push rod.
4) Install the boot and push rod to the operating cylinder.
CL-00458
3) Separate the piston and piston spring.

NOTE:
The illustration below is for a non-turbo model.
CL-00457
E: INSPECTION
1) Check the operating cylinder for damage. If operating cylinder is damaged, replace it.
2) Check the operating cylinder for fluid leakage or
damage on the boot. If any leakage or damage is
found, replace the operating cylinder.
CL-00459
CL-18
Master Cylinder
CLUTCH SYSTEM
6. Master Cylinder
B: INSTALLATION
A: REMOVAL
1) Install the master cylinder to the body, and attach the clutch pipe to the master cylinder.
1) Thoroughly drain the brake fluid from the reservoir tank.

2) Remove the snap pin and clevis pin, and then
separate the push rod of the master cylinder from
clutch pedal.
(A)
(B)
NOTE:
Check that the pipe is routed properly.
Tightening torque:
Clutch pipe
15 Nm (1.5 kgf-m, 10.8 ft-lb)
Master cylinder
18 Nm (1.8 kgf-m, 13.0 ft-lb)
(D)
(C)
T1
T2
CL-00042
(A) Clevis pin

(B) Snap pin
CL-00163
(C) Push rod

(D) Push rod lock nut

5) Remove the clutch pipe from master cylinder.
6) Remove the master cylinder together with the
reservoir tank.
2) Apply grease to the clevis pin.

3) Connect the push rod of master cylinder to
clutch pedal, and install the new clevis pin and
snap pin.
(A)
(B)
(C)
CAUTION:
Be careful not to spill the brake fluid. Immediately wash off with water and wipe clean any
brake fluid spilled on the vehicle body, as brake
fluid will damage the painted surface.
CL-00137
CL-00045
(A) Clevis pin

(B) Snap pin
(C) Push rod
4) After bleeding air from system, ensure that the

clutch operates properly.
<Ref. to CL-23, Clutch Fluid Air Bleeding.>
Chamber.>
CL-19
Master Cylinder
CLUTCH SYSTEM
C: DISASSEMBLY
D: ASSEMBLY
1) Remove the straight pin and reservoir tank.
1) Install the clutch damper.

Tightening torque:
46.6 Nm (4.75 kgf-m, 34.4 ft-lb)
2) Apply a coat of grease to the contact surfaces of
the push rod and piston before installation.
(A)
Grease:
SILICONE GREASE G40M (Part No.
004404003)
(B)
CL-00046
(A) Reservoir tank

(B) Straight pin

(A)
CL-00054

Tightening torque:
10 Nm (1.0 kgf-m, 7 ft-lb)
E: INSPECTION
(B)
If any damage, deformation, wear, swelling, rust or

other problems are found on the cylinder, piston,
push rod, fluid reservoir, return spring, gasket, cylinder boot or hose, replace the faulty part.
CL-00047
(A) Oil seal

(B) Master cylinder
(C)
3) Move the cylinder boot towards the rear.
(B)
(A)
(G)
(A)
(D)
(F)
(E)
CL-00056
(B)
(A) Master cylinder body

(B) Return spring
CL-00048
(C) Piston
(D) Stop ring
(A) Cylinder boot

(B) Master cylinder
(E) Rod ASSY

(F) Clutch damper

CAUTION:
Be careful when removing the snap ring to prevent the rod, washer, piston and return spring
from flying out.
CL-20
(G) Cylinder boot
Clutch Pipe and Hose

CLUTCH SYSTEM
7. Clutch Pipe and Hose
B: INSTALLATION
A: REMOVAL
1) Remove the air cleaner chamber and the air intake duct. (Non-turbo model) <Ref. to IN (H4SO)-6,
REMOVAL, Air Intake Chamber.>
3) Drain the clutch fluid. <Ref. to CL-22, Clutch Fluid.>
4) Remove the clutch pipe from the clutch hose and
master cylinder.
5) Pull out the clamp, then remove the clutch hose
from the bracket.
Tightening torque:
T1: 15 Nm (1.5 kgf-m, 10.8 ft-lb)
T2: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
T3: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
T1
(A)
(A)
T3
(C)
(B)
T2
(B)
CL-00057
(A) Clamp
(D)
(B) Clutch hose
CL-00412
6) Remove the hose from operating cylinder.

7) Remove the bracket.
(A) Clutch pipe

(B) Clip
(C) Clutch hose
(D) Operating cylinder
C: INSPECTION
Check pipes and hoses for cracks, breakage or
damage. Check joints for fluid leakage. If any
cracks, breakage, damage or leakage is found, repair or replace the abnormal pipe or hose.
CL-21
Clutch Fluid
CLUTCH SYSTEM
8. Clutch Fluid
B: REPLACEMENT
A: INSPECTION
CAUTION:
Use new SUBARU genuine brake fluid.
Cover the bleeder with cloth to prevent brake
fluid from being splashed on surrounding parts
when loosening the bleeder.
Avoid mixing different brands of brake fluid
to prevent the quality of fluid from degrading.
Be careful not to allow dirt or dust to get into
the reservoir tank.

2) Inspect the fluid level using the scale on the outside of the reservoir tank. If the level is below MIN,
add fluid to bring it up to MAX, and also inspect for
leakage.
(A )
(C)
(B )
PM-00076
(A) Reservoir tank
NOTE:
During bleeding operation, keep the clutch reservoir tank filled with brake fluid to prevent entry of
air.
Clutch pedal must be operated very slowly.
Bleed air from the oil line with help of a co-worker.
The amount of brake fluid required is approximately 70 m2 (2.4 US fl oz, 2.5 Imp fl oz) for total
clutch system.
brake fluid.
FMVSS No. 116, new DOT3 or DOT4 brake fluid
5) Drain all contaminated fluid using the same
method as for air bleeding.
NOTE:
Keep the clutch reservoir tank filled with brake fluid
to prevent entry of air.
CL-22
Clutch Fluid Air Bleeding

CLUTCH SYSTEM
9. Clutch Fluid Air Bleeding
6) Tighten the air bleeder.
A: PROCEDURE
Tightening torque:
T: 7.8 Nm (0.8 kgf-m, 5.8 ft-lb)
NOTE:
Bleed air from the oil line with help of a co-worker.
3) Fit one end of a vinyl tube into the air bleeder of
the operating cylinder, and put the other end into a
brake fluid container.
(A)
CL-00261
7) After depressing the clutch pedal, make sure

that there are no leaks evident in the entire system.
8) After bleeding air from system, ensure that the
clutch operates properly.
(B)
CL-00259
(A) Clutch hose

(B) Air bleeder
4) Slowly depress the clutch pedal and keep it depressed. Then open the air bleeder to discharge air
together with the fluid. Release the air bleeder for 1
or 2 seconds. Next, with the bleeder closed, slowly
release the clutch pedal.
(B)
(A)
CL-00260
(A) Operating cylinder

(B) Vinyl tube
5) Repeat these steps until there are no more air

bubbles in the vinyl tube.
CAUTION:
Cover the bleeder with cloth to prevent brake
fluid from being splashed on surrounding parts
when loosening the bleeder.
CL-23
Clutch Pedal
CLUTCH SYSTEM
10.Clutch Pedal
9) Remove the cable clamp and disconnect the

PHV cable from the PHV.
A: REMOVAL
1) Remove the steering column. <Ref. to PS-16,
REMOVAL, Tilt Steering Column.>
2) Disconnect the connector from the stop light
switch and clutch switch.
3) Remove the snap pin that fastens the lever and
push rod to the operating rod.
4) Remove the clevis pin that fastens the lever and
push rod to the operating rod.
CAUTION:
When disconnecting the PHV cable, carefully
protect the boot and inner cable so that they do
not get damaged.
(A)
(D)
(A)
(B)
(D)
(A) PHV cable
(C)
(C)
CL-00092
(B) Clamp
(B)
CL-00090
10) Remove the nut that fastens the clutch master

cylinder.
(A) Operating rod

(B) Push rod
(C) Snap pin
(D) Clevis pin
5) Remove the accelerator pedal. <Ref. to SP

(H4SO)-3, REMOVAL, Accelerator Pedal.>
6) Remove the air cleaner case and intake duct.
(Non-turbo model) <Ref. to IN (H4SO)-5, REMOVAL, Air Cleaner Case.> <Ref. to IN (H4SO)-7, REMOVAL, Air Intake Duct.>
8) Remove the PHV adjustment nut and lock nut.
(A)
CL-00093
11) Remove the bolt and nut that fastens the brake
pedal and clutch pedal and remove the pedal assembly.
B: INSTALLATION
(B)

Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
(C)
CL-00091
(A) Adjustment nut

(B) Lock nut
(C) PHV
NOTE:
If the cable clamp is damaged, replace it with a
new part.
Always cover the outer cable end with the boot.
Be careful not to twist the accelerator cable.
Always use a new clevis pin.
2) Adjust the clutch pedal after installation. <Ref. to
CL-26, ADJUSTMENT, Clutch Pedal.>
3) Adjust the clutch switch (clutch start). <Ref. to
CL-29, ADJUSTMENT, Clutch Switch.>
4) Adjust the hill holder. (Model with hill holder)
<Ref. to BR-52, ADJUSTMENT, Hill Holder.>
CL-24
Clutch Pedal
CLUTCH SYSTEM
C: DISASSEMBLY
1) Remove the clip, assist spring, rod and bushing.
4) Remove the stopper, clip, O-ring and rod S, and

remove the spring S and bushing S.
(D)
(B)
(A)
(A)
(E)
(E)
(C)
(D)
(D)
(B) (E)
(C)
(D)
(C)
CL-00094
CL-00097
(A) Clip
(A) Clip
(B) Bushing S
(C) Spring S
(B) Assist spring

(C) Assist rod
(D) Rod S
(E) Stopper
(D) Bushing
(E) Clevis pin
5) Remove the stopper from the clutch pedal.

6) Remove the clutch pedal pad.
2) Remove the spring pin and lever.
D: ASSEMBLY
(A)
(B)
CL-00095
(A) Pin
(B) Lever
3) Remove the clutch pedal and bushing.
1) Install the stopper, etc., temporarily to the pedal

bracket.
2) Clean the clutch pedal and inside the brake pedal bore, apply grease and set the bushing inside the
bore.
Grease:
KOPR-KOTE (Part No. 003603001) or equivalent
3) Align the pedal bracket, clutch pedal and brake
pedal bore, and install the brake pedal return
spring, assist rod, spring and bushing.
NOTE:
Clean the inside of the bushings and apply grease
before installing the spacer.
4) Install the hill holder cable to the clutch pedal.
(B)
(B)
(A)
CL-00096
(A) Clutch pedal

(B) Bushing
CL-25
Clutch Pedal
CLUTCH SYSTEM
E: INSPECTION
F: ADJUSTMENT
1. CLUTCH PEDAL
1) Measure the full stroke amount of the clutch pedal.
Move the clutch pedal pads in the lateral direction

with a force of approximately 10 N (1 kgf, 2 lb) to
check that the pedal deflection is within the service
limit.
NOTE:
If excessive deflection is found, replace the bushing with new part.
Deflection of clutch pedal:
Service limit:
5.0 mm (0.197 in) or less
NOTE:
Measure the leading end of the seat cushion and
center of the pedal.
Align the seat with the seventh notch position
from the position at the very front.
Clutch pedal standard full stroke: A
130 135 mm (5.12 5.31 in)
(C)
A
(A)
(B)
CL-00078
(A) Clutch pedal (Full stroke condition)

CL-00098
(A) Clutch pedal

(B) Brake pedal
(B) Scale
(C) Seats
2) If the full stroke is not within the specified value,

loosen the clutch stopper nut to adjust.
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
3) Loosen the push rod lock nuts.
(A)
(B)
(D)
(C)
CL-00042
(A) Clevis pin

(B) Snap pin
(C) Push rod
(D) Push rod lock nut
4) Rotate the push rod to adjust.

(1) Make sure that the clutch pedal hits the
stopper bolt side when returning the clutch pedal.
CL-26
Clutch Pedal
CLUTCH SYSTEM
(2) Check that the clutch pedal hits the clutch

pedal bracket stopper at full stroke.
8) Check that the clevis pin moves smoothly by

moving it in the left and right directions.
9) Tighten the push rod lock nut.
Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
10) Measure the full stroke amount of the clutch
pedal again.
(A)
(B)

130 135 mm (5.12 5.31 in)
11) Install the clutch switch. <Ref. to CL-28, INSTALLATION, Clutch Switch.>
(F)
(C)
(E)
(D)
CL-00080
(A) Clevis hole

(B) Push rod lock nut
(C) In the longer direction
(D) In the shorter direction
(E) Push rod
(F) Clevis
5) Rotate the push rod in the shorter direction to

create clearance in the stopper bolt or the clutch
switch side.
(A)
(B)
CL-00100
(A) Clutch switch

(B) Stopper
6) Rotate the push rod in the shorter direction until

the clutch pedal hits the stopper bolt.
7) Rotate the push rod further in the longer direction 270 (in the direction of the arrow in the drawing).
(B)
(A)
CL-00101
(A) Accelerator pedal

(B) Clevis
CL-27
Clutch Switch
CLUTCH SYSTEM
11.Clutch Switch
2. CLUTCH SWITCH (CLUTCH START)
A: REMOVAL
2) Remove the instrument panel lower cover.
3) Disconnect the connector from the clutch switch.
4) Remove the clutch switches.
1) Fully depress the clutch and hold it.

2) Set the clearance of clutch pedal plate and
clutch switch to 3 3.5 mm (0.12 0.14 in) and
tighten the lock nut.
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
B: INSTALLATION
(A)
(C)
(B)
1. CLUTCH SWITCH
1) Install so that the gap between the clutch switch
and clutch pedal stopper is 0 mm (0 in).
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
CL-00104
(A) Plate
(B) Clutch switch
(C)
(C) 3 3.5 mm (0.12 0.14 in)
(A)
3) Connect the clutch switch connector.

4) Make sure that engine does not start with clutch
pedal not depressed.
5) Make sure that engine starts with clutch pedal
fully depressed.
(B)
CL-00103
(A) Clutch switch

(B) Stopper
(C) 0 mm (0 in)
2) Measure the stroke of the clutch pedal.

130 135 mm (5.12 5.31 in)
(C)
(A)
(B)
CL-00078
(A) Clutch pedal (Full stroke condition)

(B) Scale
(C) Seat
3) If the clutch pedal stroke is out of specification,

adjust the stroke. <Ref. to CL-26, ADJUSTMENT,
Clutch Pedal.>
4) Connect the clutch switch connector.
CL-28
Clutch Switch
CLUTCH SYSTEM
C: INSPECTION
D: ADJUSTMENT
1) Make sure that engine does not start with clutch

pedal not depressed. Inspect the adjustment of
clutch switch and check the clutch start circuit when
the engine starts.
2) Make sure that engine starts with clutch pedal
fully depressed. Inspect the adjustment of clutch
switch and check the clutch start circuit when the
engine does not start.
3) Check the clutch switch for continuity. If the resistance is not at the standard value, replace the
switch.
(1) Disconnect the clutch switch connector.
(2) Measure the resistance between terminal 1
and 2 of the switch.
Clutch switch
1) Loosen the lock nut of clutch switch (clutch

start).
Condition
depressed
When the clutch pedal
is not depressed
Terminal No.
Specified
resistance
No. 1 No. 2
1 M or more
No. 1 No. 2
Less than 1
(A)
(B)
CL-00424
(A) Lock nut

(B) Clutch switch (Clutch start)
2) Fully depress the clutch and hold it.

3) Adjust the gap of the clutch pedal plate and the
clutch switch to be 3 3.5 mm (0.12 0.14 in).
(A)
(C)
(B)
2 1
CL-00104
(A) Plate
(B) Clutch switch (Clutch start)
(C) 3 3.5 mm (0.12 0.14 in)
CL-00084
Clutch switch (Clutch start)

Condition
Terminal No.
Specified
resistance

depressed
No. 1 No. 2:
Less than 1
When the clutch pedal

is not depressed
No. 1 No. 2:
1 M or more
4) Tighten the lock nut.

Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
1
2
CL-00102
CL-29

CLUTCH SYSTEM

A: INSPECTION
1. CLUTCH
Symptoms
1. Clutch slippage.
It is hard to perceive clutch slippage in
the early stage, but pay attention to the
following symptoms.
Engine speeds up when shifting.
High-speed driving is not possible;
especially rapid acceleration is not
possible and vehicle speed does not
increase in proportion to the increase in
engine speed.
Power drops particularly when
ascending a slope, and there is a burning
smell of the clutch plate.
Method of testing: Park the vehicle and
fully apply the parking brake. Disengage
the clutch and shift the transmission gear
into the 1st. Gradually increase the
engine speed while gradually allowing the
clutch to engage. The clutch function is
satisfactory if the engine stalls. However,
the clutch is slipping if the vehicle does
not move forward and the engine does
not stall.
Possible cause
(a) Oil on the clutch face
Replace.
(b) Worn clutch face

(c) Deteriorated diaphragm spring
Replace.
Replace.
(d) Warped pressure plate or flywheel

(e) Defective release bearing holder
Replace.
Replace.
2. Clutch drags.
As a symptom of this problem, a harsh
scratching noise occurs and control
becomes difficult when shifting gears.
The symptom becomes more apparent
when shifting into the 1st gear. However,
because most trouble of this sort is due to
a defective synchronization mechanism,
perform the following tests.
Method of testing: <Ref. to CL-31,
DIAGNOSTIC DIAGRAM OF CLUTCH
DRAG, INSPECTION, General
Diagnostic Table.>
The problem is caused by insufficient
disengagement of the clutch if a noise
occurs during this test.
3. Clutch chatters.
Clutch chattering is an unpleasant
vibration to the whole vehicle when the
vehicle is just started with clutch partially
engaged.
(a) Worn or rusty clutch disc hub spline

(b) Excessive deflection of clutch disc
face
(c) Seized crankshaft pilot bearing
Replace the clutch disc.

Replace.
(d) Cracked clutch disc face

(e) Stuck clutch disc
(smeared by oil or water)
Replace.
Replace.
(a) Adhesion of oil on the clutch face
(b) Weak or broken torsion spring

(c) Poor contact of the disc surface or
excessively worn disc
(d) Deformed pressure plate or flywheel

Replace the problem clutch disc.
(e) Loose disc rivets

(f) Loose engine mounting

Retighten or replace mounting.
(g) Improper adjustment of the pitching

stopper
Adjust.
CL-30
Corrective action
Replace.
Replace.

CLUTCH SYSTEM
Symptoms
Possible cause
4. Noisy clutch
Examine whether the noise is generated
when the clutch is disengaged, engaged,
or partially engaged.
5. Clutch grabs suddenly.

When starting the vehicle with the clutch
partially engaged, the clutch engages
suddenly and the vehicle jumps instead
of making a smooth start.
Corrective action
(a) Broken, worn or insufficiently

lubricated release bearing
Replace the release bearing.
(b) Insufficient lubrication of the pilot

bearing
(c) Loose clutch disc hub
Replace the pilot bearing.

(d) Loose torsion spring retainer

(e) Deteriorated or broken torsion spring

(a) Grease or oil on facing

(b) Deteriorated cushioning spring

(c) Worn or rusted spline of clutch disc or

main shaft
Take off rust, apply grease or replace

clutch disc or main shaft.
(d) Deteriorated or broken torsion spring

(e) Loose engine mounting

Retighten or replace mounting.
(f) Deteriorated diaphragm spring
Replace.
2. CLUTCH PEDAL
Insufficient pedal play
Symptoms
Corrective action
Adjust the free play of the pedal.
Insufficient clutch pedal free play

Excessively worn and damaged pedal shaft and/or bushing
Adjust the free play of the pedal.

Replace with new bushing or shaft.
3. DIAGNOSTIC DIAGRAM OF CLUTCH DRAG

1
Step
CHECK GEAR NOISE.
2) Quickly shift from neutral to reverse when
idling.
CHECK GEAR NOISE.
Depress the clutch pedal when idling and shift
from neutral to reverse within 0.5 1.0 second.
Check
Yes
Is there any abnormal noise Go to step 2.
from the transmission gear?
No
Clutch is normal.
Defective transmission
or excessive clutch
drag torque. Inspect
Pilot bearing, clutch
disc, transmission and
clutch disc hub spline.
CHECK GEAR NOISE.
Is there any abnormal noise Inadequate clutch Clutch and flywheel
1) Depress the clutch pedal when idling and from the transmission gear? disengage. Inspect seizure. Inspect the
shift from neutral to reverse within 0.5 1.0
the clutch disc,
clutch disc and the
second.
clutch cover,
spline of the clutch
2) With the clutch pedal depressed, shift from
release lever, and disc hub.
neutral to reverse, reverse to neutral several
clutch pedal free
times.
play.
Is there any abnormal noise Go to step 3.
from the transmission gear?
CL-31

CLUTCH SYSTEM
CL-32
General Description
FRONT SUSPENSION
A: SPECIFICATION
Model
Non-turbo
Camber
(Tolerance: 045Differences between RH and LH 45 or less)
Caster (Reference)
Front
025
303
03 mm (00.12 in) Toe angle (sum of both wheels):
0015
Toe-in
Kingpin angle (Reference)
Wheel arch height
(Tolerance: +12 /24 mm (+0.47/0.94 in))
Camber
(Tolerance: 045Differences between RH and LH 45 or less)
Rear
Turbo
1312
437 mm
(17.20 in)
050
055
23 mm (0.0790.12 in) Toe angle

(sum of both wheels): 010015
Toe-in
Thrust angle
030
Wheel arch height (Tolerance: +12 /24 mm (+0.47/0.94 in))
NOTE:
Front and rear toe-in and front camber can be
adjusted. If the toe-in or camber tolerance exceeds
specifications, adjust toe-in and camber to the middle value of specification.
Other items indicated in the specifications table
cannot be adjusted. If other items exceed specifications, check suspension parts and connections for
deformation, and replace with new parts as required.
(1)
FS-00001
(1) Front
A B = Positive: Toe-in, Negative: Toe-out
= Individual toe angles
FS-2
440 mm
(17.32 in)
435 mm
(17.13 in)
General Description
FRONT SUSPENSION
B: COMPONENT
(1)
T5
(2)
T1
(3)
(17)
(28) T12
(4)
T6
T10
(28)
(28)
(18)
(5)
T9
(19)
(7)
(8)
T7
(21)
(6)
(28)
(16)
(20)
T13
(15)
(22)
(9)
(11)
(27)
T4
T3
(28)
(23)
(10)
(28)
T4
(24)
(14)
(13)
(12)
(28)
T2
(25)
(29)
T2
(26)
(29)
T8
(30)
T8
(31)
(28)
T11
T6
T8
FS-00243
FS-3
General Description
FRONT SUSPENSION
(1)
(2)
Front crossmember
Bolt ASSY
(17)
(18)
Dust seal
Strut mount
(3)
(4)
Housing
Washer
(19)
(20)
Spacer
Upper spring seat
(5)
(6)
Stopper rubber (Rear)

Rear bushing
(21)
(22)
Rubber seat
Dust cover
T4: 45 (4.6, 33)
(7)
(8)
Stopper rubber (Front)

Ball joint
(23)
(24)
Helper
Coil spring
T5: 50 (5.1, 37)

T6: 55 (5.6, 41)
(9)
(10)
Transverse link
Cotter pin
(25)
(26)
Damper strut
Adjusting bolt
T7: 70 (7.1, 52)

T8: 71 (7.2, 52)
(11)
Front bushing
(27)
Castle nut
(12)
(13)
Stabilizer link
Clamp
(28)
(29)
Self-locking nut
Sub frame
T10: 125 (12.7, 92.3)

T11: 175 (17.8, 129)
(14)
(15)
Bushing
Stabilizer
(30)
(31)
Cover
Clip
T12: 190 (19.4, 140)

T13: 250 (25.5, 184)
(16)
Jack-up plate
C: CAUTION
Use SUBARU genuine grease etc. or equivalent.
Do not mix grease with another grade or from other
manufacturers.
points.
FS-4

T1: 20 (2.0, 14.5)
T2: 25 (2.5, 18.1)
T3: 40 (4.1, 30) (Tighten an additional 60)
T9: 100 (10.2, 74)
General Description
FRONT SUSPENSION
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
927680000
INSTALLER &
REMOVER SET
Used for replacing the transverse link bushing.
927760000
STRUT MOUNT
SOCKET
Used for disassembling and assembling the strut

and shock mount.
ST-927680000
ST-927760000
2. GENERAL TOOL
Alignment gauge
TOOL NAME
REMARKS
Used for measuring wheel alignment.
Alignment gauge adapter

Turning radius gauge

Toe-in gauge
Dial gauge
Used for toe-in measurement.

Used for damper strut measurement.
Coil spring compressor
Used for strut assembly/disassembly.
FS-5
Wheel Alignment
FRONT SUSPENSION
2. Wheel Alignment
A: INSPECTION
Check the following items before performing the wheel alignment measurement.
Check items before measuring wheel alignment:
Tire inflation pressure
Uneven wear of RH and LH tires, or difference of sizes
Tire runout
Excessive play and wear of ball joint
Excessive play and wear of tie rod end
Excessive play of wheel bearing
Right and left wheel base imbalance
Deformation and excessive play of steering link
Deformation and excessive play of suspension parts
Check, adjust and measure the wheel alignment in accordance with the procedures indicated in the figure.
Wheel arch height (front and rear wheels)
<Ref. to FS-6, WHEEL ARCH HEIGHT, INSPECTION, Wheel Alignment.>
Camber (front and rear wheels)

<Ref. to FS-7, CAMBER, INSPECTION, Wheel Alignment.>
Caster (front wheel)

<Ref. to FS-9, CASTER, INSPECTION, Wheel Alignment.>
Steering angle
<Ref. to FS-9, STEERING ANGLE, INSPECTION, Wheel Alignment.>
Front wheel toe-in

<Ref. to FS-10, FRONT WHEEL TOE-IN, INSPECTION, Wheel Alignment.>
Rear wheel toe-in

<Ref. to FS-10, REAR WHEEL TOE-IN, INSPECTION, Wheel Alignment.>
Thrust angle
<Ref. to FS-12, THRUST ANGLE, INSPECTION, Wheel Alignment.>
1. WHEEL ARCH HEIGHT

2) Empty the vehicle so that it is at curb weight. (Empty the luggage compartment, load the spare tire, jack
and service tools, and fill up the fuel tank.)
3) Set the steering wheel in a straight-ahead position, and stabilize the suspensions by moving the vehicle
in a straight line for more than 5 m (16 ft).
4) Suspend a thread from the wheel arch (point A in the figure below) and affix at a position directly above
the center of wheel.
FS-6
Wheel Alignment
FRONT SUSPENSION
5) Measure the distance between the point A and the center of wheel.
(2)
(3)
(1)
(1)
(6)
A
(7)
(4)
(1)
(5)
(8)
FS-00012
(1)
(2)
Wheel arch height

Front fender
(4)
(5)
Front wheel arch height

Rear wheel arch height
(3)
Rear quarter
(6)
Flange bend line
Model
Non-turbo
Turbo
(7)
(8)
Point of measurement
End of spindle
Specified wheel arch height

Front
Rear
440+12/
437+12/24 mm (17.20+0.47/0.94 in)
435+12/
2. CAMBER
mm (17.32+0.47/0.94 in)
+0.47/
24 mm (17.13
0.94 in)
24
2) Set the adapter into the center of wheel, and

then set the wheel alignment gauge.
INSPECTION
1) Place the front wheel on the turning radius
gauge. Make sure the ground contacting surfaces
of the front and rear wheels are at the same height.
(3)
(1)
(2)
(1) Alignment gauge

(2) Turning radius gauge
(3) Adapter
FS-7
FS-00213
Wheel Alignment
FRONT SUSPENSION
3) Measure the camber angle in accordance with

the operation manual for wheel alignment gauge.
Front
Rear
Model
Camber
(Difference
between RH and
LH is 45 or less)
Non-turbo, Turbo
Non-turbo
025045
050045
Turbo
055045
NOTE:
Moving the adjusting bolt by one scale changes the
camber by approximately 010.
(1)
(4)
(6)
(5)
(7)
FRONT CAMBER ADJUSTMENT

1) When adjusting the front camber, adjust it to the
following value.
Model
Front
Non-turbo, Turbo
Camber
(Difference
between RH and
LH is 45 or less)
025030
2) Loosen the two self-locking nuts located at the

lower front portion of the strut.
NOTE:
When the adjusting bolt needs to be loosened or
tightened, hold its head with a wrench and turn the
self-locking nut.
3) Turn the camber adjusting bolt so that the camber is set at specification.
(2)
(3)
FS-00008
(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
To increase camber.
Rotate the left side counterclockwise.
Rotate the right side clockwise.
FS-00009
FS-00010
To decrease camber.
Rotate the left side clockwise.
Rotate the right side counterclockwise.
FS-00010
FS-00009
3) Measure the caster angle in accordance with the

operation manual for wheel alignment gauge.
4) Tighten two new self-locking nuts.

Tightening torque:
175 Nm (17.8 kgf-m, 129 ft-lb)
Model
Non-turbo, Turbo
3. CASTER
INSPECTION
4. STEERING ANGLE
1) Place the front wheel on the turning radius

gauge. Make sure the ground contacting surfaces
of the front and rear wheels are at the same height.
2) Set the adapter into the center of wheel, and
then set the wheel alignment gauge.
INSPECTION
(3)
Caster
303
1) Place the vehicle on turning radius gauge.

2) While depressing the brake pedal, turn the steering wheel fully to the left and right. With the steering
wheel held at each fully turned position, measure
both the inner and outer wheel steering angles.
Steering angle:
Model
Inner
wheel
Outer
wheel
(1)
(2)
FS-00213
(1) Alignment gauge

(2) Turning radius gauge
(3) Adapter
FS-9
Non-turbo
Turbo
3625130
3500130
3200130
3054130
Wheel Alignment
FRONT SUSPENSION
ADJUSTMENT
ADJUSTMENT
1) Turn the tie-rod to adjust the steering angle of

both inner and outer wheels.
2) Check the toe-in.
Adjust the toe-in to be within the adjustment standard value if it exceeds the allowable value.
NOTE:
Correct the boot if it is twisted.
(1)
Toe-in (adjustment standard):

02 mm (00.08 in)
1) Check that the left and right wheel steering angles are within specification.
2) Loosen the left and right side steering tie-rod
lock nuts.
3) Turn the left and right tie-rods by equal amounts
until the toe-in is at the specified value.
Both the left and right tie-rods are right-hand
threaded. To increase toe-in, turn both tie-rods
clockwise by equal amount (viewing from the inside
of vehicle).
FS-00014
(1) Lock nut
5. FRONT WHEEL TOE-IN

INSPECTION
(1)
Toe-in (tolerance):
03 mm (00.12 in)
1) Set the toe-in gauge at the height of wheel axis
center, behind the right and left front tires.
2) Mark the centers of both right and left tires, and
measure the distance A between the marks.
3) Move the vehicle forward to rotate the tires 180.
NOTE:
Be sure to rotate the tires in the forward direction.
4) Measure the distance B between the left and
right marks. Find toe-in using the following equation:
FS-00014
(1) Lock nut
4) Tighten the tie-rod lock nut.

Tightening torque:
85 Nm (8.7 kgf-m, 62.9 ft-lb)
NOTE:
Check and correct the tie rod boot if twisted.
6. REAR WHEEL TOE-IN
A B = Toe-in
INSPECTION
B
Toe-in (tolerance):
23 mm (0.080.12 in)
Refer to FRONT WHEEL TOE-IN for rear toe-in
inspection procedures.
<Ref. to FS-10, FRONT WHEEL TOE-IN, INSPECTION, Wheel Alignment.>
ADJUSTMENT
FS-00015
Adjust the toe-in to be within the adjustment standard value if it exceeds the allowable value.
Toe-in (adjustment standard):
22 mm (0.080.08 in)
FS-10
Wheel Alignment
FRONT SUSPENSION
1) Loosen the self-locking nut on the inner side of

link rear.
2) Turn the adjusting bolt until toe-in is within the

specification.
NOTE:
When loosening or tightening the adjusting bolt,
hold the bolt head and turn the self-locking nut.
NOTE:
When the left and right wheels are adjusted for toein at the same time, the movement of one scale
graduation changes toe-in by approx. 1.5 mm (0.6
in).
(1)
(2)
FS-00017
(1) Adjusting bolt

(2) Link rear
To increase toe-in.
Rotate the left side clockwise.
Rotate the right side counterclockwise.
FS-00018
FS-00019
To decrease toe-in.
Rotate the left side counterclockwise.
Rotate the right side clockwise.
FS-00019
3) Replace with a new self-locking nut and tighten.

Tightening torque:
100 Nm (10.2 kgf-m, 74 ft-lb)
FS-11
FS-00018
Wheel Alignment
FRONT SUSPENSION
7. THRUST ANGLE
ADJUSTMENT
INSPECTION
Adjust to be within the adjustment standard if it exceeds the allowed value.

2) Move the vehicle 3 to 4 meters (10 to 13 feet)
straight forward.
3) Draw the center of loci for both the front and rear
axles.
4) Measure distance L between the center lines of
the axle loci.
Thrust angle
Allowable value:
030 (when L is less than 23 mm (0.9
in), less than 30).
Thrust angle
Adjustment specifications:
020 (When L is less than 15 mm (0.6
in), under 20.)
1) Make thrust angle adjustments by turning the
toe-in adjusting bolts of the rear suspension equally
in the same direction.
2) When one rear wheel is adjusted in a toe-in direction, adjust the other rear wheel equally in toeout direction, in order to make the thrust angle adjustment.
3) When the left and right adjusting bolts are turned
by one graduation, the thrust angle will change approx. 16. [L: Approximately 12 mm (0.472 in)]
(1)
(1)
(2)
(2)
L
FS-00022
(1) Center line of loci (front axle)

L
(2) Center line of loci (rear axle)
FS-00022
(1) Center line of loci (front axle)

(2) Center line of loci (rear axle)
FS-12
Wheel Alignment
FRONT SUSPENSION
NOTE:
The thrust angle is the average value of the right
and left wheel toe angles with regard to the center
line of the body. The vehicle will advance towards
the thrust angle direction while swaying in a angle
direction.
(1)
(3)
(2)
FS-00024
(1) Front
(2) Thrust angle
(3) Body center line
Thrust angle: = ( )/2

: Rear RH wheel toe-in angle
: Rear LH wheel toe-in angle
Substitute only the positive toe-in values from each
wheel into and in the equation.
(1)
(2)
FS-00025
(1) Front
(2) Body center line
FS-13
Front Transverse Link

FRONT SUSPENSION
3. Front Transverse Link
B: INSTALLATION
A: REMOVAL
1) Temporarily tighten the two bolts used to secure

the transverse link to the body.

3) Remove the sub frame. <Ref. to FS-23, REMOVAL, Sub Frame.>
4) Remove the stabilizer link from the transverse
link.
<Ref. to FS-21, REMOVAL, Front Stabilizer.>
5) Remove the bolt securing the ball joint of the
transverse link to the housing.
NOTE:
These bolts securing the bushings are tightened to
a point where they can still move back and forth in
the oblong shaped hole in the bracket.
2) Install the bolts which connect the transverse
link to the crossmember, and temporarily tighten
with a new self-locking nut.
3) Insert the ball joint into housing.
4) Connect the stabilizer link to the transverse link,
and temporarily tighten the new self-locking nuts.
FS-00026
6) Remove the nut securing the transverse link to

the crossmember. (Do not remove the bolt.)
7) Remove the two bolts securing the bushing
bracket of the transverse link to the rear bushing location on the body.
FS-00026
5) Tighten the following points in the order shown

below when the wheels are in full contact with the
ground and vehicle is at curb weight (empty).
(1) Between transverse link and stabilizer
Tightening torque:
45 Nm (4.6 kgf-m, 33 ft-lb)
(2) Between transverse link and crossmember
Tightening torque:
125 Nm (12.7 kgf-m, 92.3 ft-lb)
(3) Between transverse link rear bushing and
body
FS-00027
8) Extract the ball joint from housing.

9) Remove the bolt securing the transverse link to
crossmember and extract the transverse link from
the crossmember.
Tightening torque:
250 Nm (25.5 kgf-m, 184 ft-lb)
6) Inspect the wheel alignment and adjust if necessary.
FS-00028
FS-14
Front Transverse Link

FRONT SUSPENSION
C: DISASSEMBLY
D: ASSEMBLY
1. FRONT BUSHING
1. FRONT BUSHING
Using the ST, press the front bushing out of place.

ST 927680000
INSTALLER & REMOVER
SET

CAUTION:
Install the front bushing in proper direction as
(1)
(2)
ST
(3)
FS-00031
2. REAR BUSHING
FS-00016
1) Place alignment marks on the transverse link

and rear bushing.
2) Loosen the nut and remove the rear bushing.
(1) Face the bushing toward the center of ball joint.

(2) Ball joint
(3) 903
2. REAR BUSHING
1) Attach the rear bushing to the transverse link
and align to the aligning marks.
2) Attach and tighten a new self-locking nut.
FS-00032
NOTE:
While holding the rear bushing so as not to change
position of aligning marks, tighten the self-locking
nut.
Tightening torque:
190 Nm (19.4 kgf-m, 140 ft-lb)
E: INSPECTION
1) Check the transverse link for wear, damage and
cracks, and correct or replace if defective.
2) Check the bushing for abnormal fatigue or damage.
3) Check the rear bushing for oil leaks.
FS-15
Front Ball Joint

FRONT SUSPENSION
4. Front Ball Joint
C: INSPECTION
A: REMOVAL
1) Measure the play of the ball joint using the following procedures. Replace with a new part if the
play exceeds the specified value.
(1) While applying 686 N (70 kgf, 154 lb) of
force in the direction shown in the figure, measure dimension 21.
1) Remove the wheels.

2) Pull out the cotter pin from the ball stud, remove
the castle nut, and extract the ball stud from the
transverse link.
3) Remove the bolts which secure the ball joint to
the housing.
FS-00035
(2) While applying 686 N (70 kgf, 154 lb) of

force in the direction shown in the figure, measure dimension 22.
FS-00034
4) Extract the ball joint from housing.
B: INSTALLATION
1) Insert the ball joint into housing.
Tightening torque (Bolt):
50 Nm (5.1 kgf-m, 37 ft-lb)
CAUTION:
Do not apply grease to the tapered portion of
ball stud.
2) Connect the ball joint to transverse link.
Tightening torque (Castle nut):
40 Nm (4.1 kgf-m, 30 ft-lb)
3) Tighten the castle nut further but within 60 until
the hole in ball stud is aligned with a slot in castle
nut. Then, insert a new cotter pin and bend it
around the castle nut.
FS-00036
(3) Determine free play using the following formula.

S = 22 21
(4) Replace with a new part if the play exceeds
the specified value.
Front ball joint
Specification for replacement: S
Less than 0.3 mm (0.012 in)
2) If the play is within specification, visually check
the dust cover.
3) Remove the ball joint and cover, and check for
wear, damage or cracks. If any damage is found,
replace the corresponding part.
4) If the dust cover is damaged, replace with a new
ball joint.
FS-16
Front Strut
FRONT SUSPENSION
5. Front Strut
6) Remove the three nuts securing strut mount to

body.
A: REMOVAL
1) Remove the wheels.
2) Remove the bolt securing the brake hose from
the strut.
FS-00037
3) Scribe an alignment mark on the camber adjusting bolt that secures the strut to the housing.
4) Remove the bolt securing the ABS wheel speed
sensor harness.
FS-00039
FS-00038
5) Remove the two bolts securing the housing to

the strut.
NOTE:
While holding the head of the adjusting bolt, loosen
the self-locking nut.
FS-17
Front Strut
FRONT SUSPENSION
B: INSTALLATION
C: DISASSEMBLY
1) Install the strut mount at upper side of strut to the

body, and tighten it with new nuts.
1) Using a coil spring compressor, compress the

coil spring.
Tightening torque:
20 Nm (2.0 kgf-m, 14.5 ft-lb)
2) Align to the alignment marks on the camber adjusting bolt and strut bottom. Using new self-locking
nuts, install the strut to the housing.
NOTE:
While holding the head of adjusting bolt, tighten the
self-locking nut.
Tightening torque:
175 Nm (17.8 kgf-m, 129 ft-lb)
3) Secure the ABS wheel speed sensor harness to
the strut.
FS-00040
2) Using the ST, remove the self-locking nut.

ST 927760000
STRUT MOUNT SOCKET
Tightening torque:
33 Nm (3.4 kgf-m, 24.3 ft-lb)
4) Install the bolts which secure the brake hose to
the strut.
ST
Tightening torque:
33 Nm (3.4 kgf-m, 24.3 ft-lb)
5) Install the wheel.
FS-00041
3) Remove the strut mount, upper spring seat and

rubber seat from the strut.
4) Gradually decrease the compression force of
compressor, and remove the coil spring.
5) Remove the dust cover and helper spring.
FS-18
Front Strut
FRONT SUSPENSION
D: ASSEMBLY
1) Before installing the coil spring, strut mount, etc.
on the strut, check the condition of air inside the
strut damper mechanism to make sure that excessive air is not inhibiting the creation of appropriate
damping force.
2) Checking for 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 fingers, move the rod up and down.
(4) If the piston rod moves more than 10 mm
(0.39 in) in the former step, purge air from the
strut.
3) Air purging procedure
(1) Place the strut vertically with the piston rod
facing up.
(2) Fully extend the piston rod.
(3) With the piston rod fully extended, place the
piston rod side down. The strut must stand vertically.
(4) Fully retract the piston rod.
(5) Repeat 3 or 4 times from the first step.
5) Set the coil spring correctly so that its end face

seats well in the spring seat as shown in the figure.
(1)
FS-00043
(1) Coil spring end face
6) Install the helper and dust cover to the piston

rod.
7) Pull the piston rod fully upward, and install the
rubber seat and spring seat.
NOTE:
Position the upper spring seat as shown in the figure.
NOTE:
After purging air from the strut, be sure to place the
strut with the piston rod facing up. If the strut is laid
down for any reason, check for the entry of air in accordance with Checking for presence of air
4) Using a coil spring compressor, compress the
coil spring.
NOTE:
Make sure that the vertical installing direction of coil
spring is as shown in the figure.
(1)
(2)
(1)
FS-00044
(1) Outside the vehicle
8) Install the strut mount to piston rod, and temporarily attach and tighten a new self locking nut.
9) Using a hex wrench to prevent strut rod from
turning, tighten the self-locking nut with the ST.
ST 927760000
STRUT MOUNT SOCKET
Tightening torque:
55 Nm (5.6 kgf-m, 41 ft-lb)
ST
(3)
FS-00042
(1) Flat (top side)

(2) Identification paint
(3) Inclined (bottom side)
FS-00041
10) Loosen the coil spring carefully.
FS-19
Front Strut
FRONT SUSPENSION
E: INSPECTION
F: DISPOSAL
Check the removed part for wear, damage and

cracks, and then repair or replace it if defective.
CAUTION:
Before handling struts filled with gas, be sure
to wear goggles to protect eyes from gas, oil
and metal shavings.
Do not disassemble the strut damper or
throw into flames.
When discarding gas filled struts, drill holes
in them to purge the gas.
1) Place the gas-filled strut on a level surface with
the piston rod fully extended.
2) Using a 2 3 mm (0.08 0.12 in) dia. drill,
make the holes in areas shown in the figure.
1. DAMPER STRUT
1) Check for oil leaks.
2) Move the piston rod up and down to check that it
operates smoothly.
3) Piston rod play
Measure the play as follows:
Fix the outer shell in place and fully extend the rod.
Set a dial gauge at the end of rod L [10 mm (0.39
in)], and then read the dial gauge indication P1
while applying a force of W [20 N (2 kgf, 4 lb)] to the
threaded portion. Apply a force of 20 N (2 kgf, 4 lb)
from the opposite direction of W, and then read
the dial gauge indication P2.
W
(1)
FS-00047
(1) 40 mm (1.57 in)

FS-00046
Play limit (P1 + P2):

0.8 mm (0.031 in)
If the play exceeds the limit, replace the strut.
2. STRUT MOUNT
Check the rubber part for abnormal deformation,
cracks or deterioration. Replace it with a new part if
defective.
3. DUST COVER
Replace with a new part if abnormally cracked or
damaged.
4. COIL SPRING
If a permanent strain is found, replaced it with a
new part. Refer to the specifications to inspect the
wheel arch height even if the vehicle is not inclined
because of a flat tire or a biased load. If the tolerance is out of specifications, replace with a new
part.
5. HELPER
Replace with a new part if abnormally cracked or
damaged.
FS-20
Front Stabilizer
FRONT SUSPENSION
6. Front Stabilizer
B: INSTALLATION
A: REMOVAL
1) Jack-up the vehicle front end and support it with

rigid racks.
2) Remove the jack-up plate from lower part of the
crossmember.
4) Remove the nuts which secure the stabilizer link
to front transverse link.
NOTE:
Use a new self-locking nut.
Install the bushing (on front crossmember side)
while aligning it with the paint mark on the stabilizer.
Make sure the bushing and stabilizer have the
same identification colors when installing.
FS-00050
FS-00048
(1) Paint mark of the stabilizer
5) Remove the bolt and nut which secures the stabilizer to the crossmember.
(2) Bushing identification color
2) Always tighten the rubber bushings with wheels

in full contact with the ground and the vehicle at
curb weight.
FS-00049
Tightening torque:
Jack-up plate to crossmember
70 Nm (7.1 kgf-m, 52 ft-lb)
Stabilizer link to front transverse link:
45 Nm (4.6 kgf-m, 33 ft-lb)
Stabilizer to crossmember
25 Nm (2.5 kgf-m, 18.1 ft-lb)
C: INSPECTION
1) Check the bushing for abnormal fatigue or damage.
2) Check that there is no deformation, cracks or
damage on the stabilizer link.
3) Make sure that the bushing is not protruding
from the hole in the stabilizer link.
FS-21
Front Crossmember
FRONT SUSPENSION
7. Front Crossmember
B: INSTALLATION
A: REMOVAL

2) Lift-up the vehicle, and remove the front wheels.
4) Remove the stabilizer and jack-up plate.
CAUTION:
Always tighten bushings with wheels in full
contact with the ground and the vehicle at curb
weight.
(1)
(2)
FS-00051
(1) Front stabilizer

(2) Front crossmember
5) Disconnect the tie-rod end from the housing.

6) Remove the front exhaust pipe.
7) Remove the front transverse link from the front
crossmember and body.
Tightening torque:
Transverse link bushing to crossmember
125 Nm (12.7 kgf-m, 92.3 ft-lb)
Stabilizer to bushing:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
Tie-rod end to housing:
27 Nm (2.75 kgf-m, 19.9 ft-lb)
Front cushion rubber to crossmember
85 Nm (8.7 kgf-m, 62.7 ft-lb)
Universal joint to pinion shaft:
24 Nm (2.4 kgf-m, 17.4 ft-lb)
Crossmember to body:
100 Nm (10.2 kgf-m, 74 ft-lb)
2) Purge air from the power steering system. <Ref.
to PS-49, Power Steering Fluid.>
C: INSPECTION
Check the crossmember for wear, damage or
cracks, and then repair or replace if faulty.
FS-00028
8) Remove the bolts attaching the engine mount

cushion rubber to crossmember.
9) Remove the steering universal joint.
10) Disconnect the power steering pipe from steering gearbox.
11) Lift the engine approx. 10 mm (0.39 in) using a
chain block.
12) Support the crossmember with a jack, remove
the nuts securing the crossmember to body and
lower the crossmember gradually along with the
steering gearbox.
CAUTION:
When pulling the crossmember downward to
remove, be careful that the tie-rod end does not
interfere with SFJ boot.
FS-22
Sub Frame
FRONT SUSPENSION
8. Sub Frame
B: INSTALLATION
A: REMOVAL

3) Remove the bolt cover.
NOTE:
Replace with a new M12 bolt.
Tightening torque:
T1: 55 Nm (5.6 kgf-m, 41 ft-lb)
T2: 71 Nm (7.2 kgf-m, 52 ft-lb)
T2
(2)
(1)
(4)
(3)
T1
(1)
(1)
FS-00053
T2
T2
T1
T2
(1)
4) Remove the clip.

FS-00056
(1) M10 30 bolts

(2) M12 87 bolts (with wax)
(4) M10 90 bolts
C: INSPECTION
FS-00054
5) Remove the sub frame.

NOTE:
Loosen bolt (1) and leave a few threads caught,
then remove the bolts in the order of (2), (3), (4),
(5), and (6).
(6)
(4)
1) Check that there is no damage or distortion of

the sub frame.
2) Check that the bolts are tightened with the specified torque. If there is looseness, tighten to the
specified torque.
Tightening torque:
T1: 55 Nm (5.6 kgf-m, 41 ft-lb)
T2: 71 Nm (7.2 kgf-m, 52 ft-lb)
T2
(2)
(2)
(1)
(1)
(5)
(6)
T1
(1)
(6)
(4)
(3)
(3)
(1)
T2
T1
FS-00055
T2
(1)
T2
FS-00056
(1) M10 30 bolts

(4) M10 90 bolts
FS-23

FRONT SUSPENSION

A: INSPECTION
1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT
Possible cause
(1) Permanent distortion or damaged coil spring
Replace.
Corrective action
(2) Rough operation of damper strut or shock absorber

(3) Installation of non-compatible strut or shock absorber
Replace.
Replace with appropriate parts.
(4) Installation of non-compatible coil spring
Replace with appropriate parts.
2. POOR RIDE COMFORT

1) Large rebound shock
2) Rocking of vehicle continues too long after running over bump and/or hump.
3) Excessive shock in bumping
Possible cause
Corrective action
(1) Damaged coil spring

(2) Overinflation of tires
Replace.
Adjust.
(3) Improper wheel arch height

(4) Fault in operation of damper strut or shock absorber
Adjust or replace coil springs with new parts.

Replace.
(5) Abnormal damage or deformation of strut mount or shock absorber

mount
Replace.
(6) Improper length (maximum or minimum) of damper strut or shock

absorber
Replace with proper parts.
(7) Abnormal damage or deformation of bushing

(8) Deformation or damage of helper in strut assembly or shock absorber
Replace.
Replace.
(9) Oil leakage from the damper strut or shock absorber
Replace.
3. NOISE
Possible cause
(1) Worn or damaged damper strut
Replace.
Corrective action
(2) Wear or damage of shock absorber components

(3) Loosening of the suspension link installing bolt
Replace.
Tighten to the specified torque.
(4) Loss or abnormal deformation of bushing

absorber
Replace.
(7) Wear or damage of the ball joint

(8) Deformation of the stabilizer clamp
Replace.
Replace.
FS-24
Replace.
General Description
REAR SUSPENSION
A: SPECIFICATION
Refer to FS section for rear suspension specifications. <Ref. to FS-2, SPECIFICATION, General
Description.>
RS-2
General Description
REAR SUSPENSION
B: COMPONENT
1. REAR SUSPENSION
T1
(1)
(20)
(2)
(22)
T4
T2
(19)
(21)
(28)
T3
(5)
(3)
(23)
T2
(4)
(18)
(24)
(22)
(6)
T8
T6
(7)
T3
(17)
(22)
(9)
(25)
(8)
(28)
T6
(12)
(26)
(11)
(10)
(22)
(27)
(13)
T9
(16)
T10
(14)
(15)
(22)
T5
(22)
(22)
T6
T7
RS-00205
(1)
(2)
Stabilizer
Stabilizer bracket
(15)
(16)
Trailing link front bushing

Trailing link bracket
(28)
(3)
(4)
Stabilizer bushing
Clamp
(17)
(18)
Cap (Protection)
Washer

T1: 20 (2.0, 14.5)
(5)
(6)
Floating bushing
Stopper
(19)
(20)
Rear crossmember
Strut mount cap
T2: 25 (2.5, 18.1)

T3: 45 (4.6, 33.2)
(7)
(8)
Stabilizer link
Rear lateral link
(21)
(22)
Strut mount
Self-locking nut
T4: 60 (6.1, 44)

T5: 90 (9.2, 66)
(9)
(10)
Bushing
Bushing
(23)
(24)
Dust cover
Coil spring
T6: 100 (10.2, 74)

T7: 115 (11.7, 85)
(11)
(12)
Front lateral link

Bushing
(25)
(26)
Helper
Rubber seat lower
T8: 130 (13.3, 96)

T9: 140 (14.3, 103)
(13)
(14)
Trailing link rear bushing

Trailing link
(27)
Damper strut
RS-3
Flange nut
T10: 200 (20.4, 148)
General Description
REAR SUSPENSION
C: CAUTION
Before disposing of shock absorbers, be sure to
bleed the gas out completely. Also, do not expose
to flames or fire.

Do not mix grease with another grade or from other
manufacturers.
points.
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
927720000
DESCRIPTION
INSTALLER &
REMOVER
REMARKS
Used for replacing the front bushing.
927730000
INSTALLER &
REMOVER
Used for replacing the rear bushing.
927700000
INSTALLER &
REMOVER
Used for replacing the lateral link bushing.
ST-927720000
ST-927730000
ST-927700000
RS-4
General Description
REAR SUSPENSION
ILLUSTRATION
TOOL NUMBER
927690000
DESCRIPTION
INSTALLER &
REMOVER
REMARKS
Used for replacing the lateral link bushing.
ST-927690000
28099PA090
OIL SEAL PROTEC- Used for installing the rear drive shaft into the
TOR
rear differential.
For oil seal protection
28099PA100
REMOVER
ST28099PA090
Used for removing the rear drive shaft from the

rear differential.
ST28099PA100
2. GENERAL TOOL
TOOL NAME
REMARKS
Alignment gauge
Alignment gauge adapter

Turning radius gauge

Toe-in gauge

Used for toe-in measurement.
Transmission jack
Bearing puller
Used for removing and installing the suspension.

Used for removing bushings.
Coil spring compressor
Used for strut assembly/disassembly.
RS-5
Wheel Alignment
REAR SUSPENSION
2. Wheel Alignment
A: INSPECTION
NOTE:
Measure and adjust the front and rear wheel alignment together. Refer to FS section for measurement and adjustment of wheel alignment. <Ref. to
FS-6, INSPECTION, Wheel Alignment.>
RS-6
Rear Stabilizer
REAR SUSPENSION
3. Rear Stabilizer
B: INSTALLATION
A: REMOVAL

2) Remove the stabilizer link.
NOTE:
Use a new nut.
Install the stabilizer bushing while aligning it with
the paint mark on the stabilizer.
Make sure the stabilizer bushing and stabilizer
have the same identification colors (paint mark)
when installing.
RS-00010
3) Remove the bolt which secures the stabilizer to

the stabilizer bracket.
RS-00012
(1) Paint mark of the stabilizer

(2) Stabilizer bushing identification color
2) Always tighten the stabilizer bushing in the state

where the vehicle is at curb weight and the wheels
are in full contact with the ground.
RS-00011
Tightening torque:
Stabilizer link to rear lateral link
45 Nm (4.6 kgf-m, 33.2 ft-lb)
Stabilizer to stabilizer bracket
25 Nm (2.5 kgf-m, 18.1 ft-lb)
C: INSPECTION
1) Check the bushing for abnormal cracks, fatigue
or damage.
2) Check that there is no deformation, cracks or
damage on the stabilizer link.
RS-7
Rear Trailing Link

REAR SUSPENSION
4. Rear Trailing Link
C: DISASSEMBLY
A: REMOVAL
1. FRONT BUSHING
1) Loosen the rear wheel nuts.

2) Lift-up the vehicle, and then remove the rear
wheels.
3) Remove both the rear parking brake clamp and
the ABS wheel speed sensor harness.
4) Remove the bolt which attaches the trailing link
to the trailing link bracket.
Using the ST, press the front bushing out of place.

ST 927720000
INSTALLER & REMOVER
SET
(1)
(2)
ST
RS-00013
(1) Trailing link
5) Remove the bolt which attaches the trailing link

to the rear housing.
B: INSTALLATION
RS-00014
NOTE:
(1) Press
(2) Trailing link
Tightening torque:
Refer to COMPONENT of General Description for tightening torque values. <Ref. to
RS-3, COMPONENT, General Description.>
2) Always tighten bushings with wheels in full contact with the ground and the vehicle at curb weight.
RS-8
Rear Trailing Link

REAR SUSPENSION
D: ASSEMBLY
2. REAR BUSHING
1) Remove the housing. <Ref. to DS-21, REMOVAL, Rear Axle.>
2) Using the ST, press the rear bushing out.
ST 927730000
INSTALLER & REMOVER
SET
1. FRONT BUSHING
Using the ST, press the bushing into the trailing
link.
ST 927720000
INSTALLER & REMOVER
SET
CAUTION:
Turn ST plunger upside down and press it until
the plunger end surface contacts the trailing
link end surface.
(1)
(2)
ST
(3)
RS-00015
(1) Press
(2) Housing
RS-00017
(1) Press
(2) Front bushing
(3) Trailing link
RS-9
Rear Trailing Link

REAR SUSPENSION
2. REAR BUSHING
1) Using the ST, press the bushing into the trailing
link.
ST 927730000
INSTALLER & REMOVER
SET
2) Press the ST plunger until bushing flange protrudes beyond the trailing link.
ST 927730000
INSTALLER & REMOVER
SET
NOTE:
If it is difficult to press the bushing into the trailing
link, dilute TIRE LUBE with water and apply it to the
inner surface of ST as a lubricant.
ST
(1)
Specified lubricant:
TIRE LUBE : Water = 1 : 3
(1)
(2)
ST
RS-00019
(1) Plunger
(2) Flange
RS-00018
(1) Press
RS-10
Rear Trailing Link

REAR SUSPENSION
3) Turn the trailing link upside down. Press the ST

plunger in the direction opposite that outlines in the
former procedure until bushing is correctly positioned in trailing link.
ST 927730000
INSTALLER & REMOVER
SET
RS-00020
(1) Press
(2) Plunger
4) Install the housing. <Ref. to DS-24, INSTALLATION, Rear Axle.>
E: INSPECTION
Check the trailing link for bending, corrosion or
damage.
RS-11
Rear Strut
REAR SUSPENSION
5. Rear Strut
B: INSTALLATION
A: REMOVAL
1) Using new self-locking nuts, and attach the strut

mount to the body.
1) Remove the strut cap of the quarter trim.

2) Loosen the rear wheel nuts.
wheels.
4) Remove the brake hose clip and remove the
brake hose from rear strut.
Tightening torque:
20 Nm (2.0 kgf-m, 14.5 ft-lb)
2) Using new self-locking nuts, and attach the rear
strut to housing.
Tightening torque:
200 Nm (20.4 kgf-m, 148 ft-lb)
3) Attach the brake hose to lower side of the strut,
then insert brake hose clip.
4) Lower the vehicle and tighten wheel nut.
Tightening torque:
90 Nm (9.2 kgf-m, 66 ft-lb)
5) Attach the strut cap to the rear quarter trim.
RS-00021
C: DISASSEMBLY
(1) Brake hose clip

(2) Brake hose
5) Remove the bolts which secure the rear strut to

the housing.
Refer to the Front Struts for the procedures to disassemble the rear strut. <Ref. to FS-18, DISASSEMBLY, Front Strut.>
D: ASSEMBLY
Refer to Front Strut for assembly procedures.
<Ref. to FS-19, ASSEMBLY, Front Strut.>
E: INSPECTION
Refer to Front Strut for inspection procedures.
<Ref. to FS-20, INSPECTION, Front Strut.>
F: DISPOSAL
Refer to Front Strut for disposal procedures. <Ref.
to FS-20, DISPOSAL, Front Strut.>
RS-00022
CAUTION:
Do not apply excessive tension to the brake
hose and ABS wheel speed sensor harness.
6) Remove the nuts which secure the strut mount
to the vehicle body.
RS-00200
RS-12
Lateral Link
REAR SUSPENSION
6. Lateral Link
B: INSTALLATION
A: REMOVAL
1) Install in the reverse order of removal. Observe

the following instructions.
Attaching the DOJ to the differential <Ref. to DS35, INSTALLATION, Rear Drive Shaft.>.
Always tighten bushings with wheels in full contact with the ground and the vehicle at curb weight.
Tighten the nut with the bolt head fixed in place
when installing the adjusting bolt.
1) Loosen the wheel nuts. Lift up the vehicle, and

remove the wheels.
2) Remove the stabilizers.
3) Remove the ABS wheel speed sensor harness
from the trailing link.
4) Remove the bolts which secure the trailing link to
the housing.
CAUTION:
Always use a new self-locking nut and DOJ
circlip.
Always use the ST so that DOJ splines do not
damage the side oil seal.
ST 28099PA090 OIL SEAL PROTECTOR
C: DISASSEMBLY
1) Check the bushing type by referring to the following table.
2) Select the ST according to the type of bushings
used.
RS-00024
(1) Rear housing

(2) Trailing link
5) Remove the bolts which secure the lateral link

assembly to the rear housing.
6) Remove the DOJ from rear differential using the
ST.
ST 28099PA100 REMOVER
Bushing
Bushing A
ST: INSTALLER & REMOVER SET

927700000
Bushing B
Bushing C
927690000
927700000
(3)
(2)
(1)
(4)
(5)
(1)
RS-00025
(1) Bushing A
(2) Bushing B
(1) Bolt
(2) DOJ
CAUTION:
Be careful not to damage the side bearing retainer. Always use the bolt shown in figure, as
supporting points for the ST during removal.
7) Scribe an alignment mark on the rear lateral link
adjustment bolt and crossmember.
8) Remove the bolts securing the front and rear lateral links to the crossmember, and detach the lateral link.
CAUTION:
To loosen the adjusting bolt, always loosen the
nut while holding the head of adjusting bolt.
RS-13
(3) Bushing C
(4) Front
(5) Outside of body
RS-00206
Lateral Link
REAR SUSPENSION
3) Using the ST, press the bushing out.
3) Using the ST, press the bushing into place.
RS-00030
RS-00029
(1) Press
(2) Lateral link
(1) Press
(2) Bushing
(3) Lateral link
D: ASSEMBLY
1) Use the same ST as the one used during disassembly.
2) If it is difficult to press the bushing into the trailing
link, dilute TIRE LUBE with water and apply it to the
inner surface of ST as a lubricant.
4) Press the ST plunger until bushing flange protrudes beyond the trailing link.
Specified lubricant:
TIRE LUBE: Water = 1 : 3
RS-00031
(1) Press
(2) Plunger
(3) Lateral link
(4) Flange
RS-14
Lateral Link
REAR SUSPENSION
5) Turn the lateral link upside down. Press the ST

plunger in the direction opposite that outlines in the
former procedure until bushing is correctly positioned in trailing link.
RS-00032
(1) Press
(2) Plunger
(3) Lateral link
E: INSPECTION
Visually check the lateral link for damage and deformation.
RS-15
Rear Crossmember
REAR SUSPENSION
7. Rear Crossmember
C: INSPECTION
A: REMOVAL
Inspect the removed parts for wear and damage.

Repair or replace if defective.
CAUTION:
Do not apply excessive tension to the ABS
wheel speed sensor harness.
1) Separate the front exhaust pipe from the rear exhaust pipe.
3) Remove the rear differential.
<Ref. to DI-19, REMOVAL, Rear Differential.>
4) Place a transmission jack under the rear crossmember.
RS-00033
5) Remove the bolts securing the crossmember to

the vehicle body, and remove the crossmember.
RS-00207
6) Scribe an alignment mark on the rear lateral link

cam bolt and crossmember.
7) Remove the front and rear lateral links by loosening the nuts.
B: INSTALLATION
NOTE:
Discard the removed self-locking nut and replace
it with a new part.
Tighten the nut with the bolt head secured when
installing the adjusting bolt.
2) Install the rear differential.
<Ref. to DI-20, INSTALLATION, Rear Differential.>
3) Always tighten bushings with wheels in full contact with the ground and the vehicle at curb weight.
RS-16

REAR SUSPENSION

A: INSPECTION
1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT
Possible cause
(1) Permanent distortion or damaged coil spring
Replace.
Corrective action
(2) Rough operation of damper strut or shock absorber

(3) Improper installation of strut or shock absorber
Replace.
(4) Installation of the wrong coil spring
2. POOR RIDE COMFORT

1) Large rebound shock
2) Rocking of vehicle continues too long after running over bump and/or hump.
3) Excessive shock in bumping
Possible cause
Corrective action

Replace.
Adjust.
(3) Improper wheel arch height

(4) Fault in operation of damper strut or shock absorber
Adjust or replace the coil springs with new parts.

Replace.
(5) Damage or deformation of strut mount or shock absorber mount

(6) Improper installation (maximum or minimum) of damper strut or shock
absorber
(7) Damage or deformation of bushing
Replace.
(8) Deformation or damage of helper in strut assembly or shock absorber

(9) Oil leakage from the damper strut or shock absorber
Replace.
Replace.
Replace.
3. NOISE
Possible cause
(1) Worn or damaged damper strut
Replace.
Corrective action
(2) Wear or damage of shock absorber components

(3) Loosening of the suspension link installing bolt
Replace.
(4) Damage or deformation of bushing

absorber
Replace.

(7) Wear or damage of the ball joint
Replace.
Replace.
(8) Deformation of the stabilizer clamp
Replace.
RS-17

REAR SUSPENSION
RS-18
General Description
WHEEL AND TIRE SYSTEM
A: SPECIFICATION
WT-00001
(1) Offset
(2) P.C.D.
Model
Tire size
Rim size
P215/60 R16 94H
16 61/2JJ,
16 61/2J
16 61/2JJ
XT
L.L.Bean
P215/55 R17 93H

P215/60 R16 94H
17 7JJ
16 61/2JJ
X, XS, XT
L.L.Bean
T135/80 D16
16 4T
X
XS
Front and rear
Spare tire
*1 X, *1 XS
Rim offset
mm (in)
P.C.D. mm (in)
48 (1.89)
100 (3.94) Dia.
50 (1.97)
100 (3.94) Dia.
Equipped with a spare tire of the same size as the front and rear tire.
*1:
Vehicle for Canada

NOTE:
Vehicles for Canada excluding non-turbo model are supplied with T-type spare tires for temporary use.
Front and rear
Model
Tire size
X, XS,
L.L.Bean
T-type Tire
Tire inflation pressure kPa (kgf/cm2, psi)

Low load
Full load
P215/60 R16 94H
Front: 200 (2.0, 29)

Rear: 190 (1.9, 28)
Front: 200 (2.0, 29)

Rear: 250 (2.5, 36)
XT
P215/55 R17 93H
Front: 220 (2.2, 32)

Rear: 210 (2.1, 30)
Front: 220 (2.2, 32)

Rear: 220 (2.2, 32)
XT
T135/80 D16
420 (4.2, 60)
NOTE:
Rear tire inflation pressure when towing a trailer
16-inch tire
280 kPa (2.8 kg/cm2, 41 psi)
17-inch tire
250 kPa (2.5 kg/cm2, 36 psi)
1. SERVICE DATA
Part
Steel wheel
Aluminum wheel
Axial runout
Radial runout
1.5 mm (0.059 in)

1.0 mm (0.039 in)
WT-2
General Description
2. ADJUSTING PARTS
Wheel balancing
Standard:
Dynamic unbalance
Service limit
5 g (0.18 oz) or less
Balance weight part number

(Adhesive type weight for
aluminum wheel)
28101AG131
37.5 g (1.32 oz)
28101AG141
28101AG151
40 g (1.41 oz)
42.5 g (1.50 oz)
28101AG161
28101AG171
45 g (1.59 oz)
47.5 g (1.68 oz)
28101AG181
28101AG191
50 g (1.76 oz)
52.5 g (1.85 oz)
28101AG201
28101AG211
55 g (1.94 oz)
57.5 g (2.03 oz)
28101AG221
28101AG231
60 g (2.12 oz)
62.5 g (2.20 oz)
28101AG241
28101AG251
65 g (2.29 oz)
67.5 g (2.38 oz)
28101AG261
28101AG271
70 g (2.47 oz)
72.5 g (2.56 oz)
28101AG281
28101AG291
75 g (2.65 oz)
77.5 g (2.73 oz)
Weight

(For steel wheel)
28101TC000
5 g (0.18 oz)
28101SA060
28101SA070
10 g (0.35 oz)
15 g (0.53 oz)
28101SA080
28101SA090
20 g (0.71 oz)
25 g (0.88 oz)
28101SA160
28101SA170
30 g (1.06 oz)
35 g (1.23 oz)
28101SA180
28101SA190
40 g (1.41 oz)
45 g (1.59 oz)
28101SA200
28101SA210
50 g (1.76 oz)
55 g (1.94 oz)
28101SA220
60 g (2.12 oz)

(Knock-on type weight for
aluminum wheel)
Weight
28101AG301
28101AG311
80 g (2.82 oz)
82.5 g (2.91 oz)
28101SA000
28101SA010
5 g (0.18 oz)
10 g (0.35 oz)
28101AG321
28101AG331
85 g (3.00 oz)
87.5 g (3.09 oz)
28101SA020
28101SA030
15 g (0.53 oz)
20 g (0.71 oz)
28101AG341
28101AG351
90 g (3.17 oz)
92.5 g (3.26 oz)
28101SA040
28101SA100
25 g (0.88 oz)
30 g (1.06 oz)
28101AG361
28101AG371
95 g (3.35 oz)
97.5 g (3.44 oz)
28101SA110
28101SA120
35 g (1.23 oz)
40 g (1.41 oz)
28101AG381
100 g (3.53 oz)
B: PREPARATION TOOL
28101SA130
28101SA140
45 g (1.59 oz)
50 g (1.76 oz)
1. GENERAL TOOL
28101SA150
55 g (1.94 oz)
60 g (2.12 oz)
Weight

aluminum wheel)
28101AG001
5 g (0.18 oz)
28101AG011
28101AG021
7.5 g (0.26 oz)

10 g (0.35 oz)
28101AG031
28101AG041
12.5 g (0.44 oz)

15 g (0.53 oz)
28101AG051
28101AG061
17.5 g (0.62 oz)

20 g (0.71 oz)
28101AG071
28101AG081
22.5 g (0.79 oz)

25 g (0.88 oz)
28101AG091
28101AG101
27.5 g (0.97 oz)

30 g (1.06 oz)
28101AG111
28101AG121
32.5 g (1.15 oz)

35 g (1.23 oz)
Weight
WT-3
TOOL NAME
REMARKS
Air pressure gauge

Dial gauge
Used for measuring tire air pressure.

Used for measuring wheel runout.
Tire
2. Tire
1. TIRE ROTATION
A: INSPECTION
1) Take stones, glass, nails etc. out of the tread
groove.
2) Replace the tire.
Rotate tires periodically (12,500 km/7,500 miles) as

shown in the figure, in order to prevent uneven
wear and to prolong life.
When the direction of tire rotation is not specified
CAUTION:
When replacing a tire, make sure to use only
tires of the same size, construction and load
range as originally installed.
(1) If large cracks on side wall, damage or
cracks on the tread is found.
(2) When the tread wear indicator appears as
a solid band across the tread.
(3) If a crack is found on the tire valve, replace
the valve.
WT-00113
(1) Front
When the direction of tire rotation is specified
1
WT-00002
(1) Tread wear indicator

WT-00115
(2) Tire tread

(1) Front
WT-4
Steel Wheel
3. Steel Wheel
C: INSPECTION
A: REMOVAL
1) Deformation or damage to the rim may cause air

leakage. Check the rim flange for deformation,
cracks or damage, and repair or replace as necessary.
2) Jack-up the vehicle until tires clear the floor.
3) Slowly rotate the wheel to check rim runout using a dial gauge.
1) Apply the parking brake, and position select lever to P or LOW.

2) Set the shop jacks or a lift to the specified points,
and support the vehicle with its wheels slightly contacting the floor.
3) Loosen the wheel nuts.
4) Raise the vehicle until its wheels are off the
ground using the jack or a lift.
5) Remove the wheel nuts and wheels.
NOTE:
When removing the wheels, be careful not to
damage the hub bolts.
Place the wheels with their outer sides facing upward to prevent wheels from being damaged.
B: INSTALLATION
WT-00004
1) Remove dirt from the mating surface of the

wheel and brake rotor.
2) Attach the wheel to the hub by aligning the wheel
bolt holes with the hub bolts.
3) Temporarily attach the wheel nuts to the hub
bolts. (In the case of aluminum wheels, use SUBARU genuine wheel nuts for aluminum wheels.)
4) Tighten the nuts by hand, making sure the wheel
hub hole is aligned correctly to the guide portion of
hub.
5) Tighten opposing wheel nuts in sequence to the
specified torque. Use a wheel nut wrench.
Axial runout limit

Radial runout limit
1.5 mm (0.059 in)
(1)
(1)
(1)
Wheel nut tightening torque:

100 Nm (10.2 kgf-m, 73.8 ft-lb)
WT-00005
CAUTION:
Tighten the wheel nuts in two or three steps
by gradually increasing the torque on opposing
nuts, until they reach the specified torque. For
drum brake model, excess tightening of wheel
nuts may cause wheels to judder.
Do not push the wrench by foot. Always use
both hands when tightening the nuts.
Make sure the bolt, nut and the nut seating
surface of the wheel are free from oil.
6) If a wheel is removed for replacement or for repair of a puncture, retighten the wheel nuts to the
specified torque after driving 1,000 km (600 miles).
(1) Approx. 7 mm (0.28 in)
4) If the rim runout exceeds specifications, remove

the tire from wheel and check runout with the dial
gauge attached to positions shown in the figure.
5) If the measured runout still exceeds specifications, replace the wheel.
WT-5
Aluminum Wheel
4. Aluminum Wheel
A: REMOVAL
Refer to Steel Wheels for removal procedure of
aluminum wheels. <Ref. to WT-5, REMOVAL,
Steel Wheel.>
B: INSTALLATION
Refer to Steel Wheels for installation procedure of
aluminum wheels. <Ref. to WT-5, INSTALLATION,
Steel Wheel.>
C: INSPECTION
Refer to Steel Wheels for inspection procedure of
aluminum wheels. <Ref. to WT-5, INSPECTION,
Steel Wheel.>
Rim runout:
Axial runout limit
Radial runout limit
1.0 mm (0.039 in)
D: CAUTION
Aluminum wheels are easily scratched. To maintain their appearance and safety, be careful of the
following:
1) Be careful not to damage the aluminum wheels
during removal, installation, wheel balancing, etc.
After removing aluminum wheels, place them on a
rubber mat etc.
2) When washing the aluminum wheel, use neutral
synthetic detergent and water. Avoid using the
cleansers containing abrasives, hard brushes or an
automatic car washer.
WT-6
Wheel Balancing
5. Wheel Balancing
A: ADJUSTMENT
NOTE:
Change the setting of wheel balancer to adhesive
type weight if adhesive type weight is adopted.
1) Remove the balance weights.
CAUTION:
Be careful not to damage the wheel.
Completely remove the two-sided tape of the
adhesive type weight from the wheel.
2) Using the wheel balancer, measure wheel balance.
3) Select a weight close to the value measured by
wheel balancer.

aluminum wheel)
28101AG031
12.5 g (0.44 oz)
28101AG041
28101AG051
15 g (0.53 oz)
17.5 g (0.62 oz)
28101AG061
28101AG071
20 g (0.71 oz)
22.5 g (0.79 oz)
28101AG081
28101AG091
25 g (0.88 oz)
27.5 g (0.97 oz)
28101AG101
28101AG111
30 g (1.06 oz)
32.5 g (1.15 oz)
28101AG121
28101AG131
35 g (1.23 oz)
37.5 g (1.32 oz)
28101AG141
28101AG151
40 g (1.41 oz)
42.5 g (1.50 oz)
Weight

(For steel wheel)
28101TC000
5 g (0.18 oz)
28101AG161
28101AG171
45 g (1.59 oz)
47.5 g (1.68 oz)
28101SA060
28101SA070
10 g (0.35 oz)
15 g (0.53 oz)
28101AG181
28101AG191
50 g (1.76 oz)
52.5 g (1.85 oz)
28101SA080
28101SA090
20 g (0.71 oz)
25 g (0.88 oz)
28101AG201
28101AG211
55 g (1.94 oz)
57.5 g (2.03 oz)
28101SA160
28101SA170
30 g (1.06 oz)
35 g (1.23 oz)
28101AG221
28101AG231
60 g (2.12 oz)
62.5 g (2.20 oz)
28101SA180
28101SA190
40 g (1.41 oz)
45 g (1.59 oz)
28101AG241
28101AG251
65 g (2.29 oz)
67.5 g (2.38 oz)
28101SA200
28101SA210
50 g (1.76 oz)
55 g (1.94 oz)
28101AG261
28101AG271
70 g (2.47 oz)
72.5 g (2.56 oz)
28101SA220
60 g (2.12 oz)
28101AG281
28101AG291
75 g (2.65 oz)
77.5 g (2.73 oz)

(Knock-on type weight for
aluminum wheel)
Weight
28101AG301
28101AG311
80 g (2.82 oz)
82.5 g (2.91 oz)
28101SA000
28101SA010
5 g (0.18 oz)
10 g (0.35 oz)
28101AG321
28101AG331
85 g (3.00 oz)
87.5 g (3.09 oz)
28101SA020
28101SA030
15 g (0.53 oz)
20 g (0.71 oz)
28101AG341
28101AG351
90 g (3.17 oz)
92.5 g (3.26 oz)
28101SA040
28101SA100
25 g (0.88 oz)
30 g (1.06 oz)
28101AG361
28101AG371
95 g (3.35 oz)
97.5 g (3.44 oz)
28101SA110
28101SA120
35 g (1.23 oz)
40 g (1.41 oz)
28101AG381
100 g (3.53 oz)
28101SA130
28101SA140
45 g (1.59 oz)
50 g (1.76 oz)
28101SA150
55 g (1.94 oz)
60 g (2.12 oz)
Weight

aluminum wheel)
28101AG001
5 g (0.18 oz)
28101AG011
28101AG021
7.5 g (0.26 oz)

10 g (0.35 oz)
Weight
WT-7
Wheel Balancing
4) Install the selected weight to the point designated by the wheel balancer.
CAUTION:
Remove grease from the applying surface of
adhesive type weight for wheel.
Press the adhesive type weight by 25 N (2.5
kgf, 5.6 lbf) or more per 5 g (0.18 oz) for 2 seconds or more to attain close contact.
Total application of the adhesive type weight
should be 100 g (3.53 oz) or less.
5) Using the wheel balancer, measure the wheel
balance again. Check that wheel balance is correctly adjusted.
6) Use Subaru genuine balance weights.
NOTE:
55 g (1.94 oz) weight used with aluminum wheel
is not available.
Knock-on type balance weight can be used for
any of 15- to 16-inch wheels.
A
(1)
(2)
WT-00107
(1) Knock-on type weight for aluminum wheel

(2) Knock-on type weight for steel wheel
Service limit: A
Knock-on type weight for steel wheel:
2.0 mm (0.079 in)
Knock-on type weight for aluminum wheel:
5.0 mm (0.197 in)
WT-8
T-type Tire
6. T-type Tire
A: NOTE
Vehicles for Canada excluding non-turbo model
are supplied with T type spare tires for temporary
use.
CAUTION:
Do not use a tire chain with the T-type tire.
Because of the smaller tire size, a tire chain will
not fit properly and will result in damage to the
vehicle and the tire.
Do not drive at a speed greater than 80 km/h
(50 MPH).
Drive as slowly as possible and avoid passing over bumps.
B: REPLACEMENT
Refer to Steel Wheels for removal and installation
procedures of the T Type. <Ref. to WT-5, REMOVAL, Steel Wheel.>
CAUTION:
The T-type tire is only for temporary use. Replace with a conventional tire as soon as possible.
C: INSPECTION
1) Check the tire air pressure.
Specifications:
420 kPa (4.2 kg/cm2, 60 psi)
2) Take stones, glass, nails, etc. out of the tread
groove.
3) Check the tires for deformation, cracks, partial
wear, or wear.
CAUTION:
Replace the tire with a new part if faulty.
WT-9


A: INSPECTION
Symptoms
Vehicle sways
Possible cause
Improperly inflated tire.
Adjust the tire pressure. Refer to

specifications for the tire air pressure.
<Ref. to WT-2, SPECIFICATION,
Inspect the tire referring to
Abnormal tire wear in this table, and
perform the indicated
procedures and replace the tire.
Abnormal wear
Front wheel alignment
Check the front wheel alignment. <Ref.

to FS-6, INSPECTION, Wheel
Alignment.>
Rear wheel alignment
Check the rear wheel alignment. <Ref.

to RS-6, INSPECTION, Wheel
Alignment.>
Front strut
Check the front strut. <Ref. to

FS-20, INSPECTION, Front Strut.>
Rear strut
Check the rear strut. <Ref. to

RS-12, INSPECTION, Rear Strut.>
Front axle
Check the front axle. <Ref. to

DS-20, INSPECTION, Front Axle.>
Check the rear axle. <Ref. to DS-28,
INSPECTION, Rear Axle.>
specifications for the tire air presure.
Rear axle
Abnormal vehicle pitching
Abnormal wear
Inspect the tire referring to Abnormal

tire wear in this table, and
perform the indicated procedures and
replace the tire.
Inspect the front stabilizer. <Ref. to
FS-21, INSPECTION, Front
Stabilizer.>
Alignment.>
Front stabilizer
Abnormal wheel vibration
Corrective action

Alignment.>

Inspect the tire referring to Abnormal
tire wear in this table, and perform the
indicated procedures and replace the
tire.
Abnormal wear
Wheel is out of balance.
Adjust wheel balance. <Ref. to WT-7,

ADJUSTMENT, Wheel Balancing.>
Front axle
Check the front axle. <Ref. to DS-20,

INSPECTION, Front Axle.>
Rear axle
WT-10

Symptoms
Uneven tire wear
Possible cause
Corrective action
Adjust wheel balance. <Ref. to WT-7,
Alignment.>
Alignment.>

WT-11

WT-12
General Description
DIFFERENTIALS
A: SPECIFICATION
When replacing a rear differential assembly, select the correct assembly according to the following table.
NOTE:
Using a different rear differential assembly will cause the drive train and tires to drag or emit abnormal noise.
Model
Rear differential type
Non-turbo, rear drum brake

MT
AT
T type (Model without LSD)
LSD type
Identification
Type of gear
Gear ratio (Number of gear teeth)
Non-turbo, rear disc brake

MT
T2
TP
4.111 (37/9)
4.444 (40/9)
Turbo
AT
MT
T type (Model with LSD)
AT
Viscous coupling
CF
CF
JP
Hypoid gear
4.111 (37/9) 4.444 (40/9)
JP
4.444 (40/9)
4.111 (37/9)
0.8 2 (0.8 US qt, 0.7 Imp qt)

GL-5
Oil capacity
Identification

Recommended oil
CAUTION:
Each oil manufacturer uses different base oil
and additives. Thus, do not mix two or more
brands.
DI-00001
( C)
( F)
(1)
(2)
(3)
GL-5
(4)
-30 -26 -15 -5 0
-22 -15 5 23 32
15
59
25 30
77 86
90
85W
80W
75W -90
MT-00001
(1) Item
(2) Differential gear oil
1. SERVICE DATA
Drive pinion bearing preload (for new bearing)
Side gear backlash
Measure with spring measurement

(Measured from the companion
flange bolt) N (kgf, lbf)
Measure with torque wrench
Nm (kgf-m, ft-lb)
mm (in)
17.7 38.8 (1.8 4.0, 4.0 8.7)

0.67 1.47 (0.07 0.15, 0.49 1.08)
0.10 0.20 (0.004 0.008)
Side bearing standard width

Hypoid driven gear to drive pinion backlash
mm (in)
mm (in)
20.00 (0.7874)
0.10 0.20 (0.004 0.008)
Hypoid driven gear back surface runout
mm (in)
0.05 (0.0020) or less
DI-2
General Description
DIFFERENTIALS
2. ADJUSTING PARTS
Measure with spring measurement
(Measured from the companion flange
bolt) N (kgf, lbf)
Measure with torque wrench Nm
(kgf-m, ft-lb)
Part No.
Drive pinion bearing preload

(for new bearing)
Preload adjusting collar
Preload adjusting washer
Pinion height adjusting washer
Side gear backlash
17.7 38.8 (1.8 4.0, 3.8 8.7)

0.67 1.47 (0.07 0.15, 0.49 1.08)
Length
mm (in)
383695201
383695202
56.2 (2.213)
56.4 (2.220)
383695203
383695204
56.6 (2.228)
56.8 (2.236)
383695205
383695206
57.0 (2.244)
57.2 (2.252)
Part No.
383705200
Thickness mm (in)
2.59 (0.1020)
383715200
383725200
2.57 (0.1012)
2.55 (0.1004)
383735200
383745200
2.53 (0.0996)
2.51 (0.0988)
383755200
383765200
2.49 (0.0980)
2.47 (0.0972)
383775200
383785200
2.45 (0.0965)
2.43 (0.0957)
383795200
383805200
2.41 (0.0949)
2.39 (0.0941)
383815200
383825200
2.37 (0.0933)
2.35 (0.0925)
383835200
383845200
2.33 (0.0917)
2.31 (0.0909)
Part No.
383495200
Thickness mm (in)
3.09 (0.1217)
383505200
383515200
3.12 (0.1228)
3.15 (0.1240)
383525200
383535200
3.18 (0.1252)
3.21 (0.1264)
383545200
383555200
3.24 (0.1276)
3.27 (0.1287)
383565200
383575200
3.30 (0.1299)
3.33 (0.1311)
383585200
383595200
3.36 (0.1323)
3.39 (0.1335)
383605200
383615200
3.42 (0.1346)
3.45 (0.1358)
383625200
383635200
3.48 (0.1370)
3.51 (0.1382)
383645200
383655200
3.54 (0.1394)
3.57 (0.1406)
383665200
383675200
3.60 (0.1417)
3.63 (0.1429)
383685200
3.66 (0.1441)
mm (in)
0.1 0.2 (0.004 0.008)
DI-3
General Description
DIFFERENTIALS
Side gear thrust washer

(Model without LSD)
Side bearing standard width
mm (in)
Side bearing retainer shim
Hypoid driven gear to drive pinion backlash

Hypoid driven gear runout on its back
surface
Part No.
Thickness mm (in)
383445201
383445202
0.75 0.80 (0.0295 0.0315)

0.80 0.85 (0.0315 0.0335)
383445203
0.85 0.90 (0.0335 0.0354)

20.00 (0.7874)
Part No.
383475201
Thickness mm (in)
0.20 (0.0079)
383475202
383475203
0.25 (0.0098)
0.30 (0.0118)
383475204
383475205
0.40 (0.0157)
0.50 (0.0197)
0.10 0.20 (0.004 0.008)
Allowable limit
mm (in)
0.05 (0.0020)
DI-4
General Description
DIFFERENTIALS
B: COMPONENT
1. REAR DIFFERENTIAL WITHOUT LSD
(1)
(18)
(19)
(21)
(2)
(20)
(3)
(4)
(19)
(5)
(20)
(18)
( 1 ) (21)
(22)
(25)
(26)
T4
(27)
T1
(16)
(28)
T3
T3
(15)
(14)
(24)
T2
(30)
(13)
(17)
(23)
(29)
(6)
(7)
T1
(13)
(14)
(15)
(8)
(16)
(17)
(9)
(10)
(12)
T5
(11)
DI-00494
(1)
Hypoid driven gear and drive pinion set
(13)
(14)
Side bearing
O-ring
(26)
(27)
Stud bolt
Oil filler plug
(2)
(3)

Rear bearing
(15)
(16)

Side bearing retainer
(28)
(29)
Oil drain plug

Rear cover
(4)
(5)
Bearing preload adjusting collar

Bearing preload adjusting washer
(17)
(18)
Side oil seal

(30)
Differential case
(6)
(7)
Differential carrier
Front bearing
(19)
(20)
Side gear
Pinion mate gear

T1: 10.5 (1.1, 7.7)
(8)
(9)
Collar
Pilot bearing
(21)
(22)
Pinion mate gear washer

Pinion shaft lock pin
T2: 29.5 (3.0, 21.8)

T3: 49 (5.0, 36.2)
(10)
(11)
Front oil seal

Companion flange
(23)
(24)
Gasket
Pinion mate shaft
T4: 103 (10.5, 76)

T5: 181.5 (18.5, 134)
(12)
Self-locking nut
(25)
Air breather cap
DI-5
General Description
DIFFERENTIALS
2. REAR DIFFERENTIAL WITH LSD

(1)
(2)
(3)
(4)
(5)
(1)
(21)
(23)
T4
T1
(22)
T3
(20)
(15)
(19)
(24)
(13)
T3
(17)
(18)
T2
(6)
(16)
(14)
(14)
(15)
(7)
(13)
T1
(16)
(17)
(8)
(10)
T5
(12)
(9)
(11)
DI-00002
(1)
Hypoid driven gear and drive pinion set
(11)
(12)
Companion flange
Self-locking nut
(21)
(22)
Air breather cap

Stud bolt
(2)
(3)

Rear bearing
(13)
(14)
Side bearing
O-ring
(23)
(24)
Oil filler plug

Oil drain plug
(4)
(5)
Bearing preload adjusting collar

Bearing preload adjusting washer
(15)
(16)

Side bearing retainer
(6)
(7)
Differential carrier
Front bearing
(17)
(18)
Side oil seal

Gasket
T1: 10.5 (1.1, 7.7)

T2: 29.5 (3.0, 21.8)
(8)
(9)
Spacer
Pilot bearing
(19)
Differential case
(Viscous coupling type)
T3: 49 (5.0, 36.2)

T4: 103 (10.5, 76)
(10)
Front oil seal
(20)
Rear cover
T5: 181.5 (18.5, 134)
DI-6
General Description
DIFFERENTIALS
3. REAR DIFFERENTIAL MOUNTING SYSTEM
(5)
T3
(9)
(6)
(7)
T4
(2)
(7)
(1)
(7)
(7)
T4
(8)
T6
(4)
(3)
(7)
T3
(6)
T6
(3)
(7)
T1
T5
T2
(8)
T4
T5
T1
DI-00483
(1)
(2)
Front differential member

Differential bracket
(8)
(9)
Differential mount bracket

Crossmember
(3)
(4)
Differential mount lower bracket

Differential mount front cover
T2: 50 (5.1, 36.9)

T3: 70 (7.1, 51.6)
(5)
(6)
Plate
Stopper
T4: 90 (9.2, 66.4)

T5: 100 (10.2, 73.8)
(7)
Bushing
T6: 128 (13.8, 97.6)
DI-7

T1: 33 (3.4, 24.3)
General Description
DIFFERENTIALS
C: CAUTION
Use SUBARU genuine gear oil, grease or the
equivalent. Do not mix gear oil, grease, etc. with
those of different grades or from other manufacturers.
points.
Apply gear oil onto sliding or revolving surfaces
Before installing the O-ring or snap ring, apply a
sufficient amount of gear oil to avoid damage and
deformation.
DI-8
General Description
DIFFERENTIALS
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
398477701
HANDLE
Used for installing the front and rear bearing

cones.
398477702
DRIFT
Used for press-fitting the bearing cone of differential carrier (front).
398217700
ATTACHMENT SET
Stand for rear differential carrier disassembly

and assembly.
498447120
INSTALLER
Used for installing the front oil seal.
ST-398477701
ST-398477702
ST-398217700
ST-498447120
DI-9
General Description
DIFFERENTIALS
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
498427200
FLANGE WRENCH
Used for preventing rotation of companion flange

when loosening and tightening self-lock nut.
398467700
DRIFT
Used for removing pinion, pilot bearing and front

bearing cone.
399780104
WEIGHT
Used for installing the front bearing cone and the

pilot bearing companion flange.
899580100
INSTALLER
Used for press-fitting the front bearing cone and

pilot bearing.
899904100
STRAIGHT PIN
REMOVER
Used for driving out differential pinion shaft lock

pin.
ST-498427200
ST-398467700
ST-399780104
ST-899580100
ST-899904100
DI-10
General Description
DIFFERENTIALS
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
498247001
MAGNET BASE
Used for measuring backlash between side

gear and pinion, and hypoid driven gear.
Used together with DIAL GAUGE
(498247100).
498247100
DIAL GAUGE
Used for measuring backlash between side

gear and pinion, and hypoid driven gear.
Used together with MAGNET BASE
(498247001).
398507704
BLOCK
Used for adjusting pinion height and preload.
398177700
INSTALLER
Used for installing the rear bearing cone.
398457700
ATTACHMENT
Used for removing the side bearing retainer.
ST-498247001
ST-498247100
ST-398507704
ST-398177700
ST-398457700
DI-11
General Description
DIFFERENTIALS
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
398477703
DRIFT 2
Used for press-fitting bearing race (rear) of differential carrier.
398437700
DRIFT
Used for installing the side oil seal.
398507702
DUMMY SHAFT
398507703
DUMMY COLLAR
398517700
REPLACER
Used for removing rear bearing cone.
ST-398477703
ST-398437700
ST-398507702
ST-398507703
ST-398517700
DI-12
General Description
DIFFERENTIALS
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
398487700
DRIFT
Used for press-fitting side bearing cone.
398507701
DIFFERENTIAL
CARRIER GAUGE
Used for adjusting pinion height.
398527700
PULLER ASSY
Used for removing front oil seal.

Used for removing side bearing cup.
399527700
PULLER SET
Used for taking out the side bearing cone.

(1) BOLT (899521412)
(2) PULLER (399527702)
(3) HOLDER (399527703)
(4) ADAPTER (398497701)
(5) BOLT (899520107)
(6) NUT (021008000)
28099PA090
OIL SEAL
PROTECTOR
Used for installing the rear drive shaft to the

rear differential.
For oil seal protection
ST-398487700
ST-398507701
ST-398527700
(3)
(4)
(2)
(5)
(1)
(6)
ST-399527700
ST28099PA090
DI-13
General Description
DIFFERENTIALS
ILLUSTRATION
TOOL NUMBER
398237700
DESCRIPTION
REMARKS
DRIFT
Used for installing side bearing.
28099PA100
DRIVE SHAFT
REMOVER
Used for removing the rear drive shaft from rear

differential.
399703600
PULLER ASSY
Used for removing companion flange.
899874100
INSTALLER
Used for installing the companion flange.
PULLER ASSY
Used for removing the differential side bearing

cone.
ST-398237700
ST28099PA100
ST-399703600
ST-899874100
18759AA000
ST18759AA000
DI-14
General Description
DIFFERENTIALS
2. GENERAL TOOL
TOOL NAME
REMARKS
Transmission jack
Puller
Used for removing and installing the rear differential.

Used for removing the side bearing retainer.
Thickness gauge
Tire lever
Used for measuring clearance.

Used for removing the rear drive shaft.
DI-15

DIFFERENTIALS
2. Differential Gear Oil
B: REPLACEMENT
A: INSPECTION

racks.
2) Remove the oil drain plug and filler plug, and
drain the gear oil.
1) Remove the filler plug, and then check the gear

oil. If it is contaminated or deteriorated, replace the
gear oil. <Ref. to DI-16, REPLACEMENT, Differential Gear Oil.>
2) Check that the gear oil level is up to the bottom
of filler plug or the oil temperature switch hole. If the
level is low, check that there is no oil leakage and
fill the oil up to the bottom of filler plug.
CAUTION:
Be careful not to get burned, because gear oil
becomes extremely hot after running.
(A)
DI-00048
(B)
(A) Filler plug

DI-00049
(B) Drain plug
(A) Filler plug

(B) Drain plug
3) Tighten the oil drain plug.
3) When checking is completed, tighten the filler

plug.
NOTE:
Apply liquid gasket to the drain plug.
Liquid gasket:
equivalent
Tightening torque:
49 Nm (5.0 kgf-m, 36.2 ft-lb)
NOTE:
Liquid gasket:
equivalent
Tightening torque:
49 Nm (5.0 kgf-m, 36.2 ft-lb)
4) Fill the differential carrier with gear oil to the bottom of filler plug.
NOTE:
Carefully refill oil while watching the level. Excessive or insufficient oil must be avoided.
Oil capacity:
0.8 2 (0.8 US qt, 0.7 Imp qt)
(A)
(B)
DI-00049
(A) Filler plug

(B) Drain plug
DI-16

DIFFERENTIALS
5) Install the filler plug.

NOTE:
Apply liquid gasket to the filler plug.
Liquid gasket:
equivalent
Tightening torque:
49 Nm (5.0 kgf-m, 36.2 ft-lb)
DI-17

DIFFERENTIALS
3. Front Differential Assembly

A: NOTE
1. AT MODEL
For front differential of automatic transmission, refer to the AT section. <Ref. to 4AT-101, Front Differential Assembly.>
2. MT MODEL
For front differential of manual transmission, refer
to MT section. <Ref. to 5MT-67, Front Differential
Assembly.>
DI-18
Rear Differential
DIFFERENTIALS
4. Rear Differential
10) Remove the lower bracket.

(A)
A: REMOVAL
3) Shift the select lever or gear shift lever to neutral.
4) Release the parking brake.
racks.
Non-turbo model
Turbo model
8) Remove the clamps and bracket of parking
brake cable.
DI-00122
(A) Lower bracket
11) Support the rear differential with the transmission jack.
DI-00055
12) Remove the self-locking nuts and bolts.
DI-00051
9) Remove the DOJ of rear drive shaft from rear differential using ST. <Ref. to DI-39, REPLACEMENT, Rear Differential Side Oil Seal.>
ST 28099PA100 DRIVE SHAFT REMOVER
DI-00056
ST
(A)
DI-00052
(A) Bolt
DI-19
Rear Differential
DIFFERENTIALS
13) Remove the bolts which secure the differential

front member to the vehicle.
Loosen the bolt A first, then remove the bolt B.
17) Remove the rear differential from the differential front member.
NOTE:
Instruct your co-worker to hold the differential front
member so that it will not fall.
DI-00059
(B)
(A)
B: INSTALLATION
(B)

1) Position the differential front member with the
vehicle by passing the member under the parking
brake cable and securing it to rear differential.
DI-00057
(A) Bolt A
(B) Bolt B
14) Remove the bolt A.

15) Suspend the rear drive shaft to the rear crossmember using wire.
NOTE:
When installing the rear differential front member,
be careful of the order for installation of the upper
and lower stoppers.
2) Install the DOJ of the drive shaft into the rear differential. <Ref. to DI-39, REPLACEMENT, Rear
Differential Side Oil Seal.>
ST 28099PA090 SIDE OIL SEAL PROTECTOR
DI-00053
16) While slowly lowering the transmission jack,

move the rear differential forward, and remove the
differential front member and the rear differential
from vehicle.
ST
DI-00060
3) Installing procedure hereafter is in the reverse

order of removal.
4) After installing, fill the differential carrier with
gear oil up to the bottom of the filler plug hole. <Ref.
to DI-16, Differential Gear Oil.>
DI-00058
DI-20
Rear Differential
DIFFERENTIALS
C: DISASSEMBLY
To detect the real cause of trouble, inspect the following items before disassembling.
Tooth contact of hypoid driven gear and drive
pinion, and backlash
Hypoid driven gear runout on its back surface
Total preload of drive pinion
1) Set the ST on vise and install the differential assembly to ST.
ST 398217700
ATTACHMENT
4) Remove the bolts, and then remove the rear

cover.
(B)
(A)
DI-00063
(A) Rear cover

(B) Differential carrier
5) Keep the side bearing retainers RH and LH separately for easier reassembly. Remove the side
bearing retainer attaching bolts, set the ST to differential case, and extract the side bearing retainers
RH and LH with a puller.
ST
DI-00061
2) Drain the gear oil by removing the plug.

3) Remove the air breather cap.
NOTE:
Do not attempt to replace the air breather cap unless necessary.
Replace the air breather cap with a new part
when removing.
NOTE:
Each shim, which is installed to adjusted the side
bearing preload, should be kept together with its
mating retainer.
ST 398457700
ATTACHMENT
ST
(A)
(B)
DI-00064
DI-00062
(A) Air breather cap

(B) Rear cover
6) Pull out the differential case assembly from differential carrier.

NOTE:
Be careful not to hit the teeth against the case.
DI-00065
7) Remove the O-ring from side bearing retainer.

8) Remove the oil seal from the side bearing retainer. <Ref. to DI-39, REPLACEMENT, Rear Differential Side Oil Seal.>
DI-21
Rear Differential
DIFFERENTIALS
9) Using the ST, remove the bearing cup from the

side bearing retainer.
ST 398527700
PULLER ASSY
12) Drive out the pinion shaft lock pin from hypoid
driven gear side (Model without LSD).
NOTE:
The lock pin is staked at the pin hole end on the differential carrier. Do not drive it out forcibly before
removing the stake.
ST 899904100
ST
DI-00066
10) Remove the bearing cone with ST.

NOTE:
Do not attempt to disassemble the parts unless
necessary.
Set the puller so that its claws catch the edge of
the bearing cone.
Never mix up the RH and LH bearing races and
cones.
ST 18759AA000 PULLER ASSY
ST
DI-00237
13) Draw out the pinion mate shaft and remove pinion mate gears, side gears and thrust washers.
(Model without LSD)
NOTE:
The gears should be marked or kept separated
right and left, and front and rear as well as thrust
washers.
DI-00316
11) Remove the hypoid driven gear by loosening

the hypoid driven gear bolts.
DI-00238
(A) Side gear

(B) Pinion mate gear
(C) Thrust washer
(D) Differential case
(E) Pinion mate shaft
DI-00068
DI-22
Rear Differential
DIFFERENTIALS
14) Remove the self-locking nut while holding the

companion flange with ST.
ST 498427200
FLANGE WRENCH
17) Remove the rear bearing cone from drive pinion by supporting the cone with ST.
NOTE:
Place the replacer so that its center-recessed side
faces the pinion gear.
ST 398517700
REPLACER
ST
ST
DI-00071
15) Extract the companion flange with a puller.

DI-00074
18) Remove the front oil seal from differential carrier using ST.
ST 398527700
PULLER ASSY
DI-00072
16) Press the end of drive pinion shaft and extract it

together with rear bearing cone, pinion height adjusting washer and washer.
NOTE:
Hold the drive pinion so as not to drop it.
ST 398467700
DRIFT
DI-00075
19) Remove the pilot bearing together with front

bearing cone using ST.
ST 398467700
DRIFT
ST
ST
DI-00073
(D)
(C)
(B)
(A)
DI-00076
(A) Pilot bearing

(B) Collar
(C) Front bearing
(D) Rear bearing cup
DI-23
Rear Differential
DIFFERENTIALS
20) When replacing the bearings, hit out the front

bearing cup and rear bearing cup in this order from
outside of the case using a brass bar.
(A)
(B)
DI-00077
(A) 2 cutout portions along diagonal lines

(B) Tap alternately with brass bar.
D: ASSEMBLY
NOTE:
Check and adjust each part during assembly.
Keep the shims and washers in order, so that
they are not improperly installed.
Thoroughly clean the surfaces on which the
shims, washers and bearings are to be installed.
Apply gear oil when installing the bearings and
thrust washers.
Be careful not to mix up the RH and LH bearing
races.
Use a new O-ring and gasket.
Replace the oil seal with a new part at every disassembly. Install the oil seal.
Apply grease to the lips.
Be careful not to mix up the differential oil seal
RH and LH.
DI-00078
1) Adjusting preload for front and rear bearings

Adjust the bearing preload between front and rear
bearings with collar and washer. Pinion height adjusting washer is not affected by this adjustment.
The adjustment must not be carried out with oil seal
inserted.
(1) Install the rear bearing race (rear) into differential carrier with ST1 and ST2.
ST2 398477703 DRIFT 2
ST2
ST1
DI-00079
(2) Install the rear bearing race (front) into differential carrier with ST1 and ST2.
ST2 398477702 DRIFT
DI-24
Rear Differential
DIFFERENTIALS
(3) Insert the ST1 into carrier with the pinion

height adjusting washer and rear bearing cone
fitted onto it.
NOTE:
If tooth contact is normal in the inspection before
disassembling, verify that the washer is not deformed, and then re-use the used washer.
Use new rear bearing cone.
(4) Install the preload adjusting collar and
washer, front bearing cone, ST2, companion
flange, and washer and self-locking nut.
ST1 398507702 DUMMY SHAFT
ST2 398507703 DUMMY COLLAR
(A)
(B)
(C)
ST2
ST1
Initial load:
17.7 38.8 N (1.8 4.0 kgf, 4.0 8.7 lb)
DI-00117
Initial torque:
0.67 1.47 Nm (0.07 0.15 kgf-m, 0.49
1.08 ft-lb)
DI-00080
(A) Pinion height adjusting washer

(B) Preload adjusting collar
DI-00481
(C) Preload adjusting washer
(5) Rotate the ST1 by hand to make it secured,

and tighten the self-locking nut while measuring
the preload with spring balance. Select the preload adjusting washer and collar so that the
specified preload is obtained when nut is tightened to the specified torque.
NOTE:
Be careful not to give excessive preload.
When tightening the self-locking nut, lock ST1
with ST2 as shown in the figure.
ST1 398507704 BLOCK
Preload adjusting
washer
Tightening torque:
181.5 Nm (18.5 kgf-m, 134 ft-lb)
Preload adjusting
collar
ST1
ST2
DI-00081
DI-25
Part No.
Thickness mm
(in)
383705200
383715200
2.59 (0.1020)
2.57 (0.1012)
383725200
383735200
2.55 (0.1004)
2.53 (0.0996)
383745200
383755200
2.51 (0.0988)
2.49 (0.0980)
383765200
383775200
2.47 (0.0972)
2.45 (0.0965)
383785200
383795200
2.43 (0.0957)
2.41 (0.0949)
383805200
383815200
2.39 (0.0941)
2.37 (0.0933)
383825200
383835200
2.35 (0.0925)
2.33 (0.0917)
383845200
Part No.
2.31 (0.0909)
Length mm (in)
383695201
383695202
56.2 (2.213)
56.4 (2.220)
383695203
383695204
56.6 (2.228)
56.8 (2.236)
383695205
57.0 (2.244)
383695206
57.2 (2.252)
Rear Differential
DIFFERENTIALS
2) Adjusting drive pinion height:

Adjust the drive pinion height with washer installed
between the rear bearing cone and the back of pinion gear.
(1) Attach ST2.
ST2 398507701 DIFFERENTIAL CARRIER
GAUGE
ST3
ST1
RH
NOTE:
Use copies of this page.
T
To
Thickness of pinion height adjusting washer mm

(in)
Thickness of washer temporally inserted mm (in)
N
H
Clearance of thickness gauge mm (in)

Figure marked on drive pinion head
Memo:
(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 washer 383605200.
ST2

(A)
LH
DI-00083
(A) Pinion height adjusting washer
(2) Measure the clearance N between the end

of ST2 and the end surface of ST1 by using a
thickness gauge.
NOTE:
Make sure there is no clearance between the case
and ST2.
GAUGE
ST2
ST1
DI-00084
(3) Obtain the thickness of pinion height adjusting washer to be inserted from the following formula, and replace the temporarily installed
washer with this one.
T = To + N (H 0.01) 0.20 mm (0.008 in)
DI-26
Part No.
383495200
Thickness mm (in)
3.09 (0.1217)
383505200
383515200
3.12 (0.1228)
3.15 (0.1240)
383525200
383535200
3.18 (0.1252)
3.21 (0.1264)
383545200
383555200
3.24 (0.1276)
3.27 (0.1287)
383565200
383575200
3.30 (0.1299)
3.33 (0.1311)
383585200
383595200
3.36 (0.1323)
3.39 (0.1335)
383605200
383615200
3.42 (0.1346)
3.45 (0.1358)
383625200
383635200
3.48 (0.1370)
3.51 (0.1382)
383645200
383655200
3.54 (0.1394)
3.57 (0.1406)
383665200
383675200
3.60 (0.1417)
3.63 (0.1429)
383685200
3.66 (0.1441)
Rear Differential
DIFFERENTIALS
3) Install the selected pinion height adjusting washer on drive pinion, and press the rear bearing cone
into position with ST.
ST 398177700
INSTALLER
6) Insert the collar, then press-fit the pilot bearing

with ST1 and ST2.
ST2
ST
ST1
DI-00085
DI-00088
4) Insert the drive pinion into the differential carrier,

and install the selected bearing preload adjusting
collar and washer.
(A)
(B)
7) Fit a new oil seal with ST.

NOTE:
Press-fit until the oil seal end comes 1 mm (0.04
in) inward from end of carrier.
Apply grease to the oil seal lips.
ST 498447120
INSTALLER
(C)
ST
(D)
DI-00086
(A) Drive pinion

(B) Bearing preload adjusting collar
DI-00089
(C) Bearing preload adjusting washer

(D) Differential carrier
8) Press-fit the companion flange with ST1 and

ST2.
5) Press-fit the front bearing cone into case with

ST1, ST2 and ST3.
NOTE:
Be careful not to damage the bearing.
ST1
ST3
ST1
ST2
ST2
DI-00090
DI-00087
9) Apply Lock Tite on the drive pinion shaft thread

and new self-locking nut seat.
Lock Tite:
DI-27
Rear Differential
DIFFERENTIALS
10) Attach the self-locking nut. Then, tighten it with

the ST.
ST 498427200
FLANGE WRENCH
Tightening torque:
181.5 Nm (18.5 kgf-m, 134 ft-lb)
NOTE:
Apply gear oil on both sides of the washer and on
the side gear shaft before installing.
Insert the pinion mate shaft into the differential
case by aligning the lock pin holes.
ST
DI-00091
11) Measure the initial torque or the initial load.

Initial load:
17.7 38.8 N (1.8 4.0 kgf, 4.0 8.7 lb)
DI-00239
(1) Measure the side gear backlash.

Side gear backlash:
0.10 0.20 mm (0.004 0.008 in)
DI-00117
Initial torque:
0.67 1.47 Nm (0.07 0.15 kgf-m, 0.49
1.08 ft-lb)
DI-00240
(2) Adjust the side gear backlash as specified

by selecting side gear thrust washer.
DI-00481
12) Assembling differential case

Install the side gears and pinion mate gears, with
their thrust washers and pinion mate shaft, into the
differential case. (Model without LSD)
Part No.

Thickness mm (in)
383445201
383445202
0.75 0.80 (0.0295 0.0315)

0.80 0.85 (0.0315 0.0335)
383445203
0.85 0.90 (0.0335 0.0354)
(3) Check the condition of rotation after applying oil to the gear tooth surfaces and thrust surfaces.
(4) After inserting the pinion shaft lock pin into
differential case, stake the both sides of the
hole to prevent pin from falling off.
DI-28
Rear Differential
DIFFERENTIALS
13) Apply Loc Tite to bolt threads and install the hypoid driven gear to differential case.
Lock Tite:
equivalent
(3) Install the side bearing retainer shims to retainers RH and LH from which they were installed.
NOTE:
Replace the broken or corroded side retainer shim
and O-ring with new parts of same thickness.
NOTE:
Tighten diagonally while tapping the bolt heads.

Part No.
Thickness mm (in)
Tightening torque:
103 Nm (10.5 kgf-m, 76.0 ft-lb)
383475201
383475202
0.20 (0.0079)
0.25 (0.0098)
383475203
383475204
0.30 (0.0118)
0.40 (0.0157)
383475205
0.50 (0.0197)
(4) Align the arrow mark on differential carrier

with the mark on side retainer during installation.
DI-00068
14) Press the side bearing into differential case using ST.
ST 398237700
DRIFT
NOTE:
Replace the O-ring with a new part.
Be careful that the bearing roller does not damage the side bearing cone.
(A)
ST
DI-00097
DI-00095
(A) Arrow mark
15) Press the side bearing cone into the side bearing retainer using the ST.
ST 398487700
DRIFT
16) Adjusting the side bearing retainer shims
(1) The hypoid driven gear backlash and the
side bearing preload can be adjusted by the
side bearing retainer shim thickness.
(2) Install the differential case assembly into differential carrier in the reverse order of disassembly.
(5) Tighten the side bearing retainer bolts.

Tightening torque:
10.5 Nm (1.1 kgf-m, 7.7 ft-lb)
DI-00487
DI-00065
DI-29
Rear Differential
DIFFERENTIALS
(6) Measure the backlash between hypoid driven gear and drive pinion. Set the magnet base
on differential carrier. Align the contact point of
dial gauge with the tooth surface of hypoid driven gear, and move the hypoid driven gear while
securing the drive pinion. Read the value indicated on dial gauge. If the backlash is not within
the range of specifications, adjust the side bearing retainer shim using the following procedures.
When backlash exceeds 0.2 mm (0.008 in):
Reduce the hypoid driven gear back surface
shim thickness and increase the hypoid driven
gear tooth surface side shim thickness.
When backlash is less than 0.1 mm (0.004
in):
Increase the hypoid driven gear back surface
shim thickness and reduce the tooth surface
side shim thickness.
Backlash:
0.10 0.20 mm (0.004 0.008 in)
17) Recheck the backlash between hypoid driven

gear and pinion.
Backlash:
0.10 0.20 mm (0.004 0.008 in)
DI-00099
18) Check the hypoid driven gear runout on its

back surface, and make sure that pinion and hypoid driven gear rotates smoothly.
If the hypoid driven gear runout on its rear face exceeds the limit, check for any foreign objects between hypoid driven gear and differential case, and
for any deformation of the case or gear.
Hypoid driven gear runout on its back surface:
0.05 mm (0.0020 in) or less
DI-00099
(7) At the same time, measure the amount of

the drive pinion preload. Compared with the resistance when differential case is not installed,
if the total preload is not within specification, adjust the thickness of side bearing retainer
shims, increasing/reducing both shims by an
even amount at a time.
Total preload:
20.7 54.4 N (2.1 5.5 kgf, 4.7 12.2 lb)
DI-30
DI-00101
Rear Differential
DIFFERENTIALS
19) Checking and adjusting the tooth contact of hypoid driven gear
(1) Apply an even coat of red lead on both sides
of three or four teeth on the hypoid driven gear.
Check the contact pattern after rotating the hypoid driven several revolutions back and forth
until a definite contact pattern appears on the
hypoid driven gear.
(2) When the contact pattern is not correct, readjust.
NOTE:
Be sure to wipe off the red lead completely after the
adjustment is completed.
Correct tooth contact
Check item: Tooth contact pattern is slightly
shifted toward toe side under no-load rotation.
(When driving, it moves towards the heel side.)
Face contact
Check item: Backlash is too large.
Contact pattern
AT-00208
Corrective action: Increase the thickness of pinion

for bringing the drive pinion closer to the hypoid
driven gear.
(A)
(B)
MT-01401
AT-00212
(A) Toe side

(B) Heel side
DI-31
Rear Differential
DIFFERENTIALS
Flank contact
Check item: Backlash is too small.
Contact pattern
Toe contact (inside contact)

Check item: Contact area is too small.
Contact pattern
AT-00209
AT-00210

for moving the drive pinion away from hypoid driven
gear.

for moving the drive pinion away from hypoid driven
gear.
AT-00213
AT-00213
DI-32
Rear Differential
DIFFERENTIALS
Heel contact (outside end contact)

Check item: Contact area is too small.
Contact pattern
(2) Hypoid gear backlash

Backlash:
0.10 0.20 mm (0.004 0.008 in)
AT-00211
DI-00099
Corrective action: Increase the thickness of pinion

for bringing the drive pinion close to the hypoid driven gear.
21) Remove the RH and LH side bearing retainer.

22) Install the O-rings and the side bearing retainer
shims to both the left and right side bearing retainers.
23) Install the oil seals to the left and right side
bearing retainers. <Ref. to DI-39, REPLACEMENT,
Rear Differential Side Oil Seal.>
24) Align the arrow mark on differential carrier with
the mark on side retainer during installation.
(A)
AT-00212
20) If proper tooth contact is not obtained, once

again adjust the drive pinion height by changing the
RH and LH side bearing retainer shims and the hypoid gear backlash.
(1) Drive pinion height
GAUGE
ST2
DI-00097
(A) Arrow mark
25) Apply liquid gasket to the bolts indicated by arrow marks, and install the side bearing retainer.
Liquid gasket:
equivalent
Tightening torque:
10.5 Nm (1.1 kgf-m, 7.7 ft-lb)
ST1
DI-00084
T = To + N (H 0.01) 0.20 (mm)

Place:
T = Thickness of the pinion height adjusting
washer (mm)
To = Thickness of the washer temporarily assembled (mm)
N = Clearance measured by thickness gauge
(mm)
H = Figure marked on drive pinion head
DI-33
DI-00461
Rear Differential
DIFFERENTIALS
26) Install the new gasket and rear cover and tighten the bolts to specified torque.
Tightening torque:
29.5 Nm (3.0 kgf-m, 21.8 ft-lb)
DI-00113
27) Install the new air breather cap.

(A)
(B)
DI-00062
(A) Air breather cap

(B) Rear cover
28) Install the drain plug and filler plug.

Tightening torque:
49 Nm (5.0 kgf-m, 36.2 ft-lb)
E: INSPECTION
Wash all the disassembled parts clean, and examine them for wear, damage and other defects. Repair or replace the defective parts as necessary.
1) Hypoid driven gear and drive pinion
If there is evidently an abnormal tooth contact,
find out the cause and adjust until the teeth contact
correctly. Replace the gear if there is an excessive
worn or an incapable adjustment.
If crack, cutout or seizure is found, replace the
parts as a set. Slight damage of some teeth can be
corrected by oil stone or the like.
2) Bearing
Replace if seizure, peeling, wear, rust, dragging
during rotation, noise or other defect is evident.
3) Oil seal
Replace if deformed or damaged, and at every disassembling.
4) Differential carrier
Replace if the bearing bores are worn or damaged.
5) Differential case
Replace if its sliding surfaces are worn or cracked.
6) Companion flange
Replace if the oil seal lip contacting surface has
flaws.
1. SIDE GEAR BACKLASH

Using a dial gauge, check the backlash of side
gear. (Model without LSD)
Side gear backlash:
0.1 0.2 mm (0.004 0.008 in)
If the side gear backlash is not within the specification, select the side gear thrust washer and adjust
the side gear backlash as specified.
DI-00315
DI-34
Rear Differential
DIFFERENTIALS
2. HYPOID DRIVEN GEAR BACKLASH
5. TOTAL PRELOAD
Using a dial gauge, check the backlash of hypoid

driven gear.
Using a spring balance, check the total preload.
Hypoid driven gear backlash:

0.1 0.2 mm (0.004 0.008 in)
If the hypoid driven gear backlash is not within the
specification, adjust the side bearing preload or repair if necessary.
Total preload:
20.7 54.4 N (2.1 5.5 kgf, 4.7 12.2 lb)
If the increase of the resistance is not within the
specification, adjust the side bearing retainer
shims.
DI-00117
DI-00099
6. COMPANION FLANGE
3. HYPOID DRIVEN GEAR RUNOUT ON ITS

BACK SURFACE
Using a dial gauge, check the hypoid driven gear
runout on its back surface.
Hypoid driven gear runout on its back surface:
0.05 mm (0.0020 in) or less
If the hypoid driven gear runout exceeds 0.05 mm
(0.0020 in), replace the hypoid driven gear.
1) If rust or dirt is attached to the companion flange,

remove them.
2) Set a dial gauge at a companion flange surface
(mating surface of propeller shaft and companion
flange), and then measure the companion flange
runout.
Limit of runout:
0.08 mm (0.0031 in)
DI-00360
DI-00101
4. TOOTH CONTACT BETWEEN HYPOID

DRIVEN GEAR AND DRIVE PINION
3) Set the gauge inside of the companion flange,

and measure the runout.
Inspect the tooth contact between hypoid driven

gear and drive pinion. <Ref. to DI-24, ASSEMBLY,
Rear Differential.>
Limit of runout:
0.08 mm (0.0031 in)
DI-00361
DI-35
Rear Differential
DIFFERENTIALS
4) If either runout exceeds the limit, move the

phase of companion flange and drive pinion 90
each, and find the point where the runout is within
the limit.
5) If the runout exceeds the limit after changing the
phase, replace the companion flange and recheck
the runout.
6) If the runout exceeds the limit after replacing the
companion flange, the drive pinion may be assembled incorrectly or bearing is faulty.
F: ADJUSTMENT
1. SIDE GEAR BACKLASH
Adjust the side gear backlash.
<Ref. to DI-24, ASSEMBLY, Rear Differential.>
2. HYPOID DRIVEN GEAR BACKLASH

Adjust the hypoid driven gear backlash.
3. TOOTH CONTACT BETWEEN HYPOID

DRIVEN GEAR AND DRIVE PINION
Adjust the tooth contact between hypoid driven
gear and drive pinion gear.
4. TOTAL PRELOAD
Adjust the side bearing shim.
DI-36
Rear Differential Front Oil Seal

DIFFERENTIALS
5. Rear Differential Front Oil

Seal
11) Extract the companion flange using ST.

ST 399703600
PULLER ASSY
ST
A: REPLACEMENT
5) Remove the oil drain plug, and drain gear oil.
DI-00196

ST 398527700
PULLER ASSY
DI-00048
(A) Filler plug

(B) Drain plug
ST
6) Install the oil drain plug.
DI-00197
NOTE:
13) Install a new oil seal using ST.

NOTE:
Apply oil to the outer circumference of the oil seal.
ST 498447120
INSTALLER
Liquid gasket:
equivalent
Tightening torque:
49 Nm (5.0 kgf-m, 36.2 ft-lb)
7) Jack-up the rear wheels and support with rigid
racks.
9) Remove the propeller shaft from the vehicle.
<Ref. to DS-12, REMOVAL, Propeller Shaft.>
10) Remove the self-locking nut while holding the
companion flange with ST.
ST 498427200
FLANGE WRENCH
ST
DI-00198
14) Install the companion flange.

NOTE:
Use a plastic hammer to install companion flange.
15) Apply Lock Tite on the drive pinion shaft thread
and new self-locking nut seat.
ST
Lock Tite:
equivalent
DI-00194
DI-37
Rear Differential Front Oil Seal

DIFFERENTIALS
16) Tighten the self-locking nut to the specified

torque so that the companion flange preload becomes the same value as that before replacing the
oil seal.
ST 498427200
FLANGE WRENCH
NOTE:
Tightening torque:
181.5 Nm (18.5 kgf-m, 134 ft-lb)
ST
DI-00199
17) Hereafter, reassemble in the reverse order of

disassembly.
DI-38
Rear Differential Side Oil Seal

DIFFERENTIALS
6. Rear Differential Side Oil Seal

A: INSPECTION
Make sure that there is no oil leakage from side oil
seal.
If there is oil leakage, replace the oil seal.
(3) Remove the ABS wheel speed sensor cable

clamp and the parking brake cable guide from
the trailing link.
(A)
B: REPLACEMENT
racks.
Non-turbo model
Turbo model
6) Remove the DOJ of rear drive shaft from rear differential.
clamp and the parking brake cable clamp from
bracket.
(B)
DI-00202
(A) Parking brake cable guide

(B) ABS wheel speed sensor cable clamp
(4) Remove the rear stabilizer link.
RS-00010
(A)
(5) Remove the bolts which secure the trailing

link to the housing.
(B)
DI-00200
(A) ABS wheel speed sensor cable clamp

(B) Parking brake cable clamp
DI-00204

clamp from the trailing link.
DI-00201
(6) Remove the bolts which secure the front

and rear lateral links to the rear housing.
DI-00205
(7) Remove the DOJ from the rear differential

by using ST.
DI-39
Rear Differential Side Oil Seal

DIFFERENTIALS
NOTE:
When removing the DOJ from the rear differential,
fit the ST to the bolts (A) as shown in figure so as
not to damage the side bearing retainer.
9) Install a new side oil seal using the ST.

NOTE:
Apply chassis grease to the oil seal lips.
ST 398437700
DRIFT
ST
DI-00209
10) Insert the DOJ into rear differential.

(1) Attach the ST to rear differential.
DI-00206
(A) Bolt
7) Suspend the rear drive shaft to the rear crossmember using wire.
DI-00225
(2) Install the spline shaft until the spline portion

is inside the side oil seal using ST.
DI-00053
ST
8) Remove the oil seal using ST.

ST 398527700
PULLER ASSY
DI-00060
(3) Remove the ST.

28099PA090 SIDE OIL SEAL PROTECTOR
11) Hereafter, reassemble in the reverse order of
disassembly.
ST
ST
DI-00208
DI-40
Rear Differential Member

DIFFERENTIALS
7. Rear Differential Member
B: INSTALLATION
A: REMOVAL

1) Position the differential front member with the
vehicle by passing the member under the parking
brake cable and securing it to rear differential.

3) Move the select lever or gear shift lever to N.
racks.
Non-turbo model
Turbo model
7) Remove the rear differential front member.
NOTE:
When removing the rear differential front member,
work the removal procedure as rear differential.
<Ref. to DI-19, REMOVAL, Rear Differential.>
8) Remove the rear differential member.
NOTE:
When installing the differential front member, be
careful of the order for installation of the stoppers.
DI-00058
2) Insert the DOJ of the rear drive shaft into the rear
differential.
NOTE:
Before inserting, replace the side oil seal with a
new part.
ST
DI-00060
3) Hereafter, install in the reverse order of removal.
DI-41
Rear Differential Member

DIFFERENTIALS
C: DISASSEMBLY
D: ASSEMBLY
NOTE:
Clean the rear differential member before working.
1) Remove the bolts (A) and (B) which secure the
differential front member and the differential mount
bracket.
1) Temporarily tighten bolts (A) that secure the

front differential assembly and differential mount.
(A)
DI-00229
2) Tighten the nut of mounting bolt (B).

(A)
DI-00227
Tightening torque:
128 Nm (13.0 kgf-m, 94.4 ft-lb)
(B)
(B)
DI-00484
DI-00485
3) Tighten the nut of mounting bolt (A).

Tightening torque:
70 Nm (7.1 kgf-m, 51.6 ft-lb)
(A)
DI-00227
E: INSPECTION
1) Check the rear differential member for damage,
bend or corrosion.
If damage, bend or corrosion is excessive, replace
the rear differential member.
2) Check bushings of rear differential member for
cracking, hardening or damage.
If cracking, hardening or damage is excessive, replace rear differential member.
DI-42

DIFFERENTIALS

A: INSPECTION
Symptom or trouble
1. Oil leakage
Possible cause
Remedy
(1) Worn, scratched, or incorrectly seated

front or side oil seal. Cut-away, battered
or excessively worn sliding surface of
companion flange.
(2) Clogged or damaged air breather.
Clean, repair or replace.
(3) Loose bolts on the side retainer, or

incorrectly fitted O-rings.
Tighten the bolts to specified torque.

Replace the O-ring.
(4) Loose rear cover attaching bolts or

damaged gasket.
(5) Loose oil filler or drain plug.
Tighten the bolts to specified torque.

Replace gasket and apply liquid gasket.
Retighten and apply liquid gasket.
(6) Wear, damage or incorrectly fitting for

side retainer and oil seal.
Correct or replace.
2. Seizure
NOTE:
Incorrect or damaged parts should be
replaced, and also other parts should be
thoroughly checked for any defect and
should be repaired or replaced as
required.
(1) Improper backlash for hypoid gear.

(2) Excessive preload for side, rear or
front bearing.
Readjust or replace.
(3) Insufficient or improper oil used.
Replace the incorrect part and fill with

specified oil to specified level.
3. Damage
NOTE:
Damaged parts should be replaced, and
also other parts should be thoroughly
checked for any defect and should be
repaired or replaced as required.

(2) Insufficient or excessive preload for
side, rear or front bearing.
(3) Excessive backlash for differential
gear.
Replace.
(4) Loose bolts and nuts such as hypoid

driven gear bolt.
Retighten.
(5) Damage due to overloading.

(1) Excessive backlash for hypoid gear.
Replace.
Readjust.
(2) Excessive backlash for differential

gear.
Replace gear or thrust washer.
(3) Insufficient preload for front or rear

bearing.
(4) Loose drive pinion nut.
Readjust.
4. Noises when starting or shifting

gears
NOTE:
Noises may be caused by differential
assembly, universal joint, wheel bearing,
etc. Identify what is actually making noise
before disassembling.
5. Noises when cornering
Correct or replace.
Replace gear or thrust washer.
(5) Loose bolts and nuts such as side

bearing retainer attaching bolt.
(1) Damaged differential gear.

(2) Excessive wear or damage of thrust
washer.
(3) Broken pinion mate shaft.
Replace.
Replace.
(4) Seized or damaged side bearing.
Replace.
DI-43
Replace.

DIFFERENTIALS
Symptom or trouble
6. Gear Noise
NOTE:
Since noises from engine, muffler,
transmission, propeller shaft, wheel
bearings, tires and body are sometimes
mistaken for noises from differential assembly, be careful in checking them.
Inspection methods to locate noises
include coasting, accelerating, cruising,
and jacking-up all four wheels. Perform
these inspections according to the
condition of trouble. When listening to
noises, shift the gear into four wheel drive
and fourth speed position, trying to pick up
only differential noise.
Possible cause
Remedy
(1) Improper tooth contact of hypoid gear. Readjust or replace hypoid gear set.
Readjust.
(3) Scored or chipped teeth of hypoid
gear.
Replace hypoid gear set.
(4) Seized hypoid gear.

(5) Improper preload for front or rear
bearings.
Replace hypoid gear set.

Readjust.
(6) Seized, cut-away or chipped front or

rear bearing.
Replace.
(7) Seized, cut-away or chipped side

bearing.
Replace.
(8) Differential gear is vibrating.
Replace.
DI-44
General Description
TRANSFER CASE
A: NOTE
For a general description, refer to the 4AT and the
5MT sections.
AT model:
<Ref. to 4AT-2, General Description.>
MT model:
<Ref. to 5MT-2, General Description.>
TC-2

TRANSFER CASE
2. Transfer Case and Extension

Case Assembly
A: NOTE
For removal, installation and inspection, refer to the
5MT section. <Ref. to 5MT-39, Transfer Case and
Extension Case Assembly.>
TC-3
Transfer Clutch
TRANSFER CASE
3. Transfer Clutch
A: NOTE
4AT section. <Ref. to 4AT-72, Transfer Clutch.>
TC-4
Oil Seal
TRANSFER CASE
4. Oil Seal
A: NOTE
4AT or the 5MT section.
AT model:
<Ref. to 4AT-45, Extension Case Oil Seal.>
MT model:
<Ref. to 5MT-33, Oil Seal.>
TC-5
Transfer Drive Gear

TRANSFER CASE
5. Transfer Drive Gear

A: NOTE
5MT section. <Ref. to 5MT-43, Transfer Drive
Gear.>
TC-6

TRANSFER CASE
6. Transfer Driven Gear

A: NOTE
5MT section. <Ref. to 5MT-45, Transfer Driven
Gear.>
TC-7

TRANSFER CASE
7. Reduction Drive Gear

A: NOTE
4AT section. <Ref. to 4AT-82, Reduction Drive
Gear.>
TC-8

TRANSFER CASE
8. Reduction Driven Gear

A: NOTE
4AT section. <Ref. to 4AT-80, Reduction Driven
Gear.>
TC-9
Center Differential
TRANSFER CASE
9. Center Differential
A: NOTE
5MT section. <Ref. to 5MT-47, Center Differential.>
TC-10

TRANSFER CASE
10.Transfer Clutch Pressure

Test
A: NOTE
For inspection, refer to the 4AT section.
<Ref. to 4AT-36, Transfer Clutch Pressure Test.>
TC-11

TRANSFER CASE
TC-12
General Description
DRIVE SHAFT SYSTEM
A: SPECIFICATION
1. PROPELLER SHAFT
Model
Propeller shaft type
AT
MT
EDJ
Propeller shaft length: L

Front propeller shaft joint-to-joint length: L1
mm (in)
mm (in)
Rear propeller shaft joint-to-joint length: L2
mm (in)
D1
684 (26.93)
63.5 (2.50)
D2
57.5 (2.26)
Outer diameter of tube:
mm (in)
1292 (50.87)
608 (23.93)
L1
1352 (53.23)
668 (26.30)
L2
D1
D2
DS-00396
DS-2
General Description
DRIVE SHAFT SYSTEM
2. FRONT DRIVE SHAFT ASSEMBLY

Specification
AC + AARi
L1 mm (in)
D mm (in)
Non-turbo, Turbo AT
Boot band
identification color
Blue
319.8 (12.59)
24.9 (0.98)
Turbo MT
320.2 (12.61)
24.9 (0.98)
Model
(C)
(A)
(B)
DS-00397
(A)
D mm (in)
(B)
L1 mm (in)
(C)
Boot band
3. REAR DRIVE SHAFT ASSEMBLY

Specification
Model
EBJ + DOJ RH
EBJ + DOJ LH
All models
No. of shaft
identification groove
L1 mm (in)
D mm (in)
2
1
367.4 (14.5)
357.4 (14.1)
24 (0.9)
24 (0.9)
(1)
(3)
(2)
DS-00019
(1)
Identification groove
(2)
L1 mm (in)
DS-3
(3)
D mm (in)
General Description
DRIVE SHAFT SYSTEM
B: COMPONENT
1. PROPELLER SHAFT
(1)
(3)
(3)
T2
(2)
T1
DS-00368
(1)
(2)
Propeller shaft
Rear differential
(3)
Bushing

T1: 31 (3.2, 23.1)
T2: 52 (5.3, 38.3)
DS-4
General Description
DRIVE SHAFT SYSTEM
2. FRONT AXLE
(1)
(2)
(3)
(4)
(5)
(6)
(8)
(9)
(7)
(7)
(10)
(7)
(11)
(12)
(18)
(13)
(14)
(15)
(20)
(16)
(17)
(19)
DS-00393
(1)
(2)
Circlip
Baffle plate
(9)
(10)
Boot (AC)
AC ASSY
(17)
(18)
Outer oil seal

Hub bolt
(3)
(4)
Outer race
Snap ring
(11)
(12)
Baffle plate
Tone wheel
(19)
(20)
Hub
Axle nut
(5)
(6)
Trunnion
Retainer
(13)
(14)
Inner oil seal

Snap ring
(7)
(8)
Boot band
Boot (AARi)
(15)
(16)
Bearing
Housing
T: 220 (22.4, 162)
DS-5
General Description
DRIVE SHAFT SYSTEM
3. REAR AXLE
DS-00394
(1)
(2)
Circlip
Baffle plate (DOJ)
(10)
(11)
DOJ (Boot)
Boot
(19)
(20)
Outer oil seal

Tone wheel
(3)
(4)
Outer race (DOJ)

Snap ring
(12)
(13)
EBJ ASSY
Baffle plate
(21)
(22)
Hub bolt
Hub
(5)
(6)
Inner race
Ball
(14)
(15)
Inner oil seal 2

Inner oil seal 3
(23)
Axle nut
(7)
(8)
Cage
Circlip
(16)
(17)
Housing
Bearing

T1: 13 (1.3, 9.4)
(9)
Boot band
(18)
Snap ring
DS-6
T2: 190 (19.4, 140)
General Description
DRIVE SHAFT SYSTEM
C: CAUTION

Do not mix grease etc. of different grades or manufacturers.
points.
Before installing snap rings, apply sufficient
amount of grease to avoid damage and deformation.
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
922431000
AXLE SHAFT
INSTALLER
Used for installing the axle shaft into housing.

Used together with ADAPTER (927390000).
925091000
BAND TIGHTENING
TOOL
Used for tightening the boot band.

(A) Jig for the band
(B) Ratchet wrench
926470000
AXLE SHAFT
PULLER
Used for removing the axle shaft.
ST-922431000
(A)
(B)
ST-925091000
ST-926470000
DS-7
General Description
DRIVE SHAFT SYSTEM
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
927060000
HUB REMOVER
Used for removing front hub.

Used together with HUB STAND (927080000).
927420000
HUB REMOVER
Used for removing rear hub.

927080000
HUB STAND
Used for disassembling and assembling hub bolt

in hub.
927100000
BEARING PULLER

front housing bearing.
Used together with HOUSING STAND
(927400000).
927140000
AXLE SHAFT
PULLER PLATE
Same as plate 2 included in AXLE SHAFT

PULLER (926470000).
ST-927060000
ST-927420000
ST-927080000
ST-927100000
ST-927140000
DS-8
General Description
DRIVE SHAFT SYSTEM
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
927390000
ADAPTER
Used as an adapter for AXLE SHAFT

927400000
HOUSING STAND

front housing bearing.
Used together with BEARING PULLER
(927100000).
927410000
OIL SEAL
INSTALLER
Used for installing oil seal into front housing.

(927400000).
927430000
HOUSING STAND
Used for disassembling and assembling rear

housing bearing.
Used together with BEARING PULLER
(927440000).
927120000
HUB INSTALLER
Used for installing hub.
ST-927390000
ST-927400000
ST-927410000
ST-927430000
ST-927120000
DS-9
General Description
DRIVE SHAFT SYSTEM
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
927440000
BEARING
REMOVER

rear wheel bearing.
(927430000).
927460000
OIL SEAL
INSTALLER
Used for installing the outer oil seal.

(927430000).
927450000
HUB INSTALLER
Used for pressing in the hub bearing into the

hub.
28399SA010
OIL SEAL
PROTECTOR
Used for installing front drive shaft into front

differential.
For protecting the oil seal.
28399SA000
DRIVE SHAFT
REMOVER
Used for removing the front drive shaft from the

front differential.
ST-927440000
ST-927460000
ST-927450000
ST28399SA010
ST28399SA000
DS-10
General Description
DRIVE SHAFT SYSTEM
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
18675AA000
DIFFERENTIAL
SIDE OIL SEAL
INSTALLER

seal.
28099PA090
OIL SEAL
PROTECTOR
Used for installing the rear drive shaft to the

rear differential.
For protecting the oil seal.
28099PA100
DRIVE SHAFT
REMOVER
Used for removing the rear drive shaft from the

rear differential.
28099AC000
BOOT BAND PLIER
Used for tightening front AC boot band.
ST18675AA000
ST28099PA090
ST28099PA100
ST28099AC000
2. GENERAL TOOL
TOOL NAME
REMARKS
Puller
Dial gauge
Used for removing the ball joint from knuckle arm.

Used for inspecting the propeller shaft run-out.
Snap ring pliers

Extension cap
Used for installing and removing the snap ring.

When removing the propeller shaft, used to prevent gear oil or
ATF fluid from leaking.
DS-11
Propeller Shaft
DRIVE SHAFT SYSTEM
2. Propeller Shaft
7) Remove the differential mount front cover.
A: REMOVAL
NOTE:
Before removing propeller shaft, wrap metal
parts with a cloth or rubber material.
In case of a EDJ type, wrap the metal parts at the
rubber boot of EDJ with a cloth or rubber material
before removing propeller shaft, as shown in the
figure. Rubber boot may be damaged due to interference with adjacent metal parts while bending the
EDJ during removal.
DS-00016
8) Apply alignment marks on appropriate parts before removal.
(A)
DS-00239

2) Move the select lever or the gear shift lever to
N.
racks.
Non-turbo model
Pipe.>
Turbo model
Non-turbo model
Turbo model
DS-00330
(A) Alignment mark
9) Remove the three bolts holding the propeller

shaft to the rear differential.
10) Remove the remaining bolt.
11) Remove the two bolts which hold center bearing to the body.
DS-12
DS-00029
Propeller Shaft
DRIVE SHAFT SYSTEM
12) Remove the propeller shaft from transmission.

CAUTION:
Be careful not to damage the oil seals and
contact surface of the sleeve yoke.
Cover the center exhaust pipe with a cloth to
keep off any ATF or oil spilled from transmission when removing the propeller shaft.
2) Align the alignment marks and connect the

flange yoke and rear differential.
Tightening torque:
31 Nm (3.2 kgf-m, 23.1 ft-lb)
(A)
DS-00330
(A) Alignment mark

DS-00030
13) Install an extension cap to the transmission.

NOTE:
If an extension cap is not available, place a vinyl
bag over the opening and tie with string to prevent
gear oil or ATF from leaking.
(A)
3) Using new bolts, install the differential mount

front cover.
(1) Temporarily tighten the bolt A while pushing
the cover towards the front of the vehicle.
(2) Tighten the bolts B to the specified torque.
(3) Tighten the bolts A to the specified torque.
(4) Tighten the remaining bolts to the specified
torque.
Tightening torque:
90 Nm (9.2 kgf-m, 66 ft-lb)
(B)
DS-00031
(A) Extension cap
B: INSTALLATION
(A)
1) Insert the sleeve yoke into the transmission and

attach the center bearing to the body.
Tightening torque:
52 Nm (5.3 kgf-m, 38.3 ft-lb)
DS-00029
DS-00020
4) Install the center exhaust pipe.

Non-turbo model
<Ref. to EX (H4SO)-7, INSTALLATION, Center Exhaust Pipe.>
Turbo model
Exhaust Pipe.>
Non-turbo model
Turbo model
DS-13
Propeller Shaft
DRIVE SHAFT SYSTEM
C: INSPECTION
NOTE:
Do not disassemble the propeller shaft. Check the
following items and replace if necessary.
1) Dents or cracks on the tube surface
2) Deformation or uneven wear on the splines
3) Unsmooth joint operation or abnormal noise
4) Center bearing free play, noise or unsmooth operation.
5) Uneven wear or damaged oil seal
6) Damaged center bearing
Check the following points with the propeller shaft
installed in the vehicle.
4) Turn the propeller shaft by hand to see if there is

any excessive free play in the splines. Also move
the yoke to see if there is any excessive free play at
the spiders or bearings.
DS-00035
1. JOINTS AND CONNECTIONS

Non-turbo model
Pipe.>
Turbo model
2) Remove the heat shield cover. (If equipped)
3) Check for any looseness of the yoke flange
mounting bolts which connect to the rear differential and center bearing bracket mounting bolts.
2. SPLINES AND BEARING LOCATIONS

Non-turbo model
Pipe.>
Turbo model
Non-turbo model
Turbo model
3. RUNOUT OF PROPELLER SHAFT

Non-turbo model
Pipe.>
Turbo model
Non-turbo model
Turbo model
4) Set the dial gauge with its indicator stem at the
center of the propeller shaft tube.
5) Turn the propeller shaft slowly by hands to check
for runout of the propeller shaft.
Runout:
Limit:
0.6 mm (0.024 in)
(A)
(B)
DS-00036
(A) Propeller shaft

(B) Dial gauge
DS-14
Propeller Shaft
DRIVE SHAFT SYSTEM
4. CENTER BEARING FREE PLAY

Non-turbo model
Pipe.> <Ref. to EX (H4SO)-7, REMOVAL, Center
Exhaust Pipe.>
Turbo model
<Ref. to EX(H4DOTC)-6, REMOVAL, Front Exhaust Pipe.> <Ref. to EX(H4DOTC)-8, REMOVAL,
Center Exhaust Pipe.>
Non-turbo model
Turbo model
4) Move the propeller shaft near the center bearing
up, down, left, right by hand, to check for any abnormal free play of the bearings.
DS-00037
DS-15
Front Axle
DRIVE SHAFT SYSTEM
3. Front Axle
7) Remove the cotter pin and castle nut securing

the tie-rod end to the housing knuckle arm.
A: REMOVAL
(A)

2) Lift the crimped section of axle nut.
(B)
(C)
DS-00042
(A) Cotter pin

(B) Castle nut
(C) Tie-rod
DS-00038
3) Remove the axle nut using a socket wrench

while depressing the brake pedal.
CAUTION:
Remove the axle nut while there is no load being applied to the axle. Failure to do so may
damage the wheel bearings.
4) Remove the stabilizer link.
8) Using a puller, remove the tie-rod ball joint from

knuckle arm.
DS-00043
9) Remove the ABS wheel speed sensor assembly

and harness.
DS-00039
5) Remove the disc brake caliper from the housing,

and suspend it from strut using a wire.
6) Remove the disc rotor from the hub.
NOTE:
If the disc rotor seizes up within hub, drive disc rotor
out by installing an 8 mm bolt in screw hole on the
rotor.
DS-00044
10) Remove the transverse link ball joint from the

housing.
DS-00041
DS-00045
DS-16
Front Axle
DRIVE SHAFT SYSTEM
11) Remove the front drive shaft assembly from the

hub. If it is hard to remove, use the STs.
ST1 926470000 AXLE SHAFT PULLER
PLATE
CAUTION:
Whenever the front drive shaft has been pulled
out, always replace the differential side retainer
oil seal on the transmission side with a new
seal.
12) Hang the front drive shaft on the vehicle body
using a wire.
6) Install the tie-rod end ball joint to the knuckle arm

using the castle nut.
Tightening torque:
27 Nm (2.75 kgf-m, 19.9 ft-lb)
CAUTION:
When connecting the tie-rod, do not hit the cap
at bottom of tie-rod end with a hammer.
7) Tighten the castle nut to specified torque and
tighten further within 60 until the pin hole is aligned
with the slot in nut. Bend the cotter pin to lock.
(A)
ST1
(B)
(C)
DS-00042
ST2
DS-00040
(A) Cotter pin
13) After scribing an alignment mark on the camber

adjusting bolt head, remove bolts connecting the
housing and strut, and disconnect the housing from
the strut.
(B) Castle nut

(C) Tie-rod
8) Install the disc rotor to hub.

9) Install the disc brake caliper on the housing.
Tightening torque:
80 Nm (8.2 kgf-m, 59 ft-lb)
10) Connect the stabilizer link.
11) Using ST1 and ST2, pull the front drive shaft
into the required position.
ST1 922431000 AXLE SHAFT INSTALLER
DS-00046
B: INSTALLATION
1) Temporarily tighten the front axle to the front
strut.
2) Insert the front drive shaft into the front axle.
3) Tighten the axle nut temporarily.
4) Install the transverse link ball joint to the housing.
ST
DS-00104
Tightening torque:
50 Nm (5.1 kgf-m, 37 ft-lb)
5) Align the alignment mark on the camber adjusting bolt head, and tighten the housing and strut using a new self-locking nut.
Tightening torque:
175 Nm (17.8 kgf-m, 129 ft-lb)
12) While pressing the brake pedal, tighten a new

axle nut to the specified torque.
Tightening torque:
220 Nm (22.4 kgf-m, 162 ft-lb)
CAUTION:
Be sure to tighten the axle nut to specified
torque. Do not overtighten it as this may damage the wheel bearing.
DS-17
Front Axle
DRIVE SHAFT SYSTEM
13) After tightening the axle nut, lock it securely.
CAUTION:
Be careful not to scratch the polished area of
the hub.
DS-00048
14) Install the ABS wheel speed sensor on the

housing.
Tightening torque:
32 Nm (3.3 kgf-m, 24 ft-lb)
15) Install the wheel and tighten the wheel nuts to
specified torque.
DS-00050
3) Remove the disc cover from housing.
Tightening torque:
100 Nm (10.2 kgf-m, 73.8 ft-lb)
C: DISASSEMBLY
1) Using ST1, securely support the housing and
hub.
2) Attach ST2 to housing and drive hub out.
ST1 927060000 HUB REMOVER
ST2 927080000 HUB STAND
DS-00051
4) Remove the outer and inner oil seals using a flat

tip screwdriver.
5) Remove the snap ring using a flat tip screwdriver.
CAUTION:
Be careful not to damage the housing during removal.
ST1
ST2
ST1
DS-00052
6) Using ST1, securely support the housing.

ST2
DS-00049
If inner bearing race remains in the hub, remove it

with a suitable tool (commercially available tools).
DS-18
Front Axle
DRIVE SHAFT SYSTEM
7) Using ST2, press the inner race, and push out

the outer race of the bearing.
ST1 927400000 HOUSING STAND
ST2 927100000 BEARING PULLER
4) Using ST1 and ST2, press a new bearing into

place.
ST2 927100000 BEARING PULLER
CAUTION:
Always press the outer race when installing
bearings.
Be careful not to remove the plastic lock from
the inner race when installing the bearings.
ST2
ST2
ST1
DS-00053
8) Using the ST and a hydraulic press, push out the

hub bolts.
ST 927080000
HUB STAND
ST1
DS-00056
ST
5) Using a pliers, securely install the snap ring.
DS-00054
D: ASSEMBLY
NOTE:
When the hub is removed from housing, replace
the bearing set and oil seal with new parts.
1) Attach the hub to the ST securely.
ST 927080000
HUB STAND
DS-00057
6) Using the ST1 and ST2, press the outer oil seal
until it contacts the bottom of housing.
ST1
ST
ST2
DS-00055
2) Using a press, press the new hub bolts until their

seating surfaces contact the hub.
NOTE:
Use the 12 mm (0.47 in) dia. holes in the HUB
STAND to prevent bolts from tilting.
3) Clean the dust or foreign particles from inside
the housing.
DS-19
DS-00058
Front Axle
DRIVE SHAFT SYSTEM
7) Using the ST1 and ST2, press the inner oil seal
until it contacts the circlip.
E: INSPECTION
1) While moving the front tire up and down by hand,
check that there is no looseness in the bearing, and
check that the wheel rotates smoothly.
ST1
ST2
DS-00059
DS-00061
8) Invert the ST and housing (up and down).

ST 927400000
HOUSING STAND
9) Apply sufficient grease to the oil seal lip.
2) Inspect the play in the axial direction using a dial

gauge. Replace the hub bearing if the play exceeds
the limit value.
Grease:
SHELL 6459N
Limit:
Max:
0.05 mm (0.0020 in)
NOTE:
If specified grease is not available, remove the
bearing grease and apply Auto Rex A instead.
CAUTION:
Do not mix different types of grease.
10) Install the disc cover to housing with three
bolts.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
11) Attach the hub to ST1 securely.
12) Clean dust and foreign particles from the polished surface of hub.
13) Place ST2 against the bearing inner race to
press the bearing into the hub.
ST2 927120000 HUB INSTALLER
ST2
ST1
DS-00060
DS-20
DS-00062
Rear Axle
DRIVE SHAFT SYSTEM
4. Rear Axle
8) Disconnect the parking brake cable end from the

parking lever.
A: REMOVAL
1. DISC BRAKE
wheels.
4) While applying the parking brake, remove the
axle nut using a socket wrench.
CAUTION:
5) Return the parking brake lever and loosen the
self locking nut.
(1)
DS-00065
(1) Cable end
9) Disconnect the rear stabilizer from the rear lateral link.

10) Remove the bolts which secure the trailing link
(1)
(2)
PB-00104
(1) Parking brake lever

(2) Self-locking nut
DS-00066
6) Remove the disc brake caliper from the back

plate, and suspend it from strut using a piece of
wire.
11) Remove the bolts which secure the lateral assembly to the rear housing.
DS-00067
DS-00064
7) Remove the disc rotor from the hub.

NOTE:
rotor.
DS-21
Rear Axle
DRIVE SHAFT SYSTEM
12) Remove the rear ABS wheel speed sensor

from the back plate.
2. DRUM BRAKE
wheels.
CAUTION:
5) Return the parking brake lever and loosen the
self locking nut.
(1)
DS-00069
(1) ABS wheel speed sensor
13) Disengage the BJ assembly from the hub

splines, and remove the rear drive shaft assembly.
If it is hard to remove, use the STs.
PLATE
(1)
CAUTION:
Be careful not to damage the oil seal lip when
removing the rear drive shaft.
When rear drive shaft is to be replaced, also
replace the inner oil seal with a new seal.
(2)
PB-00104

6) Remove the brake drum from hub.

7) If it is difficult to remove brake drum, remove the
adjusting hole cover from the back plate, and then
turn the adjusting screw using a slot-type screwdriver until the brake shoe separates from the
drum.
(1)
ST1
ST2
(2)
DS-00068
14) Remove the bolts which secure the rear housing to strut, and separate the two.
(5)
(3)
(4)
(6)
(1) Back plate

(2) Wheel cylinder
(3) Adjuster ASSY pole
(4) Adjusting lever
(5) Tightening direction
DS-00070
(6) Press
DS-22
DS-00072
Rear Axle
DRIVE SHAFT SYSTEM
NOTE:
rotor.
11) Disconnect the rear stabilizer from the rear lateral link. Remove the bolts which secure the trailing
link assembly to the rear housing.
DS-00066
DS-00073
8) Using a flare-nut wrench, disconnect the brake

pipe from the wheel cylinder. Place a cover on the
brake pipe attachment hole of the wheel cylinder, to
prevent entry of foreign particles.
12) Remove the bolts which secure the lateral link

DS-00067
13) Remove the rear ABS wheel speed sensor

from the back plate.
DS-00074
9) Cover the end of the brake pipe with a vinyl

sheet or equivalent to prevent brake fluid from leaking out.
10) Disconnect the parking brake cable end from
the parking brake lever.
(1)
DS-00069
(1)
DS-00065
(1) Cable end
DS-23
Rear Axle
DRIVE SHAFT SYSTEM
14) Disengage the BJ assembly from the hub

splines, and remove the rear drive shaft assembly.
NOTE:
If it is hard to remove, use the STs.
PLATE
4) Using new self-locking nuts, temporarily attach

the rear housing assembly and the rear lateral link
assembly.
CAUTION:
Be careful not to damage the oil seal lip when
removing the rear drive shaft.
When rear drive shaft is to be replaced, also
replace the inner oil seal with a new seal.
DS-00067

the rear housing assembly and the trailing link assembly.
ST1
ST2
DS-00068
15) Remove the bolts which secure the rear housing to strut, and separate the two.
DS-00066
6) Using new self-locking nuts, secure the rear

housing assembly and the strut assembly.
Tightening torque:
196 Nm (20 kgf-m, 145 ft-lb)
7) Using new self-locking nuts, install the rear stabilizer and rear lateral link.
Tightening torque:
44 Nm (4.5 kgf-m, 32.5 ft-lb)
8) Connect the parking brake cable to the parking
brake lever.
9) Install the disc rotor on the rear housing assembly.
10) Install the disc brake caliper on the back plate.
DS-00070
B: INSTALLATION
1. DISC BRAKE
1) Temporarily tighten the rear axle to the strut.
2) Insert the rear drive shaft into the rear axle.
CAUTION:
Be careful not to damage the inner oil seal lip.
Tightening torque:
52 Nm (5.3 kgf-m, 38.3 ft-lb)
DS-00064
DS-24
Rear Axle
DRIVE SHAFT SYSTEM
11) Adjust the parking brake lever stroke by turning

the adjuster. <Ref. to PB-5, ADJUSTMENT, Parking Brake Lever.>
12) While applying the parking brake, tighten a new
axle nut using the socket wrench. After tightening,
crimp the axle nut.

the rear housing assembly and the rear lateral link
assembly.
Tightening torque:
190 Nm (19.4 kgf-m, 140 ft-lb)
CAUTION:
Do not overtighten it as this may damage the
wheel bearing.
13) Install the rear ABS wheel speed sensor.
DS-00067

the rear housing assembly and the trailing link assembly.
(1)
DS-00069

specified torque.
Tightening torque:
100 Nm (10.2 kgf-m, 73.8 ft-lb)
15) Make the tires completely touch the ground.
CAUTION:
weight.
16) Tighten the rear housing assembly and lateral
link assembly installation bolts.
Tightening torque:
140 Nm (14.3 kgf-m, 103 ft-lb)
17) Tighten the rear housing assembly and trailing
Tightening torque:
90 Nm (9.2 kgf-m, 66 ft-lb)
2. DRUM BRAKE
1) Temporarily tighten the rear axle to the strut.
CAUTION:
Be careful not to damage the inner oil seal lip.
DS-00066
6) Using new self-locking nuts, secure the rear

housing assembly and the strut assembly.
Tightening torque:
196 Nm (20 kgf-m, 145 ft-lb)
7) Using new self-locking nuts, install the rear stabilizer and rear lateral link.
Tightening torque:
44 Nm (4.5 kgf-m, 32.5 ft-lb)
brake lever.
9) Clean the brake pipe connection. Using a flarenut wrench, connect the brake pipe to the wheel
cylinder.
10) Connect the parking brake cable to the lever.
11) Install the brake drum on the rear housing assembly.
12) Bleed air from brake system. <Ref. to BR-41,
REPLACEMENT, Brake Fluid.>
13) Adjust the parking brake lever stroke by turning
the adjuster. <Ref. to PB-5, ADJUSTMENT, Parking Brake Lever.>
axle nut using a socket wrench. After tightening,
crimp the axle nut.
Tightening torque:
190 Nm (19.4 kgf-m, 140 ft-lb)
DS-25
Rear Axle
DRIVE SHAFT SYSTEM
CAUTION:
Do not overtighten it as this may damage the
wheel bearing.
15) Attach the rear ABS wheel speed sensor to the
back plate.
3) Remove the outer and inner oil seals using a flat

tip screwdriver.
4) Remove the snap ring using a flat tip screwdriver.
CAUTION:
Be careful not to damage housing during removal.
(1)
DS-00069

DS-00089

specified torque.
Tightening torque:
100 Nm (10.2 kgf-m, 73.8 ft-lb)
5) Using ST1 and ST2, remove the bearing by

pressing the inner race.
ST2 927440000 BEARING REMOVER
ST2
CAUTION:
weight.
Tightening torque:
140 Nm (14.3 kgf-m, 103 ft-lb)
Tightening torque:
90 Nm (9.2 kgf-m, 66 ft-lb)
C: DISASSEMBLY
1) Using ST1 and ST2, remove the hub from the
rear housing.
ST2 927420000 HUB REMOVER
ST1
DS-00090
6) Remove the tone wheel bolts and remove the

tone wheel from the hub.
7) Using ST, press the hub bolt out.
ST 927080000
HUB STAND
CAUTION:
Be careful not to hammer the hub bolts. This
may deform the hub.
ST
ST2
DS-00054
ST1
DS-00088
2) Remove the back plate from the rear housing.
DS-26
Rear Axle
DRIVE SHAFT SYSTEM
D: ASSEMBLY
NOTE:
When the hub is removed from the housing, replace the bearing set and oil seal.
1) Using the ST, press the new hub bolt into place.
NOTE:
Make sure the hub bolt contacts the hub.
Use the 12 mm (0.47 in) hole in the ST to prevent
the hub bolt from tilting during installation.
ST 927080000
HUB STAND
3) Clean the housing interior completely. Using

ST1 and ST2, press the bearing into the housing.
ST2 927440000 BEARING REMOVER
CAUTION:
Always press the outer race when installing
bearings.
Be careful not to remove the plastic lock from
the inner race when installing the bearings.
ST2
ST
ST1
DS-00094
4) Using a pliers, securely install the snap ring.
DS-00055
2) Remove the foreign particles (dust, rust, etc.)

from the mating surfaces of hub tone wheel, and install the tone wheel to the hub.
(1)
NOTE:
Make sure the tone wheel contacts the hub.
Be careful not to damage the tone wheel teeth.
DS-00095
(1) Pliers
(1)
DS-00093
5) Using the ST1 and ST2, press the outer oil seal
until it comes in contact with snap ring.
ST2
(1) Tone wheel
(1)
ST1
DS-00096
(1) Snap ring
DS-27
Rear Axle
DRIVE SHAFT SYSTEM
6) Invert both ST1 and housing (up and down).

7) Using ST2, press the inner oil seal into the housing until it touches the bottom.
11) Using ST1 and ST2, press the bearing into the
hub.
ST2 927450000 HUB INSTALLER
ST2
ST2
(1)
ST1
ST1
DS-00169
DS-00097
8) Using ST1 and ST2, press the sub seal into

place.
ST2
(1) Back plate
E: INSPECTION
1) While moving the rear tire up and down by hand,
check that there is no looseness of the bearing, and
check that the wheel rotates smoothly.
ST1
DS-00098
9) Apply sufficient grease to the oil seal lip.
DS-00183
Grease:
SHELL 6459N
NOTE:
If specified grease is not available, remove the
bearing grease and apply Auto Rex A instead.
CAUTION:
Do not mix different types of grease.
10) Install the back plate to the rear housing.
2) Inspect the play in the axial direction using a dial

gauge. Replace the hub bearing if the play exceeds
the limit value.
Limit:
Max:
0.05 mm (0.0020 in)
Tightening torque:
52 Nm (5.3 kgf-m, 38.3 ft-lb)
DS-00062
DS-28
Front Drive Shaft

DRIVE SHAFT SYSTEM
5. Front Drive Shaft
9) Remove the bolts which secure the ball joint. Remove the transverse link from the front housing.
A: REMOVAL
2) Drain the transmission gear oil. (MT model)
3) Drain the differential gear oil. (AT model)
FS-00026
10) Pull out the front drive shaft from the front axle.
If it is hard to remove, use ST1 and ST2.
PLATE
DS-00038
5) Depress the brake pedal and remove the axle

nut using a socket wrench.
CAUTION:
6) Remove the cotter pin and castle nut. Using a
puller, remove the tie-rod end.
CAUTION:
When removing the drive shaft, do not hammer the shaft.
Do not damage the oil seal and tone wheel.
When replacing the front drive shaft, also replace the inner oil seal.
ST1
ST2
DS-00040
DS-00043
7) Remove the bracket of the ABS wheel speed

sensor.
DS-00017
8) Remove the front stabilizer link from the transverse link.
DS-29
Front Drive Shaft

DRIVE SHAFT SYSTEM
11) Using the ST, remove the front drive shaft from
the transmission.
NOTE:
The direction of the ST differs by type of the
transmission to be installed.
For AT model, use ST with the AT stamped
side facing the transmission side. For MT model,
use the ST with the MT stamped side facing the
transmission side.
4) Using the ST, install the front drive shaft to the

transmission while protecting the differential side
retainer oil seal.
CAUTION:
Be careful not to allow the ST to contact the
holder area.
ST
AT-00110
5) Install the ball joint to the front axle.

Tightening torque:
50 Nm (5.1 kgf-m, 37 ft-lb)
6) Install the stabilizer link.
Tightening torque:
45 Nm (4.6 kgf-m, 33 ft-lb)
ST
MT-00080
B: INSTALLATION
1) Using the ST, replace the differential side retainer oil seal with a new seal.
SEAL INSTALLER
CAUTION:
Always replace the differential side retainer oil
seal with a new seal after removing the drive
shaft.
ST
FS-00026
7) Install the tie-rod end.

Tightening torque:
27 Nm (2.75 kgf-m, 19.9 ft-lb)
CAUTION:
When connecting the tie-rod, do not hit the cap
at bottom of tie-rod end with a hammer.
MT-00103
2) Insert the front drive shaft into the front axle.

DS-30
Front Drive Shaft

DRIVE SHAFT SYSTEM
8) Tighten the castle nut to specified torque and

tighten further within 60 until the pin hole is aligned
with the slot in nut. Bend the cotter pin to lock.
(A)
11) While pressing the brake pedal, tighten a new

axle nut to the specified torque.
Tightening torque:
220 Nm (22.4 kgf-m, 162 ft-lb)
CAUTION:
(B)
(C)
DS-00042
(A) Cotter pin

(B) Castle nut
(C) Tie-rod end
9) Check whether or not the AARi retainer has

moved from its prescribed position.
DS-00048
13) Install the ABS wheel speed sensor bracket.

Tightening torque:
32 Nm (3.3 kgf-m, 24 ft-lb)
14) Add the transmission gear oil. (MT model)
15) Add the differential gear oil. (AT model)
(1)
Tightening torque:
100 Nm (10.2 kgf-m, 73.8 ft-lb)
DS-00018
C: DISASSEMBLY
(1) Retainer
10) Using ST1 and ST2, pull the front drive shaft
into the required position.
1) Place alignment marks on the shaft and outer

race.
DS-00106
2) Remove the AARi boot band and boot.

ST
DS-00104
DS-31
Front Drive Shaft

DRIVE SHAFT SYSTEM
D: ASSEMBLY
CAUTION:
Be careful not to damage the boot.
NOTE:
Use specified grease.
Grease:
AARi side:
ONE LOUVER C (Part No. 28395SA000)
1) Pass the AARi boot and the retainer through the
shaft and place at the center.
2) Align the alignment marks and install the trunnion on the shaft.
DS-00107
3) Remove the AARi outer race from the shaft assembly.

4) Wipe off grease.
CAUTION:
This grease is a special type of grease. Do not
mix it with other grease.
5) Place alignment marks on the trunnion and
shaft.
DS-00110
3) Fill 100 to 110 g (3.53 to 3.88 oz) of specified

grease into the interior of AARi outer race.
4) Apply a thin coat of specified grease to the free
ring and trunnion.
5) Align the alignment marks of the shaft and outer
race, and install the outer race.
DS-00110
6) Remove the snap ring and trunnion.
DS-00106
6) Apply an even coat of the specified grease 30 to

40 g (1.06 to 1.41 oz) to the entire inner surface of
boot.
7) Install the AARi boot taking care not to twist it.
DS-00111
7) Remove the AARi boot.

CAUTION:
Be sure to wrap shaft splines with vinyl tape to
protect the boot from scratches.
CAUTION:
The inside of the larger end of the AARi boot
and the boot groove is to be cleaned so as to be
free of grease and other foreign substances.
When installing the AARi boot, position the
outer race of the AARi at the center of the
stroke.
DS-32
Front Drive Shaft

DRIVE SHAFT SYSTEM
E: INSPECTION
8) Check the position of the retainer.
(1)
DS-00018
(1) Retainer
Y
ONL
9) Install the new large boot band and small boot

band at the required positions.
10) Tighten the boot bands using ST, torque
wrench and socket flex handle.
ST 28099AC000 BOOT BAND PLIER
Check the removed parts for damage, wear, corrosion etc. Repair or replace if defective.
1) AARi
Check for seizure, corrosion, damage and excessive play.
2) Shaft
Check for excessive bending, twisting, damage
and wear.
3) AC
4) Boot
Check for wear, warping, breakage and scratches.
5) Grease
Check for discoloration and fluidity.
(C)
(B)
(A)
(D)
ST
(E)
DS-00120
(A) Large boot band

(B) Boot
(C) Torque wrench
(D) Socket flex handle
(E) AARi
Clearance at the crimped section of the boot

band:
Large boot band
1 mm (0.04 in) or less
Small boot band
11) Extend and retract the AARi repeatedly to ensure an equal grease coating.
DS-33
Rear Drive Shaft

DRIVE SHAFT SYSTEM
6. Rear Drive Shaft
7) Remove the bolts which secure the front and

rear lateral link to the housing.
A: REMOVAL
wheels.
3) Lift the crimped section of the axle nut.
DS-00067
8) Remove the rear ABS wheel speed sensor from

the back plate.
DS-00038

CAUTION:
5) Remove the rear stabilizer link.
(1)
DS-00069
9) Remove the rear drive shaft from the rear axle. If

it is hard to remove, use ST1 and ST2 to remove
the brake disc rotor.
PLATE
RS-00010
6) Remove the bolts which secure the trailing link to

the housing.
CAUTION:
Do not hammer the drive shaft when removing it.
Do not damage the oil seal and tone wheel.
ST1
ST2
DS-00122
DS-00066
DS-34
Rear Drive Shaft

DRIVE SHAFT SYSTEM
10) Remove the rear drive shaft from the rear differential by using the ST.
CAUTION:
As shown in the figure, set the ST to the bolt (A)
without damaging the side bearing retainer.
B: INSTALLATION
3) Using the ST, install the rear drive shaft to the
rear differential while protecting the oil seal.
ST 28099PA090 OIL SEAL PROTECTOR
ST
DI-00060
4) Using new self-locking nuts, temporarily tighten

the front and rear lateral links to the housing.
DI-00206
DS-00067
(A) Bolt

the trailing link to the housing.
DS-00066
DS-35
Rear Drive Shaft

DRIVE SHAFT SYSTEM
6) Install the stabilizer link.
Tightening torque:
45 Nm (4.6 kgf-m, 33 ft-lb)
DS-00048

RS-00010
Tightening torque:
100 Nm (10.2 kgf-m, 73.8 ft-lb)
7) Install the ABS wheel speed sensor.

Tightening torque:
32 Nm (3.3 kgf-m, 24 ft-lb)
CAUTION:
weight.
Tightening torque:
140 Nm (14.3 kgf-m, 103 ft-lb)
(1)
DS-00069
Tightening torque:
90 Nm (9.2 kgf-m, 66 ft-lb)
8) Using ST1 and ST2, pull the rear drive shaft to

the required location.
ST
DS-00123
9) While applying the parking brake pedal, tighten

the new axle nut to the specified torque.
Tightening torque:
190 Nm (19.4 kgf-m, 140 ft-lb)
CAUTION:
DS-36
Rear Drive Shaft

DRIVE SHAFT SYSTEM
C: DISASSEMBLY
1) Straighten the bent claw at the larger end of the
DOJ boot.
2) Loosen the band by means of a flat tip screwdriver or pliers, being careful not to damage the
boot.
Disassemble while being careful not to lose

ball bearings (6 pcs).
(A)
(B)
DS-00126
(A) Outer race

(B) Grease
DS-00124
3) Remove the boot band on the small end of DOJ

boot in the same manner.
4) Remove the larger end of DOJ boot from DOJ
outer race.
5) Pry and remove the circlip at the neck of DOJ
outer race with a screwdriver.
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 move the cage.
9) Using pliers, remove the snap ring fixing the inner race to the shaft.
10) Take out the DOJ inner race.
11) Take off the DOJ cage from shaft and remove
the DOJ boot.
12) Wrap vinyl tape around the spline part of shaft.
13) Remove the EBJ boot using the same procedures as for the DOJ boot.
NOTE:
The EBJ is a non-disassembly part, so the axle disassembly stops here.
DS-00125
6) Take out the DOJ outer race from the shaft assembly.
7) Wipe off the grease and take out the ball bearings.
CAUTION:
The grease is a special grease (grease for
constant velocity joints). Do not mix with other
greases.
DS-37
Rear Drive Shaft

DRIVE SHAFT SYSTEM
D: ASSEMBLY
6) Install the removed cage, to the inner race fixed

onto the shaft.
NOTE:
Use specified grease.
Grease:
EBJ side
NTG2218-M (Part No. 28395AG010)
DOJ side:
NKG205 (Part No. 28495AG000)
1) Install the EBJ boot to the specified position, and
fill it with 60 to 70 g (2.12 to 2.47 oz) of specified
grease.
2) Place the DOJ boot at the center of shaft.
3) Wrap vinyl tape around the spline part of shaft.
4) Insert the DOJ cage onto shaft.
NOTE:
Fit the cage with the protruding section aligned with
the track on the inner race, and turn by a half pitch.
(B)
(A)
DS-00129
CAUTION:
The cage has a set orientation. Insert the cage
with the cutout portion facing the shaft side.
(A) Inner race

(B) Cage
7) Fill 80 to 90 g (2.82 to 3.17 oz) of specified

grease into the inner side of the DOJ outer race.
8) Apply a thin coat of specified grease to the cage
pocket and six ball bearings.
9) Insert the six ball bearings into the cage pocket.
10) Align the outer race track and ball positions,
and place the shaft, inner race, cage and ball bearings in the original positions, then fix outer race in
place.
(A)
(B)
DS-00395
(A) Cage
(B) Cutout portion
(A)
(B)
5) Install the DOJ inner race on shaft and fix the

snap ring in place with pliers.
CAUTION:
Confirm that the snap ring is completely fitted
in the shaft groove.
DS-00126
(A) Outer race

(B) Grease
DS-00128
DS-38
Rear Drive Shaft

DRIVE SHAFT SYSTEM
11) Install the circlip in the groove on the DOJ outer

race.
CAUTION:
Make sure that the balls, cage and inner race
are firmly fitted in the outer race of the DOJ.
Take care not to place the matching position
of the circlip in the ball groove of outer race.
Pull the shaft lightly to make sure that the circlip is completely fitted in the groove.
17) Tap the clip with the punch provided at the end
of the ST.
ST 925091000
BAND TIGHTENING TOOL
CAUTION:
Tap to an extent that the boot underneath is not
damaged.
DS-00133
18) Cut off the band with an allowance of about 10

mm (0.39 in) left from the clip and bend this allowance over the clip.
DS-00125
12) Apply an even coat of the specified grease [20

to 30 g (0.71 to 1.06 oz)] to the entire inner surface
of boot. Also apply grease to the shaft.
13) Install the DOJ boot taking care not to twist it.
NOTE:
The inside of the larger end of DOJ boot and the
boot groove is to be cleaned so as to be free from
grease and other foreign substances.
When installing the DOJ boot, position the outer
race of DOJ at center of the stroke.
14) Put a new band through the clip and wind twice
in the band groove of the boot.
15) Pinch the end of band with pliers. Hold the clip
and tighten securely.
CAUTION:
When tightening the boot, exercise care so that
the air within the boot is appropriate.
16) Tighten the band using the ST.
ST 925091000
BAND TIGHTENING TOOL
CAUTION:
Tighten the band until it cannot be moved by
hand.
CAUTION:
Make sure that the end of the band is in close
contact with clip.
19) Install EBJ boot in the same manner.
20) Extend and retract the DOJ repeatedly to provide an equal coating of grease.
E: INSPECTION
Check the removed parts for damage, wear, corrosion etc. Repair or replace if defective.
1) DOJ (Double Offset Joint)
Check for seizure, corrosion, damage, wear and
excessive play.
2) Shaft
Check for excessive bending, twisting, damage
and wear.
3) EBJ
4) Boot
Check for wear, warping, breakage and scratches.
5) Grease
Check for discoloration and fluidity.
DS-00132
DS-39

DRIVE SHAFT SYSTEM

A: INSPECTION
NOTE:
Vibration while cruising may be caused by an unbalanced tire, improper tire inflation pressure, improper
wheel alignment, etc.
Symptom
Noise or vibration from propeller shaft
Abnormal wheel vibration
Possible cause
Check the center bearing. <Ref. to

DS-15, CENTER BEARING FREE PLAY,
INSPECTION, Propeller Shaft.>
Runout of propeller shaft
Check for deflection of the propeller shaft.

<Ref. to DS-14, RUNOUT OF PROPELLER
SHAFT, INSPECTION, Propeller Shaft.>
Loose or gap at connections
Check the joints and connectors. <Ref. to

DS-14, JOINTS AND CONNECTIONS,
Check the spline and bearing. <Ref. to DS-14,
SPLINES AND BEARING LOCATIONS,
Check the wheel balance. <Ref. to WT-7,
Check the wheel alignment. <Ref. to
FS-6, INSPECTION, Wheel Alignment.>

Wheel alignment
Front strut
Check the front strut. <Ref. to FS-20,

INSPECTION, Front Strut.>
Rear strut
Check the rear strut. <Ref. to RS-12,

INSPECTION, Rear Strut.>
Front drive shaft
Check the front drive shaft. <Ref. to DS-33,

INSPECTION, Front Drive Shaft.>
Check the rear drive shaft. <Ref. to DS-39,
INSPECTION, Rear Drive Shaft.>
Check the wheel alignment. <Ref. to DS-20,
INSPECTION, Front Axle.>
Rear drive shaft

Front axle
Rear axle
Noise from the underbody
Corrective action
Center bearing
Check the wheel balance. <Ref. to WT-7,

Wheel alignment
Check the wheel alignment. <Ref. to FS-6,

INSPECTION, Wheel Alignment.>
Front strut
Check the front strut. <Ref. to FS-20,

INSPECTION, Front Strut.>
Check the rear strut. <Ref. to RS-12,
INSPECTION, Rear Strut.>
Rear strut
DS-40
General Description
ABS
A: SPECIFICATION
Item
ABS wheel speed

sensor
ABS wheel speed sensor gap
Front
Rear
0.3 0.8 mm (0.012 0.031 in)

0.7 1.2 mm (0.028 0.047 in)
ABS wheel speed sensor resistance
Front
Rear
1.250.25 k
1.150.115 k
Identifications of harness
(Colors)
G sensor
Specification
Front
RH
LH
Red
Blue
Rear
RH
LH
White
Yellow
AT
2.30.2 V
L6
MT
L7
G sensor voltage
ABSCM & H/U identification
ABS-2
General Description
ABS
B: COMPONENT
1. SENSOR
ABS00129
(1)
(2)
G sensor
Rear ABS wheel speed sensor
RH
(3)
Adjusting spacer
(4)
(5)
Rear ABS wheel speed sensor LH Tightening torque: Nm (kgf-m, ft-lb)

Front ABS wheel speed sensor LH
T1: 18 (1.8, 13.0)
(6)
Front ABS wheel speed sensor

RH
ABS-3
T2: 33 (3.4, 24.6)
General Description
ABS
2. ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)

(3)
(4)
(5)
(2)
(7)
(6)
(1)
(9)
(8)
(10)
T1
T2
T3
(11)
ABS00799
(1)
ABS control module and hydraulic

control unit (ABSCM&H/U)
(6)
(7)
Primary inlet
Secondary inlet
(2)
(3)
Front outlet RH
Rear outlet LH
(8)
(9)
Damper
Spacer
(4)
(5)
Rear outlet RH
Front outlet LH
(10)
(11)
Damper
Bracket

T1: 7.5 (0.76, 5.5)
T2: 33 (3.4, 24.6)
T3: 38 (3.8, 27.5)
C: CAUTION
the battery.
points.
ABS-4
General Description
ABS
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
1B020XU0
DESCRIPTION
SUBARU SELECT
MONITOR KIT
REMARKS
English: 22771AA030 (Without printer)
ST1B020XU0
2. GENERAL TOOL
TOOL NAME
Circuit tester
REMARKS
Pressure gauge
Oscilloscope

TORX BIT E5
Used for replacing ABSCM.
ABS-5
ABS Control Module and Hydraulic Control Unit (ABSCM&H/U)

ABS
2. ABS Control Module and Hydraulic Control Unit (ABSCM&H/U)

A: REMOVAL
2) Remove the air cleaner case to make it easier to
remove the ABSCM&H/U. <Ref. to IN(H4DOTC)-8,
REMOVAL, Air Cleaner Case.>
3) Use an air gun to blow off any water around the
ABSCM&H/U.
8) Remove the nuts and remove the ABSCM&H/U.

CAUTION:
Do not drop or bump the ABSCM&H/U.
Do not turn the ABSCM&H/U upside down or
place it sideways for storage.
Be careful not to let foreign matter enter into
ABSCM&H/U.
Be careful that no water enters the connectors.
NOTE:
A contact fault may occur if the terminal is wet.
4) Lift the lock lever and disconnect the ABSCM&H/U connector.
CAUTION:
Do not pull on the harness when disconnecting
the connector.
ABS00542
9) Remove the ABSCM&H/U bracket.
ABS00541
5) Remove the harness clip.

6) Disconnect the brake pipes from the ABSCM&H/
U.
7) Wrap the brake pipe with a vinyl bag so as not to
spill the brake fluid on the vehicle body.
CAUTION:
If brake fluid is spilled on the vehicle body,
wash it off immediately with water and wipe
clean.
ABS-6

ABS
B: INSTALLATION
C: REPLACEMENT
1) Install the ABSCM&H/U bracket.
CAUTION:
Because the seal of the ABSCM cannot be replaced, do not pull or peel it by lifting it up.
Because the screw of the H/U will become
slightly worn in every replacement procedure, 5
times is the maximum number of times for replacement. If a problem is found such as not
being able to torque the screw to specifications
even before 5 replacement operations are performed, replace the H/U body.
When installing the ABSCM, always use new
screws.
When the sealing surface of the ABSCM or H/
U is dirty or damaged and it cannot be removed
or repaired, replace with a new part.
1) Remove the ABSCM&H/U. <Ref. to ABS-6, REMOVAL, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).>
2) To prevent entry of foreign objects and brake fluid leakage, plug the oil pressure port of the ABSCM&H/U using a screw plug, etc.
3) Set the pump motor section of the removed ABSCM&H/U face down on a vise.
Tightening torque:
33 Nm (3.4 kgf-m, 24.6 ft-lb)
2) Install the ABSCM&H/U by aligning the damper
groove of the ABSCM&H/U to the bracket side
claw.
NOTE:
Check the identification marks of the ABSCM&H/U.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
ABS00542
3) Connect the brake pipes to their correct positions on the ABSCM&H/U.

Tightening torque:
15 Nm (1.5 kgf-m, 10.8 ft-lb)
4) Using cable clip, secure the ABSCM&H/U harness to the bracket.
5) Connect the connector to the ABSCU&H/U.
NOTE:
NOTE:
Be sure to remove all foreign matter from inside
the connector before connecting.
Make sure that the ABSCM&H/U connector is
securely locked.
6) Connect the grounding wire of the ABSCM&H/U
and apply rust-prevention wax.
7) Install the air cleaner case. <Ref. to
IN(H4DOTC)-8, INSTALLATION, Air Cleaner
Case.>
8) Bleed air from the brake system.
ABS-7
(1)
(2)
ABS00430
(1) Aluminum plate, etc.

(2) Vise

ABS
4) Using TORX BIT E5, remove the four screws of

ABSCM.
11) Using a TORX BIT E5, tighten the screws in

the order of (1) through (4) again.
NOTE:
These screws cannot be reused.
Tightening torque:
3 Nm (0.3 kgf-m, 2.2 ft-lb)
12) Check that there is no gap in the mating surface between ABSCM and H/U.
13) Install the ABSCM&H/U to the vehicle. <Ref. to
ABS-7, INSTALLATION, ABS Control Module and
Hydraulic Control Unit (ABSCM&H/U).>
ABS00431
5) Slowly pull out the ABSCM upward from the H/U.

NOTE:
To prevent damaging the coil section, remove the
ABSCM straight up from H/U without twisting.
6) Make sure there is no dirt or damage on the sealing surface of the H/U.
CAUTION:
Do not clean the ABSCM & H/U by applying
compressed air.
Even if damage is found on the H/U seal, do
not attempt repair by filing or with a metal
scraper. To remove the seal residue, always
use a plastic scraper. Do not use chemical such
as paint thinner, etc., to clean.
7) Position the coil of the new ABSCM to align with
the H/U valve.
8) To prevent deformation of the ABSCM housing
cover, hold the corner of ABSCM and install it to the
H/U without tilting.
9) Using a TORX BIT E5, attach/tighten new
screws in the order of (1) through (4).
CAUTION:
Always use new screws.
Tightening torque:
1.5 Nm (0.15 kgf-m, 1.1 ft-lb)
(1)
(4)
(3)
(2)
ABS00432
10) Check that there is no foreign matter in mating

surface between the ABSCM & H/U.
ABS-8

ABS
D: INSPECTION
1) Check the connection and seating of the connector.
2) Check the mark used for ABSCM&H/U identification.
Identification mark
Model
L6
L7
AT
MT
6) When the hydraulic unit begins to work, first the

FL side performs decompression, hold and compression, and then the FR side performs decompression, hold and compression.
7) Read the values indicated on the pressure
gauge and check if the fluctuation of the values between decompression and compression meets the
standard values. Also check whether any irregular
tightness of the brake pedal can be felt.
Initial value
(1)
When
depressurized
When
pressurized
ABS00384
(1) Identification mark
1. CHECKING THE HYDRAULIC UNIT ABS

OPERATION BY PRESSURE GAUGE
2) Remove the air bleeder screws from FL and FR
caliper bodies.
3) Connect two pressure gauges to FL and FR caliper bodies.
CAUTION:
Use a pressure gauge used exclusively for
brake fluid measurement.
Do not use a pressure gauge used previously
for measurement of transmission oil pressure,
as the piston seal may expand and deform.
NOTE:
Wrap sealing tape around the pressure gauge.
Front wheel
Rear wheel
3,500 kPa
(35 kgf/cm2,
498 psi)
3,500 kPa
(35 kgf/cm2,
498 psi)
500 kPa
(5 kgf/cm2, 71 psi)
or less
500 kPa
(5 kgf/cm2, 71 psi)
or less
3,500 kPa
(35 kgf/cm2,
498 psi)
or more
3,500 kPa
(35 kgf/cm2,
498 psi)
or more
8) Disconnect the pressure gauges from FL and FR

caliper bodies.
9) Remove the air bleeder screws from RL and RR
caliper bodies.
10) Install the air bleeder screws of FL and FR caliper bodies.
11) Connect two pressure gauges to RL and RR
caliper bodies.
12) Bleed the air of the FL and FR caliper bodies.
13) Perform ABS sequence control. <Ref. to ABS11, ABS Sequence Control.>
RR side performs decompression, hold and compression, and then the RL side performs decompression, hold and compression.
gauges and check if it is within specification.
16) After checking, remove the pressure gauges
from the caliper bodies.
17) Install the air bleeder screws of RL and RR caliper bodies.
ABS00134
4) Bleed air from the pressure gauge.

ABS-9

ABS
2. CHECKING THE HYDRAULIC UNIT ABS

OPERATION WITH THE BRAKE TESTER
1) In the case of AWD AT models, install a spare
fuse to the FWD connector in the main fuse box to
simulate FWD vehicles.
(1)
(2)
6) When the hydraulic unit begins to work, check

the following work sequence.
(1) The FL side performs decompression, hold
and compression in sequence, and subsequently the FR side repeats the cycle.
(2) The RR side performs decompression, hold
and compression in sequence, and the RL side
repeats the same cycle next.
7) Read values indicated on the brake tester and
check if the fluctuation of the values between decompression and compression meets the standard
values.
Initial value
ABS00135
When
depressurized
(1) Main fuse box

(2) FWD connector
NOTE:
Since a viscous coupling is used in the center differential on MT models, AWD circuit cut-off cannot
be performed.
2) Prepare for the ABS sequence control operation.
<Ref. to ABS-11, ABS Sequence Control.>
3) Set the front wheels or rear wheels on the brake
tester and set the select lever position to the N
range.
When pressurized
Front wheel
1,000 N
(100 kgf, 221 lb)
500 N
(50 kgf, 110 lb)
or less
1,000 N
(100 kgf, 221 lb)
or more
Rear wheel
1,000 N
(100 kgf, 221 lb)
500 N
(50 kgf, 110 lb)
or less
1,000 N
(100 kgf, 221 lb)
or more
8) After checking, press the brake pedal and check

whether any irregular tightness of the brake pedal
can be felt.
(1)
ABS00136
(1)
ABS00137
(1) Brake tester
4) Operate the brake tester.

ABS-10
ABS Sequence Control

ABS
3. ABS Sequence Control

A: OPERATION
1) While the ABS sequence control is being performed, the operation of the hydraulic unit can be
checked using the brake tester or pressure gauge
after the hydraulic unit solenoid valve operation.
2) ABS sequence control can be started by diagnosis connector or Subaru Select Monitor.
1. ABS SEQUENCE CONTROL WITH SUBARU SELECT MONITOR

NOTE:
If a problem occurs, sequence control will not operate. In this case, diagnose the failure. <Ref. to
ABS(diag)-2, PROCEDURE, Basic Diagnostic Procedure.>
connector under the drivers side instrument panel
lower cover.
4) Set the Subaru Select Monitor to BRAKE CONTROL mode.
5) When the Function check sequence is selected, the ABS sequence control will start.
6) Execute the following operations when the message Press the brake pedal so that the brake pedal force is between 100 and 150 kgf is displayed.
(1) When using a brake tester, press the brake
pedal pad with a force of 981 N (100 kgf, 221
lb).
(2) When using a pressure gauge, press the
brake pedal so that the pressure gauge indicates 3,432 kPa (35 kg/cm2, 498 psi).
CAUTION:
On models with the hill holder feature, do not
step on the clutch pedal.
7) OK will be displayed. Select the [OK].
8) The brake system being operated is displayed
on the Subaru Select Monitor.
ABS-11

ABS
2. CONDITIONS FOR ABS SEQUENCE CONTROL
(24)
(25)
(4)
ON
(5)
OFF
(1)
(6)
(7)
(27)
ON
OFF
HIGH
(9)
(10)
(11)
(12)
(2)
(26)
(13)
(14)
(15)
(16)
(17)
(18)
(28)
(27)
(28)
(29)
(30)
LOW
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
(31)
(27)
(31)
(27)
(8)
(3)
(19)
(20)
(21)
(22)
(23)
ABS00781
(1)
Operation guide line of the

sequence control
(10)
(11)
FL decompression valve
FL compression valve
(21)
(22)
FR wheel cylinder pressure

RR wheel cylinder pressure
(2)
Operation pattern of sequence

control
(12)
(13)
FR decompression valve
FR compression valve
(23)
(24)
RL wheel cylinder pressure

4 km/h (2 MPH) or less
(3)
Operating pressure of sequence

control
(14)
(15)
RR decompression valve
RR compression valve
(25)
(26)
10 km/h (6 MPH) or less

Approx. 2 sec.
(4)
(5)
All wheel speed

Ignition key
(16)
(17)
RL decompression valve
RL compression valve
(27)
(28)
1.0 second
1.4 seconds
(6)
(7)
ABS warning light

Stop light switch
(18)
(19)
Pump motor
Master cylinder pressure
(29)
(30)
0.6 seconds
Within 0.5 second
(8)
(9)
A point
Valve relay
(20)
FL wheel cylinder pressure
(31)
0.4 seconds
NOTE:
The control operation starts from point A.
HIGH indicates high voltage.
LOW indicates low voltage.
ABS-12

ABS
B: SPECIFICATION
1. ABS SEQUENCE CONTROL COMPLETE
CONDITION
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 the brake pedal is released during sequence control and the stop light switch is becomes
OFF.
3) After completion of the sequence control.
4) When a malfunction is detected.
ABS-13
Front ABS Wheel Speed Sensor

ABS
4. Front ABS Wheel Speed Sensor
5) Remove the bolts which secure front ABS wheel

speed sensor to the housing, and remove the front
ABS wheel speed sensor.
A: REMOVAL
CAUTION:
Be careful not to damage the pole piece and
the face of the teeth located at tip of the sensor
during removal.
Do not pull on the sensor harness during removal.

2) Disconnect the ABS wheel speed sensor connector located next to the front strut mounting
house in the engine compartment.
3) Remove the bolts which secure the sensor harness to the strut.
ABS00142
ABS00140
4) Remove the bolts which secure the sensor harness to the body.
(1)
(2)
ABS00141
(1) To the front ABS wheel speed sensor connector

(2) Bracket
ABS-14

ABS
B: INSTALLATION
1) Temporarily install the front ABS wheel speed
sensor on the housing.
CAUTION:
Be careful not to hit the ABS wheel speed sensor pole piece and tone wheel against adjacent
metal parts during installation.
3) Check the clearance of the sensor. <Ref. to

ABS-16, SENSOR GAP, INSPECTION, Front ABS
Wheel Speed Sensor.>
If clearance is outside of the standard value, readjust by using the spacer (Part No. 26755AA000).
ABS wheel speed sensor gap standard value:
0.3 0.8 mm (0.012 0.031 in)
Tightening torque:
33 Nm (3.4 kgf-m, 24.6 ft-lb)
ABS00142
2) Install the front ABS wheel speed sensor on the

strut and the wheel apron bracket.
ABS00142
NOTE:
Check the identification (mark) on the harness to
make sure there is no warpage. (RH: Red, LH:
Blue)
4) After confirmation of the ABS wheel speed sensor clearance, connect the connector to the ABS
wheel speed sensor.
Tightening torque:
33 Nm (3.4 kgf-m, 24.6 ft-lb)
(1)
(2)
C: INSPECTION
1. ABS WHEEL SPEED SENSOR
ABS00141
(1) To the front ABS wheel speed sensor connector

(2) Bracket
1) Check the pole piece of the ABS wheel speed

sensor for foreign particles or damage. If necessary, clean the pole piece or replace the ABS wheel
speed sensor.
2) Measure the ABS wheel speed sensor resistance.
If resistance is outside the standard value, replace
with a new ABS wheel speed sensor.
2 1
ABS00143
Terminal No.
1 and 2
ABS-15
Specification
1.250.25 k

ABS
NOTE:
Check the ABS wheel speed sensor cable for discontinuity. If necessary, replace with a new part.
2. SENSOR GAP
1) Measure the distance A between the ABS
wheel speed sensor surface and sensor pole face.
3. OUTPUT VOLTAGE
Output voltage can be checked by the following
method. Install a resistor and condenser, then rotate the wheel about 2.75 km/h (2 MPH) or equivalent.
Standard value of output voltage:
0.12 1 V (at 20 Hz)
NOTE:
Regarding terminal numbers, refer to 1. ABS
WHEEL SPEED SENSOR. <Ref. to ABS-15, ABS
WHEEL SPEED SENSOR, INSPECTION, Front
ABS Wheel Speed Sensor.>
60 mV
0
ABS00144
60 mV
2) Measure the distance B between the surface

where the front axle housing meets the ABS wheel
speed sensor, and the tone wheel.
20 Hz
(1)
NOTE:
Measure so that the gauge touches the apex of the
tone wheel teeth.
(1)
17.8 K
562
5%
5%
1 nF
(2)
33 nF
20 %
(2)
B
(2)
ABS00145
ABS00146
(1) Axle housing
(1) Oscilloscope
(2) Tone wheel
(2) Terminals
3) Find the gap between the ABS wheel speed sensor pole face and the surface of the tone wheel
teeth by entering and calculating the measured values in the formula below.
ABS wheel speed sensor gap = B A
D: ADJUSTMENT
Adjust the gap
26755AA000).

0.3 0.8 mm (0.012 0.031 in)
NOTE:
ABS-16
using
spacers
(Part
No.
Rear ABS Wheel Speed Sensor

ABS
5. Rear ABS Wheel Speed Sensor

A: REMOVAL
3) Remove the rear seat and disconnect the rear
ABS wheel speed sensor connector.
4) Remove the rear sensor harness bracket from
the rear trailing link and bracket.
5) Remove the rear ABS wheel speed sensor from
the back plate.
B: INSTALLATION
1) Attach the hub to the rear tone wheel and attach
the rear housing. <Ref. to DS-27, ASSEMBLY,
Rear Axle.>
2) Temporarily attach the rear ABS wheel speed
sensor to the back plate.
CAUTION:
Be careful not to hit the ABS wheel speed sensor pole piece and tone wheel against adjacent
metal parts during installation.
(1)
CAUTION:
Be careful not to damage the pole piece and
the face of the teeth located at tip of the sensor
during removal.
Do not pull on the sensor harness during removal.
ABS00147
(1)
(1) Rear ABS wheel speed sensor
3) Install the rear drive shaft to the rear housing

and rear differential spindle. <Ref. to DS-24, INSTALLATION, Rear Axle.>
4) Install the rear sensor harness on the rear trailing link.
ABS00147
Tightening torque:
33 Nm (3.4 kgf-m, 24.6 ft-lb)
(1) Rear ABS wheel speed sensor
6) Remove the rear tone wheel when removing the

hub from the housing and hub assembly. <Ref. to
DS-21, REMOVAL, Rear Axle.>
(1)
(2)
ABS00148
(1) Rear sensor harness

(2) Trailing link
ABS-17

ABS
5) Check the clearance of the sensor. <Ref. to

ABS-18, SENSOR GAP, INSPECTION, Rear ABS
Wheel Speed Sensor.> When the clearance is
within standard values, tighten the ABS wheel
speed sensor to the back plate at the specified
torque.
0.7 1.2 mm (0.028 0.047 in)
C: INSPECTION
1) Check the pole piece of the ABS wheel speed
sensor for foreign particles or damage. If necessary, clean the pole piece or replace the ABS wheel
speed sensor.
2) Measure the ABS wheel speed sensor resistance.
If resistance is outside the standard value, replace
with a new ABS wheel speed sensor.
Tightening torque:
33 Nm (3.4 kgf-m, 24.6 ft-lb)
2 1
NOTE:
Check the identification (mark) on the harness to
make sure there is no warpage. (RH: White, LH:
Yellow)
6) After confirmation of the ABS wheel speed sensor clearance, connect the connector to the ABS
wheel speed sensor.
ABS00143
Terminal No.
Specification
1 and 2
1.150.115 k
NOTE:
Check the ABS wheel speed sensor cable for discontinuity. If necessary, replace with a new part.
2. SENSOR GAP
Check the gap between the tone wheel and the
ABS wheel speed sensor around the entire circumference.
NOTE:
If clearance is narrow, adjust by using the spacer
(Part No. 26755AA000).
If clearance is wide, check the output voltage and
replace the ABS wheel speed sensor or tone wheel
if the output voltage is outside the specification.
0.7 1.2 mm (0.028 0.047 in)
(1)
(2)
(3)
ABS00149
(1) Tone wheel

(3) Sensor gap
ABS-18

ABS
3. OUTPUT VOLTAGE
D: ADJUSTMENT
Output voltage can be checked by the following

method. Install a resistor and condenser, then rotate the wheel about 2.75 km/h (2 MPH) or equivalent.
Adjust the gap

26755AA000).
Standard value of output voltage:

0.12 1 V at (20 Hz)
NOTE:
Regarding terminal numbers, refer to 1. ABS
WHEEL SPEED SENSOR. <Ref. to ABS-18, ABS
WHEEL SPEED SENSOR, INSPECTION, Rear
ABS Wheel Speed Sensor.>
60 mV
0
60 mV
20 Hz
(1)
17.8 K
562
5%
5%
33 nF
1 nF
20 %
(2)
(2)
ABS00146
(1) Oscilloscope
(2) Terminals
ABS-19
using
spacers
(Part
No.
Front Tone Wheel

ABS
6. Front Tone Wheel

A: REMOVAL
The front tone wheel is integrated with the front
drive shaft. Refer to the section on Front Drive
Shaft.
<Ref. to DS-29, REMOVAL, Front Drive Shaft.>
B: INSTALLATION
The front tone wheel is integrated with the front
drive shaft. Refer to the section on Front Drive
Shaft
<Ref. to DS-30, INSTALLATION, Front Drive
Shaft.>
C: INSPECTION
Visually check the tone wheels teeth (44 pieces)
for cracks or dents. If necessary, replace with a
new tone wheel.
NOTE:
Replace the AC assembly with a new part if there is
any defect found on the tone wheel, since it is unitized with the AC assembly of the drive shaft.
ABS-20
Rear Tone Wheel

ABS
7. Rear Tone Wheel

A: REMOVAL
The rear tone wheel is attached to the rear hub. Refer to Rear Axle.
<Ref. to DS-21, REMOVAL, Rear Axle.>
B: INSTALLATION
The rear tone wheel is attached to the rear hub. Refer to Rear Axle.
<Ref. to DS-24, INSTALLATION, Rear Axle.>
C: INSPECTION
new tone wheel.
ABS-21
G Sensor
ABS
8. G Sensor
B: INSTALLATION
A: REMOVAL
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
CAUTION:
Do not drop or bump the G sensor.
ABS00150
2) Remove the console cover.

<Ref. to EI-38, REMOVAL, Console Box.>
3) Disconnect the connector from the G sensor.
4) Remove the G sensor from the body.
CAUTION:
Do not drop or bump the G sensor.
The G sensor integrated with the bracket. Do
not disassemble.
ABS00612
ABS-22
G Sensor
ABS
C: INSPECTION
1
2
Step
CHECK SUBARU SELECT MONITOR.
CHECK G SENSOR.
2) Remove the G sensor from vehicle.
3) Connect the connector to the G sensor.
5) Measure the voltage between G sensor
(B292) No. 2 (+) No. 3 ():
CHECK G SENSOR.
Measure the voltage between G sensor connector terminals.
(B292) No. 2 (+) No. 3 ():
CHECK G SENSOR.
(B292) No. 2 (+) No. 3 ()
CHECK G SENSOR.
3) Set the Subaru Select Monitor to the
BRAKE CONTROL mode.
4) Set the display in the {Current Data Display
& Save} mode.
5) Read the G sensor output voltage.
CHECK G SENSOR.
1) Remove the console box.
2) Remove the G sensor from vehicle. (Do not
disconnect the connector.)
3) Read the Subaru Select Monitor display.
CHECK G SENSOR.
Read the Subaru Select Monitor display.
Check
Yes
Is a Subaru Select Monitor
Go to step 5.
available?
Is the voltage 2.30.2 V when G Go to step 3.
sensor is in a horizontal position?
No
Go to step 2.
Is the voltage between 3.90.2 Go to step 4.

V when G sensor is inclined forward 90?
Replace the G sensor.
Is the voltage 0.70.2 V when

the G sensor is inclined backward 90?
G sensor is normal.
Is the indicated reading on the Go to step 6.

monitor display 00.1 m/s 2?
Is the numerical value 9.80.1 Go to step 7.

m/s2 when G sensor is inclined
forward 90?
Is the numerical value 9.80.1 G sensor is norm/s2 when G sensor is inclined mal.
back 90?
ABS-23
G Sensor
ABS
ABS-24

ABS (DIAGNOSTICS)

A: PROCEDURE
CAUTION:
Remove foreign matter (dust, water, oil etc.) from the ABSCM&H/U connector during removal and installation.
NOTE:
To check harness for broken wires or short circuits, shake the suspected trouble spot or connector.
Refer to Check List for Interview. <Ref. to ABS(diag)-4, Check List for Interview.>
1
Step
CHECK PRE-INSPECTION.
ABS(diag)-4, Check List for Interview.>
2) Before performing diagnostics, check the
components which might affect ABS problems.
<Ref. to ABS(diag)-8, INSPECTION, General
Description.>
CHECK INDICATION OF DTC ON SCREEN.
3) Turn the ignition switch to ON and run the
NOTE:
If the communication function of the Subaru Select Monitor cannot be executed normally,
check the communication circuit. <Ref. to
ABS(diag)-19, COMMUNICATION FOR INITIALIZING IMPOSSIBLE, INSPECTION, Subaru Select Monitor.>
4) Read the DTC. <Ref. to ABS(diag)-24,
OPERATION, Read Diagnostic Trouble Code
(DTC).>
5) Record all DTCs and freeze frame data.
1) Perform the inspection using General Diagnostic Table. <Ref. to ABS(diag)-69, General
Diagnostic Table.>
ABS(diag)-18, CLEAR MEMORY MODE,
ABS(diag)-25, Inspection Mode.>
READ DIAGNOSTIC TROUBLE CODE,
Check that there is no DTC displayed.
Check
Yes
Are components which might Go to step 2.
affect the ABS problem operating correctly?
No
Repair or replace
each component.
Is DTC displayed?
Go to step 3.
Go to step 4.
Does the ABS warning light go Finish the diagno- Check using ABS
off after turning the ignition
sis.
Diagnostic Proceswitch ON?
dure. <Ref. to
ABS(diag)-22,
WITHOUT DTC,
INSPECTION,
Subaru Select
Monitor.>
ABS(diag)-2

ABS (DIAGNOSTICS)
Step
PERFORM DIAGNOSIS.
1) Refer to List of Diagnostic Trouble Code
(DTC). <Ref. to ABS(diag)-35, LIST, List of
2) Correct the cause of trouble.
ABS(diag)-18, CLEAR MEMORY MODE,
ABS(diag)-25, Inspection Mode.>
Check
Is DTC displayed?
ABS(diag)-3
Yes
No
Repeat step 1 to 4 Finish the diagnountil DTC does not sis.
appear.

ABS (DIAGNOSTICS)

A: CHECK
Check the following items regarding condition of the vehicle.
1. STATE OF ABS WARNING LIGHT

ABS warning light
comes on.
Always
Sometimes
Only once
Does not come on
When and for how long does it come on?
Ignition key position
LOCK
ACC
ON (Before starting engine)
START
ON (After starting engine, while engine is running)
ON (After starting engine, engine is stopped)
Timing
Immediately after turning the ignition to ON

Immediately after turning the ignition to START
When accelerating
While driving at a constant speed
When decelerating
km/h
km/h
MPH
MPH
km/h
MPH
When turning to the right
Steering angle:
Steering time:
deg
Sec.
When turning to the left
Steering angle:
Steering time:
deg
Sec.
When other electrical parts are operating

Parts name:
Operating condition:
ABS(diag)-4

ABS (DIAGNOSTICS)
2. STATE OF BRAKE WARNING LIGHT

Brake warning light
comes on.
Always
Sometimes
Only once
Does not come on
When pulling the parking brake lever.
When releasing the parking brake lever.
When and for how long does it come on?
LOCK
ACC
ON (Before starting engine)
START
ON (After starting engine, while engine is running)
ON (After starting engine, engine is stopped)
Timing
Immediately after turning the ignition to ON

When accelerating
When decelerating
km/h
MPH
km/h
MPH
km/h
Steering angle:
MPH
deg
Steering time:
Steering angle:
Sec.
deg
Steering time:
Sec.

Parts name:
ABS(diag)-5

ABS (DIAGNOSTICS)
3. SYMPTOMS
ABS operating condition
Does not operate.

Operates only when applying the brakes suddenly.
Vehicle speed:
Procedures for stepping on the brake pedal:

a) Operating time:
b) Operating noise:
Occurs. /
What kind of noise?
Sec.
Does not occur.

Knocking
Gong gong
Thump
Buzz
Gong gong buzz
Others :
c) Reaction force of brake pedal
Condition of vehicle
Sticks
Weak pedal resistance
Strong pedal resistance
Others :
a) Directional stability cannot be obtained or the steering does not respond when applying brakes:
Yes /
No
When:
When spinning out
Others :
b) Directional stability cannot be obtained or the steering does not respond when accelerating:
Yes /
No
When:
When spinning out
Others :
c) Poor brake performance:
What kind:
d) Poor acceleration:
Yes /
Yes /
No
Braking distance is long.
Brakes lock or drag.
Pedal stroke is long.
Pedal sticks.
Others :
No
What kind:
Fails to accelerate.
Engine stalls.
Others :
e) Occurrence of vibration:
Yes /
No
Where
What kind:
Yes /
No
Where
What kind:
g) Other troubles occurred:
What kind:
Yes /
No
ABS(diag)-6
km/h
MPH

ABS (DIAGNOSTICS)
4. CONDITIONS UNDER WHICH TROUBLE OCCURS

Environment
a) Weather
Fine
Cloudy
Rainy
Snowy
Others :
b) Ambient temperature
C (F)
c) Road
a) Brakes
Inner city
Suburbs
Highway
Local street
Uphill
Downhill
Paved road
Gravel road
Muddy road
Sandy place
Others :
Dry
Wet
Covered with fresh snow
Covered with hardened snow
Frozen slope
Others :
Deceleration:
Temporary
b) Accelerator
Intermittent /
Acceleration:
Intermittent /
Temporary
km/h
d) Road surface
Condition
c) Vehicle speed
d) Tire inflation pressure
e) Degree of wear
kPa
Front LH tire:
Rear RH tire:
kPa
kPa
Rear LH tire:
Front RH tire:
kPa
Front LH tire:
Rear RH tire:
Rear LH tire:
f) Genuine parts are used.:
Yes /
No
g) Tire chain is attached:

Yes /
No
h) T-type tire is used.:
Yes /
No
i) Condition of suspension alignment:
j) Loaded state:
k) Repair parts are used.:
Contents:
Yes /
No
l) Others:
ABS(diag)-7
MPH
Advancing
When accelerating
When decelerating
At low speed
When turning
Others :
Front RH tire:
General Description
ABS (DIAGNOSTICS)
Rear <Ref. to BR-21, INSPECTION, Rear Brake

Pad.> <Ref. to BR-23, INSPECTION, Rear Disc
Rotor.>
A: CAUTION
AIRBAG
Airbag system wiring harness is routed near the
ABS wheel speed sensor and ABSCM&H/U.
7. TIRE
Check the tire specifications, tire wear and air pressure. <Ref. to WT-2, SPECIFICATION, General
Description.>
CAUTION:
All airbag system wiring harness and connectors are colored yellow. Do not use the electrical test equipment on these circuits.
wiring harness when servicing the ABS wheel
speed sensor and ABSCM&H/U.
B: INSPECTION
Before performing diagnosis, check the following
item which might affect ABS problems.
1. BATTERY
Measure the battery voltage and check electrolyte.
Standard voltage:
12 V or more
Specific gravity:
1.260 or more
2. GROUND
Check the tightness of ABS ground (B302) bolt.
3. BRAKE FLUID
1) Check the brake fluid level.
2) Check the brake fluid for leaks.
4. HYDRAULIC UNIT
Check the hydraulic unit.
When using the brake tester <Ref. to ABS-10,
CHECKING THE HYDRAULIC UNIT ABS OPERATION WITH THE BRAKE TESTER, INSPECTION,
ABS Control Module and Hydraulic Control Unit
(ABSCM&H/U).>
When not using the brake tester <Ref. to ABS-9,
CHECKING THE HYDRAULIC UNIT ABS OPERATION BY PRESSURE GAUGE, INSPECTION,
ABS Control Module and Hydraulic Control Unit
(ABSCM&H/U).>
5. BRAKE DRAG
Check for brake drag.
6. BRAKE PAD AND ROTOR

Check the brake pad and rotor.
Front <Ref. to BR-16, INSPECTION, Front Brake
Pad.> <Ref. to BR-17, INSPECTION, Front Disc
Rotor.>
ABS(diag)-8
General Description
ABS (DIAGNOSTICS)
C: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
1B020XU0
Description
SUBARU SELECT
MONITOR KIT
REMARKS
Used for diagnosing the electrical system.
ST1B020XU0
2. GENERAL TOOL
TOOL NAME
Circuit tester
Oscilloscope
REMARKS
ABS(diag)-9

ABS (DIAGNOSTICS)

A: LOCATION
(6)
(5)
(11)
(3)
(7)
(10)
(1)
(11)
(3)
(2)
(2)
(12)
(8)
(9)
(2)
(4)
(3)
(11)
(11)
(2)
(3)
ABS00850
(1)

(6)
Brake warning light (EBD warning

light)
(2)
(3)
ABS wheel speed sensor

Tone wheel
(7)
Data link connector
(4)
(5)
Master cylinder
ABS warning light
(8)
(9)
G sensor
Stop light switch
ABS(diag)-10
(10)
Proportioning valve (Model without EBD)
(11)
(12)
Caliper body
Transmission control module (for
AT model only)

ABS (DIAGNOSTICS)
(1)
(6)
(5)
ABS00579
ABS00551
(8)
(7)
ABS00618
ABS00580
REAR
FRONT
(3)
(2)
(2)
ABS00019
ABS(diag)-11
(3)
ABS00028
Control Module I/O Signal

ABS (DIAGNOSTICS)
5. Control Module I/O Signal

(1)
B301
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
ABS00620
(1)

connector
NOTE:
Terminal numbers in ABSCM&H/U connector are shown in the figure.
ABS warning light illuminates when the connector is removed from ABSCM&H/U.
ABS(diag)-12

ABS (DIAGNOSTICS)
Front LH wheel
Terminal No.
(+) ()
1 16
Front RH wheel
Rear LH wheel
65
32
Description
(Wheel speed sensor)
Input/Output signal
0.12 1 V (at 20 Hz)
Rear RH wheel
CAN communication circuit (+) (for AT models only)
19 4
26
2.5 1.5 V pulse signal
CAN communication circuit () (for AT models only)

Valve relay power supply *1
11
14 15
3.5 2.5 V pulse signal

10 15 V
Motor relay power supply *1

Power supply
13 15
24 10
10 15 V
4.75 5.25 V
G Sensor
10
21 10
2.1 2.5 V when the vehicle is on level surface
Stop light switch *1
20 15
Less than 1.5 V when the stop light is OFF; otherwise,

10 15 V when the stop light is ON.
ABS warning light
22 15
Brake warning light (EBD warning light)
8 15
7 15
Power supply *1
18 15
After turning the ignition switch ON, 10 15 V during

1.5 seconds and less than 1.5 V after 1.5 seconds passed.
After turning the ignition switch ON, 10 15 V during
1.5 seconds and less than 1.5 V after 1.5 seconds passed.
Less than 1.5 V when no data is received.
0 12 V pulse (in communication)
10 15 V when the ignition switch is ON.
15
Grounding line
Ground
Output
*1: Measure the I/O signal voltage after removing the connector from the ABSCM&H/U terminal.
ABS(diag)-13

ABS (DIAGNOSTICS)
B: WIRING DIAGRAM
(3)
(28)
(5)
(1)
(29)
(18)
(19)
(2)
(6)
(20)
(16)
(17)
(4)
(21)
M
(22)
(7)
(8)
(9)
(23)
(10)
(11)
(12)
(24)
(13)
(25)
(14)
(26)
(15)
(27)
ABS00895
(1)
Battery
(11)
Front outlet solenoid valve RH
(21)
Stop light switch
(2)
(3)
Ignition switch
(12)
(13)
Rear inlet solenoid valve LH

Rear outlet solenoid valve LH
(22)
(23)
Stop light
G Sensor
Front ABS wheel speed sensor RH
(4)
ABS control module
(14)
Rear inlet solenoid valve RH
(24)
(25)
(5)
(6)
Valve relay
Motor relay
(15)
(16)
Rear outlet solenoid valve RH

Parking brake switch
(26)
(27)
Rear ABS wheel speed sensor LH

Rear ABS wheel speed sensor RH
(7)
(8)
Motor
Front inlet solenoid valve LH
(17)
(18)
Brake fluid level switch

Data link connector
(28)

(AT models)
(9)
(10)
Front outlet solenoid valve LH

Front inlet solenoid valve RH
(19)
(20)
ABS warning light

Brake warning light
(29)
Engine control module
ABS(diag)-14

ABS (DIAGNOSTICS)
C: WAVEFORM
(1)
[V]
(2)
9 10
11 12
7 8
14 15
(3) 20 Hz:0.12 1 V
20 Hz
ABS00400

(2) Terminal No.
(3) Standard output voltage
ABS(diag)-15

ABS (DIAGNOSTICS)

A: OPERATION
ABS(diag)-9, SPECIAL TOOL, PREPARATION
TOOL, General Description.>
2) Connect the diagnosis cable to Subaru Select
Monitor.
link connector.
side).
If a particular DTC is not stored in memory properly at the occurrence of problem (due to a drop in
ABSCM&H/U power supply etc.), the DTC suffixed
with a question mark ? is displayed on Subaru Select Monitor display screen. This shows it may be
an unreliable reading.
9) If communication is not possible between the
ABS and the Subaru Select Monitor, check the
communication circuit. <Ref. to ABS(diag)-19,
COMMUNICATION FOR INITIALIZING IMPOSSIBLE, INSPECTION, Subaru Select Monitor.>
10) When DTC is not displayed, check the meter
circuit and the CAN communication circuit. <Ref. to
ABS(diag)-22, WITHOUT DTC, INSPECTION,
Display
Contents to be monitored
The current DTC is displayed on Subaru
Current
Select Monitor display screen.
The latest DTC from the history of previPrevious
ous problems is displayed on Subaru
The second latest DTC from the history
Second previous of previous problems is displayed on the
Subaru Select Monitor display screen.
(1)
ABS00113
Third previous
(1) Data link connector
(2) Connect the diagnosis cable to data link

connector.
CAUTION:
Do not connect the scan tools other than the
screen, select {Brake Control}.
7) Select the [OK] after the {ABS} is displayed.
8) On the ABS Diagnosis screen, select {DTC
Display}.
NOTE:
For details concerning operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
For details concerning DTCs, refer to List of Diagnostic Trouble Code (DTC). <Ref. to ABS(diag)35, List of Diagnostic Trouble Code (DTC).>
Up to 3 DTCs are displayed in the order of detection.
ABS(diag)-16
The third latest DTC from the history of

previous problems is displayed on Subaru Select Monitor display screen.

ABS (DIAGNOSTICS)

2) On the System Selection Menu display screen, select the {Brake Control}.
3) Select the [OK] after {ABS} is displayed.
4) On the Brake Control Diagnosis display screen, select the {Current Data Display/Save}.
5) On the Display Menu screen, select the data display method.
6) Using the scroll key, scroll the display screen up or down until necessary data is shown.
Display
FR Wheel Speed
FL Wheel Speed
RR Wheel Speed
Wheel speed detected by front ABS wheel speed sensor RH is displayed.
Wheel speed detected by front ABS wheel speed sensor LH is displayed.
Wheel speed detected by rear ABS wheel speed sensor RH is displayed.
Unit of measure
km/h or MPH
km/h or MPH
km/h or MPH
RL Wheel Speed
Wheel speed detected by rear ABS wheel speed sensor LH is displayed.
BLS Signal
G Sensor
Brake ON/OFF is displayed.

Vehicle acceleration detected by analog G sensor is displayed.
ON or OFF
m/s (m/s2)
Valve Relay Signal

ABS Warning Light
Valve relay operation signal is displayed.

ON operation of the ABS warning light is displayed.
ON or OFF
ON or OFF
EBD Warning Light

Motor Relay Monitor
ON operation of the EBD warning light is displayed.

Motor relay monitor voltage is displayed.
ON or OFF
V
IG power supply voltage

ABS Control Flag
Voltage supplied to ABSCM&H/U is displayed.

ABS control condition is displayed.
V
ON or OFF
ABS OK B Signal
ABS system normal/abnormal is displayed.
OK or NG
km/h or MPH
NOTE:
ABS(diag)-17

ABS (DIAGNOSTICS)
5. FREEZE FRAME DATA

{2. Each System Check}.
screen, select the {Brake Control}.
3) Select the [OK] after {ABS} is displayed.
4) On the Brake Control Diagnosis display
screen, select {Clear Memory}.
NOTE:
Data stored at the time of trouble occurrence is
shown on the display.
Each time a trouble occurs, the latest information
is stored in the freeze frame data in memory.
Up to 3 freeze frame data will be stored.
If freeze frame data is not stored in memory
properly (due to a drop in ABS control module power supply etc.), a DTC suffixed with a question mark
? is displayed on Subaru Select Monitor display
screen. This shows it may be an unreliable reading.
Display
Clear memory?
DTC deleting function
5) When Done and Turn ignition switch OFF is

shown on the display screen, turn the ignition
switch OFF and close the Subaru Select Monitor.
NOTE:
For details concerning operation procedure, refer
to the SUBARU SELECT MONITOR OPERATION
MANUAL.
4. ABS SEQUENCE CONTROL

Display
ABS
sequence
control
Operate the valve and
pump motor continuously
to perform the ABS
sequence control.
Index No.
<Ref. to ABS-11,
ABS Sequence
Control.>
Display
Wheel speed detected by front ABS
FR Wheel
wheel speed sensor RH is displayed in
Speed
km/h or MPH.
Wheel speed detected by front ABS
FL Wheel Speed wheel speed sensor LH is displayed in
km/h or MPH.
Wheel speed detected by rear ABS
RR Wheel
wheel speed sensor RH is displayed in
Speed
km/h or MPH.
RL Wheel
Speed
Wheel speed detected by rear ABS

wheel speed sensor LH is displayed in
km/h or MPH.
IG power supply
voltage
Voltage supplied (V) to ABSCM&H/U is

displayed.
G Sensor
Vehicle acceleration detected by analog

G sensor is displayed.
Motor Relay
Monitor
BLS Signal
Vehicle speed
ABS Control
Flag
Power Supply
Failure
ABS(diag)-18
Motor relay condition is displayed.

Brake ON/OFF is displayed.
Vehicle speed calculated by ABS control
module is displayed.
ABS control condition is displayed.
Whether abnormal voltage occurred or
not is displayed during malfunction.

ABS (DIAGNOSTICS)
B: INSPECTION
1. COMMUNICATION FOR INITIALIZING IMPOSSIBLE
TROUBLE SYMPTOM:
Communication is impossible between ABS and Subaru Select Monitor.
WIRING DIAGRAM:
SBF-1
BATTERY
SBF-4
SBF-5
F44
B61
IGNITION
SWITCH
DATA LINK
CONNECTOR
16
7
No.18
B40
B301
ABSCM & H/U
B301
B40
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
15
18
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
F44
1 2 3
5 6 7
4
8
ABS00904
ABS(diag)-19

ABS (DIAGNOSTICS)
10
Step
Check
Is the ignition switch ON?
Yes
Go to step 2.
CHECK BATTERY.
2) Measure the battery voltage.
Go to step 3.

tery terminal?
CHECK SUBARU SELECT MONITOR COM- Are the system name and
Go to step 8.
MUNICATION.
model year displayed on Sub1) Turn the ignition switch to ON.
aru Select Monitor?
whether communication to other systems can
Replace the
MUNICATION.
model year displayed on Sub- ABSCM&H/U.
aru Select Monitor?
<Ref. to ABS-6,
2) Disconnect the ABSCM&H/U connectors.
ABS Control Mod3) Turn the ignition switch to ON.
ule and Hydraulic
4) Check whether communication to other sysControl Unit
tems can be executed normally.
(ABSCM&H/U).>
Go to step 7.
EACH CONTROL MODULE AND DATA LINK more?
CONNECTOR.
2) Disconnect the ABSCM&H/U, ECM and
TCM.
CHECK OUTPUT SIGNAL FOR ABSCM&H/ Is the voltage less than 1 V?
Go to step 8.
U.
2) Measure the voltage between ABSCM&H/U
CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 0.5 Go to step 9.
ABSCM&H/U AND DATA LINK CONNEC?
TOR.
Measure the resistance between ABSCM&H/U
connector and data link connector.
(B301) No. 7 (B40) No. 7:
CHECK INSTALLATION OF ABSCM&H/U
Is the ABSCM&H/U connector Go to step 10.
CONNECTOR.
inserted into ABSCM&H/U until
the clamp locks onto it?
CHECK POWER SUPPLY CIRCUIT.
Go to step 11.
1) Turn the ignition switch to ON. (Engine OFF)
between ABSCM&H/U connector and chassis
ground.
ABS(diag)-20
No
Turn the ignition
switch to ON, and
select ABS mode
using Subaru
Select Monitor.
Charge or replace
the battery.
Go to step 4.
Go to step 5.
Go to step 6.
Repair the harness

and connector
Repair the harness

and connector
Repair harness
and connector
between
ABSCM&H/U and
Insert ABSCM&H/
U connector into
ABSCM&H/U.
Repair open circuit
of harness
between
ABSCM&H/U and
battery.

ABS (DIAGNOSTICS)
11
12
Step
Check
Yes
CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 0.5 Go to step 12.
ABSCM&H/U AND CHASSIS GROUND.
?
between ABSCM&H/U and chassis ground.
CHECK POOR CONTACT OF CONNECTOR. Is there poor contact in control Repair the connecmodule power supply, ground tor.
circuit and data link connector?
ABS(diag)-21
No
Repair the open
ABSCM&H/U and
inhibitor side connector, and poor
contact of coupling
connector.
Replace the
ABSCM only. <Ref.
to ABS-7,
REPLACEMENT,
ABS Control Module and Hydraulic
Control Unit
(ABSCM&H/U).>

ABS (DIAGNOSTICS)
2. WITHOUT DTC
Defective combination meter
Open circuit of harness
TROUBLE SYMPTOM:
ABS warning light does not go off.
NO TROUBLE CODE will be displayed on the Subaru Select Monitor.
NOTE:
When the ABS warning light is OFF and NO TROUBLE CODE is displayed on Subaru Select Monitor, the
system is in normal condition.
WIRING DIAGRAM:
BATTERY
SBF-1
SBF-4
IGNITION
SWITCH
B36
i1
No.14
ABS
WARNING
LIGHT
BRAKE
WARNING
LIGHT
No.18
B9
C3
C6
23
i3
C:
i11
22
B301
ABSCM & H/U
B301
i10
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
15
B36
18
i10
i1
B38
B:
B:
REVERSE
CIRCUIT
26
REVERSE
CIRCUIT
COMBINATION
METER
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
B36
B38
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
C:
i11
1 2 3 4 5 6 7 8 9 10
ABS00783
ABS(diag)-22

ABS (DIAGNOSTICS)
Step
Check
CHECK SUBARU SELECT MONITOR DATA. Is ON indicated?
1) Select {Current Data Display & Save} in
2) Read the condition of ABS warning light.
Yes
No
Replace the
Go to step 2.
ABSCM only. <Ref.
to ABS-7,
REPLACEMENT,
Control Unit
(ABSCM&H/U).>
CHECK WIRING HARNESS.
Is the resistance less than 0.5 Go to step 3.
Repair harness
Measure the resistance between ABSCM con- ?
and connector
nector and combination meter connector.
between
ABSCM&H/U and
(i11) No. 6 (B301) No. 22:
combination meter.
CHECK POOR CONTACT OF CONNECTOR. Is there poor contact in ABSCM Repair the connec- Check the combiconnector and combination
tor.
nation meter.
meter connector?
ABS(diag)-23

ABS (DIAGNOSTICS)

Code (DTC)
A: OPERATION
For details about reading of DTCs, refer to Subaru
Select Monitor. <Ref. to ABS(diag)-16, Subaru Select Monitor.>
ABS(diag)-24
Inspection Mode
ABS (DIAGNOSTICS)
8. Inspection Mode
A: PROCEDURE
Reproduce the malfunction occurrence condition
as much as possible.
Drive the vehicle at a speed more than 40 km/h (25
MPH) for at least one minute.
ABS(diag)-25
Clear Memory Mode

ABS (DIAGNOSTICS)

A: OPERATION
For details concerning DTC clear operation, refer to
Subaru Select Monitor. <Ref. to ABS(diag)-16,
ABS(diag)-26
ABS Warning Light / Brake Warning Light Illumination Pattern

ABS (DIAGNOSTICS)
10.ABS Warning Light / Brake Warning Light Illumination Pattern

A: INSPECTION
(4)
(3)
(3)
(2)
(1)
(7)
(6)
(6)
(5)
(8)
(7)
(6)
(6)
(9)
(10)
(11)
ABS00442
(1)
Ignition switch
(5)
ABS warning light
(9)

light)
(2)
(3)
OFF
ON
(6)
(7)
Light OFF
Light ON
(10)
(11)
Parking brake
Released
(4)
Start
(8)
Approx. 2 sec.
ABS(diag)-27

ABS (DIAGNOSTICS)
1) When the ABS warning light and brake warning light do not illuminate in accordance with this illumination
pattern, it can be thought that there is an electrical problem.
2) When the ABS warning light remains constantly OFF, check the combination meter circuit. <Ref. to
ABS(diag)-29, ABS WARNING LIGHT DOES NOT COME ON, ABS Warning Light / Brake Warning Light Illumination Pattern.>
3) When the ABS warning light does not go off, check the combination meter circuit. <Ref. to ABS(diag)-31,
ABS WARNING LIGHT DOES NOT GO OFF, ABS Warning Light / Brake Warning Light Illumination Pattern.>
4) When the brake warning light does not go off, check the brake warning circuit and the combination meter
circuit. <Ref. to ABS(diag)-33, BRAKE WARNING LIGHT DOES NOT GO OFF, ABS Warning Light / Brake
Warning Light Illumination Pattern.>
NOTE:
Even though the ABS warning light does not go off after approximately 2 seconds from ABS warning light illumination, the ABS function operates normally when the warning light goes off while driving at approximately
12 km/h (7 MPH). However, the ABS system does not work while the ABS warning light is illuminated.
ABS(diag)-28

ABS (DIAGNOSTICS)
B: ABS WARNING LIGHT DOES NOT COME ON

Defective harness
TROUBLE SYMPTOM:
When the ignition switch is turned ON (engine OFF), ABS warning light does not come on.
WIRING DIAGRAM:
BATTERY
SBF-1
SBF-4
IGNITION
SWITCH
B36
i1
No.14
ABS
WARNING
LIGHT
BRAKE
WARNING
LIGHT
No.18
B9
C3
C6
23
i3
C:
i11
22
B301
ABSCM & H/U
B301
i10
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
15
B36
18
i10
i1
B38
B:
B:
REVERSE
CIRCUIT
26
REVERSE
CIRCUIT
COMBINATION
METER
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
B36
B38
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
C:
i11
1 2 3 4 5 6 7 8 9 10
ABS00783
ABS(diag)-29

ABS (DIAGNOSTICS)
1
2
Step
CHECK ILLUMINATION OF OTHER LIGHTS.
Turn the ignition switch to ON. (Engine OFF)
READ DTC.
Read the DTC. <Ref. to ABS(diag)-24, Read
CHECK GROUND SHORT OF HARNESS.
1) Turn the ignition OFF.
2) Disconnect the connector (B301) from the
ABSCM&H/U.
3) Disconnect the connector (i11) from combination meter.
4) Measure the resistance between ABSCM
CHECK ABSCM.
1) Connect the connector (B301) to the
ABSCM&H/U.
2) Turn the ignition ON.
3) Immediately after turning ignition switch ON
(within approximately 2 seconds), measure the
resistance of harness between the combination
Check
Do other warning lights illuminate?
Is DTC displayed?
Yes
Go to step 2.
No
Go to step 3.
more?
Perform the diagnosis according to

DTC.
Go to step 4.
Repair harness
and connector
between
ABSCM&H/U and
combination meter.
more?
ABS(diag)-30
Replace the
ABSCM only. <Ref.
to ABS-7,
REPLACEMENT,
Control Unit
(ABSCM&H/U).>

ABS (DIAGNOSTICS)
C: ABS WARNING LIGHT DOES NOT GO OFF

TROUBLE SYMPTOM:
When starting the engine, the ABS warning light is kept on.
WIRING DIAGRAM:
BATTERY
SBF-1
SBF-4
IGNITION
SWITCH
B36
i1
No.14
ABS
WARNING
LIGHT
BRAKE
WARNING
LIGHT
No.18
B9
C3
C6
23
i3
C:
i11
22
B301
ABSCM & H/U
B301
i10
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
15
B36
18
i10
i1
B38
B:
B:
REVERSE
CIRCUIT
26
REVERSE
CIRCUIT
COMBINATION
METER
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
B36
B38
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
C:
i11
1 2 3 4 5 6 7 8 9 10
ABS00783
ABS(diag)-31

ABS (DIAGNOSTICS)
3
4
Step
READ DTC.
1) Turn the ignition OFF.
ABSCM&H/U.
4) Measure the resistance between ABSCM
connector and combination meter connector.
(B301) No. 22 (i11) No. 6:
CHECK POOR CONTACT OF CONNECTOR.
Check for poor contact in all connectors.
CHECK ABSCM.
1) Connect the connector (B301) to the
ABSCM&H/U.
3) Measure the resistance between combination meter connector and chassis ground.
Check
Is DTC displayed?
Is the resistance less than 0.5

?

?
ABS(diag)-32
Yes
No
nosis according to
DTC.
Go to step 3.
Repair the harness
connector between
ABSCM&H/U and
combination meter.

tor.
Check the combi- Replace the
nation meter.
ABSCM only. <Ref.
to ABS-7,
REPLACEMENT,
Control Unit
(ABSCM&H/U).>

ABS (DIAGNOSTICS)
D: BRAKE WARNING LIGHT DOES NOT GO OFF

Brake warning light circuit is shorted.
Defective sensor/connector
TROUBLE SYMPTOM:
After starting the engine, the brake warning light remains lit though the parking lever is released.
NOTE:
If the ABS warning light is lit, perform the diagnosis of ABS WARNING LIGHT DOES NOT GO OFF, then
the diagnosis of BRAKE WARNING LIGHT DOES NOT GO OFF after repairing it. <Ref. to ABS(diag)-31,
ABS WARNING LIGHT DOES NOT GO OFF, ABS Warning Light / Brake Warning Light Illumination Pattern.>
WIRING DIAGRAM:
BATTERY
SBF-4
SBF-1
IGNITION
SWITCH
No.14
B36
i1
31
i12
i10
C:
i11
C3
A7
BRAKE FLUID
LEVEL SWITCH
A:
REVERSE
B:
CIRCUIT
i3
26
BRAKE
WARNING
LGINT
B9
B38
1
2
DIODE
B99
B16
3
4
R3
24
B301
B95
DAYTIME RUNNING
LIGHT CONTROL MODULE
ABSCM & H/U
R4
6
10
PARKING BRAKE
SWITCH
B96
E
B16
B38
B301
1
2
12 13 14 15
B:
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
i10
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
C:
B36
i11
1 2 3 4 5 6 7 8 9 10
A:
B99
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
i12
B95
B96
1 2 3
4 5 6
7 8 9 10 11 12 13 14
1 2 3 4
1 2 3 4 5
6 7 8 9 10
ABS00784
ABS(diag)-33

ABS (DIAGNOSTICS)
8
9
Step
CHECK INSTALLATION OF ABSCM&H/U
CONNECTOR.
2) Check that the ABSCM&H/U connector is
inserted to ABSCM&H/U until the clamp locks
onto it.
READ DTC.
CHECK BRAKE FLUID AMOUNT.
Check the amount of brake fluid in the reservoir
tank of the master cylinder.
CHECK BRAKE FLUID LEVEL SWITCH.
1) Disconnect the level switch connector (B16)
from master cylinder.
2) Measure the resistance of master cylinder
terminals.
Terminals
No. 1 No. 2:
CHECK PARKING BRAKE SWITCH.
1) Disconnect the connector (R4) from parking
brake switch.
3) Measure the resistance between parking
brake switch terminal and chassis ground.
CHECK HARNESS.
ABSCM&H/U.
3) Measure the resistance between the
ABSCM&H/U connector and combination
meter connector.
(B301) No. 8 (i11) No. 3:
Check for poor contact in all connectors.
CHECK ABSCM.
1) Connect the connector to ABSCM&H/U.
Check
Is the connector firmly
inserted?
Yes
Go to step 2.
No
Insert the
ABSCM&H/U connector until the
clamp locks completely.
Is DTC displayed?

nosis according to
DTC.
Is the amount of brake fluid
Go to step 4.
Replenish brake
between the lines of MAX and
fluid to the speciMIN?
fied value.
Go to step 5.
Replace the masmore?
ter cylinder.
more?
Go to step 6.
Replace the parking brake switch.
more?
Go to step 7.
Repair the harness

connector between
combination meter
and parking brake
switch.

?
Go to step 8.
Repair the harness

between the
ABSCM&H/U and
the combination
meter.

tor.
Check the combi- Replace the
nation meter.
ABSCM only. <Ref.
to ABS-7,
REPLACEMENT,
Control Unit
(ABSCM&H/U).>

?
ABS(diag)-34

ABS (DIAGNOSTICS)

A: LIST
DTC
Content of diagnosis
Display
Reference target
Front Right ABS Sensor Circuit Open or

Shorted Battery
<Ref. to ABS(diag)-38, DTC 21 ABS

WHEEL SPEED SENSOR MALFUNCTION
FR SENSOR (BROKEN WIRE, INPUT
VOLTAGE TOO HIGH), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
21
ABS wheel speed senFront ABS wheel

sor malfunction (Brospeed sensor RH
ken wire, short)
22
ABS wheel speed senAbnormal signal of

sor malfunction (ABS
front ABS wheel speed
wheel speed sensor
sensor RH
abnormal signal)
Front Right ABS Sensor Signal
23
ABS wheel speed senFront ABS wheel

sor malfunction (Brospeed sensor LH
ken wire, short)
Front Left ABS Sensor

Circuit Open or
Shorted Battery
24

front ABS wheel speed
wheel speed sensor
sensor LH
abnormal signal)
Front Left ABS Sensor

Signal
25
ABS wheel speed senRear ABS wheel

sor malfunction (Brospeed sensor RH
ken wire, short)
Rear Right ABS Sensor Circuit Open or

Shorted Battery

RR SENSOR (BROKEN WIRE, INPUT
26

rear ABS wheel speed
wheel speed sensor
sensor RH
abnormal signal)
Rear Right ABS Sensor Signal
<Ref. to ABS(diag)-43, DTC 26 REAR ABS

WHEEL SPEED SENSOR RH MALFUNCTION (ABS WHEEL SPEED SENSOR
ABNORMAL SIGNAL), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
27
ABS wheel speed senRear ABS wheel

sor malfunction (Brospeed sensor LH
ken wire, short)
Rear Left ABS Sensor

Circuit Open or
Shorted Battery
28
29
31
Abnormal signal of
rear ABS wheel speed
ABS wheel speed sensensor LH
wheel speed sensor
abnormal signal)
Abnormal ABS wheel
speed sensor on any
one of four sensors
Inlet valve malfunction

in hydraulic unit
Front inlet valve RH
Rear Left ABS Sensor

Signal
Any One of Four ABS

Sensors Signal
FR Hold Valve malfunction
ABS(diag)-35
<Ref. to ABS(diag)-43, DTC 22 FRONT ABS

WHEEL SPEED SENSOR RH MALFUNCTION (ABS WHEEL SPEED SENSOR
FL SENSOR (BROKEN WIRE, INPUT
<Ref. to ABS(diag)-43, DTC 24 FRONT ABS
WHEEL SPEED SENSOR LH MALFUNCTION (ABS WHEEL SPEED SENSOR

RL SENSOR (BROKEN WIRE, INPUT
<Ref. to ABS(diag)-44, DTC 28 REAR ABS
WHEEL SPEED SENSOR LH MALFUNCTION (ABS WHEEL SPEED SENSOR
WHEEL SPEED SENSOR SIGNAL MALFUNCTION IN ONE OF FOUR WHEELS,
<Ref. to ABS(diag)-51, DTC 31 FRONT
INLET SOLENOID VALVE RH MALFUNCTION IN ABS CONTROL MODULE AND
HYDRAULIC CONTROL UNIT (ABSCM&H/
U), Diagnostic Procedure with Diagnostic

ABS (DIAGNOSTICS)
DTC
32
33
Outlet valve malfunction in hydraulic unit

in hydraulic unit
Display
Front outlet valve RH
Front inlet valve LH
FR Pressure Reducing
Valve malfunction
FL Hold Valve malfunction

INLET SOLENOID VALVE LH MALFUNCTION IN ABS CONTROL MODULE AND
34
Front outlet valve LH
FL Pressure Reducing
Valve malfunction
35

in hydraulic unit
Rear inlet valve RH
RR Hold Valve malfunction
36
Rear outlet valve RH
RR Pressure Reducing Valve malfunction
37

in hydraulic unit
Rear inlet valve LH
RL Hold Valve malfunction
38
Rear outlet valve LH
Reference target
OUTLET SOLENOID VALVE RH MALFUNCTION IN ABS CONTROL MODULE
AND HYDRAULIC CONTROL UNIT
(ABSCM&H/U), Diagnostic Procedure with
RL Pressure Reducing Valve malfunction

OUTLET SOLENOID VALVE LH MALFUNCTION IN ABS CONTROL MODULE AND
<Ref. to ABS(diag)-51, DTC 35 REAR
INLET SOLENOID VALVE RH MALFUNCTION IN ABS CONTROL MODULE AND
<Ref. to ABS(diag)-51, DTC 36 REAR OUTLET SOLENOID VALVE RH MALFUNCTION IN ABS CONTROL MODULE AND
<Ref. to ABS(diag)-51, DTC 37 REAR
INLET SOLENOID VALVE LH MALFUNCTION IN ABS CONTROL MODULE AND
<Ref. to ABS(diag)-52, DTC 38 REAR OUTLET SOLENOID VALVE LH MALFUNCTION
IN ABS CONTROL MODULE AND
<Ref. to ABS(diag)-54, DTC 41 ABS CONTROL MODULE MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to ABS(diag)-56, DTC 42 POWER
VOLTAGE MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
41
ABS control module malfunction
ECM
42
Power voltage malfunction
Power Supply Voltage

Failure
47
Defective CAN communication line
CAN communication
link
<Ref. to ABS(diag)-58, DTC 47 IMPROPER

CAN COMMUNICATION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
51
Defective valve relay
Valve Relay
<Ref. to ABS(diag)-60, DTC 51 VALVE

RELAY MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
ABS(diag)-36

ABS (DIAGNOSTICS)
DTC
Display
52
Motor/motor relay on failure
54
Stop light switch circuit malfunction
56
Faulty G sensor output voltage or output signal

error
Reference target
<Ref. to ABS(diag)-62, DTC 52 MOTOR/

MOTOR RELAY MALFUNCTION, DiagnosMotor and Motor Relay
tic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to ABS(diag)-64, DTC 54 FAULTY
Brake Light Switch
STOP LIGHT SWITCH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to ABS(diag)-66, DTC 56 G SENSOR
OUTPUT VOLTAGE MALFUNCTION, DiagG Sensor Failure
nostic Procedure with Diagnostic Trouble
Code (DTC).>
ABS(diag)-37

ABS (DIAGNOSTICS)

A: DTC 21 ABS WHEEL SPEED SENSOR MALFUNCTION FR SENSOR (BROKEN WIRE, INPUT VOLTAGE TOO HIGH)
NOTE:
Refer to DTC 27 for diagnostic procedure. <Ref. to ABS(diag)-39, DTC 27 ABS WHEEL SPEED SENSOR
MALFUNCTION RL SENSOR (BROKEN WIRE, INPUT VOLTAGE TOO HIGH), Diagnostic Procedure with
B: DTC 23 ABS WHEEL SPEED SENSOR MALFUNCTION FL SENSOR (BROKEN WIRE, INPUT VOLTAGE TOO HIGH)
NOTE:
C: DTC 25 ABS WHEEL SPEED SENSOR MALFUNCTION RR SENSOR (BROKEN WIRE, INPUT VOLTAGE TOO HIGH)
NOTE:
ABS(diag)-38

ABS (DIAGNOSTICS)
D: DTC 27 ABS WHEEL SPEED SENSOR MALFUNCTION RL SENSOR (BROKEN WIRE, INPUT VOLTAGE TOO HIGH)
Defective ABS wheel speed sensor (broken wire, input voltage too high)
TROUBLE SYMPTOM:
ABS does not operate.
WIRING DIAGRAM:
19
7
TWISTED PAIR LINE
F45
B6
B99
R73
F94
F45
6
19
TWISTED PAIR LINE
R72
TWISTED
PAIR LINE
R3
B6
1
2
R72
1
2
R73
1
2
1
2
FRONT ABS
WHEEL SPEED
SENSOR LH
FRONT ABS
WHEEL SPEED
SENSOR RH
REAR ABS
WHEEL SPEED
SENSOR LH
REAR ABS
WHEEL SPEED
SENSOR RH
B301
12
2 1
17
18
B99
F94
2 1
TWISTED PAIR LINE
3
2
TWISTED PAIR LINE
TWISTED PAIR LINE
TWISTED PAIR LINE

B62
19
4
ABSCM & H/U
6
5
1
16
B301
13
14
15
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
ABS(diag)-39
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
ABS00896

ABS (DIAGNOSTICS)
Step
CHECK OUTPUT OF ABS WHEEL SPEED
SENSOR USING SUBARU SELECT MONITOR.
2) Read the ABS wheel speed sensor output
corresponding to the faulty system in Subaru
Select Monitor display mode.
CHECK INSTALLATION OF ABS WHEEL
SPEED SENSOR.
Check
Yes
Does the speed indicated on
Go to step 2.
the display change in response
to the speedometer reading
during acceleration or deceleration when the steering wheel
is in the straight-ahead position?
Is the ABS wheel speed sensor Go to step 3.
installation bolt tightened to 33
Nm (3.3 kgf-m, 24 ft-lb)?
CHECK ABS WHEEL SPEED SENSOR GAP. Is the gap within the following?
Measure the gap between the ABS wheel
Front wheel: 0.3 0.8 mm
speed sensor protrusion and tone wheel.
(0.012 0.031 in); Rear
wheel: 0.7 1.2 mm (0.028
0.047 in)
CHECK TONE WHEEL RUNOUT.

Measure the tone wheel runout.
CHECK POOR CONTACT OF CONNECTOR. Is there poor contact in connecTurn the ignition switch to OFF.
tors between ABSCM&H/U and
ABS wheel speed sensor?
CHECK ABSCM&H/U.
Is the same DTC still output?
2) Erase the memory.
3) Perform the Inspection Mode.
4) Read the DTC.
No
Go to step 8.
Is the runout less than 0.05 mm

(0.0020 in)?
Is there any other DTC

detected?
Tighten the ABS

wheel speed sensor installation
bolts.
Go to step 4.
Adjust the gap.
NOTE:
Adjust the gap using spacers (Part
No. 26755AA000).
If spacers cannot
correct the gap, replace the worn
sensor or worn
tone wheel.
Go to step 5.
Replace the tone
wheel. Front: <Ref.
to ABS-20, Front
Tone Wheel.>
Rear: <Ref. to
ABS-21, Rear
Tone Wheel.>
tor.
Replace the
ABSCM only. <Ref.
to ABS-6, ABS
Control Module
and Hydraulic Control Unit
(ABSCM&H/U).>
DTC.
CHECK OTHER DTC DETECTION.
Is the resistance within the fol- Go to step 9.

CHECK ABS WHEEL SPEED SENSOR.
lowing? Front: 1 1.5 k
Rear: 1.025 1.265 k
2) Disconnect the connector from the ABS
wheel speed sensor.
3) Measure the resistance of ABS wheel
speed sensor terminals while shaking the harness lightly.
Terminals
Front RH No. 1 No. 2:
Front LH No. 1 No. 2:
Rear RH No. 1 No. 2:
Rear LH No. 1 No. 2:
ABS(diag)-40
Go to step 7.
Temporary poor
contact occurs.
NOTE:
Check the harness
and connector between ABSCM&H/
U and ABS wheel
speed sensor.
Replace the ABS
wheel speed sensor. Front: <Ref. to
ABS-14, Front
ABS Wheel Speed
Sensor.> Rear:
<Ref. to ABS-17,
Rear ABS Wheel
Speed Sensor.>

ABS (DIAGNOSTICS)
10
11
12
13
Step
CHECK BATTERY SHORT OF ABS WHEEL
SPEED SENSOR.
2) Measure the voltage between ABS wheel
speed sensor and chassis ground.
Terminals
Front RH No. 1 (+) Chassis ground ():
Front LH No. 1 (+) Chassis ground ():
Rear RH No. 1 (+) Chassis ground ():
Rear LH No. 1 (+) Chassis ground ():
SPEED SENSOR.
Terminals
ABSCM&H/U AND ABS WHEEL SPEED
SENSOR.
2) Connect the connector to the ABS wheel
speed sensor.
3) Measure the resistance between
ABSCU&H/U connector terminals.
DTC 21; (B301) No. 6 No. 5:
DTC 23; (B301) No. 1 No. 16:
DTC 25; (B301) No. 19 No. 4:
DTC 27; (B301) No. 3 No. 2:
CHECK BATTERY SHORT OF HARNESS.
Measure the voltage between ABSCM&H/U
DTC 21; (B301) No. 6 (+) Chassis
ground ():
ground ():
DTC 25; (B301) No. 19 (+) Chassis
ground ():
ground ():
ground ():
ground ():
DTC 25; (B301) No. 19 (+) Chassis
ground ():
ground ():
Check
Yes
Go to step 10.
No
Replace the ABS
ABS-14, Front
ABS Wheel Speed
Sensor.> Rear:
<Ref. to ABS-17,
Rear ABS Wheel
Speed Sensor.>
Go to step 11.
Replace the ABS

ABS-14, Front
ABS Wheel Speed
Sensor.> Rear:
<Ref. to ABS-17,
Rear ABS Wheel
Speed Sensor.>

lowing? Front: 1 1.5 k
Rear: 1.025 1.265 k
Repair the harness

connector between
ABSCM&H/U and
ABS wheel speed
sensor.
Go to step 13.
Repair the harness

between
ABSCM&H/U and
ABS wheel speed
sensor.
Go to step 14.
Repair the harness

between
ABSCM&H/U and
ABS wheel speed
sensor.
ABS(diag)-41

ABS (DIAGNOSTICS)
14
Step
SPEED SENSOR.
Check
Yes
No
Tighten the ABS
bolts.
Go to step 16.
Adjust the gap.
NOTE:
No. 26755AA000).
If spacers cannot
sensor or worn
tone wheel.
Go to step 17.
Replace the tone
wheel. Front: <Ref.
to ABS-20, Front
Tone Wheel.>
Rear: <Ref. to
ABS-21, Rear
Tone Wheel.>
Go to step 18.
Replace the
ABSCM&H/U and
ABS wheel speed
sensor. Front:
<Ref. to ABS-14,
Front ABS Wheel
Speed Sensor.>
Rear: <Ref. to
ABS-17, Rear ABS
Wheel Speed Sensor.> and <Ref. to
ABS-6, ABS Control Module and
Hydraulic Control
Unit (ABSCM&H/
U).>
Go to step 19.
Repair the harness
between
ABSCM&H/U and
ABS wheel speed
sensor. Replace
the ABSCM&H/U.
<Ref. to ABS-6,
Control Unit
(ABSCM&H/U).>
tor.
15
CHECK ABS WHEEL SPEED SENSOR GAP. Is the gap within the following?
(0.012 0.031 in); Rear
wheel: 0.7 1.2 mm (0.028
0.047 in)
16

Is the runout less than 0.05 mm

(0.0020 in)?
17
CHECK GROUND SHORT OF ABS WHEEL

SPEED SENSOR.
2) Measure the resistance between ABS
wheel speed sensor and chassis ground.
Terminals
Front RH No. 1 Chassis ground:
Front LH No. 1 Chassis ground:
Rear RH No. 1 Chassis ground:
Rear LH No. 1 Chassis ground:
more?
18

more?
speed sensor.
ABSCM&H/U connectors and chassis ground.
DTC 21; (B301) No. 6 Chassis ground:
CHECK POOR CONTACT OF CONNECTOR. Is there poor contact in connectors between ABSCM&H/U and
CHECK ABSCM&H/U.
Is the same DTC still output? Replace the
ABSCM only.
4) Read the DTC.
19
20
ABS(diag)-42
Go to step 21.

ABS (DIAGNOSTICS)
21
Step
Check
detected?
Yes
No
Perform the diag- Temporary poor
nosis according to contact occurs.
DTC.
NOTE:
Check the harness
and connector between ABSCM&H/
U and ABS wheel
speed sensor.
E: DTC 22 FRONT ABS WHEEL SPEED SENSOR RH MALFUNCTION (ABS

WHEEL SPEED SENSOR ABNORMAL SIGNAL)
NOTE:
Refer to DTC 28 for diagnostic procedure. <Ref. to ABS(diag)-44, DTC 28 REAR ABS WHEEL SPEED SENSOR LH MALFUNCTION (ABS WHEEL SPEED SENSOR ABNORMAL SIGNAL), Diagnostic Procedure
F: DTC 24 FRONT ABS WHEEL SPEED SENSOR LH MALFUNCTION (ABS

NOTE:
G: DTC 26 REAR ABS WHEEL SPEED SENSOR RH MALFUNCTION (ABS

NOTE:
ABS(diag)-43

ABS (DIAGNOSTICS)
H: DTC 28 REAR ABS WHEEL SPEED SENSOR LH MALFUNCTION (ABS

Defective ABS wheel speed sensor signal (noise, abnormal signal, etc.)
TROUBLE SYMPTOM:
WIRING DIAGRAM:
19
7
TWISTED PAIR LINE
F45
B6
B99
R73
F94
F45
TWISTED
PAIR LINE
B6
1
2
R72
1
2
R73
FRONT ABS
WHEEL SPEED
SENSOR RH
REAR ABS
WHEEL SPEED
SENSOR LH
REAR ABS
WHEEL SPEED
SENSOR RH
B301
12
6
19
TWISTED PAIR LINE
R72
R3
1
2
1
2
FRONT ABS
WHEEL SPEED
SENSOR LH
2 1
17
18
B99
F94
2 1
TWISTED PAIR LINE
3
2
TWISTED PAIR LINE
TWISTED PAIR LINE
TWISTED PAIR LINE

B62
19
4
ABSCM & H/U
6
5
1
16
B301
13
14
15
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
Step
corresponding to the faulty system in Subaru
Select Monitor display mode.
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
ABS00896
Check
Yes
Go to step 2.
ABS(diag)-44
No
Go to step 7.

ABS (DIAGNOSTICS)
9
10
11
Step
Check
Yes
No
CHECK POOR CONTACT OF CONNECTOR. Is there poor contact in connec- Repair the connec- Go to step 3.
tors between ABSCM&H/U and tor.
CHECK CAUSE OF SIGNAL NOISE.
Is the car telephone or the radio Go to step 4.
Install the car
properly installed?
phone or radio
properly.
Is there a noise source (such as Install the noise
Go to step 5.
an antenna) installed near the source apart from
sensor harness?
the sensor harness.
CHECK ABSCM&H/U.
Go to step 6.
ABSCM only. <Ref.
to ABS-6, ABS
Control Module
4) Read the DTC.
(ABSCM&H/U).>
Perform the diag- It results from a
detected?
nosis according to temporary noise
DTC.
interference.
Tighten the ABS
SPEED SENSOR.
wheel speed senNm (3.3 kgf-m, 24 ft-lb)?
sor installation
bolts.
CHECK ABS WHEEL SPEED SENSOR GAP. Is the gap within the following? Go to step 9.
Adjust the gap.
NOTE:
(0.012 0.031 in)
Adjust the gap usRear wheel: 0.7 1.2 mm
ing spacers (Part
(0.028 0.047 in)
No. 26755AA000).
If spacers cannot
sensor or worn
tone wheel.
PREPARE OSCILLOSCOPE.
Is an oscilloscope available?
Go to step 10.
Go to step 11.
CHECK ABS WHEEL SPEED SENSOR SIG- Is the oscilloscope pattern the Go to step 14.
Go to step 11.
NAL.
same voltage as shown in the
table? <Ref. to ABS(diag)-12,
ELECTRICAL SPECIFICA3) Connect the oscilloscope to the connector. TION, Control Module I/O Sig4) Turn the ignition switch to ON.
nal.>
5) Start the wheel, and measure the voltage at
the specified frequency. <Ref. to ABS(diag)-12,
ELECTRICAL SPECIFICATION, Control Module I/O Signal.>
NOTE:
When this inspection is completed, ABSCM&H/
U may record DTC 29 or DTC 56.
DTC 22; (B6) No. 1 (+) No. 2 ():
DTC 24; (F94) No. 1 (+) No. 2 ():
DTC 26; (B99) No. 6 (+) No. 19 ():
DTC 28; (B99) No. 18 (+) No. 17 ():
CHECK CONTAMINATION OF ABS WHEEL Is the ABS wheel speed sensor Thoroughly
Go to step 12.
SPEED SENSOR OR TONE WHEEL.
piece or the tone wheel conremove dirt or
Remove the disc rotor or drum from the hub
taminated by dirt or other for- other foreign mataccording to the DTC.
eign matter?
ter.
ABS(diag)-45

ABS (DIAGNOSTICS)
Step
CHECK DAMAGE OF ABS WHEEL SPEED
SENSOR OR TONE WHEEL.
Check
Is there damage in the protrusion of the ABS wheel speed
sensor or the tone wheel?
13

Is the runout less than 0.05 mm Go to step 14.

(0.0020 in)?
14
CHECK RESISTANCE OF THE ABS WHEEL

SPEED SENSOR.
wheel speed sensor.
3) Measure the resistance of the ABS wheel
speed sensor connector terminals by shaking
the harness lightly.
SPEED SENSOR.
Measure the resistance between ABS wheel
ABSCM&H/U AND ABS WHEEL SPEED
SENSOR.
speed sensor.
ABSCM&H/U connector terminals.
DTC 22; (B301) No. 6 No. 5:
DTC 24; (B301) No. 1 No. 16:
DTC 26; (B301) No. 19 No. 4:
DTC 28; (B301) No. 3 No. 2:

lowing?
Front: 1 1.5 k
Rear: 1.025 1.265 k
12
15
16
more?
Yes
Go to step 13.
Go to step 16.

lowing?
Front: 1 1.5 k
Rear: 1.025 1.265 k
ABS(diag)-46
No
Replace the ABS
wheel speed sensor or tone wheel.
Front: <Ref. to
ABS-14, Front
ABS Wheel Speed
Sensor.> Rear:
<Ref. to ABS-17,
Rear ABS Wheel
Speed Sensor.>
and front: <Ref. to
ABS-20, Front
Tone Wheel.>
Rear: <Ref. to
ABS-21, Rear
Tone Wheel.>
Replace the tone
wheel. Front: <Ref.
to ABS-20, Front
Tone Wheel.>
Rear: <Ref. to
ABS-21, Rear
Tone Wheel.>
Replace the ABS
ABS-14, Front
ABS Wheel Speed
Sensor.> Rear:
<Ref. to ABS-17,
Rear ABS Wheel
Speed Sensor.>
Replace the ABS

ABS-14, Front
ABS Wheel Speed
Sensor.> Rear:
<Ref. to ABS-17,
Rear ABS Wheel
Speed Sensor.>
Repair the harness
connector between
ABSCM&H/U and
ABS wheel speed
sensor.

ABS (DIAGNOSTICS)
19
Step
Measure the resistance between the
ABSCM&H/U connector and chassis ground.
CHECK THE ABSCM&H/U GROUND CIRCUIT.
ABSCM&H/U and chassis ground.
20
21
22
CHECK ABSCM&H/U.
4) Read the DTC.
23
17
18
Check
more?
Yes
Go to step 18.
No
Repair the harness
connector between
ABSCM&H/U and
ABS wheel speed
sensor.

?
Go to step 19.
Repair the
ABSCM&H/U
ground harness.
Is there poor contact in connec- Repair the connec- Go to step 20.

tors between ABSCM&H/U and tor.
Is the car telephone or the radio Go to step 21.
Install the car
properly installed?
phone or radio
properly.
Go to step 22.
sensor harness?
the sensor harness.
Go to step 23.
ABSCM only. <Ref.
to ABS-6, ABS
Control Module
(ABSCM&H/U).>
Perform the diag- It results from a
detected?
nosis according to temporary noise
DTC.
interference.
NOTE:
Though the ABS
warning light remains on at this
time, this is normal.
Drive the vehicle at
more than 12 km/h
(7.46 MPH) in order to turn ABS
warning light off.
Be sure to drive the
vehicle and check
that the warning
light goes off.
ABS(diag)-47

ABS (DIAGNOSTICS)
I:
DTC 29 ABS WHEEL SPEED SENSOR SIGNAL MALFUNCTION IN ONE OF

FOUR WHEELS

Defective ABS wheel speed sensor signal (noise, abnormal signal, etc.)
Defective magnetic encoder
When a wheel is turned freely for a long time
TROUBLE SYMPTOM:
EBD does not operate.
NOTE:
Brake warning light comes on as well as the ABS warning light.
WIRING DIAGRAM:
19
7
TWISTED PAIR LINE
F45
F94
2 1
19
4
6
19
TWISTED PAIR LINE
TWISTED
PAIR LINE
B6
1
2
R72
1
2
R73
FRONT ABS
WHEEL SPEED
SENSOR RH
REAR ABS
WHEEL SPEED
SENSOR LH
REAR ABS
WHEEL SPEED
SENSOR RH
B99
B301
F45
12
2 1
R3
1
2
1
2
FRONT ABS
WHEEL SPEED
SENSOR LH
R73
17
18
B99
F94
B6
TWISTED PAIR LINE
3
2
TWISTED PAIR LINE
TWISTED PAIR LINE
TWISTED PAIR LINE

B62
R72
ABSCM & H/U
6
5
1
16
B301
13
14
15
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
ABS(diag)-48
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
ABS00896

ABS (DIAGNOSTICS)
Step
Check
WHETHER A WHEEL TURNED FREELY OR Did the wheels turn freely for
NOT.
more than one minute, such as
when the vehicle is jacked-up,
under full-lock cornering or
when the wheels are not in contact with road surface?
Yes
No
ABS is normal.
Go to step 2.
Erase the memory.
NOTE:
This
diagnostic
trouble code may
sometimes occur if
the wheels turn
freely for a long
time, for example
when the vehicle is
towed or jackedup, or when steering wheel is continuously turned all
the way.
Go to step 3.
Replace the tire.
CHECK TIRE SPECIFICATIONS.

CHECK WEAR OF TIRE.
CHECK TIRE PRESSURE.
Are the tire specifications correct?

Is the tire worn excessively?
Is the tire pressure correct?

SPEED SENSOR.

CHECK ABS WHEEL SPEED SENSOR GAP. Is the gap within the following? Go to step 7.
(0.012 0.031 in); Rear
wheel: 0.7 1.2 mm (0.028
0.047 in)
7
8
PREPARE OSCILLOSCOPE.
CHECK ABS WHEEL SPEED SENSOR SIGNAL.
3) Connect the oscilloscope according to the
DTC.
the specified frequency. <Ref. to ABS(diag)-12,
NOTE:
When this inspection is completed, ABSCM&H/
U may record DTC 29.
Front RH (B6) No. 1 (+) No. 2 ():
Front LH (F94) No. 1 (+) No. 2 ():
Rear RH (B99) No. 6 (+) No. 19 ():
Rear LH (B99) No. 17 (+) No. 18 ():
CHECK CONTAMINATION OF ABS WHEEL
Remove the disc rotor or drum from the hub.
3
4
Replace the tire.

Go to step 5.
Go to step 8.
Is the oscilloscope pattern the Go to step 12.
same voltage as shown in the
table? <Ref. to ABS(diag)-12,
Is the ABS wheel speed sensor

piece or the tone wheel contaminated by dirt or other foreign matter?
ABS(diag)-49
Thoroughly
remove dirt or
other foreign matter.
Go to step 4.
Adjust the tire
pressure.
Tighten the ABS
bolts.
Adjust the gap.
NOTE:
No. 26755AA000).
If spacers cannot
sensor or worn
tone wheel.
Go to step 9.
Go to step 9.
Go to step 10.

ABS (DIAGNOSTICS)
10
Step
11

12
CHECK ABSCM&H/U.
5) Read the DTC.
13
Check
Are there cracked or damaged
teeth in the protrusion of the
ABS wheel speed sensor or the
tone wheel?
Yes
No
Replace the ABS Go to step 11.
Front: <Ref. to
ABS-14, Front
ABS Wheel Speed
Sensor.> Rear:
<Ref. to ABS-17,
Rear ABS Wheel
Speed Sensor.>
and front: <Ref. to
ABS-20, Front
Tone Wheel.>
Rear: <Ref. to
ABS-21, Rear
Tone Wheel.>
Replace the tone
(0.0020 in)?
wheel. Front: <Ref.
to ABS-20, Front
Tone Wheel.>
Rear: <Ref. to
ABS-21, Rear
Tone Wheel.>
Go to step 13.
ABSCM only. <Ref.
to ABS-6, ABS
Control Module
(ABSCM&H/U).>
Perform the diag- Temporary poor
detected?
nosis according to contact occurs.
DTC.
ABS(diag)-50

ABS (DIAGNOSTICS)
J: DTC 31 FRONT INLET SOLENOID VALVE RH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
NOTE:
Refer to DTC 38 for diagnostic procedure. <Ref. to ABS(diag)-52, DTC 38 REAR OUTLET SOLENOID
VALVE LH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/
U), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
K: DTC 32 FRONT OUTLET SOLENOID VALVE RH MALFUNCTION IN ABS

CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
NOTE:
L: DTC 33 FRONT INLET SOLENOID VALVE LH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
NOTE:
M: DTC 34 FRONT OUTLET SOLENOID VALVE LH MALFUNCTION IN ABS

CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
NOTE:
N: DTC 35 REAR INLET SOLENOID VALVE RH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
NOTE:
O: DTC 36 REAR OUTLET SOLENOID VALVE RH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
NOTE:
P: DTC 37 REAR INLET SOLENOID VALVE LH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
NOTE:
ABS(diag)-51

ABS (DIAGNOSTICS)
Q: DTC 38 REAR OUTLET SOLENOID VALVE LH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
Defective inlet solenoid valve or outlet solenoid valve in ABSCM&H/U
TROUBLE SYMPTOM:
NOTE:
WIRING DIAGRAM:
SBF-1
BATTERY
SBF-4
GENERATOR
No.18
IGNITION
SWITCH
15
18
B301
ABSCM & H/U
B301
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
ABS00785
ABS(diag)-52

ABS (DIAGNOSTICS)
Step
CHECK INPUT VOLTAGE OF ABSCM&H/U.
CHECK ABSCM&H/U.
4) Read the DTC.
Check
Yes
Go to step 2.
No
Repair the
ABSCM&H/U
power circuit.

?
Go to step 3.
Repair the
ABSCM&H/U
ground harness.
Is there poor contact in connec- Repair the connector between generator, battery tor.
and ABSCM&H/U?
Is the same DTC displayed?
Replace the
ABSCM&H/U.
<Ref. to ABS-6,
Control Unit
(ABSCM&H/U).>
Is there any other DTC disCheck DTC using
played?
List of Diagnostic
Trouble Code
(DTC). <Ref. to
ABS(diag)-35, List
ABS(diag)-53
Go to step 4.
Go to step 5.
Temporary poor
contact occurs.

ABS (DIAGNOSTICS)
R: DTC 41 ABS CONTROL MODULE MALFUNCTION

Defective ABSCM&H/U
TROUBLE SYMPTOM:
NOTE:
WIRING DIAGRAM:
ABSCM & H/U
15
B301
B301
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
ABS00586
ABS(diag)-54

ABS (DIAGNOSTICS)
Step
Check
CHECK THE ABSCM&H/U GROUND CIRIs the resistance less than 0.5
CUIT.
?
ABSCM&H/U and chassis ground.
CHECK POOR CONTACT OF CONNECTOR. Is there poor contact of the connector between the battery,
ignition switch and ABSCM&H/
U?
Is the car telephone or the radio
properly installed?
CHECK ABSCM&H/U.
4) Read the DTC.
Yes
Go to step 2.
No
Repair the
ABSCM&H/U
ground harness.

tor.
Go to step 4.
Properly install the

car telephone or
the wireless transmitter.
Go to step 5.

sensor harness?
the sensor harness.
Replace the
Go to step 6.
ABSCM only. <Ref.
to ABS-7,
REPLACEMENT,
Control Unit
(ABSCM&H/U).>
Is there any other DTC disCheck DTC using Temporary poor
played?
List of Diagnostic contact occurs.
Trouble Code
(DTC). <Ref. to
ABS(diag)-35, List
ABS(diag)-55

ABS (DIAGNOSTICS)
S: DTC 42 POWER VOLTAGE MALFUNCTION

Power supply voltage of the ABSCM&H/U is too low or too high.
TROUBLE SYMPTOM:
EBD may not operate.
NOTE:
If EBD does not operate, the brake warning light illuminates in addition to ABS warning light. Both warning
lights go off if voltage returns.
WIRING DIAGRAM:
SBF-1
BATTERY
SBF-4
GENERATOR
No.18
IGNITION
SWITCH
15
18
B301
ABSCM & H/U
B301
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
ABS00785
ABS(diag)-56

ABS (DIAGNOSTICS)
Step
Check
CHECK GENERATOR.
2) Run the engine at idle after warming up.
3) Measure the voltage between generator terminal B and chassis ground.
Terminals
Generator B terminal (+) Chassis
ground ():
Are the positive and negative
battery terminals tightened
securely?
CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage 10 15 V?
3) Operate devices such as headlights, air
conditioner, defogger, etc. which produce an
electrical load.
CHECK THE ABSCM&H/U GROUND CIRIs the resistance less than 0.5
CUIT.
?
CHECK POOR CONTACT OF CONNECTOR. Is there poor contact in connector between generator, battery
and ABSCM&H/U?
CHECK ABSCM&H/U.
4) Read the DTC.
Is there any other DTC displayed?
ABS(diag)-57
Yes
Go to step 2.
No
Repair the generator.
Go to step 3.
Tighten the terminal.
Go to step 4.
Repair the
ABSCM&H/U
power circuit.
Go to step 5.
Repair the
ABSCM&H/U
ground harness.

tor.
Replace the
Go to step 7.
ABSCM only. <Ref.
to ABS-7,
REPLACEMENT,
Control Unit
(ABSCM&H/U).>
Check DTC using Temporary poor
Trouble Code
(DTC). <Ref. to
ABS(diag)-35, List

ABS (DIAGNOSTICS)
T: DTC 47 IMPROPER CAN COMMUNICATION

CAN communication line is damaged or circuit is shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
F301
ABSCM&H/U
B301
13
14
15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
11
26
12
B55
5 6
14 15 16
25 26 27
33 34 35
18
17
TWISTED PAIR LINE
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
TCM
B55
ABS00897
Step
Check
CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 0.5
ABSCM&H/U AND TCM.
?
2) Disconnect the connector from ABSCM&H/
U and TCM.
3) Measure the resistance of the harness connector between ABSCM&H/U and TCM.
(B301) No. 26 (B55) No. 18:
(B301) No. 11 (B55) No. 17:
ABS(diag)-58
Yes
Go to step 2.
No
Repair or replace
the harness connector between
ABSCM&H/U and
TCM.

ABS (DIAGNOSTICS)
Step
CHECK GROUND SHORT OF HARNESS
CONNECTOR BETWEEN ABSCM&H/U AND
TCM.
CHECK BATTERY SHORT OF HARNESS
CONNECTOR BETWEEN ABSCM&H/U AND
TCM.
CHECK ABSCM&H/U.
(B55) No. 17 (B55) No. 18:
CHECK POOR CONTACT OF ABSCM&H/U.
Check
more?
Yes
Go to step 3.
No
Repair or replace
ABSCM&H/U and
TCM.
Repair or replace
ABSCM&H/U and
TCM.
Is the resistance 1206 ?
Go to step 6.
Go to step 5.
Repair the poor

contact of
ABSCM&H/U connector.
Replace the
ABSCM only. <Ref.
to ABS-7,
REPLACEMENT,
Control Unit
(ABSCM&H/U).>
Go to step 7.
CHECK TCM.
ABSCM&H/U connector terminals.
(B301) No. 11 (B301) No. 26:
CHECK POOR CONTACT OF TCM CONNEC- Is there poor contact?
TORS.
CHECK DTC DETECTION.
Is DTC 47 output?
CHECK IF DTC P1718 FOR TCM SYSTEM IS Is DTC P1718 output?

OUTPUT.
ABS(diag)-59
Go to step 8.
Repair the poor

contact of TCM
connector.
Replace the
ABSCM only. <Ref.
to ABS-7,
REPLACEMENT,
Control Unit
(ABSCM&H/U).>
Replace the TCM.
<Ref. to 4AT-61,
REMOVAL, Transmission Control
Module (TCM).>
Replace the TCM.

<Ref. to 4AT-61,
(TCM).>
Go to step 9.
Replace the
ABSCM only. <Ref.
to ABS-7,
REPLACEMENT,
Control Unit
(ABSCM&H/U).>

ABS (DIAGNOSTICS)
U: DTC 51 VALVE RELAY MALFUNCTION

TROUBLE SYMPTOM:
EBD does not operate depending on the trouble contents.
NOTE:
Brake warning light comes on as well as ABS warning light when EBD does not operate.
WIRING DIAGRAM:
BATTERY
SBF-7
IGNITION
SWITCH
No.8
SBF-4
SBF-3
SBF-1
PUMP
MOTOR
18
12
B61
13
2
14
F49
15
B61
F44
No.18
F44
E
ABS
MOTOR
GROUND
VALVE
RELAY
RR
OUTLET
RR
INLET
RL
OUTLET
RL
INLET
FR
OUTLET
FR
INLET
MOTOR
RELAY
F49
F44
1 2 3 4
5 6 7 8
FL
OUTLET
FL
INLET
SOLENOID
VALVE
ABSCM & H/U
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
ABS00898
ABS(diag)-60

ABS (DIAGNOSTICS)
Step
CHECK VALVE RELAY IN ABSCM&H/U.
ABSCM&H/U terminals.
Terminals
No. 14 No. 15:
Check
Yes
Go to step 2.
No
Repair the harness
connector between
battery and
ABSCM&H/U.

?
Go to step 3.
Repair the
ABSCM&H/U
ground harness.
more?
Go to step 4.
Replace the
ABSCM only. <Ref.
to ABS-7,
REPLACEMENT,
Control Unit
(ABSCM&H/U).>
tor between generator, battery tor.
and ABSCM&H/U?
Go to step 6.
Replace the
CHECK ABSCM&H/U.
ABSCM only. <Ref.
to ABS-7,
REPLACEMENT,
ABS Control Mod4) Read the DTC.
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
Is there any other DTC disCheck DTC using Temporary poor
played?
Trouble Code
(DTC). <Ref. to
ABS(diag)-35, List
ABS(diag)-61

ABS (DIAGNOSTICS)
V: DTC 52 MOTOR/MOTOR RELAY MALFUNCTION

Defective motor
Defective motor relay
TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
SBF-7
IGNITION
SWITCH
No.8
SBF-4
SBF-3
SBF-1
PUMP
MOTOR
18
12
B61
13
2
14
F49
15
B61
F44
No.18
F44
E
ABS
MOTOR
GROUND
VALVE
RELAY
RR
OUTLET
RR
INLET
RL
OUTLET
RL
INLET
FR
OUTLET
FR
INLET
MOTOR
RELAY
F49
F44
1 2 3 4
5 6 7 8
FL
OUTLET
FL
INLET
SOLENOID
VALVE
ABSCM & H/U
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
ABS00898
ABS(diag)-62

ABS (DIAGNOSTICS)
Step
CHECK FOR LOOSENED GROUND BOLT.
Check for looseness in the ABSCM&H/U motor
ground bolt (B302).
CHECK GROUND CIRCUIT OF MOTOR.
CHECK ABSCM&H/U.
4) Read the DTC.
Check
Is ground bolt loosened?
Yes
No
Tighten the bolt to Go to step 2.
13 Nm (1.3 kgf-m,
9.4 ft-lb) torque.
Go to step 3.
Repair the harness
connector between
battery and
ABSCM&H/U.

?
Go to step 4.
Repair the
ABSCM&H/U
ground harness.
Go to step 5.
Repair the harness

connector between
battery, ignition
switch and
ABSCM&H/U.

?
Go to step 6.
Repair the
ABSCM&H/U
ground harness.
Is there poor contact in connec- Repair the connector between generator, battery tor.
and ABSCM&H/U?
Replace the
ABSCM&H/U.
<Ref. to ABS-6,
Control Unit
(ABSCM&H/U).>
played?
List of Diagnostic
Trouble Code
(DTC). <Ref. to
ABS(diag)-35, List
ABS(diag)-63
Go to step 7.
Go to step 8.
Temporary poor
contact occurs.
NOTE:
Though the ABS
warning light remains on at this
time, this is normal.
Drive the vehicle at
more than 12 km/h
(7 MPH) in order to
turn ABS warning
light off. Be sure to
drive the vehicle
and check that the
warning light goes
off.

ABS (DIAGNOSTICS)
W: DTC 54 FAULTY STOP LIGHT SWITCH

Defective stop light switch
WIRING DIAGRAM:
SBF-1
BATTERY
No.16
SBF-2
STOP LIGHT
SWITCH
2
3
20
B65
B301
B65
1 2
3 4
ABSCM & H/U
B301
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
ABS00787
ABS(diag)-64

ABS (DIAGNOSTICS)
3
4
Step
CHECK OUTPUT OF STOP LIGHT SWITCH
USING SUBARU SELECT MONITOR.
2) Release the brake pedal.
3) Read the stop light switch signal in Subaru
Select Monitor.
CHECK OUTPUT OF STOP LIGHT SWITCH
2) Read the stop light switch output in Subaru
Select Monitor.
CHECK IF STOP LIGHTS COME ON.
CHECK OPEN CIRCUIT IN HARNESS.
CHECK ABSCM&H/U.
4) Read the DTC.
Check
Is OFF displayed on the
screen?
Yes
Go to step 2.
No
Go to step 3.
Is ON displayed on the
screen?
Go to step 5.
Go to step 3.
Does the stop light illuminate? Go to step 4.

Go to step 5.
Is there poor contact in the con- Go to step 6.

nector between stop light
switch and ABSCM&H/U?
Replace the
ABSCM only. <Ref.
to ABS-7,
REPLACEMENT,
Control Unit
(ABSCM&H/U).>
played?
List of Diagnostic
Trouble Code
(DTC). <Ref. to
ABS(diag)-35, List
ABS(diag)-65
Repair the stop

light circuit.
Repair the harness
between stop light
switch and
ABSCM&H/U connector.
Repair the connector.

Go to step 7.
Temporary poor
contact occurs.

ABS (DIAGNOSTICS)
X: DTC 56 G SENSOR OUTPUT VOLTAGE MALFUNCTION

Defective G sensor
TROUBLE SYMPTOM:
WIRING DIAGRAM:
ABSCM & H/U
24
21
10
B301
1
2
3
B292
ABS
G SENSOR
B292
1 2 3
B301
12
13
14
15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
ABS00788
ABS(diag)-66

ABS (DIAGNOSTICS)
Step
Check
WHETHER A WHEEL TURNED FREELY OR Have the wheels spun free of
NOT.
load when the vehicle is lifted
up, or during driving on a rough
road?
CHECK OUTPUT OF G SENSOR USING
Is the reading indicated on disSUBARU SELECT MONITOR.
play 1.2 1.2 m/s when the G
sensor is horizontal?
2) Read the G sensor output on Subaru Select
Monitor.
CHECK POOR CONTACT OF CONNECTOR. Is there poor contact in connectors between ABSCM&H/U and
G sensor?
CHECK ABSCM&H/U.
4) Read the DTC.
Is there any other DTC displayed?
CHECK INPUT VOLTAGE OF G SENSOR.

3) Remove the G sensor from vehicle. (Do not
disconnect the connector.)
(B292) No. 1 (+) No. 3 ():
CHECK OPEN CIRCUIT IN G SENSOR OUTPUT HARNESS AND GROUND HARNESS.
ABSCU&H/U connector terminals.
(B301) No. 21 No. 10:
CHECK GROUND SHORT IN G SENSOR
OUTPUT HARNESS.
1) Disconnect the connector from the G sensor.
Yes
No
ABS is normal.
Go to step 2.
Erase the memory.
Go to step 3.
Go to step 6.

tor.
Replace the
ABSCM only. <Ref.
to ABS-7,
REPLACEMENT,
Control Unit
(ABSCM&H/U).>
Check DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
ABS(diag)-35, List
Go to step 7.
Go to step 5.
Temporary poor
contact occurs.
Repair the harness

connector between
the G sensor and
ABSCM&H/U.

and 2.4 k?
Go to step 8.
Repair the harness

connector between
the G sensor and
ABSCM&H/U.
more?
Go to step 9.
Repair the harness

between the G
sensor and
ABSCM&H/U.
ABS(diag)-67

ABS (DIAGNOSTICS)
10
11
12
Step
CHECK G SENSOR.
1) Connect the connector to G sensor.
(B292) No. 2 (+) No. 3 ():
CHECK G SENSOR.
(B292) No. 2 (+) No. 3 ():
CHECK G SENSOR.
(B292) No. 2 (+) No. 3 ():
13
CHECK ABSCM&H/U.
4) Read the DTC.
14
Check
Yes
Is the voltage 2.1 2.5 V when Go to step 10.
G sensor is in horizontal position?
No
Replace G sensor.
<Ref. to ABS-22, G
Sensor.>

the G sensor is inclined forward
to 90?
Replace G sensor.
<Ref. to ABS-22, G
Sensor.>

G sensor is inclined back 90?
Replace G sensor.
<Ref. to ABS-22, G
Sensor.>
Is there poor contact in connec- Repair the connectors between ABSCM&H/U and tor.
G sensor?
Replace the
ABSCM only. <Ref.
to ABS-7,
REPLACEMENT,
Control Unit
(ABSCM&H/U).>
played?
List of Diagnostic
Trouble Code
(DTC). <Ref. to
ABS(diag)-35, List
Go to step 13.
ABS(diag)-68
Go to step 14.
Temporary poor
contact occurs.

ABS (DIAGNOSTICS)

A: INSPECTION
Symptoms
Problem parts
ABSCM&H/U (solenoid valve)

Brake (caliper, piston and pad)
Wheel alignment
Tire specifications, tire wear and air pressures
Incorrect wiring or piping connections
Road surface (uneven, camber)
Brake (pad)
Long braking/stopping distance

Brake (pad)
Air in brake line
Wheel locks.
ABSCM&H/U (solenoid valve, motor)

Vehicle is pulled to either right or

left side.
Vehicle instability during braking
Vehicle spins.
Brake drag
Poor brake performance
Long brake pedal stroke

Vehicle vertical pitching
Unstable or uneven braking
Excessive pedal vibration

Noise from the ABSCM&H/U
Vibration and/or noise

(while driving on slippery roads)
Noise from front of vehicle
Noise from rear of vehicle

Master cylinder
Brake (caliper and piston)
Parking brake
Axle and wheels
Brake pedal play
Air in brake line
Brake pedal play
Suspension play or fatigue (reduced damping)
Road surface (uneven)
Brake (caliper, piston and pad)

ABSCM&H/U (mount bushing)
Brake line
ABSCM&H/U (mount bushing)

Master cylinder
Brake (caliper, piston, pad and rotor)
Brake line
Brake booster and check valve
Suspension play or fatigue
Brake (caliper, piston, pad and rotor)
Parking brake
Brake line
Suspension play or fatigue
ABS(diag)-69

ABS (DIAGNOSTICS)
ABS(diag)-70
General Description
VEHICLE DYNAMICS CONTROL (VDC)
A: SPECIFICATION
Item
ABS wheel speed sensor gap
Yaw rate and lateral G sensor

VDCH/M identification
Identification of VDCCM.
ABS wheel speed sensor resistance
Front
Rear
Front/Rear
Front LH
Front RH
Identifications of harness (Colors)
Rear LH
Rear RH
Lateral G sensor voltage
VDC-2
Standard value or identification

0.3 0.8 mm (0.012 0.031 in)
0.7 1.2 mm (0.0276 0.0472 in)
1.250.25 k/1.150.115 k
Blue
Red
Yellow
White
2.5 0.2 V
D3
N9
General Description
B: COMPONENT
(1)
(2)
(3)
(5)
(4)
(2)
VDC00165
(1)
(2)
(3)

Adjusting spacer
Rear tone wheel
(4)
(5)
Housing
VDC-3

T: 33 (3.3, 23.9)
General Description
2. YAW RATE and LATERAL G SENSOR
(1)
VDC00038
(1)
Yaw rate and lateral G sensor

T: 18 (1.8, 13.0)
3. STEERING ANGLE SENSOR
VDC00039
(1)
Steering angle sensor
(2)
Connector
VDC-4
General Description
4. VDC CONTROL MODULE (VDCCM)
(1)
T2
(2)
T1
VDC00308
(1)
(2)
VDC control module (VDCCM)

Bracket

T1: 7.5 (0.76, 5.5)
T2: 18 (1.8, 13.0)
VDC-5
General Description
5. VDC HYDRAULIC CONTROL MODULE (VDCH/M)
VDC00041
(1)
(2)
(3)
(4)
(5)
(6)
Relay box
Motor relay
Valve relay
Cap
Bracket
VDC hydraulic control module
(VDCH/M)
(7)
Damper
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Stud bolt
Pressure sensor
Ground terminal
Front LH outlet
Secondary inlet
Front RH outlet
Primary inlet
Rear LH outlet
(16)
Rear RH outlet

T1: 13 (1.3, 9.4)
T2: 18 (1.8, 13.0)
T3: 33 (3.3, 23.9)
T4: 38 (3.8, 27.5)
CAUTION:
Parts other than the valve relay and motor relay cannot be disassembled.
C: CAUTION
Wear work clothing, including a cap, protective goggles and protective shoes during operation.
Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement.
Be careful not to burn your hands, because each part on the vehicle is hot after running.
Be sure to tighten fasteners including bolts and nuts to the specified torque.
Place shop jacks or rigid racks at the specified points.
Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from the battery.
VDC-6
General Description
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
1B020XU0
DESCRIPTION
SUBARU SELECT
MONITOR KIT
REMARKS
Used for troubleshooting for the electrical system.
ST1B020XU0
2. GENERAL TOOL
TOOL NAME
Circuit tester
Pressure gauge
Oscilloscope
Steering puller
REMARKS
Used for removing the steering wheel.
VDC-7
VDC Control Module (VDCCM)

2. VDC Control Module (VDCCM)
B: INSTALLATION
A: REMOVAL
Tightening torque:
Refer to COMPONENT of General Description. <Ref. to VDC-5, VDC CONTROL MODULE (VDCCM), COMPONENT, General
Description.>
VDC00042
2) Remove the glove box.

3) Remove the two nuts which secures the bracket.
CAUTION:
After installation, always make the following
two settings.
SRS roll connector and steering angle sensor
centering setting
Yaw rate & lateral G sensor 0 point setting
These two procedures are required to make the
VDCCM recognize what position the vehicle is
in later. Refer to Adjustments for the procedures for above settings. <Ref. to VDC-9, ADJUSTMENT, VDC Control Module (VDCCM).>
C: INSPECTION
Check the VDCCM identification.
Refer to SPECIFICATION for the identification
mark. <Ref. to VDC-2, SPECIFICATION, General
Description.>
(2)
VDC00303
4) Disable the securing holder and disconnect the

connector from VDCCM.
(1)
VDC00265

(2) VDCCM
VDC00304
5) Remove the VDCCM.
VDC00305
6) Remove the bracket from VDCCM.
VDC-8
VDC Control Module (VDCCM)

D: ADJUSTMENT
When the following replacement, removal and installation are performed, be sure to perform the
centering setting of steering angle sensor and to
set the zero point of the yaw rate & lateral G sensor.
VDCCM
Yaw rate & lateral G sensor
Steering wheel parts (Including airbag)
Suspension parts
Wheel alignment adjustment
1. WITH SUBARU SELECT MONITOR

1) Park the vehicle straight on a level surface.
(Place the gear in P or N range and run the engine.)
2) Check that steering wheel is positioned at the
center. (When the center position is not correct, adjust the wheel alignment.)
3) Set the Subaru Select Monitor to the vehicle,
and select Set mode Str. A. Sen. N & Lat. Gsen.
0p in the Function Check Sequence display.
(Follow the instructions on the screen.)
4) When the above work is completed, select Current Data Display & Save on the Brake Control
display screen, and check that the steering angle
sensor displays 0 deg.
5) If 0 deg is not displayed on the screen, repeat
the above steps and check whether 0 deg is displayed.
6) Drive for approximately 10 minutes, then check
that the ABS warning light and VDC warning light
do not light.
7) Also, when driving, repeat steps 1 to 6 if there is
any unnecessary operation of the VDC (VDC indicator light or buzzer) or if steering is unnecessarily
pulled by the system.
VDC-9
VDC Hydraulic Control Module (VDCH/M)

3. VDC Hydraulic Control Module (VDCH/M)

A: REMOVAL
1. VDCH/M
7) Remove the two bolts which hold the VDCH/M,

then remove the VDCH/M from the engine room.
CAUTION:
The VDCH/M is not to be disassembled. Do
not attempt to loosen the bolts and nuts.
Do not drop or bump the VDCH/M.
Do not turn VDCH/M upside down or place it
sideways.
Be careful to prevent foreign particles from
getting into the VDCH/M.
After installing the new VDCH/M, tighten the
bracket bolts then apply rust-proofing wax
(Nippeco LT or GB) to the bracket bolts.
Do not pull on the harness when disconnecting the harness connector.
VDC00042
2) Remove the air intake duct from engine room to

make it easier to remove the VDCH/M.
3) Disconnect the connector from the VDCH/M.
CAUTION:
Be careful to keep water and other foreign materials from coming into contact with the VDCH/
M terminals.
4) Remove the cable clip.
5) Remove the brake pipes from the VDCH/M.
CAUTION:
Wrap the brake pipe in a vinyl bag so that brake
fluid does not splash on the vehicle body.
6) Remove the ground wire of the VDCH/M.
VDC00047
2. RELAY BOX
2) Remove the air intake duct from engine room to
make it easier to remove the relay box.
3) Disconnect the connector from relay box.
4) Remove the cable clip.
5) Remove the bolts which secure the relay box,
and remove the relay box and connector bracket.
VDC00048
CAUTION:
Do not drop or bump the relay box.
VDC-10

B: INSTALLATION
2. RELAY BOX
1. VDCH/M
1) Install the relay box and connector bracket.
1) Install the VDCH/M.
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
VDC00047
VDC00048
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
2) Secure the grounding wire of the VDCH/M and
apply the specified grease to the ground terminals.
Specified grease:
Nippeco LT or GB
2) Affix the relay box connector to the connector

bracket.
CAUTION:
Match the connector to the corresponding
socket.
3) Connect the connector to the relay box.
Tightening torque:
33 Nm (3.3 kgf-m, 23.9 ft-lb)
3) Connect brake pipes to the VDCH/M connectors.
Tightening torque:
15 Nm (1.5 kgf-m, 10.8 ft-lb)
4) Fasten the VDCH/M connector to the connector
bracket.
CAUTION:
Match the connector to the corresponding
socket.
5) Connect the connector to VDCH/M.
VDC00049
(1) Relay box connector

(2) VDCH/M connector
4) Install the air intake duct.

C: INSPECTION
VDC00049
1) Check the connection and fixture of the connector.

2) Inspect the valve relay and motor relay for broken wires or short circuits.
3) Inspect the identification of the VDCH/M.
(1) Relay box connector

(2) VDCH/M connector
6) Install the air intake duct.

VDC-11

Refer to SPECIFICATION for the identification

mark. <Ref. to VDC-2, SPECIFICATION, General
Description.>
(1)
(2)
VDC00266

(2) VDCH/M
Condition
When not applying voltage
Terminal No.
85 86
30 87a
30 87
30 87a
Standard
10310
Less than 0.5
1 M or more
1 M or more
87
87a
87
85
Valve relay
When voltage (DC 12 V)
is applied between terminal numbers 85 and 86.
86
30 87
Less than 0.5
87a
85
86
30
30
VDC00050
When not applying voltage
85 86
30 87
8010
1 M or more
87
85
Motor relay
When voltage (DC 12 V)

is applied between terminal numbers 85 and 86.
85
30 87
Less than 0.5
87
86
30
30
86
VDC00051
VDC-12

1. CHECKING THE VDC HYDRAULIC CONTROL MODULE (VDCH/M) ABS OPERATION BY PRESSURE GAUGE
1) Lift-up the vehicle and remove the wheel.
2) Disconnect the air bleeder screws from FL and
FR caliper bodies.
CAUTION:
NOTE:
9) Install the air bleeder screws of FL and FR caliper bodies.

10) Remove the air bleeder screws from RL and
RR caliper bodies.
caliper bodies.
12) Bleed air from RL and RR caliper bodies, and
pressure gauge.
13) Perform ABS sequence control. <Ref. to VDC16, ABS Sequence Control.>
14) When the VDCH/M begins to work, first the RR
side performs decompression, hold and compression, and then the RL side performs decompression, hold and compression.
17) Install the air bleeder screws of RL and RR caliper bodies.
18) Bleed air from the brake line.
2. CHECKING THE VDC HYDRAULIC CONTROL MODULE (VDCH/M) ABS OPERATION WITH BRAKE TESTER
ABS00009

6) When the VDCH/M begins to work, first the FL
side performs decompression, hold and compression, and then the FR side performs decompression, hold and compression.
7) Read values indicated on the pressure gauge
and check whether the fluctuation of the values between decompression and compression meets the
standard values. Also check whether any irregular
tightness of the brake pedal can be felt.
Initial value
When depressurized
When pressurized
Front wheel
3,500 kPa
(36 kgf/cm2, 508
psi)
500 kPa
(5 kgf/cm2, 73 psi)
or less
3,500 kPa
(36 kgf/cm2, 508
psi)
or more
1) Prepare for ABS sequence control. <Ref. to

VDC-16, ABS Sequence Control.>
tester and set the select lever position to the N
range.
(1)
ABS00011
Rear wheel
3,500 kPa
(36 kgf/cm2, 508
psi)
500 kPa
(5 kgf/cm2, 73 psi)
or less
3,500 kPa
(36 kgf/cm2, 508
psi)
or more

caliper bodies.
(1)
ABS00012
(1) Brake tester
VDC-13


5) When the VDCH/M begins to work, check the
following working sequence.
(1) The FL wheel performs decompression,
hold and compression in sequence, and subsequently the FR wheel repeats the cycle.
(2) The RR wheel performs decompression,
hold and compression in sequence, and subsequently the RL wheel repeats the cycle.
check if the fluctuation of the values between decompression and compression meets specification.
Initial value
When depressurized
When pressurized
Front wheel
1,000 N
(102 kgf, 224 lb)
500 N
(51 kgf, 112 lb)
or less
1,000 N
(102 kgf, 224 lb)
or more
Rear wheel
1,000 N
(102 kgf, 224 lb)
500 N
(51 kgf, 112 lb)
or less
1,000 N
(102 kgf, 224 lb)
or more
7) After checking, press the brake pedal and check

whether any irregular tightness of the brake pedal
can be felt.
3. CHECKING THE VDC HYDRAULIC CONTROL MODULE (VDCH/M) VDC OPERATION BY PRESSURE GAUGE
1) Lift-up the vehicle and remove the wheel.
2) Disconnect the air bleeder screws from FL and
FR caliper bodies.
CAUTION:
NOTE:

5) Perform VDC sequence control.
<Ref. to VDC-19, VDC Sequence Control.>
6) When the VDCH/M begins to work, first the FL
side performs hold, decompression, and compression, and then the FR side performs decompression, hold and compression.
7) Read values indicated on the pressure gauge
and check if the fluctuation of the values between
decompression and compression meets the standard values. Also check whether any irregular tightness of the brake pedal can be felt.
When pressurized
When depressurized
Front wheel
Rear wheel
2,000 kPa
3,000 kPa
(31 kg/cm2, 435 psi) (20 kg/cm2, 290 psi)
or more
or more
500 kPa
500 kPa
(5 kg/cm2, 73 psi)
(5 kg/cm2, 73 psi)
or less
or less

caliper bodies.
9) Connect the air bleeder screws to the FL and FR
caliper bodies.
10) Remove the air bleeder screws from RL and
RR caliper bodies.
caliper bodies.
12) Bleed air from RL and RR caliper bodies, and
pressure gauge.
13) Perform VDC sequence control.
RR side performs hold, decompression, and compression, and then the RL side performs hold, decompression, and compression.
17) Connect the air bleeder screws to RL and RR
caliper bodies.
18) Bleed air from the brake line.
VDC00052
VDC-14

4. CHECKING THE VDC HYDRAULIC CONTROL MODULE (VDCH/M) VDC OPERATION BRAKE TESTER
1) Prepare for the VDC sequence control.
tester and set the select lever position to the N range.
VDC00053
VDC00054
(1) Brake tester

5) When the VDCH/M begins to work, check the
working sequence in the following order.
(1) The FL wheel performs decompression,
hold and compression in sequence, and subsequently the FR wheel repeats the cycle.
(2) The RR wheel performs decompression,
hold and compression in sequence, and subsequently the RL wheel repeats the cycle.
check if the fluctuation of the values between decompression and compression meets specification.
When pressurized
When depressurized
Front wheel
2,000 N
(203 kgf, 447 lb)
or more
500 N
(51 kgf, 112 lb)
or less
Rear wheel
1,000 N
(102 kgf, 224 lb)
or more
500 N
(51 kgf, 112 lb)
or less
7) After inspection, check whether any irregular

brake pedal tightness cab be felt.
VDC-15

4. ABS Sequence Control

A: OPERATION
1) While the ABS sequence control is being performed, the operation of the VDCH/M can be
checked after the operation of the VDCH/M solenoid valve, using the brake tester or pressure
gauge.
2) ABS sequence control can be started by the
1. ABS SEQUENCE CONTROL WITH SUBARU SELECT MONITOR

1) Connect the Subaru Select Monitor to the Subaru data link connector under the drivers side instrument panel lower cover.
4) Set the Subaru Select Monitor to BRAKE CONTROL mode.
5) When the Function check sequence is selected, the ABS sequence control will start.
6) Execute the following operations when the message Press Brake Pedal with braking force of 100
to 150 kgf is displayed.
(1) When using a brake tester, press the brake
pedal with a force of 1,000 N (102 kgf, 224 lb).
(2) When using the pressure gauge, press the
brake pedal so as to make the pressure gauge
indicate 3,500 kPa (36 kg/cm2, 508 psi).
7) OK will be displayed. Select the OK.
VDC-16

2. CONDITIONS FOR ABS SEQUENCE CONTROL

V max < 4 km/h (2.5 MPH)
V max < 10 km/h (6 MPH)
(4)
(6)
(7)
OFF
(31)
OFF
(35)
OFF
(35)
OFF
(35)
ON
(5)
(33)
(32)
(33)
(32)
(34)
(1)
(8)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(2)
(19)
(20)
OFF
OFF
OFF
OFF
OFF
OFF
(33)
ON
ON
OFF
ON
OFF
(22)
OFF
(25)
(9)
OFF
OFF
(24)
ON
OFF
(21)
(23)
ON
ON
ON
ON
OFF
ON
OFF
ON
OFF
ON
(26)
(27)
(3)
(28)
(29)
(30)
VDC00353
VDC-17

(1)

sequence control
(2)

control
(3)

control
(4)
(5)
(6)
(7)
(8)
(9)
(10)
All wheel speeds

Point A
Ignition switch
ABS warning light
VDC warning light
0.4 second
VDC operation indicator light
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
Pressure sensor
Valve relay
Secondary cut valve
Primary cut valve
Secondary suction valve
Primary suction valve
FL outlet solenoid valve
FL inlet solenoid valve
FR outlet solenoid valve
FR inlet solenoid valve
RR outlet solenoid valve
RR inlet solenoid valve
RL outlet solenoid valve
NOTE:
Operation starts from point A.
B: SPECIFICATION
1. CONDITIONS FOR COMPLETION OF
ABS SEQUENCE CONTROL
When the following conditions develop, the ABS
sequence control stops and ABS operation is returned to the normal mode.
10 km/h (6 MPH).
2) When the brake pedal is released during sequence control and the stop lamp switch is becomes OFF.
4) When a problem is detected.
VDC-18
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
RL inlet solenoid valve

Pump motor
1.5 seconds
1.4 seconds
1.0 second
0.6 second
Light ON
VDC Sequence Control

5. VDC Sequence Control

A: OPERATION
1) While the VDC sequence control is performed,
the operation of the VDCH/M can be checked after
operation of the VDCH/M solenoid valve, using the
brake tester or pressure gauge.
2) VDC sequence control can be started by Subaru
Select Monitor.
1. VDC SEQUENCE CONTROL WITH SUBARU SELECT MONITOR

1) Connect the Subaru Select Monitor to the Subaru data link connector, located next to the lower
cover under the drivers side instrument panel.
4) Set the Subaru Select Monitor to the BRAKE
CONTROL mode.
5) When the VDC Check Mode is selected from
the Function check sequence menu, the VDC sequence control will start.
6) OK will be displayed. Select the OK.
VDC-19

2. CONDITIONS FOR VDC SEQUENCE CONTROL
V max < 4 km/h (2.5 MPH)

V max < 10 km/h (6 MPH)
(4)
(6)
(7)
OFF
(31)
OFF
(37)
OFF
(37)
OFF
(37)
ON (35)
(34)
(32)
(33)
(33)
(34)
(36)
(1)
(8)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(2)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(37)
OFF
OFF
OFF
OFF
OFF
ON
ON
(39)
(5)
ON
ON
(9)
OFF
OFF
ON
ON
OFF
ON
(36)
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
OFF
ON
ON
(26)
(27)
(3)
(28)
(29)
(30)
VDC00354
VDC-20

(1)

sequence control
(2)

control
(3)

control
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
All wheel speeds

Within 0.4 second
Ignition switch
ABS warning light
VDC warning light
0.4 second
VDC operation indicator light
Pressure sensor
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
Valve relay
Secondary cut valve
Primary cut valve
Primary suction valve
FL outlet solenoid valve
FL inlet solenoid valve
FR outlet solenoid valve
FR inlet solenoid valve
RR outlet solenoid valve
RR inlet solenoid valve
RL outlet solenoid valve
RL inlet solenoid valve
Pump motor
NOTE:
Operation starts from point A.
B: SPECIFICATION
1. CONDITIONS FOR COMPLETION OF
VDC SEQUENCE CONTROL
When the following conditions develop, the VDC
sequence control stops and VDC operation is returned to the normal mode.
10 km/h (6 MPH).
2) When the brake pedal is pressed during sequence control and the stop lamp switch is set to
ON.
4) When a problem is detected.
VDC-21
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)

1.5 seconds
Point A
1.0 second
3.4 seconds
Engine ON
1.6 seconds
Light ON
0.8 second
Yaw Rate & Lateral G Sensor

6. Yaw Rate & Lateral G Sensor
B: INSTALLATION
A: REMOVAL

CAUTION:
Do not install the yaw rate & lateral G sensors
facing an incorrect direction. There is an arrow
mark on the sensor showing the front direction
of the vehicle.
VDC00042

<Ref. to EI-38, Console Box.>
3) Disconnect the connector from yaw rate & lateral
G sensor.
4) Remove the yaw rate & lateral G sensor.
CAUTION:
Do not drop or bump the yaw rate & lateral G
sensor.
The sensor and bracket is considered a single part. Do not disassemble.
VCD00389
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
CAUTION:
Do not drop or bump the yaw rate & lateral G
sensor. After installation, always make the following two settings.
Steering angle sensor centering setting
in later. Refer to VDCCM Adjustments for procedures regarding the above settings. <Ref. to
VDC-9, ADJUSTMENT, VDC Control Module
(VDCCM).>
VDC00390
VDC-22

C: INSPECTION
1. LATERAL G SENSOR SIGNAL
1
2
Step
CHECK SUBARU SELECT MONITOR.
Check
Is the Subaru Select Monitor
available?
CHECK YAW RATE & LATERAL G SENSOR. Is the voltage 2.3 2.7 V?
1) Move the vehicle to a level surface.
3) Connect the connector to the yaw rate &
lateral G sensor.
5) Measure the voltage between connector
terminals of the yaw rate & lateral G sensor
when the yaw rate & lateral G sensor is horizontally positioned.
(B230) No. 5 (+) No. 6 ()
1) Remove the yaw rate & lateral G sensors
from vehicle.
terminals of the yaw rate & lateral G sensor
when the yaw rate & lateral G sensor are
inclined 90 to the right.
(B230) No. 5 (+) No. 6 ()
NOTE:
When the yaw rate & lateral G sensor is moved
with its power supply on, DTC of yaw rate & lateral G sensor may be recorded.
Measure the voltage between connector terminals of the yaw rate & lateral G sensor when
the yaw rate & lateral G sensor are inclined 90
to the left.
(B230) No. 5 (+) No. 6 ()
NOTE:
CHECK YAW RATE & LATERAL G SENSOR. Is the reading indicated on
monitor display 2.3 to 2.7 V?
2) Connect the Subaru data link connector to
the data link connector.
4) Set the Subaru Select Monitor to {Current
Data Display & Save} mode.
5) Set the screen to the {Current Data Display
& Save} mode.
6) Read the output voltage of yaw rate & lateral G sensor when the vehicle is in a flat horizontal position.
NOTE:
VDC-23
Yes
Go to step 5.
No
Go to step 2.
Go to step 3.
Replace the yaw

rate & lateral G
sensor.
Go to step 4.
Replace the yaw

rate & lateral G
sensor.
Yaw rate & lateral Replace the yaw

G sensors are nor- rate & lateral G
mal.
sensor.
Go to step 6.
Replace the yaw

rate & lateral G
sensor.

Step
CHECK YAW RATE & LATERAL G SENSOR.
from vehicle. (Do not disconnect the connector.)
3) Read the Subaru Select Monitor display
when the yaw rate & lateral G sensor are
inclined 90 to the right.
NOTE:
Read the Subaru Select Monitor display when
the yaw rate & lateral G sensor are inclined 90
to the left.
NOTE:
Check
Is the reading indicated on
Yes
Go to step 7.
No
Replace the yaw
rate & lateral G
sensor.
Is the reading indicated on


mal.
sensor.
2. YAW RATE SENSOR SIGNAL
Step
Check
CHECK YAW RATE & LATERAL G SENIs the voltage 2.1 to 2.9 V?
SORS USING AN OSCILLOSCOPE.
2) Set the oscilloscope to the connector terminal of yaw rate & lateral G sensor.
Positive probe; (B230) No. 4
Grounding wire; (B230) No. 6
4) Measure the signal voltage indicated on
oscilloscope. <Ref. to VDC(diag)-16, WAVEFORM, MEASUREMENT, Control Module I/O
Signal.>
INSPECT USING AN OSCILLOSCOPE.
Is the voltage 5 V?
2) Set the oscilloscope to the connector terminal of yaw rate & lateral G sensor.
Positive probe; (B230) No. 2
Grounding wire; (B230) No. 6
4) Measure the signal voltage indicated on
oscilloscope. <Ref. to VDC(diag)-16, WAVEFORM, MEASUREMENT, Control Module I/O
Signal.>
VDC-24
Yes
Go to step 2.
No
Replace the yaw
rate & lateral G
sensor.

mal.
sensor.
Steering Angle Sensor

7. Steering Angle Sensor
5) Remove the screw securing the steering column

lower cover.
A: REMOVAL
LI-00401
VDC00042
2) Remove the airbag module. <Ref. to AB-14, REMOVAL, Drivers Airbag Module.>
6) Remove the two screws securing the steering

column upper cover.
7) Unlock the harness band and disconnect the
connector of the steering angle sensor.
WARNING:
Always refer to Air Bag System before performing service on the air bag modules.
<Ref. to AB-4, CAUTION, General Description.>
3) Remove the steering wheel nut.
NOTE:
Always remove the steering wheel with it positioned straight-ahead.
VDC00061
(1) Harness band

(2) Connector
8) Remove the bolt which secure the roll connector

and steering angle sensor to the steering column.
VDC-00279
4) Pull off the steering wheel from the shaft using a

steering puller.
(1)
VDC00062
VDC-00280
(1) Steering puller
VDC-25

9) Remove the roll connector and steering angle

sensor.
4) Tighten the bolts which secure the roll connector

and steering angle sensor to the steering column.
VDC00063
VDC00066
NOTE:
Do not rotate the steering angle sensor because
the center position will be recognized by the VDCCM.
B: INSTALLATION
CAUTION:
Check that front wheels are positioned in a
straight ahead direction.
1) Install the steering angle sensor to the steering
column while confirming that the sensor is positioned as shown in the figure.
VDC00064
2) Align the roll connector with the center.

<Ref. to AB-20, INSTALLATION, Roll Connector.>
3) Place the roll connector on top of the steering
angle sensor, then tighten the bolts that secure the
roll connector and steering angle sensor.
5) Put the steering wheel in a neutral position and

install it onto the steering shaft.
Tightening torque:
45 Nm (4.6 kgf-m, 33.3 ft-lb)
Column cover-to-steering wheel clearance:
2 4 mm (0.08 0.16 in)
CAUTION:
Insert the roll connector guide pin into the
guide hole on lower end of steering wheel surface, being careful not to damage them. Remove by drawing out the airbag system
connector, horn connector and cruise control
connectors from the guide hole of steering
wheel lower end.
6) Install the airbag module to the steering wheel.
<Ref. to AB-14, INSTALLATION, Drivers Airbag
Module.>
WARNING:
Always refer to Air Bag System before servicing.
<Ref. to AB-4, CAUTION, General Description.>
VDC00042
VDC00065
VDC-26

CAUTION:
After installation, always make the following
two settings.
SRS roll connector and steering angle sensor
center setting
in later. Refer to VDCCM Adjustments for procedures regarding the above settings. <Ref. to
VDC-9, ADJUSTMENT, VDC Control Module
(VDCCM).>
C: INSPECTION
Refer to VDC (Diagnostics) Section for inspection
procedures of the steering angle sensor.
<Ref. to VDC(diag)-105, DTC 71 STEERING ANGLE SENSOR OFFSET IS TOO BIG, Diagnostic
<Ref. to VDC(diag)-107, DTC 71 CHANGE
RANGE OF STEERING ANGLE SENSOR IS TOO
BIG, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).> <Ref. to VDC(diag)-109, DTC 71
STEERING ANGLE SENSOR MALFUNCTION,
Diagnostic Procedure with Diagnostic Trouble
Code (DTC).> <Ref. to VDC(diag)-111, DTC 71
STEERING ANGLE SENSOR COMMUNICATION,
Code (DTC).>
VDC-27

8. Front ABS Wheel Speed Sensor

A: NOTE
Vehicles equipped with VDC have the same ABS
wheel speed sensor as installed on vehicles
equipped with ABS. Refer to Front ABS Wheel
Speed Sensor for removal, installation and inspection procedure.
<Ref. to ABS-14, Front ABS Wheel Speed Sensor.>
VDC-28

9. Rear ABS Wheel Speed Sensor

A: NOTE
Vehicles equipped with VDC have the same ABS
wheel speed sensor as installed on vehicles
equipped with ABS. Refer to Rear ABS Wheel
Speed Sensor for removal, installation and inspection procedure.
<Ref. to ABS-17, Rear ABS Wheel Speed Sensor.>
VDC-29
Front Tone Wheel

10.Front Tone Wheel

A: NOTE
The front tone wheel is built into the front drive
shaft. For removal, installation and inspection, refer
to the DS section.
<Ref. to DS-29, Front Drive Shaft.>
VDC-30
Rear Tone Wheel

11.Rear Tone Wheel

A: REMOVAL
Remove the bolt to remove the hub from the tone
wheel.
B: INSTALLATION
Remove any dirt on the contact surface of the hub
and tone wheel, then install the tone wheel to the
hub using the bolts.
<Ref. to DS-24, INSTALLATION, Rear Axle.>
C: INSPECTION
new tone wheel.
VDC-31
VDC OFF Switch

12.VDC OFF Switch

A: REMOVAL
VDC00042
2) Remove the instrument panel lower cover. <Ref.

to EI-39, REMOVAL, Instrument Panel Assembly.>
3) Disconnect the VDC OFF switch connector,
push outside, and press the VDC OFF switch.
VDC-00281
B: INSTALLATION
C: INSPECTION
(1)
2
1
6 5 4 3
VDC00263
(1) VDC OFF switch side
Inspect the resistance between VDC OFF switch

terminals.
Switch position
OFF
ON
Tester connection
35
35
Standard
1 M or more
Less than 1
If NG, replace the VDC OFF switch.
VDC-32

VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS)

A: PROCEDURE
NOTE:
To check harness for broken wires or short circuits, shake it while holding it or the connector.
Check List for Interview <Ref. to VDC(diag)-3, Check List for Interview.>
1
Step
PERFORM THE PRE-INSPECTION.
VDC(diag)-3, Check List for Interview.>
2) Before performing diagnosis, inspect the
unit which might influence the VDC problem.
<Ref. to VDC(diag)-8, INSPECTION, General
Description.>
3) Turn the ignition switch to ON and the Subaru Select Monitor ON.
4) Read the DTC. <Ref. to VDC(diag)-23,
(DTC).>
1) Inspect using General Diagnostic Table.
<Ref. to VDC(diag)-139, INSPECTION, General Diagnostic Table.>
VDC(diag)-25, OPERATION, Clear Memory
Mode.>
VDC(diag)-24, OPERATION, Inspection
Mode.>
4) Read the DTC. <Ref. to VDC(diag)-23,
(DTC).>
5) Check the DTC is not displayed.
PERFORM DIAGNOSIS.
VDC(diag)-34, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
NOTE:
Refer to List of Diagnostic Trouble Code
(DTC) for the DTC list. <Ref. to VDC(diag)-28,
LIST, List of Diagnostic Trouble Code (DTC).>
VDC(diag)-25, OPERATION, Clear Memory
Mode.>
VDC(diag)-24, OPERATION, Inspection
Mode.>
Check
Is the component that might
influence the VDC problem
working properly?
Yes
Go to step 2.
No
Repair or replace
each component.
Is DTC displayed?
Go to step 4.
Go to step 3.
Is the warning light pattern nor- Finish the diagnomal? <Ref. to VDC(diag)-26,
sis.
Warning Light Illumination Pattern.>
Is DTC displayed?
VDC(diag)-2
Check the warning

light. Refer to List
of Diagnostic Trouble Code (DTC)
for the contents of
the diagnosis.
<Ref. to
VDC(diag)-28, List

(DTC). <Ref. to
VDC(diag)-34,
(DTC).>


A: CHECK
Inspect the following item about the vehicles state.
1. STATE OF ABS/VDC WARNING LIGHT

ABS/VDC warning
lights illuminate.
Timing
Always
Sometimes
Only once
Does not come on
When and for how long does it illuminate?
LOCK
ACC
ON (before starting engine)
START
ON after starting (Engine is running)
Immediately after turning the ignition ON.
When accelerating
When decelerating
km/h
km/h
MPH
MPH
km/h
MPH
Steering angle:
Steering time:
deg
Sec.
Steering angle:
Steering time:
deg
Sec.

Part name:
VDC(diag)-3

2. STATE OF VDC WARNING LIGHT/VDC OFF INDICATOR LIGHT

VDC warning light/
VDC OFF indicator
light illuminate.
Timing
Always
Sometimes
Only once
Does not come on
LOCK
ACC
START
ON after starting (Engine is stopped)
When accelerating
When decelerating
km/h
MPH
km/h
MPH
km/h
Steering angle:
MPH
deg
Steering time:
Steering angle:
Sec.
deg
Steering time:
Sec.

Part name:
VDC(diag)-4

3. STATE OF VDC OPERATION INDICATOR LIGHT

VDC operation indicator light illuminate.
Timing
Always
Sometimes
Only once
Does not come on
LOCK
ACC
START
ON after starting (Engine is stopped)
When accelerating
When decelerating
km/h
MPH
km/h
MPH
km/h
Steering angle:
MPH
deg
Steering time:
Steering angle:
Sec.
deg
Steering time:
Sec.

Part name:
VDC(diag)-5

4. CONDITIONS UNDER WHICH TROUBLE OCCURS

Environment
a) Weather
Fine
Cloudy
Rainy
Snowy
Others:
b) Ambient temperature
C (F)
c) Road
Inner city
Suburbs
Highway
Local street
Uphill
Downhill
Paved road
Gravel road
Muddy road
Sandy place
Straight road
Sharp curve
Gentle curve
S-curve
Road with a slope on both sides
Others:
d) Road surface
Dry
Wet
Covered with fresh snow
Covered with hardened snow
Frozen slope
Others:
VDC(diag)-6

Condition
a) Brakes
Deceleration:
Temporary
b) Accelerator
Intermittent /
Acceleration:
Intermittent /
Temporary
km/h
c) Vehicle speed
G
G
MPH
Advancing
When accelerating
When decelerating
At low speed
When turning
Others:
d) Tire inflation pressure
e) Degree of wear
Front RH tire:
Front LH tire:
kPa
kPa
Rear RH tire:
Rear LH tire:
kPa
kPa
Front RH tire:
Front LH tire:
Rear RH tire:
Rear LH tire:
f) Steering wheel
Sharp turn
Gentle turn
Straight
Slow return
Fast return
g) Tire/Wheel size
Within specification
Except specification (
)
Summer tire
Studless tire (Manufacture:
h) Tire type
i) Chain is passed around tires:
j) T-type tire is used. :
Yes /
k) Condition of wheel alignment:
l) Loading state:
m) Repair parts are used:
Yes /
No
No
Yes /
No
Part name:
n) Others:
VDC(diag)-7
General Description
6. BRAKE PAD AND ROTOR
A: CAUTION
AIRBAG
The airbag system wiring harness is routed near
the ABS wheel speed sensor VDCCM and VDCH/
U.
CAUTION:
wiring harness when servicing the ABS wheel
speed sensor, VDCCM and VDCH/U.
Check the brake pad and rotor.

Front <Ref. to BR-16, INSPECTION, Front Brake
Pad.>, <Ref. to BR-17, INSPECTION, Front Disc
Rotor.>
Rear <Ref. to BR-21, INSPECTION, Rear Brake
Pad.>, <Ref. to BR-22, Rear Disc Rotor.>
7. TIRE
Check the tire specifications, tire wear and air pressure. <Ref. to WT-2, SPECIFICATION, General
Description.>
B: INSPECTION
Before performing diagnosis, check the following
items which might affect VDC problems.
1. BATTERY
Measure the battery voltage and check electrolyte.
Standard voltage:
12 V or more
Specific gravity:
1.260 or more
2. GROUND
Check the tightening of VDC ground bolt.
3. BRAKE FLUID
1) Check the brake fluid level. <Ref. to BR-41, INSPECTION, Brake Fluid.>
2) Check for brake fluid leaks. <Ref. to BR-41, INSPECTION, Brake Fluid.>
4. HYDRAULIC UNIT
Check the VDCH/U.
When using the brake tester <Ref. to VDC-15,
CHECKING THE VDC HYDRAULIC CONTROL
MODULE (VDCH/M) VDC OPERATION BRAKE
TESTER, INSPECTION, VDC Hydraulic Control
Module (VDCH/M).>
When not using the brake tester <Ref. to VDC14, CHECKING THE VDC HYDRAULIC CONTROL MODULE (VDCH/M) VDC OPERATION BY
PRESSURE GAUGE, INSPECTION, VDC Hydraulic Control Module (VDCH/M).>
5. BRAKE DRAG
Check for brake drag.
VDC(diag)-8
General Description
C: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
1B020XU0
DESCRIPTION
SUBARU SELECT
MONITOR KIT
REMARKS
Used for diagnosing electrical system.
ST1B020XU0
2. GENERAL TOOL
TOOL NAME
Circuit tester
Oscilloscope
REMARKS
VDC(diag)-9


A: LOCATION
(8)
(9)
(6)
(7)
(5)
(10)
(1)
(16)
(13)
(12)
(14)
(14)
(14)
(4)
(11)
(13)
(15)
(2)
(12)
(13)
(12)
(13)
(3)
(14)
(12)
VDC00282
(1)
VDC hydraulic control unit

(VDCH/U)
(7)
(8)

ABS warning light
(11)
(12)

Tone wheel
(2)
(3)

Master cylinder
(9)
VDC warning light/VDC OFF

indicator light
(13)
(14)
Wheel cylinder
(4)
(5)
VDC OFF switch

VDC indicator light
(10)

(TCM)
(15)
(16)

Pressure sensor
(6)
Brake warning light

(EBD warning light)
VDC(diag)-10

(5)
(6)
(7)
(8)
(9)
VDC00283
(1)
VDC00009
(16)
(15)
VDC00273
VDC00004
FRONT
REAR
(12)
(14)
VDC00167
VDC(diag)-11
VDC00008


B310
12
10
2
4
6
8
14
16
18
20
22
24
26
28
11
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56 57 58 59 60 61 62 63 64 65 66
67
68
69
70
71
72
73
74
75
76
77
78
79 80 81 82 83
10
2
4
6
8
3
5
7
9
29
30
31
32
33
34
35
36
37
38
56 57 58 59 60 61 62 63 64 65 66
67
68
10
12
11
38
68
39
69
14
13
40
70
41
71
16
15
42
72
43
73
18
17
44
74
45
75
19
46
76
20
19
46
76
47
77
21
48
78
28
22
24
26
27
23
25
49
50
51
52
53
54
55
79 80 81 82 83
VDC00010
NOTE:
Terminal numbers in the VDCCM connector are as shown in the figure.
When the connector is removed from VDCCM, the connector switch closes the circuit between terminals
No. 53 and 54. Then, ABS warning light and brake warning light (EBD warning light) illuminates.
VDC(diag)-12

Description
Ignition switch
ABS
Front wheel LH
wheel
Front wheel RH
speed
Rear wheel LH
sensor
(Wheel
Rear wheel RH
speed
sensor)
Yaw rate
& lateral
G sensor
Terminal
No.
(+) ()
28 1
19 21
Output (Yaw rate sensor)
65 64
Reference (Yaw rate sensor)
66 64
Test
67 64
64
CAN communication line (+)
83 1
CAN communication line ()
81 1
Relay box Motor relay drive

Motor monitor
Front inlet (hold) solenoid valve
LH
Front inlet (hold) solenoid valve
RH
Rear inlet (hold) solenoid valve
LH
Rear inlet (hold) solenoid valve
RH
VDCH/U
Pressure
sensor
When the ignition switch is ON, 10 15 V.
0.12 1 V (at 20 Hz)
17 18
11 64
50 64
Valve relay power supply

Valve relay drive
Measured value and measuring condition
13 14
15 16
Output (Lateral G sensor)

Power supply
Ground
Input/Output signal
2.2 2.8 V, when the vehicle is on level surface

Waveform <Ref. to VDC(diag)-16, WAVEFORM, MEASUREMENT,
Control Module I/O Signal.>
2.1 2.9 V
1 V 5 cycles for a 40 ms pulse signal. <Ref. to VDC(diag)-16,
WAVEFORM, MEASUREMENT, Control Module I/O Signal.>
2.5 1.5 V pulse signal <Ref. to VDC(diag)-16, WAVEFORM, MEASUREMENT, Control Module I/O Signal.>
3.5 2.5 V pulse signal <Ref. to VDC(diag)-16, WAVEFORM, MEASUREMENT, Control Module I/O Signal.>
27 1
48 1

When the ignition switch is ON, less than 15 V.
22 1
1.5 V or less (ABS/TCS/VDC Operation): 10 V or more (ABS/TCS/

VDC not operated)
91
1.5 V or less (ABS/TCS/VDC Operation): 10 V or more (ABS/TCS/

VDC not operated)
24 1
31
31 1
23 1
Front outlet (decompression)

solenoid valve LH
26 1
Front outlet (decompression)

solenoid valve RH
29 1
When the valve turns OFF, 10 15 V. When the valve turns ON,
less than 1.5 V.
Rear outlet (decompression)

solenoid valve LH
Rear outlet (decompression)
solenoid valve RH
Primary cut solenoid valve
34 1
Secondary cut solenoid valve

Primary suction solenoid valve
35 1
32 1
Secondary suction solenoid

valve
30 1
Power supply
Primary output
77 75
76 75
When the ignition switch is ON, 4.75 5.25 V.

0.48 0.72 V (when the brake pedal is released)
75
44 75
0.48 0.72 V (when the brake pedal is released)
Ground
Secondary output
41
25 1
VDC(diag)-13

Description
Terminal
No.
(+) ()
VDC indicator light
72 1
VDC warning light/VDC OFF indicator light
61 1
ABS warning light
53 1
38 1
VDC OFF switch
40 1
Ground
Ground
55
Brake warning light (EBD warning light)
54 1
Input/Output signal
Measured value and measuring condition
After turning the ignition switch to ON, less than 1.5 V during 1.5 seconds and 10 15 V after 1.5 seconds passed.
0 12 V pulse signal (in communication)
0 V (While pressing the switch)
VDC(diag)-14

B: WIRING DIAGRAM
(22)
(27)
(23)
(21)
(24)
(26)
(25)
(28)
(3)
(2)
(29)
(30)
(4)
(31)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(32)
(1)
(33)
(34)
(5)
(18)
(35)
(19)
(20)
(36)
VDC00271
(1)
(14)
Primary suction solenoid valve
(26)
Ignition relay
(2)
(3)
Relay box
Valve relay
(15)
(16)
Primary cut solenoid valve

Secondary suction solenoid valve
(27)
(28)
Battery
(4)
(5)
Motor relay
VDC hydraulic control unit
(VDCH/U)
(17)
(18)
Secondary cut solenoid valve

Motor
(29)

RH
(6)
Front inlet valve LH
(19)
(20)
Primary pressure sensor

Secondary pressure sensor
(30)
(31)
(7)
(8)
Front outlet valve LH

Front inlet valve RH
(21)
(22)
VDC OFF switch

ABS warning light

RH
(32)
(9)
(10)
Front outlet valve RH

Rear inlet valve LH
(23)
(33)
(34)
(11)
(12)
Rear outlet valve LH

Rear inlet valve RH
(24)
(25)
(35)
(13)
Rear outlet valve RH
VDC indicator light

Brake warning light
(EBD warning light)

(TCM)
(36)
Data link connector
VDC(diag)-15

C: MEASUREMENT
Measure the input and output signal voltages.
NOTE:
Measure while the VDCCM connector cover is removed. <Ref. to VDC(diag)-18, VDCCM Connector Cover.>
1. WAVEFORM
(1)
(V)
(2)
2
10
2.1 2.9 V
(4)
5.0 V
(3)
0
0
(5)
VDC00012
(1)
(2)
Yaw rate sensor

Terminals No. 65 64
(3)
(4)
Terminals No. 67 64
Vehicle is at a standstill.
VDC(diag)-16
(5)
20 ms

(1)
(V)
(4)
4
(2)
1.5 V
2.5 V
0
4
(3)
2.5 V
3.5 V
VDC00013
(1)
CAN communication line
(2)
Terminals No. 83 1
(3)
Terminals No. 81 1
VDC(diag)-17
(4)
5 ms
VDCCM Connector Cover

6. VDCCM Connector Cover

A: REMOVAL
2) Disconnect the connectors from VDCCM.
3) Remove the band.
4) Remove the cable clamp cover.
5) Remove the screw securing the connector cover.
VDC00014
(1) Connector cover

(2) Band
(3) Cable clamp cover
6) Remove the connector cover.
VDC00015
B: INSTALLATION
NOTE:
Align the rib on the connector cover with the connector hole before installation.
VDC00016
(1) Rib
(2) Hole
VDC(diag)-18


A: OPERATION
1. READ DTC
link connector.
portion of the instrument panel (on the drivers
side).
NOTE:
<Ref. to VDC(diag)-28, List of Diagnostic Trouble
Code (DTC).>
Up to 3 DTCs are displayed in the order of detection.
If a particular DTC is not stored in memory properly at the occurrence of problem (due to a drop in
ABSCM&H/U power supply etc.), the DTC suffixed
with a question mark ? is displayed on Subaru Select Monitor display screen. This shows it may be
Display
The current DTC is displayed on Subaru

Old
The latest DTC from the history of previous problems is displayed on Subaru
(1)
VDC00284

connector.
4) Turn the ignition switch to ON (engine is OFF),
screen, select the {Brake Control}.
7) Select the [OK] after the {VDC} is displayed.
8) On the Brake Control Diagnosis screen, select the {Diagnostic Code(s) Display}.
Contents of Display
Current
Second previous The second latest DTC from the history

of previous problems is displayed on the
Subaru Select Monitor display screen.
Third previous
The third latest DTC from the history of
previous problems is displayed on Subaru Select Monitor display screen.
VDC(diag)-19


4) On the Brake Control Diagnosis display screen, select the {Current Data Display/Save} .
5) On the Data Display Menu screen, select the {Data Display}.
6) Using the scroll key, scroll the display screen up or down until the desired data is shown on the screen.
Display
FR Wheel Speed
FL Wheel Speed
RR Wheel Speed
Wheel speed detected by front ABS wheel speed sensor RH is displayed.
Wheel speed detected by front ABS wheel speed sensor LH is displayed.
Wheel speed detected by rear ABS wheel speed sensor RH is displayed.
Unit of measure
km/h
km/h
km/h
RL Wheel Speed
Wheel speed detected by rear ABS wheel speed sensor LH is displayed.

Yaw Rate Sensor
Steering wheel angle detected by steering angle sensor is displayed.

Vehicle angular speed detected by yaw rate sensor is displayed.
deg
deg (deg/s)
Pressure Sensor (P)
Brake fluid pressure detected by the primary pressure sensor is displayed.
bar
Pressure Sensor (S)
m/s (m/s2)
IG Power Supply Voltage
Brake fluid pressure detected by the secondary pressure sensor is displayed.

Vehicle lateral direction acceleration detected by lateral G sensor is displayed.
Voltage supplied to the VDCCM is displayed.
Valve Relay Signal

Motor Relay Signal
The valve relay operating condition is displayed.

The motor relay operating condition is displayed.
ON or OFF
ON or OFF
Motor Relay Monitor

VDC Operation Light

VDC operation condition is displayed.
ON or OFF
ON or OFF
VDC Warning Light
ON/OFF condition of the VDC warning light/VDC OFF indicator light is

displayed. (ON is displayed when there is a VDC failure.)
ON or OFF
ABS Warning Light

VDC OFF Light
ON or OFF
EBD Warning Light
ON/OFF condition of the ABS warning light is displayed.

ON/OFF condition of the VDC warning light/VDC OFF indicator light is
displayed. (ON/OFF is displayed by operating the VDC OFF switch and
EAM signal.)
ON/OFF condition of the EBD warning light is displayed.
EAM Signal
PATA Signal
Engine control command signal is displayed.

ON/OFF condition of the VDC OFF switch is displayed.
1 or 0
ON or OFF
Gear Position
Gear position is displayed by number.

0: N or P, 1: 1st, 2: 2nd, 3: 3rd, 4: 4th, 7: R
Engine Speed
PW Signal
Engine speed is displayed.

Acceleration opening is displayed.
Car Line
Vehicle type is displayed by number. Normally 1
Lateral G Sensor
km/h
bar
ON or OFF
ON or OFF
rpm
%
NOTE:
VDC(diag)-20


1) On the Main Menu display screen, select the {2. Each System Check}.
4) On the Brake Control Diagnosis display screen, select the {Clear Memory}.
5) When the Done is shown on the display screen, turn the Subaru Select Monitor and ignition switch to
OFF.
NOTE:
4. FUNCTION CHECK
Display
ABS check mode
VDC check mode
Steering angle sensor neutral
& lateral G sensor 0 pt mode
Contents of Display
Operate the valve and pump motor by turns to
perform the ABS sequence control.
Operate the valve and pump motor by turns to
perform the VDC sequence control.
Set the steering angle sensor neutral position
and the lateral G sensor 0 points.
VDC(diag)-21
Index No.
<Ref. to VDC-16, ABS Sequence Control.>
<Ref. to VDC-25, Steering Angle Sensor.>

5. FREEZE FRAME DATA

NOTE:
Data stored at the time of failure occurred is shown on display.
Each time a failure occurs, the latest information is stored in the freeze frame data in memory.
1 freeze frame data is stored.
If a freeze frame data is not properly stored in memory (due to a drop in VDCCM power supply, etc.), a
DTC suffixed with a question mark ? appears on the Subaru Select Monitor display. This shows it may be
FREEZE FRAME DATA LIST
Display
FR Wheel Speed
FL Wheel Speed
Wheel speed detected by the front ABS wheel speed sensor RH is displayed in km/h.
Wheel speed detected by the front ABS wheel speed sensor LH is displayed in km/h.
RR Wheel Speed
Wheel speed detected by the rear ABS wheel speed sensor RH is displayed in km/h.
RL Wheel Speed
Wheel speed detected by the rear ABS wheel speed sensor LH is displayed in km/h.
Steering wheel angle detected by steering angle sensor is displayed.
Yaw Rate Sensor

Lateral G Sensor
Vehicle angular speed detected by the yaw rate sensor is converted and displayed in volts.
Vehicle lateral direction acceleration detected by lateral G sensor is converted and displayed
in volts.
Brake fluid pressure detected by the primary pressure sensor is converted and displayed in
volts.
Brake fluid pressure detected by the secondary pressure sensor is converted and displayed
in volts.
Primary Pressure Sensor

Secondary Pressure Sensor
Vehicle Speed
Required Torque
The vehicle speed is displayed.

Engine torque required by the driver is displayed.
Current Torque
Target Torque
Current engine torque is displayed.

The target torque is displayed.
Acceleration Opening Angle

Engine Speed
Acceleration opening is displayed.

Engine speed is displayed.
Gear Position
IG Power Supply Voltage
Gear position is displayed.

Voltage supplied to VDC control module is displayed.
ABS Warning Light

EBD Warning Light
ON/OFF condition of the ABS warning light is displayed.

ON/OFF condition of the EBD warning light is displayed.
VDC Warning Light
ON/OFF condition of the VDC warning light/VDC OFF indicator light is displayed. (ON is displayed when there is a VDC failure.)
VDC OFF Light
ON/OFF condition of the VDC warning light/VDC OFF indicator light is displayed. (ON/OFF is
displayed by operating the VDC OFF switch and EAM signal.)
VDC Operation Light

Valve Relay Signal
ON/OFF condition of VDC OFF indicator light is displayed.

The valve relay operating condition is displayed.
Motor Relay Driving Vibration

Motor Relay Monitor

Decreasing Required Torque

EAM Signal
Engine torque decrease request is displayed.

Engine control command signal is displayed.
VDC O Control Flag

VDC U Control Flag
VDC operation condition (over-steering) is displayed.

VDC operation condition (under-steering) is displayed.
ABS Control Flag

VDC OK B Signal
ABS operating condition is displayed.

VDC sensor normal flag
VDC(diag)-22


Code (DTC)
A: OPERATION
For details concerning DTC, refer to the Subaru
Select Monitor. <Ref. to VDC(diag)-19, Subaru
Select Monitor.> When doing so, read the detail
code displayed under the DTC at the same time.
VDC(diag)-23
Inspection Mode
9. Inspection Mode
A: OPERATION
Reproduce the malfunction occurrence condition
as much as possible.
Drive the vehicle for ten minutes or more.
NOTE:
While driving normally, check that the vehicle does
not veer to the left or right from the straight-ahead
direction.
VDC(diag)-24
Clear Memory Mode


A: OPERATION
Subaru Select Monitor. <Ref. to VDC(diag)-19,
VDC(diag)-25
Warning Light Illumination Pattern

11.Warning Light Illumination Pattern

A: INSPECTION
(6)
(5)
(4)
(3)
(1)
(3)
(2)
(9)
(7)
(10)
(8)
(8)
(11)
(9)
(12)
(8)
(8)
(14)
(9)
(13)
(8)
(8)
VDC00274
(1)
(2)
Ignition switch
OFF
(7)
(8)
ABS warning light

Light OFF
(12)
(3)
(4)
ON
Engine start
(9)
(10)
Light ON
Approx. 2 sec.
(13)
(14)
(5)
(6)
Engine start
Parking brake released
(11)

light)
VDC indicator light

Few seconds (Depends on the
coolant temperature)
VDC(diag)-26
Warning Light Illumination Pattern

1) When warning lights or indicator lights do not illuminate in accordance with this illumination pattern, there must be an electrical malfunction.
2) When warning lights or indicator lights remain
constantly OFF, repair or diagnose the warning
light or indicator light circuits. <Ref. to VDC(diag)37, ABS WARNING LIGHT, VDC WARNING
LIGHT/VDC OFF INDICATOR LIGHT,BRAKE
WARNING LIGHT (EBD WARNING LIGHT) OR
VDC INDICATOR LIGHT DOES NOT COME ON,
Code (DTC).> <Ref. to VDC(diag)-40, ABS WARNING LIGHT, VDC WARNING LIGHT/VDC OFF INDICATOR LIGHT, BRAKE WARNING LIGHT
(EBD WARNING LIGHT) DOES NOT GO OFF, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).> <Ref. to VDC(diag)-43, VDC INDICATOR
LIGHT DOES NOT GO OFF, Diagnostic Procedure
NOTE:
Even though the ABS warning light does not go
out approx. after 2 seconds from ABS warning light
illumination, the ABS system operates normally
when the warning light goes out while driving at approximately 12 km/h (7.46 MPH). However, the
ABS does not work while the ABS warning light is illuminated.
If the vehicle has been standing for some time in
a low temperature area, there are instances in
which the VDC warning light/VDC OFF indicator
light will take several minutes to turn off. This is due
to the low engine coolant temperature, and is not a
malfunction.
If one wheel is locked, or turns freely, a change is
generated in the drive transmission to the other
wheels. The status of the change in drive differs
from what occurs during normal operation. This
status is detected by the ABS wheel speed sensor.
The ABS and VDC warning lights will illuminate.
When the vehicle is operated while all four wheels
are lifted off the ground, or the four wheels are
placed on rollers, the VDCCM sometimes detects a
problem in the speed sensor, and the ABS and
VDC warning lights illuminate. In this case, this is
not a malfunction. Erase the DTC from the memory.
VDC(diag)-27


A: LIST
DTC
Detail
code
No.
Display
Communication for
initialization impossi- Subaru Select Monitor
ble
communication failure
No DTC
No DTC
No DTC
21
6A0XH
22
68CXH
68EXH
690XH
694XH
23
620XH
24
60CXH
60EXH
610XH
614XH
25
660XH
26
64CXH
64EXH
650XH
654XH
27
6E0XH
28
6CCXH
6CEXH
6D0XH
6D4XH
Front Right ABS

Sensor Circuit Open
or Shorted Battery
Front Right ABS
Wheel Sensor Signal Malfunction
Even when the DTC is not

displayed on the Subaru
Select Monitor display, the
ABS warning light, VDC
warning light/VDC OFF
indicator light and VDC
operation indicator light do
not come on.
ABS warning light, VDC
warning light/VDC OFF
indicator light and brake
warning light (EBD warning
light) do not come on.
VDC operation indicator
light does not extinguish.
Open or Short Circuit in
Front ABS Wheel Speed
Sensor RH Circuit
Reference target
<Ref. to VDC(diag)-34, COMMUNICATION FOR INITIALIZING IS IMPOSSIBLE (SUBARU SELECT MONITOR
COMMUNICATION MALFUNCTION), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to VDC(diag)-37, ABS WARNING LIGHT, VDC
WARNING LIGHT/VDC OFF INDICATOR LIGHT,BRAKE
WARNING LIGHT (EBD WARNING LIGHT) OR VDC
INDICATOR LIGHT DOES NOT COME ON, Diagnostic
<Ref. to VDC(diag)-40, ABS WARNING LIGHT, VDC

WARNING LIGHT/VDC OFF INDICATOR LIGHT, BRAKE
WARNING LIGHT (EBD WARNING LIGHT) DOES NOT
GO OFF, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to VDC(diag)-43, VDC INDICATOR LIGHT DOES

NOT GO OFF, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to VDC(diag)-44, DTC 21 FRONT RIGHT ABS
SENSOR CIRCUIT OPEN OR SHORT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Front ABS wheel speed

sensor RH signal error
<Ref. to VDC(diag)-49, DTC 22 FRONT RIGHT ABS

SENSOR SIGNAL, Diagnostic Procedure with Diagnostic
Front Left ABS Sensor Circuit Open or

Shorted Battery
Front Left ABS
Wheel Speed Sensor Signal Malfunction

Front ABS Wheel Speed
Sensor LH Circuit
<Ref. to VDC(diag)-44, DTC 23 FRONT LEFT ABS SENSOR CIRCUIT OPEN OR SHORT, Diagnostic Procedure
Front ABS wheel speed

sensor LH signal error
<Ref. to VDC(diag)-49, DTC 24 FRONT LEFT ABS SENSOR SIGNAL, Diagnostic Procedure with Diagnostic
Open/High Input of
Rear ABS Wheel
Speed Sensor RH

Rear ABS Wheel Speed
Sensor RH Circuit
<Ref. to VDC(diag)-44, DTC 25 REAR RIGHT ABS SENSOR CIRCUIT OPEN OR SHORT, Diagnostic Procedure
Rear ABS wheel speed

sensor RH signal error
<Ref. to VDC(diag)-49, DTC 26 REAR RIGHT ABS SENSOR SIGNAL, Diagnostic Procedure with Diagnostic

Rear ABS Wheel Speed
Sensor LH Circuit
<Ref. to VDC(diag)-45, DTC 27 REAR LEFT ABS SENSOR CIRCUIT OPEN OR SHORT, Diagnostic Procedure
Rear ABS wheel speed

sensor LH signal error
<Ref. to VDC(diag)-50, DTC 28 REAR LEFT ABS SENSOR SIGNAL, Diagnostic Procedure with Diagnostic
Rear Right ABS

Open/High Input of
Rear ABS Wheel
Speed Sensor LH
Rear Left ABS
VDC(diag)-28

DTC
29
Detail
code
No.
604XH
606XH
608XH
644XH
646XH
648XH
684XH
686XH
688XH
6C4XH
6C6XH
6C8XH
702XH
704XH
720XH
70CXH
31
320XH
32
360XH
33
220XH
34
260XH
35
2A0XH
36
2E0XH
37
3A0XH
38
3E0XH
Display
Reference target
Any One of Four

ABS Sensors Signal
FR hold valve malfunction

FR pressure reducing valve malfunction
FL hold valve malfunction
FL pressure reducing valve malfunction
RR hold valve malfunction
RR pressure reducing valve malfunction
RL hold valve malfunction
RL pressure reducing valve malfunction
One sensor signal error of

any of the four ABS wheel
speed sensors
<Ref. to VDC(diag)-55, DTC 29 ANY OF WHEEL SENSORS SIGNAL, Diagnostic Procedure with Diagnostic
Front inlet solenoid valve

RH malfunction
<Ref. to VDC(diag)-58, DTC 31 FRONT SOLENOID

RIGHT INLET VALVE MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Front outlet solenoid valve

RH malfunction
Front inlet solenoid valve
LH malfunction
Front outlet solenoid valve
LH malfunction
Rear inlet solenoid valve
RH malfunction
<Ref. to VDC(diag)-64, DTC 32 FRONT RIGHT OUTLET

SOLENOID VALVE MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to VDC(diag)-58, DTC 33 FRONT LEFT INLET
<Ref. to VDC(diag)-64, DTC 34 FRONT LEFT OUTLET
<Ref. to VDC(diag)-58, DTC 35 REAR RIGHT INLET
Rear outlet solenoid valve

RH malfunction
<Ref. to VDC(diag)-64, DTC 36 REAR RIGHT OUTLET

Rear inlet solenoid valve LH

malfunction
<Ref. to VDC(diag)-58, DTC 37 REAR LEFT INLET

Rear outlet solenoid valve

LH malfunction
<Ref. to VDC(diag)-64, DTC 38 REAR LEFT OUTLET

VDC(diag)-29

DTC
41
Detail
code
No.
000XH
002XH
004XH
006XH
014XH
016XH
018XH
024XH
026XH
028XH
02CXH
02EXH
030XH
03AXH
03EXH
034XH
036XH
038XH
9D4XH
9E0XH
42
7CEXH
7D0XH
44
9A0XH
45
970XH
45
972XH
46
9CEXH
47
788XH
78CXH
7A0XH
7A4XH
Display
ECM
VDCCM malfunction
Low power supply

voltage
AT communication
Different control
module specification
Power supply voltage malfunction

TCM communication line
malfunction
Incorrect VDCCM
AT ECM
5 V power supply
51
Reference target
Improper CAN communication
048XH
Valve relay OFF

malfunction
064XH
Valve relay ON malfunction
06AXH
Valve relay test malfunction
<Ref. to VDC(diag)-70, DTC 41 ECM, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to VDC(diag)-72, DTC 42 POWER VOLTAGE MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to VDC(diag)-74, DTC 44 TCM COMMUNICATION
CIRCUIT, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to VDC(diag)-76, DTC 45 INCORRECT VDC CONTROL MODULE SPECIFICATIONS, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
TCM error specifications
<Ref. to VDC(diag)-76, DTC 45 TCM MALFUNCTION,

(DTC).>
5 V power supply voltage

error
<Ref. to VDC(diag)-77, DTC 46 ABNORMAL VOLTAGE

OF 5V POWER SUPPLY, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to VDC(diag)-80, DTC 47 CAN COMMUNICATION,

Defective CAN communicaDiagnostic Procedure with Diagnostic Trouble Code
tion line
(DTC).>
<Ref. to VDC(diag)-83, DTC 51 VALVE RELAY OFF MALFUNCTION/ VALVE RELAY TEST MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to VDC(diag)-89, DTC 51 VALVE RELAY ON FAILURE, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to VDC(diag)-83, DTC 51 VALVE RELAY OFF MALFUNCTION/ VALVE RELAY TEST MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
VDC(diag)-30

DTC
52
Detail
code
No.
Display
5A0XH
Motor/Motor relay
OFF malfunction
58EXH
Motor/Motor relay
ON malfunction
Reference target
Defective motor and motor

relay OFF
<Ref. to VDC(diag)-93, DTC 52 MOTOR/MOTOR RELAY

OFF MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Defective motor and motor

relay ON
<Ref. to VDC(diag)-96, DTC 52 MOTOR/MOTOR RELAY

ON MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Defective motor
<Ref. to VDC(diag)-100, DTC 52 MOTOR MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
ECM communication malfunction
<Ref. to VDC(diag)-103, DTC 57 ECM COMMUNICATION CIRCUIT, Diagnostic Procedure with Diagnostic
Motor
58CXH
EGI ECM signal
57
820XH
61
4A0XH
VDC switching valve

1 (S)
62
4E0XH
VDC switching valve

1 (P)
63
520XH
VDC switching valve

2 (S)
64
560XH
VDC switching valve

2 (P)
148XH
Steering angle sensor offset is too big
14AXH
71
142XH
144XH
146XH
158XH
15AXH
15CXH
15EXH
14CXH
14EXH
150XH
152XH
160XH
Change range of
steering angle sensor is too big
Secondary cut valve malfunction

Primary cut valve malfunction
malfunction
Primary suction valve malfunction
<Ref. to VDC(diag)-58, DTC 61 SECONDARY CUT

<Ref. to VDC(diag)-59, DTC 62 PRIMARY CUT SOLENOID VALVE MALFUNCTION, Diagnostic Procedure with
<Ref. to VDC(diag)-64, DTC 63 SECONDARY SUCTION
<Ref. to VDC(diag)-65, DTC 64 PRIMARY SUCTION
The steering angle sensor

offset is too large.
<Ref. to VDC(diag)-105, DTC 71 STEERING ANGLE

SENSOR OFFSET IS TOO BIG, Diagnostic Procedure
The steering angle sensor

change range is too large.
<Ref. to VDC(diag)-107, DTC 71 CHANGE RANGE OF

STEERING ANGLE SENSOR IS TOO BIG, Diagnostic
Defective steering angle

sensor

SENSOR MALFUNCTION, Diagnostic Procedure with
Signals from the steering

angle sensor are not sent.

SENSOR COMMUNICATION, Diagnostic Procedure with
Steering angle sensor output
No signal from
steering angle sensor
VDC(diag)-31

DTC
72
Detail
code
No.
180XH
182XH
184XH
186XH
188XH
18BXH
18EXH
190XH
192XH
194XH
196XH
198XH
19AXH
1A0XH
Reference target
Yaw rate sensor output
Yaw rate sensor output

error
Yaw rate sensor

power/output
Voltage input to the yaw

rate sensor exceeds specifications.
<Ref. to VDC(diag)-114, DTC 72 ABNORMAL YAW RATE

SENSOR OUTPUT, Diagnostic Procedure with Diagnostic
<Ref. to VDC(diag)-116, DTC 72 VOLTAGE INPUTTED

TO YAW RATE SENSOR EXCEEDS SPECIFICATION,
(DTC).>
<Ref. to VDC(diag)-118, DTC 72 ABNORMAL YAW RATE
SENSOR REFERENCE VOLTAGE, Diagnostic Procedure
YAW RATE SENSOR SIGNAL IS TOO BIG, Diagnostic
Yaw rate sensor reference
18CXH
Excessive variation
amount of yaw rate
sensor output
The yaw rate sensor signal

Excessive amount of
lateral G sensor output offset
The lateral G sensor offset

is too large.
<Ref. to VDC(diag)-122, DTC 73 LATERAL G SENSOR

OFFSET IS TOO BIG, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Lateral G sensor output

malfunction
<Ref. to VDC(diag)-122, DTC 73 ABNORMAL LATERAL

G SENSOR OUTPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
1C0XH
1C6XH
1D8XH
1CCXH
1D2XH
1E0XH
120XH
122XH
74
19CXH
1C8XH
1CAXH
73
Display
110XH
112XH
10AXH
Lateral G sensor
output
Excessive variation
amount of lateral G
sensor output
Excessive lateral G
sensor output
Lateral G sensor
power/output
Yaw rate sensor reference

voltage malfunction
The lateral G sensor

Excessive Lateral G Sensor
Signal
Voltage input to the lateral
G sensor exceeds specifications.

LATERAL G SENSOR SIGNAL IS TOO BIG, Diagnostic
<Ref. to VDC(diag)-123, DTC 73 EXCESSIVE LATERAL
G SENSOR SIGNAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to VDC(diag)-125, DTC 73 VOLTAGE INPUTTED
TO LATERAL G SENSOR EXCEEDS SPECIFICATION,
(DTC).>
Primary pressure
sensor power/output
Voltage input to the primary pressure sensor

exceeds specifications.
Secondary pressure sensor power/

output
Primary pressure
sensor offset is too
big
Secondary pressure sensor offset is
too big
Differential pressure
of pressure sensor
is too big
Voltage input to the second- <Ref. to VDC(diag)-131, DTC 74 SECONDARY PRESary pressure sensor
SURE SENSOR POWER/OUTPUT, Diagnostic Proceexceeds specifications.
dure with Diagnostic Trouble Code (DTC).>
<Ref. to VDC(diag)-133, DTC 74 PRIMARY PRESSURE
The primary pressure senSENSOR OFFSET IS TOO BIG, Diagnostic Procedure
sor offset is too big.
<Ref. to VDC(diag)-134, DTC 74 SECONDARY PRESThe secondary pressure
SURE SENSOR OFFSET IS TOO BIG, Diagnostic Procesensor offset is too big.
dure with Diagnostic Trouble Code (DTC).>
The differential pressure of <Ref. to VDC(diag)-136, DTC 74 DIFFERENTIAL PRESthe pressure sensor is too
SURE OF PRESSURE SENSOR IS TOO BIG, Diagnostic
big.
<Ref. to VDC(diag)-128, DTC 74 PRIMARY PRESSURE

SENSOR POWER/OUTPUT, Diagnostic Procedure with
VDC(diag)-32

If either of the following multiple of DTC are in the memory, check the part that corresponds to the first DTC.
If a problem is not detected, check the portions that correspond to the other DTC in the order that the codes
appear.
Combination of DTC
Problem portions
46 5 V power supply voltage error

74 Voltage input to the pressure sensor
(B310) No. 77 lead circuit is

shorted to the ground or battery.
44 TCM communication circuit

71 Signals from the steering angle sensor
are not sent.
(B310) No. 83 or 81 lead circuits

are open.
51 Valve relay
are not sent.

open.

are not sent.
51 Valve relay
44 TCM communication circuit

open.
73 Voltage input to the lateral G sensor

72 Voltage input to the yaw rate sensor

open.
VDC(diag)-33
Reference target
<Ref. to VDC(diag)-77, DTC 46 ABNORMAL VOLTAGE OF 5V POWER SUPPLY,
<Ref. to VDC(diag)-111, DTC 71 STEERING ANGLE SENSOR COMMUNICATION,
<Ref. to VDC(diag)-123, DTC 73 EXCESSIVE LATERAL G SENSOR SIGNAL, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>


A: COMMUNICATION FOR INITIALIZING IS IMPOSSIBLE
(SUBARU SELECT MONITOR COMMUNICATION MALFUNCTION)
TROUBLE SYMPTOM:
The ABS warning light is kept on.
WIRING DIAGRAM:
BATTERY
SBF-4 50A
SBF-1 120A
IGNITION SWITCH
GENERATOR
1
55
B40
38
28
NO.18 15A
DATA LINK CONNECTOR
E
B310
VDC CONTROL MODULE
B40
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B310
12
2
4
6
8
14
16
18
20
22
24
26
28
10
11
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56 57 58 59 60 61 62 63 64 65 66
67
68
69
70
71
72
73
74
75
76
77
78
79 80 81 82 83
VDC00488
VDC(diag)-34

10
Step
Check
Is the ignition switch turned
ON?
Yes
Go to step 2.
CHECK BATTERY.
Go to step 3.

tery terminal?
CHECK SUBARU SELECT MONITOR COM- Are the system name and year Go to step 8.
MUNICATION.
displayed on Subaru Select
Monitor?
Go to step 9.
MUNICATION.
model year displayed on Subaru Select Monitor?
2) Disconnect the VDCCM connector.
3) Check whether communication to other systems can be executed normally.
Go to step 7.
CONNECTOR.
2) Disconnect the VDCCM connector.
CHECK OUTPUT SIGNAL FOR VDCCM.
Repair the harness
and connector
2) Measure the voltage between data link conbetween each connector and chassis ground.
trol module and
data link connec(B40) No. 7 (+) Chassis ground ():
tor.
CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 0.5 Repair the harness
?
and connector
VDCCM AND DATA LINK CONNECTOR.
Measure the resistance between VDCCM conbetween VDCCM
and data link connector and data link connector.
nector.
(B310) No. 38 (B40) No. 7:
Is the VDCCM connector
Go to step 10.
CHECK INSTALLATION OF VDCCM CONinserted into the VDCCM until
NECTOR.
the clamp is secured?
1) Turn the ignition switch to ON (engine is
OFF).
between the VDCCM connector and chassis
ground.
VDC(diag)-35
Go to step 11.
No
Turn the ignition
switch to ON, and
select VDCCM
mode using Subaru Select Monitor.
Charge or replace
the battery.
Go to step 4.
Go to step 5.
Go to step 6.
Repair the harness

and connector
Go to step 8.
Go to step 9.
Insert the VDCCM

connector into the
VDCCM until the
clamp is secured.
Repair open circuit
of harness
between VDCCM
and battery.

11
12
Step
Check
Yes
VDCCM AND CHASSIS GROUND.
2) Disconnect the connector from VDCCM and
transmission.
between VDCCM and chassis ground.
CHECK THE POOR CONTACT OF CONNEC- Is there poor contact in control Repair the connecTOR.
module power supply, ground tor.
line and in the data link connector?
VDC(diag)-36
No
Repair the open
VDCCM and inhibitor switch connector, and the poor
Replace the
VDCCM. <Ref. to
VDC-8, VDC Control Module
(VDCCM).>

B: ABS WARNING LIGHT, VDC WARNING LIGHT/VDC OFF INDICATOR

LIGHT,BRAKE WARNING LIGHT (EBD WARNING LIGHT) OR VDC
INDICATOR LIGHT DOES NOT COME ON
ABS warning light circuit is open or shorted.
VDC warning light/VDC OFF indicator light circuit is open or shorted.
VDC operation indicator light circuit is open or shorted.
Brake warning light (EBD warning light) circuit is open or shorted.
TROUBLE SYMPTOM:
When the ignition switch is ON (engine OFF), ABS warning light, VDC warning light/VDC OFF indicator light,
VDC operation indicator light or brake warning light (EBD warning light) does not come on.
NOTE:
When the VDC OFF switch is held down for 10 seconds or more while the engine is running, the VDC warning light/VDC OFF indicator light will turn off and any following switch operations will be ignored. To recover
VDC operation, turn the ignition switch from OFF to ON again.
VDC(diag)-37

WIRING DIAGRAM:
BATTERY
IGNITION SWITCH
SBF-4
SBF-1 120A
NO.14 10A
NO.18 15A
B36
5
i1
VDC OPERATION
INDICATOR LIGHT
COMBINATION METER
i12
i10
c:
i11
i1
VDC OFF SWITCH
20
23
26
i3
B36
a:
b:
b20
c3
c7
c6
PARKING BRAKE/
BRAKE FLUID
WARNING LIGHT
ABS WARNING LIGHT
VDC WARNING LIGHT/

VDC OFF
INDICATOR LIGHT
b9
i1
B38
B36
B310
2
1
3 4 5 6
55
40
i12
4 5 6
1 2 3
7 8 9 10 11 12 13 14
B318
VDC CONTROL MODULE
a:
B318
72
54
53
61
28
5
3
b:
i10
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
c:
i11
1 2 3 4 5 6 7 8 9 10
B38
B36
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B310
2
4
6
8
14
16
18
20
22
24
26
28
10
11
12
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56 57 58 59 60 61 62 63 64 65 66
67
68
69
70
71
72
73
74
75
76
77
78
79 80 81 82 83
VDC00489
Step
Check
CHECK ILLUMINATION OF OTHER WARN- Do other warning lights illumiING LIGHT.
nate?
Turn the ignition switch to ON (engine is OFF).
VDC(diag)-38
Yes
Go to step 2.
No
Repair the combination meter. <Ref.
to IDI-10, Combination Meter.>

Step
CHECK BULBS.
3) Check the ABS warning light bulb, VDC
warning light bulb, VDC operation indicator light
bulb or the brake warning light bulb, and the
VDC OFF indicator light bulb.
CHECK BATTERY SHORT OF LIGHT HARNESS.
1) Disconnect the VDCCM connector from the
VDCCM.
2) Fit one sheet of paper (thickness 1.5 mm
(0.059 in)) into the switch of the VDCCM connector.
4) Measure the voltage between VDC connector and chassis ground.
ABS warning light
VDC warning light
Brake warning light
VDC indicator light
2) Install the ABS warning light bulb to the
combination meter.
3) Install the combination meter.
6) Measure the voltage between VDCCM connector and chassis ground.
ABS warning light
VDC warning light
Brake warning light
VDC indicator light
Check
Is the bulb OK?
Yes
Go to step 3.
No
Replace the defective bulbs. <Ref. to
IDI-11, DISASSEMBLY, Combination Meter.>
Go to step 4.
Repair the light

harness.
Go to step 5.
Repair the wiring

harness.
Is there poor contact in connectors between combination

meter and the VDCCM?
CHECK WARNING LIGHT AND INDICATOR Do the ABS warning light, VDC
LIGHT.
warning light, brake warning
1) Connect the connector to the VDCCM.
light, VDC operation indicator
light and VDC OFF indicator
light illuminate?
VDC(diag)-39

tor.
Temporary poor
contact occurs.
Replace the
VDCCM. <Ref. to
(VDCCM).>

C: ABS WARNING LIGHT, VDC WARNING LIGHT/VDC OFF INDICATOR LIGHT,

BRAKE WARNING LIGHT (EBD WARNING LIGHT) DOES NOT GO OFF
ABS warning light circuit is open or shorted.
VDC control warning light/VDC OFF indicator light circuit is open or shorted.
Brake warning light (EBD warning light) circuit is open or shorted.
Diagnosis circuit is open.
VDC OFF switch is shorted.
TROUBLE SYMPTOM:
When starting the engine, the ABS warning light and VDC warning light/VDC OFF indicator light are kept
ON.
After starting the engine, the brake warning light (EBD warning light) is kept on even though the parking
brake is released.
NOTE:
When pressing the VDC OFF switch for 10 seconds or more while the engine is running, the VDC OFF indicator lights go off and the switch cannot be operated any more. To recover VDC operation, turn the ignition
switch from OFF to ON again.
When the engine coolant temperature is too low, the VDC OFF indicator light illuminates. The light will turn
off when the engine is warmed up.
VDC(diag)-40

WIRING DIAGRAM:
BATTERY
IGNITION SWITCH
SBF-4
SBF-1 120A
NO.14 10A
NO.18 15A
B36
5
i1
VDC OPERATION
INDICATOR LIGHT
COMBINATION METER
i12
i10
c:
i11
i1
VDC OFF SWITCH
20
23
26
i3
B36
a:
b:
b20
c3
c7
c6
PARKING BRAKE/
BRAKE FLUID
WARNING LIGHT
ABS WARNING LIGHT
VDC WARNING LIGHT/

VDC OFF
INDICATOR LIGHT
b9
i1
B38
B36
B310
2
1
3 4 5 6
55
40
i12
4 5 6
1 2 3
7 8 9 10 11 12 13 14
B318
VDC CONTROL MODULE
a:
B318
72
54
53
61
28
5
3
b:
i10
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
c:
i11
1 2 3 4 5 6 7 8 9 10
B38
B36
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B310
2
4
6
8
14
16
18
20
22
24
26
28
10
11
12
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56 57 58 59 60 61 62 63 64 65 66
67
68
69
70
71
72
73
74
75
76
77
78
79 80 81 82 83
VDC00489
VDC(diag)-41

Step
CHECK INSTALLATION OF VDCCM CONNECTOR.
Check
Is the VDCCM connector
inserted into the VDCCM until
the clamp is secured?
CHECK THE FAILURE LIGHT.

Check the lights that do not extinguish.
Are the VDC warning light/VDC Go to step 7.

OFF indicator lights the ones
that do not turn OFF?
Are the ABS warning light and Go to step 4.
brake warning light (EBD warning light) still off?

CHECK PROTRUSION OF THE VDCCM.
Is the protrusion damaged?
2) Check the damage to the VDCCM terminal
protrusion.
10
11
CHECK VDCCM POWER SUPPLY.

CHECK POOR CONTACT OF VDCCM CON- Is there poor contact in the
NECTOR.
VDCCM connector?
OPERATION OF VDC OFF SWITCH.

1) Operate the VDC OFF switch.
2) Turn the ignition switch to OFF once and
turn ON again.
CHECK ENGINE COOLANT TEMPERATURE.
CHECK VDC OFF SWITCH.

Remove and check VDC OFF switch. <Ref. to
VDC-32, VDC OFF Switch.>
VDCCM.
CHECK VDC OFF SWITCH HARNESS.
3) Check the insulation between ECM connector terminal and chassis ground.
Yes
Go to step 2.
No
Insert the VDCCM
connector into the
VDCCM until the
clamp is secured.
Go to step 3.
Repair the front

wiring harness.
Replace the
Go to step 5.
VDCCM. <Ref. to
(VDCCM).>
Go to step 6.
Repair the power
supply circuit of the
VDCCM.
Repair the connec- Replace the

tor.
VDCCM. <Ref. to
(VDCCM).>
Do the VDC warning light/VDC VDC is normal.
Go to step 8.
OFF indicator light extinguish?
Warm up the engine. Is there a VDC is normal.

change in the VDC warning
light/VDC OFF indicator light
illumination conditions?
Is the VDC OFF switch normal? Go to step 10.
Do the VDC warning light/VDC Go to step 11.

OFF indicator light remain off?
more?
VDC(diag)-42
Go to step 9.
Replace the VDC

OFF switch.
Repair the wiring
harness.
Replace the
Repair the VDC
VDCCM. <Ref. to OFF switch circuit.
(VDCCM).>

D: VDC INDICATOR LIGHT DOES NOT GO OFF

VDC operation indicator light circuit is open or shorted.
TROUBLE SYMPTOM:
When starting the engine, the VDC indicator light remains ON.
WIRING DIAGRAM:
BATTERY
IGNITION SWITCH
SBF-4
SBF-1 120A
NO.14 10A
NO.18 15A
B36
5
i1
VDC OPERATION
INDICATOR LIGHT
COMBINATION METER
i12
i10
c:
i11
i1
VDC OFF SWITCH
20
23
26
i3
B36
a:
b:
b20
c3
c7
c6
PARKING BRAKE/
BRAKE FLUID
WARNING LIGHT
ABS WARNING LIGHT
VDC WARNING LIGHT/

VDC OFF
INDICATOR LIGHT
b9
i1
B38
B36
B310
2
1
3 4 5 6
55
40
i12
4 5 6
1 2 3
7 8 9 10 11 12 13 14
B318
VDC CONTROL MODULE
a:
B318
72
54
53
61
28
5
3
b:
i10
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
c:
i11
1 2 3 4 5 6 7 8 9 10
B38
B36
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B310
2
4
6
8
14
16
18
20
22
24
26
28
10
11
12
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56 57 58 59 60 61 62 63 64 65 66
67
68
69
70
71
72
73
74
75
76
77
78
79 80 81 82 83
VDC00489
VDC(diag)-43

Step
Check
Is the VDC operation indicator
light off?
VDCCM.
Yes
No
Replace the
Repair the wiring
VDCCM. <Ref. to harness.
(VDCCM).>
E: DTC 21 FRONT RIGHT ABS SENSOR CIRCUIT OPEN OR SHORT

NOTE:
Refer to DTC 27 for the diagnostic procedure. <Ref. to VDC(diag)-45, DTC 27 REAR LEFT ABS SENSOR
CIRCUIT OPEN OR SHORT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
F: DTC 23 FRONT LEFT ABS SENSOR CIRCUIT OPEN OR SHORT

NOTE:
G: DTC 25 REAR RIGHT ABS SENSOR CIRCUIT OPEN OR SHORT

NOTE:
VDC(diag)-44

H: DTC 27 REAR LEFT ABS SENSOR CIRCUIT OPEN OR SHORT

Defective ABS wheel speed sensor (broken wire, input voltage too high)
TROUBLE SYMPTOM:
VDC does not operate.
WIRING DIAGRAM:
B6
1
55
1
2
1
2
TWISTED PAIR LINE
R3
2
1
F94
6
19
17
18
B99
TWISTED PAIR LINE
7
19
2
1
TWISTED PAIR LINE
F45
18
17
TWISTED PAIR LINE
TWISTED PAIR LINE
TWISTED PAIR LINE

B62
TWISTED PAIR LINE
16
15
VDC CONTROL MODULE
13
14
19
21
B310
R73
R72
E
FRONT ABS
WHEEL SPEED
SENSOR LH
FRONT ABS
WHEEL SPEED
SENSOR RH
R72
F94
R73
B6
2 1
REAR ABS
WHEEL SPEED
SENSOR LH
REAR ABS
WHEEL SPEED
SENSOR RH
F45
B99
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
2 1
B310
12
10
2
4
6
8
14
16
18
20
22
24
26
28
11
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56 57 58 59 60 61 62 63 64 65 66
67
68
69
70
71
72
73
74
75
76
77
78
79 80 81 82 83
VDC00490
VDC(diag)-45

Step
corresponding to the faulty area in the Subaru
Select Monitor data display mode.
SPEED SENSOR.
Check
Yes
Go to step 2.
during acceleration/deceleration when the steering wheel is
in the straight-ahead position?

installation bolt tightened to
3310 Nm (3.41.0 kgf-m,
24.67.2 ft-lb)?
CHECK CLEARANCE OF ABS WHEEL
Is the clearance within the fol- Go to step 4.
SPEED SENSOR.
lowing? Front wheel: 0.3 0.8
Measure the clearance between the tone wheel mm (0.012 0.031 in); Rear
and protrusion around the entire area around wheel: 0.7 1.2 mm (0.0276
the wheel.
0.0472 in)
No
Go to step 8.
Tighten the ABS

bolts.
Adjust the clearance.
NOTE:
No. 26755AA000).
If spacers cannot
sensor or worn
tone wheel.
Repair the tone
(0.0020 in)?
wheel. Front: <Ref.
to VDC-30, Front
Tone Wheel.>
Rear: <Ref. to
VDC-31, Rear
Tone Wheel.>
tors between VDCCM and ABS tor.
wheel speed sensor?
Go to step 7.
Is the same DTC displayed
Replace the
CHECK VDCCM.
again?
VDCCM. <Ref. to
VDC-8, VDC Con2) Erase the memory.
trol Module
(VDCCM).>
4) Read the DTC.
Are other DTCs displayed?
Go to the diagnosis Temporary poor
corresponding to contact occurs.
the DTC.
NOTE:
Check the harness
and connector between
VDCCM
and ABS wheel
speed sensor.
CHECK ABS WHEEL SPEED SENSOR.
Is the resistance as shown
Go to step 9.
Replace the ABS
below? Front: 1.0 1.5 k,
wheel speed sen2) Disconnect the connector from the ABS
Rear: 1.025 1.265 k
sor. Front: <Ref. to
wheel speed sensor.
VDC-28, Front
ABS Wheel Speed
wheel speed sensor connector terminals.
Sensor.> Rear:
Terminals
<Ref. to VDC-29,
Rear ABS Wheel
Speed Sensor.>
VDC(diag)-46

10
11
12
Step
SPEED SENSOR.
Terminals
SPEED SENSOR.
Terminals
VDCCM AND ABS WHEEL SPEED SENSOR.
speed sensor.
3) Measure the resistance between VDCCM
connectors.
DTC 21
(B310) No. 14 No. 13:
DTC 23
(B310) No. 21 No. 19:
DTC 25
(B310) No. 18 No. 17:
DTC 27
(B310) No. 16 No. 15:
Measure the voltage between VDCCM connector and chassis ground.
DTC 21
DTC 23
DTC 25
DTC 27
Check
Yes
Go to step 10.
No
Replace the ABS
VDC-28, Front
ABS Wheel Speed
Sensor.> Rear:
<Ref. to VDC-29,
Rear ABS Wheel
Speed Sensor.>
Go to step 11.
Replace the ABS

VDC-28, Front
ABS Wheel Speed
Sensor.> Rear:
<Ref. to VDC-29,
Rear ABS Wheel
Speed Sensor.>

Rear: 1.025 1.265 k
Go to step 12.
Repair the harness

connector between
VDCCM and ABS
wheel speed sensor.
Go to step 13.
Repair the harness

between VDCCM
and ABS wheel
speed sensor.
VDC(diag)-47

13
14
15
Step
Check
Yes
Go to step 14.
DTC 21
DTC 23
DTC 25
DTC 27
SPEED SENSOR.
3310 Nm (3.41.0 kgf-m,
24.67.2 ft-lb)?
CHECK ABS WHEEL SPEED SENSOR
CLEARANCE.
and protrusion around the entire area around wheel: 0.7 1.2 mm (0.0276
the wheel.
0.0472 in)
16
CHECK FOR RUNOUT OF THE HUB AND

TONE WHEEL.
(0.0020 in)?
Measure the runout of the hub and tone wheel.
17
CHECK POOR CONTACT OF CONNECTOR. Is there poor contact in connectors between VDCCM and ABS
wheel speed sensor?
CHECK THE VDCCM.
4) Read the DTC.
18
19
VDC(diag)-48
Go to step 18.
Replace the
VDCCM. <Ref. to
(VDCCM).>
Go to the diagnosis
corresponding to
the DTC.
No
Repair the harness
between VDCCM
and ABS wheel
speed sensor.
Tighten the ABS

bolts.
NOTE:
No. 26755AA000).
If spacers cannot
sensor or worn
tone wheel.
Repair the hub and
tone wheel. Front:
<Ref. to VDC-28,
Front ABS Wheel
Speed Sensor.>
Rear: <Ref. to
VDC-29, Rear
ABS Wheel Speed
Sensor.>
Repair the connector.
Go to step 19.
Temporary poor
contact occurs.
NOTE:
Check the harness
and connector between
VDCCM
and ABS wheel
speed sensor.

I:
DTC 22 FRONT RIGHT ABS SENSOR SIGNAL
NOTE:
SIGNAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
J: DTC 24 FRONT LEFT ABS SENSOR SIGNAL

NOTE:
K: DTC 26 REAR RIGHT ABS SENSOR SIGNAL

NOTE:
VDC(diag)-49

L: DTC 28 REAR LEFT ABS SENSOR SIGNAL

Defective ABS wheel speed sensor signal (noise, irregular signal, etc.)
TROUBLE SYMPTOM:
NOTE:
At this time, the brake warning light illuminates as well as the VDC and ABS warning light.
WIRING DIAGRAM:
B6
1
55
1
2
1
2
TWISTED PAIR LINE
R3
2
1
F94
6
19
17
18
B99
TWISTED PAIR LINE
7
19
2
1
TWISTED PAIR LINE
F45
18
17
TWISTED PAIR LINE
TWISTED PAIR LINE
TWISTED PAIR LINE

B62
TWISTED PAIR LINE
16
15
VDC CONTROL MODULE
13
14
19
21
B310
R73
R72
E
FRONT ABS
WHEEL SPEED
SENSOR LH
FRONT ABS
WHEEL SPEED
SENSOR RH
R72
F94
R73
B6
2 1
REAR ABS
WHEEL SPEED
SENSOR LH
REAR ABS
WHEEL SPEED
SENSOR RH
F45
B99
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
2 1
B310
12
10
2
4
6
8
14
16
18
20
22
24
26
28
11
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56 57 58 59 60 61 62 63 64 65 66
67
68
69
70
71
72
73
74
75
76
77
78
79 80 81 82 83
VDC00490
VDC(diag)-50

Step
corresponding to the faulty area in the Subaru
Select Monitor data display mode.
Check
Yes
Go to step 2.
No
Go to step 7.
Is there poor contact in connec- Repair the connectors between VDCCM and ABS tor.
wheel speed sensor?
Are the radio wave devices and Go to step 4.
electric components installed
correctly?
Go to step 3.
Install the noise

sources away from
the sensor harness.
CHECK VDCCM.
Replace the
again?
VDCCM. <Ref. to
VDC-8, VDC Con3) Perform the Inspection Mode.
trol Module
4) Read the DTC.
(VDCCM).>
Temporary noise
interference
occurs.
SPEED SENSOR.
3310 Nm (3.41.0 kgf-m,
24.67.2 ft-lb)?
CLEARANCE.
and protrusion around the wheel.
wheel: 0.7 1.2 mm (0.0276
0.0472 in)
CHECK USING OSCILLOSCOPE.
Are causes of the noise (such

as an antenna) installed near
the sensor harness?
VDC(diag)-51
Go to step 10.
Install the radio

wave devices and
electric components properly.
Go to step 5.
Go to step 6.
Go to the diagnosis
corresponding to
the DTC.
Tighten the ABS
bolts.
NOTE:
No. 26755AA000).
If spacers cannot
sensor or worn
tone wheel.
Go to step 11.

10
11
12
13
Step
1) Jack up the vehicle until all four wheels are
off the ground.
3) Remove the VDCCM connector cover.
<Ref. to VDC(diag)-18, VDCCM Connector
Cover.>
4) Connect the oscilloscope to the connector.
the specified frequency.
NOTE:
When this inspection is completed, VDCCM
may record DTC 29.
DTC 22
(B310) No. 14 (+) No. 13 ():
DTC 24
(B310) No. 21 (+) No. 19 ():
DTC 26
(B310) No. 18 (+) No. 17 ():
DTC 28
(B310) No. 16 (+) No. 15 ():
CHECK CONTAMINATION OF ABS WHEEL
Remove the disc rotor from the hub according
to the DTC.

Check
Yes
same waveform as shown in
the figure? <Ref. to ABS-16,
OUTPUT VOLTAGE, INSPECTION, Front ABS Wheel Speed
Sensor.>
Is the ABS wheel speed sensor

piece or the tone wheel contaminated by dirt or other foreign matter?
Is there breakage or damage in
the protrusion of the ABS wheel
speed sensor or the tone
wheel?
No
Go to step 11.
Thoroughly
Go to step 12.
remove dirt or
Front: <Ref. to
VDC-28, Front
ABS Wheel Speed
Sensor.> <Ref. to
VDC-30, Front
Tone
Wheel.>Rear:<Ref
. to VDC-29, Rear
ABS Wheel Speed
Sensor.> <Ref. to
VDC-31, Rear
Tone Wheel.>
Repair the tone
(0.0020 in)?
wheel. Front: <Ref.
to VDC-30, Front
Tone Wheel.>
Rear: <Ref. to
VDC-31, Rear
Tone Wheel.>
VDC(diag)-52

14
15
16
17
18
19
Step
CHECK RESISTANCE OF THE ABS WHEEL
SPEED SENSOR.
wheel speed sensor.
wheel speed sensor connector terminals.
Terminals
SPEED SENSOR.
Measure the resistance between ABS wheel
Terminals
VDCCM AND ABS WHEEL SPEED SENSOR.
speed sensor.
VDCCM connector terminals.
DTC 22
(B310) No. 14 No. 13:
DTC 24
(B310) No. 21 No. 19:
DTC 26
(B310) No. 18 No. 17:
DTC 28
(B310) No. 16 No. 15:
CHECK GROUND SHORT CIRCUIT OF HARNESS.
Measure the resistance between VDCCM connector and chassis ground.
DTC 22
DTC 24
DTC 26
DTC 28
CHECK GROUND CIRCUIT OF VDCCM.
Measure the resistance between VDCCM and
chassis ground.
Check
Rear: 1.025 1.265 k
Yes
Go to step 15.
No
Replace the ABS
VDC-28, Front
ABS Wheel Speed
Sensor.> Rear:
<Ref. to VDC-29,
Rear ABS Wheel
Speed Sensor.>
more?
Go to step 16.

Rear: 1.025 1.265 k
Go to step 17.
Replace the ABS

VDC-28, Front
ABS Wheel Speed
Sensor.> Rear:
<Ref. to VDC-29,
Rear ABS Wheel
Speed Sensor.>
Repair the harness
connector between
VDCCM and ABS
wheel speed sensor.
more?
Go to step 18.
Repair the harness

connector between
VDCCM and ABS
wheel speed sensor.

?
Go to step 19.
Repair the
VDCCM ground
harness.
Is there poor contact in connec- Repair the connec- Go to step 20.

tors between VDCCM and ABS tor.
wheel speed sensor?
VDC(diag)-53

20
Step
Check
Yes
Are the radio wave devices and Go to step 21.
correctly?
21

the sensor harness?
22
CHECK VDCCM.
4) Read the DTC.

again?
23
VDC(diag)-54
Install the noise

sources away from
the sensor harness.
Replace the
VDCCM. <Ref. to
(VDCCM).>
Go to the diagnosis
corresponding to
the DTC.
No
Install the radio
wave devices and
Go to step 22.
Go to step 23.
Temporary noise
interference
occurs.

M: DTC 29 ANY OF WHEEL SENSORS SIGNAL

Defective ABS wheel speed sensor signal (noise, irregular signal, etc.)
Faulty tone wheel
When a wheel is turned freely for a long time
TROUBLE SYMPTOM:
EBD does not operate. (Depends on the content of the malfunction.)
NOTE:
WIRING DIAGRAM:
B6
1
55
1
2
1
2
TWISTED PAIR LINE
R3
2
1
F94
6
19
17
18
B99
TWISTED PAIR LINE
7
19
2
1
TWISTED PAIR LINE
F45
18
17
TWISTED PAIR LINE
TWISTED PAIR LINE
TWISTED PAIR LINE

B62
TWISTED PAIR LINE
16
15
VDC CONTROL MODULE
13
14
19
21
B310
R73
R72
E
FRONT ABS
WHEEL SPEED
SENSOR LH
FRONT ABS
WHEEL SPEED
SENSOR RH
R72
F94
R73
B6
2 1
REAR ABS
WHEEL SPEED
SENSOR LH
REAR ABS
WHEEL SPEED
SENSOR RH
F45
B99
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
2 1
B310
12
10
2
4
6
8
14
16
18
20
22
24
26
28
11
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56 57 58 59 60 61 62 63 64 65 66
67
68
69
70
71
72
73
74
75
76
77
78
79 80 81 82 83
VDC00490
VDC(diag)-55

Step
CHECK WHETHER A WHEEL TURNED
FREELY OR NOT.
Check
Did the wheels turn freely for
more than one minute, such as
when the vehicle is jacked-up,
under full-lock cornering or
when the tires are not in contact
with road surface?
CHECK TIRE SPECIFICATIONS.
3
4
CHECK WEAR OF TIRE.

CHECK TIRE AIR PRESSURE.
Is the tire specification appropriate?

Is the tire worn excessively?
Is the tire pressure correct?

SPEED SENSOR.
7
8
Yes
No
VDC is normal.
Go to step 2.
Delete the DTC.
NOTE:
There are cases in
which the DTC is
displayed
when
the wheel is freely
rotated for a long
period of time,
such as when the
vehicle is towed,
jacked up, or held
where the steering
wheel is turned
completely one direction.
Go to step 3.
Replace the tire.
Replace the tire.
Go to step 5.

3310 Nm (3.31.0 kgf-m,
247 ft-lb)?
CLEARANCE.
and protrusion around the wheel.
wheel: 0.7 1.2 mm (0.0276
0.0472 in)
CHECK WITH AN OSCILLOSCOPE.

1) Jack up the vehicle until all four wheels are
off the ground.
<Ref. to VDC(diag)-18, REMOVAL, VDCCM
Connector Cover.>
4) Connect the oscilloscope to the connector.
the specified frequency.
NOTE:
When this inspection is completed, VDCCM
may record DTC 29.
(B310) No. 14 (+) No. 13 () (Front RH):
(B310) No. 21 (+) No. 19 () (Front LH):
(B310) No. 18 (+) No. 17 () (Rear RH):
(B310) No. 16 (+) No. 15 () (Rear LH):
Go to step 8.
same waveform as shown in
the figure? <Ref. to ABS-16,
OUTPUT VOLTAGE, INSPECTION, Front ABS Wheel Speed
Sensor.>
VDC(diag)-56
Go to step 4.
Adjust the tire
pressure.
Tighten the ABS
bolts.
NOTE:
No. 26755AA000).
If spacers cannot
sensor or worn
tone wheel.
Go to step 9.
Go to step 9.

10
Step
Check
CHECK CONTAMINATION OF ABS WHEEL Is the ABS wheel speed sensor
piece or the tone wheel conRemove the disc rotor from the hub.
taminated by dirt or other foreign matter?
CHECK DAMAGE OF ABS WHEEL SPEED Is there breakage or damage in
the protrusion of the ABS wheel
speed sensor or the tone
wheel?
11

12
CHECK VDCCM.
5) Read the DTC.
13
Yes
No
Thoroughly
Go to step 10.
remove dirt or
Front: <Ref. to
VDC-28, Front
ABS Wheel Speed
Sensor.> and
<Ref. to VDC-30,
Front Tone
Wheel.> Rear:
<Ref. to VDC-29,
Rear ABS Wheel
Speed Sensor.>
and <Ref. to VDC31, Rear Tone
Wheel.>
Repair the tone
(0.0020 in)?
wheel. Front: <Ref.
to VDC-30, Front
Tone Wheel.>
Rear: <Ref. to
VDC-31, Rear
Tone Wheel.>
Replace the
Go to step 13.
again?
VDCCM. <Ref. to
(VDCCM).>
VDC(diag)-57

the DTC.
NOTE:
The ABS warning
light will remain lit
until the vehicle
reaches approximately 12 km/h
(7.46 MPH) even if
the memory is
cleared. This is
normal.

N: DTC 31 FRONT SOLENOID RIGHT INLET VALVE MALFUNCTION

NOTE:
Refer to DTC 62 for the diagnostic procedure. <Ref. to VDC(diag)-59, DTC 62 PRIMARY CUT SOLENOID
VALVE MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
O: DTC 33 FRONT LEFT INLET SOLENOID VALVE MALFUNCTION

NOTE:
P: DTC 35 REAR RIGHT INLET SOLENOID VALVE MALFUNCTION

NOTE:
Q: DTC 37 REAR LEFT INLET SOLENOID VALVE MALFUNCTION

NOTE:
R: DTC 61 SECONDARY CUT SOLENOID VALVE MALFUNCTION

NOTE:
VDC(diag)-58

S: DTC 62 PRIMARY CUT SOLENOID VALVE MALFUNCTION

Defective VDCH/U solenoid valve
TROUBLE SYMPTOM:
NOTE:
VDC(diag)-59

WIRING DIAGRAM:
B61
F44
SBF-7 50A
BATTERY
SBF-1 120A
SBF-3 50A
2
B369
RELAY BOX
VALVE RELAY
VDCH/U
B370
B368
SECONDARY PRESSURE
SENSOR
14
VDC5
44
24
26
3
29
31
4
23
25
32
34
30
35
4
22
48
27
VDC4
5
1
VDC1 VDC2
PRIMARY PRESSURE
SENSOR
1
2
15
13
16
VDC7
FL INLET SOLENOID VALVE

FL OUTLET SOLENOID VALVE
FR INLET SOLENOID VALVE
FR OUTLET SOLENOID VALVE
RL INLET SOLENOID VALVE
RL OUTLET SOLENOID VALVE
RR INLET SOLENOID VALVE
RR OUTLET SOLENOID VALVE
PRIMARY SUCTION SOLENOID VALVE
PRIMARY CUT SOLENOID VALVE
SECONDARY SUCTION SOLENOID VALVE
SECONDARY CUT SOLENOID VALVE
VDC6
8
4
5
1
6
2
7
3
10
9
11
12
30
87
85
86
30
85
86
87
87a
MOTOR RELAY
75
76
77
VDC3
NO.8 30A
B310 VDC CONTROL MODULE
B369
VDC6
VDC5
VDC7
F44
(BLACK)
B370
VDC1
1 2
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
87
85 87a 86
30
87
85
86
1 2 3
5 6 7
4
8
1 2 3
4 5 6
30
B310
12
10
2
4
6
8
14
16
18
20
22
24
26
28
11
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56 57 58 59 60 61 62 63 64 65 66
67
68
69
70
71
72
73
74
75
76
77
78
79 80 81 82 83
VDC00491
VDC(diag)-60

Step
CHECK RESISTANCE OF SOLENOID
VALVE.
2) Disconnect the two connectors (VDC1, F91)
from VDCH/U.
3) Measure the resistance between VDCH/U
DTC 31
(VDC5) No. 5 (VDC2) No. 2:
DTC 33
(VDC5) No. 8 (VDC2) No. 2:
DTC 35
(VDC5) No. 7 (VDC2) No. 2:
DTC 37
(VDC5) No. 6 (VDC2) No. 2:
DTC 61
(VDC5) No. 9 (VDC2) No. 2:
DTC 62
(VDC5) No. 12 (VDC2) No. 2:
CHECK SOLENOID VALVE GROUND
SHORT.
Measure the resistance between VDCH/U connector and chassis ground.
DTC 31
(VDC5) No. 5 Chassis ground:
DTC 33
DTC 35
DTC 37
DTC 61
DTC 62
CHECK SOLENOID VALVE BATTERY
SHORT.
1) Disconnect the connector from VDCCM.
2) Measure the voltage between VDCH/U connector and chassis ground.
DTC 31
(VDC5) No. 5 (+) Chassis ground ():
DTC 33
DTC 35
DTC 37
DTC 61
DTC 62
Check
Yes
9.04 ?
No
Replace the
VDCH/U. <Ref. to
VDC-10, VDC
Hydraulic Control
Module (VDCH/
M).>
more?
Go to step 3.
Replace the
VDCH/U. <Ref. to
VDC-10, VDC
Hydraulic Control
Module (VDCH/
M).>
Go to step 4.
Replace the
VDCH/U. <Ref. to
VDC-10, VDC
Hydraulic Control
Module (VDCH/
M).>
VDC(diag)-61

Step
Check
SHORT.
DTC 31
DTC 33
DTC 35
DTC 37
DTC 61
DTC 62
DTC 31
DTC 33
DTC 35
DTC 37
DTC 61
DTC 62
DTC 31
DTC 33
DTC 35
DTC 37
DTC 61
DTC 62
VDC(diag)-62
Yes
Go to step 5.
No
Replace the
VDCH/U. <Ref. to
VDC-10, VDC
Hydraulic Control
Module (VDCH/
M).>
Go to step 6.
Repair the harness

between VDCCM
and VDCH/U.
Go to step 7.
Repair the harness

between VDCCM
and VDCH/U.

10
11
Step
DTC 31
DTC 33
DTC 35
DTC 37
DTC 61
DTC 62
VDCCM AND VDCH/U.
1) Connect the connectors (B368) to VDCH/U.
VDCCM connector and VDCH/U connector.
DTC 31
(B310) No. 3 (VDC2) No. 2:
DTC 33
(B310) No. 24 (VDC2) No. 2:
DTC 35
(B310) No. 23 (VDC2) No. 2:
DTC 37
(B310) No. 31 (VDC2) No. 2:
DTC 61
(B310) No. 34 (VDC2) No. 2:
DTC 62
(B310) No. 35 (VDC2) No. 2:
CHECK THE VDCCM.

4) Read the DTC.
Check
more?
Yes
Go to step 8.
No
Repair the harness
between VDCCM
and VDCH/U.

10 ?
Repair the connector between

VDCCM and
VDCH/U.
Is there poor contact in connector between the VDCCM and

VDCH/U?
again?
VDC(diag)-63

tor.
Repair the
Go to step 11.
VDCCM. <Ref. to
(VDCCM).>
the DTC.

T: DTC 32 FRONT RIGHT OUTLET SOLENOID VALVE MALFUNCTION

NOTE:
Refer to DTC 64 for the diagnostic procedure. <Ref. to VDC(diag)-65, DTC 64 PRIMARY SUCTION SOLENOID VALVE MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
U: DTC 34 FRONT LEFT OUTLET SOLENOID VALVE MALFUNCTION

NOTE:
V: DTC 36 REAR RIGHT OUTLET SOLENOID VALVE MALFUNCTION

NOTE:
W: DTC 38 REAR LEFT OUTLET SOLENOID VALVE MALFUNCTION

NOTE:
X: DTC 63 SECONDARY SUCTION SOLENOID VALVE MALFUNCTION

NOTE:
VDC(diag)-64

Y: DTC 64 PRIMARY SUCTION SOLENOID VALVE MALFUNCTION

Defective VDCH/U solenoid valve
TROUBLE SYMPTOM:
NOTE:
VDC(diag)-65

WIRING DIAGRAM:
B61
F44
SBF-7 50A
BATTERY
SBF-1 120A
SBF-3 50A
2
B369
RELAY BOX
VALVE RELAY
VDCH/U
B370
B368
SECONDARY PRESSURE
SENSOR
14
VDC5
44
24
26
3
29
31
4
23
25
32
34
30
35
4
22
48
27
VDC4
5
1
VDC1 VDC2
PRIMARY PRESSURE
SENSOR
1
2
15
13
16
VDC7

VDC6
8
4
5
1
6
2
7
3
10
9
11
12
30
87
85
86
30
85
86
87
87a
MOTOR RELAY
75
76
77
VDC3
NO.8 30A
B369
VDC6
VDC5
VDC7
F44
(BLACK)
B370
VDC1
1 2
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
87
85 87a 86
30
87
85
86
1 2 3
5 6 7
4
8
1 2 3
4 5 6
30
B310
12
10
2
4
6
8
14
16
18
20
22
24
26
28
11
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56 57 58 59 60 61 62 63 64 65 66
67
68
69
70
71
72
73
74
75
76
77
78
79 80 81 82 83
VDC00491
VDC(diag)-66

Step
CHECK RESISTANCE OF SOLENOID
VALVE.
2) Disconnect two connectors (VDC1, B368)
from VDCH/U.
DTC 32
(VDC5) No. 1 (VDC2) No. 2:
DTC 34
(VDC5) No. 4 (VDC2) No. 2:
DTC 36
(VDC5) No. 3 (VDC2) No. 2:
DTC 38
(VDC5) No. 2 (VDC2) No. 2:
DTC 63
(VDC5) No. 10 (VDC2) No. 2:
DTC 64
(VDC5) No. 11 (VDC2) No. 2:
SHORT.
DTC 32
DTC 34
DTC 36
DTC 38
DTC 63
DTC 64
SHORT.
DTC 32
DTC 34
DTC 36
DTC 38
DTC 63
DTC 64
Check
4.8 ?
Yes
Go to step 2.
No
Replace the
VDCH/U. <Ref. to
VDC-10, VDC
Hydraulic Control
Module (VDCH/
M).>
more?
Go to step 3.
Replace the
VDCH/U. <Ref. to
VDC-10, VDC
Hydraulic Control
Module (VDCH/
M).>
Go to step 4.
Replace the
VDCH/U. <Ref. to
VDC-10, VDC
Hydraulic Control
Module (VDCH/
M).>
VDC(diag)-67

Step
Check
SHORT.
DTC 32
DTC 34
DTC 36
DTC 38
DTC 63
DTC 64
DTC 32
DTC 34
DTC 36
DTC 38
DTC 63
DTC 64
DTC 32
DTC 34
DTC 36
DTC 38
DTC 63
DTC 64
VDC(diag)-68
Yes
Go to step 5.
No
Replace the
VDCH/U. <Ref. to
VDC-10, VDC
Hydraulic Control
Module (VDCH/
M).>
Go to step 6.
Repair the harness

between VDCCM
and VDCH/U.
Go to step 7.
Repair the harness

between VDCCM
and VDCH/U.

10
11
Step
DTC 32
DTC 34
DTC 36
DTC 38
DTC 63
DTC 64
VDCCM AND VDCH/U.
VDCCM connector and VDCH/U connector.
DTC 32
(B310) No. 29 (VDC2) No. 1:
DTC 34
(B310) No. 26 (VDC2) No. 1:
DTC 36
(B310) No. 25 (VDC2) No. 1:
DTC 38
(B310) No. 4 (VDC2) No. 1:
DTC 63
(B310) No. 32 (VDC2) No. 1:
DTC 64
(B310) No. 30 (VDC2) No. 1:
CHECK THE VDCCM.

4) Read the DTC.
Check
more?
Yes
Go to step 8.
No
Repair the harness
between VDCCM
and VDCH/U.

6 ?
Repair the harness

connector between
VDCCM and
VDCH/U.

VDCH/U?
again?
VDC(diag)-69

tor.
Replace the
Go to step 11.
VDCCM. <Ref. to
(VDCCM).>
the DTC.

Z: DTC 41 ECM
VDCCM malfunction
TROUBLE SYMPTOM:
NOTE:
WIRING DIAGRAM:
1
55
B310 VDCCM
B310
2
4
6
8
14
16
18
20
22
24
26
28
10
11
12
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56 57 58 59 60 61 62 63 64 65 66
67
68
69
70
71
72
73
74
75
76
77
78
79 80 81 82 83
VDC00029
VDC(diag)-70

Step
Check
?
and chassis ground.
CHECK POOR CONTACT OF CONNECTOR. Is there poor contact of the connectors between the battery,
ignition switch and VDCCM?
Are the radio wave devices and
correctly?

the sensor harness?
CHECK VDCCM.
4) Read the DTC.

again?
VDC(diag)-71
Yes
Go to step 2.
No
Repair the
VDCCM ground
harness.

tor.
Go to step 4.
Install the radio

wave devices and
Go to step 5.
Install the noise

sources away from
the sensor harness.
Replace the
Go to step 6.
VDCCM. <Ref. to
(VDCCM).>
the DTC.

AA:DTC 42 POWER VOLTAGE MALFUNCTION

Power voltage for VDCCM is low.
VDCCM voltage is too high. (Warning lights go off if voltage returns.)
TROUBLE SYMPTOM:
EBD does not operate. (When the voltage is excessively low or high)
NOTE:
WIRING DIAGRAM:
BATTERY
SBF-4
SBF-1
IGNITION SWITCH
1
55
28
No.18 15A
GENERATOR
E
B310
VDCCM
B310
2
4
6
8
14
16
18
20
22
24
26
28
10
11
12
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56 57 58 59 60 61 62 63 64 65 66
67
68
69
70
71
72
73
74
75
76
77
78
79 80 81 82 83
VDC00030
VDC(diag)-72

Step
Check
CHECK GENERATOR.
2) Run the engine at idle after warming up.
3) Measure the voltage between generator terminal B and chassis ground.
Terminals
Generator B terminal Chassis ground:
Are the positive and negative
battery terminals clamped
tightly?
CHECK VDCCM INPUT VOLTAGE.
?
and chassis ground.
CHECK POOR CONTACT OF CONNECTOR. Is there poor contact in connectors between generator, battery
and VDCCM?
CHECK VDCCM.
again?
4) Read the DTC.
VDC(diag)-73
Yes
Go to step 2.
No
Repair the generator.
Go to step 3.
Tighten the clamp

of terminal.
Go to step 4.
Repair the harness

connectors
between the battery, ignition switch
and VDCCM.
Go to step 5.
Repair the
VDCCM ground
harness.

tor.
Replace the
Go to step 7.
VDCCM. <Ref. to
(VDCCM).>
the DTC.

AB:DTC 44 TCM COMMUNICATION CIRCUIT

TCM communication malfunction
TROUBLE SYMPTOM:
WIRING DIAGRAM:
STEERING
ANGLE SENSOR
TWISTED PAIR LINE
B231
DATA LINK
CONNECTOR
6
18
B54
14
17
TCM
27
B136
35
ECM
TWISTED PAIR LINE
TWISTED PAIR LINE

7
B40
81
83
27
38
TWISTED PAIR LINE
TWISTED PAIR LINE
B310
VDC
CONTROL
MODULE
B:
B40
B231
1 2 3 4 5 6 7 8
1 2 3 4
C: B136
B54
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
9 10 11 12 13 14 15 16
5 6
14 15 16
25 26 27
33 34 35
B310
1
29
30
31
32
33
34
35
56 57 58 59 60 61 62 63 64 65
10
9
36
66
37
67
12
11
38
68
39
69
14
13
40
70
41
71
16
15
42
72
43
73
18
17
44
74
45
75
20
19
46
76
47
77
22
21
48
78
49
79
24
26
28
23
25
27
50
51
52
53
54
55
80 81 82 83
VDC00492
VDC(diag)-74

2
3
Step
Check
CHECK HARNESS RESISTANCE.
2) Disconnect the two connectors from the
TCM.
(B55) No. 18 No. 17:
CHECK POOR CONTACT OF CONNECTOR. Is there poor contact in TCM
connector?
CHECK TCM.
again?
5) Read the DTC.
VDC(diag)-75
Yes
Go to step 2.
No
Repair the harness
between TCM and
VDCCM.

tor.
Replace the TCM. Go to step 4.
<Ref. to 4AT-61,
(TCM).>
the DTC.

AC:DTC 45 INCORRECT VDC CONTROL MODULE SPECIFICATIONS

Different control module specification
TROUBLE SYMPTOM:
Step
CHECK THE VDCCM SPECIFICATION.
Check the VDCCM identification mark.
Check
Yes
Do the VDCCM identification
Go to step 2.
mark and vehicle specification
match?
CHECK TCM SPECIFICATION.

Check the TCM identification mark.
Do the TCM identification mark Go to step 3.

and vehicle specification
match?
CHECK TCM.
1) Replace the TCM. <Ref. to 4AT-61, Transmission Control Module (TCM).>
4) Read the DTC.
CHECK TCM.

again?
Go to step 4.
In the current diagnosis, is the

same DTC displayed again?
Go to the diagnosis Go to step 5.

corresponding to
the DTC.
Go to step 6.
Defect exists in
original VDCCM.
CHECK VDCCM.
1) Install the original TCM.
again?
2) Replace the VDCCM. <Ref. to VDC-8, VDC
Control Module (VDCCM).>
5) Read the DTC.
CHECK VDCCM.
Is the same DTC as current
diagnosis still displayed?
Replace the TCM.

<Ref. to 4AT-61,
(TCM).>
No
Replace the
VDCCM. <Ref. to
(VDCCM).>
Replace the TCM.
<Ref. to 4AT-61,
(TCM).>
Defect exists in
original TCM.
Proceed with the

diagnosis corresponding to the
DTC.
AD:DTC 45 TCM MALFUNCTION

TCM or VDCCM malfunction
TROUBLE SYMPTOM:
1
Step
CHECK AT SYSTEM.
2) Check the DTC in AT system.
Check
Yes
No
Is the DTC of AT system stored Repair the AT sys- Replace the
in memory?
tem.
VDCCM. <Ref. to
(VDCCM).>
VDC(diag)-76

AE:DTC 46 ABNORMAL VOLTAGE OF 5V POWER SUPPLY

5 V power supply voltage malfunction
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B310
44
75
76
77
66
67
50
65
11
64
VDC CONTROL MODULE
B368
14
1
2
3
4
5
6
15
13
16
B230
YAW RATE & LATERAL G SENSOR
B230
1 2 3
4 5 6
SECONDARY
PRESSURE SENSOR
PRIMARY
PRESSURE SENSOR
VDC5
VDCH/U
B368
4
8
12
16
3
7
11
15
2
6
10
14
1
5
9
13
B310
12
10
2
4
6
8
14
16
18
20
22
24
26
28
11
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56 57 58 59 60 61 62 63 64 65 66
67
68
69
70
71
72
73
74
75
76
77
78
79 80 81 82 83
VDC00386
VDC(diag)-77

Step
CHECK GROUND SHORT IN SENSOR AND
HARNESS.
(B310) No. 50 Chassis ground (lateral
G sensor):
(B310) No. 77 Chassis ground (pressure sensor):
1) Disconnect the connector from the defective
sensor.
and chassis ground.
(B310) No. 50 Chassis ground (lateral
G sensor):
(B310) No. 77 Chassis ground (pressure sensor):
CHECK BATTERY SHORT IN SENSOR AND
HARNESS.
Measure the voltage between VDCCM and
chassis ground.
(B310) No. 50 (+) Chassis ground ()
(lateral G sensor):
(pressure sensor):
CHECK BATTERY SHORT IN SENSOR AND
HARNESS.
(lateral G sensor):
(pressure sensor):
2) Disconnect the connector from the defective
sensor.
3) Measure the voltage between VDCCM and
chassis ground.
(lateral G sensor):
(pressure sensor):
Check
more?
Yes
Go to step 3.
more?
Replace the defec- Repair or replace

tive sensor.
VDCCM and the
defective sensor.
No
Go to step 2.
Go to step 5.
Go to step 5.
Is the voltage less than 0.5 V? Replace the
VDCCM. <Ref. to
(VDCCM).>
VDC(diag)-78
Repair or replace
VDCCM and the
defective sensor.

Step
Check
Yes
Is the voltage less than 0.5 V? Replace the defec1) Turn the ignition switch to ON.
tive sensor.
chassis ground.
(lateral G sensor):
(pressure sensor):
VDC(diag)-79
No
Repair or replace
VDCCM and the
defective sensor.

AF:DTC 47 CAN COMMUNICATION

CAN communication line is damaged or circuit is shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
STEERING
ANGLE SENSOR
TWISTED PAIR LINE
B231
DATA LINK
CONNECTOR
6
18
B54
14
17
TCM
27
B136
35
ECM
TWISTED PAIR LINE
TWISTED PAIR LINE

7
B40
81
83
27
38
TWISTED PAIR LINE
TWISTED PAIR LINE
B310
VDC
CONTROL
MODULE
B:
B40
B231
1 2 3 4 5 6 7 8
1 2 3 4
C: B136
B54
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
9 10 11 12 13 14 15 16
5 6
14 15 16
25 26 27
33 34 35
B310
1
29
30
31
32
33
34
35
56 57 58 59 60 61 62 63 64 65
10
9
36
66
37
67
12
11
38
68
39
69
14
13
40
70
41
71
16
15
42
72
43
73
18
17
44
74
45
75
20
19
46
76
47
77
22
21
48
78
49
79
24
26
28
23
25
27
50
51
52
53
54
55
80 81 82 83
VDC00492
VDC(diag)-80

Step
CHECK HARNESS BETWEEN VDCCM,
STEERING ANGLE SENSOR AND TCM.
2) Disconnect the connectors from the
VDCCM, TCM, ECM and the steering angle
sensor.
VDCCM, TCM, ECM and the steering angle
sensor.
(B310) No. 83 (B55) No. 18:
(B310) No. 81 (B55) No. 17:
(B310) No. 83 (B231) No. 2:
(B310) No. 81 (B231) No. 1:
(B310) No. 83 (B136) No. 27:
(B310) No. 81 (B136) No. 35:
CHECK HARNESS BETWEEN STEERING
ANGLE SENSOR AND TCM.
Measure the resistance between TCM and the
steering angle sensor.
(B54) No. 18 (B231) No. 2:
(B54) No. 17 (B231) No. 1:
CHECK HARNESS BETWEEN STEERING
ANGLE SENSOR AND ECM.
Measure the resistance between ECM and the
(B231) No. 2 (B136) No. 27:
(B231) No. 1 (B136) No. 35:
chassis ground.
chassis ground.
Check
?
Yes
Go to step 4.
No
Go to step 2.

?
Go to step 3.
Repair or replace
the harness connector between the
TCM and the steering angle sensor.

?
Repair or replace
VDCCM and ECM.
Repair or replace
steering angle sensor and ECM.
more?
Go to step 5.
Repair or replace
the harness connectors between
the VDCCM, TCM,
ECM and the
Repair or replace
the VDCCM, TCM,
ECM and the
Repair or replace
the VDCCM, TCM,
ECM and the
Go to step 8.

chassis ground.
CHECK STEERING ANGLE SENSOR.
Go to step 9.
2) Connect the connector to the steering angle
sensor.
(B310) No. 83 No. 81:
VDC(diag)-81

10
11
12
13
14
15
16
17
Step
Check
Yes
CHECK POOR CONTACT OF CONNECTOR. Is there poor contact in steering Repair or replace
angle sensor?
the steering angle
sensor connector.
CHECK VDCCM.
Go to step 11.
1) Connect the connector to VDCCM.
more?
2) Disconnect the connector from steering
angle sensor.
terminals of the steering angle sensor.
(B231) No. 1 No. 2:
CHECK POOR CONTACT OF CONNECTOR. Is there poor contact in the
Repair or replace
VDCCM?
the VDCCM connector.
CHECK TCM.
Go to step 13.
more?
3) Measure the resistance between the steering angle sensor terminals.
(B231) No. 1 No. 2:
Repair or replace
TCM?
the TCM connector.
CHECK ECM.
Go to step 15.
3) Measure the resistance between the steering angle sensor terminals.
(B231) No. 1 No. 2:
CHECK POOR CONTACT OF CONNECTOR. Is there poor contact in ECM? Repair or replace
the ECM connector.
CHECK VDCCM.
Go to step 16.
4) Read the DTC.
Go to step 17.
again?
CHECK AT SYSTEM DTC DISPLAY.
No
Replace the steering angle sensor.
Go to step 10.
Replace the
VDCCM.
Go to step 12.
Replace the TCM.
Go to step 14.
Replace the ECM.
Temporary poor
contact occurs.
Go to the diagnosis
corresponding to
the DTC.
Is the DTC P1718 of the AT sys- Replace the steer- Replace the
tem displayed?
ing angle sensor. VDCCM.
VDC(diag)-82

AG:DTC 51 VALVE RELAY OFF MALFUNCTION/ VALVE RELAY TEST

MALFUNCTION
NOTE:
When the DTC 74 check is executed, DTC 51 is stored, but this does not indicate an error in the valve relay.
TROUBLE SYMPTOM:
EBD does not operate. (Depends on the content of the malfunction.)
NOTE:
VDC(diag)-83

WIRING DIAGRAM:
B61
F44
SBF-7 50A
BATTERY
SBF-1 120A
SBF-3 50A
2
B369
RELAY BOX
VALVE RELAY
VDCH/U
B370
B368
SECONDARY PRESSURE
SENSOR
14
VDC5
44
24
26
3
29
31
4
23
25
32
34
30
35
4
22
48
27
VDC4
5
1
VDC1 VDC2
PRIMARY PRESSURE
SENSOR
1
2
15
13
16
VDC7

VDC6
8
4
5
1
6
2
7
3
10
9
11
12
30
87
85
86
30
85
86
87
87a
MOTOR RELAY
75
76
77
VDC3
NO.8 30A
B369
VDC6
VDC5
VDC7
F44
(BLACK)
B370
VDC1
1 2
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
87
85 87a 86
30
87
85
86
1 2 3
5 6 7
4
8
1 2 3
4 5 6
30
B310
12
10
2
4
6
8
14
16
18
20
22
24
26
28
11
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56 57 58 59 60 61 62 63 64 65 66
67
68
69
70
71
72
73
74
75
76
77
78
79 80 81 82 83
VDC00491
VDC(diag)-84

Step
CHECK RESISTANCE OF VALVE RELAY.
2) Remove the valve relay from the relay box.
3) Measure the resistance between valve relay
terminals.
Terminals
No. 85 No. 86:
CHECK CONTACT POINT OF VALVE RELAY.
1) Connect the battery to the valve relay terminals No. 85 and No. 86.
terminals.
Terminals
No. 30 No. 87:
Measure the resistance between valve relay
terminals.
Terminals
No. 30 No. 87a:
1) Disconnect the battery from the valve relay
terminals.
terminals.
Terminals
No. 30 No. 87:
terminals.
Terminals
No. 30 No. 87a:
CHECK VALVE RELAY SHORT.
terminals.
Terminals
No. 86 No. 87:
No. 86 No. 87a:
CHECK POWER SUPPLY FOR VALVE RELAY.
1) Disconnect the connectors (B369) from
relay box.
3) Measure the voltage between the relay box
Check
Yes
113 ?
No
Replace the valve
relay.

?
Go to step 3.
Replace the valve

relay.
more?
Go to step 4.
Replace the valve

relay.
more?
Go to step 5.
Replace the valve

relay.

?
Go to step 6.
Replace the valve

relay.
more?
Go to step 7.
Replace the valve

relay.
Go to step 8.
Repair the harness

between battery
and relay box connector. Check fuse
No. 8.
VDC(diag)-85

10
11
12
13
14
Step
CHECK GROUND SHORT AND OPEN CIRCUIT ON POWER SUPPLY CIRCUIT OF RELAY BOX.
1) Disconnect the connector (VDC1) from
VDCH/U.
2) Connect the connectors (B369) to relay box.
4) Measure the relay box voltage.
Valve relay installation point No. 87 (+)
Chassis ground ():
CHECK OPEN CIRCUIT OF RELAY BOX
CONTROL CIRCUIT.
relay box.
3) Measure the resistance between the relay
box connector and valve relay installation point.
(VDC4) No. 5 Valve relay installation
point No. 85:
point No. 86:
CHECK GROUND SHORT CIRCUIT OF THE
RELAY BOX CONTACT POINT CIRCUIT.
Measure the resistance between the relay box
CHECK OPEN CIRCUIT OF VALVE RELAY
CONTROL SYSTEM HARNESS CIRCUIT.
connector and relay box connector.
(B310) No. 48 (B370) No. 5:
(B310) No. 27 (B370) No. 1:
CHECK GROUND SHORT OF THE VALVE
RELAY CONTROL SYSTEM HARNESS.
CHECK OPEN CIRCUIT OF THE RELAY BOX
CONTACT POINT CIRCUIT.
Measure the resistance between the VDCH/U
connector and valve relay installation point.
point No. 30:
CHECK GROUND SHORT CIRCUIT IN THE
Check
Yes
Go to step 9.
No
Replace the relay
box and check fuse
No. 8.

?
Go to step 10.
Replace the relay

box.
more?
Go to step 11.
Replace the relay

box and check fuse
SBF6.

?
Go to step 12.
Repair the harness

between VDCCM
and relay box.
more?
Go to step 13.
Repair the harness

between VDCCM
and relay box.

?
Go to step 14.
Replace the relay

box.
more?
Go to step 15.
Replace the relay

box and check fuse
No. 8.
VDC(diag)-86

15
16
17
18
Step
CHECK RESISTANCE OF HOLD VALVE
AND CUT SOLENOID VALVE.
1) Disconnect the connector from VDCH/U.
(VDC5) No. 8 (VDC2) No. 2:
(VDC5) No. 5 (VDC2) No. 2:
(VDC5) No. 6 (VDC2) No. 2:
(VDC5) No. 7 (VDC2) No. 2:
(VDC5) No. 9 (VDC2) No. 2:
(VDC5) No. 12 (VDC2) No. 2:
CHECK RESISTANCE OF DECOMPRESSION VALVE.
Measure the resistance between VDCH/U connector terminals.
(VDC5) No. 4 (VDC2) No. 2:
(VDC5) No. 1 (VDC2) No. 2:
(VDC5) No. 2 (VDC2) No. 2:
(VDC5) No. 3 (VDC2) No. 2:
(VDC5) No. 10 (VDC2) No. 2:
(VDC5) No. 11 (VDC2) No. 2:
SHORT.
Check
Yes
9.04 ?
No
Replace the
VDCH/U. <Ref. to
VDC-10, VDC
Hydraulic Control
Module (VDCH/
M).>

4.54 ?
Replace the
VDCH/U. <Ref. to
VDC-10, VDC
Hydraulic Control
Module (VDCH/
M).>
more?
Go to step 18.
CHECK GROUND SHORT CIRCUIT OF HAR- Is the resistance 1 M or

NESS.
more?
Go to step 19.
Replace the
VDCH/U and
check all of the
fuses. <Ref. to
VDC-10, VDC
Hydraulic Control
Module (VDCH/
M).>
Repair the harness
between VDCH/U
and VDCCM.
VDC(diag)-87

19
20
21
22
23
Step
VDCCM AND VDCH/U.
VDCCM connector and VDCH/U.
(B310) No. 3 (VDC2) No. 2:
(B310) No. 24 (VDC2) No. 2:
(B310) No. 23 (VDC2) No. 2:
(B310) No. 31 (VDC2) No. 2:
(B310) No. 35 (VDC2) No. 2:
(B310) No. 34 (VDC2) No. 2:
VDCCM AND VDCH/U.
Measure the resistance between the VDCCM
(B310) No. 29 (VDC2) No. 2:
(B310) No. 26 (VDC2) No. 2:
(B310) No. 25 (VDC2) No. 2:
(B310) No. 4 (VDC2) No. 2:
(B310) No. 30 (VDC2) No. 2:
(B310) No. 32 (VDC2) No. 2:
CHECK VDCCM.
4) Read the DTC.
Check
10.0 ?
Yes
Go to step 20.
No
Repair the harness
and connector
between the
VDCH/U and the
VDCCM.

6.0 ?
Go to step 21.
Repair the harness

connector between
the VDCH/U and
the VDCCM.

VDCH/U?

tor.
VDC(diag)-88
Replace the
Go to step 23.
VDCCM. <Ref. to
(VDCCM).>
the DTC.

AH:DTC 51 VALVE RELAY ON FAILURE

NOTE:
When the DTC 74 check is executed, DTC 51 is stored, but this does not indicate an error in the valve relay.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B61
F44
SBF-7 50A
1
NO.8 30A
BATTERY
SBF-1 120A
SBF-3 50A
B369
RELAY BOX
VALVE RELAY
VDCH/U
B368
SECONDARY PRESSURE
SENSOR
14
VDC5
B370
44
24
26
3
29
31
4
23
25
32
34
30
35
4
22
48
27
VDC4
5
1
VDC1 VDC2
PRIMARY PRESSURE
SENSOR
1
2
15
13
16
VDC7

VDC6
8
4
5
1
6
2
7
3
10
9
11
12
30
87
85
86
30
85
86
87
87a
MOTOR RELAY
75
76
77
VDC3
B369
VDC6
VDC5
VDC7
F44
(BLACK)
B370
VDC1
1 2
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
87
85 87a 86
30
87
85
86
1 2 3
5 6 7
4
8
1 2 3
4 5 6
30
B310
12
10
2
4
6
8
14
16
18
20
22
24
26
28
11
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56 57 58 59 60 61 62 63 64 65 66
67
68
69
70
71
72
73
74
75
76
77
78
79 80 81 82 83
VDC00491
VDC(diag)-89

Step
3) Connect the battery to the valve relay terminals No. 85 and No. 86.
terminals.
Terminals
No. 30 No. 87:
terminals.
Terminals
No. 30 No. 87a:
1) Disconnect the battery from the valve relay
terminals.
terminals.
Terminals
No. 30 No. 87:
terminals.
Terminals
No. 30 No. 87a:
CHECK VALVE RELAY SHORT.
terminals.
Terminals
No. 86 No. 87:
No. 86 No. 87a:
CHECK BATTERY SHORT CIRCUIT IN THE
relay box.
Check
?
Yes
Go to step 2.
No
Replace the valve
relay.
more?
Go to step 3.
Replace the valve

relay.
more?
Go to step 4.
Replace the valve

relay.

?
Go to step 5.
Replace the valve

relay.
more?
Go to step 6.
Replace the valve

relay.
Go to step 7.
Replace the relay

box. Check fuse
No. 8 and SBF3.
Go to step 8.
Replace the relay

box. Check fuse
No. 8 and SBF3.
VDC(diag)-90

10
11
12
13
Step
CHECK BATTERY SHORT OF THE VALVE
3) Disconnect the connector from VDCH/U.
CHECK BATTERY SHORT OF THE VALVE
1) Disconnect the (VDC1) connector from the
relay box.
SHORT.
Check
Yes
Go to step 9.
No
Repair the harness
between VDCCM
and relay box and
check all of the
fuses.
Go to step 10.
Repair the harness

between VDCCM
and relay box and
check all of the
fuses.
Go to step 11.
Replace the relay

box.
Go to step 12.
Replace the relay

box.
Go to step 13.

SHORT.
Go to step 14.
Replace the
VDCH/U and
check all of the
fuses. <Ref. to
VDC-10, VDC
Hydraulic Control
Module (VDCH/
M).>
Replace the
VDCH/U and
check all of the
fuses. <Ref. to
VDC-10, VDC
Hydraulic Control
Module (VDCH/
M).>
VDC(diag)-91

14
15
16
17
18
Step
CHECK VDCCM.
4) Read the DTC.
Check
Yes
Go to step 15.
No
Repair the harness
between VDCH/U
and VDCCM and
check all of the
fuses.
Go to step 16.
Repair the harness

between VDCH/U
and VDCCM and
check all of the
fuses.

VDCH/U?

tor.
VDC(diag)-92
Replace the
Go to step 18.
VDCCM. <Ref. to
(VDCCM).>
the DTC.

AI: DTC 52 MOTOR/MOTOR RELAY OFF MALFUNCTION

TROUBLE SYMPTOM:
WIRING DIAGRAM:
B61
F44
SBF-7 50A
1
NO.8 30A
BATTERY
SBF-1 120A
SBF-3 50A
B369
RELAY BOX
VALVE RELAY
VDCH/U
B368
SECONDARY PRESSURE
SENSOR
14
VDC5
B370
44
24
26
3
29
31
4
23
25
32
34
30
35
4
22
48
27
VDC4
5
1
VDC1 VDC2
PRIMARY PRESSURE
SENSOR
1
2
15
13
16
VDC7

VDC6
8
4
5
1
6
2
7
3
10
9
11
12
30
87
85
86
30
85
86
87
87a
MOTOR RELAY
75
76
77
VDC3
B369
VDC6
VDC5
VDC7
F44
(BLACK)
B370
VDC1
1 2
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
87
85 87a 86
30
87
85
86
1 2 3
5 6 7
4
8
1 2 3
4 5 6
30
B310
12
10
2
4
6
8
14
16
18
20
22
24
26
28
11
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56 57 58 59 60 61 62 63 64 65 66
67
68
69
70
71
72
73
74
75
76
77
78
79 80 81 82 83
VDC00491
VDC(diag)-93

Step
CHECK MOTOR GROUND STATUS.
CHECK CONTACT POINT OF MOTOR RELAY.

2) Remove the motor relay from the relay box.
3) Measure the resistance between motor
relay terminals.
Terminals
No. 30 No. 87:
CHECK MOTOR RELAY SHORT.
Measure the resistance between motor relay
terminals.
Terminals
No. 85 No. 30:
No. 85 No. 87:
CHECK GROUND SHORT CIRCUIT IN RELAY BOX CIRCUIT.
relay box.
box connector unit and chassis ground.
CHECK BATTERY SHORT CIRCUIT IN RELAY BOX CIRCUIT.
Measure the voltage between the relay box connector and chassis ground.
CHECK HARNESS GROUND SHORT BETWEEN RELAY BOX AND VDCCM.
CHECK HARNESS BATTERY SHORT BETWEEN RELAY BOX AND VDCCM.
Check
Is the motor ground terminal
tightened to 3310 Nm
(3.31.0 kgf-m, 247 ft-lb)?
more?
Yes
Go to step 2.
Go to step 3.
No
Tighten the motor
ground terminal
clamp.
Replace the motor
relay.
more?
Go to step 4.
Replace the motor

relay.
more?
Go to step 5.
Replace the relay

box.
Go to step 6.
Replace the relay

box.
Go to step 7.
Replace the relay

box.
more?
Go to step 8.
Repair the harness

between VDCCM
and relay box.
Check the fuse
SBF holder.
Go to step 9.
Repair the harness

between VDCCM
and relay box.
Go to step 10.
Repair the harness

between VDCCM
and relay box.
VDC(diag)-94

10
11
12
Step
Check
tors between the VDCH/U,
relay box and VDCCM?
CHECK VDCCM.
4) Read the DTC.
VDC(diag)-95
Yes
No
tor.
Replace the
VDCCM. <Ref. to
(VDCCM).>
Go to the diagnosis
corresponding to
the DTC.
Go to step 12.
Temporary poor
contact occurs.
NOTE:
The ABS warning
until the vehicle
(7.46 MPH) even
when the memory
is cleared. This is
normal.

AJ:DTC 52 MOTOR/MOTOR RELAY ON MALFUNCTION

TROUBLE SYMPTOM:
WIRING DIAGRAM:
B61
F44
SBF-7 50A
1
NO.8 30A
BATTERY
SBF-1 120A
SBF-3 50A
B369
RELAY BOX
VALVE RELAY
VDCH/U
B368
SECONDARY PRESSURE
SENSOR
14
VDC5
B370
44
24
26
3
29
31
4
23
25
32
34
30
35
4
22
48
27
VDC4
5
1
VDC1 VDC2
PRIMARY PRESSURE
SENSOR
1
2
15
13
16
VDC7

VDC6
8
4
5
1
6
2
7
3
10
9
11
12
30
87
85
86
30
85
86
87
87a
MOTOR RELAY
75
76
77
VDC3
B369
VDC6
VDC5
VDC7
F44
(BLACK)
B370
VDC1
1 2
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
87
85 87a 86
30
87
85
86
1 2 3
5 6 7
4
8
1 2 3
4 5 6
30
B310
12
10
2
4
6
8
14
16
18
20
22
24
26
28
11
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56 57 58 59 60 61 62 63 64 65 66
67
68
69
70
71
72
73
74
75
76
77
78
79 80 81 82 83
VDC00491
VDC(diag)-96

Step
CHECK RESISTANCE OF MOTOR RELAY.
relay terminals.
Terminals
No. 85 No. 86:
1) Connect the battery to motor relay terminals
No. 85 and No. 86.
relay terminals.
Terminals
No. 30 No. 87:
CHECK MOTOR RELAY SHORT.
Measure the resistance between motor relay
terminals.
Terminals
No. 85 No. 30:
No. 85 No. 87:
CHECK INPUT VOLTAGE OF RELAY BOX.
relay box.
CHECK INPUT VOLTAGE OF MOTOR RELAY.
and chassis ground.
Motor relay installation point No. 87 (+)
Chassis ground ():
CHECK OPEN CIRCUIT OF THE RELAY BOX
CONTACT POINT CIRCUIT.
2) Disconnect the connectors (VDC2), (B370)
from relay box.
box connector and motor relay installation point.
(VDC1) No. 1 Motor relay installation
point No. 30:
MONITOR SYSTEM.
connector and motor relay installation point.
point No. 30:
Check
Yes
90 ?
No
Replace the motor
relay.

?
Go to step 3.
Replace the motor

relay.
more?
Go to step 4.
Replace the motor

relay.
Go to step 5.
Repair the harness

connector between
battery and relay
box and check the
fuse SBF-holder.
Go to step 6.
Replace the relay

box.

?
Go to step 7.
Replace the relay

box.

?
Go to step 8.
Replace the relay

box.
VDC(diag)-97

10
11
12
13
14
15
Step
CONTROL CIRCUIT.
Measure the resistance between the motor
relay installation point and the relay box connector.
point No. 86:
CONTROL CIRCUIT.
2) Measure the resistance between the motor
relay installation point and the valve relay installation point.
Motor relay installation point No. 86
Valve relay installation point No. 30:
CHECK GROUND SHORT CIRCUIT IN RELAY BOX CIRCUIT.
Measure the voltage between the relay box connector and chassis ground.
CHECK OPEN CIRCUIT OF RELAY CONTROL SYSTEM HARNESS CIRCUIT.
Measure the resistance between VDCCM connector and relay box connector.
(B310) No. 22 (B370) No. 4:
(B310) No. 9 (B370) No. 6:
CHECK HARNESS GROUND SHORT BETWEEN RELAY BOX AND VDCCM.
Check
?
Yes
Go to step 9.
No
Replace the relay
box.

?
Go to step 10.
Replace the relay

box.
more?
Go to step 11.
Replace the relay

box.
Go to step 12.
Replace the relay

box.
Go to step 13.
Replace the relay

box.

?
Go to step 14.
Repair the harness

connector between
the VDCCM and
relay box.
more?
Go to step 15.
Repair the harness

between VDCCM
and relay box.
Check the fuse
SBF holder.
Go to step 16.
Repair the harness

between VDCCM
and relay box.
Check the fuse
SBF holder.
VDC(diag)-98

16
17
18
19
Step
Check
CHECK HARNESS BATTERY SHORT BEIs the voltage less than 1 V?
TWEEN RELAY BOX AND VDCCM.
CHECK VDCCM.
4) Read the DTC.
VDC(diag)-99
Yes
Go to step 17.
No
Repair the harness
between VDCCM
and relay box.
Check the fuse
SBF holder.

tor.
Replace the
VDCCM. <Ref. to
(VDCCM).>
Go to the diagnosis
corresponding to
the DTC.
Go to step 19.
Temporary poor
contact occurs.
NOTE:
The ABS warning
until the vehicle
(7.46 MPH) even
when the memory
is cleared. This is
normal.

AK:DTC 52 MOTOR MALFUNCTION

Defective motor
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B61
F44
SBF-7 50A
1
NO.8 30A
BATTERY
SBF-1 120A
SBF-3 50A
B369
RELAY BOX
VALVE RELAY
VDCH/U
B368
SECONDARY PRESSURE
SENSOR
14
VDC5
B370
44
24
26
3
29
31
4
23
25
32
34
30
35
4
22
48
27
VDC4
5
1
VDC1 VDC2
PRIMARY PRESSURE
SENSOR
1
2
15
13
16
VDC7

VDC6
8
4
5
1
6
2
7
3
10
9
11
12
30
87
85
86
30
85
86
87
87a
MOTOR RELAY
75
76
77
VDC3
B369
VDC6
VDC5
VDC7
F44
(BLACK)
B370
VDC1
1 2
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
87
85 87a 86
30
87
85
86
1 2 3
5 6 7
4
8
1 2 3
4 5 6
30
B310
12
10
2
4
6
8
14
16
18
20
22
24
26
28
11
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56 57 58 59 60 61 62 63 64 65 66
67
68
69
70
71
72
73
74
75
76
77
78
79 80 81 82 83
VDC00491
VDC(diag)-100

Step
3) Connect the battery to motor relay terminals
No. 85 and No. 86.
relay terminals.
Terminals
No. 30 No. 87:
1) Disconnect the battery from the motor relay
terminals.
relay terminals.
Terminals
No. 30 No. 87:
CHECK INPUT VOLTAGE OF RELAY BOX.
relay box.
CHECK INPUT VOLTAGE OF MOTOR RELAY.
and chassis ground.
Motor relay installation point No. 87 (+)
Chassis ground ():
CHECK MOTOR GROUND STATUS.
Check
?
Yes
Go to step 2.
No
Replace the motor
relay.
more?
Go to step 3.
Replace the motor

relay.
Go to step 4.
Repair the harness

connector between
battery and relay
box and check the
fuse SBF-holder.
Go to step 5.
Replace the relay

box.
Is the motor ground terminal

Go to step 6.
tightened to 3310 Nm
(3.31.0 kgf-m, 247 ft-lb)?
CHECK VDCCM MOTOR DRIVE TERMINAL. Does the voltage fall from 10 V Go to step 7.
13 V to less than 1.5 V, and
2) Remove the VDC connector cover. <Ref. to then rise to 10 V 13 V again
VDC(diag)-18, REMOVAL, VDCCM Connector when checking the ABS
Cover.>
sequence control?
4) Install the motor relay.
5) Check the ABS sequence control. <Ref. to
VDC-16, ABS Sequence Control.>
6) Measure the voltage between VDCCM connector terminals.
(B310) No. 22 (+) No. 1 ():
Can the motor revolution noise Go to step 8.
CHECK MOTOR OPERATION.
(engine sound) be heard when
Check the ABS sequence control. <Ref. to
checking the ABS sequence
VDC-19, VDC Sequence Control.>
control?
VDC(diag)-101
Tighten the motor

ground terminal
clamp.
Replace the
VDCCM. <Ref. to
(VDCCM).>
Replace the
VDCH/U. <Ref. to
VDC-10, VDC
Hydraulic Control
Module (VDCH/
M).>

10
Step
Check
CHECK VDCCM.
4) Read the DTC.
VDC(diag)-102
Yes
No
tor.
Replace the
VDCCM. <Ref. to
(VDCCM).>
Go to the diagnosis
corresponding to
the DTC.
Go to step 10.
Temporary poor
contact occurs.
NOTE:
The ABS warning
until the vehicle
(7.46 MPH) even
when the memory
is cleared. This is
normal.

AL:DTC 57 ECM COMMUNICATION CIRCUIT

Communication malfunction between engine control module
TROUBLE SYMPTOM:
WIRING DIAGRAM:
STEERING
ANGLE SENSOR
TWISTED PAIR LINE
B231
DATA LINK
CONNECTOR
6
18
B54
14
17
TCM
27
B136
35
ECM
TWISTED PAIR LINE
TWISTED PAIR LINE

7
B40
81
83
27
38
TWISTED PAIR LINE
TWISTED PAIR LINE
B310
VDC
CONTROL
MODULE
B:
B40
B231
1 2 3 4 5 6 7 8
1 2 3 4
C: B136
B54
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
9 10 11 12 13 14 15 16
5 6
14 15 16
25 26 27
33 34 35
B310
1
29
30
31
32
33
34
35
56 57 58 59 60 61 62 63 64 65
10
9
36
66
37
67
12
11
38
68
39
69
14
13
40
70
41
71
16
15
42
72
43
73
18
17
44
74
45
75
20
19
46
76
47
77
22
21
48
78
49
79
24
26
28
23
25
27
50
51
52
53
54
55
80 81 82 83
VDC00492
VDC(diag)-103

2
3
Step
Check
CHECK HARNESS RESISTANCE.
2) Disconnect the connectors from the ECM.
3) Measure the resistance between ECM connector terminals.
(B136) No. 35 No. 27:
CHECK POOR CONTACT OF CONNECTOR. Is there poor contact in ECM
connector?
CHECK ECM.
again?
5) Read the DTC.
VDC(diag)-104
Yes
Go to step 2.
No
Repair the harness
between ECM and
VDCCM.

tor.
Replace the ECM. Go to step 4.

the DTC.

AM:DTC 71 STEERING ANGLE SENSOR OFFSET IS TOO BIG

Defective steering angle sensor
TROUBLE SYMPTOM:
WIRING DIAGRAM:
STEERING
ANGLE SENSOR
TWISTED PAIR LINE
B231
DATA LINK
CONNECTOR
6
18
B54
14
17
TCM
27
B136
35
ECM
TWISTED PAIR LINE
TWISTED PAIR LINE

7
B40
81
83
27
38
TWISTED PAIR LINE
TWISTED PAIR LINE
B310
VDC
CONTROL
MODULE
B:
B40
B231
1 2 3 4 5 6 7 8
1 2 3 4
C: B136
B54
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
9 10 11 12 13 14 15 16
5 6
14 15 16
25 26 27
33 34 35
B310
1
29
30
31
32
33
34
35
56 57 58 59 60 61 62 63 64 65
10
9
36
66
37
67
12
11
38
68
39
69
14
13
40
70
41
71
16
15
42
72
43
73
18
17
44
74
45
75
20
19
46
76
47
77
22
21
48
78
49
79
24
26
28
23
25
27
50
51
52
53
54
55
80 81 82 83
VDC00492
VDC(diag)-105

Step
CHECK STEERING WHEEL.
1) Drive the vehicle on a flat road.
2) Stop the vehicle in a straight forward direction.
3) Check the steering wheel angle.
CHECK VDCCM.
5) Read the DTC.
Check
Yes
Is the deviation from the center Go to step 2.
of steering wheel less than 5?
No
Perform the centering adjustment
of steering wheel.

Replace the
Go to step 3.
VDCCM. <Ref. to
(VDCCM).>

the DTC.
VDC(diag)-106

AN:DTC 71 CHANGE RANGE OF STEERING ANGLE SENSOR IS TOO BIG

TROUBLE SYMPTOM:
WIRING DIAGRAM:
STEERING
ANGLE SENSOR
TWISTED PAIR LINE
B231
DATA LINK
CONNECTOR
6
18
B54
14
17
TCM
27
B136
35
ECM
TWISTED PAIR LINE
TWISTED PAIR LINE

7
B40
81
83
27
38
TWISTED PAIR LINE
TWISTED PAIR LINE
B310
VDC
CONTROL
MODULE
B:
B40
B231
1 2 3 4 5 6 7 8
1 2 3 4
C: B136
B54
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
9 10 11 12 13 14 15 16
5 6
14 15 16
25 26 27
33 34 35
B310
1
29
30
31
32
33
34
35
56 57 58 59 60 61 62 63 64 65
10
9
36
66
37
67
12
11
38
68
39
69
14
13
40
70
41
71
16
15
42
72
43
73
18
17
44
74
45
75
20
19
46
76
47
77
22
21
48
78
49
79
24
26
28
23
25
27
50
51
52
53
54
55
80 81 82 83
VDC00492
VDC(diag)-107

Step
CHECK THE VDCCM.
5) Read the DTC.
Check
Is the same DTC as current
diagnosis still displayed?
Yes
No
Replace the
Go to step 2.
VDCCM. <Ref. to
(VDCCM).>
Proceed with the

diagnosis corresponding to the
DTC.
VDC(diag)-108
Temporary poor
contact occurs.

AO:DTC 71 STEERING ANGLE SENSOR MALFUNCTION

TROUBLE SYMPTOM:
WIRING DIAGRAM:
STEERING
ANGLE SENSOR
TWISTED PAIR LINE
B231
DATA LINK
CONNECTOR
6
18
B54
14
17
TCM
27
B136
35
ECM
TWISTED PAIR LINE
TWISTED PAIR LINE

7
B40
81
83
27
38
TWISTED PAIR LINE
TWISTED PAIR LINE
B310
VDC
CONTROL
MODULE
B:
B40
B231
1 2 3 4 5 6 7 8
1 2 3 4
C: B136
B54
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
9 10 11 12 13 14 15 16
5 6
14 15 16
25 26 27
33 34 35
B310
1
29
30
31
32
33
34
35
56 57 58 59 60 61 62 63 64 65
10
9
36
66
37
67
12
11
38
68
39
69
14
13
40
70
41
71
16
15
42
72
43
73
18
17
44
74
45
75
20
19
46
76
47
77
22
21
48
78
49
79
24
26
28
23
25
27
50
51
52
53
54
55
80 81 82 83
VDC00492
VDC(diag)-109

Step
CHECK STEERING WHEEL.
3) Check the steering wheel angle.
CHECK OUTPUT OF STEERING ANGLE
2) Read the steering sensor output on Subaru
Select Monitor display.
CHECK DRIVING ROAD.
Interview whether the vehicle was driven on the
road with banks or sandy surface.
CHECK VDCCM.
5) Read the DTC.
Check
Is the angle from the center of
steering wheel less than 5?
Yes
Go to step 2.
No
Center the steering
wheel.
Does the output of the steering Go to step 3.

sensor change on the monitor
when the steering wheel turns
either way?
Replace the steering angle sensor.
Was the vehicle driven on the

road with banks or sandy surface?

VDC(diag)-110
If driven on the
Go to step 4.
road with banks or
sandy surface, the
VDCCM stores the
DTC occasionally.
Replace the
Go to step 5.
VDCCM. <Ref. to
(VDCCM).>
the DTC.

AP:DTC 71 STEERING ANGLE SENSOR COMMUNICATION

TROUBLE SYMPTOM:
WIRING DIAGRAM:
STEERING
ANGLE SENSOR
TWISTED PAIR LINE
B231
DATA LINK
CONNECTOR
6
18
B54
14
17
TCM
27
B136
35
ECM
TWISTED PAIR LINE
TWISTED PAIR LINE

7
B40
81
83
27
38
TWISTED PAIR LINE
TWISTED PAIR LINE
B310
VDC
CONTROL
MODULE
B:
B40
B231
1 2 3 4 5 6 7 8
1 2 3 4
C: B136
B54
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
9 10 11 12 13 14 15 16
5 6
14 15 16
25 26 27
33 34 35
B310
1
29
30
31
32
33
34
35
56 57 58 59 60 61 62 63 64 65
10
9
36
66
37
67
12
11
38
68
39
69
14
13
40
70
41
71
16
15
42
72
43
73
18
17
44
74
45
75
20
19
46
76
47
77
22
21
48
78
49
79
24
26
28
23
25
27
50
51
52
53
54
55
80 81 82 83
VDC00492
VDC(diag)-111

Step
Check
CHECK STEERING ANGLE SENSOR POW- Is the voltage 10 15 V?
ER SUPPLY.
2) Disconnect the connector from steering
angle sensor.
4) Measure the voltage between the steering
angle sensor and chassis ground.
CHECK VDCCM OUTPUT VOLTAGE.
Cover.>
chassis ground.
CHECK POOR CONTACT OF CONNECTOR. Is there poor contact in the yaw
rate sensor connector?
CHECK GROUND CIRCUIT OF STEERING

ANGLE SENSOR.
Measure the resistance between steering angle
sensor and chassis ground.
CHECK STEERING ANGLE SENSOR HARNESS.
1) Connect the connector to the steering angle
sensor.
2) Disconnect the connector from VDCCM.
(B310) No. 81 No. 83:
CHECK STEERING ANGLE SENSOR.
5) Read the DTC.
CHECK VDCCM.
2) Replace the steering angle sensor.
5) Read the DTC.
Yes
Go to step 4.
No
Go to step 2.

between yaw rate
sensor and
VDCCM.
Repair or replace
Replace the
VDCCM. <Ref. to
(VDCCM).>
Repair the steering
angle sensor
ground harness.

?
Go to step 5.

between the steering angle sensor
and VDCCM.

Go to step 8.

the DTC.
Replace the
Go to step 9.
VDCCM. <Ref. to
(VDCCM).>

VDC(diag)-112
Go to step 7.

Step
Check
VDC(diag)-113
Yes
No
Go to the diagnosis Original steering
corresponding to angle sensor malthe DTC.
function

AQ:DTC 72 ABNORMAL YAW RATE SENSOR OUTPUT

Defective yaw rate sensor
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B310
64
65
11
67
50
66
VDC
CONTROL MODULE
3
5
B312
B230
YAW RATE &

LATERAL G SENSOR
B230
1 2 3
4 5 6
B312
1 2 3
4 5 6
B310
12
10
2
4
6
8
14
16
18
20
22
24
26
28
11
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56 57 58 59 60 61 62 63 64 65 66
67
68
69
70
71
72
73
74
75
76
77
78
79 80 81 82 83
VDC00290
VDC(diag)-114

Step
Check
CHECK DRIVING ROAD.
Interview whether the vehicle was driven on the road with banks or sandy surroad with banks or sandy surface.
face?
Yes
No
If driven on the
Go to step 2.
road with banks or
sandy surface, the
VDCCM stores the
DTC occasionally.
CHECK YAW RATE & LATERAL G SENSOR Is the yaw rate & lateral G sen- Go to step 3.
Tighten the yaw
INSTALLATION.
sor tightened securely?
rate & lateral G
Check the yaw rate & lateral G sensor installasensor securely.
tion.
CHECK OUTPUT OF YAW RATE & LATERAL Is the resistance 05.25 deg/s? Go to step 4.
Replace the yaw
G SENSOR USING SUBARU SELECT MONIrate & lateral G
TOR.
sensor. <Ref. to
VDC-22, Yaw Rate
2) Stop the vehicle in a straight forward direc& Lateral G Sention.
sor.>
4) Read the yaw rate & lateral G sensor output
on the Subaru Select Monitor display.
CHECK OUTPUT OF STEERING ANGLE
Is the resistance 02.5 deg?
Go to step 5.
Perform the cenSENSOR USING SUBARU SELECT MONItering adjustment
TOR.
of steering wheel.
4) Read the steering angle sensor output on
the Subaru Select Monitor display.
CHECK YAW RATE & LATERAL G SENSOR. In the current diagnosis, is the Go to step 7.
Go to step 6.
5) Read the DTC.
the DTC.
CHECK VDCCM.
In the current diagnosis, is the Go to step 8.
Replace the
VDCCM. <Ref. to
2) Replace the yaw rate & lateral G sensor.
trol Module
(VDCCM).>
5) Read the DTC.
CHECK THE DTC DISPLAY.
Go to the diagnosis Malfunction in origcorresponding to inal yaw rate & latthe DTC.
eral G sensor.
VDC(diag)-115

AR:DTC 72 VOLTAGE INPUTTED TO YAW RATE SENSOR EXCEEDS

SPECIFICATION
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B310
64
65
11
67
50
66
VDC
CONTROL MODULE
3
5
B312
B230
YAW RATE &

LATERAL G SENSOR
B230
1 2 3
4 5 6
B312
1 2 3
4 5 6
B310
12
10
2
4
6
8
14
16
18
20
22
24
26
28
11
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56 57 58 59 60 61 62 63 64 65 66
67
68
69
70
71
72
73
74
75
76
77
78
79 80 81 82 83
VDC00290
VDC(diag)-116

Step
Check
CHECK YAW RATE & LATERAL G SENSOR Is the voltage 10 15 V?
POWER SUPPLY.
2) Disconnect the connector from yaw rate &
lateral G sensor.
4) Measure the voltage between yaw rate &
lateral G sensor and chassis ground.
Cover.>
chassis ground.
CHECK POOR CONTACT OF CONNECTOR. Is there poor contact in connector between yaw rate & lateral G
sensor?
Yes
Go to step 4.
CHECK YAW RATE & LATERAL G SENSOR

HARNESS.
and yaw rate & lateral G sensor.
(B310) No. 65 (B230) No. 4:
chassis ground.
chassis ground.
chassis ground.

?
Go to step 5.
more?
Go to step 6.
Repair the harness

between yaw rate
& lateral G sensor
and VDCCM.
Repair the harness

between yaw rate
& lateral G sensor
and VDCCM.
Is the voltage less than 0.5 V? Replace the yaw

rate & lateral G
sensor. <Ref. to
VDC-22, Yaw Rate
& Lateral G Sensor.>
Repair the harness

between yaw rate
& lateral G sensor
and VDCCM.
VDC(diag)-117
No
Go to step 2.

between yaw rate
& lateral G sensor
and VDCCM.
Repair or replace
Replace the
VDCCM. <Ref. to
(VDCCM).>
Repair the harness
between yaw rate
& lateral G sensor
and VDCCM.

AS:DTC 72 ABNORMAL YAW RATE SENSOR REFERENCE VOLTAGE

TROUBLE SYMPTOM:
WIRING DIAGRAM:
B310
64
65
11
67
50
66
VDC
CONTROL MODULE
3
5
B312
B230
YAW RATE &

LATERAL G SENSOR
B230
1 2 3
4 5 6
B312
1 2 3
4 5 6
B310
12
10
2
4
6
8
14
16
18
20
22
24
26
28
11
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56 57 58 59 60 61 62 63 64 65 66
67
68
69
70
71
72
73
74
75
76
77
78
79 80 81 82 83
VDC00290
Step
Check
POWER SUPPLY.
lateral G sensor.
lateral G sensor and chassis ground.
VDC(diag)-118
Yes
Go to step 4.
No
Go to step 2.

Step
Check
Connector Cover.>
chassis ground.
CHECK POOR CONTACT OF CONNECTOR. Is there poor contact in connector between yaw rate & lateral G
sensor?
Yes
Go to step 3.
No
Repair the harness
between yaw rate
& lateral G sensor
and VDCCM.
Repair or replace

HARNESS.
(B310) No. 66 (B230) No. 1:
chassis ground.
chassis ground.
chassis ground.
2) Install the yaw rate & lateral G sensor to the
body.
Cover.>
(B310) No. 66 (+) No. 64 ():

?
Go to step 5.
Replace the
VDCCM. <Ref. to
(VDCCM).>
Repair the harness
between yaw rate
& lateral G sensor
and VDCCM.
more?
Go to step 6.
Repair the harness

between yaw rate
& lateral G sensor
and VDCCM.
Repair the harness

between yaw rate
& lateral G sensor
and VDCCM.
Repair the harness

between yaw rate
& lateral G sensor
and VDCCM.
Replace the yaw

rate & lateral G
sensor. <Ref. to
VDC-22, Yaw Rate
VDC(diag)-119
Replace the
VDCCM. <Ref. to
(VDCCM).>

AT:DTC 72 CHANGE RANGE OF YAW RATE SENSOR SIGNAL IS TOO BIG

TROUBLE SYMPTOM:
WIRING DIAGRAM:
B310
64
65
11
67
50
66
VDC
CONTROL MODULE
3
5
B312
B230
YAW RATE &

LATERAL G SENSOR
B230
1 2 3
4 5 6
B312
1 2 3
4 5 6
B310
12
10
2
4
6
8
14
16
18
20
22
24
26
28
11
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56 57 58 59 60 61 62 63 64 65 66
67
68
69
70
71
72
73
74
75
76
77
78
79 80 81 82 83
VDC00290
VDC(diag)-120

Step
Check
CHECK DRIVING ROAD.
Interview whether the vehicle was driven on the road with banks or sandy surroad with banks or sandy surface.
face?
Yes
No
If driven on the
Go to step 2.
road with banks or
sandy surface, the
VDCCM stores the
DTC occasionally.
CHECK YAW RATE & LATERAL G SENSOR Is the yaw rate & lateral G sen- Go to step 3.
Tighten the yaw
INSTALLATION.
rate & lateral G
Check the yaw rate & lateral G sensor installasensor securely.
tion.
Go to step 6.
Go to step 4.
POWER SUPPLY.
lateral G sensor.
lateral sensor and the chassis ground.
between yaw rate
& lateral G sensor
and VDCCM.
Connector Cover.>
chassis ground.
CHECK POOR CONTACT OF CONNECTOR. Is there poor contact in connec- Repair or replace Replace the
tor between yaw rate & lateral G the VDCCM con- VDCCM. <Ref. to
sensor?
nector.
(VDCCM).>
CHECK YAW RATE & LATERAL G SENSOR Is the resistance less than 0.5 Go to step 9.
Go to step 7.
GROUND CIRCUIT.
?
Measure the resistance between the yaw rate &
lateral G sensor and the chassis ground.
Is the resistance less than 0.5 Repair the harness Go to step 8.
1) Disconnect the connectors from VDCCM. ?
between yaw rate
& lateral G sensor
and VDCCM.
Connector Cover.>
and chassis ground.
Repair or replace Replace the
the VDCCM con- VDCCM. <Ref. to
VDCCM connector?
nector.
(VDCCM).>
VDC(diag)-121

10
11
12
13
Step
HARNESS.
(B310) No. 65 (B230) No. 4:
(B310) No. 66 (B230) No. 1:
(B310) No. 67 (B230) No. 2:
chassis ground.
chassis ground.
chassis ground.
2) Install the yaw rate & lateral G sensor to the
body.
lateral G sensor connector terminals.
(B310) No. 66 (+) No. 64 ():
Check
?
Yes
Go to step 10.
No
Repair the harness
between yaw rate
& lateral G sensor
and VDCCM.
more?
Go to step 11.
Repair the harness

between yaw rate
& lateral G sensor
and VDCCM.
Repair the harness

between yaw rate
& lateral G sensor
and VDCCM.
Repair the harness

between yaw rate
& lateral G sensor
and VDCCM.
Replace the yaw

rate & lateral G
sensor. <Ref. to
VDC-22, Yaw Rate
Replace the
VDCCM. <Ref. to
(VDCCM).>
AU:DTC 73 LATERAL G SENSOR OFFSET IS TOO BIG

NOTE:
Refer to DTC 73 for the diagnostic procedure. <Ref. to VDC(diag)-123, DTC 73 EXCESSIVE LATERAL G
SENSOR SIGNAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AV:DTC 73 ABNORMAL LATERAL G SENSOR OUTPUT

NOTE:
AW:DTC 73 CHANGE RANGE OF LATERAL G SENSOR SIGNAL IS TOO BIG

NOTE:
VDC(diag)-122

AX:DTC 73 EXCESSIVE LATERAL G SENSOR SIGNAL

Lateral G sensor malfunction
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B310
64
65
11
67
50
66
VDC
CONTROL MODULE
3
5
B312
B230
YAW RATE &

LATERAL G SENSOR
B230
1 2 3
4 5 6
B312
1 2 3
4 5 6
B310
12
10
2
4
6
8
14
16
18
20
22
24
26
28
11
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56 57 58 59 60 61 62 63 64 65 66
67
68
69
70
71
72
73
74
75
76
77
78
79 80 81 82 83
VDC00290
VDC(diag)-123

Step
INSTALLATION.
Check the yaw rate & lateral G sensor installation.
CHECK OUTPUT OF LATERAL G SENSOR
1) Stop the vehicle on a flat road.
CHECK VDCCM.
4) Read the DTC.
Check
Yes
Is the yaw rate & lateral G sen- Go to step 2.
No
Tighten the yaw
rate & lateral G
sensor securely.
Is the resistance 2.50.2 V?
Go to step 3.
Replace the yaw

rate & lateral G
sensor. <Ref. to
VDC-22, Yaw Rate
Is there poor contact in connector between VDCCM and yaw

rate & lateral G sensor?

tor.
VDC(diag)-124
Replace the
Go to step 5.
VDCCM. <Ref. to
(VDCCM).>
the DTC.

AY:DTC 73 VOLTAGE INPUTTED TO LATERAL G SENSOR EXCEEDS

SPECIFICATION
Lateral G sensor malfunction
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B310
64
65
11
67
50
66
VDC
CONTROL MODULE
3
5
B312
B230
YAW RATE &

LATERAL G SENSOR
B230
1 2 3
4 5 6
B312
1 2 3
4 5 6
B310
12
10
2
4
6
8
14
16
18
20
22
24
26
28
11
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56 57 58 59 60 61 62 63 64 65 66
67
68
69
70
71
72
73
74
75
76
77
78
79 80 81 82 83
VDC00290
VDC(diag)-125

Step
Check
CHECK OUTPUT OF YAW RATE & LATERAL Is the resistance 2.50.2 V?
G SENSOR USING SUBARU SELECT MONITOR.
1) Stop the vehicle on a flat road.
tor between VDCCM and yaw
CHECK VDCCM.
4) Read the DTC.

INPUT VOLTAGE.
lateral G sensor.
(B230) No. 3 (+) No. 6 ():
2) Measure the resistance between yaw rate &
Terminals
No. 3 No. 5:
CHECK OPEN CIRCUIT FOR OUTPUT HARNESS AND GROUND HARNESS OF YAW
RATE & LATERAL G SENSOR.
1) Connect the connector to the yaw rate & lateral G sensor.
(B310) No. 11 No. 64:
CHECK GROUND SHORT IN YAW RATE &
LATERAL G SENSOR HARNESS.
lateral G sensor.
Yes
Go to step 2.

tor.
Replace the
VDCCM. <Ref. to
(VDCCM).>
Go to the diagnosis
corresponding to
the DTC.
Go to step 6.

4.9 k?
Go to step 7.

4.9 k?
Go to step 8.
more?
Go to step 9.
VDC(diag)-126
No
Go to step 5.
Go to step 4.
Temporary poor
contact occurs.
Repair the harness
or connector
between yaw rate
& lateral G sensor
and VDCCM.
Replace the yaw

rate & lateral G
sensor. <Ref. to
VDC-22, Yaw Rate
Repair the harness
between yaw rate
& lateral G sensor
and VDCCM.
Repair the harness

between yaw rate
& lateral G sensor
and VDCCM.

10
11
12
13
14
Step
from vehicle.
3) Connect the connector to the yaw rate & lateral G sensor.
(B230) No. 5 (+) No. 6 ():
Measure the voltage between yaw rate & lateral
G sensor connector terminals.
(B230) No. 5 (+) No. 6 ():
Check
Yes
yaw rate & lateral G sensor is
on a level?

yaw rate & lateral G sensor is
inclined 90 to the left?
No
Replace the yaw
rate & lateral G
sensor. <Ref. to
VDC-22, Yaw Rate
Replace the yaw

rate & lateral G
sensor. <Ref. to
VDC-22, Yaw Rate
CHECK YAW RATE & LATERAL G SENSOR. Is the voltage 1.3 1.7 V when Go to step 12.
Replace the yaw
Measure the voltage between yaw rate & lateral yaw rate & lateral G sensor is
rate & lateral G
G sensor connector terminals.
inclined 90 to the right?
sensor. <Ref. to
VDC-22, Yaw Rate
(B230) No. 5 (+) No. 6 ():
tor between VDCCM and yaw tor.
Go to step 14.
In the current diagnosis, is the Replace the
CHECK VDCCM.
VDCCM. <Ref. to
trol Module
(VDCCM).>
4) Read the DTC.
the DTC.
VDC(diag)-127

AZ:DTC 74 PRIMARY PRESSURE SENSOR POWER/OUTPUT

Primary pressure sensor malfunction
TROUBLE SYMPTOM:
WIRING DIAGRAM:
44
75
76
77
B310 VDCCM
4
5
B312
14
15
13
16
B368
SECONDARY
PRESSURE SENSOR
PRIMARY
PRESSURE SENSOR
VDC5
VDCH/U
B312
VDC5
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
1 2 3
4 5 6
B310
12
10
2
4
6
8
14
16
18
20
22
24
26
28
11
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56 57 58 59 60 61 62 63 64 65 66
67
68
69
70
71
72
73
74
75
76
77
78
79 80 81 82 83
VDC00443
VDC(diag)-128

Step
CHECK GROUND CIRCUIT OF PRESSURE
SENSOR.
VDCH/U.
2) Remove the cover from VDCCM. <Ref. to
VDC(diag)-18, REMOVAL, VDCCM Connector
Cover.>
and chassis ground.
Check
?
Yes
Go to step 4.
No
Go to step 2.

?
Replace the harness between

VDCH/U and
VDCCM.
Go to step 3.

VDCCM connector?
Repair or replace
Replace the
VDCCM. <Ref. to
(VDCCM).>
Go to step 5.
CHECK POWER SUPPLY FOR PRESSURE Is the voltage 4.75 5.25 V?

SENSOR.
NOTE:
When performing this inspection, DTC 51
VALVE RELAY MALFUNCTION is stored.
However, this does not indicate a malfunction of
valve relay.
2) Measure the voltage between VDCH/U connector terminals.
(B368) No. 16 (+) No. 15 ():
Cover.>
(B310) No. 77 (+) No. 75 ():
VDCCM connector?
VDC(diag)-129
Go to step 7.

between VDCH/U
and VDCCM.
Repair or replace
Replace the
VDCCM. <Ref. to
(VDCCM).>

10
11
12
13
Step
Measure the voltage between VDCH/U connector and chassis ground.
CHECK INPUT VOLTAGE OF PRESSURE
SENSOR.
Cover.>
7) Do not depress the brake pedal.
(B310) No. 76 (+) No. 75 ():
CHECK VDCCM.
4) Read the DTC.
Check
more?
Yes
Go to step 8.
No
Repair the harness
between VDCH/U
and VDCCM.
Repair the harness

between VDCH/U
and VDCCM.
Repair the harness

between VDCH/U
and VDCCM.
Go to step 11.
Replace the
VDCH/U. <Ref. to
VDC-10, VDC
Hydraulic Control
Module (VDCH/
M).>
Is there poor contact in connectors between VDCCM and

pressure sensor?

tor.
VDC(diag)-130
Replace the
Go to step 13.
VDCCM. <Ref. to
(VDCCM).>
the DTC.

BA:DTC 74 SECONDARY PRESSURE SENSOR POWER/OUTPUT

Secondary pressure sensor malfunction
TROUBLE SYMPTOM:
WIRING DIAGRAM:
44
75
76
77
B310 VDCCM
4
5
B312
14
15
13
16
B368
SECONDARY
PRESSURE SENSOR
PRIMARY
PRESSURE SENSOR
VDC5
VDCH/U
B312
VDC5
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
1 2 3
4 5 6
B310
12
10
2
4
6
8
14
16
18
20
22
24
26
28
11
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56 57 58 59 60 61 62 63 64 65 66
67
68
69
70
71
72
73
74
75
76
77
78
79 80 81 82 83
VDC00443
VDC(diag)-131

Step
CHECK GROUND CIRCUIT OF PRESSURE
SENSOR.
VDCH/U.
Cover.>
and chassis ground.
Check
?
Yes
Go to step 4.
No
Go to step 2.

?
Replace the harness between

VDCH/U and
VDCCM.
Go to step 3.

VDCCM connector?
Repair or replace
Replace the
VDCCM. <Ref. to
(VDCCM).>
Go to step 5.
CHECK POWER SUPPLY FOR PRESSURE Is the voltage 4.75 5.25 V?

SENSOR.
NOTE:
When performing this inspection, DTC 51
VALVE RELAY MALFUNCTION is stored.
However, this does not indicate a malfunction of
valve relay.
2) Measure the voltage between VDCH/U connector terminals.
(B368) No. 16 (+) No. 15 ():
VDC(diag)-18, VDCCM Connector Cover.>
(B310) No. 77 (+) No. 75 ():
VDCCM connector?
VDC(diag)-132
Go to step 7.

between VDCH/U
and VDCCM.
Repair or replace
Replace the
VDCCM. <Ref. to
(VDCCM).>

10
11
12
13
Step
SENSOR.
Cover.>
(B310) No. 44 (+) No. 75 ():
CHECK VDCCM.
4) Read the DTC.
Check
more?
Yes
Go to step 8.
No
Repair the harness
between VDCH/U
and VDCCM.
Repair the harness

between VDCH/U
and VDCCM.
Repair the harness

between VDCH/U
and VDCCM.
Go to step 11.
Replace the
VDCH/U. <Ref. to
VDC-10, VDC
Hydraulic Control
Module (VDCH/
M).>
Is there poor contact in connectors between VDCCM and

pressure sensor?

tor.
Go to step 13.
Replace the
VDCCM. <Ref. to
(VDCCM).>
the DTC.
BB:DTC 74 PRIMARY PRESSURE SENSOR OFFSET IS TOO BIG

NOTE:
Refer to DTC 74 for the diagnostic procedure. <Ref. to VDC(diag)-134, DTC 74 SECONDARY PRESSURE
SENSOR OFFSET IS TOO BIG, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
VDC(diag)-133

BC:DTC 74 SECONDARY PRESSURE SENSOR OFFSET IS TOO BIG

Pressure sensor malfunction
TROUBLE SYMPTOM:
WIRING DIAGRAM:
44
75
76
77
B310 VDCCM
4
5
B312
14
15
13
16
B368
SECONDARY
PRESSURE SENSOR
PRIMARY
PRESSURE SENSOR
VDC5
VDCH/U
B312
VDC5
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
1 2 3
4 5 6
B310
12
10
2
4
6
8
14
16
18
20
22
24
26
28
11
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56 57 58 59 60 61 62 63 64 65 66
67
68
69
70
71
72
73
74
75
76
77
78
79 80 81 82 83
VDC00443
VDC(diag)-134

Step
CHECK USER DRIVING METHOD.
Interview the user about their driving habits.
Check
Yes
Are the acceleration pedal and Erase the normal
brake pedal depressed simulta- DTC for the VDC.
neously while driving?
NOTE:
If the vehicle is
driven while both
the
accelerator
pedal and brake
pedal are used, the
DTC is sometimes
stored in memory.
CHECK OUTPUT OF THE PRESSURE SEN- Is the output value 0.60.12 V Go to step 3.
SOR USING SUBARU SELECT MONITOR.
when the brake pedal is not
depressed?
2) Read the pressure sensor output on the
Subaru Select Monitor display.
CHECK VDCCM.
In the current diagnosis, is the Replace the
VDCCM. <Ref. to
VDC-8, VDC Con3) Perform the Inspection Mode.
trol Module
4) Read the DTC.
(VDCCM).>
Go to the diagnosis
corresponding to
the DTC.
VDC(diag)-135
No
Go to step 2.
Replace the
VDCH/U. <Ref. to
VDC-10, VDC
Hydraulic Control
Module (VDCH/
M).>
Go to step 4.
Temporary poor
contact occurs.

BD:DTC 74 DIFFERENTIAL PRESSURE OF PRESSURE SENSOR IS TOO BIG

Pressure sensor malfunction
TROUBLE SYMPTOM:
WIRING DIAGRAM:
44
75
76
77
B310 VDCCM
4
5
B312
14
15
13
16
B368
SECONDARY
PRESSURE SENSOR
PRIMARY
PRESSURE SENSOR
VDC5
VDCH/U
B312
VDC5
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
1 2 3
4 5 6
B310
12
10
2
4
6
8
14
16
18
20
22
24
26
28
11
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56 57 58 59 60 61 62 63 64 65 66
67
68
69
70
71
72
73
74
75
76
77
78
79 80 81 82 83
VDC00443
VDC(diag)-136

Step
VDCH/U.
SENSOR.
Cover.>
(B310) No. 76 (+) No. 75 ():
(B310) No. 44 (+) No. 75 ():
CHECK FOR BRAKE FLUID LEAKS.
Check for fluid leaks between brake master cylinder and VDCH/U.
CHECK BRAKE MASTER CYLINDER.
Check the brake master cylinder oil pressure.
<Ref. to BR-39, OPERATION CHECK (WITH
GAUGE), INSPECTION, Brake Booster.>
CHECK BRAKE PEDAL STROKE.
Measure the stroke of the brake pedal at 50 kg
(110 lb).
SENSOR.
1) Depress the brake pedal with the force of 50
kg (110 lb).
(B310) No. 76 (+) No. 75 ():
(B310) No. 44 (+) No. 75 ():
Check
more?
Yes
Go to step 2.
No
Repair the harness
between VDCH/U
and VDCCM.
Repair the harness

between VDCH/U
and VDCCM.
Repair the harness

between VDCH/U
and VDCCM.
Go to step 5.
Replace the
VDCH/U. <Ref. to
VDC-10, VDC
Hydraulic Control
Module (VDCH/
M).>
Is brake fluid leaking?
Retighten or
replace.
Go to step 6.
Is oil pressure normal?
Go to step 7.
Replace the master cylinder.
Is the stroke less than 105 mm Go to step 8.

(4.13 in)?
Bleed the air of

brake system.
Replace the
VDCH/U. <Ref. to
VDC-10, VDC
Hydraulic Control
Module (VDCH/
M).>
VDC(diag)-137

10
11
Step
Check
CHECK POOR CONTACT OF CONNECTOR. Is there poor contact in connectors between VDCCM and
pressure sensor?
CHECK VDCCM.
4) Read the DTC.
VDC(diag)-138
Yes
No
tor.
Go to step 11.
Replace the
VDCCM. <Ref. to
(VDCCM).>
the DTC.


A: INSPECTION
Symptom
Long braking/
stopping distance
Main probable cause

VDCH/U
VDCCM
Brake pad
Air in brake line
Tire specifications, tire wear and air
pressure
Incorrect wiring or piping
Wheels lock-up. VDCH/U

VDCCM
ABS wheel speed sensor or clearance
of sensor malfunction
Other probable cause

ABS wheel speed sensor or clearance of sensor malfunction
Defective steering angle sensor or improper
neutral position
Yaw rate & lateral G sensor installation malfunction
Master cylinder
Brake caliper
Disc rotor
Brake pipe
Brake booster
neutral position
Brake caliper
Brake pipe
Brake drag
VDCH/U
VDCCM
Master cylinder
Brake caliper
Parking brake
Axle & wheels
Brake pedal play

neutral position
Brake pad
Brake pipe
Brake pedal
stroke is large.
Air in brake line

Brake pedal play
Vehicle pitching
VDCH/U
VDCCM
Uneven road surface
Suspension play or fatigue (Decreased
damping force)
VDCH/U
VDCCM
Brake caliper
Brake pad
Uneven road surface
pressure

neutral position
neutral position
Master cylinder
Disc rotor
Brake pipe
Axle & wheels
Crown shaped road/road with banks
Suspension play or fatigue (Decreased damping force)
Unbalance
braking or
unbalanced
braking effect
VDC(diag)-139
VDCH/U
Master cylinder
Brake caliper
Brake pad
Brake pipe
Brake booster

Symptom
Vibration and
noise
When braking
suddenly
When accelerating suddenly
When driving
on slippery road
surfaces
Main probable cause
Excessive
brake pedal
vibration
Uneven road surface

Noise from
VDCH/U
VDCH/U (mount bushing)

Brake pipe
Noise from the

front side of
vehicle
VDCH/U (mount bushing)

Master cylinder
Brake caliper
Brake pad
Disc rotor
Brake pipe
Brake booster
damping force)
In-vehicle noise

VDCH/U
Brake booster
VDCCM
neutral position
Axle & wheels
Tire specifications, tire wear and air pressure
VDCCM
neutral position
Noise from the

rear side of
vehicle

Brake caliper
Brake pad
Disc rotor
Parking brake
Brake pipe
damping force)
Axle & wheels

Engine speed does not increase,

or engine stalls when suddenly
accelerated or driving on slippery
road surface.
VDCH/U
VDCCM
Master cylinder
Brake caliper
Parking brake

neutral position
Brake pad
Brake pipe
VDC(diag)-140

Symptom
Poor straight
directional stability of TCS
Wanders to left
or right from
straight forward
direction.
Vehicle spins.
Steering wheel drags when driving.
VDC operates while driving normally.
Main probable cause
VDCH/U
VDCCM
Defective steering angle sensor or
improper neutral position
Yaw rate & lateral G sensor installation
malfunction
Brake caliper
Brake pad
Wheel alignment
Uneven road surface
pressure
VDCH/U
VDCCM
malfunction
Brake pad
pressure
VDCH/U
VDCCM
malfunction
Incorrect wiring or hose connections
Power steering system
Disc rotor
Brake pipe
Axle & wheels
VDCH/U
VDCCM
malfunction
Wheel alignment
Uneven road surface
damping force)
pressure
Power steering system
VDC(diag)-141
Brake caliper
Brake pipe
Brake caliper
Brake pad
Disc rotor
Wheel alignment
Uneven road surface

Symptom
VDC warning light/VDC OFF indicator light does not come on when
the VDC OFF switch is
depressed.
NOTE:
When pressing the VDC OFF
switch for 10 seconds or more
while the engine is running, the
VDC OFF indicator lights go off
and the switch cannot be operated
any more. To recover VDC operation, turn the ignition switch from
OFF to ON again.
Main probable cause
Harness
VDC warning light/VDC OFF indicator
light bulb
VDC OFF switch
VDC(diag)-142
General Description
BRAKE
A: SPECIFICATION
Model
2.5 X
Type
Effective disc diameter
Front disc
brake
Rear disc
brake
42.8 mm (1.685 in) 2

117.8 50.5 11.0 mm
(4.638 1.988 0.433 in)
Clearance adjustment
Type
Disc (Floating type)
Effective disc diameter
Disc thickness Diameter
Effective cylinder diameter
230 mm (9.06 in)

10 266 mm
(0.39 10.47 in)
38.1 mm (1.500 in)
Effective drum diameter

Lining dimensions
(Length Width Thickness)
Type
Brake
booster
24 294 mm
(0.94 11.57 in)

Pad dimensions
Type
Master cylinder
Disc (Floating type, ventilated)

244 mm (9.61 in)
Disc thickness Diameter
Pad dimensions
Rear drum
brake
2.5 XS, 2.5 XT, L.L.Bean
Automatic adjustment
89.4 33.7 9.0 mm

(3.520 1.327 0.354 in)
Drum
(Leading-Trailing type)
228.6 mm (9 in)
19 mm (0.75 in)
219.4 35.0 4.1 mm

(8.64 1.378 0.161 in)
Tandem
Effective diameter
Reservoir type
25.4 mm (1 in)
Sealed type
205 cm3 (12.51 cu in)
Vacuum suspended
Brake fluid reservoir capacity

Type
Effective diameter
8 + 9 tandem type
Dual circuit system
Brake line
Brake fluid
CAUTION:
Avoid mixing brake fluid of different
brands to prevent fluid performance from
degrading.
When filling brake fluid, be careful not
to allow any dust into the reservoir.
Use new DOT3 or 4 brake fluid when replacing or refilling fluid.
FMVSS No. 116, DOT3 or DOT4
BR-2
General Description
BRAKE
NOTE:
Refer to the PB section for parking brake specifications. <Ref. to PB-2, SPECIFICATION, General Description.>
Item
Front brake
Rear brake (Disc type)
Standard
Limit
Pad thickness
Disc thickness
11 mm (0.43 in)
24 mm (0.94 in)
1.5 mm (0.059 in)

22 mm (0.87 in)
Disc runout
Pad thickness
9 mm (0.35 in)
0.075 mm (0.0030 in)

1.5 mm (0.059 in)
Disc thickness
Disc runout
10 mm (0.39 in)
8.5 mm (0.335 in)

0.07 mm (0.0028 in)
Rear brake (Drum type)
Inside diameter
Lining thickness
228.6 mm (9 in)
4.1 mm (0.161 in)
230.6 mm (9.08 in)

1.5 mm (0.059 in)
Rear brake (Disc type parking)
Inside diameter
Lining thickness
170 mm (6.69 in)

3.2 mm (0.126 in)
171 mm (6.73 in)

1.5 mm (0.059 in)
Parking brake
Lever stroke
Brake fluid pressure

with engine stopped
Brake booster
Brake pedal
Brake fluid pressure

and vacuum pressure
with engine running at
66.7 kPa (500 mmHg,
19.69 inHg)
Free play
7 to 8 notches when pulled with a force of 196 N (20 kgf, 44 lb)

Brake pedal operation
force
147 N (15 kgf, 33 lb)
686 kPa (7 kg/cm2, 100 psi)
294 N (30 kgf, 66 lb)

147 N (15 kgf, 33 lb)
1,765 kPa (18 kg/cm2, 256 psi)

6,468 kPa (65 kg/cm2, 938 psi)
294 N (30 kgf, 66 lb)
10,297 kPa (105 kg/cm2, 1,493 psi)
Fluid pressure
0.5 2.0 mm (0.02 0.08 in) [Depress brake pedal with a force of less than 10 N (1 kgf, 2 lb).]
BR-3
General Description
BRAKE
B: COMPONENT
1. FRONT DISK BRAKE
T1
T3
(2)
(3)
(4)
(1)
T4
(5)
(6)
(7)
(10)
(8)
(9)
(11)
(4)
(18)
T2
(16)
(15)
(14)
(13)
(12)
(17)
BR-00358
(1)
(2)
Caliper body
Air bleeder screw
(9)
(10)
Bushing
Support
(17)
(18)
(3)
(4)
Guide pin (Green)

Pin boot
(11)
(12)
Pad clip
Outer shim
(5)
(6)
Piston seal
Piston
(13)
(14)
Outer pad
Inner pad
T1: 8 (0.8, 5.8)

T2: 18 (1.8, 13.0)
(7)
(8)
Piston boot
Lock pin (Yellow)
(15)
(16)
Rubber coat shim

Inner shim
T3: 26 (2.7, 19.2)

T4: 80 (8.2, 59)
BR-4
Disc rotor
Disc cover
General Description
BRAKE
2. REAR DISC BRAKE

T1
(2)
(3)
T2
(4)
(1 )
(5)
(10)
(6)
(7)
(8)
(14)
(9)
(12)
(33)
(4)
(11)
(14)
T3
(1 7)
(1 5 )
(1 6 )
(11)
(13)
(18)
(19)
(20)
(23)
(21)
(24)
(25)
(26)
T3
(27)
(22)
(28)
(3 2 )
(31)
(30)
(29)
BR-00326
(1)
(2)
Caliper body
Air bleeder screw
(14)
(15)
Shim
Shoe hold-down pin
(27)
(28)
Primary shoe return spring

Adjusting spring
(3)
(4)
Guide pin (Green)

Pin boot
(16)
(17)
Cover
Back plate
(29)
(30)
Adjuster
Shoe hold-down cup
(5)
(6)
Piston seal
Piston
(18)
(19)
Retainer
Spring washer
(31)
(32)
Shoe hold-down spring

Disc rotor
(7)
(8)
Piston boot
Boot ring
(20)
(21)
Parking brake lever

Parking brake shoe (Secondary)
(33)
Bushing
(9)
(10)
Lock pin (Yellow)

Support
(22)
(23)
Parking brake shoe (Primary)

Strut

T1: 8 (0.8, 5.8)
(11)
(12)
Pad clip
Inner pad
(24)
(25)
Strut shoe spring

Shoe guide plate
(13)
Outer pad
(26)
Secondary shoe return spring
BR-5
T2: 37 (3.8, 27.5)

T3: 52 (5.3, 38.3)
General Description
BRAKE
3. REAR DRUM BRAKE

(1)
(8)
T2
(2)
(3)
T1
(4)
(5)
(6)
(9)
(12)
(13)
(7)
(5)
(14)
(8)
(4)
(3)
(15)
(17)
(18)
(24)
(10)
(19)
(11)
(22)
(16)
(20)
T3
(21)
(23)
BR-00004
(1)
(2)
Air bleeder cap

Air bleeder screw
(11)
(12)
Upper shoe return spring

Retainer
(21)
(22)
Lower shoe return spring

Adjusting spring
(3)
(4)
Dust boots
Piston
(13)
(14)
Washer
Parking brake lever
(23)
(24)
Brake drum
Plug
(5)
(6)
Cup
Spring
(15)
(16)
Brake shoe (Trailing)

Brake shoe (Leading)
(7)
(8)
Wheel cylinder body

Hold-down pin
(17)
(18)

Hold-down cup
T1: 8 (0.8, 5.8)

T2: 10 (1.0, 7.2)
(9)
(10)
Plug
Back plate
(19)
(20)
Adjusting lever
Adjuster ASSY
T3: 52 (5.3, 38.3)
BR-6
General Description
BRAKE
4. MASTER CYLINDER
(1)
(2)
(10)
(3)
(9)
(8)
(4)
(5)
(6)
(7)
BR-00153
(1)
(2)
Cap
Filter
(6)
(7)
Secondary piston
Cylinder body
(10)
(3)
(4)
Reservoir tank
Piston retainer
(8)
(9)
Cylinder pin
Seal

T: 14 (1.4, 10.1)
(5)
Primary piston
BR-7
Pin
General Description
BRAKE
5. FRONT BRAKE PIPES AND HOSES
(A)
(B)
T2
(8)
T2
(8)
T1
T1
T1
T2
T1
T2
(1)
T1
(1)
T1
(2)
(2)
T1
T1
T1
T1
(5)
(7)
T4
(9)
(7)
(5)
T1
(5)
T4
(3)
(4)
T1
(3)
(6)
(5)
(9)
T2
(6)
T2
(10)
T2
T4
(4)
T1
T2
T4
(6)
(6)
BR-00564
(A)
AT model
(B)
MT model
(1)
(2)
Front brake pipe ASSY

Two-way connector
(7)

(3)
(4)
Front brake hose RH

Front brake hose LH
(8)
(9)
Bracket
Master cylinder
T2: 18 (1.8, 13.0)

T3: 19 (1.9, 13.7)
(5)
(6)
Clamp
Gasket
(10)
(11)
Hill holder
Hill holder
T4: 32 (3.3, 23.6)
BR-8

T1: 15 (1.5, 10.8)
General Description
BRAKE
6. CENTER AND REAR BRAKE PIPES AND HOSES

(5)
(8)
(4)
(8)
T2
(9)
T2
(7)
(8)
(3)
T1
(8)
T1
(2)
(6)
T1
T2
(8)
T2
T1
T1
T2
(9)
(1)
BR-00565
(1)
(2)
Center brake pipe ASSY

Two-way connector
(6)
Rear brake hose LH (Disc brake

model)
(3)
(4)
Rear brake pipe ASSY

Rear brake hose RH (Disc brake
model)
(7)
Rear brake hose LH (Drum brake

model)
(8)
Brake hose clamp
(5)
Rear brake hose RH (Drum brake

model)
BR-9
(9)
Gasket

T1: 15 (1.5, 10.8)
T2: 18 (1.8, 13.0)
General Description
BRAKE
7. BRAKE BOOSTER
(11)
(10)
(8)
(12)
(7)
(1)
(2)
(4) (5) (6)

(3)
(9)
BR-00008
(1)
Push rod
(5)
Filter
(9)
Valve body
(2)
(3)
Return spring
Reaction disc
(6)
(7)
Silencer
Operating rod
(10)
(11)
Plunger valve
Diaphragm plate
(4)
Key
(8)
Poppet valve ASSY
(12)
Valve return spring
BR-10
General Description
BRAKE
8. BRAKE PEDAL
AT model
BR-00139
(1)
(2)
Stopper
Bushing
(6)
(7)
Brake pedal pad

Brake pedal
(3)
(4)
Pedal bracket
Stop light switch
(8)
(9)
Clevis pin
Brake pedal spring
(5)
Snap pin
BR-11

T1: 8 (0.8, 5.8)
T2: 18 (1.8, 13.0)
T3: 29 (3.0, 21.7)
General Description
BRAKE
MT model
(7)
(3)
(27)
(11)
(4)
T2
(26)
T1
(2)
T2
T2
(25)
(24)
T1
(11)
(23)
T1
(21)
(20)
(2)
(1)
T1
(1)
(22)
(19) (18)
(14)
(13)
(14)
(4)
(8)
(2)
(2)
(12)
(17)
(16)
(7)
(15)
(12) (11)
(5)
(1)
(6)
(9)
(10)
BR-00154
(1)
(2)
Stopper
Bushing
(12)
(13)
Clutch clevis pin

Assist rod A
(23)
Clutch switch (Model with cruise

control)
(3)
(4)
Spring pin
Snap pin
(14)
(15)
Clip
Assist spring
(24)
(25)
Stop light switch

Pedal bracket
(5)
(6)
Brake pedal pad

Brake pedal
(16)
(17)
Assist bushing
Assist rod B
(26)
(27)
Clutch master cylinder bracket

Lever
(7)
(8)
Clevis pin
Brake pedal spring
(18)
(19)
Spring S
Rod S
(9)
(10)
Clutch pedal pad

Clutch pedal
(20)
(21)
Bushing S
Clip
(11)
Bushing C
(22)
Clutch switch (Starter interlock)
BR-12
T1: 8 (0.8, 5.8)

T2: 18 (1.8, 13.0)
General Description
BRAKE
9. HILL HOLDER
(6)
(1)
(1)
(3)
T2
(2)
(4)
(5)
T1
BR-00121
(1)
Clamp
(4)
Adjusting nut
(2)
(3)
PHV cable
PHV (Pressure hold valve)
(5)
(6)
Lock nut
To clutch pedal
C: CAUTION
points.
Before installing O-rings or snap rings, apply sufficient amount of fluid to avoid damage and deformation.
Keep fluids away from the vehicle body. If any
fluid contacts the vehicle body, immediately flush
the area with water.
BR-13

T1: 3.5 (0.36, 2.6)
T2: 18 (1.8, 13.0)
General Description
BRAKE
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
926460000
WHEEL CYLINDER
3/4ADAPTER
REMARKS
Used for installing the cup to the wheel cylinder
piston. (Size 3/4 in)
ST-926460000
2. GENERAL TOOL
TOOL NAME
Snap ring pliers
Brake pipe wrench
REMARKS
Used for removing and installing snap rings.
Used for removing and installing brake pipes.
BR-14
Front Brake Pad

BRAKE
2. Front Brake Pad

A: REMOVAL
4) Remove the lower caliper bolts.
5) Raise the caliper body and support it.
(4) Apply a rod with less than 12 mm (0.47 in)

diameter to the shaded area of brake pad, and
strike the rod with a hammer to remove brake
pad.
NOTE:
The brake hose must not be disconnected from the
caliper body.
6) Remove the pad.
BR-00014
BR-00012
NOTE:
If the brake pad is difficult to remove, proceed as
follows:
(1) Remove the caliper body from support.
(2) Remove the support.
(3) Place the support between wooden blocks
in the vise.
(1)
(2)
BR-00013
(1) Support
(2) Wooden block
BR-15
Front Brake Pad

BRAKE
B: INSTALLATION
C: INSPECTION
1) Apply a thin coat of Molykote AS880N (Part No.

K0777YA010) to the contact surface between pad
and pad clip.
K0777YA010) to the contact surface between inner
pad and the rubber coat shim.
Check the thickness A of pad.
NOTE:
Do not apply grease between the outer pad and
the outer shim.
Do not install the inner shim and outer shim incorrectly.
CAUTION:
Replace the pad if there is oil or grease adhering to the pad surface.
A
BR-00016
Pad thickness
Standard
11 mm (0.43 in)
Wear limit
1.5 mm (0.06 in)
NOTE:
Always replace the pads of both sides as a set.
Replace pad clips if they are twisted or worn.
A wear indicator is installed on inner pad. If the
pad is worn to the limit, the end of wear indicator
contacts disc rotor, and a squeaking sound is heard
as the wheel rotates. If the sound is heard, replace
the pad.
Replace the pad if there is oil or grease on it.
BR-00015
3) Install the pad to support.

4) Install the caliper body to the support.
Tightening torque:
26 Nm (2.7 kgf-m, 19.2 ft-lb)
NOTE:
If it is difficult to push the piston during pad replacement, loosen the air bleeder to facilitate work.
BR-16
Front Disc Rotor

BRAKE
3. Front Disc Rotor
C: INSPECTION
A: REMOVAL
1) Check the front wheel bearing play and axle hub

runout before the inspection of disc rotor runout
limit. <Ref. to DS-20, INSPECTION, Front Axle.>
2) Secure the disc rotor by tightening the five wheel
nuts.
3) Set a dial gauge 10 mm (0.39 in) inward from the
disc rotor outer circumference. Rotate the disc rotor
to check runout. If the disc rotor runout exceeds the
limit, resurface the disc rotor. After resurfacing,
check disc rotor thickness as in step 4).

4) Remove caliper body and support from the
housing, and suspend it from the strut using a wire.

0.075 mm (0.0030 in)
BR-00017
5) Remove the disc rotor.

NOTE:
If it is difficult to remove the disc rotor from hub,
drive an 8 mm bolt into the threads B of the rotor,
then remove the rotor.
BR-00019
4) Set a micrometer in 10 mm (0.39 in) inward from

disc rotor outer perimeter, and then measure the
disc rotor thickness. If the thickness of disc rotor
exceeds the service limit, replace with a new disc
rotor.
B
A
BR-00018
6) Remove mud and foreign matter from caliper

body assembly and support.
B
A
B: INSTALLATION
1) Install the disc rotor.
2) Install the caliper body and the support to housing.
Tightening torque:
80 Nm (8.2 kgf-m, 59 ft-lb)
BR-00018
Disc rotor
thickness A
BR-17
Standard
Limit
24 mm
(0.94 in)
22 mm
(0.87 in)
Disc rotor
outer dia.
294 mm
(11.57 in)
Front Disc Brake Assembly

BRAKE
4. Front Disc Brake Assembly

A: REMOVAL
CAUTION:
Do not let brake fluid come into contact with the
painted surface of the vehicle body. Completely
wash away with water immediately and wipe off
if it was accidental.
4) Remove the union bolt, and disconnect the
brake hose from the caliper body assembly.
BR-00021
5) Remove the bolt securing lock pin (Yellow) to

caliper body assembly.
BR-00022
6) Raise the caliper body assembly, and then move

it toward vehicle center to separate it from the support.
7) Remove the support from housing.
NOTE:
Remove the support only when replacing the rotor
or support. It need not be removed when servicing
the caliper body assembly.
BR-00023
BR-18

BRAKE
B: INSTALLATION
C: DISASSEMBLY
1) Install the support to the housing.

Tightening torque:
80 Nm (8.2 kgf-m, 59 ft-lb)
and pad clip.
K0777YA010) to the contact surface between inner
pad and the rubber coat shim.
NOTE:
Do not apply grease between the outer pad and
the outer shim.
Do not install the inner shim and outer shim incorrectly.
CAUTION:
Be careful not to allow foreign matter to enter
the brake hose connector.
2) Using a standard screwdriver, remove the boot
ring from piston.
3) Remove the piston boot from piston end.
4) Place a wooden block in caliper body as shown
in the figure to prevent the piston from jumping out
and being damaged, then gradually apply compressed air via installation hole of brake hose to
push piston out.
(1)
BR-00026
BR-00024
(1) Place a wood block with 30 mm (1.18 in) wide.

Tightening torque:
26 Nm (2.7 kgf-m, 19.2 ft-lb)
6) Connect the brake hose using the new gaskets.
5) Remove the piston seal from caliper body cylinder.

CAUTION:
Do not damage the caliper body cylinder and
piston seal groove.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
(1)
CAUTION:
When connecting the brake hose, do not twist
it.
7) Bleed air from the brake system. <Ref. to BR-42,
Air Bleeding.>
BR-00027
(1) Piston seal
6) Remove the pin boot, then remove the lock pin

(yellow) and the guide pin (green).
BR-19

BRAKE
D: ASSEMBLY
1) Clean the inside of the caliper body using brake
fluid.
2) Apply a coat of brake fluid to piston seal and install piston seal in the groove on caliper body.
3) Apply a coat of brake fluid to the inner surface of
the caliper body cylinder and entire outer surface of
the piston.
4) Apply a coat of specified grease to the piston
boot and install it into the groove on tip of caliper
body cylinder.
Grease:
NIGLUBE RX-2 (Part No. K0779GA102)
(1)
: (3)
(2)
BR-00030
Grease:
5) Insert the piston into caliper body cylinder.
(1) Pin boot
CAUTION:
Do not force the piston into caliper body cylinder.
(2) Lock pin (yellow) or guide pin (green)

(3) Grease applied area
8) Insert the lock pin (yellow) and guide pin (green)

and each pin boots into the support.
E: INSPECTION
1) Repair or replace the faulty parts.
2) Check the caliper body and piston for uneven
wear, damage or rust.
3) Check rubber parts for damage or deterioration.
BR-00028
6) Position the piston boot in the grooves on caliper

body cylinder and piston.
(3)
(2)
(4)
(1)
BR-00122
(1) Piston
(2) Piston boot
(3) Caliper body
(4) Piston seal
7) Apply a coat of the specified grease to the outer

surface of lock pin (yellow) and guide pin (green),
cylinder inner surface, and pin boot grooves.
BR-20
Rear Brake Pad

BRAKE
5. Rear Brake Pad
C: INSPECTION
A: REMOVAL
Check the thickness A of pad.

wheels.
4) Remove the lower caliper bolts.
A
BR-00016
Pad thickness
BR-00123
5) Raise the caliper body and support it.

NOTE:
The brake hose must not be disconnected from the
caliper body.
6) Remove the pad.
NOTE:
If it is difficult to remove the brake pad, use the
same procedure as front disc brake pad.
<Ref. to BR-15, REMOVAL, Front Brake Pad.>
Standard
9 mm (0.354 in)
Wear limit
1.5 mm (0.059 in)
NOTE:
Always replace the pads of both sides as a set.
Replace pad clips if they are twisted or worn.
A wear indicator is installed on inner pad. If the
pad is worn to the limit, the end of wear indicator
contacts disc rotor, and a squeaking sound is heard
as the wheel rotates. If the sound is heard, replace
the pad.
Replace the pad if there is oil or grease on it.
BR-00032
B: INSTALLATION
and pad clip.
CAUTION:
Replace the pad if there is oil or grease adhering to the pad surface.
Tightening torque:
37 Nm (3.8 kgf-m, 27.5 ft-lb)
NOTE:
If it is difficult to push the piston during pad replacement, loosen the air bleeder to facilitate work.
BR-21
Rear Disc Rotor

BRAKE
6. Rear Disc Rotor
(2) If it is difficult to remove the disc rotor from

hub, drive an 8 mm bolt into the threads B of the
rotor, then remove the rotor.
A: REMOVAL
wheels.
2) Pull down and release the parking brake.
3) Remove the two mounting bolts and remove the
disc brake assembly.
B
A
BR-00036
B: INSTALLATION
BR-00124
4) Suspend the disc brake assembly so that the

hose is not stretched.

2) Adjust the parking brake. <Ref. to PB-9, ADJUSTMENT, Parking Brake Assembly (Rear Disc
Brake).>
NOTE:
If it is difficult to remove the disc rotor, perform the
following two methods in order.
(1) Using a flat tip screwdriver, turn the adjuster
until the parking brake shoe is apart enough
from disc rotor.
(2)
(3)
(1)
(4)
BR-00155
(1) Adjuster
(2) Cover
(3) Flat tip screwdriver
(4) Back plate
BR-22
Rear Disc Rotor

BRAKE
C: INSPECTION
1) Check the rear wheel bearing play and axle hub
runout before the inspection of disc rotor runout.
<Ref. to DS-28, INSPECTION, Rear Axle.>
2) Secure the disc rotor by tightening the five wheel
nuts.
3) Set a dial gauge 10 mm (0.39 in) inward from the
disc rotor outer circumference. Rotate the disc rotor
to check runout. If the disc rotor runout exceeds the
limit, resurface the disc rotor. After resurfacing,
check disc rotor thickness as in step 4).
0.070 mm (0.0027 in)
BR-00037
4) Set a micrometer in 10 mm (0.39 in) inward from

disc rotor outer perimeter, and then measure the
disc rotor thickness. If the thickness of disc rotor
exceeds the service limit, replace with a new disc
rotor.
B
A
BR-00036
Disc rotor
thickness A
Standard
Limit
10 mm
(0.39 in)
8.5 mm
(0.335 in)
Disc rotor
outer dia.
266 mm
(10.47 in)
BR-23
Rear Disc Brake Assembly

BRAKE
7. Rear Disc Brake Assembly
B: INSTALLATION
A: REMOVAL
1) Install the disc rotor to hub.

2) Install the support to the housing.
CAUTION:
wheels.
4) Disconnect the brake hose from caliper body assembly.
5) Remove the bolt securing lock pin (Yellow) to
caliper body assembly.
Tightening torque:
52 Nm (5.3 kgf-m, 38.3 ft-lb)
and pad clip.
Tightening torque:
37 Nm (3.8 kgf-m, 27.5 ft-lb)
6) Connect the brake hose using the new gaskets.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
CAUTION:
it.
Air Bleeding.>
(1)
BR-00125
(1) Caliper body
6) Raise the caliper body, and then move it toward

vehicle center to separate it from the support.
7) Remove the support from housing.
NOTE:
Remove the support only when replacing the rotor
or support. It need not be removed when servicing
the caliper body assembly.
CAUTION:
Be careful not to allow foreign matter to enter
the brake hose connector.
BR-24

BRAKE
C: DISASSEMBLY
4) Remove the piston seal from caliper body cylinder.
1) Remove the boot ring.
CAUTION:
Do not damage the caliper body cylinder and
piston seal groove.
(1)
BR-00040
(1) Boot ring

BR-00043
2) Remove the piston boot.
5) Remove the lock pin sleeve and pin boot from

caliper body.
6) Remove the guide pin (green) and pin boot.
BR-00041
3) Place a wooden block in caliper body as shown

in the figure to prevent the piston from jumping out
and being damaged, then gradually apply compressed air via installation hole of brake hose to
push piston out.
(1)
BR-00042
(1) Place a wood block with 30 mm (1.18 in) wide.
BR-25

BRAKE
D: ASSEMBLY
1) Clean the inside of the caliper body using brake
fluid.
2) Apply a coat of brake fluid to piston seal and install piston seal in the groove on caliper body.
3) Apply a coat of brake fluid to the inner surface of
caliper body cylinder and entire outer surface of
piston.
4) Apply a coat of specified grease to the piston
boot and install it into the groove on tip of caliper
body cylinder.
7) Apply a coat of the specified grease to the outer

surface of lock pin (yellow) and guide pin (green),
outer surface of the lock pin sleeve, cylinder inner
surface, and pin boot grooves.
Grease:
(1)
: (3)
(2)
Grease:
5) Insert the piston into caliper body cylinder.
CAUTION:
Do not force the piston into caliper body cylinder.
6) Position the piston boot in the grooves on caliper
body cylinder and piston, then install the boot ring.
BR-00030
(1) Pin boot

(2) Lock pin (yellow) or guide pin (green)
(3) Grease applied area
8) Insert the guide pin boot to the support.

9) Install the lock pin boot to the support, and then
insert the lock pin sleeve into the specified position.
E: INSPECTION
(1)
(2)
(3)
(4)
BR-00029
1) Repair or replace the faulty parts.

2) Check the caliper body and piston for uneven
wear, damage or rust.
3) Check rubber parts for damage or deterioration.
(1) Piston boot

(2) Boot ring
(3) Piston seal
(4) Caliper body
BR-26
Rear Drum Brake Shoe

BRAKE
8. Rear Drum Brake Shoe
6) Hold the hold-down pin by securing rear of back

plate with your hand.
A: REMOVAL
wheels.
5) Remove the brake drum from brake assembly.
(1)
NOTE:
If it is difficult to remove the brake drum, remove
the adjusting hole cover from back plate, then turn
the adjuster assembly claws using a flat tip screwdriver until the brake shoe separates from the
drum.
(1)
BR-00048
(1) Hold-down cup

(2) Hold-down pin
7) Rotate the hold down cup and remove from the

hold down pin.
8) Disconnect the lower shoe return spring from the
brake shoe.
(2)
(5)
(2)
(3)
(4)
(6)
BR-00046
(1) Back plate

(2) Wheel cylinder ASSY
(3) Adjuster ASSY claws
BR-00049
(4) Adjusting lever

9) Remove each brake shoe along with the adjuster from the back plate.
(6) Push direction
If the brake drum is difficult to remove, drive it out

by installing an 8-mm bolt into bolt hole in brake
drum.
CAUTION:
Be careful not to excessively bend the parking
brake cable when removing the brake shoes.
(1)
(2)
(3)
(6)
(4)
(5)
BR-00047

(2) Adjuster ASSY
(3) Back plate
(4) Lower shoe return spring
(5) Parking lever
(6) Brake shoe (Trailing)
BR-27
BR-00050

BRAKE
10) Disconnect the parking brake cable from the

parking brake lever.
B: INSTALLATION
1) Clean the back plate and wheel cylinder assembly.
2) Apply grease to the portions indicated by arrows
in the figure.
Brake grease:
Dow Corning Molykote M 7439 (Part No.
003602001)
(1)
(2)
(3)
BR-00051
(1) Parking brake cable

11) Remove the upper shoe return spring and adjusting spring from the brake shoe.
BR-00053
3) Apply grease to the adjusting screw and both

ends of adjuster.
(1)
(2)
Brake grease:
003602001)
BR-00052
(1) Upper shoe return spring

(2) Adjusting spring
BR-00054
4) Attach the upper shoe return spring to the brake

shoe.
lever.
6) While positioning the brake shoe (one at a time)
in the groove of the wheel cylinder, secure the
brake shoe in place.
(1)
(2)
BR-00055

BR-28

BRAKE
7) Fix the shoes in place by connecting the holddown cup to the hold-down pin.
8) Install the lower shoe return spring.
9) Set the outside diameter of brake shoes 0.5 to
0.8 mm (0.020 to 0.031 in) smaller in comparison
with the inside diameter of the brake drum.
C: INSPECTION
1) Measure the lining thickness. If it exceeds the
service limit, replace the brake shoe with a new
part.
Lining thickness
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 severe, replace them.
3) If the tension of the shoe return spring is very
low, replace it. Be careful not to confuse the upper
and lower shoe return springs.
BR-29
Rear Drum Brake Drum

BRAKE
9. Rear Drum Brake Drum
C: INSPECTION
A: REMOVAL
1) If the inside surface of the brake drum has

scratches, perform inspection. And, if it is unevenly
worn, has narrow streaks on the surface, or the outside surface of brake drum is damaged, correct or
replace it.
2) Measure the brake drum inside diameter. If it exceeds service limits, replace with a new brake
drum.

wheels.
5) Remove the brake drum from brake assembly.
NOTE:
If it is difficult to remove the brake drum, remove
the adjusting hole cover from the back plate, then
turn the adjuster assembly claws using a flat tip
screwdriver until the brake shoe separates from the
drum.
Drum inner diameter: L

Standard:
228.6 mm (9 in)
Service limit:
230.6 mm (9.08 in)
(1)
(2)
(5)
(3)
(4)
L
(6)
BR-00046
(1) Back plate

(3) Adjuster ASSY claws
(4) Adjusting lever
(6) Push direction
If the brake drum is difficult to remove, drive it out

by installing an 8-mm bolt into bolt hole in brake
drum.
BR-00047
B: INSTALLATION
Set the outside diameter of brake shoes 0.5 to 0.8
mm (0.020 to 0.031 in) smaller in comparison with
the inside diameter of the brake drum.
BR-30
BR-00058
Rear Drum Brake Assembly

BRAKE
10.Rear Drum Brake Assembly
B: INSTALLATION
A: REMOVAL
1) Clean the back plate and wheel cylinder assembly.

2) Install the wheel cylinder assembly on the back
plate, and tighten bolts.
CAUTION:
wheels.
5) Remove the brake drum from the brake assembly. <Ref. to BR-30, REMOVAL, Rear Drum Brake
Drum.>
6) Remove the brake shoe. <Ref. to BR-27, REMOVAL, Rear Drum Brake Shoe.>
7) Disconnect the brake hose. <Ref. to BR-44,
REAR BRAKE HOSE (DRUM BRAKE), REMOVAL, Brake Hose.>
8) Remove the hub.
9) Disconnect the ABS wheel speed sensor from
the back plate.
10) Remove the rear drum brake assembly.
Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
BR-00061
3) Apply grease to the portions indicated by arrows

in the figure.
Brake grease:
003602001)
BR-00053
4) Install the brake assembly on housing, and tighten the bolts to install back plate.
BR-00060
11) Remove the bolts holding the wheel cylinder

assembly on the back plate, and remove the wheel
cylinder assembly.
Tightening torque:
52 Nm (5.3 kgf-m, 38.3 ft-lb)
BR-00060
BR-00061
5) Install the hub. <Ref. to DS-24, INSTALLATION,

Rear Axle.>
BR-31

BRAKE
6) Connect the brake hose, and tighten the brake

hose flange nut.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
C: DISASSEMBLY
1) Remove the right and left dust boots from the
wheel cylinder.
(1)
(2)
CAUTION:
it.
7) Install the ABS wheel speed sensor on the back
plate.
(3)
(4)
Tightening torque:
32 Nm (3.3 kgf-m, 23.6 ft-lb)
8) Apply grease to the adjusting screw and both
ends of adjuster.
(5)
(6)
(7)
BR-00066
(1) Air bleeder cap
Brake grease:
003602001)
(2) Air bleeder screw

(3) Spring
(4) Wheel cylinder body
(5) Cup
(6) Piston
(7) Dust boots
2) Remove the piston, cup, spring and air bleeder

screw and cap.
BR-00054
9) Install the brake shoe. <Ref. to BR-28, INSTALLATION, Rear Drum Brake Shoe.>
10) Install the brake drum. <Ref. to BR-30, INSTALLATION, Rear Drum Brake Drum.>
11) After installing the rear drum brake assembly,
bleed air from the brake line. <Ref. to BR-42, Air
Bleeding.>
BR-32

BRAKE
D: ASSEMBLY
1) Clean all parts with brake fluid. Check and replace faulty parts.
Cup and boot damage or fatigue
Wheel cylinder body, piston and spring damage
or rust
(1) When attaching the cup, use the ST and apply brake fluid to the sliding surfaces to make installation smoother. Be careful of the direction
of the cup at this time.
(2) The ST is available in different sizes.
3) Apply rubber grease to the boot inside as shown

in figure.
CAUTION:
Never use brake grease.
Grease:
CAUTION:
When replacing with the repair kit, make sure
that the sizes of wheel cylinder body and cup
are the same as those being replaced.
ST: ADAPTER
Size
Part No.
19 mm (3/4 in)
926460000
BR-00068
E: INSPECTION
If the deformation or wear of back plate, shoe, etc.
are severe, replace them.
CAUTION:
When assembling, be careful that the wheel cylinder does not become scratched, and that no
dust enters.
(1)
ST
(2)
(1)
(2)
BR-00067
(1) Cup
(2) Piston
BR-33
Master Cylinder
BRAKE
11.Master Cylinder
C: REPLACEMENT
A: REMOVAL
1) Remove mud and dirt from the surface of brake

master cylinder.
2) Secure the master cylinder in a vise.
3) Remove the pin which secures the reservoir tank
to master cylinder, and then remove the reservoir
tank and grommet.
4) Remove the cylinder pin with magnetic pick-up
tool while pushing in the primary piston by screwdriver which is wrapped with tape.
CAUTION:
1) Drain brake fluid from reservoir tank completely.
2) Disconnect the harness connector of the fluid
level gauge.
3) Remove the brake pipes from master cylinder.
4) Remove the master cylinder mounting nuts, and
remove the master cylinder from the brake booster.
(1)
B: INSTALLATION
Tightening torque:
Master cylinder mounting nut
14 Nm (1.4 kgf-m, 10.1 ft-lb)
Piping flare nut
15 Nm (1.5 kgf-m, 10.8 ft-lb)
BR-00069
(1) Cylinder pin (straight pin)
CAUTION:
Be sure to use recommended brake fluid.
PROCEDURE, Air Bleeding.>
5) Raise the claw and remove the piston retainer.

Hold the piston retainer while working, because the
piston may fly out with force.
BR-00070
6) Extract the primary piston assembly and secondary piston assembly straight out while taking
care not to scratch the inner surface of the cylinder.
7) Use brake fluid to wash the inside wall of master
cylinder and the piston assembly. Check for any
damage, deformation, wear or rust. Replace the
master cylinder assembly as a unit if faulty.
8) Apply brake fluid to the inner surface of master
cylinder and piston assembly.
9) Make sure that the inner surface of master cylinder and the piston assembly are free of foreign
matter. Install the primary piston assembly and the
secondary piston assembly to master cylinder,
while taking care not to scratch the master cylinder
inner surface.
10) Install the cylinder pin while pushing in the primary piston by the screwdriver which is wrapped
with tape.
BR-34
Master Cylinder
BRAKE
11) Install the piston retainer and secure it with the

claw.
D: INSPECTION
Check the master cylinder for oil leakage.
NOTE:
After replacing the piston kit, if an oil leakage is
found even though there is no damage or scratches
on the inside of the cylinder, the master cylinder inner wall may be worn. In this case, replace the
master cylinder as an assembly.
BR-00070
12) Install the seal to reservoir tank.
(1)
BR-00072
(1) Seal
13) Install the reservoir tank to the master cylinder,

and secure with pin.
BR-35
Brake Booster
BRAKE
12.Brake Booster
3) Remove the brake booster while avoiding the

brake pipe.
A: REMOVAL
1) Remove or disconnect the following parts of engine compartment.
(1) Disconnect the connector of brake fluid level
gauge.
(2) Remove the brake pipes from master cylinder.
(3) Remove the master cylinder installation nut.
(4) Disconnect the vacuum hose from brake
booster.
2) Remove the following parts from the pedal
bracket.
(1) Snap pin and clevis pin
(2) Four brake booster installation nuts
NOTE:
Be careful not to drop the brake booster. If the
booster is dropped, replace it.
Use special care when handling the operating
rod.
If excessive force is applied to operating rod, angle may cause change in excess of 3, and it may
result in damage to the master cylinder.
Be careful when placing the brake booster on
floor.
Do not change the push rod length. If it has been
changed, reset the projected length L to the standard length.
Standard:
Model with ABS
L = 10.05 mm (0.396 in)
(1)
L
BR-00074
(2)
CAUTION:
Do not disassemble the brake booster.
If external force is applied from above when
brake booster is placed in this position, the resin portion as indicated by P may be damaged,
so be careful how it is placed.
(3)
(4)
(1)
BR-00073
(1) Nut
(2) Clevis pin
(3) Snap pin
(4) Operating rod
BR-00075
(1) Force
BR-36
Brake Booster
BRAKE
B: INSTALLATION
4) Connect the vacuum hose to brake booster.
1) Check and adjust the operating rod of the brake

booster.
Standard: L
144.6 mm (5.69 in)
If it is out of specification, adjust it with the brake
booster operating rod.
L
BR-00078
BR-00076
2) Mount the brake booster in position.

3) Connect the operating rod to brake pedal with a
clevis pin and snap pin.
5) Mount the master cylinder onto the brake booster.

6) Connect the brake pipes to the master cylinder.
7) Connect the connector of the brake fluid level
gauge.
8) Measure the clearance between the threaded
end of stop light switch and the stopper.
If it is not within the specification, adjust it by adjusting the position of the stop light switch. <Ref. to BR50, ADJUSTMENT, Stop Light Switch.>
CAUTION:
Do not rotate the stop light switch.
Stop light switch clearance: A
0.3 mm (0.012 in)
(1)
(2)
BR-00079
(3)
9) Apply grease to the operating rod connecting pin

to prevent it from wear.
10) Bleed air from the brake system. <Ref. to BR42, Air Bleeding.>
(4)
BR-00073
(1) Nut
(2) Clevis pin
Tightening torque (air bleeder screw):

8 Nm (0.8 kgf-m, 5.8 ft-lb)
11) Perform a road test to make sure the brakes do
not drag.
(3) Snap pin

(4) Operating rod
BR-37
Brake Booster
BRAKE
C: INSPECTION
OPERATION CHECK
1. OPERATION CHECK (WITHOUT GAUGES)
1) While the engine is OFF, depress the brake pedal several times applying the same pedal force, to
check for a change in pedal height.
CAUTION:
When checking operation, be sure to apply the
parking brake securely.
(1)
(2)
CHECK WITHOUT GAUGES

This method can not determine which portion is defective exactly. But it is possible to identify the outline of the defect by performing the check
according to the following procedures.
AIR TIGHTNESS CHECK
BR-00081
Start the engine, and idle it for 1 to 2 minutes, then

turn it OFF. Depress the brake pedal several times
applying the normal pedal force. The pedal stroke
should be the longest at the 1st depression, and it
should become shorter at each successive depression. If the depressed pedal height is not changed,
the brake booster is faulty.
(1)
(1) When engine is stopped

(2) When engine is started
2) With brake pedal depressed, start the engine.

3) As the engine starts, the brake pedal should
move slowly toward floor. If the pedal height is not
changed, the brake booster is faulty.
NOTE:
If faulty, check correctly with gauge.
(2)
LOADED AIR TIGHTNESS CHECK

Depress the brake pedal while the engine is running, and turn the engine OFF with the pedal depressed. Keep the pedal depressed for 30
seconds. If the pedal height does not change, the
function of brake booster is normal. If the pedal
height increases, it is faulty.
(5)
(4)
(3)
BR-00080
NOTE:
If faulty, check correctly with gauge.
(1) Normal
(2) Not OK
(3) 1st
(4) 2nd
(5) 3rd
NOTE:
In case of defective operation, inspect the condition of the check valve and vacuum hose as well.
Replace them if faulty, and perform the test
again.
If a defect is not improved, check correctly using
a gauge.
BR-38
Brake Booster
BRAKE
2. OPERATION CHECK (WITH GAUGE)

CAUTION:
When checking operation, be sure to apply the
parking brake securely.
CHECK WITH GAUGE
Connect the gauge as shown in the figure. After
bleeding air from pressure gauge, perform each
check.
(1)
(2)
(3)
(4)
(5)
2) Stop the engine and check the gauge. If the vacuum pressure drop within 15 seconds after stopping the engine is less than 3.3 kPa (25 mmHg,
0.98 inHg), the function of brake booster is normal.
If faulty, the cause may be one of the following.
Check valve malfunction
Leak from vacuum hose
Leak from shell joint section or stud bolt welded
section
Damaged diaphragm plate
Leak from valve body seal and bearing section
Leak from plate and seal assembly section
Leak from poppet valve assembly section
LOADED AIR TIGHTNESS CHECK
1) Start the engine and depress the brake pedal
with a pedal force of 196 N (20 kgf, 44 lb). Keep the
engine idling until vacuum pressure indicates B
point of gauge = 66.7 kPa (500 mmHg, 19.69 inHg)
with the pedal depressed.
BR-00082
(1)
(1) Pressure gauge

(2) Vacuum gauge
(2)
B
(3)
(3) Adapter hose

(4) Vacuum hose
(5) Pedal force gauge
AIR TIGHTNESS CHECK
(4)
1) Start the engine and keep it running until vacuum pressure indicates A point of vacuum gauge =
66.7 kPa (500 mmHg, 19.69 inHg). Do not depress
the brake pedal at this time.
(1)
(2)
BR-00084
(1) Pressure gauge

(2) Vacuum gauge
(3) Pedal force gauge

(4) Depressed
BR-00083
(1) Pressure gauge

(2) Vacuum gauge
2) Stop the engine and check the vacuum gauge.

If the vacuum pressure drop within 15 seconds after stopping the engine is less than 3.3 kPa (25
mmHg, 0.98 inHg), the function of brake booster is
normal.
If defective, refer to AIR TIGHTNESS CHECK.
<Ref. to BR-38, INSPECTION, Brake Booster.>
3) If the brake booster is faulty, replace it with a
new part.
LACK OF BOOSTING ACTION CHECK
Turn the engine OFF, and set the value of the vacuum gauge to 0. Then, check the fluid pressure
when the brake pedal is depressed. The pressure
must be greater than the specification listed.
Brake pedal
operation force
Fluid pressure
BR-39
147 N
(15 kgf, 33 lb)
686 kPa
(7 kg/cm2, 100 psi)
294 N
(30 kgf, 66 lb)
17.65 kPa
(18 kg/cm2, 256 psi)
Brake Booster
BRAKE
BOOSTING ACTION CHECK

Set the vacuum gauge reading to 66.7 kPa (500
mmHg, 19.69 inHg) with the engine running. Then,
check the fluid pressure when the brake pedal is
depressed. The pressure must be greater than the
specification listed.
Brake pedal
operation force
147 N
(15 kgf, 33 lb)
294 N (30 kgf, 66 lb)
Fluid pressure
6,468 kPa
(66 kg/cm2, 938
psi)
10,297 kPa
(105 kg/cm2, 1,493
psi)
BR-40
Brake Fluid
BRAKE
13.Brake Fluid
A: INSPECTION
1) Check that the brake fluid level remains between
MIN and MAX. If out of the specified range, refill or
drain fluid. If the fluid level becomes close to MIN,
check the brake pad for wear and refill fluid.
2) Check the fluid for discoloration. If the fluid color
has excessively changed, drain the fluid and refill
with new fluid.
B: REPLACEMENT
CAUTION:
NOTE:
While working, keep the reservoir tank filled with
brake fluid to eliminate entry of air.
Operate the brake pedal slowly.
For convenience and safety, perform work with 2
people.
The required amount of brake fluid is approximately 500 m2 (16.9 US fl oz, 17.6 Imp fl oz) for
entire brake system.
1) Lift-up the vehicle and set rigid racks at the specified locations, or keep the vehicle lifted.
2) Remove both the front and rear wheels.
brake fluid.
Refer to SPECIFICATION of General Description. <Ref. to BR-2, SPECIFICATION, General
Description.>
Repeat the same procedure as for bleeding air
from the brake line, until new brake fluid comes out
from vinyl tube. <Ref. to BR-42, PROCEDURE, Air
Bleeding.>
NOTE:
Perform the brake fluid replacement starting from
the wheel cylinder farthest from the master cylinder.
BR-41
Air Bleeding
BRAKE
14.Air Bleeding
6) Repeat steps 4) and 5) several times.

7) Remove the plastic bag.
8) Install the brake pipe to the master cylinder.
A: PROCEDURE
CAUTION:
1. MASTER CYLINDER
NOTE:
When the master cylinder is disassembled or
when the reservoir tank is empty, bleed the master
cylinder.
If bleeding of the master cylinder is not necessary, omit the following procedures, and perform
bleeding of the brake line. <Ref. to BR-42, BRAKE
LINE, PROCEDURE, Air Bleeding.>
1) Fill the master cylinder reservoir tank with brake
fluid.
Tightening torque:
Model with ABS
15 Nm (1.5 kgf-m, 10.8 ft-lb)
9) Bleed air from the brake line. <Ref. to BR-42,
BRAKE LINE, PROCEDURE, Air Bleeding.>
2. BRAKE LINE
1) When the master cylinder is disassembled or
when the reservoir tank is empty, bleed the master
cylinder before bleeding the brake line. <Ref. to
BR-42, MASTER CYLINDER, PROCEDURE, Air
Bleeding.>
2) Fill the master cylinder reservoir tank with brake
fluid.
NOTE:
While bleeding air, keep the reservoir tank filled
with brake fluid to prevent entry of air.
3) Attach one end of the vinyl tube to the air bleeder
and the other end to the brake fluid container.
NOTE:
During air bleeding, keep the reservoir tank filled
with brake fluid to prevent entry of air.
2) Disconnect the brake line at primary and secondary sides.
3) Wrap the master cylinder with a plastic bag.
4) Slowly depress the brake pedal and keep it depressed.
BR-00087
4) Depress the brake pedal several times and keep

it depressed.
5) Loosen the air bleeder screw to drain brake fluid.
Tighten the air bleeder quickly, and release the
brake pedal.
6) Repeat the steps 4) to 5) until there are no more
air bubbles in the vinyl tube.
7) Repeat the steps from 2) to 6) above to bleed air
from each wheel.
BR-00090
5) Close the outlet plug with your finger, and release the brake pedal.
NOTE:
Perform the air bleeding operation starting from the
wheel cylinder closest to the master cylinder.
8) Securely tighten the air bleeder screws.
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
9) Check the entire system for brake fluid leaks.
BR-00091
BR-42
Air Bleeding
BRAKE
10) Check the pedal stroke.

Idle the engine after warm-up, depress the brake
pedal with a force of 500 N (51 kgf, 112 lbf), and
measure the distance between the brake pedal and
steering wheel. Release the pedal, and measure
the distance between pedal and steering wheel
again.
(1)
1
2
1
(2)
BR-00094
(1) Steering wheel

(2) Toe board
Specification of pedal stroke:

When depressing the pedal with a force of
500 N (51 kgf, 112 lbf)
11) If the distance is more than specified, there is a
possibility that air is in the brake line. Bleed the
brake line of all air until the pedal stroke meets the
specification.
12) Operate the hydraulic control unit in the sequence control mode. <Ref. to ABS-11, ABS Sequence Control.>
13) Check the pedal stroke again.
14) If the distance is more than specified, there is a
possibility that air is in the hydraulic unit. Repeat
above steps 2) to 9) until pedal stroke meets the
specification.
15) Fill brake fluid up to the MAX level of reservoir
tank.
16) Test run the vehicle and ensure that the brakes
operate normally.
BR-43
Brake Hose
BRAKE
15.Brake Hose
3. REAR BRAKE HOSE (DRUM BRAKE)
A: REMOVAL
1. FRONT BRAKE HOSE
1) Separate the brake pipe from the brake hose using a flare nut wrench.
2) Remove the clamp, strut mount bolts and union
bolt.
2) Remove the two clamps.
3) Disconnect the brake hose from the wheel cylinder.
(1)
(2)
(2)
(1)
(3)
(3)
(1)
(2)
BR-00126
(1) Brake pipe

(2) Brake hose
BR-00095
(3) Brake hose clamp
(1) Brake hose

(2) Brake pipe
2. REAR BRAKE HOSE (DISC BRAKE)

2) Remove the clamp and union bolt.
(2)
(1)
(3)
(3)
BR-00096
(1) Brake pipe

(2) Brake hose
BR-44
Brake Hose
BRAKE
B: INSTALLATION
Tightening torque (brake pipe flare nut):

15 Nm (1.5 kgf-m, 10.8 ft-lb)
1. FRONT BRAKE HOSE

1) Secure the brake hose to strut mount.
(2)
Tightening torque:
32 Nm (3.3 kgf-m, 23.6 ft-lb)
2) Install the brake hose to the caliper using new
gasket.
(1)
(3)
(3)
Tightening torque (union bolt):

18 Nm (1.8 kgf-m, 13.0 ft-lb)
BR-00096
(1) Brake pipe

(2) Brake hose
3. REAR BRAKE HOSE (DRUM BRAKE)

1) Attach the brake hose to the wheel cylinder.
BR-00021
3) Position the disc in straight position and route

the brake hose through the hole in the bracket on
the wheel apron side.
CAUTION:
Do not twist the brake hose.
4) Temporarily tighten the flare nut which connects
brake pipe and hose.
5) Secure the brake hose to wheel apron bracket
with clamp.
6) While holding the hexagonal part of brake hose
fitting with a wrench, tighten the flare nut to the
specified torque.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
2) Attach the brake hose to the bracket of the strut
using the clamp.
3) Route the brake hose through the bracket hole in
the vehicle body, and connect to the brake pipe.
Tightening torque:
15 Nm (1.5 kgf-m, 10.8 ft-lb)
(1)
(2)
(2)
Tightening torque (brake pipe flare nut):

15 Nm (1.5 kgf-m, 10.8 ft-lb)
7) Bleed air from brake system.
(3)
(3)
(1)
2. REAR BRAKE HOSE (DISC BRAKE)

1) Route the brake hose through the hole of bracket, and lightly tighten the flare nut to connect brake
pipe.
2) Insert the clamp to secure brake hose.
3) Install the brake hose to caliper using new gasket.
Tightening torque (union bolt):
18 Nm (1.8 kgf-m, 13.0 ft-lb)
4) While holding the hexagonal part of brake hose
fitting with a wrench, tighten the flare nut to the
specified torque.
BR-00126
(1) Brake pipe

(2) Brake hose
C: INSPECTION
Ensure there are no cracks, breakage, or damage
on hoses. Check the joint for fluid leakage. If any
cracks, breakage, damage or leakage is found, repair or replace the hose.
NOTE:
Check locations that are hard to see and reverse
side of parts using a mirror.
BR-45
Brake Pipe
BRAKE
16.Brake Pipe
A: REMOVAL
NOTE:
center brake pipe.
CAUTION:
wiring harness when servicing the center brake
pipe.
When removing brake pipes, use a brake pipe
wrench.
When removing the brake pipe, do not bend.
B: INSTALLATION
NOTE:
center brake pipe.
CAUTION:
wiring harness when servicing the center brake
pipe.
When installing brake pipes, use a brake pipe
wrench.
When installing the brake pipe, do not bend.
After installing the brake pipe and hose,
bleed air.
After installing the brake hoses, make sure
that they do not contact the tires or suspension
assembly, etc.
Brake pipe tightening torque:
15 Nm (1.5 kgf-m, 10.8 ft-lb)
C: INSPECTION
Ensure there are no cracks, breakage, or damage
on pipes. Check the joint for fluid leakage. If any
cracks, breakage, damage or leakage is found, repair or replace the pipe.
NOTE:
Check the part, which is difficult to see such as the
backside using a mirror.
BR-46
Brake Pedal
BRAKE
17.Brake Pedal
2. MT MODEL
A: REMOVAL
1. AT MODEL
2) Remove the instrument panel lower cover from
instrument panel.
3) Remove the clevis pins which secure the brake
pedal to the brake booster operating rod. Also disconnect the stop light switch connector.
4) Remove the two bolts and four nuts which secure brake pedal to pedal.
1) Remove the steering bolt.

2) Raise the vehicle on a lift and remove the two
bolts which secure the steering unit to the underside of the body.
4) Remove the instrument panel lower cover from
instrument panel.
5) Disconnect the following parts from pedal bracket.
Operating rod of brake booster
Connector (stop light switch, etc.)
6) Remove the clevis pin which secures the lever
and push rod.
7) Remove the nut which secures the clutch master
cylinder.
8) Remove the steering assembly.
9) Remove the accelerator pedal.
10) Remove the bolts and nuts which secure the
pedal bracket.
(1)
(2)
BR-00128
B: INSTALLATION
(3)

BR-00140
(1) Clevis pin

(2) Snap pin
(3) Operating rod
CAUTION:
If the cable clamp is damaged, replace it with
a new part.
Never fail to cover outer cable end with boot.
Be careful not to twist the accelerator cable.
Always use a new clevis pin.
2) Adjust the clutch pedal. <Ref. to CL-26, ADJUSTMENT, Clutch Pedal.>
3) Check the brake pedal after installation. <Ref. to
BR-49, INSPECTION, Brake Pedal.>
BR-47
Brake Pedal
BRAKE
C: DISASSEMBLY
4) Remove the bushing, spring and stopper.
1. AT MODEL
1) Remove the brake switch. <Ref. to BR-50, REMOVAL, Stop Light Switch.>
2) Unbolt, and then remove the brake pedal.
BR-00130
(1) Stopper
(2) Bushing
(3) Brake pedal
(4) Brake pedal spring
BR-00100
3) Remove the bushing, stopper and spring.
5) Remove the brake pedal pad.
D: ASSEMBLY
1) Position the stop light switch, etc. to the brake
pedal.
2) Clean the inside of bores of the clutch pedal and
brake pedal, apply grease, and set bushings into
the bores.
3) Align bores of the pedal bracket, clutch pedal
and brake pedal, attach brake pedal return spring
and clutch pedal effort reduction spring (vehicles
equipped with hill holder), then install the pedal
bolt.
BR-00101
(1) Bushing
(2) Stopper
(3) Brake pedal
NOTE:
Clean up the inside of bushings and apply a thin
coat of grease before installing the spacer.
(4) Brake pedal spring
Tightening torque:
T: 29 Nm (3.0 kgf-m, 21.7 ft-lb)
4) Remove the brake pedal pad.
2. MT MODEL
1) Remove the brake switch. <Ref. to BR-50, REMOVAL, Stop Light Switch.>
2) Remove the clutch pedal. <Ref. to CL-25, DISASSEMBLY, Clutch Pedal.>
3) Remove the clutch master cylinder bracket.
BR-00102
4) After attaching the brake pedal to the vehicle,

adjust the position of the stop light switch. <Ref. to
BR-50, ADJUSTMENT, Stop Light Switch.>
BR-00129
BR-48
Brake Pedal
BRAKE
E: INSPECTION
2) Check the position of pedal pad.
1) Move the brake and clutch pedal pads in the lateral direction with a force of approx. 10 N (1 kgf, 2
lb), and check the pedal deflection is in the range of
specifications.
Pedal height: L
148 mm (5.83 in)
CAUTION:
If excessive deflection is found, replace the
bushing with new part.
Brake pedal free play: A

1 3 mm (0.04 0.12 in) [Depress brake
pedal with a force of less than 10 N (1 kgf, 2
lb).]
(1)
Deflection of the brake and clutch pedal:

Service limit:
AT model
(3)
(4)
A
(2)
L
BR-00106
(1)
(1) Stop light switch

(2) Mat
(3) Toe board
(4) Operating rod
BR-00105
3) If it is not within the specification, adjust it by adjusting the brake booster operating rod length.
(1) Brake pedal
MT model
(1)
(2)
BR-00104
(1) Clutch pedal

(2) Brake pedal
BR-49
Stop Light Switch

BRAKE
18.Stop Light Switch
CAUTION:
A: REMOVAL
2) Disconnect the stop light switch connector.
3) Loosen the nuts, unscrew the stop light switch,
and remove stop light switch.
Stop light switch clearance: A

0.3 mm (0.012 in)
(1)
B: INSTALLATION
1) Install the stop light switch onto the bracket with

screws and position it with the nut.
2) Adjust the stop light switch position, and then
tighten the nut.
<Ref. to BR-50, ADJUSTMENT, Stop Light
Switch.>
(2)
(3)
BR-00110
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)

(2) Stopper
C: INSPECTION
(3) Brake pedal
1) If the stop light switch does not operate properly

(or if it is not secured at the specified position), replace with a new part.
Specified position: L
2 mm (0.079 in)
3) If it is not within the specification, adjust it by adjusting the position of the stop light switch.
CAUTION:
D: ADJUSTMENT
Loosen the lock nut, and adjust the stop light switch
position until the clearance A between the threaded
end of the stop light switch and stopper becomes
0.3 mm (0.012 in). Then, tighten the lock nut.
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
(1)
(2)
BR-00109
(3)
2) Measure the clearance between the threaded

end of stop light switch and the stopper.
(4)
(5)
BR-00111

(2) Lock nut A
(3) Lock nut B
(4) Stopper
(5) Brake pedal
NOTE:
Tighten lock nut B until the threaded end of switch
contacts with stopper. Hold the switch so that it
does not rotate, then loosen the lock nut B approx.
60. The clearance will become approximately 0.3
mm (0.012 in).
BR-50
Hill Holder
BRAKE
19.Hill Holder
CAUTION:
When removing the PHV, take great care that no
foreign objects enter inside.
A: REMOVAL
1. PHV (PRESSURE HOLD VALVE)
1) Drain brake fluid from the master cylinder reservoir tank.
2) Remove the adjusting nut and lock nut.
(1)
(1)
(2)
BR-00133
(1) PHV
2. PHV CABLE
(3)
1) Remove the adjusting nut and lock nut.
BR-00131
(1)
(1) Adjusting nut
(2)
(2) Lock nut

(3) PHV
3) Remove the cable clamp, and disconnect the

CAUTION:
When disconnecting the PHV cable, protect it
carefully so as not to damage the boot and inner cable.
(3)
BR-00131
(1) Adjusting nut

(2) Lock nut
(3) PHV
2) Remove the cable clamp, and disconnect the

(1)
(2)
CAUTION:
When disconnecting the PHV cable, protect it
carefully so as not to damage the boot and inner cable.
BR-00132
(1) PHV cable

(2) Clamp
4) Disconnect the brake pipes from the PHV.

CAUTION:
the painted surface of the vehicle body. Completely wash away with water immediately and
wipe off if it was accidental.
Use a pipe wrench so that the hex head of the
flare nut is not damaged.
5) Separate the PHV from the side frame, along
with the support.
(1)
(2)
BR-00132
(1) PHV cable

(2) Clamp
3) Remove the cable clamp from the clutch pedal

bracket.
4) Remove the PHV cable.
BR-51
Hill Holder
BRAKE
B: INSPECTION
Inspect the following items for the removed parts,
and replace those that apply.
1) If the PHV cable boot is damaged or deteriorated, or if the inner cable is damaged or rusted.
2) Check for weak return springs, damage, and
rust.
3) Check that the rotation of the ball can be heard
when the PHV is tilted and the lever is moved
smoothly.
CAUTION:
The PHV cannot be disassembled. If it requires
replacement, replace the entire PHV assembly.
CAUTION:
If the cable clamp is damaged, replace it with
a new part.
Do not bend the PHV cable sharply to avoid
damage.
2) Apply grease to the following points.
Return spring hook position
Lever cable end portion.
Grease:
KOPR-KOTE (Part No. 003603001)
3) Adjust the PHV cable. <Ref. to BR-52, ADJUSTMENT, Hill Holder.>
1. PHV (PRESSURE HOLD VALVE)
CAUTION:
After replacing with a new PHV cable, operate
the clutch pedal approximately 30 times to
break it in, then perform adjustment.
1) Attach the PHV to the side frame.
D: ADJUSTMENT
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
2) Connect the brake pipe to the PHV.
Perform inspection of stop, start performance on a

hill with an incline of 3 or more.
1) If the vehicle will not stop:
Tighten the adjusting nut of the PHV cable.
2) If the vehicle does not advance properly:
Case A If the hill holder is released after the
clutch is connected (engine stalls easily):
Loosen the adjusting nut gradually until a smooth
start is possible.
Case B If the hill holder is released before the
clutch is connected (vehicle moves backward):
Tighten the adjusting nut so that the hill holder releases after connecting the clutch pedal. (Case A)
then perform the same adjustment as for Case A.
C: INSTALLATION
Tightening torque:
15 Nm (1.5 kgf-m, 10.8 ft-lb)
CAUTION:
Check that there is no deformation or damage
on the brake pipe. If necessary, replace with a
new part.
3) Attach the PHV cable to the PHV.
CAUTION:
If the cable clamp (and clip) is damaged, replace it with a new part.
Do not bend the PHV cable sharply to avoid
damage.
4) Connect the PHV cable with a clip.
5) Apply grease to the following points.
Return spring hook position
Lever cable end portion.
CAUTION:
When turning the adjusting nut, always make
sure that the PHV cable does not turn.
(1)
Grease:
KOPR-KOTE (Part No. 003603001)
Air Bleeding.>
7) Adjust the PHV cable. <Ref. to BR-52, PHV CABLE, INSTALLATION, Hill Holder.>
(2)
(3)
BR-00131
CAUTION:
After replacing with a new PHV cable, operate
the clutch pedal approximately 30 times to
break it in, then perform adjustment.
(1) Adjusting nut

(2) Lock nut
(3) PHV
2. PHV CABLE
1) The installation of the PHV cable is performed in
the reverse order of removal.
3) Tighten the lock nut.

Tightening torque:
3.5 Nm (0.36 kgf-m, 2.6 ft-lb)
BR-52

BRAKE

A: INSPECTION
1. Insufficient braking
2. Unstable or uneven
braking
Corrective action
(1) Fluid leakage from the hydraulic mechanism
Correct or replace. (cup, piston seal, piston boot,

master cylinder piston kit, pipe or hose)
(2) Entry of air into the hydraulic mechanism

(3) Excessively wide shoe clearance
Bleed air.
(4) Wear, deteriorated surface material, water or

Replace, grind or clean.
fluid on lining
(5) Improper operation of master cylinder, disc cal- Correct or replace.
iper, brake booster or check valve
(1) Fluid on the lining, drum or rotor
Correct the cause of fluid leakage, and clean or
replace.
(2) Drum or rotor problem
(3) Worn brake drum, or damage to the drum
caused by entry of sand
(4) Improper lining contact, deteriorated surface,
deteriorated or wear lining material
(5) Deformed back plate
Repair or replace the drum or rotor.

Repair by grinding, or replace.

(7) Defective wheel alignment
Adjust air pressure.

Adjust alignment.
Repair by grinding, or replace.

Correct or replace.
(8) Loose back plate or the support installation bolt Tighten to the specified torque.
(9) Loose wheel bearing
Replace.
3. Excessive pedal
stroke
4. Brake dragging or
improper brake return
(10) Defective hydraulic system

(11) Unstable effect of parking brake
Replace the cylinder, brake pipe or hose.

Check, adjust or replace the rear brake and cable
system.
(1) Entry of air into the hydraulic mechanism

(2) Excessive play in the master cylinder push rod
Bleed air.
Adjust.
(3) Fluid leakage from the hydraulic mechanism
Correct or replace. (cup, piston seal, piston boot,

master cylinder piston kit, pipe or hose)
(4) Improperly adjusted shoe clearance

(5) Improper lining contact or worn lining
Adjust.
Correct or replace.
(1) Insufficient pedal play

(2) Improper master cylinder return
Adjust play.
Clean or replace the cylinder.
(3) Clogged hydraulic mechanism

Replace.
(4) Improper return or adjustment of parking brake Repair or adjust.
5. Brake noise (1)

(creaking sound)
6. Brake noise (2)

(hissing sound)
(5) Weakened spring tension or breakage of shoe

return spring
Replace the spring.
(6) Excessively narrow shoe clearance

(7) Improper disc caliper operation

Correct or replace.
(8) Faulty wheel bearing

(1) Hardened or deteriorated lining
Replace.
Replace the shoe assembly or pad.
(2) Worn lining

(3) Loose back plate or the support installation bolt Tighten to the specified torque.
(4) Loose wheel bearing
(5) Dirty drum or rotor

Clean the drum or rotor, or clean/replace the
brake assembly.
(1) Worn lining

(2) Improperly installed brake shoe or pad

Repair or replace the shoe assembly or pad.
(3) Loose or bent drum or rotor
Retighten or replace.
BR-53

BRAKE
7.Brake noise (3)
(click sound)
Corrective action
In the case of the disc brake:

(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

anchor
BR-54
Supply grease.
General Description
PARKING BRAKE
A: SPECIFICATION
Model
Type
Effective drum diameter
mm (in)
Lining dimensions
Lever stroke
Rear drum brake
Rear disc brake
Rear brake mechanical

228.6 (9)
Mechanical, drum in disc rear brakes

170 (6.69)
219.4 35.0 4.1

(8.64 1.378 0.161)
163.1 30.0 3.2

(6.42 1.181 0.126)
mm (in)
Automatic adjusting
notches/N (kgf, lb)
Manual adjustment
7 8/196 (20, 44)
B: COMPONENT
PB-00001
(1)
(2)
Back plate
Retainer
(8)
(9)
Strut
Shoe guide plate
(15)
(16)

Shoe hold-down pin
(3)
(4)
Spring washer
Lever
(10)
(11)
Primary return spring

Secondary return spring
(17)
Adjusting hole cover
(5)
(6)
Parking brake shoe (Primary)

Parking brake shoe (Secondary)
(12)
(13)
Adjusting spring
Adjuster

T: 53 (5.4, 39.1)
(7)
Strut spring
(14)
Shoe hold-down cup
PB-2
General Description
PARKING BRAKE
2. PARKING BRAKE CABLE

(4)
(9)
(8)
T2
T1
(9)
T2
(4)
(7)
T1
(6)
(10)
T1
(3)
(2)
(5)
(1)
PB-00106
(1)
(2)
Parking brake lever

(5)
(6)
Equalizer
Bracket
(10)
(3)
(4)
Self-locking nut
Clamp (Rear disc brake model
only)
(7)
(8)
Clamp
Parking brake cable RH

T1: 18 (1.8, 13.0)
(9)
Cable guide
PB-3
Parking brake cable LH
T2: 32 (3.3, 23.6)
General Description
PARKING BRAKE
C: CAUTION
Do not mix grease etc. of different grades or manufacturers.
points.
Before securing a part in a vise, place cushioning
material such as wood blocks, aluminum plate or
cloth between the part and the vise.
Make sure grease does not come into contact
with the parking shoes.
PB-4
Parking Brake Lever

PARKING BRAKE
2. Parking Brake Lever
C: INSPECTION
A: REMOVAL
While pulling the parking brake lever upward, count

the notches.

2) Remove the rear wheels.
5) Loosen the parking cable self-locking nut and
console bracket.
6) Disconnect the parking brake switch connector.
7) Remove the parking brake lever.
Lever stroke:
7 to 8 notches when pulled with a force of 196
N (20 kgf, 44 lb)
If it is not within the specified value, adjust the parking brake. <Ref. to PB-9, ADJUSTMENT, Parking
Brake Assembly (Rear Disc Brake).>
D: ADJUSTMENT
1) Remove the console cover. <Ref. to EI-38, REMOVAL, Console Box.>
2) Forcefully pull the parking brake lever 3 to 5
times.
3) Rotate to adjust the selflocking nut so that the lever stroke of the parking brake lever is 7 to 8 notches when applying the parking brake with force of
196 N (20 kgf, 44 lb).
PB-00103
8) Straighten the tab on the parking brake lever and

remove the cable.
Lever stroke:
N (20 kgf, 44 lb)
(1)
(2)
PB-00104
PB-00004


(2) Cable
4) Install the console cover. <Ref. to EI-38, INSTALLATION, Console Box.>
B: INSTALLATION
Tightening torque:
Parking brake lever
18 Nm (1.8 kgf-m, 13.0 ft-lb)
2) Be sure to adjust the lever stroke. <Ref. to PB-5,
ADJUSTMENT, Parking Brake Lever.>
PB-5
Parking Brake Cable

PARKING BRAKE
3. Parking Brake Cable

A: REMOVAL
2) Remove the rear wheels.
5) Loosen the parking cable self-locking nut and
console bracket.
6) Remove the parking brake lever.
10) Remove the parking brake cable from rear

brake.
Disc brake
<Ref. to PB-7, REMOVAL, Parking Brake Assembly (Rear Disc Brake).>
Drum brake
<Ref. to BR-31, Rear Drum Brake Assembly.>
11) Remove the clamp from the rear brake.
12) Remove the bolt and bracket from trailing link
bracket.
13) Remove the bolt and clamp from rear floor.
PB-00009
PB-00103
7) Roll up the floor mat and remove the clamps.
14) Remove the grommet from the rear floor.

15) Remove the cable assembly from the cabin by
pulling it forcefully rearward.
16) Detach the parking brake cable from cable
guide at rear trailing link.
B: INSTALLATION
PB-00007
8) Remove the equalizer cover.

9) Remove the inner cable end from equalizer.
NOTE:
Be sure to pass the cable through the tunnel in the
cable guide.
2) Be sure to adjust the lever stroke. <Ref. to PB-5,
ADJUSTMENT, Parking Brake Lever.>
C: INSPECTION
Check the removed cable and replace if damaged,
rusty or having problems.
1) Check the cable for smooth operation.
2) Check the inner cable for damage and rust.
3) Check the outer cable for damage, bends and
cracks.
4) Check the boot for damage, cracks, and corrosion.
PB-00008
(1) Equalizer
(2) Inner cable end
PB-6
Parking Brake Assembly (Rear Disc Brake)

PARKING BRAKE
4. Parking Brake Assembly

(Rear Disc Brake)
(2) If disc rotor is seized up on the hub, drive the

disc rotor out by pushing two 8 mm bolts in
holes B on the rotor.
A: REMOVAL
2) Remove the two mounting bolts and remove the
brake caliper assembly.
(1)
B
A
BR-00036
5) Remove the shoe return spring from the parking

brake assembly.
6) Remove the front shoe hold down spring and pin
with pliers.
BR-00034
(1) Brake caliper ASSY
3) Suspend the brake caliper assembly so that the

hose is not stretched.
NOTE:
If the disc rotor is difficult to remove, try the following two methods in order.
(1) Turn the adjusting screw using a flat tip
screwdriver until the brake shoe moves adequately away from the disc rotor.
(2)
(3)
PB-00013
7) Remove the strut and strut spring.

8) Remove the adjuster assembly from the parking
brake assembly.
9) Remove the brake shoe.
10) Remove the rear shoe hold down spring and
pin with pliers.
11) Remove the parking brake cable from the parking brake lever.
(1)
(4)
BR-00155
(1) Adjusting screw

(2) Adjusting hole cover (rubber)
(4) Back plate
PB-00014
(1) Parking brake cable

12) Using a flat tip screwdriver, raise the retainer.

Remove the parking lever and washer from brake
shoe.
PB-7

PARKING BRAKE
B: INSTALLATION
CAUTION:
Be sure the lining surface is free from oil and
grease.
1) Apply brake grease to the following locations.
Brake grease:
Brake Grease (Part No. 003602002)
Six contact surfaces of the shoe rim and the back
plate packing
Contact surface of the shoe wave and the anchor
pin
Contact surface of the lever and strut
Contact surface of the shoe wave and the adjuster assembly
Contact surface of the shoe wave and the strut
Contact surface of the lever and the shoe wave
2) Insert the primary side brake shoe into the anchor pin groove.
3) Secure the brake shoe with the shoe hold-down
pin and the cup.
4) Install the plate to the anchor pin, and then assemble the primary return spring to the anchor pin.
NOTE:
Install the strut spring of both right and left
wheels facing the front of the vehicle.
Install the adjuster assembly with screw section
on the left side.
PB-00016
(1) LH
7) Install the secondary return spring and the adjusting spring.

(1)
(2)
(4)
(3)
(2)
(1)
(3)
(5)
(7)
(6)
(8)
PB-00017
(4)
(1) Lever
(5)
(2) Secondary brake shoe

(3) Strut spring
PB-00015
(1) Primary return spring
(4) Strut
(5) Secondary return spring
(2) Anchor pin

(3) Plate
(6) Adjuster
(7) Hold-down cup
(4) Primary shoe

(5) Shoe hold-down pin and cup
(8) Adjusting spring
5) Install the parking brake cable to the parking

brake lever.
6) Assemble the strut and adjuster, and then secure the secondary side brake shoe with the shoe
hold-down pin and cup.
8) Adjust the parking brake. <Ref. to PB-9, ADJUSTMENT, Parking Brake Assembly (Rear Disc
Brake).>
9) Drive the vehicle to break-in the parking brake
lining.
(1) Drive the vehicle at about 35 km/h (22
MPH).
(2) With the parking brake release button
pushed in, pull the parking brake lever gently.
(3) Drive the vehicle for about 200 m (0.12 mile)
in this condition.
(4) Wait 5 to 10 minutes for the parking brake to
cool down. Repeat this procedure once more.
(5) After breaking-in, re-adjust the parking
brakes.
PB-8

PARKING BRAKE
C: INSPECTION
2. LEVER STROKE
1) Measure the brake disc rotor inside diameter. If

the disc is scored or worn, replace the brake disc
rotor.
1) Remove the console box lid. <Ref. to EI-38, REMOVAL, Console Box.>
2) Forcefully pull the parking brake lever 3 to 5
times.
3) Rotate to adjust the selflocking nut so that the lever stroke of the parking brake lever is 7 to 8 notches when applying the parking brake with force of
196 N (20 kgf, 44 lb).
Disc rotor inside diameter:

Standard:
170 mm (6.69 in)
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)
Lever stroke:
N (20 kgf, 44 lb)
(1)
NOTE:
Replace the right and left brake shoe as a set.
D: ADJUSTMENT
(2)
1. SHOE CLEARANCE
PB-00104
1) Remove the adjusting hole cover from the back

plate.
2) Turn the adjusting screw using a flat tip screwdriver until the brake shoe is in close contact with
the disc rotor.

4) Install the console box lid. <Ref. to EI-38, INSTALLATION, Console Box.>
(2)
(3)
(1)
(4)
PB-00032
(1) Adjusting screw

(2) Adjusting hole cover (rubber)
(4) Back plate
3) Turn back (downward) the adjusting screw 3 to 4

notches.
4) Install the adjusting hole cover to the back plate.
PB-9

PARKING BRAKE

A: INSPECTION
Symptoms
Brake drag
Noise from brake
Possible cause
Corrective action
Parking brake lever misadjustment.

Parking brake cable does not move.
Adjust.
Correct or replace.
Parking brake shoe clearance is misadjusted.

Return spring is faulty.
Adjust.
Replace.
Return spring is faulty.

Shoe hold-down spring is faulty.
Replace.
Replace.
PB-10
General Description
POWER ASSISTED SYSTEM (POWER STEERING)
A: SPECIFICATION
Model
Whole system
Gearbox
Non-turbo model
Minimum turning radius

Steering angle (Inside Outside)
Steering wheel diameter
Maximum number of rotations
m (ft)
5.4 (17.7)
36 25 32 00
mm (in)
3.1
Type
Backlash
3.0
Integral Rack and Pinion
0 (Automatic adjusting)
Rotary valve
Vane pump
Reservoir tank
Specific output
cm3 (cu in)/rev.
Relief pressure
kPa (kg/cm2, psi)
Hydraulic fluid control

2 (US qt, Imp qt)/min.
Adjusted flow
RPM range
rpm
Description
Hydraulic oil
(Power steering
system)
Steering wheel
Steering angle
Steering shaft
Steering gearbox
(Power steering
system)
6,700 7,400
7,650 8,340
(68 75, 970 1,070)
(78 85, 1,110 1,210)
Engine speed sensitive
1,000 rpm: 6.6 (7.0, 5.8)
3,000 rpm: 5.3 (5.6, 4.7)
1,000 rpm: 7 (7.4, 6.2)

3,000 rpm: 5 (5.3, 4.4)
670 9,869
595 8,925
Clockwise (when observed from pulley side)
ATF DEXRON III or equivalent
Free play
Inner wheel
0.3 (0.3, 0.3)

0.7 (0.7, 0.6)
mm (in)
Outer wheel
Clearance between the steering wheel and column cover
Sliding resistance
Input shaft play
Installed on body
7.2 (0.439)
Reservoir
tank
Whole
system
Capacity
2 (US qt, Imp qt)
Rack shaft play

in the radial
direction
35 00 30 54
375 (14.8)
Valve (Power steering system)

Type
Pump
(Power steering
system)
Turbo model
Right-turn
steering
mm (in)
N (kgf, lb)
17 (0.67)
3625130
3500130
3200130
3054130
3.0 (0.118)
400 (40.8, 89.9) or less
mm (in)
0.19 (0.0075) or less
Left-turn
steering
mm (in)
Horizontal free play:

0.15 (0.0059) or less
Vertical free play:
0.3 (0.012) or less
In radial
direction
mm (in)
0.18 (0.0071) or less
In axial
direction
mm (in)
0.5 (0.020) or less
Rotation resistance
Maximum allowance:
9.33 (0.95, 2.10) or less
N (kgf, lb)
Left and right
Difference between right and left sliding resistance: 20% or
less
PS-2
General Description
Model
Pulley shaft
Oil pump
(Power steering
system)
Pulley
Regular pressure
Steering wheel
effort
(Power steering
system)
Non-turbo model
Free play in
the radial
direction
Free play in
the axial
direction
Ditch
deflection
Rotation
resistance
0.4 (0.016) or less
mm (in)
0.9 (0.035) or less
mm (in)
1.0 (0.039) or less
N (kgf, lb)
kPa (kg/cm2, psi)
At standstill with engine idling

on paved road
At standstill with engine stalled
on paved road
Recommended power steering fluid
mm (in)
Turbo model
9.22 (0.94, 2.07) or less

981 (10, 142) or less
N (kgf, lb)
31.4 (3.2, 7.1) or less
N (kgf, lb)
294.2 (30, 66.2) or less
Manufacturer
B.P.
CALTEX
ATF DEXRON III or equivalent
CASTROL
MOBIL
SHELL
TEXACO
NOTE:
The table below lists various clearances that must be correctly adjusted to ensure the normal vehicle operation without interference noise, or any other faults. <Ref. to PS-54, INSPECTION OF CLEARANCE, INSPECTION, General Diagnostic Table.>
PS-3
General Description
B: COMPONENT
1. STEERING WHEEL AND COLUMN
(1)
(2)
(3)
T2
T3
(7 )
(4)
(5 )
T1
(6 )
PS-00605
(1)
(2)
Bushing
Steering shaft
(5)
(6)
Steering wheel
Airbag module
(3)
(4)
Steering roll connector

Column cover
(7)
Steering wheel lower cover
PS-4

T1: 1.2 (0.12, 0.9)
T2: 25 (2.5, 18.1)
T3: 45 (4.6, 33.2)
General Description
2. POWER ASSISTED SYSTEM
T4
(1) T12
(5)
(4)
(8)
(9)
T2
(3)
(31)
(6)
(4)
(2)
T8
T1
(4)
(19)
(7)
(12)
(20)
(30)
(10)
T4
T2
(11)
T3
(16)
(15)
T9
T8
T2
T5
(18)
(19)
T11
T6
T5
(13)
(17)
T7
(14)
T9
(21)
T16
T9
(22)
(23)
(36)
(24)
(37)
(25)
(32)
T13
(33) (34)
(47)
(51)
(26)
(27)
(38)
T10
(39)
(40)
T15
(50)
(42)
(36)
T8
(44)
(41)
(35)
(45)
(48)
(37)
T18
(46)
T14
T13
(52)
(43)
(49)
(54)
(56)
T17
(38)
(45)
(44)
T16
T14
(53)
(55)
T10
(43) (39)
(46)
(40)
(41)
(42)
(28)
(29)
PS-00689
PS-5
General Description
(1)
(2)
Eye bolt
Pipe C
(27)
(28)
Oil seal
Rack
(52)
(53)
Holder
Bushing
(3)
(4)
Gasket
Clip
(29)
(30)
Back-up washer
Suction hose
(54)
(55)
Oil seal
Oil seal
(5)
(6)
Pipe D
Clamp E
(31)
(32)
Return hose
Lock nut
(56)
O-ring
(7)
(8)
O-ring
Cap
(33)
(34)
Adjusting screw
Spring

T1: 6 (0.6, 4.3)
(9)
(10)
Reservoir tank
Reservoir tank bracket
(35)
(36)
Sleeve
Adapter
T2: 7.4 (0.75, 5.4)

T3: 8 (0.8, 5.8)
(11)
Pulley
(37)
Clamp
T4: 13 (1.3, 9.4)
(12)
(13)
Oil pump
Bracket
(38)
(39)
Cotter pin
Castle nut
T5: 15 (1.5, 10.8)

T6: 15.7 (1.6, 11.6)
(14)
(15)
Belt tension nut

Bushing
(40)
(41)
Dust cover
Clip
T7: 22 (2.2, 15.9)

T8: 24 (2.4, 17.4)
(16)
(17)
Belt cover
Pipe E
(42)
(43)
Tie-rod end
Clip
T9: 25 (2.5, 18.1)

T10: 27 (2.75, 19.9)
(18)
(19)
Pipe F
Clamp plate
(44)
(45)
Boot
Boot band
T11: 37.3 (3.8, 27.5)

T12: 39 (4.0, 28.9)
(20)
(21)
Universal joint
Dust cover
(46)
(47)
Tie-rod
Sheet pad
T13: 60 (6.1, 44.1)

T14: 83 (8.5, 61.5)
(22)
(23)
Plug
O-ring
(48)
(49)
Pipe B
Pipe A
T15: 39 (4.0, 28.9)

T16: 64 (6.5, 47.0)
(24)
(25)
Oil seal
Pinion and valve ASSY
(50)
(51)
Steering body
Oil seal
T17: 20 (2.0, 14.5)

T18: 90 (9.0, 65.1)
(26)
Seal ring
PS-6
General Description
3. OIL PUMP
(1)
PS-00024
(1)
Power steering oil pump ASSY
C: CAUTION
Be careful not to burn your hands, because each
Use SUBARU genuine power steering fluid,
grease etc. or the equivalent. Do not mix fluid,
grease etc. of different grades or manufacturers.
points.
Apply power steering fluid onto sliding or revolving surfaces before installation.
Before installing the O-ring or snap ring, apply a
sufficient amount of gear oil to avoid damage and
deformation.
PS-7
General Description
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
925700000
WRENCH
Used for removing and installing Tie-rod.

Apply this tool to rack.
925711000
PRESSURE
GAUGE
926200000
STAND
Used when inspecting characteristics of the

gearbox assembly and disassembly.
ADAPTER HOSE A
Used together with PRESSURE GAUGE

(925711000).
ST-925700000
ST-925711000
ST-926200000
34099AC010
ST34099AC010
PS-8
General Description
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
34099AC020
ADAPTER HOSE B
Used together with PRESSURE GAUGE

(925711000).
REMARKS
926230000
WRENCH
For the lock nut when adjusting backlash of gearbox.
34099PA100
WRENCH
Used when measuring the rotating resistance of

gearbox assembly.
34199AE040
OIL CHARGE
GUIDE
Used for charging power steering fluid.
GUIDE
Used for installing the holder assembly into the

rack housing.
ST34099AC020
ST-926230000
ST34099PA100
ST34199AE040
926250000
ST-926250000
PS-9
General Description
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
927490000
INSTALLER A, B, C
Used for installing the oil seal to the rack assembly.
927580000
REMOVER
Used for removing the back-up ring and oil seal.
34199AE000
GUIDE
Used for installing the rack and seal into housing

assembly.
34199FE000
INSTALLER &
REMOVER
Used for removing and installing the rack oil seal

(outer & inner).
34199AE010
INSTALLER
Used for installing the rack oil seal (outer).
ST-927490000
ST-927580000
ST34199AE000
ST34199FE000
ST34199AE010
PS-10
General Description
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
34099FA060
PUNCH HOLDER
Used for crimping.
34099FA070
BASE
Used for the support housing assembly.
34099FA080
PUNCH
Used for removing crimps.
34199AE090
PLUG WRENCH
Used for removing the plug.
34199AE100
OIL SEAL PLUG

REMOVER
Used for removing the oil seal plug.
ST34099FA060
ST34099FA070
ST34099FA080
ST34199AE090
ST34199AE100
PS-11
General Description
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
34199AE110
OIL SEAL PLUG

INSTALLER
Used for installing the oil seal plug.
34199AE120
GEARBOX OIL
SEAL REMOVER
Used for removing the gearbox oil seal.
34199AE130
GEARBOX OIL
SEAL INSTALLER
Used for installing the gearbox oil seal.
ST34199AE110
ST34199AE120
ST34199AE130
2. GENERAL TOOL
Spring scale
TOOL NAME
REMARKS
Used for measuring tightening torque.
Snap ring pliers

Dial gauge
Used for removing and installing snap ring.

Used for measuring the steering gearbox.
Hand clamp pliers

Steering wheel puller
Used for crimping the boot band.

Used for removing the steering wheel.
PS-12
Steering Wheel
2. Steering Wheel
C: INSPECTION
A: REMOVAL
1) Check the steering wheel for deformation. If the

deformation is excessive, replace the steering
wheel.
2) Check the splines on the steering wheel for damage. If the damage is excessive, replace the steering wheel.
3) If the steering wheel spokes are not horizontal
when wheels are set in the straight ahead position,
or error is more than 5 on the periphery of the
steering wheel, correctly re-install the steering
wheel.

2) Set the tire to the straight-ahead position.
WARNING:
Always refer to Airbag System before performing service on the airbag modules. <Ref. to
AB-4, CAUTION, General Description.>
4) Place alignment marks on the steering wheel
and steering shaft.
(1)
PS-00513
PS-00030
(1) Within 5
(1) Alignment mark
5) Remove the steering wheel nut, and then draw

out the steering wheel from the shaft using a steering puller.
B: INSTALLATION
WARNING:
1) Align the center position of the roll connector.
<Ref. to AB-20, ADJUSTMENT, Roll Connector.>
NOTE:
Align the alignment marks on the steering wheel
and steering shaft.
Tightening torque:
45 Nm (4.6 kgf-m, 33.2 ft-lb)
Column cover to steering wheel clearance
2 4 mm (0.08 0.16 in)
CAUTION:
guide hole on the lower end of the steering
wheel surface. Avoid damaging the pin.
PS-13
Universal Joint
3. Universal Joint
2) Match the alignment marks, and insert the universal joint into the serrations of gearbox assembly.
3) Tighten the bolt.
A: REMOVAL
1) Remove the steering wheel. <Ref. to PS-13, REMOVAL, Steering Wheel.>
2) Place alignment marks on universal joint.
3) Remove the universal joint bolt, and then remove the universal joint.
Tightening torque:
24 Nm (2.4 kgf-m, 17.4 ft-lb)
CAUTION:
Do not excessively tighten the torque on the
universal joint bolts. Overtightening will make
the steering wheel heavy.
Standard clearance between gearbox to DOJ:
5) Install the steering wheel and airbag module.
<Ref. to PS-13, INSTALLATION, Steering Wheel.>
WARNING:
PS-00031
B: INSTALLATION
1) Align the cutout portion at the serrated section of
the steering shaft and yoke, then insert the universal joint into the steering shaft.
C: INSPECTION
Check for wear, damage or any other faults. Replace as necessary.
Service limit:
Free play of the universal joint:
0 mm (0 in)
Maximum value of swing torque:
0.3 N (0.03 kgf, 0.07 lb)
(1)
(2)
PS-00033
(1) Swing torque

(2) Play
PS-00032
(1) Cutout portion

(2) Yoke
(3) Steering shaft
(4) Steering shaft side
(5) Gearbox side
PS-14
Universal Joint
Measure the swing torque of universal joint.

Service limit:
Maximum load:
3.8 N (0.39 kgf, 0.86 lb) or less
Service limit:
Maximum load:
7.3 N (0.74 kgf, 1.64 lb) or less
PS-00037
PS-00034
(1) Yoke (Steering column side)
(1) Yoke (Gearbox side)
Service limit:
Maximum load:
3.8 N (0.39 kgf, 0.86 lb) or less
PS-00035
(1) Yoke (Gearbox side)
Service limit:
Maximum load:
7.3 N (0.74 kgf, 1.64 lb) or less
PS-00036
(1) Yoke (Steering column side)
PS-15
Tilt Steering Column

4. Tilt Steering Column

A: REMOVAL
PS-00038
(1)
Tilt steering column
(2)
Universal joint

T1: 24 (2.4, 17.4)
T2: 25 (2.5, 18.1)

5) Remove the universal joint. <Ref. to PS-14, REMOVAL, Universal Joint.>

6) Remove the trim panel under instrument panel.
WARNING:
PS-16

7) Knee guard panel and steering column lower

cover.
3) Tighten the steering shaft mounting bolts under

instrument panel.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
4) Connect all the connectors under the instrument
panel.
5) Connect the airbag system connector at the harness spool.
(1)
PS-00025
(1) Knee guard panel
8) Remove all connectors from the steering column.

9) Remove the two bolts under instrument panel
securing the steering column.
NOTE:
Make sure to apply double lock.
6) Install the lower column cover with tilt lever held
in the lowered position.
7) Install the universal joint. <Ref. to PS-14, INSTALLATION, Universal Joint.>
9) Install the steering wheel. <Ref. to PS-13, INSTALLATION, Steering Wheel.>
CAUTION:
guide hole on lower end of steering wheel surface to prevent damage.
10) Install the airbag module to the steering wheel.
WARNING:
Always refer to Airbag System before performing the service operation. <Ref. to AB-4,
CAUTION, General Description.>
PS-00040
10) Pull out the steering shaft assembly from the

hole on toe board.
CAUTION:
Be sure to remove the universal joint before
removing steering shaft assembly installing
bolt, when removing the steering shaft assembly or when lowering it to service other parts.
Do not loosen the tilt lever when the steering
column is not secured to the vehicle.
B: INSTALLATION
1) Set the grommet to the toe board.
C: DISASSEMBLY
Remove the two screws securing the upper steering column covers, and the two screws securing
the combination switch, and then remove related
parts.
D: ASSEMBLY
Insert the combination switch to the upper column
shaft, and install the upper column cover. Then
route the ignition key harness and combination
switch harness between the column cover mounting bosses.
Tightening torque:
1.2 Nm (0.12 kgf-m, 0.9 ft-lb)
CAUTION:
Do not overtorque the screw.
PS-00041
2) Insert the end of the steering shaft into the toe

board grommet.
PS-17

E: INSPECTION
1. BASIC INSPECTION
Measure the overall length of steering column. If
not within specification, replace it.
Specification:
Overall length L
808.61.5 mm (31.830.059 in)
PS-00042
2. AIRBAG MODEL INSPECTION

WARNING:
Refer to Airbag System for airbag model inspection procedure. <Ref. to AB-4, CAUTION,
PS-18
Steering Gearbox
5. Steering Gearbox
A: REMOVAL
3) Loosen the front wheel nuts.
7) Remove the front exhaust pipe assembly. (Nonturbo model)
Pipe.>
WARNING:
The exhaust pipe is extremely hot. Be careful
not to burn your hand.
8) After pulling off the cotter pin and removing the
castle nut, use a puller to remove the tie-rod end
from the knuckle arm.
10) Remove the one pipe joint at the center of gearbox assembly, and connect a vinyl hose to the pipe
and the joint. Discharge the fluid by turning the
steering wheel fully clockwise and counterclockwise. Discharge the fluid similarly from other pipes.
(2)
(1)
PS-00026
(1) Pipe A
(2) Pipe B
11) Remove the universal joint. <Ref. to PS-14,

REMOVAL, Universal Joint.>
12) Disconnect the lower pipe C from gearbox assembly first, and upper pipe D second.
(1)
(2)
PS-00043
(1) Castle nut

(2) Tie-rod end
PS-00027
(3) Knuckle arm
(1) Pipe C
(2) Pipe D
9) Remove the jack-up plate and front stabilizer.
13) Remove the clamp bolts securing the gearbox

assembly to the crossmember, and remove the
gearbox.
(1)
PS-00044
(1) Jack-up plate

PS-00028
(1) Clamp
PS-19
Steering Gearbox
B: INSTALLATION
1) Insert the gearbox assembly into the crossmember, being careful not to damage the gearbox assembly boot.
2) Tighten the gearbox assembly to the crossmember bracket via clamp with bolt, and tighten to the
specified torque.
6) After tightening the castle nut to the specified

tightening torque, tighten it further within 60 until
the cotter pin hole is aligned with slot in the nut. Fit
the cotter pin into nut, and then bend the pin to lock.
(A)
(B)
Tightening torque:
60 Nm (6.1 kgf-m, 44.1 ft-lb)
(1)
(C)
DS-00042
(A) Cotter pin

(B) Castle nut
(C) Tie-rod end
PS-00028
(1) Clamp
3) Connect the pipe D first to gearbox, then lower

pipe C.
Tightening torque:
15 Nm (1.5 kgf-m, 10.8 ft-lb)
(1)
(2)
PS-00027
(1) Pipe C
(2) Pipe D
4) Install the universal joint. <Ref. to PS-14, INSTALLATION, Universal Joint.>

5) Connect the tie-rod end and knuckle arm, and
tighten with castle nut.
7) Install the front stabilizer to vehicle. <Ref. to FS21, INSTALLATION, Front Stabilizer.>
8) Install the front exhaust pipe assembly. (Non-turbo model) <Ref. to EX (H4SO)-5, INSTALLATION,
Front Exhaust Pipe.>
9) Install the sub frame. <Ref. to FS-23, INSTALLATION, Sub Frame.>
10) Install the under cover. <Ref. to EI-20, INSTALLATION, Front Under Cover.>
12) Install the steering wheel. <Ref. to PS-13, INSTALLATION, Steering Wheel.>
14) Tighten the wheel nuts to the specified torque.
Tightening torque:
90 Nm (9.1 kgf-m, 65.8 ft-lb)
16) Pour fluid into the reservoir, and bleed the air.
<Ref. to PS-49, Power Steering Fluid.>
17) Check for fluid leaks.
18) Install the jack-up plate.
20) Check the fluid level in the reservoir tank.
Tightening torque:
27 Nm (2.75 kgf-m, 19.9 ft-lb)
CAUTION:
When connecting, do not hit the cap at the bottom of tie-rod end with hammer.
PS-20
Steering Gearbox
21) After adjusting toe-in and steering angle, tighten the lock nut on the tie-rod end.
4) Move the clip of the boot using the pliers, and

then slide the boot to the tie-rod end side.
Tightening torque:
83 Nm (8.5 kgf-m, 61.5 ft-lb)
NOTE:
When adjusting toe-in, hold the boot as shown to
prevent it from being rotated or twisted. If it becomes twisted, straighten it.
(1)
PS-00661
(1) Clip
5) Using a flat tip screwdriver, remove the band

from boot.
NOTE:
Replace the boot if there is damage, cracks or deterioration.
PS-00051
C: DISASSEMBLY
1) Disconnect the four pipes from gearbox.
NOTE:
Remove the pipes E and F, which are fixed to the
clamp plate, as a unit.
2) Secure the gearbox assembly removed from the
vehicle in a vise using a ST.
ST 926200000
STAND
CAUTION:
Secure the gearbox assembly in a vise using ST
as shown. Do not affix the gearbox to the vice
without this ST.
PS-00054
(1) Band
6) Using the ST, loosen the lock nut.

ST 926230000
WRENCH
ST
ST
PS-00029
3) Remove the tie-rod end and lock nut from gearbox assembly.
PS-21
PS-00089
Steering Gearbox
7) Tighten the adjusting screw until it can no longer

be tightened.
11) Clean any dirt adhered to the input shaft. Remove the dust cover, paying attention not to
scratch the housing or input shaft and not to allow
foreign matter to enter gear box interior.
CAUTION:
Wrap a tape around the input shaft spline in order not to damage the dust cover.
(1)
PS-00109
8) Remove the tie-rod using a 32 mm (1.26 in)

wrench or adjustable wrench.
PS-00497
(1)
(1) Dust cover
12) Align the ST pin with plug hole to install. Rotate

the ST counterclockwise to remove plug.
ST 34199AE090 PLUG WRENCH
PS-00662
(1) Tie-rod
9) Loosen the adjusting screw, and remove the

spring and sleeve.
10) Disconnect the pipes A and B from steering
body and control valve housing.
ST
(1)
(1)
(2)
PS-00646
(1) Pipe A
(2) Pipe B
PS-00648
(1) Plug
PS-22
Steering Gearbox
13) Remove the valve assembly paying attention

not to scratch the seal ring or valve housing inner
surfaces.
15) Attach the ST on the valve side of rack, and

press out the outer side oil seal while taking care
that the rack and the steering body inner surface do
not come into contact with each other.
ST 34199FE000 INSTALLER & REMOVER
NOTE:
Block the pipe connection of steering body to prevent fluid from flowing out.
(1)
(2)
PS-00649
(1) Valve ASSY

(2) Seal ring
14) Remove the holder using a 32 mm (1.26 in)

wrench or adjustable wrench.
PS-00064
(1) Rack piston

(2) Outer side oil seal
PS-00063
PS-23
Steering Gearbox
16) Insert the ST from the valve side and press the
back-up ring and oil seal out.
ST 927580000
REMOVER
18) If the cylinder edge is deformed in a convex

shape, repair using an oil stone.
PS-00067
19) Remove the oil seal using ST and push out

from the plug.
ST 34199AE100 OIL SEAL PLUG REMOVER
NOTE:
Do not apply force on the plug edge surface.
PS-00065
17) Using ST1 and ST2, repair the crimped portion

of cylinder.
ST1 34099FA080 PUNCH
ST2 34099FA070 BASE
PS-00068
(1) Oil seal

(2) O-ring
20) Set the ST at a size shown in the figure.

ST 34199AE120 GEARBOX OIL SEAL REMOVER
PS-00069
(1) 70 mm (2.76 in)
PS-00066
(1) Cylinder
PS-24
Steering Gearbox
21) Set the stopper to gearbox, then insert the tip of

the ST to the gearbox.
23) While fixing the 2-surface widths, pull out the oil
seal by rotating nut.
CAUTION:
Take care not to scratch the gearbox inner surface.
(1)
(1)
(2)
(2)
PS-00650
(1) Stopper
(2) Oil seal
PS-00652
22) By fixing the 2-surface widths, press-in the rod

while rotating it and catch the oil seal.
(1) 2-surface widths

(2) Nut
D: ASSEMBLY
1) Apply a coat of grease to the inside and outside
of the new oil seal.
(1)
Steering grease:
ONE LUBER MO (Part No. 003608001)
2) Verify the direction of the oil seal and installation
position. Using the ST and a press, press-fit the oil
seal into the gearbox.
ST 34199AE130 GEARBOX OIL SEAL INSTALLER
(2)
(1)
ST
PS-00651
PS-00653
(1) Rod
(1) Oil seal
(2) 2-surface widths
PS-25
Steering Gearbox
3) Attach the steering body to ST as shown in the

figure. Apply a coat of grease to needle bearing.
ST 926200000
STAND
6) Install the back-up washer from the gear side of

rack.
CAUTION:
Make sure the needle bearing is free from defects. If it is faulty, replace the steering body
with a new part.
(1)
(2)
(1)
ST
(3)
PS-00656
(1) Oil seal

(2) Back-up washer
(3) Rack
PS-00654
(1) Steering body
4) Using the ST B and ST C, attach the oil seal to

ST A.
ST 927490000
INSTALLER A, B, C
NOTE:
Face the oil seal in the direction as shown in the figure.
ST B
7) Attach the ST on rack, equally apply a thin coat

of grease to the rack and ST, and then install the oil
seal.
ST 926250000
GUIDE
CAUTION:
Be careful not to scratch the oil seal lips with
the inner ring section of piston.
(3)
ST A
ST C
ST
(2)
(1)
(A)
PS-00657
PS-00075
(1) Rack piston inner ring

(A) Oil seal
(3) Rack
5) Insert the ST A with oil seal assembled from the

gear side of rack. Remove the oil seal from ST A
near piston, and then remove the ST A from rack.
(C)
(B)
ST A
(A)
PS-00655
(A) Oil seal

(B) Rack
(C) Piston
PS-26
Steering Gearbox
8) Apply a coat of grease to the grooves in rack,

sliding surface of sleeve and sealing surface of piston. Attach the ST on the end of steering body cylinder. Then insert the rack into steering body from
cylinder side.
ST 34199AE000 GUIDE (OIL SEAL)
10) Make the ST2 and pipe pass through rack, and
then press-in the ST1, ST 2 and the outer side oil
seal 2 using a press.
ST1 34199AE000 GUIDE (OIL SEAL)
ST2 34199AE010 INSTALLER (OIL SEAL)
CAUTION:
Do not allow grease to block the air vent hole on
rack.
PS-00081
(1) Pipe
PS-00079
(1) Cylinder side of steering body
11) Install a new holder to the cylinder side of steering body.
(2) Air vent hole

(3) Oil seal
Tightening torque:
64 Nm (6.5 kgf-m, 47.0 ft-lb)
(4) Rack
9) Slowly push the inner side oil seal using the

press until the distance from the ST to the end of
the rack is 65 mm (2.56 in).
ST 34199AE000 GUIDE (OIL SEAL)
CAUTION:
Make sure that there are no scratches on the inner wall of the ST. Otherwise there is a possibility of the oil seal being damaged when it is
installed.
65 mm
(2.56 in)
PS-00080
(1) Rack piston

(2) Inner side oil seal
(3) Back-up ring
PS-27
PS-00063
Steering Gearbox
12) Attach the ST on rack cylinder. Using the press,

press in the ST until the groove on the ST alines
with the edge of the holder.
ST 34199FE000 INSTALLER & REMOVER
13) Using the ST, crimp the steering body at one

point less than 3 mm (0.12 in) from holder.
CAUTION:
Be careful not to deform the holder.
ST 34099FA060 PUNCH HOLDER
ST
(A)
(B)
ST
PS-00083
PS-00084
(1) Groove
(2) Holder
(A) Holder
(B) 3 mm (0.12 in)
(3) Rack piston

(4) Oil seal
(5) Back-up ring
14) Roll a vinyl tape on the serration portion of

valve assembly, and then apply grease on the tape
surface.
PS-00085
(1) Vinyl tape
PS-28
Steering Gearbox
15) Apply a coat of grease on the gear teeth of the

valve assembly, and then attach the valve assembly taking care not to scratch oil seal and seal ring.
17) Attach the plug using ST.

ST 34199AE090 PLUG WRENCH
Tightening torque:
64 Nm (6.5 kgf-m, 47.0 ft-lb)
ST
(1)
(2)
(1)
PS-00658
PS-00659
(1) Seal ring

(2) Oil seal
(1) Plug
16) Apply grease on the oil seal circumference, and

then press it into the plug using ST and a press. Replace the O-rings of plug circumference with new
O-rings.
ST 34199AE110 OIL SEAL PLUG INSTALLER
18) Install the dust cover and then remove the vinyl
tape.
(1)
CAUTION:
Install the oil seal paying attention to correct direction.
PS-00497
(1) Dust cover
PS-00087
(1) Plug
(2) O-ring
(3) Oil seal
19) Temporarily tighten the tie-rod to the rack end,

and then operate the rack from lock to lock for two
or three times to make it fit in. Remove any grease
blocking the air vent hole.
CAUTION:
If operating the rack from lock to lock without
installing tie-rods, it may damage the oil seal.
Always install the tie-rods LH and RH.
PS-29
Steering Gearbox
20) Apply a coat of grease to the sliding surface of

seat pad, sleeve and seating surface of spring, and
then insert sleeve into steering body.
Charge the adjusting screw with grease, and then
insert the spring into adjusting screw. Then install
on the steering body.
25) Tighten the adjusting screw.

(1) Tighten the adjusting screw to the specified
torque, then loosen it.
Tightening torque:
9.8 Nm (1.0 kgf-m, 7.2 ft-lb)
torque, then loosen it.
Tightening torque:
4.9 Nm (0.50 kgf-m, 3.6 ft-lb)
torque, then loosen it 26.
Tightening torque:
4.9 Nm (0.50 kgf-m, 3.6 ft-lb)
26) Install the lock nut. While holding the adjusting
screw with a wrench, tighten the lock nut using ST.
ST 926230000
WRENCH
PS-00090
(1) Sheet pad
Tightening torque (lock nut):

39 Nm (4.0 kgf-m, 28.9 ft-lb)
(2) Sleeve
(3) Spring
(4) Adjusting screw
(5) Lock nut
21) Tighten the adjusting screw to the specified

torque.
Tightening torque:
7.4 Nm (0.75 kgf-m, 5.4 ft-lb)
NOTE:
After tightening with the specified torque, loosen it
by 25.
22) Remove the tie-rod.
23) Check that the play, or looseness, is at the
standard value. <Ref. to PS-33, SERVICE LIMIT,
INSPECTION, Steering Gearbox.>
24) Loosen the adjusting screw, and then apply liquid gasket to at least 1/3 of the entire perimeter of
adjusting screw thread.
NOTE:
Hold the adjusting screw with a wrench to prevent it
from turning while tightening the lock nut.
27) Install the tie-rod into rack.
Tightening torque:
90 Nm (9.0 kgf-m, 65.1 ft-lb)
NOTE:
Check the mating face of rack and tie-rod for foreign matter such as dust etc.
28) Apply a coat of grease to the tie-rod groove,
and then install the boot to the housing.
NOTE:
Make sure that the boot is installed without unusual
inflation or deflation.
Liquid gasket:
THREE BOND 1141
PS-00094
(1)
PS-00660
(1) Apply liquid gasket to at least 1/3 of entire

perimeter.
PS-30
Steering Gearbox
29) Crimp the boot so that the clearance of the boot

band crimp portion becomes 2 mm (0.08 in) or less.
Installed tie-rod length: L

31.2 mm (1.23 in)
NOTE:
Use a new band.
L
(A)
PS-00097
33) Inspect the gearbox as follows.

Holding the A tie-rod end, repeat movement from
lock to lock two or three times as quickly as possible.
Holding the B tie-rod end, turn a few times as
slowly as possible.
Finally, make sure that the boot is installed in the
specified position without inflating.
(B)
A
PS-00095
(A) Boot band

(B) 2 mm (0.08 in) or less
30) Fix the boot end with small clip.
PS-00098
34) Remove the gearbox from ST.

ST 926200000
STAND
PS-00096
(1) Clip
31) After installing, check that the boot end is installed to the groove of the tie-rod.
32) If the tie-rod end has been removed, screw in
lock nut and tie-rod end to the screwed portion of
tie-rod, and tighten the lock nut temporarily in a position as shown in the figure.
PS-31
Steering Gearbox
E: INSPECTION
1. BASIC INSPECTION
1) Clean all the disassembled parts, and check for wear, damage or any other faults, then repair or replace
as necessary.
2) When disassembling, check the inside of gearbox assembly for water. If any water is found, carefully
check the boot for damage, and the input shaft dust seal, adjusting screw and boot clips for poor sealing. If
faulty, replace with new parts.
No.
Parts
Input shaft
Dust seal
Rack and pinion
Gearbox unit
Boot
Tie-rod
Tie-rod end
Inspection
(1) Bent input shaft
(2) Damage on serration
(1) Crack or damage
(2) Wear
Corrective action
If there is excessive bend or damage, replace the entire
gearbox assembly.
If the outer wall slips, the lip is worn out or damage is
found, replace it with a new dust seal.
Poor mating of rack with pinion
(1) Adjust the backlash properly.

By measuring the turning torque of the gearbox and the
sliding resistance of rack, check if the rack and pinion
engages uniformly and smoothly with each other. (Refer
to SERVICE LIMIT)
(2) Pull out the entire rack to allow viewing of the teeth,
and check for damage.
If a problem of either (1) or (2) is found, replace the entire
gearbox assembly.
(1) Bending of the rack shaft

(2) Bending of the cylinder portion
(3) Crack or damage on cast iron
portion
Replace the gearbox assembly with a new part.
(4) Wear or damage on rack bushing
If the free play of the rack shaft in the radial direction is

out of the specified range, replace the gearbox assembly
with a new part. (Refer to SERVICE LIMIT)
(5) Wear on input shaft bearing
If the free play of the input shaft in the radial direction is

out of the specified range, replace the gearbox assembly
with a new part. (Refer to SERVICE LIMIT)
Crack, damage or deterioration

(1) Looseness of ball joint
(2) Bend of tie-rod
Damage or deterioration of dust
seal
Replace.
Adjusting screw
spring
Deterioration
Replace.
9
10
Boot clip
Sleeve
Deterioration
Damage
Replace.
Replace.
11
Pipe
(1) Damage to flared surface

(2) Damage to flare nut
(3) Damage to pipe
Replace.
PS-32
Replace.
Replace.
Steering Gearbox
2. SERVICE LIMIT
Make a measurements as follows. If it exceeds the
specified service limits, adjust or replace.
NOTE:
When making a measurement, hold the gearbox
assembly in a vise using the ST. Do not hold the
gearbox in a vice by inserting aluminum plates etc.
between the vise and gearbox assembly.
ST 926200000
STAND
3. RACK SHAFT FREE PLAY IN THE RADIAL DIRECTION

Right-turn steering
Service limit:
0.19 mm (0.0075 in) or less
Condition
L: 5 mm (0.20 in)
P: 122.6 N (12.5 kgf, 27.6 lb)
Rack shaft sliding resistance:

Service limit:
400 N (41 kgf, 90 lb) or less
PS-00101
Left-turn steering
PS-00099
Service limit:
Direction
Direction
0.15 mm (0.0059 in) or less
Condition
L: 5 mm (0.20 in)
P: 98 N (10 kgf, 22 lb)
L
PS-00100
P
PS-00102
PS-33
Steering Gearbox
4. INPUT SHAFT PLAY
5. TURNING RESISTANCE OF GEARBOX
In radial direction
Service limit:
0.18 mm (0.0071 in) or less
Condition
P: 98 N (10 kgf, 22 lb)
Using the ST, measure gearbox turning resistance.

ST 34099PA100 WRENCH
Service limit:
Maximum allowable resistance:
9.33 N (0.95 kgf, 2.10 lb) or less
Difference between right and left turning resistance:
Less than 20%
PS-00103
In axial direction
Service limit:
Condition
P: 20 49 N (2 5 kgf, 4 11 lb)
PS-00105
PS-00104
6. OIL LEAKAGE
b
a
(1)
(5)
(4) (3) (2)
(6)
c
e
d
c
c
c
PS-00690
(1)
Power cylinder
(3)
Rack piston
(5)
Input shaft
(2)
Cylinder
(4)
Rack
(6)
Valve housing
PS-34
Steering Gearbox
1) If a fluid leak is found, clean the fluid completely

from the suspect area, and turn the steering wheel
30 to 40 times to the left and right from lock to lock,
with the engine running, and check again for leaks
immediately, and also after a few hours have
passed
2) Cause and solution for oil leakage from a
The oil seal is damaged. Replace the valve assembly with a new part.
3) Cause and measure for oil leakage from b
The torsion bar O-ring is damaged. Replace the
valve assembly with a new part.
4) Cause and measure for oil leakage from c
The pipe is damaged. Replace the faulty pipe or Oring.
5) If the leak is other than a, b, c or 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 fluid from
surrounding areas. Then, turn the steering wheel
from lock to lock 30 to 40 times with the engine running, then re-inspect the leaking area immediately
after and several hours after this operation.
(1) Cause and solution for oil leakage from d
The cylinder seal is damaged. Replace the rack
bushing with a new part.
(2) Cause and solution for oil leakage from e
There are two possible causes. Perform the following step first. Remove the pipe assembly B
from the valve housing, and close the circuit using ST.
ST 926420000
PLUG
Turn the steering wheel from lock to lock 30 to
40 times with the engine running, then inspect
the leaking section immediately after and several hours after this operation.
If leakage from e is found again:
The oil seal of pinion and valve assembly is damaged. Replace the pinion and valve assembly with
a new part. Or replace the oil seal and the parts that
are damaged during disassembly with new parts.
If oil stops leaking from e:
The oil seal of rack housing is damaged. Replace
the oil seal and parts that are damaged during disassembly with new parts.
F: ADJUSTMENT
1) Adjust the front toe. <Ref. to FS-10, FRONT
WHEEL TOE-IN, INSPECTION, Wheel Alignment.>
Standard of front toe:
IN 3 OUT 3 mm (IN 0.12 OUT 0.12 in)
PS-00107
(1) Lock nut
2) Adjust the steering angle of the steering wheel.

Steering angle:
Model
Inner
wheel
Outer
wheel
Non-turbo
Turbo
3625130
3500130
3200130
3054130

when wheels are set in the straight ahead position,
or error is more than 5 on the periphery of the
steering wheel, correctly re-install the steering
wheel.
(1)
PS-00513
(1) Within 5

with vehicle set in the straight ahead position after
this adjustment, correct it by turning the right and
left tie-rods in the opposite direction from each other by the same angle.
PS-35
Pipe Assembly
6. Pipe Assembly
4) Remove the clamp E from pipe C and D.
A: REMOVAL
(1)

2) Lift-up the vehicle and remove the jack-up plate.
(3)
(2)
(5)
(4)
PS-00044
(1) Jack-up plate
3) Remove the one pipe joint at the center of gearbox assembly, and connect a vinyl hose to the pipe
and the joint. Discharge the fluid by turning the
steering wheel fully clockwise and counterclockwise. Discharge the fluid similarly from other pipes.
PS-00176
(1) Return hose

(2) Pressure hose
(3) Clamp E
(4) Pipe C
(2)
(5) Pipe D
5) Disconnect the pipe C and D from the gearbox.
(1)
PS-00026
(1) Pipe A
(2) Pipe B
(1)
(2)
PS-00027
(1) Pipe C
(2) Pipe D
6) Remove the air intake duct. <Ref. to IN (H4SO)7, REMOVAL, Air Intake Duct.>
7) Remove the bolt A.
PS-36
Pipe Assembly
8) Disconnect the pipe C from oil pump. Disconnect

the pipe D from the return hose.
2) Temporarily connect the pipes C and D to the

gearbox assembly.
CAUTION:
Do not allow fluid from the hose end to come
into contact with pulley belt.
To prevent foreign matter from entering the
hose and pipe, cover the open ends with clean
cloth.
(1)
(3)
(2)
(1)
(6)
(2)
(4)
(3)
(5)
PS-00177
(1) Bolt A
(2) Pipe C
(3) Pipe D
(7)
PS-00178
B: INSTALLATION
(1) Return hose

(2) Pressure hose
1) Temporarily tighten the two bolts (bolts A) fixing

pipe C and D in place.
(3) Approx. 30 mm (1.18 in)

(4) Clamp E
NOTE:
Visually check that the hose between tank and pipe
D is not bent or twisted.
(5) Pipe C
(6) Pipe D
(7) Pipe (on gearbox assembly side)
3) Temporarily install clamp E on pipes C and D.
(1)
(2)
NOTE:
Make sure that the character 8 on each clamp is
positioned on the same side, as shown in the figure.
(3)
PS-00177
(1)
(1) Bolt A
(2) Pipe C
(2)
(3) Pipe D
(1) Connect pipe D to the reservoir tank.

(2) Install the pipe C to the oil pump using a new
gasket.
PS-00608
Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
(3) Tighten the two bolts (bolts A) fixing pipe C
and D in place.
4) Tighten the clamp E.
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
Tightening torque:
7.4 Nm (0.75 kgf-m, 5.4 ft-lb)
(1) Clamp E
(2) Pipe C
PS-37
Pipe Assembly
5) Tighten the joint nut.
7) Install the jack-up plate.

8) Install the air intake duct, the air cleaner upper
cover and the air intake boot. <Ref. to IN (H4SO)-7,
INSTALLATION, Air Intake Duct.>
10) Fill with the specified fluid.
Tightening torque:
15 Nm (1.5 kgf-m, 10.8 ft-lb)
6) Connect pipe A and B to the four pipe joints of
the gearbox assembly. Connect the upper pipe B
first, and lower pipe A.
CAUTION:
Never start the engine before feeding the fluid
otherwise the vane pump might be seize.
11) Finally, check clearance between pipes or hoses as shown in the figure.
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
(2)
Clearance:
(1)
PS-00026
(1) Pipe A
(2) Pipe B
If the cruise control actuator and power steering hose clearance is less than 10 mm (0.39 in), move section
(A) held in place by the clamp, or bend (B) to adjust.
(B)
(1)
(2)
(A)
(3)
PS-00179
(1)
High-pressure hose
(2)
No interference is allowed
between hoses.
PS-38
(3)
Clearance between crossmember

and pipe: 3 8 mm (0.12 0.31 in)
Pipe Assembly
C: INSPECTION
Check all disassembled parts for wear, damage or
other problems. Repair or replace the defective
parts as necessary.
Part
Inspection
Corrective
action
Pipe
O-ring fitting surface damage

Nut damage
Pipe damage
Replace with
a new part.
Clamp
Loose clamps
Replace with
a new part.
Hose
Flare surface damage

Flare nut damage
Outer surface cracks
Outer surface wear
Clip damage
End coupling or adapter
deformation
Replace with
a new part.
Trouble
CAUTION:
Although the surface layer materials of rubber
hoses have excellent weathering resistance,
heat resistance and resistance for low temperature brittleness, they will be damaged chemically by brake fluid, battery electrolyte, engine
oil and automatic transmission fluid and their
service lives will be very shortened. Wipe off
hoses immediately if any of these come into
contact with the hoses.
Since resistances for heat and low temperature
brittleness gradually declines according to
long periods of exposure to hot or cold conditions, 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 areas and in
frequent driving conditions where a lot of steering work is required.
Particularly when there is continuous operation
of the relief valve for over 5 seconds, the life of
the hoses, oil pump, and fluid will be shortened
due to overheating.
Possible cause
Malfunction of the relief valve
Corrective action
Replace.
Instruct customers.
Replace the oil pump.
Poor cold characteristic of fluid

Improper connection
Replace fluid.
Correct.
Loosening of the clip

Poor cold characteristic of fluid
Retighten.
Replace fluid.
Wrong layout, tensioned

Excessive play of engine due to deterioration of
engine mounting rubber
Replace the hose.
Excessive holding time of relief status

Pressure hose burst
Disconnection of the return

hose
Fluid slightly leaking out of

hose
Improper stop position of pitching stopper
Power steering fluid, brake fluid, engine oil, or electrolyte coming into contact with the hose surface
Replace the parts if defective.

Replace.
Instruct customer.
Replace.
Replace.
Be careful during service work.
Hard steering work in a short period of time during

extreme cold weather.
Replace.
Instruct customers.
Excessive holding time of relief status

Excessive tightening torque for return hose clip
Crack on hose
Replace the parts if defective.
PS-39
Pipe Assembly
NOTE:
There are conditions in which a fluid leak is diagnosed, but is not actually leaking. 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.
(16)
(11)
(18)
(9)
(10)
(14)
(17)
(15)
(3)
(20)
(12)
(12)
(4)
(19)
(8)
(7)
(2)
(1)
(21)
(5)
(8)
(6)
(13)
PS-00022
PS-40
Pipe Assembly
Fluid leaking area
Possible cause
Corrective action
Insufficient tightening of flare nuts, dirt accumulation, damage to flare or flare nut or eye
bolt
Loosen and retighten. Replace if ineffective.
Improper installation of hoses or poor clamping
Retighten or replace the clamp.
Damaged O-ring or gasket
Replace the O-ring, gasket pipe or hose

with new parts. If there is still no improvement, replace the gearbox assembly.
Leakage from hose (11), (12) and

(13) in the figure
Crack or damage in hose

Crack or damage in hose hardware
Replace with a new part.

Leakage from surrounding of cast iron

portion of oil pump, (14) and (15) in
the figure
Damaged O-ring
Damaged gasket
Crack in the reservoir tank
Replace the reservoir tank.
Damaged cap packing

Crack in root of filler neck
Replace the cap.

Replace the reservoir tank.
Fluid level too high
Adjust the fluid level.
Damaged oil seal
Replace the oil seal.
Damaged packing or oil seal
Replace the problem parts.
Damage in control valve
Replace the control valve.
Leakage from the connections of

pipes and hoses, numbered with (1)
through (10) in the figure
Leakage from reservoir (16) and (17)

in the figure
Leakage from filler neck of (18)
Leakage from power cylinder of gearbox area (19) in the figure
Leakage from (20), (21) in the figure
and control valve of gearbox
PS-41
Oil Pump
7. Oil Pump
A: REMOVAL
2) Remove the pulley belt cover.
3) Loosen the lock bolt and slider bolt and remove
the power steering pump drive V-belt.
CAUTION:
When securing the oil pump bracket in a vice,
hold the oil pump bracket with the least possible force between two pieces of wood.
PS-00128
8) Remove the bolt from the rear side of oil pump.

9) Disassemble the oil pump and bracket by inserting a flat tip screwdriver as shown in the figure.
PS-00125
4) Disconnect the connector from power steering

pump switch.
5) Disconnect pipe C and suction hose from oil
pump.
CAUTION:
hose, cover the open ends with a clean cloth.
PS-00129
B: INSTALLATION
(1)
1) Install the oil pump to bracket.

(1) Place the oil pump bracket in a vise. Tighten
the bushing using a 12.7 mm (1/2) type 14and 21- mm box wrench until it is in contact with
the oil pump mounting surface.
(2)
CAUTION:
When securing the oil pump bracket in a vice,
hold the oil pump bracket with the least possible force between two pieces of wood.
PS-00181
(1) Suction hose

(2) Pipe C
6) Remove the installation bolt of the power steering pump bracket.
PS-00135
(1) Bushing
(2) Nut
PS-00127
7) Place the oil pump bracket in a vise, and remove

the two bolts from the front side of the oil pump.
PS-42
(3) 21 mm
(4) 14 mm
(5) Bolt
Oil Pump
(2) Secure the oil pump to the bracket.
3) Install pipe C and the suction hose to the oil pump.

Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
Tightening torque:
15.7 (1.6 kgf-m, 11.6 ft-lb)
CAUTION:
If the hose is twisted, there is a danger that it
may contact other parts.
(1)
PS-00128
(2)
Tightening torque:
37.3 (3.8 kgf-m, 27.5 ft-lb)
PS-00181
(1) Suction hose

(2) Pipe C
4) Connect the connector to the power steering

pump switch.
5) Install the V-belts to the oil pump.
6) Check the tension of the V-belt. <Ref. to
ME(H4SO)-41, INSPECTION, V-belt.>
7) Tighten the belt tension bolt.
PS-00137
2) Attach the installation bolts of the power steering

pump bracket.
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
8) Install the belt cover.
10) Fill with the specified power steering fluid.
<Ref. to PS-49, Power Steering Fluid.>
CAUTION:
Never start the engine before feeding the fluid
otherwise the vane pump might be seize.
PS-00127
PS-43
Oil Pump
C: INSPECTION
1. BASIC INSPECTION
Perform the following inspection procedures and replace faulty parts.
No.
Part
Oil pump (Exterior)
Inspection
(1) Crack, damage or oil leakage
Measure the radial play and axial play.

If any of these exceeds the service limit, replace the
oil pump with a new part.
(2) Play of pulley shaft

(1) Damage
Pulley
Corrective action
Replace the oil pump with a new part.
(2) Bend
Measure the V groove deflection.

If it exceeds the service limit, replace the pulley with a
new part.
(1) Faulty or seized of vane pump
Check the rotating resistance of pulley.

If it exceeds the service limit, replace the oil pump with
new part.
Oil pump (Interior)
O-ring
Cracking or deterioration
If the a string is wrapped on the pulley and rotated,

and the oil pump emits a noise that is markedly different in tone and loudness from a sound of a new oil
pump, replace the oil pump with a new part.
Bracket
Cracking
(2) Bend in the shaft or damage to

bearing
PS-44
Oil Pump
2. SERVICE LIMIT
2) Deflection of the pulley groove
Make a measurements as follows. If it exceeds the

service limit, replace with a new part.
Service limit:
CAUTION:
When securing the oil pump on a vise, hold
the oil pump with the least possible force between two pieces of wood.
Do not set the outside of the flow control
valve or the pulley section on a vise; doing so
may deform the deform the exterior or the pulley. Select properly sized wood pieces.
1) Play of the pulley shaft
NOTE:
Read the value for one surface of V groove, and
then set a dial on the other face and read the value.
Condition:
P: When applying a force of 9.8 N (1.0 kgf, 2.2 lb)
Service limit:
Play in the radial direction (Direction
(1)
PS-00147
)
(1) Dial gauge
3) Rotating resistance of pulley

Service limit:
Maximum load:
9.22 N (0.94 kgf, 2.07 lb) or less
PS-00145
NOTE:
A rather higher value may be indicated when pulley starts turning.
Measure the load during rotation to make a judgment.
(1) Dial gauge
Axial play (Direction

)
(1)
PS-00148
(1) Spring balance

P
(1) Dial gauge
PS-00146
3. HYDRAULIC PRESSURE
NOTE:
Be sure to complete all items aforementioned in
INSPECTION, prior to measuring hydraulic pressure. Otherwise, pressure can not be measured
correctly. <Ref. to PS-50, INSPECTION, General
Diagnostic Table.>
Do not leave the valve of pressure gauge closed
or hold the steering wheel at lock for 5 seconds or
more in any case, this can damage the oil pump.
Before attaching a pressure gauge, place cloth
at locations where fluid is expected to spill. Wipe off
any spilt fluid completely after the measurement.
PS-45
Oil Pump
1) Regular pressure measurement

(1) Connect the ST1, ST2 and ST3.
ST1 925711000 PRESSURE GAUGE
ST2 34099AC020 ADAPTER HOSE B
ST3 34099AC010 ADAPTER HOSE A
(2) Remove the air intake duct.
(3) Disconnect the pipe C from pump.
(4) Using the gasket (Part No. 34621AC021)
and bolt (Part No. 34620AC010), install the ST2
to pump instead of pipe C.
(3) Measure the relief pressure.

(1)
(2)
PS-00153
(A) Close
(3)
PS-00177
(1) Bolt A
(2) Pipe C
(3) Pipe D
(5) Attach the ST3 to the end of pipe C which is

removed from pump.
(6) Replenish power steering fluid up to the
specified level.
(7) Open the valve, and start the engine.
(8) Measure the regular pressure.
Service limit:
Turbo model
7,650 8,340 kPa (78 85 kg/cm2,1,110
1,210 psi)
Non-turbo model
6,700 7,400 kPa (68 75 kg/cm2, 971
1,073 psi)
(4) If it is not within the specification, replace the
oil pump.
3) Measure the working pressure.
(1) Using the ST, measure the working pressure.
(2) Open the valve.
(3) Measure the working pressure of control
valve by turning steering wheel from stop to
stop.
A
A
PS-00152
(A) Open
PS-00152
Service limit:
981 kPa (10 kg/cm2, 142 psi) or less
(9) If it is not within the specification, replace the
problem part for the following problems. (Pipe
or hose clogged, leaks from fluid line, and mixture of foreign matter in fluid line)
2) Measure the relief pressure.
(1) Using the STs, measure the relief pressure.
(2) Close the valve.
(A) Open
Service limit:
Turbo model
7,650 8,340 kPa (78 85 kg/cm2,1,110
1,210 psi)
Non-turbo model
6,700 7,400 kPa (68 75 kg/cm2, 971
1,073 psi)
PS-46
Oil Pump
(4) If it is out of specification, measure the

steering effort. <Ref. to PS-53, MEASUREMENT OF STEERING EFFORT, INSPECTION, General Diagnostic Table.> If it is not
within specification, replace the control valve itself or control valve and pinion as a single unit,
using new parts.
PS-47
Reservoir Tank
8. Reservoir Tank
C: INSPECTION
A: REMOVAL
Check the reservoir tank for cracks, breakage or

damage. If a failure is found, replace the reservoir
tank.
1) Remove the air intake duct. <Ref. to IN (H4SO)7, REMOVAL, Air Intake Duct.>
2) Drain fluid from the reservoir tank.
3) Disconnect the pipe D from the return hose and
suction hose from the oil pump.
CAUTION:
hose and pipe, cover the open ends with clean
cloth.
(1)
(2)
(3)
PS-00182
(1) Suction hose

(2) Pipe D
(3) Return hose
4) Remove the reservoir tank from the bracket by

pulling it upwards.
B: INSTALLATION
1) Install the reservoir tank to the bracket.
2) Connect the pipes D to the return hose and suction hose to the oil pump.
(1)
(2)
(3)
PS-00182
(1) Suction hose

(2) Pipe D
(3) Return hose
3) Replenish the specified power steering fluid up

to the specified level. <Ref. to PS-2, SPECIFICATION, General Description.>
PS-48
Power Steering Fluid

9. Power Steering Fluid
4) Set ST on the top of reservoir tank and fill it

about half way with the specified fluid.
ST 34199AE040 OIL CHARGE GUIDE
A: SPECIFICATION
Recommended power steering fluid <Ref. to PS-2,
SPECIFICATION, General Description.>
B: INSPECTION
1) Check the power steering fluid for deterioration
or contamination. If the fluid is highly deteriorated
or contaminated, drain it and refill with new fluid.
2) Check the joints and units for oil leakage. If any
oil leaks are found, repair or replace the applicable
part.
3) Inspect the fluid level of reservoir tank with vehicle on level surface and engine stopped.
If the level is at MIN. point or below, add fluid to
keep the level in the specified range of the indicator. If at MAX. point or above, drain fluid by using
a syringe or the like.
(1) If the power steering fluid temperature is
20C (68F) or less, read the fluid level on the
COLD side.
(2) If the power steering fluid temperature is
80C (176F) or more, inspect the fluid level on
the HOT side.
COLD MAX.
HOT MAX.
HOT MIN.
COLD MIN.
PS-00159
C: REPLACEMENT
2) Remove the jack-up plate.
3) Remove the pipe joint in the center of gearbox
assembly, and connect the vinyl hose to the pipe
and joint. Turn the steering wheel to drain the fluid
out.
PS-00160
5) Maintaining the fluid level of Step 4), continue to

turn the steering wheel slowly from lock to lock until
the bubbles stop appearing on oil surface.
6) If the steering wheel is turned in a low fluid level
condition, air will be sucked into the pipe. If air has
entered, leave it for about half an hour and then repeat step 5) again.
8) Continue to turn the steering wheel slowly from
lock to lock again until the bubbles stop appearing
on oil surface, while keeping the fluid at the level in
Step 4).
Normally bubbles will stop appearing after turning
the steering wheel from lock to lock three times.
9) In case bubbles do not stop appearing in the
tank, leave it for about half an hour and then repeat
step 4) again.
10) Lower the vehicle, and then idle the engine.
11) Continue to turn the steering wheel from lock to
lock until the bubbles stop appearing and change of
the fluid level is within 3 mm (0.12 in).
12) In case the following happens, leave it about
half an hour and then do step 8) to 11) again.
(1) The fluid level changes over 3 mm (0.12 in).
(2) Bubbles remain on the upper surface of the
fluid.
(3) Screeching noise is generated from oil
pump.
13) Check for fluid leakage after turning steering
wheel from lock to lock with the engine running.
PS-49


A: INSPECTION
Trouble
Steering effort is heavy in all
ranges.
Steering effort is heavy at
stand still.
Steering wheel vibrates
when turning.
Vehicle leads to one side or

the other
Returning force of steering
wheel to center is poor.
Steering wheel vibrates
when turning.
Possible cause
Corrective action
1. Pulley belt
Unequal length of pulley belts
Contact with oil or grease
Looseness or damage of the pulley belt
Poor uniformity of the pulley belt cross section
Pulley belt is touching the pulley bottom.
Poor revolution of pulleys (except oil pump pulley)
Poor revolution of oil pump pulley
Adjust or replace.
2. Tire and wheel

Improper tires out of specifications
Improper wheels out of specification
Tires not properly inflated*1
Replace or reinflate.
3. Fluid
Low fluid level
Air entry in fluid
Dust entry in fluid
Fluid deterioration
Inadequate warm-up of fluid *2
Refill, bleed air, replace or

instruct customer.
4. Idle speed
Low idle speed
Excessive drop of idle speed at start or when turning the
steering wheel *3
Adjust or instruct customer.
5. Measure the hydraulic pressure. <Ref. to PS-45, HYDRAULIC PRESSURE, INSPECTION, Oil Pump.>
Replace the problem parts.
6. Measure the steering wheel effort. <Ref. to PS-53, MEASUREMENT OF STEERING EFFORT, INSPECTION, General
Diagnostic Table.>
1. Fluid line
Folded hose
Flattened pipe
2. Tire and wheel
Flat tire
Mixed use of different tires
Mixed use of different wheels
Uneven tire wear
Unequal tread remaining
Unequal pressure of tire
3. Front alignment
Improper or unequal caster
Improper or unequal toe-in
Loose suspension connections
4. Others
Damaged joint assembly
Unbalanced height
Unbalanced weight
5. Measure the steering wheel effort. <Ref. to PS-53, MEASUREMENT OF STEERING EFFORT, INSPECTION, General
Diagnostic Table.>
Adjust or replace.
Correct or replace.
Correct or replace.
Adjust or retighten.
Replace, adjust or instruct customer.
Adjust or replace.
*1 If the tires or wheels are wider than standard, the load to power steering system is increased. Accordingly, in a condition where
the fluid has not yet warmed up, the relief valve may work before reaching the maximum turning angle. In this case, steering effort
may be heavy. When the measured hydraulic pressure is normal, there is no problem.
*2 In cold weather, steering effort may be heavy due to increased flow resistance of cold fluid. After warming-up engine, turn the
steering wheel from stop to stop several times to warm-up the fluid. If steering effort reduces normally, the power steering is functioning normally.
*3 In cold weather or with insufficient warm-up of the engine, steering effort may be heavy due to excessive drop of idling when
turning the steering wheel. In this case, it is recommended to start the vehicle by increasing engine speed a little higher than usual. If steering effort reduces normally, the power steering is functioning normally.
PS-50

1. ABNORMAL NOISE & VIBRATION

CAUTION:
Do not keep the relief valve operating for over 5
seconds at a time or the inner parts of the oil
pump may be damaged due to rapid increase of
fluid temperature.
NOTE:
A screeching noise may be heard immediately
after the engine start in extremely cold conditions.
In this case, if the noise goes away when the vehicle warms up, the system is functioning normally.
This is due to the fluid characteristics in extremely
cold condition.
The oil pump normally makes a small whining
noise due to its mechanism. Even if a noise is
heard when steering wheel is turned at stand still,
there is no abnormal function in the system provided that the noise eliminates when the vehicle is
driving.
Trouble
Hiss noise (continuous)
While engine is running.
When turning the steering wheel with the brake

applied when the vehicle is parked, a screeching
noise may be generated by the brake disc and
pads. This is not a fault in the steering system.
There may be a small vibration around the steering devices when turning the steering wheel at
standstill, even though the component parts are operating properly
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
the steering wheel, fluid temperature and braking
conditions.
These conditions do not indicate a problem in the
system.
Confirm vibration for an AT model, by applying the
parking brake on a concrete surface, shifting into
the D range, and turning the steering wheel repeatedly at from slow to rapid, step by step.
Possible cause
The relief valve emits an operating sound when steering
wheel is completely turned in either direction. (Do not
keep this condition over 5 seconds.)
Relief valve emits an operating sound when steering
wheel is not turned. This means that the relief valve is
defective.
Rattling noise (intermittent) when

engine is running.
Knocking
When turning steering wheel in
both directions with small angle
repeatedly at engine ON or OFF.
Grinding noise (continuous)
Squeal, squeak (intermittent or

continuous)
Corrective action
Normal
Interference with adjacent parts
Check the clearance. <Ref. to

PS-54, INSPECTION OF
CLEARANCE, INSPECTION,
General Diagnostic Table.>
Correct if necessary.
<Ref. to PS-39, INSPECTION,
Pipe Assembly.>
Loosened attachment of the oil pump, reservoir tank,

pump bracket, gearbox or crossmember
Retighten.
Loose oil pump pulley or other pulley(s)

Retighten.
Looseness of the linkage, play in the steering, improper
tightening (looseness) of suspension joints or steering col- Retighten or replace.
umn
Replace faulty parts in the gearSound generates from the inside of gearbox or oil pump.
box or oil pump.
Excessive backlash
Adjust and retighten.
Loosened lock nut for adjusting backlash
Insufficient tightening or play in the tie-rod or tie-rod end
Retighten or replace.
Air in vane pump
Inspect and retighten the fluid

line connection.
Refill the fluid and vent air.
Vane pump seizing

Oil pump pulley bearing seized

Folded hose, flattened pipe

Improper adjustment of pulley belt
Damaged or over tensioned pulley belt
Unequal length of pulley belts
Replace.
Runout or dirty V-groove surface of oil pump pulley
Clean or replace.
PS-51
Adjust or replace.
(Replace two belts as a set.)

Trouble
Sizzling noise (continuous)
Possible cause
Fluid aeration
Damaged pipe of gearbox
Faulty inside of hose or pipe
Flattened hose or pipe
Problem inside the reservoir tank
Missing reservoir tank cap
Whistle (continuous)
Whine or growl (intermittent or
continuous)
While engine is running with/
without steering turned.
Grinding noise (continuous)

While engine is running with the
steering turned.
Vibration
While engine is running with/
without steering turned.
Corrective action
Fix the faulty part causing aeration.
Replace the fluid and vent air.
Faulty pipe of gearbox or faulty hose

Looseness of oil pump, oil pump bracket attachment
Replace the pipe.

Repair or replace.
Replace.
Install cap.
Replace the faulty parts of the
gearbox or the hose.
Retighten.
Fault inside of oil pump or hose
Replace the oil pump or hose, if

the noise can be heard when
vehicle is running as well as
being stopped.
Torque converter growl, air conditioner compression growl
Remove the power steering pulley belt and check.
Fault inside of gearbox
Replace the faulty parts of gearbox.
Faulty steering shaft bearing

Occurs when turning the steering wheel with brakes (service or parking) applied.
Apply grease or replace.

If the noise goes away when
brake is released, it is normal.
Engine speed is too low.
Adjust, and notify customer.

Repair faulty part
Vent air.
Replace the faulty parts in gearbox and oil pump.
Retighten.
Air in vane pump

Damaged valve in oil pump or gearbox
Excessive play in steering, looseness of suspension parts
PS-52

2. MEASUREMENT OF STEERING EFFORT

1
10
11
Step
CHECK STEERING EFFORT.
1) Stop the vehicle on paved road.
4) Install a spring scale on the steering wheel.
5) Pull the spring scale at a right angle to the
steering wheel, and measure both right and left
steering wheel efforts.
NOTE:
When turning the steering more quickly than
necessary from one direction to the other at an
engine speed over 2,000 rpm, steering effort
may be heavy. This is caused by flow characteristic of the fluid in the oil pump and is not a defect.
CHECK STEERING EFFORT.
1) Stop the engine.
2) Pull the spring scale at a right angle to the
steering wheel, and measure both right and left
steering wheel efforts.
CHECK STEERING WHEEL EFFORT.
1) Remove the universal joint.
2) Measure the steering wheel effort.
CHECK STEERING WHEEL EFFORT.
Measure the steering wheel effort.
CHECK UNIVERSAL JOINT.

Measure the swing torque of the joint (yoke of
steering column side). <Ref. to PS-14,
INSPECTION, Universal Joint.>
CHECK UNIVERSAL JOINT.
Measure the swing torque of the joint (yoke of
gearbox side). <Ref. to PS-14, INSPECTION,
Universal Joint.>
FRONT WHEEL CHECK.
Check the front wheels.
Check
Is the steering effort less than
29.4 N (3.0 kgf, 6.6 lb)?
Yes
Go to step 2.
No
Adjust the backlash.
Is the steering effort less than

314 N (35 kgf, 77 lb)?
Go to step 3.
Perform the adjustment.
Is steering effort less than 2.26 Go to step 4.

N (0.23 kgf, 0.51 lb)?
Is the steering effort difference Go to step 5.
in the left and right directions is
less than 1.08 N (0.11 kgf, 0.24
lb)?
Is the swing torque of the uni- Go to step 6.
versal joint less than 7.3 N
(0.74 kgf, 1.64 lb)?
Is the swing torque of the universal joint less than 7.3 N
(0.74 kgf, 1.64 lb)?
Does the front wheels have

unsteady revolution or rattling,
or does the brakes drag?
CHECK TIE-ROD ENDS.
Is there any unsteady revoluRemove the tie-rod ends.
tion or rattling of suspension tierod ends?
BALL JOINT CHECK.
Is there any unsteady revoluRemove the ball joint.
tion or rattling of suspension
ball joints?
CHECK GEARBOX.
Is the rotating resistance of
Measure the rotating resistance of the gearbox. steering gearbox less than 9.33
<Ref. to PS-34, TURNING RESISTANCE OF N (0.95 kgf, 2.09 lb)? Is the difGEARBOX, INSPECTION, Steering Gearbox.> ference between right and left
sides less than 20%?
CHECK GEARBOX.
Is the sliding resistance of
Measure the sliding resistance of the gearbox. steering gearbox less than 304
<Ref. to PS-33, SERVICE LIMIT, INSPECN (31 kgf, 68 lb)? Is the differTION, Steering Gearbox.>
ence between the right and left
sliding resistances less than
20%?
PS-53
Check, adjust and

replace if necessary.
Check, adjust and
Replace with a
new part.
Go to step 7.
Replace with a
new part.
Inspect, readjust
and replace if necessary.
Inspect and
Inspect and
Go to step 11.
Go to step 8.
Steering effort is
normal.
Go to step 9.
Go to step 10.
Readjust the backlash, and if ineffective, replace the

faulty parts.
Readjust the backlash, and if ineffective, replace the
faulty parts.

3. INSPECTION OF CLEARANCE
This table lists various clearances that must be correctly adjusted to ensure the normal vehicle driving without interfering noise, or any other faults.
Install locations
Minimum allowance
(1) Crossmember to pipe

(2) DOJ to shaft or joint
5 mm (0.20 in)
14 mm (0.55 in)
(3) DOJ to valve housing

(4) Pipe to pipe
11 mm (0.43 in)
2 mm (0.08 in)
(5) Stabilizer to pipe

(6) Exhaust pipe to pipe
5 mm (0.20 in)
11 mm (0.43 in)
(7) Exhaust pipe to gear box bolt

(8) Side frame to hose A and B
15 mm (0.59 in)
10 mm (0.39 in)
(9) Cruise control pump Hoses A and B
15 mm (0.59 in)
(10) Pipe portion of hose A to pipe portion of hose B
1.5 mm (0.059 in)
(10)
(5)
(7)
(9)
(4)
(6)
(3)
(1)
(8)
(2)
PS-00193
PS-54
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
A: SPECIFICATION
1. HEATER SYSTEM
Item
Specifications
Heating capacity
5.0 kW (4,300 kcal/h, 17,062 BTU/h)

or more
Air flow rate
280 m3 (9,888 cu ft)/h
Max air flow rate
480 m3 (16,951 cu ft)/h
Heater core size

(height length width)
134.1 224.3 32 mm
(5.28 8.83 1.26 in)
Auto A/C (Brushless motor)
230 W or less
Type
Blower motor
Fan type and size
(diameter width)
Manual A/C (Cylinder motor)

260 W or less
Sirocco fan type
150 75 mm (5.91 2.95 in)
Condition
Mode selector switch: HEAT
Temperature control switch: FULL HOT
Temperature difference between hot water
and inlet air: 65C (149F)
Hot water flow rate: 360 2 (95.1 US gal,
79.2 Imp gal)/h
Heat mode (FRESH), FULL HOT at 12.5 V
Temperature control switch: FULL COLD
Blower fan speed: 4th position
Mode selector lever: Recirculation
12.5 V
12.5 V
2. A/C SYSTEM
Auto A/C model
Item
Specifications
Reheat air-mix type
Type of air conditioner
5.0 kW
(4,300 kcal/h, 17,064 BTU/h)
Cooling capacity
HFC-134a (CH2FCF3)
[60050 g (1.320.11 lb)]
Refrigerant
Compressor
Magnet clutch
Type
Discharge
Vane rotary, fix volume (DKV-14G)

140 cm3 (8.54 cu in)/rev
Max. permissible speed

Type
7,000 rpm
Dry, single-disc type
Power consumption
Type of belt
38 W (DC12 V-25C)
V-belt 4 PK
Pulley dia. (effective dia.)

Pulley ratio
Condenser
Type
Core face area
Corrugated fin (Sub cool type)

0.247 m2 (2.69 sq ft)
Core thickness
Radiation area
16 mm (0.63 in)
5.9 m2 (63.51 sq ft)
Receiver drier
Expansion valve
Effective inner capacity

Type
Evaporator
Type
Dimension (height length
width)
Blower fan
125 mm (4.92 in)

1.064
Fan type
Power consumption
AC-2
220 cm3 (13.42 cu in)

External average pressure equation
Single tank
176.5 266 60 mm
(6.95 10.47 2.36 in)
Sirocco fan
150 75 mm (5.91 2.95 in)
230 W or less at 12.5 V
General Description
Item
Condenser fan (Sub fan)
Radiator fan (Main fan)
Specifications
Motor type
Power consumption
Magnet
120 W at 12 V
Fan outer diameter

Motor type
320 mm (12.6 in)

Magnet
Power consumption
Fan outer diameter
120 W at 12 V
320 mm (12.6 in)
Idling speed (A/C ON)

Low-pressure switch
working pressure
Triple switch
(Pressure switch)
High-pressure switch
working pressure
Middle-pressure switch
operating pressure
OFF ON
800100 rpm
17725 kPa
(1.800.25 kg/cm2, 25.603.56 psi)
20630 kPa
(2.100.31 kg/cm2, 29.864.41 psi)
ON OFF
2,940200 kPa
(29.982.03 kg/cm2, 426.3228.87 psi)
ON OFF
590200 kPa
(6.022.03 kg/cm2, 85.628.87 psi)
1,370120 kPa
(13.971.22 kg/cm2, 198.6517.35 psi)
1,770100 kPa
(18.051.02 kg/cm2, 256.8114.50 psi)
Difference
ON OFF
OFF ON
(3)
(1)
Thermo-control amplifier working temperature

(Evaporator outlet air)
(2)
(4)
AC-00601
(1) ON
(2) OFF
(3) 1.50.3C (370.4F)
(4) 1.00.5C (350.9F)
Manual A/C model

Item
Specifications
Reheat air-mix type
Type of air conditioner

Cooling capacity
5.0 kW (4,300 kcal/h, 17,064 BTU/h)

HFC-134a (CH2FCF3)
[60050 g (1.320.11 lb)]
Vane rotary, fix volume (DKV-14G)
Refrigerant
Type
Compressor
Discharge
Max. permissible speed
Type
Power consumption
Magnet clutch
Type of belt
Pulley dia. (effective dia.)
Pulley ratio
Type
Condenser
140 cm3 (8.54 cu in) per rotation

7,000 rpm
Dry, single-disc type
38 W (DC12 V-25C)
V-belt 4 PK
125 mm (4.92 in)
1.064
Corrugated fin (Sub cool type)
Core face area

Core thickness
0.247 m2 (2.69 sq ft)

16 mm (0.63 in)
Radiation area
5.9 m2 (63.51 sq ft)
AC-3
General Description
Item
Receiver drier
Expansion valve
Specifications
Effective inner capacity
Type
220 cm3 (13.42 cu in)

External average pressure equation
Type
Evaporator
Single tank
176.5 266 60 mm
(6.95 10.47 2.36 in)
Sirocco fan
Dimensions (W H T)
Fan type
Blower fan

Power consumption
150 75 mm (5.91 2.95 in)

260 W or less at 12.5 V
Motor type
Power consumption
Magnet
120 W at 12 V
Fan outer diameter
320 mm (12.6 in)
Radiator fan (Main fan)
Motor type
Power consumption
Magnet
120 W at 12 V
Idling speed (A/C ON)
Fan outer diameter

MPFI model
320 mm (12.6 in)

800100 rpm
Condenser fan (Sub fan)
Low-pressure switch
working pressure
Triple switch
(Pressure switch)
High-pressure switch
working pressure
Middle-pressure switch
operating pressure
ON OFF
17725 kPa
(1.800.25 kg/cm2, 25.603.56 psi)
OFF ON
20630 kPa
(2.100.31 kg/cm2, 29.864.41 psi)
ON OFF
2,940200 kPa
(29.982.03 kg/cm2, 426.3228.87 psi)
590200 kPa
(6.022.03 kg/cm2, 85.628.87 psi)
1,370120 kPa
(13.971.22 kg/cm2, 198.6517.35 psi)
1,770100 kPa
(18.051.02 kg/cm2, 256.8114.50 psi)
Difference
ON OFF
OFF ON
(3)
(1)
Thermo control amplifier working temperature

(Evaporator outlet air)
(2)
(4)
AC-00601
(1) ON
(2) OFF
(3) 1.50.3C (370.4F)
(4) 1.00.5C (350.9F)
AC-4
General Description
B: COMPONENT
1. HEATER COOLING UNIT
Auto A/C model
(19)
(18)
(19)
T
(17)
(20)
(23)
(21)
(22)
T
(15)
(7)
(6)
(13)
(4)
(5)
(3)
(12)
(9)
(14)
(2)
(16)
(1)
(8)
(10)
(11)
AC-00206
(1)
Evaporator cover
(10)
Heater core
(19)
O-ring
(2)
(3)
Mode actuator
Mode main lever
(11)
(12)
Drain hose
Mix actuator
(20)
(21)
Expansion valve
Evaporator
(4)
(5)
Vent door lever

Foot door lever
(13)
(14)
Mix door lever

Foot door lever (B)
(22)
(23)
Evaporator lining
Evaporator sensor
(6)
(7)
Mode actuator link

Defroster lever
(15)
(16)
Upper case
Aspirator
(8)
(9)
Foot duct
Lower case
(17)
(18)
Packing
Cooling unit pipe
AC-5
T: 7.5 (0.76, 5.5)
General Description
Manual A/C model

(16)
(15)
(16)
T
(14)
(17)
(20)
(18)
(19)
T
(13)
(6)
(5)
(11)
(3)
(4)
(2)
(12)
(8)
(1)
(7)
(9)
(10)
AC-00207
(1)
(2)
Evaporator cover
Mode main lever
(9)
(10)
Heater core
Drain hose
(17)
(18)
Expansion valve
Evaporator
(3)
(4)
Vent door lever

Foot door lever
(11)
(12)
Mix actuator lever

Foot door lever
(19)
(20)
Evaporator lining
Evaporator sensor
(5)
(6)
Mode actuator link

Defroster lever
(13)
(14)
Upper case
Packing
(7)
(8)
Foot duct
Lower case
(15)
(16)
Cooling unit pipe

O-ring
AC-6
T: 7.5 (0.76, 5.5)
General Description
2. BLOWER MOTOR UNIT

Auto A/C model
(4)
(6)
(7)
(2)
(3)
(1)
(9)
(5)
(8)
AC-01473
(1)
(2)
Upper case
Intake door actuator
(4)
(5)
Link lever
Filter cover
(7)
(8)
Lower case
Blower motor ASSY
(3)
FRESH/RECIRC link
(6)
Cover
(9)
Air conditioner filter
AC-7
General Description
Manual A/C model

(4)
(7)
(8)
(2)
(3)
(1)
(6)
(10)
(5)
(9)
AC-01474
(1)
(2)
Upper case
(5)
(6)
Filter cover
Blower resistor
(8)
(9)
Lower case
Blower motor ASSY
(3)
(4)
FRESH/RECIRC link
Link rod
(7)
Cover
(10)
Air conditioner filter
AC-8
General Description
3. CONTROL UNIT
Auto A/C model
(6)
(5)
(3)
(4)
(2)
(1)
AC-01462
(1)
(2)
Control dial
Switch
(3)
(4)
Control case (front)

Front cover
AC-9
(5)
(6)
Control unit circuit

Control case (rear)
General Description
Manual A/C model

(9)
(11)
(10)
(4)
(8)
(1)
(2)
(3)
(6)
(5)
(7)
AC-01415
(1)
(2)
Panel
Temperature adjustment dial
(5)
(6)
A/C switch
FRESH/RECIRC switch
(9)
(10)
Mode switch cable

Temperature adjustment cable
(3)
(4)
Fan speed control dial

Mode switch dial
(7)
(8)

Switch board
(11)
Valve
AC-10
General Description
4. AIR CONDITIONING UNIT
(5)
(6)
T2
(7)
(3)
(6)
(6)
(1)
(2)
(6)
(4)
T1
T2
T1
(6)
AC-01365
(1)
(2)
Condenser
High-pressure hose
(5)
(6)
Compressor
O-ring
(3)
(4)
Low-pressure hose
Pipe
(7)
Triple pressure switch
AC-11

T1: 7.4 (0.75, 5.4)
T2: 15 (1.5, 10.8)
General Description
5. COMPRESSOR
T5
(4)
T5
T5
(5)
T3
T2
(3)
(1)
(2)
(7)
T4
(6)
T4
T1
AC-00004
(1)
(2)
Idler pulley bracket

Idler pulley adjuster
(7)
Compressor belt cover (Non-turbo

model)
(3)
(4)
Idler pulley
Compressor bracket
T2: 22.6 (2.3, 16.6)

T3: 23.0 (2.35, 17.0)
(5)
(6)
Compressor
V-belt
T4: 28.9 (2.95, 21.3)

T5: 35 (3.6, 26)
AC-12

T1: 4.0 (0.40, 2.95)
General Description
6. HEATER DUCT
(1)
(3)
(5)
(2)
(4)
(6)
AC-00212
(1)
(2)
Front defroster nozzle

Side defroster duct (LH)
(3)
(4)
Side defroster duct (RH)

Side ventilation duct (LH)
C: CAUTION
1. HFC-134A A/C SYSTEM
The cooling system components for the HFC134a system such as the refrigerant and compressor oil are different from the conventional CFC-12
system components and they are incompatible with
each other.
(5)
(6)
Side ventilation duct (RH)

Rear heater duct
Vehicles with the HFC-134a system can be identified by the label (A) attached to the vehicle.
Before maintenance, check which A/C system is installed to the vehicle.
(A)
AC-01410
AC-13
General Description
2. COMPRESSOR OIL
4. HANDLING OF REFRIGERANT
HFC-134a compressor oil has no compatibility

with that for CFC-12 system.
Use only the manufacturer-authorized compressor oil for the HFC-134a system; only use
ZXL200PG.
Do not mix multiple compressor oils.
If CFC-12 compressor oil is used in the HFC-134a
A/C system, the compressor may become stuck
due to poor lubrication, or the refrigerant may leak
due to swelling of rubber parts.
On the other hand, if HFC-134a compressor oil is
used in a CFC-12 A/C system, the durability of the
A/C system will be lowered.
HFC-134a compressor oil is very hygroscopic.
When replacing or installing/removing A/C parts,
immediately isolate the oil from atmosphere using a
plug or tape. In order to avoid moisture, store the oil
in a container with its cap tightly closed.
The refrigerant boils at approx. 30C (22F).

When handling it, be sure to wear protective goggles and protective gloves. Direct contact of the refrigerant with skin may cause frostbite.
If the refrigerant gets into your eye, avoid rubbing
your eyes with your hands. Wash your eye with
plenty of water, and receive medical treatment from
an eye doctor.
Do not heat a service can. If a service can is 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 40C (104F) max.
Do not drop or impact a service can. (Observe
the precautions and operation procedure described
on the refrigerant can.)
When the engine is running, do not open the
high-pressure valve of manifold gauge. The highpressure gas will back-flow resulting in an explosion of the can.
Provide good ventilation and do not work in a
closed area.
In order to prevent from global warming, avoid
releasing HFC-134a into the atmosphere. Using a
refrigerant recovery system, discharge and reuse
it.
3. REFRIGERANT
The CFC-12 refrigerant cannot be used in the
HFC-134a A/C system. The HFC-134a refrigerant
also cannot be used in the CFC-12 A/C system.
If an incorrect or no refrigerant is used, it will result in poor lubrication and the compressor itself
may be damaged.
(A)
(C)
(B)
(D)
(F)
(E)
AC-00007
(A) Goggles
(B) Gloves
(C) Avoid open flame
(D) No direct heat on container
(E) Do not discharge
(F) Loosen
AC-14
General Description
5. O-RING CONNECTIONS
Always use a new O-ring.
In order to keep the O-rings free of lint which will
cause a refrigerant gas leak, perform operations
without gloves and cloth.
Apply compressor oil to O-rings to avoid sticking,
Use a torque wrench to tighten the O-ring fittings.
Over-tightening will damage the O-ring and tube
end distortion.
If the operation is interrupted before completing
a pipe connection; recap the tubes, components
and fittings with a plug or tape to prevent dirt from
entering.
Use oil specified in the service manual to lubricate the O-rings.

Apply oil to the top and sides of O-rings before installation.
Apply the oil to the area including the O-rings and
tube beads.
AC-00010
(A)
After tightening, use a clean cloth to remove the

excess oil from the connections and any oil which
may have run on the vehicle body or other parts.
If any leakage is suspected after tightening, do
not further tighten the connections, but disconnect
the connections, remove the O-rings, and check
the O-rings, threads, and connections.
AC-00008
D: PREPARATION TOOL
(A) Seal
Visually check the surfaces and mating surfaces

of O-rings, threads and connecting points. If a failure is found, replace the applicable parts.
Install the O-rings straight against the groove of
the tube.
(A)
(B)
(D)
(C)
CAUTION:
When working on vehicles with HFC-134a system, only use HFC-134a specified tools and
parts. Do not mix with those of CFC-12. If HFC134a and CFC-12 refrigerant or compressor oil
is mixed, it will result in poor lubrication and
the compressor itself may be destroyed.
In order to prevent the mixture of 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.
(C)
AC-00009
(A) O-ring
(B) OK
(C) NG
(D) Groove
AC-15
Tool & screw type
HFC-134a
Millimeter size
CFC-12
Inch size
Valve type
Quick joint type
Screw-in type
General Description
Description
Tools and Equipment

Wrench
Various WRENCHES will be required to service any A/C system. A 7 to
40 Nm (0.7 to 4.1 kg-m, 5 to 30 ft-lb) torque wrench and various crowfoot wrenches will be needed. Open end or flare nut wrenches will be
needed to hold the tube and hose fittings.
AC-00213
Applicator bottle
A small APPLICATOR BOTTLE is recommended to apply refrigerant
oil to the various parts. It can be available at a hardware or drug store.
AC-00012
Manifold gauge set

A MANIFOLD GAUGE SET (with hoses) can be obtained at either a
refrigerant supplier or an automotive equipment supplier.
AC-00013
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.
AC-00014
Syringe
A graduated plastic SYRINGE will be needed to add oil into the system
again. A syringe can be available at a pharmacy or drug store.
AC-00015
AC-16
General Description
Description
Tools and Equipment

Vacuum pump
A VACUUM PUMP (in good working condition) is necessary, and may
be obtained from either a refrigerant supplier or an automotive equipment supplier.
AC-00016
Can tap
A CAN TAP for the 397 g (14 oz.) can is available at an automotive
equipment supplier.
AC-00017
Thermometer
Pocket THERMOMETERS are available from either industrial hardware stores or commercial refrigeration supply houses.
AC-00018
Electronic leak detector

An ELECTRONIC LEAK DETECTOR can be available at either a specialty tool supplier or an A/C equipment supplier.
AC-00019
Weight scale
A WEIGHT SCALE such as an electronic charging scale or a bathroom scale with digital display will be needed, if a 13.6 kg (30 lb) refrigerant container is used.
AC-00020
AC-17
Refrigerant Pressure with Manifold Gauge Set

2. Refrigerant Pressure with

Manifold Gauge Set
8) Put in RECIRC position.

9) Turn the blower control switch to HI.
10) Read the gauge.
A: PROCEDURE
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 35C (86 95F)
1) Place the vehicle in the shade and windless condition.

3) Connect the manifold gauge set.
4) Open all windows and close all doors.
5) Increase the engine to 1,500 rpm.
6) Turn on the A/C switch.
7) Turn the temperature control switch to MAX
COOL.
B: INSPECTION
Symptom
High-pressure side is unusually high.
High-pressure side is unusually low.
Low-pressure side is unusually high.
Low-pressure side is unusually low.
Probable cause
Defective condenser fin motor
Clogged condenser fin
Too much refrigerant
Air inside the system
Defective receiver dryer
Defective compressor
Not enough refrigerant
Clogged expansion valve
Expansion valve frozen temporarily by
moisture.
Defective compressor
Defective expansion valve
Too much refrigerant
Not enough refrigerant
Clogged expansion valve
Expansion valve frozen temporarily by
moisture.
Saturated receiver dryer
AC-18
Repair order
Replace the fan motor.
Clean the condenser fin.
Discharge refrigerant.
Replace the receiver dryer.
After evacuating again, charge an
appropriate amount of refrigerant.
Replace the compressor.
Check for leaks.
Replace the expansion valve.
Fully evacuate the expansion valve.
Replace the compressor.

Discharge refrigerant.
Check for leaks.
Replace the receiver dryer.
Refrigerant Recovery Procedure

3. Refrigerant Recovery
Procedure
4) Install the low-/high-pressure hoses to the service ports on the low-/high-pressure sides of the
vehicle respectively.
A: PROCEDURE
CAUTION:
During operation, be sure to wear protective
goggles and protective gloves.
Connect the refrigerant recovery system with
the manifold gauge set to discharge the refrigerant from the A/C system and reuse it.
When reusing the discharged refrigerant,
keep service cans on hand. Because the recovery rate with the recovery system is approx.
90%, service cans are necessary to charge the
refrigerant.
Follow the detailed operation procedure described in the operation manual attached to the
refrigerant recovery system.
1) Perform the compressor oil return operation.
<Ref. to AC-24, PROCEDURE, Compressor Oil.>
2) Stop the engine.
3) Make sure the valves on low-/high-pressure
sides of manifold gauge set are fully closed.
(1)
(2)
(3)
AC-00147
(1) Low-pressure side service port

(2) High-pressure side service port
(3) Close
5) Connect the center hose to the refrigerant recovery system.

6) Follow the operation manual to activate the refrigerant recovery system.
(3)
(1)
(4)
(2)
(6)
(5)
(3)
(1)
(2)
AC-00146
L: Low pressure gauge

H: High-pressure gauge
(1) Low pressure valve
(2) Vacuum pump valve
(3) High pressure valve
(4) For low pressure
(5) For vacuum pump
(6) For high pressure
AC-19
Refrigerant Charging Procedure

4. Refrigerant Charging
Procedure
2) Install the low-/high-pressure hoses to the service ports on the vehicle.
A: PROCEDURE
CAUTION:
During operation, be sure to wear safety goggles and protective gloves.
If air is mixed in refrigeration cycle, poor
cooling may result, and also if moisture is
mixed in refrigeration cycle, clogging (freezing)
or rust may result.
Before charging the refrigerant, evacuate the
system using vacuum pump to remove air and
moisture in the system. Moisture can be evaporated and removed easily even at normal temperature, if the system is evacuated using
vacuum pump.
1) Close all valves of the manifold gauge.
(1)
(2)
(3)
H
AC-00147
(1) Low-pressure side service port

(2) High-pressure side service port
(3)
(1)
(3) Close
(4)
(2)
CAUTION:
Be sure that the hoses are securely connected.
3) Connect the center manifold hose of the manifold gauge to the vacuum pump.
4) Operate the vacuum pump, then open the low-/
high-pressure sides of the valve. Next, open the
center manifold hose valve to begin vacuuming.
(6)
(5)
(3)
(1)
(2)
AC-00146
(2)
L: Low pressure gauge

H: High-pressure gauge
(1) Low pressure valve
(1)
(2) Vacuum pump valve

(3) High pressure valve
AC-00148
(4) For low pressure

(5) For vacuum pump
(6) For high pressure
(1) Vacuum pump

(2) Open
CAUTION:
Be sure to evacuate the system using vacuum
pump.
AC-20

5) After 5 minutes of evacuation, when the reading

of the low pressure gauge is 100.0 kPa (750 mmHg, 29.5 inHg) or higher, close the valves on the
center manifold hose and stop the vacuum pump.
6) Keep the status for 5 to 10 minutes after closing
both the low pressure side and high pressure side
valves, then check if there is any change in the low
pressure gauge indicator. When the gauge indicator changes, it is a sign of leakage. Check and repair the connections of the pipe and hose. After
repairing fault, repeat from step 1).
7) If there is a leak, continue vacuuming for another
20 to 30 minutes.
8) Close all the valves and stop the vacuum pump.
9) Following the can tap operation manual to install
it to the refrigerant can.
13) Loosen the center manifold hose connection on

the manifold gauge set (if applicable, press a purge
valve on the manifold gauge) only for a couple of
seconds to allow the air in the center manifold hose
to be bled by the refrigerant pressure.
AC-00216
14) Open the high pressure side valve and the low
pressure side valve on the manifold gauge and fill
the coolant.
(1)
(2)
(1)
(2)
AC-00214
(1) Tap valve

(2) Center manifold hose
AC-00217
10) Disconnect the center manifold hose from the

vacuum pump, and connect the hose to the tap
valve.
11) When a refrigerant recovery container is used,
measure the refrigerant amount in use using a
weight scale. Then, connect with the center manifold hose.
(1)
(2)
AC-00215
(1) Refrigerant recovery container

(2) Weight scale
12) Open the valve on the HFC-134a source.
(1) Open
(2) Open
CAUTION:
When starting the engine and filling, do not
open the high pressure side valve. Always
make sure to fill from the lower pressure side.
15) Close all valves when the gauge indicator
reaches 200 kPa (1,500 mmHg, 59.1 inHg).
16) Using a leak tester, check the system for coolant leaks.
17) After checking for coolant leaks, fill the coolant
to the prescribed level.
18) If the HFC-134a source is empty, close all
valves, close the valve on the can tap, and replace
the empty source with a new part. After replacing
HFC-134a source with a new part, and purging the
air, restart the work.
19) If the filling efficiency of the coolant worsens,
close all valves.
20) Check that the valves on low-/high-pressure
sides are closed. Start the engine with the A/C
switch OFF.
21) To prevent damaging the compressor, turn the
A/C switch ON and OFF several times quickly.
AC-21

22) Set up the vehicle to the following status:

CAUTION:
When starting the engine and filling, do not
open the high pressure side valve. Always
make sure to fill from the lower pressure side.
A/C switch ON
Engine running at 1,500 rpm
Blower speed setting to HI
Temperature setting to MAX COOL
Air inlet setting to RECIRC
Window open
23) Open the low pressure side valve and fill the
coolant to the prescribed level.
24) After filling the coolant, close all valves and remove the hose from the service port.
25) Mount the cap to the service port.
AC-22
Refrigerant Leak Check

5. Refrigerant Leak Check

A: INSPECTION
1) Operate the A/C system for approx. 10 minutes,
and check that the high-side pressure shows at
least 690 kPa (7.03 kg/cm2, 100 psi). Then stop the
engine to start the leak test.
2) Starting from the connection between high-pressure pipe and evaporator, check the system for
leaks along the high-pressure side through the
compressor. The following items must be checked
thoroughly.
3) Check the joint and seam between pressure
switch (triple pressure switch) and high-pressure
pipe.
4) Check the connections between condenser and
pipes, and welded joints on the condenser.
The leak tester may detect the oil on the condenser
fins as a leak.
5) Check the joint between compressor and hoses.
6) Check the machined area of compressor and
other joints on the compressor.
7) Check the compressor shaft seal at the area
near the center of compressor clutch pulley.
Some shaft seals show a slight amount of leakage
about 10 g (0.4 oz) per year. This is not a problem.
8) Starting from the connection between low-pressure pipe and evaporator, check the system for
leakage along the low-pressure side through the
compressor. The following items must be checked
thoroughly.
Connection between 2 parts
Connection between pipe and plate
9) Visually check the rubber area of the flexible

hose for cracks.
Check the entire length of the flexible hose, especially the connection with the metal hose end.
CAUTION:
Carefully check the external surface of hoses
and tubes at approx. 25 mm (0.98 in) per second.
(A)
AC-00036
(A) Flexible hose
10) Disconnect the drain hose from heater case,

and check the hose end for at least 10 seconds.
After the test is finished, reconnect the drain hose.
11) Turn the ignition key to the ON position, and
run the blower at high speed for approx. 1 minute.
Stop the blower to check the ventilation grille on the
instrument panel. While moving the tester closer to
the grille, run the blower for 1 or 2 seconds, then
stop it. Check the grille at that point for at least 10
seconds.
AC-00037
AC-00035
12) Check the valve in the service port.

13) Visually check the rubber seal in the service
port cap.
AC-00038
AC-23
Compressor Oil
6. Compressor Oil
A: PROCEDURE
NOTE:
Before making repairs, conduct the oil return operation to return the compressor oil to the compressor in circulation with the refrigerant.
1) Increase the engine to 1,500 rpm.
3) Turn the temperature control switch to MAX
COOL.
4) Put in RECIRC position.
5) Turn the blower control switch to HI.
6) Leave in this condition for 10 minutes.
B: REPLACEMENT
NOTE:
After replacing the component, add an appropriate amount of compressor oil.
When replacing the compressor, the new compressor will already have the specified amount of
oil in it. Install the new compressor after removing
the same amount of oil that is remaining in the compressor removed.
Replacement parts
Amount of oil replenishment
Evaporator
Approximately 50 cm3 (1.7 US fl oz,

1.8 Imp fl oz)
Condenser

1.1 Imp fl oz)
Hose layout
Receiver drier

0.4 Imp fl oz)
0.4 Imp fl oz)
AC-24
Blower Motor Unit Assembly

7. Blower Motor Unit Assembly
C: INSPECTION
A: REMOVAL
Inspection of auto A/C brushless motor operation.

Connect the motor connector terminal 1 from the
battery to the positive (+) lead and terminals 2 and
5 at the same time to the negative () lead. Make
sure the motor runs smoothly.

3) Loosen the nut to remove support beam stay.
1
2
5
5
AC-00218
1
AC-00244
4) Disconnect the connectors of the blower motor

and intake actuator register.
AC-00219
5) Loosen the bolt and nut to remove blower motor

unit assembly.
AC-00220
B: INSTALLATION
Tightening torque:
Refer to COMPONENT of General Description. <Ref. to AC-5, HEATER COOLING
UNIT, COMPONENT, General Description.>
<Ref. to AC-7, BLOWER MOTOR UNIT, COMPONENT, General Description.>
AC-25
Blower Resistor (Manual A/C Model)

8. Blower Resistor (Manual A/C

Model)
A: REMOVAL
2) Disconnect the blower resistor connector.
3) Loosen the two screws and remove the blower
resistor.
AC-00221
B: INSTALLATION
C: INSPECTION
0.4
0.7
1.5
3
6
MO
MH
ML
L
3
AC-00245
Measure the blower resistor resistance.

Terminal No.
21
Standard
Approximately 0
24
26
Approximately 0.4
Approximately 1.1
23
Approximately 2.6
If NG, replace the blower resistor.
AC-26
Heater Core
9. Heater Core
6) Loosen the screws to remove lower case.
A: REMOVAL
1) Remove the heater and cooling unit. <Ref. to
AC-32, REMOVAL, Heater and Cooling Unit.>
2) Open the heater core pipe cover.
AC-00046
7) Remove the heater core.
AC-00222
3) Loosen the screws to remove the mode actuator.
AC-00223
B: INSTALLATION
AC-00043
4) Loosen the screws to remove the foot duct.
AC-00044
5) Loosen the screws to remove evaporator cover.
AC-00867
AC-27
Control Unit
10.Control Unit
A: REMOVAL
2) For manual A/C, remove the mode cable and air
mix cable from the each link of the heater unit.
3) Remove the console front cover. <Ref. to EI-39,
REMOVAL, Instrument Panel Assembly.>
4) Loosen the four screws on the backside of the
center console panel and remove the control unit.
AC-01463
B: INSTALLATION
AC-28
Compressor
11.Compressor
9) Loosen the bolts and remove the compressor

bracket.
A: INSPECTION
1. MAGNETIC CLUTCH CLEARANCE
Check the clearance of entire circumference
around the drive plate and pulley.
Standard:
0.3 0.6 mm (0.0118 0.0236 in)
2. MAGNETIC CLUTCH OPERATION

1) Disconnect the compressor connector.
2) Connect the battery positive (+) terminal to the
No. 3 terminal of the compressor connector.
AC-00336
AC-00048
10) Loosen the bolts, then remove the bracket from

the compressor.
3) Confirm the magnet clutch engagement.

If NG, replace the compressor.
B: REMOVAL
1) Perform the compressor oil return operation.
<Ref. to AC-24, PROCEDURE, Compressor Oil.>
2) Turn the A/C switch to OFF and stop the engine.
3) Using the refrigerant recovery system, discharge refrigerant. <Ref. to AC-19, PROCEDURE,
Refrigerant Recovery Procedure.>
REMOVAL, V-belt.> <Ref. to ME(H4DOTC)-40,
REMOVAL, V-belt.>
7) Remove the low-pressure hose and high-pressure hose.
AC-00051
C: INSTALLATION
2) Replace the O-rings on low-/high-pressure hoses with new parts, then apply compressor oil.
3) After replacing the compressor, adjust amount of
compressor oil. <Ref. to AC-24, PROCEDURE,
Compressor Oil.>
4) Charge refrigerant. <Ref. to AC-20, PROCEDURE, Refrigerant Charging Procedure.>
Tightening torque:
Refer to COMPONENT of General Description. <Ref. to AC-11, AIR CONDITIONING
<Ref. to AC-12, COMPRESSOR, COMPONENT, General Description.>
AC-00049
8) Disconnect the compressor harness from body

harness.
AC-29
Condenser
12.Condenser
B: INSTALLATION
A: REMOVAL
3) Disconnect the pressure hose and pipe from the
condenser.
CAUTION:
Replace the O-rings on hoses or pipes with new
parts, and then apply compressor oil. Confirm
that lower guide of condenser fits into holes on
radiator panel.
AC-00092
AC-00246
4) Remove the radiator bracket (A).
Tightening torque:
<Ref. to CO(H4SO)-7, RADIATOR AND ELECTRIC FAN, COMPONENT, General Description.>
C: INSPECTION
(A)
AC-00053
5) Remove two bolts. While lifting condenser, pull it

out through space between the radiator and the radiator panel.
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 leakage from the condenser.
If a failure is found, replace the condenser with a
new part.
AC-00091
CAUTION:
Be careful not to damage the radiator fins and
condenser fins. If a damaged fin is found, repair
it using a thin screwdriver.
If the condenser is replaced, add appropriate
amount of compressor oil to the compressor.
<Ref. to AC-24, REPLACEMENT, Compressor
Oil.>
AC-30
Condenser (Sub Fan)

13.Condenser (Sub Fan)

A: REMOVAL
<Ref. to CO(H4SO)-34, REMOVAL, Radiator Main
Fan and Fan Motor.>
B: INSTALLATION
<Ref. to CO(H4SO)-37, INSTALLATION, Radiator
Main Fan and Fan Motor.>
AC-31
Heater and Cooling Unit

14.Heater and Cooling Unit

A: REMOVAL
3) Drain LLC from the radiator.
4) Remove the bolts securing expansion valve and
pipe in engine compartment. Release the heater
hose clamps in engine compartment to disconnect
the hoses.
AC-00870
5) Remove the instrument panel. <Ref. to EI-39,

REMOVAL, Instrument Panel Assembly.>
6) Remove the support beam.
7) Remove the blower motor unit assembly. <Ref.
to AC-25, REMOVAL, Blower Motor Unit Assembly.>
8) Disconnect the servo motor connector.
9) Loosen the bolt and nuts and remove the heater
and cooling unit.
AC-00055
B: INSTALLATION
Tightening torque:
Refer to COMPONENT of General Description. <Ref. to AC-5, HEATER COOLING
AC-32
Evaporator
15.Evaporator
A: REMOVAL
1) Recover the coolant and disconnect the toe
board A/C pipe. <Ref. to AC-19, PROCEDURE,
3) Remove the blower motor unit assembly. <Ref.
to AC-25, REMOVAL, Blower Motor Unit Assembly.>
4) Loosen the screws to remove evaporator cover.
AC-00867
5) Remove the auto A/C hose in the unit.

6) Rotate the evaporator core top portion to the
front of the vehicle and the bottom portion to lay
over into the compartment, then pull out the heater
case to the left side.
7) Loosen the two bolts to remove the expansion
valve.
AC-00868
CAUTION:
If the evaporator is replaced, add an appropriate amount of compressor oil to evaporator.
<Ref. to AC-24, REPLACEMENT, Compressor
Oil.>
B: INSTALLATION
NOTE:
Replace the O-rings on the pipes with new parts,
and then apply compressor oil.
AC-33
Hose and Tube

16.Hose and Tube
B: INSTALLATION
A: REMOVAL
CAUTION:
When disconnecting/connecting hoses, do
not apply an excessive force to them. Confirm
that no torsion and excessive tension is
charged after installing.
Seal the disconnected hose with a plug or vinyl tape to prevent dirt from entering.
Replace the O-rings on the hoses or pipes
with new parts, and then apply compressor oil.
CAUTION:
When disconnecting/connecting hoses, do
not apply an excessive force to them. Confirm
that no torsion and excessive tension is
charged after installing.
Seal the disconnected hose with a plug or vinyl tape to prevent dirt from entering.
3) Remove the evaporator unit attaching bolts (A).
4) Remove the low-pressure hose attaching bolts
(B).
5) Disconnect the low-pressure hose from evaporator unit.
6) Disconnect the low-pressure hose from compressor.
7) Remove the low-pressure hose from vehicle.
8) Remove the high-pressure hose attaching bolts
(C).
9) Disconnect the high-pressure hose from compressor.
10) Disconnect the high-pressure hose from condenser.
11) Remove the high-pressure hose from vehicle.
12) Remove the high-pressure tube attaching bolt
(D).
13) Remove the high-pressure tube from vehicle.
(B)
Tightening torque:
C: INSPECTION
NOTE:
If any cracks, damage, or expansion are found in
the hose, replace it with new parts.
(A)
(C)
(D)
AC-01366
AC-34
Relay and Fuse

17.Relay and Fuse
B: INSPECTION
A: LOCATION
2
5
3
(2)
4
1
(3)
(4)
(1)
3
5
(5)
1
(6)
(a)
(7)
(b)
AC-00093
AC-01386
(a) Relay holder (Turbo model)

(b) Main fuse box
(1) A/C relay (Turbo model)
(2) Main fan relay
(3) Sub fan relay
(4) A/C relay (Non-turbo model)
(1) (2): Continuity exists.

(3) (4): Continuity exists.
(3) (5): Continuity does not exist.
While applying battery voltage to the terminal between (1) and (2), check continuity between (3) and
(5).
If no continuity exists, replace the relay with a new
part.
(5) Fan mode relay

(6) Main fan 30A fuse
(7) Sub fan 30A fuse
AC-35
Pressure Switch (Triple Pressure Switch)

18.Pressure Switch (Triple Pressure Switch)

A: INSPECTION
1) Connect the manifold gauge to the service valve on the high-pressure side.
2) Start the air conditioner, and check the operating pressure of switch by turning the compressor (magnet
clutch) to ON/OFF. Operation of each switch is as follows.
(10)
(5)
(4)
(1)
(11)
(10)
(6)
(7)
(2)
(11)
(10)
(9)
(3)
(8)
(11)
(12)
(13)
(13)
(15)
(14)
AC-01433
(1)
High pressure switch
(2)
(3)
Middle pressure switch

Low pressure switch
(8)
(4)
2,350200 kPa
(242 kg/cm2, 34128 psi)
20630 kPa
(2.10.3 kg/cm2, 304 psi)
(9)
17725 kPa
(1.80.3 kg/cm2, 264 psi)
(5)
2,940200 kPa
(30.02 kg/cm2, 42728 psi)
(6)
1,770100 kPa
(181 kg/cm2, 25614 psi)
(7)
1,370120 kPa
(141 kg/cm2, 19914 psi)
(10)
ON
(11)
(12)
OFF
Operative range of compressor
(13)
(14)
Inoperative range of compressor

Pressure is low
(15)
Pressure is high
NOTE:
High pressure switch turns the compressor (magnet clutch) to OFF when the refrigerant pressure becomes extremely high, in order to prevent the evaporator, air conditioner piping and expansion valve from
getting damaged or frozen.
Middle pressure switch effectively controls the radiator fan output by judging high load/low load in normal
pressure range.
Low pressure switch turns the compressor (magnet clutch) to OFF, judging as low refrigerant level when
the refrigerant pressure becomes extremely low, in order to prevent the possible seizure when the compressor rotates.
AC-36
Ambient Sensor (Auto A/C Model)

19.Ambient Sensor
(Auto A/C Model)
A: REMOVAL
3) Disconnect the ambient sensor connector.
4) Remove the ambient sensor from the radiator
lower panel.
AC-00125
B: INSTALLATION
C: INSPECTION
<Ref. to AC(diag)-30, AMBIENT SENSOR, Diagnostic Procedure for Sensors.>
AC-37
Sunload Sensor (Auto A/C Model)

20.Sunload Sensor
(Auto A/C Model)
A: REMOVAL
2) Disconnect the sunload sensor connector.
AC-00126
CAUTION:
Be careful not to damage the sensors and interior trims when removing.
B: INSTALLATION
C: INSPECTION
<Ref. to AC(diag)-36, SUNLOAD SENSOR, Diagnostic Procedure for Sensors.>
AC-38
In-vehicle Sensor (Auto A/C Model)

21.In-vehicle Sensor
(Auto A/C Model)
A: REMOVAL
3) Remove the in-vehicle sensor from the instrument panel.
AC-01196
4) Disconnect the connector and aspirator hose.
AC-01197
CAUTION:
Be careful not to damage the sensors and interior trims when removing.
B: INSTALLATION
C: INSPECTION
<Ref. to AC(diag)-32, IN-VEHICLE SENSOR, Diagnostic Procedure for Sensors.>
AC-39
Air Vent Grille

22.Air Vent Grille

A: REMOVAL
1. CENTER GRILLE
2) Remove the center console panel. <Ref. to EI39, REMOVAL, Instrument Panel Assembly.>
3) Loosen two screws to remove the center air vent
grille.
AC-00060
2. SIDE GRILLE
Remove the side vent grill by prying four points.
AC-00249
B: INSTALLATION
C: INSPECTION
The direction and amount of air should be adjusted
smoothly.
The adjustment should be maintained in each position.
AC-40
Heater Duct
23.Heater Duct
A: REMOVAL
2) Remove the front seats. <Ref. to SE-7, REMOVAL, Front Seat.>
3) Remove the front side sill cover.
4) Turn over the floor mat and remove the cover of
the part engaging the heater unit, then remove the
heater duct.
B: INSTALLATION
AC-41
Heater Vent Duct

24.Heater Vent Duct

A: REMOVAL
2) Remove the instrument panel. <Ref. to EI-39, REMOVAL, Instrument Panel Assembly.>
3) Remove the screws.
4) Remove the heater vent duct.
AC-00224
B: INSTALLATION
AC-42
A/C Filter
25.A/C Filter
A: REPLACEMENT
3) Remove the A/C filter cover and remove the A/C
filter.
AC-01464
AC-43


A: INSPECTION
Symptom
Repair order
Fuse
Blower motor relay
Blower motor
Does not run.
Wiring harness
Blower motor
Blower motor register (Manual A/C model)
Blower switch
Noise
Blower motor
Refrigerant
Fuse
Air conditioning relay
Does not run.
Wiring harness
Magnet clutch
Compressor
Pressure switch
Compressor
A/C switch
Blower switch
Noise
V-belt
Magnet clutch
Compressor
Fuse
Condenser fan
Does not run.
Sub fan relay

Wiring harness
Noise
Condenser fan motor

Refrigerant
V-belt
Magnet clutch
Compressor
Pressure switch
Blower fan relay, blower motor
A/C switch
Cold air not emitted.
Blower switch
Wiring harness
Heater duct
Heater vent duct
Control unit
Expansion valve
Evaporator
Air mix actuator (Auto A/C), Temperature adjustment cable
(Manual A/C)
Engine coolant
Aspirator hose
Warm air not emitted.
Blower switch
(Manual A/C)
Heater core
AC-44

Symptom
Temperature of air from vents does not change.
Unable to switch blow vents.
Repair order
Wiring harness
(Manual A/C)
Temperature adjustment switch
Wiring harness
Mode actuator (Auto A/C), Mode switch cable (Manual A/C)
MODE switch
Wiring harness
Unable to switch suction vents.
FRESH/RECIRC actuator
FRESH/RECIRC switch
AC-45

AC-46

HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

A: PROCEDURE
1
Step
Check
START INSPECTIONS.
Does the self-diagnosis oper1) Perform the pre-inspection. <Ref. to
ate?
AC(diag)-3, INSPECTION, General Description.>
2) Perform the self-diagnosis. <Ref. to
AC(diag)-9, OPERATION, Diagnostic Chart for
Self-diagnosis.>
IDENTIFY MALFUNCTION PART.
Can the malfunction part be
Identify the malfunction part with self-diagnosis. confirmed?
Yes
Go to step 2.
No
<Ref. to AC(diag)12, A/C OR SELFDIAGNOSIS SYSTEMS DO NOT
OPERATE, Diagnostics for A/C
System Malfunction.>
Go to step 3.
Repair the malfunctioning part in

accordance with
each diagnostic
chart.
CHECK COMPARTMENT TEMPERATURE. Does the compartment temper- Go to step 4.
<Ref. to AC(diag)1) Turn on the A/C switch.
ature change?
16, COMPART2) Turn the temperature control dial at maxiMENT TEMPERAmum cool position.
TURE DOES NOT
3) Check the compartment temperature
CHANGE, OR A/C
change.
SYSTEM DOES
NOT RESPOND
PROMPTLY, Diagnostics for A/C
CHECK A/C SYSTEM RESPONSE.
Does the A/C system respond A/C system is nor- <Ref. to AC(diag)Change the temperature setting, and check the quickly?
mal.
16, COMPARTresponse of A/C system.
MENT TEMPERATURE DOES NOT
CHANGE, OR A/C
SYSTEM DOES
NOT RESPOND
PROMPTLY, Diagnostics for A/C
AC(diag)-2
General Description
2. ASPIRATOR HOSE
A: CAUTION
Doing so may immediately damage the auto A/C
control module.
engine is running.
electronic parts such as auto A/C control module
etc.
3) Before disconnecting the connectors of sensors
and the auto A/C control module, be sure to turn off
the ignition switch.
Otherwise, the auto A/C control module may be
damaged.
4) Every A/C-related part is a precision part. Do not
drop them.
5) The airbag system wiring harness is routed near
the A/C control panel (auto A/C control module)
and junction box.
CAUTION:
The airbag system wiring harnesses and connectors are all yellow in color. Do not use the
electrical test equipment on these circuits.
wiring harness when servicing the A/C control
panel (auto A/C control module) and junction
box.
B: INSPECTION
Before performing the diagnosis, check the following items which may cause problems in the A/C
system.
1. BATTERY

2) Turn the temperature control dial at maximum
hot position.
3) Set the air flow control dial to the DEF position.
4) Turn the fan speed control dial to the maximum
position.
5) Approach a strip of paper in front of the in-vehicle sensor suction port (A) of the auto A/C control
module, and check that air is being sucked into the
port by seeing the paper moving towards the port.
NOTE:
Be careful not to let the paper get sucked into the
port.
Hold the paper approx. 5 mm (0.02 in) away from
port when the suction force is not very strong.
(a)
(a)
(b)
AC-01155
6) If the paper does not move at all, remove the

lower cover <Ref. to AC-28, REMOVAL, Control
Unit.> and check for improper connection of the aspirator hose, lower cover, and heater unit, and fix
them if necessary.
3. REFRIGERANT LINE
Check the connection for A/C line (A) and highpressure pipe.
1) Measure the battery voltage and check electrolyte.
(A)
Standard voltage:
12 V
Specific gravity:
1.260 or more
2) Check the condition of the fuses for A/C system
power supply and other fuses.
3) Check the condition of harness and harness
connector connections.
AC-01409
4. CONTROL LINKAGE
1) Check the state of mode door linkage.
2) Check the state of air mix door linkage.
3) Check the state of FRESH/RECIRC door linkage.
AC(diag)-3
General Description
5. CONTROL SWITCHES
Start the engine and warm-up completely.
1) Inspection using switches
No.
Point to check
Switch operation
Air flow control dial
Fan speed control dial Turn the dial to the right.
FRESH/RECIRC
switch
A/C switch
Auto function
Operate in order from
1).
Defroster Interlock
Function
Turn the dial to the right.
Judgment standard
Outlet opening switches in order to AUTO
VENT BILEVEL HEAT DEF/HEAT
DEF each time the dial is turned.
Fan speeds switch OFF AUTO 1st
2nd 3rd 4th 5th 6th 7th each
time the dial is turned.
Press the FRESH/RECIRC switch.
Inlet opening switches RECIRC FRESH

RECIRC each time the switch is pressed. (The
LED lights for RECIRC.)
Press the FRESH/RECIRC switch for a longer

period of time. (1 second or more)
The LED blinks twice and the system switches

to AUTO.
Turn the A/C switch to ON with the fan speed control dial is set to other than OFF position.
Press the FRESH/RECIRC switch for a longer
period of time. (1 second or more)
1) Set the following dial and switch to AUTO.
FRESH/RECIRC switch
A/C switch
2) Turn the temperature control dial completely to
the left, and set to the maximum cool position.
3) Turn the temperature control dial to the right
slowly up to the maximum warm position.
The LED lights and the compressor operates.

The LED blinks twice and the system switches
to AUTO.
Outlet air temperature: COOL
Fan speed: Max.
Outlet opening: VENT
Inlet opening: RECIRC
Compressor: AUTO
Outlet air temperature: COOL HOT

Fan speed: AUTO
Outlet opening: AUTO
Inlet opening: AUTO
Compressor: AUTO
Outlet air temperature: HOT

Fan speed: Max.
4) Turn the temperature control dial fully to the
Outlet opening: HEAT
right, to the maximum hot position.
Inlet opening: FRESH
Compressor: AUTO
Outlet opening: AUTO
Fan speed: AUTO
Set the air flow control dial to the DEF or the DEF/
Outlet opening: DEF or DEF/HEAT
HEAT position.
Inlet opening: FRESH
Compressor: ON
Press the rear defogger switch.
The LED lights.
2) Inspection of illumination control

No.
1
Point to check
Illumination
Switch operation
Turn the lighting switch ON.
AC(diag)-4
Judgment standard
Illumination comes on. If the LED lights, the
LED will dim.


A: LOCATION
1. ENGINE COMPARTMENT
(4)
(3)
(2)
(1)
(2)
(3)
(1)
(5)
(4)
AC-01368
(1)
A/C compressor
(3)
A/C relay (Turbo model)
(2)
A/C relay (Non-turbo model)
(4)
Pressure switch
AC(diag)-5
(5)
Ambient sensor

2. PASSENGER COMPARTMENT
(3)
(4)
(2)
(5)
(6)
(1)
(7)
(4)
(6)
(1)
(7)
(5)
(3)
AC-01189
(1)
(2)
Mode door actuator

In-vehicle sensor
(3)
Sunload sensor
(4)
(5)

Blower motor
AC(diag)-6
(6)
(7)
Evaporator sensor
Air mix door actuator
Auto A/C Control Module I/O Signal

4. Auto A/C Control Module I/O Signal

10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
To B:
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
To A:
i49
i48
AC-00099
AC(diag)-7
Auto A/C Control Module I/O Signal

Connector &
Terminal No.
B9
B8
B7
Content
Mode door actuator
B6
B5
B4
B3
Sunload sensor
B2
Evaporator sensor
Measuring condition
Switch the outlet opening to VENT DEF.
Switch the outlet opening to DEF VENT.
Switching the air mix door from COOL HOT
Switching the air mix door from HOT COOL
Ignition switch: ON
Ignition switch: OFF, ACC, ON
Ignition switch: ON, With Normal Sunload (No sunload:
5 V)
Ignition switch: ON
Air mix door: COOL position
Air mix door: HOT position
Specified value
*2
*1
Battery voltage
Battery voltage
3V
Less than 5 V
0.5 V
4.5 V
B1
Air mix door actuator PBR signal
B20
B19
Intake door actuator signal
Inlet opening: FRESH (Other positions: 12 V)

Inlet opening: MIX (Other positions: 12 V)
0V
0V
B18
B17
A/C ON signal
Inlet opening: RECIRC (Other positions: 12 V)

A/C: ON (A/C OFF: 0 V)
0V
8 10 V
B16
B15
Blower motor control

Blower fan ON signal
*3
When blower fan is rotating (Not rotating: 12 V)
*3
0V
B13
B12
B11
A7

In-vehicle sensor
Ground
Air mix door actuator PBR specified voltage
When the engine coolant temperature is 49C (120F).
8.9 V
Continuity to chassis ground
Ignition switch: ON
5V
BI-LEVEL, DEF
5V
VENT, HEAT, DEF/HEAT

HEAT, DEF/HEAT, DEF
0V
5V
A5
Mode door actuator position

detection signal
Outlet
opening
A4

detection signal
Outlet
opening
A1
Illumination power supply
A16
Sensor ground circuit
A14
Combination meter (Ambient tem*3

perature signal)
A13

detection signal
Outlet
opening
VENT, BI-LEVEL, HEAT

DEF/HEAT, DEF
5V
0V
A12

detection signal
Outlet
opening
VENT, DEF/HEAT
BI-LEVEL, HEAT, DEF
5V
0V
A10
A/C cut signal
A/C: ON
Pressure switch operated
A9
Illumination ground
VENT, BI-LEVEL
Ignition switch: ON, Light switch: ON
0V
Battery voltage
Ignition switch: ON, Light switch: OFF

0V
0
*3
Battery voltage
0V
0
*1: Shows the battery voltage while the motor is running. When stopped, it will output 0 V, or the pulse signals of the battery voltage.
*2: Shows the battery voltage while the motor is running. When stopped, it shows 0 V.
*3: Unable to measure the voltage because it is a pulse signal.
B: WIRING DIAGRAM
<Ref. to WI-79, WIRING DIAGRAM, Air Conditioning System.>
AC(diag)-8
Diagnostic Chart for Self-diagnosis

5. Diagnostic Chart for Self-diagnosis

A: OPERATION
(2)
(5)
(4)
75
AUTO
65
85
A /C
OFF
PUSH
AUTO
PUSH
(1)
PUSH
(6)
(3)
AC-01413
(1)
Temperature control dial
(3)
(5)
FRESH/RECIRC switch
(2)
A/C switch
(4)
(6)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(10)
(10)
(8)
(9)
AC-01072
(1)
(2)
Normal operation
Set the air flow control dial to the
AUTO position, and the fan speed
control dial to the AUTO position.
Then, turn the ignition switch from
OFF to ON while holding down the
FRESH/RECIRC switch and the
A/C switch.
(3)
(4)
(5)
(6)
Turn the fan speed control dial

switch to the OFF position, or the
ignition switch from ON to OFF.
Self-diagnosis function
(7)
(8)
Press the rear defogger switch.

Sensor check (Step operation)
(9)
Output device operation (Step

operation)
Display check
After completing the display check
(approximately 8 seconds)
(10)
Press the A/C switch.
AC(diag)-9

Step
SET SELF-DIAGNOSIS MODE BY OPERATING CONTROL PANEL.
2) Set the air flow control dial to the AUTO
position.
3) Set the fan speed control dial to the AUTO
position.
4) Turn the ignition switch to ON while pressing
the FRESH/RECIRC switch and the A/C switch.
5) The A/C control panel LED will blink.
CHECK THE LIGHTING OF THE LED.
Check whether the A/C control panel LED
blinks. (Lighting and extinguishing repeated 8
times.)
SENSOR MALFUNCTION CHECK.
1) The A/C switch LED turns off and the sensor
inspection is started, after the LED check is
completed or when the rear defogger switch is
pressed.
2) Switch the air flow control dial to check the
sensors.
3) If there is no problem with the sensors, the
FRESH/RECIRC switch LED will light, regardless of the position of the air flow control dial.
NOTE:
At this time, the rear defogger LED will light if
there are previous failures. For current failures,
it will turn off.
It is possible to judge whether there is an open
or short circuit by using the blinking patterns of
the FRESH/RECIRC switch.
OPERATION CHECK OF ACTUATORS,
COMPRESSOR AND FAN MOTOR.
1) Press the A/C switch. (At this time, the A/C
switch LED illuminates.)
2) Operate the fan speed control dial to check
the operations of each of the actuator, compressor and fan motor.
<Ref. to AC(diag)-11, OPERATING MODE
TABLE, OPERATION, Diagnostic Chart for
Self-diagnosis.>
NOTE:
Switching the fan speed control dial position enables the individual check of each step.
Check
Does the self-diagnosis function operate?
Yes
Go to step 2.
No
<Ref. to AC(diag)12, A/C OR SELFDIAGNOSIS SYSTEMS DO NOT
OPERATE, Diagnostics for A/C
Are all LEDs blinking?
Go to step 3.
Go to step 5.
Does the LED of the FRESH/

RECIRC switch illuminate?
Go to step 4.
Check the relationship of the air flow

control dial position and sensors
using the sensor
check list, and
check/repair sensors that have
failed. <Ref. to
AC(diag)-11, SENSOR CHECK
TABLE, OPERATION, Diagnostic
Chart for Self-diagnosis.>
Do the actuators, compressor,

and fan motor operate according to the operating mode
table? <Ref. to AC(diag)-11,
OPERATING MODE TABLE,
OPERATION, Diagnostic Chart
for Self-diagnosis.>
Either turn the fan

control dial to the
OFF position, or
turn the ignition
switch to the OFF
position to quit the
self-diagnosis
function.
Refer to each of
the diagnostics for
the actuator, compressor and fan
motor to repair the
areas that have
malfunctioned.
<Ref. to AC(diag)12, Diagnostics for
A/C System Malfunction.> <Ref. to
AC(diag)-21, Diagnostic Procedure
for Actuators.>
CHECK POOR CONTACT.
Is there poor contact in the auto Repair the poor
Replace the auto
Check poor contact of auto A/C control module A/C control module connector? contact in the auto A/C control modconnector.
A/C control module ule.
connector.
AC(diag)-10

1. SENSOR CHECK TABLE

NOTE:
When checking the sunload sensor indoor or in the shade, an open circuit might be indicated. Always check
the sunload sensor at a location exposed to direct sunlight.
No.
Target for inspection
Air flow control dial position
1
2
In-vehicle sensor
Ambient sensor
AUTO
VENT
3
4
Evaporator sensor
Sunload sensor *1
B/L
HEAT
5
6
Air mix door actuator PBR

Meter communication
D/H
DEF
*1: For a sunload sensor open circuit, only the current malfunction is displayed. (However, it is possible to display past failures
for short circuits.)
The LED blinking pattern for open circuit failures
(3)
The LED blinking pattern for short circuit failures
(3)
(3)
(1)
(3)
(1)
(2)
(2)
AC-01073
AC-01074
(1) Light ON
(1) Light ON
(2) Light OFF

(3) Approx. 1 sec.
(2) Light OFF

(3) Approx. 0.2 sec.
2. OPERATING MODE TABLE

Step
Fan control dial position

Fan speed (%)
AUTO
24.0
1st
24.0
2nd
34.0
3rd
45.0
4th
42.0
5th
59.0
6th
71.0
7th
100.0
Mode door actuator

VENT
FRE
VENT
REC
VENT
REC
B/L
FRE
HEAT
FRE
HEAT
FRE
D/H
FRE
DEF
FRE
Maximum
cool (0%)
Maximum
cool (0%)
Maximum
cool (0%)
Mid (50%)
Mid (50%)
Maximum
hot (100%)
Maximum
hot (100%)
Maximum
hot (100%)
Compressor
(Magnet clutch)
OFF
ON
ON
ON
ON
ON
ON
ON
AC(diag)-11
Diagnostics for A/C System Malfunction

6. Diagnostics for A/C System Malfunction

A: A/C OR SELF-DIAGNOSIS SYSTEMS DO NOT OPERATE
TROUBLE SYMPTOM:
Set temperature is not indicated on the display, switch LEDs are faulty or switches do not operate.
Self-diagnosis system does not operate.
WIRING DIAGRAM:
F/B No.17
IGNITION
SWITCH
BATTERY
SBF-4
SBF-1
M/B No.2
10
21
B201
11
i40
i49
AUTO A/C CONTROL MODULE
i49
(GRAY)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B201
7 8 9 10 11
1 2 3 4 5 6
12 13 14 15 16 17 18 19 20 21 22 23 24
AC(diag)-12
AC-01372

Step
CHECK FUSE.
2) Remove the fuse No. 2 from main fuse box.
CHECK FUSE.
2) Remove the fuse No. 17 from fuse & relay
box.
CHECK AUTO A/C CONTROL MODULE
POWER CIRCUIT.
1) Pull out the auto A/C control module connector.
2) Measure the voltage between auto A/C control module connector terminal and chassis
ground after turning the ignition switch OFF.
POWER CIRCUIT.
Measure the voltage between auto A/C control
module connector terminal and chassis ground
after turning the ignition switch to the ON position.
GROUND CIRCUIT.
auto A/C control module and chassis ground
after turning the ignition switch to the ON position.
CHECK POOR CONTACT.
Check poor contact of auto A/C control module
connector.
Check
Yes
Replace the fuse.
No
Go to step 2.
Replace the fuse.
Go to step 3.
Go to step 4.
Repair the short

circuit in harness
for power supply
line.
Go to step 5.
Repair the short

circuit in harness
for power supply
line.
Repair the short

circuit in harness
for ground line.
Is there poor contact in the con- Repair the connec- Replace the auto
nector?
tor.
A/C control module.
AC(diag)-13

B: BLOWER FAN DOES NOT ROTATE

TROUBLE SYMPTOM:
Blower motor does not rotate.
Blower motor does not change speeds.
WIRING DIAGRAM:
BATTERY
F/B No.1
SBF-3
SBF-1
F/B No.2
IGNITION
SWITCH
F/B No.17
SBF-4
BLOWER MOTOR
RELAY
2
1
3
4
18
B50
BLOWER MOTOR
1
2
5
22
B202
i41
i49
15
16
B87
(GRAY)
B50
B87
i49
1 2
3 4
1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B202
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
AC-01373
AC(diag)-14

Step
CHECK FUSE.
1) Remove fuse No. 1, 2 and 17 from fuse &
relay box.
CHECK POWER SUPPLY FOR BLOWER
MOTOR.
2) Turn the fan speed control dial to the right.
3) Measure the voltage between blower motor
and chassis ground.
CHECK BLOWER MOTOR RELAY.
2) Remove the blower motor relay.
3) Connect the battery positive (+) terminal to
terminal No. 1 of blower motor connector, and
negative () terminal to terminal No. 3.
4) Measure the resistance between terminals
No. 2 and 4.
Terminals
No. 2 No. 4:
CHECK BLOWER MOTOR.
1) Disconnect the connector from the blower
motor.
2) Connect the battery positive (+) terminal to
terminal No. 1 of the blower motor connector,
and negative () terminal to terminals No. 2 and
5.
3) Make sure the blower motor runs.
CHECK POOR CONTACT.
connector.
Check
Is any of the fuses blown out?
Yes
Replace the fuse.
No
Go to step 2.
Is the voltage 8 V or more (at

normal temperature)?
Go to step 3.
Repair the open

circuit of blower
motor power supply line harness.
Replace the blower

motor relay.
Does the blower motor run?
Replace the blower

motor.
Go to step 5.
nector?
tor.
A/C control module.
AC(diag)-15

C: COMPARTMENT TEMPERATURE DOES NOT CHANGE, OR A/C SYSTEM

DOES NOT RESPOND PROMPTLY
TROUBLE SYMPTOM:
Compartment temperature does not change.
A/C system does not respond quickly.
WIRING DIAGRAM:
Non-turbo model
IGNITION
SWITCH
F27
RELAY HOLDER
F/B No.17
SUB FAN FUSE

30A
BATTERY
SBF-1
SBF-4
4
F/B No.18
1
MAIN FAN FUSE

30A
2
MAIN FAN MOTOR
31
34
32
30
MAIN FAN RELAY

-1
F17
1
9
5
7
8
6
FAN MODE RELAY
M
2
28
25
27
29
SUB FAN RELAY

-2
18
17
15
19
SUB FAN MOTOR

F45
F16
A/C RELAY
B62
PRESSURE SWITCH
1
2
4
3
M
2
B7
COMPRESSOR
1
F24
F2
18
21
24
B202
12
11
10
MAGNET
CLUTCH
B: B135
ECM
B: B135
F24
F16
B7
F17
1 2
1
4
2
F45
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
i49
C: B136
B15
B17
A10
A:
i48
B:
i49
(GRAY)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
A:
F2
C: B136
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
B:
i41
C23
B16
C33
C9
C29
C18
B100
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4
10 11 12 13 14
B202
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
5 6 7 8 9
15 16 17 18 19 20
F27
i48
(GRAY)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
(BLACK)
RELAY HOLDER
5 6 7 10 15 16 17 20 25 26 27 30
18
28
31
11
8
21
9 12 13 14 19 22 23 24 29 32 33 34
35
36
AC-01369
AC(diag)-16

Turbo model
IGNITION
SWITCH
F27
RELAY HOLDER
F/B No.17
SUB FAN FUSE

30A
BATTERY
SBF-1
SBF-4
4
F/B No.18
1
MAIN FAN FUSE

30A
2
MAIN FAN MOTOR
31
34
32
30
MAIN FAN RELAY

-1
F17
1
9
5
7
8
6
FAN MODE RELAY
M
2
28
25
27
29
SUB FAN RELAY

-2
A/C RELAY
10
7
9
11
SUB FAN MOTOR
F45
3
F16
F9
B62
PRESSURE SWITCH
1
2
4
3
M
2
B7
COMPRESSOR
1
F24
F2
18
21
24
B202
12
11
10
MAGNET
CLUTCH
B: B135
ECM
F24
F16
B: B135
B7
F17
1 2
1
4
2
B15
B17
A10
i41
C24
B16
C33
C9
C29
C18
B100
C: B136
A:
i48
B:

A:
C: B136
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
i49
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
i48
(GRAY)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B:
i49
(GRAY)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
F2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
F9
B202
1
F45
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
3
4
5
6
12
7 8 9
10
11
13
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
F27
(BLACK)
RELAY HOLDER
5 6 7 10 15 16 17 20 25 26 27 30
18
28
31
11
8
21
9 12 13 14 19 22 23 24 29 32 33 34
35
36
AC-01370
AC(diag)-17

Step
CHECK FUSE.
2) Remove the main fan fuse and sub fan fuse
of the main fuse box.
CHECK POWER SUPPLY FOR PRESSURE
SWITCH.
switch.
3) Measure the voltage between pressure
switch harness connector and chassis ground.
SWITCH AND A/C RELAY.
2) Remove the A/C relay of the fuse box.
3) Measure the resistance of the A/C relay and
pressure switch connector.
Non-turbo model
(F27) No. 17 (B7) No. 2:
Turbo model
(F9) No. 7 (B7) No. 2:
CHECK PRESSURE SWITCH.
Measure the resistance between the pressure
switch terminals.
Terminals
No. 1 No. 2:
CHECK A/C CUT SIGNAL CIRCUIT.
1) Disconnect the connector from the auto A/C
control module.
2) Measure the resistance between the auto A/
C control module and the pressure switch connector.
(i48) No. 10 (B7) No. 2:
CHECK A/C ON SIGNAL CIRCUIT.
and the auto A/C control module connector.
Non-turbo model
(B136) No. 23 (i49) No. 17:
Turbo model
(B136) No. 24 (i49) No. 17:
CHECK A/C RELAY.
1) Remove the A/C relay of the fuse box.
2) Check the A/C relay. <Ref. to AC-35,
INSPECTION, Relay and Fuse.>
Check
Yes
Replace the fuse.
No
Go to step 2.
Go to step 3.
Repair the open

circuit in harness
of pressure switch
Repair the open

A/C relay and pressure switch.
Replace the pressure switch.
Repair the open

circuit of the harness between auto
A/C control module
and pressure
switch.
Repair the open

A/C control module
and ECM.
Does the relay operate normally?
Replace the A/C

relay.
AC(diag)-18
Go to step 8.

10
11
12
13
14
Step
CHECK POWER SUPPLY TO MAGNET
CLUTCH OF A/C COMPRESSOR.
1) Turn the ignition switch to OFF, and connect
the A/C relay and all disconnected connectors.
2) Start the engine and turn the A/C switch ON.
3) Turn the temperature control dial at maximum cool position.
4) Measure the voltage between magnet
clutch connector and chassis ground.
CHECK MAIN FAN MOTOR OPERATION.
3) Check the operation of the main fan motor.
CHECK POWER SUPPLY TO MAIN FAN MOTOR.
CAUTION:
Be careful not to overheat the engine during
repair.
2) Disconnect the connector from the main fan
motor.
3) Start the engine, and warm it up until engine
coolant temperature increases over 100C
(212F).
to ON.
5) Measure the voltage between main fan
motor connector and chassis ground.
CHECK MAIN FAN MOTOR GROUND CIRCUIT.
2) Measure the resistance between main fan
motor connector and chassis ground.
CHECK MAIN FAN MOTOR.
Connect the positive terminal (+) of the battery
to No. 1 terminal of the main fan motor connector, and the negative () terminal to No. 2 terminal. Check that the main fan motor is running.
CHECK POOR CONTACT OF THE MAIN FAN
MOTOR CONNECTOR.
Check poor contact of main fan motor connector.
CHECK SUB FAN MOTOR OPERATION.
1) Start the engine and turn the A/C switch ON.
2) Check the operation of the sub fan motor.
Check
Yes
Is the voltage 10.5 V or more (at Go to step 9.
No
Repair the open
circuit in harness
of the A/C compressor power circuit.
Does the main fan motor oper- Go to step 14.

ate normally?
Go to step 10.
Go to step 11.
Repair the open

circuit in harness
of main fan motor
Repair the open

circuit in harness
of main fan motor
ground circuit.
Is the main fan motor rotating? Go to step 13.
Replace the main

fan motor with a
new one.
Is there poor contact in the con- Go to step 14.

nector?
Repair the poor

contact of main fan
motor connector.
Does the sub fan motor operate Go to step 19.

normally?
Go to step 15.
AC(diag)-19

15
16
17
18
19
Step
CHECK POWER SUPPLY TO SUB FAN MOTOR.
CAUTION:
Be careful not to overheat the engine during
repair.
motor.
3) Start the engine, and warm it up until engine
coolant temperature increases over 100C
(212F).
to ON.
5) Measure the voltage between sub fan motor
CHECK SUB FAN MOTOR GROUND CIRCUIT.
2) Measure the resistance between the sub
fan motor connector and chassis ground.
CHECK SUB FAN MOTOR.
to No. 1 terminal of the sub fan motor connector,
and the negative () terminal to No. 2 terminal.
Check that the sub fan motor is running.
CHECK POOR CONTACT OF THE SUB FAN
MOTOR CONNECTOR.
Check for poor contact of sub fan motor connector.
CHECK FOR POOR CONTACT OF THE
AUTO A/C CONTROL MODULE CONNECTOR.
connector.
Check
Yes
Go to step 16.
No
Repair the open
circuit in the harness of the sub fan
motor power supply circuit.
Repair the open

circuit in the harness of sub fan
motor ground circuit.
Does the sub fan motor rotate? Go to step 18.
Replace the sub

fan motor with a
new one.

nector?
contact of sub fan
motor connector.
Go to step 19.
nector?
tor.
A/C control module.
AC(diag)-20
Diagnostic Procedure for Actuators

7. Diagnostic Procedure for Actuators

A: INTAKE DOOR ACTUATOR
TROUBLE SYMPTOM:
FRESH/RECIRC mode is not changed.
WIRING DIAGRAM:
IGNITION
SWITCH
BATTERY
i49
AUTO A/C CONTROL

MODULE
19
SBF-1
20
SBF-4
18
F/B No.17
12
13
14
i41
B202
B91
INTAKE
DOOR
ACTUATOR
B91
i49
1 2 3 4
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
(GRAY)
AC(diag)-21
B202
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
AC-01374

Step
CHECK POWER SUPPLY FOR INTAKE
DOOR ACTUATOR.
2) Disconnect the intake door actuator connector.
4) Measure the voltage between intake door
actuator connector and chassis ground.
CHECK HARNESS BETWEEN AUTO A/C
CONTROL MODULE AND INTAKE DOOR
ACTUATOR.
2) Disconnect the auto A/C control module
connector.
3) Measure the resistance between intake
door actuator connector and auto A/C control
module connector.
(i49) No. 18 (B91) No. 2:
(i49) No. 20 (B91) No. 1:
(i49) No. 19 (B91) No. 3:
CHECK OPERATION OF INTAKE DOOR ACTUATOR.
1) Connect the intake door actuator connector.
2) Ground the auto A/C control module connector with a suitable wire.
3) Turn the ignition switch to ON, and check the
operation of intake door actuator.
CHECK OPERATION OF INTAKE DOOR ACTUATOR.
2) Ground the auto A/C control module connector with a suitable wire.
3) Turn the ignition switch to ON, and check the
operation of intake door actuator.
Check
Yes
Go to step 2.
No
Check for open or
short circuit in the
harness between
intake door actuator and fuse.
Repair the open

circuit in harness
between auto A/C
control module and
intake door actuator.
Is the intake door actuator

moved to FRESH?
Go to step 4.
Replace the intake

door actuator.
Is the intake door actuator

moved to RECIRC?
Replace the auto

A/C control module.
Replace the intake

door actuator.
AC(diag)-22

B: MODE DOOR ACTUATOR

TROUBLE SYMPTOM:
Air flow outlet is not changed.
WIRING DIAGRAM:
A13
A4
A16
AUTO A/C
CONTROL MODULE
i49
A12
B8
B:
A5
i48
B9
A:
15
11
10
i41
10
B202
B77
MODE DOOR
ACTUATOR
B77
(BROWN)
1 2 3 4 5 6 7 8 9 10
i48
(GRAY)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
i49
(GRAY)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B202
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
AC-01375
AC(diag)-23

Step
CHECK THE POWER SUPPLY OF THE
AUTO A/C CONTROL MODULE.
2) Set the air flow control dial to the VENT
position.
3) Press the defroster switch and measure the
voltage between the auto A/C control module
and the chassis ground when switching from
VENT to DEF.
CHECK THE POWER SUPPLY OF THE ACTUATOR.
1) Set the air flow control dial to the VENT
position.
2) Press the defroster switch and measure the
voltage between the mode door actuator harness connector terminal and the chassis
ground when switching from VENT to DEF.
CHECK AUTO A/C CONTROL MODULE SIGNALS.
1) Press the defroster switch.
2) Turn the air flow control dial to VENT and
measure the voltage between the auto A/C control module and the chassis ground when
switching from DEF to VENT.
CHECK THE SIGNALS OF THE ACTUATOR.
1) Press the defroster switch.
2) Turn the air flow control dial to the VENT
position and measure the voltage between the
mode door actuator harness connector terminal
and the chassis ground when switching from
DEF to VENT.
CHECK THE ACTUATOR.
2) Disconnect the connector from the mode
door actuator.
3) Connect the positive terminal (+) of the battery to No. 1 terminal of the mode door actuator,
and the negative () terminal to No. 2 terminal.
Check whether the actuator is running.
4) Connect the negative () terminal of the battery to No. 1 and the positive terminal (+) to No.
2 terminal and check whether the actuator is
running.
CHECK AUTO A/C CONTROL MODULE SIGNAL VOLTAGE.
2) Turn the air flow control dial and measure
the voltage between auto A/C control module
harness connector terminal and chassis ground
for each mode.
Check
Yes
Go to step 2.
No
Replace the auto
A/C control module.

Go to step 3.
Repair the open

circuit of harness
between the auto
A/C control module
and mode door
actuator.
Go to step 4.
Replace the auto

A/C control module.

Go to step 5.
Repair the open

circuit of harness
between the auto
A/C control module
and mode door
actuator.
Does the motor operate normally?
Go to step 6.
Replace the mode

door actuator.
Is the voltage approx. 5 V at the Go to step 9.

HEAT, D/H and DEF positions;
and approx. 0 V at the VENT
and BI-LEVEL positions?
AC(diag)-24
Go to step 7.

10
11
Step
CHECK AUTO A/C CONTROL MODULE SIGNAL POWER.
door actuator.
4) Measure the voltage between the mode
door actuator harness connector terminal and
chassis ground.
CONTROL MODULE AND MODE DOOR ACTUATOR.
control module and mode door actuator.
between the auto A/C control module and mode
door actuator.
(i48) No. 4 (B77) No. 5:
for each mode.
door actuator.
door actuator harness connector and chassis
ground.
door actuator.
(i48) No. 12 (B77) No. 6:
(i48) No. 12 (B77) No. 9:
Check
Is the voltage approx. 5 V?
Yes
Go to step 9.
No
Go to step 8.
Is the resistance less than 1 ? Replace the auto

A/C control module.
Repair the open

circuit of harness
between the auto
A/C control module
and mode door
actuator.

VENT position; and approx. 0 V
at the BI-LEVEL, HEAT and
DEF positions?
Go to step 10.
Go to step 11.
Go to step 12.

A/C control module.
AC(diag)-25
Repair the open

circuit of harness
between the auto
A/C control module
and mode door
actuator.

12
13
14
15
16
Step
harness connector and chassis ground for each
mode.
door actuator.
door actuator harness connector terminal and
chassis ground.
door actuator.
(i48) No. 5 (B77) No. 4:
(i48) No. 5 (B77) No. 7:
for each mode.
door actuator.
4) Measure the voltage between mode door
actuator.
Check
Yes
BI-LEVEL and DEF positions;
and approx. 0 V at the VENT,
HEAT and D/H positions?
No
Go to step 13.
Go to step 14.
Go to step 15.

A/C control module.
Repair the open

circuit of harness
between the auto
A/C control module
and mode door
actuator.

VENT, BI-LEVEL and HEAT
positions; and approx. 0 V at
the D/H and DEF positions?
Go to step 16.
Go to step 17.
AC(diag)-26
Go to step 18.

17
18
19
Step
door actuator.
(i48) No. 13 (B77) No. 8:
CHECK ACTUATOR GROUND CIRCUIT.
control module.
door actuator.
(i48) No. 16 (B77) No. 10:
CHECK POOR CONTACT.
connector.
Check
Yes
A/C control module.
No
Repair the open
circuit of harness
between the auto
A/C control module
and mode door
actuator.
Is the resistance less than 1 ? Replace the mode Repair the open
door actuator.
circuit of harness
between the auto
A/C control module
and mode door
actuator.
nector?
tor.
A/C control module.
AC(diag)-27

C: AIR MIX DOOR ACTUATOR
B6
6
A7
B7
AUTO A/C
CONTROL MODULE
A16
i49
B:
B1
i48
A:
TROUBLE SYMPTOM:
Outlet air temperature does not change.
WIRING DIAGRAM:
i65
AIR MIX DOOR
ACTUATOR
i65
1
2
3 4 5 6
A:
i48
(GRAY)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B:
i49
(GRAY)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
AC(diag)-28
AC-01376

Step
CHECK POWER SUPPLY FOR AIR MIX
DOOR ACTUATOR PBR.
2) Disconnect the air mix door actuator connector.
3) Turn the ignition switch and AUTO switch
ON.
4) Measure the voltage between auto A/C control module connector terminals.
(i48) No. 7 (+) (i48) No. 16 ():
DOOR ACTUATOR.
after turning the temperature control dial to
maximum COOL position.
DOOR ACTUATOR.
after turning the temperature control dial to
maximum HOT position.
CONTROL MODULE AND AIR MIX DOOR
ACTUATOR.
1) Turn the A/C and ignition switch to OFF.
2) Disconnect the auto A/C control module
connector.
3) Measure the resistance between auto A/C
control module and air mix door actuator connector.
(i65) No. 1 (i49) No. 1:
(i65) No. 2 (i49) No. 7:
(i65) No. 3 (i48) No. 16:
(i65) No. 4 (i48) No. 7:
(i65) No. 6 (i49) No. 6:
CHECK AIR MIX DOOR ACTUATOR PBR
SIGNAL.
1) Connect the auto A/C control module and
air mix door actuator connector.
2) Turn the ignition switch and AUTO switch
ON.
3) Check the voltage between auto A/C control
module connector terminals while changing the
setting temperature between maximum COOL
and maximum HOT.
(i49) No. 1 (+) (i48) No. 16 ():
CHECK POOR CONTACT.
and connector.
Check
Yes
Go to step 2.
No
Replace the auto
A/C control module.

Go to step 3.
Replace the auto

A/C control module.

Go to step 4.
Replace the auto

A/C control module.
Repair the open

circuit of harness
between auto A/C
control module and
air mix door actuator.
Is the voltage 0.5 (Max. HOT)

4.5 (Max. COOL) V?
Replace the air mix

door actuator.
Go to step 6.
nector?
tor.
A/C control module.
AC(diag)-29
Diagnostic Procedure for Sensors

8. Diagnostic Procedure for Sensors

A: AMBIENT SENSOR
TROUBLE SYMPTOM:
Fan speed is not switched when the fan speed control dial is in AUTO position.
Failure related to the ambient sensor is indicated in self-diagnosis.
WIRING DIAGRAM:
i10
24
25
30
COMBINATION METER
i1
2
1
24
i3
B38
B36
1
2
18
17
B62
F45
F78
19
B202
AMBIENT
SENSOR
14
i41
i48
AUTO A/C
CONTROL MODULE
i10
i48
F78
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
1 2
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
B202
B36
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
F45
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
AC-01371
AC(diag)-30

Step
CONTROL MODULE AND COMBINATION
METER.
2) Disconnect the connector from auto A/C
control module and the combination meter.
the auto A/C control module and combination
meter.
(i10) No. 30 (i48) No. 14:
CHECK AMBIENT SENSOR CIRCUIT.
Check the ambient sensor circuit. <Ref. to IDI-9,
CHECK OUTSIDE TEMPERATURE INDICATOR, INSPECTION, Combination Meter System.>
CHECK POOR CONTACT.
connector.
Check
Yes
No
Repair the open
A/C control module
and combination
meter.
Is the ambient sensor circuit

normal?
Repair the ambient

sensor circuit.
Go to step 3.
nector?
tor.
A/C control module.
AC(diag)-31

B: IN-VEHICLE SENSOR
TROUBLE SYMPTOM:
Blower fan speed, outlet port and inlet port do not change after turning the AUTO switch ON
Failure related to the in-vehicle sensor is indicated in self-diagnosis.
i55
A:
i55
1 2
A:
i48
(GRAY)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
i48
B:
A16
B12
IN-VEHICLE
SENSOR
AUTO A/C
CONTROL
MODULE
i49
B:
i49
(GRAY)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
AC-01377
AC(diag)-32

Step
CHECK IN-VEHICLE SENSOR.
2) Remove the driver side lower cover.
3) Disconnect the connector from in-vehicle
sensor.
terminals of in-vehicle sensor.
Terminals
No. 1 No. 2:
CHECK INPUT SIGNAL FOR IN-VEHICLE
SENSOR.
2) Measure the voltage between in-vehicle
sensor harness connector terminal and chassis
ground.
OUTPUT SIGNAL.
2) Pull out the auto A/C control module.
terminals of auto A/C control module.
(i49) No. 12 (+) (i48) No. 16 ():
CONTROL MODULE AND IN-VEHICLE SENSOR.
control module.
auto A/C control module and in-vehicle sensor.
(i55) No. 2 (i49) No. 12:
CONTROL MODULE AND IN-VEHICLE SENSOR.
auto A/C control module and in-vehicle sensor.
(i55) No. 1 (i48) No. 16:
CHECK POOR CONTACT.
connector.
Check
Yes
Is the resistance approximately Go to step 2.
2.7 k at 20C (68F)?
No
Replace the invehicle sensor.
Go to step 5.
Go to step 3.
Go to step 4.
Go to step 6.
Repair the open

A/C control module
and in-vehicle sensor.
Repair the open

A/C control module
and in-vehicle sensor.
nector?
tor.
A/C control module.
AC(diag)-33

C: EVAPORATOR SENSOR
WIRING DIAGRAM:
B256
EVAPORATOR
SENSOR
15
B202
A:
B256
1
2
3
B202
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
i48
B:
B2
A16
i41
i49
A:
AUTO A/C
CONTROL
MODULE
i48
(GRAY)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B:
i49
(GRAY)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
AC-01378
AC(diag)-34

Step
CHECK EVAPORATOR SENSOR.
3) Disconnect the connector from evaporator
sensor.
terminals of the evaporator sensor.
Terminals
No. 1 No. 3:
CHECK INPUT SIGNAL FOR EVAPORATOR
SENSOR.
2) Measure the voltage between evaporator
sensor harness connector terminal and chassis
ground.
OUTPUT SIGNAL.
2) Pull out the auto A/C control module.
(i49) No. 2 (+) (i48) No. 16 ():
AUTO A/C CONTROL MODULE AND EVAPORATOR SENSOR.
control module.
auto A/C control module and evaporator sensor.
(B256) No. 1 (i49) No. 2:
AUTO A/C CONTROL MODULE AND EVAPORATOR SENSOR.
auto A/C control module and evaporator sensor.
(B256) No. 3 (i48) No. 16:
CHECK POOR CONTACT.
connector.
Check
Yes
Is the resistance approximately Go to step 2.
2.7 k at 20C (68F)?
No
Replace the evaporator sensor.
Go to step 5.
Go to step 3.
Go to step 4.
Go to step 6.
Repair the open

circuit of harness
between auto A/C
control module and
evaporator sensor.
Repair the open

circuit of harness
between auto A/C
control module and
evaporator sensor.
nector?
tor.
A/C control module.
AC(diag)-35

D: SUNLOAD SENSOR
TROUBLE SYMPTOM:
Sensor identifies that sunlight is at maximum. Then, A/C system is controlled to COOL side.
Sensor identifies that sunlight is at minimum. Then, A/C system is controlled to HOT side.
NOTE:
When the sunload sensor is checked indoors or in the shade, an open circuit might be indicated. Always
check the sunload sensor at a location exposed to direct sunlight.
WIRING DIAGRAM:
i51
SUNLOAD
SENSOR
23
22
i3
B38
20
15
B202
A:
i51
i48
B:
i49
B3
A16
i41
AUTO A/C
CONTROL
MODULE
A:
B38
1 2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
i48
(GRAY)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B:
i49
(GRAY)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B202
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
AC-01379
AC(diag)-36

Step
CHECK INPUT VOLTAGE TO SUNLOAD
SENSOR.
2) Measure the input voltage to sunload sensor.
AUTO A/C CONTROL MODULE AND SUNLOAD SENSOR.
control module.
between the auto A/C control module and sunload sensor.
(i51) No. 2 (i49) No. 3:
AUTO A/C CONTROL MODULE AND SUNLOAD SENSOR.
the auto A/C control module and sunload sensor.
(i51) No. 1 (i48) No. 16:
CHECK INPUT VOLTAGE FOR AUTO A/C
CONTROL MODULE.
1) Connect the auto A/C control module connector.
(i49) No. 3 (+) (i48) No. 16 ():
CHECK POOR CONTACT.
connector.
Check
Yes
Go to step 3.
No
Go to step 2.
Repair the harness

between auto A/C
control module and
sunload sensor.
Repair the harness

between auto A/C
control module and
sunload sensor.
Is the voltage approx. 2.5 V?
Replace the sunload sensor.
Go to step 5.
Is there poor contact of the con- Repair the connec- Replace the auto
nector?
tor.
A/C control module.
AC(diag)-37
Diagnostics with Phenomenon

9. Diagnostics with Phenomenon

A: GENERAL DIAGNOSTIC TABLE
Symptom
Problem parts
A/C system fails to operate.
Fuse is blown out.
Fuse
Connector (Poor contact)
Illumination cannot dim.
Fuse
Auto A/C control module
Blower fan does not rotate or fan speed cannot be controlled.
Fuse
Ground
Blower fan motor
Blower fan relay

Mode door actuator
In-vehicle sensor, ambient sensor, evaporator sensor and
sunload sensor
In-vehicle sensor aspirator hose
A/C relay
Compressor (Magnet clutch)
Radiator fan motor
Radiator fan relay
sunload sensor
Unable to switch suction vents.
Unable to switch vents.
The compartment temperature does not rise.

(Warm air does not come out.)
The compartment temperature does not lower.

(Cold air does not come out.)
Compartment temperature is higher or lower than setting temperature.
Compartment temperature does not quickly respond to setting

temperature.
Radiator fan does not rotate during A/C operation.
Fuse
Ground
Blower fan motor
Blower fan relay
A/C relay
Compressor (Magnet clutch)
Evaporator sensor

sunload sensor
sunload sensor
Radiator fan motor
Radiator fan relay
AC(diag)-38
General Description
AIRBAG SYSTEM
A: COMPONENT
1. SRS AIRBAG
(1)
(4)
T3
(2)
T3
(12)
(3)
(2)
T2
T4
(11)
(9)
(10)
(13)
A
(5)
T5
(8)
T2
(6)
A
(12)
(7)
T1
AB-01533
(1)
Combination switch ASSY with roll

connector
(7)
Wiring harness rear

Side airbag module
Wiring harness center

T1: 7.5 (0.8, 5.5)
T2: 7.4 (0.75, 5.4)
(2)
TORX bolt T30
(8)
(9)
(3)
(4)
Airbag module ASSY (Driver)

Airbag module ASSY (Passenger)
(10)
(11)
Wiring harness front

Front sub sensor
T3: 10 (1.0, 7.2)

T4: 20 (2.0, 14.5)
(5)
(6)
Airbag control module

Side airbag sensor
(12)
(13)
Nut
Bolt
T5: 25 (2.5, 18.1)
AB-2
General Description
AIRBAG SYSTEM
2. SEAT POSITION SENSOR
(1)
(2)
AB-01468
(1)
Drivers seat
(2)
Seat position sensor
AB-3
General Description
AIRBAG SYSTEM
B: CAUTION
When servicing a vehicle, be sure to turn the ignition switch to OFF, disconnect the ground cable
from battery, and wait for more than 20 seconds
before starting work.
The airbag system is fitted with a backup power
source. Be careful that the airbag may deploy after
disconnecting the battery ground cable, if you do
not wait for more than 20 seconds before starting
the service of airbag system.
When checking, use a test harness (1). Damage

to connector terminal cause malfunction. Do not directly apply the tester probe to connector terminal
of airbag.
NG
N
G
OK
O
K
(1)
FU-00009
If the airbag warning light illuminates, repair the

vehicle immediately. Be careful that the airbag or
pretensioner may inflate incorrectly, or not inflate in
collision without repair.
If sensors, airbag module, airbag control module,
pretensioner or harness is deformed or damaged,
replace with new parts.
Do not check continuity of the airbag modules for

drivers side, passengers side, or pretensioner.
NG
N
G
NG
NG
AB-01536
AB-01537
AB-01534
When checking the airbag system, be sure to

use a digital circuit tester. Use of an analog circuit
tester may cause the airbag to activate erroneously
due to a minimal current inside tester.
OK
K
NG
N
G O
AB-01535
AB-4
General Description
AIRBAG SYSTEM
Do not drop any parts of the airbag system, subject them to high temperature over 93C (199F), or
let water, oil or grease get on them; the internal
parts may be damaged and reliability greatly lowered.
When airbag control module, front sub sensor,

side airbag sensor and curtain airbag sensor are
removed, do not reuse the bolts and nuts. Always
use new bolts and nuts.
Either of the airbag modules for drivers, passengers and side or the pretensioner must not be disassembled.
NG
NG
NG
NG
AB-01541
The removed front seat with airbag module must

be kept at least 200 mm (8 in) away from walls and
other objects.
(1)
AB-01538
If damage, open circuit or rust is found on airbag

system wiring harness, do not use a soldering
equipment to repair. Replace the faulty harness
with a new genuine part.
AB-00128
(1) 200 mm (8 in) or more
NG
N
G
AB-01539
Do not allow water or oil to come in contact with

the connector terminals. Also, do not touch the connector terminals.
Do not use the airbag or pretensioner parts from

other vehicles. Always replace the defective parts
with new parts.
Never reuse a deployed airbag and pretensioner.
When painting or performing sheet metal work
on the front part of the vehicle, including the front
wheel apron, front fender and front side frame, remove the front sub sensors and wiring harness of
airbag system.
NG
N
G
AB-01540
AB-5
General Description
AIRBAG SYSTEM
When painting or performing sheet metal work

on the side of the vehicle, including the side sill,
center pillar and front and rear doors, remove the
side airbag sensors and wiring harness of the airbag system.
NG
N
G
AB-01542
Do not discard an undeployed airbag module or

pretensioner.
After removing the parts of airbag system, keep
them with the pad facing upward on a dry, clean,
and flat surface away from heat and light sources,
and moisture and dust.
AB-00056
When airbag control module, front sub sensor

and side airbag sensor are removed, do not reuse
the bolts and nuts. Always use new bolts and nuts.
AB-6
General Description
AIRBAG SYSTEM
When storing the removed airbag module, do not place with the pad side facing down. Do not place any
objects on top of the airbag module. Do not stack other airbag modules on top of each other. If the airbag
module pads are in contact with other objects, it may lead to a major accident when the airbag is deployed
unexpectedly.
(1)
OK
NG
NG
(2)
OK
NG
NG
AB-01543
(1)
Drivers airbag module
(2)
Passengers airbag module
C: PREPARATION TOOL
1. GENERAL TOOL
TOOL NAME
TORX
T30
REMARKS
Used for removal/installation of drivers airbag module
AB-7
Airbag Connector
AIRBAG SYSTEM
2. Airbag Connector
2. DRIVERS AIRBAG (BETWEEN AIRBAG

HARNESS AND ROLL CONNECTOR) AND
SIDE AIRBAG
A: PROCEDURE
1. POWER SUPPLY
1) How to disconnect:
(1) With the lock arm (A) pushed in, move the
connector in the direction of arrow.
(1) Push the lock arm (A).
slide lock (B) in the direction of arrow.
(B)
(A)
(A)
AB-00017
AB-01518
CAUTION:
When pulling the slide lock or disconnecting
connector, be sure to hold the connector, not
the harness.
2) How to connect:
Holding the connector (A), and push it in carefully
until a clicking sound is heard.
(3) With the slide lock pulled, release the lock

arm (return to original position) and disconnect
the connector.
CAUTION:
the harness.
(A)
AB-00018
AB-01519
CAUTION:
Be sure to insert the connector in until it is
locked. Then pull it gently to make sure that it is
locked.
2) How to connect:
Holding the connector, push it in securely until a
clicking sound is heard.
CAUTION:
locked.
AB-00019
AB-8
Airbag Connector
AIRBAG SYSTEM
3. DRIVERS AIRBAG MODULE AND PRETENSIONER
4. FRONT SUB-SENSOR AND SIDE AIRBAG SENSOR
(1) Using a flat tip screwdriver, pull the push
lock upward to unlock.
Holding outer part (A), pull it in the direction of arrow.
CAUTION:
the harness.
AB-00478
(2) Pull the connector to disconnect from drivers airbag module assembly or retractor assembly.
AB-00024
2) How to connect:
NOTE:
You cannot connect the connector when the push
lock is in the lock position. Move the push lock to
the release position to connect the connector.
AB-00479
2) How to connect:
Connect the connector in the reverse order of disconnecting. At this time, be sure to insert the push
lock until a clicking sound is heard.
CAUTION:
Do not touch the outer section since outer
side (A) will move back.
locked.
CAUTION:
locked.
Be sure to push the push lock in securely.
AB-00025
AB-00480
AB-9
Airbag Connector
AIRBAG SYSTEM
5. PASSENGERS AIRBAG
(1) Move the slide lock (A) in the direction of arrow.
(A)
AB-00021
(2) With the slide lock pushed, pull it in the direction of arrow and disconnect the connector.
AB-00022
CAUTION:
the harness.
2) How to connect:
CAUTION:
locked.
AB-00023
AB-10
Inspection Locations After a Collision

AIRBAG SYSTEM
3. Inspection Locations After a

Collision
7) Use the Subaru Select Monitor to check whether

the drivers seat position sensor and the front left/
right seat belt buckle switches are operating normally.
A: REPLACEMENT
Replace the following parts when the airbag is deployed.
1. FRONT COLLISION
1) Drivers airbag module
2) Passengers airbag module
3) Drivers seat belt (Pretensioner)
4) Passengers seat belt (Pretensioner)
5) Airbag control module
6) Front sub sensor
7) Roll connector
8) Occupant detection system and seat cushion
pad
2. SIDE COLLISION
1) Airbag control module
2) Side airbag module (operating side seat back)
3) Side airbag sensor (Operating side)
3. INSPECTION OF OTHER PARTS

Check for the following parts, and replace the damaged parts with new parts.
1) Steering wheel and steering shaft
Check the steering shaft for mounting conditions
and deflection of front and rear, upward and downward directions, and deflection of front and rear direction with tilt lever released. (After a collision,
absorbing part of steering shaft may have been operated.)
2) Check the connector of airbag module, pretensioner, etc. for damage, and also check each harness for pinch and connector damage. Replace the
harness as a unit if damage is found.
3) Check the seat cushion frame, backrest, seat rail
and headrest for deformation, distortion, crack, and
installing condition and play.
4) If deformation or cracks are seen in the seat
cushion frame of the passengers seat, replace the
occupant detection system.
5) If there are tears or loosening in the passengers
seat cushion cover, it may interfere with the proper
operation of the occupant detection system. Replace with a new cushion cover.
6) If the seat cushion cover is removed or replaced,
make sure to perform occupant detection system
adjustment after installing the seat. <Ref. to OD(diag)-17, SYSTEM CALIBRATION (REZEROING),
Failure to do so may cause improper activation of
passengers airbag.
B: INSPECTION
If the vehicle is involved in a collision on any side,
even if it is a slight collision, be sure to check the
following systems.
1. DRIVERS AIRBAG MODULE

1) Check for the following, and replace the damaged parts with new parts.
Airbag module is cracked or deformed.
Harness and/or connector is cracked, deformed
or open. Harness wire is exposed.
The module surface is fouled with grease, oil,
water or cleaning solvent.
2) When installing a new drivers airbag module,
check the following. If necessary, install a new airbag module and steering wheel.
The steering wheel is in the way, making it difficult to install the airbag module.
The clearance between the drivers airbag module and steering wheel is not constant.
When steering wheel deformation in axial and
vertical directions exceed limits.
Specification:
Axial deflection A
Less than 6 mm (0.24 in)
Vertical deflection L
Less than 17 mm (0.67 in)
L
A
AB-00028
2. PASSENGERS AIRBAG MODULE

Check for the following, and replace the damaged
parts with new parts.
Airbag module is cracked or deformed.
Mounting bracket is cracked or deformed.
AB-11

AIRBAG SYSTEM
3. SIDE AIRBAG MODULE
6. SIDE AIRBAG SENSOR

Front seat is damaged or deformed.
or open.
Harness wire is exposed.
If the section of vehicle as shown in the figure is

damaged, check the following items and replace
the damaged parts with new parts.
4. AIRBAG CONTROL MODULE

Control unit is cracked or deformed.
Connector is scratched or deformed.
Airbag is deployed.
Side airbag is deployed.
5. FRONT SUB SENSOR

If the section of vehicle as shown in the figure is
damaged, check the following items and replace
the damaged parts with new parts.
AB-00030
Side airbag sensor is cracked or deformed.

Connector is scratched or cracked.
Side airbag is deployed. (operating side)
7. ROLL CONNECTOR
Combination switch or steering roll connector is
cracked or deformed.
AB-00029
Front sub sensor is cracked or deformed.

Connector is scratched or cracked.
Airbag is deployed.
AB-12

AIRBAG SYSTEM
8. STEERING SHAFT
Overall length of steering column should be within specification.
2) After checking the installing condition of passengers seat, perform the system calibration of occupant detection system. <Ref. to OD(diag)-17,
SYSTEM CALIBRATION (REZEROING), OPERATION, Subaru Select Monitor.>
11.BELT TENSION SENSOR
Specification:
Overall length L
808.61.5 mm (31.830.06 in)

Belt tension sensor is scratched, cracked, or deformed.
AB-00717
If necessary, replace it with new part.
9. DRIVERS SEAT
Seat belt buckle switch or seat position sensor
body/bracket is cracked or deformed.
10.PASSENGERS SEAT
1) Check for the following, and replace the damaged parts with new parts.
Seat belt buckle body/bracket is scratched,
Backrest frame for crack or deformation
Headrest for deformation or play
If the seat cushion cover and seat back cover is
scratched or frayed, replace with a new cover and
readjust the system. <Ref. to OD(diag)-17, SYSTEM CALIBRATION (REZEROING), OPERATION, Subaru Select Monitor.>
CAUTION:
If any of the following applies, replace the seat
cushion pad and frame assembly. Do not disassemble.
Cracks or deformation is found in the seat
cushion frame or seat cushion pad.
Scratches, cracks, or deformation is found
on the occupant detection system pressure
sensor hoses, occupant detection control module, or attachment brackets of the control module.
Harness and/or connector is cracked, deformed or open. Harness wire is exposed.
AB-13
Drivers Airbag Module

AIRBAG SYSTEM
4. Drivers Airbag Module
B: INSTALLATION
A: REMOVAL
CAUTION:
Refer to CAUTION of General Description
before handling the airbag module. <Ref. to AB4, CAUTION, General Description.>
To prevent the misconnection, the connector
is colored. Connect the harness side connector
to the same color of module side connector.
CAUTION:
1) Position the front wheels straight ahead. (After
moving a vehicle more than 5 m (16 ft) with front
wheels positioned straight ahead, make sure that
the vehicle moves straight ahead.)
wait for at least 20 seconds before starting work.
4) Using TORX bit T30 (1), remove the two
TORX bit bolts on the side of steering wheel.
CAUTION:
Do not allow harness and connectors to interfere or get tangled up with other parts.
Tightening torque:
Refer to COMPONENT of General Description. <Ref. to AB-2, SRS AIRBAG, COMPONENT, General Description.>
C: INSPECTION
(1)
CC-00018
5) Disconnect the horn harness.

6) Disconnect the airbag connector on the back of
airbag module, and then remove the airbag module. <Ref. to AB-8, PROCEDURE, Airbag Connector.>
CAUTION:
Airbag module, harness, connector and mounting bracket are damaged. <Ref. to AB-11, DRIVERS
AIRBAG
MODULE,
INSPECTION,
Inspection Locations After a Collision.>
AB-00622
7) Refer to CAUTION for handling of a removed

airbag module. <Ref. to AB-4, CAUTION, General
Description.>
AB-14
Passengers Airbag Module

AIRBAG SYSTEM
5. Passengers Airbag Module

A: REMOVAL
CAUTION:
4) Disconnect the airbag connector.
5) Remove the three bolts, and then carefully remove the airbag module.
AB-00590
6) Refer to CAUTION for handling of a removed

airbag module. <Ref. to AB-4, CAUTION, General
Description.>
B: INSTALLATION
CAUTION:
Do not allow harness and connectors to interfere or get tangled up with other parts.
Tightening torque:
C: INSPECTION
CAUTION:
Airbag module, harness, connector and mounting
bracket are damaged. <Ref. to AB-11, PASSENGERS AIRBAG MODULE, INSPECTION, Inspection Locations After a Collision.>
AB-15
Side Airbag Module

AIRBAG SYSTEM
6. Side Airbag Module
7) Remove the side airbag module (A) from backrest frame assembly.
A: REMOVAL
CAUTION:
NOTE:
Remove the passengers side by referring to drivers side.
3) Remove the front seat. <Ref. to SE-7, REMOVAL, Front Seat.>
4) Remove the clip from reverse side of seat cushion assembly and slide rail IN (A), and then remove
the side airbag harness.
(A)
AB-00476
B: INSTALLATION
CAUTION:
Be sure to perform the system calibration for
occupant detection system after passengers
seat installation. <Ref. to OD(diag)-17, SYSTEM
CALIBRATION (REZEROING), OPERATION,
1) Make sure that there is no foreign matter on side
airbag module.
2) Install the side airbag module (A) to backrest
frame assembly.
(A)
AB-00474
5) Remove the backrest cover. <Ref. to SE-9, DISASSEMBLY, Front Seat.>

6) Remove the side airbag harness from backrest
frame assembly.
Tightening torque:
7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
(A)
AB-00452
AB-00945
AB-16
Side Airbag Module

AIRBAG SYSTEM
3) Install the side airbag harness to backrest frame

assembly.
NOTE:
Secure the harness to its original position of seat.
AB-00945
4) Install the backrest cover. <Ref. to SE-16, ASSEMBLY, Front Seat.>

5) Install the side airbag harness to slide rail IN (A),
then secure the connector to the bracket on the
back side of the seat cushion assembly.
C: INSPECTION
CAUTION:
parts with new parts. <Ref. to AB-12, SIDE AIRBAG MODULE, INSPECTION, Inspection Locations After a Collision.>
1) With side collision (when side airbag is deployed)
Side airbag module assembly
Backrest pad assembly
Backrest frame assembly
Backrest cover assembly
2) When any damage is found by visual check
Headrest assembly
Bushing
Slide rail OUT
Slide rail IN
Seat cushion frame assembly (Passengers
side)
Seat hinge cover
Seat lifter lever
Reclining lever
Side airbag harness and connector on body side
3) With side collision (when side airbag is not deployed)
Check the seat and airbag module visually, and
then replace them with new parts if damaged or
cracked.
Specially inspect the damage of airbag module
body, mounting bracket and harness connector.
4) Without side collision (dirt and damage of cover)
Replace the corresponding part with a new part.
(A)
AB-00474
6) Recline the seat or slide it backward and forward, and check there is no contact between the
seat backrest assembly, cushion cover assembly
and side airbag harness.
AB-17
Airbag Control Module

AIRBAG SYSTEM
7. Airbag Control Module

A: REMOVAL
CAUTION:
Do not disassemble the airbag control module.
If the airbag control module is deformed or if
the damage from water is suspected, replace
the airbag control module with a new part.
Do not drop the airbag control module.
After removal, keep the airbag control module on a dry, clean surface away from moisture,
heat and dust.
4) Remove the center console panel. <Ref. to EI39, REMOVAL, Instrument Panel Assembly.>
5) Disconnect the connector from airbag control
module.
6) Remove the four bolts and remove the airbag
control module.
AB-00035
B: INSTALLATION
CAUTION:
Do not reuse the bolts and nuts.
Always use new bolts and nuts.
Be sure to put the water protection cover
over the connector.
Tightening torque:
C: INSPECTION
Control module, connector, and mounting bracket are damaged.
Airbag is deployed.
AB-18
Side Airbag Sensor

AIRBAG SYSTEM
8. Side Airbag Sensor

A: REMOVAL
3) Remove the front outer belt. <Ref. to SB-10,
FRONT OUTER BELT, REMOVAL, Front Seat
Belt.>
4) Detach the side airbag sensor, and then disconnect the airbag connector.
AB-00036
B: INSTALLATION
CAUTION:
Tightening torque:
C: INSPECTION
Bracket connector for side airbag sensor is damaged.
AB-19
Roll Connector
AIRBAG SYSTEM
9. Roll Connector
A: REMOVAL
3) Remove the drivers airbag module. <Ref. to AB14, Drivers Airbag Module.>
5) Remove the steering column cover.
6) Remove the screws, and then remove the roll
connector.
AB-00911
B: INSTALLATION
2) Before installing steering wheel, be sure to adjust the direction of roll connector with steering.
C: INSPECTION
Combination switch and roll connector are
D: ADJUSTMENT
1) Check that front wheels are positioned in straight
ahead direction.
2) Turn the roll connector pin (A) clockwise until it
stops.
3) Turn the roll connector pins (A) approx. 3.25
turns until marks are aligned.
(A)
AB-00594
AB-20
Front Sub Sensor

AIRBAG SYSTEM
10.Front Sub Sensor

A: REMOVAL
3) Remove the front grille and the front grille side.
<Ref. to EI-16, REMOVAL, Front Grille.>
4) Disconnect the connector from front sub sensor.
AB-00040
5) Loosen the nut and remove the front sub sensor.
AB-00116
B: INSTALLATION
CAUTION:
Tightening torque:
C: INSPECTION
Front sub sensor, mounting bracket and connector are damaged.
Airbag is deployed.
AB-21
Front Sub Sensor

AIRBAG SYSTEM
AB-22

AIRBAG SYSTEM (DIAGNOSTICS)

A: PROCEDURE
1
Step
CHECK AIRBAG WARNING LIGHT.
Check
Yes
Does airbag warning light turn Go to step 2.
on?
READ DTC.
Is the normal code being
<Ref. to AB(diag)-29, READ DIAGNOSTIC
detected?
TROUBLE CODE (DTC), OPERATION, Subaru
Select Monitor.>
PERFORM DIAGNOSIS.
Is DTC being displayed?
1) Judge the possible cause from List of Diagnostic Trouble Code <Ref. to AB(diag)-42, List
of Diagnostic Trouble Code (DTC).>.
2) Inspect the DTC using List of Diagnostic
Trouble Code (DTC).
AB(diag)-35, Clear Memory Mode.>
AB(diag)-34, Inspection Mode.>
6) Read any other DTCs displayed.
AB(diag)-2
No
<Ref. to AB(diag)37, Airbag Warning
Light Failure.>Go
to Airbag Warning
Light Failure.
Finish the diagno- Go to step 3.
sis.
Perform the proce- Finish the diagnodure 1) to 5) in step sis.

3.


A: CHECK
Customers name
Date vehicle brought in
Inspectors name
/
Odometer reading
Date Problem Occurred
Weather
Registration No.
km
V.I.N.
miles
Registration Year
Fine
Cloudy
Rainy
Snowy
Others :
Temperature
C (F)
Road Condition
Flat road
Uphill
Downhill
Gravel road
Others :
Vehicle operation
Starting
Idling
Driving
Constant speed
Accelerating
Decelerating
Turning
Others:
Details of problem
Airbag warning light operation

DTC output
Normal (After turning the ignition switch to ON, illuminates for 6 seconds then goes off.)
Remains ON
Light OFF
OK code
DTC:(Code:
)
AB(diag)-3


A: LOCATION
(8)
AB12
(9)
AB20
(11)
AB56
AB28
AB11
(4)
AB15
(20)
AB61
AB59
(13)
(1)
AB27
(6)
(15)
AB4
AB8
B34
AB55
AB3
(3)
AB58
AB50
AB7
AB51
(5)
AB26
(16)
AB29
AB2
(17)
AB9
AB38
(2)
(18)
AB52
(14)
AB37
AB18
B31
AB14
AB13
(7)
AB1
(19)
AB10
(10) (12)
AB19
AB-01545
(1)
(2)
Front sub sensor (RH)

Front sub sensor (LH)
(8)
(9)
Airbag rear harness (RH)

Side airbag sensor (RH)
(15)
Occupant detection control module
(3)
Airbag control module with built-in

safing and electric sensor
(10)
(11)
Side airbag sensor (LH)

Seat belt pretensioner (RH)
(16)
(17)
Buckle switch (LH)

Seat position sensor (LH)
(4)
(5)
Airbag main harness

Roll connector
(12)
(13)
Seat belt pretensioner (LH)

Side airbag inflator (RH)
(18)
(19)
Buckle switch (RH)

Airbag rear harness (LH)
(6)
(7)
Passengers airbag inflator

Drivers airbag inflator
(14)
Side airbag inflator (LH)
(20)
Belt tension sensor (RH)
Connector No.
(AB1)
(AB2)
(AB3)
(AB4)
(AB7)
(AB8)
(AB9)
(AB10)
(AB11)
(AB12)
(AB13)
(AB14)
Pin
Color
8
White
4
Yellow
28
Yellow
4
Yellow
12
Yellow
12
Yellow
2
Yellow
4
Yellow
2
Yellow
4
Yellow
2
Yellow
2
Yellow
Male/Female
Male
Female Female Female Female Female Female Female Female Female Female
Male
Connector No. (AB15)

Pin
2
(AB20)
2
(AB26)
4
(AB27)
4
(AB28)
2
(AB29)
2
(AB37)
2
(AB38)
2
(AB50)
2
(AB51)
2
Color
Yellow Yellow
Black
Black
Male/Female Female Female Female Female
Yellow
Male
Yellow
Male
Yellow
Male
Yellow
Male
Orange Black
Female Female
Yellow
Male
Yellow
Female

Pin
Color
2
Yellow
(AB18)
2
(AB19)
2
(AB55)
(AB56)
(AB58)
(AB59)
(AB61)
2
Black
3
Brown
3
Gray
6
Gray
6
Gray
Male
Female
AB(diag)-23


A: LOCATION
(8)
AB12
(9)
AB20
(11)
AB56
AB28
AB11
(4)
AB15
(20)
AB61
AB59
(13)
(1)
AB27
(6)
(15)
AB4
AB8
B34
AB55
AB3
(3)
AB58
AB50
AB7
AB51
(5)
AB26
(16)
AB29
AB2
(17)
AB9
AB38
(2)
(18)
AB52
(14)
AB37
AB18
B31
AB14
AB13
(7)
AB1
(19)
AB10
(10) (12)
AB19
AB-01545
(1)
(2)
Front sub sensor (RH)

Front sub sensor (LH)
(8)
(9)
Airbag rear harness (RH)

Side airbag sensor (RH)
(15)
(3)
Airbag control module with built-in

safing and electric sensor
(10)
(11)
Side airbag sensor (LH)

Seat belt pretensioner (RH)
(16)
(17)
Buckle switch (LH)

Seat position sensor (LH)
(4)
(5)
Airbag main harness

Roll connector
(12)
(13)
Seat belt pretensioner (LH)

Side airbag inflator (RH)
(18)
(19)
Buckle switch (RH)

Airbag rear harness (LH)
(6)
(7)
Passengers airbag inflator

Drivers airbag inflator
(14)
Side airbag inflator (LH)
(20)
Belt tension sensor (RH)
Connector No.
(AB1)
(AB2)
(AB3)
(AB4)
(AB7)
(AB8)
(AB9)
(AB10)
(AB11)
(AB12)
(AB13)
(AB14)
Pin
Color
8
White
4
Yellow
28
Yellow
4
Yellow
12
Yellow
12
Yellow
2
Yellow
4
Yellow
2
Yellow
4
Yellow
2
Yellow
2
Yellow
Male/Female
Male
Female Female Female Female Female Female Female Female Female Female
Male

Pin
2
(AB20)
2
(AB26)
4
(AB27)
4
(AB28)
2
(AB29)
2
(AB37)
2
(AB38)
2
(AB50)
2
(AB51)
2
Color
Yellow Yellow
Black
Black
Yellow
Male
Yellow
Male
Yellow
Male
Yellow
Male
Orange Black
Female Female
Yellow
Male
Yellow
Female

Pin
Color
2
Yellow
(AB18)
2
(AB19)
2
(AB55)
(AB56)
(AB58)
(AB59)
(AB61)
2
Black
3
Brown
3
Gray
6
Gray
6
Gray
Male
Female
AB(diag)-23
Airbag Control Module I/O Signal

5. Airbag Control Module I/O Signal

(2)
(1)
(3)
6 5 4 3 2 1
6 5 4
3 2 1
17 16 15 14 13 12 11 10 9 8 7
6 5 4 3 2 1
12 11 10 9 8 7
28 27 26 25 24 23 22 21 20 19 18
12 11 10 9 8 7
AB-01085
Terminal numbers in airbag control module connector are shown in the figure.
Airbag warning light illuminates when the connector is removed from airbag control module.
AB(diag)-24
Airbag Control Module I/O Signal

Item
Control module terminal No.

(1) - 12
Data link connector

Combination meter
Common use fuse
(1) - 3
(1) - 6
Passengers airbag module level one
Dedicated fuse
+
(1) - 5
(1) - 10
Passengers airbag module level two
(1) - 11
(1) - 8
Drivers airbag module level one
(1) - 7
(1) - 14
(1) - 13
Drivers airbag module level two
(1) - 16
(1) - 17
Front sub sensor LH
Power supply and communication

GND
(1) - 15
(1) - 26
Front sub sensor RH

GND
(1) - 9
(1) - 20
Ground line (GND)
(1) - 27
(1) - 28
Passengers airbag OFF indicator light

Passengers airbag ON indicator light
(1) - 1
(1) - 18
Seat belt buckle switch LH
(2) - 11
(2) - 8
Seat position sensor LH
(2) - 3
(2) - 4
Seat belt pretensioner LH
(2) - 2
(2) - 1
Side airbag sensor LH

GND
(2) - 7
(2) - 9
(2) - 10
(2) - 12
Side airbag module LH
(2) - 6
(2) - 3
Seat belt pretensioner RH
(3) - 5
(3) - 6
Side airbag sensor RH

GND
(3) - 12
(3) - 10
(3) - 9
(3) - 7
Side airbag module RH
(3) - 1
(3) - 2
(3) - 11
(3) - 8
B: WIRING DIAGRAM
Refer to the WI section wiring diagram. <Ref. to WI-85, WIRING DIAGRAM, Airbag System.>
AB(diag)-25
Airbag Connector
6. Airbag Connector
2. DRIVERS AIRBAG MODULE AND PRETENSIONER
A: PROCEDURE
1. BUCKLE SWITCH AND OCCUPANT DETECTION CONTROL MODULE
(1) Using a flat tip screwdriver, pry the push
lock upward to unlock.
(2) With the slide lock (A) moved, disconnect
the connector.
(A)
AB-00478
(2) Pull the connector to disconnect from drivers airbag module assembly or retractor assembly.
AB-00721
CAUTION:
the harness.
2) How to connect:
AB-00479
2) How to connect:
Connect the connector in the reverse order of disconnecting. At this time, be sure to insert the push
lock until a clicking sound is heard.
(A)
AB-00016
CAUTION:
locked.
Be sure to push the push lock in securely.
CAUTION:
locked.
AB-00480
NOTE:
You cannot connect the connector when the push
lock is in the lock position. Move the push lock to
the release position to connect the connector.
AB(diag)-26
Airbag Connector
3. DRIVERS AIRBAG (BETWEEN AIRBAG

MAIN HARNESS AND ROLL CONNECTOR)
AND PASSENGERS AIRBAG
(1) Push in the slide lock (A) in the direction of
arrow.
4. SIDE AIRBAG
(1) Push the lock arm (A).
slide lock (B) in the direction of arrow.
(B)
(A)
(A)
AB-00017
AB-00722
(2) With the slide lock pushed in, disconnect the

connector.
(3) With the slide lock moved, release the lock

arm (return to original position) and disconnect
the connector.
CAUTION:
the harness.
AB-00022
CAUTION:
the harness.
2) How to connect:
CAUTION:
locked.
AB-00023
AB(diag)-27
AB-00018
Airbag Connector
5. FRONT SUB SENSOR, SIDE AIRBAG

SENSOR AND SEAT POSITION SENSOR
Holding outer part (A), pull it in the direction of arrow.
CAUTION:
When pulling the slide lock, be sure to hold the
connector, not the harness.
AB-00024
2) How to connect:
CAUTION:
Do not touch the outer section since outer
side (A) will move back.
locked.
AB-00025
AB(diag)-28


A: OPERATION
(DTC)
When malfunction of the airbag system occurs, the
DTC stored in airbag control module will be read
out.
AB(diag)-8, SPECIAL TOOL, PREPARATION
TOOL, General Description.>
link connector.
(1) The data link connector is located in the lower portion of the instrument panel (on the drivers side).
EN-00334

connector.
CAUTION:
screen, select the {Airbag System}.
7) Select the [OK] after the {**MY AIRBAG SYSTEM} is displayed.
8) On the Airbag System screen, select the
{DTC Display}.
NOTE:
For details concerning DTCs, refer to List of Diagnostic Trouble Code (DTC). <Ref. to AB(diag)42, List of Diagnostic Trouble Code (DTC).>
AB(diag)-29

2. DISPLAY OF STATUS INFORMATION

Check the operating condition of each sensor in the event of malfunction in the seat belt buckle switch and
seat position sensor, or when the seat belt buckle switch and seat position sensor has been replaced.
2) On the System Selection Menu display screen, select the {Airbag System}.
3) On the Airbag System display screen, select the {Status Data}.
The following table is for support data.
Item
Display Contents

Seat position sensor RH
Front position *9/Rear position *10 /Other *11/Initial Setting *11 / *2

*2

Seat belt buckle switch RH
Belted *3/Unbelted*4 /Other *5/Initial Setting *1 / *6

Passengers airbag status
ON *7/OFF *8 /Initial Setting *1
*1: Displayed when it is initial.

*2: Seat position sensor not supported
*3: Seat belt fastened
*4: Seat belt not fastened
*5: Displayed when data other than belt fastened or not fastened, (such as breakdowns) is entered.
*6: Seat belt buckle switch not supported
*7: Passengers seat airbag operating state
*8: Passengers seat airbag non-operating state
*9: Seat position is at the front end.
*10: Seat position is at the rear end.
*11: Displayed when data other than seat position (forward/rear), is entered (ie. breakdown data)
NOTE:
MANUAL.

Clear the DTC stored in the airbag control module after repairing the airbag system. (After the breakdown is
recovered, the breakdown code for completed recoveries are read out when the next breakdown occurs if the
memory clear work is not performed.)
3) On the {Airbag System} menu screen, select the {Clear Memory}.
4) When the Clear Memory? is shown on the screen, select the [OK].
5) When Done is displayed, close the Subaru Select Monitor.
NOTE:
MANUAL.
AB(diag)-30

B: INSPECTION
1. COMMUNICATION FOR INITIALIZING IMPOSSIBLE
TROUBLE SYMPTOM:
Communication is impossible between the airbag control module and the Subaru Select Monitor.
WIRING DIAGRAM:
SBF-5
SBF-1
BATTERY
SBF-4
F44
B61
IGNITION
SWITCH
DATA LINK
CONNECTOR
16
No.6
No.11
7
B40
B31
AB1
27
28
12
AB3
AIRBAG CONTROL MODULE
AB3
B31
B40
4 5 6
1 2 3
7 8 9 10 11 12 13 14 15 16 17
1
2 3
4 5 6 7 8
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
F44
1 2 3
5 6 7
4
8
18 19 20 21 22 23 24 25 26 27 28
AB-01546
AB(diag)-31

Step
Check
Is the ignition switch ON?
Yes
Go to step 2.
CHECK BATTERY.
Go to step 3.

tery terminal?
Go to step 9.
MUNICATION.
model year displayed on Sub1) Turn the ignition switch to ON.
aru Select Monitor?
Replace the airbag
MUNICATION.
model year displayed on Sub- control module.
aru Select Monitor?
<Ref. to AB-18,
2) Disconnect the battery ground cable, and
Airbag Control
wait more than 20 seconds.
Module.>
3) Disconnect the airbag control module connector.
5) Check whether communication to other systems can be executed normally.
Go to step 7.
CONNECTOR.
2) Disconnect the airbag control module,
ABSCM&H/U, ECM and TCM.
CHECK OUTPUT SIGNAL TO THE AIRBAG Is the voltage less than 1 V?
Go to step 8.
CONTROL MODULE.
1) Turn the ignition switch to ON in the condition of step 6.
2) Measure the voltage between data link connector and chassis ground.
AB(diag)-32
No
Turn the ignition
switch to ON, and
select the airbag
mode using the
Subaru Select
Monitor.
Charge or replace
the battery.
Go to step 4.
Go to step 5.
Go to step 6.
Repair the harness

and connector
data link connector. (Replace the
harness without
repairing the airbag harness.)
Repair the harness
and connector
data link connector. (Replace the
harness without
repairing the airbag harness.)

10
11
Step
Check
CHECK THE HARNESS BETWEEN THE AIR- Is the resistance less than 10
BAG CONTROL MODULE AND DATA LINK ?
CONNECTOR.
1) Turn ignition switch OFF, disconnect the battery ground cable, and wait more than 20 seconds.
2) Disconnect connector (AB3) from airbag
control module.
3) Connect the connector (1R) in the test harness R to connector (AB3).
4) Measure resistance between connector
(4R) in the test harness R and data link connector.
(4R) No. 18 (B40) No. 10:
(2R) in the test harness R and chassis ground.
(2R) No. 1 (+) Chassis ground ():
Yes
Go to step 9.
Repair the harness

between the airbag
control module and
the battery. Or
replace the airbag
main harness
along with the bulkhead harness.
Repair the harness
CHECK BETWEEN THE AIRBAG CONTROL Is the resistance less than 10 Go to step 11.
?
between the airbag
MODULE AND CHASSIS GROUND.
control module and
the chassis
ground. Or replace
the airbag main
harness along with
(2R) No. 10 Chassis ground:
the bulkhead har(2R) No. 11 Chassis ground:
ness.
CHECK POOR CONTACT OF CONNECTOR. Is there poor contact in the con- Repair the connec- Replace the only
tor. (For airbag
trol module power supply,
airbag control
ground circuit and data link con- system connecmodule. <Ref. to
tors, do not repair AB-18, REMOVAL,
nector?
but replace the
Airbag Control
entire harness.)
Module.>
2. WITHOUT DTC
TROUBLE SYMPTOM:
Airbag warning light remains on.
NO TROUBLE CODE will be displayed on the
For detailed operation procedures, refer to Airbag
Warning Light Failure. <Ref. to AB(diag)-37, Airbag Warning Light Failure.>
NOTE:
When the airbag warning light is OFF and NO
TROUBLE CODE is displayed on Subaru Select
Monitor, the system is operating properly.
AB(diag)-33
Go to step 10.
No
Repair the harness
between the airbag
control module and
the data link connector. Or replace
the airbag main
harness along with
the bulkhead harness.
Inspection Mode
8. Inspection Mode
A: PROCEDURE
Recreate the condition by referring to the fault conditions described in the check list.
AB(diag)-34
Clear Memory Mode


A: OPERATION
Clear the memory in the following steps after the
malfunction is repaired.
Subaru Select Monitor. <Ref. to AB(diag)-30,
CLEAR MEMORY MODE, OPERATION, Subaru
Select Monitor.>
AB(diag)-35
Airbag Warning Light Illumination Pattern

10.Airbag Warning Light Illumination Pattern

A: INSPECTION
Turn the ignition switch to ON, and confirm that the
airbag warning light remains on for approx. 6 seconds then turns off afterwards.
(2)
ON
(1)
OFF
(3)
AB-00135
(1) Airbag warning light

(2) Approx. 6 sec.
AB(diag)-36
Airbag Warning Light Failure

11.Airbag Warning Light Failure

A: AIRBAG WARNING LIGHT REMAINS ON
Airbag warning light failure
Airbag control module to airbag warning light circuit is shorted or open.
Grounding circuit is faulty.
Airbag control module is faulty.
Improper connection of (AB1) and (B31)
Improper connection of (AB3) to airbag control module
CAUTION:
Before diagnosing the airbag system, be sure to turn the ignition switch to OFF, disconnect the
ground terminal from battery, and wait more than 20 seconds before starting to work.
When inspecting the airbag main harness, disconnect the airbag module connectors of the drivers
and passengers seats for safety.
WIRING DIAGRAM:
i10
C:
COMBINATION METER
i11
IGNITION SWITCH
No .14
AIRBAG
WARNING
LIGHT
AIRBAG
CIRCUIT
B9
C8
19
B36
i1
28
B10
i3
B38
BATTERY
B:
B31
AB1
E
AB3
AB3
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 28
B31
AIRBAG CONTROL
MODULE
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
1
2 3
4 5 6 7 8
B36
B:
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
C:
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
i10
i11
1 2 3 4 5 6 7 8 9 10
AB-01547
AB(diag)-37

Step
Check
READ DTC.
Is DTC displayed?
Read the DTC. <Ref. to AB(diag)-29, READ
DIAGNOSTIC TROUBLE CODE (DTC),
CHECK POOR CONTACT.
Is there poor contact in the con1) Turn ignition switch OFF, disconnect the bat- nector (AB3)?
tery ground cable, and wait more than 20 seconds.
2) Check that firm contact is secured between
the airbag control module and the connector
(AB3).
CHECK AIRBAG MAIN HARNESS.

1) Remove the instrument panel lower cover,
disconnect the connector (AB26) and (AB2).
2) Disconnect the connectors (AB27) and
(AB4) of the passengers airbag module.
3) Disconnect the connector (AB3) from airbag
control module, and connect the connector (1R)
in the test harness R.
4) Connect the battery ground terminal and
turn the ignition switch to ON.
5) Connect two connectors, (5R) and (6R) in
the test harness R.
NOTE:
After the problem has been eliminated, disconnect connectors (5R) and (6R).
CHECK GROUND CIRCUIT.
control module.
3) Connect the connector (1R) in the test harness R to body harness connector (AB3).
CHECK AIRBAG MAIN HARNESS AND
BULKHEAD HARNESS.
1) Disconnect the connector (5R) and (6R).
(i11) in the test harness R and connector (2R).
(2R) No. 7 (i11) No. 8:
CHECK POOR CONTACT OF CONNECTORS
(AB1) AND (B31).
2) Confirm that firm contact is secured
between connectors (AB1) and (B31).
Does the airbag warning light

go off?
Yes
No
nosis according to
DTC.
Replace the body Go to step 3.
harness along with
airbag main harness or airbag control module, if it is
not eliminated the
poor contact of
connectors. <Ref.
to AB-18, Airbag
Control Module.>
Go to step 4.
Go to step 5.

?
Replace the airbag Repair the chassis

ground circuit.
control module.
<Ref. to AB-18,
Airbag Control
Module.>

?
Go to step 6.
Go to step 7.
Is there poor contact in connec- Repair the bulktors (AB1) and (B31)?
head harness or
replace the airbag
main harness
along with the body
harness.
AB(diag)-38

Step
Check the airbag main harness for abnormalities.
Check
Is anything unusual to airbag
main harness?
AB(diag)-39
Yes
No
Replace the airbag Repair the bulkmain harness
head harness.
along with the bulkhead harness.

B: AIRBAG WARNING LIGHT REMAINS OFF

Blown fuse No. 14 (in fuse box)
Body harness is open.
Airbag warning light failure
Airbag main harness is faulty.
CAUTION:
WIRING DIAGRAM:
i10
C:
COMBINATION METER
i11
IGNITION SWITCH
No .14
B9
AIRBAG
WARNING
LIGHT
AIRBAG
CIRCUIT
19
C8
B36
i1
28
B10
i3
B38
BATTERY
B:
B31
AB1
E
AB3
AB3
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 28
B31
AIRBAG CONTROL
MODULE
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
1
2 3
4 5 6 7 8
B36
B:
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
C:
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
i10
i11
1 2 3 4 5 6 7 8 9 10
AB-01547
AB(diag)-40

Step
Check
Yes
Do the warning lights except for Go to step 2.
Turn the ignition switch to ON, and confirm that the airbag turn on?
warning light embedded in the combination
meter is turned on.
CHECK DTC.
Is DTC displayed?
Read the DTC. <Ref. to AB(diag)-29, READ
CHECK FUSE NO. 14 (IN MAIN FUSE BOX). Is fuse No. 14 (in the main fuse
Remove the fuse No. 14 and perform visual
box) blown out?
inspection.

DTC.
No
Check the combination meter. <Ref.
to IDI-3, Combination Meter System.>
Go to step 3.
Replace the fuse Go to step 4.

No. 14. If fuse No.
14 is blown out
again, go to step 4.
CHECK AIRBAG WARNING LIGHT CIRCUIT Does airbag warning light turn Go to step 5.
Check the combi(IN COMBINATION METER).
on?
nation meter. <Ref.
1) Turn ignition switch OFF, disconnect the batto IDI-10, Combitery ground cable, and wait more than 20 secnation Meter.>
onds.
2) Disconnect the connector (AB1) from (B31).
Does airbag warning light turn Replace the airbag Replace the airbag
1) Turn ignition switch OFF, disconnect the bat- on?
control module.
main harness
tery ground cable, and wait more than 20 sec<Ref. to AB-18,
along with the body
onds.
Airbag Control
harness.
2) Connect the connector (AB1) to (B31).
Module.>
control module.
AB(diag)-41


A: LIST
DTC
Display
Reference
11
Drivers Airbag failure
Airbag main harness circuit is open, shorted or

shorted to ground.
Airbag module harness (drivers side) circuit is
open, shorted or shorted to ground.
Roll connector circuit is open, shorted or shorted to
ground.
Drivers airbag module is faulty.
<Ref. to AB(diag)-46,
DTC 11 DRIVERS AIRBAG FAILURE, Diagnostic Chart with Trouble
Code.>
12
Passengers Airbag failure

shorted to ground.
Airbag module harness (passengers side) circuit is
Passengers airbag module is faulty.
DTC 12 PASSENGERS
AIRBAG FAILURE,
Diagnostic Chart with
Trouble Code.>
15
Code.>
16
21
Airbag ECM failure
Airbag main harness circuit (drivers side) is shorted

to power supply.
Airbag module harness circuit (drivers side) is
shorted to power supply.
Roll connector is shorted to power supply.
Airbag main harness circuit (passengers side) is
Airbag module harness circuit (passengers side) is
22
Front Airbag Firing output
23
Connector to Airbag ECM failure
24
IG1 open
25
IG2 open
Front airbag module and seat belt pretensioner (LH/

RH) are inflated.
DTC 16 PASSENGERS
AIRBAG FAILURE,
Trouble Code.>
DTC 21 AIRBAG ECM
FAILURE, Diagnostic
Chart with Trouble
Code.>
DTC 22 FRONT AIRBAG FIRING OUTPUT,
Trouble Code.>
Improper connection of (AB3), (AB7) and (AB8) to air- <Ref. to AB(diag)-58,

bag control module
DTC 23 CONNECTOR
TO AIRBAG ECM, Diagnostic Chart with Trouble
Code.>

Airbag main harness circuit is open.
Fuse No. 11 (in joint box) is blown.
Airbag rear harness circuit is open.
Airbag rear harness circuit is open.
AB(diag)-42
DTC 24 IG1 OPEN,
Trouble Code.>
DTC 25 IG2 OPEN,
Trouble Code.>

DTC
26
Display
Passengers Airbag Indicator Failure Passengers airbag indicator is faulty.

shorted to ground.
27
ODS Communication error
Communication to the occupant detection control

module is faulty.
Airbag rear harness circuit is open, shorted or
shorted to ground, or shorted to power supply.
Occupant detection harness is faulty.
Occupant detection system is faulty.
Occupant detection sensor is faulty.
Occupant detection control module is faulty.
29
ODS Failure
2A
ODS Calibration error
2B
ODS system wrong parts
Wrong airbag control module is installed.

Wrong occupant detection system is installed.
2C
Belt Tension Sensor failure
Passengers seat belt tension sensor is faulty.

shorted to ground, or shorted to power supply.
31
Front Sub Sensor RH failure
Front sub sensor harness (RH) circuit is shorted.

Front sub sensor harness (RH) circuit is open.
Front sub sensor (RH) is faulty.
32
Front Sub Sensor LH failure
Front sub sensor harness (LH) circuit is shorted.

Front sub sensor harness (LH) circuit is open.
Front sub sensor (LH) is faulty.
33
Front Sub Sensor RH failure
Reference
DTC 26 PASSENGERS
AIRBAG INDICATOR
FAILURE, Diagnostic
Chart with Trouble
Code.>
DTC 27 ODS COMMUNICATION ERROR,
Trouble Code.>
Refer to Occupant
Detection System for
DTC 29. <Ref. to
AB(diag)-66, DTC 29
ODS FAILURE, Diagnostic Chart with Trouble
Code.>
System calibration (Rezeroing) of the occupant detec- Refer to Occupant

tion system was not ended normally.
DTC 2A. <Ref. to
AB(diag)-66, DTC 2A
ODS CALIBRATION
ERROR, Diagnostic
Chart with Trouble
Code.>
AB(diag)-43
Refer to Occupant
DTC 2B. <Ref. to
AB(diag)-66, DTC 2B
ODS SYSTEM WRONG
PARTS, Diagnostic
Chart with Trouble
Code.>
Refer to Occupant
DTC 2C. <Ref. to
AB(diag)-66, DTC 2C
BELT TENSION SENSOR FAILURE, Diagnostic Chart with Trouble
Code.>
DTC 31 FRONT SUB
SENSOR RH FAILURE,
Trouble Code.>
DTC 32 FRONT SUB
SENSOR LH FAILURE,
Trouble Code.>
DTC 33 FRONT SUB
SENSOR RH FAILURE,
Trouble Code.>

DTC
Display
34
Front Sub Sensor LH failure
36
Seat Position Sensor LH Failure
37
Reference
DTC 34 FRONT SUB
SENSOR LH FAILURE,
Trouble Code.>
Drivers seat position sensor is faulty.

shorted to ground.
DTC 36 SEAT POSITION SENSOR LH
FAILURE, Diagnostic
Chart with Trouble
Code.>
Buckle Switch RH Failure
Passengers buckle switch circuit is open, shorted

or shorted to ground.
shorted to ground.
38
Buckle Switch LH Failure
41
Side Airbag RH failure
Drivers buckle switch circuit is open, shorted or

shorted to ground.
shorted to ground.
Side airbag harness (RH) circuit is faulty.
Side airbag module (RH) is faulty.
42
Side Airbag LH failure
Side airbag harness (LH) circuit is faulty.

Side airbag module (LH) is faulty.
Refer to Occupant
DTC 37. <Ref. to
AB(diag)-73, DTC 37
BUCKLE SWITCH RH
FAILURE, Diagnostic
Chart with Trouble
Code.>
DTC 38 BUCKLE
SWITCH LH FAILURE,
Trouble Code.>
DTC 41 SIDE AIRBAG
RH FAILURE, Diagnostic Chart with Trouble
Code.>
DTC 42 SIDE AIRBAG
LH FAILURE, Diagnostic
Chart with Trouble
Code.>
45
Side Airbag RH failure
Side airbag harness (RH) is shorted to power supply.

DTC 45 SIDE AIRBAG
RH FAILURE, Diagnostic Chart with Trouble
Code.>
46
Side Airbag LH failure
Side airbag harness (LH) is shorted to power supply.

DTC 46 SIDE AIRBAG
LH FAILURE, Diagnostic
Chart with Trouble
Code.>
51
Side Airbag Sensor RH failure
Side airbag sensor (RH) is faulty.

Side airbag harness (RH) circuit is faulty.
52
Side Airbag Sensor LH failure
Side airbag sensor (LH) is faulty.

Side airbag harness (LH) circuit is faulty.
53
Side Airbag Sensor RH failure
DTC 51 SIDE AIRBAG
SENSOR RH FAILURE,
Trouble Code.>
DTC 52 SIDE AIRBAG
SENSOR LH FAILURE,
Trouble Code.>
DTC 53 SIDE AIRBAG
SENSOR RH FAILURE,
Trouble Code.>
AB(diag)-44

DTC
Display
54
Side Airbag Sensor LH failure
DTC 54 SIDE AIRBAG
SENSOR LH FAILURE,
Trouble Code.>
55
Side Curtain Airbag Firing output
Side airbag module is deployed.
61
Belt Pretensioner RH failure
62
Belt Pretensioner LH failure
Seat belt pretensioner (RH) circuit is open, shorted

Pretensioner is faulty.
Pretensioner harness is faulty.
Seat belt pretensioner (LH) circuit is open, shorted
DTC 55 SIDE CURTAIN
AIRBAG FIRING OUTPUT, Diagnostic Chart
with Trouble Code.>
DTC 61 BELT PRETENSIONER RH FAILURE,
Trouble Code.>
DTC 62 BELT PRETENSIONER LH FAILURE,
Trouble Code.>
65
Belt Pretensioner RH failure
Seat belt pretensioner (RH) circuit is shorted to

power supply.
DTC 65 BELT PRETENSIONER RH FAILURE,
Trouble Code.>
66
Belt Pretensioner LH failure
Seat belt pretensioner (LH) circuit is shorted to

power supply.
DTC 66 BELT PRETENSIONER LH FAILURE,
Trouble Code.>
71
Code.>
72

shorted to ground.
Airbag module harness (drivers side) circuit is
Roll connector circuit is open, shorted or shorted to
ground.
shorted to ground.
Airbag module harness (passengers side) circuit is
75
Code.>
76
Airbag main harness circuit (drivers side) is shorted

to power supply.
Airbag module harness circuit (drivers side) is
Airbag main harness circuit (passengers side) is
Airbag module harness circuit (passengers side) is
AB(diag)-45
Reference
DTC 72 PASSENGERS
AIRBAG FAILURE,
Trouble Code.>
DTC 76 PASSENGERS
AIRBAG FAILURE,
Trouble Code.>
Diagnostic Chart with Trouble Code

13.Diagnostic Chart with Trouble Code

A: DTC 11 DRIVERS AIRBAG FAILURE
Airbag harness is open, shorted or shorted to ground.
Airbag module harness (drivers side) is open, shorted or shorted to ground.
Roll connector circuit is open, shorted or shorted to ground.
CAUTION:
When inspecting the airbag main harness, disconnect the drivers airbag module and passengers
airbag module connectors for safety.
NOTE:
Before diagnosing, prepare the two airbag resistors (98299PA040).
WIRING DIAGRAM:
17
16
13
14
AB3
1
2
3
4
AB2
AB26
STEERING
ROLL CONNECTOR
AB38
1
2
1
2
AB37
AIRBAG MODULE
(DRIVER SIDE)
AB2
AB3
1 2 3 4
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
AB37
AB38
1 2
1 2
18 19 20 21 22 23 24 25 26 27 28
AB-01456
AB(diag)-46

Step
Check for poor contact of the connectors
between the airbag control module and the
drivers airbag module.
CHECK DRIVERS AIRBAG MODULE.
2) Remove the drivers airbag module.
3) Connect connector (1N) in the test harness
N to the connector (AB38).
4) Connect the airbag resistor to the connector
(2N) in the test harness N.
5) Connect the connector (1Q) in the test harness Q to connector (AB37).
(2Q) in the test harness Q.
CHECK ROLL CONNECTOR.
2) Disconnect the test harness N from connector (AB38).
3) Disconnect the test harness Q from connector (AB37).
disconnect the connector (AB26) from (AB2).
5) Connect the connector (1P) in the test harness P to connector (AB2).
6) Connect the airbag resistor to the connectors (2P) and (3P) in the test harness P.
CHECK AIRBAG MAIN HARNESS (DRIVERS AIRBAG HARNESS).
2) Disconnect the airbag resistor from the connectors (2P) and (3P) in the test harness P.
(AB27) from the passengers airbag module.
(2R) in the test harness R and connector (2P)
and (3P) in the test harness P.
(2R) No. 2 (2P) No. 1:
(2R) No. 4 (2P) No. 2:
(2R) No. 8 (3P) No. 3:
(2R) No. 12 (3P) No. 4:
Check
Yes
No
Replace the airbag Go to step 2.
harness.

illuminate for 6 seconds then
turn off?
Replace the
Go to step 3.
drivers airbag
module. <Ref. to
AB-14, Drivers Airbag Module.>

turn off?
Go to step 4.
Replace the roll
connector. <Ref. to
AB-20, Roll Connector.>

?
Go to step 5.
AB(diag)-47
Replace the airbag

main harness
along with the body
harness.

Step
Measure resistance between connector (2R)
terminals in the test harness R.
(2R) No. 2 (2R) No. 4:
(2R) No. 8 (2R) No. 12:
CHECK AIRBAG CONTROL MODULE.
4) Read the DTC.
Check
more?
Yes
Go to step 6.

control module.
<Ref. to AB-18,
Airbag Control
Module.>
Check DTC using Finish the diagnoList of Diagnostic sis.
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
AB(diag)-48
No
Replace the airbag
main harness
along with the body
harness.

B: DTC 12 PASSENGERS AIRBAG FAILURE

Airbag module harness (passengers side) is open, shorted or shorted to ground.
CAUTION:
NOTE:
WIRING DIAGRAM:
7
8
10
11
AB3
1
2
4
3
AB4
INFLATOR
(PASSENGER SIDE)
AB3
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
AB4
1 2 3 4
18 19 20 21 22 23 24 25 26 27 28
AB-00621
AB(diag)-49

Step
between the airbag control module and the passengers airbag module.
CHECK PASSENGERS AIRBAG MODULE.
2) Disconnect the connectors (AB27) from
3) Connect connector (1P) in the test harness
P to connector (AB4).
CHECK AIRBAG MAIN HARNESS (PASSENGERS AIRBAG HARNESS).
(2R) No. 3 (2P) No. 1:
(2R) No. 5 (2P) No. 2:
(2R) No. 9 (3P) No. 3:
(2R) No. 13 (3P) No. 4:
Measure resistance between connector (2R) in
the test harness R and chassis ground.
(2R) No. 3 (2R) No. 5:
(2R) No. 9 (2R) No. 13:
4) Read the DTC.
Check
Yes
No
harness.

turn off?
Replace the passengers airbag

module. <Ref. to
AB-15, Passengers Airbag Module.>
Go to step 3.

?
Go to step 4.
Replace the airbag

main harness
along with the body
harness.
more?
Go to step 5.
Replace the airbag

main harness
along with the body
harness.

control module.
<Ref. to AB-18,
Airbag Control
Module.>
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
AB(diag)-50

C: DTC 15 DRIVERS AIRBAG FAILURE

Airbag harness (drivers side) is shorted to power supply.
Airbag module harness (drivers side) is shorted to power supply.
CAUTION:
NOTE:
WIRING DIAGRAM:
17
16
13
14
AB3
1
2
3
4
AB2
AB26
STEERING
ROLL CONNECTOR
AB38
1
2
1
2
AB37
AIRBAG MODULE
(DRIVER SIDE)
AB2
AB3
1 2 3 4
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
AB37
AB38
1 2
1 2
18 19 20 21 22 23 24 25 26 27 28
AB-01456
AB(diag)-51

Step
3) Connect the connector (AB38) to the connector (1N) in the test harness N.
turn the ignition switch to ON. (engine OFF)
Check
Yes
No
harness.

turn off?
Replace the
Go to step 3.
drivers airbag
module. <Ref. to

turn off?
Go to step 4.
Replace the roll
connector. <Ref. to
Go to step 5.
AB(diag)-52
Replace the airbag

main harness
along with the body
harness.

Step
4) Read the DTC.
Check
AB(diag)-53
Yes
No
control module.
<Ref. to AB-18,
Airbag Control
Module.>
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List

D: DTC 16 PASSENGERS AIRBAG FAILURE

Airbag harness (Passengers side) is shorted to power supply.
Airbag module harness (passengers side) is shorted to power supply.
CAUTION:
NOTE:
WIRING DIAGRAM:
7
8
10
11
AB3
1
2
4
3
AB4
INFLATOR
(PASSENGER SIDE)
AB3
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
AB4
1 2 3 4
18 19 20 21 22 23 24 25 26 27 28
AB-00621
AB(diag)-54

Step
4) Read the DTC.
Check
Yes
No
harness along with
the body harness.

turn off?

module. <Ref. to
Go to step 3.
Go to step 4.
Replace the airbag

main harness
along with the body
harness.

control module.
<Ref. to AB-18,
Airbag Control
Module.>
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
AB(diag)-55

E: DTC 21 AIRBAG ECM FAILURE

CAUTION:
When replacing the airbag module, seat belt pretensioner, roll connector, control module and sensor, reconnect each part and check that the warning light operates properly.
1
Step
Check
CHECK WHETHER DTC 21 IS INDICATED. Is DTC 21 displayed on Subaru
1) Read the DTC. <Ref. to AB(diag)-29, READ Select Monitor?
3) Read the DTC again.
AB(diag)-56
Yes
No
Replace the airbag Temporary poor
control module.
contact occurs.
<Ref. to AB-18,
Airbag Control
Module.>

F: DTC 22 FRONT AIRBAG FIRING OUTPUT

WIRING DIAGRAM:
5
6
7
8
10
11
17
16
2
1
13
14
AB8
AB3
AB7
1
2
3
4
AB2
AB26
STEERING ROLL
CONNECTOR
AB4
1
2
4
3
1
2
1
2
AB20
2
1
AB38
AB37
2
1
AB19
AB27
AIRBAG MODULE
(DRIVER SIDE)
PRETENSIONER LH
AB2
AB4
1 2 3 4
AIRBAG MODULE
(PASSENGER SIDE)
AB3
AB7
AB8
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
1 2 3 4 5 6
1 2 3 4 5 6
7 8 9 10 11 12
7 8 9 10 11 12
18 19 20 21 22 23 24 25 26 27 28
PRETENSIONER RH
AB37
AB19
1 2
AB20
AB38
1 2
AB-01552
This code is indicated when the front airbag and pretensioner activates.
Once this code is displayed, the memory cannot be cleared. Therefore replace the following parts.
Airbag Control Module <Ref. to AB-18, Airbag Control Module.>
Drivers airbag module <Ref. to AB-14, Drivers Airbag Module.>
Passengers airbag module <Ref. to AB-15, Passengers Airbag Module.>
Front sub sensor of both sides <Ref. to AB-21, Front Sub Sensor.>
Front seat belt outer with pretensioner of both sides. <Ref. to SB-10, Front Seat Belt.>
Steering roll connector <Ref. to AB-20, Roll Connector.>
Occupant detection system (passengers seat cushion & frame assembly) <Ref. to SE-14, PASSENGERS SEAT, DISASSEMBLY, Front Seat.>
AB(diag)-57

G: DTC 23 CONNECTOR TO AIRBAG ECM

Improper connection of (AB3), (AB7) and (AB8) to airbag control module
CAUTION:
1
Step
Check
CHECK POOR CONTACT OF CONNECTORS Is there rust or damage on the
(AB3), (AB7) AND (AB8).
harness connector and the
1) Turn ignition switch OFF, disconnect the bat- control module connector?
2) Disconnect the connectors (AB3), (AB7)
and (AB8) from the airbag control module.

(AB3), (AB7) AND (AB8).
1) Reconnect the connector securely.
4) Read the DTC.

turn off?
AB(diag)-58
Yes
No
control module.
<Ref. to AB-18,
Airbag Control
Module.>Replace
the airbag main
harness along with
the body harness.
Replace the side
airbag main harness along with the
body harness.
Go to step 3.
Replace the airbag
control module.
<Ref. to AB-18,
Airbag Control
Module.>
control module.
<Ref. to AB-18,
Airbag Control
Module.>
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List

H: DTC 24 IG1 OPEN

Airbag main harness is open.
CAUTION:
WIRING DIAGRAM:
IGNITION SWITCH
No .11
BATTERY
B31
AB1
AB3
B31
1
2 3
4 5 6 7 8
AIRBAG CONTROL
MODULE
AB3
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 28
AB-01548
AB(diag)-59

Step
Check
control module.
CHECK FUSE NO. 11 (IN JOINT BOX).
1) Confirm that the ignition switch is turned to
OFF.
2) Remove and visually check the fuse No. 11
(in the joint box).

4) Read the DTC.
AB(diag)-60
Yes
No
control module.
<Ref. to AB-18,
Airbag Control
Module.>
Replace the fuse

No. 11. If fuse No.
11 is blown out
again, repair the
body harness.
Replace the airbag
main harness
along with the body
harness.
Replace the airbag
control module.
<Ref. to AB-18,
Airbag Control
Module.>
Check DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
Go to step 3.
Go to step 4.

I:
DTC 25 IG2 OPEN

Airbag harness is open.
CAUTION:
WIRING DIAGRAM:
IGNITION SWITCH
BATTERY
No .6
B31
AB1
AB3
AB3
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
AIRBAG CONTROL
MODULE
B31
1
2 3
4 5 6 7 8
18 19 20 21 22 23 24 25 26 27 28
AB-01549
AB(diag)-61

Step
Check
control module.
OFF.
(in the joint box).

4) Read the DTC.
AB(diag)-62
Yes
No
control module.
<Ref. to AB-18,
Airbag Control
Module.>
Replace the fuse

No. 6. If fuse No. 6
is blown out again,
repair the body
harness. Or
replace the airbag
main harness
along with the body
harness.
Replace the airbag
control module.
<Ref. to AB-18,
Airbag Control
Module.>
Check DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
Go to step 3.
Go to step 4.

J: DTC 26 PASSENGERS AIRBAG INDICATOR FAILURE

Passengers airbag indicator is faulty.
CAUTION:
When inspecting the airbag harness, disconnect the airbag module connector and seat belt pretensioner for safety.
WIRING DIAGRAM:
18
AB3
AB1
10
11
B31
B38
i3
i59
CLOCK
AB3
4 5 6
1 2 3
7 8 9 10 11 12 13 14 15 16 17
i59
B31
B38
1 2 3 4 5 6 7 8 9 10
1
2
3 4 5 6
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
18 19 20 21 22 23 24 25 26 27 28
AB-01492
AB(diag)-63

Step
CHECK POOR CONTACT.
2) Confirm that firm contact is secured for the
connector between the airbag control module
and clock.
control module.
NOTE:
If normal, the indicator is not illuminated for both
ON and OFF.
2) Remove the clock and then disconnect the
connector (i59).
4) Measure resistance between connectors
(2R) and (4R) in the test harness R and chassis
ground.
(2R) No. 14 (4R) No. 17:
CHECK AIRBAG HARNESS.
(2R) and (4R) in the test harness R and connector (i59).
(2R) No. 14 (i59) No. 7:
(4R) No. 17 (i59) No. 8:
CHECK BODY HARNESS.
(i59) and chassis ground.
Check
Is there poor contact in any
connector?
Yes
No
harness connector.
Is the passengers airbag indicator turned on?
Go to step 3.
more?
Replace the clock. Repair the bulk<Ref. to IDI-17,

head harness. Or
Clock.>
replace the airbag
main harness
along with the body
harness.

?
Go to step 5.
Replace the clock. Repair the clock

<Ref. to IDI-17,
power supply line.
Clock.>
AB(diag)-64
Go to step 4.
Repair the bulkhead harness. Or

replace the airbag
main harness
along with the body
harness.

K: DTC 27 ODS COMMUNICATION ERROR

Communication to the occupant detection control module is faulty.
Occupant detection harness (seat harness) is faulty.
Airbag rear harness circuit is open, shorted or shorted to ground, or shorted to power supply.
AIRBAG CONTROL
MODULE
11
AB8
AB61
10
AB59
AB62
OCCUPANT DETECTION
CONTROL MODULE
AB8
AB61
AB62
1 2 3 4 5 6
1 2 3
4 5 6
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
7 8 9 10 11 12
AB-01550
AB(diag)-65

Step
control module.
3) Disconnect connector (AB59) from the connector (AB61) on the lower side of passengers
seat.
5) Connect the connector (1AB) in the test harness AB to connector (AB61).
(4R) in the test harness R and connector (2AB)
in the test harness AB.
(4R) No. 12 (2AB) No. 1:
(4R) No. 10 (2AB) No. 2:
CHECK OCCUPANT DETECTION SYSTEM.
1) Connect connector (AB8) to airbag control
module.
2) Connect connector (AB61) and connector
(AB59).
3) Connect the battery ground cable.
4) Check the occupant detection system.
<Ref. to OD(diag)-2, Basic Diagnostic Procedure.>
Check
?
Yes
Go to step 2.
No
Replace the airbag
rear harness (RH)
along with the body
harness.
more?
Go to step 3.
Replace the airbag

rear harness (RH)
along with the body
harness.
Is there a malfunction in the

occupant detection system?
Repair the occuFinish the diagnopant detection sys- sis.

tem. <Ref. to
OD(diag)-2, Basic
Diagnostic Procedure.>
L: DTC 29 ODS FAILURE

NOTE:
Refer to Occupant Detection System for DTC 29. <Ref. to OD(diag)-28, DTC 29 ODS FAILURE, Diagnostic
M: DTC 2A ODS CALIBRATION ERROR

NOTE:
Refer to Occupant Detection System for DTC 2A. <Ref. to OD(diag)-25, DTC 2A ODS CALIBRATION ERROR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
N: DTC 2B ODS SYSTEM WRONG PARTS

NOTE:
Refer to Occupant Detection System for DTC 2B. <Ref. to OD(diag)-25, DTC 2B ODS SYSTEM WRONG
PARTS, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
O: DTC 2C BELT TENSION SENSOR FAILURE

NOTE:
Refer to Occupant Detection System for DTC 2C. <Ref. to OD(diag)-26, DTC 2C BELT TENSION SENSOR FAILURE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AB(diag)-66

P: DTC 31 FRONT SUB SENSOR RH FAILURE

Front sub sensor harness (RH) is shorted, open or shorted to power supply.
Airbag harness is shorted, open or shorted to power supply.
CAUTION:
WIRING DIAGRAM:
AIRBAG
CONTROL MODULE
TWISTED PAIR LINE
20
9
AB3
1
2
AB15
FRONT SUB SENSOR RH
AB15
AB3
1 2
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 28
AB-01465
AB(diag)-67

Step
between the airbag control module and the front
sub sensor (RH).
FRONT SUB SENSOR HARNESS.
control module.
6) Disconnect the front sub sensor (RH), and
connect the connector (1H) in test harness H to
connector (AB15).
(3R) in the test harness R and connector (3H) in
the test harness H.
(3R) No. 7 (3H) No. 5:
(3R) No. 9 (3H) No. 6:
CHECK AIRBAG MAIN HARNESS (FRONT
SUB SENSOR HARNESS RH).

4) Read the DTC.
Check
Yes
No
tor.

?
Go to step 3.
Replace the airbag

main harness
along with the body
harness.
more?
Replace the front

sub sensor (RH).
<Ref. to AB-21,
Front Sub Sensor.>
Replace the airbag
control module if
not operating normally even after
replacing the sensor. <Ref. to AB18, Airbag Control
Module.>
Replace the airbag
control module.
<Ref. to AB-18,
Airbag Control
Module.>
Check DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
Go to step 4.
AB(diag)-68
Go to step 5.

Q: DTC 32 FRONT SUB SENSOR LH FAILURE

Front sub sensor harness (LH) is shorted, open or shorted to power supply.
CAUTION:
WIRING DIAGRAM:
AIRBAG CONTROL
MODULE
TWISTED PAIR LINE
15
26
AB3
1
2
AB13
TWISTED PAIR LINE
AB14
2
1
AB18
FRONT SUB SENSOR LH
AB3
AB13
AB18
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
1 2
1 2
18 19 20 21 22 23 24 25 26 27 28
AB-01551
AB(diag)-69

Step
sub sensor (LH).
SUB SENSOR HARNESS LH).
control module.
6) Disconnect the front sub sensor (LH), and
connector (AB18).
the test harness H.
(3R) No. 6 (3H) No. 5:
(3R) No. 8 (3H) No. 6:

4) Read the DTC.
Check
Yes
No
main harness
along with the body
harness.

?
Go to step 3.
Replace the airbag

main harness
along with the body
harness.
more?
Replace the front

sub sensor (LH).
<Ref. to AB-21,
Front Sub Sensor.>
Replace the airbag
control module if
Module.>
Replace the airbag
control module.
<Ref. to AB-18,
Airbag Control
Module.>
Check DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
Go to step 4.
AB(diag)-70
Go to step 5.

R: DTC 33 FRONT SUB SENSOR RH FAILURE

If the DTC 33 is displayed, the circuit within the front sub sensor (RH) is faulty. Replace the front sub sensor
(RH). <Ref. to AB-21, Front Sub Sensor.>
S: DTC 34 FRONT SUB SENSOR LH FAILURE

If the DTC 34 is displayed, the circuit within the front sub sensor (LH) is faulty. Replace the front sub sensor
(LH). <Ref. to AB-21, Front Sub Sensor.>
AB(diag)-71

T: DTC 36 SEAT POSITION SENSOR LH FAILURE

Airbag rear harness (LH) circuit is open, shorted or shorted to ground.
CAUTION:
WIRING DIAGRAM:
3
4
AB7
2
1
AB52
SEAT POSITION SENSOR LH
AB7
1 2 3 4 5 6
AB52
1 2
7 8 9 10 11 12
AB-01467
AB(diag)-72

Step
CHECK SEAT POSITION SENSOR (LH).
2) Disconnect connector (AB52) from seat
position sensor (LH).
3) Connect connector (2Y) in the test harness
Y to connector (AB52).
CHECK AIRBAG REAR HARNESS (SEAT
POSITION SENSOR HARNESS (LH).
control module.
4) Disconnect the seat position sensor (LH),
and connect the connector (1H) in test harness
H to connector (AB52).
the test harness H.
(3R) No. 1 (3H) No. 5:
(3R) No. 3 (3H) No. 6:
CHECK AIRBAG REAR HARNESS.
4) Read the DTC.
Check
Yes
No
main harness.

turn off?
Replace the seat Go to step 3.

position sensor
(LH) along with the
drivers slide rail
assembly. <Ref. to
SE-7, Front Seat.>

?
Go to step 4.

?

rear harness (LH)
along with the body
harness.

control module.
<Ref. to AB-18,
Airbag Control
Module.>
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
Replace the airbag

rear harness (LH)
along with the body
harness.
U: DTC 37 BUCKLE SWITCH RH FAILURE

NOTE:
Refer to Occupant Detection System for DTC 37. <Ref. to OD(diag)-29, DTC 37 BUCKLE SWITCH RH
FAILURE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AB(diag)-73

V: DTC 38 BUCKLE SWITCH LH FAILURE

Drivers buckle switch circuit is open, shorted or shorted to ground.
CAUTION:
WIRING DIAGRAM:
11
8
AB7
1
2
AB51
BUCKLE SWITCH LH
AB7
AB51
1 2 3 4 5 6
1 2
7 8 9 10 11 12
AB-01469
AB(diag)-74

Step
CHECK SEAT BELT BUCKLE SWITCH (LH).
2) Disconnect the connector (AB51) from
buckle switch (LH).
CHECK AIRBAG REAR HARNESS (BUCKLE
SWITCH HARNESS (LH)).
control module.
4) Disconnect the seat belt buckle switch (LH),
and connect the connector (1D) in test harness
D to connector (AB51).
(4R) in the test harness R and connector (3D) in
the test harness D.
(4R) No. 11 (3D) No. 3:
(4R) No. 9 (3D) No. 4:
4) Read the DTC.
Check
Yes
No
main harness.

turn off?

belt buckle switch
(LH). <Ref. to SB10, Front Seat
Belt.>

?
Go to step 4.

?

rear harness (LH)
along with the body
harness.

control module.
<Ref. to AB-18,
Airbag Control
Module.>
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
AB(diag)-75
Replace the airbag

rear harness (LH)
along with the body
harness.

W: DTC 41 SIDE AIRBAG RH FAILURE

Side airbag harness (RH) is faulty.
CAUTION:
When inspecting the side airbag harness, disconnect the side airbag module connector, and seat
belt pretensioner connector for safety.
WIRING DIAGRAM:
2
1
12
9
7
10
AB8
SIDE AIRBAG
SENSOR RH
AB11
AB12
1 2
1 2 3 4
AB11
2
1
4
3
2
1
AB12
INFLATOR
(SIDE RH)
AB8
1 2 3 4 5 6
7 8 9 10 11 12
AB-01494
AB(diag)-76

Step
between the airbag control module, side airbag
module (RH) and the side airbag sensor (RH).
CHECK SIDE AIRBAG MODULE.
2) Disconnect the connector (AB11) from the
side airbag module (RH), and connect the connector (1F) in test harness F to connector
(AB11).
3) Connect airbag resistor to connector (3F) in
the test harness F.
CHECK SIDE AIRBAG HARNESS (RH).
seat belt pretensioner (RH).
3) Disconnect the airbag resistor from test harness F.
control module.
5) Connect connector (1R) in the test harness
R to the connector (AB8).
(3R) in the test harness R and connector (3F) in
the test harness F.
(3R) No. 18 (3F) No. 4:
(3R) No. 20 (3F) No. 3:
(3R) No. 18 (3R) No. 20:
Measure resistance between the connector
4) Read the DTC.
Check
Yes
No
rear harness (RH)
along with the body
harness.

turn off?

seat along with
side airbag module
(RH). <Ref. to SE7, Front Seat.>

?
Go to step 4.
Replace the side

airbag harness
along with the body
harness.
more?
Go to step 5.
Replace the side

airbag harness
along with the body
harness.
more?
Go to step 6.
Replace the side

airbag harness
along with the body
harness.

control module.
<Ref. to AB-18,
Airbag Control
Module.>
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
AB(diag)-77

X: DTC 42 SIDE AIRBAG LH FAILURE

Side airbag harness (LH) is faulty.
CAUTION:
WIRING DIAGRAM:
7
10
12
9
5
6
AB7
AB9
4
3
2
1
2
1
INFLATOR
(SIDE LH)
AB9
AB10
1 2
1 2 3 4
AB10
SIDE AIRBAG
SENSOR LH
AB7
1 2 3 4 5 6
7 8 9 10 11 12
AB-01495
AB(diag)-78

Step
module (LH) and the side airbag sensor (LH).
side airbag module (LH), and connect the connector (1F) in test harness F to connector
(AB9).
the test harness F.
CHECK SIDE AIRBAG HARNESS (LH).
seat belt pretensioner (LH).
3) Disconnect the airbag resistor from test harness.
control module.
the test harness F.
(3R) No. 12 (3F) No. 3:
(3R) No. 10 (3F) No. 4:
(3R) No. 12 (3R) No. 10:
4) Read the DTC.
Check
Yes
No
rear harness (LH)
along with the body
harness.

turn off?

seat along with
side airbag module
(LH). <Ref. to SE7, Front Seat.>

?
Go to step 4.
Replace the side

airbag harness
along with the body
harness.
more?
Go to step 5.
Replace the side

airbag harness
along with the body
harness.
more?
Go to step 6.
Replace the side

airbag harness
along with the body
harness.

control module.
<Ref. to AB-18,
Airbag Control
Module.>
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
AB(diag)-79

Y: DTC 45 SIDE AIRBAG RH FAILURE

Side airbag harness is shorted to power supply.
CAUTION:
WIRING DIAGRAM:
2
1
12
9
7
10
AB8
SIDE AIRBAG
SENSOR RH
AB11
AB12
1 2
1 2 3 4
AB11
2
1
4
3
2
1
AB12
INFLATOR
(SIDE RH)
AB8
1 2 3 4 5 6
7 8 9 10 11 12
AB-01494
AB(diag)-80

Step
(AB11).
the test harness F.
control module.
4) Read the DTC.
Check
Yes
No
rear harness (RH)
along with the body
harness.

turn off?

seat along with
side airbag module
Go to step 4.

control module.
<Ref. to AB-18,
Airbag Control
Module.>
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
AB(diag)-81
Replace the side

airbag harness
along with the body
harness.

Z: DTC 46 SIDE AIRBAG LH FAILURE

CAUTION:
WIRING DIAGRAM:
7
10
12
9
5
6
AB7
AB9
4
3
2
1
2
1
INFLATOR
(SIDE LH)
AB9
AB10
1 2
1 2 3 4
AB10
SIDE AIRBAG
SENSOR LH
AB7
1 2 3 4 5 6
7 8 9 10 11 12
AB-01495
AB(diag)-82

Step
(AB9).
the test harness F.
control module.
4) Read the DTC.
Check
Yes
No
rear harness (LH)
along with the body
harness.

turn off?

seat along with
side airbag module
Go to step 4.

control module.
<Ref. to AB-18,
Airbag Control
Module.>
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
AB(diag)-83
Replace the side

airbag harness
along with the body
harness.

AA:DTC 51 SIDE AIRBAG SENSOR RH FAILURE

CAUTION:
WIRING DIAGRAM:
2
1
12
9
7
10
AB8
SIDE AIRBAG
SENSOR RH
AB11
AB12
1 2
1 2 3 4
AB11
2
1
4
3
2
1
AB12
INFLATOR
(SIDE RH)
AB8
1 2 3 4 5 6
7 8 9 10 11 12
AB-01494
AB(diag)-84

Step
3) Disconnect connector (AB11) from side airbag module (RH).
control module.
6) Disconnect connector (AB12) from the side
airbag sensor (RH), and connect connector
(2V) in test harness V to connector (AB12).
(4R) in the test harness R and connector (3V) in
the test harness V.
(4R) No. 5 (3V) No. 2:
(4R) No. 6 (3V) No. 4:
(4R) No. 7 (3V) No. 1:
(4R) No. 8 (3V) No. 5:
CHECK SIDE AIRBAG HARNESS.
the test harness R, and the resistance between
connector (4R) in the test harness R and chassis ground.
(4R) No. 5 (4R) No. 7:
(4R) No. 5 (4R) No. 6:
(4R) No. 5 (4R) No. 8:
(4R) No. 6 (4R) No. 7:
(4R) No. 6 (4R) No. 8:
(4R) No. 7 (4R) No. 8:
4) Read the DTC.
Check
Yes
No
rear harness (RH)
along with the body
harness.

?
Go to step 3.
Replace the side

airbag harness
along with the body
harness.
more?
Go to step 4.
Replace the side

airbag harness
along with the body
harness.
Replace the side Go to step 5.

airbag sensor
(RH). <Ref. to AB19, Side Airbag
Sensor.> Replace
the airbag control
module if not operating normally
even after replacing the sensor.
<Ref. to AB-18,
Airbag Control
Module.>
AB(diag)-85

Step
Check
AB(diag)-86
Yes
No
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List

AB:DTC 52 SIDE AIRBAG SENSOR LH FAILURE

CAUTION:
WIRING DIAGRAM:
7
10
12
9
5
6
AB7
AB9
4
3
2
1
2
1
INFLATOR
(SIDE LH)
AB9
AB10
1 2
1 2 3 4
AB10
SIDE AIRBAG
SENSOR LH
AB7
1 2 3 4 5 6
7 8 9 10 11 12
AB-01495
AB(diag)-87

Step
airbag module (LH).
control module.
airbag sensor (LH), and connect connector (2V)
in test harness V to connector (AB10).
the test harness V.
(4R) No. 4 (3V) No. 2:
(4R) No. 3 (3V) No. 4:
(4R) No. 2 (3V) No. 1:
(4R) No. 1 (3V) No. 5:
(4R) No. 4 (4R) No. 3:
(4R) No. 4 (4R) No. 2:
(4R) No. 4 (4R) No. 1:
(4R) No. 3 (4R) No. 2:
(4R) No. 3 (4R) No. 1:
(4R) No. 2 (4R) No. 1:
4) Read the DTC.
Check
Yes
No
rear harness (LH)
along with the body
harness.

?
Go to step 3.
Replace the side

airbag harness
along with the body
harness.
more?
Go to step 4.
Replace the side

airbag harness
along with the body
harness.

airbag sensor
(LH). <Ref. to AB19, Side Airbag
Sensor.> Replace
the airbag control
<Ref. to AB-18,
Airbag Control
Module.>
AB(diag)-88

Step
Check
Yes
No
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
AC:DTC 53 SIDE AIRBAG SENSOR RH FAILURE

If the 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.>
AD:DTC 54 SIDE AIRBAG SENSOR LH FAILURE

If the code 54 is displayed, the circuit within the side airbag sensor (LH) is faulty. Replace the side airbag sensor (LH).
AE:DTC 55 SIDE CURTAIN AIRBAG FIRING OUTPUT

This code is indicated when the side airbag and pretensioner activates.
When this code is displayed, the memory cannot be cleared. Replace the following parts.
Front seat with side airbag module (Operating side)<Ref. to SE-7, Front Seat.>
Side airbag sensor (Operating side) <Ref. to AB-19, Side Airbag Sensor.>
Front outer seat belt with pretensioner (Operating side)<Ref. to SB-10, Front Seat Belt.>
AB(diag)-89

AF:DTC 61 BELT PRETENSIONER RH FAILURE

Seat belt pretensioner (RH) circuit is open, shorted or shorted to ground.
Airbag harness is faulty.
CAUTION:
WIRING DIAGRAM:
AIRBAG CONTROL
MODULE
5
AB8
AB20
PRETENSIONER RH
AB20
1 2
AB8
1 2 3 4 5 6
7 8 9 10 11 12
AB-01553
AB(diag)-90

Step
between the airbag control module and the seat
belt pretensioner (RH).
CHECK SEAT BELT PRETENSIONER.
4) Connect airbag resistor to connector (2N) in
the test harness N.
4) Disconnect connectors (AB7) and (AB8)
from airbag control module.
(3R) in the test harness R and connector (2N) in
the test harness N.
(3R) No. 17 (2N) No. 1:
(3R) No. 19 (2N) No. 2:
(3R) No. 17 (3R) No. 19:
4) Read the DTC.
Check
Yes
No
rear harness (RH)
along with the body
harness.

turn off?

belt pretensioner
(RH). <Ref. to SB10, Front Seat
Belt.>

?
Go to step 4.
Replace the side

airbag harness
along with the body
harness.
more?
Go to step 5.
Replace the side

airbag harness
along with the body
harness.
more?
Go to step 6.
Replace the side

airbag harness
along with the body
harness.

control module.
<Ref. to AB-18,
Airbag Control
Module.>
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
AB(diag)-91

AG:DTC 62 BELT PRETENSIONER LH FAILURE

Seat belt pretensioner (LH) circuit is open, shorted or shorted to ground.
CAUTION:
WIRING DIAGRAM:
AIRBAG CONTROL
MODULE
2
AB7
AB19
PRETENSIONER LH
AB19
1 2
AB7
1 2 3 4 5 6
7 8 9 10 11 12
AB-01554
AB(diag)-92

Step
belt pretensioner (LH).
the test harness N.
airbag module (LH).
the test harness N.
(3R) No. 11 (2N) No. 1:
(3R) No. 13 (2N) No. 2:
(3R) No. 11 (3R) No. 13:
4) Read the DTC.
Check
Yes
No
rear harness (LH)
along with the body
harness.

turn off?

belt pretensioner
Belt.>

?
Go to step 4.
Replace the side

airbag harness
along with the body
harness.
more?
Go to step 5.
Replace the side

airbag harness
along with the body
harness.
more?
Go to step 6.
Replace the side

airbag harness
along with the body
harness.

control module.
<Ref. to AB-18,
Airbag Control
Module.>
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
AB(diag)-93

AH:DTC 65 BELT PRETENSIONER RH FAILURE

Seat belt pretensioner (RH) circuit is shorted to power supply.
CAUTION:
WIRING DIAGRAM:
AIRBAG CONTROL
MODULE
5
AB8
AB20
PRETENSIONER RH
AB20
1 2
AB8
1 2 3 4 5 6
7 8 9 10 11 12
AB-01553
AB(diag)-94

Step
the test harness N.
4) Read the DTC.
Check
Yes
No
rear harness (RH)
along with the body
harness.

turn off?

belt pretensioner
Belt.>
Go to step 4.

control module.
<Ref. to AB-18,
Airbag Control
Module.>
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
AB(diag)-95
Replace the side

airbag harness
along with the body
harness.

AI: DTC 66 BELT PRETENSIONER LH FAILURE

Seat belt pretensioner (LH) circuit is shorted to power supply.
CAUTION:
WIRING DIAGRAM:
AIRBAG CONTROL
MODULE
2
AB7
AB19
PRETENSIONER LH
AB19
1 2
AB7
1 2 3 4 5 6
7 8 9 10 11 12
AB-01554
AB(diag)-96

Step
the test harness N.
airbag module (LH).
4) Read the DTC.
Check
Yes
No
rear harness (LH)
along with the body
harness.

turn off?

belt pretensioner
Belt.>
Go to step 4.

control module.
<Ref. to AB-18,
Airbag Control
Module.>
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
AB(diag)-97
Replace the side

airbag harness
along with the body
harness.

AJ:DTC 71 DRIVERS AIRBAG FAILURE

Airbag main harness circuit is open, shorted or shorted to ground.
Airbag module harness (drivers side) circuit is open, shorted or shorted to ground.
CAUTION:
When inspecting the airbag main harness, disconnect the airbag module connectors and seat belt
pretensioner of the drivers and passengers seats for safety.
NOTE:
Prior to starting diagnosis, prepare two airbag resistors (98299PA040).
WIRING DIAGRAM:
17
16
13
14
AB3
1
2
3
4
AB2
AB26
STEERING
ROLL CONNECTOR
AB38
1
2
1
2
AB37
AIRBAG MODULE
(DRIVER SIDE)
AB2
AB3
1 2 3 4
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
AB37
AB38
1 2
1 2
18 19 20 21 22 23 24 25 26 27 28
AB-01456
AB(diag)-98

Step
5) Connector (1Q) in the test harness Q to connector (AB37).
(2R) No. 2 (2P) No. 1:
(2R) No. 4 (2P) No. 2:
(2R) No. 8 (3P) No. 3:
(2R) No. 12 (3P) No. 4:
Check
Yes
No
main harness
along with the body
harness.

turn off?
Replace the
Go to step 3.
drivers airbag
module. <Ref. to

turn off?
Replace the roll

Go to step 4.
connector. <Ref. to

?
Go to step 5.
AB(diag)-99
Replace the airbag

main harness
along with the body
harness.

Step
(2R) No. 2 (2P) No. 4:
(2R) No. 8 (2P) No. 12:
4) Read the DTC.
Check
more?
Yes
Go to step 6.

control module.
<Ref. to AB-18,
Airbag Control
Module.>
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
AB(diag)-100
No
Replace the airbag
main harness
along with the body
harness.

13.Diagnostic Chart with Trouble Code

A: DTC 11 DRIVERS AIRBAG FAILURE
Airbag module harness (drivers side) is open, shorted or shorted to ground.
CAUTION:
NOTE:
WIRING DIAGRAM:
17
16
13
14
AB3
1
2
3
4
AB2
AB26
STEERING
ROLL CONNECTOR
AB38
1
2
1
2
AB37
AIRBAG MODULE
(DRIVER SIDE)
AB2
AB3
1 2 3 4
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
AB37
AB38
1 2
1 2
18 19 20 21 22 23 24 25 26 27 28
AB-01456
AB(diag)-46

Step
(AB27) from the passengers airbag module.
(2R) No. 2 (2P) No. 1:
(2R) No. 4 (2P) No. 2:
(2R) No. 8 (3P) No. 3:
(2R) No. 12 (3P) No. 4:
Check
Yes
No
harness.

turn off?
Replace the
Go to step 3.
drivers airbag
module. <Ref. to

turn off?
Go to step 4.
Replace the roll
connector. <Ref. to

?
Go to step 5.
AB(diag)-47
Replace the airbag

main harness
along with the body
harness.

Step
(2R) No. 2 (2R) No. 4:
(2R) No. 8 (2R) No. 12:
4) Read the DTC.
Check
more?
Yes
Go to step 6.

control module.
<Ref. to AB-18,
Airbag Control
Module.>
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
AB(diag)-48
No
Replace the airbag
main harness
along with the body
harness.

B: DTC 12 PASSENGERS AIRBAG FAILURE

Airbag module harness (passengers side) is open, shorted or shorted to ground.
CAUTION:
NOTE:
WIRING DIAGRAM:
7
8
10
11
AB3
1
2
4
3
AB4
INFLATOR
(PASSENGER SIDE)
AB3
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
AB4
1 2 3 4
18 19 20 21 22 23 24 25 26 27 28
AB-00621
AB(diag)-49

Step
(2R) No. 3 (2P) No. 1:
(2R) No. 5 (2P) No. 2:
(2R) No. 9 (3P) No. 3:
(2R) No. 13 (3P) No. 4:
(2R) No. 3 (2R) No. 5:
(2R) No. 9 (2R) No. 13:
4) Read the DTC.
Check
Yes
No
harness.

turn off?

module. <Ref. to
Go to step 3.

?
Go to step 4.
Replace the airbag

main harness
along with the body
harness.
more?
Go to step 5.
Replace the airbag

main harness
along with the body
harness.

control module.
<Ref. to AB-18,
Airbag Control
Module.>
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
AB(diag)-50

C: DTC 15 DRIVERS AIRBAG FAILURE

Airbag harness (drivers side) is shorted to power supply.
Airbag module harness (drivers side) is shorted to power supply.
CAUTION:
NOTE:
WIRING DIAGRAM:
17
16
13
14
AB3
1
2
3
4
AB2
AB26
STEERING
ROLL CONNECTOR
AB38
1
2
1
2
AB37
AIRBAG MODULE
(DRIVER SIDE)
AB2
AB3
1 2 3 4
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
AB37
AB38
1 2
1 2
18 19 20 21 22 23 24 25 26 27 28
AB-01456
AB(diag)-51

Step
3) Connect the connector (AB38) to the connector (1N) in the test harness N.
turn the ignition switch to ON. (engine OFF)
Check
Yes
No
harness.

turn off?
Replace the
Go to step 3.
drivers airbag
module. <Ref. to

turn off?
Go to step 4.
Replace the roll
connector. <Ref. to
Go to step 5.
AB(diag)-52
Replace the airbag

main harness
along with the body
harness.

Step
4) Read the DTC.
Check
AB(diag)-53
Yes
No
control module.
<Ref. to AB-18,
Airbag Control
Module.>
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List

D: DTC 16 PASSENGERS AIRBAG FAILURE

Airbag harness (Passengers side) is shorted to power supply.
Airbag module harness (passengers side) is shorted to power supply.
CAUTION:
NOTE:
WIRING DIAGRAM:
7
8
10
11
AB3
1
2
4
3
AB4
INFLATOR
(PASSENGER SIDE)
AB3
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
AB4
1 2 3 4
18 19 20 21 22 23 24 25 26 27 28
AB-00621
AB(diag)-54

Step
4) Read the DTC.
Check
Yes
No
harness along with
the body harness.

turn off?

module. <Ref. to
Go to step 3.
Go to step 4.
Replace the airbag

main harness
along with the body
harness.

control module.
<Ref. to AB-18,
Airbag Control
Module.>
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
AB(diag)-55

E: DTC 21 AIRBAG ECM FAILURE

CAUTION:
1
Step
Check
CHECK WHETHER DTC 21 IS INDICATED. Is DTC 21 displayed on Subaru
1) Read the DTC. <Ref. to AB(diag)-29, READ Select Monitor?
3) Read the DTC again.
AB(diag)-56
Yes
No
Replace the airbag Temporary poor
control module.
contact occurs.
<Ref. to AB-18,
Airbag Control
Module.>

F: DTC 22 FRONT AIRBAG FIRING OUTPUT

WIRING DIAGRAM:
5
6
7
8
10
11
17
16
2
1
13
14
AB8
AB3
AB7
1
2
3
4
AB2
AB26
STEERING ROLL
CONNECTOR
AB4
1
2
4
3
1
2
1
2
AB20
2
1
AB38
AB37
2
1
AB19
AB27
AIRBAG MODULE
(DRIVER SIDE)
PRETENSIONER LH
AB2
AB4
1 2 3 4
AIRBAG MODULE
(PASSENGER SIDE)
AB3
AB7
AB8
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
1 2 3 4 5 6
1 2 3 4 5 6
7 8 9 10 11 12
7 8 9 10 11 12
18 19 20 21 22 23 24 25 26 27 28
PRETENSIONER RH
AB37
AB19
1 2
AB20
AB38
1 2
AB-01552
This code is indicated when the front airbag and pretensioner activates.
Once this code is displayed, the memory cannot be cleared. Therefore replace the following parts.
Drivers airbag module <Ref. to AB-14, Drivers Airbag Module.>
Passengers airbag module <Ref. to AB-15, Passengers Airbag Module.>
Front sub sensor of both sides <Ref. to AB-21, Front Sub Sensor.>
Front seat belt outer with pretensioner of both sides. <Ref. to SB-10, Front Seat Belt.>
Steering roll connector <Ref. to AB-20, Roll Connector.>
Occupant detection system (passengers seat cushion & frame assembly) <Ref. to SE-14, PASSENGERS SEAT, DISASSEMBLY, Front Seat.>
AB(diag)-57

G: DTC 23 CONNECTOR TO AIRBAG ECM

Improper connection of (AB3), (AB7) and (AB8) to airbag control module
CAUTION:
1
Step
Check
CHECK POOR CONTACT OF CONNECTORS Is there rust or damage on the
(AB3), (AB7) AND (AB8).
harness connector and the
1) Turn ignition switch OFF, disconnect the bat- control module connector?
2) Disconnect the connectors (AB3), (AB7)
and (AB8) from the airbag control module.

(AB3), (AB7) AND (AB8).
1) Reconnect the connector securely.
4) Read the DTC.

turn off?
AB(diag)-58
Yes
No
control module.
<Ref. to AB-18,
Airbag Control
Module.>Replace
the airbag main
harness along with
the body harness.
Replace the side
airbag main harness along with the
body harness.
Go to step 3.
Replace the airbag
control module.
<Ref. to AB-18,
Airbag Control
Module.>
control module.
<Ref. to AB-18,
Airbag Control
Module.>
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List

H: DTC 24 IG1 OPEN

Airbag main harness is open.
CAUTION:
WIRING DIAGRAM:
IGNITION SWITCH
No .11
BATTERY
B31
AB1
AB3
B31
1
2 3
4 5 6 7 8
AIRBAG CONTROL
MODULE
AB3
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 28
AB-01548
AB(diag)-59

Step
Check
control module.
OFF.
(in the joint box).

4) Read the DTC.
AB(diag)-60
Yes
No
control module.
<Ref. to AB-18,
Airbag Control
Module.>
Replace the fuse

No. 11. If fuse No.
11 is blown out
again, repair the
body harness.
Replace the airbag
main harness
along with the body
harness.
Replace the airbag
control module.
<Ref. to AB-18,
Airbag Control
Module.>
Check DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
Go to step 3.
Go to step 4.

I:
DTC 25 IG2 OPEN

Airbag harness is open.
CAUTION:
WIRING DIAGRAM:
IGNITION SWITCH
BATTERY
No .6
B31
AB1
AB3
AB3
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
AIRBAG CONTROL
MODULE
B31
1
2 3
4 5 6 7 8
18 19 20 21 22 23 24 25 26 27 28
AB-01549
AB(diag)-61

Step
Check
control module.
OFF.
(in the joint box).

4) Read the DTC.
AB(diag)-62
Yes
No
control module.
<Ref. to AB-18,
Airbag Control
Module.>
Replace the fuse

No. 6. If fuse No. 6
is blown out again,
repair the body
harness. Or
replace the airbag
main harness
along with the body
harness.
Replace the airbag
control module.
<Ref. to AB-18,
Airbag Control
Module.>
Check DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
Go to step 3.
Go to step 4.

J: DTC 26 PASSENGERS AIRBAG INDICATOR FAILURE

Passengers airbag indicator is faulty.
CAUTION:
WIRING DIAGRAM:
18
AB3
AB1
10
11
B31
B38
i3
i59
CLOCK
AB3
4 5 6
1 2 3
7 8 9 10 11 12 13 14 15 16 17
i59
B31
B38
1 2 3 4 5 6 7 8 9 10
1
2
3 4 5 6
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
18 19 20 21 22 23 24 25 26 27 28
AB-01492
AB(diag)-63

Step
CHECK POOR CONTACT.
2) Confirm that firm contact is secured for the
connector between the airbag control module
and clock.
control module.
NOTE:
If normal, the indicator is not illuminated for both
ON and OFF.
2) Remove the clock and then disconnect the
connector (i59).
(2R) and (4R) in the test harness R and chassis
ground.
(2R) No. 14 (4R) No. 17:
(2R) and (4R) in the test harness R and connector (i59).
(2R) No. 14 (i59) No. 7:
(4R) No. 17 (i59) No. 8:
CHECK BODY HARNESS.
(i59) and chassis ground.
Check
Is there poor contact in any
connector?
Yes
No
harness connector.
Is the passengers airbag indicator turned on?
Go to step 3.
more?
Replace the clock. Repair the bulk<Ref. to IDI-17,

head harness. Or
Clock.>
replace the airbag
main harness
along with the body
harness.

?
Go to step 5.
Replace the clock. Repair the clock

<Ref. to IDI-17,
power supply line.
Clock.>
AB(diag)-64
Go to step 4.
Repair the bulkhead harness. Or

replace the airbag
main harness
along with the body
harness.

K: DTC 27 ODS COMMUNICATION ERROR

Communication to the occupant detection control module is faulty.
Occupant detection harness (seat harness) is faulty.
Airbag rear harness circuit is open, shorted or shorted to ground, or shorted to power supply.
AIRBAG CONTROL
MODULE
11
AB8
AB61
10
AB59
AB62
OCCUPANT DETECTION
CONTROL MODULE
AB8
AB61
AB62
1 2 3 4 5 6
1 2 3
4 5 6
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
7 8 9 10 11 12
AB-01550
AB(diag)-65

Step
control module.
3) Disconnect connector (AB59) from the connector (AB61) on the lower side of passengers
seat.
5) Connect the connector (1AB) in the test harness AB to connector (AB61).
(4R) in the test harness R and connector (2AB)
in the test harness AB.
(4R) No. 12 (2AB) No. 1:
(4R) No. 10 (2AB) No. 2:
1) Connect connector (AB8) to airbag control
module.
2) Connect connector (AB61) and connector
(AB59).
4) Check the occupant detection system.
<Ref. to OD(diag)-2, Basic Diagnostic Procedure.>
Check
?
Yes
Go to step 2.
No
Replace the airbag
rear harness (RH)
along with the body
harness.
more?
Go to step 3.
Replace the airbag

rear harness (RH)
along with the body
harness.
Is there a malfunction in the

occupant detection system?
Repair the occuFinish the diagnopant detection sys- sis.

tem. <Ref. to
OD(diag)-2, Basic
Diagnostic Procedure.>
L: DTC 29 ODS FAILURE

NOTE:
Refer to Occupant Detection System for DTC 29. <Ref. to OD(diag)-28, DTC 29 ODS FAILURE, Diagnostic
M: DTC 2A ODS CALIBRATION ERROR

NOTE:
Refer to Occupant Detection System for DTC 2A. <Ref. to OD(diag)-25, DTC 2A ODS CALIBRATION ERROR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
N: DTC 2B ODS SYSTEM WRONG PARTS

NOTE:
Refer to Occupant Detection System for DTC 2B. <Ref. to OD(diag)-25, DTC 2B ODS SYSTEM WRONG
PARTS, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
O: DTC 2C BELT TENSION SENSOR FAILURE

NOTE:
Refer to Occupant Detection System for DTC 2C. <Ref. to OD(diag)-26, DTC 2C BELT TENSION SENSOR FAILURE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AB(diag)-66

P: DTC 31 FRONT SUB SENSOR RH FAILURE

Front sub sensor harness (RH) is shorted, open or shorted to power supply.
CAUTION:
WIRING DIAGRAM:
AIRBAG
CONTROL MODULE
TWISTED PAIR LINE
20
9
AB3
1
2
AB15
FRONT SUB SENSOR RH
AB15
AB3
1 2
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 28
AB-01465
AB(diag)-67

Step
sub sensor (RH).
FRONT SUB SENSOR HARNESS.
control module.
6) Disconnect the front sub sensor (RH), and
connector (AB15).
the test harness H.
(3R) No. 7 (3H) No. 5:
(3R) No. 9 (3H) No. 6:
SUB SENSOR HARNESS RH).

4) Read the DTC.
Check
Yes
No
tor.

?
Go to step 3.
Replace the airbag

main harness
along with the body
harness.
more?
Replace the front

sub sensor (RH).
<Ref. to AB-21,
Front Sub Sensor.>
Replace the airbag
control module if
Module.>
Replace the airbag
control module.
<Ref. to AB-18,
Airbag Control
Module.>
Check DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
Go to step 4.
AB(diag)-68
Go to step 5.

Q: DTC 32 FRONT SUB SENSOR LH FAILURE

Front sub sensor harness (LH) is shorted, open or shorted to power supply.
CAUTION:
WIRING DIAGRAM:
AIRBAG CONTROL
MODULE
TWISTED PAIR LINE
15
26
AB3
1
2
AB13
TWISTED PAIR LINE
AB14
2
1
AB18
FRONT SUB SENSOR LH
AB3
AB13
AB18
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
1 2
1 2
18 19 20 21 22 23 24 25 26 27 28
AB-01551
AB(diag)-69

Step
sub sensor (LH).
control module.
6) Disconnect the front sub sensor (LH), and
connector (AB18).
the test harness H.
(3R) No. 6 (3H) No. 5:
(3R) No. 8 (3H) No. 6:

4) Read the DTC.
Check
Yes
No
main harness
along with the body
harness.

?
Go to step 3.
Replace the airbag

main harness
along with the body
harness.
more?
Replace the front

sub sensor (LH).
<Ref. to AB-21,
Front Sub Sensor.>
Replace the airbag
control module if
Module.>
Replace the airbag
control module.
<Ref. to AB-18,
Airbag Control
Module.>
Check DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
Go to step 4.
AB(diag)-70
Go to step 5.

R: DTC 33 FRONT SUB SENSOR RH FAILURE

If the DTC 33 is displayed, the circuit within the front sub sensor (RH) is faulty. Replace the front sub sensor
(RH). <Ref. to AB-21, Front Sub Sensor.>
S: DTC 34 FRONT SUB SENSOR LH FAILURE

If the DTC 34 is displayed, the circuit within the front sub sensor (LH) is faulty. Replace the front sub sensor
(LH). <Ref. to AB-21, Front Sub Sensor.>
AB(diag)-71

T: DTC 36 SEAT POSITION SENSOR LH FAILURE

CAUTION:
WIRING DIAGRAM:
3
4
AB7
2
1
AB52
SEAT POSITION SENSOR LH
AB7
1 2 3 4 5 6
AB52
1 2
7 8 9 10 11 12
AB-01467
AB(diag)-72

Step
CHECK SEAT POSITION SENSOR (LH).
2) Disconnect connector (AB52) from seat
position sensor (LH).
CHECK AIRBAG REAR HARNESS (SEAT
POSITION SENSOR HARNESS (LH).
control module.
4) Disconnect the seat position sensor (LH),
and connect the connector (1H) in test harness
H to connector (AB52).
the test harness H.
(3R) No. 1 (3H) No. 5:
(3R) No. 3 (3H) No. 6:
4) Read the DTC.
Check
Yes
No
main harness.

turn off?

position sensor
(LH) along with the
drivers slide rail
assembly. <Ref. to
SE-7, Front Seat.>

?
Go to step 4.

?

rear harness (LH)
along with the body
harness.

control module.
<Ref. to AB-18,
Airbag Control
Module.>
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
Replace the airbag

rear harness (LH)
along with the body
harness.
U: DTC 37 BUCKLE SWITCH RH FAILURE

NOTE:
Refer to Occupant Detection System for DTC 37. <Ref. to OD(diag)-29, DTC 37 BUCKLE SWITCH RH
FAILURE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AB(diag)-73

V: DTC 38 BUCKLE SWITCH LH FAILURE

Drivers buckle switch circuit is open, shorted or shorted to ground.
CAUTION:
WIRING DIAGRAM:
11
8
AB7
1
2
AB51
BUCKLE SWITCH LH
AB7
AB51
1 2 3 4 5 6
1 2
7 8 9 10 11 12
AB-01469
AB(diag)-74

Step
CHECK SEAT BELT BUCKLE SWITCH (LH).
2) Disconnect the connector (AB51) from
buckle switch (LH).
CHECK AIRBAG REAR HARNESS (BUCKLE
SWITCH HARNESS (LH)).
control module.
4) Disconnect the seat belt buckle switch (LH),
and connect the connector (1D) in test harness
D to connector (AB51).
(4R) in the test harness R and connector (3D) in
the test harness D.
(4R) No. 11 (3D) No. 3:
(4R) No. 9 (3D) No. 4:
4) Read the DTC.
Check
Yes
No
main harness.

turn off?

belt buckle switch
Belt.>

?
Go to step 4.

?

rear harness (LH)
along with the body
harness.

control module.
<Ref. to AB-18,
Airbag Control
Module.>
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
AB(diag)-75
Replace the airbag

rear harness (LH)
along with the body
harness.

W: DTC 41 SIDE AIRBAG RH FAILURE

CAUTION:
WIRING DIAGRAM:
2
1
12
9
7
10
AB8
SIDE AIRBAG
SENSOR RH
AB11
AB12
1 2
1 2 3 4
AB11
2
1
4
3
2
1
AB12
INFLATOR
(SIDE RH)
AB8
1 2 3 4 5 6
7 8 9 10 11 12
AB-01494
AB(diag)-76

Step
(AB11).
the test harness F.
3) Disconnect the airbag resistor from test harness F.
control module.
the test harness F.
(3R) No. 18 (3F) No. 4:
(3R) No. 20 (3F) No. 3:
(3R) No. 18 (3R) No. 20:
4) Read the DTC.
Check
Yes
No
rear harness (RH)
along with the body
harness.

turn off?

seat along with
side airbag module

?
Go to step 4.
Replace the side

airbag harness
along with the body
harness.
more?
Go to step 5.
Replace the side

airbag harness
along with the body
harness.
more?
Go to step 6.
Replace the side

airbag harness
along with the body
harness.

control module.
<Ref. to AB-18,
Airbag Control
Module.>
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
AB(diag)-77

X: DTC 42 SIDE AIRBAG LH FAILURE

CAUTION:
WIRING DIAGRAM:
7
10
12
9
5
6
AB7
AB9
4
3
2
1
2
1
INFLATOR
(SIDE LH)
AB9
AB10
1 2
1 2 3 4
AB10
SIDE AIRBAG
SENSOR LH
AB7
1 2 3 4 5 6
7 8 9 10 11 12
AB-01495
AB(diag)-78

Step
(AB9).
the test harness F.
control module.
the test harness F.
(3R) No. 12 (3F) No. 3:
(3R) No. 10 (3F) No. 4:
(3R) No. 12 (3R) No. 10:
4) Read the DTC.
Check
Yes
No
rear harness (LH)
along with the body
harness.

turn off?

seat along with
side airbag module

?
Go to step 4.
Replace the side

airbag harness
along with the body
harness.
more?
Go to step 5.
Replace the side

airbag harness
along with the body
harness.
more?
Go to step 6.
Replace the side

airbag harness
along with the body
harness.

control module.
<Ref. to AB-18,
Airbag Control
Module.>
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
AB(diag)-79

Y: DTC 45 SIDE AIRBAG RH FAILURE

CAUTION:
WIRING DIAGRAM:
2
1
12
9
7
10
AB8
SIDE AIRBAG
SENSOR RH
AB11
AB12
1 2
1 2 3 4
AB11
2
1
4
3
2
1
AB12
INFLATOR
(SIDE RH)
AB8
1 2 3 4 5 6
7 8 9 10 11 12
AB-01494
AB(diag)-80

Step
(AB11).
the test harness F.
control module.
4) Read the DTC.
Check
Yes
No
rear harness (RH)
along with the body
harness.

turn off?

seat along with
side airbag module
Go to step 4.

control module.
<Ref. to AB-18,
Airbag Control
Module.>
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
AB(diag)-81
Replace the side

airbag harness
along with the body
harness.

Z: DTC 46 SIDE AIRBAG LH FAILURE

CAUTION:
WIRING DIAGRAM:
7
10
12
9
5
6
AB7
AB9
4
3
2
1
2
1
INFLATOR
(SIDE LH)
AB9
AB10
1 2
1 2 3 4
AB10
SIDE AIRBAG
SENSOR LH
AB7
1 2 3 4 5 6
7 8 9 10 11 12
AB-01495
AB(diag)-82

Step
(AB9).
the test harness F.
control module.
4) Read the DTC.
Check
Yes
No
rear harness (LH)
along with the body
harness.

turn off?

seat along with
side airbag module
Go to step 4.

control module.
<Ref. to AB-18,
Airbag Control
Module.>
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
AB(diag)-83
Replace the side

airbag harness
along with the body
harness.

AA:DTC 51 SIDE AIRBAG SENSOR RH FAILURE

CAUTION:
WIRING DIAGRAM:
2
1
12
9
7
10
AB8
SIDE AIRBAG
SENSOR RH
AB11
AB12
1 2
1 2 3 4
AB11
2
1
4
3
2
1
AB12
INFLATOR
(SIDE RH)
AB8
1 2 3 4 5 6
7 8 9 10 11 12
AB-01494
AB(diag)-84

Step
control module.
airbag sensor (RH), and connect connector
(2V) in test harness V to connector (AB12).
the test harness V.
(4R) No. 5 (3V) No. 2:
(4R) No. 6 (3V) No. 4:
(4R) No. 7 (3V) No. 1:
(4R) No. 8 (3V) No. 5:
CHECK SIDE AIRBAG HARNESS.
(4R) No. 5 (4R) No. 7:
(4R) No. 5 (4R) No. 6:
(4R) No. 5 (4R) No. 8:
(4R) No. 6 (4R) No. 7:
(4R) No. 6 (4R) No. 8:
(4R) No. 7 (4R) No. 8:
4) Read the DTC.
Check
Yes
No
rear harness (RH)
along with the body
harness.

?
Go to step 3.
Replace the side

airbag harness
along with the body
harness.
more?
Go to step 4.
Replace the side

airbag harness
along with the body
harness.

airbag sensor
(RH). <Ref. to AB19, Side Airbag
Sensor.> Replace
the airbag control
<Ref. to AB-18,
Airbag Control
Module.>
AB(diag)-85

Step
Check
AB(diag)-86
Yes
No
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List

AB:DTC 52 SIDE AIRBAG SENSOR LH FAILURE

CAUTION:
WIRING DIAGRAM:
7
10
12
9
5
6
AB7
AB9
4
3
2
1
2
1
INFLATOR
(SIDE LH)
AB9
AB10
1 2
1 2 3 4
AB10
SIDE AIRBAG
SENSOR LH
AB7
1 2 3 4 5 6
7 8 9 10 11 12
AB-01495
AB(diag)-87

Step
airbag module (LH).
control module.
airbag sensor (LH), and connect connector (2V)
in test harness V to connector (AB10).
the test harness V.
(4R) No. 4 (3V) No. 2:
(4R) No. 3 (3V) No. 4:
(4R) No. 2 (3V) No. 1:
(4R) No. 1 (3V) No. 5:
(4R) No. 4 (4R) No. 3:
(4R) No. 4 (4R) No. 2:
(4R) No. 4 (4R) No. 1:
(4R) No. 3 (4R) No. 2:
(4R) No. 3 (4R) No. 1:
(4R) No. 2 (4R) No. 1:
4) Read the DTC.
Check
Yes
No
rear harness (LH)
along with the body
harness.

?
Go to step 3.
Replace the side

airbag harness
along with the body
harness.
more?
Go to step 4.
Replace the side

airbag harness
along with the body
harness.

airbag sensor
(LH). <Ref. to AB19, Side Airbag
Sensor.> Replace
the airbag control
<Ref. to AB-18,
Airbag Control
Module.>
AB(diag)-88

Step
Check
Yes
No
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
AC:DTC 53 SIDE AIRBAG SENSOR RH FAILURE

If the code 53 is displayed, the circuit within the side airbag sensor (RH) is faulty. Replace the side airbag
sensor (RH).
AD:DTC 54 SIDE AIRBAG SENSOR LH FAILURE

If the code 54 is displayed, the circuit within the side airbag sensor (LH) is faulty. Replace the side airbag sensor (LH).
AE:DTC 55 SIDE CURTAIN AIRBAG FIRING OUTPUT

This code is indicated when the side airbag and pretensioner activates.
When this code is displayed, the memory cannot be cleared. Replace the following parts.
Front seat with side airbag module (Operating side)<Ref. to SE-7, Front Seat.>
Side airbag sensor (Operating side) <Ref. to AB-19, Side Airbag Sensor.>
Front outer seat belt with pretensioner (Operating side)<Ref. to SB-10, Front Seat Belt.>
AB(diag)-89

AF:DTC 61 BELT PRETENSIONER RH FAILURE

Seat belt pretensioner (RH) circuit is open, shorted or shorted to ground.
CAUTION:
WIRING DIAGRAM:
AIRBAG CONTROL
MODULE
5
AB8
AB20
PRETENSIONER RH
AB20
1 2
AB8
1 2 3 4 5 6
7 8 9 10 11 12
AB-01553
AB(diag)-90

Step
the test harness N.
the test harness N.
(3R) No. 17 (2N) No. 1:
(3R) No. 19 (2N) No. 2:
(3R) No. 17 (3R) No. 19:
4) Read the DTC.
Check
Yes
No
rear harness (RH)
along with the body
harness.

turn off?

belt pretensioner
Belt.>

?
Go to step 4.
Replace the side

airbag harness
along with the body
harness.
more?
Go to step 5.
Replace the side

airbag harness
along with the body
harness.
more?
Go to step 6.
Replace the side

airbag harness
along with the body
harness.

control module.
<Ref. to AB-18,
Airbag Control
Module.>
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
AB(diag)-91

AG:DTC 62 BELT PRETENSIONER LH FAILURE

Seat belt pretensioner (LH) circuit is open, shorted or shorted to ground.
CAUTION:
WIRING DIAGRAM:
AIRBAG CONTROL
MODULE
2
AB7
AB19
PRETENSIONER LH
AB19
1 2
AB7
1 2 3 4 5 6
7 8 9 10 11 12
AB-01554
AB(diag)-92

Step
the test harness N.
airbag module (LH).
the test harness N.
(3R) No. 11 (2N) No. 1:
(3R) No. 13 (2N) No. 2:
(3R) No. 11 (3R) No. 13:
4) Read the DTC.
Check
Yes
No
rear harness (LH)
along with the body
harness.

turn off?

belt pretensioner
Belt.>

?
Go to step 4.
Replace the side

airbag harness
along with the body
harness.
more?
Go to step 5.
Replace the side

airbag harness
along with the body
harness.
more?
Go to step 6.
Replace the side

airbag harness
along with the body
harness.

control module.
<Ref. to AB-18,
Airbag Control
Module.>
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
AB(diag)-93

AH:DTC 65 BELT PRETENSIONER RH FAILURE

Seat belt pretensioner (RH) circuit is shorted to power supply.
CAUTION:
WIRING DIAGRAM:
AIRBAG CONTROL
MODULE
5
AB8
AB20
PRETENSIONER RH
AB20
1 2
AB8
1 2 3 4 5 6
7 8 9 10 11 12
AB-01553
AB(diag)-94

Step
the test harness N.
4) Read the DTC.
Check
Yes
No
rear harness (RH)
along with the body
harness.

turn off?

belt pretensioner
Belt.>
Go to step 4.

control module.
<Ref. to AB-18,
Airbag Control
Module.>
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
AB(diag)-95
Replace the side

airbag harness
along with the body
harness.

AI: DTC 66 BELT PRETENSIONER LH FAILURE

Seat belt pretensioner (LH) circuit is shorted to power supply.
CAUTION:
WIRING DIAGRAM:
AIRBAG CONTROL
MODULE
2
AB7
AB19
PRETENSIONER LH
AB19
1 2
AB7
1 2 3 4 5 6
7 8 9 10 11 12
AB-01554
AB(diag)-96

Step
the test harness N.
airbag module (LH).
4) Read the DTC.
Check
Yes
No
rear harness (LH)
along with the body
harness.

turn off?

belt pretensioner
Belt.>
Go to step 4.

control module.
<Ref. to AB-18,
Airbag Control
Module.>
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
AB(diag)-97
Replace the side

airbag harness
along with the body
harness.

AJ:DTC 71 DRIVERS AIRBAG FAILURE

Airbag main harness circuit is open, shorted or shorted to ground.
Airbag module harness (drivers side) circuit is open, shorted or shorted to ground.
CAUTION:
When inspecting the airbag main harness, disconnect the airbag module connectors and seat belt
pretensioner of the drivers and passengers seats for safety.
NOTE:
Prior to starting diagnosis, prepare two airbag resistors (98299PA040).
WIRING DIAGRAM:
17
16
13
14
AB3
1
2
3
4
AB2
AB26
STEERING
ROLL CONNECTOR
AB38
1
2
1
2
AB37
AIRBAG MODULE
(DRIVER SIDE)
AB2
AB3
1 2 3 4
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
AB37
AB38
1 2
1 2
18 19 20 21 22 23 24 25 26 27 28
AB-01456
AB(diag)-98

Step
5) Connector (1Q) in the test harness Q to connector (AB37).
(2R) No. 2 (2P) No. 1:
(2R) No. 4 (2P) No. 2:
(2R) No. 8 (3P) No. 3:
(2R) No. 12 (3P) No. 4:
Check
Yes
No
main harness
along with the body
harness.

turn off?
Replace the
Go to step 3.
drivers airbag
module. <Ref. to

turn off?
Replace the roll

Go to step 4.
connector. <Ref. to

?
Go to step 5.
AB(diag)-99
Replace the airbag

main harness
along with the body
harness.

Step
(2R) No. 2 (2P) No. 4:
(2R) No. 8 (2P) No. 12:
4) Read the DTC.
Check
more?
Yes
Go to step 6.

control module.
<Ref. to AB-18,
Airbag Control
Module.>
Trouble Code
(DTC). <Ref. to
AB(diag)-42, List
AB(diag)-100
No
Replace the airbag
main harness
along with the body
harness.

AK:DTC 72 PASSENGERS AIRBAG FAILURE

Airbag harness circuit is open, shorted or shorted to ground.
Airbag module (passengers side) circuit is open, shorted or shorted to ground.
CAUTION:
When inspecting the airbag main harness, disconnect the airbag modules of the drivers and the
passengers seats for safety.
NOTE:
WIRING DIAGRAM:
7
8
10
11
AB3
1
2
4
3
AB4
INFLATOR
(PASSENGER SIDE)
AB3
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
AB4
1 2 3 4
18 19 20 21 22 23 24 25 26 27 28
AB-00621
AB(diag)-101

OCCUPANT DETECTION SYSTEM (DIAGNOSTICS)

A: PROCEDURE
1
Step
CHECK WARNING LIGHT.
Check whether the airbag warning light in combination meter illuminates.
CHECK INDICATION OF DTC.
3) Turn the ignition switch to ON and run the
4) Read the DTC. <Ref. to OD(diag)-19,
(DTC).>
NOTE:
If the communication function of the Subaru Select Monitor cannot be executed normally,
check the communication circuit. <Ref. to
OD(diag)-18, COMMUNICATION FOR INITIALIZING IMPOSSIBLE, INSPECTION, Subaru Select Monitor.>
PERFORM DIAGNOSIS.
1) Judge the possible cause from List of Diagnostic Trouble Code <Ref. to OD(diag)-24, List
of Diagnostic Trouble Code (DTC).>.
2) Inspect the DTC using Chart of Diagnostic
Trouble Code (DTC).
OD(diag)-21, OPERATION, Clear Memory
Mode.>
OD(diag)-20, PROCEDURE, Inspection
Mode.>
6) Read any other DTCs displayed.
Check
illuminate?
Yes
Go to step 2.
Is DTC displayed?
Go to step 3.
Is DTC displayed?
Perform the proce- Finish the diagnodure 1) to 5) in step sis.

3.
OD(diag)-2
No
DTC.
<Ref. to AB(diag)37, Airbag Warning
Light Failure.> Go
to Airbag Warning
Light Failure.
General Description
B: INSPECTION
A: CAUTION
Measure the battery voltage and specific gravity of

electrolyte, and check the electrolyte amount.
1) If the seat cushion cover is removed or replaced,

adjustment after installing the seat to the vehicle.
<Ref. to OD(diag)-17, SYSTEM CALIBRATION
(REZEROING), OPERATION, Subaru Select Monitor.>
Failure to do so may cause improper operation of
the occupant detection system.
2) As the occupant detection control module and
the occupant detection sensor of occupant detection system (passengers seat only) is securely
fixed to the seat cushion frame, never remove the
occupant detection control module and pressure
sensor from the seat cushion frame.
3) Do not replace the seat cushion pad by itself. Be
sure to replace the seat cushion pad & frame assembly as a unit. The seat cushion pad and cushion frame are adjusted as a set at the time of
manufacture. If parts from other vehicles or cushion
pad and cushion frame of other set is used, the occupant detection system will not function properly.
4) If the seat cushion cover is removed, always replace the wires of the seat cushion cover with new
wires.
Failure to do so may immediately damage the occupant detection system.
engine is running. A large counter electromotive
force will be generated in the generator, and this
voltage may damage electronic parts such as occupant detection control module etc.
sensor and control module, be sure to turn the ignition switch to OFF and wait for 20 seconds or more.
Occupant detection control module may be damaged.
8) Every part relating to occupant detection system
is a precision part. Do not drop them.
Standard voltage: 12 V or more

Specific gravity: 1.260 or more
Electrolyte: between the upper level and lower
level
CAUTION:
The connectors of airbag system are yellow.
Do not use the electrical test equipment on
these circuits.
wiring harness when servicing the occupant
detection system.
Refer to cautions on airbag system when repairing occupant detection system. <Ref. to
OD(diag)-3
General Description
C: PREPARATION TOOL
CAUTION:
To measure the voltage and resistance of airbag system component and occupant detection system
component, be sure to use the specified test harness.
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
1B020XU0
DESCRIPTION
SUBARU SELECT
MONITOR KIT
ST1B020XU0
OD(diag)-4
REMARKS
General Description
TEST HARNESS D
ILLUSTRATION
3D
TOOL NUMBER
98299AG060
DESCRIPTION
TEST HARNESS D
REMARKS
Used when measuring voltage and resistance of
front seat belt buckle switch.
2D
1D
ST98299AG060
3D
2D
1
2
6
3
2
1
1D
3D
1
2
3 4 5 6
1D
2D
AB-01068
TEST HARNESS U
ILLUSTRATION
7U
TOOL NUMBER
DESCRIPTION
REMARKS
98299AG000
TEST HARNESS U
Used when measuring voltage and resistance of

airbag control module.
6U
8U
9U
5U
4U
3U
2U
1U
ST98299AG000
OD(diag)-5
General Description
1U
26 34 30 33 31 25 23 36 28 48 47 37 27 21 4 18 20 19 62 61 63 49 6 10 5 9 56 60 55 59 8 12 7 11 39 22 41 53 57 54 58 40 46 29 35 45 2 51 1 52 32 38 44 42 43 24 3 50 14 67 13 16 15 17 64 66 65 68
6U
4U
1
6
7
8U
8
1
10
11
12
13
14
15
7U
16
1
17
18
3
4
3U
5
6
1
2
4
5
9U
6
1
10
11
12
13
14
15
10
16
11
17
12
18
13
19
14
20
2U
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
5U
1U
52 51
50 49
60 59 58 57 56 55 54 53
68 67 66 65 64 63 62 61
2U
2 1
26 25 24
23 22 21 4 3
37 36 35 34 33 32 31 30 29 28 27 12 11 10 9 8 7 6 5
48 47 46 45 44 43 42 41 40 39 38 20 19 18 17 16 15 14 13
1 2 3
4 5 6
7 8 9 10 11 12 13 14
3U
1 2 3 4 5
6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
4U
5U
6U
7U
8U
9U
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
2
1
6 5 4 3
1
2
3 4 5 6
2
1
6 5 4 3
1 2
AB-00930
OD(diag)-6
General Description
TEST HARNESS Y
ILLUSTRATION
1Y
TOOL NUMBER
98299AG040
DESCRIPTION
TEST HARNESS Y
REMARKS
Used for diagnosing seat belt buckle switch.
2Y
ST98299AG040
1Y
2
2Y
1Y
2Y
AB-01069
OD(diag)-7
General Description
TEST HARNESS AB
ILLUSTRATION
TOOL NUMBER
98299XA000
DESCRIPTION
REMARKS
TEST HARNESS AB Used when measuring voltage and resistance of
occupant detection system.
ST98299XA000
1AB
2AB
OD-00029
OD(diag)-8
General Description
TEST HARNESS AE
ILLUSTRATION
TOOL NUMBER
98299XA030
DESCRIPTION
REMARKS
TEST HARNESS AE Adapter harness of TEST HARNESS Y
Used for diagnosing seat belt buckle switch.
ST98299XA030
1
2AE
1AE
OD-00026
OD(diag)-9
General Description
TEST HARNESS AC
ILLUSTRATION
TOOL NUMBER
98299XA010
DESCRIPTION
REMARKS
TEST HARNESS AC Used for diagnosing seat belt tension sensor.
ST98299XA010
A
B
C
AC
OD-00027
OD(diag)-10
General Description
TEST HARNESS AD
ILLUSTRATION
TOOL NUMBER
98299XA020
DESCRIPTION
REMARKS
TEST HARNESS AD Used for measuring voltage and resistance of
seat belt tension sensor.
ST98299XA020
1AD
2AD
OD-00028
2. GENERAL TOOL
TOOL NAME
Circuit tester
REMARKS
OD(diag)-11


A: LOCATION
(1)
(2)
(2)
(4)
OD-00057
(1)
(2)
(3)
Occupant detection sensor

Seat belt tension sensor
(4)
Buckle switch (Passengers seat)
(2)
(1)
OD-00016
(3)
OD-00048
OD(diag)-12
OD-00049

(A)
(1)
(2)
(B)
(1)
(2)
OD-00031
(A)
For North America model
(B)
For Canada model
(1)
Passengers airbag OFF indicator

light
(2)
Passengers airbag ON indicator

light
OD(diag)-13
Airbag Connector
4. Airbag Connector
A: PROCEDURE
Buckle switch
1) How to disconnect
(2) With the slide lock (A) moved, disconnect
the connector.
(A)
AB-00721
CAUTION:
the harness.
2) How to connect
(A)
AB-00016
CAUTION:
locked.
OD(diag)-14


CAUTION:
Never remove the occupant detection control module, occupant detection sensor and seat frame.
They are integrated into one unit.
Because the measuring of the I/O signal of the occupant detection control module is prohibited,
there is no list of terminal numbers.
Terminal
No.
Terminal name
IG power supply
Airbag control module communication
Input/Output value
Remarks
(COM)
9
10
Airbag control module communication
(GND)
(Vcc)
5
4
0V
05V
Ground
Belt tension sensor power supply
Belt tension sensor
(Vout)
(GND)
16
14
0.5 4.5 V
0V
Sensor output voltage

Sensor ground
(Vcc)
(Vout)
6
7
05V
0.5 4.5 V
Pressure sensor power supply

Sensor output voltage
(GND)
15
1
0V
0 IG voltage
Sensor ground
IG voltage when the switch is ON
(GND)
0V
Switch ground
Occupant detection sensor

Buckle switch
Buckle switch
9 16 V
Open collector terminal
When ignition switch ON

Communication line
B: WIRING DIAGRAM
Refer to the electrical wiring diagram. <Ref. to WI-85, Airbag System.>
OD(diag)-15


A: OPERATION
1. READ DIAGNOSTIC TROUBLE CODE (DTC)
When malfunction of the airbag system and the occupant detection system occurs, the DTC stored in airbag
control module will be read out.
Refer to DTC readout of airbag system (diagnosis). <Ref. to AB(diag)-29, OPERATION, Subaru Select Monitor.>
NOTE:
MANUAL.
For details concerning DTCs, refer to List of Diagnostic Trouble Code (Airbag system, Occupant detection
system). <Ref. to AB(diag)-42, List of Diagnostic Trouble Code (DTC).> <Ref. to OD(diag)-24, List of Diagnostic Trouble Code (DTC).>
2. DISPLAY OF STATUS INFORMATION

Check the operating condition of each sensor in the event of malfunction in the seat belt buckle switch and
seat position sensor, or when the seat belt buckle switch and seat position sensor has been replaced.
3) On the Airbag System display screen, select the {Status Data}.
Contents

Seat position sensor RH
Front position *1/Rear position*2 /Other *3/Initial Setting *3 / *5

*5

Seat belt buckle switch RH

Passengers airbag control status
ON *10/OFF *11 /Initial Setting *4
*1: Seat position is at the front end.

*2: Seat position is at the rear end.
*3: Displayed when data other than seat position (forward/rear) is entered (such as breakdown data).
*4: Displayed when it is initial.
*5: Seat position sensor not supported
*6: Seat belt fastened
*7: Seat belt not fastened
*8: Displayed when data other than belt fastened or not fastened, (such as breakdowns) is entered.
*9: Seat belt buckle switch not supported
*10: Passengers seat airbag operating state
*11: Passengers seat airbag non-operating state
NOTE:
MANUAL.
OD(diag)-16


Clear the DTC stored in the airbag control module
after repairing the airbag system and occupant detection system. (After the breakdown is recovered,
the breakdown code for completed recoveries are
read out when the next breakdown occurs if the
memory clear work is not performed.)
screen, select the {Airbag System}.
3) On the {Airbag System} menu screen, select the
{Clear Memory}.
4) When the Clear Memory? is shown on the
screen, select the [OK].
5) When Done is displayed, close the Subaru Select Monitor.
NOTE:
For details concerning the operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
5) See service manual. And check vehicle condition for successfully completing the rezeroing. is
displayed on the screen. Inspect the following
items and adjust the vehicle condition.
Adjust the seat backrest to the upright position.
Adjust the slide to the rear end position.
Do not place anything on the top of the seat
cushion.
Sit on the seat cushion to smooth the seat surface.
Check that the passengers seat belt is not inserted into the buckle, not tense, or not stuck.
Check that ambient temperature is in a range
from 0 40C (32 104F).
6) Re-zeroing Adjust the passenger seat to the
condition shown in service manual is displayed on
the screen. Slide the passengers seat to the rear
end, make sure that the backrest is adjusted to the
most upright position, and select the [OK].
4. SYSTEM CALIBRATION (REZEROING)

NOTE:
When replacing the occupant detection system, or
when removing and disassembling the passengers seat cushion cover, always perform the system calibration after installing a seat in the vehicle.
CAUTION:
When trouble occurs in the system during calibration process, DTC 2A OCCUPANT DETECTION CALIBRATION FAILURE of the airbag
system is detected and the airbag warning light
lights. In this case, after turning the ignition
switch to OFF once, redo the system calibration
(Rezeroing), or after clearing the cause of the
failure, perform the system calibration again.
1) Park empty vehicle on a level surface.
screen, select the {Occupant detection system}.
4) On the Occupant Detection System display
screen, select the {Zero Point Adjustment}.
OD-00025
7) When the Re-zeroing Unbelt the Passenger

seatbelt Continue: OK, Quit: NO is displayed,
make sure the passengers seatbelt is disconnected from the buckle, then select the [OK].
8) When the Re-zeroing Empty the passenger
seat Continue: OK, Quit: NO is displayed, make
sure that the passengers seat is empty, airbag
OFF indicator illuminates and airbag ON indicator
does not illuminate, and then select the [OK].
NOTE:
After selecting the [OK], Now processing
Wait for a while. Do not touch or give impact to vehicle and seat is displayed. Do not touch or rock
the vehicle while the message is displayed.
During the system calibration process, if the
Re-zeroing is unsuccessful See service manual
Press OK to END is displayed, go to step 10).
9) When the re-zeroing is normally completed,
Re-zeroing is successfully completed Press OK
to END is displayed. Select the [OK] and turn the
ignition switch to OFF to complete.
OD(diag)-17

10) During the system calibration process, if Rezeroing is unsuccessful See service manual Press
OK to END is displayed, turn the ignition switch to
OFF once and turn it ON again, then read the DTC
of the airbag system. <Ref. to AB(diag)-29, OPERATION, Subaru Select Monitor.>
When DTC is input, fix the fault and then perform
the system calibration. When DTC is not input,
check the seat and vehicle status and then perform
the system calibration again. <Ref. to OD(diag)-17,
SYSTEM CALIBRATION (REZEROING), OPERATION, Subaru Select Monitor.>
NOTE:
When the re-zeroing is unsuccessful, there could
be occupant detection system failure or the seat
and the vehicle does not match. When the airbag
warning light illuminates, read the DTC of the airbag system, and perform the diagnosis while referring to List of Diagnostic Trouble Code. <Ref. to
AB(diag)-29, OPERATION, Subaru Select Monitor.> <Ref. to AB(diag)-42, LIST, List of Diagnostic
B: INSPECTION
1. COMMUNICATION FOR INITIALIZING
IMPOSSIBLE
TROUBLE SYMPTOM:
Communication is impossible between the airbag
control module and the Subaru Select Monitor.
Refer to Initial Communication Impossible in the
DTC of the airbag system (diagnosis). <Ref. to
AB(diag)-31, INSPECTION, Subaru Select Monitor.>
2. WITHOUT DTC
TROUBLE SYMPTOM:
Airbag warning light remains on.
NO TROUBLE CODE will be displayed on the
For detailed operation procedures, refer to Airbag
Warning Light Failure. <Ref. to AB(diag)-37, Airbag Warning Light Failure.>
NOTE:
When the airbag warning light is OFF and NO
TROUBLE CODE is displayed on Subaru Select
Monitor, the system is operating properly.
OD(diag)-18


Code (DTC)
A: OPERATION
For details about reading of DTCs, refer to Subaru
Select Monitor. <Ref. to AB(diag)-29, Subaru Select Monitor.>
OD(diag)-19
Inspection Mode
8. Inspection Mode
A: PROCEDURE
Recreate the circumstance by referring to the conditions described in the checklist.
OD(diag)-20
Clear Memory Mode


A: OPERATION
Clear the memory in the following steps after the
malfunction is repaired.
Subaru Select Monitor. <Ref. to AB(diag)-29,
OD(diag)-21
Airbag Warning Light Illumination Pattern

10.Airbag Warning Light

Illumination Pattern
A: INSPECTION
Turn the ignition switch to ON, and confirm that the
airbag warning light remains on for approx. 6 seconds then turns off afterwards.
(2)
ON
(1)
OFF
(3)
AB-00135
(1) Airbag warning light

(2) Approx. 6 sec.
OD(diag)-22
Passengers Airbag ON/OFF Indicator Light Illumination Pattern

11.Passengers Airbag ON/OFF Indicator Light Illumination Pattern

A: INSPECTION
(6)
(6)
(5)
(5)
(1)
(5)
(12)
(6)
(6)
(6)
(5)
(5)
(5)
(2)
(13)
(9)
(8)
(7)
(7)
(3)
(11)
(4)
(10)
(10)
OD-00010
(1)
Passengers airbag ON indicator

light
(4)
(5)
Ignition switch
Light OFF
(9)
(10)
Adult
OFF
(2)
Passengers airbag OFF indicator

light
(6)
(7)
Light ON
Empty
(11)
(12)
ON
Approx. 6 sec.
(3)
Occupant seating
(8)
Child
(13)
Approx. 2 sec.
OD(diag)-23


A: LIST
DTC
2A
2B
2C
27
29
37
Display
ODS Calibration Error
ODS System Wrong Parts
Belt Tension Sensor Failure
Occupant Detection System

Improper Communication
Occupant Detection System Failure
Buckle Switch RH Failure
System calibration (Rezeroing) was not
completed normally.
Wrong airbag control module was
installed.
Wrong occupant detection system was
installed.
Passengers seat belt tension sensor is
faulty.
Airbag rear harness circuit is open or
shorted.
Occupant detection control module and
airbag control module communication is
faulty.
Airbag rear harness circuit is open or
shorted.
Short circuit to the ground or the power supply.
Occupant detection control module is
faulty.
Passengers buckle switch circuit is open,
shorted or shorted to ground.
OD(diag)-24
Reference
<Ref. to OD(diag)-25, DTC 2A
ODS CALIBRATION ERROR,
Diagnostic Procedure with
Diagnostic Trouble Code
(DTC).>
<Ref. to OD(diag)-25, DTC 2B
ODS SYSTEM WRONG
PARTS, Diagnostic Procedure
with Diagnostic Trouble Code
(DTC).>
<Ref. to OD(diag)-26, DTC
2C BELT TENSION SENSOR FAILURE, Diagnostic
Procedure with Diagnostic
<Ref. to OD(diag)-28, DTC 27

ODS COMMUNICATION
ERROR, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>

ODS FAILURE, Diagnostic
Procedure with Diagnostic
BUCKLE SWITCH RH FAILURE, Diagnostic Procedure
with Diagnostic Trouble Code
(DTC).>


A: DTC 2A ODS CALIBRATION ERROR
System calibration (Rezeroing) was not completed properly.
1
Step
PERFORM RE-ZEROING.
Perform the system calibration using the Subaru Select Monitor. <Ref. to OD(diag)-16,
Check
Is the system calibration completed correctly?
Yes
No
Finish the diagno- Follow the system
sis.
calibration procedures. <Ref. to
OD(diag)-16,
B: DTC 2B ODS SYSTEM WRONG PARTS

Wrong airbag control module is installed.
Wrong occupant detection system is installed.
1
Step
2) Replace the passengers seat cushion pad
and seat cushion frame assembly. <Ref. to SE7, REMOVAL, Front Seat.> <Ref. to SE-9, DISASSEMBLY, Front Seat.>
4) Connect Subaru Select Monitor to the data
link connector and perform the system calibration. <Ref. to OD(diag)-16, OPERATION, Subaru Select Monitor.>
CHECK AIRBAG CONTROL SYSTEM.
2) Replace the airbag control module. <Ref. to
AB-16, REMOVAL, Side Airbag Module.>
4) Connect Subaru Select Monitor to the data
link connector and perform the system calibration. <Ref. to OD(diag)-16, OPERATION, Subaru Select Monitor.>
Check
Yes
No
Finish the diagno- Go to step 2.
sis.
Finish the diagno- Check between the

sis.
occupant detection
control module and
airbag control
module.
OD(diag)-25

C: DTC 2C BELT TENSION SENSOR FAILURE

Passengers seat belt tension sensor is faulty.
Airbag main harness circuit is open or shorted.
WIRING DIAGRAM:
TO POWER SUPPLY CIRCUIT
BELT TENSION SENSOR

B34
(YELLOW)
FB-37
F/B FUSE NO.6
(IG)
1 2
AB63
AB53
B34
2
1 2 3
4 5 6
AB50
AB63
4
AB53
(BROWN)
1 2 3
AB54
16
14
AB67
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
OCCUPANT DETECTION
CONTROL MODULE
AB67
OD-00055
OD(diag)-26

Step
between the occupant detection control module
and belt tension sensor.
CHECK BELT TENSION SENSOR.
2) Disconnect the belt tension sensor connector (AB63) from the airbag harness.
3) Connect the test harness AC to the connector (AB63).
2) Disconnect the test harness AC from the
belt tension sensor connector (AB63).
3) Connect the test harness AD (1AD) to the
connector (AB63).
4) Disconnect the airbag harness connector
(AB62), and connect connector (1AB) of test
harness AB.
5) Measure the resistance between test harness terminals.
(2AB) No. 5 (2AD) No. 1:
(2AB) No. 4 (2AD) No. 3:
(2AB) No. 6 (2AD) No. 2:
Measure the resistance between test harness
terminals, and between test harness terminal
and chassis ground.
(2AB) No. 4 (2AD) No. 1:
(2AB) No. 4 (2AD) No. 2:
(2AB) No. 4 Chassis ground:
(2AB) No. 5 (2AD) No. 2:
(2AB) No. 5 Chassis ground:
2) Measure the voltage between test harness
and chassis ground.
(2AD) No. 1 (+) Chassis ground ():
(2AD) No. 3 (+) Chassis ground ():
Check

illuminate for approximately 6
seconds and go off?
Yes
No
Reconnect the
Go to step 2.
connector. If the
fault is not fixed,
replace the airbag
harness.
belt outer. <Ref. to
SB-10, REMOVAL,
Front Seat Belt.>
Replace the airbag

harness.
more?
Go to step 5.
Replace the airbag

harness.
Is the voltage 1 V or less?
Replace the airbag Check the occuharness.

pant detection harness, and if any
fault is found,
replace the occupant detection harness. If no fault is
found in the occupant detection harness, replace the
seat cushion frame
assembly. <Ref. to
SE-9, DISASSEMBLY, Front Seat.>
OD(diag)-27

D: DTC 27 ODS COMMUNICATION ERROR

Perform the diagnosis by following diagnostic procedures for the airbag system. <Ref. to AB(diag)-65, DTC
27 ODS COMMUNICATION ERROR, Diagnostic Chart with Trouble Code.>
E: DTC 29 ODS FAILURE

Side airbag harness is faulty.
1
Step
Check
CHECK POOR CONTACT OF CONNECTOR. Is there poor contact?
and airbag control module.
Yes
Reconnect the
connector. If the
fault is not fixed,
replace the airbag
harness.
CHECK DIAGNOSTIC TROUBLE CODE
Is 2C BELT TENSION SENPerform the diag(DTC).
SOR FAILURE or 37 BUCKLE nosis according to
Read diagnostic trouble code (DTC) for the air- SWITCH FAILURE displayed each DTC.
bag system.
as the diagnostics code?
OD(diag)-28
No
Go to step 2.
Check the occupant detection harness, and if any

fault is found,
replace the occupant detection harness. If the fault is
not fixed, replace
the occupant
detection system.
<Ref. to SE-9, DISASSEMBLY, Front
Seat.>

F: DTC 37 BUCKLE SWITCH RH FAILURE

Passengers seat buckle switch circuit is open, shorted or shorted to ground.
Seat harness circuit is open, shorted or shorted to ground.
WIRING DIAGRAM:
BUCKLE
SWITCH
AB66
1 2
AB66
AB67
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
OCCUPANT DETECTION
CONTROL MODULE
AB67
OD-00056
Step
Check
CHECK POOR CONTACT OF CONNECTOR. Is there poor contact?
and buckle switch.
Yes
Reconnect the
connector. If the
fault is not fixed,
replace the airbag
harness.
CHECK BUCKLE SWITCH.
Does the airbag warning light Replace the buckle
1) Turn the ignition switch to OFF, disconnect illuminate for 6 seconds and go switch. <Ref. to
the battery ground cable, and wait for more than off?
SB-10, REMOVAL,
20 seconds.
Front Seat Belt.>
2) Disconnect the buckle switch connector
(AB66).
3) Connect the test harness AE (1AE) and test
harness connector Y to the buckle switch connector (AB66).
OD(diag)-29
No
Go to step 2.
Check the occupant detection harness, and if any

fault is found,
replace the occupant detection harness. If the fault is
not fixed, replace
the occupant
detection system.

OD(diag)-30
General Description
SEAT BELT SYSTEM
A: COMPONENT
1. FRONT SEAT BELT
Drivers side
T2
(1)
(2)
T3
(3)
T1
T2
(4)
T2
SB-00322
(1)
Adjustable anchor ASSY
(3)
Outer belt ASSY
(2)
Anchor cover
(4)
Inner seat belt ASSY

T1: 7.5 (0.76, 5.5)
T2: 30 (3.1, 22)
T3: 53 (5.4, 39)
SB-2
General Description
SEAT BELT SYSTEM
Passengers side
T3
(1)
(2)
T2
(3)
T3
T1
(5)
(6)
(4)
T2
T2
(7)
T2
SB-00332
(1)
(2)

Shoulder anchor
(5)
(6)
Outer belt ASSY

Belt tension sensor
(3)
(4)
Anchor cover
Seat belt retractor
(7)
SB-3

T1: 7.5 (0.76, 5.5)
T2: 30 (3.1, 22)
T3: 53 (5.4, 39)
General Description
SEAT BELT SYSTEM
2. REAR SEAT BELT
T1
T1
(6)
(2)
(1)
(6)
T2
(7)
T1
T1
(3)
(4)
(5)
T1
T1
T1
SB-00057
(1)
(2)
Outer seat belt RH

Outer seat belt center
(5)
(6)
Inner seat belt LH

Anchor cover
(3)
(4)
Outer seat belt LH

Inner seat belt RH
(7)
SB-4

T1: 30 (3.1, 22)
T2: 53 (5.4, 39)
General Description
SEAT BELT SYSTEM
B: CAUTION
Before starting the work, turn the ignition switch
to OFF, disconnect the battery ground cable and
wait for 20 seconds or more.
The pretensioner system has a backup power
source. Be careful because the pretensioner might
deploy if you do not wait for 20 seconds or more before starting work.
Do not drop or apply any impact to the pretensioner.
If oil, grease or water gets on the pretensioner,
wipe it off immediately with a dry cloth.
Do not expose the pretensioner to high temperature or flame.
Do not allow current to flow through or voltage to

reach the pretensioner. Do not use a circuit tester
to check resistance of the pretensioner.
Do not disassemble or attempt to repair the pretensioner. If it is dented, cracked or deformed, replace it with a new part.
Do not use the airbag or pretensioner parts from
other vehicles. Always replace the parts with new
parts.
When handling a seat belt with deployed pretensioner, wear gloves and goggles. Wash your hands
afterwards.
Do not reuse a seat belt with deployed pretensioner.
If the material gets in your eyes or on your skin
during deployment, wash it away with clean water,
and then consult a doctor.
C: PREPARATION TOOL
1. GENERAL TOOL
TOOL NAME
TORX T50
REMARKS
Used for removing and installing the inner seat belt assembly.
SB-5
Pretensioner Connector
SEAT BELT SYSTEM
2. Pretensioner Connector
A: PROCEDURE
Refer to airbag connectors in the airbag section.
<Ref. to AB-8, PROCEDURE, Airbag Connector.>
SB-6
Seat Belt Warning System

SEAT BELT SYSTEM
3. Seat Belt Warning System

A: WIRING DIAGRAM
<Ref. to WI-103, WIRING DIAGRAM, Seat Belt Warning System.>
B: INSPECTION
TROUBLE SYMPTOM:
Seat belt warning light does illuminate or it remains illuminating.
Buzzer does not beep.
1
Step
CHECK BODY INTEGRATED UNIT POWER
SUPPLY.
2) Measure the voltage between body integrated unit connector and chassis ground.
CHECK HARNESS BETWEEN BODY INTEGRATED UNIT AND CHASSIS GROUND.
2) Disconnect the connector from body integrated unit.
3) Measure the resistance between body integrated unit harness connector and chassis
ground.
CHECK SEAT BELT SWITCH AND HARNESS.
1) Pull out the tongue plate from the drivers
seat belt buckle.
2) Measure the resistance between body integrated unit harness connector and chassis
ground.
CHECK SEAT BELT SWITCH AND HARNESS.
1) Insert the tongue plate to the drivers seat
belt buckle in the condition of step 3.
2) Measure the resistance between body integrated unit connector and chassis ground.
CHECK HARNESS BETWEEN BODY INTEGRATED UNIT AND SEAT BELT SWITCH.
body integrated unit connector and seat belt
switch.
Without power seat
(B281) No. 3 (R8) No. 2:
With power seat
(B281) No. 3 (R188) No. 8:
Check
Yes
Go to step 2.
No
Check the harness
battery.

?
Go to step 3.
Check the harness

chassis ground.
more?
Go to step 4.
Check the harness

between body integrated unit connector and chassis
ground.

?
Go to step 7.
Go to step 5.

?
Go to step 6.
Check the harness

between body integrated unit connector and seat belt
switch.
SB-7

SEAT BELT SYSTEM
10
11
12
Step
CHECK HARNESS BETWEEN SEAT BELT
seat belt switch and chassis ground.
Without power seat
With power seat
CHECK SEAT BELT SWITCH.
seat belt buckle.
2) Measure the resistance between seat belt
switch terminals.
Without power seat
(R8) No. 1 (R8) No. 2:
With power seat
(R188) No. 8 (R188) No. 4:
CHECK SEAT BELT SWITCH.
1) Insert the tongue plate to the drivers seat
belt buckle.
2) Measure the resistance between seat belt
switch terminals.
Without power seat
(R8) No. 1 (R8) No. 2:
With power seat
(R188) No. 8 (R188) No. 4:
meter and chassis ground.
CHECK POOR CONTACT.
Check for poor contact in seat belt warning light
circuit.
CHECK THE BODY INTEGRATED UNIT.
seat belt buckle.
4) Check if the seat belt warning light illuminates.
CHECK THE BODY INTEGRATED UNIT.
seat belt buckle.
4) Check if the seat belt warning light illuminates and the buzzer sounds.
Check
?
Yes
Go to step 7.
No
Check harness
between seat belt
switch and chassis
ground.
more?
Go to step 8.
Replace the inner

seat belt assembly.

?
Go to step 9.
Replace the inner

seat belt assembly.
Go to step 10.
Check wiring harness and combination meter, then

repair or replace
them.
Repair the poor

contact.
Go to step 11.
Does the seat belt warning light Go to step 12.

illuminate?
Inspect the connector or harness.

If not defective,
replace the seat
belt warning light
bulb in the combination meter.
Does the seat belt warning light A temporary poor Replace the body
illuminate and the buzzer
contact of connec- integrated unit.
sound for 6 seconds?
tor or harness may
be the cause.
Check for poor
contact.
SB-8

SEAT BELT SYSTEM
4. Inspection Locations After a

Collision
A: INSPECTION
Check for the following, and replace with new parts
if necessary.
Center pillar lower trim is discolored or cracked.
Wiring harness and connector are damaged.
SB-9
Front Seat Belt

SEAT BELT SYSTEM
5. Front Seat Belt
CAUTION:
Do not drop or apply any impact to the pretensioner.
Since the pretensioner and bracket are integrated as a unit, do not disassemble them.
A: REMOVAL
1. FRONT OUTER BELT
1) Fold the backrest all the way forward, and then
move the front seat all the way forward.
2) Before working, turn the ignition switch to OFF,
disconnect the battery ground cable, and wait more
than 20 seconds.
3) Remove the center pillar lower trim. <Ref. to EI43, REMOVAL, Lower Inner Trim.>
4) Remove the anchor cover. Loosen the shoulder
anchor bolt, and then detach the shoulder anchor
from center pillar.
2. FRONT INNER BELT

1) Turn the ignition switch to OFF, disconnect the
battery ground cable, and wait more than 20 seconds.
3) Disconnect the seat belt warning light connector
under the seat.
4) Remove the harness clips from the seat rail.
5) Remove the anchor bolt, and then detach the inner belt.
SB-00003
5) Pull off the floor mat to remove the bolt.
SB-00006
B: INSTALLATION
CAUTION:
The parts on right and left are not identical.
Before installation, make sure that the correct
part is used.
Be careful not to twist the belts during installation.
SB-00004
6) Disconnect the connectors of pretensioner and

belt tension sensor, and remove the front outer
belt.
7) Remove the center pillar upper trim. <Ref. to EI42, REMOVAL, Upper Inner Trim.>
8) Remove the two bolts to remove the adjustable
anchor assembly.
Tightening torque:
<Ref. to SB-2, FRONT SEAT BELT, COMPONENT, General Description.>
C: INSPECTION
if necessary.
Pretensioner is cracked or deformed.
Seat belt is slackened, bent or worn. Seat belt is
abnormally wound or extended.
Inner belt is deformed or damaged.
Seat belt buckle cannot be engaged properly.
SB-00005
SB-10
Rear Seat Belt

SEAT BELT SYSTEM
6. Rear Seat Belt
8) Remove the two bolts to remove the adjustable

anchor assembly.
A: REMOVAL
1. OUTER BELT RH AND LH
2) Remove the rear seat. <Ref. to SE-17, REMOVAL, Rear Seat.>
4) Remove the seat belt lower anchor bolt.
SB-00011
2. OUTER SEAT BELT CENTER

1) Remove the anchor cover. Remove the bolt, and
then remove the shoulder anchor from the pillar.
SB-00008
5) Remove the anchor cover. Remove the two

bolts, and then remove the shoulder anchor from
the pillar.
SB-00009
SB-00009

7) Remove the bolts, and then detach the outer belt
side.
2) Remove the strut cap. <Ref. to EI-44, REMOVAL, Rear Quarter Trim.>
3) Remove the rear rail trim. <Ref. to EI-44, REMOVAL, Rear Quarter Trim.>
4) Remove the rear pillar upper trim. <Ref. to EI-44,
5) Remove the rear skirt trim. <Ref. to EI-44, REMOVAL, Rear Quarter Trim.>
6) Remove the rear quarter lower trim. <Ref. to EI44, REMOVAL, Rear Quarter Trim.>
7) Remove the snap lock carefully, and then remove the cover (B). Pull the outer seat belt center
tongue (A) from the hole to one side of the trim.
SB-00012
SB-00010
8) Remove the clips, and then hang the roof trim

back end from the roof.
SB-11
Rear Seat Belt

SEAT BELT SYSTEM
9) Disconnect the harness and connectors, and

then remove the outer seat belt center assembly.
SB-00036
3. INNER BELT
1) Remove the rear cushion.
2) Remove the bolt, and then detach the inner belt.
SB-00014
B: INSTALLATION
CAUTION:
During installation, make sure that the seat
belts are not twisted.
After installation, make sure that the seat
belts are smoothly extended and wound.
Tightening torque:
<Ref. to SB-4, REAR SEAT BELT, COMPONENT, General Description.>
C: INSPECTION
if necessary.
Seat belt is slackened, bent or worn.
Seat belt is abnormally wound or extended.
Inner belt is deformed or damaged.
Seat belt buckle cannot be engaged properly.
SB-12
General Description
LIGHTING SYSTEM
A: SPECIFICATION
Front turn signal light
12 V 55 W/60 W (Halogen)
D2R 35 W/60 W (HID)
12 V 21 W
Clearance light
Front side marker light
12 V 5 W
12 V 5 W
Headlight
Front fog light
12 V 51 W
12 V 5/21 W
Tail/stop light
Rear combination light
Turn signal light

Back-up light
12 V 21 W
12 V 16 W
Standard type
Rear spoiler built-in type
12 V 10 W
12 V 1.3 W
License plate light

High-mounted stop light
12 V 5 W
Room light
Spot map light
12 V 8 W
12 V 8 W
Luggage room light
12 V 5 W
B: CAUTION
Before removing or installing parts, always disconnect the battery ground cable from battery.
When replacing the radio, control unit, and other
parts provided with memory functions, record the
memory contents before disconnecting the battery
ground cable. Otherwise, the memory is cleared.
Reassemble the parts in the reverse order of disassembly procedure unless otherwise indicated.
Adjust parts to the given specifications.
Connect the connectors and hoses securely during reassembly.
After reassembly, make sure functional parts operate smoothly.
WARNING:
The airbag system wiring harness is routed
near electrical parts and switches. All airbag
system wiring harnesses and connectors are
yellow. Do not use the electrical test equipment on these circuits.
wiring harness when servicing electrical
parts and switches.
C: PREPARATION TOOL
1. GENERAL TOOL
TOOL NAME
Circuit tester
REMARKS
Used for measuring
resistance and voltage.
LI-2
Headlight and Tail Light System

LIGHTING SYSTEM
2. Headlight and Tail Light System
3. TAIL AND ILLUMINATION RELAY

Measure the resistance between tail and illumination relay terminals when connecting terminal No. 4
to the battery positive terminal and terminal No. 3 to
the battery ground terminal.
A: WIRING DIAGRAM
1. HEADLIGHT
<Ref. to WI-105, WIRING DIAGRAM, Headlight
System.>
(1)
2. CLEARANCE LIGHT AND ILLUMINATION LIGHT
(2)
(1)
(3)
(4)
(2)
<Ref. to WI-114, WIRING DIAGRAM, Clearance

Light and Illumination Light System.>
(3)
(4)
B: INSPECTION
LI-00001
1. HEADLIGHT SWITCH
<Ref. to LI-9, INSPECTION, Combination Switch
(Light).>
Continuity
Yes
No
2. HEADLIGHT RELAY
Measure the headlight relay resistance between
terminals when connecting terminal No. 4 to the
battery positive terminal and terminal No. 3 to the
battery ground terminal.
(1)
(2)
(1)
(3)
(4)
(2)
(3)
(4)
LI-00001
Continuity
Yes
No
Terminal No.
Standard
1 and 2
Less than 1
1 M or more
LI-3
Terminal No.
1 and 2
Standard
Less than 1
1 M or more
Front Fog Light System

LIGHTING SYSTEM
3. Front Fog Light System

A: WIRING DIAGRAM
1. FRONT FOG LIGHT
<Ref. to WI-111, WIRING DIAGRAM, Front Fog
Light System.>
B: INSPECTION
1. FRONT FOG LIGHT SWITCH
Measure the front fog light switch resistance.
LI-00051
Switch position
OFF
ON
Terminal No.
Standard
3 and 5
1 M or more
Less than 1
2. FRONT FOG LIGHT RELAY

Connect terminal No. 4 to battery positive terminal
and terminal No. 3 to battery ground terminal, and
measure the front fog light relay resistance between terminals.
(1)
(2)
(1)
(3)
(4)
(2)
(3)
(4)
LI-00001
Continuity
Yes
No
Terminal No.
Standard
1 and 2
Less than 1
1 M or more
LI-4
Turn Signal Light and Hazard Light System

LIGHTING SYSTEM
4. Turn Signal Light and Hazard

Light System
A: WIRING DIAGRAM
1. TURN SIGNAL LIGHT AND HAZARD
LIGHT
<Ref. to WI-117, WIRING DIAGRAM, Turn Signal
Light and Hazard Light System.>
B: INSPECTION
1. TURN SIGNAL SWITCH
<Ref. to LI-9, INSPECTION, Combination Switch
(Light).>
2. HAZARD SWITCH
Measure the hazard switch resistance.
4 3 2 1
8 7 6 5
LI-00002
Switch position
OFF
Terminal No.
6 and 7
Standard
Less than 1
ON
1, 3 and 4
7 and 8
Less than 1
Less than 1
3. TURN SIGNAL AND HAZARD MODULE

Connect the battery and the turn signal light bulb to
the module, as shown in the figure. The module is
properly functioning if it blinks when power is supplied to the circuit.
LI-00003
LI-5
Back-up Light System

LIGHTING SYSTEM
5. Back-up Light System
2. INHIBITOR SWITCH (AT MODEL)

Measure the inhibitor switch resistance.
A: WIRING DIAGRAM
1. BACK-UP LIGHT
<Ref. to WI-112, WIRING DIAGRAM, Back-up
Light System.>
6 5 4 3 2 1
12 11 10 9 8 7
B: INSPECTION
1. BACK-UP LIGHT SWITCH (MT MODEL)
Measure the back-up light switch resistance.
LI-00005
(A)
Switch position
When the shift
lever is in R
range
2 1
Other positions
(B)
2 1
4 3
LI-00317
(A) Non-turbo model

(B) Turbo model
Switch position
Terminal No.
When shift lever is

set in reverse
position
Non-turbo model:
1 and 2
Turbo model:
2 and 4
Other positions
Standard
Less than 1
1 M or more
LI-6
Terminal No.
1 and 2
Standard
Less than 1
1 M or more
Stop Light System

LIGHTING SYSTEM
6. Stop Light System

A: WIRING DIAGRAM
1. STOP LIGHT
<Ref. to WI-113, WIRING DIAGRAM, Stop Light
System.>
B: INSPECTION
1. STOP LIGHT SWITCH
Measure the stop light switch resistance.
(A)
2 1
(B)
2 1
4 3
LI-00064
(A) Model without cruise control

(B) Model with cruise control
Switch position
Terminal No.
Standard
When brake pedal

is depressed
1 and 2:
Model without
cruise control
2 and 3:
Model with cruise
control
Less than 1
When brake pedal

is released
1 M or more
LI-7
Room Light System

LIGHTING SYSTEM
7. Room Light System

A: WIRING DIAGRAM
1. ROOM LIGHT
<Ref. to WI-119, WIRING DIAGRAM, Interior Light
System.>
B: INSPECTION
1. DOOR SWITCH
Measure the door switch resistance.
1
2
3
LI-00007
Switch position
When door is
opened
When door is
closed
Terminal No.
Standard
Less than 1
1 and 3
1 M or more
2. REAR GATE LATCH SWITCH

Measure the rear gate latch switch resistance.
Switch position
Terminal No.
When rear gate is

opened
When rear gate is
closed
1 and 2
Standard
Less than 1
1 M or more
LI-8
Combination Switch (Light)

LIGHTING SYSTEM
8. Combination Switch (Light)
C: INSPECTION
A: REMOVAL
Measure the combination switch resistance.

3) Remove the screws which secure upper column
cover to lower column cover.
(A)
8
17
2
7 6 5 4 3
16 15141312 11 10
1
9
LI-00401
4) Disconnect the connector from combination

switch.
5) Remove the screws which secure the switch,
then remove the switch.
(B)
2 1
4 3
LI-00052
(A) Lighting switch and turn signal switch connector

(B) Parking switch connector
1. LIGHTING SWITCH
LI-00068
B: INSTALLATION
Switch position
OFF
Terminal No.
Standard
1 M or more
Tail
Head
14 and 16
13, 14 and 16
Less than 1
Less than 1
2. DIMMER AND PASSING SWITCH
Switch position
Terminal No.
Standard
Passing
Low beam
7, 8 and 16
16 and 17
Less than 1
Less than 1
High beam
7 and 16
Less than 1
3. TURN SIGNAL SWITCH

Switch position
Terminal No.
Standard
Left
Neutral
1 and 2
Less than 1
1 M or more
Right
2 and 3
Less than 1
4. PARKING SWITCH
LI-9
Switch position
Terminal No.
Standard
OFF
ON
2 and 4
1 and 4
Less than 1
Less than 1
Headlight Assembly
LIGHTING SYSTEM
9. Headlight Assembly
4) Use a drier to warm up the area around the seal

through the bulb installation hole.
A: REMOVAL
2) Remove the air intake duct (when right side
headlight is removed). <Ref. to IN (H4SO)-5, REMOVAL, Air Cleaner Case.>
3) Remove the front bumper. <Ref. to EI-21, REMOVAL, Front Bumper.>
4) Remove the four bolts and disconnect the connectors, and then detach the headlight assembly.
CAUTION:
Avoid heating one specific point of the seal portion and heating the headlight assembly to
120C (248F) or more.
LI-00579
5) Remove the hook, and then take the lens off the
headlight assembly.
6) Remove the packing (A) from seal groove.
CAUTION:
Completely remove the packing not to leave
any residue behind.
(A)
LI-00477
LI-00060
B: INSTALLATION
(A) Packing
C: DISASSEMBLY
2. HID HEADLIGHT BALLAST
1. LENS
CAUTION:
Do not operate with wet hands.
As the lightening circuit on the HID headlights uses high voltage, be sure to confirm that
the power supply is turned off before working
on it.
Do not leave the headlight without a ballast
for a long time. Dust, moisture, etc. entering the
headlight may affect its performance.
2) Remove the headlight assembly. <Ref. to LI-10,
REMOVAL, Headlight Assembly.>
CAUTION:
Do not touch the bulb glass portion.
Do not touch inside the lens (extension portion) or reflector portion.
Replace the packing with a new part.
REMOVAL, Headlight Assembly.>
2) Disconnect the headlight bulb connector.
3) Remove the back cover and then remove the
bulb.
LI-10
Headlight Assembly
LIGHTING SYSTEM
7) Turn the beam adjustment screw so that the

beam is facing upward, then create space for the
socket portion to pass through the inside of the
light.
3) Remove the back cover.
CAUTION:
The reflector should not interfere with the extension case.
8) Place the socket portion toward the front side of
the reflector bracket.
9) Turn the beam adjustment screw so that the
beam is facing downward, then create space for
the socket portion to pass under the reflector bracket.
LI-00478
4) Disconnect the harness connector.
CAUTION:
The reflector should not interfere with the extension case.
10) Remove the socket from headlight from below
the housing.
CAUTION:
The socket should not get sandwiched between
the reflector and the light housing.
LI-00479
5) Loosen the screws to remove ballast.
LI-00480
6) Disconnect the connector from the headlight ballast.
LI-00481
CAUTION:
Be careful because the notch is easily bent.
LI-11
Headlight Assembly
LIGHTING SYSTEM
D: ASSEMBLY
E: ADJUSTMENT
1. LENS
1. HEADLIGHT AIMING
1) Cut the tip of packing (A) at an angle of 45.

2) With the cut end facing upward, insert packing
(A) into the seal groove.
CAUTION:
Turn off the light before adjusting the headlight
aiming. If it is necessary to inspect the aiming,
do not turn on the light for more than two minutes.
CAUTION:
If the packing protrudes, slowly take it off the
groove.
Do not stretch the packing. If the packing is
stretched, seal fails.
(A)
LI-00061
(A) Packing
3) After making a round of the seal, cut its tip at an

angle of 45, with its length 10 mm (0.39 in) longer
than the circumference of seal so that the tip overlaps the other. Then, press it onto the seal, using a
screwdriver.
NOTE:
Before checking the headlight beam level, be sure
of the following:
The area around the headlight does not have
any scratch, damage or other type of deformation.
Vehicle is parked on a level surface.
The inflation pressure of tires is correct.
Vehicles fuel tank is full.
1) Bounce the vehicle several times to normalize
the suspension.
2) Make certain that someone is seated in the drivers seat.
3) Measure the distance between the low beam
valve centers and the height of the valve center.
4) Cover the headlight that is not being adjusted
with a cloth.
5) Turn the headlights on and then adjust the low
beam while displaying the beam on the screen.
10mm
LI-00062
4) Match the positions of the lens and headlight assembly, and then insert the lens into the headlight
assembly.
5) Engage the hooks.
6) Put the seal portion of headlight assembly into
the water and check that water does not enter inside the headlight.
CAUTION:
Be sure that water does not enter inside the
headlight through the bulb socket and ventilation hole.
LI-12
Headlight Assembly
LIGHTING SYSTEM
NOTE:
Adjust the vertical beam level (A) first, then horizontal beam level (B) using a screwdriver.
(B)
(A)
LI-00531
(A)
W1
W2
W2
W
W1
(A)
h
(B)
H
3m (10 ft)
LI-00054
(A) Vehicle center

h mm (in) at 3 m (10 ft)
(B) Bulb center marking

21 (0.83)
LI-13
Headlight Bulb
LIGHTING SYSTEM
10.Headlight Bulb
A: REMOVAL
1. HALOGEN TYPE
CAUTION:
Because the halogen bulb operates at a high
temperature, dirt and oil on the bulb surface reduces the bulbs service life. Hold the flange
portion when replacing the bulb and never
touch the glass portion.
The entering of dust, moisture, etc. into the
headlight may affect its performance. Therefore, never leave the headlight without a bulb
for extended periods of time.
2) Remove the air intake duct (when right side
headlight is removed). <Ref. to IN (H4SO)-5, REMOVAL, Air Cleaner Case.>
5) Remove the light bulb retaining spring to remove
the bulb.
LI-00478
LI-00479
5) Remove the light bulb retaining spring to remove

the bulb.
LI-00580
2. HID TYPE
CAUTION:
As the lightening circuit uses high voltage,
be sure to confirm that the power supply is
turned off before working on it.
When replacing the bulb, hold the flange portion and never touch the glass portion.
Do not leave the headlight without a bulb for
a long time. Dust, moisture, etc. entering the
headlight may affect its performance.
HID TYPE, REMOVAL, Headlight Bulb.>
LI-14
LI-00049
LI-00050
Headlight Bulb
LIGHTING SYSTEM
B: INSTALLATION
C: INSPECTION
1. HALOGEN TYPE
1) Visually check the bulb for blow out.
2) Check the bulb specification.
<Ref. to LI-2, SPECIFICATION, General Description.>
3) If NG, replace the bulb with a new part.
2. HID TYPE
CAUTION:
Do not touch the harness, inner headlight, or
any metallic portion of the headlight when the
light is illuminated (when the lighting switch is
turned on).
When performing a lighting test, make sure
that the headlight is mounted on the vehicle,
and the power supply is connected to the connector on the vehicles side.
2) Install a specified HID bulb for headlight lighting
test.
3) If the headlight does not illuminate, replace the
bulb with a new part.
4) Check the HID ballast.
Check the ballast in the following methods and
judge if it can be reused or not.
(1) Perform the cold start (turning on the lights
after the headlights is gone off for more than 10
minutes) and hot start (turning on the headlights
for more than 15 minutes turning off the lights
for one minute turning on the lights again)
several times and check if the headlights are lit
surely.
(2) Check the lighting condition from immediately after the cold start until the stable condition (approx. 5 min.), to make sure that the
unstable condition (flicker etc.) does not occur.
(3) Attach the two bulbs having been used for
the same period of time to the right and left
headlights and keep the headlights for approx.
30 minutes lit. Check the difference of brightness between right and left headlights.
5) If NG, replace the ballast with a new part.
LI-15
Front Turn Signal Light Bulb

LIGHTING SYSTEM
11.Front Turn Signal Light Bulb

A: REMOVAL
2) Remove the three clips holding the mud guard.
EI-01310
3) Turn over the mud guard and turn the socket and
then remove the bulb.
LI-00532
B: INSTALLATION
C: INSPECTION
LI-16
Clearance/Parking Light Bulb

LIGHTING SYSTEM
12.Clearance/Parking Light Bulb

A: REMOVAL
2) Remove the six clips holding the upper part of
bumper face and turn over the upper part of
bumper face.
3) Turn the socket and remove the bulb.
LI-00533
B: INSTALLATION
C: INSPECTION
LI-17
Front Side Marker Light Bulb

LIGHTING SYSTEM
13.Front Side Marker Light Bulb

A: REMOVAL
2) Remove the three clips holding the mud guard.
EI-01310
3) Turn over the mud guard, turn the socket and

then remove the bulb.
B: INSTALLATION
C: INSPECTION
LI-18
Front Fog Light Assembly

LIGHTING SYSTEM
14.Front Fog Light Assembly
C: ADJUSTMENT
A: REMOVAL
Fog light aiming

3) Remove the lower side bolt.
NOTE:
Before checking the fog light beam level, be sure of
the following:
The area around the fog light does not have any
scratch, damage or other type of deformation.
Vehicle is parked on a level surface.
The inflation pressure of tires is correct.
Vehicles fuel tank is full.
1) Bounce the vehicle several times to normalize
the suspension.
2) Make certain that someone is seated in the drivers seat.
3) Measure the height of fog light center.
4) Disengage the three clips, and then turn over the
mud guard.
LI-00484
4) Remove the upper side clip, and then detach the

fog light assembly.
EI-01310
LI-00485
B: INSTALLATION
LI-19
Front Fog Light Assembly

LIGHTING SYSTEM
5) Adjust the front fog light pattern by inserting a

Phillips screwdriver to the adjusting hole.
(1)
LI-00581
(1) Adjusting hole
(A)
(A)
h
(h)
H
(B)
LI-00403
(A)
Vehicle center
h dimension mm (in)
(B)
3 m (10 ft)
60 (2.4)
LI-20
(H)
Height of fog light center (mm)
Front Fog Light Bulb

LIGHTING SYSTEM
15.Front Fog Light Bulb

A: REMOVAL
2) Disengage the three clips, and then turn over the
mud guard.
EI-01310
3) Remove the spring retainer then detach the fog

light bulb.
LI-00486
B: INSTALLATION
C: INSPECTION
LI-21
Rear Combination Light Assembly

LIGHTING SYSTEM
16.Rear Combination Light Assembly

A: REMOVAL
2) Remove the two bolts, and then detach the rear
combination light after disconnecting the connector.
LI-00487
LI-00488
B: INSTALLATION
LI-22
Tail/Stop Light Bulb

LIGHTING SYSTEM
17.Tail/Stop Light Bulb

A: REMOVAL
1) Remove the rear combination light assembly.
<Ref. to LI-22, REMOVAL, Rear Combination Light
Assembly.>
LI-00489
B: INSTALLATION
C: INSPECTION
LI-23
Rear Turn Signal Light Bulb

LIGHTING SYSTEM
19.Rear Turn Signal Light Bulb

A: REMOVAL
1) Remove the rear combination light assembly.
<Ref. to LI-22, REMOVAL, Rear Combination Light
Assembly.>
LI-00492
B: INSTALLATION
C: INSPECTION
LI-25
License Plate Light

LIGHTING SYSTEM
20.License Plate Light

A: REMOVAL
1) Remove the license plate light mounting screw
(A) and then remove the lens.
(A)
LI-00034
2) Remove the bulb.
B: INSTALLATION
C: INSPECTION
LI-26
High-mounted Stop Light

LIGHTING SYSTEM
21.High-mounted Stop Light

A: REMOVAL
1. REAR SPOILER BUILT-IN TYPE
2) For model with roof spoiler, remove the roof
spoiler.
3) Unpeel the tape on the backside of the highmounted stop light and remove the nuts, to remove
the high-mounted stop light.
LI-00494
2. STANDARD TYPE
2) Remove the screws (a) and then detach the cover (b).
3) Remove the screws (c) and then detach the
high-mounted stop light while disconnecting the
connector.
(c)
(b)
(a)
LI-00683
B: INSTALLATION
C: INSPECTION
LI-27
Side Turn Signal Light Assembly

LIGHTING SYSTEM
22.Side Turn Signal Light Assembly

A: REMOVAL
2) Remove the scalp cap. <Ref. to GW-11, REPLACEMENT, Scalp Cap.>
3) Disconnect the harness connector, remove the 3
mounting screws and then remove the side turn
signal light assembly.
LI-00293
B: INSTALLATION
C: INSPECTION
1) Install the side turn signal light assembly and
check that it blinks normally.
2) If it does not blink normally, replace the side turn
signal light assembly with a new part.
NOTE:
Since a LED (Light Emitting Diode) is used for the
side turn signal light, replace the side turn signal
light assembly if the LED does not turn on.
LI-28
Spot Map Light

LIGHTING SYSTEM
23.Spot Map Light

A: REMOVAL
2) Insert a flat tip screwdriver into the notch on the
lens and remove it by prying.
LI-00038
3) Remove the spot map light mounting screw.
LI-00678
4) Disconnect the harness connectors and remove

the spot map light.
B: INSTALLATION
C: INSPECTION
1. SPOT MAP LIGHT BULB
2. SPOT MAP LIGHT SWITCH

Measure the spot map light switch resistance.
Switch position
Terminal No.
Standard
OFF
ON
1 and 2
1 M or more
185.4
LI-29
Room Light
LIGHTING SYSTEM
24.Room Light
A: REMOVAL
2) Remove the lens (A) and mounting screws (B).
(B)
(B)
(A)
LI-00040
3) Disconnect the harness connector and remove

the room light.
B: INSTALLATION
C: INSPECTION
1. ROOM LIGHT BULB
2. ROOM LIGHT SWITCH

Measure the room light switch resistance.
R52
3 2 1
LI-00041
Switch position
OFF
Terminal No.
Standard
1 M or more
ON
DOOR
1 and 3
1 and 2
1.50.5
1.50.5
LI-30
Luggage Room Light

LIGHTING SYSTEM
25.Luggage Room Light
C: INSPECTION
A: REMOVAL
1. LUGGAGE ROOM LIGHT BULB

2) Remove the lens (A) and mounting screws (B) of
the luggage room light.

2. LUGGAGE ROOM LIGHT SWITCH

Measure the luggage room light switch resistance.
(3)
(1)
(B)
(2)
(B)
LI-00043
(A)
LI-00042

the luggage room light.
B: INSTALLATION
LI-31
Switch position
OFF
Terminal No.
Standard
1 M or more
ON
DOOR
1 and 3
1 and 2
1.50.5
1.50.5
Luggage Room Light

LIGHTING SYSTEM
LI-32
General Description
WIPER AND WASHER SYSTEMS
A: SPECIFICATION
Front wiper motor
Input
12 V 72 W or less
Rear wiper motor
Input
Pump type
12 V 42 W or less
Centrifugal
Input
Pump type
12 V 36 W or less
Centrifugal
Input
12 V 36 W or less
Front washer pump

Rear washer pump
B: COMPONENT
1. FRONT WIPER
T1
T1
T2
(5)
(4)
T2
T1
(1)
(3)
(1)
(3)
(2)
(2)
WW-00302
(1)
(2)
Wiper rubber
Wiper blade ASSY
(3)
Wiper arm
(4)
(5)
Wiper link
Wiper motor

T1: 6.0 (0.61, 4.4)
T2: 20 (2.0, 14.5)
WW-2
General Description
2. REAR WIPER
(5)
T1
(6)
(7)
T2
(8)
(9)
T3
(4)
(10)
(1)
(3)
(2)
WW-00382
(1)
(2)
Wiper rubber
Wiper blade ASSY
(6)
(7)
Cushion
Spacer B
(3)
(4)
Wiper arm
Wiper motor
(8)
(9)
Nut
Cap
(5)
Spacer A
(10)
Wiper arm cover

T1: 6.0 (0.61, 4.4)
T2: 7.5 (0.76, 5.5)
T3: 8.0 (0.82, 5.9)
WW-3
General Description
3. WASHER TANK
(1)
(2)
(4)
(1)
(3)
T
(7)
(6)
T
(7)
(1)
(8)
(5)
(2)
(2)
WW-00419
(1)
(2)
Washer nozzle
Washer hose
(5)
(6)
Front washer motor

Rear washer motor
(3)
(4)
Washer tank
Washer tank cap
(7)
(8)
Grommet
Washer motor cover
C: CAUTION
After reconnection, make sure each part operates
normally.
Be careful with the airbag system wiring harness
which passes near electrical parts and switches.
All airbag system wiring harness and connectors
are colored yellow. Do not use a tester equipment
on these circuits.
Care must be taken when connecting the washer
hose so that no bending, jamming, etc. are caused.

T: 6.0 (0.61, 4.4)
If even a small amount of silicon oil or grease enters tank and washer fluid passages, an oil film will
be formed on the glass, and will cause the wiper to
chatter and judder. Be careful no oil comes into
contact with the system.
WW-4
Wiper and Washer System

2. Wiper and Washer System

A: WIRING DIAGRAM
1. WIPER AND WASHER (FRONT)
<Ref. to WI-121, WIRING DIAGRAM, Front Wiper and Washer System.>
2. WIPER AND WASHER (REAR)

<Ref. to WI-122, WIRING DIAGRAM, Rear Wiper and Washer System.>
B: INSPECTION
Symptom
Wiper and washers do not operate.
Repair order
(1) Wiper fuse (F/B No. 14, 15)
(2) Combination switch
(3) Wiper motor
(4) Wiring harness
(2) Wiper motor
(3) Wiring harness
Wipers do not operate in LO or HI.
Wipers do not operate in INT.

(2) Wiper motor
(3) Wiring harness
Washer motor does not operate.
(1) Washer switch

(2) Washer motor
(3) Wiring harness
Wipers do not operate when washer switch is turned to ON.
(1) Wiper motor

(2) Wiring harness
Washer fluid spray does not operate properly.
(1) Washer motor

(2) Washer hose and nozzle
WW-5
Combination Switch (Wiper)

3. Combination Switch (Wiper)
C: INSPECTION
A: REMOVAL
Inspect the continuity between each connector

terminal.

3) Loosen the screw to remove a steering column
lower cover.
4) Remove the steering column upper cover
mounting screw.
9 8
18 17
WW-00309
7 6 5 4 3
16 15 14 13 12
2 1
11 10
5) Disconnect the connector from combination

switch.
6) Loosen the screw to remove the combination
switch.
WW-00301
Front
Switch position
LO
Terminal No.
7 and 17
Standard
Less than 1
HI
Washer ON
8 and 17
2 and 11
Less than 1
Less than 1
Washer ON
2 and 12
Between any
two of following terminals:
2, 10, 12, 13
Less than 1
INT
ON
2 and 13
2 and 10
Less than 1
Less than 1
Washer ON
2 and 10
10 and 12
2 and 12
Less than 1
OFF
WW-00300
Rear
B: INSTALLATION
1 M or more
If continuity is not as specified, replace the switch.

Intermittent operation inspection
Inspect wiper switch separately
1) Set the voltmeter between switch terminal No. 7
(+) and No. 2 ().
2) Connect the battery between switch terminal No.
17 (+) and No. 2 ().
3) Turn the front wiper switch to INT.
4) Connect the battery (+) to switch terminal No. 16
for 5 seconds.
WW-6
Combination Switch (Wiper)

5) Connect battery () to switch terminal No. 16

and measure the voltage during intermittent operation.
Terminals
No. 7 No. 2:
(D)
(A)
(B)
(C)
WW-00385
(A) Approx. 12 V
(B) Approx. 0 V
(C) Intermittent stationary time
(D) Connect battery () to terminal No. 16.
6) Perform step 1) to 5) when intermittent control

switch is in MIN or MAX.
Intermittent stationary time:
MIN: Approx. 2 sec.
MAX: Approx. 16 sec.
7) If operation is not as specified, replace the
switch.
WW-7
Wiper Blade
4. Wiper Blade
C: DISASSEMBLY
A: REMOVAL
1. FRONT
1. FRONT
Pull side (A) of the wiper rubber stopper and remove the rubber from the blade assembly.
While pushing the locking clip (A) up, pull out the
blade assembly to the direction of the arrow and remove it from the wiper arm.
3
(A)
2
3
WW-00009
2. REAR
Pull the wiper rubber top slightly from stopper (A)
and pull out completely.
WW-00064
2. REAR
Turn the blade in the direction of arrow (A) and remove it from arm.
(A)
(1)
(2)
WW-00112
(3)
(A)
WW-00207
(A) Turn the wiper blade.

(1) Wiper arm
(2) Wiper blade
(3) Wiper blade attachment section
B: INSTALLATION
2) Confirm that the clip is locked securely.
WW-8
Wiper Blade
D: ASSEMBLY
2) Insert the wiper rubber until its top end protrudes

approx. 20 mm (0.79 in) from stopper (D).
1. FRONT
1) Insert the wiper rubber onto the blade so that the
stopper is in the position shown.
(A)
WW-00199
(A) 20 mm (0.79 in)

WW-00196
2) Make sure the wiper rubber is securely fastened

to the pull stopper (A).
3) Insert the wiper rubber into claw (A).
WW-00147
WW-00037
E: INSPECTION
1) When the wiper does not operate properly, inspect the following item.
Make sure the movable part of blade assembly
moves smoothly.
Make sure the wiper rubber is not deformed or
damaged.
2) Replace with a new part if damage is found.
2. REAR
WW-00421
1) Insert the wiper rubber into claw (B).
A
B
WW-00198
WW-9
Washer Tank and Motor

5. Washer Tank and Motor
E: INSPECTION
A: REMOVAL
Apply battery voltage to the connector terminal of

the washer motor and make sure the motor operates.

4) Remove the clip holding washer water supply
tap.
2 1
WW-00173
WW-00342
5) Remove three bolts, hose and connector, and

then remove the washer tank.
WW-00384
B: INSTALLATION
Tightening torque:
6.0 Nm (0.61 kgf-m, 4.4 ft-lb)
C: DISASSEMBLY
Pull out the washer motor from tank.
WW-00344
D: ASSEMBLY
2) Confirm that water does not leak from installation area of motor.
WW-10
Front Wiper Arm

6. Front Wiper Arm

A: REMOVAL
2) Remove the cap.
3) Loosen the nut to remove the arm.
WW-00047
B: INSTALLATION
2) Operate the wiper once.
3) Align the wiper blade to ceramic print point mark
(A) of front window panel.
(A)
WW-00048
Tightening torque:
Refer to COMPONENT of General Description. <Ref. to WW-2, FRONT WIPER, COMPONENT, General Description.>
C: ADJUSTMENT
Operate the wiper once. Align the wiper blade to
ceramic print point mark (A) of front window panel.
(A)
WW-00048
WW-11
Front Wiper Motor and Link

7. Front Wiper Motor and Link
B: INSTALLATION
A: REMOVAL
1) Install the wiper link to the vehicle, then connect

the motor connector.
3) To confirm that the motor is at the auto stop position, connect the harness to the motor and turn
the wiper switch ON/OFF once.
5) Tighten the nut where rod (A) and link plate (B) is
aligned in a straight line.

2) Remove the cowl panel. <Ref. to EI-31, REMOVAL, Cowl Panel.>
3) Disconnect the connector of motor.
4) Loosen the bolts and nuts to remove the wiper
link.
(B)
(A)
WW-00050
WW-00052
5) Loosen the bolts and nuts to remove the motor.

Tightening torque:
Refer to COMPONENT of General Description. <Ref. to WW-2, FRONT WIPER, COMPONENT, General Description.>
WW-00051
WW-12
Front Wiper Motor and Link

C: INSPECTION
1) When the battery is connected to the terminal of
connectors as shown in the figure, confirm that the
motor operates at low speed.
4) Connect the battery and confirm that the motor

stops at the automatic stop position after the motor
operates at low speed again.
3 2 1
5 4
3 2 1
5 4
WW-00306
WW-00303
2) When the battery is connected to the terminal of

connectors as shown in the figure, confirm that the
wiper motor operates at high speed.
3 2 1
5 4
WW-00304
3) Connect the battery to terminals of the connector, and remove the terminal connection with motor
rotating at low speed, and stop the wiper motor in
mid-operation.
3 2 1
5 4
WW-00305
WW-13
Front Washer Nozzle

8. Front Washer Nozzle

A: REMOVAL
1) Remove the washer hose from the washer nozzle.
2) Open the clips on the underside of the front hood
with a thin screwdriver or other tool, and remove
the washer nozzle.
WW-00023
B: INSTALLATION
C: INSPECTION
Make sure the nozzle and hose are not clogged.
Make sure the hose is not bent.
It is not possible to adjust the ejection position of
the washer liquid because it is the scatter nozzle.
If the spray position is largely different from the
position shown as follows, replace the washer nozzle.
In ejection position:
A: 250 mm (9.84 in)
B: 345 mm (13.58 in)
A
(c)
PI-00015
(C) Nozzle
WW-14
Rear Wiper Arm

9. Rear Wiper Arm
C: ADJUSTMENT
A: REMOVAL
1) Operate the rear wiper once.

2) Align the blade to center of the rear defogger
heat wire (A).
1) Detach the wiper arm cover (A).
(A)
WW-00191
WW-00348
2) Loosen the nut to remove the wiper arm.
WW-00192
B: INSTALLATION
2) Operate the rear wiper once.
3) Align the blade to center of the rear defogger
heat wire (A).
(A)
WW-00348
Tightening torque:
Refer to COMPONENT of General Description. <Ref. to WW-3, REAR WIPER, COMPONENT, General Description.>
WW-15
Rear Wiper Motor

10.Rear Wiper Motor
C: INSPECTION
A: REMOVAL
1) Connect the battery to the wiper motor connector and confirm that wiper motor operates.

2) Remove the rear wiper arm.
3) Remove the cap (A), nut (B), and spacer (C)
from rear wiper shaft.
2 1
4 3
(A)
(B)
(C)
WW-00030
2) Connect the battery to terminals of the connector, and remove the terminal connection with motor
rotating, and stop the wiper motor in mid-operation.
WW-00346
4) Remove the rear gate lower trim. <Ref. to EI-47,

REMOVAL, Rear Gate Trim.>
5) Unclip the clip of harness and disconnect connector of wiper motor.
6) Loosen the bolts to remove the wiper motor assembly (A).
2 1
4 3
WW-00031
3) Connect the battery and confirm that the motor

stops at the automatic stop position after the motor
operates at low speed again.
WW-00028
2 1
4 3
B: INSTALLATION
2) Install the rear wiper cushion with the arrow
mark facing up, as shown in the figure.
WW-00032
WW-00029
Tightening torque:
Refer to COMPONENT of General Description. <Ref. to WW-3, REAR WIPER, COMPONENT, General Description.>
WW-16
Rear Washer
11.Rear Washer
A: REMOVAL
1) Remove the rear gate upper trim. <Ref. to EI-47,
REMOVAL, Rear Gate Trim.>
2) Remove the washer hose from the washer nozzle.
3) Push the anchor of the washer nozzle body with
a flat tip screwdriver or equivalent, and remove the
washer nozzle.
WW-00201
B: INSTALLATION
2) Adjust the position of the washer liquid sprayer.
<Ref. to WW-17, ADJUSTMENT, Rear Washer.>
C: INSPECTION
Make sure the nozzle and hose are not clogged.
Make sure the hose is not bent.
D: ADJUSTMENT
1) Turn the wiper switch to OFF position.
2) When the vehicle stops, adjust the washer liquid
ejection position as shown in the figure.
In ejection position:
A: 35 mm (1.38 in)
B: 72
(1)
WW-00054
(1) Nozzle
WW-17
Wiper Control Relay

12.Wiper Control Relay
C: INSPECTION
A: REMOVAL
1) Disconnect the connector from the wiper control

relay.
2) Connect the positive (+) probe from the battery
to terminal 8 and the negative () probe to terminal
6. Connect the positive (+) probe from the voltage
meter to terminal 3 and the negative () probe to
the ground.

2) Remove the quarter lower trim RH. <Ref. to EI44, REMOVAL, Rear Quarter Trim.>
3) Loosen the nut to remove the control unit.
WW-00034
B: INSTALLATION
WW-00035
3) Measure the voltage when the wiper relay operates.
(A)
(B)
(D)
(C)
(E)
(F)
WW-00055
(A) Switch position

(B) Voltage
(C) ON
(D) 12 V
(E) 0 V
(F) 92 sec.
If operation is not as specified, replace the switch.
WW-18
General Description
ENTERTAINMENT
A: CAUTION
Before disassembling or reassembling parts, always disconnect the battery ground cable from battery. When replacing the radio, control unit, and
other parts provided with memory functions, record
the memory contents before disconnecting the battery ground cable. Otherwise, the memory is
cleared.
B: PREPARATION TOOL
1. GENERAL TOOL
TOOL NAME
REMARKS
Circuit tester
Conductive silver composition

(DUPONT No. 4817 or
equivalent)
Used for repairing antenna

wire.
ET-2
Radio System
ENTERTAINMENT
2. Radio System
A: WIRING DIAGRAM
1. RADIO BODY
<Ref. to WI-124, WIRING DIAGRAM, Audio System.>
B: INSPECTION
Symptom
Repair order
No power coming in. (No display and no sound from speakers)
1. Check the fuse and power supply for radio.

2. Check the radio ground.
3. Remove the radio for repair.
A specific speaker does not operate.
1.
2.
1.
2.
3.
4.
Check the speaker.

Check the output circuit between radio and speaker.
Check the radio ground.
Check the generator.
Check the ignition coil.
Remove the radio for repair.
1.
2.
3.
4.
5.
Check the antenna.

Check the antenna amplifier.
Check the noise suppressor.
Check the radio ground.
Remove the radio for repair.
Radio generates noise with engine running.
Volume is low in AM and FM modes or interference noise

occurs.
ET-3
Front Accessory Power Supply Socket System

ENTERTAINMENT
3. Front Accessory Power Supply Socket System

A: WIRING DIAGRAM
1. FRONT ACCESSORY POWER SUPPLY
SOCKET
<Ref. to WI-126, WIRING DIAGRAM, Front Accessory Power Supply Socket System.>
ET-4
Rear Accessory Power Supply Socket System

ENTERTAINMENT
4. Rear Accessory Power Supply Socket System

A: WIRING DIAGRAM
1. REAR ACCESSORY POWER SOCKET
<Ref. to WI-127, WIRING DIAGRAM, Rear Accessory Power Supply Socket System.>
ET-5
Radio Body
ENTERTAINMENT
5. Radio Body
A: REMOVAL
5) While pulling on the lower portion of the center

console panel, insert a flat tip screwdriver into the
portion (A) to remove the claw.

2) Remove the front cover. <Ref. to EI-38, REMOVAL, Console Box.>
3) Affix the thick protective tape (A) to the instrument panel pad to protect the surface.
CAUTION:
Be very careful because it is possible to damage the instrument panel if the flat tip screwdriver is inserted into any other area than
specified.
NOTE:
Affix the protective tape so that it covers the vertical
wall in the back of the gap between the panel center and the pad.
(A)
(A)
ET-00156
(A)
(A) Position for inserting the flat tip screwdriver
ET-00154

(C)
(C)

7) Remove the fitting screws, and slightly pull the
radio out from the center console.
8) Disconnect the harness connectors and antenna
feeder cord.
B: INSTALLATION
(B)
(A)
(A)
ET-00155
(A) Screw
(B) Clip
(C) Claw
ET-6
Tweeter
ENTERTAINMENT
6. Tweeter
A: REMOVAL
2) Remove the gusset cover.
3) Remove the tweeter mounting screws.
ET-00004

the tweeter.
B: INSTALLATION
ET-7
Front Speaker
ENTERTAINMENT
7. Front Speaker
A: REMOVAL
2) Remove the front door trim. <Ref. to EI-34, REMOVAL, Front Door Trim.>
3) Remove the front speaker mounting screws.
ET-00003

the front speaker.
B: INSTALLATION
ET-8
Rear Speaker
ENTERTAINMENT
8. Rear Speaker
A: REMOVAL
2) Remove the rear door trim. <Ref. to EI-35, REMOVAL, Rear Door Trim.>
3) Remove the rear speaker mounting screws.
ET-00005

the rear speaker.
B: INSTALLATION
ET-9
Woofer
ENTERTAINMENT
9. Woofer
A: REMOVAL
2) Remove the rear seat belt, rear seat, rear quarter upper, rear quarter lower, insulator and luggage
floor mat.
3) Remove the woofer trim.
4) Remove the woofer mounting screws and clip
(A).
(A)
(A)
(B)
ET-00216
5) Disconnect the harness connector (B) and detach the woofers.
B: INSTALLATION
ET-10
Antenna
ENTERTAINMENT
10.Antenna
B: REPAIR
A: INSPECTION
1) Clean the antenna wire and surrounding area

with a cloth dampened by alcohol.
2) Paste a thin masking film on the glass along broken wire.
3) Apply the conductive silver composition (DUPONT No. 4817 or equivalent) on the broken portion with a drawing pen.
Measure the resistance between the antenna terminal and each antenna wire.
If an antenna wire is OK, resistance will be less
than 1 . If an antenna wire is broken, resistance
will be more than 1 M.
NOTE:
When checking the continuity, wind a piece of aluminum foil around the tip of tester probe and press
foil against wire with your finger.
(A)
(A)
(B)
(C)
(C)
ET-00009
(A) Broken portion

(B) Masking film
(B)
(C) Conductive silver composition
ET-00007
4) Dry out the deposited portion.

5) After repair has been completed, measure the
resistance in repaired wire.
(A) Tester probe

(B) Aluminum foil
(C) Antenna wire
To locate the broken point, move the probe along

antenna wire.
ET-00008
ET-11
Antenna Amplifier
ENTERTAINMENT
11.Antenna Amplifier
A: REMOVAL
2) Remove the rear quarter upper trim. <Ref. to EI44, REMOVAL, Rear Quarter Trim.>
3) Disconnect the harness connectors and terminals.
4) Remove the mounting screw and detach the antenna amplifier.
ET-00223
B: INSTALLATION
C: INSPECTION
Measure the resistance of antenna amplifier.
(1)
(3)
(2)
ET-00224
1) Inspecting for poor insulation (shorting) of the

cord crimping
Terminal No.
1 and Amplifier body
Standard
10 k or more

10 k or more
10 k or more
2) Check antenna amp

Disconnect each connector, then measure the direct current value at the above locations using the
tester checker.
Standard:
(+B = 13.5 V) 5010 mA
ET-12
Front Accessory Power Supply Socket

ENTERTAINMENT
12.Front Accessory Power Supply Socket

A: REMOVAL
2) Remove the front cover. <Ref. to EI-38, REMOVAL, Console Box.>
the front accessory power supply socket.
ET-00016
B: INSTALLATION
ET-13
Rear Accessory Power Supply Socket

ENTERTAINMENT
13.Rear Accessory Power Supply Socket

A: REMOVAL
1. FRONT
3) Disconnect the harness connector, and remove
the accessory power supply socket.
ET-00168
2. REAR
2) Remove the rear quarter lower trim. <Ref. to EI44, REMOVAL, Rear Quarter Trim.>
3) Disconnect the harness connector, and remove
the accessory power supply socket.
ET-00194
B: INSTALLATION
ET-14
AUX Input Terminal

ENTERTAINMENT
14.AUX Input Terminal

A: REMOVAL
2) Remove the console front cover. <Ref. to EI-38,
REMOVAL, Console Box.>
3) Remove the tab (A), and remove AUX input terminal.
(A)
ET-00212
B: INSTALLATION
ET-15
AUX Input Terminal

ENTERTAINMENT
ET-16
General Description
COMMUNICATION SYSTEM
A: CAUTION
the memory contents before disconnecting the battery ground cable. Otherwise, the memory is
cleared.
B: PREPARATION TOOL
1. GENERAL TOOL
TOOL
NAME
Circuit
tester
REMARKS
COM-2
Horn System
2. Horn System
A: WIRING DIAGRAM
1. HORN
<Ref. to WI-128, WIRING DIAGRAM, Horn System.>
B: INSPECTION
1. HORN RELAY
Measure the security horn relay resistance between terminals (indicated in the table below) when
connecting terminal No. 4 to battery positive terminal and terminal No. 3 to battery ground terminal.
(1)
(2)
(1)
(3)
(4)
(2)
(3)
(4)
COM00001
Continuity
Yes
No
Terminal No.
Standard
1 and 2
Less than 1
1 M or more
COM-3
Horn
3. Horn
A: REMOVAL
3) Remove the horn bracket mounting bolt (A).
the horn assembly (B).
(A)
(A)
(B)
(B)
COM00040
B: INSTALLATION
C: INSPECTION
With 12 V direct current supply between horn terminal and case ground, check that the horn sounds
properly.
COM00020
COM-4
Horn Switch
4. Horn Switch
A: REMOVAL
WARNING:
Before servicing, be sure to read the notes in
the AB section for proper handling of the drivers airbag module. <Ref. to AB-4, CAUTION,
NOTE:
Horn switch is a unit with the drivers airbag module.
2) Remove the drivers airbag module. <Ref. to AB14, REMOVAL, Drivers Airbag Module.>
B: INSTALLATION
C: INSPECTION
Measure the resistance between horn switch terminal and airbag module bracket.
(1)
(2)
COM00037
(1) Horn switch terminal

(2) Airbag module bracket
Switch position
When airbag
module bracket is
pushed
When airbag
module bracket is
separated
Terminal No.
Horn switch terminal and airbag

module bracket
Resistance
Less than 1
1 M or more
COM-5
Horn Switch
COM-6
General Description
GLASS/WINDOWS/MIRRORS
A: COMPONENT
1. FIXED GLASS
(6)
(2)
(3)
(4)
(10)
(5)
(1)
(13)
(9)
(12)
(8)
(7)
(3)
(8)
(8)
(6)
(11)
GW-00421
(1)
Windshield glass
(6)
Fastener
(10)
Spring
(2)
(3)
Dam rubber
Molding
(7)
(8)
Rear quarter glass

Locating pin
(11)
(12)
Cover C pillar
Seal A
(4)
(5)
Rearview mirror mount

Locating pin
(9)
Rear gate glass
(13)
Seal B
GW-2
General Description
2. FRONT DOOR GLASS
(1)
(8)
(9)
T1
(4)
(7)
T1
(3)
(2)
T2
(5)
(6)
T2
T3
GW-00522
(1)
(2)
Glass
Door sash (Front)
(6)
(7)
Guide rail
Holder (Front)
(3)
(4)
Door sash (Rear)

Regulator ASSY
(8)
(9)
Holder guide
Slider
(5)
Motor ASSY
GW-3

T1: 7.5 (0.75, 5.4)
T2: 14 (1.4, 10.3)
T3: 6 (0.6, 4.3)
General Description
3. REAR DOOR GLASS
(2)
(3)
(7)
T2
(6)
T1
(4)
(1)
T1
T2
(5)
GW-00420
(1)
(2)
Door sash (Front)

Glass
(5)
(6)
Motor ASSY
Holder (Front)
(3)
(4)
Door sash (Rear)

Regulator ASSY
(7)
Holder (Rear)
GW-4

T1: 7.5 (0.75, 5.4)
T2: 14 (1.4, 10.3)
General Description
4. MIRROR
(6)
(4)
(9)
(7)
(1)
(4)
(5)
(4)
(2)
(3)
(8)
(5)
GW-00525
(1)
(2)
Outer mirror (Large size)

Outer mirror (Standard size)
(4)
(5)
Mirror
Scalp cap
(7)
(8)
Spring
Side turn signal light
(3)
Outer mirror (with side turn signal

light)
(6)
Mount
(9)
Rearview mirror
B: CAUTION
When electrical connectors are disconnected, always conduct an operational check after connecting them again.
Avoid impact and damage to the glass.
GW-5
General Description
C: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
61299AE000
DESCRIPTION
SPACER
REMARKS
Used for adjusting the upper end position of door
glass. (Glass thickness: 5 mm (0.197 in))
ST61299AE000
2. GENERAL TOOL
TOOL NAME
REMARKS
Circuit tester
Piano wire
Used for checking voltage and continuity.

Used for removing the window glass.
Windshield glass knife
Used for removing the window glass.
GW-6
Power Window System

2. Power Window System

A: WIRING DIAGRAM
1. POWER WINDOW
<Ref. to WI-129, WIRING DIAGRAM, Power Window System.>
B: INSPECTION
Symptom
All power windows do not operate.
Particular window does not operate.

Window Lock does not operate.
Repair order
1.
2.
3.
4.
Fuse (SBF-6) (F/B No. 18)

Power window circuit breaker
Power window relay
Wiring harness
1. Power window main switch

2. Power window sub-switch
3. Power window motor
4. Wiring harness
Power window main switch
GW-7
Power Window Control Switch

3. Power Window Control

Switch
2. SUB-SWITCH
2) Remove the screw securing the switch panel.
A: REMOVAL
1. MAIN SWITCH
2) Remove the screw cover by using a flat tip
screwdriver.
GW-00302
3) Remove the switch panel.
GW-00300
3) Loosen the screw to remove power window main

switch.
GW-00303
B: INSTALLATION
GW-00301
GW-8
Power Window Control Switch

C: INSPECTION
2. SUB-SWITCH
1. MAIN SWITCH
1) Remove the main switch. <Ref. to GW-8, MAIN
SWITCH, REMOVAL, Power Window Control
Switch.>
2) Turn the window lock switch to UNLOCK.
3) Connect the battery and the main switch as
shown in the following figure.
1) Remove the sub-switch. <Ref. to GW-8, SUBSWITCH, REMOVAL, Power Window Control
Switch.>
2) Measure the sub-switch resistance.
3
2 1
8 7 6 5 4
3 2 1
7 6 5 4
16 15 14 13 12 11 10 9 8
GW-00524
12V
Switch position
Passengers
side,rea
r
GW-00523
4) Measure the main switch resistance.
Drivers
side
Switch position
Terminal No.
UP
13 and 2
1 and 5
Less than 1
1 and 5
2 and 5
13 and 1
2 and 5
13 and 1
2 and 5
13 and 6
7 and 5
Less than 1
5 and 6
5 and 7
Less than 1
13 and 7
6 and 5
11 and 13
10 and 5
5 and 11
5 and 10
13 and 11
10 and 5
Less than 1
UP
13 and 16
15 and 5
Less than 1
OFF
5 and 15
5 and 16
Less than 1
DOWN
13 and 15
16 and 5
Less than 1
OFF
DOWN
AUTO DOWN
UP
Passengers
side
OFF
DOWN
UP
Rear LH
OFF
DOWN
Rear
RH
Standard
UP
OFF
DOWN
Terminal No.
8 and 5
4 and 7
6 and 5
4 and 7
Less than 1
8 and 7
6 and 5
Less than 1
3) Replace the sub-switch if faulty.
Less than 1
Less than 1
Less than 1
Less than 1
Less than 1
Less than 1
5) Replace the main switch if faulty.
GW-9
Standard
Less than 1
Remote Control Mirror System

4. Remote Control Mirror System

A: WIRING DIAGRAM
1. REMOTE CONTROL MIRROR
<Ref. to WI-134, WIRING DIAGRAM, Remote Control Mirror System.>
B: INSPECTION
Symptom
Repair order
All function does not operate.
1. Fuse (F/B No. 4) (F/B No. 13) (F/B No. 17) (F/B No. 18)
2. Mirror switch
3. Wiring harness
One side of the mirror motor does not operate.
1. Mirror switch
2. Mirror motor
3. Wiring harness
Mirror heater does not operate.
1. Mirror switch
2. Mirror heater
3. Wiring harness
GW-10
Scalp Cap
5. Scalp Cap
2. STANDARD SIZE OUTER MIRROR
A: REPLACEMENT
1) Put the mirror side down.

2) Insert a thin screw driver, push the clip part of
scalp cap, and then remove the scalp cap.
1. OUTER MIRROR WITH SIDE TURN SIGNAL LIGHT

1) Remove the mirror. <Ref. to GW-14, REPLACEMENT, Outer Mirror.>
2) Press-in the upper side clips (A) from inside of
outer mirror.
(A)
(A)
GW-00224
(A)
3) Insert the claw at the lower side of scalp cap to

the door mirror.
GW-00467
3) Pull the scalp cap frontward of outer mirror, remove the upper side clips (A) and lower side hooks
(B), and then remove the scalp cap.
GW-00299
4) Install the scalp cap securely.

(A)
(B)
GW-00468
4) Insert the lower hooks (B) of scalp cap to the outer mirror and push the upper clips (A) in.
(A)
(B)
GW-00519
5) Install the scalp cap securely.

CAUTION:
Do not remove the scalp cap forcibly. The lower
hooks may be damaged.
GW-11
Outer Mirror Assembly

6. Outer Mirror Assembly
C: INSPECTION
A: REMOVAL
1. OUTER MIRROR WITH SIDE TURN SIGNAL LIGHT (MODEL WITHOUT MIRROR
HEATER)
1) Remove the door trim. <Ref. to EI-34, REMOVAL, Front Door Trim.>
2) Remove the mirror gusset cover.
: (1)
1) Check to ensure that the outer mirror moves

properly when the battery voltage is applied to terminals.
1 2
3
4 5 6 7 8
GW-00061
(1) Hook
GW-00512
3) Disconnect the outer mirror connector.

4) Remove the grommet, and loosen the screws to
remove the outer mirror assembly.
Switch position
Terminal No.
OFF
UP
6 (+) and 3 ()
DOWN
LEFT
3 (+) and 6 ()
7 (+) and 8 ()
RIGHT
8 (+) and 7 ()
2) Replace the mirror if defective.
2. OUTER MIRROR WITH SIDE TURN SIGNAL LIGHT (MODEL WITH MIRROR HEATER)
GW-00010
B: INSTALLATION

3 4
1 2
5 6 7 8 9 10
GW-00513
Switch position
Terminal No.
OFF
UP
7 (+) and 3 ()
DOWN
LEFT
3 (+) and 7 ()
8 (+) and 9 ()
RIGHT
9 (+) and 8 ()
GW-12
Outer Mirror Assembly


(MODEL WITHOUT MIRROR HEATER)
1 2 3
4 5 6
GW-00520
Switch position
OFF
Terminal No.
UP
DOWN
1 (+) and 3 ()
3 (+) and 1 ()
LEFT
RIGHT
2 (+) and 3 ()
3 (+) and 2 ()

(MODEL WITH MIRROR HEATER)
1 2 3 4
5 6 7 8
GW-00521
Switch position
Terminal No.
OFF
UP
2 (+) and 4 ()
DOWN
LEFT
4 (+) and 2 ()
3 (+) and 4 ()
RIGHT
4 (+) and 3 ()
GW-13
Outer Mirror
7. Outer Mirror
A: REPLACEMENT
1) Face the mirror upward.
2) Use a flat tip screwdriver to remove clip (A).
3) Lift the mirror lower part to remove hooks (B).
(A)
(B)
GW-00279
4) Disconnect the mirror heater connector from the

end part of the mirror. (Model with mirror heater)
GW-00280
5) Catch the hooks (B) and install clips (A).
(B)
(A)
GW-00450
CAUTION:
When removing the mirror, be careful not to
damage the back surface of mirror with a flat tip
screwdriver.
When installing the mirror, insert the hook
and clip securely.
GW-14
Front Door Glass

9. Front Door Glass
7) Remove the rear end of door weather strip and

weather strip outer.
A: REMOVAL
2) Remove the front speaker. <Ref. to ET-8, REMOVAL, Front Speaker.>
3) Remove the sealing cover. <Ref. to EB-13, REMOVAL, Front Sealing Cover.>
4) Remove the outer mirror assembly. <Ref. to
GW-12, REMOVAL, Outer Mirror Assembly.>
5) Remove the front end of door weather strip and
gusset.
GW-00015
8) Operate the power window switch to move glass

to position shown in the figure, and then remove
the three nuts from the service holes.
GW-00017
9) Remove the door glass.

CAUTION:
Since the gear may be disengaged, do not
turn regulator in the closing direction after removing glass.
GW-00013
B: INSTALLATION
CAUTION:
Make sure that glass holder (front), holder
guide, and slider of the regulator are placed securely in sash.
2) Adjust the front door glass. <Ref. to GW-17, ADJUSTMENT, Front Door Glass.>
GW-00014
Tightening torque:
Refer to COMPONENT of General Description. <Ref. to GW-3, FRONT DOOR GLASS,
COMPONENT, General Description.>
GW-16
Front Door Glass

C: ADJUSTMENT
NOTE:
Before adjustment, ensure that all adjusting nuts of
stabilizer, upper stopper and sash are loose, and
door glass rises up to the point that it comes in contact with weather strip.
1) Temporarily tighten the adjusting nut on one side
of rear sash at the midpoint of slotted hole in the inner panel.
2) Temporarily tighten the regulator B channel at
the top position of slotted hole.
3) Lower the door glass 10 15 mm (0.39 0.59
in) from fully closed position. While applying an outward pressure (F) of 45.05 N (4.60.5 kgf,
10.11.1 lb) to the upper edge of glass above midpoint of two outer stabilizers, press the inner stabilizer to the glass at a pressure of 255 N (2.50.5
kgf, 5.51.1 lb) to secure it.
(1)
4) To adjust the clearance between front glass and

center pillar cover, loosen the nuts (A), and move
the rear sash back and forward until clearance becomes the value shown. (Difference up and down:
Within 1.5 mm (0.059 in))
(A)
GW-00019
(1)
(1)
A A
F
(3)
(4)
(2)
A-A
(2)
A = A
GW-00064
(4)
(1) 121 mm (0.4720.039 in)

GW-00419
(1) Fully closed position

(2) Stabilizer
5) For adjustment of the upper and lower ends of

center pillar, loosen the adjusting nut (A) of B-channel (B).
(3) 10 15 mm (0.39 0.59 in)

(4) Upper stopper
(A)
(B)
GW-00021
GW-17
Front Door Glass

6) Adjust so that the upper and lower ends of center pillar are the same size.
(1)
(3)
(2)
7) For glass stroke adjustment, attach special tool

to the glass, close door, and raise the glass to the
top edge using regulator until positional relationship between glass and weather strip becomes as
shown. And secure the glass so that the upper
stopper touches the glass holder without fail.
ST 61299AE000 SPACER (GLASS THICKNESS: 5 mm (0.197 in) FOR
DOOR GLASS)
(1)
(5)
A
(2)
(4)
(1)
(3)
(2)
GW-00336
(1) 2.2 3.8 mm (0.0870.150 in)

(2) When reusing the weather strip:
8.5 10.5 mm (0.335 0.413 in)
When replacing the weather strip:
7.5 9.5 mm (0.295 0.374 in)
(3) ST
(6)
GW-00139
(1) Narrow
(2) Wide
(3) Glass tilts too far rearward
(4) Glass tilts too far forward
For preventing wind noise, adjust the glass at the

position where tip of gusset is raised up a little.
(5) Raise B channel

(6) Lower B channel
GW-00024
(A) 0 1.5 mm (0 0.059 in)
8) After stabilizer adjustment, carry out glass cohesion adjustment. First, visually ensure positional relationship between retainer & molding and glass of
the roof side, and then begin with rear sash adjustment. Adjust two adjusting bolts alternately step by
step to obtain dimensions shown below (cross-section A).
NOTE:
If two nuts are loosened at the same time, the sash
moves back and forth. Therefore, when one nut is
adjusted, secure the other.
GW-18
Front Door Glass

9) Make the same adjustment of two adjusting bolts

of rear sash.
DOOR GLASS)
(1)
12) After adjustment of the glass, close the door. If

there is a gap between outer lip of gusset and glass
surface, adjust the gap with adjusting nut (A) in lower fitting part of gusset to prevent generation of
wind noise.
13) During adjustment, loosen the other three
clamping screws.
(3)
(2)
(A)
GW-00336
(1) 2.2 3.8 mm (0.0870.150 in)
GW-00056

8.5 10.5 mm (0.335 0.413 in)
7.5 9.5 mm (0.295 0.374 in)
(3) ST
14) After adjustment, tighten the bolts and nuts.
NOTE:
Do not tilt the sash bracket to inner panel during adjustment. If tilting, the regulator does not operate
smoothly.
(1)
(4)
(3)
(2)
(5)
GW-00026
(1) Sash bracket

(2) Rear sash
(3) Adjust the lines parallel
(4) Rear sash
(5) Inner panel
10) Make adjustment of front sash in the same

manner as that of rear sash.
NOTE:
Although front and rear sashes must, as a rule, be
adjusted in the same manner, in some door installation, the adjustment in a different manner 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 applying excessive load against regulator.
11) After adjustments, tighten the nuts.
GW-19
Front Regulator and Motor Assembly

10.Front Regulator and Motor

Assembly
B: INSTALLATION
2) Adjust the front door glass. <Ref. to GW-17, ADJUSTMENT, Front Door Glass.>
A: REMOVAL
1) Remove the door glass. <Ref. to GW-16, REMOVAL, Front Door Glass.>
2) Loosen the nuts to remove the rear sash.
Tightening torque:
Refer to COMPONENT of General Description. <Ref. to GW-3, FRONT DOOR GLASS,
C: INSPECTION
1) Make sure that the power window motor rotates
properly when the battery voltage is applied to the
terminals of motor connector.
2) Change polarity of battery connection to terminals to ensure that the motor rotates in reverse direction.
GW-00027
3) Disconnect the motor connector.

4) Loosen four bolts and two nuts to remove regulator assembly.
GW-00028
5) Loosen screws to remove motor assembly.
GW-00029
GW-20
Rear Door Glass

11.Rear Door Glass
6) Loosen two screws to remove the weather strip

outer.
A: REMOVAL
3) Remove the sealing cover. <Ref. to EB-16, REMOVAL, Rear Sealing Cover.>
GW-00030
5) Remove the door weather strip.

GW-00032
7) Operate the power window switch to move the

glass to the position as shown in the figure, and remove two nuts.
GW-00031
8) Take out the door glass.

CAUTION:
GW-00057
GW-21
Rear Door Glass

B: INSTALLATION
CAUTION:
Make sure that glass holder (front) and holder
(rear) are placed securely in sash.
2) Adjust the rear door glass. <Ref. to GW-22, ADJUSTMENT, Rear Door Glass.>
2) Attach the special tool to the glass, and adjust

the glass adhesion until the dimensional value becomes as shown below.
DOOR GLASS)
(1)
Tightening torque:
Refer to COMPONENT of General Description. <Ref. to GW-4, REAR DOOR GLASS,
A
(3)
C: ADJUSTMENT
(2)
NOTE:
The rear door glass, as a rule, is adjusted in the
same manner as front glass, although they are different in dimension.
1) Adjust the glass position using the following dimensions as a guide line. (Difference up and down:
Within 1.5 mm (0.059 in))
(1)
A-A
GW-00337
(1) 2.2 3.8 mm (0.087 0.150 in)

8.5 10.5 mm (0.335 0.413 in)
7.5 9.5 mm (0.295 0.374 in)
(3) ST
(1)
NOTE:
If rear glass adhesion is higher than necessary,
glass may get caught in weather strip of center pillar corner, resulting in early wear of weather strip.
Care should be taken for adjustment.
After adjustment, move the glass up and down to
check whether it is caught.
A-A
GW-00067
(1) 121 mm (0.4720.039 in)
NOTE:
If dimensions are smaller than the given dimensions, glass may get caught in weather strip during
lifting/lowering operation and may not be fully open.
After adjustment, move the glass up and down to
check whether it is caught.
GW-22
Rear Regulator and Motor Assembly

12.Rear Regulator and Motor Assembly

A: REMOVAL
1) Remove the rear door glass. <Ref. to GW-21,
REMOVAL, Rear Door Glass.>
2) Remove the front sash.
3) Disconnect the motor connector.
4) Loosen four bolts and two nuts to remove regulator assembly.
GW-00035
5) Loosen screws to remove motor assembly.
GW-00036
B: INSTALLATION
2) Adjust the rear door glass. <Ref. to GW-22, ADJUSTMENT, Rear Door Glass.>
Tightening torque:
Refer to COMPONENT of General Description. <Ref. to GW-4, REAR DOOR GLASS,
C: INSPECTION
1) Make sure that the power window motor rotates
properly when the battery voltage is applied to the
terminals of motor connector.
2) Change polarity of battery connection to terminals to ensure that the motor rotates in reverse direction.
GW-23
Windshield Glass
13.Windshield Glass
8) For model with wiper deicer, detach the front pillar trim, then disconnect the harness connector.
A: REMOVAL
1. WHEN USING THE WINDSHIELD GLASS
KNIFE
2) Remove the glass molding.
3) Tape the body side of the circumference of windshield glass for protection.
4) Apply sufficient amount of soapy water to the adhesive part.
5) Make a cut in the adhesive part using a putty
knife so that windshield glass knife can be inserted
easily.
6) Insert the windshield glass knife into adhesive
part.
7) While holding the knife edge and windshield
glass edge at a right angle, move the windshield
glass knife in parallel to the windshield glass edge
along the surface and edge of windshield glass to
cut the adhesive part.
NOTE:
Do not twist the windshield glass knife.
Cutting of adhesive part shall be started with wider gap between windshield glass and body.
Because the locating pins are bonded to the corners of glass, use piano wire to cut the pin.
(1)
(1)
(1)
A-A
(2)
A
(4)
(3)
A
(3)
GW-00069
(1) Putty knife

(2) Tape for protection
(3) Locating pin
(4) Windshield glass knife
(2)
(1)
(3)
A-A
GW-00070
(1) Locating pin

(2) Body panel
(3) Glass
GW-24
Windshield Glass
2. USING PIANO WIRE
B: INSTALLATION

2) Remove the front molding.
3) Tape the body side of the circumference of windshield glass for protection.
4) Make a hole in the adhesive part using drill or
knife.
5) Pass the piano wire through the hole, and attach
securely both the wire ends to pieces of wood.
1) Clean the external circumference of windshield

glass with alcohol or white gasoline.
2) Remove the adhesive layer on the body using
cutter knife to obtain smooth face of 2 mm (0.08 in)
thick.
CAUTION:
Be careful not to damage the body and paint
surface.
(1)
(3)
(2)
(4)
GW-00071
GW-00039
6) Pull the wire ends alternately to cut off the adhesive part.
CAUTION:
Do not tightly pull the piano wire against the
windshield glass edge.
Be careful not to damage interior and exterior
parts.
When removal is made with area close to instrument panel, place a protection plate over it.
Pay particular attention to the removal.
Do not cross piano wires. Otherwise they
may be cut.
(1) Adhesive
(2) 2 mm (0.08 in)
(3) Dam rubber
(4) Glass
3) Clean the body with alcohol or white gasoline to

eliminate cutting powder, dust and dirt completely
from body.
GW-25
Windshield Glass
4) Adhere the dam rubber to the glass back surface.
6) Install the seal A and seal B to the molding back

side.
(4)
(2)
(3)
(1)
(1)
(2)
(4)
(3)
(4)
(4)
GW-00072
GW-00379
(1) Locating pin

(2) Dam rubber
(1) Backside lip R stopper

(2) 73 mm (2.87 in)
(3) Fastener
(4) 13 mm (0.51 in)
(3) Reference position (edge) when affixing the

seal A
5) Peel away the backing paper of the double-sided

tape. Align the molding mark (B) with the notch (A),
affix the molding to the entire circumference of the
edge of the glass, and press uniformly.
(4) Reference position (lip R stopper) when affixing

the seal B
7) Apply the primer to the adhesive surface of glass

using sponge.
Glass primer:
Dow Automotive
U-401 and U-402
GW-00042
GW-26
Windshield Glass
8) Apply the primer to the adhesive surface of

body.
11) Fit the locating pins using suction rubber cup to

install windshield glass.
Painted surface primer:

Dow Automotive
U-413
NOTE:
Primer once attached to the painted surface of
the body and the internal trim is hard to wipe off.
Mask the circumference of such area.
Let primer dry for about ten minutes before installing the glass.
Do not touch the surface coated with primer.
GW-00045
12) Lightly press the windshield glass for tight fit.

13) Make flush the adhesive surface jutted out using spatula.
14) After completion of all work, allow the vehicle to
stand for about 24 hours.
(1)
(3)
(2)
GW-00073
(1) Application of primer

(2) Glass side
(3) Body side
9) Cut off the cartridge nozzle tip as shown and set

it in sealant gun.
NOTE:
When door is opened/closed after glass is bonded, always lower the door glass first, and then
open/close it carefully.
Move the vehicle slowly.
For minimum drying time and vehicle standing
time before driving after bonding, follow instructions or instruction manual from the adhesive manufacturer.
15) After curing of adhesive, pour the water on external surface of vehicle to check that there are no
water leaks.
NOTE:
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.
16) Install the cowl panel. <Ref. to EI-31, INSTALLATION, Cowl Panel.>
(2)
(1)
(3)
(4)
GW-00074
(1) 10 13 mm (0.39 0.51 in)

(2) 13 mm (0.51 in)
(3) 10 mm (0.39 in)
(4) 15 mm (0.59 in)
10) Apply adhesive to the glass end surface as

shown.
Adhesive:
Dow Automotive
ESSEX U-400 HV
GW-27
Rearview Mirror
14.Rearview Mirror
A: REMOVAL
NOTE:
Never reuse the spring. Prepare a new spring before removal.
1) Turn the mirror base 90 clockwise or counterclockwise to remove it.
GW-00046
2) Remove the spring from the mirror base.
GW-00047
CAUTION:
Be careful not to damage the mirror surface.
3) When the mirror base is damaged, use the piano
wire or spatula to remove.
CAUTION:
Be careful not to damage the windshield glass.
B: INSTALLATION
1) When the mirror base is removed, clean the old
adhesive, and align the windshield glass mark to install.
Adhesive:
REPAIR KIT IN MR (Part No. 65029FC000)
2) Make sure the mirror base is securely attached
and then install the spring to it.
C: INSPECTION
Check that the mirror is not damaged.
Check that the spring is not damaged.
GW-28
Rear Gate Glass

15.Rear Gate Glass
B: INSTALLATION
A: REMOVAL
1) Install a new rubber strip (A) in position with the

edge (B) of the rear gate glass.
1) Remove the rear gate garnish. <Ref. to EB-20,

REMOVAL, Rear Gate Garnish.>
2) Disconnect the electrical connectors from rear
defogger terminal.
3) Remove the glass in the same procedure as for
windshield glass. <Ref. to GW-24, REMOVAL,
Windshield Glass.>
NOTE:
The locating pin is adhered to the corner portion on
the vehicles indoor side of the glass. Use the piano
wire to cut each pin.
(3)
A
(B)
(A)
GW-00049
2) Install the glass in the same procedure as for

windshield glass.
(2)
(1)
(A)
(2)
(3)
(1)
(5)
(3)
A-A
(6)
GW-00297
(7)
(4)
(1) Body panel

(2) Glass
(B)
(3) Locating pin
(3)
(2)
(7)
(1)
(4)
(5)
(8)
(9)
GW-00075
(A) Upside
(B) Left side and right side
(1) Adhesive
(2) Strip rubber
(3) Glass
(4) Primer
(5) 12 mm (0.47 in)
(6) 14 mm (0.55 in)
(7) 10 13 mm (0.39 0.51 in)
(8) 8 mm (0.31 in)
(9) 12 mm (0.47 in)
GW-29
Rear Gate Glass

3) About one hour after installation, inspect for

leaks.
NOTE:
5) Connect the rear defogger terminals.
6) Install the rear gate garnish. <Ref. to EB-20, INSTALLATION, Rear Gate Garnish.>
GW-30
Rear Window Defogger System

16.Rear Window Defogger System

A: WIRING DIAGRAM
1. REAR WINDOW DEFOGGER
<Ref. to WI-133, WIRING DIAGRAM, Rear Defogger System.>
B: INSPECTION
Symptom
Rear window defogger does not operate.
Repair order
1.
2.
3.
4.
5.
6.
7.
Fuse (M/B No. 1) (F/B No. 17)

Rear defogger relay
Rear defogger timer
Defogger switch
Rear defogger condenser
Defogger wire
Wiring harness
GW-31
Rear Window Defogger

17.Rear Window Defogger

A: INSPECTION
CAUTION:
When wiping off the stain on glass with cloth,
use a dry and soft cloth and move it in the direction of the heat wire extension to avoid damage
to the heat wire.
2) Turn the defogger switch to ON.
3) Wrap the tips of tester probe with aluminum foil
to avoid damage to heat wire.
NOTE:
If the measured value is 12 V, the circuit is open
between heat wire center and positive (+) terminal
of tester probe.
If it is 0 V, the circuit is open between heat wire
center and ground.
5) Connect the tester probe of positive lead of voltmeter to positive terminal of heat wire and move
tester probe of negative lead along the heat wire up
to the negative terminal end. If voltage changes
from zero to several volts during movement of
tester probe, heat wire is open at the voltage
change point.
B: REPAIR
1) Clean the broken portion with alcohol or white
gasoline.
2) Mask both side of wire with thin film.
3) Apply the conductive silver composition (DUPONT No. 4817) to the broken point.
(4)
(1)
(3)
(2)
(1)
GW-00076
(1) Tester probe

(2) Aluminum foil
(3)
(3) Heat wire

(4) Press
(2)
(4)
4) Measure the voltage at heat wire center (1) with

DC voltmeter.
GW-00078
(1) Broken portion

(2) Thin film
Standard voltage:
Approx. 6 V
(3) Broken wire

(4) Conductive silver composition (DUPONT No.
4817)
(1)
4) After repair, check the wire.
GW-00077
(1) Center of heat wire

Voltage
Criteria
Approx. 6 V
Approx. 12 V or 0 V
Normal
Open
GW-32
Rear Quarter Glass

18.Rear Quarter Glass

A: REMOVAL
Remove the glass in the same procedure as for windshield glass. <Ref. to GW-24, REMOVAL, Windshield
Glass.>
A
A-A
D-D
(5)
(1)
(3)
(4)
(2)
(2)
(4)
(3)
(1)
D
(5)
(2)
B-B
C-C
(6)
(2)
(3)
(3)
(1)
(7)
(8)
(5)
(5)
GW-00557
(1)
Molding
(4)
Locating pin
(7)
Weather strip
(2)
(3)
Adhesive
Compartment trim
(5)
(6)
Vehicle body
Cover C pillar
(8)
Rear door glass
GW-33
Rear Quarter Glass

B: INSTALLATION
1) Cut off the nozzle tip as shown in the figure.
(1)
(4)
(3)
(2)
(5)
(3)
(6)
(1)
GW-00079
(1) Molding
(2) Locating pin
(3) Adhesive
(4) 10 mm (0.39 in)
(5) 15 mm (0.59 in)
(6) 10 13 mm (0.39 0.51 in)
2) Install the glass in the same procedure as for

windshield glass. <Ref. to GW-25, INSTALLATION, Windshield Glass.>
NOTE:
4) After curing of adhesive, pour the water on external surface of vehicle to check that there are no water leaks.
NOTE:
GW-34
Sunroof Glass
19.Sunroof Glass
A: REMOVAL
<Ref. to SR-5, REMOVAL, Sunroof Lid.>
B: INSTALLATION
<Ref. to SR-5, INSTALLATION, Sunroof Lid.>
C: ADJUSTMENT
<Ref. to SR-5, ADJUSTMENT, Sunroof Lid.>
GW-35
Sunroof Glass
GW-36
General Description
BODY STRUCTURE
A: PREPARATION TOOL
TOOL NAME
Tram tracking gauge
Tape measure
REMARKS
Used for measuring dimension.
Used for measuring dimension.
BS-2
Datum Points
BODY STRUCTURE
2. Datum Points
A: LOCATION
NOTE:
Datum points are specified for body repair.
Guide holes, locators, and indents are provided
to facilitate panel replacement and to increase
alignment accuracy.
BS-3
Datum Points
BODY STRUCTURE
Both right and left reference points are symmetrical.

(38)
(39)
(35)
(32)
(40)
(29)
(30)
(36)
(13)
(33)
(23)
(13)
(34)
(10)
(31)
(12)
(9)
(11)
(25)
(6)
(26)
(7)
(21)
(3)
(20)
(4)
(37)
(5)
(14)
(2)
(8)
(2)
(1)
(9) (12)
(6)
(3)
(4) (5)
(8)
(1)
Radiator panel gauge hole 6 mm

(0.24 in) dia. (Vehicle center)
(2)
Radiator attaching hole 12 mm

(0.47 in) dia.
(3)
(4)
(5)
(6)
Headlight attaching hole 7 mm

(0.28 in) dia. (Symmetrical)
Frame plate gauge hole 8 mm
Bumper beam attaching hole 11
mm (0.43 in) dia. (Symmetrical)
(13)
(14)
Front glass attaching hole LH 6.5

10.5 mm (0.26 0.41 in) RH 6.5
7 mm (0.26 0.28 in)
Fender attaching hole 10 mm
(29)
Trim attaching hole 8.5 mm (0.33

in) dia. (Symmetrical)
(30)
Pad attaching hole 5 mm (0.20 in)

dia. (Symmetrical)
(31)
Harness attaching hole 7 mm

Trim attaching hole 7 mm (0.28 in)
dia. (Symmetrical)
Harness attaching hole 7 7 mm
(0.28 0.28 in) (Symmetrical)
(32)
Front door hinge attaching hole 12

(33)
(17)
Front door hinge attaching hole 12

Front door switch attaching hole
4.1 mm (0.16 in) dia. (Symmetrical)
(23)
(10)
Fender attaching hole 7 mm (0.28

Modular bracket gauge hole 8 mm
(0.31 in) dia. (Vehicle center)
(25)
Front strut attaching hole 9.5 mm

BS-00001
(16)

(12)
(15)
Fender attaching hole 10 mm

(9)
(11)
(17) (16)
(15)
(20)
(8)
(10)
(7)

RH power steering tank attaching
hole LH ATF cooler pipe attaching
hole 9 mm (0.35 in) dia.
(7)
(22)
(34)
(35)
Tonneau cover attaching hole 5.5

(21)
Rear door hinge attaching hole 12

(36)
Rear strut attaching hole 10 mm

(22)
Rear door hinge attaching hole 12

Front weather strip attaching hole
(37)
Floor mat attaching hole 8 mm

Trim attaching hole 9 9 mm
(0.35 0.35 in) (Symmetrical)
dia. (Symmetrical)
dia. (Symmetrical)
(26)
Rear weather strip attaching hole

Rear door switch attaching hole
BS-4
(38)
(39)
(40)
Datum Points
BODY STRUCTURE
(27)
(29)
(18)
(28)
(44)
(31)
(18)
(44)
(45)
(46)
(19)
(47)
(48)
(24)
(42)
(41)
(45)
(43)
(46)
(43)
(47)
(48)
(18)
(19)
(24)
Front weather strip attaching hole

dia. (Symmetrical)
dia. (Symmetrical)
(27)
Front pillar gauge hole 12 mm

(28)
Insulator attaching hole 8 mm

(29)

(31)
Harness attaching hole 7 mm

(41)
Harness attaching hole 7.5 mm

(0.30 in) dia.
(46)
Assemblies hole 12 mm (0.47 in)

dia.
(47)
(42)
(43)
(44)
Striker gauge hole 5 mm (0.20 in)

dia. (Symmetrical)
Harness attaching hole 7 7 mm
(0.28 0.28 in) dia. (Symmetrical)
BS-5
(45)
(48)
BS-00002
Combination light mounting hole

Combination light mounting hole 7
Combination light mounting hole 8
15 mm (0.31 0.59 in) (Symmetrical)
Bumper bracket attaching hole 7
Datum Points
BODY STRUCTURE
(36)
(52) (53) (54) (65) (12) (55) (56) (57) (58) (59) (60)
(61)
(66)
(62) (63)
(64)
(51)
(51)
(64)
(52) (53) (54) (65) (12) (55) (56) (57) (58) (59) (60)
(61)
(66)
(36)
(62) (63)
BS-00003
(12)
Front strut attaching hole 9.5 mm

(56)
Transverse link attaching hole 16

(36)
Rear strut attaching hole 10 mm

(57)
Subframe attaching hole 16 mm

(64)
(51)
Radiator lower frame gauge hole

12 mm (0.47 in) dia. (Symmetrical)
(58)
Transmission crossmember
attaching hole 14 mm (0.55 in )
dia. (Symmetrical)
(65)
(52)
Side frame gauge hole 20 mm

(59)
Rear side frame gauge hole 15

(53)
Subframe attaching hole 16 mm

(60)
Rear side frame gauge hole 18

(54)
Front crossmember attaching hole

(61)
(55)
Transverse link attaching hole 17

Rear differential attaching hole 16

Rear crossmember gauge hole 16
(62)
BS-6
(63)
(66)
Rear crossmember attaching hole

Rear bumper beam attaching hole
RH 15 mm (0.57 in) LH 19 15
mm (0.75 0.59 in) dia.
Front crossmember attaching hole
Rear crossmember attaching hole
Datum Points
BODY STRUCTURE
(3)
(1)
(2)
(2)
(4)
(5)
BS-00004
BS-00005
(6)
(8)
(8)
(7)
BS-01531
BS-00007
(10)
(12)
(9)
(11)
BS-00008
BS-00009
(14)
(18)
(16)
(19)
(17)
(13)
(15)
BS-00010
BS-00011
(23)
(21)
(20)
(24)
(22)
BS-00015
BS-00014
BS-7
Datum Points
BODY STRUCTURE
(27)
(25)
(28)
(26)
BS-00017
BS-00016
(29)
(34)
(31)
(30)
BS-00018
BS-00019
(37)
(32)
(35)
(36)
(33)
BS-00021
BS-00020
(38)
(42)
(39)
(40)
(41)
BS-00022
BS-00023
(43)
(44)
BS-00025
BS-00024
BS-8
Datum Points
BODY STRUCTURE
(46)
(45)
(54)
(47)
(65)
(52)
(48)
(53)
(51)
BS-00026
BS-00027
(56)
(58)
(55)
(57)
(59)
BS-00028
(60)
BS-00029
(63)
(61)
(66) (62)
BS-00030
BS-00031
(64)
BS-00032
BS-9
Datum Dimensions
BODY STRUCTURE
3. Datum Dimensions
A: MEASUREMENT
For details concerning points to measure, refer to
Position. <Ref. to BS-3, LOCATION, Datum
Points.>
NOTE:
Using a tram tracking gauge, measure all the dimensions.
When using a tape measure, carefully measure
dimensions without letting the tape measure sag or
twist.
Measure the linear dimensions between cores of
holes.
Suffixes RH and LH indicate right-hand and
left-hand.
(1)
BS-00033
(1) Tram tracking gauge
Measure at the center of the circle around the

outside of the body panel.
(1)
(3)
(2)
BS-00034
(1) Datum points

(2) Body panel
(3) Outside
BS-10
Datum Dimensions
BODY STRUCTURE
(12)
(36)
(61)
(57)(58) (59)
9(0.35) 20(0.79) 14(0.55)

317(12.48) 485(19.09)
11(0.43)
585(23.03)
77(3.03)
135(5.31)
474(18.66) 329(12.95)
356(14.02)
694(27.32)
205(8.07)
(55)
77(3.03)
206(8.11)
(64)
(62)
(52) (53) (54)

1
669(26.34)
621(24.45)
1. CENTER STRUCTURE
620(24.41)
1070(42.13)
1270(50.00)
230(9.06)
(36)
(61)
(55) (57)
(59) (60)
(58)
(56)
(62)
(59) (60)
(57)
(53)
(52)
(54)
(36)
(61)
(64)
(57)
)
44
7.
(4
)
44
2.
(5
32
6)
4.7
.5
13
7)
34.5
2)
37
7.5
4(
2(3
2)
878(
1)
(4
38
.6
07
95
88
14
6
(5
12
(4
)
.57
)
60
(39
05 5) 47.
2
4. 09(
12
24
10
11
92 4( 36 .3 8)
917(3
6.10)
(64)
(61)
(12)
(63)
05
(52)
(53)
(55)
12
(54)
(63)
920(36.22)
920(36.22)
776(30.55)
780(30.71)
838(32.99)
529(20.83)
630(24.80)
(58)
1136(44.72)
(51)
856(33.70)
1065(41.93)
860(33.86)
910(35.83)
906(35.67)
500(19.69)
(51)
1221(48.07)
(62)
(56)
(64)
1110(43.70)
(12)
(53)
(52)
(54)
(59) (60)
(53)
(62)
(55)
BS-00035
*1: Standard Line

*2: Side sill
*3: Upper surface
Unit: mm (in)
BS-11
Datum Dimensions
BODY STRUCTURE
2. SUSPENSION CROSSMEMBER
2
(62)
(65)
(66)
(63)
75(2.95)
139(5.47)
2547(100.28)
150(5.91)
205(8.07)
206(8.11)
(54)
(62)
(54)
(66)
(63)
(66)
(63)
920(36.22)
840(33.07)
860(33.86)
(65)
(65)
(54)
(62)
BS-00036
*1: Standard Line

*2: Side sill
Unit: mm (in)
BS-12
Datum Dimensions
BODY STRUCTURE
3. FRONT STRUCTURE
(13)
(10)
(13)
(9)
(6)
(12)
(11)
(10)
(12)
(9)
(2)
(14)
(6)
(1)
(8)
(3)
(2)
(15)
(8)
(4)
(5)
(7)
(3)
(4)
(5)
BS-00037
Unit: mm (in)
Dimension
Dimension
(1) to (11)
(2) RH to (11)
822 (32.36)
842 (33.15)
(7) LH to (15) LH
(8) RH to (8) LH
1,092 (42.99)
921 (36.26)
(2) LH to (11)
(3) RH to (3) LH
875 (34.45)
716 (28.19)
(9) RH to (9) LH
(9) RH to (10) RH
1,396 (54.96)
398 (15.67)
(4) RH to (4) LH
(5) RH to (5) LH
978 (38.50)
1,049 (41.30)
(9) LH to (10) LH
(9) RH to (11)
398 (15.67)
767 (30.20)
(6) RH to (6) LH
(6) RH to (9) RH
1,341 (52.80)
349 (13.74)
(9) LH to (11)
(10) RH to (11)
767 (30.20)
722 (28.43)
(6) LH to (9) LH
(6) RH to (11)
349 (13.74)
944 (37.17)
(10) LH to (11)
(10) RH to (13) RH
722 (28.43)
907 (35.71)
(6) LH to (11)
(7) RH to (14) RH
944 (37.17)
1,184 (46.61)
(10) LH to (13) LH
(11) to (12) RH
907 (35.71)
565 (22.24)
(7) LH to (14) LH
(7) RH to (15) RH
1,184 (46.61)
1,092 (42.99)
(11) to (12) LH
(12) RH to (12) LH
565 (22.24)
1,065 (41.93)
BS-13
Datum Dimensions
BODY STRUCTURE
(38)
(39)
(32)
(35)
(29)
(33)
(40)
(36)
(30)
(34)
(25)
(36)
(26)
(37)
(31)
(23)
(21)
(16)
(20) (22)
(17)
BS-00038
Unit: mm (in)
(16) RH to (20) RH
Dimension
980 (38.58)
(30) LH to (33) LH
Dimension
796 (31.34)
(16) LH to (20) LH
(17) RH to (20) RH
980 (38.58)
982 (38.66)
(31) RH to (34) RH
(31) LH to (34) LH
759 (29.88)
759 (29.88)
(17) LH to (20) LH
(21) RH to (25) RH
982 (38.66)
853 (33.58)
(35) RH to (38) RH
(35) LH to (38) LH
665 (26.18)
665 (26.18)
(21) LH to (25) LH
(22) RH to (26) RH
853 (33.58)
895 (35.24)
(35) RH to (39) RH
(35) LH to (39) LH
711 (27.99)
711 (27.99)
(22) LH to (26) LH
(23) LH to (23) RH
895 (35.24)
1,429 (56.26)
(35) RH to (40) RH
(35) LH to (40) LH
784 (30.87)
784 (30.87)
(29) RH to (32) RH
(29) LH to (32) LH
674 (26.54)
674 (26.54)
(36) LH to (36) RH
(36) RH to (37) RH
1,221 (48.07)
1,067 (42.01)
(30) RH to (33) RH
796 (31.34)
(36) LH to (37) LH
1,067 (42.01)
BS-14
Datum Dimensions
BODY STRUCTURE
4. REAR STRUCTURE
(27)
(18)
(29)
(19)
(28)
(18)
(44)
(24)
(31)
(19)
(44)
(24)
(41)
(42)
(46)
(45)
(47)
(46)
(48)
(45)
(47)
(48)
BS-00039
Unit: mm (in)
Dimension
Dimension
(18) RH to (18) LH
(19) RH to (19) LH
1,449 (57.05)
1,459 (57.44)
(41) RH to (43) RH
(41) LH to (43) LH
794 (31.26)
805 (31.69)
(27) RH to (29) RH
(27) LH to (29) LH
1,007 (39.65)
1,007 (39.65)
(42) RH to (42) LH
(44) RH to (44) LH
1,110 (43.70)
878 (34.57)
(28) RH to (31) RH
(28) LH to (31) LH
813 (32.01)
813 (32.01)
(45) RH to (45) LH
(46) RH to (46) LH
1,474 (58.03)
1,252 (49.29)
(24) RH to (24) LH
(41) RH to (41) LH
1,438 (56.61)
950 (37.40)
(47) RH to (47) LH
(48) RH to (48) LH
1,552 (61.10)
1,210 (47.64)
BS-15
Datum Dimensions
BODY STRUCTURE
BS-16
General Description
INSTRUMENTATION/DRIVER INFO
A: SPECIFICATION
Speedometer
Electric pulse type
Engine coolant temperature gauge

Fuel gauge
Combination meter
Cross coil type

Cross coil type
Tachometer
Turn signal indicator light
Electric pulse type

14 V 2 W

14 V 1.4 W
LED
ABS warning light

14 V 1.4 W
LED
HI-beam indicator light

Door open warning light
14 V 2 W
LED
Seat belt warning light

Brake warning light
LED
14 V 2 W
AWD warning light

Airbag warning light
LED
LED
Meter illumination light

AT OIL TEMP warning light
14 V 3.4 W, 14 V 2 W
LED
Cruise indicator light

14 V 1.4 W
LED
Security indicator light

Select indicator
LED
LCD
LCD back light

Cruise set indicator light
14 V 1.4 W
14 V 1.4 W
Vehicle dynamics control (VDC) indicator light

Vehicle dynamics control (VDC) warning light
B: CAUTION
Be careful not to damage the meters and instrument panel.
Be careful not to damage the meter glass.
Make sure the electrical connector is connected
securely.
After installation, make sure that each meter operates normally.
Use gloves to avoid damage and getting fingerprints on the glass surface and meter surfaces.
Do not apply excessive force to the printed circuit.
Do not drop or otherwise apply impact.
C: PREPARATION TOOL
1. GENERAL TOOL
TOOL NAME
Circuit tester
REMARKS
Used for measuring resistance and
voltage.
IDI-2
14 V 3 W
LED
Combination Meter System

2. Combination Meter System

A: WIRING DIAGRAM
1. COMBINATION METER
<Ref. to WI-136, WIRING DIAGRAM, Combination
Meter.>
2. OUTSIDE TEMPERATURE INDICATOR

<Ref. to WI-144, WIRING DIAGRAM, Outside
Temperature Display System.>
B: INSPECTION
CAUTION:
When measuring the voltage and resistance of
the ECM, TCM and 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
Symptom
Repair order
Combination meter assembly does not operate.
1. Power supply
2. Ground distribution
Speedometer does not operate.
1. Vehicle speed sensor (MT model)

TCM (AT model)
2. Harness
3. Speedometer
Tachometer does not operate.
1. ECM
2. Harness
3. Tachometer
Fuel gauge does not operate.
1. Fuel level sensor

2. Harness
3. Fuel gauge
Engine coolant temperature gauge does not operate.
1. Engine coolant temperature sensor

2. Harness
3. Engine coolant temperature gauge
Outside temperature indicator does not operate.
1. Ambient sensor
2. Harness
3. Combination meter
IDI-3
NOTE
<Ref. to IDI-4, CHECK
POWER SUPPLY AND
GROUND CIRCUIT,
INSPECTION, Combination Meter System.>
MT model: <Ref. to IDI5, CHECK VEHICLE
SPEED SENSOR,
AT model: <Ref. to IDI6, CHECK OF TRANSMISSION CONTROL
MODULE (TCM),
ENGINE CONTROL
MODULE (ECM),
FUEL LEVEL SENSOR, INSPECTION,
Combination Meter
System.>
ENGINE COOLANT
TEMPERATURE SENSOR, INSPECTION,
Combination Meter
System.>
OUTSIDE TEMPERATURE INDICATOR,

2. CHECK POWER SUPPLY AND GROUND CIRCUIT

1
Step
CHECK POWER SUPPLY FOR COMBINATION METER.
IDI-10, REMOVAL, Combination Meter.>
2) Disconnect the combination meter harness
connector.
CHECK POWER SUPPLY FOR COMBINATION METER.
Measure the voltage between combination
CHECK GROUND CIRCUIT OF COMBINATION METER.
combination meter connector and chassis
ground.
Check
Yes
Go to step 2.
No
Check the harness
for open or short
between the ignition switch and
combination meter.
Go to step 3.
Check the harness

for open or short
between the fuse
and combination
meter.

?
Replace the combination meter

printed circuit.
Repair the wiring

harness.
IDI-4

3. CHECK VEHICLE SPEED SENSOR

1
Step
CHECK VEHICLE SPEED SENSOR.
1) Lift up the vehicle and support it with rigid
racks.
2) Remove the combination meter with harness connector.
3) Drive the vehicle faster than 20 km/h (12
MPH).
WARNING:
Be careful not to get caught in the running
wheels.
CHECK VEHICLE SPEED SENSOR POWER
SUPPLY.
2) Disconnect the vehicle speed sensor harness connector.
4) Measure the voltage between the speed
sensor connector and the engine ground.
SPEED SENSOR AND ENGINE GROUND.
2) Measure the resistance between the speed
sensor connector and the engine ground.
SPEED SENSOR AND COMBINATION
METER.
2) Measure the resistance between the speed
sensor harness connector and combination
meter.
(B17) No. 1 (i10) No. 12:
Check
Yes
No
Check the speed- Go to step 2.
ometer. <Ref. to
IDI-12, REMOVAL,
Speedometer.>
Go to step 3.
Check the harness

for open or short
between the ignition switch and
vehicle speed sensor.

?
Go to step 4.
Repair the wiring

harness.

?
Replace the vehicle speed sensor.
Repair the wiring

harness.
IDI-5

4. CHECK OF TRANSMISSION CONTROL MODULE (TCM)

1
Step
Check
CHECK TCM SIGNAL.
1) Lift up the vehicle and support it with rigid
racks.
2) Drive the vehicle faster than 10 km/h (6
MPH).
WARNING:
Be careful not to get caught in the running
wheels.
CHECK THE HARNESS BETWEEN TCM
AND COMBINATION METER.
?
combination meter.
3) Measure the resistance between TCM harness connector and combination meter harness
connector.
(B56) No. 1 (i10) No. 12:
Yes
Go to step 2.
No
Check the TCM.
<Ref. to
4AT(D)(diag)-2,
Basic Diagnostic
Procedure.>
Check the speed- Repair the wiring

harness.
ometer. <Ref. to
IDI-12, REMOVAL,
Speedometer.>
5. CHECK ENGINE CONTROL MODULE (ECM)

1
Step
Check
CHECK ECM SIGNAL.
Is the voltage 014 V?
2) Measure the voltage between ECM connector and engine ground.
Non-turbo model
Turbo model
CHECK HARNESS BETWEEN COMBINAIs the resistance less than 10
TION METER AND ECM.
?
combination meter.
3) Measure the resistance between ECM harness connector and combination meter harness
connector.
Non-turbo model
(B135) No. 27 (i10) No. 12:
Turbo model
(B135) No. 26 (i10) No. 12:
IDI-6
Yes
Go to step 2.
No
Inspect the ECM.
<Ref. to
EN(H4SO)(diag)2, Basic Diagnostic
Procedure.> <Ref.
to
EN(H4DOTC)(diag
)-2, Basic Diagnostic Procedure.>
Check the tachom- Repair the wiring
eter. <Ref. to IDI- harness.
13, REMOVAL,
Tachometer.>

6. CHECK FUEL LEVEL SENSOR

1
Step
1) Remove the fuel level sensor. <Ref. to
FU(H4SO)-54, REMOVAL, Fuel Level Sensor.>
sensor terminals when the float is in FULL or
EMPTY position.
Terminals
No. 2 No. 3:
FU(H4SO)-55, REMOVAL, Fuel Sub Level Sensor.>
level sensor terminals when the float is in FULL
or EMPTY position.
Terminals
No. 1 No. 2:
CHECK HARNESS BETWEEN FUEL SUB
LEVEL SENSOR AND COMBINATION
METER.
2) Measure the resistance between the fuel
sub level sensor harness connector terminal
and combination meter harness connector terminal.
(R59) No. 1 (i11) No. 1:
CHECK HARNESS BETWEEN FUEL LEVEL
SENSOR AND FUEL SUB LEVEL SENSOR.
Measure the resistance between fuel level sensor harness connector terminal and fuel sub
level sensor harness connector terminal.
(R58) No. 3 (R59) No. 2:
CHECK FUEL LEVEL SENSOR GROUND
CIRCUIT.
Measure the resistance between fuel level sensor harness connector terminal and chassis
ground.
Check
Is the resistance 0.5 to 2.5
(FULL) and 50 to 52
(EMPTY)?
Yes
Go to step 2.
No
Replace the fuel
level sensor.
Is the resistance 0.5 to 2.5

(FULL) and 42 to 44
(EMPTY)?
Go to step 3.
Replace the fuel

sub level sensor.

?
Go to step 4.
Repair the wiring

harness.

?
Go to step 5.
Repair the wiring

harness.

?
Inspect the fuel

Repair the wiring
gauge. <Ref. to
harness.
IDI-14, REMOVAL,
Fuel Gauge.>
IDI-7

7. CHECK ENGINE COOLANT TEMPERATURE SENSOR

1
Step
SENSOR.
Check the engine coolant temperature sensor.
<Ref. to EN(H4SO)(diag)-2, Basic Diagnostic
Procedure.>
COMBINATION METER.
2) Disconnect the connector from the engine
coolant temperature sensor and combination
meter.
3) Measure the resistance between the engine
coolant temperature sensor harness connector
and combination meter harness connector.
(E8) No. 3 (i11) No. 10:
GAUGE GROUND CIRCUIT.
Measure the resistance between the combination meter harness connector terminal and
chassis ground.
Check
Yes
ture sensor OK?
No
Replace the
engine coolant
temperature sensor.

?
Go to step 3.
Repair the wiring

harness.

?
Inspect the engine Repair the wiring

coolant tempera- harness.
ture gauge. <Ref.
to IDI-15,
REMOVAL, Engine
Coolant Temperature Gauge.>
IDI-8

8. CHECK OUTSIDE TEMPERATURE INDICATOR

1
Step
CHECK POWER SUPPLY FOR AMBIENT
SENSOR.
2) Disconnect the connector from ambient
sensor.
4) Measure the voltage between ambient sensor harness connector terminal and chassis
ground.
CHECK HARNESS BETWEEN AMBIENT
SENSOR AND COMBINATION METER.
3) Measure the resistance between the ambient sensor harness connector terminal and
combination meter harness connector terminal.
(F78) No. 1 (i10) No. 25:
(F78) No. 2 (i10) No. 24:
CHECK AMBIENT SENSOR.
1) Remove the ambient sensor.
2) Check the ambient sensor. <Ref. to IDI-16,
INSPECTION, Ambient Sensor.>
CHECK OUTSIDE TEMPERATURE INDICATOR.
1) Connect the combination meter harness
connector.
2) Connect a resistor (3 k) between the terminals of ambient sensor harness connector.
3) Turn the ignition switch to ON and check the
outside temperature indicator display.
Check
Yes
Go to step 3.
No
Go to step 2.

?

printed circuit.
Repair the wiring

harness.
Is the ambient sensor OK?
Go to step 4.
Replace the ambient sensor.
Is the outside temperature indi- Repair the poor

Replace the comcator indicating 25C (77F)? contact of ambient bination meter
sensor harness
print circuit.
connector.
IDI-9
Combination Meter
3. Combination Meter
A: REMOVAL
2) Set the tilt steering at the lowest position.
3) Remove the screws and detach the meter visor.
IDI00001
4) Remove the screws of combination meter and

pull out the meter.
IDI00002
5) Disconnect the connector in the upper area of

combination meter to remove the meter.
CAUTION:
Be careful not to damage the meter or instrument panel.
Be careful not to damage the meter glass.
B: INSTALLATION
CAUTION:
Make sure the electrical connector is connected securely.
Make sure that each meter operates normally.
IDI-10
Combination Meter
C: DISASSEMBLY
CAUTION:
Use gloves to avoid damage and getting fingerprints on the glass surface and meter surfaces.
1) Disengage the claw (E) to remove case (B) from back cover (A).
2) Disengage claw (F) to remove meter glass (D) and reflector (C) from the inner case.
(C)
(D)
(E)
(F)
(A)
(B)
IDI00003
3) Pull up claw (A) in portion (B) of combination

meter printed circuit (C) with combination pliers.
Push out the speedometer (D) and tachometer (E)
and water temperature gauge & fuel gauge assembly (F) using the hole (G).
4) Pull up the claw in the center of the combination
meter printed circuit (C), and remove the printed
circuit from case (H).
1. BULB REPLACEMENT
(8)
(4)
(5)
(6) (7)
(9)
(3)
(10)
(2)
(11)
(C)
(B)
(12)
(H)
(1)
(13)
(F)
IDI00174
(1) Charge indicator light

(2) Tachometer
(A)
(3) Speedometer and tachometer

(4) HI-beam indicator light
(D)
(E)
(G)
IDI00004
(5) Turn signal indicator light (Right)

(6) Speedometer
(7) Turn signal indicator light (Left)
(8) Vehicle dynamics control (VDC) indicator
(9) Brake warning light
(10) ABS warning light
(11) Fuel gauge
(12) Engine coolant temperature gauge
(13) LCD (Outside temperature display, odometer/
tripmeter, and select indicator)
D: ASSEMBLY
IDI-11
Speedometer
4. Speedometer
A: REMOVAL
Disassemble the combination meter, and then remove the speedometer. <Ref. to IDI-11, DISASSEMBLY, Combination Meter.>
B: INSTALLATION
C: INSPECTION
Measure the speedometer resistance.
(1)
(3)
(2)
(4)
IDI00006
(1) COS
(2) COS+
(3) SIN
(4) SIN+
Terminals
SIN+ and SIN terminal
COS+ and COS terminal
2008
2008
If defective, replace the speedometer.

If OK, replace the combination meter printed circuit.
IDI-12
Tachometer
5. Tachometer
A: REMOVAL
Disassemble the combination meter, and then remove the tachometer. <Ref. to IDI-11, DISASSEMBLY, Combination Meter.>
B: INSTALLATION
C: INSPECTION
Measure the tachometer resistance.
(1)
(3)
(2)
(4)
IDI00006
(1) COS
(2) COS+
(3) SIN
(4) SIN+
Terminals
SIN+ and SIN terminal
COS+ and COS terminal
2008
2008
If defective, replace the tachometer.

IDI-13
Fuel Gauge
6. Fuel Gauge
A: REMOVAL
Disassemble the combination meter, and then remove the engine coolant temperature gauge & fuel
gauge assembly. <Ref. to IDI-11, DISASSEMBLY,
Combination Meter.>
B: INSTALLATION
C: INSPECTION
Measure the fuel gauge resistance.
(2)
(1)
(3)
IDI00007
(1) UNIT
(2) IGN
(3) GND
Terminals
IGN and GND terminal

IGN and UNIT terminal
17010
3510
UNIT and GND terminal
13610
Replace the engine coolant temperature gauge &

fuel gauge assembly if defective.
IDI-14
Engine Coolant Temperature Gauge


Gauge
A: REMOVAL
Disassemble the combination meter, and then remove the engine coolant temperature gauge & fuel
gauge assembly. <Ref. to IDI-11, DISASSEMBLY,
Combination Meter.>
B: INSTALLATION
C: INSPECTION
Measure the engine coolant temperature gauge resistance.
(1)
(3)
(2)
IDI00023
(1) GND
(2) IGN
(3) UNIT
Terminals
IGN and GND terminal
20810
IGN and UNIT terminal

UNIT and GND terminal
5610
26410
Replace the engine coolant temperature gauge &

fuel gauge assembly if defective.
IDI-15
Ambient Sensor
8. Ambient Sensor
A: REMOVAL
2) Disconnect the ambient sensor connector.
3) Remove the ambient sensor (A) from the radiator lower panel.
(A)
IDI00008
B: INSTALLATION
C: INSPECTION
Measure the ambient sensor resistance.
2 1
IDI-00009
Terminals
1 and 2
3 k/25C (77F)
If NG, replace the ambient sensor.
IDI-16
Clock
9. Clock
A: REMOVAL
2) Remove the center compartment. <Ref. to EI50, REMOVAL, Instrument Panel Center Compartment.>
3) Remove the clock from the center compartment.
(1)
IDI00194
(1) Center compartment
B: INSTALLATION
IDI-17
Clock
IDI-18
General Description
SEATS
A: COMPONENT
1. FRONT SEAT
Drivers seat (standard seat)
(1)
(3)
(4)
(2)
(23)
T1
(25)
(6)
T3
(5)
(7)
(8)
(9)
T4
(24)
(16 )
(10)
(22)
(21)
(11)
(19)
(12)
T2
(20)
(18)
(14)
(13)
(17)
T5
T4
T2
(15)
SE-00515
(1)
Backrest cover
(12)
(23)
Side airbag module ASSY
(2)
(3)
Backrest pad
Backrest frame ASSY
(13)
(14)
Inner slide rail

Connecting wire
(24)
(25)
Support pad A
Support pad B
(4)
(5)
Headrest ASSY
Headrest bushing
(15)
(16)
Outer slide rail

Tape
(6)
(7)
Seat hinge outer cover LH

Seat hinge inner cover LH
(17)
(18)
Bolt cover RH
Reclining lever
T1: 7.5 (0.8, 5.5)

T2: 10 (1.0, 7.4)
(8)
(9)
Bolt cover LH
Seat cushion cover
(19)
(20)
Seat hinge outer cover RH

Seat lifter dial
T3: 30 (3.0, 22.1)

T4: 52 (5.3, 38.3)
(10)
(11)
Seat cushion pad ASSY

Seat cushion frame ASSY
(21)
(22)
Seat hinge inner cover RH

Seat heater unit
T5: 53 (5.4, 39.0)
SE-2
General Description
SEATS
Drivers seat (power seat)
(1)
(2)
(4)
(3)
(5)
T1
(7)
T1
(9)
(6)
T2
T1
(6)
(8)
SE-00516
(1)
(2)
Seat back pad

Headrest
(6)
(7)
Hinge cover
Slide and unit ASSY
(3)
(4)
Seat back frame ASSY

Seat cushion pad
(8)
(9)
Power seat harness

Hinge ASSY
(5)
Seat cushion frame ASSY
SE-3

T1: 53 (5.4, 39)
T2: 18 (1.8, 13)
General Description
SEATS
Passengers seat
(4)
(1)
(3)
(2)
(5)
(9)
(6)
T1
(8)
(10)
T2
(12)
(7)
(20)
T3
(19)
(15)
(11)
(18)
(14)
(16)
(13)
T3
(17)
SE-00678
(1)
(2)
Backrest cover
Backrest pad
(10)
(11)
Hinge inner cover LH

Rear bolt cover inside
(18)
(19)

Tape
(3)
(4)
Backrest frame ASSY

Headrest ASSY
(12)
(13)
Seat cushion cover

Occupant detection cushion ASSY
(20)
Seat heater unit
(5)
(6)
Headrest lock bushing

Side airbag module
(14)
(15)
Rear bolt cover outside

Hinge inner cover RH

T1: 6 (0.61, 4.43)
(7)
(8)
Support pad A
Support pad B
(16)
(17)
Seat side cover outside

Reclining lever
(9)
Seat cover inside
SE-4
T2: 52 (5.3, 38.4)

T3: 53 (5.4, 39.1)
General Description
SEATS
2. REAR SEAT
(1)
(3)
(2)
(4)
(6)
(12)
T2
(5)
(4)
(18)
(7)
(13)
T2
(20)
(9)
(14)
(8)
(15)
(19)
T1
T2
(10)
T2
(16)
(17)
T2
T1
(11)
SE-00641
(1)
(2)
Webbing guide cap

Webbing guide
(9)
(10)
Seat cushion pad

Hinge CTR
(17)
(18)
Backrest pad LH
Armrest cover
(3)
(4)
Center pillow
Headrest free bushing
(11)
(12)
Hinge LH
Headrest
(19)
(20)
Rear center armrest ASSY

Armrest cover
(5)
(6)
Backrest cover RH
Backrest frame RH
(13)
(14)
Backrest knob
Striker
(7)
(8)
Backrest pad RH
Seat cushion cover
(15)
(16)
Backrest cover LH
Backrest frame LH
SE-5
T1: 24.5 (2.5, 18.1)

T2: 33 (3.4, 24.6)
General Description
SEATS
B: CAUTION
1. DRIVERS SEAT
When removing the front seat from a side airbag
loaded vehicle, follow cautions given in the airbag
section. <Ref. to AB-4, CAUTION, General Description.>
Do not remove the seat position sensor from the
seat rail.
2. PASSENGERS SEAT
When removing the front seat from a side airbag
loaded vehicle, follow cautions given in the airbag
section. <Ref. to AB-4, CAUTION, General Description.>
If the seat cushion cover is removed or replaced,
adjustment after installing the seat to the vehicle.
(REZEROING), OPERATION, Subaru Select Monitor.>
Failure to do so may cause improper operation of
the occupant detection system.
On the passengers seat, never remove the occupant detection control module or the pressure
sensor from the occupant detection cushion assembly. These are fixed to the occupant detection
cushion assembly.
Do not replace the seat cushion pad by itself. Always replace the occupant detection cushion assembly as a unit. The seat cushion pad, occupant
detection sensor, occupant detection control module and seat cushion cover are adjusted as a set at
the time of manufacture. If parts from other vehicles
or from other sets are used, the occupant detection
system will not function properly.
If the seat cushion cover is removed (including
when replacing the heater), always replace the
wires of the seat cushion cover with new wires.
C: PREPARATION TOOL
1. GENERAL TOOL
TOOL NAME
REMARKS
Long nose plier

Hog ring pliers
Used for removing the hog ring.

Used for installing the hog ring.
TORX
Used for removing and installing the

slide rail.
SE-6
Front Seat
SEATS
2. Front Seat
A: REMOVAL
1. DRIVERS SEAT (STANDARD SEAT)
1) While pressing the headrest lock button, remove
the headrest.
8) Disconnect the connector under the seat.

Side airbag connector
Seat belt warning light connector
Buckle switch connector
Position sensor connector
SE-00050
9) Remove the front seat from vehicle.
SE-00003
2) Tilt forward the backrest.

3) Slide the seat to the front end.
4) Remove the bolt cover at the rear end of slide
rail, and remove the two bolts at the rear side of
seat rail.
2. DRIVERS SEAT (POWER SEAT)

1) While pressing the headrest lock button, remove
the headrest.
SE-00062
SE-00049
5) Slide the seat to the rear end.

6) Remove the two bolts at the front side of seat
rail.
2) Tilt forward the backrest.

3) Slide the seat to the front end.
4) Remove the bolt cover at the rear end of slide
rail.
SE-00063
SE-00006

WARNING:
Perform airbag system maintenance at least 20
seconds have passed after removing the battery negative terminal. If the work is started
within 20 seconds, the airbag may deploy due
to the airbag system backup power supply.
SE-7
Front Seat
SEATS
5) Remove the two bolts at the rear side of seat rail.
3. PASSENGERS SEAT
CAUTION:
before starting the work. <Ref. to SE-6, CAUTION, General Description.>
SE-00064
6) Slide the seat to the rear end.

7) Remove the two bolts at the front side of seat
rail.
WARNING:
2) Remove the headrest.
SE-00003
SE-00065

WARNING:
9) Disconnect the connector under the seat.
Buckle switch connector
Position sensor connector
10) Disconnect the integrated connector.
3) Tilt the backrest forward, and move the seat forward.

4) Remove the rear bolt cover, and then remove
the rear side of slide rail.
5) Move the seat backward, remove the front bolt
cover, and then remove the bolt at the front side of
slide rail.
6) Disconnect all the connectors of connector holder in the backside of seat cushion.
Harness connector of occupant detection control
module
Seat heater connector (model with seat heater)
7) Remove the seat from vehicle.
SE-00070
11) Remove the front seat from vehicle.

CAUTION:
Be careful not to damage the body, seat or trim
when removing the seat from the vehicle.
SE-8
Front Seat
SEATS
B: INSTALLATION
C: DISASSEMBLY
1. DRIVERS SEAT
NOTE:
Tighten the slide rail installing bolt gradually in several steps to the specified torque in the order as
STANDARD SEAT
(1)
1) Remove the seat from vehicle. <Ref. to SE-7,

REMOVAL, Front Seat.>
2) Remove the reclining lever cover and reclining
hinge cover.
(3)
(4)
(2)
SE-00652
CAUTION:
1. Drivers seat
After installing the drivers seat, use the Subaru
Select Monitor to confirm that the seat position
sensor LH is operating properly. <Ref. to AB(diag)-30, DISPLAY OF STATUS INFORMATION,
2. Passengers seat
Be sure to perform system calibration for the
occupant detection system after passengers
seat installation. <Ref. to OD(diag)-17, SYSTEM
CALIBRATION (REZEROING), OPERATION,
Failure to do so may cause improper operation
of the occupant detection system.
SE-00040
3) Loosen the screws to remove hinge cover.
SE-00042
4) Remove the two bolts from the reclining hinge on

each left and right side.
Tightening torque:
Refer to COMPONENT of General Description. <Ref. to SE-2, FRONT SEAT, COMPONENT, General Description.>
SE-00044
SE-9
Front Seat
SEATS
8) Remove the hog ring (A) which secures the

backrest cover and backrest pad.
5) Remove the hook at bottom of seat backrest.
(A)
SE-00051
SE-00242
6) Open the fastener at the rear side of backrest.

9) Remove the headrest bushing.
NOTE:
Push outside to remove it from the inside of seat.
SE-00262
7) Remove the hog rings (A) on the front side of

backrest from the backrest frame. (Seat with side
airbag)
SE-00243
10) Pull out the backrest frame.

11) Remove the lower hog rings (A) on the front
side of backrest.
(A)
(A)
(A)
SE-00244

backrest, and then remove the backrest cover from
backrest.
(A)
SE-00246
SE-00378
SE-10
Front Seat
SEATS
13) Remove the connecting wire (A), then loosen

the bolt and nuts to remove slide rail.
16) Remove the hog rings (A), and then remove the
seat cushion cover from seat cushion pad.
: (A)
SE-00299
17) Open the fastener on the bottom of the headrest, then remove the headrest cover from the
headrest.
(A)
SE-00295
14) Remove the inner seat belt assembly.

SE-00271
POWER SEAT
1) Remove the seat from vehicle. <Ref. to SE-7,
REMOVAL, Front Seat.>
2) Remove the seat switch knob.
SE-00297
15) Remove the hooks (A), and then remove the

seat cushion frame.
(A)
SE-00382
3) Disconnect the connector of reclining motor from

the backside of seat cushion.
SE-00268
SE-00383
SE-11
Front Seat
SEATS
4) Remove the screw (A) and clips (B), and then

disconnect the seat switch connector to remove
seat hinge outer cover.
7) Remove the two bolts from the reclining hinge on

each left and right side.
(B)
(A)
(B)
SE-00392
5) Remove the screw (A) and clip (B), and then remove the seat hinge inner cover.
(B)
(A)
SE-00385
8) Remove the hook at bottom of seat backrest.

SE-00384
6) Remove the bolts, and then detach the inner

seat belt assembly.
SE-00051
9) Open the fastener at the rear side of backrest.

SE-00517
SE-00262
SE-12
Front Seat
SEATS

backrest from the backrest frame. (Seat with side
airbag)
14) Remove the two bolts on each left and right

side, and then remove the reclining motor assembly.
(A)
SE-00388
15) Remove the hog rings (A) on the surface side

of backrest, and then remove the backrest cover
from backrest.
(A)
SE-00246
11) Remove the hog ring (A) which secures the

backrest cover and backrest pad.
: (A)
SE-00372
16) Remove the clip (A) and straps (B) on the back
of seat cushion.
(A)
(B)
(A)
SE-00242
12) Remove the headrest lock bushing.

NOTE:
Push outside to remove it from the inside of seat.
SE-00389
17) Remove the bolt (A) and hook (B) on left and
right side, and then remove the seat cushion frame
from seat rail assembly.
SE-00243
13) Pull out the backrest frame assembly.
(A)
SE-13
(B)
SE-00390
Front Seat
SEATS
18) Remove the hooks (A), and then remove the

seat cushion from seat cushion frame.
(A)
(A)
SE-00391
2. PASSENGERS SEAT
CAUTION:
If the seat cushion cover is removed or replaced, make sure to perform occupant detection system adjustment after installing the seat.
(REZEROING), OPERATION, Subaru Select
Monitor.>
Failure to do so may cause improper activation
of passengers airbag.
For the passengers seat, never remove the
occupant detection control module and occupant detection sensor from the seat cushion
frame. These all are the parts of occupant detection cushion assemblies.
If the seat cushion cover is removed (including when replacing the heater), always replace
the wires of the seat cushion cover with new
wires.
1) Remove the seat from vehicle.
2) Remove the reclining lever cover.
(A)
: (A)
SE-00339
20) Remove the hooks and hog rings at the bottom

of headrest, and then remove the headrest cover
from headrest.
SE-00331
3) Remove the screw (A), clip (B) and claw (C), and
then remove the seat side cover outside.
(C)
SE-00342
(B)
(B)
(A)
SE-00480
SE-14
Front Seat
SEATS
4) Remove the screw (A) and claw (B), and then remove the seat side cover inside.
(B)
7) Remove the seat cushion pad and cover from

seat cushion frame assembly.
(A)
(A)
SE-00481
5) Remove TORX bolt, and then detach the inner

seat belt assembly.
: (A)
SE-00339
9) Refer to DRIVERS SEAT for disassembly procedures of backrest and headrest.
SE-00332
6) Remove the two reclining hinge bolts on each of

the left and right sides.
SE-00333
SE-15
Front Seat
SEATS
D: ASSEMBLY
CAUTION:
When the backrest cover is not installed securely, the side airbag module may not be deployed properly, therefore keep strictly to the
following procedure.
Be careful not to stain or damage the backrest cover during assembly.
Do not reuse hog rings.
Secure the hog ring using hog ring pliers.
Install the hog rings to the specified points
securely and make sure that no wrinkle or twisting on backrest cover.
4) Temporarily tighten the reclining hinge bolts in

the order of (1) through (4) to an extent that the seat
backrest assembly is not held securely.
(2)
(1)
(4)
(A)
(3)
(B)
1. DRIVERS SIDE
(A)
Inside the vehicle
(B)
Outside the vehicle
2. PASSENGERS SIDE
CAUTION:
If the seat cushion cover is removed or replaced, make sure to perform occupant detection system adjustment after installing the seat.
(REZEROING), OPERATION, Subaru Select
Monitor.>
Failure to do so may cause improper activation of passengers airbag.
1) Assemble the seat cushion in the reverse order
of disassembly.
2) Assemble the backrest in the reverse order of
disassembly.
3) When installing the backrest assembly to the
seat cushion assembly, fill the gap in the front side
of slide rail LH and in the rear side of slide rail RH
with cloth etc. in order to stabilize the seat cushion
assembly.
SE-00538
5) Use the reclining lever to place the backrest in

the most upright position, and check the first lock
position of recliner.
6) Hold the seat cushion assembly securely, and
tighten the reclining hinge bolts in the order described above until they reach the specified torque.
CAUTION:
Do not touch the backrest assembly when tightening the reclining hinge bolts.
7) Assemble each harness, inner seat belt assembly and each cover in the reverse order of removal.
Tightening torque:
Refer to COMPONENT of General Description. <Ref. to SE-2, FRONT SEAT, COMPONENT, General Description.>
E: INSPECTION
Check that no tear or fray is on the backrest cover
assembly.
NOTE:
When the door side of backrest cover assembly is
torn or frayed, the side airbag may not be deployed
properly. Replace it with new part in such a case.
SE-00537
SE-16
Rear Seat
SEATS
3. Rear Seat
C: DISASSEMBLY
A: REMOVAL

2) Remove the hog rings (A) from the vicinity of the
seat backrest.
1) Remove the bolt to remove the rear seat cushion.
: (A)
SE-00023
SE-00154
2) Remove the headrest.

4) Turn over the rear seat backrest.
5) Turn over the seat cover to remove the bolt.

cushion pad, then remove the cover.
: (A)
SE-00155
4) Remove the hog rings (A) from the vicinity of the

seat cushion.
SE-00153
6) Remove the rear seat backrest.
: (A)
SE-00156

cover.
SE-00025
B: INSTALLATION
Tightening torque:
Refer to COMPONENT of General Description. <Ref. to SE-5, REAR SEAT, COMPONENT, General Description.>
: (A)
SE-00157
SE-17
Rear Seat
SEATS
D: ASSEMBLY
NOTE:
Do not contaminate or damage the cover.
While installing the hog rings, prevent the seat
from getting wrinkled.
SE-18
General Description
SECURITY AND LOCKS
A: COMPONENT
1. DOOR LOCK ASSEMBLY
(6)
(5)
T1
(1)
T2
T2
T4
(3)
T3
(6)
(4)
(2)
T2
(7)
T2
(5)
T1
(3)
T2
T2
T3
(1)
(4)
T4
(2)
SL-00411
(1)
Inner remote ASSY
(6)
Door outer handle
(2)
(3)
Inner remote cover

Auto-door lock actuator
(7)
Key cylinder
(4)
(5)
Door latch
Striker

T1: 6.5 (0.66, 4.8)
T2: 7.5 (0.76, 5.5)
T3: 18 (1.8, 13.3)
T4: 1.5 (0.15, 1.1)
SL-2
General Description
SECURITY AND LOCKS
2. REAR GATE LOCK
(5)
T1
(4)
(2)
(1)
T2
T2
(3)
SL-00002
(1)
(2)
Rear gate latch

Rear gate actuator
(3)
Striker
(4)
(5)
Rear gate outer handle

Cable

T1: 7.5 (0.76, 5.5)
T2: 25 (2.5, 18.4)
SL-3
General Description
SECURITY AND LOCKS
3. FRONT HOOD LOCK AND REMOTE OPENERS
(4)
T1
(2)
(5)
T1
T2
(3)
(1)
SL-00412
(1)
(2)
Front hood lock ASSY

Lever ASSY
(3)
Front hood cable ASSY
(4)
(5)
Pull handle ASSY

Fuel cable ASSY

T1: 7.5 (0.76, 5.5)
T2: 33 (3.4, 24.6)
SL-4
General Description
SECURITY AND LOCKS
4. KEYLESS ENTRY SYSTEM

(2)
(1)
(3)
(4)
(5)
SL-00467
(1)
(2)
Keyless entry control module

Rear gate latch switch
(3)
(4)
Door switch
(5)
Horn
5. IMMOBILIZER SYSTEM
(1)
(2)
(4)
(3)
SL-00470
(1)
(2)
Antenna
Security indicator light (LED bulb)
(3)
Immobilizer control module

(IMMCM)
SL-5
(4)
Transponder
General Description
SECURITY AND LOCKS
6. SECURITY SYSTEM
(3)
(2)
(1)
(4)
(5)
(6)
(7)
SL-00468
(1)
(2)

Security indicator light (in combination meter)
(3)
(4)

Door switch
(5)
Interrupt relay
B: CAUTION
Before disassembling or reassembling parts, always disconnect the battery ground cable from battery. When repairing the radio, control module, etc.
which are provided with memory functions, record
the memory contents before disconnecting the
ground cable from battery. Otherwise, these contents are erased upon disconnection.
Reassemble the parts in the reverse order of disassembly unless otherwise indicated.
Adjust the parts to the specifications described in
this manual if so designated.
(6)
(7)
Horn relay (in main fuse box)

Horn

After reassembly, make sure all the functional
parts operate smoothly.
The wiring harnesses of the airbag system pass
near electrical parts and switches.
All the airbag system wiring harnesses and connectors are yellow. Do not use electrical test equipment on these circuits.
Be careful not to damage the airbag system wiring harness when servicing the ignition key cylinder.
SL-6
General Description
SECURITY AND LOCKS
C: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
925580000
DESCRIPTION
PULLER
REMARKS
Used for removing trim clip
ST-925580000
2. GENERAL TOOL
TOOL NAME
Circuit tester
Drill
REMARKS
Used for replacing ignition key lock.
SL-7
Door Lock Control System

SECURITY AND LOCKS
2. Door Lock Control System

A: WIRING DIAGRAM
1. DOOR LOCK CONTROL
<Ref. to WI-157, WIRING DIAGRAM, Door Lock System.>
B: INSPECTION
1. SYMPTOM CHART
Symptom
The door lock control system does
not operate.
Repair order
1. Check the fuse.
2. Check the power supply and ground circuit for

body integrated unit.
Reference
<Ref. to SL-8, CHECK FUSE,
INSPECTION, Door Lock Control
System.>
<Ref. to SL-8, CHECK POWER
SUPPLY AND GROUND CIRCUIT,
System.>
3. Check the door lock switch and the circuit.
<Ref. to SL-9, CHECK DOOR LOCK

SWITCH AND CIRCUIT, INSPECTION, Door Lock Control System.>
4. Check the door lock actuator and the circuit.
<Ref. to SL-10, CHECK DOOR

LOCK ACTUATOR AND CIRCUIT,
System.>
<Ref. to SL-9, CHECK DOOR LOCK
SWITCH AND CIRCUIT, INSPECTION, Door Lock Control System.>
LOCK ACTUATOR AND CIRCUIT,
System.>
The door lock switch does not

operate.
Check the door lock switch and circuit.
A specific door lock actuator does not

operate.
Check the door lock actuator and circuit.
2. CHECK FUSE
1
Step
Check
CHECK FUSE.
Remove and visually check the fuses No. 2 (in
the main fuse box) and No. 3 (in the fuse & relay
box).
Yes
Replace the fuse
with a new part.
No
Check the power
supply and ground
circuit. <Ref. to SL8, CHECK
POWER SUPPLY
AND GROUND
CIRCUIT,
INSPECTION,
Door Lock Control
System.>
Yes
Go to step 2.
No
Check the harness
for open or short
circuit between
body integrated
unit and fuse.

1
Step
Check
CHECK POWER SUPPLY.
1) Disconnect the harness connector of body
integrated unit.
2) Measure the voltage between harness connector terminal and chassis ground.
SL-8

SECURITY AND LOCKS
Step
Check
Measure the resistance between harness con- ?
nector terminal and chassis ground.
Yes
No
The power supply Repair the harand ground circuit ness.
are OK.
4. CHECK DOOR LOCK SWITCH AND CIRCUIT

1
Step
CHECK DOOR LOCK SWITCH CIRCUIT.
integrated unit.
2) Measure the resistance between the harness connector terminal and chassis ground
when moving the door lock switch to LOCK.
CHECK DOOR LOCK SWITCH CIRCUIT.
Measure the resistance between the harness
connector terminal and chassis ground when
the door lock switch is moved to UNLOCK.
CHECK DOOR LOCK SWITCH GROUND
CIRCUIT.
1) Disconnect the door lock switch harness
connector.
2) Measure the resistance between the door
lock switch harness connector terminal and the
body ground.
No. 5 Chassis ground:
CHECK DOOR LOCK SWITCH.
1) Measure the resistance between the door
lock switch terminals when moving the door
lock switch to LOCK.
Driver side:
No. 5 No. 9:
Passenger side:
No. 4 No. 5:
CHECK DOOR LOCK SWITCH.
Measure the resistance between the door lock
switch terminals when moving the door lock
switch to UNLOCK.
Driver side:
No. 5 No. 8:
Passenger side:
No. 2 No. 5:
Check
?
Yes
Go to step 2.
No
Go to step 3.

?
The door lock

switch is OK.
Go to step 3.
Repair the open

circuit in the harness or chassis
ground.
Replace the door

lock switch.
Is the resistance less than 1 ? Check the harness Replace the door
for open circuits or lock switch.
shorts between the
body integrated
unit and the door
lock switch.
SL-9

SECURITY AND LOCKS
5. CHECK DOOR LOCK ACTUATOR AND CIRCUIT

1
Step
Check
CHECK OUTPUT SIGNAL.
Measure the voltage between the harness connector terminal and chassis ground of body
integrated unit when moving the door lock
switch to LOCK.
Measure the voltage between the harness connector terminal and chassis ground of body
integrated unit when moving the door lock
switch to UNLOCK.
CHECK DOOR LOCK ACTUATOR.
Is the door lock actuator OK?
Check the door lock actuator.
Front Door Lock Actuator: <Ref. to SL-32, Front
Door Lock Actuator.>
Rear Door Lock Actuator: <Ref. to SL-36, Rear
Door Lock Actuator.>
Rear Gate Latch Lock Actuator: <Ref. to SL-39,
Rear Gate Latch Lock Actuator.>
SL-10
Yes
Go to step 2.
No
Replace the body
integrated unit.
Go to step 3.
Replace the body

integrated unit.
Check the harness Replace the door

for open or short
lock actuator.
circuits between
body integrated
unit and door lock
actuator.
Keyless Entry System

SECURITY AND LOCKS
3. Keyless Entry System

A: WIRING DIAGRAM
1. KEYLESS ENTRY
<Ref. to WI-148, WIRING DIAGRAM, Keyless Entry System.>
B: ELECTRICAL SPECIFICATION
1. KEYLESS ENTRY CONTROL MODULE
TO B176
13 12 11 10 9 8 7 6 5 4 3
2
1
26 25 24 23 22 21 20 19 18 17 16 15 14
SL-00469
Content
Terminal No.
Measuring condition
Battery voltage is present when the keyless transmitter UNLOCK/DISARM or LOCK/ARM button is pressed.
Battery voltage is constantly present.
Turn signal light LH
1 (OUTPUT)
Power supply (Back-up)
Keyless buzzer
3 (OUTPUT)
Door lock switch
4 (INPUT)
0 V is present when the keyless transmitter UNLOCK/DISARM or

LOCK/ARM button is pressed.
0 V is present when the door lock switch is turned to UNLOCK.
Door lock switch

Door switch
5 (INPUT)
6 (INPUT)
0 V is present when the door lock switch is turned to LOCK.

0 V is present when opening one of the doors or rear gate.
Key warning switch

Ignition switch (ON)
9 (INPUT)
10 (INPUT)
Battery voltage is present when inserting the key into ignition switch.
Battery voltage is present when ignition switch is turned to ON.
Turn signal light RH
13 (OUTPUT)
Battery voltage is present when the keyless transmitter UNLOCK/DISARM or LOCK/ARM button is pressed.
Ground
14
18 (OUTPUT)
19 (OUTPUT)
Battery voltage is present when the keyless transmitter LOCK/ARM button is pressed.
Horn relay
24 (OUTPUT)
0 V is present when the keyless transmitter LOCK/ARM button is

pressed for approx. 2 seconds, and the panic alarm is operated.
Power supply (Back-up)
26
0 V is constantly present.
Battery voltage is present when the keyless transmitter UNLOCK/DISARM button is pressed.
SL-11

SECURITY AND LOCKS
2. BODY INTEGRATED UNIT
16 15 14 13 12 11 10 9
10 9
20 19 18 17 16 15 14 13 12 11
SL-00364
Content
Terminal No.
Measuring condition
Door switch (Except drivers door)

Door switch (Drivers door)
b7 (INPUT)
b8 (INPUT)
0 V is present when opening the doors. (Except drivers door).

0 V is present when opening the drivers side door.
Door lock switch

Door lock switch
b11 (INPUT)
b12 (INPUT)
0 V is present when the door lock switch is turned to UNLOCK.

0 V is present when the door lock switch is turned to LOCK.

(LOCK)
b13 (INPUT)

(UNLOCK)
b14 (INPUT)
Battery voltage is present when the keyless transmitter UNLOCK/DISARM button is pressed.

Key warning switch
b19 (INPUT)
b20 (INPUT)

Battery voltage is present when inserting the key into ignition switch.
Power supply
Ground
a2
a4

Room light
a5 (OUTPUT)
Door and rear gate lock actuator
a6 (OUTPUT)
Door and rear gate lock actuator

(Except driver side)
a7 (OUTPUT)
Door lock actuator (Driver side)
a8 (OUTPUT)
Battery voltage is present when the keyless transmitter UNLOCK/DISARM button is pressed once.
Ground
a13
0 V is present when the keyless transmitter UNLOCK/DISARM button is

pressed.
Battery voltage is present when the keyless transmitter UNLOCK/DISARM button is pressed twice.
SL-12

SECURITY AND LOCKS
C: INSPECTION
1. SYMPTOM CHART
Symptom
None of the functions of the keyless
entry system operate.
Repair order
Reference
1. Check the keyless transmitter battery and func- <Ref. to SL-14, CHECK KEYLESS
tion.
TRANSMITTER BATTERY AND
FUNCTION, INSPECTION, Keyless
Entry System.>
2. Check the fuse.
INSPECTION, Keyless Entry System.>
3. Check the keyless entry control module power <Ref. to SL-16, CHECK POWER
supply and ground circuit.
INSPECTION, Keyless Entry System.>
4. Replace the keyless entry control module.
The keyless transmitter cannot be

registered.
<Ref. to SL-49, Keyless Entry Control

Module.>
tion.
Entry System.>
2. Check the ignition switch circuit.
<Ref. to SL-16, CHECK IGNITION

SWITCH CIRCUIT, INSPECTION,
Keyless Entry System.>
3. Check the door switch.
SWITCH, INSPECTION, Keyless
Entry System.>
Module.>
Door lock or unlock does not operate. 1. Check the keyless transmitter battery and func- <Ref. to SL-14, CHECK KEYLESS
tion.
NOTE:
If the door lock control system does
Entry System.>
not operate when using the door lock
switch, check the door lock control
2. Check the key warning switch.
<Ref. to SL-18, CHECK KEY WARNsystem. <Ref. to SL-8, INSPECTION,
ING SWITCH, INSPECTION, Keyless
Door Lock Control System.>
Entry System.>

Entry System.>
4. Check the output signal of the body integrated

unit.
The panic alarm does not operate.
<Ref. to SL-19, CHECK OUTPUT

SIGNAL OF THE BODY INTEGRATED UNIT, INSPECTION, Keyless Entry System.>
Module.>
tion.
Entry System.>
2. Check the horn operation.
<Ref. to SL-19, CHECK HORN

OPERATION, INSPECTION, Keyless
Entry System.>

Module.>
SL-13

SECURITY AND LOCKS
Symptom
Buzzer and hazard light do not
operate.
Repair order
Reference
1. Check the buzzer function.
2. Check buzzer and hazard

light operation.
<Ref. to SL-15, CHECK BUZZER

CHIRP SETTING, INSPECTION,
Buzzer
<Ref. to SL-20, CHECK KEYLESS

BUZZER, INSPECTION, Keyless
Entry System.>
<Ref. to SL-20, CHECK HAZARD
LIGHT OPERATION, INSPECTION,
Module.>
<Ref. to SL-18, CHECK ROOM
LIGHT OPERATION, INSPECTION,
Module.>
Hazard light

The room light does not operate.
1. Check the room light operation.

The door warning does not operate.

Entry System.>
BUZZER, INSPECTION, Keyless
Entry System.>
Module.>
2. Check the buzzer operation.
2. CHECK KEYLESS TRANSMITTER BATTERY AND FUNCTION

1
Step
CHECK KEYLESS TRANSMITTER BATTERY.
1) Remove the battery from the keyless transmitter. <Ref. to SL-51, REMOVAL, Transmitter.>
2) Check the battery voltage. <Ref. to SL-51,
INSPECTION, Transmitter.>
CHECK KEYLESS TRANSMITTER.
Register a keyless transmitter which operated
normally on other vehicles to the inspection target vehicle. <Ref. to SL-52, REGISTRATION
OF KEYLESS TRANSMITTER WITH SUBARU
SELECT MONITOR, REPLACEMENT, Transmitter.>
1) Close all the doors and rear gate of inspection target vehicle.
2) Using the keyless transmitter, lock and
unlock the doors and rear gate of vehicle.
Register the keyless transmitter of the inspection target vehicle to an other vehicle for which
the keyless system operates normally. <Ref. to
SL-52, REGISTRATION OF KEYLESS
TRANSMITTER WITH SUBARU SELECT
MONITOR, REPLACEMENT, Transmitter.>
Check
Yes
Go to step 2.
No
Replace the keyless transmitter
battery.
Is the inspection target vehicle Go to step 3.

operates lock and unlock normally?
Due to vehicle malfunction, continue

the keyless entry
system diagnosis.
Is the keyless transmitter regis- Go to step 4.

tered correctly?
Replace the keyless transmitter.

<Ref. to SL-52,
REGISTRATION
OF KEYLESS
TRANSMITTER
WITH SUBARU
SELECT MONITOR, REPLACEMENT,
Transmitter.>
SL-14

SECURITY AND LOCKS
Step
Check
Yes
Does the vehicle operates lock The keyless transCheck the registered keyless transmitter.
and unlock normally?
mitter is OK.
1) Close all the doors and rear gate of the vehicle for which the keyless system operates normally.
2) Using the keyless transmitter, lock and
unlock the doors and rear gate of vehicle.
No
Replace the keyless transmitter.
<Ref. to SL-52,
REGISTRATION
OF KEYLESS
TRANSMITTER
WITH SUBARU
SELECT MONITOR, REPLACEMENT,
Transmitter.>
CAUTION:
Be sure to reset the keyless transmitter of the other vehicle that was registered to the inspection target vehicle, and the vehicle for which the keyless transmitter was registered for inspection, to the
condition before performing the inspection. (Register the keyless transmitter again.)
3. CHECK BUZZER CHIRP SETTING

1
Step
Check
CHECK BUZZER CHIRP SETTING.
Does the buzzer sound?
1) Check the current setting of the buzzer
chirp.
2) Remove the key from the ignition switch.
3) Close all the doors and rear gate.
4) Press the LOCK/ARM or UNLOCK/DISARM button.
CHECK BUZZER CHIRP SETTING.
NOTE:
When steps 1) to 5) are performed with the answer-back buzzer setting OFF, the answerback buzzer setting is switched to ON.
1) Open the drivers door, and remove the key
from ignition switch.
2) Turn the center door lock switch to
UNLOCK, then insert the ignition key.
3) Remove and insert the key five times within
10 seconds from the step 2).
4) Close the drivers door within 10 seconds
from the 5th of the step 3).
5) Switch the answer-back buzzer setting
(ONOFF), then hazard light will blink three
times.
NOTE:
If the drivers door is not closed within 10 seconds, the hazard light blinks once. In this case,
retry from the beginning.
6) Press the LOCK/ARM or UNLOCK/DISARM button.
SL-15
Yes
The buzzer function is OK.
No
Go to step 2.
The buzzer function is OK.
Check the keyless

transmitter function. <Ref. to SL14, CHECK KEYLESS TRANSMITTER BATTERY
AND FUNCTION,
INSPECTION,

SECURITY AND LOCKS
4. CHECK FUSE
1
Step
Check
CHECK FUSE.
Remove and visually check the fuses No. 6 (in
the main fuse box) and No. 3 (in the fuse & relay
box).
Yes
Replace the fuse
with a new part.
No
Check the power
supply and ground
POWER SUPPLY
AND GROUND
CIRCUIT,
INSPECTION,
Yes
Go to step 2.
No
Check the harness
for open circuits
and shorts
between the keyless entry control
module and fuse.

1
Step
Check
CHECK POWER SUPPLY.
1) Disconnect the keyless entry control module harness connector.

are OK.
6. CHECK IGNITION SWITCH CIRCUIT

1
Step
Check
CHECK IGNITION SWITCH CIRCUIT.
SL-16
Yes
No
Ignition switch
Check the harness
function is normal. for open circuits or
shorts between the
keyless entry control module and the
ignition relay.

SECURITY AND LOCKS
7. CHECK DOOR SWITCH

1
Step
CHECK DOOR SWITCH CIRCUIT.
Measure the voltage between the keyless entry
control module harness connector terminal and
the body ground.
Front and rear door, rear gate:
the body ground.
Front and rear door, rear gate:
CHECK DOOR SWITCH.
1) Disconnect the door switch harness connector.
2) Measure the resistance between door
switch terminals.
Terminals
Door switch No. 1 No. 3:
Rear gate latch switch No. 1 No. 2:
CHECK DOOR SWITCH.
Measure the resistance between door switch
terminals.
Terminals
Check
Is the voltage 0 V when any
door or rear gate is opened?
Yes
Go to step 2.
Is the voltage 10 V or more

when any door or rear gate is
closed?
The door switch is Go to step 3.

OK.
Is the resistance 1 M or more Go to step 4.

when door switch is pushed?
No
Go to step 3.
Replace the door

switch.
Is the resistance less than 1 Check the harness Replace the door
when door switch is released? for open circuits
switch.
and shorts
between the keyless entry control
module and the
door switch.
SL-17

SECURITY AND LOCKS
8. CHECK KEY WARNING SWITCH

1
Step
CHECK FUSE.
Remove and visually check the fuse No. 6 (in
the main fuse box).
CHECK KEY WARNING SWITCH CIRCUIT.
2) Insert the key into ignition switch. (LOCK
position)
CHECK KEY WARNING SWITCH CIRCUIT.
1) Remove the key from ignition switch.
1) Disconnect the key warning switch harness
connector.
2) Insert the key into ignition switch. (LOCK
position)
3) Measure the resistance between key warning switch terminals.
Terminals
No. 1 No. 2:
2) Measure the resistance between key warning switch terminals.
Terminals
No. 1 No. 2:
Check
Yes
Replace the fuse
with a new part.
No
Go to step 2.
Go to step 3.
Go to step 4.
Is the voltage 0 V?
The key warning

switch is OK.
Go to step 4.
more?
Replace the key

warning switch.
Check the follow- Replace the key

ing:
warning switch.
Harness for
open circuits and
shorts between the
key warning switch
and fuse.
Harness for
open circuits and
shorts between the
key warning
switch.
9. CHECK ROOM LIGHT OPERATION

1
Step
Check
CHECK ROOM LIGHT OPERATION.
Does the room light illuminate?
Make sure the room light illuminates when the
room light switch is turned to ON.
CHECK HARNESS BETWEEN ROOM LIGHT Is the resistance less than 10
AND BODY INTEGRATED UNIT.
?
1) Disconnect the body integrated unit harness
connector and room light harness connector.
2) Measure the resistance between the body
integrated unit harness connector terminal and
room light harness connector terminal.
(B280) No. 5 (R52) No. 2:
SL-18
Yes
Go to step 2.
No
Check the room
light circuit.
Check the harness

The room light
operation circuit is for open or short
OK.
circuit between
body integrated
unit and the room
light.

SECURITY AND LOCKS
10.CHECK OUTPUT SIGNAL OF THE BODY INTEGRATED UNIT

1
Step
the chassis ground when the UNLOCK/DISARM buttons of the keyless transmitter are
pressed.
the chassis ground when the LOCK/ARM buttons of the keyless transmitter are pressed.
CHECK HARNESS BETWEEN KEYLESS ENTRY CONTROL MODULE AND BODY INTEGRATED UNIT.
1) Disconnect the keyless entry control module harness connector and the body integrated
unit harness connector.
2) Measure the resistance between keyless
entry control module harness connector terminal and body integrated unit harness connector
terminal.
(B176) No. 18 (B281) No. 14:
(B176) No. 19 (B281) No. 13:
Check
Yes
Go to step 2.
No
Replace the keyless entry control
module.
Go to step 3.

module.

?
Replace the body

integrated unit.
Check the harness

for open or short
circuit between the
body integrated
unit.
Yes
Go to step 2.
No
Check the horn circuit.

module.
Check the harness

for open circuits or
shorts between the
horn relay.
11.CHECK HORN OPERATION

1
Step
Check
CHECK HORN OPERATION.
Does the horn sound?
Make sure the horn sounds when the horn
switch is pushed.
2) Connect the harness connector terminal to
ground using a suitable lead wire.
SL-19

SECURITY AND LOCKS
12.CHECK HAZARD LIGHT OPERATION

1
Step
Check
CHECK HAZARD LIGHT OPERATION.
Does the hazard light blink?
Make sure the hazard light blinks when hazard
switch is turned to ON.
2) Close all the doors and the rear gate.
3) Measure the voltage between the keyless
entry control module harness connector terminal and the chassis ground when the LOCK/
ARM buttons of the keyless transmitter are
pressed.
Yes
Go to step 2.
No
Check the hazard
light circuit.
Check the harness Replace the keyfor open circuits or less entry control
shorts between the module.
turn signal light.
13.CHECK KEYLESS BUZZER

1
Step
CHECK FUSE.
Remove and check the fuse No. 2 (in the main
fuse box).
CHECK FOR POWER SUPPLY OF KEYLESS
BUZZER.
1) Disconnect the connector from keyless
buzzer.
buzzer harness connector terminal and the
body ground.
CHECK THE HARNESS BETWEEN KEYLESS BUZZER AND KEYLESS ENTRY CONTROL MODULE.
1) Disconnect the connector from the keyless
entry control module.
between keyless buzzer and keyless entry control module.
(F102) No. 1 (B176) No. 3:
CHECK KEYLESS BUZZER.
to No. 2 terminal of the keyless buzzer connector, and the negative () terminal to No. 1 terminal. Check the buzzer sounds.
Check
Yes
Replace the fuse
with a new part.
No
Go to step 2.
Go to step 3.
Check for open or

short circuit in the
harness between
fuse and keyless
buzzer.
Repair the harness

between keyless
buzzer and keyless
entry control module.
Replace the keyless buzzer.
SL-20

module.
Security System
SECURITY AND LOCKS
4. Security System
A: WIRING DIAGRAM
<Ref. to WI-151, WIRING DIAGRAM, Security System.>
B: ELECTRICAL SPECIFICATION
TO B176
13 12 11 10 9 8 7 6 5 4 3
2
1
26 25 24 23 22 21 20 19 18 17 16 15 14
SL-00469
Content
Turn signal light LH
Terminal No.
1 (OUTPUT)
Measuring condition
Battery voltage is present when the alarm operation is activated.
Power supply (Backup)

Door switch
2
6 (INPUT)

0 V is present when opening one of the doors or rear gate.
Impact sensor
When not applying vibration to the impact sensor, it repeats displaying the 0
V and battery voltage every 45 milliseconds.

Horn relay
10 (INPUT)
24 (OUTPUT)

0 V is present when the alarm operation is activated.
Interrupt relay
Turn signal light RH
12 (OUTPUT)
13 (OUTPUT)

Ground
14
15 (OUTPUT)
0 V is present when the alarm operation is activated.
Power supply for turn signal light

(Backup)
26
SL-21
Security System
SECURITY AND LOCKS
C: INSPECTION
1. BASIC DIAGNOSTIC PROCEDURE
NOTE:
Turbo model is the model with immobilizer.
Non-turbo model is the model without immobilizer.
1
Step
Check
Yes
SECURITY SYSTEM SETTING.
Is setting completed correctly? Go to step 2.
Turn the setting of security system ON. <Ref. to
SL-23, SECURITY SYSTEM ON/OFF SETTING, INSPECTION, Security System.>
CHECK SECURITY SYSTEM SETTING OPERATION.

1) Before starting this diagnosis, open all
doors.
2) Remove the key from ignition key cylinder,
then close all doors and rear gate.
3) Press the LOCK/ARM button of keyless
transmitter, and wait for 30 seconds.
CHECK SECURITY INDICATOR LIGHT AND
HAZARD LIGHT BLINKING.
Check the security indicator light and hazard
light blinking.
NOTE:
The blinking pattern of security indicator light is
twice within 1 second in 1 second cycle.
CHECK SECURITY ALARM OPERATION.
1) Unlock all doors using the door lock switch
on front door.
2) Open any door or rear gate.
Can the security system be

set?
CHECK SECURITY ALARM OPERATION.

Check the security alarm operation.
Do all security alarm (horn,

Go to step 6.
hazard light and security indicator light) operate? And is the
starter motor deactivated?
CHECK SECURITY ALARM CANCEL OPER- Do all security alarm (horn and Go to step 7.
ATION.
hazard light) stop? And is the
Press the UNLOCK/DISARM button of the key- starter motor activated?
less transmitter.
NOTE:
Model with immobilizer blinks once, model without immobilizer is remain off.
Go to step 3.
No
Check the ignition switch circuit.
<Ref. to SL-28,
CHECK IGNITION
SWITCH CIRCUIT,
INSPECTION,
Security System.>
Check the door
lock switch circuit.
<Ref. to SL-9,
CHECK DOOR
LOCK SWITCH
AND CIRCUIT,
INSPECTION,
Door Lock Control
System.>
Go to symptom 1.
<Ref. to SL-24,
SYMPTOM
CHART, INSPECTION, Security
System.>
Does the security indicator light Go to step 4.

and the hazard light blink?
Go to symptom 2.
<Ref. to SL-24,
SYMPTOM
System.>
Does the security alarm operate when opening any door or

rear gate?
Go to symptom 3.
<Ref. to SL-24,
SYMPTOM
System.>
Go to symptom 4.
<Ref. to SL-24,
SYMPTOM
System.>
Go to symptom 5.
<Ref. to SL-24,
SYMPTOM
System.>
SL-22
Go to step 5.
Security System
SECURITY AND LOCKS
Step
CHECK BATTERY DISCONNECT PROTECTION.
Check that the system functions properly when
the battery is disconnected temporally. <Ref. to
SL-23, CHECK BATTERY DISCONNECT
PROTECTION., INSPECTION, Security System.>
CHECK IMPACT SENSOR.
Check the sensitivity of impact sensor. <Ref. to
SL-47, CHECK IMPACT SENSOR, ADJUSTMENT, Impact Sensor.>
NOTE:
Perform this procedure only to the vehicle with
an impact sensor (dealer OP).
Check
Yes
Does the system function prop- Go to step 8.
erly when the battery is disconnected temporally?
No
Replace the keyless control module.
Is the sensitivity set properly?
Adjust the sensitivity properly. <Ref.

to SL-47, IMPACT
SENSITIVITY
ADJUSTMENT,
ADJUSTMENT,
Impact Sensor.>
2. CHECK BATTERY DISCONNECT PROTECTION.

2) Close all the doors and rear gate.
4) Press the keyless transmitter LOCK/ARM button, and wait until the security indicator light blinks
twice within 1 second in 1 second cycle.
7) Check that the security indicator light blinks
twice within 1 second in 1 second cycle after connecting the battery ground cable.
If NG, replace the keyless entry control module.
3. SECURITY SYSTEM ON/OFF SETTING

NOTE:
When steps 1) to 4) are performed with the security
system setting ON, the security system setting is
switched to OFF.
1) Close all doors and the rear gate, then sit down
on the driver seat. Press the UNLOCK button of the
keyless transmitter.
3) While turning the center door lock switch to UNLOCK, open the drivers door, and keep this condition for 10 seconds.
4) Switch the security system setting (ONOFF),
then the horn sounds.
Setting
Notification
OFF ON
ON OFF
Horn sounds once.

Horn sounds twice.
NOTE:
See the following for security system ON/OFF setting with the select monitor. <Ref. to SL-45, PROCEDURE, Security Control Unit.>
SL-23
Press the
UNLOCK/DISARM button of keyless transmitter,
and finish the diagnosis.
Security System
SECURITY AND LOCKS
4. SYMPTOM CHART
Symptom
1
The security system cannot be set.
Repair order
Reference
1. Check the keyless transmitter

function.

Entry System.>
INSPECTION, Security System.>
<Ref. to SL-26, CHECK POWER
SWITCH, INSPECTION, Security
System.>
<Ref. to SL-44, Security Control
Unit.>
<Ref. to SL-27, CHECK SECURITY
INDICATOR LIGHT CIRCUIT,
LIGHT OPERATION, INSPECTION, Security System.>
System.>
2. Check the fuse.

3. Check the keyless entry control module power supply and
ground circuit.
Security system can be set, but

the security indicator light or
hazard light does not blink.

Hazard light
5. Replace the keyless entry

control module.
Check the security indicator light
circuit.
Check the hazard light operations.
Security system does not trigger when one of the

doors is opened.
Check the door switch.
Security alarm does not activate.
All functions
Check the door switch.

System.>
Check the security indicator light

circuit.
<Ref. to SL-27, CHECK SECURITY

INDICATOR LIGHT CIRCUIT,
Horn
Check the horn.
Hazard light
Check the hazard light operations.
Starter motor
does not run.
Check the interrupt relay circuit.
Keyless transmitter
Check the keyless transmitter

function.
<Ref. to SL-27, CHECK THE

HORN, INSPECTION, Security System.>
LIGHT OPERATION, INSPECTION, Security System.>
<Ref. to SL-28, CHECK INTERRUPT RELAY CIRCUIT, INSPECTION, Security System.>
Entry System.>
Ignition switch
Check the ignition switch circuit.
The security system cannot be

cancelled.
SL-24
<Ref. to SL-28, CHECK IGNITION

SWITCH CIRCUIT, INSPECTION,
Security System.>
Security System
SECURITY AND LOCKS
5. CHECK FUSE
1
Step
Check
CHECK FUSE.
Remove and visually check the fuses No. 2, No.
6 (in the main fuse box) and No. 3 (in the fuse &
relay box).
SL-25
Yes
Replace the fuse
with a new part.
No
Check the power
supply and ground
POWER SUPPLY
AND GROUND
CIRCUIT,
INSPECTION,
Security System.>
Security System
SECURITY AND LOCKS

1
Step
Check
CHECK POWER SUPPLY.
Yes
Go to step 2.
No
Check the harness
shorts between the
fuse.

are OK.
7. CHECK DOOR SWITCH

1
Step
the body ground.
Front and rear door:
Rear gate:
the body ground.
Front and rear door:
Rear gate:
CHECK DOOR SWITCH.
1) Disconnect the door switch harness connector.
2) Measure the resistance between door
switch terminals.
Terminals
CHECK DOOR SWITCH.
Measure the resistance between door switch
terminals.
Terminals
Check
Is the voltage 0 V when each
door or rear gate is opened?
Yes
Go to step 2.
No
Go to step 3.
Is the voltage 10 V or more

The door switch is Go to step 3.
when each door or rear gate is OK.
closed?
Is the resistance more than 1

M when door switch is
pushed?
Go to step 4.
Replace the door

switch.
Is the resistance less than 1 Check the harness Replace the door
when door switch is released? for open circuits or switch.
shorts between the
door switch.
SL-26
Security System
SECURITY AND LOCKS
8. CHECK SECURITY INDICATOR LIGHT CIRCUIT

1
Step
CHECK SECURITY INDICATOR LIGHT.
CHECK POWER SUPPLY FOR SECURITY
INDICATOR LIGHT.
meter harness connector terminal and chassis
ground.
CHECK SECURITY INDICATOR LIGHT CIRCUIT.
Measure the resistance between the combination meter harness connector terminal and keyless entry control module harness connector
terminal.
(i12) No. 4 (B176) No. 15:
Check
Yes
Does the security indicator light Replace the keyilluminate?
less entry control
module.
No
Go to step 2.
Go to step 3.
Check the harness

for open or short
circuits between
combination meter
and fuse.

?
Check the harness

for open or short
circuits between
combination meter
and keyless entry
control module.
Yes
Go to step 2.
No
Check the horn circuit.

module.
Check the harness

shorts between the
horn relay.
Yes
Go to step 2.
No
Check the hazard
light circuit.
9. CHECK THE HORN

1
Step
Check
Make sure the horn sounds when the horn
switch is pushed.
10.CHECK HAZARD LIGHT OPERATION

1
Step
Check
CHECK HAZARD LIGHT OPERATION.
Does the hazard light blink?
Make sure the hazard light blinks when hazard
switch is turned to ON.
SL-27
Security System
SECURITY AND LOCKS
Step
Check
CHECK KEYLESS ENTRY CONTROL MOD- Is the voltage 1 4 V?
ULE OUTPUT SIGNAL.
2) Open the drivers window, then close all
doors and the rear gate.
3) Lock all doors with the keyless transmitter or
door lock switch to activate the security system.
4) Unlock all doors using the door lock switch.
entry control module harness connector terminal and the body ground when any door is open.
Yes
No
Check the harness Replace the keyfor open circuits or less entry control
shorts between the module.
turn signal light.
11.CHECK INTERRUPT RELAY CIRCUIT

1
Step
CHECK INTERRUPT RELAY.
Remove and check interrupt relay. <Ref. to SL48, Interrupt Relay.>
CHECK INTERRUPT RELAY POWER SUPPLY.
Measure the voltage between interrupt relay
harness connector terminal and chassis
ground.
CHECK THE HARNESS BETWEEN INTERRUPT RELAY AND KEYLESS ENTRY CONTROL MODULE.
between interrupt relay harness connector terminal and keyless entry control module harness
connector.
(B59) No. 3 (B176) No. 12:
Check
Is the interrupt relay normal?
Yes
Go to step 2.
No
Replace the interrupt relay.
Is the voltage more than 10 V Go to step 3.

when ignition switch is turned to
START?
Check the harness

shorts between the
interrupt relay and
the ignition switch.

?

module.
Check the harness

for open or short
circuits between
interrupt relay and
keyless entry control module.
Yes
Ignition switch is
normal.
No
Check the harness
shorts between the
ignition switch.
12.CHECK IGNITION SWITCH CIRCUIT

1
Step
Check
CHECK IGNITION SWITCH SIGNAL.
SL-28
Front Inner Remote

SECURITY AND LOCKS
5. Front Inner Remote

A: REMOVAL
3) Remove the one screw and two cables.
4) Remove the front inner remote.
SL-00007
B: INSTALLATION
Tightening torque:
1.5 Nm (0.15 kgf-m, 1.1 ft-lb)
NOTE:
Make sure the inner remote works properly after installation.
C: INSPECTION
1) Make sure the cable is not deformed.
2) Make sure the lever and cable move smoothly.
NOTE:
If the remote handle is a chrome plated type, check
that there is plenty of grease applied to the cable
joint of the remote handle.
If there is not enough grease, assemble the cable
after applying additional grease.
SL-29
Front Outer Handle

SECURITY AND LOCKS
6. Front Outer Handle

A: REMOVAL
CAUTION:
Do not apply excessive force to remove the
door trim. This can deform the door panel.
3) Remove the front inner remote. <Ref. to SL-29,
REMOVAL, Front Inner Remote.>
4) Remove the cable from the cable holder and allow it to be free.
5) Remove the two bolts and the rod clamp to remove front outer handle.
NOTE:
The rear side bolt can be removed from the inner
panel service hole (A) by adjusting the glass position.
(A)
SL-00009
B: INSTALLATION
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
NOTE:
Make sure the outer handle works properly after installation.
C: INSPECTION
1) Make sure the rod is not deformed.
2) Make sure the lever and rod move smoothly.
SL-30
Front Door Latch and Door Lock Actuator Assembly

SECURITY AND LOCKS
7. Front Door Latch and Door

Lock Actuator Assembly
B: INSTALLATION
A: REMOVAL
Tightening torque:
Door latch mounting screw
6.5 Nm (0.66 kgf-m, 4.8 ft-lb)
Door lock actuator mounting bolt
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)

4) Remove the front inner remote. <Ref. to SL-29,
REMOVAL, Front Inner Remote.>
5) Remove the two bolts and one nut to remove the
guide rail.
NOTE:
Make sure the lock works properly after installation.
C: INSPECTION
SL-00008
6) Remove the three screws and one bolt.
SL-00010
7) Remove the front door latch assembly, and disconnect the connector.
SL-31
Front Door Lock Actuator

SECURITY AND LOCKS
8. Front Door Lock Actuator

A: REMOVAL
1) Remove the front door latch assembly. <Ref. to
SL-31, REMOVAL, Front Door Latch and Door
Lock Actuator Assembly.>
2) Loosen two screws to remove the front door lock
actuator.
SL-00011
B: INSTALLATION
NOTE:
C: INSPECTION
1) Disconnect the door lock actuator harness connector.
2) Connect the battery to door lock actuator terminals.
2 1
4 3
2 1
4 3
SL-00012
Terminal No.
Actuator operation
No. 2 (+) and No. 4 ()

No. 4 (+) and No. 2 ()
Unlock Lock
Lock Unlock
If defective, replace the door lock actuator.
SL-32
Rear Inner Remote

SECURITY AND LOCKS
9. Rear Inner Remote

A: REMOVAL
3) Remove the one screw and two cables.
4) Remove the inner remote.
SL-00007
B: INSTALLATION
Tightening torque:
1.5 Nm (0.15 kgf-m, 1.1 ft-lb)
NOTE:
Make sure the inner remote works properly after installation.
C: INSPECTION
3) Make sure that the rear door child safety locks
operate properly.
NOTE:
If the remote handle is a chrome plated type, check
that there is plenty of grease applied to the cable
joint of the remote handle.
If there is not enough grease, assemble the cable
after applying additional grease.
SL-33
Rear Outer Handle

SECURITY AND LOCKS
10.Rear Outer Handle

A: REMOVAL
CAUTION:
Do not apply excessive force to remove the
door trim. This can deform the door panel.
3) Remove the rear inner remote. <Ref. to SL-33,
REMOVAL, Rear Inner Remote.>
4) Remove the rear door latch assembly. <Ref. to
SL-35, REMOVAL, Rear Door Latch and Door Lock
Actuator Assembly.>
5) Remove the two bolts, and then detach the rear
outer handle.
SL-00013
B: INSTALLATION
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
NOTE:
C: INSPECTION
1) Make sure there are no cracks, breakage, and
damage on plastic lever.
2) Make sure the plastic lever moves smoothly.
SL-34
Rear Door Latch and Door Lock Actuator Assembly

SECURITY AND LOCKS
11.Rear Door Latch and Door

Lock Actuator Assembly
A: REMOVAL
4) Remove the rear inner remote. <Ref. to SL-33,
REMOVAL, Rear Inner Remote.>
5) Remove the three screws and one bolt.
SL-00014
6) Disconnect the connector and then detach the

rear door latch assembly.
B: INSTALLATION
Tightening torque:
Door latch mounting screw
6.5 Nm (0.66 kgf-m, 4.8 ft-lb)
Door lock actuator mounting bolt
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
NOTE:
C: INSPECTION
SL-35
Rear Door Lock Actuator

SECURITY AND LOCKS
12.Rear Door Lock Actuator

A: REMOVAL
1) Remove the rear door latch assembly. <Ref. to
SL-35, REMOVAL, Rear Door Latch and Door Lock
Actuator Assembly.>
2) Loosen two screws to remove the rear door lock
actuator.
SL-00015
B: INSTALLATION
NOTE:
C: INSPECTION
2 1
4 3
2 1
4 3
SL-00012
Terminal No.
Actuator operation
No. 2 (+) and No. 4 ()

No. 4 (+) and No. 2 ()
Unlock Lock
Lock Unlock
If defective, replace the door lock actuator.
SL-36
Rear Gate Outer Handle

SECURITY AND LOCKS
13.Rear Gate Outer Handle

A: REMOVAL
1) Remove the rear gate trim. <Ref. to EI-47, REMOVAL, Rear Gate Trim.>
2) Remove the rear wiper motor assembly. <Ref. to
WW-16, REMOVAL, Rear Wiper Motor.>
3) Remove the rear finisher light.
4) Remove the cable and the two nuts.
SL-00016
5) Remove the rear gate outer handle.
B: INSTALLATION
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
NOTE:
C: INSPECTION
SL-37
Rear Gate Latch Assembly

SECURITY AND LOCKS
14.Rear Gate Latch Assembly

A: REMOVAL
3) Remove two bolts.
SL-00017
4) Remove the rear gate latch assembly and disconnect the connector.
5) Remove the rear gate outer handle cable, and
then remove the rear gate latch assembly.
B: INSTALLATION
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
NOTE:
C: INSPECTION
2) Make sure that the lever and cable, rear gate
latch switch, and door lock operate smoothly.
SL-38
Rear Gate Latch Lock Actuator

SECURITY AND LOCKS
15.Rear Gate Latch Lock Actuator

A: REMOVAL
1) Remove the rear gate latch assembly. <Ref. to
SL-38, REMOVAL, Rear Gate Latch Assembly.>
2) Disconnect the three claws, and then remove
the rear gate latch lock actuator from the rear gate
latch assembly.
CAUTION:
Do not apply excessive force to remove the actuator when removing it. This can deform the
area around the rear gate latch assembly claws.
SL-00018
B: INSTALLATION
CAUTION:
Align the rear gate latch assembly lever groove
and actuator lever.
NOTE:
C: INSPECTION
2 1
4 3
2 1
4 3
SL-00012
Terminal No.
No. 4 (+) and No. 2 ()
Actuator operation
Unlock Lock
No. 2 (+) and No. 4 ()
Lock Unlock
If NG, replace the rear gate latch lock actuator.
SL-39
Front Hood Lock Assembly

SECURITY AND LOCKS
16.Front Hood Lock Assembly

A: REMOVAL
2) Remove the front grille.
3) Remove the bolts, and then detach the front
hood lock assembly.
4) Remove the release cable from lock assembly.
SL-00539
B: INSTALLATION
Tightening torque:
33 Nm (3.4 kgf-m, 24.6 ft-lb)
NOTE:
Apply grease to the movable part.
Make sure the release cable works properly after
installation.
C: ADJUSTMENT
Loosen the bolt, and adjust the lock assembly while
moving it up and down.
SL-00540
D: INSPECTION
1) Check that there is no deformation or uneven
wear in the striker.
2) Check the safety lever for improper movement.
3) Check other levers and the spring for rust formation and unsmooth movement.
SL-40
Remote Openers
SECURITY AND LOCKS
17.Remote Openers
6) Rotate the fuel lock inside the quarter panel to

the left and remove.
A: REMOVAL
1. FRONT HOOD OPENER
1) Remove the hood lock assembly. <Ref. to SL40, REMOVAL, Front Hood Lock Assembly.>
2) Remove the release cable from hood lock.
3) Remove the bolt, and then detach the opener lever.
SL-00023
B: INSTALLATION
1. FRONT HOOD OPENER
2. FUEL FLAP OPENER

SL-00038
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
2. FUEL FLAP OPENER

2) Remove the center pillar lower trim and side sill
cover. Remove the rear pillar lower trim. Remove
the floor mat.
3) Remove the rear quarter trim RH. <Ref. to EI-44,
REMOVAL, Rear Quarter Trim.>Remove the clip
holding cable (A).
4) Remove the bolt, and then detach the opener
pull handle (B).
5) Remove the cable (A) from opener pull handle
(B).
C: INSPECTION
Make sure the fuel flap opens and closes smoothly.
SL-00022
SL-41
Ignition Key Lock

SECURITY AND LOCKS
18.Ignition Key Lock

A: REPLACEMENT
2) Remove the steering column. <Ref. to PS-16,
REMOVAL, Tilt Steering Column.>
3) Secure the steering column in a vise. Remove
the bolt with a drill.
SL-00024
4) Remove the ignition starter and steering lock.

5) Use a new fixer bolt. Tighten the fixer bolt to the
bolt head wrenched off.
SL-00025
B: INSPECTION
1) Remove the instrument panel lower panel.
2) Remove the lower column cover.
3) Unfasten the fixing clip which secures harness,
and then disconnect the connector of the ignition
switch from body harness.
4) Turn the ignition key plate to each position and
check the continuity between terminals of ignition
connector.
Switch
LOCK
Terminal No.
Standard
ACC
No. 1 and No. 2

No. 1 and No. 2
No. 1 and No. 4
No. 2 and No. 4
Less than 1
ON
ST
No. 1 and No. 3

No. 1 and No. 4
No. 3 and No. 4
Less than 1
Less than 1
If NG, replace the ignition switch.
SL-42
Key Lock Cylinders

SECURITY AND LOCKS
19.Key Lock Cylinders

A: REPLACEMENT
1. FRONT DOOR
3) Completely close the front door glass.
4) Remove the rod clamps (A) and lock plate (B).
Replace the key cylinder.
NOTE:
Replace the lock plate (B) with a new part.
(B)
(A)
SL-00026
SL-43
Security Control Unit

SECURITY AND LOCKS
20.Security Control Unit

A: NOTE
The control of security system is carried out in keyless entry control module.
B: REMOVAL
<Ref. to SL-49, REMOVAL, Keyless Entry Control
Module.>
C: INSTALLATION
<Ref. to SL-49, INSTALLATION, Keyless Entry
Control Module.>
SL-44

SECURITY AND LOCKS
D: PROCEDURE
1. FUNCTION SETTING (ECM CUSTOMIZING)
1) Connect the Subaru Select Monitor to the data link connector.
3) On the Main Menu display screen, select the {Each System Check} and press the [YES] key.
4) On the System Selection Menu display screen, select the {keyless unit mode} and press the [YES] key.
5) On the Keyless Unit Mode display screen, select the {ECM customizing} and press the [YES] key.
6) Change the setting with UP/DOWN key and press the [YES] key.
List of function setting item (ECM customizing)
No.
Data
Security Alarm Setup
Alarm monitor delay setting
Impact Sensor Setup
Initial
setting
value
Customize setting
ON
ON
OFF
ON
Impact Sensor Setup (OP)
ON
OFF
Delay time is 30 seconds.

Delay time is 0 seconds.
ON
Enabled when Impact Sensor Setup is set to ON. Impact

sensor function becomes activated.
OFF
OFF
ON
OFF
5
Passive arming
OFF
Security alarm (hazard and horn) in active condition.

Security alarm in inactive condition
After doors are locked by keyless entry system operation,
alarm monitor starts in following time.
OFF
Remarks
Impact sensor in inactive condition (Make sure to set models without the impact sensor to OFF).
Vehicle is controlled in impact sensor equipped mode.
(Make sure to set models without the impact sensor to
OFF. If impact sensor is set to ON, hazard and/or horn
operates after doors are locked by keyless entry system
operation (Alarm monitor start).
Vehicle is controlled in no impact sensor mode.
ON
An automatic arming feature which arms automatically even

without the user intentionally locking (ARM)
OFF
Enabled when passive arming is set to ON.
7) After setting, make sure that vehicle equipment matches the changed settings in the {Current Data Display
& Save}.
CAUTION:
The above settings most match the actual vehicle equipment for proper operation.
Do not change settings other than the above while setting equipment.
When installing a new keyless unit, perform initial setting again.
In passive mode, the system will automatically activate the security alarm but WILL NOT automatically lock the doors. Failure to lock the doors manually will result in a high security risk.
NOTE:
For details concerning the operation procedure, refer to SUBARU SELECT MONITOR OPERATION MANUAL.
8) Turn the ignition switch to OFF, and then remove the Subaru Select Monitor.
SL-45

SECURITY AND LOCKS
2. WARNING HISTORY NOTICE MODE

2) Indicator light will blink.
Check number of
times indicator
light blinked.
Condition of vehicle
Once
Minor WARNING has been activated by

the impact sensor (OP). This may indicate that your vehicle has been subject
to small shock from outside, or tampered with by an unauthorized person.
Twice
Strong WARNING has been activated

by the impact sensor (OP). This may
indicate that your vehicle has been subject to big shock from outside, or tampered with by an unauthorized person.
Three times
Five times
The ignition switch was turned ON.

One of the doors or the rear gate was
opened.
NOTE:
If ALARM/WARNING occurs during the armed
mode, the indicator light will flash at ignition OFF
ON at the next DISARM.
If ALARM/WARNING was not generated, the indicator light does not blink.
If the warnings overlap, the warning with the largest number of blinks will have priority and will blink.
For all ignition ON operation during DISARM
mode, the indicator will blink, and the record is updated at the next ARM mode.
SL-46
Impact Sensor
SECURITY AND LOCKS
21.Impact Sensor
D: ADJUSTMENT
A: REMOVAL
1. CHECK IMPACT SENSOR
NOTE:
The impact sensor is a dealer OP.
2) Close all the doors and the rear gate.
3) Press the UNLOCK button of the keyless transmitter.
4) Change the setting of impact sensor using Subaru Select Monitor.
6) Remove the impact sensor.

2) Close all windows.
3) Close all the doors and the rear gate. Leave
open the front hood.
4) Press the LOCK button of the keyless transmitter from outside of vehicle.
5) Check that after 30 seconds, the security indicator light blinks twice a second, repeating in 1 second intervals.
6) Hit the windshield with your palm continuously
and check the security alarm operates. Lift up the
front hood approx. 12 cm (4.7 in) or more, and then
drop it off to check the operation of security alarm.
7) If NG, adjust the impact sensitivity.
B: INSTALLATION
2) Close all the doors, trunk lid and rear gate.
3) Press the UNLOCK button of the keyless transmitter.
5) Install the impact sensor.
7) Change the setting of impact sensor using Subaru Select Monitor.
C: OPERATION
1. IMPACT SENSOR SETTING USING SUBARU SELECT MONITOR
link connector.
3) Select {keyless unit} from the main menu.
4) Select {ECM customizing}.
5) Make a impact monitor setting.
When installing: ON
When removing: OFF
6) Make a impact monitor ON/OFF setting.
When installing: ON
When removing: OFF
7) Turn the ignition switch to OFF, and then remove
2. IMPACT SENSITIVITY ADJUSTMENT

link connector.
3) Select {Impact Sensor} from the main menu.
4) Make a {Sensitivity Adjustment Mode}
Sensitivity can be adjusted in 11 levels (0 to 10).
Initial setting is 5.
A smaller number means it will be more sensitive.
A larger number means it will be less sensitive.
5) Turn the ignition switch to OFF, and then remove
NOTE:
Set the sensor so that it is not triggered by normal vibrations (someone reclining on the door, hit
by a ball, etc.).
Set the sensor to operate the alarm when the
windshield glass or door is hit hard repeatedly, etc,
where it can be assumed that there is an attempt to
damage the car by a burglar, etc.
Even if there is no attempt to steal or burglarize
the car, if the vehicle is subject to an equivalent
shock or vibration (from road construction, etc.),
the alarm will sound. Discuss with the customer
their parking environment to make sensitivity settings accordingly.
SL-47
Interrupt Relay
SECURITY AND LOCKS
22.Interrupt Relay
A: REMOVAL
3) Remove the mounting bolt and detach the interrupt relay (Tightened together with the fuse & relay
box bracket).
SL-00482
B: INSTALLATION
C: INSPECTION
Measure the interrupt relay resistance between terminals (indicated in the table below) when connecting terminal No. 3 to battery positive terminal and
terminal No. 1 to battery ground terminal.
Current
Terminal No.
Standard
Flow
52
54
1 M or more
Less than 1
No flow
52
54
Less than 1
1 M or more
(A)
3 2 1
4
5
SL-00483
(A) Battery
If NG, replace the interrupt relay.
SL-48
Keyless Entry Control Module

SECURITY AND LOCKS
23.Keyless Entry Control Module

A: REMOVAL
3) Remove the nut, then disconnect the connector
to remove the keyless entry control module.
SL-00047
B: INSTALLATION
SL-49
Body Integrated Unit

SECURITY AND LOCKS
24.Body Integrated Unit

A: REMOVAL
3) Remove the nut, then disconnect the connector
to remove the body integrated unit.
SL-00048
B: INSTALLATION
SL-50
Transmitter
SECURITY AND LOCKS
25.Transmitter
C: INSPECTION
A: REMOVAL
1. KEYLESS TRANSMITTER BATTERY
Measure the voltage between the battery (+) terminal and (-) terminal.
Remove the battery from the keyless transmitter.

NOTE:
Before disassembling the keyless transmitter, prevent damage by static electricity to the transmitters
printed circuit board by touching a steel piece of a
building etc. with your hand to discharge any static
from your body and clothes.
NOTE:
The battery will discharge during the measurement.
Complete the measurement within 5 seconds.
(A)
(1)
SL-00066
(A) Resistance (47 )

SL-00387
Tester connection
B: INSTALLATION
(+)
()
Battery (+)
terminal
Ground terminal
Standard
2.5 3.0 V
If NG, replace the battery. (Use CR2025 or equivalent.)
SL-51
Transmitter
SECURITY AND LOCKS
D: REPLACEMENT
1. REGISTRATION OF KEYLESS TRANSMITTER WITH SUBARU SELECT MONITOR
NOTE:
A maximum of four keyless transmitters can be
registered for each individual vehicle.
When replacing or adding a keyless transmitter,
new registration of the transmitter is necessary.
1) Connect the Subaru Select Monitor to the vehicle.
3) From the Main menu on the Subaru Select
Monitor, select the {2. Check individual system}
{7. Keyless unit mode} {8. Keyless transmitter ID
registration}.
4) Input the 8-digit ID number from the left, which is
attached to the plastic bag of the keyless transmitter or to the transmitter inner circuit board, then select the [OK].
NOTE:
Select the [ ] on the Subaru Select Monitor to increase the number, and the [ ] to decrease. Select the [<] to move to the digit in the left, and [>] to
the right.
5) The ID number you have entered will be shown.
Make sure that the ID number shown is the same
as the plastic bag.
6) Select the [OK] if the ID number is correct. If incorrect, select the [NO] to return to the step 3) and
try again.
7) ID registration in process is displayed and
registration starts.
8) ID registration done will be displayed when
the registration process is done.
9) To exit, select END: NO, and select the [NO]
to return to {8. Keyless transmitter ID registration}.
If there are additional keyless transmitters to be
registered, select Next registration: OK, and select the [OK] to return to the step 3).
NOTE:
If the registration fails, ID registration failed. Try
again. will be shown. Select the [OK] to return to
the {8. Transmitter ID registration}. And retry from
the step 2).
END: NO is shown on the Subaru Select Monitor when fourth keyless transmitter has been registered. Select the [NO] to return to {8. Keyless
transmitter ID registration}.
SL-52
Immobilizer Control Module

SECURITY AND LOCKS
26.Immobilizer Control Module

A: REMOVAL
NOTE:
Prepare the security ID plate.
Prepare all registered immobilizer keys for the
model with immobilizer.
When replacing the immobilizer control module,
register the immobilizer. At that time, a new immobilizer key is required. Refer to the REGISTRATION MANUAL FOR IMMOBILIZER.
If not replacing the immobilizer control module,
re-registration of a key used before is not required.
If not replacing the immobilizer control module, a
maximum of four keys, including the added key,
can be registered.
3) Disconnect the connector from immobilizer control module.
4) Remove the immobilizer control module.
SL-00465
B: INSTALLATION
SL-53
Immobilizer Antenna
SECURITY AND LOCKS
27.Immobilizer Antenna
A: REMOVAL
3) Remove the screws, and detach the upper column cover and lower column cover.
LI-00401
4) Disconnect the immobilizer antenna connector

(A) from body harness.
5) Remove the screws and detach the immobilizer
antenna (B).
(A)
(B)
SL-00466
B: INSTALLATION
SL-54
General Description
SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF)
A: COMPONENT
(1)
(2)
(3)
(5)
(4)
(6)
(13)
(7)
(12)
(8)
(10)
(11)
(6)
(9)
SR-00013
(1)
(2)
Sunroof lid
Rear drain ASSY
(7)
(8)
Harness
Sunshade
(12)
(13)
Deflector
Shim
(3)
(4)
Sunroof frame
Sunroof motor
(9)
(10)
Garnish
Frame bracket
(5)
(6)
Drive unit
Drain tube
(11)
Cover
T: 7.4 (0.75, 5.4)
SR-2
General Description
B: CAUTION
C: PREPARATION TOOL
the memory contents before disconnecting the battery ground cable in order to prevent memory deletion.
1. GENERAL TOOL
SR-3
TOOL NAME
Circuit tester
REMARKS
Used for measuring resistance and
voltage.
Sunroof Control System

2. Sunroof Control System

A: WIRING DIAGRAM
1. SUNROOF
<Ref. to WI-147, WIRING DIAGRAM, Sunroof Control System.>
B: INSPECTION
Symptom
Inspection order
Water leakage
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.
Wind noise
1.
2.
1.
2.
3.
4.
Check sunroof lid and roof panel for improper clearance.

Check sunshade and roof trim for improper clearance.
Check the motor mounting screws for looseness.
Check gears and bearings for wear.
Check cable for wear.
Check cable pipe for deformities.
1.
2.
3.
4.
5.
6.
1.
2.
3.
4.
5.
6.
7.
Check sunroof frame for foreign particles.

Check sunroof frame for improper installation.
Check parts for mutual interference.
Check cable slider for improper clinching.
Check cable for improper installation.
Check clutch adjusting nut for improper tightness.
Check fuse for blown out.
Check switch for improper function.
Check motor for incorrect terminal voltage.
Check the relay for improper operation.
Check poor grounding system.
Check harness for open or short and terminals for poor connections.
Check limit switch for improper operation.
Abnormal motor noise
Failure of sunroof
(Motor operates properly.)
Motor does not rotate or it rotates improperly.
SR-4
Sunroof Lid
3. Sunroof Lid
C: ADJUSTMENT
A: REMOVAL
1. ALIGNMENT OF HEIGHT BETWEEN

SUNROOF LID AND ROOF PANEL
1) Completely close the sunroof lid, and then open

the sunshade.
2) Remove the four covers (A), and then remove
the eight nuts.
Loosen the sunroof lid nuts, and then adjust the

height by adding (max: four pieces) or extracting
(min: zero pieces) shims (normally two pieces)
which are installed between the sunroof lid and the
roof panel.
Difference of height between sunroof lid and
roof panel:
2.01.0 mm (0.0790.039 in)
(C)
2.0
1.0 mm (0.079
0.039 in)
(B)
SR-00002
3) Remove the sunroof lid carefully.
B: INSTALLATION
(A)
SR-00003
(A) Shim
(B) Sunroof lid
(C) Roof panel
SR-5
Sunroof Assembly
4. Sunroof Assembly
B: INSTALLATION
A: REMOVAL

2) Remove the roof trim. <Ref. to EI-46, REMOVAL, Roof Trim.>
3) Remove the sunroof lid. <Ref. to SR-5, REMOVAL, Sunroof Lid.>
4) Disconnect the four drain tubes (A) from the sunroof frame.
5) Disconnect the sunroof harness connector.
6) Remove the bolts and then remove the frame
bracket.
CAUTION:
Be careful not to snag the harness.
NOTE:
Be sure to connect the harness connector.
When installing the drain tube, insert it securely
into drain pipe.
Length A:
SR-00005
C: DISASSEMBLY
SR-00014
7) Remove the nuts and bolts to remove the sunroof frame.
1) Remove the sunroof frame.

2) Cut the right front side sunshade claw (A).
3) Remove the right front slider.
(A)
(A)
SR-00015
(A)
SR-00006
4) Pull out the sunshade (B) from sunroof frame.
SR-00007
SR-6
Sunroof Assembly
D: ASSEMBLY
E: INSPECTION
1. CHECK FOR MOVING LOAD OF SUNSHADE
1) Attach a spring balance to sunshade edge using
a cloth.
SR-00008
2) Pull the spring balance to measure moving load

of the sunshade.
Moving load of sunshade:
Less than 25 N (2.5 kgf, 5.5 lb)
NOTE:
Moving load is larger at the beginning of pulling a
spring balance, so take a spring balance reading
while sunshade sliding smoothly.
3) If moving load exceeds specifications, check the
sunroof lid, sunshade, deflector and sunroof frame
for improper installation.
SR-7
Sunroof Motor
5. Sunroof Motor
C: ADJUSTMENT
A: REMOVAL
1) Reset the sunroof motor.

(1) Completely close the sunroof lid. At this
time, it operates intermittently in 50 mm (1.97
in) amounts. The switch must be pressed several times.
(2) Then continue pushing the switch for more
than one second to the CLOSE side.
(3) Open the sunroof lid approximately 400 mm
(15.75 in) out.
(4) Completely close the sunroof lid, then continue pushing the switch for more than one second to the CLOSE side. (This operation enables
the auto operation.)
CAUTION:
When removing the sunroof motor, completely close the sunroof.
When removing the clip, use great care not to
damage the roof trim.
1) Completely close the sunroof lid.
4) Disconnect the harness connector (A), and then
remove the sunroof motor mounting screws (B) and
nuts (C).
D: INSPECTION
1. WINDOW AUTO-REVERSE MECHANISM
(A)
1) Open the sunroof lid.

2) Forcefully push the sunroof lid in the opening direction while auto-closing, to check whether the
window auto-reverse mechanism functions.
3) Check whether the window auto-reverse mechanism operates and the roof moves back 150 mm
(5.91 in) in the opening direction.
SR-00016
CAUTION:
Do not place objects in the way to check the
auto-reverse mechanism.
(C)
(B)
(C)
B: INSTALLATION
CAUTION:
When installing the sunroof motor assembly,
be careful not to move the sunroof cable.
1) Install the sunroof motor.
2) Connect the sunroof motor harness connector of
motor assembly, and then connect the battery
ground cable to battery.
3) Reset the sunroof motor. <Ref. to SR-8, ADJUSTMENT, Sunroof Motor.>
4) Check the sunroof operation as follows:
Inspection order
(1)
(2)
(3)
(4)
(5)
NOTE:
The auto-function is cancelled when the window
auto-reverse mechanism is activated more than
five times.
If the auto function is cancelled, reset it. <Ref. to
SR-8, ADJUSTMENT, Sunroof Motor.>
Switch
position
Sunroof closes completely.

Sunroof opens 500 mm (19.7 in)
away from completely closed position.
Sunroof opens completely.
Close
Open
Sunroof closes 200 mm (7.87 in) in

front of the completely closed
position.
Sunroof closes completely.
Close
Open
Close
5) Install the roof trim. <Ref. to EI-46, INSTALLATION, Roof Trim.>
SR-8
Sunroof Switch
6. Sunroof Switch
A: REMOVAL
2) Remove the spot map light. <Ref. to LI-29, REMOVAL, Spot Map Light.>
3) Disconnect the harness connector, and then remove the sunroof switch (A).
(A)
SR-00017
B: INSTALLATION
C: INSPECTION
5 4 3 2 1
SR-00011
Inspect the continuity between each terminal during operation of the switches.
Switch
Terminal No.
Standard
Open
Close
1 and 3
3 and 4
Less than 1
Less than 1
SR-9
Sunroof Switch
SR-10
General Description
EXTERIOR/INTERIOR TRIM
A: COMPONENT
1. UNDER COVER
(1)
(2)
T
EI-01362
(1)
Front under cover
(2)
Service hole cover

T: 18 (1.84, 13.3)
2. HEAT SHIELD COVER
(2)
(1)
EI-01409
(1)
Center heat shield cover
(2)
Rear heat shield cover
EI-2
General Description
3. FRONT BUMPER
T2
T2
(6)
(4)
(5)
(6)
(7)
(9)
(8)
(2)
T1
(1)
T1
(3)
EI-01410
(1)
(2)
Bumper face
E/A Form
(6)
(7)
Side bracket
Front grille
(3)
(4)
Fog light
Upper beam
(8)
(9)
Lower beam reinforcement

Lower beam
(5)
Main beam
EI-3

T1: 7.5 (0.76, 5.53)
T2: 70 (7.1, 51)
General Description
4. REAR BUMPER
T4
T4
(2)
T4
(13)
T5
T5
(9)
(10)
(11)
(12)
(5)
T3
(4)
(7)
T4
T4
(6)
(8)
T1
T5
T2
T2
(3)
(1)
EI-01375
(1)
(2)
Bumper face
Rear bumper upper beam
(8)
(9)
Rear bumper upper beam side

Rivet
(3)
(4)
Cover rear arch

Bracket side rear bumper front
(10)
(11)
E/A Form
Main beam
T2: 4.4 (0.45, 3.26)

T3: 7.4 (0.75, 5.46)
(5)
(6)
Bracket center
Stay COMPL
(12)
(13)
Side bracket
Bumper stay
T4: 32 (3.3, 24)

T5: 93 (9.5, 68.7)
(7)
Bracket bumper side rear ASSY
EI-4

T1: 1.8 (0.18, 1.3)
General Description
5. MUD GUARD
(3)
(1)
(4)
(5)
(2)
(2)
(2)
EI-00938
(1)
(2)
Mud guard
Clip
(3)
(4)
Screw
Clip (S-shaped)
EI-5
(5)
Air flap
General Description
6. COWL PANEL
(2)
(1)
(3)
(2)
EI-01106
(1)
Cowl panel
(2)
Cowl panel side
EI-6
(3)
Seal
General Description
7. SIDE SILL SPOILER
(4)
(3)
(5)
(2)
(1)
EI-00009
(1)
(2)
Side garnish (Front fender)

Side garnish (Front door)
(3)
(4)
Side garnish (Rear door)

Side garnish (Rear quarter)
EI-7
(5)
Side garnish (Side sill)
General Description
8. ROOF RAIL
(1)
T
EI-00010
(1)
Roof rail

T: 7.5 (0.76, 5.53)
9. DOOR TRIM
(1)
(5)
(3)
(5)
(3)
(2)
(6)
(6)
(2)
(4)
(4)
(A)
(7)
(B)
EI-01108
(A)
Front door trim
(B)
Rear door trim
(1)
Gusset cover
(4)
Clip
(2)
(3)
Bracket
Upper weather strip
(5)
(6)
Trim panel
Power window switch cover
(7)
EI-8
Cover
General Description
10.REAR GATE TRIM
EI-00012
EI-9
General Description
11.CONSOLE BOX
(1)
(5)
(2)
(3)
(4)
(6)
(2)
(11)
(9)
(8)
(7)
(10)
EI-01304
(1)
(2)
Arm cover
Hinge cover
(5)
(6)
Armrest frame
Hinge rear cover
(9)
(10)
Console lid and tray

Console cover
(3)
(4)
Cup holder
Hinge front cover
(7)
(8)
Console pocket
Console box
(11)
Front cover
EI-10
General Description
12.INSTRUMENT PANEL
(11)
(16)
(13)
(2)
(3)
(4)
(6)
(14)
(1)
(15)
(8)
(5)
(7)
(12)
(9)
(10)
EI-01092
(1)
(2)
Pad and frame

Center compartment (Model
without navigation system)
(6)
(7)
Meter visor
Center panel
(12)
(13)
Grille cover
Air vent grille (Defroster)
Air vent grille

Glove box panel
(14)
(15)
Switch panel
Passengers airbag module
Glove box lid

Steering beam
(16)
Knee guard panel
(3)
Grille cover
(8)
(9)
(4)
(5)
Lower cover
Coin box
(10)
(11)
EI-11
General Description
13.INNER TRIM
(3)
T
(2)
(14)
(16)
(15)
(7)
(5)
(6)
(1)
T
(13)
(10)
(12)
(9)
(11)
(8)
(4)
EI-01306
(1)
(2)
Front pillar upper trim

Center pillar upper trim
(8)
(9)
Rear skirt trim

Side sill rear cover
(14)
(15)
Front pillar inner rib

Center pillar inner rib
(3)
(4)
Rear pillar upper trim

Rear rail trim
(10)
(11)
Center pillar lower trim

Side sill front cover
(16)
Bracket
(5)
(6)
Insulator
Rear quarter lower trim
(12)
(13)
Front garnish
Rear garnish

T: 2 (0.20, 1.46)
(7)
Strut cap
EI-12
General Description
14.ROOF TRIM
EI-00016
15.FLOOR MAT
(A)
(1)
EI-00111
(A)
Front side of vehicle
(1)
Floor mat
EI-13
General Description
16.LUGGAGE FLOOR MAT
(4)
(3)
(2)
(5)
(1)
EI-01093
(1)
(2)
Front floor mat

Floor box
(3)
(4)
Side floor mat RH

Center floor mat
EI-14
(5)
Side floor mat LH
General Description
17.COMPARTMENT ACCESSORIES
(1)
T
T
(3)
(2)
(4)
EI-01369
(1)
(2)
Hook
Sun Visor
(3)
(4)
Assist rail bracket

Assist grip (Retractable)

T: 2 (0.20, 1.46)
B: PREPARATION TOOL
TOOL NAME
Clip remover
Clip clamp pliers
REMARKS
Used for removing trim.
Used for removal of various clips and clamps.
EI-15
Front Grille
2. Front Grille
A: REMOVAL
2) Remove the upper six clips of front grille.
EI-01308
3) Pull the front grille out toward the front of the vehicle.
EI-01309
B: INSTALLATION
EI-01309
NOTE:
Be careful with the hook position.
EI-16
Front Hood Grille

3. Front Hood Grille

A: REMOVAL
1) Remove five screws and clip (A) to remove the
front hood duct.
(A)
EI-00022
2) Remove the five nuts.
EI-00023
3) Remove three black clips and remove the front

hood grille.
EI-00024
EI-17
Front Hood Grille

B: INSTALLATION
(A)
(B)
(2)
(3)
(1)
(B)
(C)
(A)
Black clip
(B)
Black clip
1) Replace the black clips (1) and (2) with new

parts. Install the clip with arrow mark facing the
front side of grille (A).
EI-00025
(C)
Bolt
4) Install the five nuts.

Tightening torque:
4.4 Nm (0.45 kgf-m, 3.25 ft-lb)
(A)
EI-00026
EI-00028
2) Replace the black clips (3) with a new part.

3) Insert the front hood grille clip and engage the
three clips.
5) Hook the two hooks (A) of hood duct to the hood

holes.
NOTE:
Make sure that the anchor portion of each clip is
firmly engaged.
(A)
EI-00029
EI-00027
EI-18
Front Hood Grille

6) Install the front hood duct with the five screws

and clip (A).
(A)
EI-00022
C: INSPECTION
Make sure that the clip is firmly engaged.
Make sure that there is no abnormal gap at whole
periphery of hood grille.
Check that there is no damage on the front hood
grille.
EI-19
Front Under Cover

4. Front Under Cover

A: REMOVAL
2) Loosen the bolts, then remove the clip and under
cover.
EI-01363
B: INSTALLATION
Tightening torque:
18 Nm (1.84 kgf-m, 13.3 ft-lb)
EI-20
Front Bumper
5. Front Bumper
6) Remove the bumper face side claws from guide

bracket (A), and remove the bumper face.
A: REMOVAL
2) Remove the six clips from underside of the
bumper (both left and right).
3) Turn over the mud guard, and remove one inside
clip that secure the front bumper to the fender.
CAUTION:
Do not pull them by force. The bumper face side
claws can be damaged.
NOTE:
The bumper can be easily pulled out by removing in
the order of (1) (5) from the fender side while lifting the bumper face upward (B).
(5)
(4)
(1)
(2)
(3)
(A)
(B)
EI-01379
7) Remove the E/A form from bumper beam.

NOTE:
Do not apply excessive force to remove the E/A
form because it is easily damaged.
EI-00572
4) Turn over the mud guard and disconnect the fog

light connector.
5) Remove the seven clips.
EI-00035
8) Remove the bumper beam.
EI-01311
EI-00094
EI-21
Front Bumper
9) Remove the 8 bolts and disassemble the front

bumper beam.
EI-00095
B: INSTALLATION
Tightening torque:
Refer to COMPONENT of General Description.
<Ref. to EI-3, FRONT BUMPER, COMPONENT, General Description.>
EI-22
Front Bumper
C: REPAIR
1. COATING METHOD FOR PP BUMPER
Process
No.
Process name
Job contents
(1)
Bumper installation
Place the bumper on a paint worktable as

required. Use the paint worktable conforming to
inner shape of bumper if possible.
(2)
EI-00038
(1) Bumper
(2) Set bumper section
2
Masking
Degreasing/
cleaning
Primer paint
Drying
Mask specified part (black base) with masking tape. Use masking tape for PP (For example,
Nichiban No. 533, etc.).
Clean all parts to be painted with white gasoline, normal alcohol, etc. to remove dirt, oil, fat, etc.
Apply primer one to all parts to be painted, using air gun. Use primer (clear).
Dry at normal temperature [10 to 15 min. at 20C (68F)].
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 paint
Metallic paint
Use section (block) paint for top coat.
Paint to be used (for each color):
Solid paint
Hardener PB
Thinner T-301
Mixture ratio:
Main agent : Hardener = 4 : 1
Viscosity: 10 to 13 seconds/20C (68F)
Film thickness: 35 45
Spraying pressure: 245 343 kPa
(2.5 3.5 kg/cm2, 36 50 psi)
Top coat paint (I)
Drying
Not required.
Top coat paint (II)
Not required.
Drying
10
Inspection
11
Removal of
masking
Use section (block) paint for top coat.

Paint to be used (for each color):
Metallic paint
Hardener PB
Thinner T-306
Mixture ratio:
Main agent : Hardener = 10 : 1
(2.5 3.5 kg/cm2, 36 50 psi)
Dry at normal temperature [at least 10 min. at
20C (68F)].
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.
Paint to be used:
Metallic paint
Hardener PB
Thinner T-301
Mixture ratio: Clear coat : Hardener = 6 : 1
(2.5 3.5 kg/cm2, 36 50 psi)
60C (140F), 60 min. or 80C (176F), 30 min.

If higher than 80C (176F), PP may be deformed. Keep maximum temperature of 80C (176F).
Check paint.
Remove the masking tape applied in procedure 2.
EI-23
Front Bumper
2. REPAIR INSTRUCTIONS FOR COLORED PP BUMPER

NOTE:
All PP bumpers are provided with a grained surface, and if the surface is damaged, it cannot normally be restored to its former condition. Damages limited to the shallow scratches that cause only a change in the luster
of the base material or coating, can be almost fully restored. Before repairing a damaged area, explain this
point to the customer and obtain an understanding about the matter. Repair methods are outlined below,
based on a classification of the extent of damage.
1) Minor damage causing only a change in the luster of the bumper due to a light touch
Almost restorable.
Process
No.
1
2
Process name
Cleaning
Sanding
Finish
Job contents
Clean the area to be repaired using water.
Grind the repairing area with #500 sand paper in a feathering motion.
Resin section
Repeatedly apply wax to the affected area
using soft cloth (such as flannel). Recommended wax: NITTO KASEI Soft 99 TIRE WAX
BLACK, or equivalent.
Polish the waxed area with clean cloth after
5 10 minutes.
Coated section
Perform either the same process as for the
resin section or process No. 18 and sub
sequent in the 3) section, depending on the
degree and nature of damage.
2) Deep damage caused by scratching with fences etc.

A dent cannot be repaired but a whitened or swelled part can be removed.
Process
No.
1
Process name
Job contents
Cleaning
Clean the damaged area with water.
Removal of
damaged area
Cut off protruding area, if any, due to collision, using a putty knife.
Sanding
Finish
Grind the affected area with #100 #500 sand paper.

Resin section
Same as Process No. 3 in the 1) section.
Coated section
Perform Process No. 12 and subsequent

operations in the 3) section.
3) Deep damage such as a break or hole that requires filling

Much of the peripheral grained surface must be sacrificed for repair. 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 the bumper as required.
Removal of parts
Remove the parts built into bumper as required.
Process name
Job contents
(1)
Bumper placement
Place the bumper on a paint worktable as

required.
It is recommended to use the paint worktable
conforming to internal shape of bumper.
(2)
EI-00038
(1) Bumper
(2) Set bumper section
4
Surface
preparation
Remove dust, oil, etc. from areas to be repaired and surrounding areas, using a suitable solvent
(NRM No. 900 Precleno, white gasoline, or alcohol, etc.).
EI-24
Front Bumper
Process
No.
Process name
Job contents
(3)
(1)
6
7
Cutting
Sanding (I)
Cleaning
If nature of damage are cracks or holes, cut a

guide slit of 20 to 30 mm (0.79 to 1.18 in) in
length along the crack or hole up to the
bumpers base surface. Next, use a knife or
grinder to carve a V-shaped groove in the area
for repair.
(4)
(2)
EI-00235
(1) Paint surface

(2) PP base surface
(3) 20 30 mm (0.79 1.18 in)
(4) 3 mm (0.12 in)
Grind beveled surface with sand paper (#40 #60) to smooth finish.
Clean the sanded surface with the same solvent as used in Procedure 4.
Grind the side just opposite the beveled area with sand paper (#40 #60) and clean using a
solvent.
Temporarily spot-weld the side, using PP welding rod and heater gun.
(1)
(2)
Temporary welding
(3)
EI-00236
(1) Welded point (Use heater gun and PP welding rod)

(2) PP base surface
(3) Beveled section
NOTE:
Do not melt welding rod until it flows out. This results in reduced strength.
Leave the welded spot unattended until it cools completely.
Using a heater gun and PP welding rod, weld the beveled spot while melting the rod and
damaged area.
(2)
(2)
(3)
(1)
Welding
EI-00237
(1) Melt hatched area

(2) Welding rod
(3) Section
NOTE:
Melt the sections indicated by hatched area.
Do not melt the welding rod until it flows out, in order to provide strength.
Always keep the heater gun 1 to 2 cm (0.4 to 0.8 in) away from the welding spot.
Leave the welded spot unattended until it cools completely.
EI-25
Front Bumper
Process
No.
Process name
Job contents
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)
EI-00042
Sand the welded spot smooth with #240 sand paper.

Mask the black substrate section using masking tape.
Recommended masking tape: Nichiban No. 533 or equivalent
11
Masking
12
Cleaning/
degreasing
Completely clean the entire coated area, using solvent similar to that used in Procedure 4.
Primer coating
Apply a coat of primer to the repaired surface and its surrounding areas. Mask these areas, if
necessary.
Recommended primer: Mp/ 364 PP Primer
NOTE:
Always use a spray gun with spraying pressure of 245 to 343 kPa (2.5 to 3.5 kg/cm2, 36 to 50 psi)
for primer coating.
13
Leave the repaired area unattended at 20C (68F) for 10 to 15 minutes until primer is half-dry.
NOTE:
If dirt or dust comes in contact with the coated area, wipe it off with a cloth dampened with alcohol.
(Do not use thinner since the coated area tends to melt.)
Apply primer surfacer to the repaired area two or three times at an interval of 3 5 minutes.
Recommended surfacer:
UPS 300 Flex Primer
No. 303 UPS 300 Exclusive hardener
NPS 725 Exclusive Reducer (thinner)
Mixture ratio: 2 : 1 (UPS 300 : No. 303)
Coating film thickness: 40 50
14
Leave unattended
15
Primer surfacer
coating
16
17
Drying
Sanding (III)
Allow the coated surface to dry for 20 minutes at 20C (68F) [or 30 minutes at 60C (140F)].
Sand the coated surface and its surrounding areas using #400 sand paper and water.
18
Cleaning/
degreasing
Same as Process No. 12.
Top coat (I)
Solid paint
Use a block coating method.
Recommended paint:
Suncryl (SC)
No. 307 Flex Hardener
SC Reducer (thinner)
Mixture ratio: 3: 1
Suncryl (SC) : No. 307 Flex Hardener
Spraying thickness: 245 343 kPa
(2.5 3.5 kg/cm2, 36 50 psi)
Metallic paint
Use a block coating method.
Recommended paint:
Suncryl (SC)
Mixture ratio: 3: 1
Spraying thickness: 245 343 kPa
(2.5 3.5 kg/cm2, 36 50 psi)
Not required.
Leave unattended at 20C (68F) for at least 10

minutes until the topcoated area is half-dry.
NOTE:
Be careful to keep dust or dirt from coming in
contact with the affected area.
19
20
Leave unattended
EI-26
Front Bumper
Process
No.
Process name
Job contents
Apply a clear coat three times at an interval of 3
to 5 minutes.
Recommended paint:
SC710 Overlay Clear
Not required.
Mixture ratio: 3 : 1
(2.5 3.5 kg/cm2, 36 50 psi)
Allow the coated surface to dry for two hours at 20C (68F) [or 30 minutes at 60C (140F)].
NOTE:
Do not allow the temperature to exceed 80C (176F) since this will deform the PP substrate.
21
Top coat (II)
22
Drying
23
25
Inspection
Removal of masking
Parts installation
Install parts on the bumper in reverse order of removal.
26
Bumper installation
Install the bumper.
24
Carefully check the condition of the repaired area.

Remove the masking tape applied in Process No. 11 and 13.
EI-27
Rear Bumper
6. Rear Bumper
5) Remove the rear combination light assembly on

both sides. <Ref. to LI-22, REMOVAL, Rear Combination Light Assembly.>
6) Remove the two clips on both sides.
A: REMOVAL
2) Remove the bolts and clips.
EI-00045
7) Remove the floor box.

8) Remove the rear skirt trim.
9) Remove four nuts to remove the rear bumper.
EI-00043
3) Remove the clips from the bumper and bracket.
EI-00046
NOTE:
Rear bumper beam assembly is heavy. When removing the rear bumper beam assembly, two persons are necessary to do the work.
10) Remove the bolts, and then remove the bracket
from bumper.
EI-00044
4) When removing the rear bumper beam assembly, remove the six bolts from bumper stay.
EI-00047
EI-00096
EI-28
Rear Bumper
11) Remove the clips to remove the bumper upper

beam.
EI-00048
12) Remove the four bolts, and then remove the

side bracket and bumper stay.
EI-00097
B: INSTALLATION
Tightening torque:
Refer to COMPONENT of General Description.
<Ref. to EI-4, REAR BUMPER, COMPONENT,
C: REPAIR
Refer to front bumper repair. <Ref. to EI-23, REPAIR, Front Bumper.>
EI-29
Mud Guard
7. Mud Guard
A: REMOVAL
1) Jack-up the vehicle.
2) Remove the wheels. <Ref. to WT-5, REMOVAL,
Steel Wheel.> or <Ref. to WT-6, REMOVAL, Aluminum Wheel.>
3) Remove the clips to remove the air flap.
4) Remove the screws and clips to remove the mud
guard.
EI-00963
B: INSTALLATION
EI-30
Cowl Panel
8. Cowl Panel
A: REMOVAL
2) Remove the wiper arm. <Ref. to WW-11, REMOVAL, Front Wiper Arm.>
3) Remove the clip and remove the cowl side panel.
EI-01411
4) Loosen the clips to remove the cowl panel.
: (A)
EI-01542
(A) Clip
B: INSTALLATION
EI-31
Side Sill Spoiler

9. Side Sill Spoiler

A: REMOVAL
Remove the screw (A) and clips (B), and remove
the side spoiler.
(B)
(B)
(A)
(B)
(B)
(B)
(B)
(B)
EI-01367
B: INSTALLATION
EI-32
Side Garnish
10.Side Garnish
B: INSTALLATION
A: REMOVAL
1) Affix the double-sided tape (SUMITOMO 3M

5305 or the equivalent) after applying the primer
(SUMITOMO 3M K-500 or the equivalent) widely
around the area where the double-sided tape is affixed.
1) Make a cut in the edge of the garnish using a cutter, then manually remove the garnish by pulling it.
NOTE:
Be careful because the garnish and clip can be
damaged if you pull unnecessarily hard on them.
2) Apply masking tape around the position where
the double-sided tape is affixed on the side garnish.
3) Apply solvent (SUMITOMO 3M 4000 or the
equivalent) to the position where the double-sided
tape is affixed.
NOTE:
Use the double-sided tape with 1 mm (0.04 in)
thickness and 5 mm (0.2 in) width.
(1)
(2)
NOTE:
Wipe immediately when the solvent is applied to
the garnish surface.
Do not use solvent to the body which has been
repaired with lacquer paint.
4) Cover the area where solvent is applied using
plastic wrap, and then heat the double-sided tape
for 5 to 15 minutes in 40 60C (104 140F) using a heat light.
5) Peel the double-sided tape on the side garnish
using steps 3 and 4.
EI-00109
(1)
NOTE:
If the double-sided tape does not come completely
off using the steps outlined above, use a scraper.
(2)
EI-00110
(1) Double-sided tape

(2) Front side
2) Heat the vehicle to 40 to 60C (104 140F),

and the garnish 20 to 30C (68 86F) using a
heat light.
3) Peel the backing paper off the double-sided tape
and position the clip with the body hole. Be careful
not to let air enter the adhesive surface. Manually
push on the tape with approximately 69 98 N (7
10 kgf, 15 22 lbf) of force.
NOTE:
To keep the adhesion, do not wash the vehicle
within 24 hours from installation.
Be careful not to move it up or down after application.
C: INSPECTION
Make sure the side garnish is not greatly
scratched or cracked.
Make sure the clip is not damaged.
EI-33
Front Door Trim

11.Front Door Trim

A: REMOVAL
CAUTION:
Do not apply excessive force to the clip. There
is the possibility of the clip being damaged.
2) Remove the gusset cover.
3) Pull up the inner remote cover to remove upper
hook. Pull down the inner remote cover to remove
lower hook. Remove the inner remote cover.
EI-00054
4) Remove the power window control switch. <Ref.

to GW-8, REMOVAL, Power Window Control
Switch.>
5) Remove the clips of trim panel using clip remover to remove the trim panel.
EI-00055
B: INSTALLATION
EI-34
Rear Door Trim

12.Rear Door Trim

A: REMOVAL
CAUTION:
Do not apply excessive force to the clip. There
is the possibility of the clip being damaged.
2) Pull up the inner remote cover to remove upper
hook. Pull down the inner remote cover to remove
lower hook. Remove the inner remote cover.
EI-00054
3) Remove the power window control switch. <Ref.

to GW-8, REMOVAL, Power Window Control
Switch.>
4) Remove the clips of trim panel using clip remover to remove the trim panel.
EI-00098
B: INSTALLATION
EI-35
Glove Box
13.Glove Box
A: REMOVAL
1) Open the glove box.
2) Loosen the screws to remove glove box.
(A)
(A)
EI-00221
(A) Clip
B: INSTALLATION
EI-36
Roof Rail
14.Roof Rail
A: REMOVAL
2) Remove the five installing nuts.
3) Carefully remove the clip on the front end in the horizontal direction, then remove the roof rail in the upward
direction.
A
A
C
EI-00058
NOTE:
When removing the C clip, apply force to it in the horizontal direction and then remove in the upward direction
while bending the a section side claw out of the way.
B: INSTALLATION
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.53 ft-lb)

CAUTION:
When removing or installing the roof rail, be
careful not to scratch the body panel with the
stud bolt of roof rail.
EI-37
Console Box
15.Console Box
5) Loosen the screws.
A: REMOVAL
2) Remove the console front cover.
(A)
(A)
(A)
(A)
(A)
AC-01151
(A) Hook
3) Remove the shift knob. (MT model)

4) Loosen the screws to remove console cover.
EI-01408
6) Remove the console side panel hooks to remove

the console box.
(B)
(B)
(A)
(A)
EI-01373
(A) Clip
(B) Clip
EI-00062
B: INSTALLATION
EI-38
Instrument Panel Assembly

16.Instrument Panel Assembly
A: REMOVAL
(C)
(C)
CAUTION:
harness when servicing the instrument panel.
(B)
1. REMOVING ONLY THE INSTRUMENT

PANEL
(A)
(A)
ET-00155

2) Loosen the screws to remove lower cover.
(A) Screw
(B) Clip
(C) Claw
(A)
(A)
7) While pulling on the lower portion of the center

console panel, insert a flat tip screwdriver into the
portion (A) to remove the claw.
(A)
CAUTION:
Be very careful because it is possible to damage the instrument panel if the flat tip screwdriver is inserted into any other area than
specified.
EI-01043
(A) Clip
(A)
(A)
3) Disconnect the in-vehicle sensor hose and connector.

4) Remove the console front cover and console
cover. <Ref. to EI-38, REMOVAL, Console Box.>
5) Affix the thick protective tape (A) to the instrument panel pad to protect the surface.
NOTE:
Affix the protective tape so that it covers the vertical
wall in the back of the gap between the panel center and the pad.
ET-00156
(A) Position for inserting the flat tip screwdriver
8) Disconnect the A/C control panel and hazard

switch connectors.
(A)
ET-00154
EI-39

9) Remove the screws and clips to remove the side

console panel.
18) Remove the instrument panel assembly.

NOTE:
Remove the front pillar upper trim as required.
<Ref. to EI-42, REMOVAL, Upper Inner Trim.>
19) Disconnect the harness connector of the combination meter.
CAUTION:
Do not pull the harness when disconnecting
connector.
2. REMOVAL OF INSTRUMENT PANEL

WITH THE STEERING BEAM
EI-00103

2) Loosen the screws and clips (A) to remove the
lower cover.
(A)
(A)
(A)
EI-00062
10) Remove the passenger airbag module. <Ref.

to AB-15, REMOVAL, Passengers Airbag Module.>
11) Remove the two bolts which secure steering
column. <Ref. to PS-16, REMOVAL, Tilt Steering
Column.>
12) Loosen the four bolts that secure the instrument panel. (The lower bolt should not be removed
as it is used for alignment.)
EI-01043
3) Remove the console front cover and console

cover. <Ref. to EI-38, REMOVAL, Console Box.>
4) Loosen the screws and clip to remove the side
console panel.
EI-00103
EI-00223
13) Remove the combination meter assembly.

<Ref. to IDI-10, REMOVAL, Combination Meter.>
14) Loosen the instrument panel attaching screws.
15) Remove the instrument panel center compartment. <Ref. to EI-50, REMOVAL, Instrument Panel
Center Compartment.>
16) Remove the radio. <Ref. to ET-6, REMOVAL,
Radio Body.>
17) Remove the instrument panel side cover (both
sides), the loosen the two bolts.
5) Remove the steering column.

6) Loosen the four bolts that secure the instrument
panel.
EI-00223
EI-40

7) Remove the drivers and passengers side airbag modules. <Ref. to AB-14, REMOVAL, Drivers
Airbag Module.> <Ref. to AB-15, REMOVAL, Passengers Airbag Module.>
8) Loosen the steering beam bolts.
9) Loosen the brake pedal attaching bolts. <Ref. to
BR-47, REMOVAL, Brake Pedal.>
10) Remove the two clips on the leading end of the
instrument panel assembly.
11) Remove the instrument panel assembly.
CAUTION:
Do not pull the harness when disconnecting
connector.
NOTE:
If necessary, make alignment marks for easy reassembly.
When storing the removed instrument panel,
place it standing up on the floor.
EI-00068
B: INSTALLATION
CAUTION:
Be careful not to snag the harness.
Make sure to connect the harness connector.
NOTE:
When setting the instrument panel into position,
push the hook into grommet (A) on the body panel.
(A)
(A)
(A)
EI-00069
EI-41
Upper Inner Trim

17.Upper Inner Trim

A: REMOVAL
1) Remove the lower inner trim. <Ref. to EI-43, REMOVAL, Lower Inner Trim.>
2) Remove the front moulding (A).
3) Remove the front pillar upper trim (B).
4) Detach the front seat belt shoulder anchor, then
remove the center pillar upper trim (C).
(A)
(C)
(B)
: (D)
EI-00105
(D) Clip
B: INSTALLATION
CAUTION:
Be sure to securely hook claws of inner trim
panel to body flange.
NOTE:
When installing the center pillar upper trim and the
front pillar upper trim, be sure to set the front moulding as shown in figure.
(B)
(A)
(C)
(D)
(E)
(F)
EI-00106
(A) Outside
(B) Inside
(C) Molding
(D) Weather strip
(E) Trim
(F) Body
EI-42
Lower Inner Trim

18.Lower Inner Trim

A: REMOVAL
1) Remove the side sill front cover (A).
2) Remove the rear seat cushion <Ref. to SE-17,
REMOVAL, Rear Seat.>, and then remove the side
sill rear cover (B).
3) Remove the center pillar lower trim (C).
(C)
(B)
(A)
: (D)
EI-00072
(D) Clip
B: INSTALLATION
CAUTION:
EI-43
Rear Quarter Trim

19.Rear Quarter Trim
B: INSTALLATION
A: REMOVAL

2) Remove the side sill rear cover.
3) Remove the rear rail trim (A).
4) Loosen the screws to remove the strut cap.
5) Remove the rear seat belt shoulder anchor.
6) Loosen the screws and clips to remove the rear
quarter upper trim (B).
7) Remove the rear skirt trim (C).
8) Loosen the screws and clips to remove the rear
quarter lower trim (D).
CAUTION:
NOTE:
When installing the rear quarter upper trim, be sure
to set the rear molding as shown in the figure.
(B)
(A)
(C)
(D)
(E)
(A)
(F)
EI-00106
(A) Outside
(B) Inside
(C) Molding
(D) Weather strip
(B)
(E) Trim
(F) Body
(C)
(D)
: (E)
: (F)
EI-01370
(E) Clip
(F) Hook
EI-44
Sun Visor
20.Sun Visor
A: REMOVAL
Remove the mounting screws and detach the sun
visor (A) and hook (B).
(B)
(A)
EI-01095
B: INSTALLATION
EI-45
Roof Trim
21.Roof Trim
8) Remove the clips, and then remove the roof trim.
A: REMOVAL
CAUTION:
When removing the clip, use great care not to
damage the roof trim.
2) Remove the overhead console. (Model with sunroof) <Ref. to SR-9, REMOVAL, Sunroof Switch.>
3) Remove the room light. <Ref. to LI-30, REMOVAL, Room Light.>
4) Remove the sun visor and hook on both sides.
<Ref. to EI-45, REMOVAL, Sun Visor.>
5) Remove the assist grip cap, and remove the assist grip (A).
EI-00939
B: INSTALLATION
(A)
EI-00075
6) Remove the upper inner trim. <Ref. to EI-42, REMOVAL, Upper Inner Trim.>
7) Remove the rear quarter upper trim shown in the
figure. <Ref. to EI-44, REMOVAL, Rear Quarter
Trim.>
(1) Remove the rear rail trim (A).
(2) Remove the rear quarter upper trim (B) of
both sides.
(A)
(B)
: (C)
EI-01371
(C) Clip
EI-46
Rear Gate Trim

22.Rear Gate Trim

A: REMOVAL
CAUTION:
Be careful not to damage the clips or their
holes.
Remove the rear gate inner handle (A) from the
rear gate, and remove the trim panel.
(A)
EI-00078
B: INSTALLATION
EI-47
Floor Mat
23.Floor Mat
A: REMOVAL
1) Remove the front seats. <Ref. to SE-7, REMOVAL, Front Seat.>
2) Remove the rear seat cushion. <Ref. to SE-17,
REMOVAL, Rear Seat.>
3) Remove the console box. <Ref. to EI-38, Console Box.>
4) Remove the side sill front cover, side sill rear
cover and center pillar lower trim. <Ref. to EI-43,
REMOVAL, Lower Inner Trim.>
5) Remove the footrest and clip from the floor mat.
6) Remove the mat hook.
7) Remove the mat from toe board area.
8) Remove the mat from rear heater duct.
9) Roll the mat, and then take it out of opened rear
door.
(A)
(1)
EI-00079
(A) Front side of vehicle

(1) Floor mat
B: INSTALLATION
NOTE:
Secure the mat firmly with hook and Velcro tape.
Insert the mat edge firmly into the groove of side
sill cover.
EI-48
Luggage Floor Mat

24.Luggage Floor Mat

A: REMOVAL
1) Remove the backside mat from the rear seat
backrest.
2) Remove the clips, then detach the rear floor
mats and boxes.
EI-01096
B: INSTALLATION
EI-49
Instrument Panel Center Compartment

25.Instrument Panel Center

Compartment
A: REMOVAL
2) Use a flat tip screwdriver to pry off the clip.
:A
EI-00081
(A) Clip
3) Remove the instrument panel center compartment from the instrument panel.
4) Disconnect the clock connector.
B: INSTALLATION
EI-50
Heat Shield Cover

26.Heat Shield Cover

A: REMOVAL
1. CENTER HEAT SHIELD COVER
Loosen four bolts to remove the center heat shield
cover.
EI-00107
2. REAR HEAT SHIELD COVER

1) Remove the muffler. <Ref. to EX (H4SO)-9, REMOVAL, Muffler.>
2) Loosen the four bolts to remove the rear heat
shield cover.
EI-00108
B: INSTALLATION
EI-51
Heat Shield Cover

EI-52
General Description
EXTERIOR BODY PANELS
A: SPECIFICATION
(A)
(D)
(C)
(B)
(F)
(E)
(1)
(2)
(2)
(3)
(B)
(A)
(3)
(4)
(6)
(C)
(7)
(8)
(4)
(5)
(D)
(E),(F)
EB-00090
(1)
(2)
Front hood panel

Front fender panel
(4)
(5)
Rear door panel

Rear quarter panel
(3)
Front door panel
(6)
Door panel
(7)
(8)
Side sill
Side sill garnish
Section
(A)
Part
Front hood panel to Front fender panel
Standard
3.51.0 mm (0.140.04 in)
(B)
(C)
Front fender panel to Front door panel

Front door panel to Rear door panel
4.71.0 mm (0.190.04 in)

5.11.0 mm (0.200.04 in)
(D)
(E), (F)
Rear door panel to Rear quarter panel

Door panel to Side sill
4.61.0 mm (0.180.04 in)

7.01.5 mm (0.280.06 in)
EB-2
General Description
B: COMPONENT
1. FRONT HOOD
(1)
T1
(2)
T2
(3)
EB-00314
(1)
(2)
Front hood panel

Hinge
(3)
Seal

T1: 25 (2.5, 18)
T2: 37 (3.8, 27)
EB-3
General Description
2. FRONT FENDER
(1)
T
EB-00254
(1)
Front fender panel

T: 7.5 (0.76, 5.5)
EB-4
General Description
3. FRONT DOOR
T7
(2)
T1
(3)
(4)
(10)
(1)
(5)
T6
T4
(9)
T6
T5
T3
(7)
T6
T1
(6)
T4
T2
T2
T3
(8)
T6
T2
T2
(13)
(12)
(11)
EB-00231
(1)
(2)
Gusset
Weather strip
(8)
(9)
Lower hinge
Upper hinge

T1: 7.5 (0.76, 5.5)
(3)
(4)
Stabilizer (outer)
Stabilizer (inner)
(10)
(11)
Key cylinder (Drivers side only)

Front sash
T2: 14 (1.4, 10.3)

T3: 25 (2.5, 18.1)
(5)
(6)
Door panel
Checker
(12)
(13)
Rear sash
Guide rail
T4: 30 (3.1, 22)

T5: 33 (3.4, 24)
(7)
Sealing cover
T6: 6 (0.6, 4.4)

T7: 1.5 (0.15, 1.1)
EB-5
General Description
4. REAR DOOR
(1)
T6
T1
(4)
(2)
(3)
T6
T3
T1
T2
(5)
(10)
T4
T3
T2
T5
T5
(6)
(8)
(9)
T5
(7)
T5
EB-00174
(1)
(2)
Weather strip
Stabilizer (outer)
(6)
(7)
Sealing cover
Front sash

T1: 7.5 (0.76, 5.5)
(3)
(4)
Stabilizer (inner)
Door panel
(8)
(9)
Rear sash
Lower hinge
T2: 25 (2.5, 18)

T3: 30 (3.1, 22)
(5)
Checker
(10)
Upper hinge
T4: 33 (3.4, 24)

T5: 14 (1.4, 10.3)
T6: 1.5 (0.15, 1.1)
EB-6
General Description
5. REAR GATE
T3
(2)
(3)
T1
T1
(1)
T2
T1
(4)
T1
EB-00317
(1)
(2)
Damper stay
Hinge
(3)
(4)
Rear gate panel

Rear gate garnish

T1: 7.5 (0.76, 5.5)
T2: 14 (1.4, 10.3)
T3: 25 (2.5, 18.1)
EB-7
General Description
C: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
925610000
DESCRIPTION
WRENCH
REMARKS
Used for removing and installing door hinge.
ST-925610000
2. GENERAL TOOL
TOOL NAME
Support jack
Support stand
REMARKS
Used for supporting door panel.
Used for supporting the rear gate panel.
EB-8
Front Hood
2. Front Hood
C: ADJUSTMENT
A: REMOVAL
1) Use a hinge mounting holes to align the front

hood longitudinally and laterally.
1) Open the front hood to remove the washer nozzles.

2) Release the clips to remove the front hood insulator.
EB-00009
EB-00256
3) Remove the bolts to disconnect the hood from

hinges.
2) Adjust the height at the front end of front hood.

<Ref. to SL-40, ADJUSTMENT, Front Hood Lock
Assembly.>
3) Rotate the front hood buffer to adjust lateral
height.
EB-00258
EB-00009
B: INSTALLATION
2) Adjust the clearance between front hood panel
and front fender panel. Clearance must be equal at
both sides.
Tightening torque:
Refer to COMPONENT of General Description. <Ref. to EB-3, FRONT HOOD, COMPONENT, General Description.>
EB-9
Front Fender
3. Front Fender
A: REMOVAL
2) Remove the front bumper face. <Ref. to EI-21,
REMOVAL, Front Bumper.>
3) Remove the mud guard. <Ref. to EI-30, REMOVAL, Mud Guard.>
4) Remove the side sill spoilers. <Ref. to EI-32, REMOVAL, Side Sill Spoiler.>
5) Remove the side protector. <Ref. to EI-33, REMOVAL, Side Garnish.>
6) Loosen the bolts and clips to remove the front
fender panel.
EB-00259
B: INSTALLATION
2) When the front fender panel is installed, the
clearance between front fender panel and front
hood panel must be equal.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
EB-10
Front Door
4. Front Door
11) Remove the checker bolts.
A: REMOVAL
3) Remove the outer mirror assembly. <Ref. to
GW-12, REMOVAL, Outer Mirror Assembly.>
4) Remove the front sealing cover. <Ref. to EB-13,
REMOVAL, Front Sealing Cover.>
5) Remove the front door glass. <Ref. to GW-16,
REMOVAL, Front Door Glass.>
6) Remove the front door regulator and motor.
<Ref. to GW-20, REMOVAL, Front Regulator and
Motor Assembly.>
7) Remove the front door latch assembly. <Ref. to
SL-31, REMOVAL, Front Door Latch and Door
Lock Actuator Assembly.>
8) Remove the front outer handle. <Ref. to SL-30,
REMOVAL, Front Outer Handle.>
9) Remove the front pillar lower trim to disconnect
connector from the body harness.
EB-00014
12) Remove the door-side bolts for upper and lower hinges to remove front door panel.
EB-00015
13) Remove the attaching bolts (on the body side)

for the upper and lower hinges using the ST to remove the door hinges.
ST 925610000
WRENCH
EB-00012
10) Put a wooden block on jack and place jack under the door. Support the door with a jack to protect
it from damage.
ST
EB-00016
EB-00013
NOTE:
When supporting the door with jack, work carefully
so that you do not deform the hinge portion of door
during work.
EB-11
Front Door
B: INSTALLATION
2) Apply grease to the moving part of door hinges.
3) Refer to COMPONENT of General Description for tightening torque. <Ref. to EB-5, FRONT
DOOR, COMPONENT, General Description.>
C: ADJUSTMENT
1) Using the ST, loosen the body-side bolts of the
upper and lower hinges to align the position for vertical and horizontal direction of the front door panel.
ST 925610000
WRENCH
ST
EB-00016
2) Loosen the door-side bolts of the upper and lower hinges to align the position for vertical and horizontal direction of front door panel on the front side.
EB-00015
3) Loosen the screws (A) and tap striker (B) using a

plastic hammer to adjust the striker to align the position of front door panel vertically and laterally at
the rear end.
CAUTION:
Do not use an impact wrench. Welding area on
the striker nut plate is easily broken.
(A)
(B)
EB-00017
EB-12
Front Sealing Cover

5. Front Sealing Cover

A: REMOVAL
4) Remove the door trim bracket.
EB-00034
5) Remove the sealing cover.

NOTE:
Carefully remove the butyl tape. Excessive force
will easily break the cover.
If cover gets broken, replace it with a new part.
EB-00018
B: INSTALLATION
2) When replacing the sealing cover, use the butyl
tape.
3) Press the butyl tape-applied area firmly to prevent any floating on surface.
Butyl tape:
3M8626 or equivalent
NOTE:
Apply a uniform bead of butyl tape.
Attach the sealing cover, keeping it from becoming wrinkled.
Breaks in the bead will allow water leakage and
contamination.
C: INSPECTION
If the sealing cover gets damaged, replace it with a
new part.
EB-13
Rear Door
6. Rear Door
10) Remove the checker bolts.
A: REMOVAL
3) Remove the rear sealing cover. <Ref. to EB-16,
REMOVAL, Rear Sealing Cover.>
4) Remove the rear door glass. <Ref. to GW-21,
REMOVAL, Rear Door Glass.>
5) Remove the rear door regulator and motor.
<Ref. to GW-23, REMOVAL, Rear Regulator and
Motor Assembly.>
6) Remove the rear door latch. <Ref. to SL-35, REMOVAL, Rear Door Latch and Door Lock Actuator
Assembly.>
7) Remove the rear outer handle. <Ref. to SL-34,
REMOVAL, Rear Outer Handle.>
8) Remove the rubber duct (A) from center pillar,
and disconnect the connector of the door harness.
EB-00014
11) Remove the door-side bolts for upper and lower hinges to remove the rear door panel.
EB-00015
12) Remove the attaching bolts (on the body side)

for the upper and lower hinges using the ST to remove the door hinges.
ST 925610000
WRENCH
(A)
B: INSTALLATION
EB-00288
9) Put a wooden block on jack and place jack under

the door. Support the door with a jack to protect it
from damage.

2) Apply grease to the moving part of door hinges.
3) Refer to COMPONENT of General Description for tightening torque. <Ref. to EB-6, REAR
DOOR, COMPONENT, General Description.>
EB-00013
NOTE:
When supporting the door with jack, work carefully
so that you do not deform the hinge portion of door
during work.
EB-14
Rear Door
C: ADJUSTMENT
1) Using the ST, loosen the body-side bolts of the
upper and lower hinges to align the position for vertical and horizontal direction of the rear door panel.
ST 925610000
WRENCH
ST
EB-00016
2) Loosen the door-side bolts of the upper and lower hinges to align the position for vertical and horizontal direction of rear door panel on the front side.
EB-00015
3) Loosen the screws (A) and tap the striker (B) using a plastic hammer to adjust the striker to align
the position of rear door panel vertically and laterally at the rear end.
CAUTION:
Do not use an impact wrench. Welding area on
the striker nut plate is easily broken.
(A)
(B)
EB-00017
EB-15
Rear Sealing Cover

7. Rear Sealing Cover

A: REMOVAL
3) Remove the rear speaker. <Ref. to ET-9, REMOVAL, Rear Speaker.>
4) Remove the door trim bracket.
EB-00034
5) Remove the sealing cover.

NOTE:
Carefully remove the butyl tape. Excessive force
will easily break the cover.
If cover gets broken, replace it with a new part.
EB-00018
B: INSTALLATION
2) When replacing the sealing cover, use the butyl
tape.
3) Press the butyl tape-applied area firmly to prevent any floating on surface.
Butyl tape:
3M8626 or equivalent
NOTE:
Apply a uniform bead of butyl tape.
Attach the sealing cover, keeping it from becoming wrinkled.
Breaks in the bead will allow water leakage and
contamination.
C: INSPECTION
If the sealing cover gets damaged, replace it with a
new part.
EB-16
Rear Gate
8. Rear Gate
11) Support the rear gate using a support stand

while removing the rear gate damper stay mounting
bolts.
A: REMOVAL
1. REAR GATE PANEL
2) Open the rear gate.
4) Remove the rear wiper motor. <Ref. to WW-16,
REMOVAL, Rear Wiper Motor.>
5) Remove the rear gate garnish assembly. <Ref.
to EB-20, REMOVAL, Rear Gate Garnish.>
6) Remove the rear gate outer handle. <Ref. to SL37, REMOVAL, Rear Gate Outer Handle.>
7) Remove the rear gate latch assembly. <Ref. to
SL-38, REMOVAL, Rear Gate Latch Assembly.>
8) Disconnect the connectors of rear wiper, rear
defogger, and other lighting devices.
9) Disconnect the washer hose.
10) Remove the rubber duct (A) connection, and
pull out the harness and washer hose from the rear
gate.
EB-00021
EB-00022
NOTE:
When the support stand that is supporting the rear
gate is released, rear gate may hit and damage the
body. To prevent this, place a shop cloth between
body and rear gate.
12) Loosen the rear gate bolts to remove the rear
gate.
(A)
EB-00020
EB-00023
EB-17
Rear Gate
2. REAR GATE DAMPER STAY
B: INSTALLATION
1) Open the rear gate. Support the rear gate using

the support stand.
1. REAR GATE PANEL

2) Install the rear gate panel with uniform clearance
to the body.
3) Refer to COMPONENT of General Description for tightening torque. <Ref. to EB-7, REAR
GATE, COMPONENT, General Description.>
NOTE:
Support the rear gate with a support stand before
starting the work.
EB-00021
NOTE:
After the rear gate damper stay is removed, the
rear gate cannot stay in the open position. Support
the rear gate with a support stand when removing
the bolts.
CAUTION:
Do not damage piston rods and oil seals.
Never disassemble cylinders: They contain
gas.
2) Loosen the bolts to remove rear gate damper
stay from the rear gate.
1) Install mounting bolt (A) to the rear gate panel

and body.
Tightening torque:
14 Nm (1.4 kgf-m, 10.3 ft-lb)
2) Securely install the rear gate damper stay (B) to
the mounting bolt (A).
(B)
(A)
EB-00025
3) Tighten the upper side bolt of the rear gate

damper stay.
Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
EB-00024
EB-18
Rear Gate
C: DISPOSAL
CAUTION:
Gas is colorless, odorless, and harmless. However, gas pressure may spray cutting powder or
oil. Be sure to wear dust-resistant goggles.
1) Cover with a vinyl sack as shown in the figure.
(1)
(2)
EB-00031
(1) Rear gate damper stay

(2) Vinyl sack
NOTE:
Prevent the vinyl sack from being caught by drill
cutting edge
2) Lift the body side slightly with piston rods fully
extended, and secure the body side on vise stand.
Drill a hole in 2 to 3 mm (0.08 to 0.12 in) diameter at
a point 10 to 200 mm (0.39 to 7.87 in) from door
side, and bleed rear gate damper stay gas stay
completely.
(1)
(2)
(3)
(4)
(7)
(5)
(6)
EB-00032
(1) Body side

(2) Door side
(3) 190 mm (7.48 in)
(4) 10 mm (0.39 in)
(5) Piston rod
(6) Cylinder
(7) Portion to be drilled
EB-19
Rear Gate Garnish

9. Rear Gate Garnish

A: REMOVAL
2) Remove the 5 flange nuts from the rear gate
panel inner side (vehicle side).
3) Remove the license plate light assembly connector from the rear gate panel inner side (luggage
compartment side).
4) Close the gate and then remove the rear gate
garnish assembly by pulling it manually.
CAUTION:
Be careful not to pull by force. It may damage
the clip and license plate light harness.
(1)
(2)
EB-00299
(1) Rear garnish ASSY

(2) License plate light
B: INSTALLATION
C: INSPECTION
Make sure the rear gate garnish is not greatly
scratched or cracked.
EB-20
General Description
CRUISE CONTROL SYSTEM
A: COMPONENT
(1)
(3)
(4)
(5)
(6)
(7)
(2)
CC-00315
(1)
Cruise indicator and cruise set

indicator light
(3)
(4)

(2)
Inhibitor switch (AT model)
(5)
Clutch switch (MT model)
CC-2
(6)
(7)
Stop light & brake switch

Neutral position switch (MTmodel)
General Description
B: CAUTION
Before disassembling or reassembling parts, always disconnect the battery ground cable from battery. When repairing the radio, control module, etc.
which are provided with memory functions, record
the memory contents before disconnecting the
ground cable from battery. All memory is cleared.
Adjust the parts to specifications specified in this
manual.
After reassembly, ensure functional parts operate properly.
C: PREPARATION TOOL
TOOL NAME
Circuit tester
TORX bit T30
REMARKS
Used for measuring
resistance and voltage.
Used for removing the cruise
control command switch.
CC-3
Cruise Control Unit

2. Cruise Control Unit

A: NOTE
The control of cruise control system is carried out in
engine control module (ECM).
B: REMOVAL
<Ref. to FU(H4SO)-40, REMOVAL, Engine Control
Module (ECM).> <Ref. to FU(H4DOTC)-44, REMOVAL, Engine Control Module (ECM).>
C: INSTALLATION
<Ref. to FU(H4SO)-40, INSTALLATION, Engine
Control Module (ECM).> <Ref. to FU(H4DOTC)44, INSTALLATION, Engine Control Module
(ECM).>
CC-4
Cruise Control Command Switch

3. Cruise Control Command

Switch
B: INSTALLATION
A: REMOVAL
C: INSPECTION
WARNING:
Before servicing, be sure to read the notes in
the AB section for proper handling of the
drivers airbag module. <Ref. to AB-4, CAUTION, General Description.>
1) Set the front wheels in straight ahead position.
4) Using TORX BIT T30 (1), loosen the two
TORX bolts which secure drivers airbag module.
Measure the cruise control command switch resistance.
1 2 3
CC-00252
(1)
CC-00018
5) Disconnect the airbag module connector on

back of the airbag module.
7) Remove the four screws to remove the lower
cover from steering wheel.
Switch
CANCEL
SET/COAST
RESUME/
ACCEL
Position
Terminal No.
Standard value
All OFF
2 and 3
Approx. 4 k
CANCEL
SET/COAST
ON
ON
2 and 3
2 and 3
Less than 1
Approx. 250
RESUME/
ACCEL
ON
2 and 3
Approx. 1500
OFF
1 and 2
1 M or more
ON
1 and 2
Less than 1
MAIN
If NG, replace the cruise control command switch.
CC-00181
8) Remove one screw to remove the cruise control

command switch from lower cover.
CC-00182
CC-5
Stop Light & Brake Switch

4. Stop Light & Brake Switch

A: REMOVAL
2) Disconnect the connector from the stop & brake
switch, and then remove the switch. <Ref. to BR50, REMOVAL, Stop Light Switch.>
B: INSTALLATION
C: INSPECTION
Measure the resistance of brake switch (A) and
stop light switch (B).
(A)
2 1
4 3
(B)
1 2 3 4
CC-00022
Switch
Pedal
Terminal No.
Standard value
Brake
Released
Depressed
1 and 4
1 and 4
Less than 1
1 M or more
Stop light
Released
Depressed
2 and 3
2 and 3
1 M or more
Less than 1
If NG, replace the stop & brake switch.
CC-6
Clutch Switch
5. Clutch Switch
A: REMOVAL
2) Disconnect the connector from the clutch switch,
and then remove the switch. <Ref. to CL-24, REMOVAL, Clutch Pedal.>
B: INSTALLATION
C: INSPECTION
Measure the clutch switch resistance.
CC-00023
Switch
Pedal
Terminal No.
Standard value
Clutch
Released
Depressed
1 and 2
1 and 2
Less than 1
1 M or more
If NG, replace the clutch switch.
CC-7
Inhibitor Switch
6. Inhibitor Switch
A: REMOVAL
2) Disconnect the connector from inhibitor switch,
then remove the switch. <Ref. to 4AT-48, REMOVAL, Inhibitor Switch.>
B: INSTALLATION
C: INSPECTION
Measure the inhibitor switch resistance.
6 5 4 3 2 1
12 11 10 9 8 7
CC-00024
Select lever
Position
P
N
Other than P or N
Terminal No.
Standard value
Less than 1
7 and 12
Less than 1
1 M or more
If NG, replace the inhibitor switch.
CC-8

7. Neutral Position Switch

A: REMOVAL
2) Disconnect the connector from the neutral position switch, and remove the switch. <Ref. to 5MT35, BACK-UP LIGHT SWITCH AND NEUTRAL
POSITION SWITCH, REMOVAL, Switches and
Harness.>
B: INSTALLATION
C: INSPECTION
Measure the resistance of neutral position switch.
Non-turbo model
2 1
MT-00110
Gear shift position
Terminal No.
Neutral position
Other positions
1 and 2
Less than 1
Over 1 M
Turbo model
2 1
4 3
MT-00111
Gear shift position

Neutral position
Other positions
Terminal No.
1 and 3
Less than 1
Over 1 M
If NG, replace the neutral position switch.
CC-9

CC-10

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

A: PROCEDURE
1
2
3
Step
CHECK MALFUNCTION INDICATOR LIGHT.
Check that malfunction indicator light illuminates.
CHECK CRUISE INDICATOR LIGHT.
Make sure the cruise indicator light blinks.
CHECK CRUISE CONTROL MAIN SWITCH
OPERATION.
Check cruise control main switch operation.
(Ensure the cruise indicator light illuminates.)
Check
Yes
Does the malfunction indicator Go to step 5.
light illuminate?
No
Go to step 2.
Does the cruise indicator light Go to step 5.

blink?
Is the cruise control main switch Go to step 4.
turned on? (Does the cruise
indicator light illuminate?)
Go to step 3.
CHECK CRUISE CONTROL SET OPERATION.

Check the cruise control set operation.
PERFORM CRUISE CONTROL CANCEL
CONDITIONS DIAGNOSIS.
Perform the cruise cancel conditions diagnosis.
Can the cruise control be set

while driving at more than 40
km/h (25 MPH)?
Is DTC displayed?
CHECK VEHICLE SPEED IS HELD WITHIN

SET SPEED.
Make sure the vehicle speed is held within set
speed.
Is the vehicle speed kept within Go to step 7.

setting speed 3 km/h (2
MPH) ? (Make sure that on a
level road.)
CHECK RESUME/ACCEL OPERATION.

Does the vehicle speed
Go to step 8.
Check the RESUME/ACCEL switch operation. increase or return to set speed
after RESUME/ACCEL switch
has been pressed?
CHECK SET/COAST OPERATION.

Check the SET/COAST switch operation.
Does the vehicle speed

decrease after SET/COAST
switch has been pressed?
CC(ETC)(diag)-2
Go to step 6.
Go to List of Diagnostic Trouble

Code (DTC).
<Ref. to
CC(ETC)(diag)13, List of Diagnostic Trouble Code
(DTC).>
Go to step 9.
Go to symptom 1.
<Ref. to
CC(ETC)(diag)-9,
DIAGNOSTIC
PROCEDURE
WITH PHENOMENON, Diagnostics
with Phenomenon.>
Go to step 5.
Go to symptom 2.
<Ref. to
CC(ETC)(diag)-9,
DIAGNOSTIC
PROCEDURE
with Phenomenon.>
Go to symptom 3.
<Ref. to
CC(ETC)(diag)-9,
DIAGNOSTIC
PROCEDURE
with Phenomenon.>
Go to symptom 4.
<Ref. to
CC(ETC)(diag)-9,
DIAGNOSTIC
PROCEDURE
with Phenomenon.>
Go to symptom 5.
<Ref. to
CC(ETC)(diag)-9,
DIAGNOSTIC
PROCEDURE
with Phenomenon.>

Step
CHECK CANCEL OPERATION.
Check the CANCEL switch operation.
Check
Yes
Is the cruise control released Go to step 10.
after CANCEL switch has been
pressed?
10
CHECK CRUISE CONTROL RELEASE OPERATION.

Check the cruise control release operation.
11

12

No
Go to symptom 6.
<Ref. to
CC(ETC)(diag)-9,
DIAGNOSTIC
PROCEDURE
with Phenomenon.>
Go to symptom 7.
after brake pedal has been
<Ref. to
depressed?
CC(ETC)(diag)-9,
DIAGNOSTIC
PROCEDURE
with Phenomenon.>
Go to symptom 8.
after depressing the clutch
<Ref. to
pedal?
CC(ETC)(diag)-9,
DIAGNOSTIC
PROCEDURE
with Phenomenon.>
Is the cruise control released Finish the diagno- Go to symptom 9.
after shifting to the neutral posi- sis.
<Ref. to
tion?
CC(ETC)(diag)-9,
DIAGNOSTIC
PROCEDURE
with Phenomenon.>
CC(ETC)(diag)-3
General Description
A: CAUTION
All airbag system wiring harnesses and connectors are yellow. Do not use the electrical test equipment on
these circuits.
Be careful not to damage the airbag system wiring harness when servicing the cruise control command
switch. Airbag system wiring harness is routed near the cruise control command switch.
B: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
1B020XU0
DESCRIPTION
SUBARU SELECT
MONITOR KIT
REMARKS
Troubleshooting for the electrical system.
ST1B020XU0
2. GENERAL TOOL
TOOL NAME
Circuit tester
REMARKS
C: INSPECTION
1. BATTERY
Measure the battery voltage and specific gravity of electrolyte.
Standard voltage:
12 V or more
Specific gravity:
1.260 or more
CC(ETC)(diag)-4


A: LOCATION
(1)
(3)
(4)
(5)
(6)
(7)
(2)
CC-00315
(1)
Cruise indicator light and cruise

set indicator light
(3)
(4)

(2)
(5)
CC(ETC)(diag)-5
(6)
(7)

Neutral position switch (MT
model)

4. Engine Control Module (ECM)

I/O Signal
A: WIRING DIAGRAM
<Ref. to WI-90, NON-TURBO MODEL, WIRING
DIAGRAM, Cruise Control System.>
<Ref. to WI-93, TURBO MODEL, WIRING DIAGRAM, Cruise Control System.>
CC(ETC)(diag)-6


side).
A: OPERATION
The on-board diagnosis function of the cruise control system uses Subaru Select Monitor.
The on-board diagnosis function operates in two
categories, which are used depending on the type
of problems;
1) Cruise Control 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 driving although cruise cancel condition is not entered.
(2) Cruise control memory in ECM stores the
cancel condition (Code No.) which occurred
during driving. When there are multiple cancel
conditions (Code No.), they are shown on the
CAUTION:
The cruise control memory stores not only
the cruise cancel which occurred (although
cancel operation is not entered by the driver),
but also the cancel condition input by the
driver.
The latest content of memory (current code)
is cleared when ignition switch is turned to
OFF. However, the content of memory for troubleshooting switches related to the system or
cruise control, is stored as a diagnostic history
(memory code) even after the ignition switch
has been turned to OFF.
2) Real-time Diagnosis:
Real-time diagnosis function is used to determine
whether or not the input signal system is in good order, according to signal emitted from switches, sensors, etc.
(1) Vehicle cannot be driven at cruise speed
when the problem occurs in the cruise control
system or relevant circuits.
(2) Monitor the signal conditions from switches
and sensors.
2. CRUISE CONTROL CANCEL CONDITIONS DIAGNOSIS

link connector.
CC-00134

connector.
4) Start the engine and turn the cruise control main
switch to ON.
On the system selection display screen, select the
{Engine Control System}. Select the [OK] after the
information of engine type is displayed.
7) Drive vehicle at 40 km/h (25 MPH) or more and
set the cruise control.
CAUTION:
When performing diagnosis, observe the legal speed limit on the road.
DTC will also appear when cruise control is
cancelled by the drivers operation. Do not confuse them.
Make sure an assistant is present in order to
support diagnosis while driving. Have the assistant operate the select monitor.
8) If the set cruise speed is canceled by itself (without any cancel operations) or if the cruise control
cannot be set by performing the set operation, a
DTC will appear on select monitor display when
{Check Cancel Code} is selected on the engine
malfunction diagnosis display screen.
NOTE:
The DTC has a {Current code} and {Memory code}.
{Current code} displays the latest code that occurred in this check drive, and {Memory code} displays the code recorded in the previous driving
condition. Also, DTC's for diagnosis of switches relating to the system and cruise control are listed in
the {Memory code}.
CC(ETC)(diag)-7

9) Clear the engine DTC memory. <Ref. to

EN(H4SO)(diag)-44, OPERATION, Clear Memory
Mode.> <Ref. to EN(H4DOTC)(diag)-50, OPERATION, Clear Memory Mode.>
The DTC of system and cruise control switches are
cleared by a memory clear operation for the engine.
NOTE:
DTC will be cleared by turning ignition switch to
OFF.
3. REAL-TIME DIAGNOSIS
2) Turn the ignition switch and cruise control main
switch to ON.
7) On the Engine Diagnosis screen, select the
{Current Data Display/Save}.
8) Make sure that normal indication is displayed
when controls are operated as indicated below:
Depress and release the brake pedal. (Stop light
switch and brake switch are turned to ON.)
Turn the SET/COAST switch to ON.
Turn the RESUME/ACCEL switch to ON.
Turn the CANCEL switch to ON. (The SET/
COAST switch and RESUME/ACCEL switch
are turned to ON at the same time.)
Depress or release the clutch pedal.
Place the shift lever in any position other than
neutral.
NOTE:
For the DTC, refer to the List of Diagnostic Trouble Code (DTC). <Ref. to CC(ETC)(diag)-13, List of
CC(ETC)(diag)-8

6. Diagnostics with Phenomenon

A: DIAGNOSTIC PROCEDURE WITH PHENOMENON
Symptom
Repair area
Reference
Cruise control main switch is

not turned to ON.
(Cruise indicator light does
not illuminate.)
(1) Check the cruise indicator

light.
<Ref. to CC(ETC)(diag)-11, CHECK CRUISE INDICTOR

LIGHT., Diagnostics with Phenomenon.>
(2) Check the cruise control

command switch.
<Ref. to CC(ETC)(diag)-15, DTC 11, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Cruise control cannot be set.
(1) Check the cruise control

command switch.
(2) Check stop light switch

and brake switch.
2
(3) Check clutch switch.
(4) Check the neutral switch.
(5) Check vehicle speed

sensor.
Vehicle speed is not held

within set speed 3 km/h
(2 MPH).
Check the vehicle speed

sensor.
CC(ETC)(diag)-9

Symptom
Repair area
Vehicle speed does not

increase or does not return to
set speed after RESUME/
ACCEL switch has been
pressed.
Check the RESUME/ACCEL

switch.
Vehicle speed does not

decrease after SET/COAST
switch has been pressed.
Check the SET/COAST

switch.
Cruise control is not released

after CANCEL switch has
been pressed.
Check the CANCEL switch.

after brake pedal has been
depressed.
Check the stop light switch

and brake switch.

after clutch pedal has been
depressed.
after shifting to the neutral
position.
Check the clutch switch.
Check the neutral switch.
Reference
CC(ETC)(diag)-10

B: CHECK CRUISE INDICTOR LIGHT.

TROUBLE SYMPTOM:
Cruise control can be set, but the cruise indicator light does not illuminate.
WIRING DIAGRAM:
B36
BATTERY
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
SBF-4
IGNITION
SWITCH
B38
F/B No.14
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
B135
5
B36
i1
B9
COMBINATION METER
B:
i10
C:
i11
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
B:
CUSTOM
CPU
ILLUMINATION
CIRCUIT
CRUISE
CONTROL
WARNING
LIGHT
i10
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
CRUISE SET
INDICATOR LIGHT
i11
B21
C5
C:
1 2 3 4 5 6 7 8 9 10
21
7
i3
B38
6
3
SBF-1
B135
ECM
CC-00455
CC(ETC)(diag)-11

Step
CHECK CRUISE INDICATOR LIGHT CIRCUIT.
2) Disconnect the harness connector of the
combination meter.
2) Disconnect the harness connector of ECM.
harness connector and the combination meter
harness connector.
(B135) No. 6 (i11) No. 5:
(B135) No. 3 (i10) No. 21:
Connect the ECM harness connector terminal
to ground using a suitable lead wire.
Check
Yes
Go to step 2.
No
Check fuse No.
13 (in fuse & relay
box).
Check for open
or shorted circuits
between the combination meter and
fuse & relay box.

?
Go to step 3.
Repair the harness.
Does the cruise indicator light

illuminate?
Check the poor

contact of ECM
connector.
Replace the meter

main assembly.
CC(ETC)(diag)-12


A: LIST
DTC
Item
Contents of diagnosis
Reference
11
Main switch
Main switch of cruise control command switch is turned

to OFF, and then the cruise control is released.
This DTC is displayed

without operating the main
switch.
<Ref. to CC(ETC)(diag)15, DTC 11, Diagnostic
without depressing the
brake pedal.
12
Stop light switch or brake switch is turned to ON, and

then the cruise control is released.
13
Clutch switch
Clutch switch is turned to ON, and then the cruise control

is released.
14
Neutral switch is turned to ON, and then the cruise control is released.
15
Cancel switch
Cancel switch is turned to ON, and then the cruise control is released.
16
Ignition switch
21
Cruise control switch malfunction when ignition

switch is turned to ON
When the ignition switch is turned to ON, each switch of

cruise control command switch is already turned to ON.
22
Vehicle speed variation is

abnormal.
Malfunction of vehicle speed signal variation is detected. <Ref. to CC(ETC)(diag)25, DTC 22, Diagnostic

without depressing the
clutch pedal. <Ref. to
CC(ETC)(diag)-19, DTC
13, Diagnostic Procedure
with Diagnostic Trouble
Code (DTC).>
without shifting to neutral
position.

without operating the cancel switch.
Ignition switch is turned to OFF, and then the cruise con- This DTC is displayed
trol is released.
without operating the ignition switch. <Ref. to
CC(ETC)(diag)-24, DTC
16, Diagnostic Procedure
with Diagnostic Trouble
Code (DTC).>
CC(ETC)(diag)-13

because the ignition
switch was turned ON
without operating the
cruse control switch.

DTC
Item
24
Cruise control-related
switch is abnormal.
25
Brake switch input circuit

is abnormal.
31
Engine speed signal
32
Out of vehicle speed range

of cruise control operation
34
Prohibition when accelera- The vehicle has been driven at higher speed than set
tor position is continued to vehicle speed for an abnormally long time (approxibe large.
mately 10 minutes) during cruise driving.
35
Prohibition when vehicle

speed feedback is impossible.
Set vehicle speed cannot be kept because of some reasons (steep uphill, parking brake, abnormal decrease of
engine output, etc.) during cruise driving.
43
ABS/VDC malfunction
ABS is operated during cruise driving or cruise setting.
61
Brake switch malfunction
62

malfunction
63
Vehicle speed variation

malfunction 1
64
Engine sensor related

sensor malfunction 1
65
Cruise control related

switch malfunction 1
66
Cruise control computational malfunction
Reference
Open circuit in cruise control switch detected while driv<Ref. to CC(ETC)(diag)ing in cruise. (Judged as a system without cruise control) 25, DTC 24, Diagnostic
Malfunction of brake switch input circuit in ECM is
<Ref. to CC(ETC)(diag)detected.
25, DTC 25, Diagnostic
Abnormal increase of engine speed is detected.
Gear is placed in Neutral, 1st or Reverse position.

The vehicle speed exceeded the controllable speed
range while driving in cruise.
even though set operation
Set operation was performed at vehicle speed unavail- was repeated after
able for setting.
increasing vehicle speed
RESUME operation was performed without memoto a cruise possible
rized vehicle speed.
speed.

Stop light switch or brake switch malfunction is detected. <Ref. to CC(ETC)(diag)26, DTC 61, Diagnostic
Neutral position switch malfunction is detected.

Malfunction of vehicle speed signal variation is detected. <Ref. to CC(ETC)(diag)26, DTC 63, Diagnostic
Malfunction related to the engine is detected.

Cruise control command switch malfunction is detected. <Ref. to CC(ETC)(diag)(While the switch is pressed ON for a long time (approxi- 26, DTC 65, Diagnostic
Procedure with Diagnosmately two minutes), an ON stuck open circuit is
tic Trouble Code (DTC).>
detected.)
Malfunction of cruise control computer is detected.
CC(ETC)(diag)-14


8. Diagnostic Procedure with Diagnostic Trouble Code (DTC)

A: DTC 11
DTC for cruise control command switch.
TROUBLE SYMPTOM:
Cruise control cannot be set. (Cancelled immediately.)
Cruise control cannot be released.
WIRING DIAGRAM:
B40
CRUISE CONTROL
COMMAND SWITCH
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
CANCEL
SWITCH
MAIN
SWITCH
RESUME/
ACCEL
SWITCH
SET/
COAST
SWITCH
B68
ST3
1
2 3
4 5 6 7 8
STEERING ROLL
CONNECTOR
B: B135
C: B136
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
B68
MT
NEUTRAL
POSITION SWITCH
12
1
13
B40
B25
MT
T2
REF. TO STARTER
SYSTEM
[ST(AT/NA)-01]
5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30
31 32 33 34 35
DATA LINK
CONNECTOR
ST3
1 2 3
AT
B25
B: B135
C31
C6
B24
B12
1 2
C: B136 ECM
CC-00456
CC(ETC)(diag)-15

Step
CHECK CRUISE CONTROL COMMAND
SWITCH CIRCUIT.
1) Remove the drivers airbag module. <Ref. to
AB-14, REMOVAL, Drivers Airbag Module.>
2) Disconnect the harness connector of cruise
control command switch.
(ST3) No. 1 (+) Chassis ground ():
(ST3) No. 3 (+) Chassis ground ():
CHECK CANCEL SWITCH.
2) Remove the cruise control command
switch. <Ref. to CC-5, REMOVAL, Cruise Control Command Switch.>
3) Measure the resistance between switch terminals when the CANCEL switch is pressed
and not pressed.
Terminals
No. 2 No. 3:
CHECK SET/COAST SWITCH.
Measure the resistance between switch terminals when SET/COAST switch is pressed and
not pressed.
Terminals
No. 2 No. 3:
Check
Yes
Go to step 2.
No
Check the harness
between cruise
control command
switch and ECM for
open or shorted
circuit.
Is the resistance approx. less Go to step 3.

than 1 when the CANCEL
switch is pressed? Is the resistance approx. 4 k when the
CANCEL switch is not
pressed?
Replace the cruise

control command
switch.
<Ref. to CC-5,
Cruise Control
Command
Switch.>
Is the resistance approx. 250 Go to step 4.

when SET/COAST switch is
pressed? Is the resistance
approx. 4 k when SET/
COAST switch is not pressed?
Replace the cruise

control command
switch.
<Ref. to CC-5,
Cruise Control
Command
Switch.>
CHECK RESUME/ACCEL SWITCH CIRCUIT. Is the resistance approx. 1,500 Replace the ECM. Replace the cruise
Measure the resistance between switch termi- when RESUME/ACCEL
<Ref. to
control command
nals when RESUME/ACCEL switch is pressed switch is pressed? Is the resis- FU(H4SO)-40,
switch.
and not pressed.
tance approx. 4 k when
Engine Control
<Ref. to CC-5,
Terminals
RESUME/ACCEL switch is not Module (ECM).>
Cruise Control
No. 2 No. 3:
pressed?
<Ref. to
Command
FU(H4DOTC)-44, Switch.>
Engine Control
Module (ECM).>
CC(ETC)(diag)-16

B: DTC 12
DTC for stop light switch and brake light switch.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
STOP LIGHT SWITCH
AND BRAKE SWITCH
MT
:MT MODEL
AT
:AT MODEL
NA
:NON-TURBO
MODEL
:TURBO MODEL
STOP LIGHT
SWITCH
1 2
3 4
BRAKE
SWITCH
B107
2
TB
B65
F/B No.18
F/B No.16
B65
B281
MT
MAGNET
CLUTCH (MT)
1 2
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
2
1
B107
SBF-2
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
C: B136
5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30
31 32 33 34 35
MT
SBF-4
SBF-1
F/B No.11
IGNITION
SWITCH
B19
B9
B28 B28
B20 B20
TB
C25 C25
NA
B19 B27
BATTERY
AT
AT
B281
B: B135
ECM
C: B136
BODY
INTEGRATED
UNIT
CC-00457
CC(ETC)(diag)-17

Step
Check
CHECK STOP LIGHT SWITCH AND BRAKE Is the voltage 10 V or more?
SWITCH CIRCUIT.
2) Disconnect the stop light switch and brake
switch harness connector.
CHECK STOP LIGHT SWITCH AND BRAKE Is the voltage 10 V or more?
SWITCH CIRCUIT.
Measure the voltage between harness connector terminal and chassis ground.
Yes
Go to step 2.
No
Check fuse No.
16 (in fuse & relay
box).
Check for open
or short in the harness between stop
light/brake switch
and fuse & relay
box.
Go to step 3.
CHECK STOP LIGHT SWITCH AND BRAKE

SWITCH CIRCUIT.
integrated unit.
4) Measure the resistance between harness
connector terminals of ECM and of body integrated unit, and between harness connector
terminals of stop light switch and of brake
switch.
(B281) No. 9 (B65) No. 3:
(B135) No. 20 (B65) No. 4:
CHECK STOP LIGHT SWITCH AND BRAKE
SWITCH.
Remove and check the stop light switch and
brake switch. <Ref. to CC-6, Stop Light & Brake
Switch.>

?
Go to step 4.
Check fuse No.

18 (in fuse & relay
box).
Check for open
or short in the harness between stop
light/brake switch
and fuse & relay
box.
Check the clutch
switch and circuit.
Repair the harness.
Are the stop light switch and

brake switch OK?
Stop light switch

and brake switch
circuit are OK.
CC(ETC)(diag)-18
Replace the stop

light switch and
brake switch.

C: DTC 13
DTC for clutch switch.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
STOP LIGHT SWITCH
AND BRAKE SWITCH
MT
:MT MODEL
AT
:AT MODEL
NA
:NON-TURBO
MODEL
:TURBO MODEL
STOP LIGHT
SWITCH
1 2
3 4
BRAKE
SWITCH
B107
2
TB
B65
F/B No.18
F/B No.16
B65
B281
MT
MAGNET
CLUTCH (MT)
1 2
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
2
1
B107
SBF-2
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
C: B136
5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30
31 32 33 34 35
MT
SBF-4
SBF-1
F/B No.11
IGNITION
SWITCH
B19
B9
B28 B28
B20 B20
TB
C25 C25
NA
B19 B27
BATTERY
AT
AT
B281
B: B135
ECM
C: B136
BODY
INTEGRATED
UNIT
CC-00457
CC(ETC)(diag)-19

Step
2) Disconnect the clutch switch harness connector.
3) Measure the resistance between clutch
switch harness connector terminal and ECM
harness connector terminal.
(B107) No. 1 (B136) No. 25:
Remove and check the clutch switch. <Ref. to
CC-7, Clutch Switch.>
Check
Yes
Go to step 2.
No
Check fuse No.
18 (in fuse & relay
box).
Check open or
shorted circuit of
harness between
clutch switch and
fuse & relay box.

?
Go to step 3.
Repair the harness.
Is clutch switch OK?
Clutch switch circuit is OK.
Replace the clutch

switch.
CC(ETC)(diag)-20

D: DTC 14
DTC for neutral position switch.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
Turbo model
B136
1 2
31
ECM
T12
B128
1 2
3 4
B136
T2
NEUTRAL
POSITION
SWITCH
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
T12
2
5 6
14 15 16
25 26 27
33 34 35
1
T9
B128
E
GE
CC-00458
CC(ETC)(diag)-21

Non-turbo model
B136
B25
ECM
31
1 2
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
T2
NEUTRAL
POSITION
SWITCH
5 6
14 15 16
25 26 27
33 34 35
B25
2
1
E
GE
CC-00459
CC(ETC)(diag)-22

Step
CHECK NEUTRAL POSITION SWITCH CIRCUIT.
2) Disconnect the neutral position switch harness connector.
Turbo model
Non-turbo model
CHECK NEUTRAL POSITION SWITCH CIRCUIT.
2) Measure resistance between harness connector terminal of neutral position switch and
chassis ground.
Turbo model
Non-turbo model
Remove and check the neutral position switch.
Check
Yes
Go to step 2.
No
Check for open or
short in the harness between neutral position switch
and ECM.

?
Go to step 3.
Repair the harness.
Is the neutral position switch

OK?
The neutral posi- Replace the neution switch circuit is tral position switch.
working properly.
E: DTC 15
Malfunction of cancel switch is detected.
Refer to DTC 11 for diagnostic procedure.
CC(ETC)(diag)-23

F: DTC 16
DTC for ignition switch.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B135
BATTERY
SBF-1
SBF-4
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
24 25
20 21 22 23
26 27
32 33
34 35
28 29 30 31
F/B No.11
NA
TB
19 27
IGNITION
SWITCH
B135
ECM
CC-00460
Step
Check
2) Disconnect the ECM harness connector.
Turbo model
Non-turbo model
CC(ETC)(diag)-24
Yes
Check the poor
contact of ECM
connector.
No
Check fuse No.
11 (in fuse & relay
box).
Check the harness for open or
short circuit
between ignition
switch and ECM.

G: DTC 21
Cruise control command switch malfunction is detected.
H: DTC 22
Open or shorted circuit in vehicle speed sensor system.
TROUBLE SYMPTOM:
Cruise control cannot be set. (Cancelled immediately.)
WIRING DIAGRAM:
1
I:
Step
CHECK ABS WARNING LIGHT.
2) After the initial operation of combination
meter is completed, check if the ABS warning
light continues to illuminate.
Check
Yes
No
Does the ABS warning contin- Check the
Go to step 2.
ues to illuminate?
ABSCM.
<Ref. to
ABS(diag)-2,
PROCEDURE,
Basic Diagnostic
Procedure.>
CHECK VEHICLE SPEED SENSOR SIGNAL. Is the vehicle speed displayed Replace the ECM. Replace the vehi1) Connect the Subaru Select Monitor to the on the Subaru Select Monitor? <Ref. to
cle speed sensor.
FU(H4DOTC)-44,
2) Turn the ignition switch and Subaru Select
REMOVAL, Engine
Monitor switch to ON.
Control Module
3) Select {Engine} from the main menu.
(ECM).>
4) Then select {Current Data Display & Save}.
5) Drive the vehicle and check the vehicle
speed sensor signal.
DTC 24
Malfunction of cruise control related switch is detected.

J: DTC 25
Malfunction of brake switch input circuit is detected.
Refer to engine diagnostic procedure for diagnostic procedure.
<Ref. to EN(H4SO)(diag)-2, PROCEDURE, Basic Diagnostic Procedure.>
<Ref. to EN(H4DOTC)(diag)-2, PROCEDURE, Basic Diagnostic Procedure.>
K: DTC 31
Malfunction of engine speed signal is detected.
Abnormal increase of engine speed is detected.
Gear is placed in 1st or Reverse position.
Set cruise again while driving in 2nd or higher gear. If a DTC is not detected, it is operating normally.
L: DTC 32
Out of system vehicle speed range detected.
M: DTC 34
Malfunction of acceleration opening duration is detected.
The vehicle has been driven at higher speed than set vehicle speed for a long time (approximately 10 minutes) during cruise driving.
DTC is detected when driving for a long period of time at higher speed than the cruise set vehicle speed by
operating the accelerator pedal.
Cancel the cruise setting. If the DTC is not detected again, it is normal.
CC(ETC)(diag)-25

N: DTC 35
Malfunction of acceleration opening duration is detected.
The vehicle has been driven at higher speed than set vehicle speed for a long time (approximately 10 minutes) during cruise driving.
DTC is detected when driving for a long period of time at higher speed than the cruise set vehicle speed by
operating the accelerator pedal.
Cancel the cruise setting. If the DTC is not detected again, it is normal.
O: DTC 43
ABS/VDC malfunction is detected.
ABS malfunction is detected during cruise or during cruise setting.
Refer to ABS diagnostic procedure for diagnostic procedure.
<Ref. to ABS(diag)-2, PROCEDURE, Basic Diagnostic Procedure.>
P: DTC 61
Brake light switch malfunction is detected.
Q: DTC 62
Neutral position switch malfunction is detected.
R: DTC 63
Malfunction of vehicle speed signal variation is detected.
S: DTC 64
Malfunction related to the engine is detected.
T: DTC 65
Cruise control command switch malfunction is detected.
While the command switch is pressed ON for a long time (approximately two minutes), an ON stuck open circuit is detected.
U: DTC 66
Cruise control computational malfunction is detected.
CC(ETC)(diag)-26

IMMOBILIZER (DIAGNOSTICS)

A: PROCEDURE
1
Step
Check
Yes
CHECK ILLUMINATION OF SECURITY INDI- Does the security indicator light Go to step 2.
CATOR LIGHT.
blink?
1) Turn the ignition switch to OFF or ACC position.
2) Wait at least 60 seconds.
CHECK ILLUMINATION OF SECURITY INDI- Does the security indicator light Go to step 3.
CATOR LIGHT.
begin to blink within 1 second
Remove the key from ignition switch.
after the key is removed?
CHECK ENGINE START.

Turn the ignition switch to the START position.
CHECK ILLUMINATION OF SECURITY INDI- Does the security indicator light
CATOR LIGHT.
illuminate?
Go to step 4.
No
Check the security
indicator light circuit. <Ref. to
IM(diag)-10,
CHECK SECURITY INDICATOR
LIGHT CIRCUIT,
INSPECTION,
Diagnostics Chart
for Security Indicator Light.>
Check the ignition
switch circuit.
<Ref. to SL-42,
INSPECTION,
Ignition Key Lock.>
Go to step 5.
Check the security Immobilizer sysindicator light cir- tem is normal.

cuit. <Ref. to
IM(diag)-10,
CHECK SECURITY INDICATOR
LIGHT CIRCUIT,
INSPECTION,
Diagnostics Chart
for Security Indicator Light.>
Are DTCs indicated on display? Go to step 6.
Repair the related
parts.

data link connector. <Ref. to IM(diag)-7, Subaru
Select Monitor.>
3) Turn the ignition switch and run the Subaru
Select Monitor.
4) Read any DTC on the display.
PERFORM DIAGNOSIS.
Are DTCs indicated on display?
IM(diag)-13, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
4) Read any DTC again.
IM(diag)-2

(DTC). <Ref. to
IM(diag)-13, Diagnostic Procedure
with Diagnostic
Trouble Code
(DTC).>
General Description
A: CAUTION
CAUTION:
The airbag system wiring harness is routed
near the immobilizer control unit. All airbag
system wiring harnesses and connectors are
yellow. Do not use the electrical test equipment
on these circuits.
wiring harness when servicing the immobilizer
control module.
While diagnostic items are being checked, do
not operate radios, portable telephones, etc.
which emit electromagnetic waves near or inside the vehicle.
When repeatedly turning the ignition switch

to ON or OFF while diagnostic items are being
checked, it should be switched in cycles of
ON for at least 5 seconds OFF for at least
8 seconds.
ON
(1)
OFF
5
(2)
IM-00003
(1) Ignition switch position

(2) Sec.
If the engine fails to start with a registered ignition key, detach the ignition key from ignition
switch and wait for approx. 1 second until security indicator light begins to flash. And then
start the engine again.
Before checking the diagnostic items, obtain
all keys and security ID for the vehicle to be
checked possessed by owner.
IM-00001
When the ignition switch is being turned ON

or OFF while diagnostic items are being
checked, do not allow keys with different ID
codes be close to the ignition switch. If the ignition key is on a key holder, remove it from the
key holder before carrying out diagnoses.
IM-00002
IM(diag)-3
General Description
B: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
1B020XU0
Description
SUBARU SELECT
MONITOR KIT
REMARKS
Used for diagnosing the electrical system.
ST1B020XU0
2. GENERAL TOOL
TOOL NAME
Circuit tester
REMARKS
IM(diag)-4


A: LOCATION
(1)
(2)
(4)
(3)
IM-00118
(1)
Antenna
(2)
Security indicator light (LED bulb)
(3)
Immobilizer control module (IMM

ECM)
IM(diag)-5
(4)
Transponder
Immobilizer Control Module I/O Signal

4. Immobilizer Control Module I/

O Signal
A: WIRING DIAGRAM
1. IMMOBILIZER
<Ref. to WI-89, WIRING DIAGRAM, Immobilizer
System.>
IM(diag)-6

3. COMMUNICATION LINE CHECK
A: OPERATION
NOTE:
The communication line between ECM and immobilizer control unit can be checked in System Operation Check Mode. This is referred to as
Communication line check.
2) On the Each system check display, select the
{Engine Control System}.
3) Start the communication line check.
4) Is OK displayed on screen?
If displayed, go to step 5).
If not, go to step 6).
5) After diagnostic results, it is determined that the
circuit is not shorted. Finish the communication line
check.
6) If a problem is detected, repair the trouble
cause. <Ref. to IM(diag)-14, DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT),
Code (DTC).>
1. HOW TO USE THE SUBARU SELECT

MONITOR
2) Connect the diagnosis cable to Subaru Select
Monitor.
link connector.
side).
(1)
ABS00113
(2) Connect the diagnosis cable to data link

connector.
CAUTION:
4) Turn the ignition switch to ON (engine is OFF),
5) Using the Subaru Select Monitor, call up DTCs
and various data, then record them.

(DTC) FOR THE ENGINE
Refer to Read Diagnostic Trouble Code for information about how to display a DTC. <Ref. to IM(diag)-8, Read Diagnostic Trouble Code (DTC).>
IM(diag)-7


Code (DTC)
A: OPERATION
type is displayed.
4) On the Engine Diagnosis screen, select {DTC
Display}.
select {Current Diagnostic Code(s)} or {History Diagnostic Code(s)}.
NOTE:
MANUAL.
For detailed concerning DTC, refer to the List of
Diagnostic Trouble Codes (DTC). <Ref. to IM(diag)-12, LIST, List of Diagnostic Trouble Code
(DTC).>
IM(diag)-8
Clear Memory Mode


A: OPERATION
type is displayed.
4) On the Engine Diagnosis display screen, select the {Clear Memory}.
5) When the Done is shown on the display
screen, turn the ignition switch to OFF and then
close the Subaru Select Monitor.
NOTE:
After the memory has been cleared, the idle air
control solenoid valve must be initialized. To execute this procedure, turn the ignition switch to ON.
Wait for 3 seconds before starting the engine.
MANUAL.
IM(diag)-9
Diagnostics Chart for Security Indicator Light

8. Diagnostics Chart for Security Indicator Light

A: INSPECTION
1. CHECK SECURITY INDICATOR LIGHT CIRCUIT
WIRING DIAGRAM:
BATTERY
M/B No.2
IGNITION
SWITCH
SBF-5
B36
F/B No.11
SBF-4
SBF-1
i1
M/B No.5
COMBINATION METER
A:
i12
B:
i10
SECURITY
INDICATOR
LIGHT
F44
B61
B8
A4
36
18
i3
B38
B22
B141
24
25
15
E3
IMM ECM
1 2 3
5 6 7
i12
B36
B141
B22
1 2 3
4 5 6
7 8 9 10 11 12 13 14
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
A:
F44
4
8
B:
B38
i10
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
IM-00196
IM(diag)-10
Diagnostics Chart for Security Indicator Light

Step
CHECK SECURITY INDICATOR LIGHT.
IMM ECM.
3) Connect a resistor (100 ) between IMM
ECM harness connector terminal No. 5 and
chassis ground.
CHECK IMM ECM GROUND CIRCUIT.
Measure the resistance between IMM ECM
ground.
CHECK IMM ECM IGNITION CIRCUIT.
2) Measure the voltage between IMM ECM
ground.
CHECK IMM ECM POWER SUPPLY CIRCUIT.
ground.
Check
Yes
Does the security indicator light Go to step 2.
illuminate?
No
Go to step 5.
Repair the open

circuit of IMMCM
ground circuit.
Go to step 4.
Check the harness

for open or short
between IMM ECM
and ignition switch.
Replace the IMM

ECM <Ref. to SL53, Immobilizer
Control Module.>
and then replace
all ignition keys
(including the transponder). Then
perform teaching
operation. Refer to
the REGISTRATION MANUAL
FOR IMMOBILIZER (Pub. No.
S0820GZ).
Go to step 6.
Check the harness

for open or short
between IMM ECM
and fuse.
CHECK COMBINATION METER CIRCUIT.

meter harness connector terminal and chassis
ground.
CHECK COMBINATION METER CIRCUIT.
harness connector terminal and the combination meter harness connector terminal.
(B141) No. 5 (i12) No. 4:
IM(diag)-11
Faulty LED.
print circuit. <Ref.
to IDI-11, DISASSEMBLY, Combination Meter.>
Check the harness

for open or short
fuse.
Repair the harness

or connector.


A: LIST
DTC
Item
Index No.
<Ref. to IM(diag)-13, DTC P1571 REFERENCE
CODE INCOMPATIBILITY, Diagnostic Procedure
P1571
Reference code incompatibility

between IMM ECM and ECM
P1572
IMM Circuit Failure

(Expect Antenna Circuit)
Communication failure between

IMM ECM and ECM
P1574
Failure of IMM ECM to verify key

(transponder) ID code or transponder key failure
P0513
Incorrect immobilizer key (Use of

unregistered key in IMM ECM)
P1576
EGI Control Module

EEPROM
ECM malfunctioning
<Ref. to IM(diag)-17, DTC P1576 EGI CONTROL

MODULE EEPROM, Diagnostic Procedure with
P1577
IMM Control Module

EEPROM
IMM ECM malfunctioning
<Ref. to IM(diag)-18, DTC P1577 IMM CONTROL

MODULE EEPROM, Diagnostic Procedure with
P1570
Antenna
Faulty antenna
<Ref. to IM(diag)-19, DTC P1570 ANTENNA, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to IM(diag)-14, DTC P1572 IMM CIRCUIT

FAILURE (EXCEPT ANTENNA CIRCUIT), Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to IM(diag)-16, DTC P1574 KEY COMMUNICATION FAILURE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to IM(diag)-17, DTC P0513 INCORRECT
IMMOBILIZER KEY, Diagnostic Procedure with
NOTE:
Perform the engine DTC when a DTC other than immobilizer DTC is detected. <Ref. to EN(H4DOTC)(diag)70, List of Diagnostic Trouble Code (DTC).>
IM(diag)-12


A: DTC P1571 REFERENCE CODE INCOMPATIBILITY
Reference code incompatibility between IMM ECM and ECM
1
Step
PERFORM TEACHING OPERATION ON IGNITION KEY.
Perform teaching operation on all keys of the
vehicle. Refer to the REGISTRATION MANUAL FOR IMMOBILIZER.
CHECK DTC.
Check
Is teaching operation for all
keys completed?
Is there any DTC related to

immobilizer except DTC
P1571?
IM(diag)-13
Yes
END
Eliminate the
cause of DTC
other than DTC
P1571, and perform the teaching
operation again.
No
Go to step 2.
Replace the ECM

and IMM ECM
<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>
<Ref. to SL-53,
Immobilizer Control Module.>, and
then replace all
ignition keys
perform teaching
operation. Refer to
S0820GZ).

B: DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT)

Communication failure between IMM ECM and ECM
WIRING DIAGRAM:
IGNITION
SWITCH
BATTERY
SBF-1
SBF-5
F/B No.11
SBF-4
M/B No.5
F44
B61
7
IMMOBILIZER
ANTENNA
36
B142
B22
C: B136 ECM
B141
24
14
23
10
25
15
C26
C34
E3
IMM ECM
B142
C: B136
2 1
1
5
9
13
F44
1 2 3
5 6 7
2
6
10
14
3
7
11
15
HR
B22
B141
F60
4
8
12
16
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
1 2 3 4
5 6
9 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
31 32 33 34 35
28 29 30
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
4
8
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
IM-00197
IM(diag)-14

Step
CHECK IMM ECM POWER SUPPLY CIRCUIT.
IMM ECM.
ground.
ground.
CHECK IMM ECM GROUND CIRCUIT.
2) Measure the resistance between IMM ECM
ground.
CHECK HARNESS BETWEEN IMM ECM
AND ECM.
1) Disconnect the harness connector from the
ECM and IMM ECM.
2) Measure the resistance between IMM ECM
harness connector terminal and ECM harness
connector terminal.
(B141) No. 10 (B136) No. 26:
CHECK HARNESS BETWEEN IMM ECM
AND ECM.
harness connector terminal and ECM harness
connector terminal.
(B141) No. 23 (B136) No. 34:
CHECK HARNESS OF COMMUNICATION
LINE.
ground.
CHECK HARNESS OF COMMUNICATION
LINE.
Measure the voltage between ECM harness
connector terminal and engine ground.
Check
Yes
Go to step 2.
No
Check the harness
for open or short
between IMM ECM
and fuse.
Go to step 3.
Check the harness

for open or short
between IMM ECM
and ignition switch.
Repair the open

circuit of IMMCM
ground circuit.
Repair the open

circuit of harness
between IMM ECM
and ECM.
Repair the open

circuit of harness
between IMM ECM
and ECM.
Is the voltage 0 V?
Go to step 7.
There is a short circuit in the battery

voltage circuit or
ignition switch
ON circuit.
Repair the harness
between IMM ECM
and ECM.
Is the voltage 0 V?
Go to step 8.
There is a short circuit in the battery

voltage circuit or
ignition switch
ON circuit.
Repair the harness
between IMM ECM
and ECM.
IM(diag)-15

Step
Check
CHECK ECM BY COMMUNICATION LINE
Does Communication Line not
CHECK.
Shorted appear on the
1) Connect the harness connector to ECM.
screen?
IMM ECM.
3) Perform communication line check. <Ref. to
IM(diag)-7, COMMUNICATION LINE CHECK,
Yes
Replace the IMM
Control Module.>
and then replace
all ignition keys
perform teaching
operation. Refer to
S0820GZ).
No
Replace the ECM.
<Ref. to
FU(H4DOTC)-44,
Engine Control
Module
(ECM).>Then perform teaching
operation. Refer to
S0820GZ).
C: DTC P1574 KEY COMMUNICATION FAILURE

Failure of IMM ECM to verify key (transponder) ID code or transponder key failure
1
Step
CHECK IMM ECM FUNCTION.
Insert the key to ignition switch (LOCK position),
then measure changes in voltage between
antenna connector.
Check
Is the voltage 30 30 V
(Approximately 0.1 seconds
after key was inserted)? Is the
voltage 0 V (Approximately 1
seconds after key was
inserted)?

CHECK IGNITION KEY (TRANSPONDER).
2) Start the engine using other keys that have
undergone the teaching operation.
IM(diag)-16
Yes
Go to step 2.
No
Replace the IMM
Control Module.>
and then replace
all ignition keys
perform teaching
operation. Refer to
S0820GZ).
Replace the igni- Replace the IMM
tion key (including ECM <Ref. to SLthe transponder). 53, Immobilizer
Then perform
Control Module.>
teaching operaand then replace
tion. Refer to the
all ignition keys
REGISTRATION (including the tranMANUAL FOR
sponder). Then
IMMOBILIZER
perform teaching
(Pub. No.
operation. Refer to
S0820GZ).
S0820GZ).

D: DTC P0513 INCORRECT IMMOBILIZER KEY

Incorrect immobilizer key (Use of unregistered key in IMM ECM)
1
Step
vehicle. Refer to the REGISTRATION MANUAL FOR IMMOBILIZER (Pub. No. S0820GZ).
vehicle. Refer to the REGISTRATION MANUAL FOR IMMOBILIZER (Pub. No. S0820GZ).
Check
keys completed?

keys completed?
Yes
END
END
No
Replace all ignition
keys (including the
transponder). Go
to step 2.
Replace the IMM
Control Module.>
and then replace
all ignition keys
perform teaching
operation. Refer to
S0820GZ).
E: DTC P1576 EGI CONTROL MODULE EEPROM

ECM malfunctioning
Inaccessible ROM in ECM during key registration
1
Step
PERFORM REGISTRATION ON IGNITION
KEY.
Perform registration on all keys of the vehicle.
Refer to the REGISTRATION MANUAL FOR
IMMOBILIZER.
KEY.
IMMOBILIZER.
KEY.
IMMOBILIZER.
Check
Yes
Is registration for all keys com- Verify that the
pleted?
engine starts with
all registered keys
pleted?
engine starts with
all registered keys
pleted?
engine starts with
all registered keys
IM(diag)-17
No
Go to step 2.
Go to step 3.
Replace the ECM.

<Ref. to
FU(H4DOTC)-44,
Engine Control
Module (ECM).>

F: DTC P1577 IMM CONTROL MODULE EEPROM

IMM ECM malfunctioning
Inaccessible ROM in IMM ECM.
1
Step
KEY.
IMMOBILIZER.
KEY.
IMMOBILIZER.
KEY.
IMMOBILIZER.
Check
Yes
pleted?
engine starts with
all registered keys
pleted?
engine starts with
all registered keys
pleted?
engine starts with
all registered keys
IM(diag)-18
No
Go to step 2.
Go to step 3.
Replace the IMM

ECM. <Ref. to SL53, REMOVAL,
Immobilizer Control Module.>Replace all
ignition keys
perform teaching
operation. Refer to
S0820GZ).

G: DTC P1570 ANTENNA

Faulty antenna
WIRING DIAGRAM:
2
1
IMMOBILIZER ANTENNA
1
14
B142
B141
IMM ECM
B141
B142
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
2 1
IM-00106
Step
CHECK ANTENNA CIRCUIT.
2) Disconnect the harness antenna connector
from the IMM ECM. <Ref. to SL-54, Immobilizer
Antenna.>
3) Measure the resistance of the antenna circuit.
(B141) No. 1 No. 14:
Measure the resistance between antenna harness connector and chassis ground.
Measure the resistance between antenna harness connector and chassis ground.
2) Measure the voltage between antenna harness connector and chassis ground.
Check
Yes
No
Replace the
antenna. <Ref. to
SL-54, Immobilizer Antenna.>
Is the resistance less than 10 ? Replace the

antenna. <Ref. to
Go to step 3.
Is the resistance less than 10 ? Replace the

antenna. <Ref. to
Go to step 4.
Is the voltage 0 V?
Replace the
antenna. <Ref. to
IM(diag)-19
Go to step 5.

Step
Measure the voltage between antenna harness
CHECK IMM ECM FUNCTION.
2) Connect the antenna harness connector to
IMM ECM.
3) Insert the key to ignition switch, then measure changes in voltage between antenna harness connector.
Check
Is the voltage 0 V?
Yes
Go to step 6.
Is the voltage 30 30 V
(Approximately 0.1 seconds
after key was inserted)? Is the
voltage 0 V (Approximately 1
seconds after key was
inserted)?
Go to step 7.

CHECK IGNITION KEY (TRANSPONDER).
2) Start the engine using other keys that have
undergone the teaching operation.
IM(diag)-20
No
Replace the
antenna. <Ref. to
Replace the IMM

Control Module.>
and then replace
all ignition keys
perform teaching
operation. Refer to
S0820GZ).
Replace the igni- Replace the IMM
tion key (including ECM <Ref. to SLthe transponder). 53, Immobilizer
Then perform
Control Module.>
teaching operaand then replace
tion. Refer to the
all ignition keys
REGISTRATION (including the tranMANUAL FOR
sponder). Then
IMMOBILIZER
perform teaching
(Pub. No.
operation. Refer to
S0820GZ).
S0820GZ).

WIRING SYSTEM
5) The circuit is in good order. If a problem such as

a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction.
A: BASIC PROCEDURES
The most important purpose of diagnostics is to
quickly determine which part is malfunctioning, to
save time and labor.
2. IDENTIFICATION OF TROUBLE SYMPTOM

Determine what the problem is based on the symptom.
3. PROBABLE CAUSE OF TROUBLE

Look at the wiring diagram and check the systems
circuit. Then check the switch, relay, fuse, ground,
etc.
2. CIRCUIT CONTINUITY CHECKS

1) Disconnect the battery terminal or connector so
there is no voltage between the check points.
Contact the two leads of an ohmmeter to each of
the check points.
If the circuit has diodes, reverse the two leads and
check again.
2) Use an ohmmeter to check for diode continuity.
When contacting the negative lead to the diode
positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there
should be no continuity.
4. LOCATION AND REPAIR OF TROUBLE

1) Using the diagnostics, narrow down the causes.
2) If necessary, use a voltmeter, ohmmeter, etc.
3) Before replacing certain component parts
(switch, relay, etc.), check the power supply,
ground, for open wiring harness, poor connectors,
etc. If no problem is encountered, check the component parts.
Continuity
No continuity
5. SYSTEM OPERATION CHECK
WI-02740
After repairing, ensure that the system operates

properly.
B: BASIC INSPECTION
1. VOLTAGE MEASUREMENT
3) The symbol indicates that continuity

exists between two points or terminals. For example, when a switch position is at 3, continuity exists among terminals 1, 3 and 6, as shown in the
table below.
1) Using a voltmeter, connect the negative lead to a

good ground point or negative battery terminal and
the positive lead to the connector or component terminal.
2) Contact the positive lead of the voltmeter on
connector (A). The voltmeter will indicate a voltage.
3) Shift the positive lead to connector (B). The voltmeter will indicate no voltage.
To power
supply
FUSE
Terminal
Switch Position
OFF
1
2
3
4
Switch
Light
WI-02741
(A)
(B)
V
WI-02739
4) With the test set-up held as it is, turn the switch

ON. The voltmeter will indicate a voltage and, at the
same time, the light will come on.
WI-3

WIRING SYSTEM
3. HOW TO DETERMINE AN OPEN CIRCUIT
4. HOW TO DETERMINE A SHORT CIRCUIT
1) With voltmeter:
An open circuit is determined by measuring the
voltage between respective connectors and ground
using a voltmeter, starting with the connector closest to the power supply. The power supply must be
turned ON so that current flows in the circuit. If voltage is not present between a particular connector
and ground, the circuit between that connector and
the previous connector is open.
1) With test light:

Connect a test light (rated at approx. 3 watts) in
place of the blown fuse and allow current to flow
through the circuit. Disconnect one connector at a
time from the circuit. Starting with the one located
farthest from the power supply. If the test light goes
out when a connector is disconnected, the wiring
between that connector and the next connector
(farther from the power supply) is shorted.
Open circuit or wiring
Test lamp
Shorted wiring
Fuse holder
0V
12V
WI-02742
WI-02744
2) With ohmmeter:
Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors.
When the ohmmeter indicates infinite, the wiring
is open.
Open circuit
2) With ohmmeter:
Disconnect all affected connectors, and check continuity between each connector and ground. When
the ohmmeter indicates continuity between a particular connector and a ground, that connector is
shorted.
Shorted connector
WI-09860
WI-02745
WI-4

WIRING SYSTEM
C: HOW TO READ WIRING DIAGRAMS

1. WIRING DIAGRAM
The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery.
Sketches and codes are used in the diagrams. They should read as follows:
Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state
which is viewed from the front.
4
Viewed from this direction
WI-02746
The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the
sketch, the highest pole number refers to the number of poles which the connector has. For example, the
sketch of the connector shown in figure indicates the connector has 9 poles.
Connector shown in wiring diagram
Connector used in vehicle

Sketch
Symbol
Number of poles
Double frames
Indicates a lock
is included.
Numbered in order from upper

right to lower left.
Indicates the number of poles.
Indicates a lock is included.
Numbered in order from upper

left to lower right
Single frame
WI-02747
WI-5

WIRING SYSTEM
When one set of connectors is viewed from the

front side, the pole numbers of one connector are
symmetrical to those of the other. When these two
connectors are connected as a unit, the poles
which have the same number are joined.
The following color codes are used to indicate

the colors of the wires.
Color code
Color
L
B
Blue
Black
Y
G
Yellow
Green
R
W
Red
White
Br
Lg
Brown
Light green
Gr
P
Gray
Pink
Or
Sb
Orange
Sky blue
V
SA
Purple
Sealed (Inner)
SB
Sealed (Outer)
WI-00107
WIRING DIAGRAM:
The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list.
The sketch of each connector in the wiring diagram usually shows the (A) side of the connector.
The relationship between the wire color, terminal
number and connector is described in the figure.
YG
NOTE:
A wire which runs in one direction from a connector
terminal sometimes may have a different color from
that which runs in the other direction from that terminal.
YL
i2
BR
RW
F4
1
3
i2
SA
1 2
3 4
(A)
Wire color :
BR (No. 1 terminal)
RW (No. 3 terminal)
WI-02748
In the wiring diagram, connectors which have no

terminal number refer to one-pole types. Sketches
of these connectors are omitted intentionally.
B
F10
B
B15
WI-00109
WI-6
10
9
SB
YL
YG
22
SB
20
SA
SB
SB
YL
YG
2
1
SA
WI-00110

WIRING SYSTEM
Each unit is either directly grounded to the body

or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems.
The wire color code, which consists of two letters

(or three letters including Br or Lg), indicates the
standard color (base color of the wire covering) by
its first letter and the stripe marking by its second
letter.
Y B
Marking color :
Reference color :
Black
Yellow
Direct ground
WI-03797
The table lists the nominal sectional areas and

allowable currents of the wires.
CAUTION:
When replacing or repairing a wire, be sure to
use the same size and type of the wire which
was originally used.
The ground points shown in the wiring diagram

refer to the following:
NOTE:
All wiring harnesses are provided with a ground
point which should be securely connected.
NOTE:
The allowable current in the table indicates the
tolerable amperage of each wire at an ambient
temperature of 40C (104F).
The allowable current changes with ambient
temperature. Also, it changes if a bundle of more
than two wires is used.
GF-1
GF-2
: CHASSIS GROUND
GB-1
GB-4
: CHASSIS GROUND
GR-1
GR-2
: CHASSIS GROUND
mm2
No. of
strands/
strand diameter
Outside
Allowable
diameter of
current
wiring
Amps/
mm 40C (104F)
0.3
0.5
7/0.26
7/0.32
1.8
2.2 (or 2.0)
7
12
0.75
0.85
30/0.18
11/0.32
2.6 (or 2.4)

2.4 (or 2.2)
16
16
1.25
2
16/0.32
26/0.32
2.7 (or 2.5)

3.1 (or 2.9)
21
28
3
5
41/0.32
65/0.32
3.8 (or 3.6)

4.6 (or 4.4)
38
51
50/0.45
5.5
67
WI-7
: ENGINE GROUND
GE
GA
GR
Nominal sectional area
Indirect terminal
ground
WI-02750
GAB-1
: AIRBAG HARNESS
: RADIO GROUND
WI-05670

WIRING SYSTEM
Relays are classified as normally-open or normally-closed.

The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF.
Relay type
Energizing circuit OFF
Energizing circuit ON
4-pole
Normally-open type
6-pole
Normally-closed type
4-pole
Mixed type
6-pole
Key to symbols:
: Current flows.
: Current does not flow.
WI-02752
WI-8

WIRING SYSTEM
Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The
location of each connector in the actual vehicle is
determined by reading the first character of the
connector (for example, a F for F8, i for i16, etc.)
and the type of wiring harness. The first character
of each connector number corresponds to the area
or system of the vehicle.
Symbol
Wiring harness and cord
F
B
Front wiring harness

Bulkhead wiring harness
Engine wiring harness

Transmission cord, Rear oxygen sensor
cord
Door cord LH & RH, Rear gate cord
Rear door cord LH & RH
T
D
i
Instrument panel wiring harness

Rear wiring harness,
Fuel tank cord,
Roof cord
R
AB
Airbag wiring harness
F58
F27
F19
F22
F34
F96
F47
F23
F100
F21
F5
F98
Each connector number

shown in wiring diagram
corresponds to that in
the vehicle.
FRONT TURN SIGNAL

LIGHT LH (UPPER)
2
BG
F19
FRONT TURN SIGNAL
LIGHT LH (LOWER)
3
BG
F22
F3
(GRAY)
F19
(GRAY)
1 2
WI-02753
WI-9

WIRING SYSTEM
D: SYMBOLS IN WIRING DIAGRAMS

A number of symbols are used in each wiring diagram to easily identify parts or circuits.
P-SUP-02
P-SUP-02
FUSE No. & RATING

SBF-6 30A
WIRE TRACING
ON EXTENDED
WIRING DIAGRAMS
No.1 20A
No.8 15A
M
L
K
J
I
H
G
F
E
BG
H1
LOW
SMJ
RL
R
B:
YL
LB
2
1
P-SUP-04
P-SUP-03
P-SUP-03
P-SUP-04
P-SUP-03
P-SUP-04
No.5 10A
A: B51
F45
i5
B62
HIGH
P-SUP-04
D7
D4 LgB
HEADLIGHT LH
P-SUP-04
FUSE &
RELAY
BOX
(F/B)
LB
GR
LW
MB-5
HEADLIGHT
RELAY
BG G7
MB-10
FB-16
MB-11
M/B FUSE NO. 9 F/B FUSE NO. 11
(IG)
WR G4
SMJ

MB-10
M/B FUSE NO. 8
P-SUP-04
D11 Or
5
G
F38
P-SUP-04
RL
SYMBOLS OF
WIRE
CONNECTION
AND CROSSING
F36
POWER SUPPLY
CIRCUIT
H/L(2L)-01
MB-11
BW
2
RL
F68
L
7
LW
F39
LR
3
LR
CONNECTOR-1
R
No.9 15A
No.2 15A
HEADLIGHT
RELAY
LH
HEADLIGHT
RELAY
RH
No.3 10A
P-SUP-02
SBF-4 50A
RELAY
SBF-2 50A
SBF-1 100A
MAIN FUSE BOX (M/B)
SBF-3 50A
Example
C: B52
D: B152
E: B158
F23
F:
R
YL
DIMMER & PASSING

SWITCH
A1
CONNECTOR-2
SMJ
REF. TO ST (MT)-01
RY
HL
17
17
YB
16
16
13
13
LY
SPECIFICATION
CLASSIFICATION
OFF
TC
FB-34
LY
FB-35
FB-37
8
7
FB-36
REF. TO ST (AT)-01
OR WR
HF
HU
HC
G1
B36
B61
LIGHTING SWITCH
B71
EL
C: B52
YB
RY
G: F41
(GRAY)
1
2 3
4 5 6 7
REF. TO FOG (H4)-01
DIODE
REF. TO FOG (H6)-01
A: B51
1 2
3
4 5 6 7 8
SD : SEDAN
SD
P
WG
B112
DIODE
17
R3
P
B99
SD
WG
OR : WITHOUT REAR DEFOGGER

WR : WITH REAR DEFOGGER
BL
3
2
BR D10
R
YL
F44
LW B1
LW
R
YL
F7
UP LOW PASS
1
3
A3
LW
LW
2
HIGH
LOW
A2
SPECIFICATION
CLASSIFICATION
F40
G: F41
HEADLIGHT RH
WG : WAGON
HR
B112
F7
(BLACK)
F44
1 2
F23
(BLACK)
1 2 3 4
5 6 7 8
R4
PARKING
BRAKE
SWITCH
GROUND
R1
P
B97
HARNESS
REPAIR KIT
CONNECTOR SKETCH
REF. TO GND-02
WI-04721
WI-10

WIRING SYSTEM
1. RELAY
10.SYMBOLS OF WIRE CONNECTION AND

CROSSING
A symbol used to indicate a relay.
2. CONNECTOR 1
The sketch of the connector indicates the one-pole
types.
Symbol
Refers to wires which are

connected and branched
at the dot point.
Symbol
Refers to wires which are

crossed but not connected.
3. WIRING CONNECTION
Some wiring diagrams are indicated in foldouts for
convenience. Wiring destinations are indicated
where necessary by corresponding symbols.
(When two pages are needed for clear indication)
WI-02755
4. FUSE NO. & RATING

The FUSE No. & RATING corresponds with that
used in the fuse box (main fuse box, fuse and joint
box).
11.POWER SUPPLY ROUTING
Each connector is indicated by a symbol.

Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form.
For example, terminal number G4 refers to No.
4 terminal of connector (G: F41) shown in the connector sketch.
A symbol is used to indicate the power supply in

each wiring diagram.
MB-5, MB-6, etc., which are used as powersupply symbols throughout the text, correspond
with those shown in POWER SUPPLY ROUTING
in the wiring diagram.
Accordingly, using POWER SUPPLY ROUTING
and wiring diagrams permits service personnel to
understand the entire electrical arrangement of a
system.
6. CONNECTOR SKETCH
12.CLASSIFICATION BY SPECIFICATION
Each connector sketch clearly identifies the

shape and color of a connector as well as terminal
locations. Non-colored connectors are indicated in
natural color.
When more than two types of connector number
are indicated in a connector sketch, it means that
the same type connectors are used.
When the wiring diagram differ according to vehicle specifications, the specification difference is
described by using abbreviations.
For V.I.N., refer to the ID section. <Ref. to ID-2,
IDENTIFICATION NUMBER AND LABEL LOCATIONS, IDENTIFICATION, Identification.>
5. CONNECTOR 2
7. GROUND
Each grounding point can be located easily by referring to the corresponding wiring harness.
8. DIODE
A symbol is used to indicate a diode.
13.HARNESS REPAIR KIT

The connector adapting to Harness repair kit is
shown as HR in the right-upper of connector number. Refer to Harness Repair Kit for harness repair kit. <Ref. to WI-184, SPECIFICATION,
Harness Repair Kit.>
9. WIRE TRACING ON EXTENDED WIRING

DIAGRAMS
For a wiring diagram extending over at least two
pages, a symbol (consisting of the same characters
with arrows), facilitates wire tracing from one page
to the other.
A A, B B
WI-11

WIRING SYSTEM
E: CONNECTOR SYMBOL IN WIRING HARNESS

A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors.
Standard type: Female

Pole: From 1 to 8
Pole: From 9 to 20
Pole: More than 21
Standard type: Male
Water proof type: Female

Pole: From 1 to 8
Pole: From 9 to 20
Pole: More than 21
Water proof type: Male
WI-02756
WI-12

WIRING SYSTEM
F: ABBREVIATION IN WIRING DIAGRAMS

Abbr.
A/B
A/C
A/F
ABS
ABSCM
Abbr.
Full name
OP
P
Airbag
Air Conditioner
Air/Fuel (Air fuel ratio sensor)
PASS
PCV
Antilock Brake System

Antilock Brake System Control Module
ACC
AT
Accessory
Automatic Transmission
ATF
AUX

Auxiliary Audio Input Terminal
P-VIGN
R
Full name
Optional Parts or Open
Parking Range
Passing
Purge Control Valve
P-V Ignition Relay
Reverse Range
RH
RL
Right Hand
Rear Left
Rear Left Down
Rear Left Up
AVCS
Active Valve Control System
RLD
RLU
AWD
B
All Wheel Drive

Battery
RR
RRD
Rear Right
Rear Right Down
CAN
COM
Controller Area Network

Computer
RRU
SBF
Rear Right Up
Slow Blow Fuse
CPC
CPU
Canister Purge Control

Central Integrated Circuit
ST
TCM
Starter
AT Control Module
Drive Range or Down

Ground
TGV
U
Tumble Generator Valve

Up
D
E
EBD
ECM
EEPROM
WASH
Electric Brake Distribution

Engine Control Module
Electronically Erasable and Programmable Read Only Memory
EGI
EGR
Electric Gasoline Injection

Exhaust Gas Recirculation
ELR
F/B
Emergency Locking Retractor

Fuse & Relay Box
FL
FLD
Front Left Hand

Front Left Down
FLU
FR
Front Left Up
Front Right Hand
FRD
FRU
Front Right Down

Front Right Up
FWD
GND
Front Wheel Drive

Ground
H/L
HI
Headlight
High
HID
I/F
High Intensity Discharge

Interface
IG
INT
Ignition
Intermittent
LCD
LH
Liquid Crystal Display

Left Hand
LO
M
Low
Motor
M/B
MT
Main Fuse Box

Manual Transmission
N
NA
Neutral Range
Natural Aspiration
WI-13
Washer
Working Precautions
WIRING SYSTEM
2. Working Precautions
A: PRECAUTIONS WHEN WORKING
WITH THE PARTS MOUNTED ON
THE VEHICLE
1) When working under a vehicle which is jackedup, always be sure to use rigid rack.
2) The parking brake must always be applied during working. Also, in automatic transmission vehicles, keep the select lever set to the P (Parking)
range.
3) Be sure the workshop is properly ventilated
when running the engine. Further, be careful not to
touch the belt or fan while the engine is operating.
4) Be careful not to touch hot metal parts, especially radiator and the exhaust system immediately after the engine has been turned off.
5) Some connectors are provided with a lock. One

type of such a connector is disconnected by pushing the lock, and the other, by moving the lock up.
In either type the lock shape must be identified before attempting to disconnect the connector.
To connect, insert the connector until it snaps and
confirm that it is connected securely.
EXAMPLE
B: PRECAUTIONS IN TROUBLE DIAGNOSIS AND REPAIR OF ELECTRIC PARTS

1) The battery cable must be disconnected from
the batterys (-) terminal, and the ignition switch
must be set to the OFF position, unless otherwise
required by the diagnostics.
2) Securely fasten the wiring harness with clamps
and clips so that the harness does not interfere with
the body end parts or edges and bolts or screws.
3) When installing parts, be careful not to catch
them on the wiring harness.
4) When disconnecting a connector, do not pull the
wires, but pull while holding the connector body.
WI-02758
6) When checking continuity between connector

terminals, or measuring voltage across the terminal
and ground, always contact tester probe(s) on terminals from the wiring connection side. If the probe
is too thick to gain access to the terminal, use mini
test leads.
To check water-proof connectors (which are not accessible from the wiring side), contact test probes
on the terminal side being careful not to bend or
damage terminals.
WI-02757
WI-09366
7) Sensors, relays, electrical unit, etc., are sensitive to strong impacts.

Handle them with care so that they are not dropped
or mishandled.
WI-14
Power Supply Circuit

WIRING SYSTEM
3. Power Supply Circuit

P-SUP-01
P-SUP-01
A: WIRING DIAGRAM
MAIN FUSE BOX (M/B)
MAIN FAN
: 30A
FAN
MODE
RELAY
SUB FAN
: 30A
SBF-7
SBF
-8
AIR
CUT1
RELAY
A/C
RELAY
AIR
CUT2
RELAY
TB
NA
TB
SBF
-5
No. 1
SBF
-6
FWD SWITCH
FAN
RELAY
-1
FAN
RELAY
-2
Horn
relay
No. 6
No. 9
No. 5
No. 8
No. 4
H/L
relay
RH
No. 7
No. 3
SBF-2
SBF-1
SBF-3
SBF-4
No. 2
H/L
relay
LH
NA
: NON-TURBO MODEL
TB
: TURBO MODEL
SECONDARY AIR FUSE BOX (TURBO MODEL)
A/C
RELAY
AIR
PUMP
RELAY
SBF-9
No.10
FUSE & BOX (F/B)
No.13
No.14
No.7
No.1
No.15
No.8
No.2
No.16
No.9
No.3
No.17
No.10
No.4
No.18
No.11
No.5
No.19
No.12
No.6
WI-13117
WI-15

WIRING SYSTEM
P-SUP-02
P-SUP-02
BATTERY
BATTERY CURRENT
CURRENT FROM IGNITION SWITCH
"IG" TERMINAL
OTHER CURRENTS
CURRENT FROM IGNITION SWITCH
"ACC" TERMINAL
SBF-1 120A
MAIN FUSE BOX (M/B)
F35
F25
GENERATOR
2
1
LR
BW
HEADLIGHT
RELAY RH
P-SUP-03
P-SUP-03
P-SUP-03
HEADLIGHT
RELAY LH
F26
LW
RL
GR
F39
SBF-7 30A
1
3
W
WG
2
4
W
WG
No.8 15A
3
LR
SBF HOLDER
No.9 15A
: NON-TURBO MODEL
No.3 10A
NA
SBF-8 30A
1
2
(BLACK)
F26
1 2 3
HR
(GREEN)
F34
2
(BLACK)
MB-3
MB-2
MB-1
ALT
SBF-7
SBF-8
F35
P-SUP-05
NA
F34
NA
F39
1 2 3 4
5 6 7 8
WI-14971
WI-16

WIRING SYSTEM
P-SUP-03
SBF-6 30A
SBF-4 50A
SBF-3 50A
2
F36
F38
W
BW
No.1 20A
3
No.2 15A
WL
F68
LR
No.5 15A
4
WR
No.7 20A
SBF-2 50A
SBF-5 30A
1
F37
RG
BL
F39
HORN
RELAY
BR
P-SUP-02
No.4 10A
P-SUP-02
YR
P-SUP-02
No.6 15A
P-SUP-03
MAIN FUSE BOX (M/B)
F36
F68
F37
F39
1 2 3
1 2
3 4
1 2 3
4 5 6
1 2 3 4
5 6 7 8
P-SUP-05
P-SUP-05
P-SUP-05
P-SUP-05
P-SUP-04
P-SUP-04
P-SUP-05
P-SUP-04
MB-11
MB-10
MB-12
MB-9
MB-8
MB-7
MB-6
MB-5
MB-4
E
F
G
H
I
J
K
L
WI-12323
WI-17
P-SUP-04
G
P-SUP-05
F8
E8
WR
F9
LR
F4
A3
A2
BG
P-SUP-03
Or
P-SUP-03
I
L
J
D11
P-SUP-03
FB-3
FB-2
P-SUP-04
WIRING SYSTEM
No.6 15A
No.11 15A
REAR
DEFOGGER
RELAY
No.17 15A
B52
No.18 15A
B: B271
C:
No.12 10A
B51
No.5 10A
A:
TAIL &
ILLUMINATION
RELAY
FUSE &
RELAY
BOX (F/B)
D: B152
R
FB-21
A4
A5
C4
R
GY
TB-37
FB-20
D5
GOr C1
FB-18
GR
GOr G2
FB-17
FB-19
GOr B7
FB-36
G3
GB
FB-16
C5
GB
FB-15
B1
GB
FB-35
D1
B4
RL
FB-14
E5
WR
FB-13
BP
FB-11
D2
BR D12
FB-10
C7
V
B2
V
FB-9
FB-34
C6
LR
A1
B3
A6
LR
G1
RY
FB-6
D7
D4
RY D10
BG
F41
FB-5
F40
G:
G4
F:
G7
E: B158
TRAILER CONNECTOR
R1
LR
B97
R79
C:
B52
1 2 3
4 5 6
G:
F41
1
4
B97
(GRAY)
2 3
6 7
(BLACK)
1 2 3 4
5 6 7 8
A:
B51
FB-12
R79
FB-8
LR
FB-7
(BLUE)
1 2
3
4 5 6 7 8
F:
1
5
F40
2
3
6 7 8
(BROWN)
4
9
E: B158 (GRAY)
1
6
2
7
3
8
4 5
9 10
B: B271 (BLUE)
D: B152
1 2 3
4 5
6 7 8 9 10 11 12
WI-15217
WI-18

WIRING SYSTEM
OFF ACC ON ST
P-SUP-03
W
F46
P-SUP-03
WL
B108
14
WL
F45
P-SUP-04
P-SUP-03
P-SUP-03
P-SUP-03
B
ACC
IG
WL
ST
P-SUP-05
P-SUP-05
IGNITION SWITCH
B72
B62
IGNITION RELAY
WL
10
13
11
F
G
H
GW
B225
BW
F6
FUSE &
RELAY
BOX (F/B)
B11
R
F3
L
F2
F7
Y
E7
E6
G
E9
REF. TO GND
[GND-02]
B51
B: B271
No.13 20A
No.3 15A
No.1 15A
No.2 15A
No.7 15A
No.8 30A
No.16 20A
No.19 15A
No.10 10A
No.4 15A
No.9 15A
No.15 30A
No.14 10A
A:
C:
B52
D: B152
F40
G:
F41
1
2
B: B271 (BLUE)
D: B152
1 2 3
4 5
6 7 8 9 10 11 12
1 2
3 4
A:
(GRAY)
(BLUE)
F:
1
5
F40
2
3
6 7 8
(BROWN)
4
9
IG
B51
1 2
3
4 5 6 7 8
D
ACC
F41
FB-32
B52
FB-30
C:
G:
FB-31
(BLUE)
FB-29
FB-26
FB-25
FB-24
B72
FB-28
(BLACK)
FB-27
F46
FB-23
FB-22
P-SUP-02
ST
D3
A8
RW
E1
WB D8
RW D6
D9
RL
G5
RY
LY
E3
LW E10
C2
B8
B6
B9
C3
YB
YB
YG
E2
E4
GR
GR
F1
E: B158
F:
E: B158 (GRAY)
1
6
2
7
3
8
4 5
9 10
1
2 3
4 5 6 7
F45
(BLACK)
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B225
(BLACK)
1 2
3 4
5 6
9 14 15 16 19 24 25 26 29 34 35 36
30
10
17
20
27
37
11 12 13 18 21 22 23 28 31 32 33 38
7 8
RELAY BLOCK
WI-19
WI-12205

WIRING SYSTEM
No.
MB-1
Load
Secondary air relay holder (Fuse)
MB-2
A/C relay holder (Fuse)

Combination meter
MB-3
Headlight RH
Headlight LH
MB-4
MB-5
Horn
MB-6
Horn switch
Key warning switch
No.
FB-6
Front clearance light RH

Headlight beam leveler LH
FB-7
MB-7
MB-8
MB-9
Headlight beam leveler RH

Side marker light RH
Trailer connector
Headlight beam leveler switch
License plate light
Rear combination light LH

Hazard switch
TCM
Load
Side marker light LH
Front clearance light LH
FB-8
Rear combination light RH

Audio
Diode

Combination meter
HID diode
Spot map light

Room light
ECM
Data link connector
Clock
Key illumination
Fuel pump relay

Main relay
FB-9
Luggage room light

Illumination light

A/F & oxygen sensor relay
FB-10
Combination meter
Parking switch
MB-10
MB-11
Fuse (Seat heater)

FB-11
ECM
Lighting switch
MB-12
Keyless buzzer
Combination meter
FB-12
Parking switch
Daytime running light relay
FB-13
SBF-7

ABS control module
Rear defogger
SBF-8
VDC control module

A/F & oxygen sensor relay
ALT
ACC
Combination meter
Fuse (Rear wiper)
IG
Hazard switch
Power window relay

Data link connector

Vehicle speed sensor (MT model)

Back-up light switch (MT model)
Interrupt relay

ABS control module
Turn signal switch

Trailer connector
VDC control module

Impact sensor
ST
FB-2
Hazard switch
Turn signal light
FB-3
Manual A/C control module

ECM
FB-15

FB-16
FB-17
Fan relay - 1
A/C relay
Fan mode relay
Fan relay - 2
Rear turn signal light LH

Parking switch
HID relay
FB-5
FB-14
FB-18
Front turn signal light LH
WI-20
Wiper deicer switch

WIRING SYSTEM
No.
FB-19
Load
Ignition coil No. 1 (Turbo model)
ECM
Rear wheel speed sensor (AWD)
Fuel pump relay
FB-20

FB-21
FB-22

Combination meter
High beam relay
FB-23
Clock
Combination switch (Wiper)
Front washer motor
Front wiper motor
FB-24
FB-25
Audio
Compass mirror
Clock
Seat heater relay
TCM
Front accessory power supply socket
Remote control mirror switch
FB-26
Rear accessory relay

Rear accessory relay
FB-27
FB-28
Stop light switch

ABS control module
FB-29
VDC control module

Front fog light relay
FB-30
FB-31
Blower fan relay

Impact sensor
FB-32
FB-34
Wiper deicer and mirror heater relay

Illumination light
Clock
FB-35
FB-36
Wiper deicer and mirror heater relay

A/C pressure switch
Blower fan relay
Intake actuator
FB-37
WI-21
Ground Circuit
WIRING SYSTEM
4. Ground Circuit
FRONT TURN SIGNAL LIGHT LH
B
1
SUB FAN MOTOR

B
2
F19
F16
HEADLIGHT RH
(FRONT CLEARANCE LIGHT RH)
5
HEADLIGHT LH
(FRONT CLEARANCE LIGHT LH)
B
B
F7
HEADLIGHT BEAM LEVELER LH (HID MODEL)
F59
SIDE MARKER
LIGHT LH
B
HEADLIGHT BEAM LEVELER SWITCH

(HID MODEL)
B
B132
17
B100
FAN MODE RELAY

B
8
F27
F2
HEADLIGHT RH (HID MODEL)

6
1
F53
F21
1
F58
FRONT FOG LIGHT LH

1
5
F23
HEADLIGHT BEAM LEVELER RH (HID MODEL)

1
GND-01
GND-01
A: WIRING DIAGRAM
FWD FUSE HOLDER

B
35
F27
F7
HEADLIGHT LH (HID MODEL)
SECONDARY AIR PUMP

1
B
6
F23
F11
B
GF-1
GND-02
B
GF-2
B
B61
F44
GF-3
F11
(GRAY)
F58
F16
(GRAY)
HR
(GRAY)
F59
F19
1 2 3
F21
F53
(BLACK)
(BLACK)
B132
F7
1 2 3 4 5 6
F23
HR
(GRAY)
(BLUE)
F2
F44 (BLACK)
HR
(GRAY) 1
1 2 3 4
5 6 7 8 9
2 3 4
10 11 12 13 14 15 16 17 18 19 20
5 6 7 8
1 2 3
4 5 6
F27
1
(BLACK)
5 6 7 10 15 16 17 20 25 26 27 30
8
11
18
21
28
31
9 12 13 14 19 22 23 24 29 32 33 34
35
36
RELAY HOLDER
(BROWN)
(GRAY)
1 2
WI-14972
WI-22
Ground Circuit
WIRING SYSTEM
GND-02
OS
D7
D5
OUTER MIRROR ASSY LH

(WITH OUTER MIRROR TURN SIGNAL LIGHT)
10
REMOTE CONTROL MIRROR SWITCH

B
7
D61
B
B
WH
*1
GND-02
POWER WINDOW MAIN SWITCH
D5
4
D1
B30
STEERING ANGLE SENSOR (WITH VDC)
SEAT HEATER RELAY

B
36
B225
IGNITION RELAY
B
11
POWER WINDOW RELAY

B
16
B225
B225
REAR ACCESSORY RELAY
CLUTCH SWITCH (TURBO MT MODEL)

B
1
B104
B106
KEY LOCK SOLENOID (NON-TURBO MODEL)
B231

B A4
B A13
AT
B73
A: B280
KEY LOCK SOLENOID (TURBO MODEL)
6 BR
BR
B73
B194
WIPER DEICER SWITCH

B
4
B
7
B195
B193
GND-01
*1
AT
: AT MODEL
WH
: WITH OUTER MIRROR TURN SIGNAL LIGHT,

MIRROR HEATER
GND-03
: WITH OUTER MIRROR TURN SIGNAL LIGHT

WITHOUT MIRROR HEATER : 4
WITH OUTER MIRROR TURN SIGNAL LIGHT,
MIRROR HEATER : 5
WH
OH : WITH OUTER MIRROR TURN SIGNAL LIGHT

WITHOUT MIRROR HEATER
OS
OS
: WITHOUT OUTER MIRROR TURN SIGNAL LIGHT

WITH MIRROR HEATER
GB-1
B194 (BLACK)
B106
2 1
1
2
D61
1 2 3 4 5 6 7 8 9 10
B104 (BLACK)
1 2
3
4
B73
1 2 3 4
1
2
3 4 5 6
A: B280 (BLUE)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B193
B231
1 2
3
4 5 6 7 8
D7
D1
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
3 4
1 2
5 6 7 8 9
10 11 12 13 14 15
16 17
18 19
20 21 22 23 24 25
: OS
D5
4 3 2 1
8 7 6 5
D5
: OH
3
2 1
8 7 6 5 4
: WH
4 3
2 1
10 9 8 7 6 5
B225 (BLACK)
1
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
RELAY BLOCK
WI-23
D5
WI-15230
Ground Circuit
B:
CLOCK
10
B
i10
i59
REAR POWER WINDOW SUB-SWITCH LH

2
B
GND-03
COMBINATION METER
B10 B
D25
D22
28
i3
B270
B
B38
B
GND-03
WIRING SYSTEM
VDC OFF SWITCH (WITH VDC)
COMBINATION SWITCH (LIGHT)

10
16
B
B
B318
B71
FRONT WIPER MOTOR
2
B
FRONT DOOR SWITCH LH

B
3
B267
B8
WIPER DEICER
2
TURN SIGNAL & HAZARD MODULE

2
B
B32
B177
GND-02
B199
B177
B32
(BLACK)
1 2
3
1
2
i59
1
2
3
(GREEN)
1 2 3 4 5 6 7 8 9 10
B8
B267
HR
(GRAY)
B318 (BROWN )
B:
B71
1
9
2
10
3 4 5 6
11 12 13 14 15
7
16
8
17
GND-04
B198
1
2
3 4 5 6
1 2 3
4 5
i10
D22
D25
1 2 3
4 5 6 7 8
1 2
3
4 5 6 7 8
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
WI-15231
WI-24
Ground Circuit
R52
D15
COMPASS MIRROR
2
B101
R139
FUEL PUMP RELAY (TURBO MODEL)
IMPACT SENSOR
B46
B266
B90
B348
COMBINATION SWITCH
(WIPER)
INHIBITOR SWITCH (AT MODEL)

4
B
B12
B70
BRAKE FLUID LEVEL WARNING SWITCH

2
B
FRONT TURN SIGNAL LIGHT RH

1
B
B16
B117
DAYTIME RUNNING LIGHT RESISTOR

2
B
B268
B
B
B310
B306
B312
A/C PRESSURE SWITCH
B
3
SIDE MARKER LIGHT RH

1
B
B5
KEYLESS ENTRY CONTROL MODULE
B7
B320
B176
C
B
GND-03
WH
WH
: WITH OUTER MIRROR TURN SIGNAL

LIGHT, MIRROR HEATER
OH : WITH OUTER MIRROR TURN SIGNAL LIGHT,

WITHOUT MIRROR HEATER
OS
*1
GB-3
(GRAY)
HR
B305 (GRAY)
B5
(BROWN) B306
(GRAY)
1
55
VDC SHIELD JOINT CONNECTOR

B
5
FRONT FOG LIGHT RH

1
B
B102
FRONT DOOR SWITCH RH
B
3
VDC CONTROL MODULE
AT SELECT LEVER
5
B
6
B
B305
DAYTIME RUNNING LIGHT RELAY
5
B
14
D28
R50
3
B
B
D11
D15
D31
R56
D17
10
FRONT POWER WINDOW SUB-SWITCH RH

2
B
B
*1
REAR POWER WINDOW

SUB-SWITCH RH
B
2
SPOT MAP LIGHT

2
B
OUTER MIRROR ASSY RH

(WITH OUTER MIRROR TURN SIGNAL LIGHT)
D62
ROOM LIGHT
3
B
OS
GND-04
DOOR LOCK SWITCH (PASSENGER SIDE)

B
5
WH
GND-04
WIRING SYSTEM
R56
1
2
B320
1 2
B117
1
2
3 4 5 6
D15
: WH
4 3
2 1
10 9 8 7 6 5
B16 (GRAY)
B312
B348
1 2 3
4 5 6
1 2 3 4
5 6 7 8
B268
R52
1
2
3
1 2 3
D17
D31
1 2
3
4 5 6 7 8
2
11
3
12
4 5 6
13 14 15
1 2
3 4
1
2 3 4
5
1 2 3
4 5 6 7 8
1
2
3 4 5 6 7 8
GND-05
: WITH OUTER MIRROR TURN SIGNAL LIGHT,

WITHOUT MIRROR HEATER : 4
OUTER MIRROR TURN SIGNAL LIGHT,
WITH MIRROR HEATER : 5
B102
R50
(BLACK)
D15
: OS
8
17
9
18
(BLACK)
1 2
3 4
5 6 7 8 9
10 11 12 13 14 15
16 17
18 19
20 21 22 23 24 25
D15
(GRAY)
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
12
10
2
4
6
8
14
16
18
20
22
24
26
28
11
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
71
73
77
79 80 81 82 83
75
68
56 57 58 59 60 61 62 63 64 65 66
70
72
74
76
78
67
69
WI-25
: OH
3
2 1
8 7 6 5 4
4 3 2 1
8 7 6 5
B176
7
16
D62
1 2 3 4 5
D11
B70
1
10
1
4
2
GND-06
: WITHOUT OUTER MIRROR TURN SIGNAL

LIGHT, WITH MIRROR HEATER
B46
D28
B310
1
B7
3 2 1
HR
B12 (GRAY)
1 2 3 4
5 6 7 8
9 10 11 12
R139
OS
WI-15232
Ground Circuit
28
27
B87
AB3
B
BW
i15
BY
i26
BR A11
BR
A:
AIRBAG
CONTROL
MODULE
BLOWER
MOTOR
(AUTO A/C)
BY
BY
i29
BLOWER FAN
SWITCH
(MANUAL A/C)
AUDIO
BY
GND-05
AUDIO
BRACKET
EARTH
AUX TERMINAL BOX

3
BR
GND-05
WIRING SYSTEM
i67

B11
B:
i49
MANUAL A/C CONTROL MODULE

10
BY
i16
14
i41
10
i40
B202
BY
BR
BR
B201
FRONT ACCESSORY POWER SUPPLY SOCKET

2
B
B119
GND-05
ABS CONTROL MODULE

15
B
12
B
B119
1 2
3 4
B87
1 2 3 4 5 6
B202
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
GB-2
i15
1 2 3
4 5 6
B201
BY
B
GR
GB-4
i67
i16
1
2
3 4 5 6
3 4 5
1 2
6 7 8 9 10 11 12
(BLACK)
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
AB3
A:
18 19 20 21 22 23 24 25 26 27 28
GAB-1
13
14
i49
(GRAY)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B301
12
GA
B:
4 5 6
1 2 3
7 8 9 10 11 12 13 14
(YELLOW)
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
WI-26
i26
BW
GAB-2
BR
BY
B301
15
(BLACK)
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
WI-12272
Ground Circuit
GND-06
SEAT HEATER RH
1
B
SEAT HEATER SWITCH RH

B
3
R41
R42
SEAT HEATER SWITCH LH

3
B
SEAT BELT SWITCH

(MANUAL SEAT)
B
R15
R58
R57
REAR COMBINATION
LIGHT RH
5
R22
REAR DOOR SWITCH RH

3
B
R28
REAR DOOR SWITCH LH

B
3
R8
12
REAR COMBINATION LIGHT LH
R188
R188
R122
SEAT BELT SWITCH

(WITH POWER SEAT)
B
FUEL PUMP
(NON-TURBO MODEL)
FUEL PUMP CONTROL UNIT

(TURBO MODEL)
R188
POWER SEAT MOTOR

5
B
R79
SEAT HEATER LH
B
2
R43
TRAILER CONNECTOR
GND-06
WIRING SYSTEM
REAR ACCESSORY
POWER SUPPLY SOCKET
B
R26
R146
R201
R200
REAR WIPER INTERMITTENT UNIT

2
B
R16
R116
REAR ACCESSORY POWER SUPPLY SOCKET
R32
GND-07
R1
B97
GND-04
R147
JOINT GROUND CONNECTOR
GR-1
R32
R8
R200
1
2
R146
R16
1
2
R22
(BLACK)
R188
(BLACK)
1 2 3
5 6 7
4
8
1 2
3 4
1
2
3
2
B97
R42
R41
(BLUE)
R147
R26
R43
(BLUE)
1 2 3 4 5
R28
1
3
2
4
HR
R58
R79
R116
R57
1 2 3 4
5 6 7 8
1 2
3 4 5
6 7 8 9 10 11 12
R122
1 2 3
4 5 6
WI-14975
WI-27
Ground Circuit
GND-07
GND-07
WIRING SYSTEM
LICENSE PLATE LIGHT

2
REAR DEFOGGER
B
D79
D44
REAR WIPER MOTOR
REAR GATE LATCH SWITCH

2
D46
D43
D81
D80
HIGH-MOUNTED STOP LIGHT
LUGGAGE ROOM LIGHT

3
D82
D39
D34
R39
GND-06
D39
D44
(BLACK)
D46
1
2
(BLACK)
(BLACK)
D82
D43
D34
D80
1 2 3
1 2
3 4
1
2 3
4 5 6 7 8
1 2
3
4 5 6 7 8
2 1
WI-13100
WI-28
Ground Circuit
A:
B54
B:
B55
GND-08
GND-08
WIRING SYSTEM
A16
A27
A2
A1
BW B20
BL B22
BW B21
BL
BW
BL B23
TCM
10
18
14
20
19
B11
T4
TORQUE
CONVERTER
TURBINE
SPEED
SENSOR
FRONT WHEEL
SPEED
SENSOR
AT CONTROL(TRANSMISSION)
B11
1 2
HR
(GRAY)
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
HR
A:
B54
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
HR
B:
5 6
14 15 16
25 26 27
33 34 35
B55
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
24 25
26 27
20 21 22 23
28 29 30 31
32 33
34 35
WI-14976
WI-29
Ground Circuit
GND-09
MT
A: B134 C: B136 D: B137
: MT MODEL
ECM
(NON-TURBO MODEL)
FUEL GAUGE MAIN UNIT
15
BW
D7
BY
12
D2
BW
BrR D3
BOr D1
A5
BL
BL
B38
REF. TO
ENGINE ELECTRICAL
SYSTEM
[E/G(TB)-07]
VEHICLE SPEED SENSOR (MT MODEL)

BL
2
B17
PCV DIAGNOSIS CONNECTOR
B
E14
E15
(GRAY)
E61
(DARK GRAY)
E22
(BLACK)
1 2 3
D: B137
HR
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
1
3
2
4
(DARK
GRAY)
E23
3 2 1
6 5 4
BL
BL
REF. TO
ENGINE
ELECTRICAL
SYSTEM
[E/G(TB)-06]
B
BW
BW
BW
BW
BL
BL
BY
BY
52
BrR
37
BY
BY
BY
BW
BW
BR
BR
1
GE
(BLACK)
R58
1 2 3
4 5 6
HR
E57
1 2 3 4 5 6
FRONT OXYGEN
REAR
OXYGEN SENSOR
(A/F) SENSOR
C:
i11
(GREEN)
B98
R57
1 2 3 4 5 6 7 8 9 10
1 2
3 4 5
6 7 8 9 10 11 12
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
(BLACK)
A: B134
1 2
8 9 10
18 19 20
28 29 30
HR
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
E22
3
E23
E15
CRANKSHAFT
CAMSHAFT
POSITION SENSOR POSITION SENSOR
HR
B17
B
1
KNOCK
SENSOR
(LIGHT
GRAY)
(GRAY)
1 2
E10
ELECTRONIC
THROTTLE
CONTROL
E10
E14
2
Lg
2
RL
LgB
4
E3
36
BW
34 BOr
35
B22
E57
1
E61
i3
BW
R58
BW
i11
BW
B98
C9
C:
BW
R57
BL
COMBINATION METER
R15
R2
MT
BL C15
BW
GND-09
WIRING SYSTEM
C: B136
(BLACK)
B22
HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-14977
WI-30
Ground Circuit
BW
ECM
(TURBO MODEL)
C: B136 D: B137
: MT MODEL
MT
R15
BW

BW 2
R58
R57
BW
A: B134
GND-10
GND-10
WIRING SYSTEM
C9
BW
BW
i11
15
i3
12
A5
BL
MT
COMBINATION METER
C:
B98
BL
BL C15
D2
BW
BOr D1
BY D7
BrR D3
R2
BW
VEHICLE SPEED SENSOR (MT MODEL)
B38
BL
B17
BL
34 BOr
36
E3
BR
BW
BW
35
54
37
BR
BR
B22
BW
BY
BrR
REF. TO
ENGINE ELECTRICAL
SYSTEM
[E/G(TB)-09]
REF. TO
ENGINE ELECTRICAL
SYSTEM
[E/G(TB)-07]
MT
BR
BR
BR
BW
BW
SECONDARY AIR COMBINATION VALVE LH

(WITH BUILT-IN PRESSURE SENSOR)
W
4
YG
E61
E57
E10
E14
WR

BR 1
E41
SECONDARY AIR COMBINATION VALVE RH
W
KNOCK SENSOR
E10
CRANKSHAFT ELECTRONIC THROTTLE

POSITION SENSOR
CONTROL
E40
E61
(DARK GRAY)
E14
1 2
D: B137
HR
B17
(LIGHT
GRAY)
(LIGHT
GRAY)
(BLACK)
E41
(BLACK)
1 2
3 4
HR
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
R58
(BLACK)
E57
GE
C:
(BLACK)
i11
(GREEN)
HR
1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10
B98
R57
1 2
3 4 5
6 7 8 9 10 11 12
1 2 3
4 5 6
(BLACK)
B22
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
E40
A: B134
1 2
8 9 10
18 19 20
28 29 30
HR
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
C: B136
HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-14978
WI-31
Engine Electrical System

WIRING SYSTEM
5. Engine Electrical System

A: WIRING DIAGRAM
1. NON-TURBO MODEL
STARTER MOTOR

P
MT
C32
C20
AT
B27
B5
B8
B9
MT
ELECTRONIC
THROTTLE
CONTROL
RELAY
FRONT
OXYGEN
(A/F) SENSOR
REAR
OXYGEN
SENSOR
SHIELD & SENSOR

GROUND JOINT
CONNECTOR
DRAIN VALVE
B34
B18
B26
B35
D8
JOINT
GROUND
CONNECTOR
MASS AIR FLOW SENSOR
FUEL INJECTOR No. 1

FUEL INJECTOR No. 2
ECM
C28
C17
PRESSURE CONTROL SOLENOID VALVE
C2
C3
B1
B4
C4
C1
C21
C24
C13
A7
B2
A29
FUEL
PUMP
RELAY
A/F &
OXYGEN
SENSOR
RELAY
M/B FUSE No. 5
F/B FUSE No. 14
AT
IGNITION RELAY
MAIN
RELAY
F/B FUSE No. 11
M
MT
IG
ST
STARTER
INTERLOCK
RELAY
(MT MODEL)
STARTER RELAY
(AT MODEL)
INTERRUPT
RELAY
SBF-4
OFF ACC ON ST
ACC
FUEL
PUMP
1
2
3
4
5
CLUTCH SWITCH
(MT MODEL)
IGNITION SWITCH
SBF-5
AT
TO SECURITY
CONTROL MODULE
SBF-1
SBF-8
BATTERY
D9
D10
FUEL INJECTOR No. 3

FUEL INJECTOR No. 4
CPC SOLENOID
EGR SOLENOID VALVE
AT MODEL : TO F/B FUSE No. 11
MT MODEL : TO CLUTCH SWITCH
(CRUISE CONTROL)
FUEL TEMPERATURE SENSOR
TO STOP & BRAKE SWITCH

FUEL TANK PRESSURE SENSOR
TO CRUISE CONTROL SWITCH

TO CRUISE CONTROL WARNING LIGHT
TO CRUISE SET INDICATOR LIGHT
TO A/C PRESSURE SWITCH
TO A/C RELAY
TO A/C SWITCH
TO BLOWER FAN SWITCH
TO MAIN FAN RELAY
TO SUB FAN RELAY
TO BODY INTEGRATED UNIT/REAR DEFOGGER RELAY
MT : MT MODEL
TO LIGHTING SWITCH
D11
D29
A8
A9
A10
A20
B17
B32
C25
B20
B28
B24
B12
B6
B3
C33
C9
C23
B16
C18
C29
B14
B15
6
7
8
9
AT : AT MODEL
WI-12206
WI-32

WIRING SYSTEM
TWISTED
PAIR LINE
VEHICLE SPEED
SENSOR (MT MODEL)
MT
ABS CONTROL
MODULE
TCM
(AT MODEL)
AT
TO SPEEDOMETER
AT
AT
TWISTED
PAIR LINE
TWISTED PAIR LINE

AT
C27
C35
AT
COMBINATION METER
C16
I/F
LINE END
CONNECTOR
C6
FUSE
(RELAY BLOCK)
MT
TEST MODE
CONNECTOR
C12
C22
C11
OIL PRESSURE
SWITCH
FUEL
GAUGE
SUB UNIT
POWER
STEERING OIL
PRESSURE
SWITCH
FUEL
GAUGE
MAIN UNIT
B10
AT
NEUTRAL SWITCH
(MT MODEL)
ECM
C31
A12
THERMOMETER
I/F
A33
A34
A23
TACHOMETER
MALFUNCTION
INDICATOR LIGHT
OIL PRESSURE
WARNING LIGHT
ENGINE COOLANT
TEMPERATURE GAUGE
MT
IGNITION COIL
& IGNITOR
PCV DIAGNOSIS
CONNECTOR
OIL SWITCHING
SOLENOID VALVE RH
OIL SWITCHING
SOLENOID VALVE LH
ELECTRONIC THROTTLE
CONTROL
MT
PRESSURE SENSOR
ENGINE COOLANT
TEMPERATURE SENSOR
OIL TEMPERATURE
SENSOR
SHIELD & SENSOR GROUND

JOINT CONNECTOR
CAMSHAFT POSITION
SENSOR
A22
A13
CRANKSHAFT
POSITION SENSOR
A14
A24
A15
A25
B29
B23
B21
B31
B22
B30
A31
A32
D7
D3
D2
D1
6
7
8
9
DRIVER
B19
D18
D19
D6
D26
A30
D24
D25
D30
D31
A19
D4
D5
A28
A18
A6
A5
C15
TWISTED
PAIR LINE
DATA LINK CONNECTOR
1
2
3
4
5
KNOCK SENSOR
ACCELERATOR PEDAL
POSITION SENSOR
VVL DIAGNOSIS OIL

PRESSURE SWITCH LH
VVL DIAGNOSIS OIL
PRESSURE SWITCH RH
ENGINE GROUND
WI-12207
WI-33
E/G(NA)-01
E/G(NA)-01
WIRING SYSTEM
FUEL PUMP
RELAY
GR
FB-19
F/B FUSE NO.11
(IG)
B46
2
BR
GR
LgB
BY
E/G(NA)-03
E/G(NA)-02
E/G(NA)-06
FUEL PUMP ASSY

FUEL PUMP
BY
BY
12
RW
LB
BW
BW
BrW
LgB
RW
LB
R58
BW
BW
12
BL
BrW
BrW
BrW
LgB
LgB
10 LgB
YR
YR
YR
LB
LB
LB
BrY
BrY
BrY
BrY
BrW
YG
YL
YL
YL
E/G(NA)-03
GW
GW
GW
E/G(NA)-06
GOr
GOr
GOr
GOr 10
RY
R2
DRAIN
VALVE
HR
R68
HR
(GRAY)
R69
(BLACK)
R47
HR
(BLACK)
1 2 3
B: B135
FUELTANK
PRESSURE
SENSOR
REF. TO GND
[GND-06]
B46
R147
R58
1 2
3 4
1 2 3 4 5
1 2 3
4 5 6
HR
C: B136
B22 GW
B27 GR
C13 LgB
B10 BrW
R147
JOINT GROUND
CONNECTOR
PRESSURE
CONTROL
SOLENOID VALVE
B98
R15
RY
GOr
YR
R47
1
BrY
YG
YG
1
R69
2
R68
1
LgB
R57
11
B17 LB
R59
R59
BY
C28 LgB
FUEL GAUGE
SUB UNIT
BY
C17 BrY
FUEL GAUGE
MAIN UNIT
BY
B32 GOr
FUEL
TEMPERATURE
SENSOR
ECM
B98
R57
1 2
3 4 5
6 7 8 9 10 11 12
1 2
B: B135
1 2
3
8 9 10 11 12 13
20 21 22 23
28 29 30 31
HR
4 5
6 7
14 15 16 17 18 19
26 27
24 25
32 33
34 35
C: B136
HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
31 32
28 29 30
WI-34
5 6
14 15 16
25 26 27
33 34 35
WI-14979
E/G(NA)-02
E/G(NA)-02
WIRING SYSTEM

IG
IGNITION RELAY
(IG)
GR
GW
FB-22
F/B FUSE NO.14
(IG)
B36
B9
A: B54
COMBINATION METER
DRIVER
i10
C:
i11
A:
i12
B11
AT

(MT MODEL)
3
1
2
GW
GY
BL
MT
RW A1
I/F
- COM
B:
AT : AT MODEL
GY A21
I/F
MALFUNCTION
INDICATOR LIGHT
TEMPERATURE GAUGE
ENGINE COOLANT
BW C9
GW A3
WG C10
OIL PRESSURE
WARNING LIGHT
MT : MT MODEL
TCM
TACHOMETER
B17
17
MT
B36
G
17
13
RW
BL
WG
GW
B38
15
i1
14
i3
G
31
11
BL
REF. TO SPEEDOMETER
SYSTEM [SP-01]
E/G(NA)-07
C12 GY
OIL PRESSURE
SWITCH
C22
C11 RW
E11
BrB
E3
BrB
B22
E/G(NA)-08
WG
GW
E/G(NA)-01
E/G(NA)-05
MT
GR
i1
C: B136 ECM
B17
1 2 3
HR
(BLACK)
C:
i11
(GREEN)
1 2 3 4 5 6 7 8 9 10
A:
i12
(GREEN)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B36
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B22
HR
B:
i10
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
A: B54
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
HR
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
(BLACK)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-14980
WI-35

SBF-8
SBF HOLDER
(B)
E/G(NA)-05
WL
INTERRUPT RELAY
(WITH SECURITY SYSTEM)
BR
BR
RL
BR
B100
F44
8
F2
LR
WG
AT : AT MODEL
14 BR
15 WG
MT : MT MODEL
ST
IGNITION SWITCH
(ST)
BR
WG
MB-9
SBF-5
(B)
STARTER RELAY (AT MODEL)

REF. TO SECURITY
SYSTEM [SEC(NA)-01]
B225
B61
WL
WR
WL
RB
28 WR
E/G(NA)-03
E/G(NA)-03
WIRING SYSTEM
B59
27
26 WR
AT
MT
24 GY
B47
6
BR
YL
LR
GR
LgW
BR
LR
12
YL
11
B12
A/F & OXYGEN

SENSOR RELAY
WG
YR
LR
T7
J
K
L
M
E/G(NA)-05
E/G(NA)-06
E/G(NA)-08
E/G(NA)-06
STARTER INTERLOCK
RELAY (MT MODEL)
WR
YL
WR
GL
MT
B327
4
BW
T3
12
BY
AT
E/G(NA)-01
MAIN RELAY
28
27
26
24
B225
AT
E/G(NA)-01
LR
GL
GY
1 LgW
MT
ELECTRONIC THROTTLE CONTROL RELAY
CLUTCH SWITCH
(MT MODEL)
2
1
B106 STARTER MOTOR
C32 YL
B309
C20 GY
TO BATTERY TERMINAL
YL
YR
B5 BR
YL
A7 YL
B2
YG
C24 LgW
C1 YG
RL
C21 YR
YL
B14
A: B134 B: B135 C: B136 ECM
B106
1
2
B309 (BLACK)
1 2
3 4
A: B134
1 2
8 9 10
18 19 20
28 29 30
HR
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B59
B47
(GRAY)
1
3
5
B327 (GRAY)
1 2 3
4
5
(BROWN)
2
4
6
F44
B12
(BLACK)
HR
(GRAY)
T7
1 2 3 4 5 6
7 8 9 10 11 12
1 2 3 4
5 6 7 8
9 10 11 12
1 2 3 4
5 6 7 8
(BLACK)
F2
1 2 3 4
10 11 12 13 14
(BLUE)
5 6 7 8 9
15 16 17 18 19 20
B225 (BLACK)
B: B135
1 2
3
8 9 10 11 12 13
20 21 22 23
28 29 30 31
HR
4 5 6 7
14 15 16 17 18 19
26 27
24 25
32 33
34 35
C: B136
HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
9 14 15 16 19 24 25 26 29 34 35 36
10
27
30
17
20
37
11 12 13 18 21 22 23 28 31 32 33 38
RELAY BLOCK
WI-36
WI-14981
B: B135
LY
C23
HR
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
C: B136
B: B135
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
C: B136
WI-37
L
LR
C25
*1
B24 LgB
C15 BL
B20 RY
MT
REF. TO CRUISE CONTROL

SYSTEM
[C/C(NA)-0102]
REF. TO CLEARANCE LIGHT

& ILLUMINATION
LIGHTSYSTEM
[ILLUMI-01]
REF. TO REAR DEFOGGER

SYSTEM
[R/DEF-01]
REF. TO RADIATOR FAN

SYSTEM
[R/F-01]
REF. TO AIR CONDITIONING

SYSTEM
A/C(M)-01
A/C(AN)-01
*1
B28 WB
B12 GL
B3 GOr
B6
B15 BP
B14
C29 GR
C18 RL
B16 GB
Br
C9
C33 BrB
E/G(NA)-04
MT : MT MODEL
E/G(NA)-04

WIRING SYSTEM
: MT MODEL : BR
AT MODEL : GR
ECM
HR
5 6
14 15 16
25 26 27
33 34 35
WI-14982
E/G(NA)-05
*1
GrB C16
AT
OrL
Or
MT
E/G(NA)-03
C31
ECM
C6
C: B136
Or B19
B: B135
BL
E/G(NA)-05
WIRING SYSTEM
E/G(NA)-03
E/G(NA)-02
NEUTRAL SWITCH
(MT MODEL)
B125
MT
B126
GB
BL
B25
T2
TWISTED PAIR LINE
N
O
P
MT : MT MODEL
E/G(NA)-10
E/G(NA)-10
E/G(NA)-06
AT : AT MODEL
TEST MODE CONNECTOR
B25 (BROWN)
1 2
B75 (GREEN)
1
2
B76
1
2
(GREEN)
B40
BL
BL
GrB
BR
Or
B40
16
GW
8
14
B76
B75
1
BL
: MT MODEL : GB
AT MODEL : LR
OrL
*1
DATA LINK CONNECTOR
B: B135 HR
(BLACK)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
WI-14983
WI-38
E/G(NA)-01
E/G(NA)-06
B29
B23
B1
BY
B31
L
Lg B21
C3
W
YR B30
C2
W
B4
B8
ECM
B9
B
C: B136
B26
W
SB B35
Br B18
BG B34
B: B135
RW C4
E/G(NA)-06
WIRING SYSTEM
E
SHIELD &
SENSOR JOINT
CONNECTOR
E/G(NA)-01
E/G(NA)-05
C
P
SB
SB
BL
SB
SB
BY
B122
1
3
(DARK GRAY)
2
4
B122
1 2 3 4
5 6 7 8
RW
53
1
B
W
51
W
BW
YR
50
B
W
4
R
B3
1 2 3 4 5
FRONT OXYGEN
(A/F) SENSOR
HR
4 5 6 7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
R
S
T
U
E/G(NA)-08
E/G(NA)-08
E/G(NA)-11
E/G(NA)-07
B315
1
E/G(NA)-07
Lg
YR
GW
LW
B
2
E22
REAR OXYGEN
SENSOR
ACCELERATOR PEDAL POSITION SENSOR
B315 (BLACK)
E23
1 2 3 4 5 6
B: B135
1 2
3
8 9 10 11 12 13
20 21 22 23
28 29 30 31
HR
(BLACK)
BW
YR
YL
Br
4
E3
E23
B3
E22
B22
BG
E/G(NA)-03
E/G(NA)-03
(BLACK)
3 2 1
6 5 4
5 6
14 15 16
25 26 27
33 34 35
(BLACK)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B22
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-14984
WI-39

E/G(NA)-07
B
G
B
G
SB A24
A13
A14
W
R
W
R
A12
A22
A15
W
W
BY A34
BY
A18
A28
B22
12
13
14
15
16
B
W
RL
E3
G
L
8
RW
17
18
LgB
Lg
YG
G
E10 (LIGHT GRAY)
(LIGHT GRAY)
E57
B137
HR
A:
B134
HR
1
2
B22
1 2
8 9 10
18 19 20
28 29 30
(BLACK)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
G
L
BR
BW
BW
CAMSHAFT
POSITION
SENSOR
GE
(BLACK)
1 2 3 4 5 6
1 2
D:
BR
CRANKSHAFT
POSITION
SENSOR
(BLACK)
1 2 3
1 2
3
1
2
1
3
2
KNOCK
SENSOR
E/G(NA)-09
E15
E10
E14
ENGINE COOLANT
TEMPERATURE
SENSOR
& THERMOMETER
E21
B
W
RL
LW
P
LW
5
3
E8
ELECTRONIC
THROTTLE
CONTROL
E8
LW
BL
RW
LgB
4
YG
G
1
2
1
3
2
E57
PRESSURE SENSOR
(GRAY)
BrW D4
Br D5
39 BrW
38 Br
E21
(GRAY)
ECM
Lg
E/G(NA)-06
E15
YB A6
Sb A19
RG A29
LY
P
LW
LY
P
LW
E/G(NA)-02
E14
D: B137
7
20
19
E/G(NA)-06
YB
Sb
RG
A: B134
SB A25
E/G(NA)-07
WIRING SYSTEM
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
WI-14985
WI-40

E/G(NA)-08
A30
YL D18
GW D19
YL
GW
D26
B
B
WG
D6
D7
BrR D3
37 BrR
A5
BW D2
BW
BL
BOr D1
34 BOr
MT
OrB A33
BY
ECM
D: B137
P
10
33
E3
BL
32
GB
BrG
GB
BrG
RG
49
YW
47
BY
BL
36
52
BL
BY
RG
YW
E/G(NA)-06
BW
4
WG
LOr
B22
MT
(DARK GRAY)
E12
B225 (BLACK)
2
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
RELAY HOLDER
BL
BL
IGNITION COIL
& IGNITOR
GE
(DARK GRAY)
1 2 3 4
1 2
E61
E12
: MT MODEL
POWER STEERING OIL

PRESSURE SWITCH
E61
BW
BW
BY
BY
E19
BL
LOr
E/G(NA)-06
BW
35
E/G(NA)-02
BY
E/G(NA)-03
B225
GR
15A
(FUSE)
RELAY HOLDER
C: B136
OrB
A: B134
BL C15
E/G(NA)-08
WIRING SYSTEM
D: B137
HR
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
A: B134
1 2
8 9 10
18 19 20
28 29 30
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
HR
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
5 6
14 15 16
25 26 27
33 34 35
PCV DIAGNOSIS
CONNECTOR
B22
(BLACK)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-14986
WI-41
LW D31
LB D30
RW D25
RB D24
LW
LB
RW
RB
A31
R
R
A32
L
L
ECM
Or A23
D: B137
Or
A: B134
E/G(NA)-09
E/G(NA)-09
WIRING SYSTEM
24
23
28
27
21
22
B22
WL
LY
WL
LY
YG
GB
YG
GB
B
B
E72
E71
OIL TEMPERATURE
SENSOR
VVL DIAGNOSIS
OIL PRESSURE
SWITCH LH
E69
(BLUE)
D: B137 HR
E70
(BLUE)
E75
(BLACK)
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
28 29
30 31
26 27
VVL DIAGNOSIS
OIL PRESSURE
SWITCH RH
E69
E70
E75
OIL SWITCHING
SOLENOID VALVE LH
OIL SWITCHING
SOLENOID VALVE RH
A: B134 HR
1 2
8 9 10
18 19 20
28 29 30
1 2
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
LW
E/G(NA)-07
E3
B22
(BLACK)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-14987
WI-42

E/G(NA)-10
E/G(NA)-10
WIRING SYSTEM
B301
W
AT
26
B
TWISTED PAIR LINE
A:
B301 (BLACK)
12 13 14 15
1 2 3 4 5 6 7 8 8 10 11
16 17 18 19 20 21 22 23 24 25 26
B54
TCM
C: B136
C27 W
A17
A18 W
AT
AT : AT MODEL
C35
E/G(NA)-05
TWISTED PAIR LINE
AT
TWISTED PAIR LINE
TWISTED PAIR LINE
E/G(NA)-05
AT
11
ABS
CONTROL
MODULE
ECM
A: B54 HR
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
WI-14988
WI-43

E/G(NA)-11
PL
PB D10
PG D11
YL
PL
PB
PG
48
42
43
44
45
D8
GR A20
GR
30
A8
A10
L
L
29
A9
RY
YR
RY
YR
25
ECM
E16
Or
Or
LB
BR
LB
BR
GOr
E17
1
E6
1
GOr
LB
2
B22
E3
LB
BrY
LB
E5
E18
3
E4
BrY
YB
YB
LB
BrG
BrG
LB
RY
GY
RY
YR
LB
GY
WL
41
YR
E/G(NA)-06
D: B137
26
WL D29
A: B134
D9
E/G(NA)-11
WIRING SYSTEM
EGR SOLENOID VALVE

CPC SOLENOID
FUEL INJECTOR
No. 1
E4
(BLACK)
E5
(DARK GRAY)
E18
E6
1 2 3
(DARK GRAY) 4 5 6
E16
(DARK GRAY)
E17
(DARK GRAY)
(DARK GRAY)
D: B137
HR
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
FUEL INJECTOR
No. 2
FUEL INJECTOR
No. 3
FUEL INJECTOR
No. 4
A: B134 HR
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B22
(BLACK)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
1 2
WI-14989
WI-44

WIRING SYSTEM
WI-45

WIRING SYSTEM
2. TURBO MODEL
TO SECURITY
CONTROL MODULE
IGNITION SWITCH
SBF-4
OFF ACC ON ST
N
INTERRUPT
RELAY
B
ACC
ST
No. 5
No. 14
D
3
2
1
IGNITION RELAY
CLUTCH SWITCH
(MT MODEL)
1
2
3
4
5
AT
C32
MT
M/B FUSE
F/B FUSE
No. 11
F/B FUSE
10A
SBF-5
IG
AT
AT
B19
B5
C23
FUEL
PUMP
RELAY
MAIN
RELAY
ELECTRONIC
THROTTLE
CONTROL
RELAY
FRONT OXYGEN (A/F) SENSOR
B9
B8
REAR OXYGEN SENSOR
C2
C3
C4
B4
FUEL PUMP
CONTROL UNIT
WASTEGATE CONTROL SOLENOID VALVE

FUEL INJECTOR No.1
FUEL
PUMP
FUEL INJECTOR No.2

FUEL INJECTOR No.3
FUEL INJECTOR No.4
CPC SOLENOID No.1
JOINT
GROUND
CONNECTOR
CPC SOLENOID No.2
SHIELD & SENSOR

GROUND JOINT
CONNECTOR
DRAIN VALVE
PRESSURE CONTROL SOLENOID VALVE
*1
FUEL TEMPERATURE SENSOR

FUEL TANK PRESSURE SENSOR
SECONDARY AIR
COMBINATION VALVE RH
SECONDARY AIR COMBINATION VALVE RELAY 2
TO STOP &
BRAKE SWITCH
TO CRUISE CONTROL SWITCH

TO CRUISE CONTROL WARNING LIGHT
TO CRUISE SET INDICATOR LIGHT
TO A/C PRESSURE SWITCH
TO A/C RELAY
TO A/C SWITCH
TO BLOWER FAN SWITCH
TO MAIN/SUB FAN RELAY 1
TO MAIN/SUB FAN RELAY 2
TO BODY INTEGRATED UNIT
(REAR DEFOGGER RELAY)
SECONDARY AIR
COMBINATION VALVE LH
TO LIGHTING SWITCH
TO IMMOBILIZER
CONTROL MODULE
(WITH BUILT-IN
PRESSURE SENSOR)
C21
C1
C12
B33
A7
B2
D29
B18
B34
B26
B35
D8
D9
D10
D11
D29
C7
C17
C28
B17
B30
ECM
60A
STARTER MOTOR
MT
SBF-1
STARTER
INTERLOCK RELAY
(MT MODEL)
BATTERY
B1
B32
C25
B20
B28
B24
B12
B6
B3
C33
C9
C24
B16
C18
C29
B14
B15
C26
C34
C19
A27
C30
C8
6
7
8
9
10
11
WI-12217
SECONDARY AIR PUMP
SECONDARY AIR PUMP RELAY
WI-46

WIRING SYSTEM

(MT MODEL)
MT
TWISTED PAIR
LINE
VDC
CONTROL
MODULE
ABS
ABS
CONTROL
MODULE
ABS
VDC
TWISTED PAIR LINE
TWISTED PAIR LINE

LINE END CHECK CONNECTOR
MT
MT
OIL PRESSURE
SWITCH
NEUTRAL SWITCH
(MT MODEL)
THERMOMETER
AT
ECM
A29
A21
A11
FUEL
GAUGE
TEST MODE CONNECTOR
C31
ENGINE COOLANT
TEMPERATURE GAUGE
OIL PRESSURE
WARNING LIGHT
MT
IGNITION COIL No.1
IGNITION COIL No.2
IGNITION COIL No.3
IGNITION COIL No.4
TGV LH
TGV RH
ABS : WITHOUT VDC
AVCS SOLENOID LH
VDC : WITH VDC
AVCS SOLENOID RH
ELECTRONIC THROTTLE CONTROL
PRESSURE SENSOR
MT
TGV POSITION SENSOR LH

TGV POSITION SENSOR RH
ENGINE COOLANT
TEMPERATURE SENSOR
SHIELD &
SENSOR
GROUND
JOINT
CONNECTOR
AVCS CAMSHAFT POSITION SENSOR LH

AVCS CAMSHAFT POSITION SENSOR RH
CRANKSHAFT
POSITION SENSOR
A13
A14
A24
A15
A25
B22
B31
B21
B29
B23
A30
KNOCK SENSOR
ACCELERATOR PEDAL
POSITION SENSOR
D2
A22
D3
D1
A33
D7
6
7
8
9
10
11
TACHOMETER
MALFUNCTION
INDICATOR LIGHT
FUEL
GAUGE
A34
I/F
AT
B27
D18
D19
D20
D6
D26
D21
D12
D13
D22
D23
D15
D14
D17
D16
D4
D5
A18
A28
A19
A6
A5
C15
C6
A16
A26
COMBINATION METER
I/F
AT
C35
C16
C13
C22
C11
B10
TWISTED PAIR LINE
VDC
TWISTED PAIR LINE
C27
STEERING
ANGLE
SENSOR
TCM (AT MODEL)
DRIVER
1
2
3
4
5
AT
- COM
DATA LINK
CONNECTOR
AT MODEL : TO F/B FUSE No.11

*1 MT
MODEL : TO CLUTCH SWITCH
(CRUISE CONTROL)
AT : AT MODEL
POWER
STEERING
OIL
PRESSURE
SWITCH
ENGINE GROUND
MT : MT MODEL
ENGINE GROUND
WI-15233
WI-47

WIRING SYSTEM
E/G(TB)-01
E/G(TB)-01
FUEL PUMP RELAY

BR
GR
BY
FUEL PUMP
CONTROL UNIT
FB-19
F/B FUSE NO.11
(IG)
GR
B46
FUEL PUMP ASSY
BY
1
5
2
4
6
B
LgR
LgB
BW
BOr
BY
B99
7
BY
R57
1
BY
BY
BOr
LgR
21 LgR
12
BW
LgB
RW
LB
R3
R2
2
BW
BW
BW
BW
12
BL
BrW
BrW
BrW
BrW
LgB
LgB
LgB
10 LgB
RW
YR
LB
LB
LB
BrY
BrY
BrY
YG
YL
YL
YL
GW
GW
GW
GOr 10
GOr
GOr
GOr
YR
YR
YR
PRESSURE
DRAIN
CONTROL
VALVE
SOLENOID VALVE
D
E
E/G(TB)-03
E/G(TB)-06
R47
HR
(BLACK)
1 2 3
(BLACK)
JOINT GROUND
CONNECTOR
B: B135
C: B136
B19 GR
RY
R147
R47
FUELTANK
PRESSURE
SENSOR
HR
E/G(TB)-06
11
GOr
R
3
R69
YG
BrY
YG
R68
1
LgB
RY
B33 LgR
BrW
R59
3
4
C12 LgB
LB
BrY
C28 LgB
B10 BrW
B17 LB
FUEL GAUGE
SUB UNIT
B99
B98
3
R58
E/G(TB)-02
LgB
C17 BrY
FUEL GAUGE
MAIN UNIT
R69
E/G(TB)-10
REF. TO GND
[GND-04]
R15
B32 GOr
FUEL
TEMPERATURE
SENSOR
HR
R68 (GRAY)
E/G(TB)-03
R122
FUEL PUMP
R59
A
B
B
R3
ECM
REF. TO GND
[GND-06]
HR
B46
R147
R58
1 2
3 4
1 2 3 4 5
R122
R57
1 2 3
4 5 6
1 2
3 4 5
6 7 8 9 10 11 12
B98
1 2
B99
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
B: B135
HR
C: B136
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
24 25
26 27
20 21 22 23
28 29 30 31
32 33
34 35
HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
WI-14990
WI-48
E/G(TB)-02
E/G(TB)-02
WIRING SYSTEM

IG
IGNITION RELAY
(IG)
GR
GW
FB-22
F/B FUSE NO.14
(IG)
B36
MT : MT MODEL
GR
i1
: AT MODEL
B9
AT
I/F
COMBINATION METER
DRIVER
i10
C:
i11
A:
REF. TO SPEEDOMETER SYSTEM

[SP-01]
B11
G
G
17
B36
B54
TCM

(MT MODEL)
GW
GY
BL
MT
MT
B17
G
C22
C11 RW
C: B136
HR
(BLACK)
1 2
3 4
C:
i11
(GREEN)
1 2 3 4 5 6 7 8 9 10
B:
i10
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
E/G(TB)-10
E/G(TB)-09
E/G(TB)-10
E/G(TB)-08
C13 GY
E/G(TB)-01
3
1
2
RW
i1
B38
E/G(TB)-05
MT
B:
GY A21
i12
I/F
A1
RW
17
13
15
BW
WG
GW
14
i3
B17
A:
AT
- COM
RW
TEMPERATURE GAUGE
MALFUNCTION
INDICATOR LIGHT
ENGINE COOLANT
C9
WG C10
BW
BW
GW A3
GW
WG
OIL PRESSURE
WARNING LIGHT
TACHOMETER
ECM
A:
i12
(GREEN)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
B36
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
A:
B54
HR
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
31 32
28 29 30
HR
5 6
14 15 16
25 26 27
33 34 35
WI-14991
WI-49

ST
IGNITION SWITCH
(ST)
: AT MODEL
BR
BR
AT
BR
: MT MODEL
BR
MT
F2
14
F44
REF. TO SECURITY
SYSTEM [SEC(TB)-01]
B100
WL
WR
WL
RB
RL
LR
B61
BR
B59
AT
AT
MT
E/G(TB)-01
A
D
MAIN RELAY
WR
12
YL
11
B12
BW
T7
LR
E/G(TB)-05
YR
E/G(TB)-06
BR
E/G(TB)-06
YL
LgW
BR
STARTER INTERLOCK
RELAY (MT MODEL)
AT
MT
B225
B47
WR
YL
WR
GY
ELECTRONIC THROTTLE
CONTROL RELAY
RL
YG
YL
YR
12
BY
T3
E/G(TB)-01
E/G(TB)-05
INTERRUPT RELAY
(WITH SECURITY SYSTEM)
WL
MB-9
SBF-5
(B)
E/G(TB)-03
E/G(TB)-03
WIRING SYSTEM
28
27
26
24
B106
GY
B
CLUTCH SWITCH
(MT MODEL)
2
1
STARTER MOTOR
B309
YL
BR
B2
B5
C32 YL
YL
A7
C1
C21 YR
YG
C23 LgW
TO BATTERY
TERMINAL
YL
B14
A: B134
B106
1
2
B309
(BLACK)
1 2
3 4
B59
1 2 3
4
5
B: B135
(GRAY)
B47
1
3
5
C: B136
(BROWN)
2
4
6
REF. TO GND
[GND-02]
ECM
F44
1 2 3
5 6 7
B12
(BLACK)
4
8
HR
(GRAY)
T7
1 2 3 4
5 6 7 8
9 10 11 12
(BLACK)
1 2 3 4 5 6
7 8 9 10 11 12
F2
1 2 3 4
10 11 12 13 14
(BLUE)
5 6 7 8 9
15 16 17 18 19 20
B225 (BLACK)
A: B134 HR
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B: B135 HR
C: B136
1 2
3 4 5 6
7
8 9 10 11 12 13 14 15 16 17 18 19
24 25
26 27
20 21 22 23
28 29 30 31
32 33
34 35
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
31 32
28 29 30
HR
5 6
14 15 16
25 26 27
33 34 35
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
RELAY BLOCK
WI-50
WI-14992
*1
B: B135 HR
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
24 25
26 27
20 21 22 23
28 29 30 31
32 33
34 35
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
LR
B: B135
Br
C: B136
WI-51
L
C34 RW
C26 YL
B15 BP
B14
C29 GR
C18 RL
B16 GB
C24 LY
C9
C33 BrB
B3 GOr
B6
B12 GL
B24 LgB
B28 WB
*1
B20 RY
C25
REF. TO IMMOBILIZER
SYSTEM [IMB-02]
REF. TO CLEARANCE LIGHT

& ILLUMINATION
LIGHTSYSTEM
[ILLUMI-01]
REF. TO REAR DEFOGGER

SYSTEM [R/DEF-01]
REF. TO RADIATOR FAN

SYSTEM [R/F-01]
E/G(TB)-04
REF. TO AIR CONDITIONING

SYSTEM [A/C(AT)-01]
REF. TO CRUISE CONTROL

SYSTEM [C/C(TB)-0102]
E/G(TB)-04

WIRING SYSTEM
: MT MODEL :BR
AT MODEL :GR
ECM
C: B136 HR
5 6
14 15 16
25 26 27
33 34 35
WI-14993
C31
ECM
*1
Or
AT
NEUTRAL SWITCH
(MT MODEL)
MT
E/G(TB)-03
E/G(TB)-05
C: B136
B27
B: B135
GrB C16
E/G(TB)-05
WIRING SYSTEM
GB
BL
LgY
LgY
B128
T12
T2
Or
MT
E/G(TB)-03
T9
MT : MT MODEL
LINE END
CONNECTOR
OrL
AT : AT MODEL
1 : MT MODEL : GB
AT MODEL : WR
Q
R
B126
HR
B76 (GREEN) T12 (BROWN) B128 (GRAY)
1
2
1 2
1 2
3 4
BL
BL
BR
GrB
Or
GW
16
DATA LINK CONNECTOR
TEST MODE CONNECTOR
1
2
E/G(TB)-13
B40
14
BL
B76
B75
B75 (GREEN)
E/G(TB)-13
OrL
E/G(TB)-02
E/G(TB)-09
TWISTED PAIR LINE
B125
B40 (BLACK)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
HR
HR
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B: B135
5 6
14 15 16
25 26 27
33 34 35
1 2
3
8 9 10 11 12 13
20 21 22 23
28 29 30 31
4 5 6 7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
WI-14994
WI-52
E/G(TB)-06
B29
B23
B1
BY
B4
W
B31
C4
RW
B8
Lg B21
B9
GW B22
C3
ECM
D: B137
C2
C: B136
YR B30
B26
W
SB B35
Br B18
BG B34
BW D27
B: B135
E/G(TB)-06
WIRING SYSTEM
S
E/G(TB)-01
E/G(TB)-09
E
SHIELD &
SENSOR JOINT
CONNECTOR
E/G(TB)-01
BY
SB
SB
B122
YR
T
YR
O
RW
E/G(TB)-03
E/G(TB)-03
E/G(TB)-11
B18
YR
Lg
GW
B315
YR
W
YR
Br
YL
BG
YL
BW
YR
B262
B3
B127
WB
T5
B127 (BLUE)
B18
1 2
1
3
D: B137
FRONT OXYGEN
(A/F) SENSOR
MASS AIR
FLOW SENSOR
WASTEGATE CONTROL
SOLENOID
2
4
HR
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
28 29
30 31
26 27
HR
(GRAY)
T6
1 2
3 4
(DARK GRAY) B262 (GRAY)
2
4
HR
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
24 25
26 27
20 21 22 23
28 29 30 31
32 33
34 35
REAR OXYGEN
SENSOR
B3
HR
(BLACK)
1 2 3 4 5
1
3
B: B135
T6
ACCELERATOR PEDAL
POSITION SENSOR
B315 (BLACK)
1 2 3 4 5 6
C: B136
B122
1 2 3 4
5 6 7 8
HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
WI-14995
WI-53
E/G(TB)-07
A15
A14
B
B
(LIGHT GRAY)
E14 (LIGHT GRAY)
E36
(LIGHT GRAY)
1 2 3
A13
W
W
E35
1
5
9
13
2
6
10
14
3
7
11
15
A: B134
1 2
8 9 10
18 19 20
28 29 30
13
W
E/G(TB)-11
E/G(TB)-09
BL
E/G(TB)-09
1
KNOCK
SENSOR
HR
3 4
5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
E14
CRANKSHAFT
POSITION
SENSOR
HR
(BROWN)
4
8
12
16
3
B20
8
WR
W
W
WR
RY
WL
(LIGHT GRAY)
E1
E10
AVCS CAMSHAFT
POSITION
SENSOR RH
AVCS CAMSHAFT
POSITION
SENSOR LH
1 2
SB A25
A11
W
W
1
GR
2
GY
E36
E35
E10
A21
R
R
GR
WL
WL
E3
ECM
B20
RY
B22
GY
17 LgR
LgR A22
A: B134
SB A24
E/G(TB)-07
WIRING SYSTEM
B22
(BLACK)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-14996
WI-54
E/G(TB)-08
A30
R
R
L
L
LG D22
LY
LY
YG D23
R
R
LG
D16
L
L
YG
RY D14
D17
Gr
RY
D13
ECM
21
E3
LR
32
B22
PL
22
WL
YL
33
24
WB
GB
28
27
LB
YB
GW
31
9
RY
23
OrB
E/G(TB)-02
D: B137
Gr
OrB A33
D15
A: B134
D12
E/G(TB)-08
WIRING SYSTEM
AVCS
SOLENOID LH
TGV LH
LR
BR
PL
TGV RH
E/G(TB)-10
E61
E55
E51
E38
AVCS
SOLENOID RH
WL
YL
WB
GB
LB
E37
E11
E19
YB
RY
PCV DIAGNOSIS
CONNECTOR
POWER STEERING
OIL PRESSURE
OIL PRESSURE SWITCH
SWITCH
E37
(BLUE)
E38
(BLUE)
E51
(BLACK)
E55
(BLACK)
E61
(DARK GRAY)
D: B137
HR
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
A: B134 HR
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B22
(BLACK)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
1 2
WI-14997
WI-55
E/G(TB)-09
ECM
BL
C6
RY A26
YB
A6
RG A29
BY A34
Sb A19
A28
R
BY
BrR
BrW
Br
D7
D3
D4
D5
W A18
A: B134 C: B136 D: B137
BrY A16
E/G(TB)-09
WIRING SYSTEM
SHIELD &
SENSOR
JOINT CONNECTOR
E/G(TB)-06
E/G(TB)-05
E/G(TB)-02
BL
SB
SB
R
B20
16
15
B22
54 BY
37 BrR
39 BrW
38 Br
B122
E1
RY
BrY
YB
BY
RG
Sb
WG
BR
BR
W
B
E3
10
11
WR
Or
YR
19
8
H
BL
E/G(TB)-10
E/G(TB)-10
E/G(TB)-12
E/G(TB)-12
E54
WR
E50
BL
Or
YR
BL
E21
E8
BL
BL
WG
E57
U
W
W
E/G(TB)-07
E3
Y
Z
a
b
YG
E/G(TB)-07
BL
WG
20
B22
GE
ENGINE COOLANT
TEMPERATURE
SENSOR
ELECTRONIC
THROTTLE
CONTROL
E8
(LIGHT GRAY)
1 2
3
E21
(BLACK)
E57
E50
(BLACK)
1 2 3 4 5 6
E54
(BLACK)
(BLACK)
B122
B20
1 2 3 4
5 6 7 8
1 2 3
D: B137 HR
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
A: B134 HR
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
TGV
POSITION
SENSOR LH
PRESSURE
SENSOR
1
5
9
13
2
6
10
14
3
7
11
15
WI-56
HR
(BROWN)
4
8
12
16
B22
(BLACK)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
TGV
POSITION
SENSOR RH
5 6
14 15 16
25 26 27
33 34 35
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-14998
E32
E33
E34
E/G(TB)-10
BL C15
A5
BW
36
BR
BW
35
BW
53
16
E31
E32
E33
E34
IGNITION COIL
No.1
IGNITION COIL
No.2
IGNITION COIL
No.3
IGNITION COIL
No.4
D: B137
HR
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
(BLACK) 18 19 20 21 22 23
24 25
26 27
28 29
30 31
(BLACK)
A: B134
1 2
8 9 10
18 19 20
28 29 30
HR
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
GE
C: B136
HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B22
5 6
14 15 16
25 26 27
33 34 35
(BLACK)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
1
2
3
E/G(TB)-12
BR
BW
BR
BR
BW
BY
BY
BrY
BY
LY
BY
GY
3
E31
E3
E/G(TB)-09
B22
X
Y
Z
E/G(TB)-09
49
R
E/G(TB)-08
BY
: MT MODEL
MT
15
BrY
E/G(TB)-01
14
LY
E/G(TB)-02
13
GY
E/G(TB)-02
GR
MT
BL
BL
BOr D1
D6
D26
B
B
34 BOr
YG D21
YG
D2
YR D20
YR
D18
YB D19
ECM
YB
D: B137
C: B136
A: B134
BW
E/G(TB)-10
WIRING SYSTEM
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-14999
WI-57
B100
E/G(TB)-11
PG D11
PB D10
D9
PL
PG
E3
BrR
LW
44
43
45
B22
42
GW
GW
PB
PL
WR
50
E/G(TB)-12
(DARK GRAY)
E4
E6
(DARK GRAY)
E52
E16
(DARK GRAY)
1 2
E17
(DARK GRAY)
(BLACK)
D: B137 HR
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
26 27
28 29
30 31
R
2
FUEL
INJECTOR
No. 3
E17
E6
2
BrR
LW
R
F2
E16
FUEL
INJECTOR
No. 2
FUEL
INJECTOR
No. 1
CPC SOLENOID
No. 2
1 2 3 4
10 11 12 13 14
E5
1
E52
CPC SOLENOID
No. 1
E5
E4
1 2
GY
48
R
GY
GY
E/G(TB)-07
D8
YL
GY
15
YL
YL
WL
ECM
F2
41
E/G(TB)-06
D: B137
WR C7
WL D29
C: B136
E/G(TB)-11
WIRING SYSTEM
FUEL
INJECTOR
No. 4
(BLUE)
5 6 7 8 9
15 16 17 18 19 20
B22
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
(BLACK)
5 6
14 15 16
25 26 27
33 34 35
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-15000
WI-58
21
LW
22
YL
24
TO POWER
SUPPLY CIRCUIT
MB-1
SBF-1
(B)
10
WL
11
RW
12
YL
14
LW
RW
LW
F27
WL
SECONDARY AIR
COMBINATION
VALVE RELAY 1
20
F2
B100
NO.10
LW
RW
d
c
E/G(TB)-09
WL
12
WG
13
WG
WR
YL
Or
4
5
3
6
60A
RY
BR
E3
SECONDARY AIR
PUMP RELAY
9
Or
Or
20
Y
16
Y
F9
E/G(TB)-09
10A
SBF-9
47
46
B22
E/G(TB)-10
SECONDARY AIR
RELAY HOLDER
(FUSE)
F9
F27
E/G(TB)-11
E/G(TB)-12
RW
E/G(TB)-12
WIRING SYSTEM
F2
SECONDARY AIR PUMP
B100
2
1
WR
B
Or
C30
C8
C19
1
2
ECM
SECONDARY AIR
COMBINATION
VALVE LH
(WITH BUILT-IN
PRESSURE SENSOR)
E40
A27
W
B
BR
RY
BL
F11
A: B134
C: B136
E41
SECONDARY AIR
COMBINATION VALVE RH
F11
(GRAY)
E40
(BLACK)
1 2
E41
1 2 3
4 5 6
(BLACK)
F9
(BLACK)
1
3
4
5
6
7 8 9
10
11
F2
1 2 3 4
10 11 12 13 14
12
13
RELAY HOLDER
C: B136
HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
A: B134 HR
(BLUE)
5 6 7 8 9
15 16 17 18 19 20
F27
REF. TO GND
[GND-01]
1 2
8 9 10
18 19 20
28 29 30
(BLACK)
5 6 7 10 15 16 17 20 25 26 29 30
35
8
11
18
21
27
31
9 12 13 14 19 22 23 24 28 32 33 34 36
RELAY HOLDER
WI-59
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B22
(BLACK)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-15001
E/G(TB)-05
83
TWISTED PAIR LINE
81
26
TWISTED PAIR LINE
ABS
TWISTED PAIR LINE

VDC
ABS
VDC
CONTROL
MODULE
C27
W
C35
TWISTED PAIR LINE
TWISTED PAIR LINE
E/G(TB)-05
B310
ABS
CONTROL
MODULE
E/G(TB)-13
B301
ECM
C: B136
11
E/G(TB)-13
WIRING SYSTEM
AT : AT MODEL
ABS : WITHOUT VDC
AT
A17
A18 W
AT
VDC : WITH VDC
TWISTED PAIR LINE
TWISTED PAIR LINE
VDC
B231
A:
B54
TCM
STEERING
ANGLE SENSOR
B301 (BLACK)
B231
12 13 14 15
1 2 3 4
1 2 3 4 5 6 7 8 8 10 11
16 17 18 19 20 21 22 23 24 25 26
B310 (BLACK)
1
A: B54
HR
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
2
4
6
8
14
16
18
20
22
24
26
28
12
10
11
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
71
73
77
79 80 81 82 83
75
68
56 57 58 59 60 61 62 63 64 65 66
70
72
74
76
78
67
69
WI-15234
WI-60

WIRING SYSTEM
WI-61
AT Control System
WIRING SYSTEM
6. AT Control System
A: WIRING DIAGRAM
BATTERY
SBF-1
SBF-4
SBF-2
SBF-5
IGNITION SWITCH
OFF ACC ON ST
B
F/B FUSE No. 4
M/B FUSE No. 5
F/B FUSE No. 11
F/B FUSE No. 14
F/B FUSE No. 16
M/B FUSE No. 4
ACC
IG
ST
IGNITION RELAY
B12
B1
B2
STOP LIGHT SWITCH
A20
B25
COMBINATION METER
B26
B27
B13
B15
B3
TO SHIFT LOCK SOLENOID / DIODE

TO SPEEDOMETER
A21
TCM
ATF TEMP.
WARNING LIGHT
- COM
FWD PILOT LIGHT/

AWD WARNING LIGHT
A14
A13
A11
A10
I/F
A8
A7
A19
P
B10
R
RELAY HOLDER
(FWD SWITCH)
LCD
(ODO/TRIP OUT TEMP)
I/F
A22
N
D
3
2
1
INHIBITOR SWITCH
4
WI-12232
WI-62
AT Control System
WIRING SYSTEM
ABS
CONTROL
MODULE
VDC
CONTROL
MODULE
DATA LINK
CONNECTOR
1
2
ABS
VDC
ABS
A18
A17
VDC
B8
ABS : WITHOUT VDC
ECM
STEERING
ANGLE
SENSOR
VDC : WITH VDC
B11
ATF TEMPERATURE SENSOR
A23
A12
LINE PRESSURE LINEAR SOLENOID
A3
A4
LOW CLUTCH DUTY SOLENOID
TCM
B7
HIGH CLUTCH DUTY SOLENOID
B6
LOW & REVERSE DUTY SOLENOID
B5
2-4 BRAKE DUTY SOLENOID
B4
LOCK-UP DUTY SOLENOID
A6
AWD DUTY SOLENOID
A5
B20
B21
B22
B23
A27
FRONT WHEEL
SPEED SENSOR
A16
TORQUE
CONVERTER
TURBINE SPEED
SENSOR
A1
A2
A26
REAR WHEEL
SPEED SENSOR
(AWD)
A15
4
WI-15235
WI-63
AT Control System
WIRING SYSTEM
AT-01
AT-01
GR
FB-22
F/B FUSE NO.14
(IG)
B36
B9
GR
i1
AT-02
COMBINATION
METER
- CPU
B:
i10
LCD
(ODO/TRIP OUT TEMP)
AT SPORT SHIFT
INHIBITOR SWITCH
1
RL
10
LG
Lg
WG
11
BY
Gr
LB
LB
T3
T7
B12
A:
B54
A19 LB
GR
Gr
LW
A7
A8
A10 WG
A11 Lg
A13 RL
A14 GR
TCM
REF. TO GND
[GND-04]
B12
HR
(GRAY)
T7
1 2 3 4
5 6 7 8
9 10 11 12
(BLACK)
1 2 3 4 5 6
7 8 9 10 11 12
B36
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B:
i10
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
HR
A:
B54
1
2
3
4
5
6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
31 32 33 34 35
28 29 30
WI-15003
WI-64
AT Control System
AT-02
RELAY HOLDER
(FWD SWITCH)
A
I/F
i11
36
A:
i12
35
i10
C:
F27
B
B:
BR
COMBINATION
METER
- CPU
A2
YG
WR B14
C4
I/F
YL
AWD WARNING LIGHT/

FWD PILOT LIGHT
AT-01
ATF TEMP. WARNING LIGHT
AT-02
WIRING SYSTEM
BR
E
F2
1
B38
BR
WR
A22 WR
REF. TO GND
[GND-01]
B100
A:
C:
i11
(GREEN)
1 2 3 4 5 6 7 8 9 10
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
A:
i12
B54
B: B55
TCM
F2
(GREEN)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
A:
B54
HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4
10 11 12 13 14
B:
B55
1 2
3
8 9 10 11 12 13
20 21 22 23
28 29 30 31
B10 BR
A21 GY
REF. TO
SPEEDOMETER SYSTEM
[SP-01]
YG
B15 YG
YL
B13 YL
i3
B:
(BLUE)
5 6 7 8 9
15 16 17 18 19 20
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
HR
4 5 6 7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
i10
F27
1
(BLACK)
5 6 7 10 15 16 17 20 25 26 27 30
8
18
28
11
21
31
9 12 13 14 19 22 23 24 29 32 33 34
35
36
RELAY HOLDER
WI-15004
WI-65
AT Control System
WIRING SYSTEM
YB
YR
GR
IG
IGNITION RELAY
(IG)
MB-9
SBF-5
(B)
BR
YR
F44
7
12
F45
B61
YR
BR
B62
STOP LIGHT
SWITCH
LY
WB
TWISTED PAIR LINE

A:
B65
(BLACK)
1 2
3 4
F44
1 2 3
5 6 7
B:
(BLACK)
4
8
B54
B:
B55
B40
G
C22
TCM
C: B136
(BLACK)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
F45
(BLACK)
7 8 9 10 11
1 2 3 4 5 6
12 13 14 15 16 17 18 19 20 21 22 23 24
BR
16
GrB
14
BL
BL
B40
DATA LINK CONNECTOR
B
C
D
AT-04
AT-04
AT-05
BL
B8 GrB
B11
GR
GR
B1
B2
B27 YR
B26 YR
B25 YR
B12 YB
B3
RB
A20 WB
REF. TO
AT SHIFT LOCK CONTROL SYSTEM
[ATSL-02]
B65
GW
C6
2
3
AT-03
FB-19
F/B FUSE NO.11
(IG)
GW
MB-7
M/B FUSE NO.4
(B)
BR
FB-25
F/B FUSE NO.4
(ACC)
LY
AT-03

FB-27
F/B FUSE NO.16
(B)
ECM
A:
B54 HR
C: B136 HR
1
2
3
4
5
6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30
31 32 33 34 35
B55 HR
1
2
3
4
5
6
7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
WI-15005
WI-66
AT Control System
AT-03
83
TWISTED PAIR LINE
81
26
TWISTED PAIR LINE
ABS
TWISTED PAIR LINE

VDC
ABS
VDC
CONTROL
MODULE
C27
W
C35
TWISTED PAIR LINE
AT-03
B310
ABS
CONTROL
MODULE
TWISTED PAIR LINE
AT-04
B301
ECM
C: B136
11
AT-04
WIRING SYSTEM
AT : AT MODEL
ABS : WITHOUT VDC
AT
A17
A18 W
AT
VDC : WITH VDC
TWISTED PAIR LINE
TWISTED PAIR LINE
VDC
B231
A:
B54
TCM
STEERING
ANGLE SENSOR
B301 (BLACK)
B231
12 13 14 15
1 2 3 4
1 2 3 4 5 6 7 8 8 10 11
16 17 18 19 20 21 22 23 24 25 26
B310 (BLACK)
1
A: B54
HR
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
2
4
6
8
14
16
18
20
22
24
26
28
12
10
11
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
71
73
77
79 80 81 82 83
75
68
56 57 58 59 60 61 62 63 64 65 66
70
72
74
76
78
67
69
WI-15236
WI-67
HIGH CLUTCH DUTY

LOW CLUTCH DUTY
AT13
AT11
AT12
B11
HR
(GRAY)
1 2 3
1 2
3 4
1 2 3
4 5 6
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
E
E
1 2
WI-68
A:
B54
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
AT11
AT13
HR
B:
1 2
3
8 9 10 11 12 13
20 21 22 23
28 29 30 31
RB
B
LB
Or
Sb
Sb
LB
RB
Or
TORQUE CONVERTER TURBINE SPEED SENSOR
3
1
2
AT12
FRONT WHEEL SPEED SENSOR
REAR WHEEL
SPEED SENSOR (AWD)
ATF TEMPERATURE SENSOR
Y
Gr
Gr
Y
Br
Br
15
10
14
18
13
17
11
A26
A16
W
B
W
B
W
B
W
B
TCM
AT-05
A1
A2
A27
A15
GR
LY A12
WR A23
LY
A4
LR
RW A3
RW
2
WR
LOr B7
LR
1
LOr
B5
G
G
B4
Or
Or
LgR B6
A6
RY
RY
LgR
BW B21
WG A5
BW
BW B20
BL B22
BL B23
WG
BL
12
20
19
B: B55
A: B54
LINE PRESSURE LINEAR SOLENOID
LOW & REVERSE DUTY
2-4 BRAKE DUTY
LOCK-UP DUTY
AWD DUTY SOLENOID
AT-03
AT-05
AT Control System
WIRING SYSTEM
B11
T4
B55
HR
4 5 6 7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
WI-15007

WIRING SYSTEM
7. AT Shift Lock Control System
ATSL-01
ATSL-01
A: WIRING DIAGRAM
MB-6
M/B FUSE NO. 6
(B)
FB-27
F/B FUSE NO.16
(B)
LY
YB
FB-31
F/B FUSE NO. 3
(B)
WB
FB-25
F/B FUSE NO. 4
(ACC)
GB

FB-15
F/B FUSE NO.18
(IG)
STOP LIGHT
SWITCH
F44
LY
WB
B61
2
3
B65
KEY WARNING
SWITCH
INHIBITOR SWITCH
R
W
WR
1
9
GR
LB
T3
T7
1
2
B73
B12
REF. TO GND
[GND-04]
B65
1 2
3 4
(BLACK)
B73
1
2
3 4 5 6
F44
1 2 3
5 6 7
A: B280
(BLACK)
4
8
B12
HR
(GRAY)
1 2 3 4
5 6 7 8
9 10 11 12
T7
B: B281 BODY INTEGRATED UNIT
(BLACK)
1 2 3 4 5 6
7 8 9 10 11 12
B9 WB
B20 WR
A2 WB
B10 YB
B5
B19 GB
GR
A: B280
(BLUE)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
HR
B: B281 (GRAY)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
WI-15008
WI-69
A9
A4
A13
A3
RB
LR
B6
B: B281
A: B280
ATSL-02
ATSL-02
WIRING SYSTEM
AT SELECT LEVER
PARKING
SWITCH
2
RB
SHIFT LOCK
SOLENOID
KEY LOCK SOLENOID
NA
B117
RB
B
REF. TO GND
[GND-04]
B: B55
B73
B194
B3
BR
B195
*
TB
TB
NA
LR
REF. TO GND
[GND-02]
NA
: NON-TURBO MODEL
TB
: TURBO MODEL
*1
: NON-TURBO MODEL: B
: TURBO MODEL
: BR
TCM
B194 (BLACK)
1 2
B73
B117
1
2
3 4 5 6
1
2
3 4 5 6
A: B280 (BLUE)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
HR
B: B281 (GRAY)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
HR
B:
B55
1
2
3
4
5
6
7
8 9 10 11 12 13 14 15 16 17 18 19
24 25
26 27
20 21 22 23
28 29 30 31
32 33
34 35
WI-15009
WI-70
Anti-Lock Brake System

WIRING SYSTEM
8. Anti-Lock Brake System

A: WIRING DIAGRAM
FB-22
F/B FUSE NO. 14
(IG)
SBF-7
SBF HOLDER
(B)
FB-27
F/B FUSE NO. 16
(B)
GB
GR
WG
LY
ABS-01
FB-15
F/B FUSE NO. 18
(IG)
RY
ABS-01

FB-28
F/B FUSE NO. 8
(B)
STOP LIGHT
SWITCH
B36
GR
i1
B9
COMBINATION
METER
LY
WB
B65
PARKING
BRAKE/
B:
BRAKE
FLUID
WARNING C:
LIGHT
REVERSE
CIRCUIT
C3
i11
i3
WG
26
B38
WR
WB
20
B61
13
GB
18
Br
B
12
RY
14
22 LgY
RR
OUTLET
RR
INLET
RL
OUTLET
RL
INLET
FR
OUTLET
FR
INLET
PUMP
MOTOR
FL
OUTLET
FL
INLET
ABS CONTROL MODULE

SOLENOID
VALVE
B301
15
WR
Br
F44
LgY 23
i1
B36
i10
Br
2
RY
B61
REVERSE
CIRCUIT
LgY C6
RY
ABS
WARNING
LIGHT
F44
2
3
REF. TO GND
[GND-05]
VALVE RELAY MOTOR RELAY
B65
1 2
3 4
(BLACK)
F44
1 2 3
5 6 7
B:
i10
(BLACK)
4
8
C:
i11
(GREEN)
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B301 (BLACK)
B36
12
13
14
15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
WI-15250
WI-71

WIRING SYSTEM
MB-9
SBF-5
(B)
ABS-02
ABS-02
BR
GW
IG
IGNITION RELAY
(IG)
F44
BR
B61
GrB
TWISTED PAIR LINE
DATA LINK
CONNECTOR
GW
BR
16
GrB
14
BL
BL
B40
A
B
ABS-04
ABS-04
C6
BL
B301
ABS CONTROL MODULE

C: B136 ECM
F44
1 2 3 4
5 6 7 8
(BLACK)
B40
(BLACK)
1 2 3 4 5 6 7 8
B301
12
13
14
15
9 10 11 12 13 14 15 16
(BLACK)
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
C: B136
HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
WI-15010
WI-72
ABS-03
ABS-03
WIRING SYSTEM
24
21
10
19
4
3
2
6
5
1
16
ABS CONTROL MODULE
R
W
B
TWISTED PAIR LINE
R
G
B
W
B99
6
19
17
18
TWISTED PAIR LINE
W
B
F45
R
G
19
7
B62
B
W
W
BR
TWISTED PAIR LINE
TWISTED PAIR LINE
TWISTED PAIR LINE
L
G
W
BR
B301
L
G
L
G
TWISTED PAIR LINE
1
2
FRONT ABS
WHEEL SPEED
SENSOR LH
FRONT ABS
WHEEL SPEED
SENSOR RH
REAR ABS
WHEEL SPEED
SENSOR LH
REAR ABS
WHEEL SPEED
SENSOR RH
B292
1
2
3
1
2
R72
1
2
R73
R
W
B
B6
1
2
F94
B
W
TWISTED PAIR LINE
L
G
W
B
B
W
R3
B6
(GRAY)
R72
B292
F94
(GRAY)
R73
1 2 3
2 1
HR
B99
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
ABS
G SENSOR
F45
(BLACK)
7 8 9 10 11
1 2 3 4 5 6
12 13 14 15 16 17 18 19 20 21 22 23 24
2 1
B301 (BLACK)
12
13
14
15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
WI-15011
WI-73

WIRING SYSTEM
ABS-04
ABS-04
B301
W
AT
26
B
TWISTED PAIR LINE
AT
11
ABS CONTROL MODULE
TWISTED PAIR LINE
: AT MODEL
A17
A18 W
AT
AT
AT
A:
B301
12 13 14 15
(BLACK)
1 2 3 4 5 6 7 8 8 10 11
16 17 18 19 20 21 22 23 24 25 26
A: B54
B54
TCM
C27
ABS-02
C35
ABS-02
TWISTED PAIR LINE
TWISTED PAIR LINE
C: B136
ECM
HR
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
WI-74
WI-15012
Vehicle Dynamics Control System

WIRING SYSTEM
9. Vehicle Dynamics Control System

A: WIRING DIAGRAM
VDC-01
VDC-01
FB-28
F/B FUSE NO.8
(B)
RY
RY
WR
SBF-7
SBF HOLDER
(B)
F44
2
RY
WR
B61
B61
WR
F44
VDCH/U
VDCH/U
B369
VDC1
SECONDARY CUT
PRIMARY SUCTION
RR INLET
RL INLET
RR OUTLET
FR INLET
RL OUTLET
FL INLET
FR OUTLET
PRIMARY CUT
MOTOR
RELAY
FL OUTLET
PUMP MOTOR
VALVE
RELAY
SECONDARY SUCTION
VDC3
VDC2
11
B368
WG
10
12
RY
GL
9
LR
RW
3
RG
WL
2
RL
LB
1
GW
4
WB
LG
GR
VDC5
B370
LW
BW
VDC4
WB
GR
GW
LB
RL
WL
RG
RW
LR
GL
RY
WG
24
29
31
25
23
34
32
35
30
L
27
26
LG
LW
22
48
BW
9
VDC-03
B369 (GRAY)
VDC1
B370
1 2 3
4 5 6
(BLACK)
F44
1 2 3
5 6 7
(BLACK)
VDC5 (BLACK)
4
8
1
5
9
13
1 2
2
6
10
14
3
7
11
15
4
8
12
16
B310 (BLACK)
1
2
4
6
8
14
16
18
20
22
24
26
28
10
11
12
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56 57 58 59 60 61 62 63 64 65 66
67
68
69
70
71
72
73
74
75
76
77
78
79 80 81 82 83
WI-15237
WI-75

WIRING SYSTEM
B36
5
SECONDARY
PRESSURE SENSOR
B9
GR
i1
1
5
9
13
A7
Lg
i10
C:
i11
BrY B20
C3
Br
VDC OPERATION
INDICATOR LIGHT
PARKING BRAKE /
BRAKE FLUID
WARNING LIGHT
A5
B:
BrY
Lg
Br
31
26
10
BrY
72
Lg
BW
BrY
LgY
LgY 23
BW
OrW
Lg
Lg
GB
28
VDC-04
i1
54
G
77
(GREEN)
i10
B38
53 LgY
W
44
B:
i3
B36
VDC5 (BLACK)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
1 2 3 4 5 6 7 8 9 10
i12
B36
REF. TO PARKING
BRAKE /BRAKE
FLUID WARNING
LIGHT SYSTEM
[BR/W(V)-01]
VDC CONTROL MODULE
(GREEN)
i12
i1
61 OrW
A:
OrW 20
BW
6
R
75
76
BW
B62
B310
(GREEN)
A:
B
F45
i11
LgY C6
OrW C7
B368
BW
16
14
13
15
VDC5
COMBINATION METER
ABS WARNING LIGHT
VDC WARNING LIGHT/

VDC OFF INDICATOR LIGHT
PRIMARY
PRESSURE SENSOR
VDCH/U
C:
VDC-02
FB-22
F/B FUSE NO.14
(IG)
GB
BW
ALT
GENERATOR
GR
VDC-02
FB-15
F/B FUSE NO.18
(IG)
2
6
10
14
3
7
11
15
B36
F45
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
4
8
12
16
(BLACK)
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B310 (BLACK)
1
29
30
31
32
33
34
35
56 57 58 59 60 61 62 63 64 65
10
9
36
66
37
67
12
11
38
68
39
69
14
13
40
70
41
71
16
15
42
72
43
73
18
17
44
74
WI-76
45
75
20
19
46
76
47
77
22
21
48
78
49
79
24
26
28
23
25
27
50
51
52
53
54
55
80 81 82 83
WI-15238

WIRING SYSTEM
STEERING
ANGLE SENSOR
TWISTED PAIR LINE
BR
F44
BR
DATA LINK
CONNECTOR
VDC-03
1
B
B231
BR
GW
VDC-01
MB-9
SBF-5
(B)
4
IG
IGNITION RELAY
(IG)
VDC-03
B61
GW
16
BR
A18
14
A17
GrB
BL
BL
TWISTED PAIR LINE
A:
B54
TCM
TWISTED PAIR LINE
B40
C27
C: B136
C35
ECM
C6
TWISTED PAIR LINE
BL
TWISTED PAIR LINE
ECM
B231
1 2 3 4
F44
1 2 3
5 6 7
(BLACK)
4
8
B40
(BLACK)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B
81
38 GrB
B310
83
REF. TO GND
[GND-02]
C: B136
VDC CONTROL MODULE
A:
B54
HR
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
HR
5 6
14 15 16
25 26 27
33 34 35
B310 (BLACK)
1
12
10
2
4
6
8
14
16
18
20
22
24
26
28
11
3
5
7
9
13
15
17
19
21
23
25
27
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56 57 58 59 60 61 62 63 64 65 66
67
68
69
70
71
72
73
74
75
76
77
78
79 80 81 82 83
WI-15239
WI-77
13
40
55
BR
BR
TWISTED PAIR LINE
TWISTED PAIR LINE
19
19
F94
(BROWN)
R73
B312
VDC OFF
SWITCH
TWISTED PAIR LINE
1 2 3
4 5 6
FRONT ABS
WHEEL SPEED
SENSOR RH
(BROWN)
B312
B318
1 2 3
4 5 6
1
2
3 4 5 6
OrW
ON
REF. TO
CLEARANCE LIGHT
& ILLUMINATION
LIGHT SYSTEM
[ILLUMI-01]
B6
FRONT ABS
WHEEL SPEED
SENSOR LH
TWISTED PAIR LINE
YAW RATE
& LATERAL
G SENSOR
BR
B318
F94
B230
R72
B230 HR
(BLACK)
2 1
G
G
TWISTED PAIR LINE
W
2
R72
OFF
6
L
TWISTED PAIR LINE

(BROWN)
SB
F45
REAR ABS
REAR ABS
WHEEL SPEED WHEEL SPEED
SENSOR LH
SENSOR RH
B6
REF. TO GROUND
CIRCUIT [GND-04]
B62
R3
SB
W
18
17
B99
R73
VDC-04
14
L
64
19
65
11
67
50
66
G
17
18
R
15
16
B
21
VDC SHIELD
JOINT CONNECTOR
B
TWISTED PAIR LINE
VDC-02
VDC CONTROL MODULE
B310
BR
VDC-04
WIRING SYSTEM
REF. TO GROUND
CIRCUIT [GND-03]
(BLACK)
B99
F45
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
2 1
B310 (BLACK)
1
3
5
7
29
30
31
32
33
34
35
56 57 58 59 60 61 62 63 64 65
10
9
36
66
37
67
11
38
68
12
39
69
14
13
40
70
41
71
16
15
42
72
43
73
18
17
44
74
45
75
20
19
46
76
47
77
22
21
48
78
49
79
24
26
28
23
25
27
50
51
52
53
54
55
80 81 82 83
WI-15240
WI-78
Air Conditioning System

WIRING SYSTEM
10.Air Conditioning System

A: WIRING DIAGRAM
A/C(M)-01
A/C(M)-01
1. MANUAL A/C MODEL

FB-17
F/B FUSE NO.17
(IG)
BrY
GOr
BrB
2
BW
3
2
LY
BrY
A/C
PRESSURE SWITCH
GOr
EVAPORATOR
THERMO SWITCH
B256
B
B7
F45
A/C RELAY
A/C(M)-02
A/C(M)-02
A/C(M)-02
B62
BrY
Br
12
BrY
18 GOr
17 BrY
15
Br
19
F2
Br
B100
B16 GB
C23 LY
Br
C9
L
C33 BrB
F27
F24
B: B135
C: B136
MAGNET
CLUTCH
ECM
REF. TO GND
[GND-04]
COMPRESSOR
B256
B7
1 2 3
3
F2
1
4
2
1 2 3 4
10 11 12 13 14
(BLUE)
5 6 7 8 9
15 16 17 18 19 20
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
F45
(BLACK)
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B: B135 HR
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
F27 (BLACK)
5 6
14 15 16
25 26 27
33 34 35
5 6 7 10 15 16 17 20 25 26 27 30
8
11
18
21
28
31
9 12 13 14 19 22 23 24 29 32 33 34
35
36
RELAY HOLDER
WI-15013
WI-79

FB-30
F/B FUSE NO.1 (B)
F/B FUSE NO.2 (B)
BLOWER FAN RELAY
RW
GOr
FB-36
F/B FUSE NO.17
(IG)
B
C
A/C(M)-01
A/C(M)-01
RW
GOr
GB
BR
A/C(M)-01
A/C(M)-02
A/C(M)-02
WIRING SYSTEM
B50
BLOWER MOTOR
BR
BG
2
1
B87
BLOWER RESISTOR
1 2
B50
1 2
3 4
REF. TO GND
[GND-05]
14
10
15
11
12
13
BY
GB
BR
YB
RY
BW
16 LgR
17 BL
18 BW
BY
GB
BR
YB
RY
BW
LgR
BL
BW
i41
BLOWER FAN SWITCH
BW
RY
3
6
BR
LgR
BL
BW
GB
V
3
B202
GB
1
8
7
6
REF. TO
CLEARANCE LIGHT &
ILLUMINATION LIGHT
SYSTEM [ILLUMI-01]
OrW
RL
4
11
BY
10
B
9 GOr
LgR
BL
B87
REF. TO GND
[GND-05]
B86
YB
BY
i16
INTAKE
ACTUATOR
2
3
6
4
1
B91
GOr
4
i40
REF. TO REAR
DEFOGGER SYSTEM
[R/DEF-01]
B201
B
GOr
10
B
4 GOr
BG
BR
YB
RY
BW
i15
MANUAL A/C CONTROL MODULE
B91
B86
1 2 3 4
i15
(BLACK)
i16
1 2
3 4 5
6 7 8 9 10 11 12
B202
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
1 2 3
4 5 6
B201 (BLACK)
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
WI-12245
WI-80

WIRING SYSTEM
A/C(AN)-01
A/C(AN)-01
2. AUTO A/C NON-TURBO MODEL
FB-8
M/B FUSE NO. 2
(B)
GOr
LR
FB-30
F/B FUSE NO. 1 (B)
F/B FUSE NO. 2 (B)
RW
FB-36
F/B FUSE NO. 17
(IG)
GOr

FB-17
F/B FUSE NO. 17
(IG)
B50
A/C
PRESSURE SWITCH
BLOWER FAN RELAY
RW
GOr
GOr
BrY
GB
BrB
BR
BR
BLOWER MOTOR
B7
BrY
A/C RELAY
BrY
B62
F45
18 GOr
RL
BY
B87
17 BrY
15
Br
19
Br
12
F2
Br
INTAKE ACTUATOR
B100
F27
GOr
BL
LgR
1
4
2
B50 (BLACK)
1 2
3
4
A:
B91
B87
1 2 3 4
1 2 3 4 5 6
i48
18 GB
21 LY
24 BrY
22 RL
14 BL
13 LgR
12 G
A:
i41
GB
LY
BrY
RL
BL
LgR
G
B15
B17
A10
B16
B18
B20
B19
i48
(GRAY)
i49
B:
F2
1 2 3 4
10 11 12 13 14
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B202
BY
21 LR
4 GOr
10
B
B16 GB
ECM
REF. TO GND
[GND-05]
REF. TO GND
[GND-04]
C23 LY
C: B136
COMPRESSOR
B7
i40
B: B135
MAGNET
CLUTCH
B201
B4 LR
B5 GOr
B11 B
F24
C33 BrB
C9
Br
B91
AUTO A/C
CONTROL
MODULE
(BLUE)
5 6 7 8 9
15 16 17 18 19 20
B202
B: B135 HR
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
REF. TO GND
[GND-05]
B:
i49
(GRAY)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
C: B136 HR
B201 (BLACK)
F45
(BLACK)
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
F27
(BLACK)
5 6 7 10 15 16 17 20 25 26 27 30
8
11
18
21
28
31
9 12 13 14 19 22 23 24 29 32 33 34
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
35
36
RELAY HOLDER
WI-15014
WI-81
A/C(AN)-02
B:
i48
i49
B9
B8
A4
A13
A5
A12
B12
B2
A16
B6
A7
B7
B1
A1
A9
A3
B14
Or A14
RB
B3
WG B13
A:
W
YR
GY
RY
LW
L
RW
Br
YB
GY
Y
GW
WR
V
OrW
RL
R
A/C(AN)-02
WIRING SYSTEM
REF. TO REAR
DEFOGGER
SYSTEM [R/DEF-01]
REF. TO CLEARANCE
LIGHT &
ILLUMINATION LIGHT
SYSTEM [ILLUMI-01]
AIR MIX ACTUATOR
WR
GW
Y
GY
YB
1
2
4
6
3
Br
YB
W
YR
GY
RY
LW
L
Or
RB
WG
i65
IN-VEHICLE SENSOR
5
15
Br
YB
10
11
6
9
8
7
W
YR
GY
RY
LW
L
19
Or
Or
20
RB
YB
RB
1
2
YB
RW
B202
i55
18
17
PB
BR
F45
B77
PB
BR
i10
YB
Br
W
YR
GY
RY
LW
L
LW
L
YB
B256
3
1
F78
1
2
PB
B25 PB
B:
1
2
5
8
4
6
7
9
10
BR
B24 BR
I/F
1
2
PB
BR
PB
BR
2
Or
B30 Or
I/F
i51
B62
i1
YB
RB
3
E8
B36
B38
i3
BL
BL
22
23
E3
24
B22
YB
RB
11
WG
WG
17
i41
M-CPU
SUNLOAD
THERMOMETER SENSOR
F78
(BLACK) B256
i51
1
2
3
i55
E8
(LIGHT GRAY)
1 2
3
MODE ACTUATOR
COMBINATION METER
i65
A:
(BLACK)
1
2
3 4 5 6
i48
B:
(GRAY)
B36
(GRAY)
i49
B202
B77
(BROWN)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10
1 2
B22
F45
(BLACK)
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B:
i10
EVAPORATOR
THERMO SWITCH
AMBIENT SENSOR
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
(BLACK)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-12247
WI-82

WIRING SYSTEM
FB-8
M/B FUSE NO. 2
(B)
GOr
LR
FB-30
F/B FUSE NO. 1 (B)
F/B FUSE NO. 2 (B)
RW
FB-36
F/B FUSE NO. 17
(IG)
GOr

FB-17
F/B FUSE NO. 17
(IG)
BLOWER
FAN RELAY
A/C
PRESSURE SWITCH
RW
GOr
GOr
BrY
GB
BrB
BR
A/C(AT)-01
A/C(AT)-01
3. AUTO A/C TURBO MODEL
B50
B7
BLOWER MOTOR
BR
BrY
A/C RELAY
BrY
Br
11
BrY
B62
F45
10 GOr
9
RL
BY
B87
Br
12
F2
Br
INTAKE ACTUATOR
B100
F9
GOr
BL
LgR
i41
COMPRESSOR
REF. TO GND
[GND-04]
B7
1
4
2
B50 (BLACK)
1 2
3
4
B91
B87
F9
1 2 3 4
1 2 3 4 5 6
1
3
4
A:
(BLACK)
12
7 8 9
13
i48
i48
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
(BLACK)
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B: B135
HR
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
i49
AUTO A/C
CONTROL
MODULE
F2
1 2 3 4
10 11 12 13 14
REF. TO GND
[GND-05]
(BLUE)
5 6 7 8 9
15 16 17 18 19 20
B:
i49
(GRAY)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B202
11
RELAY HOLDER
F45
B:
(GRAY)
5
6
B201 (BLACK)
A:
ECM
REF. TO GND
[GND-05]
BY
GB
LY
BrY
RL
BL
LgR
G
B4 LR
B5 GOr
B11 B
C: B136
B15
B17
A10
B16
B18
B20
B19
C24 LY
B: B135
MAGNET
CLUTCH
B202
B16 GB
C9
B
i40
C33 BrB
Br
L
F24
B201
18 GB
21 LY
24 BrY
22 RL
14 BL
13 LgR
12 G
21 LR
4 GOr
B
10
B91
C: B136
HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
5 6
14 15 16
25 26 27
33 34 35
WI-15015
WI-83
i49
A/C(AT)-02
B:
B9
B8
A4
A13
A5
A12
B12
B2
A16
B6
A7
B7
B1
A1
A9
A3
B14
i48
Or A14
RB
B3
WG B13
A:
W
YR
GY
RY
LW
L
RW
Br
YB
GY
Y
GW
WR
V
OrW
RL
R
A/C(AT)-02
WIRING SYSTEM
REF. TO REAR
DEFOGGER
SYSTEM [R/DEF-01]
REF. TO CLEARANCE
LIGHT &
ILLUMINATION LIGHT
SYSTEM [ILLUMI-01]
AIR MIX ACTUATOR
WR
GW
Y
GY
YB
1
2
4
6
3
Br
YB
W
YR
GY
RY
LW
L
Or
RB
WG
i65
IN-VEHICLE SENSOR
5
15
10
11
6
9
8
7
B202
Br
YB
W
YR
GY
RY
LW
L
Or
Or
19
20
RB
YB
RW
1
2
i55
WG
YB
RB
WG
17
i41
PB
BR
PB
18
17
PB
BR
PB
BR
i10
YB
Br
W
YR
GY
RY
LW
L
LW
L
YB
B256
F78
1
2
PB
B25 PB
I/F
B77
B:
1
2
5
8
4
6
7
9
10
BR
B24 BR
I/F
F45
3
1
BR
Or
i1
B30 Or
YB
RB
1
2
i51
B62
B36
i3
YB
RB
WG
E8
B38
2
24
E3
22
23
WG
B22
M-CPU
SUNLOAD
THERMOMETER
SENSOR
F78
(BLACK)
B256
i51
1
2
3
i55
COMBINATION METER
(LIGHT GRAY)
E8
i65
(BLACK)
1
2
3 4 5 6
1 2
3
B77
(BROWN)
1 2 3 4 5 6 7 8 9 10
EVAPORATOR
THERMO SWITCH
AMBIENT SENSOR
A:
i48
(GRAY)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B36
1 2
B:
i49
B22
(GRAY)
(BLACK)
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
(BLACK)
B202
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
F45
MODE ACTUATOR
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B:
i10
B38
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
WI-84
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-15016
Airbag System
WIRING SYSTEM
11.Airbag System
A: WIRING DIAGRAM
A/B-01
FB-21
F/B FUSE NO.6
(IG)
GW
GY
GR
IG
IGNITION RELAY
(IG)
MB-9
SBF-5
(B)
FB-20
F/B FUSE NO.11
(IG)
BR
A/B-01

FB-22
F/B FUSE NO.14
(IG)
COMBINATION METER
B:
i10
C:
i11
AIRBAG
WARNING
LIGHT
AIRBAG
CIRCUIT
B9
GR
GR
GR
C8
GB
GB
19
i1
GR
B36
C6
ECM
C: B136
BR
BL
F44
28
i3
B
BR
B10
B38
B61
BL
BL
GW 8
BR 16
GrB 7
B31
C:
F44
1
2 3
4 5 6 7 8
1 2 3
5 6 7
4
8
i11
(GREEN)
1 2 3 4 5 6 7 8 9 10
GrB
YL
YR
12
18
GY
R
5
AB3
REF. TO GND
[GND-03]
B31
GR
3
AB1
REF.TO OCCUPANT
DETECTION
SYSTEM [ODS-01]
GrB
GY
6
GR
B40
DATA LINK
CONNECTOR
B40
(BLACK)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B36
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
C: B136 HR
AB3 (YELLOW)
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
B:
i10
(GREEN)
B38
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
18 19 20 21 22 23 24 25 26 27 28
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
WI-15017
WI-85
Airbag System
WIRING SYSTEM
AB13
LW
G
27
28
7
8
10
11
YB
Y
YR
YG
YL
YW
YL
YW
YBr
Br
14
13
YG
YR
YG
YR
17
16
AB3
BW
LW
G
2
1
AB14
AB15
20 YBr
9
Br
TWISTED PAIR LINE
L
G
AB18
26
15
TWISTED
PAIR LINE
TWISTED
PAIR LINE
1
2
1
2
A/B-02
FRONT SUB SENSOR RH
A/B-02
FRONT SUB SENSOR LH
4
3
1
2
AB2
YR
YL
Y
YB
AB26
1 2
AB15 (YELLOW)
AB18 (YELLOW)
B
GA
1
2
4
3
4
3
AIRBAG MODULE (DRIVER SEAT)
AB13 (YELLOW)
GAB-1
AB4
AB38
1
2
AB37
BW
YB
Y
YR
YG
YR
YL
Y
YB
STEERING
ROLL CONNECTOR
AB37 (ORANGE)
1 2
AIRBAG MODULE (PASSENGER SEAT)
AB38 (BLACK)
1 2
1 2
(YELLOW)
AB2
(YELLOW)
AB3
AB4
(YELLOW)
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
1 2 3 4
18 19 20 21 22 23 24 25 26 27 28
WI-13103
WI-86
Airbag System
A/B-03
A/B-03
WIRING SYSTEM
5
6
AB8
(YELLOW)
AB19 (BLACK)
AB11 (YELLOW)
AB20 (BLACK)
YR
YR
2
1
W
L
G
B
W
L
G
B
2
1
SIDE AIRBAG
SENSOR LH
SIDE AIRBAG
SENSOR RH
AB51 (YELLOW)
AB10 (YELLOW)
INFLATOR
RH
AB7
(YELLOW)
ELR
PRETENSIONER
RH
AB8
(YELLOW)
AB12 (YELLOW)
1 2
1 2
BUCKLE
SWITCH
LH
AB52 (YELLOW)
AB20
1
INFLATOR
LH
4
3
2
1
LB
1
SEAT
POSITION
SENSOR
AB12
4
3
2
1
ELR
PRETENSIONER
LH
AB11
AB10
AB51
AB52
2
2
1
LW
2
1
YR
YR
AB9
AB19
AB9
YG
YB
YG
YB
REF.TO OCCUPANT DETECTION

SYSTEM [ODS-01]
YR
YR
YG
YB
W
L
G
B
W
L
G
B
AB7
GW 11
GB 8
2
1
12
9
7
10
7
10
12
9
8
RB
RB
11
RW
RW
YG
YB
5
6
4
LB
LW
YR
YR
2
1
1 2
1 2 3 4 5 6
1 2 3 4 5 6
7 8 9 10 11 12
7 8 9 10 11 12
1 2
1 2 3 4
WI-12324
WI-87
Occupant Detection System

WIRING SYSTEM
12.Occupant Detection System

A: WIRING DIAGRAM
IG
IGNITION RELAY
(IG)
ODS-01
BR
FB-21
F/B FUSE NO.6
(IG)
GW
FB-22
F/B FUSE NO.14
(IG)
MB-9
SBF-5
(B)
GR
ODS-01

FB-37
F/B FUSE NO.6
(IG)
11
8
GB
AB8
GW
AIRBAG
CONTROL
MODULE
F44
BR
PRESSURE
SENSOR
B34
AB50
GW
BL
GrB
BL
16
BR
AB55 (YELLOW)
1 2
1 2
AB56 (BROWN)
AB61 (GRAY)
AB58
1 2 3
4 5 6
B31
1
2 3
4 5 6 7 8
1 2 3
B40
(BLACK)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
(YELLOW)
AB62
AB3
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 28
WI-88
DIMMER CIRCUIT
YR
18
YL
OFF
ON
YR
4
YL
1
AIRBAG
CONTROL
MODULE
B40
DATA LINK CONNECTOR
(YELLOW)
AB3
10
14
16
15
OCCUPANT DETECTION CONTROL MODULE
C: B136
AB62
B34
12 GrB
BL
C6
YR
YB
YG
YL
YR
YG
YG
YB
YB
YB
AB55
AB1
PASSENGER'S SEAT
AIRBAG WARNING LIGHT
YL
3
GrB
2
B31
R
3
YR
YB
YG
YL
AB59
PASSENGER'S SEAT
GB
i59
AB61
DIMMER CIRCUIT
GW
1
YR
L
6
B38
i3
GR
YL
YR
11
YL
G
YR
4
1
Y
YB
AB58
BUCKLE
SWITCH
RH
10
AB50
YR
AB56
BR
BELT
TENSION
SENSOR
CLOCK
ECM
F44
1 2 3
5 6 7
(BLACK)
4
8
i59
(GREEN)
1 2 3 4 5 6 7 8 9 10
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
AB8
(YELLOW)
1 2 3 4 5 6
7 8 9 10 11 12
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
WI-15018
Immobilizer System
WIRING SYSTEM
13.Immobilizer System
A: WIRING DIAGRAM
IMB-01
W
W
GR
LR
LR
MB-6
M/B FUSE NO.6
(B)
BR
MB-9
SBF-5
(B)
FB-19
F/B FUSE NO.11
(IG)
BR
IMB-01

MB-12
M/B FUSE NO.2
(B)
F44
4
B36
B61
W
LR
BR
i1
i12
LR
i10
WR
IMMOBILIZER
INDICATOR LIGHT
A:
COMBINATION
B:
METER
B8
KEY WARNING
SWITCH
B73
GR
B176
BrR 15
B142
GW
RW C34
YL C26
WG A4
WG
C: B136
BL
B38
B22
36
WG
18
i3
KEYLESS ENTRY
CONTROL MODULE
IMMOBILIZER
ANTENNA
ECM
REF. TO KEYLESS
ENTRY SYSTEM
[K/L-02]
BR
WR
BrR
BL
BL
26
15
25
BR
GR
14
RW
23
GW
YL
10
B141
LR
GR
WG
5
24
LOr
8
BR
E3
IMMOBILIZER CONTROL MODULE

GE
B142
B73
2 1
1
2
3 4 5 6
F44
1 2 3
5 6 7
(BLACK)
4
8
A:
i12
(GREEN)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B141
1
14
(GRAY)
2 3 4 5 6 7 8 9 10 11
15 16 17 18 19 20 21 22 23 24
12
25
13
26
1
14
2 3 4 5 6 7 8 9 10 11
15 16 17 18 19 20 21 22 23 24
B22
C: B136 HR
B:
i10
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
(GRAY)
B176
5 6
14 15 16
25 26 27
33 34 35
12
25
13
26
(BLACK)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-15019
WI-89
Cruise Control System

WIRING SYSTEM
14.Cruise Control System

A: WIRING DIAGRAM
C/C(NA)-01
C/C(NA)-01
1. NON-TURBO MODEL
FB-27
F/B FUSE NO.16
(B)
FB-15
F/B FUSE NO.18
(IG)
FB-19
F/B FUSE NO.11
(IG)
LY
GB
GR
STOP LIGHT &

BRAKE SWITCH
2
LY
WB
GB
RY
STEERING
ROLL CONNECTOR
GL
Br
LgB
Gr
CRUISE CONTROL SWITCH

MAIN SW
CANCEL
B65
SET/COAST
RES/ACC
CLUTCH SWITCH
2
GB
BR
AT
BL
MT
B236
B
ST1
ST3
MT
MT
B107
BL
GB
AT
B107 (BLUE)
1 2 3
1
3
1 2
C: B136
2
4
(BLACK)
T2
*2
MT : MT MODEL
C31
BL
C6
B12 GL
B24 LgB
C: B136
BODY INTEGRATED
UNIT
B65
B27 GR
*1
B20 RY
C25
B28 WB
B19 GB
B9 WB
B: B281
ST3
C/C(NA)-02
REF. TO STARTER
SYSTEM [ST(AT/NA)-01]
AT
(BROWN)
C/C(NA)-03
MT
B25
B25
A
B
NEUTRAL
POSITION SWITCH
AT
: AT MODEL
*1
*2
: MT MODEL : BR
: AT MODEL : GR
B: B135
ECM
B: B281
B236
1
2 3
4 5 6 7 8
HR
(GRAY)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B: B135
: MT MODEL : GB
: AT MODEL : LR
HR
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
WI-15020
WI-90
C/C(NA)-02
C/C(NA)-02
WIRING SYSTEM

FB-22
F/B FUSE NO.14
(IG)
GR
BR
GR
MB-9
SBF-5
(B)
GR
B9
GW
GrB
BL
BL
C5
LR
C/C(NA)-01
DIMMER CIRCUIT
COMBINATION
METER
B:
i10
C:
i11
GOr B21
BR
CRUISE SET
INDICATOR LIGHT
16
CRUISE CONTROL
INDICATOR LIGHT
DATA LINK
CONNECTOR
i1
GR
BR
B61
B40
8
B36
F44
BR
GW
IG
IGNITION RELAY
(IG)
B: B135
7
GOr
B38
B3 GOr
B6
LR
C16 GrB
LR
21
i3
C: B136
ECM
F44
1 2 3
5 6 7
(BLACK)
4
8
C:
i11
(GREEN)
B40
1 2 3 4 5 6 7 8 9 10
(BLACK)
B36
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B:
i10
(GREEN)
8 9 10 11 12 13 14
1 2 3 4 5 6 7
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B: B135 HR
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
WI-15021
WI-91
D: B137
A28
A18
Sb A19
RG A29
D5
Br
BrW D4
A: B134
C/C(NA)-03
C/C(NA)-03
WIRING SYSTEM
ECM
SHIELD & SENSOR

JOINT CONNECTOR
SB
BL
B122
Sb
RG
17
BW
Lg
E57
BR
LgB
Lg
LgB
18
20
P
19
LW
LW
E3
YG
38
B22
YG
Br
A
39 BrW
C/C(NA)-01
ELECTRONIC
THROTTLE CONTROL
GE
E57
(BLACK)
1 2 3 4 5 6
B122
1 2 3 4
5 6 7 8
D: B137
HR
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
A: B134 HR
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B22
(BLACK)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-15022
WI-92

WIRING SYSTEM
C/C(TB)-01
C/C(TB)-01
2. TURBO MODEL
FB-15
F/B FUSE NO.18
(IG)
FB-19
F/B FUSE NO.11
(IG)
LY
GB
GR

FB-27
F/B FUSE NO.16
(B)
STOP LIGHT &

BRAKE SWITCH
2
LY
WB
GB
RY
STEERING
ROLL CONNECTOR
GL
Br
LgB
Gr
CRUISE CONTROL SWITCH

MAIN SW
CANCEL
B65
SET/COAST
RES/ACC
CLUTCH SWITCH
GB
BR
AT
BL
2
MT
B236
B
ST1
ST3
MT
MT
B107
C/C(TB)-03
C/C(TB)-02
NEUTRAL
POSITION SWITCH
BL
LgY
GB
AT
T12
(BROWN)
1 2 3
1 2
B: B135
1 2
3
8 9 10 11 12 13
20 21 22 23
28 29 30 31
HR
4 5 6 7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
(BLACK)
B65
1
3
T12
T2
2
4
BL
*2
MT : MT MODEL
C6
C31
B24 LgB
REF. TO STARTER
SYSTEM[ST(AT/TB)-01]
AT
B: B135 C: B136
BODY
INTEGRATED UNIT
ST3
B12 GL
B19 GR
*1
B20 RY
C25
B28 WB
B19 GB
B9 WB
AT
B: B281
B107 (BLUE)
T9
MT
B128
ECM
B128
HR
(GRAY)
1 2
3 4
B236
1
2 3
4 5 6 7 8
B: B281
: AT MODEL
*1
*2
: MT MODEL : BR
: AT MODEL : GR
: MT MODEL : GB
: AT MODEL : WR
HR
(GRAY)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
WI-15023
WI-93
C/C(TB)-02
C/C(TB)-02
WIRING SYSTEM

FB-22
F/B FUSE NO.14
(IG)
GR
BR
GR
MB-9
SBF-5
(B)
BR
GW
IG
IGNITION RELAY
(IG)
GR
BR
5
BL
BL
B9
LR
C5
C/C(TB)-01
DIMMER CIRCUIT
COMBINATION
METER
B:
i10
C:
i11
GOr B21
GrB
CRUISE SET
INDICATOR LIGHT
BR
CRUISE CONTROL
INDICATOR LIGHT
DATA LINK
CONNECTOR
GW
16
i1
GR
B61
B40
8
B36
F44
GOr
B3 GOr
LR
LR
B6
C16 GrB
21
i3
B: B135
B38
C: B136
ECM
F44
1 2 3
5 6 7
(BLACK)
C:
4
8
i11
(GREEN)
1 2 3 4 5 6 7 8 9 10
B40
(BLACK)
B36
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B:
i10
(GREEN)
8 9 10 11 12 13 14
1 2 3 4 5 6 7
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B: B135 HR
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
1 2
3
8 9 10 11 12 13
20 21 22 23
28 29 30 31
4 5 6 7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
WI-15024
WI-94
C/C(TB)-01
A28
A18
W
ECM
Sb A19
RG A29
BrR D3
D5
Br
BrW D4
A: B134 D: B137
C/C(TB)-03
C/C(TB)-03
WIRING SYSTEM
A
SHIELD & SENSOR
JOINT CONNECTOR
SB
BL
Sb
RG
37 BrR
15
16
20
B20
19
Br
38
E3
E57
(BLACK)
1 2 3 4 5 6
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
B22
1 2
8 9 10
18 19 20
28 29 30
BW
(BLACK)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
A: B134 HR
D: B137 HR
BR
GE
HR
(BROWN)
B20
B122
1 2 3 4
5 6 7 8
BW
ELECTRONIC
THROTTLE CONTROL
GE
E57
BR
G
G
R
R
BL
BL
BR
E1
YG
B22
39 BrW
B122
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-15025
WI-95
Radiator Fan System

WIRING SYSTEM
15.Radiator Fan System

A: WIRING DIAGRAM
GOr
A/C RELAY HOLDER
R/F-01
FB-17
F/B FUSE NO.17
(IG)
A/C RELAY HOLDER
MB-1
SBF-1
(B)
GB
30A
30A
FAN
RELAY 1
BW
WR
31
34
32
30
BW
GB
RL
WL
WR
GOr
GR
YG
28
25
27
29
YB
GOr
GR
YG
FAN
RELAY 2
FAN
MODE
RELAY
RL
GR
F27
10
11
F2
RL
GR
MAIN FAN
MOTOR
SUB FAN
MOTOR
YG
B
WL
YB
1
2
F16
F17
C: B136
1
2
F27
B100
C18 RL
C29 GR
R/F-01

FB-16
F/B FUSE NO.18
(IG)
ECM
REF. TO GND
[GND-01]
F16
(GRAY)
F17
(GRAY)
1 2
F2
1 2 3 4
10 11 12 13 14
(BLUE)
5 6 7 8 9
15 16 17 18 19 20
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
F27 (BLACK)
5 6
14 15 16
25 26 27
33 34 35
5 6 7 10 15 16 17 20 25 26 27 30
18
31
8
11
21
28
9 12 13 14 19 22 23 24 29 32 33 34
35
36
RELAY BLOCK
WI-15026
WI-96
Charging System
WIRING SYSTEM
16.Charging System
A: WIRING DIAGRAM
CHG-01
CHG-01
GR
GR
FB-22
F/B FUSE NO. 14
(IG)
B36
B9
GR
GR
i1
COMBINATION METER
A:
i12
B:
i10
BW
BW A5
CHARGE
WARNING
LIGHT
10
i1
BW
BW
B36
W
F25
GENERATOR
2
LR
BW
REF. TO
POWER SUPPLY
CIRCUIT [P-SUP-02]
BW
B62
F45
F26
F26
1 2 3
HR
(GREEN) A:
i12
(GREEN)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B36
F45
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
(BLACK)
B:
i10
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
WI-15027
WI-97
Starter System
WIRING SYSTEM
17.Starter System
A: WIRING DIAGRAM
NA
ST
IGNITION SWITCH
(ST)
TB
TB : TURBO MODEL
INTERRUPT RELAY
5
WL
WL
RB
WR
: NON-TURBO MODEL : GL
TURBO MODEL : GY
*1
*2
: NON-TURBO MODEL : GY
TURBO MODEL : B
ST(MT)-01
WL
ST(MT)-01
1. MT MODEL
B176
RB
12
KEYLESS ENTRY
CONTROL MODULE
B59
STARTER INTERLOCK
RELAY
28
WR
26
WR
24
*1
27
YL
CLUTCH SWITCH
*1
*2
2
1
B106
B225
BATTERY
GY
TB NA
C20
TB
NA
C: B136
ECM
STARTER MOTOR
YL C32 C32
YL
YL A15
B
B14
A: B280
BODY INTEGRATED
UNIT
REF. TO GND [GND-02]
B106
B59
1
2
1 2 3
4
5
(GRAY)
B225
1
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
C: B136 HR
B176 (GRAY)
A: B280 (BLUE)
1
14
2 3 4 5 6 7 8 9 10 11
15 16 17 18 19 20 21 22 23 24
12
25
13
26
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
(BLACK)
9 14 15 16 19 24 25 26 29 34 35 36
10
20
27
30
37
17
11 12 13 18 21 22 23 28 31 32 33 38
RELAY BLOCK
WI-15028
WI-98
Starter System
WIRING SYSTEM
ST(AT/NA)-01
ST(AT/NA)-01
2. AT NON-TURBO MODEL
WL
ST
IGNITION SWITCH
(ST)
INTERRUPT RELAY
5
WL
WL
RB
WR
B176
RB
KEYLESS ENTRY
CONTROL MODULE
12
B59
INHIBITOR SWITCH
P
STARTER
INTERLOCK RELAY
1
12
BY
12
LR
BW
11
YL
T7
T3
WR
WR
GY
LR
B12
BATTERY
28
26
24
27
B225
GY C20
LR C31
STARTER MOTOR
C: B136
ECM
YL C32
YL A15
YL
B14
B59
(GRAY)
B12
1 2 3
4
5
HR
(GRAY)
T7
HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
(BLACK)
1 2 3 4 5 6
7 8 9 10 11 12
1 2 3 4
5 6 7 8
9 10 11 12
C: B136
A: B280
B176 (GRAY)
(BLUE)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B225
5 6
14 15 16
25 26 27
33 34 35
A: B280
BODY INTEGRATED
UNIT
1
14
2 3 4 5 6 7 8 9 10 11
15 16 17 18 19 20 21 22 23 24
12
25
13
26
(BLACK)
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
RELAY BLOCK
WI-99
WI-15029
Starter System
WIRING SYSTEM
ST(AT/TB)-01
ST(AT/TB)-01
3. AT TURBO MODEL
WL
ST
IGNITION SWITCH
(ST)
INTERRUPT RELAY
5
WL
WL
RB
WR
B176
RB
12
KEYLESS ENTRY
CONTROL MODULE
B59
INHIBITOR SWITCH
P
1
12
BY
12
BW
11
T7
T3
WR
YL
B12
BATTERY
WR C31
C: B136
STARTER MOTOR
ECM
YL C32
YL A15
YL
B14
B59
1 2 3
4
5
(GRAY)
B12
HR
(GRAY)
1 2 3 4
5 6 7 8
9 10 11 12
A: B280
BODY INTEGRATED
UNIT
HR
T7
(BLACK)
1 2 3 4 5 6
7 8 9 10 11 12
A: B280
(BLUE)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
C: B136
B176 (GRAY)
1
14
2 3 4 5 6 7 8 9 10 11
15 16 17 18 19 20 21 22 23 24
12
25
13
26
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
WI-15030
WI-100
Speedmeter System
WIRING SYSTEM
18.Speedmeter System
A: WIRING DIAGRAM
SP-01
SP-01

FB-22
F/B FUSE NO.14
(IG)
GR
GW
IG
IGNITION RELAY
(IG)
MT
B36
B9
GR
i1
COMBINATION
METER
SPEEDOMETER
B:

(MT MODEL)
i10
GW
GY
BL
I/F
DRIVER
CIRCUIT
3
1
2
B17
- COM
I/F
TB : TURBO MODEL
GY B12
MT : MT MODEL
AT : AT MODEL
i1
: NON-TURBO MODEL : BW
TURBO MODEL : BR
BL
18
*1
GY
B36
36
B22
E3
A21 GY
*1
AT
*1
MT
TCM (AT MODEL)

A:
B54
GE
HR
(BLACK) : NA
B17
1 2 3
B17
HR
(BLACK) : TB
B36
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1 2
3 4
B22
B:
i10
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
(BLACK)
HR
A:
B54
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-15031
WI-101
Power Seat System

WIRING SYSTEM
19.Power Seat System
BW
BW
MB-11
SBF-6
(B)
P/SEAT-01
P/SEAT-01
A: WIRING DIAGRAM
B61
BW
F44
POWER WINDOW
CIRCUIT
BREAKER
RECLINING
SWITCH
B41
WG
RECLINING
MOTOR
WG
B97
SLIDE
SWITCH
SLIDE MOTOR
R1
R188
FRONT TILT
SWITCH
FRONT TILT
MOTOR
R188
REAR TILT
SWITCH
B
REAR TILT
MOTOR
REF. TO GND-06
[GND-06]
B41
F44
(BLACK)
1
2
B97
(BLACK)
B188 (BLACK)
1 2 3
5 6 7
4
8
WI-08410
WI-102

WIRING SYSTEM
20.Seat Belt Warning System

S/BELT-01
S/BELT-01
A: WIRING DIAGRAM
MB-6
M/B FUSE NO. 6
(B)
GB
IG
IGNITION RELAY
(IG)
MT
GW
FB-15
F/B FUSE NO. 18
(IG)
GR

FB-22
F/B FUSE NO. 14
(IG)
B36
KEY WARNING SWITCH
i1
COMBINATION
METER
B:
i10
B9
F44
GR
SEAT BELT
WARNING
LIGHT
B61
4
WR
B18 BL
B73
i3
19

(MT MODEL)
A13
B
R188
A4
36
B22
BODY INTEGRATED
UNIT
*1
A: B280
PS
MS
BrR
BL
R3
B: B281
8
B20 WR
B99
BrR
SEAT BELT SWITCH

(WITH POWER SEAT)
B17
E3
B4
TB : TURBO MODEL
FRONT DOOR
SWITCH LH
MT
LOr
B
MS
*1
PS
BrR
AT
SEAT BELT SWITCH
3
1
2
GY
B19 GB
: NON-TURBO
MODEL : BW
TURBO MODEL : BR
LOr B8
*1
A11 BL
AT : AT MODEL
GW
GY
BL
B3 BrR
PS : POWER SEAT
B38
BL
MT : MT MODEL
11 BrR
MS : MANUAL SEAT
B267
A21 GY
R8
1
3
TCM (AT MODEL)

A:
REF. TO GND
[GND-06]
R8
1
2
HR
B17 (BLACK) : NA
1 2 3
B99
B36
B267
1
2
3
HR
B17 (BLACK) : TB
1 2
3 4
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B:
i10
(GREEN)
B73
1
2
3 4 5 6
B38
B54
GE
F44 (BLACK)
A: B280 (BLUE)
(BLACK)
R188
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
1 2 3 4
HR
5 6 7 8
A: B54
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
HR
B: B281 (GRAY)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
5 6
14 15 16
25 26 27
33 34 35
B22 (BLACK)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-15032
WI-103
Seat Heater System

WIRING SYSTEM
21.Seat Heater System

S/HEAT-01
S/HEAT-01
A: WIRING DIAGRAM
MB-10
SBF-2
(B)
L
YB
FB-25
F/B FUSE NO. 4
(ACC)
FUSE
L
LW
38
37
34
36
LW
L
YB
B
F46
1
B108
L
15A
SEAT HEATER
RELAY
B225
B99
R3
SEAT HEATER SWITCH RH
SEAT HEATER SWITCH LH

HI
OFF
REF. TO GND
[GND-02]
LO
2
Lg
RL
LO
R188
1
2
(BLACK)
R41
(BLUE)
R43
(BLUE)
1
3
2
4
R42
1 2
3 4
HI
R42
R41
REF. TO GND
[GND-06]
F46
BW
RL
R43
BW
OFF
SEAT HEATER RH
SEAT HEATER LH
Lg
REF. TO GND
[GND-06]
R188 (BLACK)
1 2 3
5 6 7
4
8
B225 (BLACK)
B99
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
9 14 15 16 19 24 25 26 29 34 35 36
10
20
27
30
37
17
11 12 13 18 21 22 23 28 31 32 33 38
RELAY BLOCK
WI-12278
WI-104
Headlight System
WIRING SYSTEM
22.Headlight System
A: WIRING DIAGRAM
H/L(BULB)-01
HEADLIGHT RELAY
F7
1
MB-8
FB-22
F/B FUSE NO. 14
(IG)
GR
HEADLIGHT RH
MB-3
M/B FUSE NO. 8
RL

MB-2
M/B FUSE NO. 9
LW
H/L(BULB)-01
1. MODEL WITHOUT HID
LW
HIGH
4
LW
YR
LOW
COMBINATION METER
HEADLIGHT LH
1
RL
HI-BEAM
INDICATOR LIGHT
HIGH
24
F45
LW B26
i3
21
B36
R
i1
B:
UP LOW PASS
HF
GR
HU
RG
RG
HL
17
YG
16
B103
REF. TO FRONT
FOG LIGHT
[FOG-01]
REF. TO FRONT
FOG LIGHT
[FOG-01]
DAYTIME RUNNING
LIGHT RELAY
YR
HC
13
TC
GR
B71
A16
B95
B95
(BROWN)
1 2 3 4
2
1
2 3 4
5
3
4
B36
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B102 (BLACK)
F45
F7
F23
YB
DAYTIME RUNNING
LIGHT RESISTOR
YB
2
B5
HR
(GRAY)
HR
(GRAY)
1 2 3
4 5 6
B:
(BLACK)
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
REF. TO GND
[GND-04]
DIODE
B103 (BLUE)
GR
A: B280
BODY
INTEGRATED
UNIT
REF. TO GND
[GND-03]
GR
B102
GR
2
EL
1 2
GR
1 OFF
(GRAY)
GR
8
LIGHTING
SWITCH
B5
i10
HI-BEAM RELAY
DIMMER &
PASSING SWITCH
B27
LW
YR
B62
F23
29
B38
YR
YR
LW
RL
20
LOW
LW
B71
A: B280 (BLUE)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
i10
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
1
9
2
10
3 4 5 6
11 12 13 14 15
7
16
8
17
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
WI-15033
WI-105
Headlight System
H/L(BULB)-02
WL
ST
IGNITION SWITCH
(ST)
STARTER INTERLOCK RELAY (AT MODEL )
INTERRUPT RELAY
28
WR
WL
27
LR
WR
26
WR
24
GY
REF. TO SECURITY
SYSTEM [SEC(NA)-01]
[SEC(TB)-01]
B225
1
12
BY
12
*3
BW
11
YL
T7
B136
C:
ECM
TA
MT
AT
MT
WR
B12
T3
YL
27
WR
26
*1
24
B225
C20 GY
NM
TM
NM
28
CLUTCH SWITCH (MT MODEL )
* 12
*
MT : MT MODEL
2
1
B106
STARTER MOTOR
AT
STARTER INTERLOCK
RELAY (MT MODEL )
: AT MODEL
: NON-TURBO MT MODEL
TO BATTERY TERMINAL
NA
: NON-TURBO AT MODEL
TM
: TURBO MT MODEL
TA
: TURBO AT MODEL
REF. TO GND
[GND-02]
YL
*
*2
*3
: NON-TURBO MT MODEL: GL
TURBO MT MODEL : GY
: NON-TURBO MT MODEL : GY
TURBO MT MODEL : B
: NON-TURBO AT MODEL : LR
TURBO AT MODEL : WR
B106
B59
1
2
1 2 3
4
5
(GRAY)
B14
A15 YL
RB
NA
INHIBITOR SWITCH (AT MODEL )
WL
B59
NA
NA
H/L(BULB)-02
WIRING SYSTEM
A: B280 BODY INTEGRATED UNIT
B12
HR
(GRAY)
1 2 3 4
5 6 7 8
9 10 11 12
B225 (BLACK)
T7
(BLACK)
1 2 3 4 5 6
7 8 9 10 11 12
A: B280 (BLUE)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
C:
B136
HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
9 14 15 16 19 24 25 26 29 34 35 36
10
20
30
37
17
27
11 12 13 18 21 22 23 28 31 32 33 38
WI-15034
RELAY BLOCK
WI-106
Headlight System
H/L(BULB)-03
BW A12
B: B281
AT
GR
B5
A: B280
LgB A1
H/L(BULB)-03
WIRING SYSTEM
1
9
L
LB
GR
B62
B99
R3
B
B12
F45
BW
: AT MODEL
Lg
AT
T3

[P-SUP-02]
T7

[P-SUP-02]
Lg
BW
BW
F25
F26
R4
LR
24 LgB
PARKING BRAKE
SWITCH
GENERATOR
REF. TO GND
[GND-04]
F26
HR
(GREEN)
B12
1 2 3
HR
(GRAY)
1 2 3 4
5 6 7 8
9 10 11 12
T7
(BLACK)
A: B280 (BLUE)
1 2 3 4 5 6
7 8 9 10 11 12
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
HR
B: B281 (GRAY)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
(BLACK)
B99
F45
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
WI-15035
WI-107
Headlight System
WIRING SYSTEM
H/L(HID)-01
H/L(HID)-01
2. MODEL WITH HID
MB-2
M/B FUSE NO.9
MB-3
M/B FUSE NO.8
FB-7
F/B FUSE NO.5
LW
RL
RY
REF. TO CLEARANCE LIGHT & ILLUMINATION

LIGHT SYSTEM [ILLLUMI-03]
COMBINATION METER
HEADLIGHT
RH
HI-BEAM
INDICATOR LIGHT
F7
HID
LOW
LW
LW
3
6
20
LW
LW
B38
R
HALOGEN
LW B26
29
i3
21
B27
LW
1
4
22
B36
i1
B:
i10
HIGH
HEADLIGHT
LH
H/L(HID)-02
F23
HID
LOW
3
6
RL
B
HID RELAY
B2
HALOGEN
1
4
WB
Or
B62
WB
RL
WB
WB
21
HIGH
REF. TO GND
[GND-01]
B2
(GRAY)
F7
F23
1 2 3
4
5
HR
(GRAY)
HR
(GRAY)
1 2 3
4 5 6
F45
REF. TO GND
[GND-01]
B36
F45
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
(BLACK)
B:
i10
H/L(HID)-02
H/L(HID)-02
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
WI-15036
WI-108
Headlight System
H/L(HID)-02

MB-8
TAIL & ILLUMINATION

RELAY
HEADLIGHT RELAY
Or
BR
PARKING SWITCH
FB-3
F/B FUSE NO.5
FB-22
F/B FUSE NO.14
(IG)
GR
FB-10
WR
FB-12
M/B FUSE NO.7
(B)
OFF ON
B
BR
OrB
WR
B69
G
24
F45
H/L(HLD)-01
B62
HI-BEAM RELAY
C
R
H/L(HID)-01
GR
RG
B103
UP LOW PASS
HF
GR
HU
RG
HL
17
YG
16
REF. TO FRONT FOG

LIGHT SYSTEM [FOG-01]
DAYTIME RUNNING
LIGHT RELAY
Or
LIGHTING SWITCH
OFF
HC
13
TC
GR
B71
GR
GY
WR
OrB
EL
A16 GY
GR
B102
H/L(HID)-02
GR
DIMMER &
PASSING SWITCH
H/L(HID)-02
WIRING SYSTEM
A: B280
HID DIODE
P
YG
G
GY
BODY
INTEGRATED
UNIT
REF. TO GND
[GND-03]
1
2
3
4
B313
DIODE
B95
B95
B69
(BROWN)
B103 (BLUE)
B313 (BROWN)
1 2
3 4
1
2
1 2 3 4
F45
3
4
B102 (BLACK)
1
2 3 4
5
A: B280 (BLUE)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B71
1
9
2
10
3 4 5 6
11 12 13 14 15
7
16
8
17
(BLACK)
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
WI-12283
WI-109
Headlight Beam Leveler System

WIRING SYSTEM
23.Headlight Beam Leveler System
HLBL-01
HLBL-01
A: WIRING DIAGRAM
FB-6
F/B FUSE NO.5
FB-7
F/B FUSE NO.5
RY
RY
HEADLIGHT LEVELER SWITCH

RY
RB
RG
OrW
B132
RG
RB
REF. TO CLEARANCE
LIGHT & ILLUMINATION
LIGHT SYSTEM
[ILLUMI-01]
17
19
F2
B
RG
RB
18
B100
HEADLIGHT BEAM LEVELER LH
HEADLIGHT BEAM LEVELER RH
RY
RY
RB
RG
F59
B
F58
REF. TO GND
[GND-01]
F58
(BLACK)
B132
F59
(BLACK)
1 2 3 4 5 6
F2
1 2 3 4
10 11 12 13 14
(BLUE)
5 6 7 8 9
15 16 17 18 19 20
1 2 3
WI-12322
WI-110
Front Fog Light System

WIRING SYSTEM
24.Front Fog Light System

A: WIRING DIAGRAM
[
HI-BEAM RELAY
REF. TO HEADLIGHT
SYSTEM
[H/L(BULB)-01]
[H/L(HID)-02]
FB-29
F/B FUSE NO.7
(B)
RL
FRONT
FOG LIGHT RELAY
GR
GR
RG
B103
19
RL
20
WB
21
RG
23
BW
FOG-01
FOG-01
FRONT FOG
LIGHT SWITCH
ON
RG
BW
OFF
B225
YL
OrW
FRONT
FOG LIGHT RH
B160
2
WB
CLEARANCE
LIGHT SYSTEM
[ILLLUMI-01]
B306
WB
DIODE
YL
YG
B62
WB
B112
FRONT
FOG LIGHT LH
F45
DIMMER &
PASSING SWITCH
UP LOW PASS
HF
HU
17
HL
16
F21
B112 (BLACK) B306 (BROWN)

F21
1 2
B103 (BLUE)
(BROWN)
1
2
1 2
YG
WB
REF. TO GND
[GND-01]
REF. TO GND
[GND-04]
REF. TO GND
[GND-03]
B160 (GRAY)
1
2
3 4 5 6
B71
F45
B71
1
9
2
10
3 4 5 6
11 12 13 14 15
7
16
8
17
(BLACK)
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B225 (BLACK)
1
9 14 15 16 19 24 25 26 29 34 35 36
20
30
10
17
27
37
11 12 13 18 21 22 23 28 31 32 33 38
WI-12284
RELAY BLOCK
WI-111
Back-up Light System

WIRING SYSTEM
25.Back-up Light System

BACK/L-01
BACK/L-01
A: WIRING DIAGRAM
GB
FB-15
F/B FUSE NO.18
(IG)
BACK-UP LIGHT SWITCH

(MT MODEL)
T1
B24
INHIBITOR SWITCH(AT MODEL)
GB
MT
NA
AT
TB
BrY
NA
MT
AT
TB
T9
WB
WB
BrY
10
BW
BW
T3
B12
T7
B128
GW
GW
GB
BrY
B99
BrY
20
BrY
BACK-UP LIGHT SWITCH

(MT MODEL)
T1
T13
GB
R3
REAR
COMBINATION LIGHT LH
6
BrY
B
R28
REAR
COMBINATION LIGHT RH
6
BrY
: MT MODEL
AT
: AT MODEL
NA
: NON-TURBO MODEL
TB
: TURBO MODEL
R26
MT
R147
JOINT GROUND
CONNECTOR
REF. TO GND
[GND-06]
B24
1 2
(GRAY)
T13
2 1
(GRAY)
HR
B128 (GRAY)
1 2
3 4
HR
(GRAY)
R147
R26
B12
1 2 3 4 5
R28
1 2 3 4
5 6 7 8
9 10 11 12
1 2 3
4 5 6
T7
(BLACK)
1 2 3 4 5 6
7 8 9 10 11 12
B99
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
WI-15037
WI-112
Stop Light System

WIRING SYSTEM
26.Stop Light System

STOP/L-01
STOP/L-01
A: WIRING DIAGRAM
LY
FB-27
F/B FUSE NO.16
(B)
STOP LIGHT SWITCH
2
3
LY
WB
WB
B65
WB
B97
R1
TRAILER CONNECTOR
WB
6
R79
STOP LIGHT LH
WB
R28
STOP LIGHT RH
WB
R26
R147
JOINT GROUND
CONNECTOR
WB
BW
R39
D34
D39
HIGH-MOUNTED
STOP LIGHT
REF. TO GND
[GND-06]
D39
2 1
(BLACK)
B65
1 2
3 4
(BLACK)
R147
R26
B97
1 2 3 4 5
R28
1 2 3
5 6 7
R79
(BLACK)
4
8
D34
1
2 3
4 5 6 7 8
1 2 3
4 5 6
WI-12286
WI-113
Clearance Light and Illumination Light System

WIRING SYSTEM
27.Clearance Light and Illumination Light System

ILLUMI-01
ILLUMI-01
A: WIRING DIAGRAM
FB-10
TAIL & ILLUMINATION RELAY
WR
BR

FB-12
M/B FUSE NO.7
(B)
FB-3
F/B FUSE NO.5
FB-34
F/B FUSE NO.12
FB-8
M/B FUSE NO.2
(B)
FB-9
F/B FUSE NO.12
FB-11
TAIL & ILLUMINATION RELAY
WR
BR
*1
B69
AT SELECT LEVER ILLUMI.
LIGHT
1
V
REF. TO HEADLIGHT
SYSTEM [H/L(HID)-02]
B119
OrW
OrW
V
OrW
VDC
OrW
A: B280
VDC
B318
WIPER DEICER SWITCH ILLUMI. LIGHT
HI
V
22
V
OrW
B132
24 OrW
OrW
HEADLIGHT BEAM LEVELER SWITCH

ILLUMI. LIGHT
V
1
10
V1
11
V2
B16 GrR
GrR 12
V3
A4
A13
B15
B201
i40
MANUAL A/C CONTROL

MODULE ILLUMI. LIGHT
OrW
CD ILLUMI. LIGHT
V
A7 OrW
ILLUMI-02
ILLUMI-02
ILLUMI-02
ILLUMI-02
OrW
: WITH VDC
HL
: EXCEPT FOR HID MODEL
HI
: HID MODEL
*1
: EXCEPT FOR HID MODEL:Or

HID MODEL:OrB
i27
B119
1 2
3 4
B73
1
2
3 4 5 6
3 4 5 6
11 12 13 14 15
B160
7
16
8
17
A:
B132
B193
i16
1 2 3 4 5 6
1 2
3
4 5 6 7 8
1 2
3 4 5
6 7 8 9 10 11 12
B117
(GRAY)
HR
B: B281 (GRAY)
A: B280 (BLUE)
i26
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B318 (BROWN)
2
1
3 4 5 6
B71
2
10
i26
1 2
3 4
1
9
VDC
i16
AUDIO ILLUMI. LIGHT
1
2
B71
i48
B69
BP
A9 OrW
i27
EL
LR
B: B281
AUTO A/C CONTROL MODULE ILLUMI. LIGHT
A:
16
B2 Lg
B18 LR
BODY INTEGRATED
UNIT
OrW
A1
HI
B193
A:
LR
Lg
TC
A14 OrW
A1
LR
14
B73
VDC OFF SWITCH ILLUMI. LIGHT

4
BP
HC
B160
LIGHTING SWITCH
KEY ILLUMINATION
FRONT FOG LIGHT SWITCH ILLUMI. LIGHT
ECM
OFF 1
B117
B: B135
BP B15
FRONT ACCESSORY
POWER SUPPLY SOCKET
ILLUMI. LIGHT
HL
HI
HL
OFF ON
Or
PARKING SWITCH
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
A:
i48
(GRAY)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
HR
B201 (BLACK)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
WI-114
B: B135
1 2
3
8 9 10 11 12 13
20 21 22 23
28 29 30 31
4 5 6 7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
WI-15241
ILLUMI-02
ILLUMI-02
WIRING SYSTEM
GR
GR
B36
20
B38
LR
LR
ILLUMI-01
ILLUMI-01
FB-22
F/B FUSE NO.14
(IG)
FB-8
M/B FUSE NO.2
(B)
YB
OrW
V
- COM
5
2
i22
I/F
COMBINATION
METER
A:
i12
B:
i10
ILLUMI-01
i22
OrW
B
28
B
ILLUMI-01
OrW 30
B10
OrW A11
ILLUMINATION LIGHT
(ODO/TRIP,AMBIENT
TEMPERATURE /
AT INDICATOR)
LCD BACK LIGHT
LCD BACK LIGHT
DRIVE
CIRCUIT
1 2 3 4
5 6 7 8
V
OrW
A10
B8
B9
LR
GR
4
6
CLOCK
HAZARD SWITCH
ILLUMI. LIGHT
LR
YB
i59
GR
i1
i3
i3
B38
C
B
i59
(GREEN)
1 2 3 4 5 6 7 8 9 10
A:
i12
(GREEN)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B36
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B:
i10
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
WI-12288
WI-115
ILLUMI-03
ILLUMI-03
WIRING SYSTEM
FB-6
F/B FUSE NO.5
FB-7
F/B FUSE NO.5
RY
RY
SIDE MARKER LIGHT LH

2
RY
B
RY
F53
FRONT CLEARANCE LIGHT LH
RY
B97
1
RY
R1
TRAILER
CONNECTOR
5
RY
F23
RY
REF. TO GND
[GND-01]
FRONT CLEARANCE LIGHT RH
LICENSE PLATE LIGHT
R79
RY
RY
RY
RY
RY
R39
D34
D80
D81
D44
F7
SIDE MARKER LIGHT RH
2
RY
REAR COMBINATION LIGHT LH
B320
RY
5
R28
REF. TO GND
[GND-04]
D44
2 1
B320
(GRAY)
F53
(GRAY)
1 2
RY
5
R26
JOINT GROUND
CONNECTOR
REAR COMBINATION LIGHT RH

R147
REF. TO GND
[GND-06]
R147
R26
1 2 3 4 5
R28
F7
F23
HR
(GRAY)
HR
(GRAY)
R79
B97
1 2 3
5 6 7
(BLACK)
4
8
(BLACK)
D34
D80
2 3
1
4 5 6 7 8
1 2
3
4 5 6 7 8
1 2 3
4 5 6
WI-15039
WI-116

WIRING SYSTEM
28.Turn Signal Light and Hazard Light System

A: WIRING DIAGRAM
TURN-01
GW
MB-6
M/B FUSE NO. 6
(B)
CONNECT
FROM FB-2
TO FB-5
BG
TURN-01

IG
IGNITION RELAY
(IG)
F44
B61
OFF
HAZARD
SWITCH
ON
7
BrR
BrR
24
BrR
BrR
B32
BY
BY
11
BY
BY
GW
GW
14
GW
TURN SIGNAL
& HAZARD
MODULE
15
LgB
LgB
12 LgB
BG
BG
13
KEYLESS ENTRY
CONTROL MODULE
BG
LgB 13
i1
B36
BG
B29 LgB
B15 BG
OrW
B176
TURN SIGNAL
SWITCH
L
i22
RH
LH
COMBINATION
METER
TURN SIGNAL
INDICATOR
LIGHT
B:
i10
BY
LgB
BG
TURN-02
TURN-02
TURN-02
12
25
13
26
B10
B71
REF. TO CLEARANCE
LIGHT SYSTEM
[ILLUMI-02]
28
B38
B
i3
REF. TO GND
[GND-03]
B32
(BLACK)
1 2
3
F44
1 2 3
5 6 7
(BLACK)
4
8
B36
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
i22
1 2 3 4
5 6 7 8
B176 (GRAY)
B71
1
9
B:
2
10
i10
3 4 5 6
11 12 13 14 15
7
16
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
8
17
1
14
2 3 4 5 6 7 8 9 10 11
15 16 17 18 19 20 21 22 23 24
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
WI-12289
WI-117

(TURN SIGNAL LIGHT )
CONNECT
FROM FB-5
TO FB-2
BG
B101
D11
OH WH
LgB
LgB
LgB
FRONT
TURN SIGNAL LIGHT LH
BG
B
D15
FRONT
TURN SIGNAL LIGHT RH
2
1
TURN-02
TURN-02
WIRING SYSTEM
LgB
B305
F19
REF. TO GND
[GND-01]
REF. TO GND
[GND-04]
TRAILER CONNECTOR
TURN-01
LgB
LgB
LgB
TURN-01
BG
BG
BG

(TURN SIGNAL LIGHT )
B97
R1
R79
WH OH
1
BG
BG
BG
D1
D5
TURN-01
REAR
TURN SIGNAL LIGHT RH
B30
REAR
TURN SIGNAL LIGHT LH
R147
JOINT GROUND
CONNECTOR
R28
BG
R26
4
5
LgB
OH :WITHOUT MIRROR HEATER

WH :WITH MIRROR HEATER
REF. TO GND
[GND-06]
HR
B305 (GRAY)
R147
HR
F19 (GRAY) 1 2 3 4 5
1 2
R26
B97
R28
1 2 3
5 6 7
R79
1 2 3
4 5 6
: OH
(BLACK)
D5
4
8
D15 : OH
3
2 1
8 7 6 5 4
WI-118
REF. TO GND
[GND-06]
: WH
D1
D15 : WH
D11
D5
4 3
2 1
10 9 8 7 6 5
1 2
3 4
5 6 7 8 9
10 11 12 13 14 15
16 17
18 19
20 21 22 23 24 25
WI-15040
Interior Light System

WIRING SYSTEM
29.Interior Light System

A: WIRING DIAGRAM
MB-6
M/B FUSE NO. 6
(B)
W
C/L-01
FB-8
M/B FUSE NO. 2
(B)
LR
C/L-01
SPOT MAP LIGHT

LR
LR
LR
B36
i1
B8
LR
R56
ROOM LIGHT
1
LR
LR
LR
YR
YR
DOOR
OPEN
WARNING
LIGHT
ON
DOOR
COMBINATION
METER
B90
B2
A5
A: B280
LG
L
LOr
LOr A14
R50
R52
A6
OFF
A:
i12
B:
i10
B: B281
BODY INTEGRATED
UNIT
Y
B7
B20 WR
B8 LOr
B36
KEY WARNING
SWITCH
LR
B97
2
1
LOr
i1
LR
LG
C/L-02
C/L-02
C/L-02
KEY
ILLUMINATION
LR
C/L-02
R1
WR
W
B73
REF. TO GND
[GND-04]
R56
R52
B73
1 2
1 2 3
1
2
3 4 5 6
B36
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B97
1 2 3
5 6 7
(BLACK)
4
8
A:
R50
1
2
3 4 5 6 7 8
B:
i10
i12
(GREEN)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
A: B280
(BLUE)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
HR
B: B281 (GRAY)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
WI-15041
WI-119
Interior Light System
C/L-01
C/L-01
C/L-01
C/L-01
FRONT DOOR
SWITCH RH
Y
B
1
3
C/L-02
C/L-02
WIRING SYSTEM
B268
FRONT DOOR
SWITCH LH
B97
1
3
B267
LOr
B
16
B99
R3
REAR DOOR
SWITCH RH
R1
1
3
Y
B
LR
R16
REAR DOOR
SWITCH LH
R38
LR
YR
D33
LUGGAGE ROOM LIGHT
Y
B
1
1
3
LR
R22
ON
Y
10
R3
D80
1
2
BODY
INTEGRATED
UNIT
A: B280
YR
B
1
2
(BLACK)
REF. TO GND
[GND-0203]
REF. TO GND
[GND-040607]
D46
D46
YR
D81
REAR GATE
LATCH SWITCH
R39
A13
D34
A4
D82
YR
L
B99
OFF
A5
DOOR
D82
R16
D33
1 2 3
R22
1 2 3 4
B267
B97
1 2 3
5 6 7
(BLACK)
4
8
D34
D80
1
2 3
4 5 6 7 8
1 2
3
4 5 6 7 8
(BLACK)
A: B280 (BLUE)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B268
B99
1
2
3
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
WI-12332
WI-120
Front Wiper and Washer System

WIRING SYSTEM
30.Front Wiper and Washer System

A: WIRING DIAGRAM
F/W-01
F/W-01
YB
FB-23
F/B FUSE NO. 15
(ACC)
FRONT
WASHER MOTOR
YB
B61
YB
YB
LgR
2
1
F44
F32
LgR
B62
15 LgR
F45
COMBINATION SWITCH
WASHER SWITCH
ON OFF
LgR 11
B
EW
INTERMITTENT
UNIT
MIST
FRONT WIPER SWITCH
OFF
FRONT WIPER MOTOR

3
YB
YB
17
GY
GY
16
INT
LO
HI
ACC
S1
BL
BL
S2
RL
RL
S3
B70
REF. TO GND
[GND-03]
F32
1 2
(GRAY)
B8
1 2 3
4 5
HR
(GRAY)
B8
REF. TO GND
[GND-04]
F44
1 2 3
5 6 7
F45
(BLACK)
4
8
B70
(BLACK)
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1
10
2
11
3
12
4 5 6
13 14 15
7
16
8
17
9
18
WI-15042
WI-121
Rear Wiper and Washer System

WIRING SYSTEM
31.Rear Wiper and Washer System

A: WIRING DIAGRAM
R/W-01
R/W-01
ACC
IGNITION SWITCH
(ACC)
FUSE
REAR
WASHER MOTOR
15A
1
YB
YB
LB
YR
LB
5
13
2
1
B225
B62
F45
F33
R116
LG
LW
GR
LB
Br
YB
REAR WIPER
INTERMITTENT UNIT
YB
YB
REAR WIPER MOTOR
REAR WIPER SWITCH
YB
YB
YB
YB
YB
LG
LG
LG
LG
LG
WASH OFF INT ON WASH

B
LB
13
LB
LB
12
GR
GR
10
15
Br
Br
13
LW
LW
LW
LW
LW
GR
Br
D80
D34
R3
R39
B99
B70
D81
D43
REF. TO GND
[GND-04]
F33
(GRAY)
1 2
D43
D34
D80
1 2
3 4
1
2 3
4 5 6 7 8
1 2
3
4 5 6 7 8
B99
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
F45
R116
(BLACK)
1 2 3 4
5 6 7 8
B70
1
10
2
11
3
12
4 5 6
13 14 15
7
16
8
17
9
18
B225 (BLACK)
(BLACK)
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
RELAY BLOCK
WI-122
WI-12293
Wiper Deicer System

WIRING SYSTEM
32.Wiper Deicer System
FB-18
F/B FUSE NO.17
(IG)
GOr
RW
FB-35
F/B FUSE NO.18
(IG)
GB
W/D-01

FB-32
F/B FUSE NO.13
(B)
W/D-01
A: WIRING DIAGRAM
WIPER DEICER RELAY

29
30
33
31
RW
RY
GB
YG
B225
WIPER DEICER
1
RY
B
B177
TIMER
GOr
YG
RY
OrW
REF. TO CLEARANCE &

ILLUMINATION LIGHT
SYSTEM [ILLUMI-01]
WIPER DEICER
SWITCH
B193
REF. TO GND
[GND-0203]
B177
1
2
B225 (BLACK)
B193
1 2
3
4 5 6 7 8
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
RELAY BLOCK
WI-12325
WI-123
Audio System
WIRING SYSTEM
33.Audio System
A1
G A9
BrW A3
LW A14
G
BrW
LW
G
12
BrW 13
20
LW
LW
14
B99
B30
R3
LW
2
1
1
2
D4
2
1
D2
LW
D1
2
1
D12
B201
G
BrW
G
BrW
G
BrW
D14
G
BrW
TWISTED PAIR LINE
WB
RY
RY
WB
D11
i40
5
6
14
15
WB
RY
5
6
B101
WB
RY
TWISTED PAIR LINE
YG
LR
WB
RY
1
21
A8
A2
WB
RY
WB
RY
RADIO
YG A10
LR A6
i26
YG
LR
A:
FRONT DOOR
TWEETER RH
FRONT DOOR
SPEAKER RH
FRONT DOOR
SPEAKER LH
FRONT DOOR
TWEETER LH
D2
D4
(BLACK)
D12
D14
(BLACK)
1
2
1 2
A:
AUDIO-01
REF. TO
CLEARANCE
LIGHT &
ILLUMINATION
LIGHT SYSTEM
[ILLUMI-01]
YG
FB-24
F/B FUSE NO. 9
(ACC)
LR

FB-8
M/B FUSE NO. 2
(B)
A7 OrW
AUDIO-01
A: WIRING DIAGRAM
i26
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B99
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B201
(BLACK)
7 8 9 10 11
1 2 3 4 5 6
12 13 14 15 16 17 18 19 20 21 22 23 24
R97
ANTENNA
AMPLIFIER
D1
D11
3 4
1 2
5 6 7 8 9
10 11 12 13 14 15
18 19
16 17
20 21 22 23 24 25
WI-08427
WI-124
Audio System
AUDIO-02
AUDIO
BRACKET
EARTH
BR A11
BY
BR
BY
A5
AUDIO
WR
BY
WF
i64
RB A13
WL
WF
B:
A4
RW A12
i26
B4
B8
Y
WA
B6
SB
WA
B5
B
WA
B1
W
WA
B2
A:
LY
AUDIO-02
WIRING SYSTEM
i29
WR
RB
LY
RW
BY
WL
WA
17
BR
BR
WR
WR
16
RB
B270
D28
W
RB
D22
RB
R3
BY
22
B201
TWISTED PAIR LINE

B266
B99
WL
RB
LY
LY
19
RW
BY
BY
TWISTED PAIR LINE
WL
RW
18
i40
B202
WL
i41
WF
: WITH WOOFER
SB
BR
WA
WA : WITH AUX
TERMUNAL
OA : WITHOUT AUX TERMUNAL
BR
W
2
D23
D29
R117
1
RB
RB
BY
WL
i67
AUX TERMINAL BOX

WOOFER
D23
R117 (BLACK)
D29
1 2
REAR DOOR
SPEAKER LH
REAR DOOR
SPEAKER RH
i67
D22
1
2
3 4 5 6
D28
i64
WA
A: i26
OA :(BLACK)
4 5 6
1 2 3
1 2 3 4
7 8 9 10 11 12 13 14
5 6 7 8
B:
REF. TO GND
[GND-05]
B201 (BLACK)
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3
4 5 6 7 8
1
2
B99
B202
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
WI-12294
WI-125
Front Accessory Power Supply Socket System

WIRING SYSTEM
34.Front Accessory Power Supply Socket System
FAPS-01
YB
FB-25
F/B FUSE NO.4
(ACC)
FAPS-01
A: WIRING DIAGRAM
FRONT ACCESSORY
POWER SUPPLY SOCKET
YB
OrW
REF. TO CLEARANCE LIGHT &

ILLUMINATION LIGHT SYSTEM
[ILLUMI-01]
B119
REF. TO GND
[GND-05]
B119
1 2
3 4
WI-12326
WI-126
Rear Accessory Power Supply Socket System

WIRING SYSTEM
35.Rear Accessory Power Supply Socket System
RAPS-01

FB-25
F/B FUSE NO. 4
(ACC)
YB
LW
FB-26
F/B FUSE NO. 19
(B)
REAR ACCESSORY
RELAY
3
LW
YB
LR
RAPS-01
A: WIRING DIAGRAM
LR
B104
B99
R3
LR
LR
REAR ACCESSORY
POWER SUPPLY SOCKET (CARGO ROOM)
R32
REAR ACCESSORY
POWER SUPPLY SOCKET (CONSOLE BOX)
LB
LB
LR
R200
R146
R201
REF. TO GND
[GND-06]
R147
JOINT GROUND
CONNECTOR
REF. TO GND
[GND-06]
REF. TO GND
[GND-02]
R32
R200
1
2
R146
1
2
B104 (BLACK)
1 2
3
4
R147
B99
1 2 3 4 5
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
WI-12295
WI-127
Horn System
WIRING SYSTEM
36.Horn System
HORN-01
HORN-01
A: WIRING DIAGRAM
MB-5
HORN RELAY
RG
RG
MB- 4
HORN RELAY
BL
B62
RG
RG
16
F45
BL
B236
ST1
F2
STEERING ROLL
CONNECTOR
5
BL
B100
B26
B176
ST4
24
F5
GR
BL
BL
RG
ST2
HORN
HORN
ST2
B236
F2
1 2 3 4 5
1
2 3
4 5 6 7 8
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
(BLUE)
KEYLESS ENTRY
CONTROL MODULE
F45
HORN SWITCH
(BLACK)
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B176 (GRAY)
1
14
2 3 4 5 6 7 8 9 10 11
15 16 17 18 19 20 21 22 23 24
12
25
13
26
WI-12296
WI-128
Power Window System

WIRING SYSTEM
37.Power Window System

A: WIRING DIAGRAM
MB-11
SBF-6
(B)
P/W-01
P/W-01
BW
GW
IG
IGNITION RELAY
(IG)
F44
2
1
BW
POWER WINDOW
CIRCUIT BREAKER
B61
BW
WG
A
B
C
P/W-02
D
E
F
P/W-02
P/W-03
P/W-04
B41
POWER WINDOW
RELAY
17
18
14
16
WG
GB
GW
B
B225
P/W-03
P/W-04
GB
25
GB
GB
13
LR
UP
FRONT LH
POWER WINDOW
MAIN SWITCH
D1
LOCK UNLOCK
B
B41
D3
1
2
F44
(GREEN)
1 2 3
5 6 7
(BLACK)
4
8
DOWN
POWER WINDOW LOCK SWITCH
D3
REF. TO GND
[GND-02]
DRIVER
CIRCUIT
D7
LR
B30
G
H
I
FRONT POWER WINDOW

MOTOR LH
D7
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
D1
1 2
3 4
5 6 7 8 9
10 11 12 13 14 15
16 17
18 19
20 21 22 23 24 25
P/W-02
P/W-03
P/W-04
B225 (BLACK)
1
9 14 15 16 19 24 25 26 29 34 35 36
17
27
37
10
20
30
11 12 13 18 21 22 23 28 31 32 33 38
RELAY BLOCK
WI-12297
WI-129
Power Window System
P/W-02
P/W-02
WIRING SYSTEM
P/W-01
P/W-01
FRONT POWER WINDOW

SUB-SWITCH RH
OFF
UP

FRONT RH
DOWN
1
GB
GB
GB
25
GB
OFF
BL
BL
23
BL
BL
23
BL
FR U
LY
LY
LY
LY
LY
FR D
D7
LR
B30
D17
DOWN
D1
B
B101
LR
L
P/W-01
D11
UP
1
2
D13
FRONT POWER WINDOW

MOTOR RH
D13
1
2
(GREEN)
REF. TO GND
[GND-04]
D17
D7
3
1 2
4 5 6 7 8
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
D1
D11
3 4
1 2
5 6 7 8 9
10 11 12 13 14 15
16 17
18 19
20 21 22 23 24 25
WI-12298
WI-130
Power Window System
P/W-03
P/W-03
WIRING SYSTEM
P/W-01
P/W-01
REAR POWER WINDOW

SUB-SWITCH LH
OFF
UP

REAR LH
DOWN
1
GB
GB
GB
GW
LW
LR
OFF
1
GB
GW
GR
GR
13
GB
10
RL U
LW
GY
GY
12
GY
11
RL D
D7
B30
B
D22
D25
DOWN
D1
B
B270
H
LR
L
P/W-01
UP
2
1
D24
REAR POWER WINDOW

MOTOR LH
D24
1
2
(GREEN)
D22
1 2 3
4 5 6 7 8
D25
1 2
3
4 5 6 7 8
REF. TO GND
[GND-03]
D7
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
D1
1 2
3 4
5 6 7 8 9
10 11 12 13 14 15
16 17
18 19
20 21 22 23 24 25
WI-12299
WI-131
Power Window System
P/W-04
P/W-04
WIRING SYSTEM
P/W-01
P/W-01
REAR POWER WINDOW

SUB-SWITCH RH
OFF
UP

DOWN
REAR RH
1
GB
OFF
GB
GB
GB
GW
GW
GW
GW
11
GW 15
FR U
LW
LW
LW
LW
10
LW
16
FR D
D7
LR
B30
D31
D28
DOWN
D1
B
B266
LR
L
P/W-01
UP
2
1
D30
REAR POWER WINDOW

MOTOR RH
D30
1
2
(GREEN)
D28
1 2 3
4 5 6 7 8
REF. TO GND
[GND-04]
D31
3
1 2
4 5 6 7 8
D7
D1
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
3 4
1 2
5 6 7 8 9
10 11 12 13 14 15
16 17
18 19
20 21 22 23 24 25
WI-12300
WI-132
Rear Defogger System

WIRING SYSTEM
38.Rear Defogger System
R/DEF-01
R/DEF-01
A: WIRING DIAGRAM
FB-15
F/B FUSE No.18
(IG)
RL
FB-13
REAR DEFOGGER
RELAY
GB
FB-14
REAR DEFOGGER
RELAY
B19 GB
A: B280
B: B281
A4
A13
B1
B14
AA
11
AA
B11
A3
RL
10
RL
MA
: MANUAL A/C
AA
: AUTO A/C
MA
AUTO A/C
CONTROL
MODULE
ECM
B14
B: B135
MA
BODY
INTEGRATED
UNIT
A10
11
RL
B201
RL
i49
i40
B:
AA
MA
i48
B97
4
10
RL
R1
RL
MANUAL
A/C CONTROL
MODULE
A:
REF. TO GND
[GND-02]
REF. TO GND
[GND-05]
i16
REAR DEFOGGER
RL
RL
RL
D79
D81
B
D80
D34
D40
R39
REF. TO GND
[GND-07]
B97
1 2 3
5 6 7
(BLACK)
4
8
D34
D80
i16
1
2 3
4 5 6 7 8
1 2
3
4 5 6 7 8
1 2
3 4 5
6 7 8 9 10 11 12
HR
B: B281 (GRAY)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B201 (BLACK)
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
A: B280
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B: B135
A:
(BLUE)
i48
(GRAY)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B:
i49
(GRAY)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
HR
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
32 33
34 35
28 29 30 31
WI-15043
WI-133

WIRING SYSTEM
39.Remote Control Mirror System

A: WIRING DIAGRAM
R/M(OS)-01
GB
FB-25
F/B FUSE NO.4
(ACC)
FB-18
F/B FUSE NO.17
(IG)
YB
MIRROR HEATER
RELAY
FB-35
F/B FUSE NO.18
(IG)
GOr
FB-32
F/B FUSE NO.13
(B)
RW
R/M(OS)-01
1. WITHOUT OUTER MIRROR TURN SIGNAL LIGHT
WIPER DEICER SWITCH
RW
RY
GB
YG
29
30
33
31
GOr
YG
B
RY
B
B225
WH OH
1
5
B30

D1
YR
MIRROR HEATER
17
D1
14
RY
REMOTE CONTROL SWITCH
RY
L
B
YR
UP DOWN
2
RB
LH RH
3
LR
TIMER
B193
B30
5
6
7
1
4
DOWN
UP
CHANGE OVER
SWITCH
L
Lg
RL
D5
MIRROR HEATER
WH OH
1
5
RY
14
RY
RL
19
RL
UP DOWN
1
19
RL
LR
RB
7
D61
LH RH
3
Lg
20
Lg
20
Lg
18
18
B101
B30
D1
D11
D15
OH : WITHOUT MIRROR HEATER

WH : WITH MIRROR HEATER
REF. TO GND
[GND-04]
D5
: OH
D15 : OH
3 2 1
6 5 4
D5
: WH
D15 : WH
B193
1 2
3
4 5 6 7 8
REF. TO GND
[GND-02]
D61
1 2 3 4 5 6 7 8 9 10
D1
D11
1 2
3 4
5 6 7 8 9
10 11 12 13 14 15
18 19
16 17
20 21 22 23 24 25
4 3 2 1
8 7 6 5
B225 (BLACK)
1
9 14 15 16 19 24 25 26 29 34 35 36
17
27
30
37
20
10
11 12 13 18 21 22 23 28 31 32 33 38
RELAY BLOCK
WI-12327
WI-134

WIRING SYSTEM
R/M(WS)-01
GB
FB-18
F/B FUSE NO.17
(IG)
YB
MIRROR HEATER
RELAY
FB-25
F/B FUSE NO.4
(ACC)
FB-35
F/B FUSE NO.18
(IG)
GOr
FB-32
F/B FUSE NO.13
(B)
RW
R/M(WS)-01
2. WITH OUTER MIRROR TURN SIGNAL LIGHT
WIPER DEICER SWITCH
RW
RY
GB
YG
29
30
33
31
GOr
YG
B
RY
B
B225
WH OH
4
B30

D1
YR
MIRROR HEATER
17
D1
RY
10
14
REMOTE CONTROL SWITCH
RY
L
UP DOWN
YR
RB
Lg
RL
LH RH
8
LR
TIMER
B193
B30
5
6
7
1
4
DOWN
UP
CHANGE OVER
SWITCH
L
D5
MIRROR HEATER
WH OH
4
10
RY
14
RY
19
RL
UP DOWN
7
RL
Lg
20
18
19
RL
Lg
20
Lg
18
LR
RB
7
D61
LH RH
D11
B101
B30
D1
D15
OH : WITHOUT MIRROR HEATER

WH : WITH MIRROR HEATER
REF. TO GND
[GND-04]
D5
: OH
D15 : OH
2 1
3
8 7 6 5 4
D5
: WH
D15 : WH
REF. TO GND
[GND-02]
B193
D61
1 2
3
4 5 6 7 8
1 2 3 4 5 6 7 8 9 10
2 1
4 3
10 9 8 7 6 5
D1
D11
3 4
1 2
5 6 7 8 9
10 11 12 13 14 15
18 19
16 17
20 21 22 23 24 25
WI-135
B225
1
(BLACK)
9 14 15 16 19 24 25 26 29 34 35 36
17
27
30
37
20
10
11 12 13 18 21 22 23 28 31 32 33 38
RELAY BLOCK
WI-12328
Combination Meter
WIRING SYSTEM
40.Combination Meter
TO C:
METER-01
METER-01
A: WIRING DIAGRAM
i11
C1
C2
C5
C6
C9
C10
TO B:
i10
B15
B1
B16
B7
B8
B29
B14
B30
TO A:
A1
A3
A4
A6
i12
A7
A8
A13
A14
WI-12301
WI-136
WI-137
ABS WARNING LIGHT
HI-BEAM INDICATOR LIGHT
SECURITY / IMMOBILIZER
INDICATOR LIGHT
DOOR
WARNING LIGHT
VDC OPERATION INDICATOR LIGHT
VDC WARNING LIGHT /

VDC OFF INDICATOR LIGHT
SEAT BELT WARNING LIGHT
METER-02
HEADLIGHT RELAY RH
B26
B8
B27
A4
A14
ABS
MALFUNCTION INDICATOR LIGHT
REVERSE
CIRCUIT
AWD WARNING LIGHT/

FWD PILOT LIGHT
ATF TEMPERATURE WARNING LIGHT
B9
IGNITION SWITCH
METER-02
DIMMER SWITCH
SECURITY/IMMOBILIZER
CONTROL MODULE
A6
B20
C7
B18
A1
ABS
CHARGE WARNING LIGHT
PARKING BRAKE/
BRAKE FLUID LEVEL
WARNING LIGHT
OIL PRESSURE WARNING LIGHT
VDC
REVERSE
CIRCUIT
BATTERY
FRONT DOOR SWITCH
DOOR SWITCH
VDC CONTROL MODULE
BODY INTEGRATED
UNIT
VDC
C6
ABS
VDC
ECM
VDC
C4
A2
VDC
VDC CONTROL MODULE
ABSCM
TCM
A3
A5
A7
C3
ABS
OIL PRESSURE SWITCH
GENERATOR
BRAKE FLUID LEVEL

WARNING SWITCH
ABS
VDC
PARKING BRAKE SWITCH
VDC CONTROL MODULE
ABSCM
Combination Meter
WIRING SYSTEM
ABS : WITHOUT
VDC
VDC : WITH VDC
A
METER-03
B
METER-03
C
METER-04
VDC
ABS
WI-15242
ECM
B10
WI-138
LCD BACK-UP LIGHT
LCD BACK-UP LIGHT
AIRBAG CIRCUIT
TURN SIGNAL INDICATOR LIGHT RH
METER-02
TURN SIGNAL INDICATOR LIGHT LH
CRUISE SET
INDICATOR LIGHT
CRUISE CONTROL
INDICATOR LIGHT
METER-02
B21
C5
C8
B29
B15
METER-03
AIRBAG CONTROL
MODULE
TURN SIGNAL SWITCH
METER-03
Combination Meter
WIRING SYSTEM
IGN
DIMMER CIRCUIT
DRIVER
D
E
F
METER-04
G
METER-04
METER-04
METER-04
WI-12303
I/F
WI-139
I/F
MT
I/F
EEPROM
LCD (ODO / TRIP /

AMBIENT TEMPERATURE /
AT INDICATOR)
DRIVER
B
A
TRIP A/B CHANGE
OVER
& RESET SWITCH
D
I/F
I/F
B30
DRIVER
I/F
SPEEDOMETER
B24
E
C
B25
METER-03
AMBIENT SENSOR
I/F
B12
AT
TACHOMETER
TCM
METER-03
B11
LOW-FUEL
WARNING LIGHT
ECM
B14
POWER
CIRCUIT
FUEL GAUGE
TCM
C1
C9
ENGINE
COOLANT
TEMPERATURE
GAUGE
H
EGI
C10
METER-03
THERMOMETER
METER-02
A11
METER-03
ILLUMINATION
LIGHT
A10
TAIL &
ILLUMINATION RELAY
METER-04
MT : MT MODEL
AT : AT MODEL
METER-04
Combination Meter
WIRING SYSTEM
I/F
I/F
- COM
WI-12304
Clock System
WIRING SYSTEM
41.Clock System
CLOCK-01
CLOCK-01
A: WIRING DIAGRAM
LR
LR
YG
YG
FB-24
F/B FUSE NO.9
(ACC)
YG
LR
FB-8
M/B FUSE NO.2
(B)
CLOCK
LCD
LCD
BACK-UP
LIGHT
LR
YG
10
OrW
OrW
YB
YB
B36
i1
PASSENGER'S
SEAT AIRBAG
WARNING LIGHT (OFF)
28
YL
YR
GR
REF. TO
CLEARANCE LIGHT &
ILLUMINATION LIGHT
SYSTEM [ILLUMI-02]
30 OrW
20
i3
7
V
B38
PASSENGER'S
SEAT AIRBAG
WARNING LIGHT (ON)
DIMMER &
STABILIZING
POWER CIRCUIT
IC
REF.TO OCCUPANT
DETECTION
SYSTEM [ODS-01]
i59
REF. TO GND
[GND-03]
i59
(GREEN)
1 2 3 4 5 6 7 8 9 10
B36
B38
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
WI-12305
WI-140
Fuel Gauge System

WIRING SYSTEM
42.Fuel Gauge System

FUEL/G-01
FUEL/G-01
A: WIRING DIAGRAM
GR
FB-22
F/B FUSE NO.14
(IG)
GR
i1
B9
B36
GR
GR
COMBINATION
METER
I/F
1 : NON-TURBO MODEL : BW
: BR
TURBO MODEL
FUEL
GAUGE
LOW-FUEL
WARNING
LIGHT
- COM
BrW C1
B10
BrW
B
B
BrW 16
28
5
BrW
i11
i3
FUEL GAUGE SUB UNIT
BrW
L
i10
C:
I/F
DRIVER
1
2
B:
BrW
BrW
B38
BrW
BrW B10
B: B135
R59
ECM
BW
R57
R58
BW
BW
R15
12
R2
BL
B98
BL
B22
36
*1
E3
*1
L
BW
3
2
REF. TO GND
[GND-03]
R59
HR
R58
HR
1 2 3
4 5 6
1 2
C:
B98
R57
i11
GE
(GREEN)
1 2 3 4 5 6 7 8 9 10
1 2
3 4 5
6 7 8 9 10 11 12
B:
B36
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B: B135
HR
i10
(GREEN)
8 9 10 11 12 13 14
1 2 3 4 5 6 7
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B22
(BLACK)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
WI-141
WI-15044
Coolant Temperature System

WIRING SYSTEM
43.Coolant Temperature System

C/TEMP-01
C/TEMP-01
A: WIRING DIAGRAM
FB-22
F/B FUSE NO.14
(IG)
*1
GR
*2
: NON-TURBO MODEL : BL
: TURBO MODEL
GR
GR
B36
: BW
: NON-TURBO MODEL : BL
: TURBO MODEL
: WG
3 : NON-TURBO MODEL : 11
GR
i1
B9
: TURBO MODEL
*4
:6
: NON-TURBO MODEL : 36
: TURBO MODEL
: 35
COMBINATION
METER
BW
15
B:
i10
C:
i11
C9
WG C10
13
ENGINE
COOLANT
TEMPERATURE
GAUGE
*2 *3
WG
B22
B22
E3
*2
BW
*4 *1
E3
*1
WG
i3
B38
BW
E8
GE
THERMOMETER
E8
C:
(LIGHT GRAY)
1 2
3
i11
B36
(GREEN)
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10
B22
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
B:
i10
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
(BLACK)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-12307
WI-142
Oil Pressure Warning Light System

WIRING SYSTEM
44.Oil Pressure Warning Light System

A: WIRING DIAGRAM
OIL/P-01
OIL/P-01
GR
FB-22
F/B FUSE NO.14
(IG)
GR
i1
B9
B36
GR
GR
COMBINATION
METER
i12
B:
i10
GW A3
OIL PRESSURE
WARNING
LIGHT
A:
: NON-TURBO MODEL : BrB
i3
:G
B38
GW
GW
14
: TURBO MODEL
GW
*1
31
B22
*1
E3
E11
OIL PRESSURE SWITCH

A:
i12
(GREEN)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B36
B22
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
(BLACK)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
B:
i10
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
34
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-12308
WI-143
Parking Brake/Brake Fluid Level Warning Light System

WIRING SYSTEM
46.Parking Brake/Brake Fluid Level Warning Light System

A: WIRING DIAGRAM
BR/W(A)-01
BR/W(A) -01
1. WITHOUT VDC
GR
FB-22
F/B FUSE NO.14
(IG)
B36
B9
GR
i1
PARKING BRAKE/
BRAKE FLUID LEVEL
WARNING LIGHT
B301
BRAKE FLUID LEVEL

WARNING SWITCH
i3
i11
Lg
BW
B36
BW
24 LgB
i10
C:
10
31
26
Br
Lg
i12
B:
i1
B38
A:
A5
BW
BW
A7
Lg
Br
Lg
Br
ABS CONTROL MODULE
Br
C3
REVERSE
CIRCUIT
COMBINATION
METER
B16
DIODE
B62
BW
F45
B99
Lg
Lg
LgB
BW
Lg
R3
3
4
B95
F26
1
R4

A1 LgB
A: B280
GENERATOR
REF. TO GND
[GND-04]
B16
1
2
(GRAY)
F26
1 2 3
HR
(GREEN)
B95
(BROWN) C:
1 2 3 4
i11
(GREEN)
1 2 3 4 5 6 7 8 9 10
PARKING BRAKE
SWITCH
A:
i12
(GREEN)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
A: B280
(BLUE)
B:
i10
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B36
B38
(GREEN)
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
(BLACK)
B99
F45
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B301 (BLACK)
12
13
14
15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
WI-15248
WI-145
Parking Brake/Brake Fluid Level Warning Light System

WIRING SYSTEM
BR/W(V)-01
BR/W(V) -01
2. WITH VDC
GR
FB-22
F/B FUSE NO.14
(IG)
B36
B9
GR
i1
COMBINATION
METER
B310
BRAKE FLUID LEVEL

WARNING SWITCH
i3
i10
C:
i11
10
31
26
B36
BW
Lg
Lg
Lg
i12
B:
i1
B38
A:
A5
BW
BW
A7
Lg
Lg
Lg
54
Br
VDC CONTROL MODULE
Br
C3
PARKING BRAKE/
BRAKE FLUID LEVEL
WARNING LIGHT
BW
B16
B62
R3
B99
LgB 24
BW
F45
Lg
Lg
Lg
LgB
F26
R4
1
3
4
BW
DIODE
B95

A1 LgB
GENERATOR
A: B280
REF. TO GND
[GND-04]
B16 (GRAY)
1
2
F26
HR
(GREEN)
1 2 3
B95 (BROWN) C:
1 2 3 4
i11
PARKING BRAKE
SWITCH
(GREEN)
A:
(GREEN)
i12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
1 2 3 4 5 6 7 8 9 10
(BLUE)
A: B280
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B:
i10
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B36
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
(BLACK)
B99
F45
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B310 (BLACK)
1
29
30
31
32
33
34
35
56 57 58 59 60 61 62 63 64 65
10
9
36
66
37
67
12
11
38
68
39
69
14
13
40
70
41
71
16
15
42
72
43
73
18
17
44
74
WI-146
45
75
20
19
46
76
47
77
22
21
48
78
49
79
24
26
28
23
25
27
50
51
52
53
54
55
80 81 82 83
WI-15249
Sunroof Control System

WIRING SYSTEM
47.Sunroof Control System

A: WIRING DIAGRAM
IG
IGNITION RELAY
(IG)
BW
BW
GW
MB-11
SBF-6
(B)
S/R-01
S/R-01
MT : MT MODEL
BW
F44
AT
B61
NA : NON-TURBO
MODEL
TB : TURBO MODEL
POWER WINDOW
CIRCUIT BREAKER
2
1
: AT MODEL
BW
WG
B41
POWER WINDOW
RELAY
17
18
14
16
WG
GB
GW
B
GB
GB
GB
GY
GB
GB
B225
VEHICLE SPEED
SENSOR (MT MODEL)
GY
MT
AT
B17
R50
B90
R55
SUNROOF
CONTROL
MODULE &
MOTOR
SUNROOF SWITCH
TCM (AT MODEL)
OPEN
BY
CLOSE
GR
A21 GY
B54
B
A:
S1
REF. TO GND
[GND-02]
B41
R55
B17
1
2
2 1
1 2 3
A:
B54
HR
(BLACK) : NA
HR
(BLACK) : TB
1 2
3 4
HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B17
S1
1 2 3 4 5
F44
1 2 3
5 6 7
(BLACK)
4
8
R50
1
2
3 4 5 6 7 8
B225 (BLACK)
5 6
14 15 16
25 26 27
33 34 35
9 14 15 16 19 24 25 26 29 34 35 36
17
27
30
37
10
20
11 12 13 18 21 22 23 28 31 32 33 38
WI-15046
RELAY BLOCK
WI-147

WIRING SYSTEM
48.Keyless Entry System

A: WIRING DIAGRAM
K/L-01
FB-15
F/B FUSE NO.18
(IG)
GB
RG
LR
BL
FB-8
F/B FUSE NO.2
(B)
LR
K/L-01

MB-12
MB-6
MB-4
MB-5
M/B FUSE NO.2
M/B FUSE NO.6
HORN RELAY
HORN RELAY
(B)
(B)
HORN
BL
BL
F5
BL
B100
4
W
YB
K/L-02
IMMOBILIZER
CONTROL MODULE
B61
RG
B62
BL
F44
16
F45
10
HORN
RG
YB
F2
LOr
BrR
B26
B141
KEYLESS BUZZER
2
LR
YB
F102
KEY WARNING
SWITCH
WR
B73
STEERING
ROLL CONNECTOR
GB
10
B19 GB
LR
2
B20 WR
BrR
26
24
15
B236
WR
ST2
RG
RG
ST4
YB
GR
HORN SWITCH
B176 KEYLESS ENTRY CONTROL MODULE
HR
F102 (BLACK)
1 2
ST2
B73
B236
1 2 3 4 5
1
2
3 4 5 6
1
2 3
4 5 6 7 8
F45
(BLACK)
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
F44
1 2 3
5 6 7
(BLACK)
4
8
B141 (GRAY)
1
14
2 3 4 5 6 7 8 9 10 11
15 16 17 18 19 20 21 22 23 24
B: B281
HR
B: B281 (GRAY)
F2
(BLUE)
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B176 (GRAY)
12
25
13
26
1
14
2 3 4 5 6 7 8 9 10 11
15 16 17 18 19 20 21 22 23 24
12
25
13
26
WI-15047
WI-148

WIRING SYSTEM
K/L-02
B176
LR
FB-8
M/B FUSE NO.2
(B)
BG
LgB 13
14
B
OrB 18
REF. TO
TURN SIGNAL LIGHT &
HAZARD LIGHT SYSTEM
ROOM
[TURN-01]
LIGHT
LR
LR
YR
COMBINATION
METER
B:
i10
A:
i12
B90
A6
L
A5
BODY
OrB B14 INTEGRATED
OrW B13 UNIT
7
B36
A: B280
8
LOr
OFF
R52
i1
K/L-01
DOOR
ON
R50
LOr A14
DOOR WARNING
LIGHT
B8
LR
LR
i1
OrW 19
B36
K/L-02
LOr B8
REF. TO IMMOBILIZER
SYSTEM [IMB-01]
B: B281
B7
A4
A13
Y
B
16
B99
R3
Y
B
R22
YR
YR
YR
YR
B
1
2
D46
D34
D80
D81
Y
B
REF. TO GND
[GND-0607]
R16
1
2
REAR GATE
LATCH SWITCH
D33
R39
1
3
D46 (BLACK)
R38
B268
1
3
REAR DOOR
SWITCH RH
REF. TO GND
[GND-0203]
B267
1
3
REAR DOOR
SWITCH LH
REF. TO GND
[GND-04]
LOr
B
FRONT DOOR
SWITCH RH
1
3
FRONT DOOR
SWITCH LH
(BLACK)
B267
B268
R52
D33
D34
D80
R16
R22
1 2 3
1 2 3 4
2 3
1
4 5 6 7 8
1 2
3
4 5 6 7 8
A:
R50
1
B:
B36
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
A: B280 (BLUE)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
i10
(GREEN)
B176 (GRAY)
B99
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
(GREEN)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
3 4 5 6 7 8
1
2
3
HR
B: B281 (GRAY)
i12
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
1
14
2 3 4 5 6 7 8 9 10 11
15 16 17 18 19 20 21 22 23 24
12
25
13
26
WI-15048
WI-149

WIRING SYSTEM
K/L-03
4
YR
YR B11
A8
R
RW B12
A7
DOOR LOCK SWITCH

LH
RG
RG
YR
24
YR
Lg
LgB
RW
16
RW
D26
D22
B270
D7
4
RG
RG
Lg
LgB
22
RG
21
LgB
LgB
RG
B30
12
B266
LgB
D1
D8
B99
RG
LgB
D28
DOOR LOCK SWITCH

RH
R3
RG
D32
FRONT DOOR LOCK

ACTUATOR
LH
LgB
YR
24
YR
RW
RW
R38
D62
REAR DOOR LOCK

ACTUATOR RH
RG
REAR DOOR LOCK

ACTUATOR LH
KEYLESS ENTRY
CONTROL MODULE
B176
RW
B: B281
LgB A6
K/L-03
A: B280
FRONT DOOR LOCK

ACTUATOR
RH
RG
Lg
D33
D80
RG
D47
D18
D33
D62
D22
D80
D26
D32
1 2 3 4
1 2 3 4 5
D28
1 2
3
4 5 6 7 8
4
2
2 3
4 5 6 7 8
1 2
3 4
D1
B99
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
D11
D18
A: B280 (BLUE)
D7
(BLACK)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
RG
LgB
B
D8
HR
B: B281 (GRAY)
22
21
REF. TO GND
[GND-04]
REF. TO GND
[GND-02]
REAR GATE LOCK

ACTUATOR
D47
RG
LgB
B101
LgB
D81
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
D11
1 2
3 4
5 6 7 8 9
10 11 12 13 14 15
16 17
18 19
20 21 22 23 24 25
WI-150
B176 (GRAY)
1
14
2 3 4 5 6 7 8 9 10 11
15 16 17 18 19 20 21 22 23 24
12
25
13
26
WI-15049
Security System
WIRING SYSTEM
49.Security System
A: WIRING DIAGRAM
SEC(NA)-01
SEC(NA)-01
1. NON-TURBO MODEL
MB-9
SBF-5
(B)
FB-15
F/B FUSE NO.18
(IG)
FB-8
M/B FUSE NO.2
(B)
BR
GB
LR
WL
IG
IGNITION RELAY
(IG)
GW

ST
IGNITION SWITCH
(ST)
INTERRUPT RELAY
: MT MODEL
AT
: AT MODEL
F44
BR
WL
WR
WL
RB
BR
5
2
3
1
MT
B59
B61
C: B136
BL
STARTER INTERLOCK
RELAY (MT MODEL)
28
27
26
24
C6
ECM
STARTER INTERLOCK
RELAY (AT MODEL)
WR
YL
WR
GL
MT
AT
DATA LINK
CONNECTOR
BL
5
28
27
26
24
WR
LR
WR
GY
4
16
GW
B225
B225
CLUTCH SWITCH
(MT MODEL)
P
2
1
BL
BR
GL
GY
MT
AT
LR
12
BY
12
YL
11
BW
T3
B12
MT
B106
GrB
7
B40
SEC(NA)-02
T7
STARTER MOTOR
AT
L
8
B348
B14
B176
ECM
IMPACT
SENSOR
KEYLESS ENTRY
CONTROL MODULE
B106
B59
1
2
1 2 3
4
5
(GRAY)
B348
F44
1 2 3 4
5 6 7 8
1 2 3
5 6 7
1
14
2 3 4 5 6 7 8 9 10 11
15 16 17 18 19 20 21 22 23 24
(BLACK)
12
25
13
26
B12
HR
(GRAY)
T7
1 2 3 4
5 6 7 8
9 10 11 12
4
8
C: B136
B176 (GRAY)
4
3
1
2
8
7
GB
10
17 GrB
RB
YL
C: B136
12
C20 GY
LR
GrB
GB
L
WG
B
TO BATTERY
TERMINAL
1 2 3 4 5 6
7 8 9 10 11 12
B40
(BLACK)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B225 (BLACK)
HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
(BLACK)
REF. TO GND
[GND-04]
5 6
14 15 16
25 26 27
33 34 35
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
RELAY BLOCK
WI-151
WI-15050
Security System
SEC(NA)-02
SEC(NA)-02
WIRING SYSTEM

FB-8
M/B FUSE NO.2
(B)
LR
BL
RG
MB-5
MB-4
HORN RELAY HORN RELAY
HORN
LR
BL
B36
6
BL
F5
F2
F45
BL
LR
B62
B8
RG
16
BL
HORN
i1
RG
4
B100
B26
COMBINATION
METER
HORN SWITCH
5
ST2
STI
RG
B:
i10
A:
i12
B236
WG A4
GR
ST4
SECURITY/
IMMOBILIZER
INDICATOR
LIGHT
WG
STEERING
ROLL CONNECTOR
18
i3
WG
B38
WG
24
15
RG
SEC(NA)-01
B176
ST2
B236
1 2 3 4 5
1
2 3
4 5 6 7 8
F45
A:
(GREEN)
F2
B176
1
14
(GRAY)
2 3 4 5 6 7 8 9 10 11
15 16 17 18 19 20 21 22 23 24
(BLUE)
B36
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
1 2 3
4 5 6
7 8 9 10 11 12 13 14
(BLACK)
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
i12
B:
12
25
13
26
i10
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
(GREEN)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
WI-12264
WI-152
Security System
SEC(NA)-03
B176
14
SEC(NA)-03
WIRING SYSTEM
B36
A6
i1
LOr A14
COMBINATION
METER
A: i12
i1
LOr
FRONT DOOR
SWITCH LH
1
3
FRONT DOOR
SWITCH RH
B36
LOr
B
B267
Y
B
B268
1
3
16
B99
1
3
REAR DOOR
SWITCH RH
REF. TO GND
[GND-03]
REF. TO GND
[GND-04]
R3
REAR DOOR SWITCH LH
R38
Y
B
YR
YR
B
D80
B
1
3
2
3
YR
B
YR
B
1
2
R22
R39
REAR GATE
LATCH SWITCH
D33
D81
D46
D34
Y
B
R16
REF. TO GND
[GND-06, 07]
D46
(BLACK)
1
2
B36
B99
(BLACK)
B267
B268
D33
D34
D80
R16
R22
1 2 3 4
1
2 3
4 5 6 7 8
1 2
3
4 5 6 7 8
1
2
3
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B176
1
14
A:
i12
(GREEN)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
(GRAY)
2 3 4 5 6 7 8 9 10 11
15 16 17 18 19 20 21 22 23 24
12
25
13
26
WI-153
WI-08446
Security System
WIRING SYSTEM
SEC(TB)-01
SEC(TB)-01
2. TURBO MODEL
IG
IGNITION RELAY
(IG)
FB-15
F/B FUSE NO.18
(IG)
FB-8
M/B FUSE NO.2
(B)
GW
GB
LR
WL
MB-9
SBF-5
(B)
BR

ST
IGNITION SWITCH
(ST)
C: B136
MT
: MT MODEL
BL
INTERRUPT RELAY
AT
5
2
3
1
: AT MODEL
BR
ECM
DATA LINK
CONNECTOR
BL
5
B61
F44
WL
WR
WL
RB
C6
BR
B59
BL
GW
BR
16
7
GrB 10
STARTER INTERLOCK
RELAY (MT MODEL)

P
28
27
26
24
WR
YL
WR
GY
MT
AT
WR
12
BY
YL
11
BW
B40
12
7
AT
MT
T3
B12
T7
B225
CLUTCH SWITCH
(MT MODEL)
A
2
1
SEC(TB)-02
GY
B
STARTER MOTOR
B106
L
8
B176
KEYLESS ENTRY
CONTROL MODULE
REF. TO GND
[GND-02]
B59
1
2
1 2 3
4
5
(GRAY)
B348
1 2 3 4
5 6 7 8
F44
1 2 3
5 6 7
B12
(BLACK)
1 2 3 4
5 6 7 8
9 10 11 12
4
8
T7
B40
(BLACK)
1 2 3 4 5 6
7 8 9 10 11 12
REF. TO GND
[GND-04]
(BLACK)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B225 (BLACK)
HR
2 3 4 5 6 7 8 9 10 11
15 16 17 18 19 20 21 22 23 24
HR
(GRAY)
IMPACT
SENSOR
C: B136
B176 (GRAY)
1
14
4
3
1
2
8
7
GB
10
B348
B14
B106
17 GrB
RB
YL
12
LR
GrB
GB
L
WG
B
TO BATTERY
TERMINAL
12
25
13
26
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
9 14 15 16 19 24 25 26 29 34 35 36
10
17
20
27
30
37
11 12 13 18 21 22 23 28 31 32 33 38
RELAY BLOCK
WI-154
WI-15051
Security System
SEC(TB)-02
SEC(TB)-02
WIRING SYSTEM
MB-5
HORN RELAY
RG
FB-8
M/B FUSE NO.2
(B)
LR
MB-4
HORN RELAY
BL
LR
HORN
BL
B36
BL
F5
RG
F45
BL
LR
B62
B8
RG
16
4
BL
B100
HORN
LR
i1
F2
B26
COMBINATION
METER
SECURITY/
IMMOBILIZER
INDICATOR
LIGHT
HORN SWITCH
5
ST4
3
STI
ST2
RG
i10
A:
i12
B236
WG A4
GR
B:
WG
STEERING
ROLL CONNECTOR
WG
18
i3
SEC(TB)-01
B38
IMMOBILIZER
CONTROL MODULE
WG
BrR
5
9
24
15
RG
BrR
B141
B176
ST2
B236
1 2 3 4 5
1
2 3
4 5 6 7 8
A:
i12
(GREEN)
F2
(BLUE)
B36
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B141 (GRAY)
F45
(BLACK)
B:
i10
(GREEN)
B38
B176 (GRAY)
1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1
14
2 3 4 5 6 7 8 9 10 11
15 16 17 18 19 20 21 22 23 24
12
25
13
26
1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
WI-12266
WI-155
Security System
B176
SEC(TB)-03
SEC(TB)-03
WIRING SYSTEM
14
B36
A6
i1
COMBINATION
METER
A:
LOr A14
i12
i1
LOr
FRONT DOOR
SWITCH LH
1
3
FRONT DOOR
SWITCH RH
B36
LOr
B
B267
1
3
B268
Y
B
16
B99
1
3
REAR DOOR
SWITCH RH
REAR DOOR SWITCH LH
REF. TO GND
[GND-03]
REF. TO GND
[GND-04]
R3
R38
Y
B
YR
YR
B
D80
B
1
3
2
3
YR
B
YR
B
1
2
R22
R39
REAR GATE
LATCH SWITCH
D33
D81
D46
D34
Y
B
R16
REF. TO GND
[GND-06, 07]
D46
(BLACK)
1
2
B36
B99
B267
B268
D33
D34
D80
R16
R22
1 2 3 4
1
2 3
4 5 6 7 8
1 2
3
4 5 6 7 8
1
2
3
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
(BLACK)
A:
i12
(GREEN)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B176 (GRAY)
1
14
2 3 4 5 6 7 8 9 10 11
15 16 17 18 19 20 21 22 23 24
12
25
13
26
WI-156
WI-08449
Door Lock System

WIRING SYSTEM
50.Door Lock System

A: WIRING DIAGRAM
A: B280 B: B281
D/L-01
YR B11
A4
RW B12
A8
A13
A7
WB
WB
RG
A2
FB-31
F/B FUSE NO. 3
(B)
LgB A6
D/L-01
DOOR LOCK
SWITCH LH
DOOR LOCK
SWITCH RH
2
YR
YR
24
YR
YR
24
YR
YR
RW
RW
RW
RW
16
RW
RW
D62
FRONT DOOR
LOCK ACTUATOR RH
D7
FRONT DOOR
LOCK ACTUATOR LH
RG
RG
22
RG
LgB
LgB 21
LgB
LgB
D18
RG
RG
21 LgB
LgB
B30
B101
D1
D8
RG
LgB
D11
22
LgB
RG
RG
RG
RG
RG
Lg
Lg
LgB
LgB
REAR DOOR
LOCK ACTUATOR LH
12
B99
R3
REAR DOOR
LOCK ACTUATOR RH
R38
LgB
RG
Lg
Lg
RG
RG
Lg
D80
B270
B266
D22
D26
RG
D33
D28
D32
LgB
RG
D81
D47
REAR GATE LOCK

ACTUATOR
D8
D32
D18
D47
D33
1 2 3 4
D62
D22
1 2 3 4 5
D28
D26
REF. TO GND
[GND-02]
D80
1 2
3
4 5 6 7 8
2 3
4 5 6 7 8
1 2
3 4
D7
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
(BLACK)
HR
B: B281 (GRAY)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
A: B280 (BLUE)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B99
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
D1
D11
1 2
3 4
5 6 7 8 9
10 11 12 13 14 15
16 17
18 19
20 21 22 23 24 25
WI-15052
WI-157
Compass Mirror System

WIRING SYSTEM
51.Compass Mirror System

COMPASS-01
COMPASS-01
A: WIRING DIAGRAM
FB-24
F/B FUSE NO.9
(ACC)
YG
GB
FB-15
F/B FUSE NO.18
(IG)

R
1
1
WB
GB
BW
10
BrY
T7
BACK-UP LIGHT
SWITCH
(MT MODEL)
T1
T3
AT
MT
B12
B24
GB
NA
COMPASS MIRROR
BrY
NA
MT
TB
AT
TB
BACK-UP LIGHT
SWITCH
(MT MODEL)
YG
BrY
BrY
B90
T1
T13
T9
YG
R50
R139
B128
GW
GW
GB
BrY
MT
: MT MODEL
AT
: AT MODEL
REF. TO GND
[GND-04]
B24
1 2
(GRAY)
T13
2 1
(GRAY)
R139
3 2 1
HR
B128 (GRAY)
1 2
3 4
(BLACK)
R50
T7
1
2
3 4 5 6 7 8
1 2 3 4 5 6
7 8 9 10 11 12
B12
HR
(GRAY)
1 2 3 4
5 6 7 8
9 10 11 12
WI-15053
WI-158
Harness Components Location

WIRING SYSTEM
52.Harness Components Location

A: LOCATION
(10)
(7)
(11)
(5)
(6)
(8)
(4)
(9)
(2)
(14)
(12)
(1)
(13)
(3)
WI-00215
(1)
(2)

(6)
(7)
Rear door cord RH

Rear wiring harness
(11)
(12)
Rear gate cord 2

Rear door cord LH
(3)
(4)

Instrument panel wiring harness
(8)
(9)
Roof cord
Fuel tank cord
(13)
(14)
Front door cord LH

Transmission cord
(5)
Front door cord RH
(10)
Rear gate cord
WI-159
Front Wiring Harness

WIRING SYSTEM
53.Front Wiring Harness

A: LOCATION
Connector
Connecting to
No.
F2
Pole
20
Color
Blue
Area
B-4
No.
B100
F5
F7
1
6
Black
Gray
C-3
B-1
Horn
Headlight RH
F9
F11
13
2
Black
Gray
B-3
B-2
Secondary air relay holder

Secondary air pump
F16
Gray
C-1
Sub fan motor
F17
F19
2
2
Gray
Gray
C-2
C-3
Main fan motor

Front turn signal light LH
F21
F23
2
6
Brown
Gray
C-3
C-3
Front fog light LH

Headlight LH
F24
F25
1
1
Gray
B-2
B-2
Compressor
Generator terminal B
F26
F27
3
36
Green
Black
B-2
B-3
Generator
A/C relay holder
F32
F33
2
2
Gray
Gray
C-4
C-3
Front washer motor

Rear washer motor
F34
F35
4
2
Black
Black
B-3
B-3
SBF holder
F36
F37
3
6
F38
F39
1
8
Brown
B-4
B-3
F40
F41
9
7
Brown
Gray
B-5
B-5
F44
F45
8
24
Black
Black
B-4
B-4
B61
B62
F46
F53
2
2
Black
Gray
B-4
C-3
B108
F58
F59
3
3
Black
Black
C-3
B-1
Headlight beam leveler LH (HID model)

Headlight beam leveler RH (HID model)
F68
F78
4
2
Black
B-4
C-1
Main fuse box (M/B)

Ambient sensor
F94
F102
2
2
Gray
Black
B-2
C-1

Keyless buzzer
B-4
B-4
Description
Main fuse box (M/B)
Fuse & relay box (F/B)

Side marker light LH
: White or natural color
WI-160
Front Wiring Harness

WIRING SYSTEM

Connector
Connecting to
No.
AB14
Pole
2
Color
Yellow
Area
B-4
AB18
Yellow
C-3
No.
AB13
Description
Front sub sensor LH
F2
AB14
F45
F46
F40
F25
F34
F7
GF-3
F59
F9
F94
F44
F35
B
F41
F39
F11
F26
F27
F24
GF-1
F68
F102
F17
F38
F37
F36
AB18
F16
F78
GF-2
F19
F23
F33
F58
F21
F53
F32
F5
WI-161
WI-12310
Bulkhead Wiring Harness (In Engine Compartment)

WIRING SYSTEM
54.Bulkhead Wiring Harness (In Engine Compartment)

A: LOCATION
1. NON-TURBO MODEL
Connector
Connecting to
No.
B3
Pole
5
Color
Black
Area
B-2
B5
B6
2
2
Gray
Gray
B-2
B-2
Daytime running light register

B7
B8
4
5
Gray
B-3
B-4
A/C pressure switch

Front wiper motor
B11
B12
20
12
Gray
Gray
B-4
B-3
B14
B16
1
2
Black
Gray
B-4
B-4
B17
B22
3
54
Black
Black
B-3
B-2
E3

B24
B25
2
2
Gray
Brown
B-3
B-3
T1
T2

Neutral switch (MT model)
B26
B301
1
26
Black
Black
C-1
B-2
Horn
ABS control module
B305
B306
2
2
Gray
Brown
B-1
C-1
Front turn signal light RH

Front fog light RH
Gray
B-1
B320
2
No.
Description
Air flow sensor
T4
T3
Transmission code (AT model)

Starter motor (Magnet)
Brake fluid level warning switch
WI-162

WIRING SYSTEM

Connector
Pole
Color
No.
AB15
Area
Yellow
Connecting to
Description
No.
C-1
Front sub sensor RH
B7
B8
B5
B301
B6
B
B3
B320
B16
B305
B14
B17
B26
B25
B12
B24
AB15
B11
B22
GAB-2
C
B306
WI-163
WI-12314

WIRING SYSTEM
2. TURBO MODEL
No.
Connector
Pole
Color
Area
Connecting to
Description
No.
B3
B5
5
2
Black
Gray
B-2
B-2
Air flow sensor

Daytime running light register
B6
B7
2
4
Gray
B-2
B-3

A/C pressure switch
B8
B11
5
20
Gray
Gray
B-4
B-4
Front wiper motor
B12
B14
12
1
Gray
Black
B-3
B-4
B16
B17
2
4
Gray
Black
B-4
B-3
B18
B20
4
16
Gray
Brown
B-3
B-2
T5
E1
B22
B26
54
1
Black
Black
B-2
C-1
E3
B127
B128
2
4
Blue
Gray
B-2
B-3
B262
B301
4
26
Gray
Black
B-2
B-2

ABS control module
B305
B306
2
2
Gray
Brown
B-1
C-1
Front turn signal light RH

Front fog light RH
B320
B368
2
16
Gray
Black
B-1
B-2
B369
B370
2
6
Gray
Black
B-2
B-2
VDC hydraulic unit
T4
T3
Transmission code (AT model)

Starter motor (Magnet)
Brake fluid level warning switch
Rear oxygen sensor
Horn
T9
Wastegate solenoid
Transmission code (MT model)
WI-164

WIRING SYSTEM

Connector
Pole
Color
No.
AB15
Area
Yellow
Connecting to
Description
No.
C-1
Front sub sensor RH
B5
B127
B8
B20
B301
B368
B6
B
B320
B262
B16
B305
B3
B26
B128
B7
B17
B18
B11
B22
B369
AB15
B14
B12
B370
GAB-2
C
B306
WI-165
WI-15243
Bulkhead Wiring Harness (In Compartment)

WIRING SYSTEM
55.Bulkhead Wiring Harness (In Compartment)

A: LOCATION
Connector
No.
B2
Pole
5
B30
Color
Gray
Connecting to
Area
C-2
No.
25
C-1
D1
B31
D-1
AB1
B32
No.
Connecting to
Description
Intake actuator
Diode (Daytime
running light)
B95
Brown
B-3
B100
20
Blue
B-2
F2
B101
25
B-5
D11
B102
Black
B-5
Instrument panel
wiring harness
B103
Blue
B-5
High-beam relay
(Daytime running
light)
Data link connector
B104
Black
C-1
C-1
Rear accessory
relay
B106
B-2
B-5
B-5
Fuel pump relay

Main relay
Clutch switch
(MT model)
B107
Blue
B-2
C-1
Blower fan relay

(Manual A/C)
Clutch switch
(MT model with
cruise control)
B108
Black
C-1
Black
C-1
Blower fan relay

(Auto A/C)
B112
Black
B-3
Blue
C-1
Fuse & relay box

(F/B)
B117
C-4
B119
C-4
B122
C-4
B125
Green
B-5
B126
Green
B-5
B132
C-2
B134
34
C-4
B135
B136
35
35
B-4
B-4
Ignition switch
Key lock solenoid
and key warning
switch
B137
31
B-4
B141
26
Test mode connector
B142
Mode actuator
(Auto A/C)
Blower fan resister
(Manual A/C)
Black
Yellow
24
C-1
B38
B40
32
16
B-1
C-3
B41
B46
B47
4
6
Black
Brown
C-4
AB5
0
i1
i3
B51
B53
B54
7
35
C-1
B-2
B55
35
C-2
B59
Gray
C-1
B61
Black
B-1
F44
B62
24
Black
B-1
F45
B65
Black
B-2
B-4
Side airbag
TCM
Interrupt relay
(Security)
Stop light & brake
switch
Parking switch
B69
B-3
B70
B71
18
17
B-3
B-3
B72
B73
B75
Green
C-2
B76
B76
Green
C-2
B75
B77
10
Brown
B-3
B86
Black
B-4
Blue
Front door cord LH

Turn signal and hazard unit
B-3
B36
Combination switch
C-2
C-3
B-4
Blower motor
(Manual A/C)
B-4
Blower motor
(Auto A/C)
B-5
Area
B87
B90
Description
HID relay
Connector
Pole Color
B91
B34
B50
No.
R50
Roof cord
F46
Front door cord RH

Daytime running
light relay

Diode
(Front fog light)
AT select lever
Front accessory
power supply socket
Shield & sensor joint
connector
B126 Line end check conB125 nector

Headlight beam leveler switch
(HID model)
ECM
B-2
Immobilizer control
module
(Turbo model)
B-2
Immobilizer antenna
(Turbo model)
B152
12
C-1
B158
B160
10
6
B176
26
B177
B193
2
8
B194
B195
2
2
WI-166
Gray
Gray
Gray
Gray
Black
Black
C-1
C-2
Fuse & relay box

(F/B)
Front fog light switch
B-5
B-5
C-2
Wiper deicer
Wiper deicer switch
C-1
C-1
B195 Joint connector (Key

B194 lock) (Turbo model)

WIRING SYSTEM
Connector
No.
B198
Pole
1
B199
B201
24
Color
Area
B-4
B-4
Black
24
No.
Description
B199 Joint ground
B198 connector
C-4
i40
C-4
i41
B202
20
8
C-4
Black
Connecting to
C-2
i41
Connector
Instrument panel
wiring harness
Instrument panel
wiring harness
(Auto A/C)
Instrument panel
wiring harness
(Manual A/C)
Fuse (Relay block)
Ignition relay
(Relay block)
B225
C-2
B230
Black
C-4
B231
C-3
B236
C-3
B256
B-4
Evaporator thermo
switch
B271
12
Blue
C-1
Fuse & relay box

(F/B)
B280
B281
16
20
Blue
Gray
B-2
B-2
B292
B309
Black
B-4
B310
83
Black
B-3
B312
B313
Brown
B-1
B315
Black
B-3
B318
Brown
C-2
B327
Gray
B-4
B348
B-4
AB1
AB2
AB3
28
AB4
AB1
3
Colo
r
Yellow
Yellow
Yellow
Yellow
Area
No.
D-1
B31
ABS G sensor
Electronic throttle
control relay
VDC control module
VDC shield joint
connector
HID diode
Accelerator position
sensor
VDC OFF switch
A/F & Oxygen
sensor relay
(Non-turbo model)
Impact sensor
WI-167
Description
Bulkhead wiring
harness
C-3
Airbag module (Driver)
C-4
B-5
Airbag module
(Passenger)
C-1
Black
B-3
Pole
Power window relay

(Relay block)
Front fog light relay
(Relay block)
Starter interlock
relay (Relay block)
Wiper deicer and
mirror heater relay
(Relay block)
Seat heater relay
(Relay block)
Yaw rate & lateral G
sensor
(with VDC)
Steering angle
sensor (with VDC)
Steering roll
connector
C-4
No.
Connecting to
AB1
4
Front sub sensor LH

WIRING SYSTEM
A
B309
B86
B177
B312
B106
B256
B310
B107
B327
B46
B91
B142
GB-2
B54
B126
B90
B141
B100
B65
B112
B47
B95
B176
B61
B77
B280
AB4
B313
B125
B32
B348
B198
B55
B199
B38
B281
B137
B69
B70
B103
B315
B36
B62
B71
B136
B87
B202
B231
B108
B236
B59
B101
B134
B122
B50
B119
B104
B102
B135
B73
B51
B40
B72
GB-3
B195
GB-4
AB2
B194
B117
B201
GR
B41
B132
B76
B75
AB13
AB3
B230
B160
B30
B31
B225
GB-1
B292
B193
B2
AB1
B34
B318
B271
B52
B152
B158
WI-168
WI-15244
Engine Wiring Harness and Transmission Cord

WIRING SYSTEM
56.Engine Wiring Harness and Transmission Cord

A: LOCATION
1. NON-TURBO MODEL
No.
Connector
Pole
Color
Connecting to
Description
Area
No.
B22
E3
E4
54
2
Black
Black
A-4
A-3
E5
E6
2
2
Dark gray
Dark gray
A-2
A-3
Fuel injector No. 1

Fuel injector No. 3
E8
E10
3
2
Light gray
Light gray
A-3
B-3
Engine coolant temperature sensor and thermometer

E11
E12
1
4
Dark gray
B-2
A-3
Oil pressure switch

Ignition coil and ignitor
E14
E15
2
2
Gray
Gray
A-4
B-4
Knock sensor
E16
E17
2
2
Dark gray
Dark gray
B-4
B-4
Fuel injector No. 2

Fuel injector No. 4
E18
E19
6
1
Dark gray
A-4
B-2
EGR solenoid valve

E21
E22
3
4
Black
Dark gray
A-3
A-2
Pressure sensor
Rear oxygen sensor
E23
E57
6
6
Black
Black
A-2
A-3

E61
E69
2
2
Dark gray
Blue
A-4
A-3

Oil switching solenoid valve RH
E70
E71
2
1
Blue
B-4
A-3
Oil switching solenoid valve LH

Variable valve lift diagnosis oil pressure switch RH
E72
E75
1
2
B-4
B-3
Variable valve lift diagnosis oil pressure switch LH

Black

CPC Solenoid
WI-169

WIRING SYSTEM
Transmission cord
No.
Connector
Pole
Color
Area
No.
Connecting to
Description
T1
T2
2
2
Gray
Brown
D-2
D-2
B24
B25
Bulkhead wiring harness (MT model)
T3
T4
12
20
Black
Gray
D-4
D-4
B12
B11
Bulkhead wiring harness (AT model)
T7
12
Black
D-4
Inhibitor switch
WI-170

WIRING SYSTEM
E57
E6
E8
E4
E3
GE-1
E5
E12
A
E21
E22
E61
E18
E14
E23
GE-2
E17
B
E19
E16
E11
E70
E72
E10
E75
E15
E69
E71
T7
T3
T2
T4
T1
< MT >
< AT >
WI-171
WI-12317

WIRING SYSTEM
2. TURBO MODEL
Connector
Connecting to
No.
E1
Pole
16
Color
Brown
Area
A-2
No.
B20
E3
E4
54
2
Black
Black
A-3
B-3
B22
E5
E6
2
2
Dark gray
Dark gray
A-2
A-2
Fuel injector No. 1

Fuel injector No. 3
E8
E10
3
2
Light gray
Light gray
B-3
B-2
Engine coolant temperature sensor and thermometer

E11
E14
1
2
Light gray
B-2
A-4
Oil pressure switch

Knock sensor
E16
E17
2
2
Dark gray
Dark gray
B-4
B-4
Fuel injector No. 2

Fuel injector No. 4
E19
E21
1
3
Black
B-3
A-3

Pressure sensor
E31
E32
3
3
B-2
B-4
Ignition coil No. 1

Ignition coil No. 2
E33
E34
3
3
Black
Black
A-3
B-4
Ignition coil No. 3

Ignition coil No. 4
E35
E36
3
3
Light gray
Light gray
A-4
A-3
AVCS camshaft position sensor LH

AVCS cam shaft position sensor RH
E37
E38
2
2
Blue
Blue
B-4
A-2
AVCS solenoid LH
AVCS solenoid RH
E40
Black
B-3
E41
Black
B-4
Secondary air combination valve RH

Secondary air combination valve LH (with pressure sensor integrated)
E50
E51
3
2
Black
Black
B-3
A-4
TGV position sensor LH

TGV LH
E52
E54
2
3
Black
Black
B-3
A-3
CPC solenoid No. 2

TGV position sensor RH
E55
E57
2
6
Black
Black
A-2
A-3
TGV RH
A-3
E61
2
Dark gray
Description
CPC solenoid No. 1
WI-172

WIRING SYSTEM
Transmission cord
No.
Connector
Pole
Color
Area
Connecting to
Description
No.
T1
T2
2
2
D-3
D-3
T3
T4
12
20
Black
Gray
D-4
D-4
B12
B11
T5
Dark gray
C-1
C-4
B18
B18

T6
Dark gray
C-3
C-5
Rear oxygen sensor (MT model)

Rear oxygen sensor (AT model)
T7
T9
12
4
Black
Gray
D-4
D-2

T12
T13
2
2
Brown
Gray
D-3
D-3
Transmission code (MT model)
B128
Neutral switch (MT model)

WI-173

WIRING SYSTEM
E61
E1
E6
E3
E54
E21
GE
E57
E38
E14
E51
E35
E36
E5
E41
E33
E55
E37
GE
E17
E31
E10
E50
E40
E11
E52
E16
E4
E8
E19
E34
E50
E32
C
T7
T12
T13
T5
T3
T4
T5
T9
T6
T6
T2
T1
< MT >
< AT >
WI-174
WI-12318
Instrument Panel Wiring Harness

WIRING SYSTEM
57.Instrument Panel Wiring Harness

A: LOCATION
Connector
No.
i1
Pole
24
i3
i10
32
30
i11
i12
10
14
i15
i16
Color
Connecting to
Area
C-1
No.
B36
B38
Green
C-1
B-2
Green
Green
B-2
B-3
Combination meter
6
12
C-4
C-4
Blower fan switch (Manual A/C)

i22
i26
8
14
B-4
B-3
Hazard switch
Audio
i27
i29
2
1
B-4
C-4
CD player illumination light

Audio bracket earth
i40
i41
24
24
i41
i48
20
16
i49
i51
20
2
i55
i59
2
10
i64
i65
i67
6
6
Black
Black
Gray
Gray
Description
C-4
C-4
B201
B202

Bulkhead wiring harness (Auto A/C)
C-4
C-4
B202
Bulkhead wiring harness (Manual A/C)
C-4
B-5

Sunload sensor
B-3
B-4
In-vehicle sensor
Clock
Black
B-3
B-3
Audio (with woofer, without AUX terminal)

Audio (with woofer and AUX terminal)
Black
B-4
C-4
Air mix actuator (Auto A/C)

AUX terminal box
Green
WI-175
Instrument Panel Wiring Harness

WIRING SYSTEM
A
i51
i59
i10
i11
i12
i55
i64
i65
i22
B
i27
i15
i16
i48
i49
i29
i41
i26
i40
i67
i3
i1
WI-176
WI-12319
Rear Wiring Harness

WIRING SYSTEM
58.Rear Wiring Harness

A: LOCATION
Rear wiring harness
Connector
Color
Black
Connecting to
No.
R1
Pole
8
R2
R3
12
24
R4
R8
1
2
R15
12
B-3
R22
R41
3
4
Blue
B-5
B-2
Rear door switch LH

Seat heater RH
R42
R43
4
4
Blue
B-3
B-3
Seat heater switch RH

Seat heater switch LH
R72
R73
2
2
B-3
C-4
Rear ABS wheel speed sensor RH

R146
R188
2
8
B-3
C-3
Rear accessory power socket

Power seat & seat heater and seat belt switch (with power seat)
Black
Black
Area
B-2
No.
B97
B-2
B-2
B98
B99
B-3
C-4
Description
Seat belt switch (Manual seat)
R57
Fuel tank cord

No.
Connector
Pole
Color
Connecting to
Description
Area
No.
B-2
B-2
R1
R2
Rear wiring harness
24
8
B-2
B-2
R3
D28
Rear door cord RH
3
3
C-4
B-2
B97
B98
8
12
B99
B266
B267
B268
Black
B270
8
Front door switch LH

Front door switch RH
C-4
D22
Area
No.
B90
Rear door cord LH
Roof cord
No.
Connector
Pole
Color
Connecting to
Description
R50
R52
8
3
B-1
A-3
R55
R56
2
2
B-2
B-3
Sunroof control unit and motor

Spot map light
B-2
Compass mirror
R139
3

Room light
WI-177
Rear Wiring Harness

WIRING SYSTEM
Fuel tank cord

Connector
No.
R47
Pole
3
R57
R58
R59
R68
Area
B-4
No.
12
6
B-3
B-3
R15
2
2
Gray
B-4
B-4
Fuel gauge sub module

Black
B-4
Drain valve
R69
2
Color
Black
Connecting to
Description
Rear wiring harness
Fuel pump assembly

No.
Connector
Pole
Color
Area
Connecting to
Description
No.
AB7
AB8
12
12
Yellow
Yellow
C-2
C-2
AB9
AB10
2
4
Yellow
Yellow
C-3
C-4
Inflator (Side LH)

Side airbag sensor LH
AB11
AB12
2
4
Yellow
Yellow
B-2
B-2
Inflator (Side RH)

Side airbag sensor RH
AB19
AB20
2
2
Black
Black
C-4
B-2
ELR pretensioner LH
ELR pretensioner RH
AB50
AB51
2
2
Yellow
Yellow
C-2
C-3
AB52
AB56
2
3
Yellow
Brown
C-3
B-2
AB61
Gray
B-2
B34

Buckle switch
Seat position sensor
Belt tension sensor
AB59
WI-178
Rear Wiring Harness

WIRING SYSTEM
R52
R139
R55
AB12
R56
R72
R15
AB20
R57
B266
R58
B268
R22
B99
AB56
B97
R68
AB61
R50
R69
R47
R59
R1
AB52
B98
AB51
R2
R8
AB9
R3
GR-1
R73
R41
C
AB7
AB8
AB50
C
AB11
AB19
AB10
B270
R146
B267
R4
R43
R188
R42
WI-179
WI-12320
Door Cord
WIRING SYSTEM
59.Door Cord
A: LOCATION
Connector
No.
D1
Pole
25
D2
D3
2
2
D4
Color
Connecting to
Area
C-2
No.
B30
Description
Green
C-3
C-3
Front door speaker LH

Front power window motor LH
Black
C-3
Front door tweeter LH

Outer mirror assembly LH (without outer mirror turn signal light,
mirror heater)
Outer mirror assembly LH (without outer mirror turn signal light,
with mirror heater)
C-3
C-3
C-3
10
C-3
D7
16
C-4
Outer mirror assembly LH (with outer mirror turn signal light, mirror heater)
Front power window main switch
D8
D11
4
25
C-4
C-1
Front door lock actuator LH

D12
D13
2
2
Green
B-1
B-2
Front door speaker LH

Front power window motor RH
D14
Black
B-1
Front door tweeter RH

Outer mirror assembly RH (without outer mirror turn signal light,
mirror heater)
Outer mirror assembly RH (without outer mirror turn signal light,
with mirror heater)
Outer mirror assembly RH (with outer mirror turn signal light,
without mirror heater)
D5
Outer mirror assembly LH (with outer mirror turn signal light,

without mirror heater)
B101
B-1
B-1
B-1
10
B-1
Outer mirror assembly RH (with outer mirror turn signal light,

mirror heater)
D17
D18
8
4
B-2
B-2
Front power window sub-switch RH

Front door lock actuator RH
D22
D23
8
2
C-4
C-4
D24
D25
2
8
D26
D28
4
8
D29
D30
2
2
D31
D32
D61
D62
D15
Green
B270
C-4
B-4
B-5
B-3

Rear door speaker LH
Rear power window motor LH
Rear power window sub-switch LH
B266
Rear door lock actuator LH

B-3
B-3
Rear door speaker RH

Rear power window motor RH
8
4
B-3
B-3
Rear power window sub-switch RH

Rear door lock actuator RH
10
5
C-3
B-2
Remote control mirror switch

Front door sub-switch
Green
WI-180
Door Cord
WIRING SYSTEM
D32
D17
D31
D62
D30
D13
D15
D29
D18
D14
B
D25
D28
D22
D5
D4
D26
D12
D11
D24
C
D1
D8
D23
D7
D61
D3
D2
WI-181
WI-08459
Rear Wiring Harness and Rear Gate Cord

WIRING SYSTEM
60.Rear Wiring Harness and Rear Gate Cord

A: LOCATION
Connector
Color
Connecting to
No.
R16
Pole
3
R26
R28
6
6
C-4
C-1
R32
R38
2
4
C-4
C-4
R39
R79
8
6
C-4
C-3
R97
R116
1
8
B-2
C-4
Antenna amplifier
Rear wiper intermittent unit
R117
R122
2
6
C-2
C-4
Woofer
Fuel pump control unit (Turbo model)
C-4
Joint ground connector
Black
R147
5
No.
Connector
Pole
Color
D33
D34
4
8
D39
D40
2
1
D43
D44
4
2
D46
D47
2
4
D79
D80
D81
D82
Black
Black
Area
C-5
No.
Description
Rear door switch RH
Rear combination light RH
Rear combination light LH
Rear accessory power socket
D33
D34
Rear gate cord

Trailer connector
Connecting to
Description
Area
No.
C-4
C-4
R38
R39
Rear wiring harness
B-3
A-3
High-mounted stop light

Rear defogger
A-2
A-2
Rear wiper motor

License plate light
Black
A-2
A-1

Rear gate lock actuator
1
8
Black
Black
B-2
A-3
Rear defogger
8
3
Black
A-3
B-3
D81
D80
Rear gate cord

Luggage room light
WI-182
Rear Wiring Harness and Rear Gate Cord

WIRING SYSTEM
D47
D46
D43
D81
D44
D80
D39
D40
D82
R26
R32
D79
R97
R122
R28
R16
R117
R116
R38
R147
D33
R79
D34
R39
WI-183
WI-12321
Harness Repair Kit

WIRING SYSTEM
61.Harness Repair Kit

A: SPECIFICATION
1. ADAPTATION TABLE
Connector No.
B3
Adaptive repair kit
TFA-034
Terminal No.
1, 2, 4, 5
Harness repair kit No.

TFA-034
TFA-042
ALL
TFA-033
ALL
TFA-036
ALL
TFA-018
TFA-034
1 2 3 4 5
TFA-042
WI-06087
B8
1 2 3
4 5
TFA-033
WI-04676
B11
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
TFA-036
WI-04677
B12
TFA-018
1 2 3 4
5 6 7 8
9 10 11 12
WI-04679
WI-184
Harness Repair Kit

WIRING SYSTEM
Connector No.
Adaptive repair kit
Terminal No.
B17
(Non-turbo MT model)
TFA-019
ALL
TFA-019
ALL
TFA-019
1, 2
3, 4
TFA-033
TFA-026
1, 2, 6
TFA-041
3 5, 7 10
TFA-032
1 2 3
WI-06088
B17
(Turbo MT model)
1 2
3 4
TFA-019
WI-06089
B18
TFA-033
1
3
TFA-026
2
4
WI-06090
B20
(Turbo model)
TFA-041
TFA-041
1 2 3 4
5
6
7
8
9
10
TFA-032
WI-11568
B54
TFA-011
TFA-011
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
31
28 29 30
5 6
14 15 16
25 26 27
32 34 35
TFA-013
WI-11569
WI-185
16
TFA-011
7 35
TFA-013
Harness Repair Kit

WIRING SYSTEM
Connector No.
Adaptive repair kit
Terminal No.
B55
TFA-011
TFA-011
17
8 35
TFA-011
TFA-013
ALL
TFA-018
17
8 17, 20
27, 30 34
TFA-011
TFA-013
18, 19, 28, 29
TFA-014
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
TFA-013
WI-11570
B128
(Turbo MT model)
TFA-018
1 2
3 4
WI-06096
B134
TFA-011
1 2
8 9 10
18 19 20
28 29 30
TFA-014
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
TFA-013
WI-11571
B135
TFA-011
TFA-011
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
TFA-014
17
TFA-011
8 20, 24
28, 32 35
TFA-013
21 23, 29
31
TFA-014
TFA-013
WI-11572
B136
TFA-011
TFA-011
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
TFA-013
WI-11573
WI-186
16
TFA-011
7 35
TFA-013
Harness Repair Kit

WIRING SYSTEM
Connector No.
Adaptive repair kit
Terminal No.
B137
17
8 31
TFA-011
TFA-013
ALL
TFA-021
ALL
TFA-016
ALL
TFA-012
ALL
TFA-033
TFA-011
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
TFA-013
WI-04697
B230
(Model with VDC)
TFA-021
1 2 3
4 5 6
WI-04700
B281
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
TFA-016
WI-11574
B292
(Model without VDC)
TFA-012
1 2 3
WI-06101
B305
TFA-033
1 2
WI-04717
WI-187
Harness Repair Kit

WIRING SYSTEM
Connector No.
Adaptive repair kit
Terminal No.
F7
TFA-033
ALL
TFA-033
ALL
TFA-033
ALL
TFA-033
ALL
TFA-018
ALL
TFA-032
1 2 3
4 5 6
WI-11576
F19
TFA-033
1 2
WI-04717
F23
TFA-033
1 2 3
4 5 6
WI-11576
F24
TFA-018
WI-06103
F26
TFA-032
1 2 3
WI-06104
WI-188
Harness Repair Kit

WIRING SYSTEM
Connector No.
Adaptive repair kit
Terminal No.
F102
1 2
ALL
TFA-018
ALL
TFA-019
ALL
TFA-029
ALL
TFA-029
ALL
TFA-032
TFA-018
WI-06109
R47
TFA-019
1 2 3
WI-06088
R58
TFA-029
1 2 3
4 5 6
WI-11578
R59
TFA-029
1 2
WI-06095
R68
TFA-032
1 2
WI-06110
WI-189
Harness Repair Kit

WIRING SYSTEM
WI-190

Subaru Forester 2007 Service Manual

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Subaru Forester 2007 Service Manual

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Foreword

How To Use This Manuals

1. How To Use This Manuals

How To Use This Manuals

: Should be lubricated with grease.

How To Use This Manuals

15.Main Shaft Assembly for Single-Range

1) Remove the manual transmission assembly

Tool number of special tool

How To Use This Manuals

How To Use This Manuals

Total height (at C.W.)

Minimum road clearance

*1: Model with sunroof

226 (23.0, 166)/4,400

319 (32.5, 235)/3,600

Reduction gear (Rear)

5MT: 5-forward speeds with synchromesh and 1-reverse

Turns, lock to lock

Macpherson strut type independent suspension

2.5 XS, 2.5 XT, CROSS SPORTS 2.5 XT,

Dual circuit hydraulic with vacuum suspension and power unit

Steel belted radial, tubeless

When replacing engine

2 (US qt, Imp qt)

2 (US qt, Imp qt)

Front differential gear oil

2 (US qt, Imp qt)

Rear differential gear oil

2 (US qt, Imp qt)

2 (US qt, Imp qt)

0.8 (0.8, 0.7)

Total vehicle weight (G.V.W.)

Leather package base

Cold zone package

Front fog light

Fully automatic air

Total vehicle weight (G.V.W.)

Leather seats and

Manual air conditioner

Total vehicle weight

Front fog light

Leather package base

2. FOR CANADA MODEL

Total vehicle weight (G.V.W.)

Leather seats and

Front fog light

Leather package base

Fully automatic air

Manual air conditioner

Total vehicle weight (G.V.W.)

Manual air conditioner

Cold zone package

Fully automatic air conditioner

7. AIRBAG MODULE AND SEAT BELT

To prevent bodily injury from unexpected airbag

Adhere to the following when handing and storing

2. VEHICLE DYNAMICS CONTROL (VDC)

9. AIRBAG SPECIAL TOOLS

15.AIR CONDITIONER REFRIGERANT

2. STATIC ELECTRICITY DAMAGE

5. PROTECTING VEHICLE UNDER MAINTENANCE

6. ENSURING SAFETY DURING WORK

7. LIFTS AND JACKS